Operating Manual

B-CONTROL II
Compressor Control System
for industrial units

Copyright 2009 BAUER Kompressoren GmbH Mnchen

Instruction Manual w High Pressure Compressor Units
1. ELECTRIC SYSTEM

1.1. COMPRESSOR CONTROL SYSTEM

The electric control is placed in the control room at the right
side of the compressor building.
The unit is only allowed to operate
WARNING
with the switch cabinet doors
closed!

For schematic diagrams refer to section F.

The values indicated in the following de

scription are merely samples from one of
many different configuration possibilit
ies. Therefore, the values indicated on the
compressor unit may be different from
the ones shown here.

1.1.1. Description
The BAUER B-Control is a free-programmable electronic
compressor control system. Communication with the user
takes place via a modern LCD touchscreen display and 10
touch keys. The control system is specially designed for
BAUER compressors.

Fig. 1 B-Control control panel and display

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 Instruction Manual w High Pressure Compressor Units
1.1.1.1. HARDWARE AND CONNECTIONS
For reference to the hardware and connections refer to the
schematic diagrams in section F.
For more detailed information about the control system,
refer to the circuit diagramme that comes with the unit. F1 F5
The configuration of the software with respect to the F2 F6
hardware is performed in the configuration file. This file is
automatically generated at factory start-up, and normally F3 F7
does not need any further modification. If a change should
become necessary due to modifications on the compressor F4 F8
unit, please contact the BAUER after-sales service dept.
F9 F10

1.1.1.2. Control and Monitoring Elements

The control and monitoring panel features an LCD
touchscreen display, 8 soft touch keys and one fwd and one
back key to control the compressor and the display. F1 Main menue
F2 Compressor 1 data
The function of the control keys is as follows: F3 Compressor 2 data
F4 Dispenser
F1 Displays main menue
F9 Back/ up
F2 Displays compressor 1 details F5 Home page
F6 Reset / page back
F3 Displays compressor 2 details F7 ON
F8 OFF
F4 Dispenser
F10 Fwd / down
F5 Displays home page 11 Touchscreen display
F6 Reset / Back to previous page Fig. 2 Operating and display elements
F7 Compressor ON
F8 Compressor OFF
F9 Back / up in menue
F10 Fwd / down in menue

After 5 min. of no action the display

returns to the homepage and logs out.

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Instruction Manual w High Pressure Compressor Units
1.1.1.3. Menu and Navigation
The LCD display contains all the important information on
the present condition of your BAUER compressor.
Home page

When switching on the compressor unit, or by pressing the

F5 key, the home page (Fig. 3) is displayed, giving the most
important general data in a very clear presentation. This
way you can find out the actual compressor status.

!
The exclamation mark in the headline shows a warning,
which has not been acknowledged yet if flashing, which
has been acknowledged if steady.

The triangle warning sign shows that there is a fault,

which has not been acknowledged yet if flashing, which
has been acknowledged if steady.
Fig. 3 Home page
The circled 0 marked with a cross on the right of the
headline means that both compressors are disabled. The O

not marked means unit is ready for operation . A I in

the circle means compressor is in stand-by. Rotating

arrows around the circle show that unit is running.

The state of compressor 1 and compressor 2 is indicated by

two circled symbols and showing that both
compressors are in stand-by. If marked with a cross, the
respective compressor is disabled . Arrows around the
circle mean unit is running . An arrow towards the circle
means that compressor I or II is master, the other one
is slave.
Beside of the compressor symbol the following values are Fig. 4 Alarm list, acknowledged
shown:
- temperature of the last compressor stage
- final pressure 1
- final pressure 2
- oil pressure
The footer contains information from the alarm list. Clicking
on the footer causes the alarm list being displayed as shown
in Fig. 4. Green ticked circles indicate that the messages are
acknowledged, small flags indicate not acknowledged as
shown in Fig. 5.

Fig. 5 Alarm list, not acknowledged

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 Instruction Manual w High Pressure Compressor Units
A click on the Bauer Kompressoren symbol causes the
compressor station data incl. the serial no. and software
version being displayed as shown in Fig. 6.

Main menu
With F1 the display changes to the main menu (Fig. 7).
The main menu is divided into 10 sub-menues (#4 is not
assigned at the present):
Homepage
Values
Trend
Setup
Logbook
Log in
Operation Fig. 6 Compressor station data

Maintenance
Setup
Logbook

Homepage is as shown in Fig. 3.

Fig. 7 Main menue

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Instruction Manual w High Pressure Compressor Units
The actual values pages show the current operating data
for the compressor, i.e. monitored pressures and
temperatures as indicated (Fig. 8).
Page 2 shows the intermediate pressure of stage 1 to 4,
blow-down pressure and the dewpoint of the compressed
medium. (Fig. 9).

The arrows at the bottom navigate to the following or

previous page.

Fig. 8 Act. values 1

Fig. 9 Act. values 2

Fig. 10 Act. values 3

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 Instruction Manual w High Pressure Compressor Units
The Trend page gives a graphical diagramme of the
pressure trends for high, mid and low storage bank, and the
ON and OFF periods of the compressor (bottom graph).

Fig. 11 Trend page

The Diagnosis page (Fig. 12) shows values for different
signal channels. They are of interest for the service
engineer, only.

Fig. 12 Diagnosis page

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Instruction Manual w High Pressure Compressor Units
The Login page (Fig. 13) enables the operator or
maintenance personnel to enter higher levels that need
authorization to take any action.
To enter a specific level (Fig. 15), enter the appropriate code
and press enter (Fig. 14).
Without entering the correct code, all parameters in any
menue shown in dark grey cannot be changed.
There are 5 different levels which require different codes:
Operation level
Maintenance level
Configuration level
B-Manager level
Programming level Fig. 13 Login page
The code for the operation level is 1000. All other codes are
listed in a file delivered with the compressor unit.

Fig. 14 Key panel

Fig. 15 Login codelevel 200

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 Instruction Manual w High Pressure Compressor Units
Operation menu page (Fig. 16)

contains four pages for setting the following parameters:

Operation mode
Control settings
Combined operation mode
Pressure settings
The operation mode page (Fig. 17) enables to choose
between different operation modes. The following
operation modes can be selected: Combined-, fully
automatic, or semi automatic operation.
Combined operation
If combined operation mode is selected the compressor
units will be controlled by the adjusted data from push Fig. 16 Operation menu
button combi.
Fully automatic operation
After manual start of the compressor unit, the operation is
controlled by the adjusted final pressure. As soon as the
final pressure is reached, the compressor will be switched
to standby. Automatic restart is effected if the pressure
decreases below the adjusted switch-on pressure (i.e. final
pressure minus adjusted hysteresis). The process will
continue until the compressor is switched off manually.
Semi automatic operation
After manual start of the compressor unit, the operation is
controlled by the adjusted final pressure. When one or both
final pressures (depending on the configuration setting) is
reached, the compressor will be switched off. Restarting is
performed manually.
Safety valve test mode
The compressor is started manually and will not be switched
off until the 0 key is pressed. The final pressure sensors are Fig. 17 Operation modes
disabled and the compressor will operate against the safety
valves. By this a safety valve blow off test can be performed
in a simple way.

Use this operation mode under survey,

only.

Leak test mode

In the leak test mode, the compressor is started manually
and will switch off automatically after having reached the
final pressure. During this mode, venting of the condensate
drain valves is disabled. The compressor remains under
pressure. By this an air tightness or leak test can be
performed in a simple way.

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Instruction Manual w High Pressure Compressor Units
On the control settings page (Fig. 18) will be defined the
regulation settings to control the compressor.
Controlpoint 1, controlpoint 2: Selection between final
pressure 1, final pressure 2, intake pressure, gas balloon
analog, gas balloon digital. The values for final pressure 1
and 2 will be adjusted at the pressure setting page.
Intake pressure, gas balloon analog, gas balloon digital will
be used for gas compressor units only.
Connection between controlpoint 1 and 2: Selection
between AND and OR, i.e. fi one controlpoint or both
controlpoints have to be reached to start or stop the
compressor.
Advice: White coloured fields are selected
values, light grey coloured fields are
changeable values and the dark gery
coloured fields are fixed and cannot be Fig. 18 Control settings
changed in current code level.

At the combined operation mode page (Fig. 19) you can

define the status of the compressor units and the operating
time of each compressor.
The control panel can be adjusted to master or slave. The
numbers of active slave and passive slave compressors as
well as the cycle time will be defined in the further fields.
The cycle time defines the runtime (in hours) of each
compressor. The master and slave function will be switched
when the defined runtime is over.
Operating hours comparison:
Select yes or no to enable or respectively to deactivate the
operating hours loadequalisation. This effects that the
compressor runtime will be compared and a balanced
working load will be reached.

Fig. 19 Combined operation mode

The pressure settings to start and stop the basic load and
peak load compressor will be adjusted on page Combi P-set
(Fig. 20).

Fig. 20 Combi P-set

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 Instruction Manual w High Pressure Compressor Units
The pressure setting page (Fig. 21) shows the adjusted
shut-off and switch on pressure.

The compressor wil be shut-off when the final pressure is

achieved. Decrease the pressure under the adjusted value
the compressor will be switched on.

The Maintenance page (Fig. 22) shows the maintenance

parameter for the respective compressor 1 or 2:
the total operating hours, the start cycles, and the target
and elapsed hours for the maintenance work to be
performed:
main service (every 4000 operating hours) Fig. 21 Pressure settings

intake filter service (cleaning, every 2000 operating hours)

oil change (every 2000 operating hours)
valve check (every 2000 operating hours) and
final separator change (indicated cycles x 10 = after 65000
cycles)
Highlighted fields are white , light grey
fields are values which can be changed,
dark grey fields are fixed.

The Setup page (Fig. 23) provides various parameters to be

set:
Language: choose between German, English and Russian
Sensor parameter setting
B-Messenger setup
Fig. 22 Maintenance page
Bus-Com. setting
Backup setting
Condensate drain valves setting
Display setup
System setup
The setting values for the compressor
units are listed in the adjusting procedure
which is delivered with the unit.
Scrolling through the sensors pages (Fig. 24) enables
setting of parameters for
final pressure, intake pressure, oil pressure, dew point,
intermediate pressures, gas balloon and blow-down
pressure as well as the temperature sensors for the last
stages, cooling air-, cooling water temperature and gas
outlet temperature. Not applied sensors are marked as
logged out.
MBU is the minimum adjustable value, MBO the maximum
adjustable value. The actual value is displayed under the =
sign. The required switch-off pressure is set in the lower Fig. 23 Setup page
right field.

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Instruction Manual w High Pressure Compressor Units
The valves menu (Fig. 25) allows setting of the condensate
drain valves and the intake valve.
The condensate valves can be set according to the type,
either normally open or closed. The interval times are set
individually for each drain valve, the normal blow-off time
is 3 seconds.
For the gas intake valve, the open and close delay times are
adjustable.
On the B-Messenger page (Fig. 26) the broadcasting of
errors and warnings can be enabled or disabled.
Fault/Warning signal broadcasting selection:
---- (none)
B-Messenger or
ER75i Fig. 24 Sensors
The broadcast time is adjustable between daily, weekly or
monthly. Two times can be set for daily broadcast. For
weekly and monthly broadcast the day and one time is
adjustable.

Fig. 25 Valves
The message filter (Fig. 27) allows to select the type of
errors and warnings of the B-Manager to be broadcasted by
selecting the message and disabling it.
The default setting is enable all.

Fig. 26 B-Messenger

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 Instruction Manual w High Pressure Compressor Units
The field ER75i (Fig. 28) is the alternative fault sensor.
Information about the compressor unit can be entered,
e.g.: unit description, type, location, operator etc.
On the following pages phone numbers for the case of
error, warning and maintenance can be entered.
The Bus-Com. page (Fig. 29) enables the selection
between different Bus-data lines. These data lines are
necessary for the communication between compressor unit
and the superordinated control.

Fig. 27 Messagefilter

Fig. 28 ER75i

Fig. 29 Bus-Com.

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Instruction Manual w High Pressure Compressor Units
The backup, display setup and set time pages are self-
explanatory.

Fig. 30 Backup

Fig. 31 Setup display

Fig. 32 Set date and time

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 Instruction Manual w High Pressure Compressor Units
The Logbook page (Fig. 33) shows all entries for actions
taken.

Fig. 33 Logbook page

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Instruction Manual w High Pressure Compressor Units
Annex

The following pages contain a list showing all fault mes

sages

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 Instruction Manual w High Pressure Compressor Units

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B-Control Fehlermeldungen Fault messages

ID Deutsch [de] English [en]

[PLC_Alarms].ID[38:0] Enddrucksensor 1 defekt
[PLC_Alarms].ID[39:1] Enddrucksensor 2 defekt
[PLC_Alarms].ID[40:2] Ansaugdrucksensor defekt
[PLC_Alarms].ID[41:3] ldrucksensor defekt oder Drehrichtung
falsch
[PLC_Alarms].ID[42:4] Zw.drucksensor 1.St. defekt
[PLC_Alarms].ID[43:5] Zw.drucksensor 2.St. defekt
[PLC_Alarms].ID[44:6] Zw.drucksensor 3.St. defekt
[PLC_Alarms].ID[45:7] Zw.drucksensor 4.St. defekt
[PLC_Alarms].ID[46:8] Kurbelgehusedrucksensor defekt
[PLC_Alarms].ID[47:9] Drucktaupunktsensor defekt
[PLC_Alarms].ID[48:10] Levelsensor Niveau Gasblase defekt
[PLC_Alarms].ID[49:11] Temperatursensor Khlluft defekt
[PLC_Alarms].ID[50:12] Temperatursensor LS defekt
[PLC_Alarms].ID[51:13] Temperatursensor Stufe 1 defekt
[PLC_Alarms].ID[52:14] Temperatursensor Stufe 2 defekt
[PLC_Alarms].ID[53:15] Temperatursensor Stufe 3 defekt
[PLC_Alarms].ID[54:16] Temperatursensor Stufe 4 defekt
[PLC_Alarms].ID[55:17] Temperatursensor Gasaustritt defekt
[PLC_Alarms].ID[56:18] Khlwassertemp.Sensor defekt
[PLC_Alarms].ID[57:19] Sensor Reserve Ch. 19 defekt
[PLC_Alarms].ID[58:20] Sensor Reserve Ch. 20 defekt
[PLC_Alarms].ID[59:21] Sensor Reserve Ch. 21 defekt
[PLC_Alarms].ID[60:22] Sensor Reserve Ch. 22 defekt
[PLC_Alarms].ID[61:23] Sensor Reserve Ch. 23 defekt
[PLC_Alarms].ID[62:24] res
[PLC_Alarms].ID[63:25] res
[PLC_Alarms].ID[64:26] Sicherheitsenddruck 1 erreicht
[PLC_Alarms].ID[65:27] Sicherheitsenddruck 2 erreicht
[PLC_Alarms].ID[66:28] Ansaugdruck zu niedrig
[PLC_Alarms].ID[67:29] Ansaugdruck zu hoch
[PLC_Alarms].ID[68:30] ldruck zu niedrig
[PLC_Alarms].ID[69:31] Zwischendruck 1 Stufe min.
[PLC_Alarms].ID[70:32] Zwischendruck 1 Stufe max.
[PLC_Alarms].ID[71:33] Zwischendruck 2. Stufe max.
[PLC_Alarms].ID[72:34] Zwischendruck 3. Stufe max.
[PLC_Alarms].ID[73:35] Zwischendruck 4. Stufe max.
[PLC_Alarms].ID[74:36] Kurbelgehusedruck min.
[PLC_Alarms].ID[75:37] Kurbelgehusedruck max.
final pressure 1 sensor faulty
final pressure 2 sensor faulty
inlet pressure sensor faulty
oil pressure sensor faulty, or rotation wrong
intermediate pressure sensor 1st stage faulty
intermediate pressure sensor 2nd stage faulty
intermediate pressure sensor 3rd stage faulty
intermediate pressure sensor 4rd stage faulty
blow down sensor faulty
cooling water temperatur sensor faulty
level sensor gas balloon faulty
temperatur sensor cooling air faulty
temperatur sensor last stage faulty
temperatur sensor stage 1 faulty
temperatur sensor stage 2 faulty
temperatur sensor stage 3 faulty
temperatur sensor stage 4 faulty
temperatur sensor gasaoutlet faulty
cooling wather temperatur sensor faulty
Sensor Reserve Ch. 19 faulty
Sensor Reserve Ch. 20 faulty
Sensor Reserve Ch. 21 faulty
Sensor Reserve Ch. 22 faulty
Sensor Reserve Ch. 23 faulty
res
res
final pressure 1 high
final pressure 2 high
intake pressure low
intake pressure high
oil pressure low
intermediate pressure 1st stage low
intermediate pressure 1st stage high
intermediate pressure 2nd stage high
intermediate pressure 3rd stage high
intermediate pressure 4rd stage high
blow down pressure low
blow down pressure high

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ID Deutsch [de] English [en]

[PLC_Alarms].ID[76:38] Drucktaupunkt zu hoch Vorwarnung
[PLC_Alarms].ID[77:39] Drucktaupunkt zu hoch / Filterstandzeit
[PLC_Alarms].ID[78:40] Niveau Gasblase zu niedrig
[PLC_Alarms].ID[79:41] Niveau Gasblase zu hoch
[PLC_Alarms].ID[80:42] Temperatur Khlluft zu niedrig
PLC_Alarms].ID[81:43] Temperatur Khlluft zu hoch
PLC_Alarms].ID[82:44] Temperatur LS zu niedrig
PLC_Alarms].ID[83:45] Temperatur LS zu hoch
PLC_Alarms].ID[84:46] Temperatur Stufe 1 zu hoch
PLC_Alarms].ID[85:47] Temperatur Stufe 2 zu hoch
PLC_Alarms].ID[86:48] Temperatur Stufe 3 zu hoch
PLC_Alarms].ID[87:49] Temperatur Stufe 4 zu hoch
PLC_Alarms].ID[88:50] Temperatur Gasaustritt zu hoch
PLC_Alarms].ID[89:51] Khlwassertemperatur min.
PLC_Alarms].ID[90:52] Klwassertemperatur max.
PLC_Alarms].ID[91:53] Reserve Ch.19 min
PLC_Alarms].ID[92:54] Reserve Ch.19 max
PLC_Alarms].ID[93:55] Reserve Ch.20 min
PLC_Alarms].ID[94:56] Reserve Ch.20 max
PLC_Alarms].ID[95:57] Reserve Ch.21 min
PLC_Alarms].ID[96:58] Reserve Ch.21 max
PLC_Alarms].ID[97:59] Reserve Ch.22 min
PLC_Alarms].ID[98:60] Reserve Ch.22 max
PLC_Alarms].ID[99:61] Reserve Ch.23 min
PLC_Alarms].ID[100:62] Reserve Ch.23 max
PLC_Alarms].ID[101:63] lniveau zu niedrig
PLC_Alarms].ID[102:64] Motorschutz / Automatenfall
PLC_Alarms].ID[103:65] Khlsystem gestrt
PLC_Alarms].ID[104:66] Lfter 1 Motorschutz ausgelst
PLC_Alarms].ID[105:67] Lfter 2 Motorschutz ausgelst
PLC_Alarms].ID[106:68] SECURUS gestrt
PLC_Alarms].ID[107:69] SECURUS Filterwechsel Vorwarnung
PLC_Alarms].ID[108:70] SECURUS Filter gesttigt
PLC_Alarms].ID[109:71] SECCANT gestrt
PLC_Alarms].ID[110:72] SECCANT CAN gestrt
PLC_Alarms].ID[111:73] Kltetrockner gestrt
PLC_Alarms].ID[112:74] Kondensatbehlter voll
PLC_Alarms].ID[113:75] Druck in Sammelleitung der Sicherheitsventile pressure in collectorpipe for safetyvalves high
zu hoch
PLC_Alarms].ID[114:76] SECURUS externes Meldegert: Filter gest
tigt
dewpoint / filterlifetime prewarning
dewpoint high / filterlifetime max
level gasballoon low
level gasballoon high
cooling air temperature low
cooling air temperature high
temperatur last stage low
temperatur last stage high
1st stage temperature high
2nd stage temperature high
3rd stage temperature high
4th stage temperature high
gasoutlet temperature high
cooling wather temperatur min.
cooling wather temperatur max.
Reserve Ch.19 min
Reserve Ch.19 max
Reserve Ch.20 min
Reserve Ch.20 max
Reserve Ch.21 min
Reserve Ch.21 max
Reserve Ch.22 min
Reserve Ch.22 max
Reserve Ch.23 min
Reserve Ch.23 max
oillevel low
motorprotection / fuse trip
cooling system faulty
fan 1 motorprotection / fuse trip
fan 1 motorprotection / fuse trip
SECURUS faulty
SECURUS filterchange prewarning
SECURUS filter satturated
SECCANT faulty
SECCANT CAN faulty
air-cool faulty
condensate container full
SECURS external: filter satturated

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ID Deutsch [de] English [en]

PLC_Alarms].ID[115:77] Verbund Slave 1 gestrt Combi slave 1 faulty
PLC_Alarms].ID[116:78] Verbund Slave 2 gestrt Combi slave 2 faulty
PLC_Alarms].ID[117:79] Verbund Slave 3 gestrt Combi slave 3 faulty
PLC_Alarms].ID[118:80] Verbund Slave 4 gestrt Combi slave 4 faulty
PLC_Alarms].ID[119:81] res res
PLC_Alarms].ID[120:82] Gaswarngert gestrt gaswarndevice faulty
PLC_Alarms].ID[121:83] Gaswarnung > 20% gaswarning > 20%
PLC_Alarms].ID[122:84] Gasalarm > 40% gasalarm > 40%
PLC_Alarms].ID[123:85] Not-Aus ATEX ausgelst ATEX emergency off TRIP
PLC_Alarms].ID[124:86] Not-Aus ausgelst emergency off TRIP
PLC_Alarms].ID[125:87] res res
PLC_Alarms].ID[126:88] SECURUS offline SECURUS offline
PLC_Alarms].ID[127:89] X2X-Link gestrt X2X-Bus to the IO-moduls disturbed
PLC_Alarms].ID[128:90] Strmelder gestrt B-Messenger faulty
PLC_Alarms].ID[129:91] Wartung Kompressor fllig compressor maintenance required
PLC_Alarms].ID[130:92] Pufferbatterie leer backup battery empty
PLC_Alarms].ID[131:93] Strungseingang 1 ausgelst alarm input 1 trip
PLC_Alarms].ID[132:94] Strungseingang 2 ausgelst alarm input 2 trip
PLC_Alarms].ID[133:95] Strungseingang 3 ausgelst alarm input 3 trip
PLC_Alarms].ID[134:96] Kompressor 1 gesperrt, manuel. Nachsch Compressor 1 faulty, please lubricate manu
mierung erforderl. ally
PLC_Alarms].ID[135:97] Kompressor 2 gesperrt, manuel. Nachsch Compressor 2 faulty, please lubricate manu
mierung erforderl. ally
PLC_Alarms].ID[136:98] Kompressor 3 gesperrt, manuel. Nachsch Compressor 3 faulty, please lubricate manu
mierung erforderl. ally
PLC_Alarms].ID[137:99] res res
PLC_Alarms].ID[138:100] Softwarelizenz passt nicht zur HW Config fits not to Hardware! -> locked

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NOTES

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