Stationary Integrated Systems

Transcription

1 Instruction Manual and Replacement Parts List Stationary Integrated Systems High Pressure Breathing Air Compressor Units UNICUS III 20 UNICUS III 26 October 22, st Edition, Rev. 2 Chg. 2 MNL Bauer Compressors, Inc. BAUER Compressors, Inc. Phone: (757) Azalea Garden Road Fax: (757) Norfolk, Virginia

2 UNICUS III 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 information and has no obligation to update these materials. This information is Bauer Compressors, Inc., and Bauer reserves to itself all rights to this publication. Bauer s customers have no right to reproduce, rewrite, modify, license or permit anyone else s use of this information, without the express written permission of Bauer Compressors, Inc. ^ WARNING This Instruction Manual and Replacement Parts List contains safety information and instructions for the UNICUS III High Pressure Breathing Air Compressor Units. You must read, understand and follow all safety precautions and instructions. 1st Edition Rev Chg Date Notes Auth 0 0 Nov. 15, 2004 JD 0 1 Feb. 22, 2005 Added Idler Wrench and Leveling Feet JD 0 2 Mar. 8, 2005 Added Air Filter Indicator & Overrun Time JD 0 3 Sept. 22, 2005 Changed 3rd Stage Intermediate Separator to P/N JD 0 4 Nov. 3, 2006 Added CFSII Bottle Riser JD 0 5 Nov. 30, 2006 Changed P/N of Oil Pressure Gauge GAG-0006W to GAG-0042W JD 0 6 Mar. 29, 2007 Change to Separator P/N Life Span JD 0 7 Oct. 30, 2007 Update ACD Solenoid P/N AC DC JD 0 8 July 18, 2008 Added After Cylinder Failure Warning CLA 0 9 Sept. 9, 2008 Converted to Securus II SS 1 0 Nov. 18, 2008 Changed Drive Chapter and P5 Securus II section SS 2 0 July 29, 2009 Converted to Maple System & Siemens electric SS 2 1 Sept. 28, 2009 Fill Hose P/N s SS 2 2 Oct. 22, 2009 Corrected Dryer Cartridge P/N SS Page i 1st Edition, Rev. 2 Chg. 2

3 MNL-0375 Table of Contents CHAPTER 1: INTRODUCTION 1.1 HOW TO USE THIS MANUAL Manual Safety Notices HOW TO USE THE REPLACEMENT PARTS LIST HOW TO USE THE APPENDIX UNIT DESCRIPTION UNIT SPECIFICATIONS UNICUS III Compressor Block, IK 150 II Compressor Drive Purification System Applicability UNICUS III Compressor Block, IK180II Compressor Drive Purification System Applicability COMPONENT LOCATIONS... 7 CHAPTER 2: OPERATING INSTRUCTIONS; MAPLE SYSTEM 2.1 DESCRIPTION Emergency Stop Button Operator Interface Run Screen Home Screen Run Alarms Login Language Choice Adjust Maintenance Setup Tools Contact STARTING AND STOPPING UNIT Before Starting To Start Unit To Stop Unit SCREEN FLOW CHAPTER 3: IK150 II AND IK180 II COMPRESSOR BLOCK 3.1 MAINTENANCE AND PARTS Description Air Flow Diagram Component Location Lubrication System Description October 22, 2009 Page ii

4 UNICUS III Oil Level Check Oil Change Interval Oil Capacity Oil Change Venting the Oil Pump Intake Filter Service Indicator Replacing the Filter Element Intermediate Separators Description Maintenance Compressor Valves and Valve Heads Functional Description Initial Operational Check of the Valves General Instructions for Changing the Valves Changing the 1st Stage Valves Removal Procedure Installation Procedure Changing the 2nd and 3rd Stage Valves Removal Procedure Installation Procedure Changing the 4th Stage Valves Discharge Valve Removal Procedure Discharge Valve Installation Procedure Inlet Valve Removal and Installation Repair and Troubleshooting Repair Troubleshooting Replacement Parts List AUTOMATIC CONDENSATE DRAIN SYSTEM Description Compressor Operating Condensate Draining Start Unloading Standstill Drainage Condensate Drain Piping Condensate Collection ACD Maintenance Replacement Parts List Condensate Collector Replacement Parts List Trouble shooting...74 CHAPTER 4: PURIFICATION SYSTEM 4.1 INTRODUCTION General Purification System Procedures Chamber Safety Bore Manual Condensate Drainage Model, Serial Number and Part Number Identification Compressor Dataplate Purification System Dataplate Cartridge Installation Dataplate Breathing Air Purification System Configurations Industrial Purification System Configurations...78 Page iii 1st Edition, Rev. 2 Chg. 2

5 MNL Cartridge Operating Life Calculating the Maximum Cartridge Operating Hours Calculating the Adjusted Cartridge Operating Hours Air Purification Cartridge Operating Hours Form P5S SECURUS II PURIFICATION SYSTEM P5S Securus II Purification System Major Components COMPONENT DESCRIPTION Oil and Water Separator Chamber Cartridge Cartridge Construction Cartridge Handling Condensate Drain Valve Check Valves Bleed Valve Pressure Maintaining Valve Safety Valve Securus II Electronic Moisture Monitor System Securus Cartridge Securus II Transmitter MAINTENANCE Oil and Water Separator Removal of the Securus II Transmitter Cartridge Replacement Leaking at the Safety Bore REPLACEMENT PARTS LIST CHAPTER 5: COMPRESSOR DRIVE; UNICUS III 5.1 VERTICAL COMPRESSOR DRIVE MAINTENANCE OF THE V-BELT AND SHEAVES Check The Sheaves Check the V-belt Replacing the Belt Replacing the Sheave REPLACEMENT PART LIST CHAPTER 6: ELECTRICAL PANEL, ASY OVERVIEW ELECTRICAL PANEL Wiring Diagram Electrical Panel Interior Access Optional Equipment AC POWER REQUIREMENTS ELECTRICAL PANEL COMPONENTS Programable Logic Controller (PLC) Replacing the PLC Installing a New Program Installing an EEPROM Hourmeter October 22, 2009 Page iv

6 UNICUS III Transformer and Fuses Motor Starter Overload Relay Starter Reset Optional Communication Modules Power Supply ALARMS Final Separator Warning Securus Electronic Moisture Monitor System Securus Cartridge Securus II Transmitter Compressor High Temperature Compressor Low Oil Pressure Compressor Overrun Timer Carbon Monoxide Monitor Alarm Condensate Fault Motor Starter Overload Trip PLC INPUTS AND OUTPUTS Analog Inputs to the PLC WIRING HARNESS LAYOUT REPLACEMENT PARTS LIST PARTS LIST FOR MODELS WITH A 5 HORSEPOWER MOTOR PARTS LIST FOR MODELS WITH A 7½ HORSEPOWER MOTOR PARTS LIST FOR MODELS WITH A 10 HORSEPOWER MOTOR PARTS LIST FOR MODELS WITH A 15 HORSEPOWER MOTOR PARTS LIST FOR MODELS WITH A 20 HORSEPOWER MOTOR TYPICAL WIRING DIAGRAM CHAPTER 7: CARBON MONOXIDE MONITOR 7.1 DESCRIPTION Component Description Isolation Valve High Pressure to Low Pressure Regulator Relief Valve Solenoid Valve Inlet Regulator Carbon Monoxide Monitor Carbon Monoxide Sensor Cell Test Gas Storage CARBON MONOXIDE MONITOR SETUP OPERATION MAINTENANCE Calibrating Carbon Monoxide Monitor Troubleshooting a Calibration Failure Carbon Monoxide Sensor Cell Replacement Carbon Monoxide Monitor Initialization Setting the LP Regulator Initialization Calibration Carbon Monoxide Monitor Test Mode Buttons Page v 1st Edition, Rev. 2 Chg. 2

7 MNL REMOTE DISPLAY SETUP REPLACEMENT PARTS LIST CHAPTER 8: CFS II MAINTENANCE 8.1 DESCRIPTION FILL STATION AIR FLOW MAINTENANCE General Maintenance Nonadjustable Valves Pressure Gauges Safety Valves Pneumatic Connections Bearings for Bottle Door Pivot Pressure Hoses Door Gas Spring REPLACEMENT PARTS LIST CFS II Assemblies Fill Hose Assemblies CHAPTER 9: UNICUS III HP AIR STORAGE 9.1 BOTTLE SPECIFICATIONS D.O.T. Department of Transportation A.S.M.E. American Society of Mechanical Engineers DESCRIPTION AND MAINTENANCE Description Maintenance Storage Bottles Pressure Gauges Tube Connections Safety Valve Pressure Hoses CHAPTER 10: CONTROLS AND INDICATORS 10.1 COMPONENT LOCATIONS CHAPTER 11: APPENDIX 11.1 SAFETY General Safety Precautions Safety Warning Labels UNPACKING, HANDLING AND INSTALLATION Unpacking and Handling Installation of the Compressor Unit Securing and Leveling the UNICUS III Ventilation Outdoor Installation Indoor Installation Natural Ventilation October 22, 2009 Page vi

8 UNICUS III Forced Ventilation Electrical Installation Electric Drive Electrical Supply LONG TERM STORAGE General Preparations Units Equipped with a Filter System Preserving the Compressor Preventive Maintenance During Storage Lubrication Oils for Preservation Reactivating the Compressor Unit REPRODUCIBLE FORMS Scheduled Maintenance Form Record of Operating Hours REFERENCE DATA Tightening Torque Values Torque Sequence Diagrams Conversion Formulas Approved Lubricants Chart Glossary of Abbreviations and Acronyms ADDITIONAL DOCUMENTS Diagrams and Drawings Other Documents Page vii 1st Edition, Rev. 2 Chg. 2

9 MNL-0375 List of Figures CHAPTER 1: INTRODUCTION Figure 1-1 Compressor Identification Plate... 2 Figure 1-2 UNICUS III... 7 Figure 1-3 UNICUS III Front Panel... 8 CHAPTER 2: OPERATING INSTRUCTIONS; MAPLE SYSTEM Figure 2-1 MNR Figure 2-2 Maple System; Run Screen Figure 2-3 Maple System; Home Screen Figure 2-4 Parameter Adjustment Screen Figure 2-5 Adjustment Keypad Figure 2-6 Table of Parameter Values Figure 2-7 Operator Interface Screen Flow CHAPTER 3: IK150 II AND IK180 II COMPRESSOR BLOCK Figure 3-1 Four Stage Compressor Air Flow Figure 3-2 IK150 II Compressor Block (Front View) Figure 3-3 IK180 II Compressor Block (Front View) Figure 3-4 Lubrication Oil System Figure 3-5 Oil Filler Sight Gauge Figure 3-6 Removing the Oil Filter Cover Figure 3-7 Replacing the Oil Filter Figure 3-8 Intake Filter Figure 3-9 2nd Stage Intermediate Separator Figure rd Stage Intermediate Separator Figure 3-11 Valve Function Figure st Stage Valve and Head Figure nd and 3rd Stages Valve Heads and Valves Figure th Stage Valve and Head Figure th Stage Discharge Valve Removal Figure 3-16 Assembly Tool Figure 3-17 Using Special Tool Figure 3-18 Crankcase Assembly Figure 3-19 Complete Crankshaft Assembly Figure 3-20 K150II 1st Stage Piston and Cylinder Figure 3-21 K180II 1st Stage Piston and Cylinder Figure nd Stage Piston and Cylinder Assembly Figure rd Stage Piston and Cylinder Figure th Stage Piston and Cylinder Assembly Figure st Stage Valve Head Assembly Figure nd Stage Valve Head Figure rd Stage Valve Head Assembly October 22, 2009 Page viii

10 UNICUS III Figure th Stage Valve Head Assembly...49 Figure 3-29 Flywheel Drive Assembly...50 Figure 3-30 Intake Filter Assembly...51 Figure nd Stage Interfilter Assembly...52 Figure rd Stage Interfilter Assembly...53 Figure 3-33 IK150 II Cooling System Assembly...54 Figure 3-34 IK180 II Cooling System Assembly...58 Figure nd Stage Intercooler...61 Figure rd Stage Intercooler...62 Figure 3-37 Lubricating System Assembly...63 Figure 3-38 Lubricating System...64 Figure 3-39 Automatic Condensate Drain System...65 Figure 3-40 ACD Operation...66 Figure 3-41 ACD System...68 Figure 3-42 Final Separator Condensate Drain Valve...69 Figure st Stage Separators Condensate Drain Valves...70 Figure 3-44 Manual Condensate Drain Valve...72 Figure 3-45 Condensate Collector...73 CHAPTER 4: PURIFICATION SYSTEM Figure 4-1 Cartridge Safety Venting...76 Figure 4-2 Purification System Dataplates (typical)...76 Figure 4-3 Correction Factor for Cartridge Operating Hours...80 Figure 4-4 Example Record of Adjusted Operating Hours...80 Figure 4-5 P5S Securus II Purification System...82 Figure 4-6 Oil and Water Separator Labels...83 Figure 4-7 Cartridge...84 Figure 4-8 Oil and Water Separator...86 Figure 4-9 Sintered Metal Filter Assembly...86 Figure 4-10 Removal of the Securus II Transmitter...87 Figure 4-11 Cartridge Replacement...88 Figure 4-12 P5 Purification System Parts List...90 Figure 4-13 Oil and Water Separator Parts List...91 Figure Chamber Assembly Parts List...92 Figure 4-15 Securus Electronic Moisture Monitor System Parts List...94 CHAPTER 5: COMPRESSOR DRIVE; UNICUS III Figure 5-1 Vertical Drive with Idler (typical)...96 Figure 5-2 UNICUS III, Vertical Drive with Idler...98 CHAPTER 6: ELECTRICAL PANEL, ASY-1058 Figure 6-1 Figure 6-2 Figure 6-3 Figure 6-4 ASY-1058 and MNR Electrical Panel Label PLC, CNT Connector Block Removal Page ix 1st Edition, Rev. 2 Chg. 2

11 MNL-0375 Figure 6-5 Hourmeter Figure 6-6 Transformer and Fuses Figure 6-7 Motor Starter (typical) Figure 6-8 Overload Relay (typical) Figure 6-9 Optional Communications Modules Figure 6-10 Power Supply Figure 6-11 Securus II Transmitter Figure 6-12 High Temperature Switch Figure 6-13 Pressure Sensor (Typical) Figure 6-14 Carbon Monoxide Monitor Figure 6-15 Condensate Level Float Switch Figure 6-16 Control Pane Figure 6-17 Electrical Panel, Front View Figure 6-18 Electrical Panel, Bottom View Figure 6-19 Electrical Panel, Interior CHAPTER 7: CARBON MONOXIDE MONITOR Figure 7-1 CO Monitor, MNR Figure 7-2 Remote Display Figure 7-3 Carbon Monoxide Monitor Flow Diagram Figure 7-4 Basic Calibration Kit Figure 7-5 Carbon Monoxide Monitor Initialization Figure 7-6 Carbon Monoxide Monitor Internal Components Figure 7-7 Carbon Monoxide Sensor Cell Removal Figure 7-8 Mode Buttons Close-up Figure 7-9 Remote Display Figure 7-10 Carbon Monoxide Monitor Assembly - Standard Figure 7-11 Carbon Monoxide Monitor Schematic CHAPTER 8: CFS II MAINTENANCE Figure 8-1 Safety Valves Figure 8-2 Special Tool, TOO Figure 8-3 CFS II Assembly Figure 8-4 CFS II Door Lock Assembly Figure 8-5 Door Handle, Pivot and Bracket Figure 8-6 CFS II Door Lock Latch Figure 8-7 CFS II Door Interlock Figure 8-8 Standard Fill Hose Assembly Figure 8-9 Multi Fill Hose Assembly CHAPTER 9: UNICUS III HP AIR STORAGE Figure 9-1 UNICUS III Storage System Figure 9-2 Safety Valve October 22, 2009 Page x

12 UNICUS III CHAPTER 10: CONTROLS AND INDICATORS Figure 10-1 Front Panel Figure 10-2 Gauge Panel Figure 10-3 Components for Remote Fill Option Figure 10-4 Front Panel Parts Figure 10-5 Gauge Panel Parts Figure 10-6 Remote Fill Option Parts CHAPTER 11: APPENDIX Figure 11-1 Lifting Devices Figure 11-2 Securing and Leveling the UNICUS III Figure 11-3 Incoming Power Wiring Label Figure Bolt and 4 Bolt Torque Sequence Page xi 1st Edition, Rev. 2 Chg. 2

13 MNL-0375 CHAPTER 1: INTRODUCTION 1.1 How To Use This Manual This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. products listed on the front cover. All instructions in this manual should be observed and carried out as written to prevent damage or premature wear to the product or the equipment served by it. If your unit is equipped with nonstandard accessories and or options, supplemental information is normally included in other documentation; i.e. OEM Manuals or additional Bauer Manuals. While every effort is made to ensure the accuracy of the information contained in this manual, Bauer Compressors, Inc. will not, under any circumstances be held accountable for any inaccuracies or the consequences thereof Manual Safety Notices Important instructions concerning the endangerment of personnel, technical safety or operator safety will be specially emphasized in this manual by placing the information in the following types of safety notices. ^ DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious 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 moderate 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 maintenance technician for proper maintenance and utilization of the equipment. October 22, 2009 Page 1

14 UNICUS III 1.2 How to Use the Replacement Parts List A lozenge in the Item Number column indicates the part number for a complete assembly. a dagger ( ) in the Qty column with or without an ellipse ( ) in the Part Number column means the part is illustrated for assembly purposes only and is not available for sale as an individual component. This part can be obtained by ordering the complete assembly. AR in the Qty column means that the item is cut or manufactured to the size which the customer specifies. A dash ( ) in the Item Number column indicates that there is more than one part number applicable to the preceding Item Number. The letters in the columns labeled Kit indicate the number of operating hours when the part is to be replaced; a = replaced every 1,000 hours, b = replaced every 2,000 hours and c= replaced every 4,000 hours. NS in the Item Number column indicates the part is not illustrated but is available. When placing an order for spare parts, please provide the following information to ensure delivery of the correct parts. The model number, date of manufacture and serial number can be found of the compressor unit identification plate on the compressor unit frame. Information Model Number Example TCom-25 Serial Number Date of Manufacture 02/2005 Quantity required 2 Part Number N04860 Part Description Valve Figure 1-1 Compressor Identification Plate BAUER COMPRESSORS, INC. NORFOLK, VIRGINIA U.S.A BAUER COMPRESSORS MODEL NO. BLOCK NO. SERIAL NO. PRESSURE PSIG CAPACITY CFM CHG. RATE CFM MOTOR HP SPEED RPM VOLTS PH HZ AMPS DATE OF MANUFACTURE LBL-004 Page 2 1st Edition, Rev. 2 Chg. 2

15 MNL-0375 ^ WARNING The use of repair parts other than those included in the Bauer Replacement Parts Lists may create unsafe conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be lifethreatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, Bauer Compressors, Inc. can bear no responsibility for equipment in which unapproved repair parts are installed. 1.3 How to Use the Appendix Information contained in the Appendix to this manual includes the following. The safety instructions applicable to this product. They must be read, understood and complied with prior to operating the product. The instructions for installing this product. They must be read, understood and complied with prior to operating the product. The instructions for long term storage (over 90 days) of this product. Reproducible Forms Reference Data Torque Values Torque Sequence Conversion Formulas Approved Lubricants Glossary of Abbreviations & Acronyms Additional Documents October 22, 2009 Page 3

16 UNICUS III 1.4 Unit Description The BAUER UNICUS III 20 and UNICUS III 26 capacities are 20.4 and 26.4 SCFM charging rate with discharge pressures up to 5,000 PSIG. Standard Features: BAUER Breathing Air Purification System Securus Electronic Moisture Monitoring System Air-cooled Interstage Coolers and Aftercooler Interstage and Final Separator with Manual Drains Interstage and Final Relief Valves Belt Guard designed to meet OSHA guidelines Inlet Filter High Temperature Switch Hourmeter Low Oil Pressure Switch Oil Pressure Gauge Final Pressure Switch Final Pressure Gauge Automatic Condensate Drain Factory Installed Optional Features: The following optional items may have been added if ordered at time of manufacture. Two additional ASME receivers Storage system with DOT cylinders Carbon Monoxide Monitor with Calibration Kit Maintenance Timer Remote Outlet Cabinet Enclosed Hose Reel Page 4 1st Edition, Rev. 2 Chg. 2

17 MNL Unit Specifications All specifications are subject to change without prior notice UNICUS III 20 Medium air Charging Rate 20.4 scfm 1 Free Air Delivery 17.0 scfm 2 Inlet pressure atmospheric Operating pressure, max. 5,000 psig Ambient temperature range 43 to 113 F (5-45 C) Weight approx. 3,350 lbs. (1,508 kgs) Compressor Block, IK 150 II No. of stages 4 No. of cylinders 4 Cylinder bore, 1st stage 4.72 in. (120mm) Cylinder bore, 2nd stage in. (60mm) Cylinder bore, 3rd stage 1.26 in. (32mm) Cylinder bore, 4th stage 0.55 in. (14mm) Piston Stroke 1.97 in.(50mm) Intermediate pressure, 1st stage psig (2-3 bar) Safety valve setting, 1st stage 73 psig (5 bar) Intermediate pressure, 2nd stage psig ( bar) Safety valve setting, 2nd stage 348 psig (24 bar) Intermediate pressure, 3rd stage 928-1,015 psig (64-70 bar) Safety valve setting, 3rd stage 1,160 psig (80 bar) Direction of rotation when facing flywheel CCW Compressor speed RPM Oil capacity 6.36 qts.(6 ltrs) Oil Pressure psig (4-6 bar) Recommended oil BAUER OIL-0024 Maximum Inclination 20 in all directions Compressor Drive Voltage Freq. Phase Power RPM Type -E VAC 60 Hz 3Φ 15 Hp 3,600 ODP Purification System Applicability The Bauer P5 Purification System with Securus II Electronic Moisture Monitoring is the standard purification system supplied. 1. Based on recharging an 80 cubic foot tank from 500 to 3000 PSIG 2. Referenced to standard inlet conditions of 68 F and 36% humidity at psia. October 22, 2009 Page 5

18 1.5.2 UNICUS III 26 Medium air Charging Rate 26.4 scfm 1 Free Air Delivery 22.0 scfm 2 Inlet pressure atmospheric Operating pressure, max. 5,000 psig Ambient temperature range 43 to 113 F (5-45 C) Weight approx. 3,625 lbs. (1,631 kgs) Compressor Block, IK180II No. of stages 4 No. of cylinders 4 Cylinder bore, 1st stage 5.07 in. (130mm) Cylinder bore, 2nd stage in. (60mm) Cylinder bore, 3rd stage 1.26 in. (32mm) Cylinder bore, 4th stage 0.55 in. (14mm) Piston Stroke 1.97 in.(50mm) Intermediate pressure, 1st stage psig (3-4 bar) Safety valve setting, 1st stage 73 psig (5 bar) Intermediate pressure, 2nd stage psig (16-18 bar) Safety valve setting, 2nd stage 348 psig (24 bar) Intermediate pressure, 3rd stage 1,015-1,088 psig (70-75 bar) Safety valve setting, 3rd stage 1378 psig (95 bar) Direction of rotation when facing flywheel CCW Compressor speed RPM Oil capacity 6.36 qts.(6 ltrs) Oil Pressure psig (4-6 bar) Recommended oil BAUER OIL-0024 Maximum Inclination 20 in all directions Compressor Drive Voltage Frequency Phase Power RPM Type -E VAC 60 Hz 3Φ 20 Hp 3,600 ODP UNICUS III Purification System Applicability The Bauer P5 Purification System with Securus II Electronic Moisture Monitoring is the standard purification system supplied. 1. Based on recharging an 80 cubic foot tank from 500 to 3000 PSIG 2. Referenced to standard inlet conditions of 68 F and 36% humidity at psia. Page 6 1st Edition, Rev. 2 Chg. 2

19 MNL Component Locations Figure 1-2 UNICUS III Remote Fill Panel (Option) 2. Remote Fill Hose (Option) 3. Cascade Panel 4. Compressor Control Panel 5. Emergency Stop Switch 6. Fill Station Controls 7. Maintenance Access 8. Fill Station October 22, 2009 Page 7

20 UNICUS III Figure 1-3 UNICUS III Front Panel Cascade Storage Pressure Gauges 2. Cascade Valves 3. Fill Select Valve 4. Inlet Pressure Gauge 5. Fill Regulator 6. Final Pressure Gauge 7. Compressor Control Panel 8. Emergency Stop Switch 9. Fill Valves 10. Bottle Fill Pressure Gauges Page 8 1st Edition, Rev. 2 Chg. 2

21 MNL-0375 CHAPTER 2: OPERATING INSTRUCTIONS; MAPLE SYSTEM 2.1 Description The following instructions apply to units that use the Maple System touchscreen Operator Interface, MNR The Electrical Panel Assembly will provide logical control and safety shutdowns for the compressor equipment. All necessary time delays, counters, shutdowns, sequencing and safety features are incorporated into a proprietary software program permanently saved into PLC memory using EEPROM technology. The software program is based on the pressure and use of the compressor. The operator uses the Operator Interface to communicate with the PLC in the Electrical Panel Assembly Controls Emergency Stop Button A Normally Closed switch when pulled out, when the E-Stop Button is pressed in, it disconnects the main power source, turning off the compressor, draining the ACD system and stopping air delivery to the consuming devices. This button is to be used in case of emergency. Normal operational stops should be accomplished using the operator interface Operator Interface The Operator Interface is a 4.3 inch, 256 color, 8 bit LCD with touchscreen operation. The Operator Interface is the input/output device for normal operation of the compressor unit. The compressor system is ready and able to operate after the Emergency Stop Switch is pulled out and the Operator Interface status lights and screen illuminates. Figure 2-1 MNR-0049 October 22, 2009 Page 9

22 UNICUS III Run Screen The inital screen after startup allows control and monitoring of the compressor unit. Figure 2-2 Maple System; Run Screen Compressor Status Indicator 2. Oil Pressure Reading 3. START Button 4. OFF Button 5. Closes Window (goes to HOME Screen) 6. Inlet Pressure (optional) 7. Alarm Indicator 8. Securus Status (optional) 9. CO Monitor Status (optional) 10. Outlet Air pressure 1. Tells weather the compressor is turned ON or OFF 2. Gives a continuous pressure reading for the compressor. This reading is taken from the oil pressure sensor on the compressor block. 3. The START and STOP buttons control the compressor. These buttons should be used for normal starting and stopping of the compressor. In an emergency the Emergency Stop button should be used. 4. This reading tells when the next maintenance is due on the compressor. 5. This X button closes the Run Screen and goes to the Home Screen. The compressor may still be operating when returning to the Home Screen. 6. In this space a continuous inlet pressure reading is provided if the unit is equipped with an inlet pressure sensor. 7. Alarms and warnings are shown if this button is pressed. 8. If the unit is equipped with a Securus monitor, the status of the Securus sensor shows here. 9. If the unit is equipped with a CO monitor, the status of the CO monitor is shown here. Page 10 1st Edition, Rev. 2 Chg. 2

23 MNL This figure shows the present output pressure Home Screen Figure 2-3 Maple System; Home Screen Run Button 2. Alarms Button 3. Login Button 4. Language Options 5. Adjustment Button 6. Maintenance Button 7. Setup Button 8. Tools Button 9. Contact Information The home screen is the main screen used to navigate to any of 10 options. To enter any of the critical options (Adjust, Setup, & Tools) which change the functions of the compressor, a login number must be entered. This feature is added to prevent unintentional changes to the unit s functions Run This button returns the user to the RUN screen, See Paragraph for further information Alarms This button displays the present alarms and allows the user to silence the alarm or reset the alarm once the fault condition has been rectified Login The login button allows the user to enter the access code. Only after the access code is entered can the following areas within the program be viewed or changed: Adjust Parameters Screen, Setup Screen, or Tools Screen Language Choice The two language buttons let the user select English or Spanish. The screens and functions remain the same, the only difference is the language displayed on the screen Adjust This button can only be accessed after using the login code. If not logged in this button will not function. The ADJUST button takes the user to the parameter adjustment pages. To change a parameter just touch the number which needs to be changed and a keypad will pop up. Punch in the new number and press the ENT key. Pressing the X button will return to the Home screen. October 22, 2009 Page 11

24 UNICUS III Another feature on this page is the PSI/BAR button. Pressures can only be set in PSI, however the displayed pressure on the RUN screen can be set to read PSI or translate it into Bar Figure 2-4 Parameter Adjustment Screen Figure 2-5 Adjustment Keypad Maintenance This button leads to the Maintenance screen. Here the maintenance tasks can be looked at in terms of hours of operation or in terms of calendar days. See Table 2-1 and 2-2 at the end of this chapter. ^ NOTE ^ All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme conditions like high temperatures or high humidity may shorten the intervals significantly. If in doubt, please contact the Bauer Product Support Department. Maintenance Records We recommend that all maintenance work be recorded, showing the date and details of the work carried out. This will help to avoid expensive repairs caused by missed maintenance work. If it is necessary to make a claim against the warranty, it will help to have proof that regular maintenance has been carried out and that the damage has not been caused by insufficient maintenance. Calendar Maintenance Intervals Each Calendar Interval Task includes all tasks in the previous Calendar Interval, i.e. All the Monthly Tasks are done along with the Annual Tasks. Operating Hours Maintenance Intervals Each Operating Hours Task includes all tasks in the previous Operating Hours Interval, i.e. All the 500 Hour Tasks are done along with the 1,000 Tasks Setup This button can only be accessed after using the login code. If not logged in this button will not function. The Setup button is used to setup the features of the unit such as CO monitor and Securus moisture monitoring system. This page offers the opportunity to turn on and off the features in the PLC program. Also they type of unit is set on the second page. When done press the X to return to the Home screen Tools The tools button is used for maintenance purposes. To use the Tools button the user must be logged in. Also the unit must be shutdown. Page 12 1st Edition, Rev. 2 Chg. 2

25 MNL Contact Pressing the contact button displays contact information for Bauer Compressors, Inc. 2.2 Starting and Stopping Unit Before Starting. 1. Check the compressor oil level, See Chapter Ensure that all panels and guards are properly installed. 3. Ensure that all doors are closed. 4. Ensure that the E-Stop Button is pulled out To Start Unit. Press the START Button on the Run Screen. (See Figure 2-2) If the pressure in the system is lower than the Start Pressure, the compressor will start. If the System pressure is higher or when the air pressure has increased to operating pressure, the compressor will automatically shutdown. The Compressor will automatically restart when the pressure drops below the Start Pressure To Stop Unit. Press the STOP Button on the Run screen. ^ WARNING Once started the compressor and drive motor will start and stop automatically. Stay clear of all moving parts whenever unit has power. ^ NOTE ^ In an emergency the compressor is shutdown by pressing in the E-Stop Button. October 22, 2009 Page 13

26 . UNICUS III Figure 2-6 Table of Parameter Values Parameter Default Low High Units PASSWORD access # s supplied by distributor 1,328 9, START PRESS SHUTDOWN PRESS SEPCNTWARNING SEPCNTALARM OVERRUNTIMER SHUTDOWNDELAY ACDF TEST TIME CO ALARM DELAY a. 15% of Shutdown Press lower pressure limit which starts compressor upper pressure limit which stops compressor # of cycles till final separator replacement warning given # of cycles till final separator replacement alarm shutdown amount of time before unit shuts down if left unattended delaye from when command is given till shtudown occurs amount of time on button held to perform ACD test time between alarm level reached and alarm gien 5,800 a 800 5,700 PSI 6, ,000 PSI 53,000 1, ,000 53,000 2,000 1,000, HRS SEC SEC SEC OIL ALARM psi at which low oil press. alarm given PSI SEPCNT RESET current # of cycles for final separator 0 1,000,000 ACD1 DELAY ON dely till ACD1 closes SEC ACD1 DRAIN TIME length of time ACD1 drains SEC ACD1 CYCLE TIME length of time between ACD1 drain cycles MIN ACD2 DELAY ON dely till ACD2 closes SEC ACD2 DRAIN TIME length of time ACD2 drains SEC ACD2 CYCLE TIME length of time between ACD2 drain cycles MIN ACD3 DELAY ON dely till ACD3 closes SEC ACD3 DRAIN TIME length of time ACD3 drains SEC ACD3 CYCLE TIME length of time between ACD3 drain cycles MIN ACDF DELAY ON delay till final ACD closes SEC ACDF DRAIN TIME length of time final ACD drains SEC ACDF CYCLE TIME length of time between final ACD drain cycles MIN BACKLIGHT ON Panel light option MIN OIL PRESS TIME time delay from startup till oil SEC DELY (TD) press. sensor is used Page 14 1st Edition, Rev. 2 Chg. 2

27 MNL-0375 Table 2-1: Calendar Maintenance Interval Tasks Task Monthly Annually Every Two Years Calibrate CO Monitor Check Oil Level Check Final Pressure Shutdown Check Automatic Condensate Drain X X X X Check V-belt Service Intake Filter Check all connections for leaks Inspect Compressor Valves Check all fasteners for tightness X X X X X Change Synthetic Oil Replace Compressor Oil Filter Replace Compressor Valves Replace CO Monitor Sensor X X X X October 22, 2009 Page 15

28 UNICUS III Table 2-2: Operating Hours Maintenance Interval Tasks Task 500 Hours 1,000 Hours 2,000 Hours 3,000 Hours Check Oil Level Check Final Pressure Shutdown Check Automatic Condensate Drain Check V-belt Service Intake Filter Check all connections for leaks Check fasteners for tightness X X X X X X X Inspect Compressor Valves X Change Synthetic Oil Replace Oil Filter Replace Compressor Valves X X X Inspect Pistons and Pistons Rings X Page 16 1st Edition, Rev. 2 Chg. 2

29 MNL Screen Flow Figure 2-7 Operator Interface Screen Flow October 22, 2009 Page 17

30 CHAPTER 3: 3.1 Maintenance and Parts IK150 II AND IK180 II COMPRESSOR BLOCK Description The IK150 II or IK180 II compressor is used to compress air up to 5000 psi. UNICUS III The IK150 II or IK180 II compressor is a four cylinder, four stage air cooled, oil lubricated reciprocating compressor. The 4th stage cylinder is lubricated by means of the forced feed lubrication system, while the other cylinders are splash lubricated. The cylinders are arranged 90 apart, with the 1st and 2nd stage, and the 3rd and 4th stage opposite each other. These compressor blocks are particularly suitable for continuous operation because of their rugged design and corrosion resistant intermediate filter and cooler assemblies Air Flow Diagram Figure 3-1 Four Stage Compressor Air Flow I IV III II Intake Manifold 2. 1st Stage Cooler 3. 2nd Stage Cooler 4. 3rd Stage Cooler 5. Aftercooler 6. 2nd Stage Separator rd Stage Separator 8. Final Separator 9. Manual Condensate Drain Valve 10. Safety Valves 11. Pressure Maintaining Valve (PMV) 12. Compressed Air Outlet Page 18 1st Edition, Rev. 2 Chg. 2

31 MNL Component Location Figure 3-2 IK150 II Compressor Block (Front View) Service Indicator 2. Intake Filter 3. Crankcase Vent Feedback Line 4. 1st Stage Cylinder 5. 2nd/3rd Inter Stage Pressure Valve 6. 2nd Stage Separator 7. 2nd Stage Cooler 8. Oil Pump Housing 9. 3rd Stage Cylinder 10. Compressed Air Outlet 11. Lifting Eyebolt st Stage Inter Cooler 13. 4th Stage Cylinder 14. 4th Stage After Cooler 15. Oil Pressure Regulating Valve 16. 3rd/4th Inter Stage Pressure Valve 17. 3rd Stage Separator 18. 1st/2nd Inter Stage Pressure Valve 19. 3rd Stage Cooler 20. 2nd Stage Cylinder 21. Oil Filler with Sight Glass 22. Condensate Outlet October 22, 2009 Page 19

32 UNICUS III Figure 3-3 IK180 II Compressor Block (Front View) Service Indicator 2. Intake Filter 3. Crankcase Vent Feedback Line 4. 1st Stage Cylinder 5. 2nd/3rd Inter Stage Pressure Valve 6. 2nd Stage Separator 7. 2nd Stage Cooler 8. Oil Pump Housing 9. 3rd Stage Cylinder 10. Compressed Air Outlet 11. Oil Drain Plug 12. Lifting Eyebolt 13. 1st Stage Auxiliary Cooler 14. 1st Stage Inter Cooler 15. 4th Stage Cylinder 16. 4th Stage After Cooler 17. Oil Pressure Regulating Valve 18. 3rd/4th Inter Stage Pressure Valve 19. 3rd Stage Separator 20. 1st/2nd Inter Stage Pressure Valve 21. 3rd Stage Cooler 22. 2nd Stage Cylinder 23. Oil Filler with Sight Glass 24. Condensate Outlet Page 20 1st Edition, Rev. 2 Chg. 2

33 MNL Lubrication System Description. The compressor is provided with forced-feed lubrication. The oil pressure is produced by a low revving gear pump. The oil pressure is between 44 psi and 87 psi (3 to 6 bar). ^ CAUTION This oil pump must be operated in the correct direction of rotation, other wise no oil pressure will be built up and the compressor may be damaged. (See Figure 3-4) The oil pump (1) is coupled to and driven by the crankshaft. It pumps oil from the crankcase through an oil filter (2) and the oil pressure regulating valve (3) to the 4th stage cylinder. The oil is then distributed by the guide piston of the 4th stage and lubricates all the moving parts of the compressor block. The oil pressure sensor (5) allows mounting for an optional oil pressure gauge or electronic pressure monitoring. Figure 3-4 Lubrication Oil System Oil Pump 2. Oil Filter 3. Oil Pressure Regulating Valve 4. Injection Line to 4th Stage 5. Oil Pressure Sensor Oil Level Check (See Figure 3-5). Check the oil level at the oil filler sight gauge on the compressor block every day before putting the compressor into operation. Oil level must never be below the minimum mark molded into the sight gauge as this will cause severe damage due to lack of lubrication. Overfilling is prevented by the design of the filler neck; i.e. oil should be filled right to the edge of the opening. October 22, 2009 Page 21

34 UNICUS III Figure 3-5 Oil Filler Sight Gauge Max Min Oil Change Interval The synthetic oil should be changed every 2,000 operating hours or biennially, whichever is reached first Oil Capacity The oil capacity is approximately 6.5 quarts (6.0 liters). The amount of oil between the minimum and maximum marks is approximately 1.7 quarts (1.6 liters) Oil Change 1. Run the compressor until it is warm. 2. Remove cap from Oil Filler Sight Gauge. 3. Open the Oil Drain Plug. 4. (See Figure 3-6) Remove two bolts (1) with a 13 mm wrench. Remove cover (2). 5. (See Figure 3-7) Remove the Oil Filter (1) from the rubber gasket at the cover. 6. Mount a new filter element and replace and fasten cover. 7. Fill new oil through filler neck to the Maximum mark on the Oil Fill Sight Gauge. 8. Pour oil in slowly, wait a few minutes until the level settles then replace cap in the Oil Fill Sight Gauge. 9. Return the unit to operation. ^ CAUTION Replace the oil filter at every oil change, otherwise when the filter becomes clogged a bypass valve opens and the oil circulates without being filtered. Page 22 1st Edition, Rev. 2 Chg. 2

35 MNL-0375 Figure 3-6 Removing the Oil Filter Cover Figure 3-7 Replacing the Oil Filter Venting the Oil Pump (See Figure 3-7). If after the start of the compressor no oil pressure builds up, venting the oil pump may be necessary, especially after maintenance and repair work. It may also be necessary if the unit has been operated in the wrong direction of rotation. 1. With the unit running, open the condensate drain valves. 2. Open Oil Pump Vent Plug (2) and wait until oil comes out bubble free. 3. Replace Oil Vent Plug. ^ CAUTION To avoid damage after maintenance the following measures should be strictly adhered to. October 22, 2009 Page 23

36 UNICUS III Intake Filter Figure 3-8 Intake Filter Service Indicator 2. Cover A dry micronic filter is used to filter intake air Service Indicator The vacuum in the intake filter is monitored by the Service Indicator (1). When the preset vacuum pressure is reached the indicator changes to red and the Filter Element (3) should be replaced Replacing the Filter Element See Figure 3-8 and proceed as follows. 1. Open clips on Filter Housing (4) and remove Cover (2). 2. Remove the Filter Element (3). 3. Clean the inside of the Filter Housing with a damp cloth. Take care to prevent any dust from entering the intake manifold. 4. Replace the Filter Element (3). 5. Mount the Cover (1) and fasten with the clips. 6. Reset the Service Indicator (1) by pressing the button Filter Element 4. Filter Housing Page 24 1st Edition, Rev. 2 Chg. 2

37 MNL-0375 Figure 3-9 2nd Stage Intermediate Separator Figure rd Stage Intermediate Separator Separator Body 2. Separator Head 3. Knurled Nut 4. O-ring 5. Center Insert 6. Gasket 7. Fitting 8. Safety Valve 1. Plate 2. Hollow Screw 3. Center Insert 4. O-ring 5. Knurled Nut 6. Gasket 7. Fitting 8. Safety Valve ^ WARNING Dynamic Loading The rapid depressurizing and repressurizing of an intermediate separator during condensate draining subjects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury or death the intermediate separator must be replaced after 85,000 load cycles. A load cycle equals one depressurization- repressurization. The Bauer recommended frequency of condensate draining is every fifteen minutes and is a balance between maximizing the life of the separator chamber and maintaining the quality of the delivered air. October 22, 2009 Page 25

38 3.1.4 Intermediate Separators UNICUS III Description Two intermediate separators are mounted on the compressor, one after the 2nd stage and another after 3rd stage. These separators are designed to remove oil and water which accumulates due to the cooling of the air after the compression process. Separation is achieved by means of centrifugal action. In the 2nd stage separator the design of the filter head provides this action. In the 3rd stage separator the centrifugal action is provided by a vortex plate additionally a sintered metal filter is provided to remove dirt contamination Maintenance The Intermediate Separators require no maintenance Compressor Valves and Valve Heads Functional Description The valve heads of the individual stages form the upper part of the cylinders. The inlet and pressure valves are fitted inside the valve heads. When the piston moves downwards, the resultant vacuum in the piston cylinder opens the inlet valve. When the piston moves upwards, the inlet valve is closed and the pressure valve opened by the pressure created in the compression process. See Figure Figure 3-11 Valve Function Intake Discharge Initial Operational Check of the Valves After roughly half an hour of operation, the valves should be checked. The outlet piping should be hot if the valves are operating properly. Note that the inlet line to the valve heads should be warm to the touch. ^ WARNING Do not touch the outlet piping with bare hands, use a thermometer. Page 26 1st Edition, Rev. 2 Chg. 2

39 MNL General Instructions for Changing the Valves Please observe the following instructions for valve maintenance: 1. Always replace valves as a complete set. 2. Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in Varsol and clean with a soft brush. 3. Check the individual components for excessive wear. If the valve seat or valve discs are dented, replace the valves. 4. Check the valve space in the valve heads for dirt, and clean if necessary. 5. Use only satisfactory gaskets and O-rings during reassembly. 6. Observe the correct sequence when reassembling. 7. After finishing all maintenance work on the valves, turn the compressor manually using the flywheel and check whether all items have been correctly installed minutes after restarting the compressor, stop the unit, let it cool down to ambient temperature, and retighten valve studs and cap nuts. Otherwise the gasket set may cause a leak. 9. Remove and check the valves every 1000 operating hours. 10. Replace the valves every 2000 operating hours to avoid fatigue failure. 11. Use an assembly tool (Bauer P/N: ) for all work on valve heads (See Figure 3-16) Changing the 1st Stage Valves. Figure st Stage Valve and Head October 22, 2009 Page 27

40 Removal Procedure. 1. See Figure Unscrew and remove cap nuts (4) and washers (3). 2. Remove Valve Head Assembly (1) from studs in cylinder. 3. Remove Valve (2) and unscrew and remove center screw (6) and washer (5) Installation Procedure 1. Fasten new Valve (2) with center screw (6) and washer (5). 2. Place assembled Valve Head (1) on studs in the cylinder. 3. Install washers (3) and cap nuts (4) and tighten to the torque value listed in the Appendix Changing the 2nd and 3rd Stage Valves See Figure 3-13 UNICUS III Figure nd and 3rd Stages Valve Heads and Valves Hex Nut 2. Cap Holder 3. Valve Caps Removal Procedure 1. Unscrew and remove hex nut (1). 2. Remove cap holder (2). 3. Insert two screwdrivers into the extraction grooves (4) of the valve caps (3) and lift out the valve caps with O-Rings (5). 4. Check and replace O-Rings if required. 5. Take out valves (6 & 9). 4. Extraction Groove 5. O-Rings 6. Inlet Valve 6. Check the valve gaskets (7) and replace if required Valve Gaskets 8. Valve Head 9. Discharge Valve Installation Procedure Page 28 1st Edition, Rev. 2 Chg. 2

41 MNL Fit valves(6 & 9) with gaskets (7) and replace. 2. Fit valve caps (3) with O-Rings (5) and replace. 3. Replace cap holder (2) in the proper position. ^ CAUTION The valve cap for the inlet valve protrudes 0.98 in (2.5 mm) out of the valve head more than the valve cap for the discharge valve. The cap holder is designed accordingly. 4. Screw on hex nut (1) and tighten with a torque wrench to the torque value listed in the Appendix Changing the 4th Stage Valves See Figure 3-14 ^ CAUTION Always change the intake and discharge valves of the 4th stage at the same time. Figure th Stage Valve and Head Inlet Valve 2. Valve Head 3. Discharge Valve 4. O-ring 5. Valve Cover 6. Gasket 7. Socket Head Screw 8. Stud 9. Gasket 10. Acorn Nut 2 1 October 22, 2009 Page 29

42 UNICUS III Discharge Valve Removal Procedure Figure th Stage Discharge Valve Removal 1. Remove piping connected to the 4th Stage Valve Head. 2. Remove Acorn Nut (1) and unscrew Stud (3) three or four turns. 3. Remove the Socket Head Screws (9) and remove the Valve Cover (8). 4. Loosen the Discharge Valve (5) first by turning it with a 13 mm wrench on the flat surfaces. 5. Put two screwdrivers into the groove of the Discharge Valve body. See Figure Lift out Discharge Valve together with the O-ring (4) Discharge Valve Installation Procedure 1. Check condition of O-ring (4) and replace if necessary 2. Put O-ring (4) into Valve Head (7). 3. Insert Discharge Valve (5) into Valve Head (7). 4. Put on Valve Cover (8). 5. Screw in Socket Head Screws (9) and tighten to the torque value listed in the Appendix 6. Tighten Stud (3) and replace Gasket (2). 7. Tighten Acorn Nut (1) with a torque wrench to the value listed in the Appendix. Page 30 1st Edition, Rev. 2 Chg. 2

43 MNL Inlet Valve Removal and Installation Figure 3-16 Assembly Tool Figure 3-17 Using Special Tool 1. If the assembly tool shown in Figure 3-16 is unavailable, place two 8 mm diameter metal pins of any length in the holes of the Valve Head (7) and secure them in a vise with the Inlet Valve (6) facing up. 2. Unscrew the Inlet Valve (6) from the Valve Head (7) using the special tool (Bauer P/N ) supplied with your unit. See Figure Repair and Troubleshooting ^ CAUTION Avoid damaging the special tool or the valve when using the tool, ensure that it is pushed firmly and properly into the sockets in the valve so that it will not tilt when it is turned Repair Repair work can be carried out on the compressor block to a certain extent but a certain level of experience and skill is necessary. It should be noted however that no repair should be carried out on the crankshaft nor on the bearings and safety valves are not repaired but always replaced October 22, 2009 Page 31

44 UNICUS III Troubleshooting Trouble Cause Remedy No oil pressure 11. Low oil level 12. Air trapped in oil pump. 1. Check oil level 2. Vent Oil Pump Oil foam in crankcase Compressor output insufficient 1. Last stage piston worn 2. Last stage pressure valve defective 1. Condensate drain valves or fittings leaking. 2. Premature opening of final safety valve. 3. Piston rings worn 4. Excessive piston clearance 5. Pipes leaking 1. Operate compressor with final stage valve head removed. If oil flows continuously out of cylinder, replace piston and sleeve. 2. Replace last stage valves. 1. Tighten and reseal. 2. Clean and adjust final safety valve. 3. Replace 4. Replace 5. Tighten Safety valves between stages releasing pressure 1. Intermediate pressure too high 2. Valves not closing properly 1. Service and clean valves. 2. Service and clean valves. Compressor running too hot. Oil residue in delivered air Compressor rotates in the wrong direction 1. Insufficient supply of cooling air 2. Intake or outlet valve not closing properly 3. Wrong direction of rotation. 1. Improper maintenance of filters, purifier cartridge saturated. 2. Wrong oil type Electrical phases not connected properly 1. Check location for adequate ventilation 2. Check and clean valves, replace as necessary 3. Check arrow on compressor and correct accordingly. 1. Service filters, change purifier cartridge. 2. Change to proper oil and clean valves. Reverse two of the three phase leads at the switch box. Do NOT change the leads at the motor terminal. Page 32 1st Edition, Rev. 2 Chg. 2

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46 UNICUS III Replacement Parts List Figure 3-18 Crankcase Assembly # KIT Qty Part No. Description Notes Crankcase Assembly 1 1 N20649 Screw Cover Plate 3 1 N15093 O-ring 4 1 N26281 Shaft Seal 5 1 N370 Self Locking Hex Nut 6 6 N58 Washer Bearing Cover 8 6 N3138 Stud 9 1 N18303 Roller Bearing 10 1 N3810 Circlip 11 1 N18304 Roller Bearing 12 1 N18432 Circlip 13 1 N2635 Circlip Page 34 1st Edition, Rev. 2 Chg. 2

47 MNL-0375 Figure 3-18 (cont.) Crankcase Assembly # KIT Qty Part No. Description Notes Gasket 15 1 N2638 Roller Bearing 16 1 N4467 Eye Bolt Washer Hexagonal Spacer 19 1 N4150 Stud Reducer 21 1 N293 Gasket 22 1 N204 Plug N16 Washer N312 Hex Head Screw Bracket 26 2 N4261 Gasket 27 2 N2796 Plug 28 1 N25638 Ball Valve 29 1 N1316 Gasket 30 1 N4570 Plug 31 8 N102 Washer 32 8 N19497 Hex Screw Crankcase Oil Sight Gauge Assembly Items N15412 O-ring Plug Gasket Oil Fill Steel Plate Steel Plate 41 1 N1314 Gasket October 22, 2009 Page 35

48 UNICUS III Figure 3-19 Complete Crankshaft Assembly # KIT Qty Part No. Description Notes Crankshaft Assembly IK150 II Only Crankshaft Assembly IK180 II Only Bushing 3 1 N4366 Dowel Screw 4 1 N108 Spring Washer 5 1 N2765 Hex Nut Spacers 7 1 N18310 Circlip 8 1 N423 Circlip Page 36 1st Edition, Rev. 2 Chg. 2

49 MNL-0375 Figure 3-20 K150II 1st Stage Piston and Cylinder # KIT Qty Part No. Description Notes st Stage Piston & Cylinder Asy 120 mm Diameter Cylinder 120 mm Diameter 2 1 N2621 O-ring 3 4 N26036 Stud Piston Assembly 120 mm Diameter Piston 6 1 N2930 Pin, Piston 7 2 N484 Ring, Retaining 8 1 N2963 Piston Ring Set 120 mm Diameter October 22, 2009 Page 37

50 UNICUS III Figure 3-21 K180II 1st Stage Piston and Cylinder # KIT Qty Part No. Description Notes st Stage Piston & Cylinder Asy 130 mm Diameter Cylinder 130 mm Diameter 2 1 N2621 O-ring 3 4 N26036 Stud Piston Assembly 130 mm Diameter Piston 6 1 N4109 Pin, Piston 7 2 N484 Ring, Retaining 8 1 N4642 Piston Ring Set 130 mm Diameter Page 38 1st Edition, Rev. 2 Chg. 2

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52 UNICUS III Figure nd Stage Piston and Cylinder Assembly Page 40 1st Edition, Rev. 2 Chg. 2

53 MNL-0375 # KIT Qty Part No. Description Notes nd Stage Piston and Cylinder Assembly Cylinder 2..c 1 N3731 O-ring 3 4 N215 Stud 4 4 N58 Washer, Flat 5..c 4 N370 Nut, Hex, Lock Compressor Piston Assembly 7 1 N2907 Piston 8 1 N1429 Pin, Piston 9 2 N484 Circlip 10 1 N1461 Piston Ring Set October 22, 2009 Page 41

54 UNICUS III Figure rd Stage Piston and Cylinder # KIT Qty Part No. Description Notes Piston and Cylinder Assembly Cylinder Guide 60 mm Diameter 2..c 1 N3731 O-ring Cylinder 32 mm Diameter 4..c 1 N7063 O-ring 5 4 N17462 Stud M8 x 80 Page 42 1st Edition, Rev. 2 Chg. 2

55 MNL-0375 Figure 3-23 (cont.) 3rd Stage Piston and Cylinder # KIT Qty Part No. Description Notes 6 4 N58 Washer, Flat 8 mm 7..c 4 N370 Nut, Hex, Lock M Piston, Guide Assembly 60 mm Diameter Piston, Guide 10 1 N15409 Pin, Piston 11 2 N1665 Circlip Piston, Floating Assembly 13 1 N4378 Piston, Floating 14 1 N16313 Piston Ring Set 32 mm Diameter October 22, 2009 Page 43

56 UNICUS III Figure th Stage Piston and Cylinder Assembly # KIT Qty Part No. Description Notes th Stage Cylinder Assembly Piston Assembly 2 1 N3731 O-ring Guide Cylinder 4 1 N7063 O-ring Cylinder 6 1 N4868 O-ring Piston and Sleeve Assembly 8 1 N23755 O-ring 9 1 N25376 Piston Ring Set Page 44 1st Edition, Rev. 2 Chg. 2

57 MNL-0375 Figure 3-24 (cont.) 4th Stage Piston and Cylinder Assembly # KIT Qty Part No. Description Notes 10 4 N370 Self Locking Hex Nut 11 4 N58 Washer 12 4 N17462 Stud October 22, 2009 Page 45

58 UNICUS III Figure st Stage Valve Head Assembly # KIT Qty Part No. Description Notes st Stage Valve Head Assembly 1 1st Stage Valve Head 2 1 N26029 Plate Valve 3 4 N16 Washer 4 4 N644 Self Locking Hex Nut 5 1 N58 Washer 6 1 N150 Allen Screw M8 x 60 Page 46 1st Edition, Rev. 2 Chg. 2

59 MNL-0375 Figure nd Stage Valve Head EIN 9 AUS # KIT Qty Part No. Description Notes nd Stage Valve Head Assembly nd Stage Valve Head 2 6 N503 Socket Head Cap Screw 3.b. 1 N4067 Valve, Inlet 4.b. 1 N4068 Valve, Discharge 5 a Gasket, Valve Cap, Valve 7 a.. 2 N3997 O-ring Press Pad 9 2 N4190 Stud 10 2 N16 Washer, Flat 11 a.. 2 N3474 Nut, Hex Lock October 22, 2009 Page 47

60 UNICUS III Figure rd Stage Valve Head Assembly EIN 9 AUS # KIT Qty Part No. Description Notes rd Stage Valve Head Assembly rd Stage Valve Head 2 6 N503 Socket Head Cap Screw 3.b. 1 N15273 Valve, Inlet 4.b. 1 N15274 Valve, Discharge 5 a Gasket, Valve Cap, Valve 7 a.. 2 N3997 O-ring Press Pad 9 2 N4190 Stud 10 2 N16 Washer, Flat 11 a.. 2 N3474 Nut, Hex Lock Page 48 1st Edition, Rev. 2 Chg. 2

61 MNL-0375 Figure th Stage Valve Head Assembly # KIT Qty Part No. Description Notes th Stage Valve Head Assembly 1.b Intake Valve Valve Head Discharge Valve 4.b. 1 N2789 O-ring Valve Head Cover 6 6 N58 Washer 7 6 N17730 Allen Screw 8 1 N2738 Stud 9 a.. 1 N3625 Gasket 10 1 N3589 Acorn Nut October 22, 2009 Page 49

62 UNICUS III Figure 3-29 Flywheel Drive Assembly # KIT Qty Part No. Description Notes Flywheel Drive Assembly V-belt Pulley Fan Blade Support Blade, Fan CCW 4 12 N19495 Hex Head Screw M6 x N100 Washer, Split Lock 6 mm Washer 7 1 N280 Washer, Split Lock 8 1 N15667 Hex Head Cap Screw M12 x 45 Page 50 1st Edition, Rev. 2 Chg. 2

63 MNL-0375 Figure 3-30 Intake Filter Assembly # KIT Qty Part No. Description Notes Intake Filter Assembly Manifold, Air Intake 2 3 N171 Socket Head Cap Screw Housing, Intake Filter Flange 5 3 N19535 Allen Screw 6 a.. 1 N25886 Element, Intake Filter Cover, Filter Housing 8 1 N2221 Indicator, Maintenance October 22, 2009 Page 51

64 UNICUS III Figure nd Stage Interfilter Assembly # KIT Qty Part No. Description Notes Interfilter Assembly 1 Filter Housing Available only with Filter Head Available only with Collar, Threaded Knurled 4 1 N3556 O-ring Tube and Baffle 6 1 N1316 Gasket, Copper 7 1 N20215 Fitting Safety Valve 6 7 Page 52 1st Edition, Rev. 2 Chg. 2

65 MNL-0375 Figure rd Stage Interfilter Assembly # KIT Qty Part No. Description Notes rd Stage Interfilter Assembly Plate Hollow Screw Inset Assembly 3 a.. 1 N3556 O-ring Knurled Ring 5 1 N1316 Gasket 6 1 N20215 Fitting Safety Valve October 22, 2009 Page 53

66 UNICUS III Figure 3-33 IK150 II Cooling System Assembly # KIT Qty Part No. Description Notes Cooling System Assembly st Stage Intercooler nd Stage Intercooler rd Stage Intercooler Aftercooler Mount M Clamp 7 12 N15414 Countersunk Screw 8 16 N58 Washer 9 14 N108 Lock Washer N370 Self Locking Hex Nut Bushing 12 4 N503 Allen Screw Page 54 1st Edition, Rev. 2 Chg. 2

67 MNL-0375 Figure 3-33 (cont.) Cooling System Assembly # KIT Qty Part No. Description Notes 13 8 N57 Hex Nut Mount 15 8 N109 Allen Screw Tube Clamp Connecting Tubing Connecting Tubing Connecting Tubing Connecting Tubing Connecting Tubing Connecting Tubing Spacer 24 8 N1042 Self Locking Hex Nut 25 8 N102 Washer 26 8 N3494 Stud 27 8 N293 Gasket 28 8 N1316 Gasket 29 5 N20231 Connector 30 4 N4530 Plug 31 4 N2144 Lock Washer 32 3 N3610 Cap Screw 33 3 N20195 Connector 34 2 N20059 Connector 35 2 N20312 Fitting 36 2 N20060 Connector 37 2 N20260 Elbow 38 2 N724 Allen Screw 39 1 N20012 Connector 40 1 N842 Gasket 41 1 N20201 Connector 42 1 N1049 Cap Screw 43 1 N16309 Plug 44 1 N20155 Adjustable Coupling 45 1 N20014 Connector Bracket Gasket Connector 49 1 N20044 Connector 50 1 N7430 Cap Screw 51 1 N20003 Elbow Coupling Fan Screen October 22, 2009 Page 55

68 UNICUS III Figure 3-33 (cont.) Cooling System Assembly # KIT Qty Part No. Description Notes Support Bracket 55 4 N542 Hex Screw Page 56 1st Edition, Rev. 2 Chg. 2

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70 UNICUS III Figure 3-34 IK180 II Cooling System Assembly # KIT Qty Part No. Description Notes Cooling System Assembly st Stage Intercooler nd Stage Intercooler rd Stage Intercooler Aftercooler Mount M Clamp 7 12 N15414 Countersunk Screw 8 16 N58 Washer 9 14 N108 Lock Washer N370 Self Locking Hex Nut Page 58 1st Edition, Rev. 2 Chg. 2

71 MNL-0375 Figure 3-34 (cont.) IK180 II Cooling System Assembly # KIT Qty Part No. Description Notes Bushing 12 4 N503 Allen Screw 13 8 N57 Hex Nut Mount 15 8 N109 Allen Screw Tube Clamp Connecting Tubing Connecting Tubing Connecting Tubing Connecting Tubing Connecting Tubing 22 2 N61 Allen Screw Spacer Disc 24 8 N1042 Self Locking Hex Nut 25 8 N102 Washer 26 8 N3494 Stud 27 8 N293 Gasket 28 8 N1316 Gasket 29 5 N20231 Connector 30 4 N4530 Plug 31 4 N2144 Lock Washer 32 3 N3610 Cap Screw 33 3 N20195 Connector 34 2 N20059 Connector Auxiliary Cooler 36 1 N20060 Connector 37 2 N20260 Elbow 38 2 N724 Allen Screw 39 1 N842 Gasket 40 1 N20118 Connector 41 1 N20201 Connector 42 1 N1049 Cap Screw 43 1 N16309 Plug 44 1 N20155 Adjustable Coupling 45 1 N20014 Connector Bracket Gasket Connector 49 1 N20044 Connector 50 1 N7430 Cap Screw October 22, 2009 Page 59

72 UNICUS III Figure 3-34 (cont.) IK180 II Cooling System Assembly # KIT Qty Part No. Description Notes 51 1 N20003 Elbow Coupling Fan Screen Support Bracket 55 4 N542 Hex Screw Safety Valve Page 60 1st Edition, Rev. 2 Chg. 2

73 MNL-0375 Figure nd Stage Intercooler , 2, 3 1, 2, # KIT Qty Part No. Description Notes nd Stage Inter-cooler Assembly 1 2 FER-0012 Ferrule 2 2 NUT-0057 Nut, Tube 3 2 N16310 Insert, Tube Clamp, Tube 5 7 N724 Socket Head Cap Screw 6 14 N102 Washer, Flat 7 7 N1042 Nut, Hex Lock 8 2 N57 Nut, Hex M Clamp 10 2 N15119 Countersunk Screw October 22, 2009 Page 61

74 UNICUS III Figure rd Stage Intercooler # KIT Qty Part No. Description Notes rd Stage Intercooler Clamp, Tube 2 7 N724 Socket Head Cap Screw 3 14 N102 Washer, Flat 4 7 N1042 Nut, Hex Lock Page 62 1st Edition, Rev. 2 Chg. 2

75 MNL-0375 Figure 3-37 Lubricating System Assembly # KIT Qty Part No. Description Notes Lubricating System Assembly Lubricating System See next Figure Gasket 3 4 N123 Socket Head Screw Connecting Tube Assembly 5 1 N20002 Connector 6 1 N4501 Gasket October 22, 2009 Page 63

76 UNICUS III Figure 3-38 Lubricating System # KIT Qty Part No. Description Notes Lubricating System 1 1 N24585 Gear Pump 2 2 N58 Washer 3 2 N19506 Hex Head Screw Oil Filter Cover 5 1 N4058 O-ring 6 1 N25327 O-ring Rubber Gasket 8 a.. 1 N25326 Filter Element 9 4 N1316 Gasket Regulating Valve 11 1 N20065 Straight Male Connector 12 1 N16309 Plug 13 1 N1049 Screw Cap 14 3 N52 Plug 15 2 N2889 Gasket 16 2 N25328 Socket Head Screw Oil Pump Case 18 2 N3489 O-ring Page 64 1st Edition, Rev. 2 Chg. 2

77 MNL Automatic Condensate Drain System Description The automatic condensate drain system operates electropneumatically and is comprised of the following: A condensate manifold Two pneumatically operated condensate drain valves An electrically controlled solenoid valve A condensate separator/silencer A condensate collector bottle Electronically controlled by the PLC The automatic condensate drain system drains the intermediate separators and the oil and water separator every 15 minutes during operation. Additionally the automatic condensate drain system unloads the compressor during the starting phase and drains these separators at shutdown of the compressor unit. Figure 3-39 Automatic Condensate Drain System Final Separator Condensate Drain Valve 2. 1st Stage Separator Drain Valves 3. Electrical Solenoid Valve 4. Condensate Drain Manifold 5. Blank Off Plate 7 6. Manual Condensate Drain Valves 7. Separator Condensate Connections 8. Control Pressure Connection 9. DIN Electrical Connector October 22, 2009 Page 65

78 UNICUS III Figure 3-40 ACD Operation Normal Operation Condensate Draining Control Pressure from Compressor Inlet Control Pressure from Compressor Inlet 4 Control Pressure Condensate Drain 1. Electrical Solenoid Valve 2. Condensate Drain Valves 3. Intermediate Separators 4. Final Separator Compressor Operating The normally open Solenoid Valve (1) controls the condensate draining of the 1st stage Intermediate Separators (3). The control pressure for the ACD System comes from the inlet to the BK15.3II compressor. As the compressor is started, the Solenoid Valve (1) is electrically energized and closes. This results in control pressure closing both Condensate Drain Valves (2) Condensate Draining Every 15 minutes the PLC Timer de-energizes the Solenoid Valve (1) for approximately 6 seconds. The Solenoid Valve (1) opens and drains the condensation from the Final Separator (4). As the pressure of the control air drops, the pistons of the 2nd stage Condensate Drain Valves (2) become unloaded and the pistons of the Condensate Drain Valves are fully raised and the condensate is drained from the Intermediate Separators (3) Start Unloading The unloading of the compressor during the starting phase is possible because of the lack of control air immediately after starting the unit. As the unit is switched on the solenoid valve (1) is energized and closes. After the compressor has attained nominal speed, pressure builds in the intermediate separators (2 and 3) and the control air closes the condensate drain valves (4 and 5). Once these valves close, the compressor delivers to the consuming device Standstill Drainage After the Selector Switch is turned to OFF and the compressor stops running, the Solenoid Valve (1) is de-energized and opens. This drains the condensate and relieves the pressure in the 1st stage Intermediate Separators (2) Condensate Drain Piping The outlet of the Condensate Drain Manifold is directed into a Condensate Collector. Page 66 1st Edition, Rev. 2 Chg. 2

79 MNL Condensate Collection The condensate drainage is a mixture of oil, water and air. The Condensate Collection Tank is where the oil and water mixture is stored until it can be disposed of properly ACD Maintenance The condensate drain valves are provided with manual drain valves to verify correct operation of the automatic system. The automatic condensate drain system must be serviced once a week as follows: 1. Open all manual drain valves one after the other. 2. Observe the drainage of condensation. 3. If the system drains more than 2 ounces of liquid per stage, either the system or the corresponding condensate drain valve is not working properly. 4. Find the fault and remedy accordingly. 5. If little or no condensation emerges, the automatic system is operating properly. 6. The Condensate Collection Tank should be emptied regularly. Due care must be taken to ensure that any oil which is drained with the condensate is disposed of properly. Check local, state and federal regulations. October 22, 2009 Page 67

80 UNICUS III Replacement Parts List Figure 3-41 ACD System Item Qty Part No. Description Notes 1 DGM-2348 Automatic Condensate Drain Sub Assembly 1 1 MFD-0036 Manifold 2 4 N04333 O-ring 3 1 N4182 Electrical Solenoid Condensate Drain Valve See Figure Condensate Drain Valve See Figure Manual Condensate Drain Valve See Figure PLT-0311 Blank Off Plate Page 68 1st Edition, Rev. 2 Chg. 2

81 MNL-0375 Figure 3-42 Final Separator Condensate Drain Valve Item Qty Part No. Description Notes Condensate Drain Valve Solenoid Valve 2 4 N210 Allen Screw M6 x N2720 O-ring 4 1 N4177 Grooved Ring Valve Piston 6 1 N3489 O-ring 7 Valve Body Available only with N2507 O-ring Valve Seat 10 1 N4178 O-ring Valve End 12 4 N1511 Allen Screw M6 x N102 Washer 14 2 N781 Allen Screw M6 x 35 October 22, 2009 Page 69

82 UNICUS III Figure st Stage Separators Condensate Drain Valves Item Qty Part No. Description Notes Condensate Drain Valve Assembly 1 4 N796 Socket Head Cap Screw 2 1 N3764 Hex Nut Top Flange Adjusting Screw 5 1 N7091 O-ring 6 1 N2720 O-ring 7 1 N04177 Sealing Ring Page 70 1st Edition, Rev. 2 Chg. 2

83 MNL-0375 Figure 3-43 (cont.) 31st Stage Separators Condensate Drain Valves Item Qty Part No. Description Notes Valve Piston 9 1 N03489 O-ring 10 Valve Body, ACD Available only with N02507 O-ring Valve Seat 13 1 N04178 O-ring Base Flange 15 4 N1511 Allen Screw 16 2 N781 Allen Screw 17 2 N102 Washer October 22, 2009 Page 71

84 UNICUS III Figure 3-44 Manual Condensate Drain Valve Item Qty Part No. Description Notes Condensate Drain Tap Drain Valve Body Seal Handle Page 72 1st Edition, Rev. 2 Chg. 2

85 MNL Condensate Collector Replacement Parts List Figure 3-45 Condensate Collector Item Qty Part No. Description Notes 1 1 CAP-0056 Condensate Collector Cover 2 1 GKT-0050 Gasket 3 2 ELM-0160 Fine Filter Element 4 2 ELM-0161 Coarse Filter Element 5 1 HUS-0050 Condensate Collector 6 1 SWT-0265 Float Switch 7 1 TNK-0092 Condensate Collection Tank 8 1 VAL-0386 Manual Drain Valve 9 1 PLU-0011 Plug 10 1 MFD-0036 ACD Manifold October 22, 2009 Page 73

86 UNICUS III Trouble shooting Trouble Cause Remedy Solenoid Valve does not drain. 1. Solenoid valve receives no electrical signal 2. Plunger of drain valve sticking 1. Check connections, Timer. Replace if necessary. 2. Clean or replace valve. Condensate Drain Valve does not drain. 1. Solenoid valve does not depressurize drain valve. 2. No control medium available. 3. Solenoid valve sticking. 4. Drain valve sticking in open position 1. Check solenoid valve, replace if necessary 2. Check supply lines 3. Clean or replace 4. Clean or replace Page 74 1st Edition, Rev. 2 Chg. 2

87 MNL-0375 CHAPTER 4: PURIFICATION SYSTEM 4.1 Introduction The purpose of all Bauer breathing air purification systems is to remove Carbon Monoxide, oil, water, taste and odor from the compressed air stream before final delivery. The purpose of all Bauer industrial air purification systems is to remove oil and water from the compressed air stream before final delivery General Purification System Procedures ^ WARNING Industrial Air Purification System cartridges do not remove Carbon Monoxide and must not be used in breathing air applications. 1. Keep an accurate record of operating hours to ensure exact attention to maintenance intervals 2. Change all cartridges before reactivating a compressor unit that has been out of service more than three months. Leave cartridges in the unit as long as it is out of service. 3. While out of service keep all condensate drain valves closed. Maintain a pressure of 700 to 1,100 psi (50 to 80 bar) within the system to prevent moisture from entering the compressor and purification system Chamber Safety Bore The chambers in all Bauer purification systems are designed to prevent pressurization if the cartridge is missing, not seated properly or damaged (See Figure 4-1). Without a cartridge properly in place the safety bore is not sealed, the air escapes into the atmosphere, no pressure can be built up and thus it is ensured that unfiltered air is not supplied to the consuming device. If air is escaping from the safety bore remove and check cartridge. If necessary replace the cartridge or O-rings. October 22, 2009 Page 75

88 UNICUS III Figure 4-1 Cartridge Safety Venting Safety Vent Safety Vent Cartridge Installed No Cartridge Installed Manual Condensate Drainage The condensate must be drained from the oil and water separator before changing any cartridge, before beginning each filling procedure and in the absence of an Automatic Condensate Drain System, every fifteen minutes during the filling procedure. This is done by slowly opening the condensate drain valves. They are opened approximately 1/3 of a turn to the left and held open until the condensate is completely drained. The condensate drain valves close by spring pressure but if necessary may be tightened by hand to ensure they are completely air tight Model, Serial Number and Part Number Identification Compressor Dataplate The model number, date of manufacture and serial number can be found on the compressor unit identification plate in the main electrical enclosure and frame. Figure 4-2 Purification System Purification System Dataplates (typical) Cartridge Installation PURIFICATION SYSTEM MODEL NO. MAX. PRESSURE AIR PROCESSED O-RING BACK-UP RING LBL- LBL- psig cu. ft. CARTRIDGE TO BE INSTALLED CARTRIDGE FOR CARTRIDGE NO Azalea Garden Road - Norfolk Virginia Phone: (757) Fax: (757) Page 76 1st Edition, Rev. 2 Chg. 2

89 MNL Purification System Dataplate Refer to the compressor unit purification system data plate (See Figure 4-2) on the compressor front to determine your purification system model and specifications Cartridge Installation Dataplate The function performed by each chamber in the purification system is determined by the type of cartridge installed in that chamber. Refer to the cartridge installation data plate on the chamber to determine the purpose and part number of the cartridge installed in that chamber. (See Figure 4-2) Breathing Air Purification System Configurations Purification System Number and Type of Cartridges Processing Capacity Dryer Purification Securus cubic ft (ft) 3 P0 Combined 3,200 P1 1 15,000 P2 1 40,000 P2 with Securus 1 67,000 P ,000 P ,000 P5 with Securus ,000 P ,000 P10 with Securus ,000 P12 a ,000 P14 a ,000 P31 Combined 11,760 P ,700 P41 with Securus 1 47,000 P ,000 P42 with Securus ,000 P ,000 P43 with Securus ,000 a. P12 and P14 have the Securus Electronic Moisture Monitor System as standard equipment. October 22, 2009 Page 77

90 UNICUS III Industrial Purification System Configurations Purification System Number and Type of Cartridges Processing Capacity Dryer Purification Securus cubic ft (ft) 3 P0 Combined 3,200 P1 1 15,000 P2 1 40,000 IP2 with Securus 1 67,000 P ,000 P ,000 IP5 with Securus ,000 P ,000 IP10 with Securus ,000 P31 Combined 11,760 IP41 with Securus 1 47,000 IP42 with Securus ,000 IP43 with Securus , Cartridge Operating Life Every Bauer Purification System is designed to process a certain volume of air before the cartridges require replacement. By using special test equipment that measures the quality of air at the outlet any quality reduction may be detected. However as most compressor owners do not have this test equipment the recommended method of determining cartridge operating life is to maintain a written record of the volume of air processed by the purification system. Each Bauer compressor block is rated to produce a standard volume of air per minute and by using this number and the air processing capability of the purification system it is possible to calculate the maximum operating hours before the cartridges need to be replaced. See Paragraph for the method of determining this figure. The ambient air temperature and its ability to cool the compressor will effect the operating life of the cartridge. See Paragraph for the method of calculating this adjustment factor. The optimum place to measure the temperature is at the inlet to the final separator as this best reflects the temperature of the air as it enters the chambers. Experience has shown that this temperature is Page 78 1st Edition, Rev. 2 Chg. 2

91 MNL-0375 approximately 10 F above the ambient temperature. Therefore for the purpose of calculating cartridge operating life use the Ambient Air Temperature plus 10 F. A form titled Air Purification Cartridge Operating Hours is found in Paragraph and in the Appendices. It is used for recording the ambient temperature, operating time and adjustment factor. It is suggested that it be copied, placed in a protective folder and kept with the unit to record the adjusted operating hours. An example of how this form is used is shown in Figure Calculating the Maximum Cartridge Operating Hours 1. From the purification system data plate (See Figure 4-2) on the purification chamber determine the Air Processed (cu.ft.) 2. From the paragraph titled Compressor Specifications in the instruction manual for your compressor unit determine the Charging Rate in SCFM of your compressor. 3. Divide the Air Processed by the Charging Rate to obtain the Maximum Operating Time in minutes 4. Divide the Maximum Operating Time in minutes by 60 to obtain the Maximum Operating Hours. 5. Record the answer on the Air Purification Cartridge Operating Hours form Calculating the Adjusted Cartridge Operating Hours 1. Using the Air Purification Cartridge Operating Hours form (FORM-0018) record the Date, Operating Hours and Ambient Air Temperature plus 10 F. 2. Using either the graph or the chart in Figure 1-4 determine the Correction Factor. 3. Divide the Operating Hours by the Correction Factor and record it under the column labeled Today. 4. Add the hours recorded in Today to the previous Total and record it as the current Total. 5. When the Total approaches the Maximum Operating Hours replace the Cartridges. October 22, 2009 Page 79

92 UNICUS III Figure 4-3 Correction Factor for Cartridge Operating Hours Cartridge Op. Hrs. Conversion Factor Ambient Temperature in C C [( F - 32) x 5/9] F [ C x 9/5 +32] Cartridge Op. Hrs. Correction factor Figure 4-4 Example Record of Adjusted Operating Hours Date Operating Hours Ambient Temp. during Compression Correction Factor Adjusted Cartridge Hours Today Total 10/19/ F (33 C) /01/ F (7.2 C) Page 80 1st Edition, Rev. 2 Chg. 2

93 MNL Air Purification Cartridge Operating Hours Form Date Operating hours Ambient temp. during compression Correction factor Adjusted cartridge hours Today Total October 22, 2009 Page 81

94 4.2 P5S Securus II Purification System UNICUS III P5S Securus II Purification System Major Components The P5S Securus II Purification System major components are an Oil and Water Separator, a Dryer Chamber and a Securus II Purification Chamber. Figure 4-5 shows the functional interconnection of all the components. Figure 4-5 P5S Securus II Purification System IN 5 OUT Oil and Water Separator 2. Condensate Drain Valve 3. Check Valves 4. Dryer Chamber 5. Securus Chamber 6. Bleed Valve 7. Pressure Maintaining Valve 8. Safety Valve 9. Securus Transmitter Page 82 1st Edition, Rev. 2 Chg. 2

95 MNL Component Description Oil and Water Separator ^ WARNING The rapid depressurizing and repressurizing of the oil and water separator during condensate draining subjects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury or death the oil and water separator (P/N ) must be replaced after a predetermined number of cycles. One load cycle equals one pressurization plus one depressurization. Units operating between 3,000 and 5,000 psi = 130,000 load cycles (32,500 hours of operation) Units operating between 5,000 and 6,000 psi = 22,000 load cycles (13,750 hours of operation) The Bauer recommended frequency of condensate draining is every fifteen minutes and is a balance between maximizing the life of the separator chamber and maintaining the quality of the delivered air. The air leaving the final stage is cooled in the aftercooler to approximately F (10-15 C) above ambient temperature and then enters the oil and water separator. The oil and water separator works by means of a sintered metal filter which separates liquid oil and water particles from the compressed air Figure 4-6 Oil and Water Separator Labels Chamber Each chamber is made up of an anodized aluminum housing and a filtering cartridge. There are two general types of filtering cartridges, drying or purifying. The cartridge type is determined by the ingredients packed in the cartridge. The chamber is named after the type of cartridge it contains, i.e. dryer chamber or purification chamber Cartridge Cartridge Construction The cartridge casing, top and bottom are aluminum and are packed with one or more of the following. 1. A catalyst to convert carbon monoxide to carbon dioxide. 2. Activated carbon which absorbs oil vapors effecting taste and odor. 3. Molecular sieve to absorb oil and water. October 22, 2009 Page 83

96 UNICUS III Figure 4-7 Cartridge Protective Cap Cartridge Handling 1. Never open the protective packaging a cartridge comes in prior to its actual use. The highly sensitive filter materials will absorb moisture from the atmosphere becoming saturated and useless. 2. Used cartridges must be disposed of in accordance with local regulations Condensate Drain Valve A manually operated valve used for maintenance and before start-up to drain the condensed liquids from the coalescing oil and water separator Check Valves Valves allowing compressed air to flow in only one direction. One is used to maintain pressure in the chamber when the compressor is not operating. The other check valve prevents back-flow from filled storage cylinders or tanks Bleed Valve A manually operated valve used to release the pressure in the chamber before maintenance Pressure Maintaining Valve The pressure maintaining valve ensures that pressure is built up in the system from the start of delivery, thus achieving constant optimum purification. It also assures proper working conditions for the final stage of compression Safety Valve The safety valve is located on the coalescing oil and water separator and acts as the safety valve for the final stage of the compressor Securus II Electronic Moisture Monitor System The Securus II Electronic Moisture Monitor System warns the operator in advance of expiration of the life of the cartridges. The Securus II Transmitter receives signals concerning the condition of the drying agent inside the Securus cartridge from the attached sensors and supplies the appropriate control signals whenever the preset threshold values have been reached Securus Cartridge The Securus Cartridge is packed with a catalyst which converts carbon monoxide to carbon dioxide, activated carbon which absorbs oil vapors, molecular sieve which absorbs oil and water and the sensor components of the Securus II Electronic Moisture Monitor System. Page 84 1st Edition, Rev. 2 Chg. 2

97 MNL Securus II Transmitter The Securus II Transmitter relays the operating condition of the Securus II Electronic Moisture Monitor System to the operator control interface. The Securus II issues a warning when the Securus cartridge is approaching saturation, to warn the user to prepare to change the Securus cartridge. Once the Securus cartridge has reached total saturation the Securus II monitor will issue an alarm condition to the operator interface and shut down the unit. Once the Securus cartridge is replaced the compressor unit can be restarted. 4.4 Maintenance Oil and Water Separator To remove the sintered metal filter proceed as follows: (See Figure 4-8). Disconnect the power and shut off the inlet supply line if applicable. 1. Depressurize the system by means of the bleed valve. 2. Remove the tubes connected to the side of the filter head (1). 3. Unscrew and remove the filter head. 4. Unscrew the sintered metal filter (2) from the filter head. 5. Remove the center screw (3) to remove the sintered metal filter. 6. Clean the sintered metal filter using hot soapy water. Blow dry with compressed air. 7. After cleaning the element, record the number of operating hours to ensure exact attention to the maintenance intervals. 8. Lubricate the threads and O-rings as well as the threaded part of the sintered metal filter with petroleum jelly. Apply sparingly. 9. Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the sintered metal filter. 10. In the event you discover corrosion, replace the corroded parts with new Bauer parts. 11. Reinstall the sintered metal filter assembly and filter head. 12. Replace all removed tubes, close all valves and check for leaks October 22, 2009 Page 85

98 UNICUS III Figure 4-8 Oil and Water Separator Figure 4-9 Sintered Metal Filter Assembly Filter Head 2. Sintered Metal Filter 3. Center Screw 4. O -rings 1. Threaded Insert 2. Filter Bottom 3. Inner Filter 4. Outer Filter 5. Filter Head Page 86 1st Edition, Rev. 2 Chg. 2

99 MNL Removal of the Securus II Transmitter. Figure 4-10 Removal of the Securus II Transmitter Securus II Transmitter 2. DIN Connector The Securus II Transmitter is removed and replaced by rotating the blue plastic Securus II Transmitter approximately ½ turn. It is not necessary to disconnect or remove the DIN Connector. NOTICE If the DIN Connector is removed, ensure that it is replaced in exactly the same position, otherwise electrical damage to the unit may occur. October 22, 2009 Page 87

100 UNICUS III Cartridge Replacement To change the purification cartridge, proceed as follows. (See Figure 4-11) Figure 4-11 Cartridge Replacement 1. Disconnect the power and shut off the inlet supply line, if applicable. 2. Depressurize the system by means of the bleed valve. 3. If the chamber is part of the Securus II Moisture Monitor System, remove the Securus II Transmitter. See Paragraph Unscrew the chamber head using the special wrench supplied. 5. Pull out the cartridge using the lifting ring on top of the cartridge. 6. Dry the inside of the chamber with a clean cloth and check for corrosion. 7. Replace all corroded parts with new Bauer parts. 8. Remove the shipping covering and the protective cap from the bottom of the cartridge. 9. Lubricate the O-rings with white petroleum jelly. Apply sparingly. 10. Install the new cartridge. Be sure the cartridge snaps into place. 11. Reinstall the chamber head. 12. Close the bleed valve, restore the power and reconnect the inlet supply line, if applicable Leaking at the Safety Bore 1. Remove the cartridge following the steps in Paragraph Install cartridge if missing. NOTICE If air is detected bleeding out from the bottom of the chamber, the cartridge has not been installed properly or is missing. Follow the instructions in Paragraph Page 88 1st Edition, Rev. 2 Chg. 2

101 MNL Remove cartridge and inspect O-rings. 4. Replace O-rings if necessary. 5. Ensure protective caps and devices have all been removed. 6. Replace cartridge following steps 8. to 11. in Paragraph October 22, 2009 Page 89

102 UNICUS III 4.5 Replacement Parts List Figure 4-12 P5 Purification System Parts List IN 5 OUT Item Qty Part No. Description Notes Oil and Water Separator See Figure Condensate Drain Valve 3 2 VAL-0007 Check Valves Dryer Chamber See Figure Securus Chamber See Figure VAL-0377 Bleed Valve 7 1 VAL-0053 Pressure Maintaining Valve 8 1 VAL-0169 Safety Valve 9 1 MNR-0042 Securus II Transmitter 24 VDC Page 90 1st Edition, Rev. 2 Chg. 2

103 MNL-0375 Figure 4-13 Oil and Water Separator Parts List 1 2 a 3 b c d e 4 c b f g 2 5 Item Qty Part No. Description Notes Oil and Water Separator Assembly 1 Separator Head Available only with N04586 O-Ring Sintered Metal Filter 3a 1 N15133 O-Ring 3b 2 N04496 O-Ring, small 3c 2 N04385 O-Ring, large 3d Sleeve Element, large 3e Sleeve Element, small 3f 1 N07091 O-Ring 3g Screw 4 Separator Housing Available only with Bottom Plug Available only with October 22, 2009 Page 91

104 UNICUS III Figure Chamber Assembly Parts List Item Qty Part No. Description Notes Chamber Assembly Tool Post Screw Cover Plate 3 Filter Head Available only with N04736 Back-up Ring 5 2 N04735 O-ring 6 Filter Housing Available only with Filter Bottom Available only with A Dryer Cartridge MS Page 92 1st Edition, Rev. 2 Chg. 2

105 This page is inserted to provide proper page sequencing

106 UNICUS III Figure 4-15 Securus Electronic Moisture Monitor System Parts List Item Qty Part No. Description Notes Securus Chamber Assembly Replaces 1 P/N in P5S 1 Bottom Plug Available only with N04736 Backup Ring 3 2 N04735 O-ring A Securus Cartridge 5 Filter Body Available only with Nut Drawback Screw Loose Pin Compression Spring Fixed Pin Page 94 1st Edition, Rev. 2 Chg. 2

107 MNL-0375 Figure 4-15 (cont.) Securus Electronic Moisture Monitor System Parts List Item Qty Part No. Description Notes Bolt Compression Spring 13 Filter Head Available only with Cover Plate Tool Post Screw Socket, RF type 17 1 MNR-0042 Securus II Transmitter 24 VDC 18 1 CON-0319 Securus II Connector October 22, 2009 Page 95

108 CHAPTER 5: COMPRESSOR DRIVE; UNICUS III UNICUS III 5.1 Vertical Compressor Drive The compressor is driven by the drive motor through a V-belt. The direction of rotation, as seen facing the flywheel, is counterclockwise. Observe the arrow on the compressor block. Check the V-belt regularly for damage and wear. See Paragraph Replace if necessary. Figure 5-1 Vertical Drive with Idler (typical) ROTATION Compressor Flywheel 2. V-belt 3. Idler Sheave (pulley) 4. Spring Tension Idler 5. Electric Motor 6. V-belt Sheave 7. Sheave Bushing 5.2 Maintenance of the V-belt and Sheaves Check The Sheaves. Before a new set of drive belts are installed, the condition of the sheaves should be checked. Dirty or rusty sheaves impair the drive s efficiency and abrade the cover of the belts, which results in premature failure. Worn sheaves shorten belt life as much as 50%. If the grooves are worn to the point where the belt bottoms, slippage may result and the belts may burn. If the side walls are dished out, the bottom shoulder ruins the belt prematurely by wearing off the bottom corners. Page 96 1st Edition, Rev. 2 Chg. 2

109 MNL Check the V-belt Check the V-belt regularly for damage and wear. Replace if necessary. V-belt tension is adjusted automatically by the spring tension idler Replacing the Belt To replace the belt use a spanner wrench or special tool if provided to pull idler pulley away from belt. The belt should be slack enough to pull off of the flywheel and motor s sheave. Replace with the correct replacement belt and let the idler slowly engage the belt, making it tight. NOTICE Do Not let the idler return until new belt is in place. If the idler does return to its neutral position it is extremely hard to get it back to the proper spring position Replacing the Sheave A gear puller can be used to remove the sheave and sheave bushing from the motor s drive shaft. Ensure the drive shaft is clean then slide the new sheave onto the drive shaft. Bolt the sheave bushing onto the sheave then tap the feathered key into the key slot. Ensure the feathered key is snug with both the shaft and sheave. There should no play once the key is in place. The feathered key should run the entire length of the bushing and sheave keyslots. October 22, 2009 Page 97

110 UNICUS III 5.3 Replacement Part List Figure 5-2 UNICUS III, Vertical Drive with Idler ROTATION Item Qty Part No. Description Notes UNICUS III IK 150 II Compressor Block 2 2 BET-0049 V-belt 3 1 SHE-0266 Idler Sheave 4 1 IDL-0009 Idler 1 BRK-0512 Idler Bracket 5 1 MTR-0024 Electric Motor 15 Hp, 3 Phase 6 1 SHE-0030 V-belt Sheave 7 1 BUS-0001 Sheave Bushing Page 98 1st Edition, Rev. 2 Chg. 2

111 MNL-0375 Figure 5-2 (cont.) UNICUS III, Vertical Drive with Idler Item Qty Part No. Description Notes UNICUS III IK 150 II Compressor Block 2 2 BET-0102 V-belt 3 1 SHE0266 Idler Sheave 4 1 IDL-0009 Idler 1 BRK-0512 Idler Bracket 5 1 MTR-0065 Electric Motor 20 Hp, 3 Phase 6 1 SHE-0241 Sheave 7 1 BUS-0020 Sheave Bushing October 22, 2009 Page 99

112 CHAPTER 6: ELECTRICAL PANEL, ASY-1058 UNICUS III 6.1 Overview The following instructions apply to units that use Electrical Panel, ASY-1058 and Operator Interface, MNR Figure 6-1 ASY-1058 and MNR-0049 The Electrical Panel, ASY-1058, provides logical control and safety shutdowns for the compressor equipment. All necessary time delays, counters, shutdowns, sequencing and safety features are incorporated into a proprietary software program permanently saved into PLC memory using EEPROM technology. The software program used in this Electrical Panel is based on the pressure and use of the compressor. The input/output device for normal operation of the compressor unit is the Operator Interface, MNR In an emergency the compressor is shutdown with the E-Stop Button. 6.2 Electrical Panel This Electrical Panel is designed for use with 5, 7½, 10, 15 or 20 horsepower electric motors. It is also designed for supply voltages from 208 VAC to 460 VAC, single or three phase and 50Hz or 60 Hz. All supply voltage options are not available with each horsepower rating. The basic panel components consist of a Programmable Logic Controller (PLC), Motor Starter, Overload Relay, Power Transformer, Fuses, Overload Reset Button, Hourmeter, terminal strips for internal Page 100 1st Edition, Rev. 2 Chg. 2

113 MNL-0375 wiring and connectors for attachment to wire harnesses. The panel is built to match the horsepower, voltage, phase and frequency of the customer s requirements Wiring Diagram The wiring diagram for your specific Compressor Unit is stored inside the Electrical Panel. If a wiring diagram for your machine is not found inside the Electrical Panel, then please call Bauer Compressors Product Support Group for a replacement. Please have the serial number of the compressor available; it is written on a label (See Figure 6-2) inside the Electrical Panel door Electrical Panel Interior Access The interior of the Electrical Panel is accessed by using a coin or screwdriver to turn the latch on the front of the Electrical Panel Optional Equipment Optional equipment which may also be housed in the Electrical Panel is any of five Communication Modules. An EEPROM Memory Module may also be an option in the Electrical Panel. 6.3 AC Power Requirements The Electrical Panel must be supplied with electricity of the correct voltage, phase, and frequency to ensure proper operation. Wiring and conduit selection must be in accordance with all national, state and local codes. The customer is responsible for providing a means of disconnection from the power source and protection from instantaneous short circuit. The Electrical Panel voltage and phase are displayed on the exterior of the Electrical Panel as well as being written on a label (See Figure 6-2) on the inside of the Electrical Panel door. In this example shown, the panel is wired for 230 volt, single phase, serial number Figure 6-2 Electrical Panel Label Norfolk, VA USA UL File No. E PANEL: Short Circuit Current: MAXIMUM RATING (AC3) 1 Ph 60 Hz 230V 10 HP 46 FLA ASY-1058 xx,xxx VE-13-E1/230V P /06 2/2009 MODEL: SERIAL: BLOCK: MFG DATE: Use 600 VAC and 60 Degree Celsius Copper Wire Only KA Terminal Wire Range Torque Line awg in-lb Ground awg in-lb CONTROL FUSE LEGEND 1FU 2FU 3FU ATQR - 3A ATQR - 3A TRM - 2A October 22, 2009 Page 101

114 6.4 Electrical Panel Components UNICUS III Programable Logic Controller (PLC) The PLC is 24 I/O and 120 VAC. The data stored in RAM is protected for 100 hours, in event of a power loss. Figure 6-3 PLC, CNT Status LEDs 2. Output LEDs 3. Output Connections Cover 4. Expansion Access Door 5. Input Connections Cover 7 6. Input LEDs 7. DIN Rail Clip 8. Communications Ports 9. Optional EEPROM Figure 6-4 Connector Block Removal 1. Notch in the Terminal Block 1 Page 102 1st Edition, Rev. 2 Chg. 2

115 MNL Replacing the PLC Replacing the PLC does not require removal of any wiring as the connections are made with push in Connector Blocks. To replace the PLC proceed as follows. 1. Turn off unit and disconnect from main power supply. 2. Lift the Input Connections Cover. See Figure 6-3, Item Insert a small flat bladed screwdriver in the notch in the back center of the Connector Block. Gently pry the Connector Block loose. See Figure Repeat Steps 2 and 3 for the to the Connector Block on the Output side of the PLC. 5. The Power Connector on the side opposite side from the DIN Rail Clip, Figure 6-3, Item 7, is removed by pulling it straight out from the PLC. 6. Unclip the PLC from the DIN Rail by using a small flat bladed screwdriver to pull the DIN Rail Clip out until the PLC is free. 7. Replace the PLC and slide the DIN Rail Clip in with the screwdriver until it is secure. 8. Replace the Power Connector by pushing it into the socket in the side of the PLC. 9. The Connector Blocks are replaced by pushing them gently down onto corresponding pins until they click into place. 10. Restore power and operate the unit Installing a New Program The PLC program can be updated in two ways. If a Bauer technician is on-site, they will connect directly to the PLC using a notebook computer. Another method to install a new program is to use an External EEPROM cartridge. The EEPROM would be programmed at the Bauer factory and shipped either to the customer or to a authorized distributor Installing an EEPROM To install or replace an EEPROM Cartridge proceed as follows: 1. Turn off unit and disconnect from main power supply. 2. Lift straight up to remove the EEPROM cover. Keep the cover. See Figure 6-3, Item The EEPROM is keyed to fit only one way and requires minimal force to insert it. 4. Push the EEPROM down until it snaps into place. 5. If the EEPROM is being retained in the PLC, restore power to the unit and operate as normal. 6. If the EEPROM is for a software update and is to be returned to Bauer or a distributor continue as follows. 7. Restore power to the unit. 8. After the software has initialized and the Home Screen is displayed, shutdown the unit and disconnect from the main power source. 9. Remove the EEPROM and replace the EEPROM protective cover. 10. Restore power and operate the unit. October 22, 2009 Page 103

116 UNICUS III Hourmeter The panel is equipped with an Hourmeter. The Hourmeter is not resettable and used to monitor the run hours of the compressor. It is powered by 120 VAC. Figure 6-5 Hourmeter Transformer and Fuses The Transformer is fitted with three fuses. The primary coil of the transformer has two fuses. The secondary coil of the transformer has one fuse. See Paragraph 6.9 to Paragraph 6.13 for the proper Bauer Part Numbers. Figure 6-6 Transformer and Fuses Transformer 2. Secondary Fuse 3. Primary Fuses Motor Starter. See Figure 6-7. This application will require an across the line IEC starter with thermal overloads and its size will be based on the voltage and motor horsepower. Control voltage is 120 VAC. See Paragraph 6.9 to Paragraph 6.13 for the proper Bauer Part Number. Page 104 1st Edition, Rev. 2 Chg. 2

117 MNL Overload Relay See Figure 6-8.The overload relay provides thermal overload protection and its size will be based on the voltage and motor horsepower. The dial is set to the Full Load Amperage (FLA) of the electric motor at the factory. If the Overload Relay is replaced set the dial to the FLA listed on the motor nameplate or the label inside the Electrical Panel. The Overload Relay plugs into the Motor Starter. See Paragraph 6.9 to Paragraph 6.13 for the proper Bauer Part Number. Figure 6-7 Motor Starter (typical) Figure 6-8 Overload Relay (typical) SRT-0233 shown RLY-0186 shown Starter Reset There is a starter reset push button on the front of the Electrical Panel. Should the electric motor have overloaded and tripped out during normal operation, then depressing this button after giving the motor some time to cool, will reset the overload relay Optional Communication Modules ASI Bus Module Profi Bus Module Analog Phone Module Ethernet Module IT- Ethernet Module CNT-0072 CNT-0073 CNT-0074 CNT-0075 CNT-0076 October 22, 2009 Page 105

118 UNICUS III Figure 6-9 Optional Communications Modules CNT-0072 CNT-0073 CNT-0074 CNT-0075 CNT-0076 Page 106 1st Edition, Rev. 2 Chg. 2

119 MNL Power Supply The Power Supply is a 24 Volt 1.3 Amp Power Supply used to provide power to the optional Communications Modules and Operator Interface, MNR It is not standard in all models. Figure 6-10 Power Supply 6.5 Alarms The following paragraphs describe the warning and alarm conditions that are monitored and controlled by the Electrical Panel Final Separator Warning The high pressure-breathing compressor is equipped with a final separator. This is a stainless steel vessel, approximately 3¾ inch diameter, located on the purification panel. To prevent fatigue failure of this vessel, the PLC program monitors the pressurization and depressurization cycles of this separator and will first issue a Warning, and then later an Alarm function. The program is set up for a 90% warning and a 100% shutdown alarm for this counter feature. The program would be configured to reflect the following values when it is built. Table 6-1: Final Separator Warning and Shutdown Cycle Count Maximum Compressor Pressure Warning Shutdown 5,000 psi 117,000 cycles 130,000 cycles 6,000 psi 49,500 cycles 55,000 cycles When the warning is displayed, the unit will still continue to function properly, but will prompt the operator to contact Bauer Compressors to make arrangements to replace the separator. When the Alarm level has been achieved, the compressor will no longer function, and will require the replacement of the separator. When this is accomplished, the unit can be reactivated by making adjustments to the PLC software. Please contact Bauer Product Support for detailed instructions. October 22, 2009 Page 107

120 UNICUS III ^ WARNING Do not attempt to override this Separator Shutdown. This feature is provided to protect operating personnel from injury or death Securus Electronic Moisture Monitor System The compressor purification system may be equipped with an optional Securus II Electronic Moisture Monitor System. The Securus II Electronic Moisture Monitor System warns the operator in advance of expiration of the life of the cartridges. The Securus II Transmitter receives signals concerning the condition of the drying agent inside the Securus cartridge from the attached sensors and supplies the appropriate control signals whenever the preset threshold values have been reached Securus Cartridge The Securus Cartridge is packed with a catalyst which converts carbon monoxide to carbon dioxide, activated carbon which absorbs oil vapors, molecular sieve which absorbs oil and water and the sensor components of the Securus II Electronic Moisture Monitor System Securus II Transmitter See Figure The Securus II Transmitter relays the operating condition of the Securus II Electronic Moisture Monitor System to the Operator Interface. The Securus II issues a warning when the Securus cartridge is approaching saturation, to warn the user to prepare to change the Securus cartridge. On a Securus Warning condition, the compressor will run normally and the warning will be shown on the Operator Interface. Once the Securus cartridge has reached total saturation the Securus II Transmitter will issue an alarm condition to the Operator Interface and shut down the unit. Once the Securus II cartridge is replaced it is possible to restart the compressor. The Securus II Transmitter is removed and replaced by rotating the blue plastic Securus II Transmitter approximately ½ turn. It is not necessary to disconnect or remove the DIN Connector. Figure 6-11 Securus II Transmitter MNR-0042 Shown Page 108 1st Edition, Rev. 2 Chg. 2

121 MNL-0375 NOTICE If the DIN Connector is removed, ensure that it is replaced in exactly the same position, otherwise electrical damage to the unit may occur Compressor High Temperature See Figure The compressor high temperature switch is mounted on the high pressure compressor block, on the third, fourth or fifth stage head, depending on model. Under normal operating conditions, the switch is closed. On a high temperature condition, the compressor will shutdown and the alarm will be displayed on the Operator Interface. Figure 6-12 High Temperature Switch Figure 6-13 Pressure Sensor (Typical) Compressor Low Oil Pressure See Figure The compressor Oil Pressure Sensor is located on the back of the compressor block, mounted with the oil pressure gauge. During start-up of the compressor, the oil pressure sensor is bypassed for a time period set in the program by OIL PRESS TD parameter. This allows the oil pressure to stabilize at operating pressure before the an alarm is sensed. After this initial time period, should the compressor lose oil pressure, the Oil Pressure Sensor will cause the alarm to be displayed on the Operator Interface Compressor Overrun Timer The compressor has an timer, where if the compressor runs continuously for a number of hours set by the OVERRUNTIMER parameter, the compressor will shutdown, and the alarm will be displayed on the Operator Interface. This is done to secure the equipment if it were to be started and left unattended Carbon Monoxide Monitor Alarm See Figure The compressor system may be equipped with an optional Carbon Monoxide Monitor. This consists of an electronic module that samples the compressed air supply. The unit will provide a continuous display of the Carbon Monoxide level in ppm, parts per million.the unit should be calibrated with a test gas monthly. Refer to the manual section on the Carbon Monoxide Monitor. If the Carbon Monoxide level becomes excessively high, then the monitor will alarm with a red light. The alarm relay in the Carbon Monoxide Monitor is connected to the PLC. Refer to Wiring Diagram for October 22, 2009 Page 109

122 UNICUS III additional information. On a Carbon Monoxide Alarm condition, the compressor will shutdown, and the alarm will be displayed on the Operator Interface. Figure 6-14 Carbon Monoxide Monitor Condensate Fault See Figure The compressor condensate level switch is located in the condensate collection tank, below the Automatic Condensate Drain separator. The switch is N.O., Normally Open, and is connected to the PLC. Refer to wiring diagram for additional information. As the condensate tank fills up the Condensate Level Float Switch rises until it closes. At this time the compressor will shutdown and the alarm will be displayed on the Operator Interface. The operator should drain the condensate from the tank and resume operation of the equipment. Figure 6-15 Condensate Level Float Switch NOTICE The compressor condensate contains some oil, and accordingly, should be disposed of in accordance with state and local regulations. Page 110 1st Edition, Rev. 2 Chg. 2

123 MNL Motor Starter Overload Trip The compressor overload relay is located in the Electrical Panel, See Figure 6-8. Under normal operating conditions, the switch is open. On an Overload Trip of the motor, the compressor will shutdown, and the Alarm will be displayed on the Operator Interface. 6.6 PLC Inputs and Outputs All PLC inputs are 24 VDC. The power supply physically exists inside the PLC. All PLC outputs are of a relay type, and are powered through the control transformer supplying 120 VAC single phase to the various loads. Please refer to Wiring Diagram for the as built specifications. Table 6-2: PLC Inputs Table 6-3: PLC Outputs I0.0 Securus II Monitor Alarm Q0.0 Motor Contactor I0.1 Overload Relay Q0.1 ACD 1 I0.2 Temperature Switch Q0.2 ACD Final I0.3 CO Monitor Alarm Q0.3 Audible Alarm I0.4 Condensate Alarm Q0.4 ACD 2 I0.5 Q0.5 Inlet Solenoid Valve or ACD 3 I0.6 Q0.6 I0.7 Seccant Monitor Alarm Q0.7 I1.0 High Inlet Pressure Switch a Q1.0 Unloader Solenoid Valve I1.1 Low Inlet Pressure Switch a Q1.1 Panel Light I1.2 I1.3 I1.4 I1.5 a. Applies only to compressors for mediums other than air Analog Inputs to the PLC. The Air Pressure Switch and the Oil Pressure Switch are connected in parallel and provide their input to the PLC through PLC Input Terminal M. October 22, 2009 Page 111

124 UNICUS III 6.7 Wiring Harness Layout Table 6-4: Wiring Harness, HNS-0116 Description Legend Wire Colors Pin PLC IN PLC Out CO Monitor (Optional) CO Brown/White 1 CO SV Black/Yellow 2 CO Common Gray/White 22 E-Stop Pushbutton 1PB Black 3 White/Red 9 ACD 1 ACD1 Blue/White 4 Q0.1 ACD Final ACDF Yellow/Black 5 Q0.2 ACD Common ACD Common Orange/White 21 Inlet Solenoid Valve or ACD 3 Violet/White 6 1SV Pink/White 7 White/Yellow 12 Q0.5 Panel Light 1LT White/Brown 8 Red/Orange 11 Unloader Solenoid Valve 3SV White/Violet 10 Red/Blue 14 Audible Alarm 1AA Blue/Yellow 13 White 15 Q1.1 Q1.0 Q0.3 Seccant Monitor Alarm SA Brown/Yellow 16 Black/Brown 17 Low Inlet Pressure Switch a 5PS Violet/Black 18 White/Blue 19 I0.7 I1.1 Spare Blue/Orange 20 Page 112 1st Edition, Rev. 2 Chg. 2

125 MNL-0375 Table 6-4: Wiring Harness, HNS-0116 Description Legend Wire Colors Pin PLC IN PLC Out Temperature Switch 1TS Yellow 23 Violet 24 Not Assigned Blue 25 Orange 26 High Inlet Pressure Switch a 3PS White/Orange 27 Red/Yellow 28 Condensate Alarm CA Gray 31 Pink 32 CO Monitor Alarm COA White/Black 33 Red/White 34 I0.2 I0.6 I1.0 I0.4 I0.3 Securus II SEC II Black/White 35 Violet/Orange 36 I0.0 Black/Orange 37 a. Applies only to compressors for mediums other than air October 22, 2009 Page 113

126 UNICUS III 6.8 Replacement Parts List Figure 6-16 Control Pane 1 2 Item Qty Part No. Description Notes 1 1 MNR-0049 Maple System, Touch Panel 2 1 SWT-0308 Emergency Stop Switch Page 114 1st Edition, Rev. 2 Chg. 2

127 MNL-0375 Figure 6-17 Electrical Panel, Front View Item Qty Part No. Description Notes 1 ASY-1058 Electrical Panel Front View 1 1 LBL-0167 Warning Label, Disconnect Power 2 1 Voltage Label 3 1 HMR-0036 Hourmeter 1 GKT-0069 Gasket, Hourmeter 4 1 OPR-0020 Overload Reset Button 5 1 IND-0005 Audible Alarm optional October 22, 2009 Page 115

128 UNICUS III Figure 6-18 Electrical Panel, Bottom View Item Qty Part No. Description Notes 1 ASY-1058 Electrical Panel Bottom View 1 1 CAB-0081 Cable, PLC to ENC MNR CAB-0075 Cable, 4 Receptacle Connector Connects to Air Pressure Sensor 3 2 CAB-0075 Cable, 4 Receptacle Connector Connects to Oil Pressure Sensor 4 3 HNS-0116 Wiring Harness, 37 Receptacle Page 116 1st Edition, Rev. 2 Chg. 2

129 This page is inserted to provide proper page sequencing

130 UNICUS III Figure 6-19 Electrical Panel, Interior Item Qty Part No. Description Notes 1 ASY-1058 Electrical Panel Interior View 1 1 CNT-0078 PLC Controller 2 1 SPL-0077 Power Supply, 24 VDC, 1.3 A 3 1 Terminal See Figure 6-19.a to Figure 6-19.j 4 1 Motor Starter See Figure 6-19.a to Figure 6-19.j 5 1 Overload Relay See Figure 6-19.a to Figure 6-19.j 6 1 SUR-0005 Suppressor (installed when required) 9 Page 118 1st Edition, Rev. 2 Chg. 2

131 MNL-0375 Figure 6-19 (cont.) Electrical Panel, Interior Item Qty Part No. Description Notes 7 1 Transformer See Figure 6-19.a to Figure 6-19.j 8 2 Fuse, Primary See Figure 6-19.a to Figure 6-19.j 9 1 Fuse, Secondary See Figure 6-19.a to Figure 6-19.j N.S. 1 CNT-0072 ASI-Bus Comm Module Optional, Not Shown 1 CNT-0073 PROFI-Bus Comm Module Optional, Not Shown 1 CNT-0074 Analog Phone Comm Module Optional, Not Shown 1 CNT-0075 Ethernet Comm Module Optional, Not Shown 1 CNT-0076 IT-Ethernet Comm Module Optional, Not Shown See the proper Figure for Qty and Part No. applicable to the Horsepower and Power Frequency supplied with your unit. October 22, 2009 Page 119

132 UNICUS III 6.9 Parts List for Models with a 5 Horsepower Motor Figure 6-19.a 5 HP, 60 Hz VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term. 208/1 TRR-0089 FUS-0092 FUS-0018 SRT-0233 RLY-0177 TER /3 TRR-0089 FUS-0092 FUS-0018 SRT-0233 RLY-0174 TER /1 TRR-0089 FUS-0090 FUS-0018 SRT-0233 RLY-0177 TER /3 TRR-0089 FUS-0090 FUS-0018 SRT-0233 RLY-0174 TER /3 TRR-0089 FUS-0075 FUS-0018 SRT-0233 RLY-0171 TER-0175 Figure 6-19.b 5 HP, 50 HZ VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term. 220/3 TRR-0089 FUS-0092 FUS-0018 SRT-0233 RLY-0174 TER /3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0171 TER /3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0171 TER /3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0171 TER-0175 Page 120 1st Edition, Rev. 2 Chg. 2

133 MNL Parts List for Models with a 7½ Horsepower Motor Figure 6-19.c 7½ HP, 60 Hz VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term. 208/1 TRR-0089 FUS-0092 FUS-0018 SRT-0241 RLY-0186 TER /3 TRR-0089 FUS-0092 FUS-0018 SRT-0233 RLY-0176 TER /1 TRR-0089 FUS-0090 FUS-0018 SRT-0241 RLY-0183 TER /3 TRR-0089 FUS-0090 FUS SRT-0233 RLY-0175 TER /3 TRR-0089 FUS-0075 FUS-0018 SRT-0233 RLY-0172 TER-0175 Figure 6-19.d 7½ HP, 50 Hz VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term. 220/3 TRR-0089 FUS-0092 FUS-0070 SRT-0233 RLY-0175 TER /3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0173 TER /3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0173 TER /3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0173 TER-0175 October 22, 2009 Page 121

134 UNICUS III 6.11 Parts List for Models with a 10 Horsepower Motor Figure 6-19.e 10 HP, 60 Hz VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term. 208/1 TRR-0090 FUS-0095 FUS-0019 SRT-0234 RLY-0180 TER /3 TRR-0090 FUS-0095 FUS-0019 SRT-0233 RLY-0177 TER /1 TRR-0090 FUS-0095 FUS-0019 SRT-0241 RLY-0185 TER /3 TRR-0090 FUS-0095 FUS-0019 SRT-0233 RLY-0177 TER /3 TRR-0090 FUS-0077 FUS-0019 SRT-0233 RLY-0174 TER-0175 Figure 6-19.f 10 HP, 50 Hz VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term. 220/3 TRR-0090 FUS-0095 FUS-0019 SRT-0241 RLY-0183 TER /3 TRR-0096 FUS-0090 FUS-0018 SRT-0233 RLY-0175 TER /3 TRR-0096 FUS-0090 FUS-0019 SRT-0233 RLY-0175 TER /3 TRR-0096 FUS-0077 FUS-0019 SRT-0233 RLY-0175 TER-0175 Page 122 1st Edition, Rev. 2 Chg. 2

135 MNL Parts List for Models with a 15 Horsepower Motor Figure 6-19.g 15 HP, 60Hz VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term. 208/3 TRR-0090 FUS-0095 FUS-0019 SRT-0241 RLY-0185 TER /3 TRR-0090 FUS-0095 FUS-0019 SRT-0241 RLY-0183 TER /3 TRR-0090 FUS-0077 FUS-0019 SRT-0233 RLY-0175 TER-0175 Figure 6-19.h 15HP, 50 Hz VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term. 220/3 TRR-0090 FUS-0095 FUS-0019 SRT-0241 RLY-0186 TER /3 TRR-0096 FUS-0090 FUS-0019 SRT-0233 RLY-0177 TER /3 TRR-0096 FUS-0090 FUS-0019 SRT-0233 RLY-0177 TER /3 TRR-0096 FUS-0077 FUS-0019 SRT-0233 RLY-0176 TER-0175 October 22, 2009 Page 123

136 UNICUS III 6.13 Parts List for Models with a 20 Horsepower Motor Figure 6-19.i 20 HP, 60 Hz VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term. 208/3 TRR-0090 FUS-0095 FUS-0018 SRT-0234 RLY-0180 TER /3 TRR-0090 FUS-0095 FUS-0019 SRT-0241 RLY-0185 TER /3 TRR-0090 FUS-0077 FUS-0019 SRT-0233 RLY-0177 TER-0175 Figure 6-19.j 20 HP, 50 Hz VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term. 220/3 TRR-0090 FUS-0095 FUS-0019 SRT-0241 RLY-0185 TER /3 TRR-0096 FUS-0090 FUS-0019 SRT-0233 RLY-0177 TER /3 TRR-0096 FUS-0090 FUS-0019 SRT-0233 RLY-0177 TER /3 TRR-0096 FUS-0077 FUS-0019 SRT-0233 RLY-0177 TER-0175 Page 124 1st Edition, Rev. 2 Chg. 2

137 MNL Typical Wiring Diagram For Reference Only October 22, 2009 Page 125

138 CHAPTER 7: CARBON MONOXIDE MONITOR UNICUS III 7.1 Description The Carbon Monoxide (CO) Monitor is a factory installed option which may have been ordered with your unit. The Carbon Monoxide Monitor, Bauer P/N; MNR-0029, is a standalone assembly, which may be installed on a compressor unit or trailer.(see Figure 7-1). The Carbon Monoxide Monitor, Bauer P/N; MNR-0033 (See Figure 7-2) appears outwardly identical to MNR-0029 but is designed for use with a remote display, which can be located up to 100 feet from the compressor unit. The Remote Display, Bauer P/N; MNR-0034, is powered by the Carbon Monoxide Monitor, MNR Figure 7-1 CO Monitor, MNR-0029 Figure 7-2 Remote Display LCD Display 2. Flow Indicator 3. Electrical Power Connection 4. Front Cover Screw 5. Air Inlet Connection 6. Zero Cal Set Switch 7. Calibration Port 1. CO Monitor, MNR Remote Display, MNR-0034 The Carbon Monoxide (CO) Monitor is designed to provide continuous monitoring of the carbon monoxide levels in breathing air. The Carbon Monoxide Monitor is enclosed in a NEMA-4X case and operates on 12 VDC or 120 VAC. Page 126 1st Edition, Rev. 2 Chg. 2

139 MNL-0375 Calibration adjustment is performed automatically by the internal microprocessor. The Carbon Monoxide Sensor Cell has a life expectancy of one and a half to three years if the calibration check is done every 30 days as recommended Component Description The following are the major components for the standard and trailer Carbon Monoxide Monitor Assembly installations. See Figure 7-3. Figure 7-3 Carbon Monoxide Monitor Flow Diagram Isolation Valve Controls the input of air from the compressor to the Carbon Monoxide Monitor High Pressure to Low Pressure Regulator Typically set for 50 psi out with 5,000 psi in Relief Valve A relief valve which is factory set to 165 psi to prevent over-pressurization of the Carbon Monoxide Monitor Solenoid Valve Allows air to flow to the Carbon Monoxide Monitor when the compressor is running Inlet Regulator A regulator the operator uses to set the appropriate rate of flow (0.5 to 0.8 SCFH) to the Carbon Monoxide Monitor Carbon Monoxide Monitor The Carbon Monoxide Monitor contains the LCD Display, Flowmeter, Microprocessor, Carbon Monoxide Sensor Cell, Air Inlet Connection and the Calibration Port Carbon Monoxide Sensor Cell. The Carbon Monoxide Sensor Cell is an electrochemical element inside the Carbon Monoxide Monitor which senses the amount of Carbon Monoxide in the airstream and produces an analog electrical signal for the control and display functions of the Carbon Monoxide Monitor Test Gas Storage This provides a place to keep Calibration Gas bottles so that the Carbon Monoxide Monitor can be calibrated in all situations. Normally these are only found only in trailer installations. 7.2 Carbon Monoxide Monitor Setup The initial setup of the Carbon Monoxide Monitor is done prior to shipping the unit. October 22, 2009 Page 127

140 UNICUS III 7.3 Operation 1. Start the compressor unit. 2. The LCD Display will show introductory messages and a warm up countdown (WARM XX). 3. After the warm up countdown of 120 seconds, the instrument will display Carbon Monoxide level readings. 4. The Inlet Regulator may be adjusted at any time to set the flow level from 0.5 to 0.8 SCFH on the Flow Indicator. 5. If the compressor is not running then a LOW FLOW indication will show on the display. 6. If carbon monoxide readings remain high or below zero calibration may be needed. 7.4 Maintenance Calibrating Carbon Monoxide Monitor. NOTICE Calibration is recommended every thirty days. 1. Before calibration, be sure that the test gas bottles in the calibration kit have an adequate amount of gas in the them. Attach the fixed flow regulator to the gas bottle and then detach it. You should hear a slight popping sound. 2. Turn on the compressor unit. The compressor itself does not have to run, because the test gas is being substituted for the air supply from the compressor. 3. The compressor unit power needs to be applied to the unit for 15 minutes so the unit can stabilize. If you attempt to calibrate before the end of this 15 minute period, TO SOON will appear on the LCD Display. 4. Lift the cap of Inlet Regulator and turn counterclockwise until it stops. This will ensure that the air flow from the compressor unit is shut off. 5. If the gas flow from the compressor unit was not shut off, a message SUPPLY OFF will appear. If this message appears, shut off the supply air and then begin the calibration process again. 6. Connect the 20 ppm Carbon Monoxide Test Gas to the fixed flow regulator and connect it to the Calibration Port of the Carbon Monoxide Monitor. 7. Turn the value on the Fixed Flow Regulator counterclockwise until the Carbon Monoxide Monitor Flow Indicator shows between 0.5 and 0.8 SCFH. 8. The Display will count down from 60 seconds. At the conclusion, the display will prompt Carbon Monoxide G SET or CAL FAILED 9. The the display will prompt REMOVE Carbon Monoxide GAS. 10. Turn the valve on the Fixed Flow Regulator clockwise until it is closed and disconnect it from the Calibration Port and disconnect the 20 ppm Carbon Monoxide Test Gas bottle from the fixed flow regulator. Page 128 1st Edition, Rev. 2 Chg. 2

141 MNL Allow 10 minutes for the remaining gas in the Carbon Monoxide Sensor Cell to dissipate after the calibration process. NOTICE If the compressor is started before the test gas dissipates, it could lead to incorrect Carbon Monoxide level readings. 12. Turn the compressor on, compressor must be running, adjust Inlet Regulator to SCFH to restore normal operations Troubleshooting a Calibration Failure If the unit fails to calibrate, it maybe due to low pressure in Test Gas Bottles, mixing up the Test Gas Bottles during calibration or an aging Carbon Monoxide Sensor Cell. 1. Ensure the Test Gas supply is adequate. See Paragraph Step Initialize the Carbon Monoxide Monitor following the procedures in Paragraph This will allow for a greater percentage of compensation for the gas. 3. If the Test Gas is good and the Carbon Monoxide Monitor still refuses to calibrate, replace the Carbon Monoxide Sensor Cell. See Paragraph If it still doesn t calibrate, contact Bauer Product Support. Figure 7-4 Basic Calibration Kit ppm Carbon Monoxide Test Gas 2. Zero Test Gas 3. Fixed Flow Regulator Carbon Monoxide Sensor Cell Replacement (See Figure 7-7) When Carbon Monoxide test gas fails to show a gas response during calibration, a new Carbon Monoxide Sensor Cell is required. Most Carbon Monoxide Sensor Cells will last from one and a half to three years. After installing a new Carbon Monoxide Sensor Cell, an initialization step permits the Carbon Monoxide Sensor Cell to be calibrated to zero regardless of the background air. Caution must be taken that the inlet air is free of carbon monoxide or an Impurity Free Air test gas is used for the initial calibration. October 22, 2009 Page 129

142 UNICUS III 1. Disconnect the power from the unit. 2. Remove the four corner screws and open the Carbon Monoxide Monitor front cover. 3. Remove the screws that hold the Carbon Monoxide Sensor Cell cover. 4. Remove the Carbon Monoxide Sensor Cell from its socket by pulling it up from the circuit board. 5. Install a new Carbon Monoxide Sensor Cell. 6. Replace the Carbon Monoxide Sensor Cell Cover, ensuring the longer screw is in its indicated hole. 7. Reassemble the Carbon Monoxide Monitor and reconnect to power. 8. Let the new Carbon Monoxide Sensor Cell warm-up for an hour before doing the Initialization. 9. See Paragraph for Carbon Monoxide Monitor Initialization procedures. ^ CAUTION Be sure the power is disconnected from the unit. ^ CAUTION Be sure the shorting wire is removed from the new Carbon Monoxide Sensor Cell Carbon Monoxide Monitor Initialization Initialization of the Carbon Monoxide Monitor will need to be done if a calibration fails, the Carbon Monoxide Sensor is replaced or any other maintenance on the internal components of the Carbon Monoxide Monitor System was performed. Page 130 1st Edition, Rev. 2 Chg. 2

143 MNL Setting the LP Regulator Figure 7-5 Carbon Monoxide Monitor Initialization 1 2 See Figure Attach a Pressure Gauge (0-100 psi) to the Outlet (1) of the Regulator (3). 2. Apply 5,000 psi to the Regulator (3) using Isolation Valve (2). 3. Loosen Jam Nut (4). 4. Using an Allen wrench turn the regulator adjusting screw (5) until the Pressure Gauge reads 50 psi with an input pressure of 5,00 psi. 5. Tighten Jam Nut (4), Remove Pressure Gauge and reattach Outlet Connection Initialization Calibration Before calibration, be sure that the test gas bottles in the Calibration Kit (See Figure 7-4) have an adequate amount of gas in the them. Attach the Fixed Flow Regulator to the gas bottle and then detach it. You should hear a slight popping sound. 2. Turn on the compressor unit. The compressor itself does not have to run, because the test gas is being substituted for the air supply from the compressor. 3. The compressor unit power needs to be applied to the unit for 15 minutes so the unit can stabilize. If you attempt to calibrate before the end of this 15 minute period, TO SOON will appear on the LCD Display. 4. Lift the cap of Inlet Regulator (6) and turn counterclockwise until it stops. This will ensure that the air flow from the compressor unit is shut off. October 22, 2009 Page 131

144 UNICUS III 5. If the gas flow from the compressor unit was not shut off, a message SUPPLY OFF will appear. If this message appears, shut off the supply air and then begin the calibration process again. 6. Depress the Zero Cal Set Switch on the front of the Carbon Monoxide Monitor with a paper clip for approximately 30 seconds. 7. Connect the Zero Gas bottle to the Fixed Flow Regulator and connect it to the Calibration Port of the Carbon Monoxide Monitor. 8. Turn the valve on the Fixed Flow Regulator counterclockwise until the Carbon Monoxide Monitor Flow Indicator shows between 0.5 and 0.8 SCFH. 9. The Display should read ZERO CAL and will count down from 60 seconds. At the conclusion, the display prompts, REMOVE ZERO GAS. 10. Turn the valve on the Fixed Flow Regulator clockwise until it is closed and disconnect it from the Calibration Port. 11. Disconnect the Zero Gas Bottle and the display will indicate 20 ppm CAL GAS REQUIRED 12. Connect the 20 ppm Carbon Monoxide Test Gas to the Fixed Flow Regulator and connect it to the Calibration Port of the Carbon Monoxide Monitor. 13. Turn the valve on the Fixed Flow Regulator counterclockwise until the Carbon Monoxide Monitor Flow Indicator shows between 0.5 and 0.8 SCFH. 14. The Display will count down from 60 seconds. At the conclusion, the display will prompt to REMOVE Carbon Monoxide GAS. 15. Turn the valve on the Fixed Flow Regulator clockwise until it is closed and disconnect it from the Calibration Port and disconnect the 20 ppm Carbon Monoxide Test Gas Bottle from the Fixed Flow Regulator. 16. Allow 10 minutes for the remaining gas in the Carbon Monoxide Sensor Cell to dissipate after the calibration process. NOTICE If the compressor is started before the test gas dissipates, it could lead to incorrect Carbon Monoxide level readings. 17. Turn the compressor on, the compressor must be running, adjust Inlet Regulator to SCFH to restore normal operations. Page 132 1st Edition, Rev. 2 Chg. 2

145 MNL-0375 Figure 7-6 Carbon Monoxide Monitor Internal Components Power Connection 2. Gas Inlet 3. Audible Alarm (not used) 4. Remote Display Connection (only MNR-0033) 5. Carbon Monoxide Sensor Cell Cover 6. Alarm Connections 7. Carbon Monoxide Sensor Cell October 22, 2009 Page 133

146 UNICUS III Figure 7-7 Carbon Monoxide Sensor Cell Removal Carbon Monoxide Monitor Test Mode Buttons ^ CAUTION Except for the Carbon Monoxide Sensor Cell, all internal Carbon Monoxide monitor parts are to be serviced only by the manufacturer. Do not adjust factory settings with the setup menu Mode Buttons unless absolutely necessary and by a trained technician. The only reason to access the setup information is to test the alarm relay interface of the control system which simulates the compressor going into an alarm state. The following describes how to access the TEST MODE. ^ CAUTION Except for testing the Display LCD, adjusting the parameters set at factory incorrectly could be dangerous. Adjustment, if necessary, must be done by a trained technician. Page 134 1st Edition, Rev. 2 Chg. 2

147 MNL-0375 Figure 7-8 Mode Buttons Close-up Unscrew the four large screws on all corners of the Front Cover (See Figure 7-3). 2. Lift the Front Cover carefully, to not harm any of the attached wires inside the Carbon Monoxide monitor. 3. Find the two white mode buttons on the left side of the motherboard (See Figure 7-8). By briefly depressing the top button six times it is possible to cycle through the set up parameters to access the TEST MODE. 4. When TEST MODE is displayed simply depress the bottom Value Change Button. Depressing the Value Change Button sends an input signal to the PLC, shutting down the compressor system and annunciating a high Carbon Monoxide alarm (reference the electrical section of this manual for more information). TEST MODE also sounds the auxiliary horn (if installed) and activates the solid squares on Front Cover LED Readout. 5. The top mode button must be depressed again to return to Normal Mode. 6. Replace Front Cover and screw in place. 7.5 Remote Display Setup 1. Mode Scroll Button 2. Value Change Button NOTICE The Remote Display must not be installed more than 100 feet from the Carbon Monoxide Monitor. (See Figure 7-9) To calibrate the Remote Display, adjust the internal potentiometer with the compressor system control switched on, so the Carbon Monoxide Monitor will be energized. However do not have October 22, 2009 Page 135

148 UNICUS III the compressor running, because the air supply from the compressor is unnecessary for the Remote Display setup. 1. To calibrate the Remote Display unit during normal operation of the compressor unit, make sure the that both the compressor and Carbon Monoxide Monitor units are on. 2. Open the Remote Display (See Figure 7-9). Find the top potentiometer and adjust it to match the Carbon Monoxide Monitor Carbon Monoxide display reading. Notice that the Carbon Monoxide Monitor rounds off to whole numbers while the Remote Relay displays decimal places, so adjust as close as possible. 3. When the display readings match, reassemble the Remote Relay. Realign readings if necessary. Figure 7-9 Remote Display 1. Remote Display Calibration Screw Page 136 1st Edition, Rev. 2 Chg. 2

149 MNL Replacement Parts List Figure 7-10 Carbon Monoxide Monitor Assembly - Standard Item Qty Part No. Description Notes ASY-0890 Carbon Monoxide Monitor Assembly 1 1 MNR-0029 Carbon Monoxide Monitor 2 1 VAL-0076 Isolation Valve 3 1 REG-0043 High - Low Pressure Regulator 4 1 VAL-0432 Safety Valve 145 psi 5 1 VAL-0348 Solenoid Valve 115 VAC 1 VAL-0349 Solenoid Valve 12 VDC 6 1 REG-0060 Inlet Regulator N.S. 1 SEN-0025 Carbon Monoxide Sensor Cell N.S. 1 CYL-0020 Zero Gas Cylinder 0 ppm N.S. 1 CYL-0016 Carbon Monoxide Test Gas Cylinder 20 ppm October 22, 2009 Page 137

150 UNICUS III Figure 7-11 Carbon Monoxide Monitor Schematic A TO REMOTE DISPLAY BOARD CONNECTS TO COMPRESSOR CONTROLS WHT/BLK CO Monitor MNR-0029/MNR No Connection. DP -. DP +. Not Used. Not Used. Not Used. NO. NC. COM. RED RELAY NO. NC. COM. YELLOW RELAY CONNECTS TO COMPRESSOR CONTROLS INCOMING POWER RECORDER OUTPUT VAC RED No Connection RED 1 Jumper B POWER BOARD INT. 24V OPER TRANSFORMER A No Connection. GND. AC 1. AC 2. INT PWR. +24 VDC. No Connection. DP -. DP +. MAX 18 AWG WIRE GND. 12V EXT. 12V OPER. REMOVE JUMPER 12V OPERATION PWR SIG B/L Remote Display Board MNR-0034 N/A N/A Display Adjustment Pot. Page 138 1st Edition, Rev. 2 Chg. 2

151 MNL-0375 CHAPTER 8: CFS II MAINTENANCE 8.1 Description The UNICUS III containment fill stations are designed and have been tested to offer the operator protection against the explosive force and resulting shrapnel should a cylinder fail during the filling operation. The fill station features fill hoses complete with bleed valves and SCBA fill adapters of choice, mechanical door interlock, and a fill control panel with individual pressure gauges. 8.2 Fill Station Air Flow Refer to the Pneumatic Diagram DGM-1137, after the Appendix. From the air inlet, compressed air flows to the Fill Pressure Regulator (R1) where the desired bottle fill pressure is set and maintained. The Regulator Inlet Pressure Gauge (P1) indicates the supply pressure to the Regulator (R1). The Regulator Outlet Pressure Gauge (P2) indicates this regulated pressure. The Fill Pressure Relief Valve (RV1) ensures against overfilling the bottle if the Fill Pressure Regulator (R1) fails. The Door Interlock Valves (V1) are operated when the door is closed and the lock bar is in the down and locked position. This prevents the filling of bottles until the door is properly closed and locked. When the Mechanical Door Interlock Valves (V1) are operated it allows compressed air to flow from the outlet of the Fill Pressure Regulator (R1) to the Fill Hoses (H1) via the Fill Hose Shut Off Valve (V2). Fill Pressure Gauge (P3) is used to monitor the progress of the recharging operation. The operator closes the Fill Hose Shut Off Valve (V2) when the bottle reaches the desired pressure, stopping the flow of air to the bottle. The optional Fill Pressure Relief Valves (RV2) can be used to allow multiple fill pressures in the same CFS II. Should the operator not close the Fill Hose Shut Off Valve (V2) when the bottle is full, the Relief Valve (RV2) will open, venting excess pressure. When the recharging operation is complete the operator presses down on the Door Handle and opens the door which disengages the Mechanical Door Interlock Valves (V1) eliminating the possibility of the flow of compressed air to the bottles. Before the bottles can be removed from the fill station the bottle valve must be closed and the pressure remaining in the Fill Hoses (H1) bled off by opening the Drain/Bleed Valve (V3). 8.3 Maintenance ^ WARNING If a cylinder fails during a filling operation, the Containment Fill Station must be considered damaged beyond repair and destroyed to prevent its ever being used again General Maintenance Develop a regular program of visual inspection, looking for clogged drains and broken or missing parts. October 22, 2009 Page 139

152 UNICUS III Nonadjustable Valves The condensate drain valve, bleed valve and check valves are not adjustable. The condensate drain valve and bleed valve have seats and seals which should be replaced if the valve leaks. Check valves are not adjustable or repairable and must be replaced if they malfunction Pressure Gauges Observe the pressure gauges daily. If the readings of any of the gauges seem to be incorrect, bleed off all system pressure. Check that the gauges correctly read zero then reapply pressure to the system. If the reading is still incorrect contact Bauer Compressors for service. All broken or damaged gauges must be replaced immediately Safety Valves Figure 8-1 Safety Valves The safety valve must be checked periodically for proper functioning. 1. Operate the compressor with the shut-off valve closed until the safety valve vents. 2. Note the pressure registered on the pressure gauge. The safety valve is adjusted at the factory to the required pressure and does not normally require maintenance or readjustment. In case readjustment does become necessary, have the safety valve adjusted by a Bauer qualified technician (contact the Bauer service department for details) or return the valve to the factory Pneumatic Connections ^ WARNING Maintenance of pipe and tubing connections should not be attempted while the unit is under pressure. Serious injury or equipment damage will result if the connection fails or is loosened. After determining that a pneumatic connection is leaking. Relieve compressed air pressure and tighten just firmly enough so that leakage is stopped (finger tight plus up to an additional ½ turn as necessary). Please note that the compression type coupling fittings are capable of exerting extreme force on the tubing and should not be tightened more than is required to seal the joint. To improve the sealing of the pipe connections and to facilitate installation, the following should be observed: Page 140 1st Edition, Rev. 2 Chg. 2

153 MNL-0375 Apply a thin layer of Never-Seez NSWT or equivalent on the outside of the ferrule during assembly. Lubricate the threads of the connector with Never-Seez NSWT or a similar PFTE base lubricant to facilitate future disassembly Bearings for Bottle Door Pivot There is no need for relubrication under normal conditions. If the setscrews should become loose, tighten as follows: Setscrew diameter Hex size Recommended torque (inch lbs) 5/16 5/ Pressure Hoses The hoses should be inspected periodically for wear and damage. If a hose is worn or damaged, remove and replace it Door Gas Spring A special tool, Spring Holder, TOO-0020 is required. Figure 8-2 Special Tool, TOO-0020 To remove and install a Door Gas Spring proceed as follows: 1. Place a piece of cardboard in the bottom of the door opening to protect the finish of the Door and Enclosure. 2. Remove the Door Stop and Mount from the inside rear of the Enclosure. 3. Lower the Door until it touches the cardboard. 4. Install the Spring Holder, TOO-0020 and raise the Door until the Holder is holding the Door Gas Spring. 5. Remove the nut on the lower mounting stud and remove the Door Gas Spring from the Door. 6. Lower the Door and allow it to rest on the cardboard. 7. Remove the nut on the upper spring mounting stud and remove the Door Gas Spring. 8. Install the replacement Door Gas Spring in the reverse order. October 22, 2009 Page 141

154 UNICUS III 8.4 Replacement Parts List CFS II Assemblies Figure 8-3 CFS II Assembly Item Qty Part No. Description Notes 1 3 HOL-0076 Bottle Holder 2 1 DOR-0002 Door 3 3 HOS-0145 Fill Whip 4 1 HAN-0057 Handle N.S. 1 SPC-0008 Bottle Riser 1 per Fill Position Page 142 1st Edition, Rev. 2 Chg. 2

155 MNL-0375 Figure 8-4 CFS II Door Lock Assembly Item Qty Part No. Description Notes 1 1 LCH-0049 Door Lock 3 Fill Positions 2 3 BUS-0120 Bushing 3 2 CYL-0059 Damper 4 1 BRK-0487 Cylinder Bracket Right 1 BRK-0486 Cylinder Bracket Left October 22, 2009 Page 143

156 UNICUS III Figure 8-5 Door Handle, Pivot and Bracket Item Qty Part No. Description Notes 1 1 MTS-0314 Mount 2 1 VIB-0035 Bumper 3 2 PIN-0047 Pin 4 2 BUS-0121 Bushing 5 2 CLR-0001 Collar Page 144 1st Edition, Rev. 2 Chg. 2

157 MNL-0375 Figure 8-5 (cont.) Door Handle, Pivot and Bracket Item Qty Part No. Description Notes 6 2 Flat Head Socket Cap Screw 5/16 x 18 x ¾ UNC 7 2 Socket Head Cap Screw 3/8-16 x 1 UNC 8 2 Socket Head Cap Screw 3/8-16 x 2 UNC 9 2 Washer, Nylon 5/ BUS-0122 Bushing 11 1 SPG-0054 Spring Right Side 1 SPG-0053 Spring Left Side October 22, 2009 Page 145

158 UNICUS III Figure 8-6 CFS II Door Lock Latch Item Qty Part No. Description Notes 1 2 LCH-0048 Latch 2 2 SPG-0052 Torsion Spring 3 2 Socket Head Shoulder Screw 3/8 x 7/8 4 6 Nylon Flat Washer 3/8 Page 146 1st Edition, Rev. 2 Chg. 2

159 MNL-0375 Figure 8-7 CFS II Door Interlock Item Qty Part No. Description Notes 1 2 VAL-0130 Interlock Valve 2 1 BRK-0488 Bracket 3 2 LEV-0018 Lever 4 1 HOS-0147 Hose 1st Fill Position 5 2 HOS-0146 Hose 2nd and 3rd Fill Positions 6 1 SCR-0078 Hex Head Cap Screw ¼-20 x 4 UNC 7 1 SPG-0056 Gas Spring 8 2 LCH-0048 Latch See Figure LCH-0049 Latch See Figure CYL-0059 Damper See Figure Hex Head Cap Screw ¼-20 x 4½ UNC October 22, 2009 Page 147

160 UNICUS III Fill Hose Assemblies Figure 8-8 Standard Fill Hose Assembly 2 3 Relief Option Item Qty Part No. Description Notes 1 1 HOS-0145 Fill Hose Bleed Valve 3 2 ELL-0018 Elbow 4 1 ADP-0112 Adapter 4,500 / 2,216 psi Cylinder 1 ADP-0113 Adapter 4,500 psi Cylinder 5 1 YOK-0001 Fill Yoke 6 1 TEE-0012 Tee 7 1 VAL-0169 Safety Valve 8 1 N04483 O-ring Page 148 1st Edition, Rev. 2 Chg. 2

161 MNL-0375 Figure 8-9 Multi Fill Hose Assembly Relief Option 6 1 Item Qty Part No. Description Notes 1 1 YOK-0001 Fill Yoke 2 3 ELL-0018 Elbow 3 1 ADP-0112 Adapter 4,500 / 2,216 psi Cylinder 1 ADP-0113 Adapter 4,500 psi Cylinder Bleed Valve 5 1 HOS-0145 Fill Hose 6 2 CON-0223 Quick Disconnect Plug 7 1 TEE-0014 Tee 8 1 VAL-0169 Safety Valve 9 1 N04483 O-ring October 22, 2009 Page 149

162 CHAPTER 9: UNICUS III HP AIR STORAGE UNICUS III 9.1 Bottle Specifications Storage systems are available to meet the code requirements of either the Department of Transportation or the American Society of Mechanical Engineers. Operating temperature range for storage systems is - 20 F to 150 F. To - 40 F is an available option D.O.T. Department of Transportation These vessels are approved by the Department of Transportation. The cylinders must be equipped with the proper cylinder valve and CGA recommended outlet. Retest period for D.O.T and 6000 psig cylinders is mandatory every five (5) years in accordance with 49/CFR Bauer can supply 5000 psig and 6000 psig D.O.T. systems complete with interpiping, pressure gauges, cylinder valves and check valve. Optional mounting racks are available A.S.M.E. American Society of Mechanical Engineers Each vessel should have a shut-off valve and an A.S.M.E. approved safety valve. Vessels with working pressures of 5000 psig, have a safety factor of 4 to 1. Vessels with working pressures of 6000 psig, have a safety factor of 3 to 1. Bauer can supply 5000 psig and 6000 psig A.S.M.E. storage systems complete with interpiping, pressure gauges, safety valves, cylinder valves and check valves. Optional mounting racks are available. Vessel D.O.T AMSE 5,000 psig 6,000 psig 5250 psig 6,600 psig Material Lightweight Steel Alloy Steel ASME SA 372 Class V Type A AISI 4130 Volume psig psig 424 5,000 psig 481 6,000 psig Working Pressure 5,000 psig 6,000 psig 5,000 psig 6,000 psig Test Pressure 7,500 psig 9,000 psig 7,875 psig 10,500 psig Diameter 9 3/8 9 9/32 9 5/8 9 5/8 Height 55 with Valve 55 without Valve Weight 158 lbs 188 lbs 400 lbs Cylinder CGA 347 CGA 702 Standard Valve Supplied Finish Primer and Topcoat Primer and Topcoat Page 150 1st Edition, Rev. 2 Chg. 2

163 MNL Description and Maintenance Description The air storage system consists of one (or more) D.O.T. or A.S.M.E. storage vessels with line valves, safety valves, interconnecting tubing, pressure gauges, check valves and mounting clamps. D.O.T. vessels are approved by the Department of Transportation for portable usage. D.O.T. systems are available at 5,000 psi and 6000 psi. A.S.M.E. vessels conform to the American Society of Mechanical Engineers codes for permanent installation. These vessels have working pressures of 5000 psig, with a safety factor of 4 to 1; and 6000 psig, with a safety factor of 3 to 1. A safety device is provided on each vessel to protect against excess pressure. It is preset at the factory and sealed. It should not be adjusted. Figure 9-1 UNICUS III Storage System October 22, 2009 Page 151

164 9.2.2 Maintenance UNICUS III Storage Bottles All storage bottles should be visually inspected internally every year. Every five (5) years, D.O.T. bottles must be hydrotested. Check local and state regulations regarding testing of ASME or D.O.T. bottles. Some states require an annual visual inspection, and hydrotesting requirements also differ from state to state Pressure Gauges 1. Observe the pressure gauges daily. 2. If the readings of any of the gauges seem to be incorrect, bleed off all system pressure. 3. Then, remove the gauge and check for wear and tear, accuracy and proper functioning by comparing it to a precision test gauge or a dead weight tester. 4. Replace all broken or damaged gauges immediately Tube Connections Pipe connections (swivel nuts): Tighten just firmly enough so that leakage is stopped (finger tight plus up to an additional ½ turn as necessary). Please note that the compression type coupling fittings are capable of exerting extreme force on the tubing and should not be tightened more than is required to seal the joint. To improve the sealing of the pipe connections and to facilitate installation apply a thin layer of Never- Seez NSWT or a similar PFTE base lubricant to the ferrule and the threads of the connector to facilitate future disassembly. Page 152 1st Edition, Rev. 2 Chg. 2

165 MNL Safety Valve Figure 9-2 Safety Valve Develop a regular program of visual inspection, looking for clogged drains and discharge pipe, dirt build-up in and around the valve seat, and broken or missing parts. Avoid excessive operation of the safety valve, as even one opening can provide a means for leakage. Safety valves should be operated only often enough to assure that they are in good working order. Do not paint, oil or otherwise cover any interior or working parts of any safety valve. They do not require any lubrication or protective coating to work properly Pressure Hoses The hoses should be inspected periodically for wear and damage. If a hose is worn or damaged, remove and replace it. October 22, 2009 Page 153

166 CHAPTER 10: CONTROLS AND INDICATORS 10.1 Component Locations UNICUS III Figure 10-1 Front Panel Cascade Panel Pressure Gauges 2. Cascade Panel Valves 3. Fill Selector Valve 4. Fill Pressure Gauge 5. Regulator Valve 6. Compressor Final Pressure Gauge 7. Compressor Control Panel 8. Emergency Stop Switch 9. Bottle Fill Valves 10. Bottle Fill Pressure Gauges Page 154 1st Edition, Rev. 2 Chg. 2

167 MNL-0375 Figure 10-2 Gauge Panel Compressor Oil Pressure Gauge 2. 1st Stage Pressure 3. 2nd Stage Pressure 4. 3rd Stage Pressure October 22, 2009 Page 155

168 UNICUS III Figure 10-3 Components for Remote Fill Option Remote Fill Regulator 2. Remote Fill Pressure Gauge 3. Remote Fill Valve 4. Storage Drain Valves 5. Hose Guide 6. Hose Stop 7. Hose 8. Bleed Valve 9. Hose Reel Page 156 1st Edition, Rev. 2 Chg. 2

169 MNL Replacement Parts List Figure 10-4 Front Panel Parts Item Qty Part No. Description Notes 1 6 VAL-0076 Needle Valve 2 9 GAG-0009W Pressure Gauge 7,500 psi 3 1 VAL way Ball Valve 4 1 REG-0039 Air Pressure Regulator 6,000 psi 5 1 MNR-0049 Compressor Control Panel Maple System, Touch Screen 6 1 SWT-0244 E-stop Switch October 22, 2009 Page 157

170 UNICUS III Figure 10-5 Gauge Panel Parts Item Qty Part No. Description Notes 1 1 GAG-0042W 2.5 Indicator psi 2 1 GAG-0006W 2.5 Indicator psi 3 1 GAG-0007W 2.5 Indicator psi 4 2 GAG-0008W 2.5 Indicator psi Page 158 1st Edition, Rev. 2 Chg. 2

171 MNL-0375 Figure 10-6 Remote Fill Option Parts Item Qty Part No. Description Notes 1 1 REG-0039 Air Pressure Regulator 6,000 psi 2 1 GAG-0009W Pressure Gauge 7,500 psi 3 5 VAL-0076 Needle Valve 4 1 GDE-0003 Hose Guide 5 1 STP-0008 Hose Stop 6 1 HOS-0164 Air Hose 75 feet 7 1 VAL Bleed Valve 8 1 REL-0009 Hose Reel 75 feet maximum October 22, 2009 Page 159

172 CHAPTER 11: APPENDIX 11.1 Safety UNICUS III General Safety Precautions Read the operating manual before installing or operating this compressor unit. Follow appropriate handling, operation and maintenance procedures from the very beginning. The maintenance schedule contains measures required to keep this compressor unit in good condition. Maintenance is simple, but must be executed regularly to achieve safe operation, maximum efficiency and long service life. We recommend that all maintenance work be recorded in a service book, showing the date and details of the work carried out. This will help to avoid expensive repairs caused by missed maintenance work. If it is necessary to make a claim against the warranty, it will help to have proof that regular maintenance has been carried out and that the damage has not been caused by insufficient maintenance. This compressor unit must be installed, operated, maintained and repaired only by authorized, trained and qualified personnel. Consult and follow all OSHA, NEMA, ASME and local regulations, laws and codes covering the installation and operation of this compressor and accessories before operating the unit. Do not operate this unit in excess of its rated capacity, speed, pressure, temperature, or otherwise than in accordance with the instructions contained in this manual. Operation of this unit in excess of the conditions set forth in this manual will subject the unit to limits which it may not be designed to withstand. Keep safety guards in place. Do not modify the compressor or its systems. Do not wear loose clothing around machinery. Loose clothing, neckties, rings, wrists watches, bracelets, hand rags, etc. are potential hazards. Provide adequate fire protection. Make sure fire extinguishers are accessible. Select alternate routes of escape and post such routes. Make sure you are equipped with all required safety equipment; hearing protection, safety glasses, hard hats, safety shoes and fire extinguisher. Visually inspect the unit before starting. Remove and/or replace any loose or broken components, tools, valves, missing equipment, etc. Do not tamper with, modify, or bypass safety and shutdown equipment. Do not tighten or adjust fitting or connections under pressure. The use of plastic pipe or rubber hose in place of steel tube or iron pipe, soldered joints or failure to ensure system compatibility of flex joints and flexible hose can result in mechanical failure, property damage, and serious injury or death. The use of plastic or nonmetallic bowls on line filters without metal guards can be dangerous. Replace damaged fan blades promptly. Fan assemblies must remain in proper balance. An unbalanced fan can fly apart and create an extremely dangerous condition. Page 160 1st Edition, Rev. 2 Chg. 2

173 MNL-0375 Allow the compressor to cool before servicing. Whenever the compressor is shut down and overheating is suspected, a minimum period of 15 minutes must elapse before opening the crankcase. Premature opening of the crankcase of an overheated unit can result in an explosion. Incorrect placement of the inlet and pressure valves in a compressor cylinder head can cause an extremely dangerous condition. Refer to the appropriate section of this manual before installing or replacing valves. Before doing any work involving maintenance or adjustment, be sure the electrical supply has been disconnected, and the complete compressor system has been vented of all internal pressure. Failure to follow these warnings may result in an accident causing personal injury and/or property damage. Before working on the electrical system, be sure to disconnect the electrical supply from the system at the circuit breaker or other manual disconnect. Do not rely on the ON/OFF switch to disconnect the electrical supply. Installer must provide an earth ground and maintain proper clearance for all electrical components. All electrical installation must be in accordance with recognized national, state, and local electrical codes. Do not use gasoline, diesel fuel or other flammable products as a cleaning solution. A compressor which has been used for gas service is unsuitable for air applications. Should the purchaser and/or user proceed to use the compressor for air service after it has been used for gas, the purchaser and/or user assumes all liability resulting therefrom without any responsibility being assumed by Bauer Compressors, Inc. The purchaser is urged to include the above provision in any agreement for resale of this compressor. The use of repair parts other than those listed in this manual or purchased from Bauer Compressors, Inc. may create unsafe conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, Bauer Compressors, Inc. can bear no responsibility for equipment in which non-approved repair parts are installed October 22, 2009 Page 161

174 UNICUS III Safety Warning Labels Notes, labels and warning signs are displayed on the compressor unit according to model, application or equipment and may include any of the following. HOT SURFACES DO NOT TOUCH! Danger of burning if cylinders, cylinder heads, or pressure lines of individual compressor stages are touched. HIGH VOLTAGE! Life threatening danger of electrical shock. Maintenance work on electric units or operating equipment should be carried out by a qualified electrician or by a person supervised by a qualified electrician according to electrical regulations. AUTOMATIC COMPRESSOR CONTROL UNIT MAY START WITHOUT WARNING! Before carrying out maintenance and repair work, switch off at the main switch and ensure the unit will not restart. THE INSTRUCTIONS MUST BE READ BEFORE OPERATING UNIT! The instruction manual and all other applicable instructions, regulations, etc. must be read and understood by the operating personnel before using the machine. HEARING PROTECTION MUST BE WORN! Hearing protectors must be worn when working on a machine which is running. DIRECTION OF ROTATION! When switching on the machine, check the arrow to ensure correct direction of rotation by the drive motor. Page 162 1st Edition, Rev. 2 Chg. 2

175 MNL Unpacking, Handling and Installation Unpacking and Handling This compressor unit is packaged according to the requirements for shipping via the requested type of carrier service. It is possible that the compressor unit could have been damaged during shipping. For this reason, we urge you to thoroughly examine the unit for possible damage and report any such damage to the shipping company immediately. Care must be taken in unpacking the compressor unit. Serious damage could result by not checking for clearance between the item being unpacked and the packaging to be removed. Handling of the unpacked unit should be performed using only the following devices. See Figure Figure 11-1 Lifting Devices Chain Hoist Fork Lift 1. Forklift 2. Chain Hoist 3. Hand Truck ^ WARNING Hand Truck Be sure the lifting devices are capable of handling the weight of the unit (see Paragraph 1.4 for the weight of the unit). Before lifting the unit, secure all loose or swinging parts to keep them from moving. Stay clear of lifted load. The compressor unit may be furnished with one or more shipping braces for shipping and handling only. After installation and before operation, these braces must be removed entirely. Under no circumstances should the braces remain installed during operation or the manufacturer s warranty for the compressor unit will be voided. The braces are all tagged and labeled. October 22, 2009 Page 163

176 UNICUS III Installation of the Compressor Unit The floor of the site must be capable of supporting the weight of the unit. Position the unit so that it is level. The maximum permissible inclination of the compressor unit is listed in Paragraph 1.4. Ensure that the compressor air intake is supplied with fresh air. The intake air must not contain any exhaust fumes or flammable vapors such as paint solvents, which may cause an internal fire. Make sure that the intake air is unobstructed and moisture in the intake air is kept to a minimum. It is important that units draw in clean air. The quality of the incoming air determines the quality of the compressed air. This is important even for industrial air, as any incoming fumes will also be compressed and will increase the toxicity to anyone working with the compressed air. If a remote control is provided, the unit must be equipped with a clearly visible plate warning the possibility of the unit starting. As an additional measure, anyone starting the unit by remote control must make sure that no one is checking or operating the unit. For this purpose, a second warning plate should be provided at the remote control unit. Observe and maintain an ambient temperature range of 43 to 113 F. ^ CAUTION The inclination values listed in Paragraph 1.4 are valid only if the oil level of the compressor is level with but does not exceed the upper mark of the oil dipstick or oil level sight glass AUTOMATIC COMPRESSOR CONTROL UNIT MAY START WITHOUT WARNING! Before carrying out maintenance and repair work, switch off at the main switch and ensure the unit will not restart. The area in which the compressor unit is installed should be well lit and easily accessible to facilitate servicing and routine maintenance. Page 164 1st Edition, Rev. 2 Chg. 2

177 MNL Securing and Leveling the UNICUS III Figure 11-2 Securing and Leveling the UNICUS III Adjusting Bolt 2. Locking Nut 3 3. Leveling Foot 4. Anchoring Foot Secure the UNICUS III to the floor using ½ bolts. The feet at the ends of the unit are used for leveling and securing the UNICUS III, the middle feet are for leveling only. Install the Adjusting Bolts (1) and Locking Nuts (2) until the Leveling Foot (3) can be attached. Adjust the all of the Adjusting Bolts until the Leveling Foot touches the ground and the UNICUS III is level. The Anchor Foot is then positioned as desired and the appropriate anchor hardware installed. The Locking Nuts are then tightened to prevent the Leveling Foot from moving Ventilation During normal compression, heat is generated by the compressor and by the drive motor or engine. For air-cooled compressor units, this heat needs to be vented away by sufficient ventilation Outdoor Installation It is recommended that all gasoline and diesel engine driven compressor units be installed outdoors. Additionally, electrically driven compressor units may be installed outdoors only if enclosed with weatherproof enclosure panels Indoor Installation The best location to install the compressor unit indoors is against an outside wall with a suitably large air vent in front of the cooling fan. Additionally, it is necessary to position an exhaust opening in the opposite wall, close to the ceiling or in the ceiling. As a basic rule of thumb, the room should be ventilated sufficiently so as to prevent the ambient room temperature from exceeding 105 F. Additional heat generating equipment or piping should be avoided or must be well insulated. October 22, 2009 Page 165