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Bauer Compressors UNICUS 4i-25 Instruction Manual And Replacement Parts List

Stationary integrated systems high pressure breathing air system
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Instruction Manual and Replacement Parts List
Stationary Integrated Systems
High Pressure Breathing Air System
UNICUS 4i - 25
September 23, 2020
BAUER Compressors, Inc.
1328 Azalea Garden Road
Norfolk, Virginia 23502-1944
2nd Edition, Rev. 0 Chg. 8
© Bauer Compressors, Inc.
MNL-0021
Phone: (757) 855-6006
Fax: (757) 855-6224
www.bauercomp.com

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Summary of Contents for Bauer Compressors UNICUS 4i-25

  • Page 1 Stationary Integrated Systems High Pressure Breathing Air System UNICUS 4i - 25 September 23, 2020 2nd Edition, Rev. 0 Chg. 8 MNL-0021 © Bauer Compressors, Inc. BAUER Compressors, Inc. Phone: (757) 855-6006 1328 Azalea Garden Road Fax: (757) 855-6224 Norfolk, Virginia 23502-1944...
  • Page 2 UNICUS 4i This information is believed to be accurate by Bauer Compressors, Inc., as of it’s date of publication, but Bauer offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information set forth herein. Bauer shall not be liable for inaccuracies in, or consequences resulting from, your use of this information.

  • Page 3: Fcc Compliance Statement

    MNL-0021 FCC Compliance Statement Changes or modifications not expressly approved by the manufacturer could void the user’s authority to operate this equipment. This product meets the applicable FCC Part 15 rules and Industry Canada's license exempt RSSs. Opera- tion is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

  • Page 4: Table Of Contents

    UNICUS 4i Table of Contents CHAPTER 1:- - - - - - - - - - - - - - - - - - - - - INTRODUCTION HOW TO USE THIS MANUAL............................1 1.1.1 Manual Safety Notices ...............................1 HOW TO USE THE REPLACEMENT PARTS LIST .....................2 HOW TO USE THE APPENDIX ............................3 UNIT SPECIFICATIONS ..............................4 1.4.1...
  • Page 5 MNL-0021 3.1.4 Intake Filter ..................................25 3.1.4.1 Description..................................25 3.1.4.2 Maintenance.................................. 25 3.1.5 Interstage Separators ................................ 26 3.1.5.1 Description..................................26 3.1.5.2 Maintenance.................................. 27 3.1.6 Compressor Valves and Valve Heads ..........................28 3.1.6.1 Functional Description..............................28 3.1.6.2 Initial Operational Check of the Valves ........................28 3.1.6.3 General Instructions for Changing the Valves......................
  • Page 6 UNICUS 4i 4.1.8 Chambers..................................81 4.1.8.1 Purification Cartridge Operating Hours Form ......................83 1P5S SECURUS II® PURIFICATION SYSTEM ......................84 4.2.1 P5S Securus II® Purification System Major Components....................84 COMPONENT DESCRIPTION............................85 4.3.1 Oil and Water Separator ..............................85 4.3.2 Chamber ...................................85 4.3.3 Cartridge ...................................85 4.3.3.1 Cartridge Construction..............................85 4.3.3.2 Cartridge Handling ...............................86...
  • Page 7 MNL-0021 6.5.1 Final Separator Warning ..............................104 6.5.2 Compressor High Temperature ............................104 6.5.3 Compressor Low Oil Pressure............................105 REPLACEMENT PARTS LIST............................. 106 CHAPTER 7: - - - - - - - - - - - - - - - - - - - - - - -RFID OPTION DESCRIPTION................................
  • Page 8 UNICUS 4i 10.2.2.5 Pressure Hoses ................................133 10.3 AUTOCASCADE SYSTEM ............................134 10.3.1 General ...................................134 10.3.2 Electrical..................................135 10.3.3 Filling the Storage Banks ...............................135 10.3.4 Filling Bottles from the Storage Banks ..........................135 10.3.5 Manual Bypass ................................135 CHAPTER 11: - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX 11.1 SAFETY ....................................136 11.1.1 General Safety Precautions.............................136...
  • Page 9 MNL-0021 List of Figures CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION Figure 1-1 Compressor Identification Label ..........................3 Figure 1-2 UNICUS 4i ................................5 Figure 1-3 UNICUS 4i Rear..............................
  • Page 10 UNICUS 4i Figure 3-17 Discharge Valve Removal .............................33 Figure 3-18 Assembly Tool...............................34 Figure 3-19 Using Special Tool ..............................34 Figure 3-20 Crankcase Assembly..............................38 Figure 3-21 Complete Crankshaft Assembly ..........................40 Figure 3-22 1st Stage Piston and Cylinder ..........................41 Figure 3-23 2nd & 4th Stage Piston and Cylinder ........................42 Figure 3-24 3rd Stage Piston and Cylinder ..........................44 Figure 3-25...
  • Page 11 MNL-0021 Figure 4-13 Oil and Water Separator Parts List........................92 Figure 4-14 27” Chamber Assembly Parts List ........................93 Figure 4-15 Securus II® Electronic Moisture Monitor System Parts List................94 CHAPTER 5: - - - - - - - - - - - COMPRESSOR DRIVE; UNICUS 4I Figure 5-1 Vertical Drive with Idler (typical).........................
  • Page 12 UNICUS 4i Figure 9-6 Door Handle, Pivot and Bracket..........................125 Figure 9-7 CFS III Door Interlock............................126 Figure 9-8 Standard Fill Hose Assemblies..........................127 Figure 9-9 Fill Whips with Options ............................128 CHAPTER 10: - - - - - - - - - - - - - UNICUS III HP AIR STORAGE Figure 10-1 UNICUS III Storage Systems..........................132 Figure 10-2...

  • Page 13: Chapter 1: Introduction

    CHAPTER 1: INTRODUCTION 1.1 How To Use This Manual This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. prod- ucts listed on the front cover. All instructions in this manual should be observed and carried out as written to prevent damage or pre- mature wear to the product or the equipment served by it.

  • Page 14: How To Use The Replacement Parts List

    UNICUS 4i CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or mod- erate injury. It may also be used to alert against unsafe practices. NOTICE NOTE advise of technical requirements that require particular attention by the operator or the mainte- nance technician for proper maintenance and utilization of the equipment.

  • Page 15: How To Use The Appendix

    MNL-0021 Figure 1-1 Compressor Identification Label 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 life- threatening, cause substantial bodily injury, and/or result in damage to the equipment.

  • Page 16: Unit Specifications

    UNICUS 4i 1.4 Unit Specifications All specifications are subject to change without prior notice. 1.4.1 UNICUS 4i - 25 Medium Charging Rate 25.2 scfm (714 l/min) Free Air Delivery 21.0 scfm (595 l/min) Inlet pressure atmospheric Operating pressure, max. 6,000 psig (420 bar) Ambient temperature range 40 - 115 °F (5 - 45 °C) Weight...

  • Page 17: Component Locations

    MNL-0021 1.5 Component Locations Figure 1-2 UNICUS 4i 1. Lab On Locale (LOL) 6. Containment Fill Station Controls 2. Electronic Auto Cascade 7. 12” Touch Screen Monitor 3. Electrical Enclosure 8. Purification 4. HP Hose Reel 9. Containment Fill Station 5.

  • Page 18: Figure 1-3 Unicus 4I Rear

    UNICUS 4i Figure 1-3 UNICUS 4i Rear 1. Air Compressor 3. HP Storage (ASME or ISO/UN) 2. Automatic Condensate Drain Assembly Page 6 2nd Edition, Rev. 0 Chg. 8...

  • Page 19: Figure 1-4 Unicus 4I Front Panel

    MNL-0021 Figure 1-4 UNICUS 4i Front Panel 1. Hose Reel Fill Valve 3. Emergency Stop Push Button 2. CFS Fill Valves 4. Touch Screen Control Monitor September 23, 2020 Page 7...

  • Page 20: Chapter 2: Operating Instructions

    UNICUS 4i CHAPTER 2: OPERATING INSTRUCTIONS The following instructions apply to the Unicus 4i. The monitor for this unit is a 15” graphic touch screen and uses a Windows 7, 64 bit operating system. Figure 2-1 Control Panel 1. Hose Reel Fill Valve 2.

  • Page 21: Admin. Main Menu Screen

    MNL-0021 Figure 2-2 Initial Screen 2.2.2 Admin. Main Menu Screen Figure 2-3 Admin. Main Menu Screen Once an administrative user has logged in they will be presented with the Admin. Main Menu screen. Along the right side are navigation keys. The HOME button presents the operator Home page, this is used to operate the unit.

  • Page 22: Personnel

    UNICUS 4i Along the left side of the screen are the following buttons which allow administrator to perform essential tasks. 2.2.2.1 PERSONNEL The personnel button will take the administrator to a page where they can ADD, DELETE, or EDIT the files for each person in the database.

  • Page 23: Cylinders

    MNL-0021 Figure 2-5 Add New Badge number Prefix Suffix Given name Middle name Family name Member of Password/PIN Status Users [4-20] Active 2.2.2.2 Cylinders Figure 2-6 Cylinders The cylinders button takes the administrator to a page similar to the personnel page however this page is for the cylinders database.

  • Page 24: Settings

    UNICUS 4i Figure 2-7 Add New Cylinder SCBA Serial # Initial Date Next Hydro Date Status 3/17/2017 3/17/2017 ACTIVE Expire Date RFID Serial # 3/17/2017 Max Pressure Setpoint The SCBA Serial # and MAX Pressure Setpoint must be entered. The Initial Date, Next Hydro Date, and Expire Date will self fill with the present date.

  • Page 25: Setup

    MNL-0021 2.2.2.3.1 Setup Figure 2-9 Setup the SETUP button allows the administrator to adjust the display of pressure as PSI or BAR and the Tem- perature as Fahrenheit or Celsius. On the Setup page the administrator can see the display of unit’s serial number, PLC program version and the monitor’s program version.

  • Page 26: Maintenance

    UNICUS 4i 2.2.2.3.3 Maintenance The maintenance screen lists the maintenance schedule by working hours, and calendar days. Also dis- played here are the Total run time of the unit and when the last maintenance was performed. 2.2.2.3.4 Gas Sensor The final button on the settings page is the gas sensor setup. This screen will walk the administrator through the steps to zero and calibrate the gas sensor if your unit is equipped with one.

  • Page 27: Home Screen

    MNL-0021 Figure 2-12 Diagnostic 2.2.3 Home Screen The HOME button at the top of the screen on the right hand side takes the administrator to the home screen that a user or guest would initially see after logging in. Figure 2-13 Home Screen, Operator This screen displays the pressure of each storage bank, the compressor’s oil pressure and final pressure.

  • Page 28: Compressor Status

    UNICUS 4i 2.2.3.1 Compressor Status Under the ADMIN button is the COMPRESSOR STATUS button. This button takes the user to the status page. Figure 2-14 Compressor Status The compressor status page displays the following ► Compressor Status ► Current Run Time ►...

  • Page 29: Remote Fill

    MNL-0021 Figure 2-15 Fill Cylinders See Paragraph 2.3 for information on mechanical aspects of filling cylinders. On the fill cylinders screen, for each cylinder to be filled, use the drop down box for each fill position to select the cylinder’s SCBA number .

  • Page 30: Fill Station Operation

    UNICUS 4i 2.3 Fill Station Operation. WARNING Every bottle is stamped with a maximum pressure and the last inspection date. Do not fill a bottle with an outdated inspection stamp. WARNING Visually inspect each bottle and valve for signs of damage before filling. Do not fill any bottles which appear to be damaged.

  • Page 31: Remote Fill Connection

    MNL-0021 3. Place the bottles to be filled into the holder and connect the fill adapters to the bottles valve using a fill hose with the CGA-346 fill adapter for 2,216 psi bottles, a CGA-347 adapter for 4,500 psi bot- tles or a SCUBA yoke for SCUBA bottles.

  • Page 32: Connecting An Air Bottle

    UNICUS 4i 2.3.1.1 Connecting an Air Bottle Connect to the air bottle valve using a fill hose with the CGA-346 fill adapter for 2,216 psi bottles, a CGA-347 adapter for 4,500 psi bottles or a SCUBA yoke for SCUBA bottles. The CGA-347 fill adapter seals on 4,500 psi rated bottle valves, but vents on lower rated pressure bottles.

  • Page 33: Description

    MNL-0021 CHAPTER 3: IK 18.1 II COMPRESSOR BLOCK 3.1 Description The IK18.1 II compressor is used to compress air up to 6,000 psi. This compressor is a four cylinder, five 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.

  • Page 34: Air Flow Diagram

    UNICUS 4i 3.1.2 Air Flow Diagram Figure 3-2 Five Stage Compressor Air Flow 1. Intake filter 8. 2nd stage Separator 2. Intercooler 1st stage 9. 4th stage Separator 3. Intercooler 2nd stage 10. Pressure Safety Valve, 1st stage 4. Intercooler 3rd stage 11.

  • Page 35: Oil Level Check

    MNL-0021 pressor block. The oil pressure sensor (2) allows mounting for an optional oil pressure gauge or elec- tronic pressure monitoring. Figure 3-3 Lubrication Oil System Figure 3-4 Oil Sight Gauge 1. Oil Pump Housing 4. Oil Pressure Regulating Valve 2.

  • Page 36: Figure 3-5 Oil Sight Gauge & Drain

    UNICUS 4i Figure 3-5 Oil Sight Gauge & Drain 1. Oil Fill Cap 2. Oil Drain Valve Figure 3-6 Removing the Oil Filter Cover Figure 3-7 Replacing the Oil Filter 1. Run the compressor until it is warm. 2. Remove cap from Oil Filler Sight Gauge. 3.

  • Page 37: Venting The Oil Pump

    MNL-0021 8. Fill new oil through filler neck to the Maximum mark on the Oil Fill Sight Gauge. 9. Pour oil in slowly, wait until the level settles then replace cap in the Oil Fill Sight Gauge. 10. Return the unit to operation. 3.1.3.6 Venting the Oil Pump CAUTION To avoid damage after maintenance the following measures should be strictly adhered to.

  • Page 38: Interstage Separators

    UNICUS 4i 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 enter- ing the intake manifold. 4.

  • Page 39: Maintenance

    MNL-0021 3.1.5.2 Maintenance The interstage Separators require no maintenance. Figure 3-9 2nd Stage Interstage Separator Figure 3-10 3rd & 4th Stage Interstage Separator 1. Separator Head 4. Center Insert 1. Separator Head 5. O-ring 2. Knurled Nut 5. Separator Body 2.

  • Page 40: Compressor Valves And Valve Heads

    UNICUS 4i 3.1.6 Compressor Valves and Valve Heads 3.1.6.1 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.

  • Page 41: Changing The 1St Stage Valves

    MNL-0021 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.

  • Page 42: Installation Procedure

    UNICUS 4i 3.1.6.4.2 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. 3.1.6.5 Changing the 2nd Stage Valves Figure 3-14 2nd Valve Head and Valves...

  • Page 43: Changing The 3Rd Stage Valves

    MNL-0021 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. 3.1.6.6 Changing the 3rd Stage Valves See Figure 3-14 Figure 3-15...

  • Page 44: Changing The 4Th/5Th Stage Valves

    UNICUS 4i 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.

  • Page 45: Discharge Valve Removal Procedure

    MNL-0021 3.1.6.7.1 Discharge Valve Removal Procedure See Figure 3-16 1. Remove piping connected to the 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.

  • Page 46: Inlet Valve Removal And Installation

    UNICUS 4i 3.1.6.7.3 Inlet Valve Removal and Installation Figure 3-18 Assembly Tool Figure 3-19 Using Special Tool 1. If the assembly tool shown in Figure 3-18 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) fac- ing up.
  • Page 47 MNL-0021 Table 3-1: Maintenance Interval Tasks Every Year or 500 Hours for Breathing Air Compressors; Every Year or 1,000 Hours for Industrial Compressors Clean Separators, Empty Condensate Tank Exchange Intake Filter Perform Leak Test and Visual Inspection Electrical Terminals must be Tightened at Each Maintenance Change Gaskets, Seals and O-Rings Included in Maintenance Kit Check Pressure Vessels, Record Number of Load Cycles Check Settings for Pressure Switches and Pressure Relief Valves...
  • Page 48 UNICUS 4i Table 3-1: Maintenance Interval Tasks (Continued) Every 4 Years or 2,000 Hours for Breathing Air Compressors; Every 4 Years or 4,000 Hours for Industrial Compressors Check Temperature Sensors, Replace if Required Change Fan Belts (if applicable) Check cylinders, pistons and piston rings Replace Drive Belt(s) Page 36 2nd Edition, Rev.

  • Page 49: Troubleshooting

    MNL-0021 3.1.7.2 Troubleshooting Trouble Cause Remedy No oil pressure 1. Low oil level 1. Check oil level 2. Air trapped in oil pump. 2. Vent Oil Pump 3. Compressor rotates in the 3. Reverse two of the three wrong direction phase leads at the switch box.

  • Page 50: Replacement Parts List

    UNICUS 4i 3.1.8 Replacement Parts List Figure 3-20 Crankcase Assembly 32 33 Item Qty Part No. Description Notes  78577 Crankcase Assembly N20649 Screw 68586 Cover Plate N15093 O-ring N26281 Shaft Seal N370 Self Locking Hex Nut Washer 78897 Bearing Cover N3138 Stud N18303...
  • Page 51 MNL-0021 Figure 3-20 (cont.) Crankcase Assembly Item Qty Part No. Description Notes 3177 Gasket N2638 Roller Bearing N4467 Eye Bolt 1492 Washer 79225 Hexagonal Spacer N4150 Stud 80197 Reducer N293 Gasket N204 Plug N1314 Gasket Washer N312 Hex Head Screw 78571 Bracket N4261...

  • Page 52: Figure 3-21 Complete Crankshaft Assembly

    UNICUS 4i Figure 3-21 Complete Crankshaft Assembly Item Qty Part No. Description Notes  161929 Crankshaft Assembly 78936 Crankshaft 68587 Bushing N4366 Dowel Screw N108 Spring Washer N2765 Hex Nut N18310 Circlip N423 Circlip † … Counterweight Available only with 161929 4220 Spacers †...

  • Page 53: Figure 3-22 1St Stage Piston And Cylinder

    MNL-0021 Figure 3-22 1st Stage Piston and Cylinder Item Qty Part No. Description Notes  79420 1st Stage Piston and Cylinder Assembly 79017 Cylinder N2621 O-ring N26036 Stud 79720 Piston Assembly #5 - 8 79719 Piston 130 mm N2930 Piston Pin N484 Circlip N2963...

  • Page 54: Figure 3-23 2Nd & 4Th Stage Piston And Cylinder

    UNICUS 4i Figure 3-23 2nd & 4th Stage Piston and Cylinder Item Qty Part No. Description Notes  127813 2nd Stage Cylinder Assembly Items 1 - 10 127812 Cylinder N3731 O-ring N215 Stud Washer N370 Self Locking Hex Nut  127779 Stepped Piston Assembly Items 6 - 10...
  • Page 55 MNL-0021 Figure 3-23 (cont.) 2nd and 4th Stage Piston and Cylinder Item Qty Part No. Description Notes 78337 Piston N35556 Piston Ring Set N29082 O-ring N215 Stud Washer N370 Self Locking Hex Nut September 23, 2020 Page 43...

  • Page 56: Figure 3-24 3Rd Stage Piston And Cylinder

    UNICUS 4i Figure 3-24 3rd Stage Piston and Cylinder Item Qty Part No. Description Notes  068595 3rd Stage Piston and Cylinder Assembly 67061 Cylinder N7063 O-ring 82295 Guide Cylinder N3731 O-ring 070013 Piston Assembly Items 6 and 7 N4378 Piston N16313 Piston Ring Set...

  • Page 57: Figure 3-25 5Th Stage Cylinder And Piston

    MNL-0021 Figure 3-25 5th Stage Cylinder and Piston Item Qty Part No. Description Notes  161926 5th Stage Piston & Cylinder Assembly 070070 Guide Piston Assembly N3731 O-ring 82295 Guide Cylinder N7063 O-ring 82480 Cylinder N4868 O-ring 79185 Piston And Sleeve Assembly Items 8 &...

  • Page 58: Figure 3-26 1St Stage Valve Head

    UNICUS 4i Figure 3-26 1st Stage Valve Head Item Qty Part No. Description Notes  79680 1st Stage Valve Head Assembly † … 1st Stage Valve Head N26029 Plate Valve Washer N644 Self Locking Hex Nut Washer N150 Allen Screw Page 46 2nd Edition, Rev.

  • Page 59: Figure 3-27 2Nd Stage Valve Head

    MNL-0021 Figure 3-27 2nd Stage Valve Head Item Qty Part No. Description Notes  068601 2nd Stage Valve Head Assembly 68491 Valve Head 56668 Gasket N4067 Intake Valve 56183 Valve Cap N3997 O-ring N4068 Pressure Valve 62924 Press Pad N3474 Self Locking Hex Nut Washer N4190...

  • Page 60: Figure 3-28 3Rd Stage Valve Head

    UNICUS 4i Figure 3-28 3rd Stage Valve Head Item Qty Part No. Description Notes  068602 3rd Stage Valve Head Assembly N3474 Self Locking Hex Nut Washer 62924 Pressure Pad N4190 Stud 127366 Valve Cap Upper N34134 O-ring N34135 Back-up Ring 56183 Valve Cap Lower N15273...

  • Page 61: Figure 3-29 4Th Stage Valve Head

    MNL-0021 Figure 3-29 4th Stage Valve Head Item Qty Part No. Description Notes  071621 4th Stage Valve Head Assembly Items 1-10  073629 Valve Head Assembly Items 1-8 07790 Intake Valve 65191 Valve Head N2789 O-ring 014121 Pressure Valve 14118 Valve Head Cover 71065...

  • Page 62: Figure 3-30 5Th Stage Valve Head

    UNICUS 4i Figure 3-30 5th Stage Valve Head Item Qty Part No. Description Notes  082096 5th Stage Valve Head Assembly 081409 Intake Valve 082087 Valve Head 014121 Discharge Valve Includes Item 4 N2789 O-ring 082086 Valve Head Cover Washer N17730 Hex Head Bolt 88609...

  • Page 63: Figure 3-31 Flywheel Drive Assembly

    MNL-0021 Figure 3-31 Flywheel Drive Assembly Item Qty Part No. DescriptionNotes  161475 Flywheel Drive AssemblyBanded 129360-RA L9010V-belt Pulley 128837 Fan Blade Support 79239 Blade, Fan CCW N19508 Hex Head ScrewM6 x 16 WAS-0029 Washer, Split Lock6 mm 68646 Washer WAS-0002 Washer, Split Lock N19523...

  • Page 64: Figure 3-32 Intake Filter Assembly

    UNICUS 4i Figure 3-32 Intake Filter Assembly Item Qty Part No. Description Notes  079706 Intake Filter Assembly 79679 Manifold, Air Intake N171 Socket Head Cap Screw 88797 Housing, Intake Filter 79464 Flange N19535 Allen Screw N25886 Element, Intake Filter N2221 Indicator, Maintenance Page 52...
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  • Page 66: Figure 3-33 1St Stage Interfilter (Optional)

    UNICUS 4i Figure 3-33 1st Stage Interfilter (Optional) Item Qty Part No. Description Notes  160918 1st Stage Interfilter Assembly N2484 Distributing Plate N2483 Baffle Funnel 61751 Tube N2480 Baffle Plate N2479 Baffle Washer N3677 Stud N1042 Hex Nut, Self Locking N20304 Screwed Socket, Elbow Page 54...
  • Page 67 MNL-0021 Figure 3-33 (cont.) 1st Stage Interfilter (Optional) Item Qty Part No. Description Notes 80261 Interfilter includes #1-7, 12, 16 & 17 N20058 Screwed Socket, Elbow N20075 Straight Male Socket N19122 O-ring N20485 Adjustable Screwed Socket 83505 Connecting Tube Assembly 83503 Connecting Tube Assembly N22966...

  • Page 68: Figure 3-34 2Nd Stage Interstage Separator

    UNICUS 4i Figure 3-34 2nd Stage Interstage Separator Item Qty Part No. Description Notes  172775 2nd Stage Interstage Separator … 060601 Filter Head … 13937 Collar, Threaded Knurled … N3556 O-ring … 161781 Insert … — Filter Housing NS … 81810 Safety Valve 24 bar...

  • Page 69: Figure 3-35 3Rd Stage Interstage Separator

    MNL-0021 Figure 3-35 3rd Stage Interstage Separator Item Qty Part No. Description Notes  172778 3rd Stage interstage Separator … 81150 Separator Head Assembly … 81148 Plate … 81643 Hollow Screw … 13937 Knurled Ring N3556 O-ring … 161781 Inset Assembly …...

  • Page 70: Figure 3-36 4Th Stage Interstage Separator

    UNICUS 4i Figure 3-36 4th Stage Interstage Separator Item Qty Part No. Description Notes  172781 3rd Stage interstage Separator … 81776 Separator Head Assembly … 81148 Plate … 81643 Hollow Screw … 69173 Knurled Ring N3556 O-ring … 166062 Inset Assembly …...
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  • Page 72: Figure 3-37 Cooling System Assembly

    UNICUS 4i Figure 3-37 Cooling System Assembly 28 27 Item Qty Part No. Description Notes  79916 Cooling System Assembly 79961 3rd Stage Intercooler 060709 Fan Screen 79967 1st stage Intercooler 79936 Aftercooler 79963 4th Stage Intercooler 79957 2nd Stage Intercooler 065410-180 Safety Valve, 4th Stage 180 bar...
  • Page 73 MNL-0021 Figure 3-37 (cont.) Cooling System Assembly Item Qty Part No. Description Notes 60751 Mounting 60716 Mounting 60717 Support 79637 Bracket 71195-M Clamp 60694-M Clamp N20310 Connector 81240 Connecting Tube 070079 Connecting Tube N20231 Straight Male Coupling N293 Gasket N20059 Fitting N1316 Gasket...

  • Page 74: Figure 3-38 Lubricating System Assembly

    UNICUS 4i Figure 3-38 Lubricating System Assembly Item Qty Part No. Description Notes  84381 Lubricating System Assembly 080345 Lubricating System See next Figure 78421 Gasket N123 Socket Head Screw 84382 Connecting Tube Assembly N20002 Connector N4501 Gasket Page 62 2nd Edition, Rev.

  • Page 75: Figure 3-39 Lubricating System

    MNL-0021 Figure 3-39 Lubricating System Item Qty Part No. Description Notes  080345 Lubricating System N24585 Gear Pump Washer N19506 Hex Head Screw 77885 Oil Filter Cover N04058 O-ring N25327 O-ring 77774 Rubber Gasket N25326 Filter Element N1316 Gasket 81050 Regulating Valve N20065 Straight Male Connector...

  • Page 76: Figure 3-40 Crankcase Venting

    UNICUS 4i Figure 3-40 Crankcase Venting Item Qty Part No. Description Notes  128426-KD Crankcase Vent Assembly 078918 Connecting Tube Assembly N20188 Male Connector N842 Gasket N20014 Male Connector N1316 Gasket Page 64 2nd Edition, Rev. 0 Chg. 8...

  • Page 77: Automatic Condensate Drain System; Asy-4011

    MNL-0021 3.2 Automatic Condensate Drain System; ASY-4011 3.2.1 Description The automatic condensate drain (ACD) system may not be on all units. It must be requested at time of ordering. The ACD system operates electropneumatically and is comprised of the following: A condensate manifold A pneumatic condensate drain valve An electrically controlled solenoid...

  • Page 78: Block Regulator Assembly

    UNICUS 4i 3.2.2 120 II Block Regulator Assembly The 120 II block requires a regulator assembly to supply control Gas/gas to the ACD drain valve. The regulator assembly consists of a pressure gauge, regulator and a safety valve. Figure 3-42 120 II Block Regulator Assembly 1.

  • Page 79: Start Unloading

    MNL-0021 approximately 10 seconds. The drain valve on the same side as the control Gas is the final separator drain. (See Figure 3-43) On 3 stage compressors ports B and C are plugged. Port A drains the 2nd stage separator. On 4 stage compressors Port C is plugged.

  • Page 80: Condensate Collector

    UNICUS 4i 3.3 Condensate Collector The processed Gas is heated by the compression process then cooled. This causes condensation within the system. The resulting moisture is removed after each compression stage with separators and is col- lected through the automatic condensate drain system. This moisture may have a small oil content.
  • Page 81 This page is inserted to provide proper page sequencing...

  • Page 82: Acd Replacement Parts List

    UNICUS 4i 3.3.1 ACD Replacement Parts List Figure 3-45 ASY-4011 Replacement Parts List Item Qty Part No. Description Notes  ASY-4024 Automatic Condensate Drain System SCR-0390 Allen Screws WAS-0057 Split Lock Washer ASY-4001 ACD Manifold See Figure 3-46 COI-0033 Solenoid, NO 24 V, 20 Watt (black) GKT-0073...
  • Page 83 MNL-0021 Figure 3-45 (cont.) ASY-4011 Replacement Parts List Item Qty Part No. Description Notes GKT-0074 Gasket Neoprene HUS-0050 Inner Housing HUS-0062 Outer Housing GKT-0078 Gasket Neoprene SWT-0424 Liquid Level Switch TNK-0092 Condensate Tank 1.75 gal. RED-0067 Reducer VAL-0437 Manual Drain Valve PLU-0198 Plug September 23, 2020...

  • Page 84: Figure 3-46 Acd Assembly, Asy-4001

    UNICUS 4i Figure 3-46 ACD Assembly, ASY-4001 Item Qty Part No. Description Notes  ASY-4001 ACD Valve SCR-0392 Allen Head Screws VAL-0634 Solenoid (body only) MFD-0060 Upper ACD PIS-0004 ACD Piston 073793 Drain Tap SCR-0393 Allen Head Screw & WAS-0057 Split Lock Washer CON-0009 Connector...
  • Page 85 MNL-0021 Figure 3-46 (cont.) ACD Assembly, ASY-4001 Item Qty Part No. Description Notes MFD-0059 Main ACD 070615 Connector VAL-0426 Check Valve 600 psi RNG-0114 O-Ring SCR-0383 Set Screw CON-0061 Connector September 23, 2020 Page 73...

  • Page 86: Figure 3-47 Acd O-Rings

    UNICUS 4i Figure 3-47 ACD O-Rings view bottom view Item Qty Part No. Description Notes RNG-0142 O-ring, ACD small 90 Duro RNG-0143 O-ring, ACD large 90 Duro N03521 O-ring, ACD pistons 75 Duro, RNG-0114 O-ring, Check Valves 90 Duro Page 74 2nd Edition, Rev.

  • Page 87: Figure 3-48 Regulator Assembly

    MNL-0021 Figure 3-48 Regulator Assembly a.Only used with IK 120 II block Item Qty Part No. Description Notes REG-0043 Pressure Regulator 6,000 psi IN; 0 - 250 psi OUT VAL-0017 Safety Valve 225 psi GAG-0028W Pressure Gauge 0 - 300 psi September 23, 2020 Page 75...

  • Page 88: Trouble Shooting

    UNICUS 4i 3.3.2 Trouble shooting Trouble Cause Remedy Solenoid does not drain. 1. Solenoid receives no elec- 1. Check connections, timer. trical signal Replace if necessary. 2. Plunger of drain valve 2. Clean or replace valve. sticking Condensate Drain Valve does not 1.

  • Page 89: Introduction

    Intake air should as close as possible to 50 °F (10 °C) and cleanest available and as dry as possible. Bauer compressors normally add approximately 18 °F (10 °C) to the intake air tem- perature.

  • Page 90: Manual Condensate Drainage

    UNICUS 4i Figure 4-1 Cartridge Safety Venting Figure 4-2 P0 & P31 Safety Venting Safety Safety Vent Vent (leaking) (no leak) Safety Safety Vent Vent No Cartridge Installed Cartridge Installed or Installed incorrectly correctly No Cartridge or Installed Cartridge Installed Incorrectly Correctly 4.1.3 Manual Condensate Drainage...

  • Page 91: Purification System Data Plate

    MNL-0021 4.1.4.2 Purification System Data Plate Refer to the compressor unit purification system data plate (Figure 4-3) on the compressor front to determine your purification system model and specifications. 4.1.4.3 Cartridge Installation Data Plate The function performed by each chamber in the purification system is determined by the type of car- tridge installed in that chamber.

  • Page 92: Industrial Purification System Configurations

    UNICUS 4i 4.1.6 Industrial Purification System Configurations Purification System Number and Type of Cartridges Processing Capacity cubic ft (ft) See Chapter Dryer Purification Securus ® Combined 3,200 … … 15,000 … … 40,000 … … 67,000 IP2 with Securus ® …...

  • Page 93: Calculating The Maximum Cartridge Operating Hours

    4.1.8 Chambers If consistent evidence shows that the maximum admissible number of load cycles has not yet been reached after five (5) years, BAUER Compressors recommends a visual inspection of the inner and outer sides of the pressure vessel. If consistent evidence shows the maximum admissible number of load cycles has not yet been reached after ten (10) years A hydrostatic pressure test shall be executed.

  • Page 94: Figure 4-4 Correction Factor For Cartridge Operating Hours

    UNICUS 4i Figure 4-4 Correction Factor for Cartridge Operating Hours 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C 32 °F 50 °F 68 °F 86 °F 104 °F 122 °F °C °F Correction Factor (°F - 32) x 5/9 °C x 9/5 +32 0.21 0.34...

  • Page 95: Purification Cartridge Operating Hours Form

    MNL-0021 4.1.8.1 Purification Cartridge Operating Hours Form Date Operat- Ambient temp. + 18°F Correction Adjusted cartridge hours ing hours during compression factor Today Total September 23, 2020 Page 83...

  • Page 96: 1P5S Securus Ii® Purification System

    UNICUS 4i 4.2 1P5S Securus II Purification System ® 4.2.1 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.

  • Page 97: Component Description

    MNL-0021 4.3 Component Description 4.3.1 Oil and Water Separator WARNING The rapid de-pressurizing and re-pressurizing of the oil and water separator during condensate drain- ing subjects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury or death the oil and water separator (P/N 079416) must be replaced after a predetermined num- ber of cycles.

  • Page 98: Securus Ii ® Electronic Moisture Monitor System

    UNICUS 4i 2. Activated carbon which absorbs oil vapors effecting taste and odor. 3. Molecular sieve to absorb oil and water. 4.3.3.2 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.

  • Page 99: Maintenance

    MNL-0021 4.4 Maintenance 4.4.1 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. De-pressurize the system by means of the bleed valve. 2.

  • Page 100: Figure 4-8 Oil And Water Separator

    UNICUS 4i Figure 4-8 Oil and Water Separator Figure 4-9 Sintered Metal Filter Assembly 1. Filter Head 3. Center Screw 1. Threaded Insert 4. Outer Filter 2. Sintered Metal Filter 4. O -rings 2. Filter Bottom 5. Filter Head 3. Inner Filter Page 88 2nd Edition, Rev.

  • Page 101: Removal Of The Securus Ii® Transmitter

    MNL-0021 4.4.1.1 Removal of the Securus II Transmitter. ® Figure 4-10 Removal of the Securus II Transmitter ® 1. Securus II Transmitter 2. DIN Connector ® The Securus II Transmitter is removed and replaced by rotating the blue plastic Securus II Transmitter ®...

  • Page 102: Leaking At The Safety Bore

    UNICUS 4i 1. Disconnect the power and shut off the inlet supply line, if applicable. 2. De-pressurize 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 Trans- ®...

  • Page 103: Replacement Parts List

    MNL-0021 4.5 Replacement Parts List Figure 4-12 P5 Purification System Parts List Item Qty Part No. Description Notes 079416 Oil and Water Separator See Figure 4-13 — — VAL-0169 Safety Valve 080144 27” Dryer Chamber See Figure 4-14 MNR-0042 Securus II Transmitter 24 VDC ®...

  • Page 104: Figure 4-13 Oil And Water Separator Parts List

    UNICUS 4i Figure 4-13 Oil and Water Separator Parts List Item Qty Part No. Description Notes  079416 Oil and Water Separator Assembly † … Separator Head Available only with 079416 N04586 O-Ring 061860 Sintered Metal Filter N15133 O-Ring N04496 O-Ring, small N04385 O-Ring, large...

  • Page 105: Figure 4-14 27" Chamber Assembly Parts List

    MNL-0021 Figure 4-14 27” Chamber Assembly Parts List Item Qty Part No. Description Notes  80144 Chamber Assembly 27” 012293 Tool Post Screw 061237 Cover Plate † … Filter Head Available only with 80144 N04736 Back-up Ring N04735 O-ring † …...

  • Page 106: Figure 4-15 Securus Ii® Electronic Moisture Monitor System Parts List

    UNICUS 4i Figure 4-15 Securus II Electronic Moisture Monitor System Parts List ® Item Qty Part No. Description Notes  80145 Securus Chamber Assembly Replaces 1 P/N 80144 in P5S ® † … Bottom Plug Available only with 80145 N04736 Backup Ring N04735 O-ring...
  • Page 107 MNL-0021 Figure 4-15 (cont.) Securus II Electronic Moisture Monitor System Parts List ® Item Qty Part No. Description Notes 059851 Bolt 002181 Compression Spring † … Filter Head Available only with 80145 060135 Cover Plate 012293 Tool Post Screw 059850 Socket, RF type MNR-0042 Securus II...

  • Page 108: Vertical Compressor Drive

    UNICUS 4i CHAPTER 5: COMPRESSOR DRIVE; UNICUS 4I 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 regu- larly for damage and wear.

  • Page 109: Check The V-Belt

    MNL-0021 5.2.2 Check the V-belt Check the V-belt regularly for damage and wear. Replace if necessary. To adjust the V-belt tension first loosen the tensioning sheave block using TOO-0120. V-belt tension is adjusted with the tensioning bolt. TOO-0120 Once the tension is correct retighten the tensioning sheave block. Figure 5-2 Tensioning 1 Figure 5-3...

  • Page 110: Replacement Part List

    UNICUS 4i 5.3 Replacement Part List Figure 5-4 UNICUS 4i, Vertical Drive with Idler Item Qty Part No. Description Notes  IK 18.1 II Compressor Block BET-0254 V-belt PLY-0012 Pulley, V-belt MTR-0514 Electric Motor 20 Hp, 3 Phase SHE-0359 Sheave 2 groove with BUS-0191...

  • Page 111: Overview

    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.

  • Page 112: Ac Power Requirements

    UNICUS 4i 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.

  • Page 113: Replacing The Plc

    MNL-0021 Figure 6-4 Connector Block Removal 1. Notch in the Terminal Block 2. Memory Card Slot 3. Network Connection View Under Input (top) Connection Cover View Under Output (bottom) Connection Cover 6.4.1.1 Replacing the PLC Replacing the PLC does not require removal of any wiring as the connections are made with push in Connector Blocks.

  • Page 114: Installing A Memory Card

    UNICUS 4i 6.4.1.3 Installing a Memory Card To install or replace a memory card proceed as follows: 1. Turn off unit and disconnect from main power supply. 2. The memory card is keyed to fit only one way and requires minimal force to insert it. 3.

  • Page 115: Overload Relay

    MNL-0021 6.4.4 Overload Relay See Figure 6-7.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.

  • Page 116: Alarms

    When the warning is displayed, the unit will still continue to function properly, but will prompt the oper- ator 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 sep- arator.

  • Page 117: Compressor Low Oil Pressure

    MNL-0021 6.5.3 Compressor Low Oil Pressure See Figure 6-10. 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.

  • Page 118: Replacement Parts List

    UNICUS 4i 6.6 Replacement Parts List Figure 6-11 Electrical Panel, Interior 11 12 15 16 Item Qty Part No. Description Notes  ASY-1191 Electrical Panel Interior View SRT-0317 Starter 65 Amps RLY-0244 Overload Relay, Adjustable 32 - 65 Amp HOL-0081 Fuse Holder, 2 Pole 30 Amp, 600 Volt with 2...
  • Page 119 MNL-0021 Figure 6-11 (cont.) Electrical Panel, Interior Item Qty Part No. Description Notes CNT-0102 Ethernet Switch CNT-0124 Communications Module CNT-0104 Siemens, CPU S7-1200 DC/DC/RLY, 1214C CNT-0111 Analog Expansion Module 8 channel IN CNT-0134 Digital Output Module CNT-0132 Analog Expansion Module 4 channel OUT September 23, 2020 Page 107...

  • Page 120: Chapter 7

    UNICUS 4i CHAPTER 7: RFID OPTION 7.1 Description The UNICUS 4i may be supplied with the Radio Frequency Identification (RFID) option. The RFID option allows the user to affix RFID tags to the cylinders to be filled using the Unicus 4i. The RFID tag is imprinted with a serial number and a record is maintained each time the bottle is filled.

  • Page 121: Functions

    MNL-0021 Functions 7.3.1 Assigning the Cylinder Attach the RFID tags securely to each cylinder. Additional tags can be ordered in lots of 25. Place a cyl- inder with the RFID tag attached into the first position in the CFS. Someone with administrator privileges must log into the touch screen program (see operations instructions chapter).

  • Page 122: Figure 7-3 Kit-0585

    UNICUS 4i Figure 7-3 KIT-0585 KIT-0585 Page 110 2nd Edition, Rev. 0 Chg. 8...

  • Page 123: Replacement Parts List

    MNL-0021 7.4 Replacement Parts List Figure 7-4 RFID Assembly Item Qty Part No. Description Notes KIT-0557 RFID Tag 25 tags per kit SEN-0158 Proximity Switch ASY-8067 RFID Holder Assembly replaces HOL-124 in CFS assembly CNT-0192 RFID Reader/Writer FLR-0211 Signal Filter September 23, 2020 Page 111...

  • Page 124: Figure 7-5 Kit-0585

    UNICUS 4i Figure 7-5 KIT-0585 Item Qty Part No. Description Notes SCR-0281 Pan Head Cap Screw SCR-0464SS Pan Head Cap Screw stainless steel TAG-0003 RFID Tag NUGT-0284SS Flex Lock Nut stainless steel BRK-1113 Bracket Page 112 2nd Edition, Rev. 0 Chg. 8...

  • Page 125: Description

    MNL-0021 CHAPTER 8: ENMET GAS MONITORS 8.1 Description The gas monitors are a factory installed option which may have been ordered with your unit. The oxygen (O), carbon monoxide (CO), and carbon dioxide (CO ) monitors sample the gas as it leaves the unit.

  • Page 126: Calibration

    UNICUS 4i Figure 8-2 Basic Calibration Kit & Test Gases 1. Calibrating Regulator 1. 20 ppm Carbon Monoxide Test Gas 2. Zero Test Gas (KIT-0439) NOTICE NFPA states that gas monitors must be calibrated on a 30 day cycle. For non-NFPA applications local, state and corporate codes must be referenced.
  • Page 127 MNL-0021 • Press the “Set Span” button. A countdown screen will appear. Once the countdown is complete the “Exit” button will appear. • Close the span gas valve and disconnect the calibration hose from the sensor. • Press the “Exit” button on the screen to complete the calibration process. •...

  • Page 128: Replacement Parts

    UNICUS 4i 8.4 Replacement Parts Figure 8-3 Regulator and Monitors Item Qty Part No. Description Notes SEN-0134 CO Monitor, Enmet (See Figure 8-4) REG-0098 Pressure Regulator set to 75 psig (5.17 barg) VAL-0384 Safety Valve @165 psig (11.4 barg) GAG-0006W Pressure Gauge 0 - 200 psig (14 barg) VAL-0510...

  • Page 129: Figure 8-4 Monitors

    MNL-0021 Figure 8-4 Monitors Item Qty Part No. Description Notes SEN-0134* Carbon Monoxide Monitor SEN-0135* Oxygen Monitor SEN-0136* Carbon Dioxide Monitor SEN-0137* Hydrogen Sulfide Monitor *Sensors 134 - 137 can be ordered new, or BCI also offers a sensor replacement program that utilizes refurbished sensors at a lower cost, but still carry the full 1-year Warranty.

  • Page 130: Figure 8-5 Calibration Components

    UNICUS 4i Figure 8-5 Calibration Components Item Qty Part No. Description Notes KIT-0439 Calibrating Regulator, Hose, & Adapter CYL-0016 CO Test Gas 20 ppm CYL-0020 CO Test Gas, Zero Gas 0 ppm Page 118 2nd Edition, Rev. 0 Chg. 8...

  • Page 131: Description

    MNL-0021 CHAPTER 9: CFS III MAINTENANCE 9.1 Description The UNICUS 4i containment fill stations are designed and have been tested to offer the operator protec- tion against the explosive force and resulting shrapnel should a cylinder fail during the filling operation. 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.

  • Page 132: Nonadjustable Valves

    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.

  • Page 133: Bearings For Bottle Door Pivot

    MNL-0021 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 facil- ® itate future disassembly. 9.3.6 Bearings for Bottle Door Pivot There is no need for relubrication under normal conditions.

  • Page 134: Replacement Parts List

    UNICUS 4i 9.4 Replacement Parts List 9.4.1 CFS III Assemblies Figure 9-3 CFS III Assembly Item Qty Part No. Description Notes HOL-0124 Bottle Holder DOR-0114 Door HOS-0145 Fill Whip HAN-0078 Handle 1.Replaced by ASY-8067 if unit has RFID option Page 122 2nd Edition, Rev.

  • Page 135: Figure 9-4 Fill Whips & Brackets

    MNL-0021 Figure 9-4 Fill Whips & Brackets Item Qty Part No. Description Notes MTS-0316 Hose Bracket HOS-0145 Fill Whip 1 per fill position MTS-0315 Hose Bracket with Whip Holder HOL-0077 Fill Whip Holder with Door Interlock Actuator with 1 PLT-0396 Plastic Wear Plate CMP-0144 Bottle Holder Bracket...

  • Page 136: Figure 9-5 Cfs Iii Door Lock Assembly

    UNICUS 4i Figure 9-5 CFS III Door Lock Assembly Item Qty Part No. Description Notes — Nylon Flat Washer 3/8” SPG-0052 Torsion Spring — Socket Head Shoulder Screw 3/8” x 7/8” LCH-0048 Latch LCH-0090 Door Lock BUS-0153 Bushing CYL-0059 Damper BRK-0673 Cylinder Bracket Right...

  • Page 137: Figure 9-6 Door Handle, Pivot And Bracket

    MNL-0021 Figure 9-6 Door Handle, Pivot and Bracket Item Qty Part No. Description Notes SPG-0078 Gas Spring Flat Head Socket Cap Screw 5/16x18 x 3/4” UNC CLR-0001 Collar BUS-0121 Bushing PIN-0047 Socket Head Cap Screw 3/8-16 x 1” UNC Washer, Nylon 5/8”...

  • Page 138: Figure 9-7 Cfs Iii Door Interlock

    UNICUS 4i Figure 9-7 CFS III Door Interlock Item Qty Part No. Description Notes BRK-0671 Bracket VAL-0130 Interlock Valve LEV-0025 Lever SCR-0078 Hex Head Cap Screw 1/4-20 x 4” UNC HOS-0147 Hose, Left HOS-0146 Hose — Hex Head Cap Screw 1/4-20 x 4 1/2”...

  • Page 139: Fill Hose Assemblies

    MNL-0021 9.5 Fill Hose Assemblies Figure 9-8 Standard Fill Hose Assemblies High High or Low Fill Only Fill 4,500 psi 4,500 / 2,216 psi Scuba Fill Fill Item Qty Part No. Description Notes HOS-0145 Fill Hose 25” 065126 Bleed Valve ELL-0018 Elbow ADP- 0112...

  • Page 140: Figure 9-9 Fill Whips With Options

    UNICUS 4i Figure 9-9 Fill Whips with Options High or Low Fill 4,500 / 2,216 psi High/Low Fill with Quick Disconnect & Safety Valve Op ons High Fill Only 4,500 psi High Fill with Quick Disconnect Op on Scuba Fill Scuba Fill with Quick Disconnect &...
  • Page 141 MNL-0021 Figure 9-9 (cont.) Standard Fill Hose Assemblies Item Qty Part No. Description Notes ADP-0113 Adapter 4,500 psi Cylinder ADP-0015 Adapter, Stainless Steel with NIP-0096 HOS-0150 Fill Hose, Scuba ELL-0031 Elbow YOK-0001 Scuba Fill Yoke with Bleed Valve September 23, 2020 Page 129...

  • Page 142: Chapter 10

    UNICUS 4i CHAPTER 10: UNICUS III HP AIR STORAGE 10.1 Bottle Specifications Storage systems are available to meet the code requirements of either the United Nations (UN) model regulations (ISO 9809-PART 2) or the American Society of Mechanical Engineers (ASME). Standard operating temperature range for storage systems is - 20 to 150 °F.

  • Page 143: Description And Maintenance

    MNL-0021 ASME Vessel 5,250 psig 6,600 psig Material Steel ASME SA 372 Class V Type A AISI 4130 Volume 424 cf @ 5,000 psig 481 cf @ 6,000 psig Working 5,000 psig 6,000 psig Pressure Test 7,875 psig 10,500 psig Pressure Diameter 9 5/8”...

  • Page 144: Maintenance

    UNICUS 4i Figure 10-1 UNICUS III Storage Systems ASME Cylinders ISO Cylinders 10.2.2 Maintenance 10.2.2.1 Storage Bottles All storage bottles should be visually inspected internally every year. Every five (5) years, D.O.T. bottles must be hydro-tested. Check local and state regulations regarding testing of ASME or D.O.T. bottles. Some states require an annual visual inspection, and hydro-testing requirements also differ from state to state.

  • Page 145: Tube Connections

    MNL-0021 10.2.2.3 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...

  • Page 146: Autocascade System

    UNICUS 4i 10.3 Autocascade System 10.3.1 General The auto cascade system utilizes Siemens PLC technology to open and close valves from up to 4 storage banks. The auto cas- cade system opens storage banks as needed and allows the com- pressor to refill the depleted storage banks in a systematic order.

  • Page 147: Electrical

    MNL-0021 10.3.2 Electrical Siemens electronics are used for this application. The PLC monitors the Pressure Transmitter continu- ously and opens solenoid valves 1-5 as needed. 10.3.3 Filling the Storage Banks When the compressor begins delivering purified compressed air it is applied to the inlet of the first prior- ity valve (5).

  • Page 148: Chapter 11

    UNICUS 4i CHAPTER 11:APPENDIX 11.1 Safety 11.1.1 General Safety Precautions • Read the operating manual before installing or operating this compressor unit. Follow appropriate handling, operation and maintenance procedures from the very beginning. The maintenance schedule contains measures required to keep this compressor unit in good condition. Maintenance is simple, but must be executed regularly to achieve safe operation, maximum efficiency and long service life.
  • Page 149 • The use of repair parts other than those listed in this manual or purchased from Bauer Compressors, Inc. may create unsafe conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment.

  • Page 150: Safety Warning Labels

    UNICUS 4i 11.1.2 Safety Warning Labels Notes, labels and warning signs are displayed on the compressor unit according to model, application or equipment and may include any of the following. HOT SURFACES DO NOT TOUCH! Danger of burning if cylinders, cylinder heads, or pressure lines of individual com- pressor stages are touched.

  • Page 151: Unpacking, Handling And Installation

    MNL-0021 11.2 Unpacking, Handling and Installation 11.2.1 Unpacking and Handling This compressor unit is packaged according to the requirements for shipping via the requested type of carrier service. It is possible that the compressor unit could have been damaged during shipping. For this reason, we urge you to thoroughly examine the unit for possible damage and report any such dam- age to the shipping company immediately.

  • Page 152: Installation Of The Compressor Unit

    UNICUS 4i 11.2.2 Installation of the Compressor Unit 11.2.2.1 General The floor site must be capable of supporting the weight of the unit. Secure the compressor unit to the floor using ½” lag bolts. Position the unit so that it is level. Permissible inclination of the compressor unit is listed in Paragraph 1.4.

  • Page 153: Ventilation

    MNL-0021 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. 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.

  • Page 154: Forced Ventilation

    The quality of Gas produced by the compressor unit is directly related to the quality of Gas that is taken in by the compressor. Bauer compressors require clean, dry, shop Gas for optimal performance. The intake Gas source must be free of contaminants such as fumes, engine exhaust, and solvents. If the intake source will be piped in adhere to the following general rules: •...

  • Page 155: Outside Gas Source

    MNL-0021 High levels of CO are another cause of breathing Gas to become contaminated. CO limits are 1,000 ppm. and most fresh Gas already contains about 330 ppm. A number of people inside poorly ventilated rooms can easily bring the CO levels up to 600 ppm or more.

  • Page 156: Installation Procedures

    UNICUS 4i 11.2.5 Installation Procedures 1. Use PVC pipe for ease of installation. 2. Ensure pipe is attached securely to the wall. 3. Terminate the PVC pipe 3 to 5 ft from the compressor intake with a stub reducer the same size as the compressor inlet housing pipe.

  • Page 157: Figure 11-4 Incoming Power Wiring Label

    MNL-0021 Figure 11-4 Incoming Power Wiring Label The use of improperly sized wire can result in sluggish operation, unnecessary tripping of overload relays and/or blowing of fuses. The following tables are provided as a guide for proper wire size 1 PHASE Full Load Amps Fuse Amps Minimum Wire Size...

  • Page 158: Pneumatic Leaks

    UNICUS 4i 3 PHASE Full Load Amps Fuse Amps Minimum Wire Size Motor 208 V 230 V 460V 208 V 230 V 460V 208 V 230 V 460V 10.6 17.5 16.7 15.2 24.2 17.5 30.8 46.2 59.4 74.8 211.2 300 mcm 250 mcm 500 mcm 350 mcm...

  • Page 159: Long Term Storage

    MNL-0021 Each unit is tested prior to leaving the manufacturing facility. All loose or leaking fittings are tightened prior to shipping. During the shipping process pneumatic connections may work loose and leaks may develop. Ensure each unit is leak tested prior to being placed in full operational usage. WARNING Never tighten or adjust fittings or connections under pressure.

  • Page 160: Preventive Maintenance During Storage

    UNICUS 4i 3. Close the shut-off valve and condensate drain valves. 4. Close the inlet port with a dust cap and/or tape. 11.3.4 Preventive Maintenance During Storage Operate the compressor once every six months as follows: 1. Remove the dust cap from the inlet port and install the inlet filter. 2.

  • Page 161: Reproducible Forms

    MNL-0021 11.4 Reproducible Forms 11.4.1 Scheduled Maintenance Form Daily Para. Date Signature September 23, 2020 Page 149...
  • Page 162 UNICUS 4i Weekly or as required. Para. Date Signature 500 Operating Hours. Para. Date Signature 1,000 Operating Hours. Para. Date Signature 2,000 Operating Hours. Para. Date Signature Page 150 2nd Edition, Rev. 0 Chg. 8...
  • Page 163 MNL-0021 3,000 Operating Hours. Para. Date Signature Annually. Para. Date Signature Biennially. (Every two years) Para. Date Signature September 23, 2020 Page 151...

  • Page 164: Cartridge Operating Hours

    UNICUS 4i 11.4.2 Cartridge Operating Hours Date Operating Ambient temp. + 18°F Correction Adjusted cartridge hours hours during compression factor Today Total Page 152 2nd Edition, Rev. 0 Chg. 8...

  • Page 165: Record Of Operating Hours

    MNL-0021 11.4.3 Record of Operating Hours Date Minutes Total Date Minutes Total Subtotal: Subtotal: September 23, 2020 Page 153...

  • Page 166: Reference Data

    UNICUS 4i 11.5 Reference Data 11.5.1 Tightening Torque Values 1. Unless otherwise specified in text, the torque values in Table 1 apply. 2. The indicated torque values are valid for bolts in greased condition. 3. Self locking nuts must be replaced on reassembly 4.

  • Page 167: Approved Lubricants Chart

    MNL-0021 11.5.4 Approved Lubricants Chart Unless otherwise specified in text, use the lubricants in Table 2. Table 11-2: Lubricant Chart Usage Lubricants O-rings, rubber and plastic parts; filter housing Parker Super “O” Lube threads, sealing rings Bolts, nuts, studs, valve parts, Copper gaskets and Never-Seez NSWT, Pipe Dope or teflon tape ®...

  • Page 168: Additional Documents

    UNICUS 4i 11.6 Additional Documents 11.6.1 Diagrams and Drawings Any included drawings, wiring diagrams, pneumatic flow diagrams, etc., will be bound next to the back cover in a hard copy manual or included as a separate file on a CD. 11.6.2 Other Documents OEM Manuals and other Bauer manuals may be included in the documentation shipping package.

  • Page 169: Unit Information

    CORRECTIONS & COMMENTS In an effort towards constant improvement, the Documentation section of Bauer Compressors, Inc. would like to give you the opportunity to suggest improvements or corrections to this manual. If you find any inaccuracies or have suggestions feel free to E-mail us at: documentation@bauercomp.com, or fill...
  • Page 170 Bauer Compressors, Inc. Attn: Documentation 1328 Azalea Garden Rd. Norfolk, VA 23502-1944 fold here tape or glue here...

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