Bauer Compressors UN 4i 25 Manuals

Manuals and User Guides for Bauer Compressors UN 4i 25. We have 1 Bauer Compressors UN 4i 25 manual available for free PDF download: Instruction Manual And Replacement Parts List

Bauer Compressors UN 4i 25 Instruction Manual And Replacement Parts List

Bauer Compressors UN 4i 25 Instruction Manual And Replacement Parts List (170 pages)

Stationary Integrated Systems High Pressure Breathing Air System

Brand: Bauer Compressors | Category: Industrial Equipment | Size: 7 MB

Table of Contents

Fcc Compliance Statement
3
Table of Contents
4
Chapter 1: Introduction

13
- How to Use this Manual
  13
- Manual Safety Notices
  13
- How to Use the Replacement Parts List
  14
- How to Use the Appendix
  15
- Figure 1-1 Compressor Identification Label
  15
- Unit Specifications
  16
- UNICUS 4I - 25
  16
- Compressor Block
  16
- Compressor Drive
  16
- Purification System Applicability
  16
- Component Locations
  17
- Figure 1-2 UNICUS 4I
  17
- Figure 1-3 UNICUS 4I Rear
  18
- Figure 1-4 UNICUS 4I Front Panel
  19
Chapter 2: Operating Instructions

20
- Figure 2-1 Control Panel
  20
- Emergency Stop Button
  20
- Operator Interface
  20
- Badge Screen
  20
- Admin. Main Menu Screen
  21
- Figure 2-2 Initial Screen
  21
- Figure 2-3 Admin. Main Menu Screen
  21
- Personnel
  22
- Figure 2-4 Personnel
  22
- Cylinders
  23
- Figure 2-5 Add New
  23
- Figure 2-6 Cylinders
  23
- Settings
  24
- Figure 2-7 Add New Cylinder
  24
- Figure 2-8 Settings
  24
- Setup
  25
- Parameters
  25
- Figure 2-9 Setup
  25
- Figure 2-10 Parameters
  25
- Maintenance
  26
- Gas Sensor
  26
- Reports
  26
- Diagnose
  26
- Figure 2-11 Reports
  26
- Home Screen
  27
- Figure 2-12 Diagnostic
  27
- Figure 2-13 Home Screen, Operator
  27
- Compressor Status
  28
- Fill Cylinders
  28
- Figure 2-14 Compressor Status
  28
- Remote Fill
  29
- Figure 2-15 Fill Cylinders
  29
- Fill Station Operation
  30
- Figure 2-16 Bottle Riser
  30
- Remote Fill Connection
  31
- Figure 2-17 Bottle Valve Sequences
  31
- Connecting an Air Bottle
  32
- Filling the Air Bottle
  32
- Removing the Air Bottle
  32
- Description
  33
- Component Location
  33
- Figure 3-1 Compressor Block (Front View)
  33
- Air Flow Diagram
  34
- Intake Filter
  34
- Lubrication System
  34
- Description
  34
- Figure 3-2 Five Stage Compressor Air Flow
  34
- Oil Level Check
  35
- Oil Change Interval
  35
- Oil Capacity
  35
- Oil Change
  35
- Lubrication Oil System Figure 3-4 Oil Sight Gauge
  35
- Figure 3-5 Oil Sight Gauge & Drain
  36
- Removing the Oil Filter Cover Figure 3-7 Replacing the Oil Filter
  36
- Venting the Oil Pump
  37
- Intake Filter
  37
- Description
  37
- Maintenance
  37
- Figure 3-8 Intake Filter
  37
- Interstage Separators
  38
- Description
  38
- Maintenance
  39
- Figure 3-9 2Nd Stage Interstage Separator
  39
- Figure 3-10 3Rd & 4Th Stage Interstage Separator
  39
- Compressor Valves and Valve Heads
  40
- Functional Description
  40
- Initial Operational Check of the Valves
  40
- General Instructions for Changing the Valves
  40
- Figure 3-11 1St Stage Valve Function
  40
- Figure 3-12 Valve Function
  40
- Changing the 1St Stage Valves
  41
- Removal Procedure
  41
- Figure 3-13 1St Stage Valve and Head
  41
- Installation Procedure
  42
- Changing the 2Nd Stage Valves
  42
- Removal Procedure
  42
- Figure 3-14 2Nd Valve Head and Valves
  42
- Changing the 3Rd Stage Valves
  43
- Removal Procedure
  43
- Installation Procedure
  43
- Figure 3-15 3Rd Stage Valve Head and Valves
  43
- Changing the 4Th/5Th Stage Valves
  44
- Figure 3-16 4Th/5Th Stage Valve and Head
  44
- Discharge Valve Removal Procedure
  45
- Discharge Valve Installation Procedure
  45
- Figure 3-17 Discharge Valve Removal
  45
- Inlet Valve Removal and Installation
  46
- Repair and Troubleshooting
  46
- Repair
  46
- Figure 3-18 Assembly Tool
  46
- Figure 3-19 Using Special Tool
  46
- Troubleshooting
  49
- Replacement Parts List
  50
- Figure 3-20 Crankcase Assembly
  50
- Figure 3-21 Complete Crankshaft Assembly
  52
- Figure 3-22 1St Stage Piston and Cylinder
  53
- Figure 3-23 2Nd & 4Th Stage Piston and Cylinder
  54
- Figure 3-24 3Rd Stage Piston and Cylinder
  56
- Figure 3-25 5Th Stage Cylinder and Piston
  57
- Figure 3-26 1St Stage Valve Head
  58
- Figure 3-27 2Nd Stage Valve Head
  59
- Figure 3-28 3Rd Stage Valve Head
  60
- Figure 3-29 4Th Stage Valve Head
  61
- Figure 3-30 5Th Stage Valve Head
  62
- Figure 3-31 Flywheel Drive Assembly
  63
- Figure 3-32 Intake Filter Assembly
  64
- Figure 3-33 1St Stage Interfilter (Optional)
  66
- Figure 3-34 2Nd Stage Interstage Separator
  68
- Figure 3-35 3Rd Stage Interstage Separator
  69
- Figure 3-36 4Th Stage Interstage Separator
  70
- Figure 3-37 Cooling System Assembly
  72
- Figure 3-38 Lubricating System Assembly
  74
- Figure 3-39 Lubricating System
  75
- Figure 3-40 Crankcase Venting
  76
- Automatic Condensate Drain System; Asy-4011
  77
- Description
  77
- Figure 3-41 Automatic Condensate Drain System
  77
- Block Regulator Assembly
  78
- ACD Operation
  78
- Figure 3-42 120 II Block Regulator Assembly
  78
- Figure 3-43 ACD Operation Diagrams
  78
- Start Unloading
  79
- Standstill Drainage
  79
- Condensate Drain Separator
  79
- ACD Maintenance
  79
- Condensate Collector
  80
- Figure 3-44 Condensate Collector
  80
- ACD Replacement Parts List
  82
- Figure 3-45 ASY-4011 Replacement Parts List
  82
- Figure 3-46 ACD Assembly, ASY-4001
  84
- Figure 3-47 ACD O-Rings
  86
- Figure 3-48 Regulator Assembly
  87
- Trouble Shooting
  88
- Introduction
  89
- General Purification System Procedures
  89
- Chamber Safety Bore
  89
- Manual Condensate Drainage
  90
- Model, Serial Number and Part Number Identification
  90
- Compressor Data Plate
  90
- Figure 4-1 Cartridge Safety Venting
  90
- Figure 4-2 P0 & P31 Safety Venting
  90
- Figure 4-3 Purification System Data Plates (Typical)
  90
- Purification System Data Plate
  91
- Cartridge Installation Data Plate
  91
- Purification System Configurations
  91
- Industrial Purification System Configurations
  92
- Cartridge Operating Life
  92
- Calculating the Maximum Cartridge Operating Hours
  93
- Calculating the Adjusted Cartridge Operating Hours
  93
- Chambers
  93
- Figure 4-4 Correction Factor for Cartridge Operating Hours
  94
- Figure 4-5 Example Record of Adjusted Operating Hours
  94
- Purification Cartridge Operating Hours Form
  95
- 1P5S Securus II® Purification System
  96
- P5S Securus II® Purification System Major Components
  96
- Figure 4-6 P5S Securus II® Purification System
  96
- Component Description
  97
- Oil and Water Separator
  97
- Chamber
  97
- Cartridge
  97
- Cartridge Construction
  97
- Figure 4-7 Oil and Water Separator Labels
  97
- Securus II ® Electronic Moisture Monitor System
  98
- Cartridge Handling
  98
- Condensate Drain Valve
  98
- Check Valves
  98
- Bleed Valve
  98
- Pressure Maintaining Valve
  98
- Safety Valve
  98
- Securus® Cartridge
  98
- Transmitter
  98
- Maintenance
  99
- Oil and Water Separator
  99
- Figure 4-8 Oil and Water Separator
  100
- Figure 4-9 Sintered Metal Filter Assembly
  100
- Removal of the Securus II® Transmitter
  101
- Cartridge Replacement
  101
- Figure 4-10 Removal of the Securus II® Transmitter
  101
- Figure 4-11 Cartridge Replacement
  101
- Leaking at the Safety Bore
  102
- Replacement Parts List
  103
- Figure 4-12 P5 Purification System Parts List
  103
- Figure 4-13 Oil and Water Separator Parts List
  104
- Figure 4-14 27" Chamber Assembly Parts List
  105
- Figure 4-15 Securus II® Electronic Moisture Monitor System Parts List
  106
- Vertical Compressor Drive
  108
- Maintenance of the V-Belt and Sheaves
  108
- Check the Sheaves
  108
- Figure 5-1 Vertical Drive with Idler (Typical)
  108
- Check the V-Belt
  109
- Replacing the Belt
  109
- Replacing the Sheave
  109
- Figure 5-2 Tensioning 1
  109
- Figure 5-3 Tensioning 2
  109
- Replacement Part List
  110
- Figure 5-4 UNICUS 4I, Vertical Drive with Idler
  110
- Overview
  111
- Electrical Panel
  111
- Wiring Diagram
  111
- Electrical Panel Interior Access
  111
- Figure 6-1 ASY-1191
  111
- Ac Power Requirements
  112
- Figure 6-2 Electrical Panel Label
  112
- Figure 6-3 PLC, CNT-0104
  112
- Electrical Panel Components
  112
- Programmable Logic Controller (PLC)
  112
- Input Leds
  112
- Replacing the PLC
  113
- Installing a New Program
  113
- Figure 6-4 Connector Block Removal
  113
- Installing a Memory Card
  114
- Hour Meter
  114
- Motor Starter
  114
- Figure 6-5 Hour Meter
  114
- Overload Relay
  115
- Power Supply
  115
- Motor Starter (Typical) Figure 6-7 Overload Relay (Typical)
  115
- Figure 6-8 Power Supply
  115
- Alarms
  116
- Final Separator Warning
  116
- Compressor High Temperature
  116
- Figure 6-9 High Temperature Switch
  116
- Figure 6-10 Pressure Sensor (Typical)
  116
- Compressor Low Oil Pressure
  117
- Replacement Parts List
  118
- Figure 6-11 Electrical Panel, Interior
  118
Chapter 7

120
- Description
  120
- Components
  120
- Figure 7-1 Components
  120
- Rfid Option
  120
- Functions
  121
- Assigning the Cylinder
  121
- Filling the Cylinder with RFID Option
  121
- Kit-0585
  121
- Figure 7-2 Add New Cylinder
  121
- Figure 7-3 KIT-0585
  122
- Replacement Parts List
  123
- Figure 7-4 RFID Assembly
  123
- Figure 7-5 KIT-0585
  124
- Description
  125
- Operation
  125
- Figure 8-1 Regulator & Monitors
  125
- Calibration
  126
- Figure 8-2 Basic Calibration Kit & Test Gases
  126
- Replacement Parts
  128
- Figure 8-3 Regulator and Monitors
  128
- Figure 8-4 Monitors
  129
- Figure 8-5 Calibration Components
  130
- Description
  131
- Fill Station Air Flow
  131
- Maintenance
  131
- General Maintenance
  131
- Nonadjustable Valves
  132
- Pressure Gauges
  132
- Safety Valves
  132
- Pneumatic Connections
  132
- Figure 9-1 Safety Valves
  132
- Bearings for Bottle Door Pivot
  133
- Pressure Hoses
  133
- Door Gas Spring
  133
- Figure 9-2 Special Tool, TOO-0020
  133
- Replacement Parts List
  134
- CFS III Assemblies
  134
- Figure 9-3 CFS III Assembly
  134
- Figure 9-4 Fill Whips & Brackets
  135
- Figure 9-5 CFS III Door Lock Assembly
  136
- Figure 9-6 Door Handle, Pivot and Bracket
  137
- Figure 9-7 CFS III Door Interlock
  138
- Fill Hose Assemblies
  139
- Figure 9-8 Standard Fill Hose Assemblies
  139
- Figure 9-9 Fill Whips with Options
  140
Chapter 10

142
Chapter 11

142
- Description and Maintenance
  143
- Description
  143
- Maintenance
  144
- Storage Bottles
  144
- Pressure Gauges
  144
- Figure 10-1 UNICUS III Storage Systems
  144
- Tube Connections
  145
- Safety Valve
  145
- Pressure Hoses
  145
- Figure 10-2 Safety Valve; VAL-0022
  145
- Autocascade System
  146
- General
  146
- Figure 10-3 Autocascade System
  146
- Electrical
  147
- Filling the Storage Banks
  147
- Filling Bottles from the Storage Banks
  147
- Manual Bypass
  147
- Chapter 11
  148
- Safety
  148
- General Safety Precautions
  148
- Safety Warning Labels
  150
- Unpacking, Handling and Installation
  151
- Unpacking and Handling
  151
- Figure 11-1 Lifting Devices
  151
- Installation of the Compressor Unit
  152
- General
  152
- Figure 11-2 Leveling Feet
  152
- Ventilation
  153
- Outdoor Installation
  153
- Indoor Installation
  153
- Natural Ventilation
  153
- Forced Ventilation
  154
- Intake Gas
  154
- Inside Gas Source
  154
- Outside Gas Source
  155
- Compressor Intake Piping
  155
- Installation Procedures
  156
- Electrical Installation
  156
- Electric Drive
  156
- Electrical Supply
  156
- Figure 11-3 Example of Gas Intake Piping
  156
- Figure 11-4 Incoming Power Wiring Label
  157
- Pneumatic Leaks
  158
- Long Term Storage
  159
- General
  159
- Preparations
  159
- Units Equipped with a Filter System
  159
- Preserving the Compressor
  159
- Preventive Maintenance During Storage
  160
- Lubrication Oils for Preservation
  160
- Reactivating the Compressor Unit
  160
- Reproducible Forms
  161
- Scheduled Maintenance Form
  161
- Cartridge Operating Hours
  164
- Record of Operating Hours
  165
- Reference Data
  166
- Tightening Torque Values
  166
- Torque Sequence Diagrams
  166
- Conversion Formulas
  166
- Figure 11-5 6 Bolt and 4 Bolt Torque Sequence
  166
- Approved Lubricants Chart
  167
- Glossary of Abbreviations and Acronyms
  167
- Additional Documents
  168
- Diagrams and Drawings
  168
- Other Documents
  168
- Unit Information
  169

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