Bauer Compressors UNICUS 4i-25 Manuals

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

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

Bauer Compressors UNICUS 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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