Stationary Integrated Systems: Instruction Manual and Replacement Parts List

Instruction Manual and Replacement Parts List
Stationary Integrated Systems

High Pressure Breathing Air Compressor Units
UNICUS III 20
UNICUS III 26
October 22, 2009
1st Edition, Rev. 2 Chg. 2

2004 - 2009 Bauer Compressors, Inc.
BAUER Compressors, Inc.

1328 Azalea Garden Road
Norfolk, Virginia 23502-1944
MNL-0375
Phone: (757) 855-6006

Fax: (757) 855-6224
www.bauercomp.com
UNICUS III
This information is believed to be accurate by Bauer Compressors, Inc., as of its 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 Bauers products, and is thus
subject to Bauers 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 2004 - 2009 Bauer Compressors, Inc., and Bauer reserves to itself all rights to this publication. Bauers customers have no right
to reproduce, rewrite, modify, license or permit anyone elses 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
Nov. 15, 2004
JD
Feb. 22, 2005 Added Idler Wrench and Leveling Feet
JD
Mar. 8, 2005
JD
Nov. 3, 2006
Nov. 30, 2006 Changed P/N of Oil Pressure Gauge GAG-0006W to GAG-0042W
JD
Mar. 29, 2007 Change to Separator P/N 079416 Life Span
JD
Oct. 30, 2007 Update ACD Solenoid P/N AC DC
JD
July 18, 2008 Added After Cylinder Failure Warning
Sept. 9, 2008
Nov. 18, 2008 Changed Drive Chapter and P5 Securus II section
SS
July 29, 2009 Converted to Maple System & Siemens electric
SS
Sept. 28, 2009 Fill Hose P/Ns
SS
Oct. 22, 2009 Corrected Dryer Cartridge P/N
SS
Page i
Notes
Auth
Added Air Filter Indicator & Overrun Time
Sept. 22, 2005 Changed 3rd Stage Intermediate Separator to P/N 081798
Added CFSII Bottle Riser
Converted to Securus II
JD
JD
CLA
SS
MNL-0375
Table of Contents
CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION
1.1 HOW TO USE THIS MANUAL......................................................................................................................................... 1
1.1.1
Manual Safety Notices ....................................................................................................................................................... 1
1.2
HOW TO USE THE REPLACEMENT PARTS LIST .................................................................................................... 2
1.3
HOW TO USE THE APPENDIX....................................................................................................................................... 3
1.4
UNIT DESCRIPTION......................................................................................................................................................... 4
1.5 UNIT SPECIFICATIONS .................................................................................................................................................. 5

1.5.1
UNICUS III 20 ................................................................................................................................................................... 5
1.5.1.1
Compressor Block, IK 150 II.......................................................................................................................................... 5
1.5.1.2
Compressor Drive........................................................................................................................................................... 5
1.5.1.3
Purification System Applicability .................................................................................................................................. 5
1.5.2
UNICUS III 26 .................................................................................................................................................................. 6
1.5.2.1
Compressor Block, IK180II............................................................................................................................................ 6
1.5.2.2
Compressor Drive........................................................................................................................................................... 6
1.5.2.3
Purification System Applicability .................................................................................................................................. 6
1.6
COMPONENT LOCATIONS ............................................................................................................................................ 7
CHAPTER 2: - - - -OPERATING INSTRUCTIONS; MAPLE SYSTEM

2.1 DESCRIPTION.................................................................................................................................................................... 9
2.1.1
Emergency Stop Button ..................................................................................................................................................... 9
2.1.2
Operator Interface .............................................................................................................................................................. 9
2.1.2.1
Run Screen.................................................................................................................................................................... 10
2.1.2.2
Home Screen................................................................................................................................................................. 11
2.1.2.2.1 Run................................................................................................................................................................................ 11
2.1.2.2.2 Alarms........................................................................................................................................................................... 11
2.1.2.2.3 Login............................................................................................................................................................................. 11
2.1.2.2.4 Language Choice .......................................................................................................................................................... 11
2.1.2.2.5 Adjust............................................................................................................................................................................ 11
2.1.2.2.6 Maintenance.................................................................................................................................................................. 12
2.1.2.2.7 Setup ............................................................................................................................................................................. 12
2.1.2.2.8 Tools ............................................................................................................................................................................. 12
2.1.2.2.9 Contact.......................................................................................................................................................................... 13
2.2 STARTING AND STOPPING UNIT............................................................................................................................... 13
2.2.1
Before Starting. ................................................................................................................................................................ 13
2.2.2
To Start Unit..................................................................................................................................................................... 13
2.2.3
To Stop Unit. .................................................................................................................................................................... 13
2.3
SCREEN FLOW ................................................................................................................................................................ 17
CHAPTER 3: - - - - - IK150 II AND IK180 II COMPRESSOR BLOCK

3.1 MAINTENANCE AND PARTS ....................................................................................................................................... 18
3.1.1
Description ....................................................................................................................................................................... 18
3.1.1.1
Air Flow Diagram......................................................................................................................................................... 18
3.1.1.2
Component Location .................................................................................................................................................... 19
3.1.2
Lubrication System .......................................................................................................................................................... 21
3.1.2.1
Description.................................................................................................................................................................... 21
October 22, 2009
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UNICUS III
3.1.2.2
Oil Level Check ............................................................................................................................................................21
3.1.2.3
Oil Change Interval.......................................................................................................................................................22
3.1.2.4
Oil Capacity ..................................................................................................................................................................22
3.1.2.5
Oil Change ....................................................................................................................................................................22
3.1.2.6
Venting the Oil Pump ...................................................................................................................................................23
3.1.3
Intake Filter ......................................................................................................................................................................24
3.1.3.1
Service Indicator ...........................................................................................................................................................24
3.1.3.2
Replacing the Filter Element ........................................................................................................................................24
3.1.4
Intermediate Separators ....................................................................................................................................................26
3.1.4.1
Description....................................................................................................................................................................26
3.1.4.2
Maintenance..................................................................................................................................................................26
3.1.5
Compressor Valves and Valve Heads ..............................................................................................................................26
3.1.5.1
Functional Description..................................................................................................................................................26
3.1.5.2
Initial Operational Check of the Valves .......................................................................................................................26
3.1.5.3
General Instructions for Changing the Valves..............................................................................................................27
3.1.5.4
Changing the 1st Stage Valves. ...................................................................................................................................27
3.1.5.4.1 Removal Procedure.......................................................................................................................................................28
3.1.5.4.2 Installation Procedure ...................................................................................................................................................28
3.1.5.5
Changing the 2nd and 3rd Stage Valves .......................................................................................................................28
3.1.5.5.1 Removal Procedure.......................................................................................................................................................28
3.1.5.5.2 Installation Procedure ...................................................................................................................................................28
3.1.5.6
Changing the 4th Stage Valves .....................................................................................................................................29
3.1.5.6.1 Discharge Valve Removal Procedure ..........................................................................................................................30
3.1.5.6.2 Discharge Valve Installation Procedure ......................................................................................................................30
3.1.5.6.3 Inlet Valve Removal and Installation ..........................................................................................................................31
3.1.6
Repair and Troubleshooting .............................................................................................................................................31
3.1.6.1
Repair............................................................................................................................................................................31
3.1.6.2
Troubleshooting ............................................................................................................................................................32
3.1.7
Replacement Parts List ....................................................................................................................................................34
3.2 AUTOMATIC CONDENSATE DRAIN SYSTEM ........................................................................................................65
3.2.1
Description .......................................................................................................................................................................65
3.2.1.1
Compressor Operating ..................................................................................................................................................66
3.2.1.2
Condensate Draining.....................................................................................................................................................66
3.2.1.3
Start Unloading .............................................................................................................................................................66
3.2.1.4
Standstill Drainage........................................................................................................................................................66
3.2.1.5
Condensate Drain Piping ..............................................................................................................................................66
3.2.1.6
Condensate Collection ..................................................................................................................................................67
3.2.2
ACD Maintenance ............................................................................................................................................................67
3.2.3
Replacement Parts List .....................................................................................................................................................68
3.2.4
Condensate Collector Replacement Parts List .................................................................................................................73
3.2.5
Trouble shooting...............................................................................................................................................................74
CHAPTER 4:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

4.1 INTRODUCTION..............................................................................................................................................................75
4.1.1
General Purification System Procedures ..........................................................................................................................75
4.1.2
Chamber Safety Bore .......................................................................................................................................................75
4.1.3
Manual Condensate Drainage...........................................................................................................................................76
4.1.4
Model, Serial Number and Part Number Identification ...................................................................................................76
4.1.4.1
Compressor Dataplate...................................................................................................................................................76
4.1.4.2
Purification System Dataplate ......................................................................................................................................77
4.1.4.3
Cartridge Installation Dataplate ....................................................................................................................................77
4.1.5
Breathing Air Purification System Configurations ..........................................................................................................77
4.1.6
Industrial Purification System Configurations .................................................................................................................78
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MNL-0375
4.1.7
Cartridge Operating Life .................................................................................................................................................. 78
4.1.7.1
Calculating the Maximum Cartridge Operating Hours ................................................................................................ 79
4.1.7.2
Calculating the Adjusted Cartridge Operating Hours................................................................................................... 79
4.1.7.3
Air Purification Cartridge Operating Hours Form........................................................................................................ 81
4.2 P5S SECURUS II PURIFICATION SYSTEM............................................................................................................ 82
4.2.1
P5S Securus II Purification System Major Components .............................................................................................. 82
4.3 COMPONENT DESCRIPTION ...................................................................................................................................... 83
4.3.1
Oil and Water Separator ................................................................................................................................................... 83
4.3.2
Chamber ........................................................................................................................................................................... 83
4.3.3
Cartridge........................................................................................................................................................................... 83
4.3.3.1
Cartridge Construction.................................................................................................................................................. 83
4.3.3.2
Cartridge Handling ....................................................................................................................................................... 84
4.3.4
Condensate Drain Valve................................................................................................................................................... 84
4.3.5
Check Valves.................................................................................................................................................................... 84
4.3.6
Bleed Valve ...................................................................................................................................................................... 84
4.3.7
Pressure Maintaining Valve ............................................................................................................................................. 84
4.3.8
Safety Valve ..................................................................................................................................................................... 84
4.3.9
Securus II Electronic Moisture Monitor System ............................................................................................................ 84
4.3.9.1
Securus Cartridge ...................................................................................................................................................... 84
4.3.9.2
Securus II Transmitter................................................................................................................................................. 85
4.4 MAINTENANCE............................................................................................................................................................... 85
4.4.1
Oil and Water Separator ................................................................................................................................................... 85
4.4.1.1
Removal of the Securus II Transmitter..................................................................................................................... 87
4.4.2
Cartridge Replacement..................................................................................................................................................... 88
4.4.2.1
Leaking at the Safety Bore ........................................................................................................................................... 88
4.5
REPLACEMENT PARTS LIST ..................................................................................................................................... 90
CHAPTER 5: - - - - - - - - - - - COMPRESSOR DRIVE; UNICUS III

5.1
VERTICAL COMPRESSOR DRIVE.............................................................................................................................. 96
5.2 MAINTENANCE OF THE V-BELT AND SHEAVES.................................................................................................. 96

5.2.1
Check The Sheaves. ......................................................................................................................................................... 96
5.2.2
Check the V-belt............................................................................................................................................................... 97
5.2.3
Replacing the Belt ............................................................................................................................................................ 97
5.2.4
Replacing the Sheave ....................................................................................................................................................... 97
5.3
REPLACEMENT PART LIST ........................................................................................................................................ 98
CHAPTER 6: - - - - - - - - - - - - ELECTRICAL PANEL, ASY-1058

6.1
OVERVIEW..................................................................................................................................................................... 100
6.2 ELECTRICAL PANEL .................................................................................................................................................. 100

6.2.1
Wiring Diagram.............................................................................................................................................................. 101
6.2.2
Electrical Panel Interior Access ..................................................................................................................................... 101
6.2.3
Optional Equipment ....................................................................................................................................................... 101
6.3
AC POWER REQUIREMENTS.................................................................................................................................... 101
6.4 ELECTRICAL PANEL COMPONENTS..................................................................................................................... 102

6.4.1
Programable Logic Controller (PLC)............................................................................................................................. 102
6.4.2
Replacing the PLC ......................................................................................................................................................... 103
6.4.3
Installing a New Program............................................................................................................................................... 103
6.4.4
Installing an EEPROM................................................................................................................................................... 103
6.4.5
Hourmeter....................................................................................................................................................................... 104
October 22, 2009
Page iv
UNICUS III
6.4.6
6.4.7
6.4.8
6.4.9
6.4.10
6.4.11
Transformer and Fuses ...................................................................................................................................................104

Motor Starter. .................................................................................................................................................................104
Overload Relay...............................................................................................................................................................105
Starter Reset....................................................................................................................................................................105
Optional Communication Modules ................................................................................................................................105
Power Supply..................................................................................................................................................................107
6.5 ALARMS ..........................................................................................................................................................................107

6.5.1
Final Separator Warning.................................................................................................................................................107
6.5.2
Securus Electronic Moisture Monitor System ..............................................................................................................108
6.5.2.1
Securus Cartridge.....................................................................................................................................................108
6.5.2.2
Securus II Transmitter...............................................................................................................................................108
6.5.3
Compressor High Temperature ......................................................................................................................................109
6.5.4
Compressor Low Oil Pressure........................................................................................................................................109
6.5.5
Compressor Overrun Timer............................................................................................................................................109
6.5.6
Carbon Monoxide Monitor Alarm..................................................................................................................................109
6.5.7
Condensate Fault ............................................................................................................................................................110
6.5.8
Motor Starter Overload Trip...........................................................................................................................................111
6.6 PLC INPUTS AND OUTPUTS ......................................................................................................................................111
6.6.1
Analog Inputs to the PLC. ..............................................................................................................................................111
6.7
WIRING HARNESS LAYOUT .....................................................................................................................................112
6.8
REPLACEMENT PARTS LIST ....................................................................................................................................114
6.9
PARTS LIST FOR MODELS WITH A 5 HORSEPOWER MOTOR.......................................................................120
6.10 PARTS LIST FOR MODELS WITH A 7 HORSEPOWER MOTOR....................................................................121

6.11
PARTS LIST FOR MODELS WITH A 10 HORSEPOWER MOTOR.....................................................................122
6.12 PARTS LIST FOR MODELS WITH A 15 HORSEPOWER MOTOR.....................................................................123

6.13 PARTS LIST FOR MODELS WITH A 20 HORSEPOWER MOTOR.....................................................................124
6.14 TYPICAL WIRING DIAGRAM ....................................................................................................................................125
CHAPTER 7:- - - - - - - - - - - - CARBON MONOXIDE MONITOR

7.1 DESCRIPTION ................................................................................................................................................................126
7.1.1
Component Description..................................................................................................................................................127
7.1.1.1
Isolation Valve ............................................................................................................................................................127
7.1.1.2
High Pressure to Low Pressure Regulator ..................................................................................................................127
7.1.1.3
Relief Valve ................................................................................................................................................................127
7.1.1.4
Solenoid Valve............................................................................................................................................................127
7.1.1.5
Inlet Regulator ............................................................................................................................................................127
7.1.1.6
Carbon Monoxide Monitor .........................................................................................................................................127
7.1.1.6.1 Carbon Monoxide Sensor Cell....................................................................................................................................127
7.1.1.7
Test Gas Storage .........................................................................................................................................................127
7.2
CARBON MONOXIDE MONITOR SETUP................................................................................................................127
7.3
OPERATION ...................................................................................................................................................................128
7.4 MAINTENANCE .............................................................................................................................................................128

7.4.1
Calibrating Carbon Monoxide Monitor..........................................................................................................................128
7.4.2
Troubleshooting a Calibration Failure............................................................................................................................129
7.4.3
Carbon Monoxide Sensor Cell Replacement .................................................................................................................129
7.4.4
Carbon Monoxide Monitor Initialization .......................................................................................................................130
7.4.4.1
Setting the LP Regulator.............................................................................................................................................131
7.4.4.2
Initialization Calibration .............................................................................................................................................131
7.4.5
Carbon Monoxide Monitor Test Mode Buttons .............................................................................................................134
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MNL-0375
7.5
REMOTE DISPLAY SETUP ........................................................................................................................................ 135
7.6
REPLACEMENT PARTS LIST .................................................................................................................................... 137
CHAPTER 8: - - - - - - - - - - - - - - - - - -CFS II MAINTENANCE

8.1
DESCRIPTION................................................................................................................................................................ 139
8.2
FILL STATION AIR FLOW.......................................................................................................................................... 139
8.3 MAINTENANCE............................................................................................................................................................. 139

8.3.1
General Maintenance...................................................................................................................................................... 139
8.3.2
Nonadjustable Valves..................................................................................................................................................... 140
8.3.3
Pressure Gauges ............................................................................................................................................................. 140
8.3.4
Safety Valves.................................................................................................................................................................. 140
8.3.5
Pneumatic Connections .................................................................................................................................................. 140
8.3.6
Bearings for Bottle Door Pivot....................................................................................................................................... 141
8.3.7
Pressure Hoses................................................................................................................................................................ 141
8.3.8
Door Gas Spring............................................................................................................................................................. 141
8.4 REPLACEMENT PARTS LIST .................................................................................................................................... 142
8.4.1
CFS II Assemblies.......................................................................................................................................................... 142
8.4.2
Fill Hose Assemblies...................................................................................................................................................... 148
CHAPTER 9: - - - - - - - - - - - - - -UNICUS III HP AIR STORAGE

9.1 BOTTLE SPECIFICATIONS ........................................................................................................................................ 150
9.1.1
D.O.T. Department of Transportation............................................................................................................................ 150
9.1.2
A.S.M.E. American Society of Mechanical Engineers .................................................................................................. 150
9.2 DESCRIPTION AND MAINTENANCE ...................................................................................................................... 151
9.2.1
Description ..................................................................................................................................................................... 151
9.2.2
Maintenance ................................................................................................................................................................... 152
9.2.2.1
Storage Bottles............................................................................................................................................................ 152
9.2.2.2
Pressure Gauges.......................................................................................................................................................... 152
9.2.2.3
Tube Connections ....................................................................................................................................................... 152
9.2.2.4
Safety Valve ............................................................................................................................................................... 153
9.2.2.5
Pressure Hoses ............................................................................................................................................................ 153
CHAPTER 10: - - - - - - - - - - - - CONTROLS AND INDICATORS

10.1 COMPONENT LOCATIONS ........................................................................................................................................ 154
CHAPTER 11: - - - - - - - - - - - - - - - - - - - - - - - APPENDIX

11.1 SAFETY............................................................................................................................................................................ 160
11.1.1 General Safety Precautions ............................................................................................................................................ 160
11.1.2 Safety Warning Labels ................................................................................................................................................... 162
11.2 UNPACKING, HANDLING AND INSTALLATION ................................................................................................. 163
11.2.1 Unpacking and Handling................................................................................................................................................ 163
11.2.2 Installation of the Compressor Unit ............................................................................................................................... 164
11.2.2.1
Securing and Leveling the UNICUS III .................................................................................................................... 165
11.2.2.2 Ventilation .................................................................................................................................................................. 165
11.2.2.2.1 Outdoor Installation .................................................................................................................................................... 165
11.2.2.2.2 Indoor Installation....................................................................................................................................................... 165
11.2.2.2.3 Natural Ventilation ..................................................................................................................................................... 166
October 22, 2009
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UNICUS III
11.2.2.2.4
11.2.2.3
11.2.2.3.1
11.2.2.3.2
Forced Ventilation ......................................................................................................................................................166

Electrical Installation ..................................................................................................................................................167
Electric Drive ..............................................................................................................................................................167
Electrical Supply.........................................................................................................................................................167
11.3 LONG TERM STORAGE ...............................................................................................................................................170

11.3.1 General ...........................................................................................................................................................................170
11.3.2 Preparations ....................................................................................................................................................................170
11.3.2.1 Units Equipped with a Filter System ..........................................................................................................................170
11.3.3 Preserving the Compressor.............................................................................................................................................170
11.3.4 Preventive Maintenance During Storage........................................................................................................................170
11.3.5 Lubrication Oils for Preservation ...................................................................................................................................171
11.3.6 Reactivating the Compressor Unit..................................................................................................................................171
11.4 REPRODUCIBLE FORMS ............................................................................................................................................172
11.4.1 Scheduled Maintenance Form .......................................................................................................................................172
11.4.2 Record of Operating Hours ...........................................................................................................................................175
11.5 REFERENCE DATA.......................................................................................................................................................176
11.5.1 Tightening Torque Values..............................................................................................................................................176
11.5.2 Torque Sequence Diagrams............................................................................................................................................176
11.5.3 Conversion Formulas......................................................................................................................................................176
11.5.4 Approved Lubricants Chart ............................................................................................................................................177
11.5.5 Glossary of Abbreviations and Acronyms .....................................................................................................................177
11.6 ADDITIONAL DOCUMENTS.......................................................................................................................................178
11.6.1 Diagrams and Drawings .................................................................................................................................................178
11.6.2 Other Documents............................................................................................................................................................178
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MNL-0375
List of Figures
CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION
Figure 1-1
Figure 1-2
Figure 1-3
Compressor Identification Plate .............................................................................................................................. 2

UNICUS III ............................................................................................................................................................. 7
UNICUS III Front Panel.......................................................................................................................................... 8
CHAPTER 2: - - - -OPERATING INSTRUCTIONS; MAPLE SYSTEM

Figure 2-1
Figure 2-2
Figure 2-3
Figure 2-4
Figure 2-5
Figure 2-6
Figure 2-7
MNR-0049............................................................................................................................................................... 9
Maple System; Run Screen ................................................................................................................................... 10
Maple System; Home Screen ................................................................................................................................ 11
Parameter Adjustment Screen ............................................................................................................................... 12
Adjustment Keypad ............................................................................................................................................... 12
Table of Parameter Values .................................................................................................................................... 14
Operator Interface Screen Flow............................................................................................................................. 17
CHAPTER 3: - - - - - IK150 II AND IK180 II COMPRESSOR BLOCK

Figure 3-1
Figure 3-2
Figure 3-3
Figure 3-4
Figure 3-5
Figure 3-6
Figure 3-7
Figure 3-8
Figure 3-9
Figure 3-10
Figure 3-11
Figure 3-12
Figure 3-13
Figure 3-14
Figure 3-15
Figure 3-16
Figure 3-17
Figure 3-18
Figure 3-19
Figure 3-20
Figure 3-21
Figure 3-22
Figure 3-23
Figure 3-24
Figure 3-25
Figure 3-26
Figure 3-27
Four Stage Compressor Air Flow.......................................................................................................................... 18

IK150 II Compressor Block (Front View) ............................................................................................................ 19
IK180 II Compressor Block (Front View) ............................................................................................................ 20
Lubrication Oil System.......................................................................................................................................... 21
Oil Filler Sight Gauge ........................................................................................................................................... 22
Removing the Oil Filter Cover .............................................................................................................................. 23
Replacing the Oil Filter ......................................................................................................................................... 23
Intake Filter ........................................................................................................................................................... 24
2nd Stage Intermediate Separator.......................................................................................................................... 25
3rd Stage Intermediate Separator .......................................................................................................................... 25
Valve Function ...................................................................................................................................................... 26
1st Stage Valve and Head...................................................................................................................................... 27
2nd and 3rd Stages Valve Heads and Valves ........................................................................................................ 28
4th Stage Valve and Head ..................................................................................................................................... 29
4th Stage Discharge Valve Removal..................................................................................................................... 30
Assembly Tool....................................................................................................................................................... 31
Using Special Tool ................................................................................................................................................ 31
Crankcase Assembly ............................................................................................................................................. 34
Complete Crankshaft Assembly ............................................................................................................................ 36
K150II 1st Stage Piston and Cylinder ................................................................................................................... 37
K180II 1st Stage Piston and Cylinder ................................................................................................................... 38
2nd Stage Piston and Cylinder Assembly ............................................................................................................. 40
3rd Stage Piston and Cylinder ............................................................................................................................... 42
4th Stage Piston and Cylinder Assembly .............................................................................................................. 44
1st Stage Valve Head Assembly............................................................................................................................ 46
2nd Stage Valve Head ........................................................................................................................................... 47
3rd Stage Valve Head Assembly........................................................................................................................... 48
October 22, 2009
Page viii
UNICUS III
Figure 3-28
Figure 3-29
Figure 3-30
Figure 3-31
Figure 3-32
Figure 3-33
Figure 3-34
Figure 3-35
Figure 3-36
Figure 3-37
Figure 3-38
Figure 3-39
Figure 3-40
Figure 3-41
Figure 3-42
Figure 3-43
Figure 3-44
Figure 3-45
4th Stage Valve Head Assembly ...........................................................................................................................49

Flywheel Drive Assembly .....................................................................................................................................50
Intake Filter Assembly...........................................................................................................................................51
2nd Stage Interfilter Assembly ..............................................................................................................................52
3rd Stage Interfilter Assembly...............................................................................................................................53
IK150 II Cooling System Assembly......................................................................................................................54
IK180 II Cooling System Assembly......................................................................................................................58
2nd Stage Intercooler.............................................................................................................................................61
3rd Stage Intercooler..............................................................................................................................................62
Lubricating System Assembly...............................................................................................................................63
Lubricating System................................................................................................................................................64
Automatic Condensate Drain System....................................................................................................................65
ACD Operation......................................................................................................................................................66
ACD System ..........................................................................................................................................................68
Final Separator Condensate Drain Valve ..............................................................................................................69
1st Stage Separators Condensate Drain Valves .....................................................................................................70
Manual Condensate Drain Valve...........................................................................................................................72
Condensate Collector.............................................................................................................................................73
CHAPTER 4:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

Figure 4-1
Figure 4-2
Figure 4-3
Figure 4-4
Figure 4-5
Figure 4-6
Figure 4-7
Figure 4-8
Figure 4-9
Figure 4-10
Figure 4-11
Figure 4-12
Figure 4-13
Figure 4-14
Figure 4-15
Cartridge Safety Venting .......................................................................................................................................76

Purification System Dataplates (typical) ...............................................................................................................76
Correction Factor for Cartridge Operating Hours .................................................................................................80
Example Record of Adjusted Operating Hours .....................................................................................................80
P5S Securus II Purification System....................................................................................................................82
Oil and Water Separator Labels.............................................................................................................................83
Cartridge ................................................................................................................................................................84
Oil and Water Separator ........................................................................................................................................86
Sintered Metal Filter Assembly .............................................................................................................................86
Removal of the Securus II Transmitter...............................................................................................................87
Cartridge Replacement ..........................................................................................................................................88
P5 Purification System Parts List ..........................................................................................................................90
Oil and Water Separator Parts List ........................................................................................................................91
27 Chamber Assembly Parts List.........................................................................................................................92
Securus Electronic Moisture Monitor System Parts List....................................................................................94
CHAPTER 5:- - - - - - - - - - - COMPRESSOR DRIVE; UNICUS III

Figure 5-1
Figure 5-2
Vertical Drive with Idler (typical) .........................................................................................................................96

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
Page ix
ASY-1058 and MNR-0049..................................................................................................................................100

Electrical Panel Label ..........................................................................................................................................101
PLC, CNT-0078...................................................................................................................................................102
Connector Block Removal...................................................................................................................................102
MNL-0375
Figure 6-5
Figure 6-6
Figure 6-7
Figure 6-8
Figure 6-9
Figure 6-10
Figure 6-11
Figure 6-12
Figure 6-13
Figure 6-14
Figure 6-15
Figure 6-16
Figure 6-17
Figure 6-18
Figure 6-19
Hourmeter............................................................................................................................................................ 104
Transformer and Fuses ........................................................................................................................................ 104
Motor Starter (typical)......................................................................................................................................... 105
Overload Relay (typical) ..................................................................................................................................... 105
Optional Communications Modules.................................................................................................................... 106
Power Supply....................................................................................................................................................... 107
Securus II Transmitter ....................................................................................................................................... 108
High Temperature Switch.................................................................................................................................... 109
Pressure Sensor (Typical).................................................................................................................................... 109
Carbon Monoxide Monitor.................................................................................................................................. 110
Condensate Level Float Switch ........................................................................................................................... 110
Control Pane ........................................................................................................................................................ 114
Electrical Panel, Front View................................................................................................................................ 115
Electrical Panel, Bottom View ............................................................................................................................ 116
Electrical Panel, Interior...................................................................................................................................... 118
CHAPTER 7: - - - - - - - - - - - - CARBON MONOXIDE MONITOR

Figure 7-1
Figure 7-2
Figure 7-3
Figure 7-4
Figure 7-5
Figure 7-6
Figure 7-7
Figure 7-8
Figure 7-9
Figure 7-10
Figure 7-11
CO Monitor, MNR-0029 ..................................................................................................................................... 126

Remote Display ................................................................................................................................................... 126
Carbon Monoxide Monitor Flow Diagram.......................................................................................................... 127
Basic Calibration Kit ........................................................................................................................................... 129
Carbon Monoxide Monitor Initialization ............................................................................................................ 131
Carbon Monoxide Monitor Internal Components ............................................................................................... 133
Carbon Monoxide Sensor Cell Removal............................................................................................................. 134
Mode Buttons Close-up....................................................................................................................................... 135
Remote Display ................................................................................................................................................... 136
Carbon Monoxide Monitor Assembly - Standard ............................................................................................... 137
Carbon Monoxide Monitor Schematic ................................................................................................................ 138
CHAPTER 8: - - - - - - - - - - - - - - - - - -CFS II MAINTENANCE

Figure 8-1
Figure 8-2
Figure 8-3
Figure 8-4
Figure 8-5
Figure 8-6
Figure 8-7
Figure 8-8
Figure 8-9
Safety Valves....................................................................................................................................................... 140

Special Tool, TOO-0020 ..................................................................................................................................... 141
CFS II Assembly ................................................................................................................................................. 142
CFS II Door Lock Assembly............................................................................................................................... 143
Door Handle, Pivot and Bracket.......................................................................................................................... 144
CFS II Door Lock Latch...................................................................................................................................... 146
CFS II Door Interlock.......................................................................................................................................... 147
Standard Fill Hose Assembly .............................................................................................................................. 148
Multi Fill Hose Assembly ................................................................................................................................... 149
CHAPTER 9: - - - - - - - - - - - - - -UNICUS III HP AIR STORAGE

Figure 9-1
Figure 9-2
UNICUS III Storage System ............................................................................................................................... 151

Safety Valve ........................................................................................................................................................ 153
October 22, 2009
Page x
UNICUS III
CHAPTER 10: - - - - - - - - - - - - CONTROLS AND INDICATORS
Figure 10-1
Figure 10-2
Figure 10-3
Figure 10-4
Figure 10-5
Figure 10-6
Front Panel...........................................................................................................................................................154
Gauge Panel .........................................................................................................................................................155
Components for Remote Fill Option ...................................................................................................................156
Front Panel Parts..................................................................................................................................................157
Gauge Panel Parts ................................................................................................................................................158
Remote Fill Option Parts .....................................................................................................................................159
CHAPTER 11: - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX

Figure 11-1
Figure 11-2
Figure 11-3
Figure 11-4
Page xi
Lifting Devices ....................................................................................................................................................163

Securing and Leveling the UNICUS III ..............................................................................................................165
Incoming Power Wiring Label ............................................................................................................................167
6 Bolt and 4 Bolt Torque Sequence.....................................................................................................................176
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.
1.1.1 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
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
Example
Model Number
TCom-25
Serial Number
32165
Date of Manufacture
02/2005
Quantity required
Part Number
N04860
Part Description
Figure 1-1
Valve
Compressor Identification Plate
BAUER COMPRESSORS, INC.

NORFOLK, VIRGINIA U.S.A
SERIAL NO.
MOTOR
CFM
PRESSURE
PSIG
CHG. RATE
CFM
SPEED
RPM
HZ
AMPS
HP
PH
VOLTS
DATE OF MANUFACTURE
Page 2
COMPRESSORS
BLOCK NO.
MODEL NO.
CAPACITY
BAUER
LBL-004
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
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
MNL-0375
1.5
Unit Specifications
All specifications are subject to change without prior notice.
1.5.1
UNICUS III 20
Medium
air
Charging Rate
20.4 scfm1
17.0 scfm2
atmospheric
5,000 psig
43 to 113 F (5 - 45 C)
approx. 3,350 lbs. (1,508 kgs)
Free Air Delivery

Inlet pressure
Operating pressure, max.
Ambient temperature range
Weight
1.5.1.1 Compressor Block, IK 150 II
No. of stages
No. of cylinders
Cylinder bore, 1st stage
Cylinder bore, 2nd stage
Cylinder bore, 3rd stage
Cylinder bore, 4th stage
Piston Stroke
Intermediate pressure, 1st stage
Safety valve setting, 1st stage
Intermediate pressure, 2nd stage
Safety valve setting, 2nd stage
Intermediate pressure, 3rd stage
Safety valve setting, 3rd stage
Direction of rotation when facing flywheel
Compressor speed
Oil capacity
Oil Pressure
Recommended oil
Maximum Inclination
4
4
4.72 in. (120mm)
2.367 in. (60mm)
1.26 in. (32mm)
0.55 in. (14mm)
1.97 in.(50mm)
29 - 44 psig (2 - 3 bar)
73 psig (5 bar)
196 - 225 psig (13.5 -15.5 bar)
348 psig (24 bar)
928 - 1,015 psig (64 - 70 bar)
1,160 psig (80 bar)
CCW
900 - 1350 RPM
6.36 qts.(6 ltrs)
58 - 87 psig (4 - 6 bar)
BAUER OIL-0024
20 in all directions
1.5.1.2 Compressor Drive
-E3
Voltage
Freq.
Phase
Power
RPM
Type
208 - 460 VAC
60 Hz
15 Hp
3,600
ODP
1.5.1.3 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 68F and 36% humidity at 14.70 psia.
October 22, 2009
Page 5
UNICUS III
1.5.2
UNICUS III 26
Medium
air
Charging Rate
26.4 scfm1
22.0 scfm2
atmospheric
5,000 psig
43 to 113 F (5 - 45 C)
approx. 3,625 lbs. (1,631 kgs)
Free Air Delivery

Inlet pressure
Operating pressure, max.
Ambient temperature range
Weight
1.5.2.1 Compressor Block, IK180II
No. of stages
No. of cylinders
Cylinder bore, 1st stage
Cylinder bore, 2nd stage
Cylinder bore, 3rd stage
Cylinder bore, 4th stage
Piston Stroke
Intermediate pressure, 1st stage
Safety valve setting, 1st stage
Intermediate pressure, 2nd stage
Safety valve setting, 2nd stage
Intermediate pressure, 3rd stage
Safety valve setting, 3rd stage
Direction of rotation when facing flywheel
Compressor speed
Oil capacity
Oil Pressure
Recommended oil
Maximum Inclination
4
4
5.07 in. (130mm)
2.367 in. (60mm)
1.26 in. (32mm)
0.55 in. (14mm)
1.97 in.(50mm)
44 - 58 psig (3 - 4 bar)
73 psig (5 bar)
232 - 261 psig (16 -18 bar)
348 psig (24 bar)
1,015 - 1,088 psig (70 - 75 bar)
1378 psig (95 bar)
CCW
900 - 1350 RPM
6.36 qts.(6 ltrs)
58 - 87 psig (4 - 6 bar)
BAUER OIL-0024
20 in all directions
1.5.2.2 Compressor Drive
-E3
Voltage
Frequency
208 - 460 VAC
60 Hz
Phase
3
Power
RPM
Type
20 Hp
3,600
ODP
1.5.2.3 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 68F and 36% humidity at 14.70 psia.
Page 6
MNL-0375
1.6
Component Locations
Figure 1-2
UNICUS III
1.
2.
3.
4.
Remote Fill Panel (Option)

Remote Fill Hose (Option)
Cascade Panel
Compressor Control Panel
October 22, 2009
5.
6.
7.
8.
Emergency Stop Switch

Fill Station Controls
Maintenance Access
Fill Station
Page 7
UNICUS III
Figure 1-3
UNICUS III Front Panel
1
7
8
2
3
9
10
4
1.
2.
3.
4.
5.
Cascade Storage Pressure Gauges

Cascade Valves
Fill Select Valve
Inlet Pressure Gauge
Fill Regulator
Page 8
6. Final Pressure Gauge

7. Compressor Control Panel
8. Emergency Stop Switch
9. Fill Valves
10. Bottle Fill Pressure Gauges
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-0049.
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
2.1.1 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.
2.1.2 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
October 22, 2009
MNR-0049
Page 9
UNICUS III
2.1.2.1 Run Screen
The inital screen after startup allows control and monitoring of the compressor unit.
Figure 2-2
Maple System; Run Screen
6
1.
2.
3.
4.
5.
Compressor Status Indicator

Oil Pressure Reading
START Button
OFF Button
Closes Window (goes to HOME Screen)
10
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
MNL-0375
10. This figure shows the present output pressure.
2.1.2.2
Home Screen
Figure 2-3
Maple System; Home Screen
1
2
5
6
7
8
1. 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 units functions.
2.1.2.2.1 Run
This button returns the user to the RUN screen, See Paragraph 2.1.2.1 for further information.
2.1.2.2.2 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.
2.1.2.2.3 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.
2.1.2.2.4 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.
2.1.2.2.5 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
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
2.1.2.2.6 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.
2.1.2.2.7 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.
2.1.2.2.8 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
MNL-0375
2.1.2.2.9 Contact
Pressing the contact button displays contact information for Bauer Compressors, Inc.
2.2
Starting and Stopping Unit
2.2.1
Before Starting.
1. Check the compressor oil level, See Chapter 3.

2. 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.
2.2.2 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.
^ WARNING
Once started the compressor and drive motor will start and stop automatically.
Stay clear of all moving parts whenever unit has power.
2.2.3 To Stop Unit.
Press the STOP Button on the Run screen.
^ NOTE ^
In an emergency the compressor is shutdown by pressing in the E-Stop Button.
October 22, 2009
Page 13
UNICUS III
.
Figure 2-6
Table of Parameter Values
Parameter
PASSWORD
access #s supplied by distributor
Default
1,328
Low
9,999
High
0000
Units
START PRESS
lower pressure limit which starts compressor
5,800a
800
5,700 PSI
SHUTDOWN PRESS
upper pressure limit which stops compressor
6,000
850
6,000 PSI
SEPCNTWARNING
# of cycles till final separator replacement warning given
53,000
1,800
900,000
SEPCNTALARM
# of cycles till final separator replacement alarm shutdown
53,000
2,000
1,000,000
OVERRUNTIMER
amount of time before unit shuts down

if left unattended
SHUTDOWNDELAY
delaye from when command is given till

shtudown occurs
10
SEC
ACDF TEST TIME
amount of time on button held to perform ACD test
10
SEC
CO ALARM DELAY
time between alarm level reached and

alarm gien
125 SEC
23
3
3
3
0
1
1
100 PSI
1,000,000
10 SEC
10 SEC
15
60 MIN
3
3
1
1
10
10
15
60 MIN
3
3
1
1
10
10
15
60 MIN
3
3
1
1
10
10
15
60 MIN
10
10
60 MIN
30
60 SEC
OIL ALARM
SEPCNT RESET
ACD1 DELAY ON
ACD1 DRAIN TIME
ACD1 CYCLE TIME
ACD2 DELAY ON
ACD2 DRAIN TIME
ACD2 CYCLE TIME
ACD3 DELAY ON
ACD3 DRAIN TIME
ACD3 CYCLE TIME
ACDF DELAY ON
ACDF DRAIN TIME
ACDF CYCLE TIME
BACKLIGHT ON
OIL PRESS TIME
DELY (TD)
a.
psi at which low oil press. alarm given

current # of cycles for final separator
dely till ACD1 closes
length of time ACD1 drains
length of time between ACD1 drain
cycles
cycles
cycles
delay till final ACD closes
length of time final ACD drains
length of time between final ACD drain
cycles
Panel light option

time delay from startup till oil
press. sensor is used
100 HRS
SEC
SEC
SEC
SEC
SEC
SEC
15% of Shutdown Press
Page 14
MNL-0375
Table 2-1: Calendar Maintenance Interval Tasks
Task
Monthly
Calibrate CO Monitor
Check Oil Level
Check Final Pressure Shutdown
Check Automatic Condensate Drain
Annually
Check V-belt
Service Intake Filter
Check all connections for leaks
Inspect Compressor Valves
Check all fasteners for tightness
Every Two Years
Change Synthetic Oil
Replace Compressor Oil Filter
Replace Compressor Valves
Replace CO Monitor Sensor
October 22, 2009
Page 15
UNICUS III
Table 2-2: Operating Hours Maintenance Interval Tasks
Task
500 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
Inspect Compressor Valves
1,000 Hours
2,000 Hours
Change Synthetic Oil
Replace Oil Filter
Replace Compressor Valves
Inspect Pistons and Pistons Rings
Page 16
3,000 Hours
MNL-0375
2.3 Screen Flow
Figure 2-7
Operator Interface Screen Flow
October 22, 2009
Page 17
UNICUS III
CHAPTER 3:
3.1
IK150 II AND IK180 II COMPRESSOR BLOCK
Maintenance and Parts
3.1.1 Description
The IK150 II or IK180 II compressor is used to compress air up to 5000 psi.
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.
3.1.1.1
Air Flow Diagram

Figure 3-1
Four Stage Compressor Air Flow

2
1
10
10
I
IV
7
5
III
II
9
10
11
10
12
8
9
1.
2.
3.
4.
5.
6.
Page 18
Intake Manifold
1st Stage Cooler
2nd Stage Cooler
3rd Stage Cooler
Aftercooler
2nd Stage Separator
7. 3rd Stage Separator

8. Final Separator
9. Manual Condensate Drain Valve
10. Safety Valves
11. Pressure Maintaining Valve (PMV)
12. Compressed Air Outlet
MNL-0375
3.1.1.2
Component Location
Figure 3-2
IK150 II Compressor Block (Front View)

11
1
12
2
3
4
5
13
14
15
16
6
17
7
8
18
19
20
9
21
10
22
1. 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
11. Lifting Eyebolt
October 22, 2009
12. 1st Stage Inter Cooler

13. 4th Stage Cylinder
14. 4th Stage After Cooler
15. Oil Pressure Regulating Valve
16. 3rd/4th Inter Stage Pressure Valve
18. 1st/2nd Inter Stage Pressure Valve
19. 3rd Stage Cooler
20. 2nd Stage Cylinder
21. Oil Filler with Sight Glass
22. Condensate Outlet
Page 19
UNICUS III
Figure 3-3
IK180 II Compressor Block (Front View)

12
13
14
15
16
4
5
17
18
19
20
21
22
9
10
11
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
11. Oil Drain Plug
12. Lifting Eyebolt
Page 20
23
24
13. 1st Stage Auxiliary Cooler

14. 1st Stage Inter Cooler
15. 4th Stage Cylinder
16. 4th Stage After Cooler
18. 3rd/4th Inter Stage Pressure Valve
20. 1st/2nd Inter Stage Pressure Valve
21. 3rd Stage Cooler
22. 2nd Stage Cylinder
23. Oil Filler with Sight Glass
24. Condensate Outlet
MNL-0375
3.1.2
Lubrication System
3.1.2.1 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
5
2
1. Oil Pump
4. Injection Line to 4th Stage
2. Oil Filter
5. Oil Pressure Sensor
3.1.2.2 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
UNICUS III
Figure 3-5
Oil Filler Sight Gauge
Max
Min
3.1.2.3 Oil Change Interval

The synthetic oil should be changed every 2,000 operating hours or biennially, whichever is reached first.
3.1.2.4 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).
3.1.2.5
Oil Change
1. Run the compressor until it is warm.

2. Remove cap from Oil Filler Sight Gauge.
3.
Open the Oil Drain Plug.
^ 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.
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.
Page 22
MNL-0375
Figure 3-6
3.1.2.6
Removing the Oil Filter Cover
Figure 3-7
Replacing the Oil Filter
Venting the Oil Pump
^ CAUTION
To avoid damage after maintenance the following measures should be strictly adhered to.
(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.
October 22, 2009
Page 23
UNICUS III
3.1.3
Intake Filter
Figure 3-8
Intake Filter
2
3
2. Cover
3. Filter Element
4. Filter Housing
A dry micronic filter is used to filter intake air.

3.1.3.1 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
3.1.3.2 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.
Page 24
MNL-0375
Figure 3-9
2nd Stage Intermediate Separator
Figure 3-10
3rd Stage Intermediate Separator
9
2
4
5
1
2
3
1
3
6
7
6
7
1.
2.
3.
4.
Separator Body
Separator Head
Knurled Nut
O-ring
5.
6.
7.
8.
Center Insert
Gasket
Fitting
Safety Valve
1.
2.
3.
4.
Plate
Hollow Screw
Center Insert
O-ring
5.
6.
7.
8.
Knurled Nut
Gasket
Fitting
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
UNICUS III
3.1.4
Intermediate Separators
3.1.4.1 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.
3.1.4.2 Maintenance
The Intermediate Separators require no maintenance.
3.1.5
Compressor Valves and Valve Heads
3.1.5.1 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. See Figure 3-11.
Figure 3-11
Intake
Valve Function
Discharge
3.1.5.2 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
MNL-0375
3.1.5.3 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.
8. 30 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: 011365) for all work on valve heads (See Figure 3-16).
3.1.5.4
Changing the 1st Stage Valves.

Figure 3-12
1st Stage Valve and Head
6
4
4
3
3
4
3
October 22, 2009
Page 27
UNICUS III
3.1.5.4.1 Removal Procedure.
1. See Figure 3-12. 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).
3.1.5.4.2 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.
3.1.5.5 Changing the 2nd and 3rd Stage Valves
See Figure 3-13
Figure 3-13
2nd and 3rd Stages Valve Heads and Valves
1
2
3
4
3
4
8
9
7
1. Hex Nut
2. Cap Holder
3. Valve Caps
4. Extraction Groove
5. O-Rings
6. Inlet Valve
7. Valve Gaskets
8. Valve Head
9. Discharge Valve
3.1.5.5.1 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).
6. Check the valve gaskets (7) and replace if required.
3.1.5.5.2 Installation Procedure
Page 28
MNL-0375
1. 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.
3.1.5.6 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 3-14
4th Stage Valve and Head
10
9
8
7
6
1. 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
October 22, 2009
Page 29
UNICUS III
3.1.5.6.1 Discharge Valve Removal Procedure
Figure 3-15
4th 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 3-15.
6. Lift out Discharge Valve together with the O-ring (4)
3.1.5.6.2 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
MNL-0375
3.1.5.6.3 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 4555-645)
supplied with your unit. See Figure 3-17.
^ 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.
3.1.6
Repair and Troubleshooting
3.1.6.1 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
UNICUS III
3.1.6.2
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
1. Last stage piston worn

2. Last stage pressure valve
defective
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.
Compressor output insufficient
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. 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.
1. Insufficient supply of cooling air

2. Intake or outlet valve not
closing properly
3. Wrong direction of rotation.
1. Check location for adequate

ventilation
2. Check and clean valves,
replace as necessary
3. Check arrow on compressor
and correct accordingly.
Oil residue in delivered air
1. Improper maintenance of
filters, purifier cartridge
saturated.
2. Wrong oil type
1. Service filters, change purifier cartridge.

2. Change to proper oil and
clean valves.
Electrical phases not connected

properly
Reverse two of the three phase

leads at the switch box. Do NOT
change the leads at the motor terminal.
Compressor rotates in the wrong

direction
Page 32
This page is inserted to provide proper page sequencing
10
4
UNICUS III
3.1.7
Replacement Parts List
Figure 3-18
Crankcase Assembly
16
1
17
2 3
4
10
18
11
12 15
56
7
19
41
20
21
22
8
24
23
13
14
25
33
26
27
34
35
36
25
23
24
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
78577
N20649
68586
N15093
N26281
N370
N58
78897
N3138
N18303
N3810
N18304
N18432
N2635
Crankcase Assembly
Screw
Cover Plate
O-ring
Shaft Seal
Self Locking Hex Nut
Washer
Bearing Cover
Stud
Roller Bearing
Circlip
Roller Bearing
Circlip
Circlip
Page 34
1
1
1
1
1
1
6
6
6
1
1
1
1
1
29
30
41
26
28
37
27 38
39 40
31 32
Notes
MNL-0375
Figure 3-18 (cont.)
Crankcase Assembly
# KIT Qty
Part No.
Description
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
3177
N2638
N4467
1492
79225
N4150
80197
N293
N204
N16
N312
78571
N4261
N2796
N25638
N1316
N4570
N102
N19497
78578
78810
N15412
80225
78808
78569
80647
78570
N1314
Gasket
Roller Bearing
Eye Bolt
Washer
Hexagonal Spacer
Stud
Reducer
Gasket
Plug
Washer
Hex Head Screw
Bracket
Gasket
Plug
Ball Valve
Gasket
Plug
Washer
Hex Screw
Crankcase
Oil Sight Gauge Assembly
O-ring
Plug
Gasket
Oil Fill
Steel Plate
Steel Plate
Gasket
1
1
1
1
1
1
1
1
1
12
12
2
2
2
1
1
1
8
8
1
1
1
1
1
1
1
1
1
October 22, 2009
Notes
Items 35 - 39
Page 35
UNICUS III
Figure 3-19
Complete Crankshaft Assembly
6
2
1
3
4
# KIT Qty
Part No.
Description
Notes
1
2
3
4
5
6
7
8
78934
79442
68587
N4366
N108
N2765
4220
N18310
N423
Crankshaft Assembly
Crankshaft Assembly
Bushing
Dowel Screw
Spring Washer
Hex Nut
Spacers
Circlip
Circlip
IK150 II Only
IK180 II Only
Page 36
1
1
1
1
1
1
3
1
1
MNL-0375
Figure 3-20
K150II 1st Stage Piston and Cylinder
7
5
6
7
4
# KIT Qty
Part No.
Description
Notes
1
2
3
4
5
6
7
8
79420
79017
N2621
N26036
79720
79719
N2930
N484
N2963
1st Stage Piston & Cylinder Asy

Cylinder
O-ring
Stud
Piston Assembly
Piston
Pin, Piston
Ring, Retaining
Piston Ring Set
120 mm Diameter
120 mm Diameter
1
1
1
4
1
1
1
2
1
October 22, 2009
120 mm Diameter
120 mm Diameter
Page 37
UNICUS III
Figure 3-21
K180II 1st Stage Piston and Cylinder
7
5
6
7
4
# KIT Qty
Part No.
Description
Notes
1
2
3
4
5
6
7
8
79704
79703
N2621
N26036
79717
79718
N4109
N484
N4642
1st Stage Piston & Cylinder Asy

Cylinder
O-ring
Stud
Piston Assembly
Piston
Pin, Piston
Ring, Retaining
Piston Ring Set
130 mm Diameter
130 mm Diameter
Page 38
1
1
1
4
1
1
1
2
1
130 mm Diameter
130 mm Diameter
10
4
UNICUS III
Figure 3-22
2nd Stage Piston and Cylinder Assembly
6
7
8
9
10
4
5
Page 40
MNL-0375
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
9
10
061048
60572
N3731
N215
N58
N370
070010
N2907
N1429
N484
N1461
2nd Stage Piston and Cylinder Assembly

Cylinder
O-ring
Stud
Washer, Flat
Nut, Hex, Lock
Compressor Piston Assembly
Piston
Pin, Piston
Circlip
Piston Ring Set
..c
..c
1
1
1
4
4
4
1
1
1
2
1
October 22, 2009
Notes
Page 41
UNICUS III
Figure 3-23
3rd Stage Piston and Cylinder
11
10
11
13
5
14
12
2
7 6
4
3
# KIT Qty
Part No.
Description
1
2
3
4
5
060107
82295
N3731
67061
N7063
N17462
Piston and Cylinder Assembly

Cylinder Guide
O-ring
Cylinder
O-ring
Stud
..c
..c
Page 42
1
1
1
1
1
4
Notes
60 mm Diameter
32 mm Diameter
M8 x 80
MNL-0375
Figure 3-23 (cont.)
3rd Stage Piston and Cylinder
# KIT Qty
Part No.
Description
Notes
6
7
8
9
10
11
12
13
14
N58
N370
070012
60087
N15409
N1665
070013
N4378
N16313
Washer, Flat
Nut, Hex, Lock
Piston, Guide Assembly
Piston, Guide
Pin, Piston
Circlip
Piston, Floating Assembly
Piston, Floating
Piston Ring Set
8 mm
M8
60 mm Diameter
..c
4
4
1
1
1
2
1
1
1
October 22, 2009
32 mm Diameter
Page 43
UNICUS III
Figure 3-24
4th Stage Piston and Cylinder Assembly

8
7
10
11
12
3
2
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
9
84380
070012
N3731
82295
N7063
82480
N4868
078043
N23755
N25376
4th Stage Cylinder Assembly

Piston Assembly
O-ring
Guide Cylinder
O-ring
Cylinder
O-ring
Piston and Sleeve Assembly
O-ring
Piston Ring Set
Page 44
1
1
1
1
1
1
1
1
1
1
Notes
MNL-0375
Figure 3-24 (cont.)
4th Stage Piston and Cylinder Assembly
# KIT Qty
Part No.
Description
10
11
12
N370
N58
N17462

Washer
Stud
4
4
4
October 22, 2009
Notes
Page 45
UNICUS III
Figure 3-25
1st Stage Valve Head Assembly
6
4
4
3
3
4
3
# KIT Qty
Part No.
Description
Notes
1
2
3
4
5
6
79680
N26029
N16
N644
N58
N150
1st Stage Valve Head Assembly

1st Stage Valve Head
Plate Valve
Washer
Washer
Allen Screw
M8 x 60
Page 46
1
4
4
1
1
MNL-0375
2nd Stage Valve Head
AUS
EIN
Figure 3-26
10
11
Part No.
Description
1
2
3
4
5
6
7
8
9
10
11
070026
60583
N503
N4067
N4068
56668
56183
N3997
62924
N4190
N16
N3474
2nd Stage Valve Head Assembly

2nd Stage Valve Head
Socket Head Cap Screw
Valve, Inlet
Valve, Discharge
Gasket, Valve
Cap, Valve
O-ring
Press Pad
Stud
Washer, Flat
Nut, Hex Lock
.b.
.b.
a..
a..
a..
October 22, 2009
6
8
# KIT Qty
1
1
6
1
1
2
2
2
1
2
2
2
Notes
Page 47
UNICUS III
3rd Stage Valve Head Assembly
AUS
EIN
Figure 3-27
10
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
9
10
11
068602
60583
N503
N15273
N15274
56668
56183
N3997
62924
N4190
N16
N3474
3rd Stage Valve Head Assembly

3rd Stage Valve Head
Valve, Inlet
Valve, Discharge
Gasket, Valve
Cap, Valve
O-ring
Press Pad
Stud
Washer, Flat
Nut, Hex Lock
Page 48
11
.b.
.b.
a..
a..
a..
1
1
6
1
1
2
2
2
1
2
2
2
Notes
MNL-0375
Figure 3-28
4th Stage Valve Head Assembly
10
9
8
7
6
3
4
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
9
10
82096
081409
82087
014121
N2789
82086
N58
N17730
N2738
N3625
N3589
4th Stage Valve Head Assembly

Intake Valve
Valve Head
Discharge Valve
O-ring
Valve Head Cover
Washer
Allen Screw
Stud
Gasket
Acorn Nut
.b.
.b.
a..
1
1
1
1
1
1
6
6
1
1
1
October 22, 2009
Notes
Page 49
UNICUS III
Figure 3-29
8
Flywheel Drive Assembly
9
1
5
4
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
79240
68623
55425
79239
N19495
N100
68646
N280
N15667
Flywheel Drive Assembly

V-belt Pulley
Fan Blade Support
Blade, Fan CCW
Hex Head Screw
Washer, Split Lock
Washer
Washer, Split Lock
Hex Head Cap Screw
Page 50
1
1
6
18
12
12
1
1
1
Notes
M6 x16
6 mm
M12 x 45
MNL-0375
Figure 3-30
Intake Filter Assembly
4
5
7
6
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
079706
79679
N171
73036
79464
N19535
N25886
79465
N2221
Intake Filter Assembly

Manifold, Air Intake
Housing, Intake Filter
Flange
Allen Screw
Element, Intake Filter
Cover, Filter Housing
Indicator, Maintenance
a..
1
1
3
1
1
3
1
1
1
October 22, 2009
Notes
Page 51
UNICUS III
Figure 3-31
2nd Stage Interfilter Assembly
8
9
2
4
5
1
3
6
7
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
077387
13937
N3556
76613
N1316
N20215
81807
Interfilter Assembly
Filter Housing
Filter Head
Collar, Threaded Knurled
O-ring
Tube and Baffle
Gasket, Copper
Fitting
Safety Valve
Page 52
1
1
1
1
1
1
Notes
Available only with 077387
MNL-0375
Figure 3-32
3rd Stage Interfilter Assembly

4
1
2
3
6
7
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
081798
81148
81643
76613
N3556
13937
N1316
N20215
78706
3rd Stage Interfilter Assembly

Plate
Hollow Screw
Inset Assembly
O-ring
Knurled Ring
Gasket
Fitting
Safety Valve
a..
1
1
1
1
1
1
1
1
1
October 22, 2009
Notes
Page 53
UNICUS III
Figure 3-33
IK150 II Cooling System Assembly

6
52
11
55
5
8
7
12
54
3
15
9
13
10
40
27
48
31
15
16
44
27
39
40
29
35
36
29
15
24
27 25
23
13
14
29
29
27
49
29
30 9
51
33
28
30
15
16
27
15
37
27
29
34
28
50
21
46
2
19
9
27
28
38
33
32
30
43
42
18
34
22
27
28
36
35
45
17
47
20
1
56
41
28
53
33
32
30
16
31
15
32
31
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
079626
079885
079927
079929
079925
79637
6069-M
N15414
N58
N108
N370
75496
N503
Cooling System Assembly

1st Stage Intercooler
2nd Stage Intercooler
3rd Stage Intercooler
Aftercooler
Mount
Clamp
Countersunk Screw
Washer
Lock Washer
Bushing
Allen Screw
Page 54
1
1
1
1
1
4
12
12
16
14
12
2
4
Notes
MNL-0375
Figure 3-33 (cont.)
# KIT Qty
Part No.
Description
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
N57
60751
N109
57070
076425
070043
079923
078918
070045
079919
55799
N1042
N102
N3494
N293
N1316
N20231
N4530
N2144
N3610
N20195
N20059
N20312
N20060
N20260
N724
N20012
N842
N20201
N1049
N16309
N20155
N20014
79812
56983
71148
N20044
N7430
N20003
060709
Hex Nut
Mount
Allen Screw
Tube Clamp
Connecting Tubing
Connecting Tubing
Connecting Tubing
Connecting Tubing
Connecting Tubing
Connecting Tubing
Spacer
Washer
Stud
Gasket
Gasket
Connector
Plug
Lock Washer
Cap Screw
Connector
Connector
Fitting
Connector
Elbow
Allen Screw
Connector
Gasket
Connector
Cap Screw
Plug
Adjustable Coupling
Connector
Bracket
Gasket
Connector
Connector
Cap Screw
Elbow Coupling
Fan Screen
8
2
8
2
1
1
1
1
1
1
4
8
8
8
8
8
5
4
4
3
3
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
October 22, 2009
Notes
Page 55
UNICUS III
Figure 3-33 (cont.)
# KIT Qty
Part No.
Description
53
54
55
60717
60716
N542
Support
Bracket
Hex Screw
Page 56
1
1
4
Notes
10
4
UNICUS III
Figure 3-34

6
11
5
8
52
35
55
10
56
12
22
13
48
40
27
31
15
54
9
3
44
27
35
40
39
8
29
28
8
29
27
49
28
27
29
30
15
16
34
28
27
29
30
51
33
37
24
26 25
23
50
21
46
36
18
14
29
28
38
33
32
30
43
42
19
36
13
27
34
15
29
45
17
47
27
28
53
16
20
1
41
33
32
22
30
16
31
15
32
31
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
9
10
080227
079885
079927
079929
079925
079637
60694-M
N15414
N58
N108
N370

1st Stage Intercooler
Aftercooler
Mount
Clamp
Countersunk Screw
Washer
Lock Washer
Page 58
1
1
1
1
1
4
12
12
16
14
12
Notes
MNL-0375
Figure 3-34 (cont.)
# KIT Qty
Part No.
Description
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
75496
N503
N57
60751
N109
57070
076425
070043
079923
078918
070045
N61
55799
N1042
N102
N3494
N293
N1316
N20231
N4530
N2144
N3610
N20195
N20059
080248
N20060
N20260
N724
N842
N20118
N20201
N1049
N16309
N20155
N20014
79812
56983
71148
N20044
N7430
Bushing
Allen Screw
Hex Nut
Mount
Allen Screw
Tube Clamp
Connecting Tubing
Connecting Tubing
Connecting Tubing
Connecting Tubing
Connecting Tubing
Allen Screw
Spacer Disc
Washer
Stud
Gasket
Gasket
Connector
Plug
Lock Washer
Cap Screw
Connector
Connector
Auxiliary Cooler
Connector
Elbow
Allen Screw
Gasket
Connector
Connector
Cap Screw
Plug
Adjustable Coupling
Connector
Bracket
Gasket
Connector
Connector
Cap Screw
2
4
8
2
8
2
1
1
1
1
1
2
4
8
8
8
8
8
5
4
4
3
3
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
October 22, 2009
Notes
Page 59
UNICUS III
Figure 3-34 (cont.)
# KIT Qty
Part No.
Description
51
52
53
54
55
56
N20003
060709
60717
60716
N542
081801
Elbow Coupling
Fan Screen
Support
Bracket
Hex Screw
Safety Valve
Page 60
1
1
1
1
4
1
Notes
MNL-0375
Figure 3-35

6
4
5
6
9
8
10
1,
2,
3
1,
2,
3
4
5
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
9
10
079927
FER-0012
NUT-0057
N16310
60738
N724
N102
N1042
N57
60694-M
N15119
2nd Stage Inter-cooler Assembly

Ferrule
Nut, Tube
Insert, Tube
Clamp, Tube
Washer, Flat
Nut, Hex Lock
Nut, Hex
Clamp
Countersunk Screw
1
2
2
2
6
7
14
7
2
4
2
October 22, 2009
Notes
Page 61
UNICUS III
Figure 3-36
1
2
3
1
2
1
# KIT Qty
Part No.
Description
1
2
3
4
79929
60738
N724
N102
N1042

Clamp, Tube
Washer, Flat
Nut, Hex Lock
Page 62
1
6
7
14
7
Notes
MNL-0375
Figure 3-37
Lubricating System Assembly
5
4
2
1
# KIT Qty
Part No.
Description
1
2
3
4
5
6
084381
080345
78421
N123
84382
N20002
N4501
Lubricating System Assembly

Lubricating System
Gasket
Socket Head Screw
Connecting Tube Assembly
Connector
Gasket
1
1
1
4
1
1
1
October 22, 2009
Notes
See next Figure
Page 63
UNICUS III
Figure 3-38
Lubricating System
3
2
4
5
6
7
10
8
18
11
9
14
12
9 13
14 15
17
9
14
16
# KIT Qty
Part No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
080345
N24585
N58
N19506
77885
N4058
N25327
77774
N25326
N1316
81050
N20065
N16309
N1049
N52
N2889
N25328
77878
N3489
Lubricating System
Gear Pump
Washer
Hex Head Screw
Oil Filter Cover
O-ring
O-ring
Rubber Gasket
Filter Element
Gasket
Regulating Valve
Straight Male Connector
Plug
Screw Cap
Plug
Gasket
Socket Head Screw
Oil Pump Case
O-ring
a..
Page 64
1
1
2
2
1
1
1
1
1
4
1
1
1
1
3
2
2
1
2
Notes
MNL-0375
3.2
Automatic Condensate Drain System
3.2.1 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
8
1
4
5
7
1.
2.
3.
4.
5.
Final Separator Condensate Drain Valve

1st Stage Separator Drain Valves
Electrical Solenoid Valve
Condensate Drain Manifold
Blank Off Plate
October 22, 2009
6.
7.
8.
9.
Manual Condensate Drain Valves

Separator Condensate Connections
Control Pressure Connection
DIN Electrical Connector
Page 65
UNICUS III
Figure 3-40
ACD Operation
Condensate Draining
Normal Operation
Control
Pressure
from
Compressor
Inlet
Control
Pressure
from
Compressor
Inlet
3
2
Control Pressure
1. Electrical Solenoid Valve

2. Condensate Drain Valves
Condensate Drain
3. Intermediate Separators
4. Final Separator
3.2.1.1 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).
3.2.1.2 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).
3.2.1.3 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.
3.2.1.4 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).
3.2.1.5 Condensate Drain Piping
The outlet of the Condensate Drain Manifold is directed into a Condensate Collector.
Page 66
MNL-0375
3.2.1.6 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.
3.2.2 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
UNICUS III
3.2.3
Figure 3-41
ACD System
1
2
3
Item Qty
1
2
3
4
5
6
7
Page 68
1
1
4
1
1
2
3
1
Part No.
Description
Notes
DGM-2348
MFD-0036
N04333
N4182
062523
061010
011430
PLT-0311
Automatic Condensate Drain Sub Assembly

Manifold
O-ring
Electrical Solenoid
Condensate Drain Valve
See Figure 3-42
See Figure 3-43
Manual Condensate Drain Valve
See Figure 3-44
Blank Off Plate
MNL-0375
Figure 3-42
Final Separator Condensate Drain Valve
3
4
5
6
7
8
9
10
13
14
11
12
Item Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
1
4
1
1
1
1
1
1
1
1
4
2
2
Part No.
Description
062523
058053
N210
N2720
N4177
57629
N3489
N2507
56691
N4178
60416
N1511
N102
N781

Solenoid Valve
Allen Screw
O-ring
Grooved Ring
Valve Piston
O-ring
Valve Body
O-ring
Valve Seat
O-ring
Valve End
Allen Screw
Washer
Allen Screw
October 22, 2009
Notes
M6 x 20
M6 x 60
M6 x 35
Page 69
UNICUS III
Figure 3-43
1st Stage Separators Condensate Drain Valves

1
2
3
4
5
6
7
8
9
10
11
17
12
13
16
14
15
Item Qty
1
2
3
4
5
6
7
Page 70
1
4
1
1
1
1
1
1
Part No.
Description
061010
N796
N3764
61007
57353
N7091
N2720
N04177
Condensate Drain Valve Assembly

Hex Nut
Top Flange
Adjusting Screw
O-ring
O-ring
Sealing Ring
Notes
MNL-0375
Figure 3-43 (cont.)
Item Qty
8
9
10
11
12
13
14
15
16
17
1
1
1
1
1
1
4
2
2
31st Stage Separators Condensate Drain Valves
Part No.
Description
057629
N03489
N02507
056691
N04178
060416
N1511
N781
N102
Valve Piston
O-ring
Valve Body, ACD
O-ring
Valve Seat
O-ring
Base Flange
Allen Screw
Allen Screw
Washer
October 22, 2009
Notes
Page 71
UNICUS III
Figure 3-44
Manual Condensate Drain Valve

2
3
Item Qty
1
2
3
Page 72
1
1
1
1
Part No.
Description
011430
068410
13283
055888
Condensate Drain Tap

Drain Valve Body
Seal
Handle
Notes
MNL-0375
3.2.4
Condensate Collector Replacement Parts List
Figure 3-45
Condensate Collector
1
2
3
5
10
6
Item Qty
1
2
3
4
5
6
7
8
9
10
1
1
2
2
1
1
1
1
1
1
Part No.
Description
CAP-0056
GKT-0050
ELM-0160
ELM-0161
HUS-0050
SWT-0265
TNK-0092
VAL-0386
PLU-0011
MFD-0036
Condensate Collector Cover

Gasket
Fine Filter Element
Coarse Filter Element
Condensate Collector
Float Switch
Condensate Collection Tank
Manual Drain Valve
Plug
ACD Manifold
October 22, 2009
Notes
Page 73
UNICUS III
3.2.5
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
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.
^ WARNING
Industrial Air Purification System cartridges do not remove Carbon Monoxide and must not be used in
breathing air applications.
4.1.1
General Purification System Procedures
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.
4.1.2 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
UNICUS III
Figure 4-1
Cartridge Safety Venting
Safety
Vent
Safety
Vent
Cartridge Installed
No Cartridge Installed
4.1.3 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.
4.1.4
Model, Serial Number and Part Number Identification
4.1.4.1 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 Dataplates (typical)
Purification System
Cartridge Installation
PURIFICATION
SYSTEM
CARTRIDGE TO BE
INSTALLED
MODEL NO.
MAX. PRESSURE
psig
CARTRIDGE FOR
AIR PROCESSED
cu. ft.
CARTRIDGE NO.
O-RING
1328 Azalea Garden Road - Norfolk Virginia 23502-1944

Phone: (757) 855-6006 Fax: (757) 855-8224
BACK-UP RING
LBL-
Page 76
LBL-
MNL-0375
4.1.4.2 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.
4.1.4.3 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).
4.1.5
Breathing Air Purification System Configurations

Purification System
Number and Type of Cartridges

Dryer
Purification
Securus
Combined
P0
Processing Capacity
cubic ft (ft)3
3,200
P1
15,000
P2
40,000
P2 with Securus
67,000
P4
60,000
P5
90,000
P5 with Securus
150,000
P10
P10 with Securus
P12a
420,000
P14 a
650,000
140,000
1
Combined
P31
230,000
11,760
P41
P41 with Securus
47,000
P42
64,000
P42 with Securus
107,000
P43
100,000
P43 with Securus
164,000
a.
28,700
P12 and P14 have the Securus Electronic Moisture Monitor System as standard equipment.
October 22, 2009
Page 77
UNICUS III
4.1.6
Industrial Purification System Configurations

Purification System
Number and Type of Cartridges

Dryer
Purification
Securus
Combined
P0
Processing Capacity
cubic ft (ft)3
3,200
P1
15,000
P2
40,000
IP2 with Securus
67,000
P4
60,000
P5
90,000
IP5 with Securus
150,000
P10
IP10 with Securus
140,000
1
Combined
P31
230,000
11,760
IP41 with Securus
47,000
IP42 with Securus
107,000
IP43 with Securus
164,000
4.1.7 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 4.1.7.1 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 4.1.7.2 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
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 4.1.7.3 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 1-5.
4.1.7.1
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.
4.1.7.2
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
UNICUS III
Figure 4-3
Correction Factor for Cartridge Operating Hours

3.5
3.0
Cartridge Op. Hrs.

Conversion Factor
2.5
2.0
1.5
1.0
0.5
0.0
0
10
20
30
Ambient Temperature in C
C
[(F - 32) x 5/9]
Figure 4-4
Date
Page 80
40
50
Cartridge Op. Hrs.

Correction factor
F
[C x 9/5 +32]
50
122
0.21
40
104
0.34
30
86
0.58
20
68
1.00
10
50
1.81
32
3.44
Example Record of Adjusted Operating Hours

Operating
Hours
Ambient Temp.
during Compression
Correction
Factor
Adjusted Cartridge Hours

Today
Total
10/19/04
92F (33 C)
0.48
16.66
16.66
11/01/04
45F (7.2 C)
2.25
1.78
18.44
MNL-0375
4.1.7.3
Air Purification Cartridge Operating Hours Form
Date
Operating
hours
Ambient temp.
during compression
Correction
factor
Adjusted cartridge hours

Today
October 22, 2009
Total
Page 81
UNICUS III
4.2
P5S 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. Figure 4-5 shows the functional interconnection of all
the components.
Figure 4-5
P5S Securus II Purification System
8
IN
OUT
5
7
3
1. Oil and Water Separator

2. Condensate Drain Valve
3. Check Valves
Page 82
4. Dryer Chamber
5. Securus Chamber
6. Bleed Valve
7. Pressure Maintaining Valve

8. Safety Valve
9. Securus Transmitter
MNL-0375
4.3
Component Description
4.3.1
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 079416) 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 18 - 27 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
4.3.2 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.
4.3.3
Cartridge
4.3.3.1 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
UNICUS III
Figure 4-7
Cartridge
Protective Cap
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.
2. Used cartridges must be disposed of in accordance with local regulations.
4.3.4 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.
4.3.5 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.
4.3.6 Bleed Valve
A manually operated valve used to release the pressure in the chamber before maintenance.
4.3.7 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.
4.3.8 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.
4.3.9 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.
4.3.9.1 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
MNL-0375
4.3.9.2 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
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. 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
UNICUS III
Figure 4-8
Figure 4-9
Sintered Metal Filter Assembly
4
2
3
1. Filter Head
3. Center Screw
2. Sintered Metal Filter 4. O -rings
Page 86
1. Threaded Insert
2. Filter Bottom
3. Inner Filter
4. Outer Filter
5. Filter Head
MNL-0375
4.4.1.1
Removal of the Securus II Transmitter.

Figure 4-10
Removal of the Securus II Transmitter
2
1
1. Securus II Transmitter
2. DIN Connector
The Securus II Transmitter is removed and replaced by rotating the blue plastic Securus II Transmitter
approximately 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
UNICUS III
4.4.2 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 4.4.1.1.
4. 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.
4.4.2.1
Leaking at the Safety Bore
1. Remove the cartridge following the steps in Paragraph 4.4.2.
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 4.4.2.1
2. Install cartridge if missing.
Page 88
MNL-0375
3. 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 4.4.2
October 22, 2009
Page 89
UNICUS III
4.5
Figure 4-12
P5 Purification System Parts List
8
IN
OUT
5
7
3
Item Qty
1
2
3
4
5
6
7
8
9
Page 90
1
1
2
1
1
1
1
1
1
Part No.
Description
Notes
079416
011430
VAL-0007
080144
080145
VAL-0377
VAL-0053
VAL-0169
MNR-0042

Check Valves
27 Dryer Chamber
Securus Chamber
Bleed Valve
Pressure Maintaining Valve
Safety Valve
Securus II Transmitter
See Figure 4-13
See Figure 4-14

See Figure 4-15
24 VDC
MNL-0375
Figure 4-13
Oil and Water Separator Parts List
a
b
c
d
e
c
4
2
5
Item Qty
1
2
3
3a
3b
3c
3d
3e
3f
3g
4
5
2
1
1
2
2
1
1
1
1
Part No.
079416
N04586
061860
N15133
N04496
N04385
061858
061859
N07091
061857
October 22, 2009
Description
Notes
Oil and Water Separator Assembly

Separator Head
O-Ring
Sintered Metal Filter
O-Ring
O-Ring, small
O-Ring, large
Sleeve Element, large
Sleeve Element, small
O-Ring
Screw
Separator Housing
Bottom Plug
Page 91
UNICUS III
Figure 4-14
27 Chamber Assembly Parts List
1
2
3
4
5
8
5
4
Item Qty
1
2
3
4
5
6
7
8
Page 92
2
2
1
2
2
Part No.
Description
Notes
80144
012293
061237
N04736
N04735
058825A
Chamber Assembly
Tool Post Screw
Cover Plate
Filter Head
Back-up Ring
O-ring
Filter Housing
Filter Bottom
Dryer Cartridge
27

MS
10
4
UNICUS III
Figure 4-15
Securus Electronic Moisture Monitor System Parts List

18
17
2
3
16
15
14
13
12
4
11
10
9
3
7
6
Item Qty
1
2
3
4
5
6
7
8
9
10
Page 94
2
2
1
1
1
1
1
1
Part No.
Description
Notes
80145
N04736
N04735
060037A
059855
059852
059854
060062
059853
Securus Chamber Assembly

Bottom Plug
Backup Ring
O-ring
Securus Cartridge
Filter Body
Nut
Drawback Screw
Loose Pin
Compression Spring
Fixed Pin
Replaces 1 P/N 80144 in P5S

MNL-0375
Figure 4-15 (cont.)
Securus Electronic Moisture Monitor System Parts List
Item Qty
Part No.
Description
11
12
13
14
15
16
17
18
059851
002181
06135
012293
059850
MNR-0042
CON-0319
Bolt
Compression Spring
Filter Head
Cover Plate
Tool Post Screw
Socket, RF type
Securus II Connector
1
1
1
2
1
1
1
October 22, 2009
Notes
24 VDC
Page 95
UNICUS III
CHAPTER 5:
5.1
COMPRESSOR DRIVE; UNICUS III
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 5.2.2. Replace if necessary.
Figure 5-1
Vertical Drive with Idler (typical)
ROT
A
ON
TI
4
5
6
7
1.
2.
3.
4.
5.2
Compressor Flywheel
V-belt
Idler Sheave (pulley)
Spring Tension Idler
5. Electric Motor
6. V-belt Sheave
7. Sheave Bushing
Maintenance of the V-belt and Sheaves
5.2.1 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 drives 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
MNL-0375
5.2.2 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.
5.2.3 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 motors 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.
5.2.4 Replacing the Sheave
A gear puller can be used to remove the sheave and sheave bushing from the motors 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
UNICUS III
5.3
Replacement Part List
Figure 5-2
UNICUS III, Vertical Drive with Idler
ROT
A
ON
TI
4
5
6
7
Item Qty
1
2
3
4
5
6
7
Page 98
1
2
1
1
1
1
1
1
Part No.
Description
IK 150 II
BET-0049
SHE-0266
IDL-0009
BRK-0512
MTR-0024
SHE-0030
BUS-0001
UNICUS III 20
Compressor Block
V-belt
Idler Sheave
Idler
Idler Bracket
Electric Motor
V-belt Sheave
Sheave Bushing
Notes
15 Hp, 3 Phase
MNL-0375
Figure 5-2 (cont.)
Item Qty
1
2
3
4
5
6
7
1
2
1
1
1
1
1
1
UNICUS III, Vertical Drive with Idler
Part No.
Description
IK 150 II
BET-0102
SHE0266
IDL-0009
BRK-0512
MTR-0065
SHE-0241
BUS-0020
UNICUS III 26
Compressor Block
V-belt
Idler Sheave
Idler
Idler Bracket
Electric Motor
Sheave
Sheave Bushing
October 22, 2009
Notes
20 Hp, 3 Phase
Page 99
UNICUS III
CHAPTER 6: ELECTRICAL PANEL, ASY-1058
6.1
Overview
The following instructions apply to units that use Electrical Panel, ASY-1058 and Operator Interface,
MNR-0049.
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-0049. 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, 7, 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
MNL-0375
wiring and connectors for attachment to wire harnesses. The panel is built to match the horsepower,
voltage, phase and frequency of the customers requirements.
6.2.1 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.
6.2.2 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.
6.2.3 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 43857.
Figure 6-2
Electrical Panel Label
Norfolk, VA 23502 USA

757-855-6006 www.bauercomp.com
UL File No. E141433
PANEL:
MODEL:
SERIAL:
BLOCK:
MFG DATE:
ASY-1058
xx,xxx
Short Circuit Current:
MAXIMUM RATING (AC3)
1 Ph 60 Hz
230V
10 HP
46 FLA
October 22, 2009
VE-13-E1/230V
100210
P0808762/06
2/2009
Use 600 VAC and 60 Degree Celsius

Copper Wire Only
KA Terminal
Wire Range
Torque
Line
awg 10-3
45 in-lb
awg 14-2
35 in-lb
Ground
CONTROL FUSE LEGEND
1FU
2FU
3FU
ATQR - 3A
ATQR - 3A
TRM - 2A
Page 101
UNICUS III
6.4
Electrical Panel Components
6.4.1 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-0078
2
3
8
7
1.
2.
3.
4.
5.
Figure 6-4
Status LEDs
Output LEDs
Output Connections Cover
Expansion Access Door
Input Connections Cover
6.
7.
8.
9.
Input LEDs
DIN Rail Clip
Communications Ports
Optional EEPROM
Connector Block Removal
1. Notch in the Terminal Block

Page 102
MNL-0375
6.4.2 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 5.
3. 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 6-4.
4. 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.
6.4.3 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.
6.4.4 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 9.
3. 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
UNICUS III
6.4.5 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
6.4.6 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
1. Transformer
2. Secondary Fuse
3. Primary Fuses
6.4.7 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
MNL-0375
6.4.8 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)
SRT-0233 shown
Figure 6-8
Overload Relay (typical)
RLY-0186 shown
6.4.9 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.
6.4.10 Optional Communication Modules
ASI Bus Module
Profi Bus Module
Analog Phone Module
Ethernet Module
IT- Ethernet Module
October 22, 2009
CNT-0072
CNT-0073
CNT-0074
CNT-0075
CNT-0076
Page 105
UNICUS III
Figure 6-9
Optional Communications Modules
CNT-0072
CNT-0073
CNT-0075
Page 106
CNT-0074
CNT-0076
MNL-0375
6.4.11 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-0049. It is not standard in all models.
Figure 6-10
6.5
Power Supply
Alarms
The following paragraphs describe the warning and alarm conditions that are monitored and controlled
by the Electrical Panel.
6.5.1 Final Separator Warning

The high pressure-breathing compressor is equipped with a final separator. This is a stainless steel vessel, approximately 3 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
UNICUS III
^ WARNING
Do not attempt to override this Separator Shutdown. This feature is provided to protect
operating personnel from injury or death.
6.5.2 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.
6.5.2.1 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.
6.5.2.2 Securus II Transmitter
See Figure 6-11. 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 turn. It is
not necessary to disconnect or remove the DIN Connector.
Figure 6-11
MNR-0042 Shown
Page 108
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.
6.5.3 Compressor High Temperature
See Figure 6-12. 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)
6.5.4 Compressor Low Oil Pressure

See Figure 6-13. 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.
6.5.5 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.
6.5.6 Carbon Monoxide Monitor Alarm
See Figure 6-14. 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
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
6.5.7 Condensate Fault

See Figure 6-15. 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
MNL-0375
6.5.8 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 Switcha
Q1.0
Unloader Solenoid Valve
I1.1
Low Inlet Pressure Switcha
Q1.1
Panel Light
I1.2
I1.3
I1.4
I1.5
a.
Applies only to compressors for mediums other than air
6.6.1 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
UNICUS III
6.7
Wiring Harness Layout

Table 6-4: Wiring Harness, HNS-0116
Description
CO Monitor (Optional)
E-Stop Pushbutton
Legend
Wire Colors
Pin
CO
Brown/White
CO SV
Black/Yellow
CO Common
Gray/White
22
1PB
Black
White/Red
PLC IN
PLC Out
ACD 1
ACD1
Blue/White
Q0.1
ACD Final
ACDF
Yellow/Black
Q0.2
ACD Common
ACD Common
Orange/White
21
Violet/White
Pink/White
White/Yellow
12
White/Brown
Red/Orange
11
White/Violet
10
Inlet Solenoid Valve or ACD

3
Panel Light
1SV
Q0.5
1LT
Q1.1
Unloader Solenoid Valve
3SV
Q1.0
Audible Alarm
1AA
Red/Blue
14
Blue/Yellow
13
White
15
Brown/Yellow
16
Black/Brown
17
Violet/Black
18
White/Blue
19
Blue/Orange
20
Q0.3
Seccant Monitor Alarm
Low Inlet Pressure Switcha
Spare
Page 112
SA
5PS
I0.7
I1.1
MNL-0375
Table 6-4: Wiring Harness, HNS-0116
Description
Temperature Switch
Legend
1TS
Wire Colors
Pin
Yellow
23
Violet
24
Blue
25
Orange
26
White/Orange
27
Red/Yellow
28
Gray
31
Pink
32
White/Black
33
Red/White
34
Black/White
35
Violet/Orange
36
Black/Orange
37
PLC IN
PLC Out
I0.2
Not Assigned
I0.6
High Inlet Pressure Switcha
Condensate Alarm
3PS
I1.0
CA
I0.4
CO Monitor Alarm
COA
I0.3
Securus II
a.
SEC II
I0.0
Applies only to compressors for mediums other than air
October 22, 2009
Page 113
UNICUS III
6.8
Figure 6-16
Control Pane
Item Qty
1
2
1
1
Page 114
Part No.
Description
MNR-0049
SWT-0308
Maple System, Touch Panel

Emergency Stop Switch
Notes
MNL-0375
Figure 6-17
Electrical Panel, Front View
4
5
Item Qty
1
2
3
4
5
1
1
1
1
1
1
1
Part No.
Description
ASY-1058
LBL-0167
HMR-0036
GKT-0069
OPR-0020
IND-0005
Electrical Panel
Front View
Warning Label, Disconnect Power
Voltage Label
Hourmeter
Gasket, Hourmeter
Overload Reset Button
Audible Alarm
optional
October 22, 2009
Notes
Page 115
UNICUS III
Figure 6-18
Electrical Panel, Bottom View
1
2
3
Item Qty
1
2
3
4
1
1
2
2
3
Page 116
Part No.
Description
Notes
ASY-1058
CAB-0081
CAB-0075
CAB-0075
HNS-0116
Electrical Panel
Cable, PLC to ENC
Cable, 4 Receptacle Connector
Cable, 4 Receptacle Connector
Wiring Harness, 37 Receptacle
Bottom View
MNR-0050
Connects to Air Pressure Sensor
Connects to Oil Pressure Sensor
10
4
UNICUS III
Figure 6-19
Electrical Panel, Interior
1
2
4
7
8
9
Item Qty
1
2
3
4
5
6
1
1
1
1
1
1
1
Page 118
Part No.
Description
Notes
ASY-1058
CNT-0078
SPL-0077
SUR-0005
Electrical Panel
PLC Controller
Power Supply, 24 VDC, 1.3 A
Terminal
Motor Starter
Overload Relay
Suppressor
Interior View
See Figure 6-19.a to Figure 6-19.j

(installed when required)
MNL-0375
Figure 6-19 (cont.)
Item Qty
7
8
9
N.S.
1
2
1
1
1
1
1
1
Electrical Panel, Interior
Part No.
Description
Notes
CNT-0072
CNT-0073
CNT-0074
CNT-0075
CNT-0076
Transformer
Fuse, Primary
Fuse, Secondary
ASI-Bus Comm Module
PROFI-Bus Comm Module
Analog Phone Comm Module
Ethernet Comm Module
IT-Ethernet Comm Module

Optional, Not Shown
Optional, Not Shown
Optional, Not Shown
Optional, Not Shown
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
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-0175
208/3
TRR-0089
FUS-0092
FUS-0018
SRT-0233
RLY-0174
TER-0175
230/1
TRR-0089
FUS-0090
FUS-0018
SRT-0233
RLY-0177
TER-0175
230/3
TRR-0089
FUS-0090
FUS-0018
SRT-0233
RLY-0174
TER-0175
460/3
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-0175
380/3
TRR-0095
FUS-0077
FUS-0018
SRT-0233
RLY-0171
TER-0175
400/3
TRR-0095
FUS-0077
FUS-0018
SRT-0233
RLY-0171
TER-0175
415/3
TRR-0095
FUS-0077
FUS-0018
SRT-0233
RLY-0171
TER-0175
Page 120
MNL-0375
6.10 Parts List for Models with a 7 Horsepower Motor
Figure 6-19.c 7 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-0175
208/3
TRR-0089
FUS-0092
FUS-0018
SRT-0233
RLY-0176
TER-0175
230/1
TRR-0089
FUS-0090
FUS-0018
SRT-0241
RLY-0183
TER-0175
230/3
TRR-0089
FUS-0090
FUS-00118
SRT-0233
RLY-0175
TER-0175
460/3
TRR-0089
FUS-0075
FUS-0018
SRT-0233
RLY-0172
TER-0175
Figure 6-19.d 7 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-0175
380/3
TRR-0095
FUS-0077
FUS-0018
SRT-0233
RLY-0173
TER-0175
400/3
TRR-0095
FUS-0077
FUS-0018
SRT-0233
RLY-0173
TER-0175
415/3
TRR-0095
FUS-0077
FUS-0018
SRT-0233
RLY-0173
TER-0175
October 22, 2009
Page 121
UNICUS III
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-0174
208/3
TRR-0090
FUS-0095
FUS-0019
SRT-0233
RLY-0177
TER-0175
230/1
TRR-0090
FUS-0095
FUS-0019
SRT-0241
RLY-0185
TER-0175
230/3
TRR-0090
FUS-0095
FUS-0019
SRT-0233
RLY-0177
TER-0175
460/3
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-0175
380/3
TRR-0096
FUS-0090
FUS-0018
SRT-0233
RLY-0175
TER-0175
400/3
TRR-0096
FUS-0090
FUS-0019
SRT-0233
RLY-0175
TER-0175
415/3
TRR-0096
FUS-0077
FUS-0019
SRT-0233
RLY-0175
TER-0175
Page 122
MNL-0375
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-0175
230/3
TRR-0090
FUS-0095
FUS-0019
SRT-0241
RLY-0183
TER-0175
460/3
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-0175
380/3
TRR-0096
FUS-0090
FUS-0019
SRT-0233
RLY-0177
TER-0175
400/3
TRR-0096
FUS-0090
FUS-0019
SRT-0233
RLY-0177
TER-0175
415/3
TRR-0096
FUS-0077
FUS-0019
SRT-0233
RLY-0176
TER-0175
October 22, 2009
Page 123
UNICUS III
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-0174
230/3
TRR-0090
FUS-0095
FUS-0019
SRT-0241
RLY-0185
TER-0175
460/3
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-0175
380/3
TRR-0096
FUS-0090
FUS-0019
SRT-0233
RLY-0177
TER-0175
400/3
TRR-0096
FUS-0090
FUS-0019
SRT-0233
RLY-0177
TER-0175
415/3
TRR-0096
FUS-0077
FUS-0019
SRT-0233
RLY-0177
TER-0175
Page 124
MNL-0375
6.14 Typical Wiring Diagram
For Reference Only
October 22, 2009
Page 125
UNICUS III
CHAPTER 7:
7.1
CARBON MONOXIDE MONITOR
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-0033.
Figure 7-1
CO Monitor, MNR-0029
Figure 7-2
Remote Display
3
4
5
6
7
1.
2.
3.
4.
LCD Display
5. Air Inlet Connection
Flow Indicator
6. Zero Cal Set Switch
Electrical Power Connection 7. Calibration Port
Front Cover Screw
1. CO Monitor, MNR-0033
2. 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
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.
7.1.1 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
7.1.1.1 Isolation Valve

Controls the input of air from the compressor to the Carbon Monoxide Monitor.
7.1.1.2 High Pressure to Low Pressure Regulator
Typically set for 50 psi out with 5,000 psi in.
7.1.1.3 Relief Valve
A relief valve which is factory set to 165 psi to prevent over-pressurization of the Carbon Monoxide
Monitor.
7.1.1.4 Solenoid Valve
Allows air to flow to the Carbon Monoxide Monitor when the compressor is running.
7.1.1.5 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.
7.1.1.6 Carbon Monoxide Monitor
The Carbon Monoxide Monitor contains the LCD Display, Flowmeter, Microprocessor, Carbon Monoxide Sensor Cell, Air Inlet Connection and the Calibration Port.
7.1.1.6.1 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.
7.1.1.7 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
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
7.4.1 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
MNL-0375
11. 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 0.5-0.8 SCFH to
restore normal operations.
7.4.2 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 7.4.1 Step 1.
2. Initialize the Carbon Monoxide Monitor following the procedures in Paragraph 7.4.4. 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 7.4.3.
4. If it still doesnt calibrate, contact Bauer Product Support.
Figure 7-4
Basic Calibration Kit
1. 20 ppm Carbon Monoxide Test Gas
2. Zero Test Gas 3. Fixed Flow Regulator
7.4.3 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
UNICUS III
1. Disconnect the power from the unit.
^ CAUTION
Be sure the power is disconnected 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.
^ CAUTION
Be sure the shorting wire is removed from the 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 7.4.4 for Carbon Monoxide Monitor Initialization procedures.
7.4.4 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
MNL-0375
7.4.4.1
Setting the LP Regulator

Figure 7-5
Carbon Monoxide Monitor Initialization
2
3
4 5
See Figure 7-5

1. 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.
7.4.4.2
Initialization Calibration
1. 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
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
9. The Display should read ZERO CAL and will count down from 60 seconds. At the conclusion,
the display prompts, REMOVE ZERO GAS.
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
14. The Display will count down from 60 seconds. At the conclusion, the display will prompt to
REMOVE Carbon Monoxide GAS.
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 0.5-0.8 SCFH to
restore normal operations.
Page 132
MNL-0375
Figure 7-6
Carbon Monoxide Monitor Internal Components
1.
2.
3.
4.
Power Connection
5. Carbon Monoxide Sensor Cell Cover
Gas Inlet
6. Alarm Connections
Audible Alarm (not used)
7. Carbon Monoxide Sensor Cell
Remote Display Connection (only MNR-0033)
October 22, 2009
Page 133
UNICUS III
Figure 7-7
7.4.5
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
MNL-0375
Figure 7-8
Mode Buttons Close-up
1
2
1. Mode Scroll Button
2. Value Change Button
1. 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
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
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
MNL-0375
7.6
Figure 7-10
Carbon Monoxide Monitor Assembly - Standard
Item Qty
1
2
3
4
5
6
N.S.
N.S.
N.S.
1
1
1
1
1
1
1
1
1
1
Part No.
Description
Notes
ASY-0890
MNR-0029
VAL-0076
REG-0043
VAL-0432
VAL-0348
VAL-0349
REG-0060
SEN-0025
CYL-0020
CYL-0016
Carbon Monoxide Monitor Assembly

Carbon Monoxide Monitor
Isolation Valve
High - Low Pressure Regulator
Safety Valve
Solenoid Valve
Solenoid Valve
Inlet Regulator
Carbon Monoxide Sensor Cell
Zero Gas Cylinder
Carbon Monoxide Test Gas Cylinder
145 psi
115 VAC
12 VDC
October 22, 2009
0 ppm
20 ppm
Page 137
UNICUS III
Figure 7-11
Carbon Monoxide Monitor Schematic

CONNECTS TO
COMPRESSOR
CONTROLS
TO
REMOTE
DISPLAY BOARD
WHT/BLK
No Connection.
CO Monitor
RED
RELAY
YELLOW
RELAY
POWER BOARD
MNR-0029/MNR-0033
DP -.
DP +.
Not Used.
Not Used.
Not Used.
NO.
NC.
COM.
NO.
NC.
COM.
CONNECTS TO
COMPRESSOR
CONTROLS
1702-113B
INCOMING
POWER
120 VAC
RED
Jumper
INT. 24V OPER

+24 VDC.
TRANSFORMER
INT PWR.
AC 2.
AC 1.
RED
No Connection.
No Connection
GND.
RECORDER
OUTPUT
A
DP -.
DP +.
No Connection.
EXT. 12V OPER.
MAX 18 AWG WIRE
GND.
12V
REMOVE JUMPER
12V OPERATION
+ + +
PWR
SIG
B/L
Remote Display Board

MNR-0034
Page 138
N/A
N/A
Display Adjustment Pot.
MNL-0375
CHAPTER 8:
8.1
CFS II MAINTENANCE
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.
^ 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.
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
8.3.1 General Maintenance

Develop a regular program of visual inspection, looking for clogged drains and broken or missing parts.
October 22, 2009
Page 139
UNICUS III
8.3.2 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.
8.3.3 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.
8.3.4
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.
8.3.5
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 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
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.
8.3.6 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
5/32
165
8.3.7 Pressure Hoses

The hoses should be inspected periodically for wear and damage. If a hose is worn or damaged, remove
and replace it.
8.3.8 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
UNICUS III
8.4
8.4.1
CFS II Assemblies
Figure 8-3
CFS II Assembly
3
1
Item Qty
1
2
3
4
N.S.
3
1
3
1
1
Page 142
Part No.
Description
Notes
HOL-0076
DOR-0002
HOS-0145
HAN-0057
SPC-0008
Bottle Holder
Door
Fill Whip
Handle
Bottle Riser
1 per Fill Position
MNL-0375
Figure 8-4
CFS II Door Lock Assembly
3
2
4
Item Qty
1
2
3
4
1
3
2
1
1
Part No.
Description
Notes
LCH-0049
BUS-0120
CYL-0059
BRK-0487
BRK-0486
Door Lock
Bushing
Damper
Cylinder Bracket
Cylinder Bracket
3 Fill Positions
October 22, 2009
Right
Left
Page 143
UNICUS III
Figure 8-5
Door Handle, Pivot and Bracket
1
2
3
4
5
7
8
11
Item Qty
1
2
3
4
5
1
1
2
2
2
Page 144
Part No.
Description
MTS-0314
VIB-0035
PIN-0047
BUS-0121
CLR-0001
Mount
Bumper
Pin
Bushing
Collar
10
Notes
MNL-0375
Figure 8-5 (cont.)
Item Qty
6
7
8
9
10
11
2
2
2
2
2
1
1
Door Handle, Pivot and Bracket
Part No.
Description
Notes
BUS-0122
SPG-0054
SPG-0053
Flat Head Socket Cap Screw

Washer, Nylon
Bushing
Spring
Spring
5/16 x 18 x UNC
3/8-16 x 1 UNC
3/8-16 x 2 UNC
5/8
October 22, 2009
Right Side
Left Side
Page 145
UNICUS III
Figure 8-6
CFS II Door Lock Latch

1
3
2
Item Qty
1
2
3
4
2
2
2
6
Page 146
Part No.
Description
Notes
LCH-0048
SPG-0052
Latch
Torsion Spring
Socket Head Shoulder Screw
Nylon Flat Washer
3/8 x 7/8
3/8
MNL-0375
Figure 8-7
Item Qty
1
2
3
4
5
6
7
8
9
10
11
2
1
2
1
2
1
1
2
1
2
1
CFS II Door Interlock
Part No.
Description
VAL-0130
BRK-0488
LEV-0018
HOS-0147
HOS-0146
SCR-0078
SPG-0056
LCH-0048
LCH-0049
CYL-0059
Interlock Valve
Bracket
Lever
Hose
Hose
Hex Head Cap Screw
Gas Spring
Latch
Latch
Damper
Hex Head Cap Screw
October 22, 2009
Notes
1st Fill Position

2nd and 3rd Fill Positions
-20 x 4 UNC
See Figure 8-6
See Figure 8-4
See Figure 8-4
-20 x 4 UNC
Page 147
UNICUS III
8.4.2
Fill Hose Assemblies
Figure 8-8
Standard Fill Hose Assembly

2
3
4
8
Relief Option
6
7
Item Qty
1
2
3
4
5
6
7
8
1
1
2
1
1
1
1
1
1
Page 148
Part No.
Description
HOS-0145
065126
ELL-0018
ADP-0112
ADP-0113
YOK-0001
TEE-0012
VAL-0169
N04483
Fill Hose
Bleed Valve
Elbow
Adapter
Adapter
Fill Yoke
Tee
Safety Valve
O-ring
Notes
4,500 / 2,216 psi Cylinder

4,500 psi Cylinder
MNL-0375
Figure 8-9
Multi Fill Hose Assembly

4
2
2
3
6
6
Relief Option
Item Qty
1
2
3
4
5
6
7
8
9
1
3
1
1
1
1
2
1
1
1
Part No.
Description
YOK-0001
ELL-0018
ADP-0112
ADP-0113
065126
HOS-0145
CON-0223
TEE-0014
VAL-0169
N04483
Fill Yoke
Elbow
Adapter
Adapter
Bleed Valve
Fill Hose
Quick Disconnect Plug
Tee
Safety Valve
O-ring
October 22, 2009
Notes
4,500 / 2,216 psi Cylinder

4,500 psi Cylinder
Page 149
UNICUS III
CHAPTER 9:
9.1
UNICUS III HP AIR STORAGE
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.
9.1.1 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. 5000 and 6000 psig
cylinders is mandatory every five (5) years in accordance with 49/CFR173.34.
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.
9.1.2 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.
D.O.T
AMSE
Vessel
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
471 cf @ 5000 psig
509 cf @ 6000 psig
424 cf @ 5,000 psig
481 cf @ 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
Weight
158 lbs
188 lbs
400 lbs
Cylinder
CGA 347
CGA 702
Standard Valve Supplied
Finish
Primer and Topcoat
Page 150
55 without Valve
Primer and Topcoat
MNL-0375
9.2 Description and Maintenance
9.2.1 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
October 22, 2009
UNICUS III Storage System
Page 151
UNICUS III
9.2.2
Maintenance
9.2.2.1 Storage Bottles

All storage bottles should be visually inspected internally every year. Every five (5) years, D.O.T. bottles
must be 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.
9.2.2.2
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.
9.2.2.3 Tube Connections
Pipe connections (swivel nuts): Tighten just firmly enough so that leakage is stopped (finger tight plus up
to an additional 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 NeverSeez NSWT or a similar PFTE base lubricant to the ferrule and the threads of the connector to facilitate
future disassembly.
Page 152
MNL-0375
9.2.2.4
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.
9.2.2.5 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
UNICUS III
CHAPTER 10: CONTROLS AND INDICATORS
10.1 Component Locations
Figure 10-1
Front Panel
1
7
8
2
3
9
10
4
1.
2.
3.
4.
5.
Page 154
Cascade Panel Pressure Gauges

Cascade Panel Valves
Fill Selector Valve
Fill Pressure Gauge
Regulator Valve
6. Compressor Final Pressure Gauge

7. Compressor Control Panel
8. Emergency Stop Switch
9. Bottle Fill Valves
10. Bottle Fill Pressure Gauges
MNL-0375
Figure 10-2
Gauge Panel
1. Compressor Oil Pressure Gauge

2. 1st Stage Pressure
October 22, 2009
3. 2nd Stage Pressure

4. 3rd Stage Pressure
Page 155
UNICUS III
Figure 10-3
Components for Remote Fill Option
2
5
6
7
3
8
1. Remote Fill Regulator

2. Remote Fill Pressure Gauge
3. Remote Fill Valve
Page 156
4. Storage Drain Valves

5. Hose Guide
6. Hose Stop
7. Hose
8. Bleed Valve
9. Hose Reel
MNL-0375
10. Replacement Parts List
Figure 10-4
Front Panel Parts

1
Item Qty
1
2
3
4
5
6
6
9
1
1
1
1
Part No.
Description
VAL-0076
GAG-0009W
VAL-0067
REG-0039
MNR-0049
SWT-0244
Needle Valve
Pressure Gauge
3-way Ball Valve
Air Pressure Regulator
Compressor Control Panel
E-stop Switch
October 22, 2009
Notes
7,500 psi
6,000 psi
Maple System, Touch Screen
Page 157
UNICUS III
Figure 10-5
Gauge Panel Parts
Item Qty
1
2
3
4
1
1
1
2
Page 158
Part No.
Description
Notes
GAG-0042W
GAG-0006W
GAG-0007W
GAG-0008W
2.5 Indicator
2.5 Indicator
2.5 Indicator
2.5 Indicator
0 - 100 psi
0 - 200 psi
0 - 600 psi
0 - 1500 psi
MNL-0375
Figure 10-6
Remote Fill Option Parts
Item Qty
1
2
3
4
5
6
7
8
1
1
5
1
1
1
1
1
Part No.
Description
Notes
REG-0039
GAG-0009W
VAL-0076
GDE-0003
STP-0008
HOS-0164
VAL -0140
REL-0009
Air Pressure Regulator

Pressure Gauge
Needle Valve
Hose Guide
Hose Stop
Air Hose
Bleed Valve
Hose Reel
6,000 psi
7,500 psi
October 22, 2009
75 feet
75 feet maximum
Page 159
UNICUS III
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.
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
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
UNICUS III
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
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
MNL-0375
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 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 11-1.
Figure 11-1
Lifting Devices
Chain Hoist
Fork Lift
1. Forklift
Hand Truck
2. Chain Hoist
3. Hand Truck
^ WARNING
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 manufacturers warranty for the compressor
unit will be voided. The braces are all tagged and labeled.
October 22, 2009
Page 163
UNICUS III
11.2.2 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.
^ 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
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.
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.
Observe and maintain an ambient temperature range of 43 to 113 F.
The area in which the compressor unit is installed should be well lit and easily accessible to facilitate servicing and routine maintenance.
Page 164
MNL-0375
11.2.2.1 Securing and Leveling the UNICUS III
Figure 11-2
Securing and Leveling the UNICUS III
1
2
1. Adjusting Bolt
2. Locking Nut
3. Leveling Foot
4. Anchoring Foot
Secure the UNICUS III to the floor using 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.
11.2.2.2 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.
11.2.2.2.1Outdoor 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.
11.2.2.2.2Indoor 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
UNICUS III
11.2.2.2.3Natural Ventilation
Natural ventilation should only be used up to a maximum drive power of 20 hp. To determine the size of
the required intake and exhaust openings, refer to the following table: .
Intake and Exhaust Openings Dependent on Room Volume (V) and Height (h)
V = 1750 ft h = 6.5 ft
V = 3500 ft h = 10 ft
V = 7000 ft h = 13 ft
Drive
Hp
Intake (ft)
Exhaust (ft)
Intake (ft)
Exhaust (ft)
Intake (ft)
Exhaust (ft)
1.3
1.1
---
---
---
---
3.2
2.7
1.3
1.1
---
---
7.5
4.5
3.8
2.6
2.2
1.3
1.1
10
9.7
8.1
6.5
5.4
2.6
2.2
15
14.5
12.4
9.7
8.1
5.8
4.8
20
20.6
17.2
15.6
12.9
9.7
8.1
11.2.2.2.4Forced Ventilation
To determine the required intake opening and exhaust flow refer to the following table:
Dependence on Room Size (V) and Height of Exhaust Opening (h)a
V = 1750 ft h = 8 ft
V = 3500 ft h = 10 ft
V = 7000 ft h = 13 ft
Intake
(ft)
Exhaust
cfm
Intake
(ft)
Exhaust
cfm
Intake
(ft)
Exhaust
cfm
25
3.3
3300
3.2
3200
3.0
3000
30
4.0
3960
3.8
3840
3.6
3600
40
5.3
5280
5.1
5120
4.8
4800
50
6.6
6600
6.4
6400
6.0
6000
60
7.9
7920
7.7
7680
7.2
7200
75
9.9
9900
9.6
9600
9.0
9000
100
13.2
13200
12.8
12800
12.0
12000
125
16.5
16500
16.0
16000
15.0
15000
150
19.8
19800
19.2
19200
18.0
18000
Drive
Hp
a.
Page 166
The intake sizes given in the above table are for a cooling air velocity of 1000 ft./min. Bauer recommends that the cooling air velocity be in the range of
600 ft./min. to 2000 ft./min.
MNL-0375
11.2.2.3 Electrical Installation
11.2.2.3.1Electric Drive
When making the electrical connections to the system, the following instructions are mandatory:
Comply with all local, state and federal regulations concerning electrical installation.
Arrange for the electrical connections to be made by a certified electrician only.
Ensure that the motor voltage, control unit voltage, and frequency conform with the main voltage and
frequency. Do not connect the compressor unit to a voltage other than the one specified on the nameplate.
Provide all necessary cables and main fuses and a master disconnect switch. The fuse protection for
the compressor must be carried out in compliance with local, state and national electrical regulations.
11.2.2.3.2Electrical Supply
The machine is factory wired according to order. If the voltage is to be changed, consult the factory for
instructions and necessary parts.
For standard models the only customer wiring necessary is from the customer supplied disconnect switch
to the compressor unit electrical enclosures All wiring should be done by a licensed electrician familiar
with national, state and local electrical codes.
The label shown in Figure 11-3 indicates the where the incoming power is connected to the compressor
unit electrical enclosure. This label must be removed before using the equipment.
Figure 11-3
October 22, 2009
Incoming Power Wiring Label
Page 167
UNICUS III
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
Fuse Ampsa
Full Load Amps
Minimum Wire Sizeb
Motor
Hp
120 V
208 V
230 V
120 V
208 V
230 V
120 V
208 V
230 V
24
13.2
12
30
20
17.5
10
---
14
34
18.7
17
50
30
25
10
10
56
30.8
28
80
50
40
7.5
80
44
40
100
70
60
10
---
55
50
---
90
60
---
a.
Dual element time delay fuse Amps.
b.
Normal Copper wire with THW, THWN, or XHHW insulation.
Page 168
MNL-0375
3 PHASE
Motor
Hp
Fuse Ampsa
Full Load Amps

208 V
230 V
460V
460V
208 V
230 V
460V
7.5
6.8
3.4
12
10
5.6
14
14
14
10.6
9.6
4.8
17.5
15
14
14
14
16.7
15.2
7.6
25
25
12
10
12
14
7.5
24.2
22
11
40
30
17.5
10
14
10
30.8
28
14
50
40
20
12
15
46.2
42
21
60
60
30
10
20
59.4
54
27
90
80
40
25
74.8
68
34
100
100
50
30
88
80
40
125
100
60
40
114
104
52
175
150
80
50
143
130
65
200
200
100
3/0
2/0
60
169
154
77
250
200
100
4/0
3/0
75
211.2
192
96
300
300
150
300
250
100
273
248
124
400
350
175
500
350
2/0
125
343.2
312
156
500
400
200
2-4/0
2-3/0
3/0
150
396
360
180
600
500
250
2-300
2-4/0
4/0
a.
Dual element time delay fuse Amps.
b.
Normal Copper wire with THW, THWN or XHHW insulation.
208 V
230 V
Minimum Wire Sizeb
In the above tables, all values are based on 1996 NEC articles 430 and 310 (NFPA 70). These values are
provided as a general guide; however, the information given on the motor nameplate supersedes the
above information.
October 22, 2009
Page 169
UNICUS III
11.3 Long Term Storage
11.3.1 General
If the compressor unit will be out of service for more than six months, it should be preserved in accordance with the following instructions:
1. Make sure that the compressor is kept indoors in a dry, dust-free room.
2. Cover the compressor with plastic sheets only if no condensation will form under the sheet.
3. Remove the sheet from time to time and clean the outside of the unit.
4. If this procedure cannot be followed, or if the compressor will be out of service for more than 24
months, please contact the Bauer Service Department for special instructions.
11.3.2 Preparations
Prior to preserving the compressor unit, it must be run until warm, i.e., up to the specified service pressure. Operate the unit for approximately 10 minutes, then carry out the following checks.
1. Check all pipes, filters and valves (including safety valves) for leakage.
2. Tighten all couplings, as required.
3. After 10 minutes, open the outlet valve and operate the compressor at adjusted minimum pressure
using the pressure maintaining valve for approximately 5 minutes.
4. After the 5 minutes, shut the compressor unit down and completely drain all separators and filters.
Close all valves.
5. Remove filter heads and lubricate the threads with petroleum jelly.
11.3.2.1 Units Equipped with a Filter System
1. Ensure that cartridges remain in the purification system chambers. This will prevent oil from entering the outlet lines as a result of preservation procedures.
2. Remove the intake filter/intake pipe completely.
11.3.3 Preserving the Compressor
1. Operate the compressor again and slowly spray approximately 0.35 oz. (10 cc) of oil into the inlet
port while the compressor is running. Keep the shut-off valve open and the condensate drain valves
closed.
2. After spraying the oil into the inlet port, run the compressor unit for an additional 5 minutes before
shutting the compressor unit down.
3. Close the shut-off valve.
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.
Page 170
MNL-0375
2. Open the outlet valve and allow the system to run approximately 5 minutes until there is outflow
from the valve and oil is visible in the sight glass of the oil regulating valve.
3. Shut down the compressor.
4. Open the condensate drain valves, depressurize the unit, then close the drain valves again.
5. Remove the intake filter and replace the dust cap on the inlet port.
11.3.5 Lubrication Oils for Preservation
1. After prolonged storage periods, the oil will age in the compressor crankcase. The oil must be
drained at least every 24 months and replaced with fresh oil.
2. The stated period can only be attained when the crankcase is sealed during the preservation period
in accordance with the preservation requirements.
3. After changing the oil, the compressor must be operated according to the instructions above.
4. Check the lubrication of the compressor during the every-six-month brief operation.
5. The oil pump is functioning properly when oil can be seen flowing through the sight glass of the oil
pressure regulator or if the oil pressure gauge indicates the prescribed pressure.
11.3.6 Reactivating the Compressor Unit
1. Remove the dust cap from the inlet port and install the intake filter.
2. Check the oil level of the compressor. If necessary, change the oil.
3. The motor must be thoroughly dry before applying power.
4. For units with a purification system, change all cartridges.
5. Run the compressor with open outlet valve for approximately 10 minutes. Check for proper operation of the lubricating system.
6. After 10 minutes, close the shut-off valve and run the system up to final pressure until the final
pressure safety valve vents. On compressor units with a compressor control system, raise the pressure switch setting the switch above normal limits to override the pressure switch. Be sure to reset
the switch after checking.
7. Check the interstage safety valves for leakage.
8. Establish the cause of any faults and remedy.
9. Stop the unit when it is running properly. The compressor is then ready for operation.
October 22, 2009
Page 171
UNICUS III
11.4 Reproducible Forms
11.4.1 Scheduled Maintenance Form
Daily
Page 172
Para.
Date
Signature
MNL-0375
Weekly or as required.
Para.
Date
Signature
500 Operating Hours.
Para.
Date
Signature
1,000 Operating Hours.
Para.
Date
Signature
Para.
Date
Signature
October 22, 2009
Page 173
UNICUS III
Para.
Date
Signature
Annually.
Para.
Date
Signature
Biennially. (Every two years)
Para.
Date
Signature
Page 174
MNL-0375
11.4.2 Record of Operating Hours
Date
Subtotal:
October 22, 2009
Minutes
Total
Date
Minutes
Total
Subtotal:
Page 175
UNICUS III
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. Pipe connections (swivel nuts) should be tightened just enough so that leakage is stopped. Not more
than finger tight plus up to an additional turn.
Table 11-1: Torque Values
Bolt or Screw
Size
Max. Torque
Hex and socket head
(M 6)
7 ft. lbs. (10 Nm)
Hex and socket head
5/16 (M 8)
18 ft. lbs. (25 Nm)
Hex and socket head
3/8 (M 10)
32 ft. lbs. (45 Nm)
Hex and socket head
(M 12)
53 ft. lbs. (75 Nm)
Hex and socket head
9/16 (M 14)
85 ft. lbs. (120 Nm)
Hex and socket head
5/8 (M 16)
141 ft.-lbs (200 Nm)
11.5.2 Torque Sequence Diagrams

Figure 11-4
5
6 Bolt and 4 Bolt Torque Sequence
11.5.3 Conversion Formulas

F = 9/5 C + 32
psi = bar x 14.5
Page 176
C = 5/9 x (F-32)
bar =psi x 0.0689
MNL-0375
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

threads, sealing rings
Parker Super O Lube
Bolts, nuts, studs, valve parts, Copper gaskets and

tube connection parts (threads, cap nut and compression rings)
Never-Seez NSWT, Pipe Dope or teflon tape
Paper gaskets
DOW Corning 732 or equivalent silicone compound applied on both sides before assembly,
High temperature connections
DOW Corning 732 or equivalent temperature resistant compound,
Tube connection ferrules,
Never-Seez NSWT
11.5.5 Glossary of Abbreviations and Acronyms
Available Only as Part of a Complete Assembly

AC
Activated Charcoal, removes odor and taste
ACD
automatic condensate drain
ASME
American Society of Mechanical Engineers
CW
clockwise
CCW
counterclockwise
CGA
Compressed Gas Association
DIN
Deutsches Institut fr Normung
DOT
Department of Transportation
E1
single phase electrical supply
E3
three phase electrical supply
HP
Chemical Catalyst, converts carbon monoxide to carbon dioxide
IAW
In Accordance With
MS
Molecular Sieve, removes moisture
NEC
National Electrical Code
NEMA
National Electrical Manufacturers Association
NFPA
National Fire Protection Association
OSHA
Occupational Safety & Health Administration
ODP
open drip-proof (motor)
OEM
Original Equipment Manufacturer
PLC
Programmable Logic Controller
PMV
pressure maintaining valve
SC
Securus Moisture Sensing Device
October 22, 2009
Page 177
UNICUS III
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 hardcopy 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 178

Stationary Integrated Systems: Instruction Manual and Replacement Parts List

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Instruction Manual and Replacement Parts List

Stationary Integrated Systems

October 22, 2009

1st Edition, Rev. 2 Chg. 2

BAUER Compressors, Inc.

Phone: (757) 855-6006

Nov. 15, 2004

Feb. 22, 2005 Added Idler Wrench and Leveling Feet

Mar. 29, 2007 Change to Separator P/N 079416 Life Span

Oct. 30, 2007 Update ACD Solenoid P/N AC DC

July 18, 2008 Added After Cylinder Failure Warning

Nov. 18, 2008 Changed Drive Chapter and P5 Securus II section

July 29, 2009 Converted to Maple System & Siemens electric

Sept. 28, 2009 Fill Hose P/Ns

Oct. 22, 2009 Corrected Dryer Cartridge P/N

Added Air Filter Indicator & Overrun Time

1st Edition, Rev. 2 Chg. 2

HOW TO USE THE REPLACEMENT PARTS LIST .................................................................................................... 2

HOW TO USE THE APPENDIX....................................................................................................................................... 3

1.5 UNIT SPECIFICATIONS .................................................................................................................................................. 5

COMPONENT LOCATIONS ............................................................................................................................................ 7

CHAPTER 2: - - - -OPERATING INSTRUCTIONS; MAPLE SYSTEM

SCREEN FLOW ................................................................................................................................................................ 17

CHAPTER 3: - - - - - IK150 II AND IK180 II COMPRESSOR BLOCK

October 22, 2009

CHAPTER 4:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

1st Edition, Rev. 2 Chg. 2

REPLACEMENT PARTS LIST ..................................................................................................................................... 90

CHAPTER 5: - - - - - - - - - - - COMPRESSOR DRIVE; UNICUS III

VERTICAL COMPRESSOR DRIVE.............................................................................................................................. 96

5.2 MAINTENANCE OF THE V-BELT AND SHEAVES.................................................................................................. 96

REPLACEMENT PART LIST ........................................................................................................................................ 98

CHAPTER 6: - - - - - - - - - - - - ELECTRICAL PANEL, ASY-1058

6.2 ELECTRICAL PANEL .................................................................................................................................................. 100

AC POWER REQUIREMENTS.................................................................................................................................... 101

6.4 ELECTRICAL PANEL COMPONENTS..................................................................................................................... 102

October 22, 2009

Transformer and Fuses ...................................................................................................................................................104

6.5 ALARMS ..........................................................................................................................................................................107

WIRING HARNESS LAYOUT .....................................................................................................................................112

REPLACEMENT PARTS LIST ....................................................................................................................................114

PARTS LIST FOR MODELS WITH A 5 HORSEPOWER MOTOR.......................................................................120

6.10 PARTS LIST FOR MODELS WITH A 7 HORSEPOWER MOTOR....................................................................121

PARTS LIST FOR MODELS WITH A 10 HORSEPOWER MOTOR.....................................................................122

6.12 PARTS LIST FOR MODELS WITH A 15 HORSEPOWER MOTOR.....................................................................123

CHAPTER 7:- - - - - - - - - - - - CARBON MONOXIDE MONITOR

CARBON MONOXIDE MONITOR SETUP................................................................................................................127

7.4 MAINTENANCE .............................................................................................................................................................128

1st Edition, Rev. 2 Chg. 2

REMOTE DISPLAY SETUP ........................................................................................................................................ 135

REPLACEMENT PARTS LIST .................................................................................................................................... 137

CHAPTER 8: - - - - - - - - - - - - - - - - - -CFS II MAINTENANCE

FILL STATION AIR FLOW.......................................................................................................................................... 139

8.3 MAINTENANCE............................................................................................................................................................. 139

CHAPTER 9: - - - - - - - - - - - - - -UNICUS III HP AIR STORAGE

CHAPTER 10: - - - - - - - - - - - - CONTROLS AND INDICATORS

CHAPTER 11: - - - - - - - - - - - - - - - - - - - - - - - APPENDIX

October 22, 2009

Forced Ventilation ......................................................................................................................................................166

11.3 LONG TERM STORAGE ...............................................................................................................................................170

1st Edition, Rev. 2 Chg. 2

Compressor Identification Plate .............................................................................................................................. 2