MNL-0375

Instruction Manual and Replacement Parts List

BAUER Compressors, Inc. Phone: (757) 855-60061328 Azalea Garden Road Fax: (757) 855-6224Norfolk, Virginia 23502-1944 www.bauercomp.com

October 22, 2009 1st Edition, Rev. 2 Chg. 2 MNL-0375 2004 - 2009 Bauer Compressors, Inc.

Stationary Integrated SystemsHigh Pressure Breathing Air Compressor UnitsUNICUS III 20UNICUS III 26

UNICUS III

Page i 1st Edition, Rev. 2 Chg. 2

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 infor-mation and has no obligation to update these materials. This information is 2004 - 2009 Bauer Com-pressors, 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.

^ WARNINGThis Instruction Manual and Replacement Parts List contains safety information and instructions forthe UNICUS III High Pressure Breathing Air Compressor Units.You must read, understand and follow all safety precautions and instructions.

1st Edition

Rev Chg Date Notes Auth

0 0 Nov. 15, 2004 JD

0 1 Feb. 22, 2005 Added Idler Wrench and Leveling Feet JD

0 2 Mar. 8, 2005 Added Air Filter Indicator & Overrun Time JD

0 3 Sept. 22, 2005 Changed 3rd Stage Intermediate Separator to P/N 081798 JD

0 4 Nov. 3, 2006 Added CFSII Bottle Riser JD

0 5 Nov. 30, 2006 Changed P/N of Oil Pressure Gauge GAG-0006W to GAG-0042W JD

0 6 Mar. 29, 2007 Change to Separator P/N 079416 Life Span JD

0 7 Oct. 30, 2007 Update ACD Solenoid P/N AC DC JD

0 8 July 18, 2008 Added After Cylinder Failure Warning CLA

0 9 Sept. 9, 2008 Converted to Securus II SS

1 0 Nov. 18, 2008 Changed Drive Chapter and P5 Securus II section SS

2 0 July 29, 2009 Converted to Maple System & Siemens electric SS

2 1 Sept. 28, 2009 Fill Hose P/Ns SS

2 2 Oct. 22, 2009 Corrected Dryer Cartridge P/N SS

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October 22, 2009 Page ii

Table of Contents

CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION

1.1 HOW TO USE THIS MANUAL......................................................................................................................................... 11.1.1 Manual Safety Notices ....................................................................................................................................................... 11.2 HOW TO USE THE REPLACEMENT PARTS LIST .................................................................................................... 21.3 HOW TO USE THE APPENDIX....................................................................................................................................... 31.4 UNIT DESCRIPTION......................................................................................................................................................... 41.5 UNIT SPECIFICATIONS .................................................................................................................................................. 51.5.1 UNICUS III 20 ................................................................................................................................................................... 51.5.1.1 Compressor Block, IK 150 II.......................................................................................................................................... 51.5.1.2 Compressor Drive........................................................................................................................................................... 51.5.1.3 Purification System Applicability .................................................................................................................................. 51.5.2 UNICUS III 26 .................................................................................................................................................................. 61.5.2.1 Compressor Block, IK180II............................................................................................................................................ 61.5.2.2 Compressor Drive........................................................................................................................................................... 61.5.2.3 Purification System Applicability .................................................................................................................................. 61.6 COMPONENT LOCATIONS ............................................................................................................................................ 7

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

2.1 DESCRIPTION.................................................................................................................................................................... 92.1.1 Emergency Stop Button ..................................................................................................................................................... 92.1.2 Operator Interface .............................................................................................................................................................. 92.1.2.1 Run Screen.................................................................................................................................................................... 102.1.2.2 Home Screen................................................................................................................................................................. 112.1.2.2.1 Run................................................................................................................................................................................ 112.1.2.2.2 Alarms........................................................................................................................................................................... 112.1.2.2.3 Login............................................................................................................................................................................. 112.1.2.2.4 Language Choice .......................................................................................................................................................... 112.1.2.2.5 Adjust............................................................................................................................................................................ 112.1.2.2.6 Maintenance.................................................................................................................................................................. 122.1.2.2.7 Setup ............................................................................................................................................................................. 122.1.2.2.8 Tools ............................................................................................................................................................................. 122.1.2.2.9 Contact.......................................................................................................................................................................... 132.2 STARTING AND STOPPING UNIT ............................................................................................................................... 132.2.1 Before Starting. ................................................................................................................................................................ 132.2.2 To Start Unit..................................................................................................................................................................... 132.2.3 To Stop Unit. .................................................................................................................................................................... 132.3 SCREEN FLOW ................................................................................................................................................................ 17

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

3.1 MAINTENANCE AND PARTS ....................................................................................................................................... 183.1.1 Description ....................................................................................................................................................................... 183.1.1.1 Air Flow Diagram......................................................................................................................................................... 183.1.1.2 Component Location .................................................................................................................................................... 193.1.2 Lubrication System .......................................................................................................................................................... 213.1.2.1 Description.................................................................................................................................................................... 21

UNICUS III

Page iii 1st Edition, Rev. 2 Chg. 2

3.1.2.2 Oil Level Check ............................................................................................................................................................213.1.2.3 Oil Change Interval.......................................................................................................................................................223.1.2.4 Oil Capacity ..................................................................................................................................................................223.1.2.5 Oil Change ....................................................................................................................................................................223.1.2.6 Venting the Oil Pump ...................................................................................................................................................233.1.3 Intake Filter ......................................................................................................................................................................243.1.3.1 Service Indicator ...........................................................................................................................................................243.1.3.2 Replacing the Filter Element ........................................................................................................................................243.1.4 Intermediate Separators ....................................................................................................................................................263.1.4.1 Description....................................................................................................................................................................263.1.4.2 Maintenance..................................................................................................................................................................263.1.5 Compressor Valves and Valve Heads ..............................................................................................................................263.1.5.1 Functional Description..................................................................................................................................................263.1.5.2 Initial Operational Check of the Valves .......................................................................................................................263.1.5.3 General Instructions for Changing the Valves..............................................................................................................273.1.5.4 Changing the 1st Stage Valves. ...................................................................................................................................273.1.5.4.1 Removal Procedure.......................................................................................................................................................283.1.5.4.2 Installation Procedure ...................................................................................................................................................283.1.5.5 Changing the 2nd and 3rd Stage Valves .......................................................................................................................283.1.5.5.1 Removal Procedure.......................................................................................................................................................283.1.5.5.2 Installation Procedure ...................................................................................................................................................283.1.5.6 Changing the 4th Stage Valves .....................................................................................................................................293.1.5.6.1 Discharge Valve Removal Procedure ..........................................................................................................................303.1.5.6.2 Discharge Valve Installation Procedure ......................................................................................................................303.1.5.6.3 Inlet Valve Removal and Installation ..........................................................................................................................313.1.6 Repair and Troubleshooting .............................................................................................................................................313.1.6.1 Repair............................................................................................................................................................................313.1.6.2 Troubleshooting ............................................................................................................................................................323.1.7 Replacement Parts List ....................................................................................................................................................343.2 AUTOMATIC CONDENSATE DRAIN SYSTEM ........................................................................................................653.2.1 Description .......................................................................................................................................................................653.2.1.1 Compressor Operating ..................................................................................................................................................663.2.1.2 Condensate Draining.....................................................................................................................................................663.2.1.3 Start Unloading .............................................................................................................................................................663.2.1.4 Standstill Drainage........................................................................................................................................................663.2.1.5 Condensate Drain Piping ..............................................................................................................................................663.2.1.6 Condensate Collection ..................................................................................................................................................673.2.2 ACD Maintenance ............................................................................................................................................................673.2.3 Replacement Parts List .....................................................................................................................................................683.2.4 Condensate Collector Replacement Parts List .................................................................................................................733.2.5 Trouble shooting...............................................................................................................................................................74

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

4.1 INTRODUCTION..............................................................................................................................................................754.1.1 General Purification System Procedures ..........................................................................................................................754.1.2 Chamber Safety Bore .......................................................................................................................................................754.1.3 Manual Condensate Drainage...........................................................................................................................................764.1.4 Model, Serial Number and Part Number Identification ...................................................................................................764.1.4.1 Compressor Dataplate...................................................................................................................................................764.1.4.2 Purification System Dataplate ......................................................................................................................................774.1.4.3 Cartridge Installation Dataplate ....................................................................................................................................774.1.5 Breathing Air Purification System Configurations ..........................................................................................................774.1.6 Industrial Purification System Configurations .................................................................................................................78

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4.1.7 Cartridge Operating Life .................................................................................................................................................. 784.1.7.1 Calculating the Maximum Cartridge Operating Hours ................................................................................................ 794.1.7.2 Calculating the Adjusted Cartridge Operating Hours................................................................................................... 794.1.7.3 Air Purification Cartridge Operating Hours Form........................................................................................................ 814.2 P5S SECURUS II PURIFICATION SYSTEM ............................................................................................................ 824.2.1 P5S Securus II Purification System Major Components .............................................................................................. 824.3 COMPONENT DESCRIPTION ...................................................................................................................................... 834.3.1 Oil and Water Separator ................................................................................................................................................... 834.3.2 Chamber ........................................................................................................................................................................... 834.3.3 Cartridge........................................................................................................................................................................... 834.3.3.1 Cartridge Construction.................................................................................................................................................. 834.3.3.2 Cartridge Handling ....................................................................................................................................................... 844.3.4 Condensate Drain Valve................................................................................................................................................... 844.3.5 Check Valves.................................................................................................................................................................... 844.3.6 Bleed Valve ...................................................................................................................................................................... 844.3.7 Pressure Maintaining Valve ............................................................................................................................................. 844.3.8 Safety Valve ..................................................................................................................................................................... 844.3.9 Securus II Electronic Moisture Monitor System ............................................................................................................ 844.3.9.1 Securus Cartridge ...................................................................................................................................................... 844.3.9.2 Securus II Transmitter................................................................................................................................................. 854.4 MAINTENANCE ............................................................................................................................................................... 854.4.1 Oil and Water Separator ................................................................................................................................................... 854.4.1.1 Removal of the Securus II Transmitter..................................................................................................................... 874.4.2 Cartridge Replacement..................................................................................................................................................... 884.4.2.1 Leaking at the Safety Bore ........................................................................................................................................... 884.5 REPLACEMENT PARTS LIST ..................................................................................................................................... 90

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

5.1 VERTICAL COMPRESSOR DRIVE.............................................................................................................................. 965.2 MAINTENANCE OF THE V-BELT AND SHEAVES .................................................................................................. 965.2.1 Check The Sheaves. ......................................................................................................................................................... 965.2.2 Check the V-belt............................................................................................................................................................... 975.2.3 Replacing the Belt ............................................................................................................................................................ 975.2.4 Replacing the Sheave ....................................................................................................................................................... 975.3 REPLACEMENT PART LIST ........................................................................................................................................ 98

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

6.1 OVERVIEW ..................................................................................................................................................................... 1006.2 ELECTRICAL PANEL .................................................................................................................................................. 1006.2.1 Wiring Diagram.............................................................................................................................................................. 1016.2.2 Electrical Panel Interior Access ..................................................................................................................................... 1016.2.3 Optional Equipment ....................................................................................................................................................... 1016.3 AC POWER REQUIREMENTS.................................................................................................................................... 1016.4 ELECTRICAL PANEL COMPONENTS ..................................................................................................................... 1026.4.1 Programable Logic Controller (PLC)............................................................................................................................. 1026.4.2 Replacing the PLC ......................................................................................................................................................... 1036.4.3 Installing a New Program............................................................................................................................................... 1036.4.4 Installing an EEPROM................................................................................................................................................... 1036.4.5 Hourmeter....................................................................................................................................................................... 104

UNICUS III

Page v 1st Edition, Rev. 2 Chg. 2

6.4.6 Transformer and Fuses ...................................................................................................................................................1046.4.7 Motor Starter. .................................................................................................................................................................1046.4.8 Overload Relay...............................................................................................................................................................1056.4.9 Starter Reset....................................................................................................................................................................1056.4.10 Optional Communication Modules ................................................................................................................................1056.4.11 Power Supply..................................................................................................................................................................1076.5 ALARMS ..........................................................................................................................................................................1076.5.1 Final Separator Warning.................................................................................................................................................1076.5.2 Securus Electronic Moisture Monitor System..............................................................................................................1086.5.2.1 Securus Cartridge.....................................................................................................................................................1086.5.2.2 Securus II Transmitter...............................................................................................................................................1086.5.3 Compressor High Temperature ......................................................................................................................................1096.5.4 Compressor Low Oil Pressure........................................................................................................................................1096.5.5 Compressor Overrun Timer............................................................................................................................................1096.5.6 Carbon Monoxide Monitor Alarm..................................................................................................................................1096.5.7 Condensate Fault ............................................................................................................................................................1106.5.8 Motor Starter Overload Trip...........................................................................................................................................1116.6 PLC INPUTS AND OUTPUTS ......................................................................................................................................1116.6.1 Analog Inputs to the PLC. ..............................................................................................................................................1116.7 WIRING HARNESS LAYOUT .....................................................................................................................................1126.8 REPLACEMENT PARTS LIST ....................................................................................................................................1146.9 PARTS LIST FOR MODELS WITH A 5 HORSEPOWER MOTOR.......................................................................1206.10 PARTS LIST FOR MODELS WITH A 7 HORSEPOWER MOTOR ....................................................................1216.11 PARTS LIST FOR MODELS WITH A 10 HORSEPOWER MOTOR.....................................................................1226.12 PARTS LIST FOR MODELS WITH A 15 HORSEPOWER MOTOR.....................................................................1236.13 PARTS LIST FOR MODELS WITH A 20 HORSEPOWER MOTOR.....................................................................1246.14 TYPICAL WIRING DIAGRAM ....................................................................................................................................125

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

7.1 DESCRIPTION ................................................................................................................................................................1267.1.1 Component Description..................................................................................................................................................1277.1.1.1 Isolation Valve ............................................................................................................................................................1277.1.1.2 High Pressure to Low Pressure Regulator ..................................................................................................................1277.1.1.3 Relief Valve ................................................................................................................................................................1277.1.1.4 Solenoid Valve............................................................................................................................................................1277.1.1.5 Inlet Regulator ............................................................................................................................................................1277.1.1.6 Carbon Monoxide Monitor .........................................................................................................................................1277.1.1.6.1 Carbon Monoxide Sensor Cell....................................................................................................................................1277.1.1.7 Test Gas Storage .........................................................................................................................................................1277.2 CARBON MONOXIDE MONITOR SETUP................................................................................................................1277.3 OPERATION ...................................................................................................................................................................1287.4 MAINTENANCE .............................................................................................................................................................1287.4.1 Calibrating Carbon Monoxide Monitor..........................................................................................................................1287.4.2 Troubleshooting a Calibration Failure............................................................................................................................1297.4.3 Carbon Monoxide Sensor Cell Replacement .................................................................................................................1297.4.4 Carbon Monoxide Monitor Initialization .......................................................................................................................1307.4.4.1 Setting the LP Regulator.............................................................................................................................................1317.4.4.2 Initialization Calibration .............................................................................................................................................1317.4.5 Carbon Monoxide Monitor Test Mode Buttons .............................................................................................................134

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7.5 REMOTE DISPLAY SETUP ........................................................................................................................................ 1357.6 REPLACEMENT PARTS LIST .................................................................................................................................... 137

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

8.1 DESCRIPTION................................................................................................................................................................ 1398.2 FILL STATION AIR FLOW .......................................................................................................................................... 1398.3 MAINTENANCE ............................................................................................................................................................. 1398.3.1 General Maintenance...................................................................................................................................................... 1398.3.2 Nonadjustable Valves..................................................................................................................................................... 1408.3.3 Pressure Gauges ............................................................................................................................................................. 1408.3.4 Safety Valves.................................................................................................................................................................. 1408.3.5 Pneumatic Connections .................................................................................................................................................. 1408.3.6 Bearings for Bottle Door Pivot....................................................................................................................................... 1418.3.7 Pressure Hoses................................................................................................................................................................ 1418.3.8 Door Gas Spring............................................................................................................................................................. 1418.4 REPLACEMENT PARTS LIST .................................................................................................................................... 1428.4.1 CFS II Assemblies.......................................................................................................................................................... 1428.4.2 Fill Hose Assemblies...................................................................................................................................................... 148

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

9.1 BOTTLE SPECIFICATIONS ........................................................................................................................................ 1509.1.1 D.O.T. Department of Transportation............................................................................................................................ 1509.1.2 A.S.M.E. American Society of Mechanical Engineers .................................................................................................. 1509.2 DESCRIPTION AND MAINTENANCE ...................................................................................................................... 1519.2.1 Description ..................................................................................................................................................................... 1519.2.2 Maintenance ................................................................................................................................................................... 1529.2.2.1 Storage Bottles............................................................................................................................................................ 1529.2.2.2 Pressure Gauges.......................................................................................................................................................... 1529.2.2.3 Tube Connections ....................................................................................................................................................... 1529.2.2.4 Safety Valve ............................................................................................................................................................... 1539.2.2.5 Pressure Hoses ............................................................................................................................................................ 153

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

10.1 COMPONENT LOCATIONS ........................................................................................................................................ 154

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

11.1 SAFETY............................................................................................................................................................................ 16011.1.1 General Safety Precautions ............................................................................................................................................ 16011.1.2 Safety Warning Labels ................................................................................................................................................... 16211.2 UNPACKING, HANDLING AND INSTALLATION ................................................................................................. 16311.2.1 Unpacking and Handling................................................................................................................................................ 16311.2.2 Installation of the Compressor Unit ............................................................................................................................... 16411.2.2.1 Securing and Leveling the UNICUS III .................................................................................................................... 16511.2.2.2 Ventilation .................................................................................................................................................................. 16511.2.2.2.1 Outdoor Installation .................................................................................................................................................... 16511.2.2.2.2 Indoor Installation....................................................................................................................................................... 16511.2.2.2.3 Natural Ventilation ..................................................................................................................................................... 166

UNICUS III

Page vii 1st Edition, Rev. 2 Chg. 2

11.2.2.2.4 Forced Ventilation ......................................................................................................................................................16611.2.2.3 Electrical Installation ..................................................................................................................................................16711.2.2.3.1 Electric Drive ..............................................................................................................................................................16711.2.2.3.2 Electrical Supply.........................................................................................................................................................16711.3 LONG TERM STORAGE ...............................................................................................................................................17011.3.1 General ...........................................................................................................................................................................17011.3.2 Preparations ....................................................................................................................................................................17011.3.2.1 Units Equipped with a Filter System ..........................................................................................................................17011.3.3 Preserving the Compressor.............................................................................................................................................17011.3.4 Preventive Maintenance During Storage........................................................................................................................17011.3.5 Lubrication Oils for Preservation ...................................................................................................................................17111.3.6 Reactivating the Compressor Unit..................................................................................................................................17111.4 REPRODUCIBLE FORMS ............................................................................................................................................17211.4.1 Scheduled Maintenance Form .......................................................................................................................................17211.4.2 Record of Operating Hours ...........................................................................................................................................17511.5 REFERENCE DATA.......................................................................................................................................................17611.5.1 Tightening Torque Values..............................................................................................................................................17611.5.2 Torque Sequence Diagrams............................................................................................................................................17611.5.3 Conversion Formulas......................................................................................................................................................17611.5.4 Approved Lubricants Chart ............................................................................................................................................17711.5.5 Glossary of Abbreviations and Acronyms .....................................................................................................................17711.6 ADDITIONAL DOCUMENTS.......................................................................................................................................17811.6.1 Diagrams and Drawings .................................................................................................................................................17811.6.2 Other Documents............................................................................................................................................................178

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List of Figures

CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTIONFigure 1-1 Compressor Identification Plate .............................................................................................................................. 2Figure 1-2 UNICUS III ............................................................................................................................................................. 7Figure 1-3 UNICUS III Front Panel.......................................................................................................................................... 8

CHAPTER 2: - - - -OPERATING INSTRUCTIONS; MAPLE SYSTEMFigure 2-1 MNR-0049............................................................................................................................................................... 9Figure 2-2 Maple System; Run Screen ................................................................................................................................... 10Figure 2-3 Maple System; Home Screen ................................................................................................................................ 11Figure 2-4 Parameter Adjustment Screen ............................................................................................................................... 12Figure 2-5 Adjustment Keypad ............................................................................................................................................... 12Figure 2-6 Table of Parameter Values .................................................................................................................................... 14Figure 2-7 Operator Interface Screen Flow............................................................................................................................. 17

CHAPTER 3: - - - - - IK150 II AND IK180 II COMPRESSOR BLOCKFigure 3-1 Four Stage Compressor Air Flow.......................................................................................................................... 18Figure 3-2 IK150 II Compressor Block (Front View) ............................................................................................................ 19Figure 3-3 IK180 II Compressor Block (Front View) ............................................................................................................ 20Figure 3-4 Lubrication Oil System.......................................................................................................................................... 21Figure 3-5 Oil Filler Sight Gauge ........................................................................................................................................... 22Figure 3-6 Removing the Oil Filter Cover .............................................................................................................................. 23Figure 3-7 Replacing the Oil Filter ......................................................................................................................................... 23Figure 3-8 Intake Filter ........................................................................................................................................................... 24Figure 3-9 2nd Stage Intermediate Separator.......................................................................................................................... 25Figure 3-10 3rd Stage Intermediate Separator .......................................................................................................................... 25Figure 3-11 Valve Function ...................................................................................................................................................... 26Figure 3-12 1st Stage Valve and Head...................................................................................................................................... 27Figure 3-13 2nd and 3rd Stages Valve Heads and Valves ........................................................................................................ 28Figure 3-14 4th Stage Valve and Head ..................................................................................................................................... 29Figure 3-15 4th Stage Discharge Valve Removal..................................................................................................................... 30Figure 3-16 Assembly Tool....................................................................................................................................................... 31Figure 3-17 Using Special Tool ................................................................................................................................................ 31Figure 3-18 Crankcase Assembly ............................................................................................................................................. 34Figure 3-19 Complete Crankshaft Assembly ............................................................................................................................ 36Figure 3-20 K150II 1st Stage Piston and Cylinder ................................................................................................................... 37Figure 3-21 K180II 1st Stage Piston and Cylinder ................................................................................................................... 38Figure 3-22 2nd Stage Piston and Cylinder Assembly ............................................................................................................. 40Figure 3-23 3rd Stage Piston and Cylinder ............................................................................................................................... 42Figure 3-24 4th Stage Piston and Cylinder Assembly .............................................................................................................. 44Figure 3-25 1st Stage Valve Head Assembly............................................................................................................................ 46Figure 3-26 2nd Stage Valve Head ........................................................................................................................................... 47Figure 3-27 3rd Stage Valve Head Assembly........................................................................................................................... 48

UNICUS III

Page ix 1st Edition, Rev. 2 Chg. 2

Figure 3-28 4th Stage Valve Head Assembly ...........................................................................................................................49Figure 3-29 Flywheel Drive Assembly .....................................................................................................................................50Figure 3-30 Intake Filter Assembly...........................................................................................................................................51Figure 3-31 2nd Stage Interfilter Assembly ..............................................................................................................................52Figure 3-32 3rd Stage Interfilter Assembly...............................................................................................................................53Figure 3-33 IK150 II Cooling System Assembly......................................................................................................................54Figure 3-34 IK180 II Cooling System Assembly......................................................................................................................58Figure 3-35 2nd Stage Intercooler.............................................................................................................................................61Figure 3-36 3rd Stage Intercooler..............................................................................................................................................62Figure 3-37 Lubricating System Assembly...............................................................................................................................63Figure 3-38 Lubricating System................................................................................................................................................64Figure 3-39 Automatic Condensate Drain System....................................................................................................................65Figure 3-40 ACD Operation......................................................................................................................................................66Figure 3-41 ACD System ..........................................................................................................................................................68Figure 3-42 Final Separator Condensate Drain Valve ..............................................................................................................69Figure 3-43 1st Stage Separators Condensate Drain Valves .....................................................................................................70Figure 3-44 Manual Condensate Drain Valve...........................................................................................................................72Figure 3-45 Condensate Collector.............................................................................................................................................73

CHAPTER 4:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEMFigure 4-1 Cartridge Safety Venting .......................................................................................................................................76Figure 4-2 Purification System Dataplates (typical) ...............................................................................................................76Figure 4-3 Correction Factor for Cartridge Operating Hours .................................................................................................80Figure 4-4 Example Record of Adjusted Operating Hours .....................................................................................................80Figure 4-5 P5S Securus II Purification System....................................................................................................................82Figure 4-6 Oil and Water Separator Labels.............................................................................................................................83Figure 4-7 Cartridge ................................................................................................................................................................84Figure 4-8 Oil and Water Separator ........................................................................................................................................86Figure 4-9 Sintered Metal Filter Assembly .............................................................................................................................86Figure 4-10 Removal of the Securus II Transmitter...............................................................................................................87Figure 4-11 Cartridge Replacement ..........................................................................................................................................88Figure 4-12 P5 Purification System Parts List ..........................................................................................................................90Figure 4-13 Oil and Water Separator Parts List ........................................................................................................................91Figure 4-14 27 Chamber Assembly Parts List.........................................................................................................................92Figure 4-15 Securus Electronic Moisture Monitor System Parts List....................................................................................94

CHAPTER 5:- - - - - - - - - - - COMPRESSOR DRIVE; UNICUS IIIFigure 5-1 Vertical Drive with Idler (typical) .........................................................................................................................96Figure 5-2 UNICUS III, Vertical Drive with Idler..................................................................................................................98

CHAPTER 6:- - - - - - - - - - - - -ELECTRICAL PANEL, ASY-1058Figure 6-1 ASY-1058 and MNR-0049..................................................................................................................................100Figure 6-2 Electrical Panel Label ..........................................................................................................................................101Figure 6-3 PLC, CNT-0078...................................................................................................................................................102Figure 6-4 Connector Block Removal...................................................................................................................................102

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

CHAPTER 7: - - - - - - - - - - - - CARBON MONOXIDE MONITORFigure 7-1 CO Monitor, MNR-0029 ..................................................................................................................................... 126Figure 7-2 Remote Display ................................................................................................................................................... 126Figure 7-3 Carbon Monoxide Monitor Flow Diagram.......................................................................................................... 127Figure 7-4 Basic Calibration Kit ........................................................................................................................................... 129Figure 7-5 Carbon Monoxide Monitor Initialization ............................................................................................................ 131Figure 7-6 Carbon Monoxide Monitor Internal Components ............................................................................................... 133Figure 7-7 Carbon Monoxide Sensor Cell Removal............................................................................................................. 134Figure 7-8 Mode Buttons Close-up....................................................................................................................................... 135Figure 7-9 Remote Display ................................................................................................................................................... 136Figure 7-10 Carbon Monoxide Monitor Assembly - Standard ............................................................................................... 137Figure 7-11 Carbon Monoxide Monitor Schematic ................................................................................................................ 138

CHAPTER 8: - - - - - - - - - - - - - - - - - -CFS II MAINTENANCEFigure 8-1 Safety Valves....................................................................................................................................................... 140Figure 8-2 Special Tool, TOO-0020 ..................................................................................................................................... 141Figure 8-3 CFS II Assembly ................................................................................................................................................. 142Figure 8-4 CFS II Door Lock Assembly............................................................................................................................... 143Figure 8-5 Door Handle, Pivot and Bracket.......................................................................................................................... 144Figure 8-6 CFS II Door Lock Latch...................................................................................................................................... 146Figure 8-7 CFS II Door Interlock.......................................................................................................................................... 147Figure 8-8 Standard Fill Hose Assembly .............................................................................................................................. 148Figure 8-9 Multi Fill Hose Assembly ................................................................................................................................... 149

CHAPTER 9: - - - - - - - - - - - - - -UNICUS III HP AIR STORAGEFigure 9-1 UNICUS III Storage System ............................................................................................................................... 151Figure 9-2 Safety Valve ........................................................................................................................................................ 153

UNICUS III

Page xi 1st Edition, Rev. 2 Chg. 2

CHAPTER 10: - - - - - - - - - - - - CONTROLS AND INDICATORSFigure 10-1 Front Panel...........................................................................................................................................................154Figure 10-2 Gauge Panel .........................................................................................................................................................155Figure 10-3 Components for Remote Fill Option ...................................................................................................................156Figure 10-4 Front Panel Parts..................................................................................................................................................157Figure 10-5 Gauge Panel Parts ................................................................................................................................................158Figure 10-6 Remote Fill Option Parts .....................................................................................................................................159

CHAPTER 11: - - - - - - - - - - - - - - - - - - - - - - - -APPENDIXFigure 11-1 Lifting Devices ....................................................................................................................................................163Figure 11-2 Securing and Leveling the UNICUS III ..............................................................................................................165Figure 11-3 Incoming Power Wiring Label ............................................................................................................................167Figure 11-4 6 Bolt and 4 Bolt Torque Sequence.....................................................................................................................176

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CHAPTER 1: INTRODUCTION1.1 How To Use This Manual

This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. prod-ucts listed on the front cover.

All instructions in this manual should be observed and carried out as written to prevent damage or pre-mature wear to the product or the equipment served by it.

If your unit is equipped with nonstandard accessories and or options, supplemental information is nor-mally 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 NoticesImportant 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.

^ DANGERDANGER indicates an imminently hazardous situation which, if not avoided, will result in death or seri-ous injury. This is limited to the most extreme situations.

^ WARNINGWARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

^ CAUTIONCAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-erate injury. It may also be used to alert against unsafe practices.

NOTICENOTE advise of technical requirements that require particular attention by the operator or the mainte-nance technician for proper maintenance and utilization of the equipment.

UNICUS III

Page 2 1st Edition, Rev. 2 Chg. 2

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 spec-ifies.

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 com-pressor unit identification plate on the compressor unit frame.

Information Example

Model Number TCom-25

Serial Number 32165

Date of Manufacture 02/2005

Quantity required 2

Part Number N04860

Part Description Valve

Figure 1-1 Compressor Identification Plate

BAUERCOMPRESSORS

BAUER COMPRESSORS, INC.NORFOLK, VIRGINIA U.S.A

LBL-004

MODEL NO. BLOCK NO.

CAPACITY CFM CHG. RATE CFMMOTOR HP SPEED RPM

SERIAL NO. PRESSURE PSIG

VOLTS PH HZ AMPSDATE OF MANUFACTUREDATE OF MANUFACTURE

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1.3 How to Use the AppendixInformation 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

^ WARNINGThe use of repair parts other than those included in the Bauer Replacement Parts Lists may create unsafe conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, Bauer Compressors, Inc. can bear no responsibility for equipment in which unapproved repair parts are installed.

UNICUS III


1.4 Unit DescriptionThe 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

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1.5 Unit SpecificationsAll specifications are subject to change without prior notice.

1.5.1 UNICUS III 20Medium airCharging Rate 20.4 scfm1

Free Air Delivery 17.0 scfm2

Inlet pressure atmosphericOperating pressure, max. 5,000 psig Ambient temperature range 43 to 113 F (5 - 45 C)Weight approx. 3,350 lbs. (1,508 kgs)

1.5.1.1 Compressor Block, IK 150 IINo. of stages 4No. of cylinders 4Cylinder bore, 1st stage 4.72 in. (120mm)Cylinder bore, 2nd stage 2.367 in. (60mm)Cylinder bore, 3rd stage 1.26 in. (32mm)Cylinder bore, 4th stage 0.55 in. (14mm)Piston Stroke 1.97 in.(50mm)Intermediate pressure, 1st stage 29 - 44 psig (2 - 3 bar)Safety valve setting, 1st stage 73 psig (5 bar)Intermediate pressure, 2nd stage 196 - 225 psig (13.5 -15.5 bar)Safety valve setting, 2nd stage 348 psig (24 bar)Intermediate pressure, 3rd stage 928 - 1,015 psig (64 - 70 bar)Safety valve setting, 3rd stage 1,160 psig (80 bar)Direction of rotation when facing flywheel CCWCompressor speed 900 - 1350 RPMOil capacity 6.36 qts.(6 ltrs)Oil Pressure 58 - 87 psig (4 - 6 bar)Recommended oil BAUER OIL-0024Maximum Inclination 20 in all directions

1.5.1.2 Compressor Drive

1.5.1.3 Purification System ApplicabilityThe Bauer P5 Purification System with Securus II Electronic Moisture Monitoring is the standard purifi-cation 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.

Voltage Freq. Phase Power RPM Type

-E3 208 - 460 VAC 60 Hz 3 15 Hp 3,600 ODP

UNICUS III


1.5.2 UNICUS III 26 Medium airCharging Rate 26.4 scfm1

Free Air Delivery 22.0 scfm2

Inlet pressure atmosphericOperating pressure, max. 5,000 psig Ambient temperature range 43 to 113 F (5 - 45 C)Weight approx. 3,625 lbs. (1,631 kgs)

1.5.2.1 Compressor Block, IK180IINo. of stages 4No. of cylinders 4Cylinder bore, 1st stage 5.07 in. (130mm)Cylinder bore, 2nd stage 2.367 in. (60mm)Cylinder bore, 3rd stage 1.26 in. (32mm)Cylinder bore, 4th stage 0.55 in. (14mm)Piston Stroke 1.97 in.(50mm)Intermediate pressure, 1st stage 44 - 58 psig (3 - 4 bar)Safety valve setting, 1st stage 73 psig (5 bar)Intermediate pressure, 2nd stage 232 - 261 psig (16 -18 bar)Safety valve setting, 2nd stage 348 psig (24 bar)Intermediate pressure, 3rd stage 1,015 - 1,088 psig (70 - 75 bar)Safety valve setting, 3rd stage 1378 psig (95 bar)Direction of rotation when facing flywheel CCWCompressor speed 900 - 1350 RPMOil capacity 6.36 qts.(6 ltrs)Oil Pressure 58 - 87 psig (4 - 6 bar)Recommended oil BAUER OIL-0024Maximum Inclination 20 in all directions

1.5.2.2 Compressor Drive

1.5.2.3 Purification System ApplicabilityThe Bauer P5 Purification System with Securus II Electronic Moisture Monitoring is the standard purifi-cation 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.

Voltage Frequency Phase Power RPM Type

-E3 208 - 460 VAC 60 Hz 3 20 Hp 3,600 ODP

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1.6 Component Locations

Figure 1-2 UNICUS III

1. Remote Fill Panel (Option)2. Remote Fill Hose (Option)3. Cascade Panel4. Compressor Control Panel

5. Emergency Stop Switch6. Fill Station Controls7. Maintenance Access8. Fill Station

1

2

3 4 5

6

7

8

UNICUS III


Figure 1-3 UNICUS III Front Panel

1. Cascade Storage Pressure Gauges2. Cascade Valves 3. Fill Select Valve4. Inlet Pressure Gauge5. Fill Regulator

6. Final Pressure Gauge7. Compressor Control Panel8. Emergency Stop Switch9. Fill Valves10. Bottle Fill Pressure Gauges

1

2

3

4 5 6

78

9

10

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CHAPTER 2: OPERATING INSTRUCTIONS; MAPLE SYSTEM2.1 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 incorpo-rated into a proprietary software program permanently saved into PLC memory using EEPROM technol-ogy. 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 ButtonA 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 InterfaceThe 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 sta-tus lights and screen illuminates.

Figure 2-1 MNR-0049

UNICUS III


2.1.2.1 Run ScreenThe inital screen after startup allows control and monitoring of the compressor unit.

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.

Figure 2-2 Maple System; Run Screen

1. Compressor Status Indicator2. Oil Pressure Reading3. START Button4. OFF Button5. Closes Window (goes to HOME Screen)

6. Inlet Pressure (optional)7. Alarm Indicator8. Securus Status (optional)9. CO Monitor Status (optional)10. Outlet Air pressure

1

2

3 4 5

6 7 8 9 10

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10. This figure shows the present output pressure.

2.1.2.2 Home Screen

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 RunThis button returns the user to the RUN screen, See Paragraph 2.1.2.1 for further information.

2.1.2.2.2 AlarmsThis 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 LoginThe login button allows the user to enter the access code. Only after the access code is entered can the fol-lowing areas within the program be viewed or changed: Adjust Parameters Screen, Setup Screen, or Tools Screen.

2.1.2.2.4 Language ChoiceThe 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.

Figure 2-3 Maple System; Home Screen

1. Run Button2. Alarms Button3. Login Button

4. Language Options5. Adjustment Button6. Maintenance Button

7. Setup Button8. Tools Button9. Contact Information

12

3

4

56789

UNICUS III


Another feature on this page is the PSI/BAR button. Pressures can only be set in PSI, however the dis-played pressure on the RUN screen can be set to read PSI or translate it into Bar

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.

Maintenance RecordsWe 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 IntervalsEach 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 IntervalsEach 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 SetupThis 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 mon-itoring 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 ToolsThe tools button is used for maintenance purposes. To use the Tools button the user must be logged in. Also the unit must be shutdown.

Figure 2-4 Parameter Adjustment Screen Figure 2-5 Adjustment Keypad

^ 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.

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2.1.2.2.9 ContactPressing 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 pres-sure is higher or when the air pressure has increased to operating pressure, the compressor will automati-cally shutdown. The Compressor will automatically restart when the pressure drops below the Start Pressure.

2.2.3 To Stop Unit.Press the STOP Button on the Run screen.

^ WARNINGOnce started the compressor and drive motor will start and stop automatically. Stay clear of all moving parts whenever unit has power.

^ NOTE ^

In an emergency the compressor is shutdown by pressing in the E-Stop Button.

UNICUS III


.

Figure 2-6 Table of Parameter Values

Parameter Default Low High UnitsPASSWORD access #s supplied by distributor 1,328 9,999 0000

START PRESS lower pressure limit which starts com-pressor 5,800

a

a. 15% of Shutdown Press

800 5,700 PSI

SHUTDOWN PRESS upper pressure limit which stops com-pressor

6,000 850 6,000 PSI

SEPCNTWARNING # of cycles till final separator replace-ment warning given

53,000 1,800 900,000

SEPCNTALARM # of cycles till final separator replace-ment alarm shutdown

53,000 2,000 1,000,000

OVERRUNTIMER amount of time before unit shuts down if left unattended

3 2 100 HRS

SHUTDOWNDELAY delaye from when command is given till shtudown occurs

4 0 10 SEC

ACDF TEST TIME amount of time on button held to per-form ACD test

2 2 10 SEC

CO ALARM DELAY time between alarm level reached and alarm gien

0 0 125 SEC

OIL ALARM psi at which low oil press. alarm given 23 3 100 PSISEPCNT RESET current # of cycles for final separator 0 1,000,000ACD1 DELAY ON dely till ACD1 closes 3 1 10 SECACD1 DRAIN TIME length of time ACD1 drains 3 1 10 SEC

ACD1 CYCLE TIME length of time between ACD1 drain cycles

15 3 60 MIN

ACD2 DELAY ON dely till ACD2 closes 3 1 10 SECACD2 DRAIN TIME length of time ACD2 drains 3 1 10 SEC


15 3 60 MIN

ACD3 DELAY ON dely till ACD3 closes 3 1 10 SECACD3 DRAIN TIME length of time ACD3 drains 3 1 10 SEC


15 3 60 MIN

ACDF DELAY ON delay till final ACD closes 3 1 10 SECACDF DRAIN TIME length of time final ACD drains 3 1 10 SEC

ACDF CYCLE TIME length of time between final ACD drain cycles

15 3 60 MIN

BACKLIGHT ON Panel light option 10 10 60 MINOIL PRESS TIME DELY (TD)

time delay from startup till oil press. sensor is used 30 4 60 SEC

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Table 2-1: Calendar Maintenance Interval Tasks

Task Monthly Annually Every Two Years

Calibrate CO Monitor X

Check Oil Level X

Check Final Pressure Shutdown X

Check Automatic Condensate Drain X

Check V-belt X

Service Intake Filter X

Check all connections for leaks X

Inspect Compressor Valves X

Check all fasteners for tightness X

Change Synthetic Oil X

Replace Compressor Oil Filter X

Replace Compressor Valves X

Replace CO Monitor Sensor X

UNICUS III


Table 2-2: Operating Hours Maintenance Interval Tasks

Task 500 Hours 1,000 Hours 2,000 Hours 3,000 Hours