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COMPRESOR SULLAIR

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ROTARY SCREW ES--8 Series 15, 20, 25 and 30 HP OPERATOR’S MANUAL AND Part Number 02250117--368 Sullair Corporation PARTS LIST AIR COMPRESSOR 11, 15, 18.5 and 22KW KEEP FOR FUTURE REFERENCE Standard and Basic Models
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Page 1: COMPRESOR SULLAIR

ROTARY SCREW

ES--8 Series

15, 20, 25 and 30 HP

OPERATOR’SMANUAL AND

Part Number 02250117--368Sullair Corporation

PARTS LIST

AIR COMPRESSOR

11, 15, 18.5 and 22KW

KEEP FORFUTURE

REFERENCE

Standard and Basic Models

Sullair Sullair
NOTE: When performing a manual search for a Sullair part number (binocular icon on tool bar above), substitute a SPACE for the HYPHEN. EXAMPLE: To find: 02250057-696 Type: 02250057 696 For further information consult 'Sullair Manual Navigation Guide' in the Bookmarks section.
Page 2: COMPRESOR SULLAIR

AIR CARESEMINAR TRAINING

Sullair Air Care Seminars are 3--day courses that provide hands--on instructionin the proper operation, maintenance and service of Sullair equipment.Individual seminars on Industrial compressors and compressor electricalsystems are presented at regular intervals throughout the year at a dedicatedtraining facility at Sullair’s corporate headquarters in Michigan City, Indiana.

Instruction includes discussion of the function and installation of Sullair serviceparts, troubleshooting of the most common problems, and actual equipmentoperation. The seminars are recommended for maintenance and servicepersonnel.

For detailed course outlines, schedule and cost information contact:

Sullair Corporate Training Department1--888--SULLAIR or 219--879--5451 (ext. 5363)

-- Or Write --Sullair Corporation3700 E. Michigan Blvd.Michigan City, IN 46360Attn: Service Training Department

Page 3: COMPRESOR SULLAIR

OPERATOR IS REQUIRED TO READENTIRE INSTRUCTION MANUAL

TABLE OF CONTENTS

Section 1 PAGE

SAFETY 1 1.1 GENERAL

1 1.2 PERSONAL PROTECTIVE EQUIPMENT

1 1.3 PRESSURE RELEASE

2 1.4 FIRE AND EXPLOSION

2 1.5 MOVING PARTS

2 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

2 1.7 TOXIC AND IRRITATING SUBSTANCES

3 1.8 ELECTRICAL SHOCK

3 1.9 LIFTING

4 1.10 ENTRAPMENT

Section 2INSTALLATION 5 2.1 LOCATION OF COMPRESSOR

5 2.2 VENTILATION AND COOLING

5 2.3 SERVICE AIR PIPING

5 2.4 COUPLING ALIGNMENT CHECK

5 2.5 FLUID LEVEL CHECK

6 2.6 MOTOR ROTATION DIRECTION CHECK

6 2.7 ELECTRICAL PREPARATION

Section 3SPECIFICATIONS 7 3.1 SPECIFICATIONS-- ES--8

8 3.2 LUBRICATION GUIDE

8 3.3 LUBRICANT CHANGE RECOMMENDATIONS

Section 4COMPRESSORSYSTEMS 13 4.1 INTRODUCTION

13 4.2 DESCRIPTION OF COMPONENTS

13 4.3 ENCAPSULATED COMPRESSOR SYSTEM,FUNCTIONAL DESCRIPTION

13 4.4 COMPRESSOR COOLING SYSTEM,FUNCTIONAL DESCRIPTION

13 4.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

15 4.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION

Page 4: COMPRESOR SULLAIR

TABLE OF CONTENTS(CONTINUED)

Section 5 PAGE

SUPERVISOR II 19 5.1 INTRODUCTION

19 5.2 KEYPAD

19 5.3 STATUS DISPLAYS

20 5.4 LAMP INDICATORS

Section 6COMPRESSOR OPERATION-SUPERVISOR II 21 6.1 INTRODUCTION

21 6.2 STANDARD PARAMETER SETUP

21 6.3 SEQUENCING PARAMETERS SETUP

22 6.4 OPERATING THE COMPRESSOR

23 6.5 PURPOSE OF CONTROLS

24 6.6 SUPERVISOR OUTPUT RELAYS

24 6.7 INITIAL START--UP PROCEDURE

24 6.8 SUBSEQUENT START--UP PROCEDURE

24 6.9 SHUTDOWN PROCEDURE

Section 7COMPRESSOR OPERATION-ELECTRO-MECHANICAL 25 7.1 INTRODUCTION

25 7.2 PURPOSE OF CONTROLS- ELECTRO-MECHANICAL

26 7.3 INITIAL START--UP PROCEDURE

26 7.4 SUBSEQUENT START--UP PROCEDURE

26 7.5 SHUTDOWN PROCEDURE

Section 8MAINTENANCE 27 8.1 INTRODUCTION

27 8.2 DAILY OPERATION

27 8.3 MOTOR BEARING LUBRICATION

27 8.4 FLUID FILTER MAINTENANCE

27 8.5 COOLER MAINTENANCE

28 8.6 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES

28 RELIEF VALVE

28 FLUID FILTER REPLACEMENT

28 AIR FILTER MAINTENANCE- STANDARD MODEL

29 AIR FILTER MAINTENACE- BASIC MODEL

29 SEPARATOR ELEMENT REPLACEMENT

29 DRIVE COUPLING INSTALLATION

30 INLET CONTROL VALVE

Page 5: COMPRESOR SULLAIR

TABLE OF CONTENTS(CONTINUED)

Section 8MAINTENANCE (CONT) 30 CONTROL SYSTEM ADJUSTMENT- ELECTRO-MECHANICAL

32 8.7 MAINTENANCE RECORD

Section 9TROUBLESHOOTING 33 9.1 INTRODUCTION

33 9.2 TROUBLESHOOTING

34 9.3 CALIBRATION

Section 10ILLUSTRATIONS AND PAGE

PARTS LIST 37 10.1 PROCEDURE FOR ORDERING PARTS

37 10.2 RECOMMENDED SPARE PARTS LIST

38 10.3 INLET CONTROL, SEAL/DRIVE GEAR AND PARTS

42 10.4 MOTOR, COUPLING, FAN AND PARTS

44 10.5 INLET FILTER, COMPRESSOR HOUSING/SUMPAND PARTS- SUPERVISOR II

48 10.6 INLET FILTER, COMPRESSOR HOUSING/SUMPAND PARTS- ELECTRO-MECHANICAL

50 10.7 COMPRESSOR COOLER SYSTEM AND PARTS

52 10.8 CONTROL BOX AND PARTS- SUPERVISOR II

56 10.9 CONTROL BOX AND PARTS- ELECTRO-MECHANICAL

58 10.10 INSTRUMENT PANEL- ELECTRO-MECHANICAL

60 10.11 ENCLOSURE

62 10.12 DECAL GROUP

68 10.13 DECAL LOCATIONS

72 10.14 DECAL LOCATIONS- ENCLOSURE

74 10.15 WIRING DIAGRAM -- FULL VOLTAGE- ELECTRO-MECHANICAL

75 10.16 WIRING DIAGRAM -- FULL VOLTAGE- SUPERVISOR II

76 10.17 WIRING DIAGRAM -- WYE--DELTA ELECTRO-MECHANICAL

77 10.18 WIRING DIAGRAM -- WYE--DELTA SUPERVISOR II

78 10.19 WIRING DIAGRAM -- WYE--DELTA EUROPEAN

Page 6: COMPRESOR SULLAIR

NOTES

Page 7: COMPRESOR SULLAIR

Section 1SAFETY

1.1 GENERALSullair Corporation and its subsidiaries design andmanufacture all of their products so they can be op-erated safely. However, the responsibility for safeoperation rests with those who use and maintainthese products. The following safety precautionsare offered as a guide which, if conscientiously fol-lowed, will minimize the possibility of accidentsthroughout the useful life of this equipment.

The compressor should be operated only by thosewho have been trained and delegated to do so, andwho have read and understood this Operator’sManual. Failure to follow the instructions, proce-dures and safety precautions in this manual can re-sult in accidents and injuries. Read thismanualpriorto startup.

NEVER start the compressor unless it is safe to doso.DONOT attempt to operate the compressorwitha known unsafe condition. Tag the compressor andrender it inoperative by disconnecting and lockingout all power at source or otherwise disabling itsprimemover, so otherswhomaynot knowof the un-safe condition, cannot attempt to operate it until thecondition is corrected.

Install, use and operate the compressor only in fullcompliance with all pertinent regulations and all ap-plicable Federal, State, and Local codes, standardsand regulations.

DO NOT modify the compressor and/or controls inany way except with written factory approval.

While not specifically applicable to all types of com-pressors with all types of prime movers, most of theprecautionary statements contained herein are ap-plicable to most compressors and the concepts be-hind these statements are generally applicable to allcompressors.

1.2 PERSONAL PROTECTIVE EQUIPMENTPrior to installing or operating the compressor, own-ers, employers and users should become familiarwith, and comply with, all applicable regulations andany applicable Federal, State and Local codes,standards, and regulations relative to personal pro-tective equipment, such as eye and face protectiveequipment, respiratory protective equipment,equipment intended to protect the extremities, pro-tective clothing, protective shields and barriers andelectrical protective equipment, as well as noise ex-posure administrative and/or engineering controlsand/or personal hearing protective equipment.

1.3 PRESSURE RELEASEA. Install an appropriate flow--limiting valve betweenthe service air outlet and the shut--off (throttle)valve, either at the compressor or at any other pointalong the air line, when an air hose exceeding 1/2”(13mm) inside diameter is to be connected to theshut--off (throttle) valve, to reduce pressure in case

of hose failure, per all applicable Federal, State andLocal codes, standards and regulations.

B.When thehose is to beused to supply amanifold,install an additional appropriate flow--limiting valvebetween the manifold and each air hose exceeding1/2” (13mm) inside diameter that is to be connectedto the manifold to reduce pressure in case of hosefailure.

C. Provide an appropriate flow--limiting valve at thebeginningof eachadditional 75 feet (23m) of hose inruns of air hoseexceeding 1/2” (13mm) insidediam-eter to reduce pressure in case of hose failure.

D. Flow--limiting valves are listed by pipe size andrated CFM. Select appropriate valves accordingly,in accordancewith their manufacturer’s recommen-dations.

E. DO NOT use air tools that are rated below themaximum rating of the compressor. Select air tools,air hoses, pipes, valves, filters, and other fittings ac-cordingly. DO NOT exceed manufacturer’s ratedsafe operating pressures for these items.

F.Secure all hose connections by wire, chain or oth-er suitable retaining devices to prevent tools or hoseends from being accidentally disconnected and ex-pelled.

G.Open fluid filler cap only whencompressor is notrunning and is not pressurized. Shut down thecompressor and bleed the sump (receiver) to zerointernal pressure before removing the cap.

H. Vent all internal pressure prior to opening anyline, fitting, hose, valve, drain plug, connection orother component, such as filters and line oilers, andbefore attempting to refill optional air line anti--icersystems with antifreeze compound.

I. Keep personnel out of line with and away from thedischarge opening of hoses or tools or other pointsof compressed air discharge.

J.Use air at pressures less than30 psig (2.1 bar) forcleaning purposes, and then only with effective chipguarding and personal protective equipment.

K. DO NOT engage in horseplay with air hoses asdeath or serious injury may result.

L. DONOT tamper with sump and unit (if provided)relief valves. Check the relief valve as recom-mended in the Maintenance Section of this manualor at a minimum of at least weekly to make sure it isnot blocked, clogged, obstructed or otherwise dis-abled. DONOT change the factory setting of the re-lief valve.

M. If the compressor is installed in an enclosedarea, it is necessary to vent the relief valve to theoutside of the structure or to an area of non--expo-sure.

1

Page 8: COMPRESOR SULLAIR

Section 1SAFETY

2

1.4 FIRE AND EXPLOSION

WARNING!

When installing a Base Load Transfer (BLT) Sys-tem, remove jumpers between 16--17 & 18--19(Dual Control Compressors) so the other com-pressor does not backfeed defeating the shut-down circuitry.

A. Clean up spills of lubricant or other combustiblesubstances immediately, if such spills occur.

B.Shut off the compressor andallow it to cool. Thenkeep sparks, flames and other sources of ignitionaway and DO NOT permit smoking in the vicinitywhen checking or adding lubricant or when refillingair line anti--icer systemswith antifreeze compound.

C. DO NOT permit fluids, including air line anti--icersystem antifreeze compound or fluid film to accu-mulate on, under, or around acoustical material, oron any external surfaces of the air compressor or oninternal surfaces of the enclosure.Wipe down usingan aqueous industrial cleaner or steam--clean as re-quired. If necessary, remove acoustical material,clean all surfaces and then replace acousticalmate-rial. Any acoustical material with a protective cover-ing that has been torn or punctured should be re-placed immediately to prevent accumulation of liq-uids or fluid film within the material. DO NOT useflammable solvents for cleaning purposes.

D. Disconnect and lock out all power at source priorto attempting any repairs or cleaning of the com-pressor or of the inside of the enclosure, if any.

E. Keep electrical wiring, including all terminals andpressure connectors in good condition. Replaceanywiring that has cracked, cut abraded or otherwisedegraded insulation, or terminals that are worn, dis-colored or corroded. Keep all terminals and pres-sure connectors clean and tight.

F. Keep grounded and/or conductive objects suchas tools away from exposed live electrical partssuch as terminals to avoid arcing which might serveas a source of ignition.

G.Removeany acousticalmaterial or othermaterialthat may be damaged by heat or that may supportcombustion and is in close proximity, prior to at-tempting weld repairs.

H. Keep suitable fully charged fire extinguisher orextinguishers nearby when servicing and operatingthe compressor.

I. Keep oily rags, trash, leaves, litter or other com-bustibles out of and away from the compressor.

J. DO NOT operate the compressor without properflow of cooling air or water or with inadequate flow oflubricant or with degraded lubricant.

K. DO NOT attempt to operate the compressor inany classification of hazardous environment unlessthe compressor has been specially designed andmanufactured for that duty.

1.5 MOVING PARTSA. Keep hands, arms and other parts of the bodyandalso clothingaway fromcouplings, fans andoth-er moving parts.

B. DO NOT attempt to operate the compressor withthe fan, coupling or other guards removed.

C. Wear snug--fitting clothing and confine long hairwhen working around this compressor, especiallywhen exposed to hot or moving parts.

D. Keep access doors, if any, closed except whenmaking repairs or adjustments.

E.Make sure all personnel are out of and/or clear ofthe compressor prior to attempting to start or oper-ate it.

F. Disconnect and lock out all power at source andverify at the compressor that all circuits are de--en-ergized to minimize the possibility of accidentalstart--up or operation, prior to attempting repairs oradjustments. This is especially important whencompressors are remotely controlled.

G. Keep hands, feet, floors, controls and walkingsurfaces clean and free of fluid, water, or other liq-uids to minimize the possibility of slips and falls.

1.6 HOT SURFACES, SHARP EDGES AND SHARPCORNERSA. Avoid bodily contact with hot fluid, hot coolant,hot surfaces and sharp edges and corners.

B. Keep all parts of the body away from all points ofair discharge.

C. Wear personal protective equipment includinggloves and head covering when working in, on oraround the compressor.

D. Keep a first aid kit handy. Seek medical assis-tance promptly in case of injury. DO NOT ignoresmall cuts and burns as they may lead to infection.

1.7 TOXIC AND IRRITATING SUBSTANCESA.DONOT use air from this compressor for respira-tion (breathing) except in full compliance with anyFederal, State or Local Codes or regulations.

DANGER!

Death or serious injury can result from inhalingcompressed air without using proper safetyequipment.

B. DONOT use air line anti--icer systems in air linessupplying respirators or other breathing air utiliza-tion equipment and DO NOT discharge air fromthese systems in unventilated or other confinedareas.

Page 9: COMPRESOR SULLAIR

Section 1SAFETY

C. Operate the compressor only in open or ade-quately ventilated areas.

D. Locate the compressor or provide a remote inletso that it is not likely to ingest exhaust fumes or othertoxic, noxious or corrosive fumes or substances.

E. Coolants and lubricants used in this compressorare typical of the industry. Care should be taken toavoid accidental ingestion and/or skin contact. Inthe event of ingestion, seek medical treatmentpromptly. Wash with soap and water in the event ofskin contact. Consult the compressor operator’smanual lubrication section for informationpertainingto compressor fluid fill.

F.Wear goggles or a full face shieldwhenaddingan-tifreeze compound to air line anti--icer systems.

G. If air line anti--icer system antifreeze compoundenters the eyes or if fumes irritate the eyes, theyshould be washed with large quantities of clean wa-ter for 15 minutes. A physician, preferably an eyespecialist, should be contacted immediately.

H. DONOT store air line anti--icer systemantifreezecompound in confined areas.

I. The antifreeze compound used in air line anti-freeze systems contains methanol and is toxic,harmful, or fatal if swallowed. Avoid contact with theskin or eyes and avoid breathing the fumes. If swal-lowed, induce vomiting by administering a table-spoon of salt, in each glass of clean, warmwater un-til vomit is clear, then administer two teaspoons ofbaking soda in a glass of clean water. Have patientlay down and cover eyes to exclude light. Call a phy-sician immediately.

1.8 ELECTRICAL SHOCKA. This compressor should be installed and main-tained in full compliance with all applicable Federal,State and Local codes, standards and regulations,including those of the National Electrical Code, andalso including those relative to equipment groundingconductors, and only by personnel that are trained,qualified and delegated to do so.

B. Keep all parts of the body and any hand--heldtools or other conductive objects away from ex-posed live parts of electrical system. Maintain dryfooting, stand on insulating surfaces and DO NOTcontact any other portion of the compressor whenmaking adjustments or repairs to exposed live partsof the electrical system. Make all such adjustmentsor repairs with one hand only, so as to minimize thepossibility of creating a current path through theheart.

C. Attempt repairs in clean, dry and well lighted andventilated areas only.

D. DO NOT leave the compressor unattended withopen electrical enclosures. If necessary to do so,thendisconnect, lock out and tag all power at sourceso others will not inadvertently restore power.

E. Disconnect, lock out, and tag all power at sourceprior to attempting repairs or adjustments to rotatingmachinery and prior to handling any ungroundedconductors.F. Dry test all shutdown circuits prior to starting thecompressor after installation.

1.9 LIFTINGA. If the compressor is provided with a lifting bail,then lift by the bail provided. If no bail is provided,then lift by sling. Compressors to be air lifted by heli-coptermust not be supportedby the lifting bail but byslings instead. In any event, lift and/or handle only infull compliancewithFederal, State and Local codes.

B. Inspect points of attachment for cracked weldsand for cracked, bent, corroded or otherwise de-graded members and for loose bolts or nuts prior tolifting.C. Make sure entire lifting, rigging and supportingstructure has been inspected, is in good conditionand has a rated capacity of at least the weight of thecompressor. If you are unsure of the weight, thenweigh compressor before lifting.D. Make sure lifting hook has a functional safetylatch or equivalent, and is fully engaged and latchedon the bail or slings.E. Use guide ropes or equivalent to prevent twistingor swingingof the compressor once it has been liftedclear of the ground.F. DO NOT attempt to lift in high winds.G.Keep all personnel out from under and away fromthe compressor whenever it is suspended.H. Lift compressor no higher than necessary.I.Keep lift operator in constant attendancewhenev-er compressor is suspended.J. Set compressor down only on a level surface ca-pable of safely supporting at least its weight and itsloading unit.K. When moving compressors by forklift truck, uti-lize fork pockets if provided. Otherwise, utilize palletif provided. If neither fork pockets or pallet are pro-vided, then make sure compressor is secure andwell balanced on forks before attempting to raise ortransport it any significant distance.L. Make sure forklift truck forks are fully engagedand tipped back prior to lifting or transporting thecompressor.M. Forklift no higher than necessary to clear ob-stacles at floor level and transport and corner atminimum practical speeds.N. Make sure pallet--mounted compressors arefirmly bolted or otherwise secured to the pallet priorto attempting to forklift or transport them. NEVERattempt to forklift a compressor that isnot secured toits pallet, as uneven floors or sudden stops maycause the compressor to tumble off, possibly caus-ing serious injury or property damage in theprocess.

3

Page 10: COMPRESOR SULLAIR

Section 1SAFETY

4

O. DO NOT use the lifting eye bolt on the compres-sor motor, if supplied, to lift the entire compressorpackage.

1.10 ENTRAPMENTA. If the compressor enclosure is large enough tohold a person and if it is necessary to enter it to per-form service adjustments, inform other personnel

before doing so, or else secure and tag the accessdoor in the open position to avoid the possibility ofothers closing and possibly latching the door withpersonnel inside.

B. Make sure all personnel are out of compressorbefore closing and latching enclosure doors.

Page 11: COMPRESOR SULLAIR

Section 2INSTALLATION

2.1 LOCATION OF COMPRESSORThe ES--8 Series compressor package may beplaced on any level surface able to support itsweight. Theunit ismounted on vibrationmounts andcan be bolted to a fixed mounting surface to avoidthe possibility of externally applied forces or vibra-tion which would disturb the piping or wiring.

2.2 VENTILATION AND COOLINGSelect a location to permit sufficient unobstructedair flow in and out of the compressor to keep the op-erating temperature stable. The minimum distancethat the machine should be from surrounding wallsand ceiling is what is needed for service and three(3) feet (0.91m) or more from the compressor fluidcooler.

2.3 SERVICE AIR PIPINGService air piping should be installed as shown inF igur e 2 -- 1. A s hut -- off v alv e s hould be ins t alled t oisolate the compressor from the service line. Alsonotice that the service line should be equipped withwater legs and condensate drains throughout thesystem.

WARNING!

“ThePlastic Pipe Institute recommends against theuse of thermoplastic pipe to transport compressedair or other compressed gases in exposed aboveground locations, e.g. in exposed plant piping.” (I)

Sullube should not be used with PVC piping sys-tems. Itmay affect thebond atcemented joints.Cer-tain other plastic materials may also be affected.

(I) Plastic Pipe Institute, Recommendation B,Adopted January 19, 1972.

2.4 COUPLING ALIGNMENT CHECKWith the compressor unit directly flange--mounted

to its drive, the coupling supplied with the compres-sor is always properly aligned for operation. Howev-er, we recommend that you re--check the couplinggap before start--up or when handling the unit. a 1.5to 3mmaxial clearance should bemaintained for thecoupling gap.

2.5 FLUID LEVEL CHECKThe Sullair air compressor is equipped with theproper amount of fluid. However, it is necessary tocheck the fluid level at installation. The level ischecked by looking at the fluid level sight tube lo-cated on the end bell.

If the sump is properly filled, the fluid level shouldcover 1/4 to 1/2 of the level range during operation.With the compressor shut down, the level should be3/4 of the sight tube. DO NOT overfill.

2.6 MOTOR ROTATION DIRECTION CHECKAfter the electrical wiring has been done, it is neces-sary to check the direction of the motor rotation.Pull out the EMERGENCY STOP button and pressonce, quickly and in succession, the (START) I and(STOP) O pads. This action will bump start the mo-tor for a very short time. When looking at the motorfrom the control panel side, view the coupling bylooking through the air inlet duct on the lower side ofthe adapter fan housing. The coupling should beturning clockwise. If the reversed rotation is noted,disconnect the power to the starter and exchangeany two of the three power input leads, then re--check rotation. A “Direction of Rotation” decal is lo-cated on the motor and cooler shroud to show prop-er motor/compressor rotation.

2.7 ELECTRICAL PREPARATIONInterior electrical wiring is performed at the factory.Required customer wiring is minimal, but should bedone by a qualified electrician in compliance with

Figure 2--1 Service Air Piping

BY -- PASSVALVES*SHUT -- OFF VALVE

(GATE VALVERECOMMENDED)

MOISTURESEPARATORAND TRAP

DRYER(OPTIONAL)

TRAPMOISTUREDRAIN**

WATERLEG**

AIR OUTLETS(NEVER TAKE AIR

FROMBOTTOM OF PIPE)

*REQUIRED ONLY WHEN COMPRESSOR IS INSTALLED WITH AN AIR DRYER.**REQUIRED FOR COMPRESSOR INSTALLATION WITHOUT AN AIR DRYER.

FROMCOMPRESSOR

5

Page 12: COMPRESOR SULLAIR

Section 2INSTALLATION

6

OSHA, National Electrical Code, and/or any otherapplicable State, Federal and local electrical codesconcerning isolation switches, fused disconnects,etc. Sullair provides a wiring diagram for use by theinstaller.

NOTE

Customer must provide electrical supply powerdisconnect within sight of machine.

A few electrical checks should be made to help as-sure that the first start--up will be trouble--free.

WARNING!

Lethal shock hazard inside. Disconnect all powerat source before opening or servicing.

1. Check incoming voltage. Be sure that compres-sor is wired for the correct incoming voltage.

2. Check starter for correct size, proper overloadrelay, and heaters.

3. Check all electrical connections for tightness.4. “DRY RUN” the electrical controls by disconnect-

ing the three (3) motor leads from the starter. Pullout the EMERGENCY STOP button on the con-trol panel.

5. Reconnect the motor leads and jog the motor fora dir ec t ion of r ot at ion c hec k as ex plained in S ec -t ion 2. 6.

NOTE

Wiring diagram for standard compressors is sup-plied on the inside cover of the Control Center.Optional compressor wiring diagrams will vary.

Page 13: COMPRESOR SULLAIR

Section 3SPECIFICATIONS

3.1 SPECIFICATIONS-- ES--8

50 Hz KW M3/MIN BAR LENGTH WIDTH HEIGHT WEIGHT dBA (I)MODEL (MM) (MM) (MM) (KG) w/ Encls./

OPEN[ENCL] OPEN[ENCL] OPEN[ENCL] OPEN[ENCL] w/o Encls.--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

15L 11 1.62 6.9 1239 [1524] 852 [914] 763 [1067] 424 [483] 70/8015HH 11 1.34 9.7 1239 [1524] 852 [914] 763 [1067] 424 [483] 70/8015XH 11 1.02 12.1 1239 [1524] 852 [914] 763 [1067] 424 [483] 70/8020L 15 2.29 6.9 1283 [1524] 852 [914] 763 [1067] 455 [513] 73/8320HH 15 1.84 9.7 1283 [1524] 852 [914] 763 [1067] 455 [513] 73/8320XH 15 1.50 12.1 1283 [1524] 852 [914] 763 [1067] 455 [513] 73/8325L 18.5 2.77 6.9 1283 [1524] 852 [914] 763 [1067] 480 [537] 75/8525HH 18.5 2.18 9.7 1283 [1524] 852 [914] 763 [1067] 480 [537] 75/8525XH 18.5 1.78 12.1 1283 [1524] 852 [914] 763 [1067] 480 [537] 75/8530L 22 3.25 6.9 1291 [1524] 852 [914] 763 [1067] 483 [542] 76/8530HH 22 2.72 9.7 1291 [1524] 852 [914] 763 [1067] 483 [542] 76/8530XH 22 2.12 12.1 1291 [1524] 852 [914] 763 [1067] 483 [542] 76/85

60 Hz HP ACFM PSIG LENGTH WIDTH HEIGHT WEIGHT dBA (I)MODEL (IN.) (IN.) (IN.) (LBS.) w/ Encls./

OPEN[ENCL] OPEN[ENCL] OPEN[ENCL] OPEN[ENCL]4 w/o Encls.

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ -- -- -- -- -- -- -- -- -- --15L 15 65 100 49 [60] 34 [42] 30 [36] 935 [1065] 70/8015HH 15 57 125 49 [60] 34 [42] 30 [36] 935 [1065] 70/8015XH 15 41 175 49 [60] 34 [42] 30 [36] 935 [1065] 70/8020H 20 76 125 51 [60] 34 [42] 30 [36] 1002 [1132] 73/8320XH 20 55 175 51 [60] 34 [42] 30 [36] 1002 [1132] 73/8325H 25 94 125 51 [60] 34 [42] 30 [36] 1055 [1185] 77/8525XH 25 75 175 51 [60] 34 [42] 30 [36] 1055 [1185] 77/8530H 30 111 125 51 [60] 34 [42] 30 [36] 1065 [1195] 78/8530XH 30 90 175 51 [60] 34 [42] 30 [36] 1065 [1195] 78/85

(I) Ratings for dBA at one meter.

COMPRESSORType: Single Stage Fluid Injected Screw CompressorMinimum Full Load Operating Pressure: 60 psig (4.2 bar)Maximum Full Load Operating Pressure: Nameplate Pressure (I)Bearing Type: Anti--frictionCooling: Pressurized FluidLubr ic ant : S ee Lubr ic ant S pec if ic at ionSump Capacity: 2.5 gallons (9.46 liters)

(I) Compressors are available for full load pressures up to 175 psig (12.1 bar), and unload pressure 185 psig(12.8 bar).

MOTOR 60Hz 50HzType: ODP, C--Flange ODP, C--FlangeSynchronous Speed: 15 & 20 HP = 1800 RPM 11KW = 1800 RPM

25 & 30 HP = 3600 RPM 18.5KW = 3600 RPMVoltage:

Standard All Sizes: 230/460 380/415Optional All Sizes: 208Optional All Sizes: 575Optional Only:

Type:Insulation Class: B--(Min.) B--(Min.)Maximum Ambient Temp.: 40 C (104 F) 40 C (104 F)

7

Page 14: COMPRESOR SULLAIR

Section 3SPECIFICATIONS

8

FLUID FILTERType: Spin on, Sullair ProprietaryMicron: 23 Microns Abs.Internal Bypass Valve Set at 25 psig (1.7 bar)

FLUID SEPARATOR ELEMENTType: Push In Cartridge, Sullair ProprietaryEfficiency at Maximum Capacity: 5PPM Maximum

3.2 LUBRICATION GUIDEFor best value and longest uninterrupted service,theES--8 compressor is factory filledand testedwitha long life lubricant.

If, due to availability or other reasons, other fluidsare required, follow Lubrication Guide below.

WARNING!

“The Plastic Pipe Institute recommends againstthe use of thermoplastic pipe to transport com-pressed air or other compressedgases inexposedabove ground locations, e.g. in exposed plant pip-ing.” (I)

Sullube should not be used with PVC piping sys-tems. It may affect the bond at cemented joints.Certain other plastic materials may also be af-fected.

(I) Plastic Pipe Institute, Recommendation B,Adopted January 19, 1972.

Maintenance of all other components is still recom-mended as indicated in the Operator’s Manual.

For light--duty high--humidity service where con-densed moisture and emulsification (mayonnaise)

may occur, the fluid change interval must be re-duced to 300 hours maximum. A non--detergentfluid with rust, oxidation and foam inhibitors andgood water separation characteristics should beused.

WARNING!

Mixing of other lubricantswithin the compressorunit will void all warranties. DO NOT mix fluids.

Contamination of non--detergent mineral fluids withtraces of ATF or detergent motor fluids may lead tooperational problems such as foaming, filter plug-ging, orifice or line plugging.

NOTE

Flush system when switching lubricant brands.

When ambient conditions exceed those noted or ifconditions warrant use of “extended” life lubricantscontact Sullair for recommendation.

Sullair encourages the user to participate in a fluidanalysis program. This could result in a fluid changeinterval that is different from those stated in thismanual.

3.3 LUBRICATION CHANGE RECOMMENDATIONS

AMBIENTTEMPERATURE LUBRICATION

FLUID & FILTER CHANGEPERIOD (HRS.)

--10_F to +90_F Sullube 8000 (I) 8000 (I) 4000 (II)(--23_C to +32_C) Sullair LLL--4--32 8000 (I) 8000 (I) 4000 (II)

SRF 1/4000 4000 4000 4000 (II)

SEPARATOR CHANGEPERIOD (HRS.)

AIR FILTER CHANGEPERIOD (HRS.)

(I) 8.000 Hours or once a year.(II) 4,000 Hours or more frequently if conditions so require.

Table 1- Compressor Lubrication Guide and Maintenance

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Section 3SPECIFICATIONS

9

Figure 3-1 Identification- Standard Model

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Figure 3-2 Identification- Basic Model

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Figure 3-3 Identification- CIS Model

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NOTES

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Section 4COMPRESSOR SYSTEMS

4.1 INTRODUCTIONYour new Sullair flood--lubricated rotary screw aircompressor will provide youwith improved reliabilityand greatly reduced maintenance.

Compared with other types of compressors, theSullair rotary screw is unique in mechanical reliabil-ity, with “nowear” and “no inspection” required of theworking parts within the compressor unit.

Read Section 7 (Maintenance) to keep your com-pressor in topoperating condition. Should any ques-tions arise which cannot be answered in the follow-ing text, call your nearest Sullair office or the SullairCorporation Service Department.

4.2 DESCRIPTION OF COMPONENTSRef er t o F igur e 4 -- 1. T he c om ponent s and as s em -blies of the ES--8 Series air compressor are clearlyshown. The complete compressor consists of anencapsulated compressor system, inlet sys-tem, cooling system, control system and super-visor control system.

The compact design of the ES--8 Series air com-pressor provides easy access to all serviceablecomponents.

4.3 ENCAPSULATED COMPRESSOR SYSTEM,FUNCTIONAL DESCRIPTIONRef er t o F igur e 4 -- 2. T he enc aps ulat ed c om pr es s orincludes compressor unit, fluid managementsystem, and drive motor. The Sullair compressorunit is a single--stage positive displacement lubri-cated type compressor. This unit is equipped withtapered roller bearings on the discharge and cylin-drical roller bearings on the inlet end for high loadcarrying capacity. This unit provides continuouspulse--free air compression to meet your needs.With a Sullair compressor there will be no mainte-nance or internal inspection of the compressor.

WARNING!

DONOT remove caps, plugs and/or other compo-nents when compressor is running or pressur-ized.

Stop compressor and relieve all internal pressurebefore doing so.

Fluid is injected into the compressor unit in largequantities and mixes directly with the air as the ro-tors turn, compressing the air. The fluid flow hasthree main functions:1. As coolant, it controls the rise of air temperature

normally associated with the heat of compres-sion.

2. It seals the leakage paths between the rotors andthe stator and also between the rotors them-selves.

3. It acts as a lubricating film between the rotors al-lowing one rotor to directly drive the other, whichis an idler.

The air/fluidmixture discharges directly into the fluidmanagement system.

The fluid cooler bypass valve helps assure propercooling by directing the fluid to the fluid cooler whendischarge temperature reaches the thermostat tem-perature setting.

During start--up in cool ambient conditions, the cool-er pressure drop may cause the filter bypass valveto open up, assuring adequate fluid supply to thecompressor.

All fluid entering the compressor unit passesthrough the replaceable fluid filter element. This re-placeable filter element contains a built--in bypassvalve. Under conditions of restricted flow throughthe element, the bypass valve helps ensure ade-quate compressor fluid flow, as well as helps pre-vent element failure.

FLUID MANAGEMENT SYSTEMThe Fluid Management System consists of a multi--chambered primary/secondary separator, the finalair/fluid separator element, cooler bypass and fluidfilter.

As compressed air/fluid enters the sump, the firstfluid separation takes place due to a reduction offlow speed coupled with a change of direction of theflow within the sump housing. The compressed airreaches the separator and the finest fluid drops andmist are separated.The minimum pressure/discharge check valve ismounted on the compressor drive housing. Its func-tions are as follows:1. Maintains a minimum sump pressure of 60 psig

(4.2 bar) under full load operation to help assureadequate fluid pressure.

2. Acts as a check valve to isolate the compressorfrom the system at shutdown or unload.

DRIVE MOTORThe Drive Motor consists of a squirrel cage induc-tionmotorwhich is connected to the integrateddrivegearing by a drive coupling.

4.4 COMPRESSOR COOLING SYSTEM, FUNC-TIONAL DESCRIPTIONThe Compressor Cooling System consists of a fluidcooler, fan and cooler shroud.

The fan is mounted on the compressor shaft. Air isdrawn through the motor adaptor by the fan and ex-its through the coolers on top of the compressor.The air provides cooling for compressor fluid andcooling of air on units with air aftercoolers.

4.5 AIR INLET SYSTEM, FUNCTIONAL DE-SCRIPTIONThe compressor inlet system consists of a dry--typeair filter and an air control valve. Reacting on a pres-sure signal, the valve closes the intake for unloadedoperation. The valve also acts as a check valveupon shutdown.

13

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Section 4COMPRESSOR SYSTEMS

1

PRESSURE RELIEFVALVE

AIR/FLUIDSEPARATORACCESS

INLET CONTROLVALVE

FLUIDFILTER

AFTER COOLER

MOTOR

AIRFILTER

FLUID COOLERMOISTURESEPARATOR

COOLINGFAN

STANDARDCOMPRESSOR

BASICCOMPRESSOR

Figure 4-1 Description of Components

4

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Section 4COMPRESSOR SYSTEMS

4.6 CONTROL SYSTEM, FUNCTIONAL DE-SCRIPTIONThe purpose of the compressor control system is toregulate the amount of air being compressed tomatch the amount of compressed air being used.The capacity control system consists of a solenoidvalve, regulator valve and an inlet valve. Thefunctional description of the control system is de-scribed below in 4 distinct phases of operation. Thefollowing description text applies to all Series ES--8compressors. For explanatory purposes, this de-scription will apply to a compressor with an operat-ing range of 100 to 110 psig (6.9 to 7.6 bar). A com-pressor with any other pressure range would oper-ate in the same manner except stated pressures.

START MODE -- 0 TO 60 PSIG (0 TO 4.2 bar)When the compressor “I” pad is depressed, thesump pressurewill quickly rise from 0 to 60 psig (0 --4.2 bar). During this period, both the pressure regu-lator and the solenoid valve are closed, the inletvalve is fully open and the compressor pumps at fullrated capacity. The rising compressor air pressureis isolated from the service line in this phase by theminimum pressure valve set at approximately 60

psig (4.2 bar).

FULL LOADMODE -- 60 TO 100 PSIG (4.2 TO 6.9bar)When the compressed air pressure rises above 60psig (4.2 bar), the minimum pressure valve opensallowing compressed air to flow into the service line.From this point on, the line air pressure is continuallymonitored by the Supervisor. The pressure regula-tor and the solenoid valve remain closed during thisphase. The inlet valve is in the fully open position aslong as the compressor is running at 100 psig (6.9bar) or below.

MODULATINGMODE -- 100 TO 110 PSIG (6.9 TO7.6 bar)If less than the rated capacity of compressed air isbeing used, the service line pressure will rise above100 psig (6.9 bar). The pressure regulator valvegradually opens, directing air pressure to the inletcontrol valve, reducing air entering the compressoruntil it matches the amount of air being used. Thecontrol system functions continually in this mannerbetween the limits of 100 to 110 psig (6.9 to 7.6 bar)in response to varying demands from the serviceline.

FLUID

AIR/FLUID

AIR

AIR/FLUIDSEPARATOR

COMPRESSORUNIT

FLUID

MOTOR

INTAKEAIR

INLET CONTROLVALVE

COOLINGFAN

Figure 4-2 Encapsulated Compressor System

15

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16

The pressure regulator has an orifice which vents asmall amount of air to the atmosphere when thepressure regulator controls the inlet control valve.The orifice also bleeds any accumulated moisturefrom the pressure regulator.

UNLOAD MODE -- IN EXCESS OF 110 PSIG (7.6bar)When a relatively small amount or no air is beingused, the service line pressure continues to rise.When it exceeds 110 psig (7.6 bar), the SupervisorControl System de--energizes the solenoid valve al-lowing sump air pressure to be supplied directly toclose the inlet valve. Simultaneously, the solenoidvalve sends a pneumatic signal to the blowdownvalve. The blowdown valve opens the sump to theatmosphere, reducing the sumppressure toapprox-imately 20 to 30 psig (1.4 to 2.1 bar). The checkvalve in the air service line prevents line pressurefrom returning to the sump.

When the line pressure drops to the lowsetting (cut--in pressure; usually 100 psig [6.9 bar] on low pres-sure [“L”] compressors and 125 psig [8.6 bar] onhigh pressure [“HH”] compressors, 175 psig [12.1bar] on [“XH”] compressors), Supervisor energizesthe solenoid valve and allows the blowdown valve toclose. The re--energized solenoid valve again pre-vents line pressure from reaching the inlet controlvalve. Should the pressure begin to rise, the pres-sure regulatorwill resume its normal function as pre-viously described.

AUTOMATIC OPERATIONFor applications with varied periods of time whenthere are no air requirements, Supervisor’s AUTO-MATIC mode allows the compressor to shutdown(time delayed) when no compressed air require-ment is present and restart as compressed air isneeded.

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NOTES

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Section 5SUPERVISOR II

18

MESSAGE DISPLAY SYSTEM GRAPHIC DISPLAY

KEYPADS

Figure 5-1 Supervisor II Panel

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Section 5SUPERVISOR II

5.1 INTRODUCTION

Refer to Figure 5--1. The Supervisor II has a two linedisplay to show temperature, pressure and status. Ithas a keypad for operating the compressor, pro-gramming the control points and selecting displays.There is a graphic illustration with lamps that light toshow the item being displayed. The lamps flash ifthat component is in an alarm condition.

5.2 KEYPAD

Thekeypad is used to control themachineaswell asdisplay status and change setpoints. Refer to figure2--1 for following key descriptions.

SSSSStop -- Used to put themachine intomanu-al stop. It is also used to clear alarm condi-tions.

OSSSS Continuous -- Starts machine if no alarmconditions are present. Also used to clearalarm conditions while machine is running.

ISSSS Auto -- Starts machine and selects automode if no alarm conditions are present.Also used to clear alarm conditions whilemachine is running.

SSSS Display -- Used to display pressures, tem-peratures andother status information (Seesection on STATUS DISPLAYS).

DSP

SSSS Logo -- Used for various functions de-scribed in later sections

SSSS Program -- Used to enter the parameterchange mode where control parametersmay be displayed and changed (See PA-RAMETER SETUP).

PRG

SSSS Up arrow -- Used in status displays to

change displays and in parameter setupmode to increment a value.

SSSS Down arrow, lamp test -- Used in statusdisplays to change displays and in parame-ter setup mode to increment a value. Whenin the default display the key will light all thelamps for three seconds.

5.3 STATUS DISPLAYS

By default the line pressure (P2) and discharge tem-perature (T1) are shown on the bottom line of thedisplay, and machine status on the top line.The following are the various machine status mes-sages that indicate the state of the compressor withLCD graphics listed below:

SSSS STOP -- Compressor is off.

SSSS STANDBY -- Compressor is off but armedto start. This state may be entered becauseof a power up, or the unload timer had ex-pired and stopped the machine. NOTE :The machine may start at any time.

SSSS STARTING -- Machine is trying to start.

SSSS OFF LOAD -- Machine is running and offloaded.

SSSS ON LOAD -- Machine is running andloaded.

SSSS FULL LD -- Machine is running and fullyloaded. This state is only displayed if themachine has a full load valve.

SSSSRMT STOP -- Compressor is off but armedto start. The machine will start when the re-mote start contact is closed. NOTE : themachine may start at any time.

SSSS SEQ STOP -- Compressor is off but armedto start. The machinewill start when the se-quencing conditions meet the criteria tostart. NOTE : the machine may start at anytime.

This default display appears as follows:

STOP110 180

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If there are alarms active they will alternately beshown with the default display. The machine statuswill be displayed for 2 seconds, then thealarms for 2seconds each. For example:

T1 HI110 180

To view other status press the DISPLY key. All tem-peratures and pressures may be displayed as wellas other status information. To scroll through thedis-plays press the up arrow or down arrow keys. Up ar-row moves to the next display, down arrow the pre-vious display. To return to the default display pressthe display key.

SSSS Separator differential pressure and themaximum limit. If the limit is exceeded, aseparator maintenance warning will be dis-played.

dP 1 4MAX 10

SSSS Sump pressure and line pressure.

P1 113P2 108

SSSS Unit discharge temperature and the maxi-mum limit. If the temperature exceeds thelimit a T1 HI shutdown will occur.

T1 210MAX 235

SSSS Total hours that the compressor has beenrunning.

HRS RUN001234.0

SSSS Total hours that the compressor has beenloaded.

HRS LOAD000987.0

SSSSLast fault log. This shows the fault on thefirst line and the runhourswhen the fault oc-curred.

T1 HI@1 234

SSSSNext to last fault log. This shows the fault onthe first line and the runhourswhen the faultoccurred.

T1 HI@2 204

5.4 LAMP INDICATORS

Embedded into the front panel schematic of thecompressor are several lamps. Pressing the lamptest key will light all the lamps for 3 seconds. EachLED lamp has the following purpose.

P1 -- If lit steady, signifies that P1 is being displayed,if flashing denotes the presence of an alarm.

P2 -- If lit steady, signifies that P2 is being displayed,if flashing denotes the presence of an alarm.

dP1 -- If lit steady, signifies that dP1 is being dis-played, if flashing denotes replacement of separatoris needed.

T1 -- If lit steady, signifies that T1 is being displayed,if flashing denotes the presence of an alarm.

MOTOR -- If flashing, indicates the motor overloadcontact has opened.

POWER ON -- Lit if 120VAC power is applied to theSupervisor II.

ON -- If lit steady, the compressor is running. If flash-ing, indicates that the compressor is armed butstopped because of restart timer not expired, re-mote stop or sequence stop. The compressor maystart at any time.

AUTO -- If lit steady, the compressor is running andin automode. If flashing, indicates that the compres-sor is armed but stopped because of restart timernot expired, remote stop or sequence stop. Thecompressor may start at any time.

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SUPERVISOR II

6.1 INTRODUCTION

While Sullair has built into this compressor a com-prehensive array of controls and indicators to as-sure you that it is operating properly, youwill want torecognizeand interpret the readingwhichwill call forservice or indicate the beginning of a malfunction.Before starting your Sullair compressor, read thissection thoroughly and familiarize yourself with thecontrols and indicators -- their purpose, location anduse.

6.2 STANDARD PARAMETER SETUPPressing the program key enters parameter displayand edit mode. Tomove to thenext parameter pressthe program key. To increment a parameter pressthe up arrow key or logo key. The logo key will incre-ment by 10. To decrement the value press the downarrow key.Theparameters are displayed in the followingorder:

SSSS Unload pressure -- The pressure wherethe machine is unloaded. For example ifthis parameter is set to 110 psi themachinewill unload when the line pressure is above110 psi.

UNLOAD100 PSI

SSSSLoad differential -- The pressure differen-tial below the unload pressure where themachine is loaded. For example, if the un-load pressure is set to 110 and the load dif-ferential is set to 10, the machine will loadwhen the line pressure goes below 100 psi.

LOAD10 PSI

SSSS P1 Max -- Maximum sump pressure. Analarm and shut down will occur when thesump pressure rises above this pressure.

P1 MAX135 PSI

SSSS Wye to delta transition timer -- For fullvoltage starters this parameter is set to 0.

WYE DELT10 SEC

SSSS Restart time -- Time to wait after power upbefore starting machine. This parameter isused to keep several machines from start-ing at the same time after power up, or todelay start until other equipment is started.If disabled themachinewill not automatical-

ly start after power up.

RST TIME10 SEC

SSSSUnloadStopTimer -- If themachine is run-ning in AUTO mode, this parameter speci-fies the amount of time that themachinewillrun unloaded before shutting off. If the timeis set less than 15minutes (for example fiveminutes), there may be times when thema-chine will run unloaded for more than fiveminutes. This is because there is anothertimer that keeps the machine from beingstarted more than four times an hour.

UNLD TIM15 MIN

SSSS Language select -- English, German,Spanish, Italian and French may be se-lected for display language.

LANGUAGEENGLISH

SSSS Units -- English or metric units may be se-lected.

UNITSENGLISH

SSSS Communications ID # -- This is the net-work address of a machine. If there is morethan one machine connected to the net-work, each machine must have a uniquenumber.

COM ID #1

SSSS Communications baud rate -- Thisshould always be selected to 9600 baud forall sequencing modes. It may be lower forslave or monitoring modes.

BAUDRATE9600

6.3 SEQUENCING PARAMETERS SETUPThe following parameters are only available on de-luxe model Supervisor II.

SSSS Sequence method -- This parameter setsthe method used for sequencing. Thechoices are DISABLED, REMOTE,SLAVE, HOURS, COM ID#. See the Se-quencing & Protocol Manual (See Recom-

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22

mended Spare Parts List) for details aboutthese modes.

SEQUENCEHOURS

SSSS Drain interval -- The time between actua-tion of the drain valve.

DRN INTV10 MIN

SSSS Drain time -- The amount of time that thedrain valve is actuated.

DRN TIM1 SEC

SSSS Last Communication Number -- Usedonly for sequencing, see Sequencing &Protocol Manual for details.

LAST COM3

SSSS Lowest Allowable Pressure -- Used onlyfor sequencing, see Sequencing & ProtocolManual for details.

LOWEST90 PSI

SSSS Recovery Time -- Used only for sequenc-ing, see Sequencing & Protocol Manual fordetails.

RECOVER10 SEC

SSSS Rotate Time -- Used only for sequencing,see Sequencing & Protocol Manual for de-tails.

ROTATE50

SSSS Machine Capacity -- Used only for se-quencing, see Sequencing & ProtocolManual for details (not implemented).

CAPACITY100

SSSS Sequence Hours -- Used only for se-quencing, see Sequencing & Protocol

Manual for details.

SEQ HRS1000

6.4 OPERATING THE COMPRESSORBefore operating the compressor the operating pa-rameters must be setup. See the previous sectionon operating parameter setup.MANUAL OPERATION MODEIn this mode the compressor will run indefinitely, aslong as temperatures and pressure remain withinthe valid operating ranges, and the motor overloador emergency stop contacts are not tripped. Press-ing the “I” will turn on the compressor and put it inmanual mode. If the compressor is already running,but in automatic mode, pressing “I” will switch op-eration tomanual. Pressing “I” while already runningin manual mode will cause the Supervisor to turn offthe common fault relay, if engaged, and clear anymaintenance indicators.To stop the compressor, press “O” If the compres-sor is already off when “O” is pressed, the commonfault relay will be turned off, if engaged, and it will tryto clear the alarm and maintenance indicators. Re-gardless of what the compressor is doing, pressing“O” puts the Supervisor in manual stop mode.AUTOMATIC OPERATION MODEIn thismode the compressorwill start if line pressure(P2) is less than the LOAD parameter. It will stop ifthe compressor runs unloaded for the number ofminutes indicated by the UNLD TIM parameter. Toput the compressor in automatic modepress “ ”. IfP2 is already less than LOAD the compressor willstart immediately, otherwise the system status willindicate STANDBY and the LEDmarked AUTO willflash.If the compressor is already running, but in continu-ous mode, pressing “ ” will switch operation to au-tomatic. Pressing “ ” while already running in auto-matic mode will cause the Supervisor to turn off thecommon fault relay, if engaged, and clear anymain-tenance indicators.In automatic mode the compressor can be stoppedmanually by pressing “O” Stopping the compressorusing “O” will put the Supervisor in manual stopmode.Regardless of whether in “automatic” or “manual”mode, control of the load solenoid will be based onthe parametersUNLD and LOAD. This operation isas follows:P2 > UNLD ----> load solenoid turned offP2 < LOAD ----> load solenoid turned on

POWER FAILURE RESTARTIf the restart timer (RST TIME parameter) is dis-abled the compressor will not try to start after a pow-er up. If this time is set to a value themachine will gointo standby after power up. When the line pressuredrops below the load setpoint, the restart timer will

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Section 6COMPRESSOR OPERATION--

SUPERVISOR II

start timing.When the timer expires themachinewillstart.

SEQUENCING MODESThe following is a brief description of sequencingmodes. For details see the Supervisor II Sequenc-ing & Protocol Manual (See Recommended SpareParts List).

SSSSDISABLED -- Responds to status and pa-rameter change messages via the RS485network but will not respond to start, stop,load or unload messages.

SSSS REMOTE -- Responds to status and pa-rameter change messages but will not re-spond to start, stop, load or unload mes-

sages. The remote inputs and outputs areenabled (start/stop, load/unload,master/lo-cal).

SSSSSLAVE -- Will respond to all messages, butwill not start or load unless commanded todo so by a message. This mode is used tocontrol the machine from amaster comput-er.

SSSS HOURS -- Sends status message aboutonce a second; starts, loads and unloadsmachines based on sequencing hours.

SSSSCOM ID # -- Sends status message aboutonce a second; starts, loads and unloadsmachines based on machine Com ID#.

6.5 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE

EMERGENCY STOP SWITCH Pushing in this switch, found adjacent to the Supervi-sor, cuts all AC outputs from the latter and de--ener-gizes the starter. A fault message (E STOP) is dis-played by the Supervisor until the button is pulled outand the “O” pad is depressed.

MINIMUM PRESSURE/CHECK VALVE Maintains a minimum of 60 psig (4.2 bar) in compres-sor sump. Valve piston restricts receiver air dischargefrom receiver/sumpwhen pressure falls to 60 psig (4.2bar). Also incorporated in this valve is a terminal checkvalve which prevents line pressure backflow into thesump during unload conditions and after shutdown.

DISCHARGE TEMPERATURE PROBE Shuts the compressor downwhen the compressor dis-charge temperature exceeds 235 F (113 C). Continu-ally monitors discharge temperature of the compres-sor.

PRESSURE RELIEF VALVE Opens sump pressure to the atmosphere if pressureinside the sump become too high.

Operation of this valve indicates that the pressure reg-ulator is either faulty or out of adjustment and that theSupervisor II Controller is not offloadingdue to improp-er setting or malfunctioning transducers.

SOLENOID VALVE Closes the inlet valve and activates blowdown valve tovent sump pressure to the atmosphere during unloadconditions and shutdowns.

PRESSURE REGULATOR Controls the intake valve position to control compres-sor output. The regulator stays closed up to a presetpressure and then opens to provide a rising controlpressure to the inlet control valve as output pressureincreases.

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6.6 SUPERVISOR OUTPUT RELAYS

RELAY OPERATION

RUN RELAY (K1) Contact closure energizes the compressor starter.*--DELTA (K2) A timed contact used to provide wye--delta transition

time.UNLOAD/LOAD (K3) Controls ON LOAD/OFF LOAD operation of the load

control solenoid valve.COMMON FAULT (K4) May be used to provide remote indication of any pre--

alarm, maintenance or fault shutdown condition.DRAIN VALVE (K5) Controls a solenoid valve to provide automatic con-

densate removal.FULL LOAD/MODULATE (K6) Used with sequencing feature.

NOTE: All output relays will handle 8 amps at 120/240 VAC.

6.7 INITIAL START--UP PROCEDUREThe followingprocedure should beused tomake theinitial start--up of the compressor.1. Read the preceding pages of this manual thor-

oughly.2. Jog motor to check for correct rotation of fan (re-

fer to Section 2.6).3. Be sure that all preparations and checks de-

scribed in the Installation Section have beenmade.

4. Open the shut--off valve to the service line.5. Check for possible leaks in piping.7. Slowly close the shut--off valve to assure proper

nameplate pressure unload setting is correct.The compressor will unload at nameplate pres-sure. If adjustments are necessary, see ControlSystem Adjustments.

7. Observe theoperating temperature. If the operat-ing temperature exceeds 200 F (93 C), the cool-ing system and installation environment shouldbe checked.

8. Open shut--off valve to the service line.9. Reinspect the compressor for temperature and

leaks the following day.

6.8 SUBSEQUENT START--UP PROCEDUREOnsubsequent start--ups, check that the proper lev-el is visible in the fluid level sight glass and simplypress “I” for manual or “ ” for automatic operation.When the compressor is running, observe the vari-ous parameter displays.

6.9 SHUTDOWN PROCEDURETo shut the compressor down, push “O” pad.

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Section 7COMPRESSOR OPERATION-

ELECTRO-MECHANICAL

Figure 7-1 Instrument Panel Group

TEMPERATUREGAUGE

PRESSUREGAUGE

HOURMETER

“POWER”INDICATOR

(RED)

“ON”INDICATOR(GREEN)

START/RUN/STOPSWITCH

7.1 INTRODUCTIONRefer to Figure 7--1. The instrumentation for theES--8 Series air compressors consists of a panelgroup which continually monitors the operatingcondition of the compressor. The standard panelgroup has the following gauges: A discharge tem-perature gauge, a line pressure gauge and anhourmeter.

SThe line(terminal) pressuregauge is con-nected to the package discharge port. Itcontinually monitors the air pressure.

SThe discharge temperature gauge/switchmonitors the temperature of the air/fluid mixture discharged from the compres-sor unit. The normal reading should beapproximately 185_F (85_C) with 70_F(21_C) ambient. The switch shuts com-pressor down above 240_F (116_C) dis-charge temperature.

SThe hourmeter records the cumulativehours of operation for the compressor. It isuseful for planning and logging service op-erations. The hourmeter is located in thedoor of the control box.

While Sullair has built into this compressor a com-prehensive array of controls and indicators to as-sure you that it is operating properly, youwill want torecognizeand interpret the readingwhichwill call forservice or indicate the beginning of a malfunction.Before starting your Sullair compressor, read thissection thoroughly and familiarize yourself with thecontrols and indicators -- their purpose, location and

use.

7.2 PURPOSE OF CONTROLS- ELECTRO-MECHANICAL

CONTROL OR INDICATOR PURPOSE

START/RUN/STOP START/RUN -- Turn switch momentarily to “I” STARTposition to start the compressor, upon release the switchwill return to the RUN position.

STOP -- Turn switch to “O” STOP position to stop com-pressor.

HOURMETER Records cumulative hours of compressor operation;useful for planning and logging service schedules.

LINE PRESSURE GAUGE Continually monitors service line air pressure.

DISCHARGE TEMPERATURE GAUGE/SWITCH Monitors temperature of the air/fluid mixture dis-charged from the compressor unit. For air--cooledcompressors normal reading is approximately 185_F(85_C ) with a 70_F (21_C) ambient temperature. Theswitch shuts the compressor down when dischargetemperature goes above 240_F (116_C).

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26

7.2 PURPOSE OF CONTROLS-- ELECTRO-MECHANICAL (CONTINUED)

CONTROL OR INDICATOR PURPOSE

PRESSURE REGULATOR Opens a pressure line between the sump and air inletvalve allowing the inlet valve to regulate air delivery ac-cording to demand.

COOLER BYPASS VALVE Regulates flow of fluid to and around the cooler.Designed to maintain a minimum operatingtemperature of 180_F (82_C); used for fastwarm--up on start--up.

MINIMUM PRESSURE/CHECK VALVE Maintainsminimumof 60psig (4.1 bar) in thecompres-sor sump. Valve piston restricts receiver air dischargefrom receiver/sumpwhen pressure falls to 60 psig (4.1bar). Also incorporated in this valve is a terminal checkvalve which prevents line pressure backflow into thesump during unload conditions and after shutdown.

PRESSURE RELIEF VALVE Protects compressor by venting compressed air in ex-cess of 200 psig (13.8 bar) to atmosphere.

MODULATING INLET VALVE Regulates the amount of air allowed to enter the aircompressor. This regulation is determined by theamount of air being used at the service line. Also actsas a check valve to prevent reverse compressor rota-tion at shut down.

SOLENOID VALVE Bypasses the pressure regulator valve causing the in-let valve to close when the compressor reachesmaxi-mum operating pressure. Also activates blowdownvalve.

PRESSURE SWITCH Senses service line pressure. When line pressurereaches maximum setting the pressure switch signalsthe solenoid valve to unload the compressor.

BLOWDOWN VALVE Vents sump pressure to theatmosphere duringunloadconditions and shutdown.

7.3 INITIAL START--UP PROCEDUREThe followingprocedure should beused tomake theinitial start--up of the compressor:

1. Read the preceding pages of this manual thor-oughly.

2. Be sure that all preparations and checks de-scribed in the Installation section have beenmade.

3. Crack open the shut off valve to the service line.4. Start the compressor by turning theSTART/RUN/

STOP selector switch to the “I” (START) positionmomentarily and release..

5. Check for possible leaks in piping.6. Slowly close the shut--off valve and check that the

setting on the pressure switch is set correctly. Ifset correctly, the compressor will unload at thedesired unload pressure. If adjustments are nec-essary, see Control System Adjustments in theMaintenance Section of the manual.

7. Observe theoperating temperature. If the operat-ing temperature exceeds 200_F (93_C), thecooling system or installation environmentshould be checked.

8. Observe maintenance indicators.9. Open shut--off valve to service line.10. Re--inspect the compressor for temperature and

leaks the following day.

7.4 SUBSEQUENT START--UP PROCEDUREOnsubsequent start--ups, check that the proper lev-el is visible in the fluid sight glass and turn theSTART/RUN/STOP selector switch to the “I”STARTpositionmomentarily and release.When thecompressor is running, observe the instrument pan-el and maintenance indicators.

7.5 SHUTDOWN PROCEDURETo shut the compressor down, simply turn the selec-tor switch to the “O” STOP position.

Page 33: COMPRESOR SULLAIR

Section 8MAINTENANCE

* Replacement Element Kit P/N 02250050-602

FLUID FILTERELEMENT*

Figure 8-1 Fluid Filter (P/N 250026-982)

8.1 INTRODUCTION

WARNING!

Before doing compressor maintenance, discon-nect compressor frompower source and lockoutpower source. Isolate compressor from line pres-sure by closing recommended discharge shut--off valve and releasing all internal pressure fromcompressor.

As youproceed in reading this section, it will be easyto see that themaintenanceprogram for theair com-pressor is quite minimal. The Supervisor monitorsthe status of the separator element. When mainte-nance to this device is required, the Supervisor willdisplay the appropriate maintenance message andflash the location LED on the graphics map as avisual reminder. See instructions for each item inSection 8.6, Parts Replacement and Adjustmentprocedures.

WARNING!

DO NOT remove caps, plugs, and/or other com-ponents when compressor is running or pressur-ized.

Stop compressor and relieve all internal pressurebefore doing so.

8.2 DAILY OPERATIONPrior to starting the compressor, it is necessary tocheck the fluid level in the sump. Should the level below, simply add the necessary amount. If the addi-tion of fluid becomes too frequent, a minor problemhas developed which is causing this excessive loss.See the Troubleshooting Section under ExcessiveFluid Consumption for a probable cause and reme-dy.

After a routine start has beenmade, a general checkof the overall compressor should bemade to assurethat the compressor is running properly.

8.3 MOTOR BEARING LUBRICATION

WARNING!

Before doing compressor maintenance, discon-nect compressor frompower source and lockoutpower source. Isolate compressor from line pres-sure by closing recommended discharge shut--off valve and releasing all internal pressure fromcompressor.

AMBIENTTEMPERATURE LUBRICATION

FLUID & FILTERPERIOD (H

--10_F to +90_F Sullube 8000(--23_C to +32_C) Sullair LLL--4--32 8000

SRF 1/4000 4000D--A Torque Fluid 1000

(I) 8.000 Hours or once a year.(II) 4,000 Hours or more frequently if conditions so require.

Table 1- Compressor Lubrication Guide and Maintenance

See motor manufacturer’s lubrication instructions.

8.4 FLUID FILTER MAINTENANCE

WARNING!

Fluid filter has internal bypass. DO NOT SUBSTI-TUTE.

Refer to figure 8-1 and 8-2. Replace the fluid filterelement under any of the following conditions:1. As recommended in the Lubrication Guide in the

Specification Section.2. Every fluid change.

8.5 COOLER MAINTENANCEIf cooler becomes restricted, use standard spray de-greaser/cleaner and brush to clean cooler. Use airpressure to blow cooler clean. Care must be takenas not to damage cooler fins.

WARNING!

Before doing compressor maintenance, discon-nect compressor frompower source and lockoutpower source. Isolate compressor from line pres-sure by closing recommended discharge shut--off valve and releasing all internal pressure fromcompressor.

27

CHANGERS.)(I) 8000 (I) 4000 (II)(I) 8000 (I) 4000 (II)

4000 4000 (II)1000 4000 (II)

SEPARATOR CHANGEPERIOD (HRS.)

AIR FILTER CHANGEPERIOD (HRS.)

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Section 8MAINTENANCE

28

Figure 8-2 Oil Fill Port Location

CONTROL BOX-RIGHT SIDE

8.6 PARTS REPLACEMENT AND ADJUSTMENTPROCEDURES

WARNING!

Before doing compressor maintenance, discon-nect compressor frompower source and lockout

power source. Isolate compressor from line pres-

* Replacement Element Kit P/N 043334

F igur e 8 -3 A ir F ilt er - S t andar d M odel ( 02250107-327)

sure by closing recommended discharge shut--off valve and releasing all internal pressure fromcompressor.

RELIEF VALVECheck the relief valve at least weekly to see that it isfunctional. DO NOT tamper with the preset factorypressure setting of the valve. DO NOT plug thevalve for any reason; should it leak, have it replaced.

FLUID FILTER REPLACEMENTRefer to Figures 8-1 and 8-2.1. To prevent spillage and loss of reusable fluid,

place a contaminate--free fluid receptacle be-neath fluid drain valve and fluid filter.

2. Drain fluid by removing fluid drain valve cap at teelocated beneath compressor (for complete fluidchange, drain fluid from cooler).

3. Using a strap wrench, remove the old elementand gasket.

4. Clean gasket seating surface.5. Apply a light film of fluid to the new gasket.6. Hand tighten new element until gasket is seated.7. Continue tightening element an additional 1/2 to

3/4 turn.8. Replace fluid. DO NOT OVERFILL.9. Restart compressor and check for leaks.

AIR FILTER MAINTENANCE-STANDARDMOD-ELRefer to Figure 8--3. Air filter (P/N 043333) mainte-nance should be performed every 6months or morefrequent if conditions so require.

WARNING!

Before doing compressor maintenance, discon-nect compressor frompower source and lockoutpower source. Isolate compressor from line pres-

Page 35: COMPRESOR SULLAIR

Section 8MAINTENANCE

*Replacement Element P/N 02250094---135

FILTERBASE

FILTERELEMENT*

PRE--FILTERELEMENT

COVER

WINGNUT

WASHER

Figure 8-4 Air Filter- Basic Model (02250069-934)

CAP

O-- RING*

Figure 8-5 Separator Element

sure by closing recommended discharge shut--off valve and releasing all internal pressure fromcompressor.

ELEMENT INSPECTION- STANDARD MODEL1. Place a bright light inside the element to inspect

for damage or leak holes. Concentrated light willshine through the element and locate any holes.

2. Inspect all gaskets and gasket contact surfacesof the housing. Should faulty gaskets be evident,correct the condition immediately.

3. If the clean element is to be stored for later use, itmust be stored in a clean container.

4. After the element has been installed, inspect andtighten (if necessary) all air inlet connectionsprior to resuming operation.

AIR FILTER ELEMENT REMOVAL- STANDARDMODEL1. Clean the exterior of the air filter housing.2. Remove the dust cap by loosening the securing

wingnut.3. Pull element from body.4. Clean the interior of the body by using a damp

cloth. DO NOT use compressed air to removethe dirt.

5. Inspect the element; replace with new element ifnecessary.

6. Re--position element into the body.7. Replace dust cap.8. Replace wingnut.9. Clean inside of dust cap.

*Repair Kit P/N 02250106-791

O-- RING*

SEPARATORELEMENT*

AIR FILTER MAINTENANCE- BASIC MODELRefer to Figure 8--4. Air filter (P/N 02250069--934)maintenance should be performed every 6 monthsor more frequent if conditions so require.

ELEMENT INSPECTION- BASIC MODEL1. Place a bright light inside the element to inspect

for damage or leak holes. Concentrated light willshine through the element and locate any holes.

2. If the clean element is to be stored for later use, itmust be stored in a clean container.

AIR FILTER ELEMENT REMOVAL- BASICMOD-EL1. Clean the exterior of the filter base and cover.2. Loosen/remove the wingnut, washer and cover.3. Remove element shield and element.4. Clean filter base with a damp cloth. DO NOT use

compressed air to remove the dirt.4. Inspect the element; replace with new element if

necessary.5. Position element and pre--filter element in place.6. Position cover over pre--filter element.7. Reinstate washer and wingnut; tighten to secure.

SEPARATOR ELEMENT REPLACEMENTRefer to Figure 8--5. The separator should bechanged once a year. Follow the procedure ex-plained below for element replacement.

WARNING!

Before doing compressor maintenance, discon-nect compressor frompower source and lockoutpower source. Isolate compressor from line pres-sure by closing recommended discharge shut--off valve and releasing all internal pressure fromcompressor.

1. Insert a 100mmmaximum length, 6mmdiameterpin into the radially drilled hole in the separatorcap. Loosen, unscrew counterclockwise and re-move the cap.

2. Pull out the old element by gripping the end of theelement with channel lock pliers or a similar tool.

3. Install new o--rings on separator cap and separa-tor element filter and oil lightly to make installa-tion easier.

4. Insert and push the new element in place.5. Reinstall the cap. Hand tighten using a 100mm

maximum length, 6mmdiameter pin in the radial-ly drilled hole.

DRIVE COUPLING INSTALLATIONRefer to Figure 8--6. For coupling installation thetools required will be one set of metric Allen

29

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Section 8MAINTENANCE

30

24mm

FLEXIBLEELEMENT

FLANGEHUB

FLANGEHUB

Figure 8-6 Hub Separation

wrenches. All ES--8 compressors are flange--mounted to the motor making them self--aligning,eliminating the need for alignment procedures.Proper hub separation is shown in Figure 8--6.

* Repair Kit P/N 02250050--614

VALVE STEM

CHECKSPRING

PISTONSPRING

PISTON

O-- RING*

O-- RING*

COVER

SCREW

Figure 8-7 Inlet Control Valve

INLET CONTROL VALVERefer to Figure 8--7. The inlet control valve normalmaintenance requires only the replacement of theo--rings. Use repair kit no. 02250050--614 and fol-low theprocedurebelow for proper disassemblyandassembly procedures.

WARNING!

Before doing compressor maintenance, discon-nect compressor frompower source and lockoutpower source. Isolate compressor from line pres-sure by closing recommended discharge shut--off valve and releasing all internal pressure fromcompressor.

WARNING!

Assure that line pressure gauge on compressorindicates “ZERO” pressure before any work isdone. Failure to comply can cause injury.

1. Remove the two (2) rear access panels whichcover the inlet valve assembly.

2. Identify and tag the plastic lines connected to theblowdown valve and disconnect.

3. Remove the 3 capscrews from the inlet valvecover.

4. Remove cover (with blowdown valve attached)and o--rings.

5. Remove piston, piston spring, check spring andvalve stem.

6. Inspect and clean all parts.7. Assemble valve stem, check spring, piston

spring and piston into inlet valve housing.8. Lubricate new o--rings and install the inner and

outer o--rings onto cover.9. Position cover in inlet valve housing and install

capscrews. Tighten capscrews to 6 ft.--lbs.(8.1Nm).

10. Reconnect the plastic lines to the appropriate fit-tings on the valve.

11. Assemble two (2) rear access panels on thecompressor.

12. Start compressor and check for leaks.

CONTROL SYSTEM ADJUSTMENT- ELEC-TRO-MECHANICALRefer to Figure 8--8. Prior to adjusting the ControlSystem, it is necessary to determine the desiredop-erating pressure range and also themaximum pres-sure at which your compressor is to operate. Thepressure must not exceed the maximum operatingpressurewhich is stamped on the compressor serialnumber nameplate. The following explanation ap-plies to a typical installation with a desired operatingrange of 100 to 110 psig (6.9 to 7.6 bar). This in-formation will apply to a compressor with any otheroperating range excepting the stated pressures.Remove the cover of the pressure switch. With theshut--off valve closed (or slightly cracked open)start the compressor. Observe the line pressuregauge and pressure switch contacts. When the linepressure reaches 110 psig (7.6 bar), the pressureswitch contacts should open. If the pressure switch

Page 37: COMPRESOR SULLAIR

Section 8MAINTENANCE

Figure 8-8 Pressure Switch (P/N 040694)

contacts do not open or they open prior to the de-sired pressure, the pressure switch setting will re-quire adjustment.

FOR PRESSURE RANGE ADJUSTMENT:1. Remove cover to pressure switch.2. Turn the range adjusting screw to the high pres-

sure setting. Turning the screwcounterclockwiselowers both the high and low pressure equally.

FOR DIFFERENTIAL ADJUSTMENT:Differential is the difference between the high andlow pressure settings. 10 psig (0.7 bar) is typical.1. Turn the differential adjusting screw to the lower

(reset) setting. Turning the screw counterclock-wise widens the differential by lowering the reset(lower) setting only.

2. When the pressure switch adjustment is com-plete, the pressure regulator should be adjustedfor the pressure at which modulation of air deliv-ery should begin. In this case that pressure willbe 103 psig (7.1 bar). The regulator is adjustedby loosening the jam nut on the end of the coneshaped cover of the pressure regulator. Whenthe jam nut is loose, turn the adjusting screwclockwise to increase or counterclockwise to de-crease the setting.

3. To set the regulator, continue closing the servicevalve, until the line pressure is 103 psig (7.1 bar).At this point regulator should pass a signal to theinlet valve to start closing it. If the line pressurekeeps on rising or if the modulation does not be-gin, adjust the regulator valve as describedabove. After adjustment line pressure should beapproximately 103 psig (7.1 bar) and 1.00 in. Hgvacuum below the inlet.

4. Now close the service valve, line pressure willstart rising. When line pressure reaches 110psig. (7.6 bar), the inlet valve will be closed to itsmaximum position. The inlet vacuum at this pointwill be around 25 in. Hg. Themachine should un-load at this point.

5. Open the service valve so the line pressure is 100psig (6.9 bar). Machine is now set for operation.Recheck the unload pressure by closing of theservice valve. Machine should unload via thepressure switch at 110 psig (7.6bar).

31

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Section 8MAINTENANCE

8.7 MAINTENANCE RECORD

MODEL NO. SERIAL NO.

DATE HOURMETER MAINTENANCEPERFORMED BY

AUTHORIZEDBY

WORK PERFORMED

32

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Section 9TROUBLESHOOTING

9.1 INTRODUCTIONThe information contained in the Troubleshootingchart is based upon both the actual applied situa-tions and extensive testing at the factory. It containssymptoms and usual causes for the describedprob-lems. However DO NOT assume that these are theonly problems that may occur. All available dataconcerning the trouble should be systematicallyanalyzed before undertaking any repair or compo-nent replacement procedures.

A detailed visual inspection is worth performing for

almost any problems which may prevent unneces-sary damage to the compressor. Always rememberto:a.Check for loose wiring.b.Check for damaged piping.c.Check for parts damaged by heat or an electrical

hort circuit, usually apparent by discoloration or aburnt odor.

Should your problem persist after making the rec-ommended check, consult your nearest Sullair rep-resentative or the Sullair Corporation factory.

9.2 TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE REMEDY

T1 HI Message Discharge Temperature Exceeded225_F (107_C) for Pre--Alarm

Discharge Temperature Exceeded235_F (113_C) for Shutdown

Ambient temperature exceeded Improve local ventilation (i.e.,105_F (41_C) remote intake of process and/or

cooling air.

Fluid Level in Sump is Too Low Check/correct fluid level.

Thermal Valve Malfunctioned Check/replace thermal valve.

Cooler Fins are Dirty Clean cooler fins.

Water Flow is Low (water--cooled Check cooling water supply (i.e.,packages only) closed valves).

Water Temperature is High (water-- Increase water flow, lower watercooled packages only) temperature.

Cooler is Plugged (water--cooled Clean tubes and/or shell -- if tubepackages only) plugging persists, provide cleaner

water.

Temperature RTD Malfunction Check connections from RTD.If adequate, replace RTD.

P1 HI Message Discharge Pressure ExceededShutdown Level Because:

P1 MAX--3psi (0.2 Bar) Exceededfor Pre--Alarm

P1 MAX Exceeded for Shutdown

Unloading Device (i.e., Blowdown Check operation of unloading device.Valve, Sullicon Actuator, OptionalSpiral Valve) Failed to Operate

Pressure Regulator Maladjusted Check operation of pressure regulator.

Solenoid Valve Failed Check operation of solenoid valve.to Operate

Control Air Signal Leaks Check tubework feeding controlsignal for leaks.

Control Air Signal Filter Clogged Service filter assembly.

SEP MNTN Message Plugged Separator Replace separator elements.

dP1 > 10 psi Check P1 & P2 pressure transducers.

P1, P2, P3 FAIL Pressure Transducer Malfunction Check connections from transducer.If connections are good, replace transducer.

33

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Section 9TROUBLESHOOTING

34

9.2 TROUBLESHOOTING (CONTINUED)

SYMPTOM PROBABLE CAUSE REMEDY

COMPRESSOR DOES NOT Air Demand Exceeds Supply Check air service lines for openBUILD FULL DISCHARGE valves or leaks.PRESSURE

Inlet Air Filter Clogged Check for maintenance messageon Supervisor display. Inspect and/orchange element.

Inlet Valve Not Fully Open Check actuation and butterfly discposition.

Pressure Sensor and/or Connections Check connections from trans--at Fault ducer. If adequate, replace trans--

ducer.

LINE PRESSURE RISES ABOVE Pressure Sensor P2 at Fault Check connections from trans--UNLOAD SETTING ducer. If adequate, replace

transducer.Unloading Device (i.e., Blowdown Check operation of unloading device.Valve, Sullicon Actuator, OptionalSpiral Valve) Failed to Operate

LINE PRESSURE RISES ABOVE Solenoid Valve Failed Check operation of solenoidUNLOAD SETTING to Operate valve.

Control Air Signal Leaks Check tubework feeding controlsignal for leaks.

Control Air Signal Filter Clogged Service filter assembly.

EXCESSIVE FLUID CONSUMPTION Clogged Return Line Strainer or Clean strainer -- screen and o--ringOrifice replacement kit available. Clean

orifice.Damaged or Improperly Gasketed Inspect separator elements andSeparator Elements gaskets. Replace if damaged.Fluid System Leaks Check tube/pipework for leaks.Fluid Level Too High Drain excess fluid.Excessive Fluid Foaming Drain and change fluid.

NOTE ON TRANSDUCERS:Whenever a sensor is suspected of fault, the recom-mended cause of action is to measure the signal(pressure, temperature, etc.) with an alternate cali-brated instrument and compare readings. If read-ings conflict, the electrical and/or tubing connec-tions should be inspected, and if no faults are evi-dent, then replace the sensor and re--evaluateagainst the calibrated instrument.

9.3 CALIBRATIONThe Supervisor II has software calibration of thepressure and temperature probes. This calibrationaffects the offset but not the slope of the pressureand temperature calculations. Because of this, themost accurate method is to heat or pressurize thetransducer to its operating value. If this is too diffi-cult, room temperature/open atmosphere calibra-tion is adequate. Calibrationmay only be donewhilemachine is stopped and unarmed.

To enter calibration mode, you must press the fol-lowing keys in sequence while in the default status

display mode: “ ”, “Y”, “B ”, PRG. Once incalibration mode, you will see a screen like the fol-lowing:

CAL P1970

In theaboveexample, “0” refers to theamount of ad-justment (in psi or _F, “97” refers to the current valueof P1).To make adjustments, Press the “Y” (UP ARROW)key to increase the value, press the “B ” (DOWNARROW / LAMP TEST) key to decrease the value.The number on the left will increase or decrease al-ways showing the total amount of adjustment.Maxi-mum adjustment is 7.

The DSP key exits, wiping out changes to the cur-rent item, while saving changes to any previousitems. The PRG key saves the current item and ad-vances to the next. All temperatures and pressuresmay be calibrated individually.

Page 41: COMPRESOR SULLAIR

35

NOTES

Page 42: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

36

ES--8 COMPRESSOR ASSEMBLY, EXPLODED VIEW

90_ ELBOW

MINIMUMPRESSUREVALVE TEE

TO SOLENOIDVALVE INLET

FLUID FILLPLUG

TO P1SUMP PRESSURE

FLUID DRAINCAP

TO FLUIDCOOLERINLET

TO FLUIDCOOLEROUTLET

TO SOLENOIDVALVE OUTLET

TO BLOWDOWNVALVE

TOAFTERCOOLER

INLET

TO AIRPRESSUREREGULATOROUTLET

TO BLOWDOWN

Page 43: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.1 PROCEDURE FOR ORDERING PARTSParts should be ordered from the nearest Sullair Representative or the Representative from whom the compres-sor/dryer was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly atthe addresses, phone or fax numbers below.

When ordering parts always indicate the Serial Number of the compressor/dryer. This can be obtained from theBill of Lading for the compressor/dryer or from the Serial Number Plate located on the compressor/dryer.

The genuine Sullair service parts listed meet or exceed the demands of this compressor. Use of replacementparts other than those approved by Sullair Corporation may lead to hazardous conditions over which Sullair Cor-poration has no control. Such conditions include, but are not limited to, bodily injury and compressor fail-ure.

SULLAIR CORPORATION3700 East Michigan Boulevard

Michigan City, Indiana 46360 U.S.A.

SULLAIR ASIA, LTD.Sullair Road, No. 1Chiwan, Shekou

Shenzhen, Guangdong PRV.PRC POST CODE 518068

SULLAIR EUROPE, S.A.Zone Des Granges BP 82

42602 Montbrison Cedex, France

Telephone: 755-6851686Fax: 755-6853473

Telephone: 33-477968470Fax: 33-477968499

Telephone: 1-219-879-5451Fax: (219) 874-1273

Fax: (219) 874-1835 (Parts)Fax: (219) 874-1288 (Service)

10.2 RECOMMENDED SPARE PARTS LIST

DESCRIPTION KIT NUMBER QUANTITY

repair kit for fluid filter 250026--982 02250050-602 1repair kit for air/fluid separator 02250106--791 1repair kit for air filter 02250107-327 043334 1repair kit for shaft seal 02250061--961 1tool kit, shaft seal 001932--005 1replacement element for thermal valve 045764 1replacement kit for coil 250028--809 250028--387 1repair kit for pressure regulator valve 250017--280 250019--435 1repair kit for inlet control valve 02250050--614 1replacement coil for solenoid valve 250030--164 250035--292 1repair kit for soleniod valve 250030--164 250038--849 1repair kit for minimum pressure/check valve 02250050--612 1repair kits for separator filter 02250052--689

Sauto drain kit 250031-245 2Ssight glass kit 250024--295 2So--ring kit 02250056--270 2

repair kit for MPF filter 250024--361 250024--427 1replacement element for coupling 250042--728 02250048--344 1fluid, Sullube (five gallons) 250022--669 1manual, Sequencing & Protocol (I) 02250057--696 1

(I) This document is required to program your personal computer to communicate with the Supervisor II panel.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

37

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Section 10ILLUSTRATIONS AND PARTS LIST

10.3 INLET CONTROL, SEAL/DRIVE GEAR AND PARTS

38

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Section 10ILLUSTRATIONS AND PARTS LIST

10.3 INLET CONTROL, SEAL/DRIVE GEAR AND PARTS

key partnumber description number quantity

1 housing, drive 02250045--827 12 screw, flat hd M6 x 12MM 865006--012 13 washer 02250048--229 14 seat, minimum pressure valve (I) 02250047--162 15 stem, minimum pressure valve 02250047--163 16 spring, minimum pressure valve (I) 02250047--296 17 piston, minimum pressure valve 02250048--908 18 o--ring, viton 1 1/4” x 3/32” (I) 826502--124 19 spring, minimum pressure valve 02250047--161 110 cap, minimum pressure valve 250035--587 111 elbow, 90 M 1/4” x 1/4” 250025--850 112 elbow, 45 37FL 1.312” 02250046--908 113 hose, medium pressure 1” x 11.25” 02250107--919 114 o--ring viton 3 1/4” x 3/32” (II) 826502--152 115 bearing 499080--206 116 gear consult factory 117 shaft, input 02250050--540 118 key, 10 x 8 x 70 865210--070 119 housing, cover drive 02250055--887 120 bearing 499080--210 121 o--ring, viton 3 1/4” x 3/32” (II) 826502--152 122 seal (II) 02250048--316 123 shim, set 3.5 x 3.0 220645 124 cover, shaft seal 250035--254 125 capscrew, M8 x 20MM 829308--020 726 hose, nylon 1/4” 02250054--861 5 ft.27 tee, swivel 1/4” x 1/4” 250025--835 128 cover, inlet control 02250119--254 129 o--ring, viton 3 1/8” x 1/8” 826502--235 130 o--ring, viton 2” x 1/8” 826502--226 131 piston, inlet valve 02250048--909 132 spring, inlet piston 250042--087 1

(Continued on page 41)

(I) For maintenance on minimum pressure valve, order kit no. 02250050--612 (Note: Items not sold separately).

(II) For maintenance on ES--8 shaft seal, order tool kit part numbers 02250061--961 and 001932--005.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

39

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Section 10ILLUSTRATIONS AND PARTS LIST

40

10.3 INLET CONTROL, SEAL/DRIVE GEAR AND PARTS

Page 47: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.3 INLET CONTROL, SEAL/DRIVE GEAR AND PARTS (CONTINUED)

key partnumber description number quantity

33 spring, inlet check 250042--088 134 stem, inlet valve 250035--584 135 element, thermal valve 045764 136 isolator, vibration 02250047--047 237 valve, shuttle 1/4” 408893 138 nipple, pipe 1/4” x close 823204--000 239 sleeve, wear (II) 02250048--317 140 screw, sltd ft point 250042--203 141 screw, socket M12 x 30MM 829312--030 8

(II) For maintenance on ES--8 shaft seal, order tool kit part numbers 02250061--961 and 001932--005.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

41

Page 48: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.4 MOTOR, COUPLING, FAN AND PARTS

42

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Section 10ILLUSTRATIONS AND PARTS LIST

10.4 MOTOR, COUPLING, FAN AND PARTS

key partnumber description number quantity

1 support, motor(15, 20, 25 HP/11, 15, 18.5 KW) 02250046--622 1Ssupport, motor (30 HP/22 KW) 02250046--624 1

2 capscrew, M12 x 30MM 829312--030 43 housing, adaptor motor

(15, 20, 25 HP/11, 15, 18.5 KW) 02250045--831 1Shousing, adaptor motor (30 HP/22 KW) 02250045--833 1

4 capscrew, hex GR8 1/2”--13 x 1 1/4” 829408--125 45 guard, fan 02250055--600 16 coupling, 1 5/8” (I) 250042--728 17 venturi, fan inlet (15, 20 HP/11, 15 KW) 02250050--241 1

Sventuri, fan inlet (25, 30 HP/18.5, 22 KW) 02250046--603 18 fan, backward inclined wheel

(15, 25, 30 HP/11, 15, 18.5 KW) (I) 02250050--539 1Sfan, backward inclined wheel(20 HP/15 KW) (I) 02250050--240 1

9 housing, fan 02250045--829 110 key, 10 x 8 x 40 865210--040 111 motor consult factory 112 screw, socket M12 x 40MM 829312--040 613 washer, 12MM 865712--370 214 nut, M12 x 1.75 825912--175 215 washer, 8MM 865408--170 116 capscrew, 8MM x 16MM 828008--016 117 washer, 12MM 865712--370 118 nut, hex M12 x 1.75 825912--175 119 isolator, vibration 75MM x 50MM 02250047--047 120 elbow, 45 liq--tite 1 1/4” (not shown) 846500--125 121 washer, conduit red. 1 1/2”--1” (not shown) 847006--040 222 spacer, shaft

(15, 20, 25 HP/11, 15, 18.5 KW) 02250049--354 1Sspacer, shaft (30 HP/22 KW) 02250049--159 1

23 angle, support cooler 02250046--915 124 insert, 6MM 02250047--083 1

(I) Pre--heating required before assembly. For maintenance, order element no. 02250048--344.

43

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

Page 50: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.5 INLET FILTER, COMPRESSOR HOUSING/SUMP AND PARTS- STANDARD

44

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Section 10ILLUSTRATIONS AND PARTS LIST

10.5 INLET FILTER, COMPRESSOR HOUSING/SUMP AND PARTS- STANDARD

key partnumber description number quantity

1 filter, air cyclopac 6 1/2” (I) 02250107--327 12 band, mounting 6 1/2” 043370 23 capscrew, M6 x 16MM 828006--016 44 washer, 6MM 865406--125 45 reducer, hose 2 1/2” x 2 1/4” 049779 16 clamp, hose 250018--550 27 elbow, rubber 90 2 1/2” 1 piece 02250048--321 18 valve, pressure relief 1/2” (200 psi/13.8 bar) 250006--938 19 nipple, air intake 02250047--425 110 hose, nylon (black) 842215--004 311 tee, branch swivel 1/4”T x 1/8”NPT 250025--834 112 plug, oil fill hex 250039--359 113 screw, drive #8 x 3/8” 839608--060 214 elbow, 90 1/8”NPT x 1/4”T 250025--849 115 plate, identification 250026--859 116 capscrew, socket M16 x 70MM 829316--070 117 hsg, inlet plate E08E 02250055--933 118 connector, tube 3/4” 811812-106 219 capscrew, socket M16 x 60MM 829316--060 420 adapter, oil filter 250025--914 121 element, fluid filter (II) 250026--982 122 washer, 8MM 865408--170 323 capscrew, socket M8 x 60MM 839308--060 324 tube, oil drain extension 02250046--999 125 tee, tube 3/4” 811412--075 126 probe, rtd 02250048--457 127 plug, oil 02250093--566 128 capscrew, M16 x 100MM 829316--100 1629 housing, bell 250034--035 130 elbow, 90 1/4” x 1/4” 250025--850 231 bushing, reducing 1/2” x 1/8” 807102--005 132 fitting, compression 250028--635 133 o--ring, viton 3 1/8” x 1/8” (III) 826502--235 1

(Continued on page 47)

(I) For maintenance on air filter no. 02250107--327, order repair kit no. 043334.

(II) For maintenance on fluid filter no. 250026--982, order repair kit no. 02250050--602.

(III) For maintenance on air/fluid separator, order repair kit no. 02250106--791.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

45

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Section 10ILLUSTRATIONS AND PARTS LIST

46

10.5 INLET FILTER, COMPRESSOR HOUSING/SUMP AND PARTS- STANDARD

Page 53: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.5 INLET FILTER, COMPRESSOR HOUSING/SUMP AND PARTS- STANDARD (CONTINUED)

key partnumber description number quantity

34 cap, separator element 250035---590 135 o--ring, viton 1 7/16” x 3/32” (III) 826502--127 136 element, separator (III) 02250106--789 137 plug, push--lok 1/4” tube 02250052--477 138 decal, fluid level see decal section 139 bail lifting 02250054--858 140 plug, 1/2”--14 x M20 02250054--857 141 nut, hex M20 thin 02250055--630 142 tee, swivel 250025--835 143 hose, nylon (white) 02250054--860 0.83 ft

(III) For maintenance on air/fluid separator, order repair kit no. 02250106--791.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

47

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Section 10ILLUSTRATIONS AND PARTS LIST

10.6 INLET FILTER, COMPRESSOR HOUSING/SUMP AND PARTS- BASIC

TO BLOWDOWN90_ ELBOW

TO SOLENOIDVALVE INLET

FLUID FILLPLUG

MINIMUMPRESSUREVALVE TEE

A

B

FLUID DRAINCAP

2

3

4

5

67

8 910

11

12

1314

15

1216

17

18

19202122

23

24

2526 27

28

2930

31

32

33

6

1

48

Page 55: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.6 INLET FILTER, COMPRESSOR HOUSING/SUMP AND PARTS- BASIC

key partnumber description number quantity

1 filter, air (I) 02250069--934 12 tee, branch swivel 1/4”T x 1/8”NPT 250025--834 13 hose, nylon 842215--004 34 washer, 8MM 865408--170 35 plug, oil fill hex 250039--359 16 plug, push--lok 1/4” tube 02250052--477 27 elbow, 90_ 1/8”NPT x 1/4”T 250025--849 18 plate, identification 250026--859 19 screw, drive #8 x 3/8” 839608--060 210 capscrew, socket M16 x 70MM 829316--070 111 housing, inlet plate 02250055--933 112 connector, tube 3/4” 02250048--819 213 capscrew, socket M16 x 60MM 829316--060 214 adapter, oil filter 250025--914 115 element, fluid filter (II) 250026--982 116 tube, oil drain extension 02250046--999 117 tee, tube 3/4” 811412--075 118 cap, tube 3/4” 250042--615 119 capscrew, M16 x 100MM 829316--100 1620 housing, bell 250034--035 121 decal, fluid level see decal section 122 elbow, 90_ 1/4” x 1/4” 250025--850 323 sender, temperature gauge 02250069--626 124 nut, hex M20 thin 02250055--630 125 bail, lifting 02250054--858 126 plug, 1/2”--14 x M20 02250054--857 127 tee, swivel 02250025--835 128 valve, pressure relief 1/2” (200 PSI) 250006--938 129 cap, separator element 250035--590 130 o--ring, viton 3 1/8” x 1/8” 826502--235 131 element, separator (III) 02250106--789 132 o--ring, viton 1 7/16” x 3/32” 826502--127 133 capscrew, socket M8 x 60MM 839308--060 3

(I) For maintenance on air filter, order repair kit no. 02250094--135.

(II) For maintenance on fluid filter, order repair kit no. 02250050--602.

(III) For maintenance on separator element, order repair kit no. 02250106--791.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR/DRYER.

49

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Section 10ILLUSTRATIONS AND PARTS LIST

50

10.7 COMPRESSOR COOLER SYSTEM AND PARTS

51 286

10

1226

A

C13

1420

23

321

25

1

2

4

27

1126

24B

16

1

25

18

1125

1

1

2515 15

7

119

22

17

3

17

251

1

19

3

8 37

9

15

TO PRESSURE SWITCHLINE PRESSURE

CHECKVALVETEE

AIRPRESSUREREGULATOR

PRESSURESWITCH

Page 57: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.7 COMPRESSOR COOLER SYSTEM AND PARTS

key partnumber description number quantity

1 insert, threaded blind 6MM 02250047--083 202 aftercooler 250040--092 13 capscrew, M6 x 12MM 829306--012 104 cooler, oil (15,20 HP) 250039--096 1

Scooler, oil (25,30 HP) 02250086--812 15 nipple, pipe 3/4” x 2” 823112--020 16 filter, air/separator/trap (I) 02250052--689 17 washer, 8MM 865408--170 78 cover, access 02250046--910 19 capscrew, 8M x 16MM 829308--016 610 elbow, tube 3/4” 02250048--820 111 washer, 6MM 865706--180 812 tube, oil in 02250047--245 113 hose, medium pressure 1” x 11.25” 02250107--919 114 elbow, 90_ 37FL 02250048--094 115 angle, support cooler 02250046--915 516 tube, oil out 02250047--244 117 grommet, rubber 040125 218 support, cooler (15,20 HP) 02250045--567 1

Ssupport, cooler (25,30 HP) 02250048--302 119 cover, end coler support 02250046--911 120 cover, access cooler support 02250048--123 121 washer, 6MM 865406--125 222 capscrew, hex 6M x 16MM 828006--016 423 elbow, 90_ swivel 1/8” NPT 250025--849 124 connector, straight thd 02250048--819 125 weatherstrip, 1/2” x 1” (ft) 245738 5.526 foam, cooler oil/air 02250052--480 227 capscrew, M6 x 20MM 829306--020 828 foam, cooler after 02250052--481 1

(I) For maintenance on air/separator trap filter no. 02250052--689, order:Sauto drain kit 250022--965 2Ssight glass kit 250024--295 2So--ring kit 02250056--270 2

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

51

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Section 10ILLUSTRATIONS AND PARTS LIST

10.8 CONTROL BOX AND PARTS- SUPERVISOR II

52

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Section 10ILLUSTRATIONS AND PARTS LIST

10.8 CONTROL BOX AND PARTS- SUPERVISOR II

key partnumber description number quantity

1 hose, nylon 1/4” 842215--004 15 ft2 elbow, 90 1/4” x 1/4” 250025--850 23 valve, pressure regulator (I) 250017--280 14 nipple, pipe 1/4” x close 823204--015 35 tee, pipe 1/4” 804415--010 16 washer, 8MM 865408--170 27 control, supervisor panel 02250071--542 18 elbow, 90 1/8” NPT x 1/4” tube 250025--849 49 bulkhead, pipe 1/8” 841500--002 210 transducer, pressure 0--200# 250039--910 211 valve, solenoid 500 psi (II) 250030--164 112 locknut, conduit 1/2” 847200--050 113 bushing, conduit plastic 1/2” 847815--050 114 support, control box 02250046--914 115 nut, hex M6 x 1.0 825906--100 416 isolator, vibration 25MM OD x 10MM wide 02250046--958 217 conduit, flex 1” 846315--100 1.2 ft18 wire, #8 black (varies with motor size) 850210--008 7.5 ft19 valve, blowdown 1/4” 02250049--634 120 silencer, 1/4” 044916 121 bulkhead, pipe 1/4” 841500--004 122 gasket, panel 02250048--822 123 operator, push/pull 250028--588 124 contact, black 250027--125 125 starter, assembly consult factory 126 connector, cord grip 250023--496 127 decal, super 2 (III) 02250073--285 128 foam, air regulator 02250052--482 129 grommet 02250047--178 230 spacer 02250047--177 231 capscrew, M6 x 20MM 829306--020 2

(Continued on page 55)

(I) For maintenance on pressure regular valve no. 250017--280, order repair kit no. 250019--453.

(II) For maintenance on valve no. 250030--164, order repair kit no. 250038--849 and replacement coil no.250035--292.

(III) This item is included with panel control no. 02250071-542 (see key number 7 above).

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

53

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Section 10ILLUSTRATIONS AND PARTS LIST

54

10.8 CONTROL BOX AND PARTS- SUPERVISOR II

Page 61: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.8 CONTROL BOX AND PARTS- SUPERVISOR II (CONTINUED)

key partnumber description number quantity

32 capscrew, socket M8 x 16MM 829308--016 233 connector, straight lq--tite 846400--100 134 nut, hex M4 x 0.7 (IV) 825904--070 835 washer, springlock M4 (IV) 838804--090 836 washer, springlock 6MM 838806--160 437 washer, pl xl ISO 7094--6--100HV 02250048--229 238 washer, ISO 7093--12--140HV 865712--370 2

(IV) This item is part of kit no. 02250051--535 and no. 02250051--536 (deluxe). To obtain this part please consultfactory.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

55

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Section 10ILLUSTRATIONS AND PARTS LIST

10.9 CONTROL BOX AND PARTS- ELECTRO-MECHANICAL

15

14

3432 6

17

18

16

33

15

34

8 11

81223

29

30

26

OUTLET

INLET

31

27

1

2

3

21

1

219 20

4

45

421

21

INLET

OUTLET

BLOWDOWNVALVE

TO MINIMUMPRESSUREVALVE TEE

TO CHECKVALVE TEE

TO INLETVALVE

2

25

1

1

12712 10

23

22

1 24189

9

1213

LINEPRESSURE

TO PRESSUREGAUGE

56

Page 63: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.9 CONTROL BOX AND PARTS- ELECTRO-MECHANICAL

key partnumber description number quantity

1 hose, nylon 1/4” 842215---004 15 ft2 elbow, 90_1/4” x 1/4” 250025--850 33 valve, pressure regulator 250017--280 14 nipple, pipe 1/4” x close 823204--015 35 tee, pipe 1/4” 804415--0106 washer, 8MM 865408--170 27 nipple, conduit8 elbow, 90_ 1/8” NPT x 1/4” tube 250025--849 49 bulkhead, pipe 1/8” 841500--002 210 elbow, corner pull 1/2” 846915--050 111 valve, solenoid 500 PSI 250030--164 112 locknut, conduit 1/2” 847200--050 113 bushing, conduit plastic 1/2” 847815--050 114 support, control box 02250046--914 115 nut, hex M6 x 1.0 825906--100 416 isolator, vibration 25MM OD x 10MM wide 02250046--958 217 conduit, flex 1” 846315--100 1.2 ft18 wire, #8 black (varies with motor size) 850210--008 7.519 v alv e, blowdown 1/ 4” 02250049- 634 120 silencer, 1/4” 044916 121 bulkhead, pipe 1/4” 841500--004 122 switch, pressure 040694 123 nipple, chase 1/2” 847815--050 124 tee, pipe galv 804415-010 125 starter, assembly consult factory 126 washer 865712--370 227 washer 02250048--229 228 foam, air regulator 02250052--482 129 grommet 02250047--178 230 spacer 02250047--177 231 capscrew, M6 x 20MM 829306--020 232 capscrew, socket M8 x 16MM 829308--016 233 connector, straight lq--tite 846400--100 134 washer, springlock 6MM 838806--160 4

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

57

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Section 10ILLUSTRATIONS AND PARTS LIST

5

10.10 INSTRUMENT PANEL- ELECTRO-MECHANICAL

1

2

34

5

6

7

8

9

10

1112

13

14

8

Page 65: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.10 INSTRUMENT PANEL- ELECTRO-MECHANICAL

key partnumber description number quantity

1 elbow, 90_ 250025---849 12 coupling, pipe 1/8” 803215--005 13 nut, hex metric M4 x .7 825904--070 84 washer, springlock M4 838804--090 85 gasket, panel 02250048--822 16 decal, panel 02250073--411 17 panel, instrument 02250069--058 18 gauge, pressure 250005--185 19 gauge, switch temperature 02250069--626 110 gasket, hourmeter 410353 111 hourmeter 042988 112 light, pilot assy green 250000--104 1

Sholder, lamp 043383 1Slens, green 043385 1Sbulb 043386 1Sgasket, lamp holder 241808 1Sgasket, lens 241809 1

13 light, pilot assy red 250000--103 1Sholder, lamp 043383 1Slens, red 043384 1Sbulb 043386 1Sgasket, lamp holder 241808 1Sgasket, lens 241809 1

14 switch, selector 3 position 02250069--625 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

59

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Section 10ILLUSTRATIONS AND PARTS LIST

6

10.11 ENCLOSURE

1

2

3

3

3

4

4

5

5

5

5

6

6

6

7

78

8

8

8

9

10

1112

13

14

15

16

0

Page 67: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.11 ENCLOSURE

key partnumber description number quantity

1 panel, roof assy 02250115---405 12 plenum 02250056--172 13 screw, hex ser washer 5/16”--18 x 3/4” 829705--075 554 nut, hex flgd 5/16”--18 825305--283 365 panel, center 224585 46 panel, door assy 02250100--067 37 panel, corner LH 224584 28 panel, fiberglass 13” x 36.5” 250020--059 39 panel, corner RH 224583 110 latch 049764 411 trim, canopy edge 250034--157 4 ft12 panel, access control side assy 02250050--301 113 panel, assy 02250056--219 114 panel, oil drip (European only) 02250051--653 115 strip, weather 1” x 1/8” 02250058--345 50 ft16 frame 014790 1

Sframe 02250057---919 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

61

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Section 10ILLUSTRATIONS AND PARTS LIST

10.12 DECAL GROUP

1

2

34

5

67

62

Page 69: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.10 DECAL GROUP

key partnumber description number quantity

1 sign, warning -- compressor fluid fill cap 049685 12 sign, danger electrocution 049850 13 sign, warning -- hot surfaces 407408 14 decal, warning auto start 041065 15 decal, danger breath air 250027--935 16 sign, warning “food grade” lube 250003--144 17 decal, rotation direction 040745 1

(Continued on page 65)

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

63

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Section 10ILLUSTRATIONS AND PARTS LIST

10.12 DECAL GROUP

8

9

10

11

12

13

64

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Section 10ILLUSTRATIONS AND PARTS LIST

10.12 DECAL GROUP (CONTINUED)

key partnumber description number quantity

8 decal, compressor fluid SRF 1/4000 (I) 02250069--391 19 decal, earth ground 02250075--046 2

Sdecal, protective earth ground (not shown) 02250075--045 1Sdecal, PE designation (not shown) 02250075--540 1

10 decal, danger hi voltage 042218 111 sign, warning ground fault 049852 112 decal, ISO 9001 02250059--288 113 decal, warning lift 02250055--510 1

(Continued on page 67)

(I) Decal will change with fluid requirement.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

65

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Section 10ILLUSTRATIONS AND PARTS LIST

10.12 DECAL GROUP

14

15

16

17

18

19

20

66

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Section 10ILLUSTRATIONS AND PARTS LIST

10.12 DECAL GROUP (CONTINUED)

key partnumber description number quantity

14 decal, warning auto start 250017---903 1Sdecal, ES--8 Supervisor II dlx info(not shown) 02250073--940 1

15 decal, fluid level E8E 02250046--871 116 decal, warning mixing fluids 02250110--891 117 decal, ES--8 black 3.5” high 02250059--138 118 decal, 24KT 2.5” (I) 02250061--016 1

j 19 decal, lift (II) 241214 220 decal, Sullair 2 1/4” x 18” black 02250059--052 1

Sdecal, Sullair 3 1/2” x 28” black (encl) 02250059--058 120 decal, ES--8 Supervisor II front

(see Figure 5--1 in Operator’s Section) 02250073--285 121 decal, ES--8 Supervisor II std info

(not shown) 02250073--939 1

(I) Used only on 24KT compressors.

(II) Used on enclosed models.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

67

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Section 10ILLUSTRATIONS AND PARTS LIST

10.13 DECAL LOCATIONS

1

2

34

5

6

7

8

9

10

11

12

13

14

15

16

4

4 17

68

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Section 10ILLUSTRATIONS AND PARTS LIST

10.13 DECAL LOCATIONS (CONTINUED)

key partnumber description number quantity

1 sign, warning “food grade” lube 250003--144 12 decal, danger breath air 250027--935 13 decal, PE designation 02250075--540 14 decal, earth ground 02250075--046 25 decal, danger hi voltage 042218 16 decal, compressor fluid SRF 1/4000 (I) 02250069--391 17 sign, danger electrocution 049850 18 decal, warning auto start 250017--903 19 decal, warning auto start 041065 110 decal, 24KT black 2.5” (II) 02250061--016 111 decal, warning 8E lift 02250055--510 112 decal, Sullair 2 1/4” x 18” black 02250059--052 113 sign, warning -- hot surfaces 407408 114 decal, warning mixing fluids (III) 02250110--891 115 sign, warning -- compressor fluid fill cap 049685 116 decal, ES--8 black 3.5” high 02250059--138 117 sign, warning ground fault 049852 1

(I) Compressor fluids may vary. Consult Sullair to verify the fluid of your compressor if you do not know the fluidtype.

(II) Decal used for 24KT fluid machines only.

(III) Decal is placed at this location for standard machine. For closed inlet machines, consult key no. 18 of thissection.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

69

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Section 10ILLUSTRATIONS AND PARTS LIST

10.13 DECAL LOCATIONS

18

19

20

22

21

70

Page 77: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.13 DECAL LOCATIONS (CONTINUED)

key partnumber description number quantity

18 sign, warning --- hot surfaces 407408 119 decal, warning mixing fluids (IV) 02250110--891 120 sign, warning -- compressor fluid fill cap 049685 121 decal, compressor fluid SRF 1/4000 (V) 02250069--391 122 decal, fluid leve E8E 02250046--871 1

(IV) Decal is placed at this location for closed inlet machine. For standard machines, consult key no. 14 of thissection.

(V)Compressor fluids may vary. Consult Sullair Corporation to verify the fluid fill of your compressor if you do notknow the fluid type.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

71

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Section 10ILLUSTRATIONS AND PARTS LIST

10.14 DECAL LOCATIONS-- ENCLOSURE

1

2

4

5

6

4

3

7

72

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Section 10ILLUSTRATIONS AND PARTS LIST

10.14 DECAL LOCATIONS-- ENCLOSURE

key partnumber description number quantity

1 decal, warning auto start 041065 12 decal, 24KT black 2.5” (I) 02250061--016 13 decal, ES--8 black 3.5” high 02250059--138 14 decal, fork lifting 241814 25 decal, Sullair 3 1/2” x 28” black (encl) 02250059--058 16 decal, danger breath air 250027--935 17 sign, warning “food grade” lube 250003--144 1

(I) Decal used for 24KT fluid machines only.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

73

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Section 10ILLUSTRATIONS AND PARTS LIST

74

10.15 WIRING DIAGRAM -- FULL VOLTAGE ELECTRO-MECHANICAL

Page 81: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.16 WIRING DIAGRAM --FULL VOLTAGE SUPERVISOR II

75

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Section 10ILLUSTRATIONS AND PARTS LIST

76

10.17 WIRING DIAGRAM -- WYE DELTA ELECTRO-MECHANICAL

Page 83: COMPRESOR SULLAIR

Section 10ILLUSTRATIONS AND PARTS LIST

10.18 WIRING DIAGRAM -- WYE DELTA SUPERVISOR II

77

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Section 10ILLUSTRATIONS AND PARTS LIST

78

10.19 WIRING DIAGRAM -- WYE DELTA- EUROPEAN

Page 85: COMPRESOR SULLAIR

NOTES

Page 86: COMPRESOR SULLAIR

Printed in U.S.A.

Specifications Subject ToChange Without Prior Notice

E00EPS

WORLDWIDE SALES AND SERVICE

R

SULLAIR EUROPE, S.A.

SULLAIR CORPORATION3700 East Michigan Boulevard

Michigan City, Indiana 46360 U.S.A.Telephone: 1--219--879--5451

Fax: (219) 874--1273Fax: (219) 874--1835 (Parts)Fax: (219) 874--1288 (Service)

SULLAIR ASIA, LTD.Sullair Road, No. 1Chiwan, Shekou

Shenzhen, Guangdong PRV.PRC POST CODE 518068Telephone: 755--6851686

Fax: 755--6853473

Zone Des Granges BP 8242602 Montbrison Cedex, France

Telephone: 33--477968470Fax: 33--477968499


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