Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
AIR COMPRESSOR
ES--8 Series
Standard and Basic Models
15, 20, 25 and 30 HP
11, 15, 18.5 and 22KW
OPERATOR’S
MANUAL AND
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Part Number 02250117--368
¤Sullair Corporation
AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are 3--day courses that provide hands--on instruction
in the proper operation, maintenance and service of Sullair equipment.
Individual seminars on Industrial compressors and compressor electrical
systems are presented at regular intervals throughout the year at a dedicated
training facility at Sullair’s corporate headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service
parts, troubleshooting of the most common problems, and actual equipment
operation. The seminars are recommended for maintenance and service
personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1--888--SULLAIR or 219--879--5451 (ext. 5363)
-- Or Write --
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
OPERATOR IS REQUIRED TO READ
ENTIRE 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 2
INSTALLATION 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 3
SPECIFICATIONS 7 3.1 SPECIFICATIONS-- ES--8
Section 4
COMPRESSOR
SYSTEMS 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
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 6
COMPRESSOR 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 7
COMPRESSOR 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 8
MAINTENANCE 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
TABLE OF CONTENTS
(CONTINUED)
Section 8
MAINTENANCE (CONT) 30 CONTROL SYSTEM ADJUSTMENT- ELECTRO-MECHANICAL
32 8.7 MAINTENANCE RECORD
Section 9
TROUBLESHOOTING 33 9.1 INTRODUCTION
33 9.2 TROUBLESHOOTING
34 9.3 CALIBRATION
Section 10
ILLUSTRATIONS AND PAGE
PARTS LIST 37 10.1 PROCEDURE FOR ORDERING PARTS
1.1 GENERAL of hose failure, per all applicable Federal, State and
Sullair Corporation and its subsidiaries design and Local codes, standards and regulations.
manufacture all of their products so they can be op-
erated safely. However, the responsibility for safe B. When the hose is to be used to supply a manifold,
operation rests with those who use and maintain install an additional appropriate flow--limiting valve
these products. The following safety precautions between the manifold and each air hose exceeding
are offered as a guide which, if conscientiously fol- 1/2” (13mm) inside diameter that is to be connected
lowed, will minimize the possibility of accidents to the manifold to reduce pressure in case of hose
throughout the useful life of this equipment. failure.
The compressor should be operated only by those C. Provide an appropriate flow--limiting valve at the
who have been trained and delegated to do so, and beginning of each additional 75 feet (23m) of hose in
who have read and understood this Operator’s runs of air hose exceeding 1/2” (13mm) inside diam-
Manual. Failure to follow the instructions, proce- eter to reduce pressure in case of hose failure.
dures and safety precautions in this manual can re-
sult in accidents and injuries. Read this manual prior D. Flow--limiting valves are listed by pipe size and
to startup. rated CFM. Select appropriate valves accordingly,
in accordance with their manufacturer’s recommen-
NEVER start the compressor unless it is safe to do dations.
so. DO NOT attempt to operate the compressor with E. DO NOT use air tools that are rated below the
a known unsafe condition. Tag the compressor and maximum rating of the compressor. Select air tools,
render it inoperative by disconnecting and locking air hoses, pipes, valves, filters, and other fittings ac-
out all power at source or otherwise disabling its cordingly. DO NOT exceed manufacturer’s rated
prime mover, so others who may not know of the un- safe operating pressures for these items.
safe condition, cannot attempt to operate it until the
condition is corrected. F. Secure all hose connections by wire, chain or oth-
er suitable retaining devices to prevent tools or hose
Install, use and operate the compressor only in full ends from being accidentally disconnected and ex-
compliance with all pertinent regulations and all ap- pelled.
plicable Federal, State, and Local codes, standards
and regulations. G. Open fluid filler cap only when compressor is not
running and is not pressurized. Shut down the
DO NOT modify the compressor and/or controls in compressor and bleed the sump (receiver) to zero
any way except with written factory approval. internal pressure before removing the cap.
While not specifically applicable to all types of com- H. Vent all internal pressure prior to opening any
pressors with all types of prime movers, most of the line, fitting, hose, valve, drain plug, connection or
precautionary statements contained herein are ap- other component, such as filters and line oilers, and
plicable to most compressors and the concepts be- before attempting to refill optional air line anti--icer
hind these statements are generally applicable to all systems with antifreeze compound.
compressors.
I. Keep personnel out of line with and away from the
1.2 PERSONAL PROTECTIVE EQUIPMENT discharge opening of hoses or tools or other points
Prior to installing or operating the compressor, own- of compressed air discharge.
ers, employers and users should become familiar J. Use air at pressures less than 30 psig (2.1 bar) for
with, and comply with, all applicable regulations and
any applicable Federal, State and Local codes, cleaning purposes, and then only with effective chip
standards, and regulations relative to personal pro- guarding and personal protective equipment.
tective equipment, such as eye and face protective K. DO NOT engage in horseplay with air hoses as
equipment, respiratory protective equipment, death or serious injury may result.
equipment intended to protect the extremities, pro-
tective clothing, protective shields and barriers and L. DO NOT tamper with sump and unit (if provided)
electrical protective equipment, as well as noise ex- relief valves. Check the relief valve as recom-
posure administrative and/or engineering controls mended in the Maintenance Section of this manual
and/or personal hearing protective equipment. or at a minimum of at least weekly to make sure it is
not blocked, clogged, obstructed or otherwise dis-
1.3 PRESSURE RELEASE abled. DO NOT change the factory setting of the re-
A. Install an appropriate flow--limiting valve between lief valve.
the service air outlet and the shut--off (throttle)
valve, either at the compressor or at any other point M. If the compressor is installed in an enclosed
along the air line, when an air hose exceeding 1/2” area, it is necessary to vent the relief valve to the
(13mm) inside diameter is to be connected to the outside of the structure or to an area of non--expo-
shut--off (throttle) valve, to reduce pressure in case sure.
1
Section 1
SAFETY
2
Section 1
SAFETY
C. Operate the compressor only in open or ade- E. Disconnect, lock out, and tag all power at source
quately ventilated areas. prior to attempting repairs or adjustments to rotating
machinery and prior to handling any ungrounded
D. Locate the compressor or provide a remote inlet conductors.
so that it is not likely to ingest exhaust fumes or other
toxic, noxious or corrosive fumes or substances. F. Dry test all shutdown circuits prior to starting the
compressor after installation.
E. Coolants and lubricants used in this compressor
are typical of the industry. Care should be taken to 1.9 LIFTING
avoid accidental ingestion and/or skin contact. In A. If the compressor is provided with a lifting bail,
the event of ingestion, seek medical treatment then lift by the bail provided. If no bail is provided,
promptly. Wash with soap and water in the event of then lift by sling. Compressors to be air lifted by heli-
skin contact. Consult the compressor operator’s copter must not be supported by the lifting bail but by
manual lubrication section for information pertaining slings instead. In any event, lift and/or handle only in
to compressor fluid fill. full compliance with Federal, State and Local codes.
B. Inspect points of attachment for cracked welds
F. Wear goggles or a full face shield when adding an- and for cracked, bent, corroded or otherwise de-
tifreeze compound to air line anti--icer systems. graded members and for loose bolts or nuts prior to
G. If air line anti--icer system antifreeze compound lifting.
enters the eyes or if fumes irritate the eyes, they C. Make sure entire lifting, rigging and supporting
should be washed with large quantities of clean wa- structure has been inspected, is in good condition
ter for 15 minutes. A physician, preferably an eye and has a rated capacity of at least the weight of the
specialist, should be contacted immediately. compressor. If you are unsure of the weight, then
H. DO NOT store air line anti--icer system antifreeze weigh compressor before lifting.
compound in confined areas. D. Make sure lifting hook has a functional safety
latch or equivalent, and is fully engaged and latched
I. The antifreeze compound used in air line anti- on the bail or slings.
freeze systems contains methanol and is toxic,
harmful, or fatal if swallowed. Avoid contact with the E. Use guide ropes or equivalent to prevent twisting
skin or eyes and avoid breathing the fumes. If swal- or swinging of the compressor once it has been lifted
lowed, induce vomiting by administering a table- clear of the ground.
spoon of salt, in each glass of clean, warm water un- F. DO NOT attempt to lift in high winds.
til vomit is clear, then administer two teaspoons of
baking soda in a glass of clean water. Have patient G. Keep all personnel out from under and away from
lay down and cover eyes to exclude light. Call a phy- the compressor whenever it is suspended.
sician immediately. H. Lift compressor no higher than necessary.
1.8 ELECTRICAL SHOCK I. Keep lift operator in constant attendance whenev-
A. This compressor should be installed and main- er compressor is suspended.
tained in full compliance with all applicable Federal, J. Set compressor down only on a level surface ca-
State and Local codes, standards and regulations, pable of safely supporting at least its weight and its
including those of the National Electrical Code, and loading unit.
also including those relative to equipment grounding
conductors, and only by personnel that are trained, K. When moving compressors by forklift truck, uti-
qualified and delegated to do so. lize fork pockets if provided. Otherwise, utilize pallet
if provided. If neither fork pockets or pallet are pro-
B. Keep all parts of the body and any hand--held vided, then make sure compressor is secure and
tools or other conductive objects away from ex- well balanced on forks before attempting to raise or
posed live parts of electrical system. Maintain dry transport it any significant distance.
footing, stand on insulating surfaces and DO NOT L. Make sure forklift truck forks are fully engaged
contact any other portion of the compressor when and tipped back prior to lifting or transporting the
making adjustments or repairs to exposed live parts compressor.
of the electrical system. Make all such adjustments
or repairs with one hand only, so as to minimize the M. Forklift no higher than necessary to clear ob-
possibility of creating a current path through the stacles at floor level and transport and corner at
heart. minimum practical speeds.
C. Attempt repairs in clean, dry and well lighted and N. Make sure pallet--mounted compressors are
ventilated areas only. firmly bolted or otherwise secured to the pallet prior
to attempting to forklift or transport them. NEVER
D. DO NOT leave the compressor unattended with attempt to forklift a compressor that is not secured to
open electrical enclosures. If necessary to do so, its pallet, as uneven floors or sudden stops may
then disconnect, lock out and tag all power at source cause the compressor to tumble off, possibly caus-
so others will not inadvertently restore power. ing serious injury or property damage in the process.
3
Section 1
SAFETY
O. DO NOT use the lifting eye bolt on the compres- before doing so, or else secure and tag the access
sor motor, if supplied, to lift the entire compressor door in the open position to avoid the possibility of
package. others closing and possibly latching the door with
personnel inside.
1.10 ENTRAPMENT
A. If the compressor enclosure is large enough to
hold a person and if it is necessary to enter it to per- B. Make sure all personnel are out of compressor
form service adjustments, inform other personnel before closing and latching enclosure doors.
4
Section 2
INSTALLATION
2.1 LOCATION OF COMPRESSOR to its drive, the coupling supplied with the compres-
The ES--8 Series compressor package may be sor is always properly aligned for operation. Howev-
placed on any level surface able to support its er, we recommend that you re--check the coupling
weight. The unit is mounted on vibration mounts and gap before start--up or when handling the unit. a 1.5
can be bolted to a fixed mounting surface to avoid to 3mm axial clearance should be maintained for the
the possibility of externally applied forces or vibra- coupling gap.
tion which would disturb the piping or wiring.
2.5 FLUID LEVEL CHECK
2.2 VENTILATION AND COOLING The Sullair air compressor is equipped with the
Select a location to permit sufficient unobstructed proper amount of fluid. However, it is necessary to
air flow in and out of the compressor to keep the op- check the fluid level at installation. The level is
erating temperature stable. The minimum distance checked by looking at the fluid level sight tube lo-
that the machine should be from surrounding walls cated on the end bell.
and ceiling is what is needed for service and three
(3) feet (0.91m) or more from the compressor fluid If the sump is properly filled, the fluid level should
cooler. cover 1/4 to 1/2 of the level range during operation.
With the compressor shut down, the level should be
2.3 SERVICE AIR PIPING 3/4 of the sight tube. DO NOT overfill.
Service air piping should be installed as shown in
Figure 2-- 1. A shut -- off valve should be installed to 2.6 MOTOR ROTATION DIRECTION CHECK
isolate the compressor from the service line. Also After the electrical wiring has been done, it is neces-
notice that the service line should be equipped with sary to check the direction of the motor rotation.
water legs and condensate drains throughout the Pull out the EMERGENCY STOP button and press
system. once, quickly and in succession, the (START) I and
(STOP) O pads. This action will bump start the mo-
! WARNING tor for a very short time. When looking at the motor
from the control panel side, view the coupling by
“The Plastic Pipe Institute recommends against the looking through the air inlet duct on the lower side of
use of thermoplastic pipe to transport compressed the adapter fan housing. The coupling should be
air or other compressed gases in exposed above turning clockwise. If the reversed rotation is noted,
ground locations, e.g. in exposed plant piping.” (I)
disconnect the power to the starter and exchange
Sullube should not be used with PVC piping sys- any two of the three power input leads, then re--
tems. It may affect the bond at cemented joints. Cer- check rotation. A “Direction of Rotation” decal is lo-
tain other plastic materials may also be affected.
cated on the motor and cooler shroud to show prop-
(I) Plastic Pipe Institute, Recommendation B, er motor/compressor rotation.
Adopted January 19, 1972.
2.7 ELECTRICAL PREPARATION
Interior electrical wiring is performed at the factory.
2.4 COUPLING ALIGNMENT CHECK Required customer wiring is minimal, but should be
With the compressor unit directly flange--mounted done by a qualified electrician in compliance with
BY -- PASS
SHUT -- OFF VALVE VALVES*
(GATE VALVE
RECOMMENDED)
WATER
FROM
LEG**
COMPRESSOR DRYER
(OPTIONAL)
5
Section 2
INSTALLATION
OSHA, National Electrical Code, and/or any other 1. Check incoming voltage. Be sure that compres-
applicable State, Federal and local electrical codes sor is wired for the correct incoming voltage.
concerning isolation switches, fused disconnects, 2. Check starter for correct size, proper overload
etc. Sullair provides a wiring diagram for use by the relay, and heaters.
installer. 3. Check all electrical connections for tightness.
4. “DRY RUN” the electrical controls by disconnect-
ing the three (3) motor leads from the starter. Pull
NOTE out the EMERGENCY STOP button on the con-
trol panel.
Customer must provide electrical supply power 5. Reconnect the motor leads and jog the motor for
disconnect within sight of machine. a direction of rotation check as explained in Sec-
tion 2.6.
A few electrical checks should be made to help as-
sure that the first start--up will be trouble--free.
NOTE
! WARNING
Wiring diagram for standard compressors is sup-
Lethal shock hazard inside. Disconnect all power plied on the inside cover of the Control Center.
at source before opening or servicing. Optional compressor wiring diagrams will vary.
6
Section 3
SPECIFICATIONS
COMPRESSOR
Type: Single Stage Fluid Injected Screw Compressor
Minimum Full Load Operating Pressure: 60 psig (4.2 bar)
Maximum Full Load Operating Pressure: Nameplate Pressure (I)
Bearing Type: Anti--friction
Cooling: Pressurized Fluid
Lubricant: See Lubricant Specification
Sump 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).
7
Section 3
SPECIFICATIONS
FLUID FILTER
Type: Spin on, Sullair Proprietary
Micron: 23 Microns Abs.
Internal Bypass Valve Set at 25 psig (1.7 bar)
8
Section 3
SPECIFICATIONS
9
Section 3
SPECIFICATIONS
10
Section 3
SPECIFICATIONS
11
NOTES
12
Section 4
COMPRESSOR SYSTEMS
4.1 INTRODUCTION The air/fluid mixture discharges directly into the fluid
Your new Sullair flood--lubricated rotary screw air management system.
compressor will provide you with improved reliability
and greatly reduced maintenance. The fluid cooler bypass valve helps assure proper
cooling by directing the fluid to the fluid cooler when
Compared with other types of compressors, the discharge temperature reaches the thermostat tem-
Sullair rotary screw is unique in mechanical reliabil- perature setting.
ity, with “no wear” and “no inspection” required of the
working parts within the compressor unit. During start--up in cool ambient conditions, the cool-
er pressure drop may cause the filter bypass valve
Read Section 7 (Maintenance) to keep your com- to open up, assuring adequate fluid supply to the
pressor in top operating condition. Should any ques- compressor.
tions arise which cannot be answered in the follow-
ing text, call your nearest Sullair office or the Sullair All fluid entering the compressor unit passes
Corporation Service Department. through the replaceable fluid filter element. This re-
placeable filter element contains a built--in bypass
4.2 DESCRIPTION OF COMPONENTS valve. Under conditions of restricted flow through
Refer to Figure 4-- 1. The components and assem- the element, the bypass valve helps ensure ade-
blies of the ES--8 Series air compressor are clearly quate compressor fluid flow, as well as helps pre-
shown. The complete compressor consists of an vent element failure.
encapsulated compressor system, inlet sys-
tem, cooling system, control system and super- FLUID MANAGEMENT SYSTEM
visor control system. The Fluid Management System consists of a multi--
chambered primary/secondary separator, the final
The compact design of the ES--8 Series air com- air/fluid separator element, cooler bypass and fluid
pressor provides easy access to all serviceable filter.
components.
As compressed air/fluid enters the sump, the first
4.3 ENCAPSULATED COMPRESSOR SYSTEM, fluid separation takes place due to a reduction of
FUNCTIONAL DESCRIPTION flow speed coupled with a change of direction of the
Refer to Figure 4-- 2. The encapsulated compressor flow within the sump housing. The compressed air
includes compressor unit, fluid management reaches the separator and the finest fluid drops and
system, and drive motor. The Sullair compressor mist are separated.
unit is a single--stage positive displacement lubri-
cated type compressor. This unit is equipped with The minimum pressure/discharge check valve is
tapered roller bearings on the discharge and cylin- mounted on the compressor drive housing. Its func-
drical roller bearings on the inlet end for high load tions are as follows:
carrying capacity. This unit provides continuous 1. Maintains a minimum sump pressure of 60 psig
pulse--free air compression to meet your needs. (4.2 bar) under full load operation to help assure
With a Sullair compressor there will be no mainte- adequate fluid pressure.
nance or internal inspection of the compressor. 2. Acts as a check valve to isolate the compressor
from the system at shutdown or unload.
13
Section 4
COMPRESSOR SYSTEMS
STANDARD
COMPRESSOR
MOISTURE
FLUID COOLER SEPARATOR
BASIC
COMPRESSOR
AIR/FLUID
SEPARATOR
ACCESS MOTOR
AFTER COOLER
INLET CONTROL
PRESSURE RELIEF VALVE
VALVE
COOLING
FAN
AIR FLUID
FILTER FILTER
14
Section 4
COMPRESSOR SYSTEMS
AIR/FLUID
SEPARATOR
MOTOR
COOLING
FAN
COMPRESSOR
UNIT
FLUID
AIR/FLUID
AIR
FLUID
15
Section 4
COMPRESSOR SYSTEMS
The pressure regulator has an orifice which vents a When the line pressure drops to the low setting (cut--
small amount of air to the atmosphere when the in pressure; usually 100 psig [6.9 bar] on low pres-
pressure regulator controls the inlet control valve. sure [“L”] compressors and 125 psig [8.6 bar] on
The orifice also bleeds any accumulated moisture high pressure [“HH”] compressors, 175 psig [12.1
from the pressure regulator. bar] on [“XH”] compressors), Supervisor energizes
the solenoid valve and allows the blowdown valve to
UNLOAD MODE -- IN EXCESS OF 110 PSIG (7.6 close. The re--energized solenoid valve again pre-
bar) vents line pressure from reaching the inlet control
When a relatively small amount or no air is being valve. Should the pressure begin to rise, the pres-
used, the service line pressure continues to rise. sure regulator will resume its normal function as pre-
When it exceeds 110 psig (7.6 bar), the Supervisor viously described.
Control System de--energizes the solenoid valve al-
lowing sump air pressure to be supplied directly to
close the inlet valve. Simultaneously, the solenoid AUTOMATIC OPERATION
valve sends a pneumatic signal to the blowdown For applications with varied periods of time when
valve. The blowdown valve opens the sump to the there are no air requirements, Supervisor’s AUTO-
atmosphere, reducing the sump pressure to approx- MATIC mode allows the compressor to shutdown
imately 20 to 30 psig (1.4 to 2.1 bar). The check (time delayed) when no compressed air require-
valve in the air service line prevents line pressure ment is present and restart as compressed air is
from returning to the sump. needed.
16
NOTES
17
Section 5
SUPERVISOR II
KEYPADS
18
Section 5
SUPERVISOR II
S Logo -- Used for various functions de- S RMT STOP -- Compressor is off but armed
scribed in later sections to start. The machine will start when the re-
mote start contact is closed. NOTE : the
machine may start at any time.
19
Section 5
SUPERVISOR II
If there are alarms active they will alternately be S Next to last fault log. This shows the fault on
shown with the default display. The machine status the first line and the run hours when the fault
will be displayed for 2 seconds, then the alarms for 2 occurred.
seconds each. For example:
T1 HI
110 180 T1 HI
@2 204
To view other status press the DISPLY key. All tem-
peratures and pressures may be displayed as well
as other status information. To scroll through the dis- 5.4 LAMP INDICATORS
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 press
the display key. Embedded into the front panel schematic of the
compressor are several lamps. Pressing the lamp
S Separator differential pressure and the test key will light all the lamps for 3 seconds. Each
maximum limit. If the limit is exceeded, a LED lamp has the following purpose.
separator maintenance warning will be dis-
played.
P1 -- If lit steady, signifies that P1 is being displayed,
dP 1 4 if flashing denotes the presence of an alarm.
MAX 10
S Sump pressure and line pressure. P2 -- If lit steady, signifies that P2 is being displayed,
if flashing denotes the presence of an alarm.
P1 113
P2 108 dP1 -- If lit steady, signifies that dP1 is being dis-
played, if flashing denotes replacement of separator
S Unit discharge temperature and the maxi- is needed.
mum limit. If the temperature exceeds the
limit a T1 HI shutdown will occur.
T1 -- If lit steady, signifies that T1 is being displayed,
T1 210 if flashing denotes the presence of an alarm.
MAX 235
S Total hours that the compressor has been MOTOR -- If flashing, indicates the motor overload
running. contact has opened.
HRS RUN
001234.0 POWER ON -- Lit if 120VAC power is applied to the
Supervisor II.
S Total hours that the compressor has been
loaded.
ON -- If lit steady, the compressor is running. If flash-
ing, indicates that the compressor is armed but
HRS LOAD stopped because of restart timer not expired, re-
000987.0 mote stop or sequence stop. The compressor may
start at any time.
SLast fault log. This shows the fault on the
first line and the run hours when the fault oc-
curred. AUTO -- If lit steady, the compressor is running and
in auto mode. If flashing, indicates that the compres-
T1 HI sor is armed but stopped because of restart timer
@1 234 not expired, remote stop or sequence stop. The
compressor may start at any time.
20
Section 6
COMPRESSOR OPERATION--
SUPERVISOR II
6.1 INTRODUCTION ly start after power up.
While Sullair has built into this compressor a com-
prehensive array of controls and indicators to as-
sure you that it is operating properly, you will want to RST TIME
recognize and interpret the reading which will call for 10 SEC
service or indicate the beginning of a malfunction.
Before starting your Sullair compressor, read this S Unload Stop Timer -- If the machine is run-
section thoroughly and familiarize yourself with the ning in AUTO mode, this parameter speci-
controls and indicators -- their purpose, location and fies the amount of time that the machine will
use. run unloaded before shutting off. If the time
is set less than 15 minutes (for example five
6.2 STANDARD PARAMETER SETUP minutes), there may be times when the ma-
chine will run unloaded for more than five
Pressing the program key enters parameter display minutes. This is because there is another
and edit mode. To move to the next parameter press timer that keeps the machine from being
the program key. To increment a parameter press started more than four times an hour.
the up arrow key or logo key. The logo key will incre-
ment by 10. To decrement the value press the down
arrow key. UNLD TIM
15 MIN
The parameters are displayed in the following order:
S Unload pressure -- The pressure where S Language select -- English, German,
the machine is unloaded. For example if Spanish, Italian and French may be se-
this parameter is set to 110 psi the machine lected for display language.
will unload when the line pressure is above
110 psi. LANGUAGE
ENGLISH
UNLOAD S Units -- English or metric units may be se-
100 PSI lected.
S Load differential -- The pressure differen-
tial below the unload pressure where the UNITS
machine is loaded. For example, if the un- ENGLISH
load pressure is set to 110 and the load dif-
ferential is set to 10, the machine will load S Communications ID # -- This is the net-
when the line pressure goes below 100 psi. work address of a machine. If there is more
than one machine connected to the net-
work, each machine must have a unique
LOAD number.
10 PSI
COM ID #
S P1 Max -- Maximum sump pressure. An 1
alarm and shut down will occur when the
sump pressure rises above this pressure. S Communications baud rate -- This
should always be selected to 9600 baud for
P1 MAX all sequencing modes. It may be lower for
135 PSI slave or monitoring modes.
21
Section 6
COMPRESSOR OPERATION--
SUPERVISOR II
mended Spare Parts List) for details about Manual for details.
these modes.
SEQ HRS
SEQUENCE 1000
HOURS
6.4 OPERATING THE COMPRESSOR
S Drain interval -- The time between actua- Before operating the compressor the operating pa-
tion of the drain valve. rameters must be setup. See the previous section
on operating parameter setup.
MANUAL OPERATION MODE
DRN INTV In this mode the compressor will run indefinitely, as
10 MIN
long as temperatures and pressure remain within
the valid operating ranges, and the motor overload
S Drain time -- The amount of time that the or emergency stop contacts are not tripped. Press-
drain valve is actuated. ing the “I” will turn on the compressor and put it in
manual mode. If the compressor is already running,
but in automatic mode, pressing “I” will switch op-
DRN TIM eration to manual. Pressing “I” while already running
1 SEC in manual mode will cause the Supervisor to turn off
the common fault relay, if engaged, and clear any
S Last Communication Number -- Used maintenance indicators.
only for sequencing, see Sequencing &
Protocol Manual for details. To stop the compressor, press “O” If the compres-
sor is already off when “O” is pressed, the common
fault relay will be turned off, if engaged, and it will try
LAST COM to clear the alarm and maintenance indicators. Re-
3 gardless of what the compressor is doing, pressing
“O” puts the Supervisor in manual stop mode.
S Lowest Allowable Pressure -- Used only AUTOMATIC OPERATION MODE
for sequencing, see Sequencing & Protocol In this mode the compressor will start if line pressure
Manual for details. (P2) is less than the LOAD parameter. It will stop if
the compressor runs unloaded for the number of
minutes indicated by the UNLD TIM parameter. To
LOWEST put the compressor in automatic mode press “ ”. If
90 PSI P2 is already less than LOAD the compressor will
start immediately, otherwise the system status will
S Recovery Time -- Used only for sequenc- indicate STANDBY and the LED marked AUTO will
ing, see Sequencing & Protocol Manual for flash.
details. If the compressor is already running, but in continu-
ous mode, pressing “ ” will switch operation to au-
RECOVER tomatic. Pressing “ ” while already running in auto-
10 SEC matic mode will cause the Supervisor to turn off the
common fault relay, if engaged, and clear any main-
S Rotate Time -- Used only for sequencing, tenance indicators.
see Sequencing & Protocol Manual for de- In automatic mode the compressor can be stopped
tails. manually by pressing “O” Stopping the compressor
using “O” will put the Supervisor in manual stop
mode.
ROTATE Regardless of whether in “automatic” or “manual”
50 mode, control of the load solenoid will be based on
the parameters UNLD and LOAD. This operation is
S Machine Capacity -- Used only for se- as follows:
quencing, see Sequencing & Protocol P2 > UNLD ----> load solenoid turned off
Manual for details (not implemented). P2 < LOAD ----> load solenoid turned on
POWER FAILURE RESTART
CAPACITY If the restart timer (RST TIME parameter) is dis-
100 abled the compressor will not try to start after a pow-
er up. If this time is set to a value the machine will go
S Sequence Hours -- Used only for se- into standby after power up. When the line pressure
quencing, see Sequencing & Protocol drops below the load setpoint, the restart timer will
22
Section 6
COMPRESSOR OPERATION--
SUPERVISOR II
start timing. When the timer expires the machine will sages. The remote inputs and outputs are
start. enabled (start/stop, load/unload, master/lo-
cal).
SEQUENCING MODES
The following is a brief description of sequencing S SLAVE -- Will respond to all messages, but
modes. For details see the Supervisor II Sequenc- will not start or load unless commanded to
ing & Protocol Manual (See Recommended Spare do so by a message. This mode is used to
Parts List). control the machine from a master comput-
er.
S DISABLED -- Responds to status and pa-
rameter change messages via the RS485 S HOURS -- Sends status message about
network but will not respond to start, stop, once a second; starts, loads and unloads
load or unload messages. machines based on sequencing hours.
S REMOTE -- Responds to status and pa- S COM ID # -- Sends status message about
rameter change messages but will not re- once a second; starts, loads and unloads
spond to start, stop, load or unload mes- machines based on machine Com ID#.
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 out
and 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 discharge
from receiver/sump when pressure falls to 60 psig (4.2
bar). Also incorporated in this valve is a terminal check
valve which prevents line pressure backflow into the
sump during unload conditions and after shutdown.
DISCHARGE TEMPERATURE PROBE Shuts the compressor down when the compressor dis-
charge temperature exceeds 235qF (113qC). Continu-
ally monitors discharge temperature of the compres-
sor.
PRESSURE RELIEF VALVE Opens sump pressure to the atmosphere if pressure
inside the sump become too high.
Operation of this valve indicates that the pressure reg-
ulator is either faulty or out of adjustment and that the
Supervisor II Controller is not offloading due to improp-
er setting or malfunctioning transducers.
SOLENOID VALVE Closes the inlet valve and activates blowdown valve to
vent sump pressure to the atmosphere during unload
conditions and shutdowns.
PRESSURE REGULATOR Controls the intake valve position to control compres-
sor output. The regulator stays closed up to a preset
pressure and then opens to provide a rising control
pressure to the inlet control valve as output pressure
increases.
23
Section 6
COMPRESSOR OPERATION--
SUPERVISOR II
6.6 SUPERVISOR OUTPUT RELAYS
RELAY OPERATION
6.7 INITIAL START--UP PROCEDURE 7. Observe the operating temperature. If the operat-
The following procedure should be used to make the ing temperature exceeds 200qF (93qC), the cool-
initial start--up of the compressor. ing system and installation environment should
1. Read the preceding pages of this manual thor- be checked.
oughly. 8. Open shut--off valve to the service line.
2. Jog motor to check for correct rotation of fan (re- 9. Reinspect the compressor for temperature and
fer to Section 2.6). leaks the following day.
3. Be sure that all preparations and checks de-
scribed in the Installation Section have been 6.8 SUBSEQUENT START--UP PROCEDURE
made. On subsequent start--ups, check that the proper lev-
4. Open the shut--off valve to the service line. el is visible in the fluid level sight glass and simply
5. Check for possible leaks in piping. press “I” for manual or “ ” for automatic operation.
7. Slowly close the shut--off valve to assure proper When the compressor is running, observe the vari-
nameplate pressure unload setting is correct. ous parameter displays.
The compressor will unload at nameplate pres-
sure. If adjustments are necessary, see Control 6.9 SHUTDOWN PROCEDURE
System Adjustments. To shut the compressor down, push “O” pad.
24
Section 7
COMPRESSOR OPERATION-
ELECTRO-MECHANICAL
7.1 INTRODUCTION Figure 7-1 Instrument Panel Group
Refer to Figure 7--1. The instrumentation for the
ES--8 Series air compressors consists of a panel
group which continually monitors the operating
condition of the compressor. The standard panel
group has the following gauges: A discharge tem-
perature gauge, a line pressure gauge and an
hourmeter.
SThe line(terminal) pressure gauge is con- TEMPERATURE
nected to the package discharge port. It GAUGE
continually monitors the air pressure.
PRESSURE “ON”
GAUGE
SThe discharge temperature gauge/ INDICATOR
switch monitors the temperature of the air/ (GREEN)
fluid mixture discharged from the compres-
HOURMETER
sor unit. The normal reading should be
approximately 185_F (85_C) with 70_F START/RUN/STOP
(21_C) ambient. The switch shuts com- SWITCH
pressor down above 240_F (116_C) dis-
charge temperature.
“POWER”
INDICATOR
SThe hourmeter records the cumulative (RED)
hours of operation for the compressor. It is
useful for planning and logging service op-
erations. The hourmeter is located in the
door 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, you will want to
recognize and interpret the reading which will call for
service or indicate the beginning of a malfunction.
Before starting your Sullair compressor, read this
section thoroughly and familiarize yourself with the
controls and indicators -- their purpose, location and use.
25
Section 6
COMPRESSOR OPERATION-
ELECTRO-MECHANICAL
7.2 PURPOSE OF CONTROLS-- ELECTRO-MECHANICAL (CONTINUED)
PRESSURE REGULATOR Opens a pressure line between the sump and air inlet
valve 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 operating
temperature of 180_F (82_C); used for fast
warm--up on start--up.
MINIMUM PRESSURE/CHECK VALVE Maintains minimum of 60 psig (4.1 bar) in the compres-
sor sump. Valve piston restricts receiver air discharge
from receiver/sump when pressure falls to 60 psig (4.1
bar). Also incorporated in this valve is a terminal check
valve which prevents line pressure backflow into the
sump 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 air
compressor. This regulation is determined by the
amount of air being used at the service line. Also acts
as 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 reaches maxi-
mum operating pressure. Also activates blowdown
valve.
PRESSURE SWITCH Senses service line pressure. When line pressure
reaches maximum setting the pressure switch signals
the solenoid valve to unload the compressor.
BLOWDOWN VALVE Vents sump pressure to the atmosphere during unload
conditions and shutdown.
7.3 INITIAL START--UP PROCEDURE 7. Observe the operating temperature. If the operat-
The following procedure should be used to make the ing temperature exceeds 200_F (93_C), the
initial start--up of the compressor: cooling system or installation environment
should be checked.
1. Read the preceding pages of this manual thor- 8. Observe maintenance indicators.
oughly. 9. Open shut--off valve to service line.
2. Be sure that all preparations and checks de- 10. Re--inspect the compressor for temperature and
scribed in the Installation section have been leaks the following day.
made.
3. Crack open the shut off valve to the service line. 7.4 SUBSEQUENT START--UP PROCEDURE
4. Start the compressor by turning the START/RUN/ On subsequent start--ups, check that the proper lev-
STOP selector switch to the “I” (START) position el is visible in the fluid sight glass and turn the
momentarily and release.. START/RUN/STOP selector switch to the “I”
5. Check for possible leaks in piping. START position momentarily and release. When the
6. Slowly close the shut--off valve and check that the compressor is running, observe the instrument pan-
setting on the pressure switch is set correctly. If el and maintenance indicators.
set correctly, the compressor will unload at the
desired unload pressure. If adjustments are nec- 7.5 SHUTDOWN PROCEDURE
essary, see Control System Adjustments in the To shut the compressor down, simply turn the selec-
Maintenance Section of the manual. tor switch to the “O” STOP position.
26
Section 8
MAINTENANCE
! WARNING
Before doing compressor maintenance, discon-
nect compressor from power source and lock out
power source. Isolate compressor from line pres-
sure by closing recommended discharge shut--
off valve and releasing all internal pressure from
compressor.
DO NOT remove caps, plugs, and/or other com- See motor manufacturer’s lubrication instructions.
ponents when compressor is running or pressur-
ized.
8.4 FLUID FILTER MAINTENANCE
Stop compressor and relieve all internal pressure
before doing so. ! WARNING
8.2 DAILY OPERATION Fluid filter has internal bypass. DO NOT SUBSTI-
Prior to starting the compressor, it is necessary to TUTE.
check the fluid level in the sump. Should the level be
low, simply add the necessary amount. If the addi- Refer to figure 8-1 and 8-2. Replace the fluid filter
tion of fluid becomes too frequent, a minor problem element under any of the following conditions:
has developed which is causing this excessive loss. 1. As recommended in the Lubrication Guide in the
See the Troubleshooting Section under Excessive Specification Section.
Fluid Consumption for a probable cause and reme- 2. Every fluid change.
dy.
8.5 COOLER MAINTENANCE
After a routine start has been made, a general check If cooler becomes restricted, use standard spray de-
of the overall compressor should be made to assure greaser/cleaner and brush to clean cooler. Use air
that the compressor is running properly. pressure to blow cooler clean. Care must be taken
as not to damage cooler fins.
8.3 MOTOR BEARING LUBRICATION
! WARNING ! WARNING
Before doing compressor maintenance, discon- Before doing compressor maintenance, discon-
nect compressor from power source and lock out nect compressor from power source and lock out
power source. Isolate compressor from line pres- power source. Isolate compressor from line pres-
sure by closing recommended discharge shut-- sure by closing recommended discharge shut--
off valve and releasing all internal pressure from off valve and releasing all internal pressure from
compressor. compressor.
27
Section 8
MAINTENANCE
Figure 8-2 Oil Fill Port Location sure by closing recommended discharge shut--
off valve and releasing all internal pressure from
compressor.
RELIEF VALVE
Check the relief valve at least weekly to see that it is
functional. DO NOT tamper with the preset factory
pressure setting of the valve. DO NOT plug the
valve for any reason; should it leak, have it replaced.
FLUID FILTER REPLACEMENT
Refer 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 tee
located beneath compressor (for complete fluid
change, drain fluid from cooler).
3. Using a strap wrench, remove the old element
and 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.
CONTROL BOX- 8. Replace fluid. DO NOT OVERFILL.
RIGHT SIDE 9. Restart compressor and check for leaks.
AIR FILTER MAINTENANCE- STANDARD MOD-
EL
Refer to Figure 8--3. Air filter (P/N 043333) mainte-
8.6 PARTS REPLACEMENT AND ADJUSTMENT nance should be performed every 6 months or more
PROCEDURES frequent if conditions so require.
! WARNING ! WARNING
Before doing compressor maintenance, discon- Before doing compressor maintenance, discon-
nect compressor from power source and lock out nect compressor from power source and lock out
power source. Isolate compressor from line pres- power source. Isolate compressor from line pres-
28
Section 8
MAINTENANCE
Figure 8-4 Air Filter- Basic Model (02250069-934) 2. If the clean element is to be stored for later use, it
must be stored in a clean container.
FILTER
ELEMENT* AIR FILTER ELEMENT REMOVAL- BASIC MOD-
EL
1. Clean the exterior of the filter base and cover.
2. Loosen/remove the wingnut, washer and cover.
3. Remove element shield and element.
COVER 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.
FILTER 5. Position element and pre--filter element in place.
BASE 6. Position cover over pre--filter element.
7. Reinstate washer and wingnut; tighten to secure.
SEPARATOR ELEMENT REPLACEMENT
PRE--FILTER Refer to Figure 8--5. The separator should be
WASHER
ELEMENT changed once a year. Follow the procedure ex-
plained below for element replacement.
WINGNUT
29
Section 8
MAINTENANCE
Figure 8-6 Hub Separation 3. Remove the 3 capscrews from the inlet valve
cover.
4. Remove cover (with blowdown valve attached)
and o--rings.
5. Remove piston, piston spring, check spring and
valve 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.
FLANGE
HUB (8.1Nm).
10. Reconnect the plastic lines to the appropriate fit-
FLEXIBLE
ELEMENT tings on the valve.
11. Assemble two (2) rear access panels on the
compressor.
FLANGE 12. Start compressor and check for leaks.
HUB
24mm
CONTROL SYSTEM ADJUSTMENT- ELEC-
TRO-MECHANICAL
Refer to Figure 8--8. Prior to adjusting the Control
System, it is necessary to determine the desired op-
erating pressure range and also the maximum pres-
sure at which your compressor is to operate. The
pressure must not exceed the maximum operating
pressure which is stamped on the compressor serial
number nameplate. The following explanation ap-
plies to a typical installation with a desired operating
range of 100 to 110 psig (6.9 to 7.6 bar). This in-
wrenches. All ES--8 compressors are flange-- formation will apply to a compressor with any other
mounted to the motor making them self--aligning, operating range excepting the stated pressures.
eliminating the need for alignment procedures.
Proper hub separation is shown in Figure 8--6. Remove the cover of the pressure switch. With the
shut--off valve closed (or slightly cracked open)
start the compressor. Observe the line pressure
gauge and pressure switch contacts. When the line
INLET CONTROL VALVE pressure reaches 110 psig (7.6 bar), the pressure
Refer to Figure 8--7. The inlet control valve normal switch contacts should open. If the pressure switch
maintenance requires only the replacement of the
o--rings. Use repair kit no. 02250050--614 and fol-
low the procedure below for proper disassembly and Figure 8-7 Inlet Control Valve
assembly procedures.
SCREW
! WARNING
O-- RING*
Before doing compressor maintenance, discon-
nect compressor from power source and lock out PISTON
power source. Isolate compressor from line pres-
sure by closing recommended discharge shut--
off valve and releasing all internal pressure from CHECK
compressor. SPRING COVER
O-- RING*
! WARNING
Assure that line pressure gauge on compressor PISTON
indicates “ZERO” pressure before any work is
done. Failure to comply can cause injury. SPRING
1. Remove the two (2) rear access panels which VALVE STEM
cover the inlet valve assembly.
2. Identify and tag the plastic lines connected to the
blowdown valve and disconnect. * Repair Kit P/N 02250050--614
30
Section 8
MAINTENANCE
31
Section 8
MAINTENANCE
32
Section 9
TROUBLESHOOTING
9.2 TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE REMEDY
P1, P2, P3 FAIL Pressure Transducer Malfunction Check connections from transducer.
If connections are good, replace transducer.
33
Section 9
TROUBLESHOOTING
COMPRESSOR DOES NOT Air Demand Exceeds Supply Check air service lines for open
BUILD FULL DISCHARGE valves or leaks.
PRESSURE
Inlet Air Filter Clogged Check for maintenance message
on Supervisor display. Inspect and/or
change element.
Inlet Valve Not Fully Open Check actuation and butterfly disc
position.
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, Optional
Spiral Valve) Failed to Operate
LINE PRESSURE RISES ABOVE Solenoid Valve Failed Check operation of solenoid
UNLOAD SETTING to Operate valve.
Control Air Signal Leaks Check tubework feeding control
signal for leaks.
Control Air Signal Filter Clogged Service filter assembly.
EXCESSIVE FLUID CONSUMPTION Clogged Return Line Strainer or Clean strainer -- screen and o--ring
Orifice replacement kit available. Clean
orifice.
Damaged or Improperly Gasketed Inspect separator elements and
Separator 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.
34
NOTES
35
Section 10
ILLUSTRATIONS AND PARTS LIST
MINIMUM
PRESSURE TO BLOWDOWN
VALVE TEE 90_ ELBOW
TO SOLENOID
VALVE INLET
TO FLUID
FLUID FILL COOLER
PLUG OUTLET
TO P1
SUMP PRESSURE
TO FLUID
COOLER
INLET
FLUID DRAIN
CAP
TO SOLENOID
VALVE OUTLET
TO TO BLOWDOWN
AFTERCOOLER VALVE
INLET
TO AIR
PRESSURE
REGULATOR
OUTLET
36
Section 10
ILLUSTRATIONS AND PARTS LIST
SULLAIR CORPORATION
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 1-219-879-5451
Fax: (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 1
repair kit for air/fluid separator 02250106--791 1
repair kit for air filter 02250107-327 043334 1
repair kit for shaft seal 02250061--961 1
tool kit, shaft seal 001932--005 1
replacement element for thermal valve 045764 1
replacement kit for coil 250028--809 250028--387 1
repair kit for pressure regulator valve 250017--280 250019--435 1
repair kit for inlet control valve 02250050--614 1
replacement coil for solenoid valve 250030--164 250035--292 1
repair kit for soleniod valve 250030--164 250038--849 1
repair kit for minimum pressure/check valve 02250050--612 1
repair kits for separator filter 02250052--689
Sauto drain kit 250031-245 2
Ssight glass kit 250024--295 2
So--ring kit 02250056--270 2
repair kit for MPF filter 250024--361 250024--427 1
replacement element for coupling 250042--728 02250048--344 1
fluid, Sullube (five gallons) 250022--669 1
manual, Sequencing & Protocol (I) 02250057--696 1
(I) This document is required to program your personal computer to communicate with the Supervisor II panel.
37
Section 10
ILLUSTRATIONS AND PARTS LIST
38
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
(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.
39
Section 10
ILLUSTRATIONS AND PARTS LIST
40
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
(II) For maintenance on ES--8 shaft seal, order tool kit part numbers 02250061--961 and 001932--005.
41
Section 10
ILLUSTRATIONS AND PARTS LIST
42
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
1 support, motor
(15, 20, 25 HP/11, 15, 18.5 KW) 02250046--622 1
Ssupport, motor (30 HP/22 KW) 02250046--624 1
2 capscrew, M12 x 30MM 829312--030 4
3 housing, adaptor motor
(15, 20, 25 HP/11, 15, 18.5 KW) 02250045--831 1
Shousing, adaptor motor (30 HP/22 KW) 02250045--833 1
4 capscrew, hex GR8 1/2”--13 x 1 1/4” 829408--125 4
5 guard, fan 02250055--600 1
6 coupling, 1 5/8” (I) 250042--728 1
7 venturi, fan inlet (15, 20 HP/11, 15 KW) 02250050--241 1
Sventuri, fan inlet (25, 30 HP/18.5, 22 KW) 02250046--603 1
8 fan, backward inclined wheel
(15, 25, 30 HP/11, 15, 18.5 KW) (I) 02250050--539 1
Sfan, backward inclined wheel
(20 HP/15 KW) (I) 02250050--240 1
9 housing, fan 02250045--829 1
10 key, 10 x 8 x 40 865210--040 1
11 motor consult factory 1
12 screw, socket M12 x 40MM 829312--040 6
13 washer, 12MM 865712--370 2
14 nut, M12 x 1.75 825912--175 2
15 washer, 8MM 865408--170 1
16 capscrew, 8MM x 16MM 828008--016 1
17 washer, 12MM 865712--370 1
18 nut, hex M12 x 1.75 825912--175 1
19 isolator, vibration 75MM x 50MM 02250047--047 1
20 elbow, 45 liq--tite 1 1/4” (not shown) 846500--125 1
21 washer, conduit red. 1 1/2”--1” (not shown) 847006--040 2
22 spacer, shaft
(15, 20, 25 HP/11, 15, 18.5 KW) 02250049--354 1
Sspacer, shaft (30 HP/22 KW) 02250049--159 1
23 angle, support cooler 02250046--915 1
24 insert, 6MM 02250047--083 1
(I) Pre--heating required before assembly. For maintenance, order element no. 02250048--344.
43
Section 10
ILLUSTRATIONS AND PARTS LIST
44
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
(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.
45
Section 10
ILLUSTRATIONS AND PARTS LIST
46
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
(III) For maintenance on air/fluid separator, order repair kit no. 02250106--791.
47
Section 10
ILLUSTRATIONS AND PARTS LIST
TO BLOWDOWN
MINIMUM 90 _ ELBOW
PRESSURE
VALVE TEE
3
TO SOLENOID
VALVE INLET
2
7
6
8 9
FLUID FILL
PLUG 10
4
33 11 A
32
31
30 6 12
29
28
26 14 13
27
25 B
15
24
23 21 20
22 19 12
16
FLUID DRAIN
CAP 17
18
48
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
(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.
49
Section 10
ILLUSTRATIONS AND PARTS LIST
1 28 5
6
4 10
1
26 12
2
A
11
27 26
C
16 13
20
25 14
24 23
B 1 TO PRESSURE SWITCH
11 LINE PRESSURE
25
3
18
21
25
1
1
17
15 17 25
15
7
9
11 25
22 1
CHECK AIR 3
VALVE PRESSURE 19
TEE REGULATOR
3
PRESSURE
SWITCH 1
15
7
9 8 3
50
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
51
Section 10
ILLUSTRATIONS AND PARTS LIST
52
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
(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).
53
Section 10
ILLUSTRATIONS AND PARTS LIST
54
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
(IV) This item is part of kit no. 02250051--535 and no. 02250051--536 (deluxe). To obtain this part please consult
factory.
55
Section 10
ILLUSTRATIONS AND PARTS LIST
12 10
TO CHECK 7
22
BLOWDOWN VALVE TEE 12
VALVE
1
2 TO MINIMUM
LINE
PRESSURE PRESSURE
2 VALVE TEE
TO INLET
19 20 VALVE 23
OUTLET 9 1 8 24
1 1
12
1 13
4 21
2
9
21
4
5
4
INLET TO PRESSURE
GAUGE
3
2 30 1
31
OUTLET
29
8 11
27 26
1
INLET
8
12
23
25
15
34
33
17
16
18 14
6
32
34
15
56
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
57
Section 10
ILLUSTRATIONS AND PARTS LIST
3
1 4
2
5
10
13 11
12
14
58
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
59
Section 10
ILLUSTRATIONS AND PARTS LIST
10.11 ENCLOSURE
4
5
7
3 8
5 6
3
4
6
8
13
9
8
7
3 5
10
12 11
14
15
16
60
Section 10
ILLUSTRATIONS AND PARTS LIST
10.11 ENCLOSURE
key part
number description number quantity
61
Section 10
ILLUSTRATIONS AND PARTS LIST
1
2
3
4
7
6
62
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
63
Section 10
ILLUSTRATIONS AND PARTS LIST
10
11
12
13
64
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
65
Section 10
ILLUSTRATIONS AND PARTS LIST
15
14
16
17
18
19
20
66
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
67
Section 10
ILLUSTRATIONS AND PARTS LIST
3
4
4 17
6
4 12
5
13
7
8
14
9
10
15
11
16
68
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
(I) Compressor fluids may vary. Consult Sullair to verify the fluid of your compressor if you do not know the fluid
type.
(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 this
section.
69
Section 10
ILLUSTRATIONS AND PARTS LIST
18
21
19
20
22
70
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
(IV) Decal is placed at this location for closed inlet machine. For standard machines, consult key no. 14 of this
section.
(V) Compressor fluids may vary. Consult Sullair Corporation to verify the fluid fill of your compressor if you do not
know the fluid type.
71
Section 10
ILLUSTRATIONS AND PARTS LIST
7 4
72
Section 10
ILLUSTRATIONS AND PARTS LIST
key part
number description number quantity
73
Section 10
ILLUSTRATIONS AND PARTS LIST
74
Section 10
ILLUSTRATIONS AND PARTS LIST
75
Section 10
ILLUSTRATIONS AND PARTS LIST
76
Section 10
ILLUSTRATIONS AND PARTS LIST
77
Section 10
ILLUSTRATIONS AND PARTS LIST
78
NOTES
WORLDWIDE SALES AND SERVICE
SULLAIR CORPORATION
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 1--219--879--5451
Fax: (219) 874--1273
Fax: (219) 874--1835 (Parts)
Fax: (219) 874--1288 (Service)
Printed in U.S.A.
Specifications Subject To
Change Without Prior Notice
E00EPS