Manual Compresor Sullair.pdf

ROTARY SCREW AIR COMPRESSOR ES -- 6 Series 5, 7.5 and 10HP 4, 5.5 and 7.5 kw

OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250057--634 ullairC or por at ion ©S

AIR CARE SEMINAR TRAINING

Sullair Air Care Seminar s 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--800 --SULLAIR or 219--879 --5451 (ext. 1816) -- Or Write -Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training Department

TABLE OF CONTENTS

Section 1

SAFETY

PAGE 1 1

1 1. G EN ER AL PERSO 1.2 NALPROTECTIVEEQUIPMENT

1

1.3 PRESSURE RELEASE

1

1.4 FIRE AND EXPLOSION

2 2

1.5 MOVING PARTS 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

5

2.1 INTRODUCTION

Section 2

DESCRIPTION

5

2.2 DESCRIPTION OF COMPONENTS

5

2.3 ENCAPSULATED COMPRESSOR SYSTEM, FUNCTIONAL DESCRIPTION

5

2.4 COMPRESSOR COOLING SYSTEM, FUNCTIONAL DESCRIPTION

5

2.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

7

2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION

8

2.7 INSTRUMENTATION, FUNCTIONAL DESCRIPTION

9

3.1 TABLE OF SPECIFICATIONS

10

3.2 COMPRESSOR LUBRICATION GUIDE

11

4.1 LOCATION OF COMPRESSOR

Section 3

SPECIFICATIONS Section 4

INSTALLATION

11

4.2 VENTILATION AND COOLING

11

4.3 SERVICE AIR PIPING

11

4.4 FLUID LEVEL CHECK AND CHANGE PROCEDURE

12

4.5 MOTOR ROTATION DIRECTION CHECK

12

4.6 ELECTRICAL PREPARATION

TABLE OF CONTENTS (CONTINUED)

Section 5

OPERATION

PAGE 13 13 14 14 14

5.1 GENERAL

15 15 15 15 15 16

6.1 GENERAL

5.2 PURPOSE OF CONTROLS 5.3 INITIAL START--UP PROCEDURE 5.4 SUBSEQUENT START--UP PROCEDURE 5.5 SHUTDOWN PROCEDURE

Section 6

MAINTENANCE

6.2 DAILY OPERATION 6.3 MOTOR BEARING LUBRICATION 6.4 FLUID FILTER MAINTENANCE 6.5 COOLER MAINTENANCE 6.6 PARTS REPLACEMENT MAINTENANCE AND ADJUSTMENT PROCEDURES FLUID FILTER REPLACEMENT AIR FILTER MAINTENANCE SEPARATOR ELEMENT REPLACEMENT MINIMUM PRESSURE/CHECK VALVE MAINTENANCE THERMOSTAT ACTUATOR MAINTENANCE CONTROL SYSTEM ADJUSTMENT FOR DIFFERENTIAL ADJUSTMENT OF AIR PRESSURE SWITCH INLET CONTROL VALVE MOTOR SHAFT SEAL REPLACEMENT

21 23

6.7 TROUBLESHOOTING 6.8 MAINTENANCE RECORD

Section 7

ILLUSTRATIONS AND PARTS LIST

25 25 26 28 30 32 34 36 38 40 44 46 48

7.1 PROCEDURE FOR ORDERING PARTS 7.2 RECOMMENDED SPARE PARTS LIST 7.3 FLUID MANAGEMENT SYSTEM 7.4 INLET FILTER 7.5 SEAL AND DRIVE GEAR 7.6 MOTOR, HOUSING AND PARTS 7.7 COMPRESSOR COOLER SYSTEM 7.8 COMPRESSOR SYSTEM 7.9 INLET CONTROL 7.10 CONTROL BOX 7.11 CANOPY AND PARTS 7.12 FRAME, CANOPY AND PARTS 7.13 WYE--DELTA ELECTRIC BOX ES--6

TABLE OF CONTENTS (CONTINUED)

Section 7

ILLUSTRATIONS AND PARTS LIST (CONT)

PAGE

50 52 56 57 58 59

7.14 WYE--DELTA ELECTRIC BOX ES--6 7.15 DECAL GROUP 7.16 WIRING DIAGRAM (SINGLE PHASE) (60 Hz) 7.17 WIRING DIAGRAM (THREE PHASE) (60 Hz) 7.18 WIRING DIAGRAM (50 Hz) 7.19 WIRING DIAGRAM (50 Hz) WYE--DELTA

NOTES

Section 1

SAFETY 1.1 GENERAL Sullair Corporation and its subsidiaries design and manufacture all of their products so they can be operated safely. However, the responsibility for safe operation rests with those who use and maintain these products. The following safety precautions are offered as a guide which, if conscientiously followed, will minimize the possibility of accidents throughout the useful life of this equipment.

The compressor should be operated only by those who have been trained and delegated to do so, and who have read and understood this Operator’s Manual. Failure to follow the instructions, procedures and safety precautions in this manual may result in accidents and injuries. NEVER start the compressor unless it is safe to do so. DO NOT attempt to operate the compressor with a known unsafe condition. Tag the compressor and render it inoperative by disconnecting and locking out all power at source or otherwise disabling its prime mover so others who may not know of the unsafe condition cannot attempt to operate it until the condition is corrected.

Install, use and operate the compressor only in full compliance with all pertinent OSHA regulations and/or any applicable Federal, State, and Local codes, standards and regulations. DO NOT modify the compressor and/or controls in any way except with written factory approval.

While not specifically applicable to all types of compressors with all types of prime movers, most of the precautionary statements contained herein are applicable to most compressors and the concepts behind these statements are generally applicable to all compressors.

1926.302(b)(7) and/or any applicable Federal, State and Local codes, standards and regulations. B. When thehose is to be used to supply a manifold, install an additional appropriate flow--limiting valve between the manifold and each air hose exceeding 1/2” (13mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure. C. Provide an appropriate flow--limiting valve at the beginning of each additional 75 feet (23m) of hose in runs of air hose exceeding 1/2” (13mm) inside diam-

eter to reduce pressure in case of hose failure. D. Flow--limiting valves are listed by pipe size and rated CFM. Select appropriate valves accordingly, in accordance with their manufacturer’s recommendations. E. DO NOT use air tools that are rated below the maximum rating of the compressor. Select air tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturer’s rated safe operating pressures for these items. F. Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled. G. Open fluid filler cap only when compressor isnot running and is not pressurized. Shut down the compressor and bleed the sump (receiver) to zero internal pressure before removing the cap. H. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before attempting to refill optional air line anti--icer systems with antifreeze compound.

I. Keep personnel out of line with and away from the discharge opening of hoses or tools or other points 1.2 PERSONAL PROTECTIVE EQUIPMENT of compressed air discharge. Prior to installing or operating the compressor, owners, 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 OSHA regulacleaning purposes, and then only with effective chip tions and/or any applicable Federal, State and Local guarding and personal protective equipment per codes, standards, and regulations relative to perOSHA Standard 29 CFR 1910.242 (b) and/or any sonal protective equipment, such as eye and face applicable Federal, State, and Local codes, stanprotective equipment, respiratory protective equipdards and regulations. ment, equipment intended to protect the extremiK. DO NOT engage in horseplay with air hoses as ties, protective clothing, protective shields andbarrideath or serious injury may result. ers and electrical protective equipment, as well as noise exposure administrative and/or engineering controls and/or personal hearing protective equip- 1.4 FIRE AND EXPLOSI ON A. Clean up spills of lubricant or other combustible ment. substances immediately, if such spills occur. 1.3 PRESSURE RELEASE B. Shut off thecompressor and allow it to cool. Then A. Install an appropriate flow--limiting valve between keep sparks, flames and other sources of ignition the service air outlet and the shut--off (throttle) away and DO NOT permit smoking in the vicinity valve, either at the compressor or at any other point when checking or adding lubricant or when refilling along the air line, when an air hose exceeding 1/2” air line anti--icer systemswith antifreeze compound. (13mm) inside diameter is to be connected to the C. DO NOT permit fluids, including air line anti--icer shut--off (throttle) valve, to reduce pressure in case of hose failure, per OSHA Standard 29 CFR system antifreeze compound or fluid film, to accu-

1

Section 1

SAFETY mulate on, under or around acoustical material, or on any external surfaces of theair compressor or on internal surfaces of the enclosure. Wipe down using an aqueous industrial cleaner or steam clean as required. If necessary, remove acoustical material, clean all surfaces and thenreplace acoustical material. Any acoustical material with a protective covering that has been torn or punctured should be replaced immediately to prevent accumulation of liquids or fluid film within the material. DO NOT use flammable solvents for cleaning purposes. D. Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the compressor or of the inside of the enclosure, if any. E. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace any wiring that has cracked, cut, abraded or otherwise degraded insulation, or terminals that are worn, discolored or corroded. Keep all terminals and pressure connectors clean and tight. F. Keep grounded and/or conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition. G. Removeany acoustical materialor other material that may be damaged by heat or that may support combustion and is in close proximity, prior to attempting weld repairs. H. Keep suitable fully charged Class BC or ABC fire extinguisher or extinguishers nearbywhenservicing and operating the compressor. I. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor. J. DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or with degraded lubricant. K. DO NOT attempt to operate the compressor in any classification of hazardous environment unless the compressor has been specially designed and manufactured for that duty. 1.5 MOVING PARTS A. Keep hands, arms and other parts of the body andalso clothing away from couplings, fansand other moving parts.

F. Disconnect and lock out all power at source and verify at the compressor that all circuits are de--energized to minimize the possibility of accidental start--up, or operation, prior to attempting repairs or adjustments. This is especially important when compressors are remotely controlled. G. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water or other liquids to minimize the possibility of slips and falls. 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS A. 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 of air discharge. C. Wear personal protective equipment including gloves and head covering when working in, on or around the compressor. D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore small cuts and burns as they may lead to infection. 1.7 TOXIC AND IRRITATING SUBSTANCES A.DO NOT use air from this compressor forresp iration(breathing) except in full compliance withOSHA Standards 29 CFR 1910 and/or any applicable Federal, State or Local codes or regulations. !

DANGER

Death or serious injury can result from inhaling compressed air with out using proper safet y equipment. See OSHA standards and/or any applicable Federa l, State, and Local codes, standards and regulations on safety equipment.

B. DO NOT use air line anti--icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems into unventilated or other confined areas. C. Operate the compressor only in open or adequately ventilated areas. D. Locate the compressor or provide a remote inlet so that it is not likely to ingest exhaust fumes or other toxic, noxious or corrosive fumes or substances.

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

E. Coolants and lubricants used in this compressor are typical of the industry. Care should be taken to avoid accidental ingestion and/or skin contact. In the event of ingestion, seek medical treatment promptly. Wash with soap and water in the event of skin contact. Consult Material Safety Data Sheet for information pertaining to fluid of fill.

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

F. Wear goggles or a full face shield when addingantifreeze compound to air line anti--icer systems.

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

2

E. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or operate it.

Section 1

SAFETY G. If air line anti--icer system antifreeze compound enters the eyes or if fumes irritate the eyes, they should be washed with large quantities of clean water for fifteen minutes. A physician, preferably an eye specialist, should be contacted immediately. H.DO NOT store air line anti--icer system antifreeze compound in confined areas. I. The antifreeze compound used in air line antifreeze systems contains methanol and is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swal-

lowed, byofadministering a tablespoon ofinduce salt, invomiting each glass clean, warm wateruntil vomit is clear, then administer two teaspoons of baking soda in a glass of clean water. Have patient lay down and cover eyes to exclude light. Call a physician immediately. 1.8 ELECTRICAL SHOCK A. This compressor should be installed and maintained in full compliance with all applicable Federal, State and Local codes, standards and regulations, including those of the National Electrical Code, and also includingthose relative to equipment grounding conductors, and only by personnel that are trained, qualified and delegated to do so. B. Keep all parts of the body and any hand--held tools or other conductive objects away from exposed live parts of electrical system. Maintain dry footing, stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system. Make all such adjustments or repairs with one hand only, so as to minimize the possibility of creating a current path through the heart. C. Attempt repairs in clean, dry and well lighted and ventilated areas only. D. DO NOT leave the compressor unattended with open electrical enclosures. If necessary to do so, then disconnect, lock out and tagall power at source so others will not inadvertently restore power. E. Disconnect, lock out, and tag all power at source prior to attempting repairs or adjustments to rotating machinery and prior to handling any ungrounded conductors. 1.9 LIFTING A. 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 helicopter must not be supported by the lifting bail but

by slings instead. In any event, lift and/or handle only in full compliance with OSHA standards 29 CFR 1910 subpart N and/or any applicable Federal, State, and Local codes, standards and regulations. B. Inspect points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifting. C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has a rated capacity of at least the weight ofthe

compressor. If you before are unsure of the weight, then weigh compressor lifting. D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail or slings. E. Use guide ropes or equivalent to prevent twisting or swinging of thecompressor once it has been lifted clear of the ground. F. DO NOT attempt to lift in high winds. G. Keep all personnel out from under and away from the compressor whenever it is suspended. H. Lift compressor no higher than necessary. I. Keep lift operator in constant attendance whenever compressor is suspended. J. Set compressor down only on a level surface capable of safely supporting at least its weight and its loading unit. K. When moving the compressor by forklift truck, utilize fork pockets if provided. Otherwise, utilize pallet if provided. If neither fork pockets or pallet are provided, then make sure compressor is secure and well balanced on forks before attempting to raise or transport it any significant distance. L. Make sure forklift truck forks are fully engaged and tipped back prior to lifting or transporting the compressor. M. Forklift no higher than necessary to clear obstacles at floor level and transport and corner at minimum practical speeds. N. Make sure pallet--mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them. NEVER attempt to forklift a compressor that isnot securedto its pallet, as uneven floors or sudden stops may cause the compressor to tumble off, possibly causing serious injury or property damagein theprocess.

3

Section 1

SAFETY 1.10 ENTRAPMENT A. If the compressor enclosure, if any, is large enoughto holda man and if itis necessary to enter it to perform service adjustments, inform other personnel before doing so, or else secure and tag the access door in the open position to avoid the possibility of others closing and possibly latching the door with personnel inside. B. Make sure all personnel are out of compressor before closing and latching enclosure doors.

4

Section 2

DESCRIPTION 2.1 INTRODUCTION Your new Sullair flood--lubricated rotary screw air 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 discharge temperature reaches the thermostat temperature setting.

Compared to other types of compressors, the Sullair rotary screw is unique in mechanical reliability, with “no wear” and “no inspection” required of the working parts within the compressor unit.

During start--up in cool ambient conditions, the cooler pressure drop will cause the filter bypass valve to open up, assuring adequate fluid supply to the compressor.

Read Section 6 (Maintenance) to keep your compressor in top operating condition. Should any questions arise which cannot be answered in the follow-

All fluid entering the compressor unit passes through the replaceable fluid filter element. This replaceable filter element contains a built--in bypass valve. Under conditions of restricted flow through the element, the bypass valve helps ensure adequate compressor fluid flow, as well as helps prevent element failure.

ing text, call your nearest Sullair office or the Sullair Corporation Service Department. 2.2 DESCRIPTION OF COMPONENTS Ref ert oF igur e2 -- 1.T hec om ponent sandas se m blies of the ES--6 Series air compressor are clearly shown. The complete compressor consists of an encapsulated compressor system, inlet system, cooling system and control system.

The compact design of the ES--6 Series air compressor provides easy access to all serviceable components. 2.3 ENCAPSULATED COMPRESSOR SYSTEM, FUNCTIONAL DESCRIPTION Ref ert oF igur e2 -- 2.T heenc aps ulat edc om pr es s or includes compressor unit, fluid management system, and motor section. The Sullair compressor unit is a single--stage positive displacement lubricated type compressor. This unit is equipped with tapered roller bearings on the discharge, and cylindrical roller bearings on theinlet end for high load carrying capacity. This unit provides continuous pulse--free air compression to meet your needs. With a Sullair compressor there will be no maintenance or internal inspection of the compressor. !

WARNING

DO NOTremo vecaps , plugsand/o r oth ercomp onents when compressor is running or pressurized. Stop compressor andrelieveall internal pressure before doing so.

Fluid is injected into the compressor unit in large quantities and mixes directly with the air as the rotors turn, compressing the air. The fluid flow has three main functions: 1. As coolant, it controls the rise of air temperature normally associated with the heat of compression. 2. It seals the leakage paths between the rotors and the stator and also between the rotors them3. Itselves. acts as a lubricating film between the rotors allowing one rotor to directly drive the other, which is an idler. The air/fluid mixture discharges directly into the fluid management system.

FLUID MANAGEMENT SYSTEM The fluid management system consists of a multi-chambered primary/secondary separator, the final air/fluid separator element, cooler bypass group and fluid filter .

As compressed air/fluid enters the sump, the first fluid separation takes place due to a reduction of flow speed coupled with a change of direction of the flow within the sump housing. Then the compressed air reaches the separator, where the finest fluid drops and mist are separated. MOTOR/DRIVE SECTION The motor/drive section consists of a squirrel cage induction motor and integrated drive gearing which is separated from the motor by a replaceable shaft

seal. The minimum pressure/discharge check valve is mounted on the compressor drive housing. Its functions are as follows: 1. Maintain a minimum sump pressure of 60 psig (4.1 bar) under full load operation to help assure adequate fluid pressure. 2. Act as a check valve to isolate the compressor from the system at shutdown or unload. 2.4 COMPRESSOR COOLI NG SYSTEM, FUNCTIONAL DESCRIPTION The compressor cooling system consists of afluid cooler, fan and cooler shroud .

The fan is mounted on the motor’s shaft end opposite the compressor. Air is drawn over the motor as well as through the cooler. The air provides motor cooling and removes compression heat from the fluid. 2.5 AIR

INLET

SYSTEM,

FUNCTIONAL

DE-

SCRIPTION The compressor inlet system consists of a dry --ty pe air filter and an air control valve . Reacting on a pressure signal, the valve closes the intake for unloaded operation. The valve also acts as a check valve upon shutdown.

5

Section 2

DESCRIPTION Figure 2--1 Description of Components

(4KW) (5.5 & 7.5KW)

AIR/FLUID SEPARATOR ELEMENT ACCESS COVER

FLUID FILL PLUG FLUID FILTER ELEMENT FLUID LEVEL SIGHT GLASS

COMPRESSOR FLUID DRAIN CAP

FLUID FILL PLUG

COMPRESSOR FLUID DRAIN CAP

6

Section 2

DESCRIPTION Figure 2--2 Encapsulated Compressor System

2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION The purpose of the compressor control system is to maintain compressor capacity to meet the system demand.

It consists of an inlet valve, solenoid valve, control lines and the motor start selector switch . The selector switch has three settings: MANUAL/ START, OFF/RESET and AUTOMATIC START/ STOP. MANUAL MODE The compressor motor will start and the air control solenoid valve will be energized. The compressor will start to deliver compressed air. When no air is being used, the service line pressure rises to the

setting (cut--out pressure) of the pressure switch. The system pressure switch opens, interrupting the electrical power to the solenoid valve. The solenoid valve allows control air to the inlet valve, unloading the compressor and the motor continues to run. When the line pressure drops to the low setting of

the pressure switch, the pressure switch closes, re-energizing the normally open solenoid valve and allowing the compressor to load again. OFF/RESET MODE The compressor motor, if running, will stop if the off/ reset position is selected. If the compressor during normal running has a fault caused by either overload or high discharge temperature, the compressor will stop. After a fault has been cleared, the compressor can not be restarted unless the Off/Reset mode is selected on the selector switch, prior to starting in any other mode of operation. AUTOMATIC MODE In the automatic mode of operation, the air system pressure switch opens, interrupting the electrical

power to the air control solenoid valve; the compressor unloads and the motor will stop. The motor will automatically restart when the compressor sump pressure drops to the minimum setpoint on the sump pressure switch and the line pressure drops below the setpoint of the air pressure switch.

7

Section 2

DESCRIPTION 2.7 INSTRUMENTATION, FUNCTI ONAL DESCRIPTION Due to the simplicity of the ES--6 Series compressor, the only instrumentation necessary is a line pressure gauge which is located on the left side of the electrical control center and a discharge temperature gauge which is located on the right side of the electrical control center. The line pressure gauge reads plant air system pressure only.

8

NOTE At compressor shutdown, the sump pressure is released to atmosphere through the solenoid valve. The line pressure gauge will continue to read system pressure.

Section 3

SPECIFICATIONS 3.1 SPECI FICATIONS -- ES-- 6

DIMENSIONS 60Hz Model ES--65H ES--65XH ES--67.5H ES--6 7.5XH ES--610H ES--610XH

HP/KW 5/4 5/4 7.5/5.5 7.5/5.5 10/7.5 10/7.5

Capacity Maximum ACFM/ Pressure M3 /MIN PSIG/BAR 18/.51 13/.37 28/.79 20/.57 38/1.08 30/.85

125/8.6 175/12 125/8.6 175/12 125/8.6 175/12

dBA (I) Length with canopy/ mm without canopy i n. 68/80 68/80 69/82 69/82 70/85 70/85

31 31 33 33 33 33

W idt h in.

787 2 13/8 787 2 13/8 838 21 3/4 838 21 3/4 838 21 3/4 838 21 3/4

H ei g ht

mm

in .

543 191/2 543 191/2 553 19 1/2 553 19 1/2 553 19 1/2 553 19 1/2

We i g h t lb . kg

mm

495 495 495 495 495 495

275 275 300 300 325 325

125 125 136 136 150 150

DIMENSIONS 50Hz Model ES--65L ES--65HH ES--650XH ES--6 7.5L ES--6 7.5HH ES--6 7.5XH ES--6 10L ES--6 10HH ES--6 10XH

HP/KW 5/4 5/4 5/4 7.5/5.5 7.5/5.5 7.5/5.5 10/7.5 10/7.5 10/7.5

Capacity Maximum ACFM/ Pressure M3 /MIN PSIG/BAR 21.2/.60 17.3/.49 13.4/.38 30/.85 24.4/.69 20.5/.58 39.2/1.11 33.9/.96 28.2/.80

110/7.5 150/10 175/12 110/7.5 150/10 175/12 110/7.5 150/10 175/12

dBA (I) Length with canopy/ mm without canopy i n. 68/80 68/80 68/80 69/82 69/82 69/82 70/85 70/85 70/85

COMPRESSOR Type: Minimum Full Load Operating Pressure: Maximum Full Load Operating Pressure: BearingType: Cooling: Lubr ic ant : Sump Capacity:

31 31 31 33 33 33 33 33 33

W idt h in.

787 2 13/8 787 213/8 787 213/8 838 21 3/4 838 21 3/4 838 21 3/4 838 21 3/4 838 21 3/4 838 21 3/4

H ei g h t

mm

in .

543 191/2 543 191/2 543 191/2 553 19 1/2 553 19 1/2 553 19 1/2 553 19 1/2 553 19 1/2 553 19 1/2

495 495 495 495 495 495 495 495 495

We i g h t lb . kg

mm 275 275 275 300 300 300 325 325 325

125 125 125 136 136 136 150 150 150

Single Stage Fluid Injected Screen Compressor 60 psi (4.1 bar) Nameplate Pressure (I) Anti--friction PressurizedFluid SeeLubr ic antS pec if ic at ion( S ec t ion3. 2) 4.6 quarts (4.35 liters)

(I) Compressors are available for pressures up to 175 psi (12.1 bar). MOTOR Type:

Synchronous Speed:

60Hz 5,7.5,10HP/ 4, 5.5 & 7.5 KW 1.15 S.F. 1800 RPM

Voltage: Standard All Sizes Optional All Sizes Optional All Sizes Optional 5HP Only Type: InsulationClass: Maximum Ambient Temp.: Shaft Diameter Fan: Key Size Fan:

230/460V 3 Phase 200V 3 Phase 575V 3 Phase 230V Single Phase Totally Enclosed Air Over “F” 40 C (104 F) Nominal 5/8” Nominal 3/16” x 3/16” x 1 1/4” 

FLUID FILTER Type: Micron:



50Hz 5,7.5,10HP/ 4, 5.5 & 7.5 KW 1500 RPM (5, 7.5HP/4, 5.5KW) 3000 RPM (10HP/7.5KW)

380/415 3 Phase 380/415 3 Phase 380/415 3 Phase 380/415 3 Phase Totally Enclosed Air Over “F” 40 C (104 F) Nominal 5/8” Nominal 3/16” x 3/16” x 1 1/4” 



Spinon,SullairProprietary 23MicronsAbs.

Internal Bypass Valve Set at 25 psig FLUID SEPARATOR ELEMENT Type: Efficiency at Maximum Capacity:

Push In Cartridge, Sullair Proprietary 5PPM Maximum

9

Section 3

SPECIFICATIONS Table 3--1, Lubrication Guide AMBIENT TEMPERATURE --10 F to +90 F (--23 C to +32 C) 





LUBRICATION

Sullube32 Sullair LLL--4--32 SRF1/4000 D--ATorqueFluid Motor Oil MIL--2104E SPEC API SF CC, CDSAE10WClassSE



FLUID CHANGE PERIOD (HRS.)

FILTER CHANGE PERIOD (HRS.)

* 8000 8000 * 4000 1000

8000 * 8000 * 4000 1000

600

600

* 8,000 Hours or once a year.

3.2 COMPRESSOR LUBRICATION GUIDE For best value and longest uninterrupted service, the ES--6 compressor is factory filled with Sullube 32, a long life lubricant, unless a different lubricant is requested. If, due to availability or other reasons, other fluids ar er equir ed,f ollowTable3 -- 1,Lubr ic at ionG uide. !

WARNING

“The Plastic Pipe Institute recommends against the use of thermoplastic pipe to transport compressedair or other compressedgasesin exposed above ground locations, e.g. in exposed plant piping.” (I)

DO NOT MIX DIFFERENT TYPES OF FLUIDS. Contamination of non--detergent mineral fluids with traces of ATF or detergent motor fluids may lead to operational problems such as foaming, filter plugging, orifice or line plugging. Flushing is required if changing to a different lubricant. !

WARNING

Mixing of other fluids within the compressor will void all warranties.

Sullube 32 should not be used with PVC piping systems. It mayaffect the bond at cemented joints. Certain other plastic materia ls may also be affected.

When ambient conditions exceed those noted or if

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

conditions warrant use of “extended” life lubricants contact Sullair for recommendation.

Maintenance of all other components is still recommended as indicated in the Operator’s Manual. For light--duty high--humidity service where condensed moisture and emulsification (mayonnaise) Figure 3--1 Center of Gravity

APPROX. 6” (15.2CM) CENTER OF GRAVITY

10

may occur, the fluid change interval must be reduced to 300 hours maximum. A non--detergent fluid with rust, oxidation and foam inhibitors and good water separation characteristics should be used.

Sullair encourages the user to participate in a fluid analysis program. This could result in a fluid change interval that is different from those stated in this manual.

Section 4

INSTALLATION joints. Certain other plastic materialsmay also be 4.1 LOCATION OF COMPRESSOR affected. The ES--6 Series compressor package may be (I) Plas tic PipeInstitu te, RecommendationB, AdoptedJanuar y placed on any level surface able to support its 19, 1972. weight. The unit should be bolted to a fixedmounting surface to avoid the possibility of externally applied 4.4 FLUID LEVEL CHECK AND CHANGE PROCEDURE forces or vibration which would disturb the piping or The Sullair air compressor is equipped with the wiring. proper amount of fluid. However, it is necessary to check the fluid level at installation. The level is 4.2 VENTILATION AND COOLING checked by looking at the fluid level sight glass loSelect a location to permit sufficient unobstructed c at edont heendbell.S eeF igur e2 -- 1. air flow in and out of the compressor to keep the operating temperature stable. The minimum distance If the sump is properly filled, the fluid level should that the machine should be from surrounding walls is what is needed for service and three (3) feet cover 1/4 to 1/2 of the sight glass during operation. DO NOT OVERFILL . (914mm) or more from the fan air discharge end of the compressor. ! WARNING 4.3 SERVICE AIR PIPING Before attempting compressor maintenance, disService air piping should be installed as shown in connect compressor from power source and lock F igur e4 -- 1.As hut -- offv alv es houldbeins t alledt o out power source. Isolate compressor from line isolate the compressor from the service line. Also pressure by closing recommended discharge notice that the service line should be equipped with shutoff valve and releasing all internal pressure from compressor. water legs and condensate drains throughout the system. ! !

WARNING

“The Plastic Pipe Institute recommends against the use of thermoplastic pipe to transport compressed air or other compressed gase s in exposed above ground locations, e.g. in exposed plant piping.” (I) Sullube 32 should not be used with PVC piping systems. It may aff ect the bond at cemented

WARNING

Assure that line pressure guage on compressor indicates “ZERO” pressure before any work is done. Failure to comply may cause injury.

When the compressor fluid is ready to be changed, the compressor needs to be shutdown with thepower to the compressor disconnected (see Warning above). Drain the fluid from the compressor using

Figure 4--1 Service Air Piping

11

Section 4

INSTALLATION t hec om pr es s orf luiddr ainc ap( S eeF igur e2 -- 1) .

installer.

Fluid capacity for the compressor can be found in Section 3, Specifications of this manual. The compressor sump is properly filled when the level on the fluid level sight tube is 3/4 of the sight tube. During operation, the fluid level should cover 1/4 to 1/2 of the sight glass. DO NOT OVERFILL.

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

4.5 MOTOR ROTATION DIRECTION CHECK After the electrical wiring has been done, it is necessary to check the direction of motor rotation. This can be done by jogging the START selector switch

on theside of the control center. When looking at the motor from the cooler end of the compressor unit, thecooler fanshould be turning clockwise. If themotor is not turning clockwise, disconnect power to the starter and exchange any two of the three power input leads, then check rotation. A direction of rotation decal is located on the motor shroud, next to the cooler to insure correct motor/ compressor rotation. 4.6 ELECTRICAL PREPARATION Interior electrical wiring is performed at the factory. Required customer wiring is minimal, but should be done by a qualified electrician in compliance with OSHA, National Electrical Code, and any other applicable State, Federal and local electrical codes concerning isolation switches, fused disconnects, etc. Sullair provides a wiring diagram for use by the

12

!

WARNING

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

1. Check incoming voltage. Be sure that compressor is wired for the correct incoming voltage. 2. Check starter for correct size, proper overload relay and heaters. 3. Check all electrical connections for tightness. 4. “Dry run” the electrical controls by disconnecting the motor leads T1, T2, and T3 from the starter. Energize the control circuits by turning thesele ctor switch to the manual and automatic positions, and check all protection devices making sure when activated, they will de--energize the starter control coil. 5. Reconnect the motor leads and jog the motor for adir ec t ionofr ot at ionc hec kasex plainedinS ec t ion4. 5. NOTE Wiring diagramfor standardcompre ssors is supplied on the inside cov er of the Contro l Center. Optional compressor wiring diagrams will vary.

Section 5

OPERATION 5.1 GENERAL

While Sullair has built into this compressor a comprehensive array of controls and indicators to assure you that it is operating properly, you will want to recognize andinterpret 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.

5.2 PURPOSE OF CONTROLS CO NT R O L O R I NDI CATO R

P UR P O S E

START SELECTOR SWITCH

The three--position switch provides selection between MANUAL/START, OFF/RESET and AUTO--MATIC/

LINE PRESSURE GAUGE

START (for further description, see Section 2). Continually monitors service line air pressure.

FLUID LEVEL SIGHT GLASS

Indicates fluid level. The level is checked by looking at the fluid level sight glass on the end bell. The fluid level should cover 1/2 to1/4 of the sight glass during operation. With the compressor shut down, the level should be 3/4 of the sight glass. DO NOT OVERFILL.

COOLER BYPASS VALVE

Regulates fluid flow to and around the cooler. Designed to maintain a minimum operating temperature of 170 F (77 C). Used for fast warm--up and start--up.

MINIMUM PRESSURE/CHECK VALVE

Maintains a minimum of 60 psig (4.1 bar) in compressor sump. Valve piston restricts receiver air discharge from receiver/sump when pressure falls to 60 psig (4.1 bar). Also incorporatedin this valve is a terminal check valve which prevents line pressure backflow into the sump during unload conditions and after shutdown.

DISCHARGE TEMPERATURE SWITCH

Shuts the compressordow n whenthe compressordis charge temperature exceeds 240F (116 C).









PRESSURE RELIEF VALVE

Opens sumpthe pressure the atmosphere pressure inside sump to become too high. should Operation of thisvalve indicates that the air pressure switch is either faulty or out of adjustment.

AIR PRESSURE SWITCH

Senses service line pressure. When line pressure reaches maximum setting, the pressure switch opens solenoid valve circuit to unload the compressor.

SOLENOID VALVE SUMP PRESSURE SWITCH (Not used on current models except with Wye--Delta starter). DISCHARGE TEMPERATURE GAUGE

Ventssu mpp ressuret hroughi nlet controlv alve toth e atmosphere during unload conditions and shutdown. Senses sump pressure and prevents compressor from starting until sump pressure has fallen below preset pressure of 10 psig (0.7bar). Continually monitors discharge temperature of the compressor.

13

Section 5

OPERATION 5.3 INITIAL START--UP PROCEDURE

The following procedure should be used to make the initial start--up of the compressor. 1. Read the preceding pages of this manual thoroughly. 2. Jog motor to check for correct rotation of fan (ref ert oS ec t ion4. 5) . 3. Be sure that all preparations and checks described in the Installation Section have been made. 4. Open the shut--off valve to the service line. 5. Start the compressor by turning the selector switch to “manual” or “automatic”. 6. Check for possible leaks in piping. 7. Slowly close the shut--off valve and check that the pressure switch is set correctly. If set correctly, the compressor will unload at nameplate pressure. If adjustments are necessary, see Control

14

System Adjustment in Section 6, Maintenance of this manual. 8. Observethe operating temperature. If the operating temperature exceeds 200 F (93 C), the cooling system and installation environment should be checked. 9. Open shut--off valve to the service line. 10. Reinspect the compressor for temperature and leaks the following day. 



5.4 SUBSEQUENT START--UP PROCEDURE

On subsequent start--ups, check that the proper level is visible in the fluid level sight glass and simply turn selectoris switch to desired control. When the compressor running, observe the instrumentation. 5.5 SHUTDOWN PROCEDURE

To shut the compressor down, simply turn selector switch to OFF/RESET position.

Section 6

MAINTENANCE 6.1 GENERAL !

1. Remove the fan guard by removing the four (4) self--tapping screws holding the guard and fan ring to the cooler. 2. Remove the 1/8” NPT plugs in the filler and drain connection for both bearings. 3. Free drain hole of any hard grease (use piece of wire if necessary). 4. Add grease (I) using a low pressure grease gun. 5. Wipe off any drained grease, and replace filler and drain plugs. 6. Replace fan guard. 7. Motor is now ready for operation.

WARNING

Before doing compressor maintenance, disconnect compressor from power source and lockout power source.Isolate compressor from linepressure by closing recommended discharge shut -off valve and releasing all internal pressure from compressor.

As you proceed in reading this section, it will be easy

(I) Use Chevron SRI--2 grease when lubricating motor bearings. Fill the cavity 1/3 to 1/2 full by repacking or use a low pressure grease gun and fill through the lubricating provisions on the motor end bell housing.

to see that the Maintenance Program for the compressor is quite minimal yet important. Seeair instructions for each item in Section 6.6, Parts Replacement and Adjustment Procedures.

6.2 DAILY OPERATION Prior to starting the compressor, it is necessary to 6.4 FLUID FILTER MAINTENANCE check the fluid level in the sump. Should the level be low, simply add the necessary amount. If the addi! WARNING tion of fluid becomes too frequent, a minor problem has developed which is causing this excessive loss. Fluid filte r has internal bypa ss. DO NOT SUBSTIS eet heTr oubles hoot ingS ec t ion( 6. 7)underE x ce s TUTE. s iv eF luidCons um pt ionf orapr obablec aus eand remedy. Replace the fluid filter element under any of the following conditions: After a routinestart has been made, a general check of the overall compressor should be made to assure 1.A sr ec om m endedint heLubr ic at ionG uidein that the compressor is running properly. Section 3. 2. Every year. 6.3 MOTOR BEARING LUBRICATION 3. Every fluid change. !

WARNING


6.5 COOLER MAINTENANCE If cooler becomes restricted, use standard spray degreaser/cleaner and brush to clean cooler. Use air pressure to blow cooler clean. Care must be taken as not to damage cooler fins. !

WARNING


S eeTable1,M ot orB ear ingLubr ic at ionS ch edule.I f lubrication instructions are shown on the motor or in a separately provided manual, they will supercede this general instruction. TABLE 1 -- MOTOR BEARING L UBRICATION SCHEDULE STANDARD CONDITIONS (I)

MODEL

5HP(4KW) 7.5 and 10HP (5.5 & 7.5KW) All Motors Over 1800 RPM

SEVERE CONDITIONS (II)

3Years 2.5 Years

1Year 10 1/2Months

6 Months

3 Months

EXTREME CONDITIONS (III)

6Months 5 1/2 Months 3 Months

(I) Eight hours per day, normal or light loading, clean 100 F (38 C) maximum ambient. (II) Twenty--four hours per day operation or shock loadings, vibration, or in dirt or dust at 100 F to 150 F (38 C to 66 C) ambient. (III) Heavy shock or vibration, dirt or dust at 100 F to 150 F (38 C to 66 C) ambient. 



















15

Section 6

MAINTENANCE 6.6 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES !

Figure 6-1 Fluid Filter (P/N250026-982) TEMPERATURE GAUGE

WARNING


FLUID FILTER REPLACEMENT Ref ert oF igur e6 -- 1. 1. To prevent spillage and loss of reusable fluid, place a contaminate--free fluid receptacle beneath 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. 8. Replace fluid. DO NOT OVERFILL. 9. Restart compressor and check for leaks. AIR FILTER MAINTENANCE Ref ert oF igur e6 -- 2.A irf ilt er( P / N250025 -- 421) maintenance shouldbe performed every six months or more frequent if conditions so require. !

FLUID FILL PLUG

*FLUID FILTER ELEMENT

FLUID DRAIN CAP * Replacement Element Kit P/N 250028--032

WARNING


AIR FILTER ELEMENT MAINTENANCE 1. When performing maintenance, care must be taken that no dirt or foreign matter enters intake housing.

2. Clean exterior of air filter cover. 3. Remove the air filter cover by loosening the wingnut securing the cover. 4. Remove element and base. Clean base and interior of cover using a damp cloth. DO NOT use compressed air to clean cover and base. 5. At this time replace element. 6. Replace cover.

COMPRESSOR LUBRICATION GUIDE AND MAINTENANCE SCHEDULE AMBIENT T E M P E R AT U R E --10F to +90 F (--23C to +32 C)

LU B R I C A T I O N Sullube32 SullairLLL--4--32 SRF 1/4000 ATF as per Dex tron II Motor Oil MIL--2104E, SPEC API SF CC, CDSAE10WClassSE

FLUID & FILTER CHANGE PERIO D (HRS.) 8000 * 8000 * 4000 1000

* 8,000 Hours or once a year. ** 4,000 Hours or more frequently if conditions so require.

16

600

SEPARATOR CHANGE PERIO D (HRS.) 8000 * 8000 * 4000 1000 600

AIR FILTER CHANGE PERIO D (HRS.) 4000 ** 4000 ** 4000 ** 4000 ** 4000**

Section 6

MAINTENANCE Figure 6--2 Air Filter (P/N 250025--421)

ELEMENT INSPECTION 1. Place a bright light inside the element to inspect for damage or leak holes. Concentrated light will shine through the element and locate any holes. 2. Inspect all gaskets and gasket contact surfaces of the housing. Should faulty gaskets be evident, correct the condition immediately. 3. If the clean element is to be stored for later use, it must be stored in a clean container. 4. After the element has been installed, inspect and tighten (if necessary) all air inlet connections prior to resuming operation. SEP TOR ELEMENT REPLACEMENT Ref eARA rt oF igur e6 -- 3.T hes epar at ors houldbe changed once a year. Follow the procedure explained below for element replacement. !

WARNING


* Replacement Element Kit P/N 250028--034

1. Insert a 4” maximum length, 1/4”diameter pininto the radially drilled hole in the separator cap. Loosen, unscrew counterclockwise and remove the cap. 2. Pull out the old element by gripping the end of the element with channel lock pliers or a similar tool. 3. Install new o--rings on separator cap and separator element filter and oil lightly to make installation easier. 4. Insert and push the new element in place.

Figure 6--3 Separator Element (P/N 250025--264)

* Replacement Element Kit P/N 250028--033

17

Section 6

MAINTENANCE Figure 6--4 Minimum Pressure/Check Valve (P/N 606058)

4. Remove the screw holding the check valve seat. Replace valve seat. Reinstall securing with LoctiteR #222. 5. Install new o--ring. Before reinstallation, lubricate with Parker Super “O” ring seal or an equivalent grease. 6. Reinstall the whole valve assembly. Tighten and secure. THERMOSTAT ACTUATOR MAINTENANCE Ref ert oF igur e6 -- 5.T heonlypar twhic hwouldev er need replacement is the thermostat valve actuator. For replacement, follow the procedure explained

below. !

WARNING


* Repair Kit P/N 250030--226 5. Reinstall the cap. Hand--tighten using a 4” maximum length, 1/4” diameter pin in the radially drilled hole. MINIMUM PRESSURE/CHECK VALVE MAINTENANCE Ref ert oF igur e6 -- 4.M inim umpr es s ur e/ c hec kv alv e

maintenance is minimal. The only parts which normally require replacement are the o--ring seal around the piston and the valve seat on the check valve. To replace any of thetwo parts, follow theprocedure explained below. !

1. To prevent spillage and loss of re--usable fluid, place a contaminate--free fluid receptacle beneath fluid drain valve and fluid filter. 2. Drain fluid by removing fluid drain cap at tee located beneath compressor. 3. Unscrew and remove hollow hex plug. 4. Remove spring and piston. 5. By using long nosed pliers, pull the actuator out. 6. Install new actuator. 7. Install piston and spring with centering guide. 8. Re--install plug. Figure 6--5 Thermostat Actuator(P/N 250025--413)

WARNING


!

WARNING

Assure that line pressure gauge on compressor indicates “ZERO” pressure before any work is done. Failure to comply can cause injury.

1. Unscrew the minimum pressure valve from the drive housing. 2. Remove all parts. 3. Clean and inspect all parts.

18

* Repair Kit P/N 250028--036

Section 6

MAINTENANCE Figure 6--6 Air Pressure Switch (P/N 250025--299)

CONTROL SYSTEM ADJUSTMENT Ref ert oF igur e6 -- 6.A llc om ponent sint heCont r ol System are designed andmanufactured to close tolerances to eliminate any need for adjustments. The only adjustment required is to set the air pressure

!

DANGER

DO NOT touch theelec tric al contacts, terminalor leadswith any part of thebodyor any uninsulated metallic object. Severe electrical shock may occur.

switch. low. This is done by following the instructions be1. Remove the pressure switch cover. 2. With the shut--off valve closed or slightly cracked open, start the compressor. 3. Observe the line pressure gauge and pressure switch contacts. When the line pressure reaches nameplate pressure, the pressure switch contacts should open. 4. If the pressure switch contacts do not open or they open prior to the desired pressure, the pressure switch setting will require adjustment (refer to Figure 6--6). To adjust the pressure switch, turn the range--adjusting screw to the high pressuresetting. Turning the screw counterclockwise lowers both the high and low pressure setting equally.

UNLOADER SOLENOID VALVE MAINTENANCE Unloader valve maintenance is minimal, but a periodic cleaning is desirable. The time between cleanings will vary depending on operating conditions. In general, if thevolt age to the coils is correct, sluggish valve operation or excessive leakage will indicate that cleaning is required.

FOR DIFFERENTIAL ADJUSTMENT OF AIR PRESSURE SWITCH:

DISASSEMBLY AND REASSEMBLY 1. Remove the retaining cap and slip the entire sole-

Differential is settings. the difference between the high and low pressure

noid off the solenoid base subassembly. 2. Unscrew the solenoid base assembly. Remove the core assembly, core spring and body gasket. 3. All parts are now accessible for cleaning or replacement. 4. Reassemble in reverse order of disassembly.

Turning the screw clockwise increases the differential, and counterclockwise decreases the differential pressure.

!

WARNING

Turn off all power,reliev e sumppress ure,and disconnect coil lead wires to the solenoid valve before making repairs.

It is not necessary to remove thevalv e from thepipe line for repairs.

19

Section 6

MAINTENANCE COIL REPLACEMENT 1. Remove the retaining cap, nameplate and cover. 2. Slip the yoke containing the coil and sleeves off the solenoid base subassembly. 3. Reassemble in reverse order of disassembly. !

WARNING


INLET CONTROL VALVE Ref ert oF igur e6 -- 7.T heonlypar t swhic hnor m ally require replacement are the piston seal on the intake valve piston and gasket. Follow this procedure for inlet control maintenance. 1. Remove the inlet filter assembly. 2. Disconnect tubing from intake control housing at 90 elbow. 3. Remove the two (2) 3/8” ferry head capscrews securing the intake control housing to the inlet plate. 4. Remove intake control housing assembly and gasket. 5. Remove retaining ring, cap and intake check spring from intake housing bore. 

6. Remove socket head capscrew, washers, and check spring from intake valve rod. 7. Remove intake valve from valv e housing. Remove intake valve rod, check spring, spring retainer and intake valve head. 8. Remove intake piston from intake/inlet control housing. Remove and discard old piston seal from intake piston. 9. Clean intake housing gasket surface andinternal piston bore. 10. Lubricate internal piston bore using lubricant supplied with kit. 11. Install new piston seal onto piston. 12. Reinstall intake valve rod, check spring, spring retainer and intake valve head into intake control housing. Install assembled intake piston into intake control bore and onto intake valve rod. 13. Install washers. Apply screw lock adhesive provided in kit to socket head capscrew. Replace socket head capscrew into the valve rod and torque socket head capscrew to 18 to 24 in.--lbs. (2.0 to 2.7Nm). 14. Install intake check spring, cap and retaining ring. 15. Replace gasket and reinstall the whole inlet control valve assembly. 16. Apply screw lock adhesive to inlet control housing assembly ferry head capscrews and install. Torque to 30 ft.--lbs. (40.7Nm). 17. Reconnect tubing to inlet control valve housing at 90 elbow. 

Figure 6--7 Inlet Control Valve

*

* * Repair Kit P/N 02250045--287

20

Section 6

MAINTENANCE 18. Reinstall air inlet filter assembly. MOTOR SHAFT SEAL REPLACEMENT Replacement of motor shaft seal requires that the compressor be separated from the drive housing. This operation requires qualified personnel.

Detailed instructions and a list of needed tooling are included in each motor shaft seal replacement kit no. 250028--035. 6.7 TROUBLESHOOTING The information contained in the Troubleshooting

chart is based upontesting both the actual applied situations and extensive at thefacto ry. It contains symptoms and usual causes for the described problems. However DO NOT assume that these are the only problems that may occur. All available data

concerning the trouble should be systematically analyzed before undertaking any repair or component replacement procedures. A detailed visual inspection is worth performing for almost any problems which may prevent unnecessary damage to the compressor. Always remember to: a. Check for loose wiring. b. Check for damaged piping. c. Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor. Should your problem persist after making the recommended check, consult your nearest Sullair representative or the Sullair Corporation factory.

TROUBLESHOOTING S Y MP T O M

P R O B A B LEC A U SE

COMPRESSOR WILL NOT START

Main Disconnect Switch Open LineFuseBlown

COMPRESSOR SHUTS DOWN WITH AIR DEMAND PRESENT

R E ME D Y Close switch. Replacefuse.

Control Transformer Fuse Blown

Replace fuse.

Motor Starter Overloads Tripped

Reset. Should trouble persist, check whether motor starter contacts are functioning properly.

Low Incoming Line Voltage

Check voltage. Should voltage check low, consult power company.

Low Incoming Voltage

Consult power company .

Excessive Operating Pressure

Defect in pressure switch; check pressure at which contact points open.

Discharge Temperature Switch Open

Cooling air flow restricted; clean cooler and check for proper ventilation. Ambient temperature is too high; provide sufficient ventilation. Low fluid level; add fluid. Clogged filter; change the fluid filter element. Thermal valve not functioning; replace element. Defective discharge temperature switch; check for a short or open circuit to probe and correct wiring.

COMPRESSOR WILL NOT BUILD UPFULLDISCHARGEPRESSURE

Air Demand Is Too Great Dirty Air Filter

Check service lines for leaks or open valves. Check filter and change element if required.

Pressure Regulator Out Of

Adjust regulator according to control

Adjustment

adjustment instructions in Section 6, Maintenance.

Defective Solenoid Valve

A normally open solenoid must energize to load compressor; check for proper operation.

21

Section 6

MAINTENANCE TROUBLESHOOTING S Y MP T O M LI N EP R E S S U R ER IS  E SA B O V E CUT--OUT PRESSURE SETTING ON PRESSURE SWITCH

EXCESSIVE COMPRESSOR FLUID CONSUMPTION

PRESSURE RELIEF VALVE OPENS REPEATEDLY

LIQUID WATER IN COMPRESSED AIR LINES

P R O B A B LEC A U SE

R E ME D Y

D ef ec tiv eS olenoidValv e

R epairs olenoidv alv e( s ee S ec tion6) .

Leak In Control System Causing Loss Of Pressure Signa ls

Check for leaks.

Defective Pressure Switch

Check that diaphragm and contacts are not damaged. Replace if necessary.

Inlet Valve Stuck Open

Inspect inlet valve and insure free operation (s eeSec ti on 6).

Clogged Return Line

Remove element cover and clean orifice.

Separator Element Damaged Or Not Functioning Properly

Change separator element.

Leak In The Lubrication System

Check all pipes, connections and components.

Excess Fluid Foaming

Drain and change.

Fluid Level Too High

Drain excess.

Shaft Seal Failure

Replace shaft seal.

Compressor Operating Pressure

See Symptom “Line Pressure Rises Above

Too High

Cut--out Pressure Setting on Pressure Switch” above

Defective Pressure Relief Valve

Replace pressure relief valve.

Water Vapor Condensation From Cooling and Compress ion Oc curs Naturally

Remove the water vapor from compressed air prior to distribution through the air sy stem. C heck operation of aftercooler and moisture separator. Install a compressed air dryer sized for the flow and dryness level required. (Note: Filters also be required to remove particulates, liquidmay oil aerosols or for oil vapor removal. Change cartridges as recommended by the filter manufacturer.) Check all drain traps routinely to insure their proper operation. Maintain them regularly.

22

Section 6

MAINTENANCE 6.8 MAINTENANCE RECORD

MODELNO.

DATE

SERIALNO.

HOURMETER

MAINTENANCE PERFORMED

WORK PERFORMED BY

AUTHORIZED BY

23

Section 7

ILLUSTRATIONS AND PARTS LIST ES--6 COMPRESSOR ASSEMBLY, EXPLODED VIEW

(5.5 AND 7.5KW)

24

Section 7

ILLUSTRATIONS AND PARTS LIST 7.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was purchased. If for any reason partscannot be obtained in this manner, contact thefact ory directlyat the address, phone numbers or fax numbers below.

When ordering parts always indicate the Serial Number of the compressor.Thiscan beobtained from theBillof Lading for the compressor or from the Serial Number Plate located on the compressor. The genuine Sullair service parts listed meet or exceed the demands of this compressor. Use of replacement parts other than those approved by Sullair Corporation may lead to hazardous conditions over which Sullair Corporation has no control. Such conditions include, but are not limited to, bodily injury and compressor failure.

SULLAIR CORPORATION Subsidiar y of Sundstrand Corporation 3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. Telephone: 1 --800 --SULLAIR (U.S. On ly) or 1--2 19 --8 79 -- 5451 Fax: (219) 874 -- 1273 Fax: (219) 874 -- 1835 (Parts) Fax (219) 874 -- 1805 (Service)

SULLAIR ASIA, LTD.

Chiwan Supply Base Bldg A5 --1 Chiwan Shenzhen, Guangdong PRV. P.R.C. Post Code 518068 Telephone: 755--6694982 FAX: 755--66 94313

SULLAIR EUROPE, S.A. Chemin de Genas BP 639 69800 Saint Priest, France Telephone: 33--72232425 Fax: 33 -- 78907168

7.2 RECOMMENDED SPARE PARTS LIST DESCRIPTION

KITNUMBER

250028 -- 032 replacement element kit for fluid filter 250026--982 replacement element kit for air/fluid separator 250025--264 250028 -- 033 250028 -- 034 replacement element kit for air filter 250025--421 250028 -- 035 repair kit for motor shaft seal 250039--218 250034 -- 267 repair kit, shaft seal installation 250028 -- 036 repair kit for thermostat actuator 250025--413 250028 -- 387 replacement kit for coil 250028--809 250038 -- 849 repair kit for solenoid valve 250030--164 250035 -- 292 replacement coil for solenoid valve 250030--164 250030 -- 226 repair kit for minimum pressure/check valve 606058 02250045 -- 287 replacement piston seal kit for air inlet control valve 02250044 -- 811 replacement piston for inlet control valve 02250045 -- 287 replacement washer for inlet control valve 250009 -- 396 fluid, Sullube 32 (one gallon) 250022 -- 669 fluid, Sullube 32 (five gallons) repair kit for ES--6 1/2” npt service connection 250026--066 250030 -- 103

QUANTITY 1

1

1 1 1 1 1 1 1 1 1 1 1 1 1 1

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

25

Section 7

ILLUSTRATIONS AND PARTS LIST 7.3 FLUID MANAGEMENT SYSTEM

26

Section 7

ILLUSTRATIONS AND PARTS LIST 7.3 FLUID MANAGEMENT SYSTEM key number

1 2 3 4 5 6 7 8 9 10

description

part number

quantity

element, fluid filter (I) 250026--982 1 adapter,fluidfilter 250025--914 1 cap,separatorelement 250026--038 1 o--ring,23/16”x3/32” 826502--139 1 element, separator air/fluid (II) 250025--264 1 o--ring,17/16”x1/16” 826502--127 1 plug, hex head 1 1/16”--12 SAE 250039--359 1 glass,sight 250025--420 1 housing,bell 250025--309 1 capscrew, ferry head 1/2”--13 x 3” 828408--300 12 screw, socket ISO4762 m12 x 20 (metric) 829312--080 12 actuator, thermostat (III) 250025--413 1 piston,thermostat 250025--415 1 spring,compression 250025--464 1 pin,roll1/4”x11/2” 827404--150 1 guide, thermostat spring 250025--417 1 o--ring (IV) 250025--419 3 plug, thermostat 1 1/16”--12 250025--418 1 decal, fluid (V) -1 S

11 12 13 14 15 16 17 18

(I) For maintenance on fluid filter element no. 250026--982, order repair kit no. 250028--032. (II) For maintenance on air/fluid separator element no. 250025--264, order repair kit no. 250028--033. (III) For maintenance on thermostat actuator no. 250025--413, order repair kit no. 250028--036. (IV) For replacement only. (V) Decal will vary with compressor fluid fill requirement. Factory fill (Sullube 32) decal part no. is 02250069--389. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

27

Section 7

ILLUSTRATIONS AND PARTS LIST 7.4 INLET FILTER

28

Section 7

ILLUSTRATIONS AND PARTS LIST 7.4 INLET FILTER key number

1 2 3 4 5 6 7

description

filter,airassembly nut,wing1/4”--20 washer,seal hood,airfilter element, air filter (I) plate,airfilterbase rod,threaded1/4”x5”

part number

250025--265 824815--004 250025--661 250025--422 250025--421 250025--423 843504--050

quantity

1 1 1 1 1 1 1

(I) For maintenance on air filter element no. 250025--421, order repair kit no. 250028--034. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

29

Section 7

ILLUSTRATIONS AND PARTS LIST 7.5 SEAL AND DRIVE GEAR

30

Section 7

ILLUSTRATIONS AND PARTS LIST 7.5 SEAL AND DRIVE GEAR key number

1 2 3 4 5 6 7 8 9

description

plate,inlet gear,driven gear,drive sleeve,wear seal, shaft Teflon/Viton (I) capscrew, ferry head 1/4”--20 x 3/4” housing,shaftseal o--ring,27/8”x3/32” spacer,gear

part number

250028--339 ConsultFactory ConsultFactory 250025--412 250039--218 828404--075 250025--312 826502--150 250039--600

quantity

1 1 1 1 1 2 1 1 1

(I) For maintenance on motor shaft seal no. 250039--218, order repair kit no. 250028--035. NOTE: Requires special tooling for removal/inst allation. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

31

Section 7

ILLUSTRATIONS AND PARTS LIST 7.6 MOTOR, HOUSING AND PARTS

7.5 & 10HP (5.5 & 7.5KW) ONLY

32

Section 7

ILLUSTRATIONS AND PARTS LIST 7.6 MOTOR, HOUSING AND PARTS key number

1

part number

description

250026--839 02250059--246 250030--547 837201--045 250030--223 250030--502 250033--369 250025--428 826502--116 250025--429 250025--430 409955 250039--678 490046--001 ConsultFactory Consult Factory Consult Factory 250040--312

16 17

housing,drive housing, drive (metric) screw, machine round head #8--32 x 1/2” washer,pl--b#8 seat, minimum pressure/check valve stem, minimum pressure/check valve spring, minimum pressure/check valve piston, minimum pressure/check valve o--ring,3/32”x3/4” spring, minimum pressure/check valve cap, minimum pressure/check valve valve, relief 1/2” 175 psig (12.1 bar) valve, relief 1/2” 200 psig (13.8 bar) plug, pipe hex soc. 1/8” NPT motor,5HP/4KW motor, 7.5HP/5.5KW motor, 10HP/7.5KW switch, temperature 212 -- normally closed connector, tube--m 5/8” x 1/2” (7.5 and 10HP/5.5 and 7.5 KW only) base,compressor capscrew, hex gr8 1/2”--13 x 1”

18 19 20 21 22

valve, minimum pressure/check (I) washer, pl--breg pltd1/2” connector, tube--m 1/2” x 1/2” bail,lifting capscrew, hex 5/16”--18 x 7/8”

606058 838208--112 810208--050 250039--904 827905--088

S

2 3 4 5 6 7 8 9 10 11

S

12 13

S S

14 15



quantity

1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1

810210--050 250026--469 829108--100

1 1 2 1 1 1 1 1

(I) For maintenance on minimum pressure/check valve no. 606058, order repair kit no. 250030--226. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

33

Section 7

ILLUSTRATIONS AND PARTS LIST 7.7 COMPRESSOR COOLER SYSTEM

7.5 & 10HP (5.5 & 7.5KW) COOLER

34

Section 7

ILLUSTRATIONS AND PARTS LIST 7.7 COMPRESSOR COOLER SYSTEM key number

1

description

duct, cooler mount (5HP/4KW) duct, cooler mount (7.5HP and 10HP/5.5 and 7.5KW) ring,cooler(5HP/4KW) ring, cooler (7.5HP and 10HP/5.5 and 7.5KW) screw, hex serrated washer 1/4”--20 x 1/2”

part number

quantity

250026--472

1

250026--471 250034--535

1

S

2

1

S

3 4 5

250034--536 829704--050

screw, hex serrated washer 1/4” x 3/4” 829704--075 plate, cooler filler (5HP/4KW) 250025--829 plate, cooler filler (7.5HP and 10HP/5.5 and 7.5KW) 250026--843 nut, hex 5/16”--18 (5HP/4KW) 825305--283 nut, hex 5/16”--18 (7.5 and 10HP/5.5 and 7.5KW) 825305--283 cooler,fluid(5HP/4KW) 250028--961 cooler, fluid and aftercooler (7.5&10HP/5.5 and 7.5KW) (I) 250026--066 orifice, fanring123/8” id 250034--537 capscrew, ferry 5/16”--18 x 1 1/2” (5HP/4KW) 828405--150 capscrew, ferry 5/16”--18 x 2” (7.5HP &10HP/5.5 and 7.5KW) 828405--200 washer, flat 5/16”id x 1 1/4”od (5HP/4KW) 250025--830 washer, flat 5/16”id x 1 1/4”od (7.5 & 10HP/5.5 and 7.5KW) 250025--830 connector, tube straight threaded 1/2” x 3/4” 811808--075 tube,1/2”od(5HP/4KW) 250026--718

1 8 4 1

S

6

1 1

S

7

2 1

S

8 9 10

1 1 1 2 1

S

11 12 13 14 15 16

tube,1/2”od cap,1/2”tube tee,tubeunion1/2” tube,1/2”od(5HP/4KW) tube, 1/2”od (7.5HP and 10HP/5.5 and 7.5KW) guard,12”fan cap,fanguard4” fan, 12” diameter (5HP/4KW) fan, 12” diameter (7.5HP and 10HP/5.5 and 7.5KW) elbow, 90 connector 7/8”--14 x 1/2”npt elbow, tube straight threaded 5/8” x 7/8” (7.5 and 10HP/5.5 and 7.5KW) tubing, aftercooler in (7.5 and 10HP/5.5 and 7.5KW) tubing, fluid cooler out (7.5 and 10HP/5.5 and 7.5KW)

250030--040 250026--350 811408--050 250026--719

2 2 1 1 1 1 1

S

17 18 19

250030--041 250028--964 250026--591 250026--253

1 1 1 1

S

20 21 22 23 24 25



screw,brassset insert, 1/4”--20 threaded blind

250026--254 250030--104

1 1

811615--062

1

250030--042

1

250030--043

1

250031--014 250034--538

1

8

(I) ES--6 1/2” npt service connection kit no. 250030--103. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

35

Section 7

ILLUSTRATIONS AND PARTS LIST 7.8 COMPRESSOR SYSTEM

36

Section 7

ILLUSTRATIONS AND PARTS LIST 7.8 COMPRESSOR SYSTEM key number

part number

description

1 2 3 4

washersealboltbuss locknut,male--M25x1 wavespring,male bearing,taper

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

housing, stator ES--6 “E” profile cover, outlet capscrew, ferry head 1/4”--20 x 11/4” locknut, femaleM17x1 wavespring,female washer, pl b--reg pltd3/8” bearing,taper capscrew, ferry head 5/16”--18 x 1” capscrew, ferry head 5/16”--18 x 2 1/4” rotor, female “E” profile (I) rotor, male “E” profile (I) capscrew, ferry head 3/8”--16 x 33/4” plate,inlet elbow, tube 90M 1/4” x 1/4” bearing, cylinder roll plain bearing, needle roller steel

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

retainer,inletbearing screw, machine flat head 1/4”--20 x 1/2” orifice, gear spray (mounting location) tube, separator fluid return tee, tube branch straight thread 1/2” x 3/4” valve,bodythermostat capscrew, ferry head 5/16”--18 x 1 1/2” fitting, separator fluid return cap, 1/2” tube od 3/4”--16 capscrew, socket head 1/4”--20 x 1/4” plate, ES--6 identification screw, drive rod plated #8 x 3/8” screw, set cup 5/8”--11 x 1/2” pin,dowel3/8”x1” capscrew, ferry 3/8”--16 x 3/4” hose,nylon1/4”

quantity

499065--007 02250055--135 02250047--887 499080--203 250029--910 250025--315 828404--125 02250055--136 02250055--485 838206--071 499025--005 828405--100 828405--225 02250055--489 02250055--490 828406--375 250028--339 250025--850 499082--705 250023--213 250025--435 831204--050 250030--545 250025--865 250041--956 250025--414 828405--150 250025--870 250026--350 828304--025 250026--859 839608--060 250033--368 499045--032 828406--075 842215--004

2 1 1 2 11 5 1 1 2 2 3 2 1 1 2 1 2 1 1 1 1 1 1 1 1 2 1 1 2 1 2 1 4 2 5ft.

(I) Machine serial numbers below 006--93007285 consult factory for rotor part numbers. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

37

Section 7

ILLUSTRATIONS AND PARTS LIST 7.9 INLET CONTROL

38

Section 7

ILLUSTRATIONS AND PARTS LIST 7.9 INLET CONTROL key number

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

description

rod, ES--6 intake control valve spring, PTO ES--6 intake check retainer, ES--6 intake control valve gasket,inletvalve head, ES--6 intake control valve housing,intakecontrol piston, ES--6 intake control valve (I) seal, ES--6 intake control piston (II) washer, Belleville spring (I) capscrew, sch #10--32 x 1/2” Nylok spring, inlet control ES--6 cap,airintake ring, retaining internal 1 3/8” elbow, 90 male 1/8” npt x 1/4” tube hose,nylon1/4” 

part number

quantity

02250044--810 1 250034--619 1 02250044--809 1 250025--425 1 02250044--808 1 250025--310 1 02250044--811 1 02250044--671 1 250031--269 2 02250043--162 1 02250042--966 1 250029--898 1 836150--137 1 250025--840 1 842215--004 5ft.

(I) For maintenance on inlet control, order piston no. 02250044--811 and washer no. 250031--269. (II) For maintenance on air intake valve pist on seal, order repair kit no. 02250045--287. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

39

Section 7

ILLUSTRATIONS AND PARTS LIST 7.10 CONTROL BOX

40

Section 7

ILLUSTRATIONS AND PARTS LIST 7.10 CONTROL BOX key number

1 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21

description

part number

quantity

Consult factory for starter group, and refer to compressor serial number. bracket,topstarter 250039--244 1 plate ES--6, access (Ref.) 250034--858 1 locknut,conduit1/2” 847200--050 3 nipple,chase1/2”npt 847815--050 2 decal, 3 position switch panel 250039--113 1 hose,nylon1/4” 842215--004 5ft. valve, solenoid 1/8” 110/120 (I) 250030--164 1 box,junction 250026--740 1 screw, hex serrated washer 1/4” x 1/2” 829704--050 9 lug 849215--004 1 nut, hexflanged1/4”--20 825304--236 9 switch,selector3position 248168 1 elbow, 90 m swvl 1/8T x 1/8 NPT 250025--849 2 pushbutton, “manual/reset” 02250045--011 1 screw, 1/4”--20 x 1/2” long 250030--162 4 fastener,suregrip 041516 2 nameplate, Sullair 1” x6” 250035--063 1 joint, compression phase 230V, 3PH 250026--615 1 phase 3 460V (not shown) 250026--615 3 insulator, splice phase 1 230V, 3PH 250006--110 1 phase 3, 460V (not shown) 250006--110 3 panel,circuitboard 250025--863 1 Consult factory for starter group, and refer to compressor serial number. t ransformer 02250045--012 1 rivet,pop1/8”x3/8” 843102--038 4 nameplate,Sullair 02250059--318 1 gauge, pressure 0--200# bar/psi 250005--185 1 tee,malebranch1/8” 250026--139 1 connector, male tube straight 1/8” x 1/4” 250025--858 1 plug,hole1/2” 045689 1 

S

22

S

23 24 25 26 27 28 29 30 31

(Continued on page 43)

(I) For maintenance on solenoid valve no. 250030--164, order repair kit no. 250038--849, and replacement coil no. 250035--292. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

41

Section 7

ILLUSTRATIONS AND PARTS LIST 7.10 CONTROL BOX

42

Section 7

ILLUSTRATIONS AND PARTS LIST 7.10 CONTROL BOX (continue d) key number

32 33 34 35 36 37 38 39 40 41 42 43 44 45

description

bushing, reducing 1/4” x 1/8” switch, pressure 0--200# (air) connector,1/2” plate ES--6, switch (Ref.) capscrew, hex 1/4”--20 x 5 1/2” 5HP singlephase capacitor, run 5HP/4KW single phase capacitor, start 5HP/4KW single phase nut, hex flanged 1/4”--20 (single phase) support, lower control box ES--6 gauge,temperature light, pilot assembly -- green hourmeter, rnd 2 1/2” 120V/60Hz (optional) gasket, hourmeter (optional) panel, gauge temperature capillary

part number

quantity

807600--005 250025--299 250026--153 250031--869

1 1 1 1

828604--550 250031--734 250031--733 825304--236 250041--860 02250043--291 250000--104 250042--224 02250056--423 02250043--320

1 2 2 1 1 1 1 1 1 1


43

Section 7

ILLUSTRATIONS AND PARTS LIST 7.11 CANOPY AND PARTS

15

5

1 13

18

10 11

14

6 7

12

9

8 16

4

17

3

2

44

Section 7

ILLUSTRATIONS AND PARTS LIST 7.11 CANOPY AND PARTS key number

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

description

cover,ES--6canopy foam, front ES--6 canopy sound soundcoat, ES--6 canopy -- right soundcoat, ES--6 canopy -- left louvers,ES--6canopy bracket, ES--6 canopy mounting -- left bracket, canopy ES--6 mounting -- right canopy,stopES--6 decal, Sullair logo (not shown) decal, ES--6 Model (not shown) decal, warning--under pressure decal, prohibit breath trim,canopyedge screw,#14x.625hex rivet, plastic1/4”x5/8” foam, ES--6 canopy sound -- top foam, ES--6 canopy sound -- rear decal, ISO 9001 (not shown)

part number

250031--542 250041--300 250032--871 250032--872 250032--309 250033--701 250033--702 250033--096 02250059--052 02250060--043 02250078--001 02250078--007 250034--157 250034--158 250034--159 250041--298 250041--299 02250059--288

quantity

1 1 1 1 1 1 1 2 1 1 1 1 2 16 4 1 1 1


45

Section 7

ILLUSTRATIONS AND PARTS LIST 7.12 FRAME, CANOPY AND PARTS

46

Section 7

ILLUSTRATIONS AND PARTS LIST 7.12 FRAME, CANOPY AND PARTS key number

1 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 45 46 47 49 51 52 55 58 60 64 65 66 67 71

description

canopy,ES--6 pan, ES--6canopybase partition, ES--6canopy rod, ES--6 canopy support footing,ES--6canopy rod,ES--6canopyhinge soundcoat, ES--6 canopy partition mounts, canopy vibration anchor,supportrod retainer, ES--6 canopy partition retainer,shakeproof screw, hex serrated washer 3/8” x 1” nut, hex flange plated 3/8”--16 isolator, 5/16”--18 x 1” diameter pad bracket, ES--6 canopy centering plug,2”hole screw, hex serrated washer 1/4” x 1/2” nut, hex flange plated 1/4”--20 washer, pl--b regular plated 3/8” bracket, canopy adjustment panel, ES--6 access (Retrofit kit only) plate, ES--6 switch (Retrofit kit only) plug, 1.2 diameter hole into pressure switch light, pilot assembly -- green gauge, temperature capillary 1/2” x 4’ (notshown) hourmeter, round 2 1/2” 120V/60Hz ES--6 gauge, pressure 0--200# bar/psi (notshown) rivet, plastic1/4”x5/8” bezel, ES--6 canopy control decal, warning auto start decal, ES--6 canopy bezel switch gasket,hourmeter nut, hex flanged plated 5/16”--18 switch,pressure

part number

250031--542 250031--545 250031--546 250032--223 250032--226 250032--308 250032--873 250032--874 250032--878 250034--582 843415--375 829706--100 825306--347 250035--188 250034--498 250034--583 829704--050 825304--236 838206--071 250025--108 250034--858 250031--869

quantity

1 1 1 1 2 1 1 4 1 3 2 4 4 2 2 1 7 7 8 2 1 1

250032--881 250000--104

1 1

02250043--291 250042--224

1 1

250038--243 250034--159 250032--227 02250077--473 02250061--884 410353 825305--283 250025--299

1 4 1 1 1 1 4 1


47

Section 7

ILLUSTRATIONS AND PARTS LIST 7.13 WYE --DELTA ELECTRIC BOX ES --6

23

DISCHARGE TEMP.

LINE PRESSURE

POWER ON

OFF/RESET ON AUTO MANUAL

T RE S E

24

48

Section 7

ILLUSTRATIONS AND PARTS LIST 7.13 WYE--DELTA ELECTRIC BOX ES --6 key number

1 2 3 4

description

hose,nylon1/4” 842215--004 valve,solenoid 250030--164 nipple,chase1/2” 847815--050 box, electric control (5.5 HP/4KW) 250031--242 box, electric control (7.5&10HP/5.5&7.5KW) 250031--243 hourmeter 250042--010 locknut,conduit1/2” 847200--050 nipple,pipe1/2”xclose 822208--000 elbow, 90 M swivel 1/4” x 1/8” 250025--849 tee,malebranch1/8” 250026--139 bushing, reducing 3/8” x 1/8” 807601--005 switch, pressure range 40--150# 250031--244 switch, 3 position selector 250034--883 block, contact with mounting base 250025--181 block, contact without mounting base 250034--882 light,unit 250027--443 lens,clear 250026--998 gauge, pressure air 0--300# 2” 02250044--361 gauge,temperature 02250043--291 bezel, ES--6 canopy control 250032--227 rivets, plastic 1/4” x 5/8” 250034--159 decal, ES--6 canopy bezel 02250061--884 button,reset ConsultFactory S

5 11 12 13 14 15 16 17



S S

18

S

19 20 21 22 23 24

part number

quantity

5ft. 1 1 1 1 1 7 1 3 1 1 1 1 1 1 1 1 1 1 1 4 1 1


49

Section 7

ILLUSTRATIONS AND PARTS LIST 7.14 WYE--DELTA ELECTRIC BOX ES --6

50

Section 7

ILLUSTRATIONS AND PARTS LIST 7.14 WYE--DELTA ELECTRIC BOX ES --6 key number

1 2 3 4 5

description

part number

quantity

tee,tube 250028--270 1 connector,liquidtight 250041--988 1 connector, male 1/4” x 1/8” 250025--858 1 terminal,block ConsultFactory fuse,2amp ConsultFactory fuse,carrier ConsultFactory fuse,4amp ConsultFactory fuse,carrier ConsultFactory CPT with tamper proof cover Consult Factory relay,control ConsultFactory contactor ConsultFactory contactor, block Consult Factory interlock, mechanical Consult Factory contactor ConsultFactory relay, (7.5HP and 10HP/5.5 and 7.5KW) Consult Factory relay, (5.5HP/4KW) Consult Factory contactor ConsultFactory timerhead ConsultFactory switch,pressure 250032--763 1 S S S

6 7 8

S

9 10

S S

11

S

12


51

Section 7

ILLUSTRATIONS AND PARTS LIST 7.15 DECAL GROUP



8 7

12

9

11

52

Section 7

ILLUSTRATIONS AND PARTS LIST 7.15 DECAL GROUP key number

1 2 3 4 5 6 7 8 8B 9

description

decal, warning -- under pressure (notshown) decal, 3 position switch panel (notshown) sign, warning -- hot surfaces

part number

quantity

02250078--001

1

250039--113

1

(notshown) 02250077--999 decal, warning auto start (notshown) 02250077--473 decal, prohibition, breath/food (notshown) 02250078--998 decal, Sullair logo (not shown) 02250059--052 decal,rotationdirection 040745 decal, compressor fluid Sullube 32 (I) 02250069--389 decal, fluid SRF 1/4000 (not shown) (I) 02250069--391 decal, earthground 02250075--046 decal, protective earth ground (not shown) 02250075--045 decal, PE designation (not shown) 02250075--540 decal, ES--6 Model (not shown) 02250060--043 decal,ISO9001 02250059--288 decal, voltage international (II) 02250069--397

1 1 1 1 1 1 1 2 1 1

S S

10 11 12

1 1 1

(Continued on page 55)

(I) Decal will change with fluid requirement. (II) Decal will vary with machine voltage. If voltage is not known, consult factory with serial number of compressor. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

53

Section 7

ILLUSTRATIONS AND PARTS LIST 7.15 DECAL GROUP

13

54

Section 7

ILLUSTRATIONS AND PARTS LIST 7.15 DECAL GROUP (continued) key number

13 14

description

decal, ES--6 canopy bezel decal, mandatory read manual (not shown)

part number

02250061--884 02250078--002

quantity

1 1


55

Section 7

ILLUSTRATIONS AND PARTS LIST 7.16 WIRING DIAGRAM (SINGLE PHASE) (60Hz)

56

Section 7

ILLUSTRATIONS AND PARTS LIST 7.17 WIRING DIAGRAM (THREE PHASE) (60Hz)

57

Section 7

ILLUSTRATIONS AND PARTS LIST 7.18 WIRING DIAGRAM (50 Hz)

58

Section 7

ILLUSTRATIONS AND PARTS LIST 7.19 WIRING DIAGRAM (50 Hz) WYE --DELTA

59

NOTES

NOTES

WORLDWIDE SALES AND SERVICE 

SULLAIR ASIA, LTD.

SULLAIR EUROPE, S.A.

ROOM 2304A Shartex Plaza Ctr. No. 88 Zun Yi Nan Rd. Shanghai, P.R.C. Telephone: 21--2192066 Fax: 21 -- 2196568

Chemin de Genas BP 639 69800 Saint Priest, France Telephone: 33--72 232425 Fax: 33 -- 78907168

SULLAIR CORPORATION

Subsidiary of Sundstrand Corporation 3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. Telephone: 1 --800 --SULLAIR (U.S.A. On ly) or 1 -- 219--8 79 --5 451 Fax: (219) 874 -- 1273 Fax: (219) 874 -- 1835 (Parts) Fax: (219) 874 -- 1805 (Service)

Printed in U.S.A. Specifications Subject To Change Without Prior Notice EN95EPS

Manual Compresor Sullair.pdf

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