Sullair 1107e Page 2 Operators Manual And Parts Lists Download

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SULLAIR

AIR CARE SEMINAR TRAINING

Sullair Air Care Seminars are 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 Contractor Maintenance and Service Personnel.

For detailed course outlines, schedule and cost information contact:

Sullair Customer Care Training Department

: 1-888-SULLAIR or

219-879-5451 (ext. 5363)

www.sullair.com

- Or Write -

Sullair Corporation

3700 E. Michigan Blvd.

Michigan City, IN 46360

Attn: Service Training Department

Summary of Contents for 1107e

Page 1: ...25HP Air Cooled Standard 24 KT PART NUMBER 02250155 844 KEEP FOR FUTURE REFERENCE SULLAIR CORPORATION The information in this document is correct at the time of printing for utility compressor serial...

Page 2: ...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 operat...

Page 3: ...AR 12 Full Load Mode 50 to 100 PSIG 3 4 to 6 9 BAR 12 Modulating Mode 100 to 110 PSIG 6 9 to 7 6 BAR 12 Unload Mode In Excess of 110 PSIG 7 6 BAR 12 Load No Load Control 12 Automatic Operation 12 Air...

Page 4: ...ntenance 40 Air Filter Element Replacement 40 Separator Maintenance 41 Separator Element Replacement 41 Pressure Regulator Adjustment 42 Water Condensate Drain Maintenance 42 Control Line Strainer 42...

Page 5: ...able to most compressors and the concepts behind these statements are generally applicable to all compressors 1 2 PERSONAL PROTECTIVE EQUIPMENT Prior to installing or operating the compressor owners e...

Page 6: ...aced 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 attempt...

Page 7: ...ound to air line anti icer systems 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 fifte...

Page 8: ...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 highe...

Page 9: ...ther 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 Read MAINTENANCE on page...

Page 10: ...fan and main motors through the combined aftercooler and fluid cooler thereby removing the compression heat from the compressed air and the cooling fluid and forces it out the top of the machine This...

Page 11: ...he first filter change and sent to the factory for analysis This is a free service The sample kit with instructions and self addressed container is to be supplied by your Sullair dealer at start up Th...

Page 12: ...the compressor unit where it lubricates cools and seals the rotors and the compression chamber As the discharge temperature rises above 185 F 85 C due to the heat of compression the thermal valve beg...

Page 13: ...THIS PAGE INTENTIONALLY LEFT BLANK DESCRIPTION SULL AIR 1100e 1500e 1800e Operator s Manual and Parts List 9...

Page 14: ...m reduces the fluid carry over to less than 1 ppm parts per million for Sullube or 2 ppm for 24KT A message on the controller indicates if abnormal pressure drop through the separator develops At this...

Page 15: ...SU_0000084 AIR 1 2 3 1 Compressor 2 Cooler 3 Moisture Separator Figure 2 3 Discharge System DESCRIPTION SULL AIR 1100e 1500e 1800e Operator s Manual and Parts List 11...

Page 16: ...e pressure regulator controls the inlet control valve The orifice also bleeds any accumulated moisture from the control lines Unload Mode In Excess of 110 PSIG 7 6 BAR When a relatively small amount o...

Page 17: ...3 Blowdown Valve 4 Pressure Regulator 5 Pressure Relief Valve 6 Receiver Tank 7 Temperature Thermistor 8 Sight Glass Upper Level 9 Sight Glass Lower Level Figure 2 4 Standard Control System DESCRIPTI...

Page 18: ...6 9 to 7 6 BAR on page 12 The inlet valve also acts as a check valve thus preventing reverse rotation when the compressor is shut down WARNING The Plastic Pipe Institute recommends against the use of...

Page 19: ...1351 31 5 800 53 2 1351 1098 498 1800 SERIES 1809e 25 53 2 1351 31 5 800 53 2 1351 1122 509 1812e 25 53 2 1351 31 5 800 53 2 1351 1122 509 I Includes standard and 24KT Rated pressure designations appe...

Page 20: ...ble for operation in higher ambient temperature MOTOR IV STANDARD MODELS Size 15 20 25HP 11 15 18KW Type TEFC Epact Efficiency Three Phase 230 460 Hz 380 415 400 50 Hz Maximum Ambient Temperature 104...

Page 21: ...Plastic Pipe Institute Recommendation B Adopted January 19 1972 Maintenance of all other components is still recommended as indicated in the Operator s Manual DO NOT MIX DIFFERENT TYPES OF FLUIDS Con...

Page 22: ...G C B D A 8 000 hours or once a year B 4 000 hours or more frequently if conditions so require C When measured pressure loss exceeds 20 psig 1 3 bar D When measured pressure loss exceeds 10 psig 0 7...

Page 23: ...THIS PAGE INTENTIONALLY LEFT BLANK SPECIFICATIONS SULL AIR 1100e 1500e 1800e Operator s Manual and Parts List 19...

Page 24: ...3 5 IDENTIFICATION AIR COOLED UNIT 02250161 035R02 1 1 2 3 6 5 SECTION 3 20 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 25: ...anel 2 Controller 3 E Stop 4 Air Out Connection 5 Air Exhaust 6 Air Inlet 7 Moisture Drain Connection 8 Incoming Customer Power Supply Location Figure 3 2 Identification Air Cooled SPECIFICATIONS SULL...

Page 26: ...3 6 PIPING AND INSTRUMENTATION AIR COOLED 02250157 525r02 Figure 3 3 Piping and Instrumentation Air Cooled SECTION 3 22 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 27: ...0049 634 1 16 strainer v type 1 4 241771 2 17 valve sol 3wno 1 4 235 n4 02250125 657 2 18 valve pressure regulator 250017 280 1 19 valve shuttle 1 4 dbl chk 408893 1 20 valve sol 2wnc 1 4 200 n4 02250...

Page 28: ...3 7 WIRING DIAGRAMS Wiring Diagram MFV 02250156_577R04 1 SECTION 3 24 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 29: ...02250156_577R04 2 Figure 3 4 Wiring Diagram MFV SPECIFICATIONS SULL AIR 1100e 1500e 1800e Operator s Manual and Parts List 25...

Page 30: ...Wiring Diagram VSD 400V 50Hz 460V 60Hz 02250156_119r04 2 SECTION 3 26 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 31: ...02250156_119r04 2 Figure 3 5 Wiring Diagram VSD 400V 50Hz 460V 60Hz SPECIFICATIONS SULL AIR 1100e 1500e 1800e Operator s Manual and Parts List 27...

Page 32: ...Wiring Diagram VSD 575V 60Hz 02250164_731r01 1 SECTION 3 28 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 33: ...02250164_731r01 2 Figure 3 6 Wiring Diagram VSD 575V 60Hz SPECIFICATIONS SULL AIR 1100e 1500e 1800e Operator s Manual and Parts List 29...

Page 34: ...SECTION 3 THIS PAGE INTENTIONALLY LEFT BLANK 30 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 35: ...ve surfaces will increase ambient noise levels NOTE Ambient temperatures above 104 F 40 C require that the high ambient option is specified for the compressor 4 2 VENTILATION AND COOLING Air Cooled Co...

Page 36: ...ation of a line filter s and the installation of isolation valve or valves These considerations are important to ensure a safe and effective system NOTE Discharged air contains a very small amount of...

Page 37: ...must provide electrical supply power disconnect within sight of machine The fuse protecting the circuit and the compressor must be selected in accordance with the data provided in the general informat...

Page 38: ...rotation is noted disconnect the power to the starter and exchange any two of the three power input leads then re check rotation A Direction of Rotation decal is located on the motor drive housing to...

Page 39: ...ure 5 1 WS Controller 5 2 CONTROLLER KEYPAD The WS Controller keypad has two main pads for compressor control To start the compressor operation press the green Start pad To stop compressor operation p...

Page 40: ...ontinue beyond the status information the display will show a list of control settings The upper line will indicate Show Setting and the name of the setting The lower line shows the present value SA_0...

Page 41: ...his LED will blink to indicate that the motor may restart The yellow Maintenance indicator comes on whenever there is recommended maintenance or a warning The text display will periodically indicate t...

Page 42: ...SECTION 5 THIS PAGE INTENTIONALLY LEFT BLANK 38 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 43: ...ble cause and remedy WARNING HIGH PRESSURE HAZARD DO NOT remove caps plugs and or other components when compressor is running or pressurized Stop compressor and relieve all internal pressure before do...

Page 44: ...Filter Assembly 6 6 AIR FILTER MAINTENANCE Refer to Figure 6 2 Air filter maintenance should be performed when the maintenance gauge shows red with the compressor running full load or once a year whi...

Page 45: ...length 6mm diameter pin into the radial drilled hole in the separator cap Loosen and rotate counterclockwise to remove the cap 2 Pull out the old element by gripping the end of the element with channe...

Page 46: ...y 12 months it is necessary to clean the strainer Remove the hex cap from the strainer and remove the strainer screen Clean the screen and reinstall If the screen is damaged the strainer assembly must...

Page 47: ...erating Pressure Separator requires maintenance Check maintenance indicator under full load conditions High pressure setting in WS Controller set wrong reset Defective valve regulator valve should cau...

Page 48: ...in Control System Causing Loss of Pressure Signals Check for leaks Inlet Valve Stuck Open Remove the intake hose and check for inlet valve operation Defective Unload Solenoid Valve Check that the val...

Page 49: ...or the flow and dryness level required Note Filters may also be required to remove particulates liquid oil aerosols or for oil vapor removal Change cartridges as recommended by the filter manufacturer...

Page 50: ...SECTION 6 THIS PAGE INTENTIONALLY LEFT BLANK 46 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 51: ...of the compressor This can be obtained from the Bill of Lading for the compressor or from the Serial Number Plate located on the compressor Refer to Figure 7 1 02250155_844_Sec7 1 Figure 7 1 SULL AIR...

Page 52: ...he Representative from whom the compressor was purchased If for any reason parts cannot be obtained in this manner contact the factory directly at the addresses phone and fax numbers listed below SECT...

Page 53: ...157 500 1 9 kit coil replacement for control solenoid valve 02250155 714 02250157 502 1 10 kit repair for condensate drain solenoid valve 02250155 715 02250157 501 1 11 kit coil replacement for conden...

Page 54: ...7 3 COMPRESSOR FRAME AND DRIVE A1 02250157 804R04 SECTION 7 50 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 55: ...15 gasket isol to frame p8 02250157 598 3 16 mtr 11 18kw 256tz frame 02250157 658 1 17 tube separator oil return 02250157 679 1 18 frame lift off p8 02250160 379 1 19 elbow 90deg m swvl 1 8 t x 1 8 02...

Page 56: ...7 3 COMPRESSOR FRAME AND DRIVE CONTINUED A1 02250157 804R04 SECTION 7 52 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 57: ...lug metric thd orng holhx m18 882018 015 1 49 nut hex metric m12 x 1 75 882112 175 5 50 screw hex serr washer m8 x 25 882608 025 6 A1 Tray Drain I Sullair offers an exchange program whereby a remanufa...

Page 58: ...7 4 AIR INLET SYSTEM 02250157_200r02 SECTION 7 54 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 59: ...mp hose 3 040343 4 6 clamp hose 2 3 8 I D 408300 010 2 7 screw self drill 1 4 x 1 2 834504 050 2 8 washer iso 7093 6 140hv 865706 180 2 9 nut serr flng m8 x 1 25 882508 125 2 10 screw hex serr washer...

Page 60: ...7 5 DISCHARGE AIR PIPING A1 A2 A3 A4 02250154_771R04 SECTION 7 56 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 61: ...1 2 866316 035 1 8 bushing red hex pltd 1 x 3 4 868904 030 1 9 bushing red hex pltd 1 1 2 x 1 868906 040 1 10 nut serr flng m8 x 1 25 882508 125 2 11 screw hex serr washer m8 x 16 882608 016 2 12 elb...

Page 62: ...7 6 FLUID PIPING 02250154 767R003 SECTION 7 58 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 63: ...2 219 1 7 screw socket iso 4762 m10 x 80mm 829310 080 2 8 elbow met st thd orfs m27 x 3 4 883627 012 2 9 union str thd iso 6149 m27 x 2 883727 012 1 10 valve thermal 195f 1 1 2 18 VARIOUS 1 A1 To flui...

Page 64: ...7 7 COOLING AND LUBRICATION SYSTEM A1 A2 A3 02250160 533R004 A4 SECTION 7 60 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 65: ...13 grip cord for so 12 4 st 3 4 250018 497 2 14 wire neoprene 12 4 so ft 850604 012 8 15 washer metric iso7089 8 865408 170 4 16 washer iso 7093 8 140hv 865708 240 3 17 nut serr flng m8 x 1 25 882508...

Page 66: ...7 8 COMPRESSOR HOUSING RECEIVER TANK AND PARTS 02250157_805r00 SECTION 7 62 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 67: ...ll E8E 02250149 395 1 9 transducer pressure 0 250 ratiometric 02250155 174 1 10 probe rtd 100 ohm plat 3 5 x 6ft 02250155 175 1 11 fitting compress adj 250028 635 1 12 O ring viton 1 7 16 x 3 32 82650...

Page 68: ...7 9 MOISTURE DRAIN 02250157_143R00 SECTION 7 64 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 69: ...200 050 2 9 elbow entrance 1 2 847715 050 1 10 wire mtw amw 16ga dk blu 850216 016 14 11 connector wire orange 851000 073 2 12 elbow pipe 90m 1 4 x 1 4 860504 025 1 13 nipple pipe hx pltd 1 4 x 1 4 86...

Page 70: ...7 10 PNEUMATIC CONTROL SYSTEM 02250154_867r02 SECTION 7 66 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 71: ...chk 408893 1 19 bulkhead pipe 1 4 npt 841500 004 1 20 nipple chase cond 1 2 847815 050 2 21 tee male pipe brass 1 4 869825 025 1 22 tee female pipe brass 1 4 878225 025 2 23 elbow pipe 90m 1 4 x 1 4 b...

Page 72: ...7 11 CONTROL SYSTEM AND ELECTRIC PARTS A1 A2 A4 A6 A7 A5 A3 02250156_917r02 SECTION 7 68 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 73: ...x 6ft 02250155 175 I 1 17 specification encl 2200 19 x 24 5 x 7 02250156 385 1 18 wire 10 gauge ground bond 12 m8 02250157 450 1 19 receptacle s4 program port nema 6p 02250159 547 1 20 cap s4 program...

Page 74: ...7 11 CONTROL SYSTEM AND ELECTRIC PARTS CONTINUED A1 A2 A4 A6 A7 A5 A3 02250156_917r02 SECTION 7 70 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 75: ...rtd probe No 02250155 175 order replacement probe P N 02250155 175 II This part may vary per machine specification Consult the Sullair factory for details III Plug unused holes in starter with hole pl...

Page 76: ...7 12 CONTROL SYSTEM AND ELECTRIC PARTS WYE DELTA A1 A7 A3 A4 A2 A6 02250165_275r00 SECTION 7 72 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 77: ...5 x6ft 02250155 175 1 18 link mech intrik ch it frm b e 02250155 676 1 19 specification encl 2200 19 x 24 5 x 7 02250156 385 1 20 wire 10 gauge ground bond 12 m8 02250157 450 1 21 receptacle s4 progr...

Page 78: ...7 12 CONTROL SYSTEM AND ELECTRIC PARTS WYE DELTA CONTINUED A1 A7 A3 A4 A2 A6 02250165_275r00 SECTION 7 74 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 79: ...shown 1 A6 P C Port 1 I This part may vary per machine specification Consult the Sullair factory for details III Plug unused holes in starter with hole plug part number 409918 002 IV 250014 827 Item 2...

Page 80: ...7 13 CONTROL SYSTEM AND ELECTRIC PARTS VSD A1 A3 A4 A2 A6 A5 A7 02250165_276r00 SECTION 7 76 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 81: ...175 1 16 specification encl 2200v 19 x 24 5 x 7 02250155 766 1 17 wire 10 gauge ground bond 12 m8 02250157 450 1 18 receptacle s4 program port nema 6p 02250159 547 1 19 cap s4 program port nema 6p 022...

Page 82: ...7 13 CONTROL SYSTEM AND ELECTRIC PARTS VSD CONTINUED A1 A3 A4 A2 A6 A5 A7 02250165_276r00 SECTION 7 78 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 83: ...ere Shown 1 A7 P C Port 1 I This part may vary per machine specification Consult the Sullair factory for details III Plug unused holes in starter with hole plug part number 409918 002 IV 250014 827 It...

Page 84: ...7 14 ENCLOSURE 02250155_649R05 SECTION 7 80 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 85: ...starter end p8 p10 02250155 824 1 10 rail roof starter end p8 p10 02250155 825 1 11 pocket drawing holder 3700 02250158 039 1 12 rail vertical starter side p8 p10 02250160 372 1 13 rail vertical p8 p1...

Page 86: ...7 15 DECAL LOCATION 02250157 768R004 A1 A2 A3 A7 A10 A7 A7 A9 A8 A8 A6 A6 A5 A9 A11 A9 A12 A7 A7 A11 A4 SECTION 7 82 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 87: ...vsd black p8 p10 p12 02250162 215 2 14 decal warning n12 elec encl protc 02250164 823 1 15 decal warning auto start 41065 1 16 decal danger hi voltage 42218 1 17 sign warning comp oil fil cap 49685 1...

Page 88: ...7 15 DECAL LOCATION CONTINUED 02250157 768R004 A1 A2 A3 A7 A10 A7 A7 A9 A8 A8 A6 A6 A5 A9 A11 A9 A12 A7 A7 A11 A4 SECTION 7 84 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 89: ...A3 Detail view of thermal valve block A4 Face of motor conduit box A5 Attach to inside of starter door A6 Attach to the bottom on inside of starter box A7 Both sides of machine A8 Attach to sub panel...

Page 90: ...ng proper safety equipment See OSHA standards on safety equipment 250027 932 DANGER Lethal shock hazard inside Disconnect all power at source before opening or servicing 049850 250019_032R01 16 5 20 0...

Page 91: ...air 250027 935 1 18 decal danger electrocution 49850 1 6 decal parallel wye motor conn 02250146 385 2 16 decal danger hi voltage 42218 1 5 decal en warning mixing fluids 02250110 891 1 20 sign warning...

Page 92: ...ur Company s Prescribed Safety Practices for Electrical Equipment 250017 903 WARNING WARNING 049852 22 27 15 Do not permit air from this equip ment to contact food stuff except in fullcompi ance with...

Page 93: ...l cap 49685 1 23 decal warning autostart 250017 903 1 19 decal warning elec shock ground fault 49852 1 22 decal warning food grade lub 250003 144 1 27 sign warning hot surfaces 407408 1 15 decal warni...

Page 94: ...2 3 7 02250075 045 02250075 540 02250155 495 8 9 02250157_703R00 02250157_732R01 10 11 02250157_749 02250158_358R00 12 02250161 967R02 13 02250162_215R01 SECTION 7 90 1100e 1500e 1800e Operator s Manu...

Page 95: ...lair com 02250155 495 2 8 decal sullair side graphics 02250157 703 2 9 decal sullair side graphic 02250157 732 1 10 decal maint kit eng 02250157 749 1 11 decal remove before start up 02250158 358 2 12...

Page 96: ...4 21 24 02250164_823r00 LIFT HERE 241814 250021 564 25 WATER DRAIN 250022 810 28 28 28 02250069 389 LLL 4 32 022500 6 9 394 02250069 394 24 KT 02250069 395 SECTION 7 92 1100e 1500e 1800e Operator s Ma...

Page 97: ...2250164 823 1 21 decal fork lifting 241814 2 24 decal rotation 3 5 lg 250021 564 1 25 decal water drain 3 3 4 x 1 250022 810 1 28 fluids fluid decal 02250069 389 I 1 fluids fluid decal 02250069 394 I...

Page 98: ...2 230V 230V 3 3 60 60 Hz H 02250069 397 02250069 397 460V 3 60 Hz 02250069 399 02250069 399 575V 3 60 Hz 02250069 400 02250069 400 32 32 380 415V 3 50 Hz 02250069 403 02250069 403 200V 3 60 Hz 0225006...

Page 99: ...02250157 736 I 1 32 voltage decal 02250069 397 I 1 voltage decal 02250069 399 I 1 voltage decal 02250069 400 I 1 voltage decal 02250069 403 I 1 voltage decal 02250069 406 I 1 I This decal will vary w...

Page 100: ...SECTION 7 THIS PAGE INTENTIONALLY LEFT BLANK 96 1100e 1500e 1800e Operator s Manual and Parts List SULL AIR...

Page 101: ...THIS PAGE INTENTIONALLY LEFT BLANK...

Page 102: ...nly or 1 219 879 5451 Fax 219 874 1273 CUSTOMER CARE for PARTS and SERVICE 1 888 SULLAIR 7855247 219 874 1835 SULLAIR ASIA LTD Sullair Road No 1 Chiwan Shekou Shenzhen Guangdong PRV PRC POST CODE 5180...

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