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TABLE OF CONTENTS

SECTION 1—SAFETY

PERSONAL PROTECTIVE EQUIPMENT

PRESSURE RELEASE

FIRE AND EXPLOSION

HOT SURFACES, SHARP EDGES AND SHARP CORNERS

TOXIC AND IRRITATING SUBSTANCES

ELECTRICAL SHOCK

SECTION 2—DESCRIPTION

DESCRIPTION OF COMPONENTS

ENCAPSULATED COMPRESSOR SYSTEM, FUNCTIONAL DESCRIP-
TION

COMPRESSOR COOLING SYSTEM FUNCTIONAL DESCRIPTION

AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

CONTROL SYSTEM, FUNCTIONAL DESCRIPTION

INSTRUMENTATION, FUNCTIONAL DESCRIPTION

SECTION 3—SPECIFICATIONS

TABLE OF SPECIFICATIONS

COMPRESSOR LUBRICATION GUIDE

LUBRICATION GUIDE - 24KT COMPRESSORS

LUBRICATION GUIDE - OPTIONAL FLUID

IDENTIFICATION, ES-6 STANDARD WITHOUT ENCLOSURE

IDENTIFICATION, ES-6 STANDARD WITH ENCLOSURE

IDENTIFICATION, ES-6 OPEN TANK MOUNT (80 GALLON)

IDENTIFICATION, ES-6 ENCLOSED TANK MOUNT (80 GALLONS)

IDENTIFICATION, ES-6 OPEN TANK MOUNT (80 GALLONS) WITH
DRYER

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Summary of Contents for ES-6 10H

Page 1: ......

Page 2: ...cated at Michigan City Indiana Instruction includes training on the function and installation of Sullair service parts troubleshooting common faults and malfunctions and actual equipment operation The...

Page 3: ...COMPRESSOR COOLING SYSTEM FUNCTIONAL DESCRIPTION 16 2 5 AIR INLET SYSTEM FUNCTIONAL DESCRIPTION 17 2 6 CONTROL SYSTEM FUNCTIONAL DESCRIPTION 17 2 7 INSTRUMENTATION FUNCTIONAL DESCRIPTION SECTION 3 SPE...

Page 4: ...DELTA 54 3 20 WIRING DIAGRAM SRS 25 100 115 230V 1 60 56 3 21 WIRING DIAGRAM SRS 9 18 220 240V 1 50 58 3 22 WIRING DIAGRAM SRS 24 30 220 240V 1 50 SECTION 4 INSTALLATION 61 4 1 LOCATION OF COMPRESSOR...

Page 5: ...TABLE OF CONTENTS SECTION 7 PARTS LIST 79 7 1 PROCEDURE FOR ORDERING PARTS 80 7 2 RECOMMENDED SERVICE PARTS LIST...

Page 6: ...TABLE OF CONTENTS...

Page 7: ...rein are applicable to most compressors and the concepts behind these statements are generally applicable to all compressors 1 2 PERSONAL PROTECTIVE EQUIPMENT A Prior to installing or operating the co...

Page 8: ...including air line anti icer system antifreeze compound or fluid film to accumulate on under or around acoustical mate rial or on any external surfaces of the air com pressor Wipe down using an aqueo...

Page 9: ...codes or regula tions B DO NOT use air line anti icer systems in air lines supplying respirators or other breathing air utili zation equipment and DO NOT discharge air from these systems into unventi...

Page 10: ...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...

Page 11: ...a cles 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 o...

Page 12: ...NOTES 12...

Page 13: ...unit is equipped with tapered roller bearings on the discharge and cylindrical roller bearings on the inlet end for high load carrying capacity This unit provides continuous pulse free air compressio...

Page 14: ...d 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 dr...

Page 15: ...Temp Gauge 5 Unload Solenoid Valve 6 Air Fluid Seperator Element Access Cover 7 Fluid Fill Plug 8 Fluid Filter Element 9 Fluid Level Sight Glass 10 Encapsulated Compressor System 11 Pressure Relief V...

Page 16: ...mpression heat from the fluid 2 5 AIR INLET SYSTEM FUNCTIONAL DESCRIPTION The compressor inlet system consists of a dry type air filter and an air control valve Reacting on a pressure signal the valve...

Page 17: ...ulator The pressure regulator will them begin to open allowing pressure to be applied to the inlet valve The pressure regulator will modulate the inlet valve to match system demand OFF RESET MODE The...

Page 18: ...18 NOTES...

Page 19: ...base weight of machine Table 3 2 50 Hz Model MODEL HP KW Cap ACFM M3 Min Max Pressure PSIG BAR dBA I with canopy without canopy DIMENSIONS Length II Width III Height IV Weight V in mm in mm in mm lb k...

Page 20: ...quarts 4 35 liters VI Compressors are available for pressures up to 175 psi 12 1 bar Table 3 4 Motor 60Hz 50Hz Type 5 7 5 10HP 4 5 5 7 5 KW 1 15 S F 5 7 5 10HP 4 5 5 7 5 KW Synchronous Speed 1800 RPM...

Page 21: ...4KT compressors are filled with a lubricant which rarely needs to be changed In the event a change of fluid is required use only Sullair 24KT fluid Sullair recommends that a 24KT sample be taken at th...

Page 22: ...rrosive gases or strong oxidizing gases are present in the air Maintenance of all other components is still recommended as indicated in the Operator s Manual CAUTION Mixing of other fluids within the...

Page 23: ...23 NOTES...

Page 24: ...ES 6 USER MANUAL SECTION 3 24 3 5 IDENTIFICATION ES 6 STANDARD WITHOUT ENCLOSURE 02250172 315 R00...

Page 25: ...CAPABLE OF SUPORTING THE WEIGHT OF PACKAGE AND RIGID ENOUGH TO MAIN TAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AND THE FOUNDATION...

Page 26: ...ES 6 USER MANUAL SECTION 3 26 3 6 IDENTIFICATION ES 6 STANDARD WITH ENCLOSURE 02250172 316 R00...

Page 27: ...ENOUGH TO MAIN TAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AND THE FOUNDATION NO PIPING LOADS MUST BE PERMITTED AT EXTERNAL CONNECTI...

Page 28: ...ES 6 USER MANUAL SECTION 3 28 3 7 IDENTIFICATION ES 6 OPEN TANK MOUNT 80 GALLON 02250170 490 R00...

Page 29: ...OR MOUNTING CAPABLE OF SUPORTING THE WEIGHT OF PACKAGE AND RIGID ENOUGH TO MAIN TAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AND THE...

Page 30: ...ES 6 USER MANUAL SECTION 3 30 3 8 IDENTIFICATION ES 6 ENCLOSED TANK MOUNT 80 GALLONS 02250170 491 R00...

Page 31: ...OF PACKAGE AND RIGID ENOUGH TO MAIN TAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AND THE FOUNDATION NO PIPING LOADS MUST BE PERMITTE...

Page 32: ...ES 6 USER MANUAL SECTION 3 32 3 9 IDENTIFICATION ES 6 OPEN TANK MOUNT 80 GALLONS WITH DRYER 02250172 307 R00...

Page 33: ...TION OR MOUNTING CAPABLE OF SUPORTING THE WEIGHT OF PACKAGE AND RIGID ENOUGH TO MAIN TAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AND...

Page 34: ...ES 6 USER MANUAL SECTION 3 34 3 10 IDENTIFICATION ES 6 ENCLOSED TANK MOUNT 80 GALLONS WITH DRYER 02250172 308 R00...

Page 35: ...WEIGHT OF PACKAGE AND RIGID ENOUGH TO MAIN TAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AND THE FOUNDATION NO PIPING LOADS MUST BE PE...

Page 36: ...ES 6 USER MANUAL SECTION 3 36 3 11 IDENTIFICATION ES 6 OPEN TANK MOUNT 120 GALLON 02250172 309 R00...

Page 37: ...OR MOUNTING CAPABLE OF SUPORTING THE WEIGHT OF PACKAGE AND RIGID ENOUGH TO MAIN TAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AND THE...

Page 38: ...ES 6 USER MANUAL SECTION 3 38 3 12 IDENTIFICATION ES 6 ENCLOSED TANK MOUNT 120 GALLON 02250172 310 R00...

Page 39: ...OF PACKAGE AND RIGID ENOUGH TO MAIN TAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AND THE FOUNDATION NO PIPING LOADS MUST BE PERMITTE...

Page 40: ...ES 6 USER MANUAL SECTION 3 40 3 13 IDENTIFICATION ES 6 OPEN TANK MOUNT 120 GALLON WITH DRYER 02250172 311 R00...

Page 41: ...ATION OR MOUNTING CAPABLE OF SUPORTING THE WEIGHT OF PACKAGE AND RIGID ENOUGH TO MAIN TAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AN...

Page 42: ...ES 6 USER MANUAL SECTION 3 42 3 14 IDENTIFICATION ES 6 ENCLOSED TANK MOUNT 120 GALLON WITH DRYER 02250172 312 R00...

Page 43: ...WEIGHT OF PACKAGE AND RIGID ENOUGH TO MAIN TAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AND THE FOUNDATION NO PIPING LOADS MUST BE PE...

Page 44: ...ES 6 USER MANUAL SECTION 3 44 3 15 PIPING AND INSTRUMENTATION DIAGRAM STANDARD AND WYE DELTA 02250101 011 R04...

Page 45: ...ve solenoid n o 500psi 02250125 655 1 5 cooler oil aftercooler es 6 250026 066 1 6 pressure gauge 250005 185 1 7 pressure switch 250025 299 1 8 valve minimum pressure check 604243 1 9 valve pressure r...

Page 46: ...ES 6 USER MANUAL SECTION 3 46 3 16 WIRING DIAGRAM DUAL CONTROL FULL VOLTAGE 2 WIRE 02250045 623 R06...

Page 47: ...3 16 ID WIRING DIAGRAM DUAL CONTROL FULL VOLTAGE 2 WIRE NOTES 1 OPTIONAL 2 REMOVE JUMPER TO ADD OPTION 3 SEE TRANSFORMER DIAGRAM FOR CORRECT PRIMARY CONNECTIONS 4 REMOVE JUMPER 6 AND 7 9 AND 2 WHEN C...

Page 48: ...ES 6 USER MANUAL SECTION 3 48 3 17 WIRING DIAGRAM DUAL CONTROL FULL VOLTAGE 3 WIRE 02250062 643 R04...

Page 49: ...SECTION 3 ES 6 USER MANUAL 49 3 17 ID WIRING DIAGRAM DUAL CONTROL FULL VOLTAGE 3 WIRE NOTES 1 OPTIONAL 2 REMOVE JUMPER TO ADD OPTION 3 SEE TRANSFORMER DIAGRAM FOR CORRECT PRIMARY CONNECTIONS...

Page 50: ...ES 6 USER MANUAL SECTION 3 50 3 18 WIRING DIAGRAM DUAL CONTROL 200 230 1 60 5 HP 606512 001 R07...

Page 51: ...SECTION 3 ES 6 USER MANUAL 51 3 18 ID WIRING DIAGRAM DUAL CONTROL 200 230 1 60 5 HP NOTES 1 OPTIONAL 2 P1 AND P2 NOT USED FOR REF ONLY...

Page 52: ...ES 6 USER MANUAL SECTION 3 52 3 19 WIRING DIAGRAM DUAL CONTROL WYE DELTA 02250058 093 R04...

Page 53: ...TION TIMER RELAY 2M WYE DELTA TRANSITION COIL S WYE DELTA START COIL 1CR RUN CONTROL RELAY 2CR POWER FAILURE RESTART RELAY H HOURMETER LT1 POWER ON LIGHT PSW1 SUMP PRESSURE SWTICH PSW2 LINE PRESSURE S...

Page 54: ...ES 6 USER MANUAL SECTION 3 54 3 20 WIRING DIAGRAM SRS 25 100 115 230V 1 60 02250171 733 R00...

Page 55: ...651KW FLA 1 00 0 076KW SRS 75 FLA 9 23 0 809KW FLA 1 00 0 076KW SRS 100 FLA 11 44 1 082KW FLA 1 00 0 076KW COMPRESSOR UN 23 V 1PH 60HZ FAN MOTOR UN230V 1PH 50 60HZ SRS 100 FLA 5 72 1 082 KW FLA 0 50...

Page 56: ...ES 6 USER MANUAL SECTION 3 56 3 21 WIRING DIAGRAM SRS 9 18 220 240V 1 50 02250171 738 R00...

Page 57: ...1PH 50 60HZ SRS 30 FLA 4 80 0 880KW FLA 0 23 0 035KW SRS 24 FLA 4 16 0 721KW FLA 0 23 0 035KW ELECTRICAL SUPPLY LINE 1 FASE NEUTRO PE CABLES SIZE 3 G 1 5 mmq COMPONENT DESCRIPTION QS MAIN SWITCH CN E...

Page 58: ...ES 6 USER MANUAL SECTION 3 58 3 22 WIRING DIAGRAM SRS 24 30 220 240V 1 50 02250171 739 R00...

Page 59: ...V 1PH 50 60HZ SRS 30 FLA 4 80 0 880KW FLA 0 23 0 035KW SRS 24 FLA 4 16 0 721KW FLA 0 23 0 035KW ELECTRICAL SUPPLY LINE 1 FASE NEUTRO PE CABLES SIZE 3 G 1 5 mmq COMPONENT DESCRIPTION QS MAIN SWITCH CN...

Page 60: ...60 NOTES...

Page 61: ...condensate drains throughout the system 4 4 FLUID LEVEL CHECK AND CHANGE PROCEDURE The Sullair air compressor is equipped with the proper amount of fluid However it is necessary to check the fluid lev...

Page 62: ...at the motor from the cooler end of the compressor unit the cooler fan should be turning clockwise If the motor is not turning clockwise disconnect power to the starter and exchange any two of the thr...

Page 63: ...run the electrical controls by discon necting the motor leads T1 T2 and T3 from the starter Energize the control circuits by Figure 4 1 Service Air Piping 1 Optional or Customer Supplied Equipment 2 B...

Page 64: ...ng sure when activated they will de energize the starter control coil 5 Reconnect the motor leads and jog the motor for a direction of rotation check as explained in Section 4 5 NOTE Assure that line...

Page 65: ...1 bar Also incorporated in this valve is a terminal check valve which prevents line pressure backflow into the sump during unload conditions and after shutdown DISCHARGE TEMPERATURE SWITCH Shuts the...

Page 66: ...sure switch is set correctly If set correctly the compressor will unload at nameplate pressure If adjustments are nec essary see Control System Adjusment in Section 6 Maintenance 8 Observe the operati...

Page 67: ...ll supersede this general instruction 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...

Page 68: ...5HP 4KW 3 Years 1 Year 6 Months 7 5 and 10HP 5 5 7 5 KW 2 5 Years 10 5 Months 5 5 Months All Motors Over 1800 RPM 6 Months 3 Months 3 Months I Eight hours per day normal or light loading clean 100 F...

Page 69: ...tening 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 Refer to Figure 6 2 Air filter P N 02250111 680 maintenance...

Page 70: ...able 3 7 Lubrication Guide Follow the procedure explained below for element replacement 1 Insert a 4 maximum length 1 4 diameter pin into the radially drilled hole in the separa tor cap Loosen unscrew...

Page 71: ...and loss of re usable fluid place a contaminate free fluid recepta cle beneath fluid drain valve and fluid filter 2 Drain fluid by removing fluid drain cap at tee located beneath compressor 3 Unscrew...

Page 72: ...l require adjustment refer to Figure 6 6 To adjust the pressure switch turn the range adjusting screw to the high pressure setting equally 6 Replace pressure switch cover PRESSURE REGULATOR ADJUSTMENT...

Page 73: ...the solenoid base subassembly 3 Reassemble in reverse order of disassembly INLET CONTROL VALVE Refer to Figure 6 7 The only parts which normally require replacement are the piston seal on the intake v...

Page 74: ...housing gasket surface and internal 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 sp...

Page 75: ...nnecessary damage to the compressor Always remember to Check for loose wiring Check for damaged piping Check for parts damaged by heat or an electrical short circuit usually apparent by discoloration...

Page 76: ...d clean ori fice Separator Element Damaged Or Not Functioning Properly Change separator element Leak In The Lubrication System Check all pipes connections and com ponents Excess Fluid Foaming Drain an...

Page 77: ...CTION 6 ES 6 USER MANUAL 77 6 9 MAINTENANCE RECORD Model No ____________________ Serial No ____________________________________________ Date Hour Meter Maintenance Record Work Performed By Authorized...

Page 78: ...78 NOTES...

Page 79: ...or the compressor or from the Serial Number Plate located on the compressor See Figure 7 1 Serial Plate Serial Number Location The genuine Sullair service parts listed meet or exceed the demands of th...

Page 80: ...0125 655 replacement coil for solenoid valve 02250125 655 9 250019 453 1 repair kit for regulator valve 250017 280 10 250030 226 1 repair kit for minimum pressure check valve 604131 11 02250045 287 1...

Page 81: ...KT 5 gallons 23 250019 662 I fluid SRF 1 4000 5 gallons I For proper amount of fluid fill please consult Table 3 7 Lubrication Guide KEY NO ORDER PART NO QTY DESCRIPTION NOTE PLEASE NOTE WHEN ORDERING...

Page 82: ...82 NOTES...

Page 83: ...NOTES 83...

Page 84: ......

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