Sullair ShopTek ST45 Operation & Maintenance Manual Download

Page: 59 / 78

ShopTek™ ST45, ST55, ST75 (

.S.

. & Mexi

) Op
erati

on & Maint

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art

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Summary of Contents for ShopTek ST45

Page 1: ...Publication date 08 31 2018 Copyright 2018 Sullair LLC All rights reserved WARRANTY NOTICE Failure to follow the instructions and procedures in this manual or misuse of this equipment will void its wa...

Page 2: ...ing on the function and installation of Sullair service parts troubleshooting common faults and malfunctions and actual equipment operation These courses are recommended for distributor service person...

Page 3: ...Safety decals 13 Section 2 Description 15 2 1 The air compression cycle 15 2 2 Air inlet system 17 2 2 1 General operation of the air inlet system 17 2 2 2 Air filter 17 2 2 2 1 Air filter element 17...

Page 4: ...with a forklift 25 4 2 2 Guidelines for moving the compressor with a crane 25 4 3 Compressor installation 25 4 3 1 Physical installation requirements 25 4 3 2 Heat rejection and ventilation requiremen...

Page 5: ...4 1 Adding compressor fluid 35 6 4 2 Changing compressor fluid 35 6 4 3 Fluid filter maintenance 36 6 4 3 1 Replacing the fluid filter element 36 6 4 4 Air filter maintenance 36 6 4 4 1 Replacing the...

Page 6: ...and related export control restrictions 7 3 Motor and air end system 46 7 4 Air inlet system 50 7 5 Fluid piping system 52 7 6 Cooling fan system 54 7 7 Fluid air separation system 56 7 8 Air discharg...

Page 7: ...ein are applicable to most compressors and the concepts behind these state ments are generally applicable to all compressors 1 2 Personal protective equipment A Prior to installing or operating the co...

Page 8: ...ical material or on any external surfaces of the air compressor Wipe down using an aqueous industrial cleaner or steam clean as required If necessary remove acoustical mate rial clean all surfaces and...

Page 9: ...ants 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...

Page 10: ...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 compress...

Page 11: ...y source using the proper energy isolating devices and tags Place lockout hasp and padlock or tag at the point of power disconnect where lockout is required by each person perform ing work Each person...

Page 12: ...nd the haz ards involved and in accordance with published service manuals Failure to observe this precau tion could result in death or severe injury WARNING Line terminals L1 L2 L3 motor terminals U V...

Page 13: ...connected to the util ity line power as severe damage to the VSD may occur NOTE Interior electrical wiring is performed at the fac tory Required customer wiring is minimal but should be done by a qual...

Page 14: ...1 Safety ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual Notes 88292021 240 R01 14 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 15: ...and the air end casing After leaving the air end the compressed air fluid mixture flows into the fluid air separation system First the fluid air separator tank separates the majority of the fluid fro...

Page 16: ...21 240 R01 16 Subject to EAR ECCN EAR99 and related export control restrictions Figure 2 1 ST45 ST55 ST75 machine layout 1 Enclosure 5 Air inlet system 2 Electric control system 6 Motor air end 3 Cool...

Page 17: ...e is energized closing the control line Because the control is not in use the inlet valve of the air end is fully open When air demand is lower than the compressor rating discharge pressure builds up...

Page 18: ...3 5 Aftercooler The aftercooler cools the compressed air to 8 12 C 14 22 F above the ambient temperature This cooling causes water vapor to condense which creates moisture in the compressed air stream...

Page 19: ...by an axial flow cooling fan pulls cooling air through louvers on both sides of the compressor This cooling air draws heat from the aftercooler before flowing out of the machine 2 5 2 Ambient tempera...

Page 20: ...ting temperature In conditions of high humidity and low operating tempera ture water formed by condensation may collect in the compressor fluid To ensure trouble free operation Sul lair ShopTek compre...

Page 21: ...bar 145 psi 10 bar 145 psi 10 bar 145 psi Voltage frequency 460 V 60 Hz Air end type Single stage oil injected rotary screw Configuration Gear driven with external inlet modulation Motor type ODP IP2...

Page 22: ...ications ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 88292021 240 R01 22 Subject to EAR ECCN EAR99 and related export control restrictions 3 3 Piping and instrumentation 88292020...

Page 23: ...CONTROL 4 COMPRESSOR UNIT 5 PROBE THERMISTER 6 GAUGE PRESSURE 7 TANK FLUID AIR SEPARATOR 8 ELEMENT FLUID AIR SEPARATOR PRIMARY 9 ELEMENT FLUID AIR SEPARATOR SECONDARY 10 VALVE MINIMUM PRESSURE 11 TRA...

Page 24: ...3 Specifications ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual Notes 88292021 240 R01 24 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 25: ...When moving the compressor with a crane lift the com pressor with slings and use guide ropes to prevent twist ing You should also use spreader bars to prevent panel damage When the compressor has been...

Page 26: ...o exceed 40 C 104 F even if the cooling air is adequately dissipated for example in a boiler room Sullair recom mends following the guidelines in Section 4 3 2 1 Poorly ventilated areas 4 4 Connection...

Page 27: ...hat it is adequate for starting and running the compres sor 4 6 1 Power supply requirements 460 VAC 3 phase 60 Hz with ground Control voltage 110 VAC 4 6 2 Checking the motor rotation direction For th...

Page 28: ...4 Installation ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual Notes 88292021 240 R01 28 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 29: ...it is installed 5 If you are installing the compressor perform the motor rotation direction check described in Section 4 6 2 6 Switch on the mains power if it is not already on 7 Press the Start butto...

Page 30: ...on troller into fault mode which prevents the compressor from restarting After the compressor cools down the fault mode may be cleared by pressing the Reset button on the controller 5 7 Motor overload...

Page 31: ...the pre set run on time the compressor will enter standby mode The compressor will automatically restart if a fall in system pressure is registered The factory setting of the run on time is 15 minutes...

Page 32: ...5 Operation ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual Notes 88292021 240 R01 32 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 33: ...id or air leaks excessive vibration or unusual sounds 6 3 Recommended maintenance schedule 6 3 1 Service at 50 operating hours Replace the fluid filter element Check the condition of the purge oil ret...

Page 34: ...it is necessary 6 3 5 Service every 4000 operating hours or semi annually Perform all checks listed for every 1000 and 2000 hours plus Replace the fluid air separator element and purge oil return line...

Page 35: ...ht by hand until it will not turn any further Ensure the O ring is properly seated 5 Run the compressor for a short period of time and check the fluid level through the sight glass adding more fluid i...

Page 36: ...more fluid if necessary see Section 6 3 7 Compressor fluid levels 6 4 3 Fluid filter maintenance Replace the fluid filter element every 1000 hours of ser vice The fluid filter service indicator will...

Page 37: ...f service Check the condition of the purge oil return line filter every 1000 hours of service for blockages or other problems Replace the purge oil return line filter when you replace the separator el...

Page 38: ...arator ele ment to the ground 11 Re tension the separator cover bolts after the compressor has reached operating tem perature 6 4 7 Minimum pressure valve maintenance 1 Shut down the compressor and bl...

Page 39: ...ative 6 Reassemble the coupling assembly The coupling shall be mounted so that the gap between the ends of the two plates is 2 3 mm 7 Replace the screws on the fixing cap 8 Replace the shroud on the f...

Page 40: ...ive dust Excessive dirt or dust the accumulated dust may interfere with the compressor s ventilation Chemical smoke steam salt mist or oil mist A very wet or very dry atmosphere Radiant heat Pests or...

Page 41: ...n very flammable areas methyl chloroform can be used Although this solvent is not com bustible under normal conditions partial ventilation is required when the smell of the solvent becomes strong 6 6...

Page 42: ...ontacts Replace transducer if contacts are normal Unloading components e g blow down valve inlet regulator valve are not working properly Check if unloading components are working normally Solenoid va...

Page 43: ...ber of the compressor You can get the serial number from the Bill of Lading for the compressor or from the Serial Number Plate located on the compressor see Figure 7 1 Serial number plate and location...

Page 44: ...027 255 88292009 685 1 Repair kit for inlet valve 88292027 255 88291010 178 1 Repair kit for pneumatic control integrated block in the air inlet valve control component assembly capacity adjustment 88...

Page 45: ...ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 7 Parts List Notes 88292021 240 R01 Subject to EAR ECCN EAR99 and related export control restrictions 45...

Page 46: ...ts List ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 88292021 240 R01 46 Subject to EAR ECCN EAR99 and related export control restrictions 7 3 Motor and air end system 88292019 151...

Page 47: ...SUPPORT AIR END WS45 75 FOR MAINTENANCE USE 11 88291005 932 1 SUPPORT MOTOR AS45 75 FOR 365TSC 12 88292013 890 2 BOOT GUARD FOR WIRE 13 1 MOTOR SEE MOTOR LIST 14 88292020 093 1 FRAME BSE ST45 55 75 A...

Page 48: ...RECEIVER TANK A6 TO RECEIVER TANK Part number Qty Description Notes 88290009 321 1 COMPRESSOR PARTS DXX163167E146S47ACM ST4508 60Hz ST4509 60Hz US 88250146 440 1 COMPRESSOR PARTS DXX163167E176S47ACM S...

Page 49: ...ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 7 Parts List Notes 88292021 240 R01 Subject to EAR ECCN EAR99 and related export control restrictions 49...

Page 50: ...Parts List ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 88292021 240 R01 50 Subject to EAR ECCN EAR99 and related export control restrictions 7 4 Air inlet system 88292019 152 R01...

Page 51: ...147 1 GASKET INL VLV LS12 50 LF SSAI 8 88291006 018 1 VALVE ASSY INLET CTL GRP AS45 75 ON OFF OTHERS 88291010 175 1 VALVE ASSY INLET CTL GRP AS45 75 REGULATING OTHERS 88292027 271 1 VALVE ASSY AIRINLE...

Page 52: ...Parts List ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 88292021 240 R01 52 Subject to EAR ECCN EAR99 and related export control restrictions 7 5 Fluid piping system 88292019 154 R...

Page 53: ...HOSE OIL INLET AIREND ST45 75 FIXED SPEED 9 88292010 002 1 CONNECTOR OIL FLTR THRMVLV 150SSAIC 10 88292017 554 2 CONNECTOR M M42X2 F M42X2SAE PORT 11 88292019 147 1 HOSE OIL AIREND ST45 75AC FIXED SPE...

Page 54: ...Parts List ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 88292021 240 R01 54 Subject to EAR ECCN EAR99 and related export control restrictions 7 6 Cooling fan system 88292019 155 R0...

Page 55: ...ADAPTER VENTURI COOLER AS45 75 3 88292017 516 1 COOLER FLUID AFTER ST45 55 ASME ST45 55 ASME 88292017 517 1 COOLER FLUID AFTER ST75 ASME ST75 ASME 88292018 732 1 COOLER FLUID AFTER ST45 55 GB ST45 55...

Page 56: ...s List ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 88292021 240 R01 56 Subject to EAR ECCN EAR99 and related export control restrictions 7 7 Fluid air separation system 88292019 1...

Page 57: ...1 2 13 837808 125 4 WASHER SPRLOCK REG PLTD 1 2 14 841215 004 3 TUBING STNLS STL 1 4 20GA FT 15 860704 025 1 ELBOW PIPE M F 1 4 X 1 4 16 869825 025 1 TEE MALE PIPE 1 4 BRASS 17 88290001 031 1 PLUG OI...

Page 58: ...O RING VITON 23 6X3 55GB3452 1 37 88842035 028 1 O RING VITON 28X3 55 GB3452 1 FOR CE TANK 38 88842035 047 1 O RING VITON47 5X3 55GB3452 1 39 88842035 069 1 O RING VITON 69X3 55 GB3452 1 40 88842035...

Page 59: ...ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 7 Parts List Notes 88292021 240 R01 Subject to EAR ECCN EAR99 and related export control restrictions 59...

Page 60: ...arts List ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 88292021 240 R01 60 Subject to EAR ECCN EAR99 and related export control restrictions 7 8 Air discharge system 88292019 156 R...

Page 61: ...ST45 75 AC 7 88291011 207 1 SUPPORT AIROC AS75 AUS 8 88291013 209 1 SEPARATOR TRAP WS250 AS132 R2 88291013 632 1 SEPARATOR TRAP WS250 FNPT 2 NPT2 9 88291007 773 1 CONNECTOR ADJUST M48X2 TO R2 R2 8829...

Page 62: ...7 Parts List ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 88292021 240 R01 62 Subject to EAR ECCN EAR99 and related export control restrictions 7 9 Control system 88292019 157 R05...

Page 63: ...0 5 10 IP68 PA6 13 88291011 111 1 TUBE FTG GRP FGK M64B 0 8M ST45 75AC US 88291011 930 1 TUBE FTG N MGQ75B OTHERS 14 88291012 012 1 CONNECTOR ELBOW G1 4MXNPT 1 8F 15 88291012 013 1 CONNECTOR G1 4FXG1...

Page 64: ...l restrictions 30 250018 428 2 CONNECTOR 1 4 TUBE X 1 4 NPT 31 88290017 336 4 HOSE HIGH PRESS 1 2X1200 32 860108 050 1 CONNECTOR 37FL MPT 1 2 X 1 2 33 250018 430 1 ELBOW 1 4 TUBE X 1 4 NPT 34 88292031...

Page 65: ...ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 7 Parts List Notes 88292021 240 R01 Subject to EAR ECCN EAR99 and related export control restrictions 65...

Page 66: ...arts List ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 88292021 240 R01 66 Subject to EAR ECCN EAR99 and related export control restrictions 7 10 Starter assembly 88292017 767 R04...

Page 67: ...pTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 7 Parts List 88292021 240 R01 Subject to EAR ECCN EAR99 and related export control restrictions 67 7 10 Starter assembly 88292017 767 R04...

Page 68: ...AL BLOCK AB 8 XT1 88290016 045 10 TERMINAL BLOCK 9 FR1 88291012 902 1 OVERLOAD RELAY AB 10 PE 88291011 071 1 PE BAR 11 88290016 046 3 TERMINAL END COVER AB 12 XT1 88290017 859 2 PE TERMINAL AB 13 EC20...

Page 69: ...ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 7 Parts List Notes 88292021 240 R01 Subject to EAR ECCN EAR99 and related export control restrictions 69...

Page 70: ...7 Parts List ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 88292021 240 R01 70 Subject to EAR ECCN EAR99 and related export control restrictions 7 11 Enclosure 8829019 158 R00...

Page 71: ...92019 586 1 COVER A ST75 AUS 9 88292019 587 2 ANGLE D ROOF CLR ST45 55AC ST45 55 88292019 588 2 ANGLE B ROOF CLR ST75AC ST75 10 88292019 589 2 PANEL C CORNER ST45 75 AC 11 88292019 590 2 ANGLE A ROOF...

Page 72: ...Parts List ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual 88292021 240 R01 72 Subject to EAR ECCN EAR99 and related export control restrictions 7 12 Decal locations 88292019 159 R00...

Page 73: ...ER HI VOLTAGE 7 049685 1 DECAL WARNING COMP OIL FIL CAP 8 049852 1 DECAL WARNING GROUND FAULT 9 049855 2 DECAL WARNING SEVER FAN INDUS 10 241814 2 DECAL FORK LIFTING 11 250021 337 1 TAG FIRST START 12...

Page 74: ...7 Parts List ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual Notes 88292021 240 R01 74 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 75: ...ig nated and ordered by outside diameter and thickness A metric nominal size is indicated by the letters DN fol lowed by a number without any unit of measure For met ric to imperial nominal size equiv...

Page 76: ...A Nominal Sizes ShopTek ST45 ST55 ST75 U S A Mexico Operation Maintenance Manual Notes 88292021 240 R01 76 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 77: ...Subject to EAR ECCN EAR99 and related export control restrictions...

Page 78: ...ons are subject to change without prior notice Subject to EAR ECCN EAR99 and related export control restrictions Sullair LLC 1 Sullair Way Michigan City IN 46360 USA www sullair com 1 800 SULLAIR USA...

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