Sullivan-Palatek 125UD Operating And Parts Manual Download

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OPERATING AND PARTS MANUAL

FOR

INDUSTRIAL ELECTRIC AIR COMPRESSORS

125, 150, 200 AND 250UD MODELS

WITH T1 MICRO PROCESSOR CONTROL

AND YASKAWA DRIVE

PALATEK, INC. dba SULLIVAN-PALATEK MICHIGAN CITY, IN 46360

04/01/2011

P/N OPM-125250T1V-010

Summary of Contents for 125UD

Page 1: ... FOR INDUSTRIAL ELECTRIC AIR COMPRESSORS 125 150 200 AND 250UD MODELS WITH T1 MICRO PROCESSOR CONTROL AND YASKAWA DRIVE PALATEK INC dba SULLIVAN PALATEK MICHIGAN CITY IN 46360 ALL RIGHTS RESERVED 04 01 2011 P N OPM 125250T1V 010 ...

Page 2: ......

Page 3: ...SOR UNIT 10 3 3 MOTOR 10 3 4 INTAKE CONTROL SYSTEM 10 3 5 COMPRESSOR LUBRICATION COOLING SYSTEM 12 3 6 COMPRESSOR DISCHARGE SYSTEM 13 3 7 VARIABLE FREQUENCY DRIVE AND ELECTRICAL PARTS 14 3 8 INSTRUMENTATION 14 SECTION 4 INSTALLATION 15 4 1 RECEIVING 15 4 2 WELDING 15 4 3 LOCATION 15 4 4 SUPPORT 15 4 5 ELECTRICAL 15 4 6 WIRING DIAGRAM YASKAWA F7 UPDRAFT AIR COOLED 16 4 7 WIRING DIAGRAM YASKAWA F7 U...

Page 4: ...L SYSTEM 125 250UD 39 7 8 DISCHARGE SYSTEM 125 150UD 41 7 9 DISCHARGE SYSTEM 200 250UD 43 7 10 MICROPROCESSOR CONTROL OPEN 125 250UD 45 7 11 MICROPROCESSOR CONTROL ENCLOSED 125 250UD 47 7 12 ENCLOSURE AIR COOLED 125 250UD 49 7 13 ENCLOSURE AIR COOLED 200 250UD 51 7 14 ENCLOSURE WATER COOLED 125 250UD 53 7 15 DECAL T1 INSTRUCTIONS YASKAWA 54 SECTION 8 WARRANTY 55 SECTION 9 GENERAL ARRANGEMENT DRAWI...

Page 5: ...ent all pressure before opening or removing any filter element line tube fitting valve plug cover connection or any other component on the air compressor or in the plant s compressed air system Remove Oil Filler Cap Caution Hot oil is present only when compressor has been turned off the disconnect switch locked open and there is no pressure in the oil separation tank Bleed off any residual pressur...

Page 6: ...arts of the body away from the fan and drive coupling Wear snug fitting protective clothing no neckties and confine long hair when working around compressor 1 5 PHYSICAL DANGERS Wear OSHA approved personal protective gear including gloves safety shoes safety glasses head covering and ear protection when working on or around the compressor Avoid bodily contact with hot oil hot surfaces sharp edges ...

Page 7: ...ith one of the same size type and ampere rating 1 8 LIFTING Lift or move the compressor only with equipment of sufficient load capacity that has been inspected and is in good condition Keep personnel out from under and away from the area when lifting or moving the compressor Lift no higher than necessary Carry as low as possible when moving Keep lifting operator in attendance whenever compressor i...

Page 8: ...issing damaged or painted over or located in such a position as to be unreadable in a given installation new Warning Signs must be ordered Be sure they are properly positioned and installed correctly WARNING If any operators are not fully conversant with the English language and or cannot comprehend the intended pictorial warnings it becomes incumbent upon the owner lesser or other responsible adm...

Page 9: ...r oxidant atmospheres contact the factory for lubricant recommendations Also for such conditions we would suggest oil analysis every 1000 hours Mixing of these or any other type of oil or synthetic fluid will void the 5 year compressor unit warranty and could result in greatly increased maintenance and service expenses 2 3 APPLICATION GUIDE Ambient Temperature Range 35 to 104 F 1 to 40 C The lower...

Page 10: ...an motor Contact the factory for any other requirements such as TEFC main drive motor 3 4 INTAKE CONTROL SYSTEM The intake control system consists of an air filter connecting rubber elbow a combination compressor inlet valve reverse flow check valve blow down valve and control pressure transducer See Intake Control Schematic The air filter is a multi stage dry type with a high efficiency cleanable...

Page 11: ... unload setting of the micro processor which will interrupt the voltage to the control solenoid to open and allow air pressure to close the inlet valve This same air pressure which is holding the inlet valve shut is also venting the pressure in the separator tank to reduce the power required If the micro processor determines that the compressor has been unloaded for 3 minutes then the compressor g...

Page 12: ...area of lower pressure at the compressor unit Fluid flows from the oil separation tank to the cooler from the cooler to the filter and from the filter to the compressor During cold starts the thermovalve is open allowing the fluid to by pass the oil cooler and go directly to the filter While warming up a gradual change occurs where the fluid flow is split partial flows being shared by both the oil...

Page 13: ...l separation element a replaceable multi layered multi media coalescing element with pleated initial stage for reduced velocity improved separation performance and extended service life Separated oil is returned to the compressor oil system via a small diameter return line or scavenger tube A sight gauge is provided to monitor the lubricoolant level in the oil separation tank and a capped oil fill...

Page 14: ...bricant cooling fan operation dirty cooler or varnish in oil cooler 3 7 VARIABLE FREQUENCY DRIVE AND ELECTRICAL PARTS The three phase electric motor drive supplied with the SULLIVAN PALATEK Plant Air Compressor has a NEMA 1 rated enclosure A separate control box contains the control power transformer the 24 volt power supply for the micro processor control the control pressure transducers and fan ...

Page 15: ...on is imposed upon the compressor cooling fan Consult the factory for assistance if heat recovery is desired MODEL 125UD 150UD 200UD 250UD MAX AIRFLOW CFM 12 500 15 000 18 500 20 000 MAX HEAT REJECTION BTU HR 330 000 418 500 550 000 600 000 Locate compressor as close as practical to where the compressed air is to be utilized This saves piping and reduces power requirements necessary to transmit co...

Page 16: ... 1 64 STRUCTURAL 1 16 DECIMAL 0 TO 12 030 12 TO 36 060 36 TO 125 A SULLIVAN PALATEK MRA none none SHEET 1 OF 1 REV 1 23 1 22 1 21 1 20 1 19 1 18 1 17 1 16 1 15 1 14 1 13 1 12 1 11 1 10 1 09 1 08 1 07 1 06 1 05 1 04 1 03 1 02 1 01 1 24 1 2 3 4 DESCRIPTION BEFORE CHANGE DATE BY NO SIZE SCALE CONFIDENTIAL INFORMATION IT MUST BE USED STRICTLY FOR THE LIMITED PURPOSE SUBMITTED AND IS SUBJECT TO RETURN ...

Page 17: ...OF 1 REV 1 23 1 22 1 21 1 20 1 19 1 18 1 17 1 16 1 15 1 14 1 13 1 12 1 11 1 10 1 09 1 08 1 07 1 06 1 05 1 04 1 03 1 02 1 01 1 24 1 2 3 4 DESCRIPTION BEFORE CHANGE DATE NO SIZE SCALE CONFIDENTIAL INFORMATION ITMUST BE USED STRICTLY FOR THE LIMITED PURPOSE SUBMITTED AND IS SUBJECT TO RETURN UPON DEMAND ANY DISCLOSURE REPRODUCTION OR OTHER USE IS EXPRESSLY PROHIBITED EXCEPT AS OTHERWISE AGREED UPON I...

Page 18: ...he top of the pipe Point of use filters coalescers regulators and or lubricators are often required Note Never use plastic air piping or plastic bowls on filters or lubricators See Section 1 Inspect piping and air hoses frequently for leaks 4 10 ADDITIONAL HELP By making the cleanest coolest air available to the compressor inlet maintenance and power consumption will be minimized The standard air ...

Page 19: ...sor oil level after it has been allowed to settle for a few minutes If it is necessary to add oil be sure to open the main power disconnect lock it out and relieve all oil separation tank pressure prior to removing fill cap to top off the tank 11 If the control or unload pressures are incorrect adjust the pressures in the microprocessor Do NOT raise the pressure without consulting the factory 5 3 ...

Page 20: ... TROUBLE SHOOTING 5 5 SHUTDOWN To stop compressor press stop key on micro processor 5 6 RESTARTS After a power failure open and lock out the main disconnect check all fuses and breakers Close disconnect switch and follow Normal Operation start up procedure Following a shutdown caused by either of the protective devices i e temperature or R O P open and lock out the main disconnect switch correct t...

Page 21: ...lysis Replace air and oil filter elements and air oil separator element sooner if excessive lubricoolant loss is experienced FOOD GRADE LONG LIFE Every 4 000 hours If using Food Grade Long Life Change Food Grade Long Life lubricoolant and inspect tank interior Replace lubricant filters and air oil separator element PALLUBE 32P LUBRICANT Every 8 000 hours If using Pallube 32p Change Pallube 32p lub...

Page 22: ...on once the filter element has been replaced 6 4 AIR OIL SEPARATOR Replace annually or if differential pressure exceeds 8psid i e fault signal is shown on micro processor H5 1 Open and lock out main disconnect 2 Disconnect main air line to aftercooler 3 Disconnect control air tubing 4 Unbolt cover in a diagonal criss cross pattern 5 Remove cover oil pick up tube and separator element 6 Drain lubri...

Page 23: ...ot bring the control set point up as this may increase the current to levels the drive will fault on Consult the factory if there are any questions If the pressure reading is cycling up and down between load and unload rapidly you can decrease the load pressure to help it gain control Don t go above the factory setting There are also some additional control parameters in the microprocessor which c...

Page 24: ...essure does not exceed the operating pressure of your machine as specified on the nameplate 2 Fault condition See microprocessor for fault Press reset to clear faults 3 Monitor temperature at micro processor normal discharge temperature should be 100 110 F 37 43 C above ambient control is set to trip at 235 245 F 112 118 C a Cooling air flow restricted Clean cooler and check for proper ventilation...

Page 25: ...ure signal Replace tubing repair leak 2 Defective blow down valve Check that sump pressure is exhausted to the atmosphere when unload solenoid opens Replace if necessary 3 Faulty inlet valve Repair or replace SYMPTOM PROBABLE CAUSES AND REMEDIES E EXCESSIVE LUBRICOOLANT CONSUMPTION 1 Clogged oil return line Clean strainer and or orifice 2 Separator element is damaged or not functioning properly Ch...

Page 26: ...SULLIVAN PALATEK__________________________________ 26 NOTES ...

Page 27: ...__________________________________SULLIVAN PALATEK 27 PARTS LISTING ...

Page 28: ...d on an exchange basis All bearings and seals have been replaced All other parts not meeting our quality standards are also replaced The air end is then factory tested prior to shipment A re manufactured air end has a warranty which is 12 months from start up date or 18 months from date of shipment in accordance with the terms set forth in the new air end warranty found in SECTION 8 ...

Page 29: ... NUMBER QTY 1 ELEMENT AIR FILTER 00521 112 1 2 ELEMENT OIL FILTER 00520 016 2 3 ELEMENT AIR OIL SEPARATOR KB08000 024 1 4 ELEMENT COUPLING SPIDER 08516 065 1 5 KIT SHAFT SEAL 31 CC1029 547 1 6 KIT TOOLS FOR SHAFT SEAL KTB31CC1029 547 1 7 KIT REPAIR INLET VALVE K09790 005 1 8 KIT REPAIR MINIMUM PRESSURE VALVE K09610 005 1 9 KIT REPAIR SOLENOID VALVE K40529 011A 1 10 VALVE SOLENOID UNLOAD 40529 011 ...

Page 30: ...SULLIVAN PALATEK__________________________________ 30 DRIVE AND BASE ASSEMBLY 125 250UD ...

Page 31: ...__________________________________SULLIVAN PALATEK 31 7 3 DRIVE AND BASE ASSEMBLY 125 250UD ...

Page 32: ...SULLIVAN PALATEK__________________________________ 32 LUBRICATION AND COOLING SYSTEM AIR COOLED 125 250UD ...

Page 33: ...4 20 09620 028 09620 028 TUBE 1 250 O D SUMP TO THERMOSTAT 1 21 90624 188 90624 188 REDUCER STRAIGHT THREAD 1 500 X 1 250 1 22 93115 002 93115 002 BOLT WHIZ 5 16 X 750 28 23 93165 003 93165 003 NUT WHIZ 5 16 42 24 90947 022 90947 022 KEY FAN MOTOR 5 16 1 25 90502 016 90502 016 SCREW SET 250 X 313 1 26 08080 040 08080 040 FAN 40 1 27 92906 008 92906 008 CLIP FAN GUARD 3 16 14 28 94302 032 94302 032...

Page 34: ...SULLIVAN PALATEK__________________________________ 34 LUBRICATION AND COOLING SYSTEM WATER COOLED 125 150UD ...

Page 35: ...T WHIZ 3 8 18 18 93115 003 BOLT WHIZ 3 8 X 3 4 4 19 08339 020 SUPPORT OIL FILTER 1 20 91928 004 PLUG PIPE 1 4 HEX 2 21 08415 005 HEAD FILTER DUAL 125 200 1 22 91553 044 CONN NT 1 4 X 1 4 MPT 2 23 GASKET OIL FILTER 2 24 00520 016 ELEMENT OIL FILTER 150 2 25 03000 014 PLATE OIL INJECTION 1 26 95206 122 BOLT SOC M12 X 40MM 4 27 80220 020 ELBOW CMS ORB 1 1 4 2 28 01528 066 SUPPORT CLR LEGS 75 100U 4 2...

Page 36: ...SULLIVAN PALATEK__________________________________ 36 LUBRICATION AND COOLING SYSTEM WATER COOLED 200 250UD ...

Page 37: ...0 SUPPORT OIL FILTER 1 20 91928 004 91928 004 PLUG PIPE 1 4 HEX 2 21 08415 005 08415 005 HEAD FILTER DUAL 125 200 1 22 91553 044 91553 044 CONN NT 1 4 X 1 4 MPT 2 23 GASKET OIL FILTER SUPPLIED WITH 24 2 24 00520 016 00520 016 ELEMENT OIL FILTER 150 2 25 03000 014 03000 014 PLATE OIL INJECTION 1 26 95206 122 95206 122 BOLT SOC M12 X 40MM 4 27 80220 020 80220 020 ELBOW CMS ORB 1 1 4 2 28 01528 066 0...

Page 38: ...SULLIVAN PALATEK__________________________________ 38 INLET AND CAPACITY CONTROL SYSTEM 125 250UD ...

Page 39: ...__________________________________SULLIVAN PALATEK 39 7 7 INLET AND CAPACITY CONTROL SYSTEM 125 250UD Item 14 Recommend Rebuilding Inlet Valve with K09790 005 Kit every 2 Years ...

Page 40: ...SULLIVAN PALATEK__________________________________ 40 DISCHARGE SYSTEM 125 150UD ...

Page 41: ... O RING SEAL TO ADAPTER 1 21 92581 200 WASHER LOCK 20MM 4 22 95201 449 BOLT HHC 20MM X 60MM 4 23 90305 064 WASHER LOCK 625 20 24 90169 006 NUT HEX 5 8 GR8 4 25 19600 065 PIPE DISCHARGE 3 000 1 26 93165 006 NUT WHIZ HEX 1 2 13 4 27 00909753 0048 FLANGE ASSEMBLY 3 000 CODE 61 1 28 90042 432 BOLT HH 5 8 X 1 625 GR8 4 29 92141 005 FITTING BULKHEAD 625 TUBE X 500 NPT 1 30 91177 008 NIPPLE PIPE 500 NPT ...

Page 42: ...SULLIVAN PALATEK__________________________________ 42 DISCHARGE SYSTEM 200 250UD ...

Page 43: ...RF 3 000 FLANGE 1 18 00633 018 GASKET E75 AIR END TO DISCHARGE 1 19 92581 200 WASHER LOCK 20MM 4 20 90305 064 WASHER LOCK 625 16 21 90169 006 NUT HEX 5 8 GR8 4 22 95201 426 BOLT HHC 20MM X 60MM 4 23 19600 041 PIPE DISCHARGE 3 000 1 24 90165 005 NUT HEX 1 2 13 4 25 90305 004 WASHER LOCK 500 4 26 90321 005 WASHER USS FLAT 500 8 27 96391 108 ELBOW CMS 625 TUBE X 500 NPT 1 28 92141 005 FITTING BULKHEA...

Page 44: ...SULLIVAN PALATEK__________________________________ 44 MICROPROCESSOR CONTROL OPEN 125 250UD ...

Page 45: ...__________________________________SULLIVAN PALATEK 45 7 10 MICROPROCESSOR CONTROL OPEN 125 250UD ...

Page 46: ...SULLIVAN PALATEK__________________________________ 46 MICROPROCESSOR CONTROL ENCLOSED 125 250UD ...

Page 47: ...PANEL INSTRUMENT 40 400UD NRM 00944 027 1 6 WEATHERSTRIP 1 000 X 125 UOM FT 09870 004 2 7 ENCLOSURE 8 X 8 X 4 00543 088 1 8 COVER ENCLOSURE SUPPLIED WITH ITEM 7 1 9 SCREW COVER SUPPLIED WITH ITEM 7 1 10 CONDUIT FLEX 500 UOM FT 96701 008 14 11 CONNECTOR CONDUIT 500 91432 001 4 12 SWITCH E STOP NC 31 85153 379 2 13 BASE E STOP PUSH BUTTON 31 85152 649 1 14 NUT HEX SERRATED 1 4 93165 002 6 15 SCREW S...

Page 48: ...SULLIVAN PALATEK__________________________________ 48 ENCLOSURE AIR COOLED 125 250UD ...

Page 49: ...CL SIDE 2 5 10947 081 PANEL SIDE SUPPORT INST 1 6 00488 025 DOOR ENCL SIDE 3 7 10947 041 PANEL SIDE SUPPORT 2 8 10947 039 PANEL CORNER MOTOR END 1 9 10947 048 PANEL BAFFLE 1 10 00947 028 PANEL END TOP FRONT 1 11 10947 045 PANEL CENTER TOP 1 12 00947 030 PANEL TOP MOTOR END 1 13 10947 042 PANEL CORNER BACK 1 14 00947 029 PANEL ENCL TOP BACK 1 15 00935 010 ANGLE SEAL STRIP CLR 4 16 10947 047 PANEL S...

Page 50: ...SULLIVAN PALATEK__________________________________ 50 ENCLOSURE AIR COOLED 200 250UD ...

Page 51: ...CL SIDE 2 5 10947 081 PANEL SIDE SUPPORT INST 1 6 00488 025 DOOR ENCL SIDE 3 7 10947 041 PANEL SIDE SUPPORT 2 8 10947 039 PANEL CORNER MOTOR END 1 9 10947 048 PANEL BAFFLE 1 10 00947 028 PANEL END TOP FRONT 1 11 10947 045 PANEL CENTER TOP 1 12 00947 030 PANEL TOP MOTOR END 1 13 10947 047 PANEL CORNER BACK 1 14 00947 029 PANEL ENCL TOP BACK 1 15 00935 009 ANGLE SEAL STRIP CLR 4 16 10947 047 PANEL S...

Page 52: ...SULLIVAN PALATEK__________________________________ 52 ENCLOSURE WATER COOLED 125 250UD ...

Page 53: ...IDE 2 5 10947 081 PANEL SIDE SUPPORT INST 1 6 00488 025 DOOR ENCL SIDE 3 7 10947 041 PANEL SIDE SUPPORT 2 8 10947 039 PANEL CORNER MOTOR END 1 9 10947 053 PANEL BAFFLE W C 1 10 00947 028 PANEL END TOP FRONT 1 11 10947 045 PANEL CENTER TOP 1 12 00947 030 PANEL TOP MOTOR END 1 13 10947 056 PANEL CORNER BACK W C 1 14 00947 029 PANEL ENCL TOP BACK 1 15 10947 072 PANEL TOP FAN MOUNTING 1 16 10947 047 P...

Page 54: ...SULLIVAN PALATEK__________________________________ 54 7 15 DECAL T1 INSTRUCTIONS YASKAWA ...

Page 55: ... service performed by someone other than a party authorized to perform warranty service if such service in the judgment of Sullivan Palatek has adversely affected the performance of the compressor the consequences of negligence misuse accident installation or storage The consequences of compressor lubrication neglect as manifested by varnishing pitting erosion of the rotors or stator or both Any p...

Page 56: ... and startup card supplied with the compressor must be completed and returned within 10 days of delivery and start up to register the compressor in to the Platinum program Eligibility for the Platinum warranty will expire 180 days after shipment of the product from the factory and can only be reestablished by application to the Sullivan Palatek Product Support department which may require a paid o...

Page 57: ...__________________________________SULLIVAN PALATEK 57 SECTION 9 GENERAL ARRANGEMENT DRAWING 9 1 PIPING AND INSTALLATION DIAGRAM 125 150UD ...

Page 58: ...SULLIVAN PALATEK__________________________________ 58 9 2 PIPING AND INSTALLATION DIAGRAM 200 250UD ...

Page 59: ...__________________________________SULLIVAN PALATEK 59 9 3 GENERAL ARRANGEMENT AIR COOLED OPEN 125 250UD ...

Page 60: ...SULLIVAN PALATEK__________________________________ 60 9 4 GENERAL ARRANGEMENT AIR COOLED ENCLOSED 125 150UD ...

Page 61: ...__________________________________SULLIVAN PALATEK 61 9 5 GENERAL ARRANGEMENT AIR COOLED ENCLOSED 200 250UD ...

Page 62: ...SULLIVAN PALATEK__________________________________ 62 9 6 GENERAL ARRANGEMENT WATER COOLED OPEN 125 250UD ...

Page 63: ...__________________________________SULLIVAN PALATEK 63 9 7 GENERAL ARRANGEMENT WATER COOLED ENCLOSED 125 250UD ...

Page 64: ...NTENANCE LOG S N SERVICE DIST FILL OUT FOR EACH SERVICE OR REPAIR MORE THAN ONE LINE MAY BE USED PER EACH SERVICE OR REPAIR THIS FORM MAY BE PHOTOCOPIED AS NEEDED DATE HOURS TEMP LINE PRESS OIL RET CLEAR OIL LEVEL SERVICE CHANGE CHANGED PART NUMBER SERVICE BY AIR OIL FILTER SEP ELE OIL ...

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