Sullivan-Palatek 100UDG Operating And Parts Manual Download

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OPERATING AND PARTS MANUAL

FOR

INDUSTRIAL ELECTRIC AIR COMPRESSORS

75UDG AND 100UDG MODELS

WITH T1 MICRO PROCESSOR CONTROL

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

10-26-2011

Part Number: OPM75100T1

Summary of Contents for 100UDG

Page 1: ...UAL FOR INDUSTRIAL ELECTRIC AIR COMPRESSORS 75UDG AND 100UDG MODELS WITH T1 MICRO PROCESSOR CONTROL PALATEK INC dba SULLIVAN PALATEK MICHIGAN CITY IN 46360 ALL RIGHTS RESERVED COPYRIGHT 2011 10 26 2011 Part Number OPM75100T1 ...

Page 2: ......

Page 3: ...0 3 2 COMPRESSOR UNIT 10 3 3 MOTOR 10 3 4 INTAKE CONTROL SYSTEM 11 3 5 COMPRESSOR LUBRICATION COOLING SYSTEM 12 3 6 COMPRESSOR DISCHARGE SYSTEM 13 3 7 STARTER AND ELECTRICAL PARTS 15 3 8 INSTRUMENTATION 15 SECTION 4 INSTALLATION 16 4 1 RECEIVING 16 4 1A WELDING 16 4 2 LOCATION 16 4 3 SUPPORT 16 4 4 ELECTRICAL 16 4 5A WIRING DIAGRAM FULL VOLTAGE STARTER STANDARD 17 4 5B WIRING DIAGRAM Y DELTA START...

Page 4: ...STEM AIR COOLED 34 7 5 INTAKE AND CAPACITY CONTROL SYSTEM 75G 100G 36 7 7 DISCHARGE SYSTEM 75 100G 38 7 8 MICROPROCESSOR CONTROL ELECTRICAL PARTS OPEN 40 7 9 MICROPROCESSOR CONTROL ENCLOSED 42 7 10 ENCLOSURE AIR COOLED UD 44 7 11 ENCLOSURE WATER COOLED UD 46 7 13A DECAL AND IDENTIFICATION 47 7 13B DECAL AND IDENTIFICATION 48 SECTION 8 WARRANTY 49 SECTION 9 GENERAL ARRANGEMENT DRAWINGS 51 9 1 P I D...

Page 5: ...ents such as OSHA NEC NFPA CSA etc WARNING Do not modify this compressor without specific written approval from the factory 1 2 PRESSURE RELEASE Operate manually the pressure relief valve s periodically to be sure there is no blockage obstruction or inability to operate Shut machine off by using stop button on Micro Processor Open and lock out disconnect switch and vent all pressure before opening...

Page 6: ... allow oil to accumulate on in or around acoustic noise material Immediately replace any oil soaked material after cleaning enclosure surface with nonflammable solvent Do not operate compressor when there is a possibility of its ingesting flammable toxic or explosive fumes mists or particles Do not operate compressor with the temperature sensor inoperative or any of its two Pressure Switches inope...

Page 7: ...applicable regulations Use food grade lubricant for such applications 1 7 ELECTRIC SHOCK Remove watches rings and keep all parts of the body tools or other conductive objects away from exposed live parts of the electrical system Maintain dry footing stand on insulating surface and do not contact any other portion of the compressor when making adjustments Turn compressor off open main disconnect an...

Page 8: ... is ready for maintenance service or trouble shooting if it is not running It may be in the Automatic Start mode Sleep mode or was not shut down properly prior to power having been shut off then when power is re applied the compressor may suddenly re start thereby creating a hazardous condition Also compressor may be wired to BLT or sequencer which might call for a start Close discharge air valves...

Page 9: ...ainted 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 administrator to be su...

Page 10: ... from the above specifications without reference to any descriptions in this manual 2 2 LUBRICATION GUIDE SULLIVAN PALATEK recommends using Palasyn 45 synthetic lubricoolant for normal plant air service For compressors running two or three shift operations extended life lubricants such as Pallube 32p or Pal extra 44 are offered as factory fill Also where incidental food contact may happen we offer...

Page 11: ...er the greatest value and lowest life cycle cost of operation The compressor package includes a direct connected electric motor driven compressor air intake capacity control system air cooled cooling system including a standard air cooled aftercooler discharge system instrument panel and electrical system They are available base mounted with or without enclosures These machines are intended for in...

Page 12: ...ing is reached the compressor inlet valve is wide open and the compressor will deliver its full rated capacity Normal Full Load Mode From 60 to 125 psi 415 to 863 kPa the minimum pressure valve is open and the compressor delivers its full rated capacity to the air receiver and or the plant air piping system Modulating Mode Whenever less than the rated capacity of the compressor is being used the s...

Page 13: ...ompressor to be off when air is required please contact the factory for adjustments to be made to the controls to avoid this problem i e adjust regulating valve lengthen run on time etc 3 5 COMPRESSOR LUBRICATION COOLING SYSTEM The cooling system consists of a fan fan motor finned tube radiator type fluid cooler thermovalve to accelerate warm up and to control operating temperature a full flow fil...

Page 14: ...E SYSTEM The compressor unit discharges a mixture of compressed air and lubricoolant directly into the oil separation tank where it accomplishes the following three functions A Primary separation by change of direction and reduction of velocity which allows the heavier droplets of lubricoolant to fall B Serves as the lubricoolant sump by collecting the hot lubricoolant prior to re circulation thro...

Page 15: ...d allow the pressure to exceed 200 psig 1380 kPa However since the opening of this valve is noisy and results in hot oil being expelled a sensor which reads sump pressure will shut the motor off at its set point normally set factory The panel mounted micro processor shows the pressure at the discharge of the MPV i e line pressure Additionally differential pressure switches which trip if the pressu...

Page 16: ...rol voltage This is to minimize the potential for arcing at the contact points of switches or relays The primary high voltage incoming power and the secondary control voltage circuits are both provided with breakers to minimize the potential for damage due to overloading or short circuit faults In addition a 24 volt output transformer is needed to supply the proper operating voltage for the micro ...

Page 17: ...g fan Consult the factory for assistance if heat recovery is desired Model 75UDG 100UDG AIRFLOW CFM 7 500 9 500 HEAT REJECTION BTU HR 220 000 300 000 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 compressed air long distances The compressor should be piped into a receiver tank prior to an...

Page 18: ... 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 UPON DEMAND ANY DISCLOSURE REPRODUCTION OR OTHER USE IS EXPRESSLY PROHIBITED EXCEPT AS OTHERWISE AGREED UPON IN WRITING THIS DOCUMENT IS THE PROPERTY OF PALATEK INC AND CONTAINS PROPRIETARY AND TRANSFORMER 110 24 VAC T112 WD 0640...

Page 19: ...IDENTIAL INFORMATION IT MUST BEUSED STRICTLY FOR THE LIMITED PURPOSE SUBMITTED ANDIS SUBJECTTO RETURN UPON DEMAND ANY DISCLOSURE REPRODUCTION OR OTHER USE IS EXPRESSLY PROHIBITED EXCEPTAS OTHERWISE AGREED UPON IN WRITING THIS DOCUMENT IS THE PROPERTY OF PALATEK INC AND CONTAINS PROPRIETARY AND T1 Y DELTA WIRING DIAGRAM WD 06413 411 C8 C7 C6 C5 C4 OPTIONAL AUXILLARY ALARM REMOTE START REMOTE LOAD S...

Page 20: ... 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 8 ADDITIONAL HELP By making the cleanest coolest air available to the compressor inlet maintenance and power consumption will be minimized On the 75 100hp the standard air fil...

Page 21: ... door close the main disconnect and start the compressor by pushing green run button With the service air valve closed allow machine to pump up to normal operating pressures and observe operation of automatic controls and look for any possible leaks Open service air valve and check operation throughout the range of pressures observing operating temperatures Push red stop button and check lubricool...

Page 22: ...ssor press Red Stop Button Note machine will take 20 seconds to shut off If motor does not stop open disconnect switch then repair as necessary 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 switches i e motor overload...

Page 23: ...analysis 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 filter and air oil separator element PALLUBE 32p LUBRICANT Every 8 000 hours If using Pallube 32p Change Pallube 32p l...

Page 24: ...ailable for severe dust conditions 5 Snap the end cover back on once the filter element has been replaced 6 4 AIR OIL SEPARATOR Replace annually or if differential pressure exceeds 8 psid 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 Rem...

Page 25: ...ess enter key twice then use up or down keys to change the unload pressure Pu H Now press enter to store this setting I Press down key to get to the load pressure Pl this is normally set at a pressure 8 to 12 PSI below the unload pressure J Press enter then use up or down keys to change setting K Press enter to store setting L Press reset double bar for 2 seconds to return to normal display M Pres...

Page 26: ...your power company 6 Power failure see start up 7 Unit locked up a Filled with oil leaking inlet valve Replace inlet valve b Unit failure replace unit SYMPTOM PROBABLE CAUSES AND REMEDIES B MACHINE SHUTS DOWN WITH AIR DEMAND PRESENT 1 Loss of control voltage Reset If trouble persists check that line pressure does not exceed the operating pressure of your machine as specified on the nameplate 2 Low...

Page 27: ...open Repair or replace 6 Micro processor control setting off See 6 5 for adjustment procedure SYMPTOM PROBABLE CAUSES AND REMEDIES D LINE PRESSURE RISES ABOVE CUTOUT PRESSURE 1 Leak in control system causing loss of pressure signal Replace tubing repair leak 2 Improperly adjusted or defective regulator Readjust or replace if necessary 3 Defective blowdown valve Check that sump pressure is exhauste...

Page 28: ...PTOM PROBABLE CAUSES AND REMEDIES F RELIEF VALVE OPENS REPEATEDLY 1 Faulty Pressure Relief Valve Replace 2 Incorrect control settings Re adjust as per 6 5 SYMPTOM PROBABLE CAUSES AND REMEDIES G LINE PRESSURE VENTING THROUGH BLOWDOWN 1 Defective Check Valve portion of Minimum Pressure Check Valve Repair or replace check valve ...

Page 29: ..._____________________________________SULLIVAN PALATEK 28 PARTS LISTING ...

Page 30: ...ured air end can be purchased on an exchange basis All bearings and seals have been replaced All other parts not meeting our quality standards are also replaced An exchange air end has a warranty that is 12 months from startup date or 18 months from date of shipment in accordance with the terms set forth in the SULLIVAN PALATEK Warranty policy on pages 52 53 ...

Page 31: ...MENDED SPARE PARTS ITEM DESCRIPTION 75 100 UDG QTY PART NO 1 ELEMENT AIR FILTER 28174 113 1 PRIMARY N A 1 SECONDARY N A 1 2 ELEMENT OIL FILTER 00520 016 1 3 ELEMENT OIL SEPARATOR K08000 025 1 4 KIT REGUL VALVE REPAIR K09661 002 1 5 VALVE SOLENOID BLOWDOWN 40529 011 1 5A KIT SOLENOID VALVE DIAPHRAM K40529 011A 1 6 VALVE PRESSURE RELIEF 03100 006 1 7 SENSOR PRESS 4 20 ma 69676 006 1 8A SENSOR TEMP K...

Page 32: ...SULLIVAN PALATEK_____________________________________ 31 MOTOR COMPRESSOR AND MOUNTING PARTS ...

Page 33: ..._____________________________________SULLIVAN PALATEK 32 7 3 MOTOR COMPRESSOR AND MOUNTING PARTS 75HP MOTOR 100HP MOTOR ODP 08741 075 ODP 08741 100 TEFC 08747 075 TEFC 08747 100 ...

Page 34: ...SULLIVAN PALATEK_____________________________________ 33 LUBRICATION AND COOLING SYSTEM AIR COOLED ...

Page 35: ...ON AND COOLING SYSTEM AIR COOLED GASKET SUPPLIED WITH OIL FILTER AND CAN T BE ORDERED SEPERATELY Water Cooled Machines 75 hp 100 hp Oil Cooler 00549 005 Oil Cooler 00549 008 After Cooler 00549 004 After Cooler 00549 005 Water Reg Valve 18338 020 Water Reg Valve 18338 020 ...

Page 36: ...SULLIVAN PALATEK_____________________________________ 35 INTAKE AND CAPACITY CONTROL SYSTEM ...

Page 37: ..._____________________________________SULLIVAN PALATEK 36 7 5 INTAKE AND CAPACITY CONTROL SYSTEM 75G 100G ...

Page 38: ...SULLIVAN PALATEK_____________________________________ 37 DISCHARGE SYSTEM 75 100G ...

Page 39: ..._____________________________________SULLIVAN PALATEK 38 7 7 DISCHARGE SYSTEM 75 100G ...

Page 40: ...SULLIVAN PALATEK_____________________________________ 39 MICROPROCESSOR CONTROL ELECTRICAL PARTS OPEN ...

Page 41: ..._____________________________________SULLIVAN PALATEK 40 7 8 MICROPROCESSOR CONTROL ELECTRICAL PARTS OPEN ...

Page 42: ...SULLIVAN PALATEK_____________________________________ 41 MICROPROCESSOR CONTROL ENCLOSED ...

Page 43: ..._____________________________________SULLIVAN PALATEK 42 7 9 MICROPROCESSOR CONTROL ENCLOSED ...

Page 44: ...SULLIVAN PALATEK_____________________________________ 43 ENCLOSURE AIR COOLED UD ...

Page 45: ..._____________________________________SULLIVAN PALATEK 44 7 10 ENCLOSURE AIR COOLED UD ...

Page 46: ...SULLIVAN PALATEK_____________________________________ 45 ENCLOSURE WATER COOLED UD ...

Page 47: ..._____________________________________SULLIVAN PALATEK 46 7 11 ENCLOSURE WATER COOLED UD WATER COOLED VENT FAN P N 18080 016 1 QUANTITY NOT SHOWN IN DRAWING ...

Page 48: ...00UDG 1 PLATE NAME S N 1 03832 043 03832 043 2 DECAL VOLTAGE 460 1 08377 001 08377 001 3 DECAL WARNING 1 08377 043 08377 043 4 DECAL WARNING 1 08377 045 08377 045 5 DECAL WARNING 1 08377 046 08377 046 6 DECAL 3 POSITION SWITCH 1 08378 048 08378 048 7 DECAL INSTRUCTIONS 1 08379 011 08379 011 8 DIAGRAM WIRING 1 12288 003 12288 005 ...

Page 49: ...P02 50 01 E 0129 02 A 2128 03 E 0080 Highlight a specific error or alarm and press ENTER to get the details Press CLEAR to go back to the listing to scroll to the next alarm Repeat for each alarm Record the information OIL TEMP HIGH P02 01 01 E 0129 3893 hrs 12 07 2007 10 15 For drive errors 0d06 and 2d07 it will flash between the error and the drive reported error All information is important to ...

Page 50: ...f 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 ...

Page 51: ...on 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...

Page 52: ...SULLIVAN PALATEK_____________________________________ 51 SECTION 9 GENERAL ARRANGEMENT DRAWINGS 9 1 P I DIAGRAM AIR COOLED ...

Page 53: ..._____________________________________SULLIVAN PALATEK 52 9 2 GENERAL ARRANGEMENT 75 100HP UDAC OPEN ...

Page 54: ...SULLIVAN PALATEK_____________________________________ 53 9 3 GENERAL ARRANGEMENT 75 100HP UDAC ENCLOSED ...

Page 55: ..._____________________________________SULLIVAN PALATEK 54 9 4 GENERAL ARRANGEMENT 75 100HP WC OPEN ...

Page 56: ...SULLIVAN PALATEK_____________________________________ 55 9 5 GENERAL ARRANGEMENT 75 100HP WC ENCLOSED ...

Page 57: ...AINTENANCE 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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