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20/12 SERIES - 2 STAGE

OPERATOR’S

MANUAL

Part Number 250041-546

Sullair Corporation, 1993

Effective 5/93

AIR COMPRESSOR

INDUSTRIAL

500 - 750 CFM

AIR-COOLED AND WATER COOLED

Содержание 20/12 Series

Страница 1: ...20 12 SERIES 2 STAGE OPERATOR S MANUAL Part Number 250041 546 ESullair Corporation 1993 Effective 5 93 AIR COMPRESSOR INDUSTRIAL 500 750 CFM AIR COOLED AND WATER COOLED ...

Страница 2: ...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 service personnel For detailed course outlines schedule and cost information contact Sullair Corporate Training Department 1 ...

Страница 3: ...UNIT FUNCTIONAL DESCRIPTION 7 2 4 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTIONAL DESCRIPTION 8 2 5 COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTION 10 2 6 CAPACITY CONTROL SYSTEM FUNCTIONAL DESCRIPTION 12 2 7 AIR INLET SYSTEM FUNCTIONAL DESCRIPTION 12 2 8 INSTRUMENT PANEL GROUP FUNCTIONAL DESCRIPTION Section 3 SPECIFICATIONS 13 3 1 TABLE OF SPECIFICATIONS 13 3 2 LUBRICATION GUIDE Section 4...

Страница 4: ...ENANCE 18 6 1 GENERAL 18 6 2 DAILY OPERATION 18 6 3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION 18 6 4 MAINTENANCE AS REQUIRED BY LUBRICATION GUIDE SECTION 3 18 6 5 FILTER MAINTENANCE 18 6 6 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES 27 6 7 MOTOR CONNECTION INSTRUCTIONS 27 6 8 TROUBLESHOOTING Section 7 RECOMMENDED SPARE PARTS 31 7 1 PROCEDURE FOR ORDERING PARTS 31 7 2 RECOMMENDED SPARE PARTS ...

Страница 5: ...wise disabled B Install an appropriate flow limiting valve between the service air outlet and the shut off throttle valve either at the compressor or at any other point along the air line when an air hose exceeding 2 13mm inside diameter is to be connected to the shut off throttle valve to reduce pressure in case of hose failure per OSHA Standard 29 CFR 1926 302 b 7 C When the hose is to be used t...

Страница 6: ... with inadequate flow of lubricant or with degraded lubricant K DO NOT attempt to operate the compressor in any classification of hazardous environment unless the compressor has been specially designed and manufactured for that duty 1 5 MOVING PARTS A Keep hands arms and other parts of the body and also clothing away from couplings fans and other moving parts B DO NOT attempt to operate the compre...

Страница 7: ...do so then disconnect lock out and tag all power at source so others will not inadvertently restore power E Disconnect lock out and tag all power at source prior to attempting repairs or adjustments to rotating machinery and prior to 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 ...

Страница 8: ...ter it to perform service adjustments inform other personnel before doing so or else secure and tag the access door in the open position to avoid the possibility of others closing and possibly latching the door with person nel inside B Make sure all personnel are out of compressor before closing and latching enclosure doors ...

Страница 9: ... Figure 2 1 and 2 2 The components of the Sullair 2 stage electric compressor include com pressor unit electric motor cooling and lubri cation system air inlet system compressor dis charge system capacity control system and in strument panel The 2 stage Sullair compressor unit is driven by an electric motor designed to provide enough horse power for more than adequate reserve at rated con ditions ...

Страница 10: ...mixture is routed through the discharge system where the fluid is separated from the air At this time the air flows to your service line and the fluid is directed through the cooling and lubrication system in preparation for reinjection 2 4 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTIONAL DESCRIPTION Refer to Figures 2 3 2 4 and 2 5 The compressor cooling and lubrication system is designed to ...

Страница 11: ...ate the unit from the cooling system The fluid stop valve solenoid valve also opens to as sist in relieving the stop valve pilot signal pressure at shutdown A portion of the fluid flowing to the compressor is routed to the anti friction bearings which support the rotors inside the compressor unit Prior to entering the compressor unit this fluid is taken through an extra fine bearing filter thus as...

Страница 12: ...le ments to the compressor unit Fluid collected at the bottom of the elements is returned to the compres sor unit by a pressure difference between the area surrounding the separator elements and the com pressor Orifices protected by strainers are in serted in the return lines to assure proper flow The sump is ASME code rated at 400 psig 27 6 bar working pressure A minimum pressure valve lo cated d...

Страница 13: ...Section 2 DESCRIPTION 9 Figure 2 5 Piping and Instrumentation RESTRICTION ...

Страница 14: ...rfly valve fully and the compressor then pumps at full rated ca pacity start Mode B The rising compressed air pressure is isolated from the service line in this phase by the minimum pressure valve set at ap proximately 160 psig 11 bar NORMAL OPERATING MODE 160 TO 340 PSIG 11 TO 23 4 BAR When the sump pressure rises above 160 psig 11 bar the minimum pressure valve opens and deliv ers compressed air...

Страница 15: ...valve directly controls the amount of air intake to the compressor in response to the operation of the Sullicon Control Section2 6 The inlet actuator cylinder holds the butterfly valve closed during the compressor start mode 2 8 INSTRUMENT PANEL GROUP FUNCTIONAL DESCRIPTION Refer to Figure 2 8 for specific location of parts de scribed The instrument panel group consists of a line pressure gauge ai...

Страница 16: ...pushbutton turns the compressor off S The RESET optional pushbutton clears the protective shutdown interlocks after a fault has been corrected S The hourmeter records the cumulative hours of operation for the compressor and is useful for plan ning and logging service operations S The separator maintenance indicator monitors the condition of the separator elements and shows red when the element res...

Страница 17: ...ee Phase 60 Cycles Size See Model Series above Speed a 1800 RPM and b 1200 RPM for 500 CFM units 3 2 LUBRICATION GUIDE Sullair standard compressors are filled with Sullube 32 fluid as factory fill MIXING OF OTHER FLUIDS WITHIN THE COMPRESSOR WILL VOID ALL WARRANTIES Sullube 32 fluid should be changed every 8000 hours when indicated by fluid analysis or once a year whichever comes first The fluid s...

Страница 18: ...14 NOTES ...

Страница 19: ... of the sight glass DO NOT OVER FILL THE FLUID LEVEL OF THE COMPRESSOR 4 5 MOTOR ROTATION DIRECTION CHECK After the electrical wiring has been done it is neces sary to check the direction of the motor rotation This can be done by jogging the START and STOP but tons on the instrument panel When looking at the motor from the end opposite the compressor unit the shaft should be turning clockwise If t...

Страница 20: ...16 NOTES ...

Страница 21: ...when the pressure drop through the filter is excessive SEPARATOR MAINTENANCE INDICATOR Indicates when separator element change is required Shows red when the pressure drop through the sepa rator elements is excessive The separators must be replaced DO NOT CLEAN FLUID LEVEL SIGHT GLASS Monitors fluid level in the sump Proper level is to fill the sight glass FLUID RETURN LINE SIGHT GLASSES Used to i...

Страница 22: ...perating pressure BLOWDOWN VALVE Vents sump pressure to the atmosphere during unload conditions and shutdown PRESSURE SWITCH Senses service line pressure When line pressure reaches maximum operating pressure the pressure switch signals the solenoid pilot valve to unload the compressor MINIMUM PRESSURE CHECK VALVE Maintains a minimum pressure of 160 psig 11 BAR in the sump This valve restricts air ...

Страница 23: ... the desired unload pressure If adjustments are nec essary see Control System Adjustments in the Maintenance Section of the manual 7 Observe the operating temperature If the operat ing temperature exceeds 230ºF 110ºC the cooling system or installation environment should be checked 8 Observe return line sight glasses and mainte nance indicators 9 Open shut off valve to service line 10 Reinspect the...

Страница 24: ...20 NOTES ...

Страница 25: ...ements are needed to rid the system of any foreign materials Perform the following mainte nance operations to prevent unnecessary problems 1 Clean the return line strainers 2 Clean the return line orifices 3 Change the bearing filter element 4 Clean the main strainer element 6 4 MAINTENANCE AS REQUIRED BY LUBRICATION GUIDE SECTION 3 1 Drain the sump and change the compressor fluid 2 Replace the be...

Страница 26: ...tall the gasket seal ring to the canister flange 5 Before reinstalling the canister to the filter head make sure mounting surface on filterhead isclean and free of dirt 6 Apply a film of fluid to the gasket seal ring and then install the canister to the filterhead Reinstallband and tighten band nut to 200 in lbs 22 6 Nm AIR FILTER MAINTENANCE Refer to Figure 6 3 Air filter maintenance should be pe...

Страница 27: ...ematically between the sump and the fluid stop valve When servicing the main fluid filter shut down the compressor and use seal kit no 001132 and follow the instruction below For element replacement order kit no 001094 1 Remove the four 4 capscrews which secure the filter head to the canister 2 Pull the canister away from the filter head The fil ter elements will be attached to the head 3 Separate...

Страница 28: ...h 2 Turn the range adjusting screw to the high pres sure unload setting Turning the screw counter clockwise lowers both the high and low pressure equally FOR DIFFERENTIAL PRESSURE ADJUSTMENT Differential is the difference between the high and low pressure settings 10 psig 0 7 bar typical Turn the differential adjusting screw to the lower re set setting Turning the screw counterclockwise widens the...

Страница 29: ...tep is to reassemble the regulator using the new parts provided in the repair kit 8 Reassemble the diaphragm pressure plate dia phragm gasket seat disc and seat disc gasket and tighten the nut All of the these parts with the exception of pressure plate are provided in the re pair kit 9 Replace the seat ring with the new seat ring pro vided 10 Replace the existing diaphragm stop 11 Next place these...

Страница 30: ...e adjusting screw until tension is real ized 19 At this time refer to the Control System Adjust ment Procedure to readjust the control pressure regulator valve FLUID STOP VALVE Refer to Figure 6 9 When servicing the fluid stop valve P N 250038 489 use repair kit numbers 250038 490 and 250038 494 Use all parts provided in the kit The valve may be serviced without remov ing it from its associated pi...

Страница 31: ...e sides of the cover in a crisscross pattern Check to see that cylinder is seated on seals on both ends RUNNING BLOWDOWN VALVE MAINTENANCE Refer to Figure 6 10 When it is necessary to repair the running blowdown valve P N 045116 use re pair kit no 047524 and follow the instructions pro vided below 1 Remove the hex nut from the bottom of the valve The poppet guide which is secured by the hex nut is...

Страница 32: ...e ex plained below for installation DISASSEMBLY 1 Remove the appropriate piping from the thermal valve before starting disassembly 2 Remove the four 4 capscrews holding the hous ing together and separate the upper housing from the lower housing 3 Pull firmly on the thermal element and remove NOTE There will be a slight resistance from the seal ring centered in the lower housing 4 Remove the seal r...

Страница 33: ... If boots or insulating material show distress as mentioned above tag and investigate to deter mine the source of thermal damage and repair the connection as necessary 5 Replace the damaged boot s with new boots as required or retape connections per National State or Local codes 6 Replace the conduit cover prior to reconnecting the power source WARNING Electrical shock hazard Disconnect all power ...

Страница 34: ...ose the in let butterfly when the pressure switch con tacts open Repair if defective Defective blowdown valve blowdown valve should exhaust sump pressure to the atmosphere when maximum operating pressure is reached Repair Discharge Temperature Thermistor Switch Open Cooling water temperature too high increase water flow Cooling water flow insufficient check water lines and valves Cooler plugged cl...

Страница 35: ...d contacts are functioning properly and are not damaged Repair or replace if necessary kit available Defective Solenoid Valve Check that Sullicon Control lever is moved to a completely stroked position when the pres sure switch contacts close Repair or replace if necessary kit available Defective Blowdown Valve Check that sump pressure is exhausted to the atmosphere when the pressure switch contac...

Страница 36: ...tive Muffler Replace Defective Pressure Switch Repair or replace Defective Solenoid Valve Repair or replace Defective Sullicon Diaphragm Replace diaphragm Incorrect Unload Stop Screw Position Reposition and tighten Incorrect Inlet Butterfly Position Reposition and tighten Inlet Butterfly Loose Reposition and tighten Plugged or Frozen Control Lines Replace or thaw as needed ...

Страница 37: ...replacement element for air filter 409264 primary 409853 1 replacement element for air filter 409264 secondary 409854 1 repair kit for fluid stop valve 250038 489 250038 490 piston and parts 1 250038 494 o rings poppet 1 replacement element for bearing filter 250019 296 602568 001 2 repair kit for shaft seal 001811A 1 repair kit for running blowdown valve 045116 047524 1 repair kit for pressure re...

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Страница 40: ... Specifications Subject To Change Without Prior Notice WORLDWIDE SALES AND SERVICE SULLAIR CORPORATION 3700 E Michigan Blvd Michigan City Indiana 46360 9990 Telephone 219 879 5451 A SUBSIDIARY OF SUNDSTRAND CORPORATION ...

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