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TABLE OF CONTENTS

(CONTINUED)

Section 5

PAGE

COMPRESSOR

OPERATION

5.1 GENERAL INTRODUCTION--STANDARD

ELECTRO/MECHANICAL

5.2 PURPOSE OF CONTROLS--STANDARD

5.3 INITIAL START--UP PROCEDURE

5.4 SUBSEQUENT START--UP PROCEDURE

5.5 SHUTDOWN PROCEDURE

5.6 GENERAL INTRODUCTION --SUPERVISOR II

5.7 SUPERVISOR II PARAMETER SETUP

5.8 OPERATING THE COMPRESSOR

5.9 PURPOSE OF CONTROLS--SUPERVISOR II

5.10 SUPERVISOR OUTPUT RELAYS

5.11 INITIAL START--UP PROCEDURE

5.12 SUBSEQUENT START--UP PROCEDURE

5.13 SHUTDOWN PROCEDURE

Section 6

SUPERVISOR II

6.1 INTRODUCTION SUPERVISOR II

6.2 KEYPAD

6.3 STATUS DISPLAYS

6.4 LAMP INDICATORS

Section 7

MAINTENANCE

7.1 INTRODUCTION

7.2 DAILY OPERATION

7.3 MOTOR BEARING LUBRICATION

7.4 FLUID FILTER MAINTENANCE

7.5 COOLER MAINTENANCE

7.6 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES

PRESSURE RELIEF VALVE

FLUID FILTER REPLACEMENT

AIR FILTER MAINTENANCE

FLUID SEPARATOR ELEMENT REPLACEMENT

MOISTURE SEPARATOR ELEMENT REPLACEMENT

CONTROL SYSTEM ADJUSTMENT- STANDARD

ELECTRO/MECHANICAL

CONTROL SYSTEM ADJUSTMENT- SUPERVISOR II

PRESSURE VALVE ADJUSTMENT- SUPERVIOSR II

INLET CONTROL VALVE

Содержание ES-11 SERIES

Страница 1: ...ROTARY SCREW ES 11 SERIES 40 and 50 HP OPERATOR S MANUAL AND Part Number 02250094 473 Sullair Corporation PARTS LIST AIR COMPRESSOR 30 and 37 KW KEEP FOR FUTURE REFERENCE...

Страница 2: ...t 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 ac...

Страница 3: ...ICAL 6 2 6 ELECTRICAL PREPARATION SUPERVISOR II 6 2 7 MOTOR ROTATION DIRECTION CHECK STANDARD ELECTRO MECHANICAL 7 2 8 MOTOR ROTATION DIRECTION CHECK SUPERVISOR II Section 3 SPECIFICATIONS 9 3 1 SPECI...

Страница 4: ...ART UP PROCEDURE 23 5 13 SHUTDOWN PROCEDURE Section 6 SUPERVISOR II 25 6 1 INTRODUCTION SUPERVISOR II 25 6 2 KEYPAD 25 6 3 STATUS DISPLAYS 26 6 4 LAMP INDICATORS Section 7 MAINTENANCE 29 7 1 INTRODUCT...

Страница 5: ...ARTS 50 9 5 MOTOR AND PARTS 52 9 6 INLET FILTER AND PARTS 54 9 7 COOLING SYSTEM AND PARTS AIR COOLED 58 9 8 COOLING SYSTEM AND PARTS WATER COOLED 64 9 9 CONTROL BOX AND PARTS STANDARD 70 9 9A CONTROL...

Страница 6: ...NOTES...

Страница 7: ...t off throttle valve either at the compressor or at any other point along the air line when an air hose exceeding 1 2 13mm inside diameter is to be connected to the shut off throttle valve to reduce p...

Страница 8: ...rags trash leaves litter or other com bustibles out of and away from the compressor J DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or...

Страница 9: ...nded with open electrical enclosures If necessary to 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 a...

Страница 10: ...ge enough to hold a person and if it is necessary to enter it to per form service adjustments inform other personnel before doing so or else secure and tag the access door in the open position to avoi...

Страница 11: ...tart up 2 3 SERVICE AIR PIPING Service air piping should be installed as shown in Figure 2 1 A shut off valve should be installed to isolate the compressor from the service line Also notice that the s...

Страница 12: ...e rotary switch on the control box door When looking at the motor from the end opposite the compressor unit the shaft should be turning clockwise If the motor shaft is not turning clockwise disconnect...

Страница 13: ...Section 2 INSTALLATION 7 Figure 2 1 Service Air Piping...

Страница 14: ...8 NOTES...

Страница 15: ...0 60 33 64 75 1850 76 50XH 53 155 175 60 33 64 75 1850 76 I Weights are approximate due to options available II Ratings for dBA at one meter COMPRESSOR Type Single Stage Fluid Injected Screw Compresso...

Страница 16: ...may occur the fluid change interval must be re duced to 300 hours maximum A non detergent fluid with rust oxidation and foam inhibitors and good water separation characteristics should be used DO NOT...

Страница 17: ...e the other which is an idler The air fluid mixture discharges directly into the fluid management system The fluid cooler bypass valve helps assure proper cooling by directing the fluid to the fluid c...

Страница 18: ...Section 4 COMPRESSOR SYSTEMS 12 Figure 4 1A Description of Components...

Страница 19: ...Section 4 COMPRESSOR SYSTEMS 13 AIR COOLED WATER COOLED Figure 4 1B Description of Components...

Страница 20: ...ximately 50 psig 3 4 bar NORMAL OPERATING MODE 50 TO 125 PSIG 3 4 TO 8 6 BAR When the pressure air rises above 50 psig 3 4 bar the minimum pressure check valve opens and deliv ers compressed air to th...

Страница 21: ...ar FULL LOAD MODE 50 TO 100 PSIG 3 5 TO 6 9 BAR When the compressed air pressure rises above 50 psig 3 5 bar the minimum pressure valve opens allowing compressed air to flow into the service line From...

Страница 22: ...Section 4 COMPRESSOR SYSTEMS 16 Figure 4 3 Pneumatic Control System Standard Supervisor II...

Страница 23: ...nually reset after the ele ment has been changed SThe separator maintenance gauge moni tors the condition of the separator element It indicates when the element restriction is excessive SThe fluid fil...

Страница 24: ...VALVE Maintains minimum of 50 psig 3 4 bar in thecompres sor sump Valve piston restricts receiver air discharge from receiver sump when pressure falls to 50 psig 3 4 bar Also incorporated in this valv...

Страница 25: ...nce indicators 5 5 SHUTDOWN PROCEDURE To shut the compressor down simply turn the selec tor switch to the O STOP position 5 6 GENERAL INTRODUCTION SUPERVISOR II Reference Supervisor II Section 6 While...

Страница 26: ...S Sequence method This parameter sets the method used for optional sequencing The choices are DISABLED REMOTE SLAVE HOURS COM ID See the Se quencing Protocol Manual See Recom mended Spare Parts List...

Страница 27: ...atic or manual mode control of the load solenoid will be based on the parameters UNLD and LOAD This operation is as follows P2 UNLD load solenoid turned off P2 LOAD load solenoid turned on POWER FAILU...

Страница 28: ...DO NOT OVERFILL COOLER BYPASS VALVE Regulates flow of fluid to and around the cooler Designed to maintain a minimum operating temperature of 185_F 85_C used for fast warm up on start up MINIMUM PRESSU...

Страница 29: ...rect rotation of motor refer to Section 2 8 3 Be sure that all preparations and checks de scribed in the Installation Section have been made 4 Open the shut off valve to the service line 5 Check for p...

Страница 30: ...24 NOTES...

Страница 31: ...and changed See PA RAMETER SETUP PRG S Up arrow Used in status displays to change displays and in parameter setup mode to increment a value S Down arrow lamp test Used in status displays to change di...

Страница 32: ...his shows the fault on the first line and the run hours when the fault occcured T1 HI 2 204 6 4 LAMP INDICATORS Embedded into the front panel schematic of the compressor are several lamps Pressing the...

Страница 33: ...Section 6 SUPERVISOR II 27 MESSAGE DISPLAY SYSTEM GRAPHIC DISPLAY KEYPADS Figure 6 1 Supervisor II Panel...

Страница 34: ...28 NOTES...

Страница 35: ...D FILTER MAINTENANCE WARNING Fluid filter has internal bypass DO NOT SUBSTI TUTE Replace the fluid filter element under any of the fol lowing conditions 1 As recommended in the Lubrication Guide in th...

Страница 36: ...sure by closing recommended discharge shut off valve and releasing all internal pressure from compressor 1 Remove the separator maintenance gauge line and fluid return line from their connections if...

Страница 37: ...witch con tacts should open If the pressure switch contacts do not open or they open prior to the desired pres sure the pressure switch setting will require adjust ment refer to Figure 7 4 FOR PRESSUR...

Страница 38: ...mpressor CONTROL SYSTEM ADJUSTMENT SUPERVI SOR II All components in the Control System are designed and manufactured to close tolerances to help elimi nate any need for adjustments DANGER DO NOT touch...

Страница 39: ...CTION instruc tions and practices when lifting this assembly In the event a new factory replacement compressor unit is required the compressor unit must be pre lu bricated prior to operation NOTE When...

Страница 40: ...Section 7 MAINTENANCE 34 Figure 7 6 Cooler Cleaning COOLER SHROUD COMPRESSOR ENCLOSURE COOLER...

Страница 41: ...Section 7 MAINTENANCE 35 MODEL NO SERIAL NO 7 7 MAINTENANCE RECORD DATE HOURMETER MAINTENANCE PERFORMED BY AUTHORIZED BY WORK PERFORMED...

Страница 42: ...36 NOTES...

Страница 43: ...tor Starter Overloads Tripped Reset Should trouble persist check whether motor starter contacts are functioning properly Low Incoming Line Voltage Check voltage Should voltage check low consult power...

Страница 44: ...contacts open or repair or replace if necessary kit available EXCESSIVE COMPRESSOR FLUID Separator Element Damaged or CONSUMPTION Not Functioning Properly Change element Leak in the Lubrication System...

Страница 45: ...sed valves Water Temperature is High water Increase water flow lower water cooled packages only temperature Cooler is Plugged water cooled Clean tubes and or shell if tube packages only plugging persi...

Страница 46: ...moisture separator Install a compressed air dryer sized for the flow and dryness level required Note Filters may also be required to remove particulates liquid oil aerosols or for oil vapor removal C...

Страница 47: ...owing the total amount of adjustment Maxi mum adjustment is r 7 The DSP key exits wiping out changes to the cur rent item while saving changes to any previous items The PRG key saves the current item...

Страница 48: ...42 NOTES...

Страница 49: ...IR EUROPE S A Zone Des Granges BP 82 42602 Montbrison Cedex France Telephone 33 477968470 Fax 33 477968499 9 2 RECOMMENDED SPARE PARTS LIST DESCRIPTION KIT NUMBER QUANTITY repair kit for fluid filter...

Страница 50: ...Section 9 ILLUSTRATIONS AND PARTS LIST 44 9 3 FRAME MOTOR COMPRESSOR AND PARTS...

Страница 51: ...8 13 washer metric m12 838812 250 2 14 capscrew 5 8 11 x 1 1 2 828410 150 4 15 capscrew 8 8 m12 x 76mm 828012 076 2 16 insert 5 16 steel 02250043 765 32 17 screw 3 8 16 x 1 1 2 829706 150 2 18 screw 4...

Страница 52: ...Section 9 ILLUSTRATIONS AND PARTS LIST 46 9 4 COMPRESSOR AND PARTS 44...

Страница 53: ...5_F 91_C V 02250092 081 1 18 screw M10X20 829310 020 1 19 adapter oil filter 02250077 706 1 20 element 02250078 544 1 21 screw M10X25 829310 025 9 22 screw 829316 060 4 23 o ring 826502 144 1 24 screw...

Страница 54: ...Section 9 ILLUSTRATIONS AND PARTS LIST 48 9 4 COMPRESSOR AND PARTS 44...

Страница 55: ...250064 663 1 32 o ring 826502 226 1 33 ring retaining 02250064 664 1 34 o ring 826502 334 1 35 screw 829306 016 1 36 o ring 826502 157 1 37 ring retaining inlet 836369 500 1 38 spring check 02250064 6...

Страница 56: ...Section 9 ILLUSTRATIONS AND PARTS LIST 50 9 5 MOTOR AND PARTS...

Страница 57: ...onduit 847008 060 2 9 ring terminal 849304 010 1 10 wire 850215 010 2 11 bushing conduit 848815 150 2 12 ring terminal 849302 010 1 13 wire 850604 012 1 15 connector wire yellow 851000 074 3 16 joint...

Страница 58: ...Section 9 ILLUSTRATIONS AND PARTS LIST 52 9 6 INLET FILTER AND PARTS STANDARD ELECTRO MECHANICAL ELECTRO MECHANICAL DELUXE AND SUPERVISOR II DELUXE FOR AIR INLET FOR AIR INLET...

Страница 59: ...1 6 filter inlet I 02250085 253 1 7 band mounting 040598 1 8 nut ring m16 x 2 582 II 02250094 650 1 9 stud m16 x 50 nom 02250094 647 1 10 nut 5 16 825305 283 2 11 screw 5 16 18 x 1 829705 100 2 12 wa...

Страница 60: ...Section 9 ILLUSTRATIONS AND PARTS LIST 54 9 7 COOLING SYSTEM AND PARTS AIR COOLED...

Страница 61: ...16 bushing reducing 1 2 x 1 4 807602 010 1 17 connector 1 4t x 1 4 npt 250018 428 1 18 nut retainer 5 16 861405 092 4 19 tee reducing 02250053 609 1 20 valve ball 1 4 npt 047115 1 21 elbow 45 deg sae...

Страница 62: ...Section 9 ILLUSTRATIONS AND PARTS LIST 56 9 7 COOLING SYSTEM AND PARTS AIR COOLED...

Страница 63: ...p 2 2kW 02250087 271 1 37 venturi panel S 22 in 56 cm 02250087 272 1 S 24 in 61 cm 250018 329 1 38 fan cooling S 22 in 56 cm 241390 1 S 24 in 61 cm 049971 1 39 motor fan Consult Factory 1 40 elbow 1 1...

Страница 64: ...Section 9 ILLUSTRATIONS AND PARTS LIST 58 9 8 COOLING SYSTEM AND PARTS WATER COOLED...

Страница 65: ...15 valve water 3 4 047398 1 16 cooler oil 02250085 718 1 17 heat exchanger air 250017 527 1 18 u bolt 1 2 x 5 pipe 829008 500 1 19 separator moisture 1 1 2 fpt I 02250078 841 1 20 connector sae seal l...

Страница 66: ...Section 9 ILLUSTRATIONS AND PARTS LIST 60 9 8 COOLING SYSTEM AND PARTS WATER COOLED...

Страница 67: ...x 1 829705 100 3 46 washer pl b r 5 16 838205 071 8 47 nut hex flanged 5 16 825305 283 2 48 connector tube m 1 1 2 x 1 1 2 810224 150 2 49 screw ser wash 5 16x3 4 829705 075 8 50 nipple pipe 1 1 2 x...

Страница 68: ...Section 9 ILLUSTRATIONS AND PARTS LIST 62 9 8 COOLING SYSTEM AND PARTS WATER COOLED...

Страница 69: ...fan 241579 1 64 support 02250085 823 1 65 screw hex ser wash 5 16 x 1 1 2 829705 150 5 66 insert 5 16 steel 02250043 765 31 67 washer pl b reg pltd 1 4 838204 071 4 68 capscrew hex gr 5 1 4 20 x 1 828...

Страница 70: ...Section 9 ILLUSTRATIONS AND PARTS LIST 64 9 9 CONTROL BOX AND PARTS STANDARD NOTE...

Страница 71: ...882 1 18 valve blowdown 1 4 II 250025 655 1 19 elbow 90 lqtite 1 2 846600 050 3 20 light pilot assy green 250000 104 2 21 plug hole seal n4 409918 002 4 22 decal 02250083 361 1 23 conduit ft 846315 05...

Страница 72: ...Section 9 ILLUSTRATIONS AND PARTS LIST 66 9 9 CONTROL BOX AND PARTS STANDARD NOTE...

Страница 73: ...1 4 tube x 1 4 npt 250028 582 2 50 elbow 1 4 tube x 1 8 npt 250018 429 2 51 plug pipe 1 8 stl 807800 005 1 52 nut hex pltd sae 10 32 825801 130 13 53 nipple chase cond 1 2 847815 050 2 54 nipple pipe...

Страница 74: ...Section 9 ILLUSTRATIONS AND PARTS LIST 68 9 9 CONTROL BOX AND PARTS STANDARD NOTE...

Страница 75: ...pe 1 4 galv 804415 010 3 67 elbow pipe 1 4 galv 803515 010 3 68 tee straight 1 8 galv 804415 005 2 69 nipple pipe 1 8 x cl sc 80 ga 823202 000 1 70 bushing red 1 4x1 8 galv 804100 005 1 71 nipple pipe...

Страница 76: ...Section 9 ILLUSTRATIONS AND PARTS LIST 70 9 9A CONTROL BOX AND PARTS SUPERVISOR II NOTE...

Страница 77: ...9 grip 02250071 379 2 20 controller 02250083 801 1 21 locknut 02250071 362 2 22 bulkhead pipe 1 8 npt 841500 002 3 23 switch vacuum 02250078 249 1 24 valve shuttle 1 4 408893 2 25 strainer III 241771...

Страница 78: ...Section 9 ILLUSTRATIONS AND PARTS LIST 72 9 9A CONTROL BOX AND PARTS SUPERVISOR II NOTE...

Страница 79: ...x cl sc 80 ga 823204 000 12 48 washer sprlock reg m4 838804 090 14 49 nut hex metric m4 x 7 825904 070 20 50 nipple pipe 1 8 x cl sc 80 ga 823202 000 2 51 washer pl br 5 16 837205 071 1 52 screw ser...

Страница 80: ...Section 9 ILLUSTRATIONS AND PARTS LIST 74 9 9B CONTROL PANEL AND PARTS ELECTRO MECHANICAL...

Страница 81: ...re 250005 185 2 2 gauge temperature 042582 1 3 gauge vacuum 250003 797 1 4 gauge differential pressure 250003 798 1 5 gauge differential pressure 250003 799 1 6 coupling galvanized pipe 803215 005 7 7...

Страница 82: ...Section 9 ILLUSTRATIONS AND PARTS LIST 76 9 10 CANOPY ACOUSTICAL PANELS AND PARTS...

Страница 83: ...1 1 11 panel acoustical insulation 02250084 758 2 12 panel acoustical insulation 02250084 761 2 13 panel acoustical insulation 02250081 477 1 14 panel acoustical insulation 02250081 400 1 15 panel aco...

Страница 84: ...Section 9 ILLUSTRATIONS AND PARTS LIST 78 9 10 CANOPY ACOUSTICAL PANELS PARTS...

Страница 85: ...78 578 1 35 panel acoustical insulation 02250084 762 1 36 panel acoustical insulation 02250081 398 2 37 panel acoustical insulation 02250081 397 2 38 grommet rubber 1 4 040125 8 39 screw 5 16x3 4 8297...

Страница 86: ...Section 9 ILLUSTRATIONS AND PARTS LIST 80 9 11 DECAL GROUP 1 2 3 4 5 6 02250077 472 2A...

Страница 87: ...685 1 2 sign danger electrocution 049850 1 2a decal electrocution 50 hertz compressors 02250077 472 1 3 sign warning hot surfaces 407408 1 4 decal warning auto start 041065 1 5 decal danger breath air...

Страница 88: ...Section 9 ILLUSTRATIONS AND PARTS LIST 82 9 11 DECAL GROUP 8 9 10 11 12 13 7...

Страница 89: ...02250075 045 1 Sdecal PE designation not shown 02250075 540 1 10 decal danger hi voltage 042218 1 11 sign warning ground fault 049852 1 12 decal ISO 9001 02250059 288 1 13 decal ES 11 warning lift 02...

Страница 90: ...Section 9 ILLUSTRATIONS AND PARTS LIST 84 9 12 WIRING DIAGRAM FULL VOLTAGE STANDARD ELECTRO MECHANICAL...

Страница 91: ...Section 9 ILLUSTRATIONS AND PARTS LIST 85 9 13 WIRING DIAGRAM FULL VOLTAGE SUPERVISOR II...

Страница 92: ...Section 9 ILLUSTRATIONS AND PARTS LIST 86 9 14 WIRING DIAGRAM WYE DELTA 50 60 HZ ELECTRO MECHANICAL...

Страница 93: ...Section 9 ILLUSTRATIONS AND PARTS LIST 87 9 15 WIRING DIAGRAM WYE DELTA 50 60 HZ SUPERVISOR II...

Страница 94: ...Section 9 ILLUSTRATIONS AND PARTS LIST 88 9 16 WIRING DIAGRAM WYE DELTA 50 HZ EUROPE ELECTRO MECHANICAL...

Страница 95: ...Section 9 ILLUSTRATIONS AND PARTS LIST 89 9 17 WIRING DIAGRAM WYE DELTA 50 HZ EUROPE SUPERVISOR II...

Страница 96: ...9 SIZE CLAMP LOAD kN DRY LUB CLAMP LOAD kN DRY LUB TIGHTENING TORQUE NDm TIGHTENING TORQUE NDm TIGHTENING TORQUE NDm CLAMP LOAD kN DRY LUB Basic pitch diameters are used to calculate torque values Coe...

Страница 97: ...NOTES...

Страница 98: ...higan City Indiana 46360 U S A Telephone 1 800 SULLAIR U S A Only or 1 219 879 5451 Fax 219 874 1273 Fax 219 874 1835 Parts Fax 219 874 1805 Service SULLAIR ASIA LTD Sullair Road No 1 Chiwan Shekou Sh...

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