Sullair ES-6 series Operator's Manual And Parts List
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Sullair ES-6 series Operator's Manual And Parts List

Rotary screw air compressor
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ROTARY SCREW

AIR COMPRESSOR

ES---6 Series
SPECIAL
4.1 KW
OPERATOR'S
MANUAL AND
PARTS LIST
KEEP FOR
REFERENCE
Part Number 02250111--- 097
eSullair Corporation
FUTURE

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  • Page 1: Air Compressor

    ROTARY SCREW AIR COMPRESSOR ES---6 Series SPECIAL 4.1 KW OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250111--- 097 eSullair Corporation...
  • Page 3 TABLE OF CONTENTS OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL Section 1 PAGE SAFETY 1.1 GENERAL 1.2 PERSONAL PROTECTIVE EQUIPMENT 1.3 PRESSURE RELEASE 1.4 FIRE AND EXPLOSION 1.5 MOVING PARTS 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS 1.7 TOXIC AND IRRITATING SUBSTANCES 1.8 ELECTRICAL SHOCK 1.9 LIFTING 1.10 ENTRAPMENT...
  • Page 4 TABLE OF CONTENTS (CONTINUED) Section 5 PAGE OPERATION 5.1 GENERAL 5.2 PURPOSE OF CONTROLS 5.3 INITIAL START--- UP PROCEDURE Section 6 MAINTENANCE 6.1 GENERAL 6.2 DAILY OPERATION 6.3 MOTOR BEARING LUBRICATION 6.4 FLUID FILTER MAINTENANCE 6.5 COOLER MAINTENANCE 6.6 PARTS REPLACEMENT MAINTENANCE AND ADJUSTMENT PROCEDURES 6.7 TROUBLESHOOTING 6.8 MAINTENANCE RECORD...

  • Page 5: General

    SAFETY 1.1 GENERAL 1926.302(b)(7) and/or any applicable Federal, Sullair Corporation and its subsidiaries design and State and Local codes, standards and regulations. manufacture all of their products so they can be op- B. When the hose is to be used to supply a mani- erated safely.

  • Page 6: Moving Parts

    Section 1 SAFETY C. DO NOT permit fluids, including air line anti--- E. Make sure all personnel are out of and/or clear of icer system antifreeze compound or fluid film, to ac- the compressor prior to attempting to start or oper- cumulate on, under or around acoustical material, ate it.

  • Page 7: Electrical Shock

    Section 1 SAFETY F. Wear goggles or a full face shield when adding helicopter must not be supported by the lifting bail antifreeze compound to air line anti---icer systems. but by slings instead. In any event, lift and/or han- dle only in full compliance with OSHA standards 29 G.

  • Page 8: Entrapment

    Section 1 SAFETY 1.10 ENTRAPMENT A. If the compressor enclosure, if any, is large enough to hold a man and if it is necessary to enter it to perform service adjustments, inform other per- sonnel before doing so, or else secure and tag the access door in the open position to avoid the possi- bility of others closing and possibly latching the door with personnel inside.

  • Page 9: Introduction

    All fluid entering the compressor unit passes questions arise which cannot be answered in the through the replaceable fluid filter element. This re- following text, call your nearest Sullair office or the placeable filter element contains a built ---in bypass Sullair Corporation Service Department.
  • Page 10 Section 2 DESCRIPTION Figure 2 ---1 Description of Components COOLING SYSTEM INLET SYSTEM BLOWDOWN VALVE AIR/FLUID SEPARATOR ELEMENT ACCESS COVER FLUID FILL PLUG FLUID DRAIN FLUID FILTER PRESSURE ELEMENT RELIEF VALVE ENCAPSULATED FLUID LEVEL FLUID COMPRESSOR SYSTEM SIGHT GLASS DRAIN CAP FLUID FILL PLUG AIR PRESSURE...
  • Page 11 Section 2 DESCRIPTION Figure 2 ---2 Encapsulated Compressor System AFTERCOOLER AND FLUID COOLER BLOWDOWN VALVE COMPRESSOR UNIT FLUID FILL PLUG DISCHARGE PRESSURE RELIEF VALVE AIR/FLUID SEPARATOR AIR/FLUID FLUID LEVEL FLUID FILTER FLUID SIGHT GLASS 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIP- pressure gauge which is located on the left side of TION the electrical control center and a discharge tem- The purpose of the compressor control system is to...
  • Page 12 NOTES...

  • Page 13: Specifications--- Es--- 6

    Micron: 23 Microns Abs. Internal Bypass Valve Set at 1.7 bar. FLUID SEPARATOR ELEMENT Type: Push In Cartridge, Sullair Proprietary Efficiency at Maximum Capacity: 5PPM Maximum 3.2 COMPRESSOR LUBRICATION GUIDE posed above ground locations, e.g. in exposed plant piping.” (I)

  • Page 14: Specifications

    Sullair for recommendation. void all warranties. DO NOT MIX DIFFERENT TYPES OF FLUIDS. Sullair encourages the user to participate in a fluid Contamination of non---detergent mineral fluids analysis program. This could result in a fluid with traces of ATF or detergent motor fluids may...
  • Page 15 Section 3 SPECIFICATIONS Figure 3 ---2 Dimensions...
  • Page 16 NOTES...

  • Page 17: Location Of Compressor

    DURE applied forces or vibration which would disturb the The Sullair air compressor is equipped with the piping or wiring. proper amount of fluid. However, it is necessary to 4.2 VENTILATION AND COOLING check the fluid level at installation.

  • Page 18: Motor Rotation Direction Check

    Fluid capacity for the compressor can be found in concerning isolation switches, fused disconnects, Section 3, Specifications of this manual. etc. Sullair provides a wiring diagram for use by the installer. 4.5 MOTOR ROTATION DIRECTION CHECK A few electrical checks should be made to help as- After the electrical wiring has been done, it is nec- essary to check the direction of motor rotation.

  • Page 19: General

    OPERATION 5.1 GENERAL call for service or indicate the beginning of a mal- While Sullair has built into this compressor a com- function. Before starting your Sullair compressor, prehensive array of controls and indicators to as- read this section thoroughly and familiarize your-...
  • Page 20 Section 5 OPERATION 5.3 INITIAL START-- UP PROCEDURE 7. Slowly close the shut ---off valve and check that The following procedure should be used to make the pressure switch is set correctly. If set correct- the initial start ---up of the compressor. ly, the compressor will unload at nameplate pressure.

  • Page 21: General

    Section 6 MAINTENANCE 6.1 GENERAL 1. Remove the fan guard by removing the four (4) self---tapping screws holding the guard and fan ring to the cooler. WARNING 2. Remove the 1/8” NPT plugs in the filler and drain connection for both bearings. Before doing compressor maintenance, discon- 3.
  • Page 22 LUBRICATION PERIOD (HRS.) PERIOD (HRS.) PERIOD (HRS.) --- 23_C to +32_C Sullube 8000 * 8000 * 4000 ** Sullair LLL --- 4--- 32 8000 * 8000 * 4000 ** SRF 1/4000 4000 4000 4000 ** 4000 ** ATF as per Dextron II...
  • Page 23 Section 6 MAINTENANCE Figure 6 ---2 Air Filter (P/N 02250110 ---591) 2. Pull out the old element by gripping the end of the element with channel lock pliers or a similar tool. 3. Install new o---rings on separator cap and sepa- AIR FILTER rator element filter and oil lightly to make installa- tion easier.
  • Page 24 Section 6 MAINTENANCE 8. Re---install plug. Figure 6 ---4 Minimum Pressure/Check Valve (P/N 606058) COIL REPLACEMENT 1. Remove the retaining cap, nameplate and cover. VALVE 2. Slip the yoke containing the coil and sleeves off SPRING* the solenoid base subassembly. 3.
  • Page 25 Section 6 MAINTENANCE 5. Open the service valve so the line pressure is 7.9 Figure 6 ---6 Pressure Switch (P/N 407778) bar. Machine is now set for operation. Recheck the unload pressure by closing of the service valve. Machine should unload via the pressure switch at 8.6 bar.
  • Page 26 Torque to 40.7 Nm. 17. Reconnect tubing to inlet control valve housing Should your problem persist after making the rec- at 90_ elbow. ommended check, consult your nearest Sullair 18. Reinstall air inlet filter assembly. representative or the Sullair Corporation factory.

  • Page 27: Troubleshooting

    Section 6 MAINTENANCE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY COMPRESSOR WILL NOT START Main Disconnect Switch Open Close switch. Line Fuse Blown Replace fuse. Control Transformer Fuse Blown Replace fuse. Motor Starter Overloads Tripped Reset. Should trouble persist, check whether motor starter contacts are functioning properly.
  • Page 28 Section 6 MAINTENANCE TROUBLESHOOTING (CONTINUED) SYMPTOM PROBABLE CAUSE REMEDY PRESSURE RELIEF VALVE Compressor Operating Pressure See Symptom “Line Pressure Rises Above OPENS REPEATEDLY Too High Cut--- out Pressure Setting on Pressure Switch” above Defective Pressure Relief Valve Replace pressure relief valve. LIQUID WATER IN COMPRESSED Water Vapor Condensation From Cooling Remove the water vapor from compressed air prior...

  • Page 29: Maintenance Record

    Section 6 MAINTENANCE 6.8 MAINTENANCE RECORD MODEL NO. SERIAL NO. AUTHORIZED MAINTENANCE WORK PERFORMED DATE HOURMETER PERFORMED...
  • Page 30 Section 7 ILLUSTRATIONS AND PARTS LIST ES-- 6 COMPRESSOR ASSEMBLY, EXPLODED VIEW...

  • Page 31: Procedure For Ordering Parts

    Lading for the compressor or from the Serial Number Plate located on the compressor. The genuine Sullair service parts listed meet or exceed the demands of this compressor. Use of replacement parts other than those approved by Sullair Corporation may lead to hazardous conditions over which Sullair Corporation has no control.

  • Page 32: Fluid Management System

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.3 FLUID MANAGEMENT SYSTEM...
  • Page 33 Section 7 ILLUSTRATIONS AND PARTS LIST 7.3 FLUID MANAGEMENT SYSTEM part number description number quantity plug, hex head 1 1/16”---12 SAE 250039---359 o---ring (I) 250025---419 housing, bell 250025---309 o---ring, 1 7/16” x 1/16” 826502---127 element, separator air/fluid (II) 250025---264 o---ring, 2 3/16” x 3/32” 826502---139 cap, separator element 250026---038...

  • Page 34: Seal And Drive Gear

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.4 SEAL AND DRIVE GEAR...
  • Page 35 Section 7 ILLUSTRATIONS AND PARTS LIST 7.4 SEAL AND DRIVE GEAR part number description number quantity plate, inlet 250028---339 bearing, cylinder roll plain 499082---705 gear, driven Consult Factory gear, drive Consult Factory spacer, gear 250039---600 sleeve, wear 250025---412 seal, shaft Teflon/Viton (I) 250039---218 housing, shaft seal 250025---312...

  • Page 36: Motor, Housing And Parts

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.5 MOTOR, HOUSING AND PARTS TO COOLER FROM COMPRESSOR UNIT (OUT) DISCHARGE NOTE: IF THE ADDITION OF FLUID BECOMES FREQUENT, A PROBLEM HAS DEVELOPED. BY REMOVING LOWER PLUG, LIQUID OIL MAY SPILL FROM HOLE; A SHAFT SEAL FAILURE MAY EXIST.
  • Page 37 Section 7 ILLUSTRATIONS AND PARTS LIST 7.5 MOTOR, HOUSING AND PARTS part number description number quantity connector, tube---M 5/8” x 1/2” 810210---050 bail, lifting 250039---904 capscrew, hex 5/16”---18 x 7/8” 827905---088 valve, minimum pressure/check (I) 606058 screw, machine rd hd #8---32 x 1/2” 250030---547 washer, pl---b #8 837201---045...

  • Page 38: Compressor Cooler System

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.6 COMPRESSOR COOLER SYSTEM AIR DISCHARGE FLUID TO COMPRESSOR DRAIN AIR TO COOLER (IN) FLUID TO COOLER (IN) FROM COMPRESSOR UNIT FROM COMPRESSOR...
  • Page 39 Section 7 ILLUSTRATIONS AND PARTS LIST 7.6 COMPRESSOR COOLER SYSTEM part number description number quantity duct, cooler mount 250026---471 screw, hex serrated washer 1/4”---20 x 1/2” 829704---050 ring, cooler 250034---536 cap, fan guard 4” 250026---591 guard, fan 02250110---568 fan, 12” dia 4 blade 250026---254 screw, brass set 250031---014...

  • Page 40: Compressor System

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.7 COMPRESSOR SYSTEM TO SUMP LINE PRESSURE PRESSURE TO PRESSURE SWITCH GAUGE TO DRY SUMP SUMP TEE TO ‘I’ BLOWDOWN VALVE TO INLET CONTROL FROM COOLER (OUT) TO DRAIN...
  • Page 41 Section 7 ILLUSTRATIONS AND PARTS LIST 7.7 COMPRESSOR SYSTEM part number description number quantity capscrew, ferry hd 1/4”---20 x 1 1/4” 828404---125 cover, outlet 250025---315 locknut, female M17 x 1 02250055---135 wavespring, female 02250055---485 bearing, taper 499080---203 locknut, male M25 x 1 02250055---135 wavespring, male 02250047---887...
  • Page 42 Section 7 ILLUSTRATIONS AND PARTS LIST 7.7 COMPRESSOR SYSTEM TO SUMP LINE PRESSURE PRESSURE TO PRESSURE SWITCH GAUGE TO DRY SUMP SUMP TEE TO ‘I’ BLOWDOWN VALVE TO INLET CONTROL FROM COOLER (OUT) TO DRAIN...
  • Page 43 Section 7 ILLUSTRATIONS AND PARTS LIST 7.7 COMPRESSOR SYSTEM (CONTINUED) part number description number quantity capscrew, ferry hd 5/16”---18 x 1 1/2” 828405---150 tube, separator fluid return 250025---865 fitting, separator fluid return 250025---870 valve, body thermostat 250025---414 screw, set cup 5/8”---11 x 1/2” 250033---368 cap, 1/2”...

  • Page 44: Inlet Filter And Inlet Control

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.8 INLET FILTER AND INLET CONTROL 13 14 TO BLOWDOWN VALVE ‘O’...
  • Page 45 Section 7 ILLUSTRATIONS AND PARTS LIST 7.8 INLET FILTER AND INLET CONTROL part number description number quantity capscrew, hex GR5 1/4”---20 x 4” 829104---400 filter, air (I) 02250110---591 stud, air filter 02250110---929 rod, intake control valve 02250044---810 spring, intake check 250034---619 retainer, intake control valve 02250044---809...

  • Page 46: Control Box

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.9 CONTROL BOX TO DRIVE HOUSING TEMPERATURE SWITCH 17 18 TO DRY SUMP TEE LINE PRESSIRE...
  • Page 47 Section 7 ILLUSTRATIONS AND PARTS LIST 7.9 CONTROL BOX part number description number quantity screw, 1/4”---20 x 1/2” 250030---162 nut, hex flgd 1/4”---20 825304---236 box, junction 250041---534 connector, liquid tight 250026---153 support, starter 02250110---532 box, electric control 02250110---232 screw, hex ser washer 1/4” x 1/2” 829704---050 panel, temp gauge 02250043---320...

  • Page 48: Decal Group

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.10 DECAL GROUP  250038- -238...
  • Page 49 (II) 02250069---403 decal, “voltage” yellow & black glbl 250038---239 decal, Sullair 2.25 x 18 blk 02250059---052 (Continued on page 47) (I) Decal will change with fluid requirement. (II) Decal will vary with machine voltage. If voltage is not known, consult factory with serial number of com- pressor.
  • Page 50 Section 7 ILLUSTRATIONS AND PARTS LIST 7.10 DECAL GROUP 02250077- -472...
  • Page 51 Section 7 ILLUSTRATIONS AND PARTS LIST 7.10 DECAL GROUP (CONTINUED) part number description number quantity decal, electrocution/hazard intnl/glbl 02250077---472 decal, ISO 9001 02250059---288 decal, ES---6 Model 02250060---043 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR...

  • Page 52: Decal Locations

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.11 DECAL LOCATIONS...
  • Page 53 “food grade” lube 250003---144 sign, danger air breathing 250027---935 decal, rotation direction 040745 decal, “voltage” yellow & black glbl 250038---239 decal, Sullair 2.25 x 18 blk 02250059---052 decal, ES---6 Model 02250060---043 decal, voltage international (I) 02250069---403 decal, electrocution/hazard intnl/glbl 02250077---472...

  • Page 54: Wiring Diagram

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.12 WIRING DIAGRAM...
  • Page 55 NOTES...
  • Page 56 SULLAIR CORPORATION Subsidiary of Sundstrand Corporation 3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. Telephone: 1-- 800-- SULLAIR (U.S.A. Only) or 1-- 219-- 879-- 5451 Fax: (219) 874-- 1253 Telephone: 1-- 888-- SULLAIR (Parts) Fax: (219) 874-- 1835 (Parts) Fax: (219) 874-- 1205 (Service) Printed in U.S.A.

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