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AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are 3--day courses that provide hands--on instruction in the proper operation, maintenance and service of Sullair equipment. Individual seminars on Industrial compressors and compressor electrical systems are presented at regular intervals throughout the year at a dedicated training facility at Sullair’s corporate headquarters in Michigan City, Indiana.
SAFETY 1.1 GENERAL of hose failure, per all applicable Federal, State and Sullair Corporation and its subsidiaries design and Local codes, standards and regulations. manufacture all of their products so they can be op- erated safely. However, the responsibility for safe B.
Section 1 SAFETY 1.4 FIRE AND EXPLOSION K. DO NOT attempt to operate the compressor in any classification of hazardous environment unless the compressor has been specially designed and WARNING manufactured for that duty. 1.5 MOVING PARTS When installing a Base Load Transfer (BLT) Sys- A.
Section 1 SAFETY C. Operate the compressor only in open or ade- E. Disconnect, lock out, and tag all power at source quately ventilated areas. prior to attempting repairs or adjustments to rotating machinery and prior to handling any ungrounded D.
Section 1 SAFETY O. DO NOT use the lifting eye bolt on the compres- before doing so, or else secure and tag the access sor motor, if supplied, to lift the entire compressor door in the open position to avoid the possibility of package.
The fan air requirement is etc. Sullair provides a wiring diagram for use by the the volume of air which must flow through the com- installer.
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OSHA, Na- above. tional Electric Code and/or any applicable local elec- trical code concerning isolation switches, fused dis- connects, etc. Sullair provides a wiring diagram for use by the installer. 2.8 MOTOR ROTATION DIRECTION CHECK- SU- PERVISOR II...
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Section 2 INSTALLATION Figure 2- -1 Service Air Piping...
Section 3 SPECIFICATIONS 3.1 SPECIFICATIONS- - ES- -11 50 Hz /MIN B A R LEN G TH WID TH H EIG H T WEIG H T ( I) dB A ( II) MO D E L ( MM) ( MM) ( MM) ( KG ) A I R C O O L E D...
(I) Plastic Pipe Institute, Recommendation B, contact Sullair for recommendation. Adopted January 19, 1972. Sullair encourages the user to participate in a fluid analysis program. This could result in a fluid change Maintenance of all other components is still recom- interval that is different from those stated in this mended as indicated in the Operator’s Manual.
Should any ques- tions arise which cannot be answered in the follow- All fluid entering the compressor unit passes ing text, call your nearest Sullair office or the Sullair through the replaceable fluid filter element. This re- Corporation Service Department.
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Section 4 COMPRESSOR SYSTEMS Figure 4-1A Description of Components...
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Section 4 COMPRESSOR SYSTEMS Figure 4-1B Description of Components AIR-COOLED WATER-COOLED...
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Section 4 COMPRESSOR SYSTEMS Figure 4-2 Integrated Compressor System an inlet valve, (located on the compressor air inlet), the minimum pressure/check valve opens and deliv- blowdown valve, solenoid valve, pressure switch, ers compressed air to the service line. From this and a pressure regulator.
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Section 4 COMPRESSOR SYSTEMS UNLOAD - - IN EXCESS OF 135 PSIG (9.3 BAR) From this point on, the line air pressure is continually LINE PRESSURE monitored by the Supervisor. The pressure regula- When no air is being used,the service line pressure tor and the solenoid valve remain closed during this rises to the setting (cut--out pressure) of the pres- phase.
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Section 4 COMPRESSOR SYSTEMS Figure 4-3 Pneumatic Control System- Standard & Supervisor II...
While Sullair has built into this compressor a com- prehensive array of controls and indicators to as- SThe separator maintenance gauge moni- sure you that it is operating properly, you will want to tors the condition of the separator element.
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Section 5 COMPRESSOR OPERATION 5.2 PURPOSE OF CONTROLS - - STANDARD (CONTINUED) CONTROL OR INDICATOR PURPOSE LINE PRESSURE GAUGE Continually monitors service line air pressure. DISCHARGE TEMPERATURE GAUGE Monitors temperature of the air/fluid mixture dis- charged from the compressor unit. For air--cooled compressors normal reading is approximately 185_F (85_C ) with a 70_F (21_C) ambient temperature.
0. 5.6 GENERAL INTRODUCTION- SUPERVISOR II WYE DELT Reference Supervisor II Section 6. While Sullair has 10 SEC built into this compressor a comprehensive array of controls and indicators to assure you that it is oper-...
Section 5 COMPRESSOR OPERATION ly start after power up. S Drain interval -- The time between actua- tion of the drain valve. RST TIME 10 SEC DRN INTV 10 MIN S Unload Stop Timer -- If the machine is run- S Drain time -- The amount of time that the ning in AUTO mode, this parameter speci- fies the amount of time that the machine will...
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Section 5 COMPRESSOR OPERATION MANUAL OPERATION MODE the parameters UNLD and LOAD. This operation is as follows: In this mode the compressor will run indefinitely, as long as temperatures and pressure remain within P2 > UNLD - -- -> load solenoid turned off the valid operating ranges, and the motor overload P2 <...
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Section 5 COMPRESSOR OPERATION 5.9 PURPOSE OF CONTROLS - - SUPERVISOR II (CONTINUED) CONTROL OR INDICATOR PURPOSE AIR END DISCHARGE PRESSURE--P1 Shuts the compressor down when the compressor dis- charge pressure exceeds P1 MAX. Continually monitors the discharge pressure of the compressor unit. Indicates pressure in compressor sump upon start--up to verify ro- tor motor rotation.
Section 5 COMPRESSOR OPERATION 5.10 SUPERVISOR OUTPUT RELAYS RELAY OPERATION RUN RELAY (K1) Contact closure energizes the compressor starter. *--DELTA (K2) A timed contact used to provide wye--delta transition time. UNLOAD/LOAD (K3) Controls ON LOAD/OFF LOAD operation of the load control solenoid valve.
Section 6 SUPERVISOR II 6.1 INTRODUCTION- -SUPERVISOR II Ref er t o F igur e 6 -- 1 and S ec t ion 5 f or inf or m at ion r e- garding your compressor with Supervisor II. The Supervisor II has a two line display to show temper- S Up arrow -- Used in status displays to ature, pressure and status.
Section 6 SUPERVISOR II S Last fault log. This shows the fault on the STOP first line and the run hours when the fault oc- 110 180 ccured. If there are alarms active they will alternately be T1 HI shown with the default display. The machine status @1 234 will be displayed for 2 seconds, then the alarms for 2 seconds each.
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Section 6 SUPERVISOR II Figure 6-1 Supervisor II Panel SYSTEM GRAPHIC DISPLAY MESSAGE DISPLAY KEYPADS...
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Section 7 MAINTENANCE 7.1 INTRODUCTION Replace the fluid filter element under any of the fol- lowing conditions: WARNING 1. A s r ec om m ended in t he Lubr ic at ion G uide in t he Specification Section. Before doing compressor maintenance, discon- 2.
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Section 7 MAINTENANCE 1. Remove the separator maintenance gauge line Figure 7-1 Fluid Filter (P/N 02250078-544) and fluid return line from their connections, if equipped. 2. Remove the 4 capscrews that secure the separa- tor housing to the compressor. Remove housing. 3.
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Section 7 MAINTENANCE do not open or they open prior to the desired pres- Figure 7-3 Separator Element (P/N 02250091-385) sure, the pressure switch setting will require adjust- m ent ( r ef er t o F igur e 7 -- 4) .
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Section 7 MAINTENANCE approximately 103 psig (7.1 bar) and 1.00 in. Hg DANGER vacuum below the inlet. DO NOT touch the electrical contacts, terminal or 4. Now close the service valve, line pressure will leads with any part of the body or any uninsulated start rising.
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Section 7 MAINTENANCE Figure 7-5 Inlet Control Valve The compressor/motor assembly may also be lifted using a forklift truck with fork extensions. To lift the entire assembly from beneath the compressor use supporting blocks for the motor. Position the blocks on the forks beneath the motor to assure lifting the assembly level.
Should your problem persist after making the rec- tematically analyzed before undertaking any repairs ommended check, consult your nearest Sullair rep- or component replacement procedures. resentative or the Sullair Corporation factory. 8.2 TROUBLESHOOTING - - STANDARD ELECTRO/MECHANICAL...
Section 8 TROUBLESHOOTING 8.2 TROUBLESHOOTING (CONTINUED) SYMPTOM PROBABLE CAUSE REMEDY COMPRESSOR SHUTS DOWN Discharge Temperature Switch Thermal valve not functioning properly; WITH AIR DEMAND PRESENT Open replace element (air- -cooled only). Water flow regulating valve not functioning properly; change (water- -cooled only). Defective discharge temperature switch;...
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Always remember a burnt odor. Should your problem persist after making the rec- a.Check for loose wiring. ommended check, consult your nearest Sullair rep- b.Check for damaged piping. resentative or the Sullair Corporation factory. 8.4 TROUBLESHOOTING - - SUPERVISOR II...
Section 8 TROUBLESHOOTING 8.4 TROUBLESHOOTING - - SUPERVISOR II (CONTINUED) SYMPTOM (DISPLAY) PROBABLE CAUSE REMEDY COMPRESSOR DOES NOT Air Demand Exceeds Supply Check air service lines for open BUILD FULL DISCHARGE valves or leaks. PRESSURE Inlet Air Filter Clogged Check for maintenance message on Supervisor display.
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Section 8 TROUBLESHOOTING The number on the left will increase or decrease al- ways showing the total amount of adjustment. Maxi- mum adjustment is The DSP key exits, wiping out changes to the cur- rent item, while saving changes to any previous items.
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.
Section 9 ILLUSTRATIONS AND PARTS LIST 9.3 FRAME, MOTOR, COMPRESSOR AND PARTS...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.3 FRAME, MOTOR, COMPRESSOR AND PARTS part number description number quantity unit,compressor Consult Factory frame 02250084--321 seal (I)(II) 02250078--044 sleeve (I)(II) 02250078--472 housing, adapter 02250075--043 seal (I)(II) 02250077--851 motor, drive Consult Factory gear Consult Factory o--ring 826502--263 isolator...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.4 COMPRESSOR AND PARTS...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.4 COMPRESSOR AND PARTS part number description number quantity unit, assembly (I) (II) (VI) Consult Factory cover,separator 02250086--168 housing, bell 02250064--668 piston 02250075--038 seat 02250075--042 retainer 02250073--424 02250075--035 cylinder,inlet valve 02250073--422 stem 02250075--037 piston 02250073--423 stem 02250073--668...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.4 COMPRESSOR AND PARTS...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.4 COMPRESSOR AND PARTS (CONTINUED) part number description number quantity o--ring 826502--263 washer 866010--035 spring 02250077--764 spring 02250077--765 o--ring 02250064--663 o--ring 826502--226 ring,retaining 02250064--664 o--ring 826502--334 screw 829306--016 o--ring 826502--157 ring,retaining--inlet 836369--500 spring,check 02250064--665 orifice 02250091--395 connector...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.5 MOTOR, AND PARTS...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.5 MOTOR AND PARTS part number description number quantity motor, main drive Consult factory conduit 846315--150 elbow 846500--150 cord grip 250018--497 fitting 846400--150 enclosure Consult factory motor, fan Consult factory washer, conduit 847008--060 ring, terminal 849304--010 wire 850215--010...
Section 9 ILLUSTRATIONS AND PARTS LIST 9.6 INLET FILTER AND PARTS AIR INLET AIR INLET STANDARD ELECTRO/MECHANICAL DELUXE ELECTRO/MECHANICAL SUPERVISOR II DELUXE...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.6 INLET FILTER AND PARTS part number description number quantity support, air filter 02250085--565 spacer, inlet filter support 02250085--595 elbow, rubber 049307 clamp,hose 040642 clamp, hose 041993 filter,inlet (I) 02250085--253 band, mounting 040598 nut,ring--m16 x 2--582 (II) 02250094--650 stud,m16 x 50(nom.) 02250094--647...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.7 COOLING SYSTEM AND PARTS- AIR-COOLED...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.7 COOLING SYSTEM AND PARTS- AIR-COOLED part number description number quantity panel, front 02250084--224 Sstandard 02250084--283 Sdeluxe SSupervisor ll 02250083--892 tube, cooler 02250091--095 angle,air piping 02250086--227 panel, louver side 02250085--868 panel,corner rear 02250083--859 connector, tube--m 1--1/2 x 1--1/2” 810224--150 elbow 02250093--177...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.7 COOLING SYSTEM AND PARTS- AIR-COOLED...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.7 COOLING SYSTEM AND PARTS- AIR-COOLED (CONTINUED) part number description number quantity nipple,pipe (80) 822204--000 elbow, pipe 1/4 galvanized 803515--010 guard, fan S 22 in. (56 cm) 241501 S 24 in. (61 cm) 241079 adapter, venturi/cooler 02250087--273 support, fan motor...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 COOLING SYSTEM AND PARTS- WATER-COOLED...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 COOLING SYSTEM AND PARTS- WATER-COOLED part number description number quantity 02250085--979 bracket 02250085--822 panel, louver side 02250085--868 panel, cooler front 02250084--224 Sstandard 02250084--283 Sdeluxe SSupervisor II 02250083--892 tube,nylon .25 odx .040w blk(ft) 02250054--861 tube, stainless--steel 02250091--134 angle...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 COOLING SYSTEM AND PARTS- WATER-COOLED...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 COOLING SYSTEM AND PARTS- WATER-COOLED (CONTINUED) part number description number quantity hose 02250087--163 elbow 02250092--524 bulkhead,pipe 1/4 npt 841500--004 valve,solenoid (II) 250039--723 nipple,pipe 3/4 x 10.0 sc 40 galv 823112--100 washer, 1/2” 838208--112 elbow, pipe 3/4”...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 COOLING SYSTEM AND PARTS- WATER-COOLED...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 COOLING SYSTEM AND PARTS- WATER-COOLED (CONTINUED) part number description number quantity guard,fan 241579 support 02250085--823 screw, hex ser wash 5/16 x 1 1/2” 829705--150 insert,5/16” steel 02250043--765 washer, pl--b reg pltd 1/4” 838204--071 capscrew, hex gr 5 1/4--20 x 1”...
Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 CONTROL BOX AND PARTS- - STANDARD NOTE...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 CONTROL BOX AND PARTS- - STANDARD part number description number quantity gasket,panel supervisor II 02250048--822 bracket 250018--146 support 02250084--823 valve, pressure regulator(I) 250017--280 panel, instrument 02250077--639 plate 02250086--265 decal 02250086--263 plate 02250086--266 specification,enclosure 02250091--079 connector,1/4”tube x 1/4”npt 250018--428...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 CONTROL BOX AND PARTS- - STANDARD NOTE...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 CONTROL BOX AND PARTS- - STANDARD (CONTINUED) part number description number quantity valve (IV) 250038--674 decal 02250086--262 gasket 02250090--872 valve,shuttle 1/4” 408893 orifice,1/4m x 1/4f x .062 028831 panel 02250089--302 connector,straight liq--tite 1/2” 846400--050 switch 250017--992...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 CONTROL BOX AND PARTS- - STANDARD NOTE...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 CONTROL BOX AND PARTS- - STANDARD (CONTINUED) part number description number quantity tee, pipe 1/4” galv 804415--010 elbow, pipe 1/4 galv 803515--010 tee,straight 1/8 galv 804415--005 nipple,pipe 1/8 x cl sc 80 ga 823202--000 bushing,red 1/4x1/8 galv 804100--005...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.9A CONTROL BOX AND PARTS - - SUPERVISOR II NOTE...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.9A CONTROL BOX AND PARTS - - SUPERVISOR II part number description number quantity block 02250051--765 plate 02250086--268 harness, wire 02250054--328 harness, wire 02250054--329 valve, pressure regulator (I) 250017--280 support 02250084--823 plate 02250086--265 specification,enclosure 02250091--079 gasket 02250086--269...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.9A CONTROL BOX AND PARTS - - SUPERVISOR II NOTE...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.9A CONTROL BOX AND PARTS - - SUPERVISOR II (cont.) part number description number quantity orifice,1/4m x 1/4f x .062 028831 conduit (ft) 846315--050 connector,straight liq--tite 1/2” 846400--050 switch 250017--992 valve 045244 elbow, 1/4”tube x 1/8”npt 250018--429 tee,male 1/4t x 1/4p 250028--582...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.9B CONTROL PANEL AND PARTS - - ELECTRO/MECHANICAL...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.9B CONTROL PANEL AND PARTS - - ELECTRO/MECHANICAL part number description number quantity gauge, pressure 250005--185 gauge, temperature 042582 gauge, vacuum 250003--797 gauge, differential pressure 250003--798 gauge, differential pressure 250003--799 coupling, galvanized pipe 803215--005 connector,1/4”tube x 1/8”npt 250018--427 tee,male 1/4t x 1/8p...
Section 9 ILLUSTRATIONS AND PARTS LIST 9.10 CANOPY, ACOUSTICAL PANELS AND PARTS...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.10 CANOPY, ACOUSTICAL PANELS AND PARTS part number description number quantity panel,corner end front 02250083--858 panel, top--motor end 02250085--252 Saircooled 02250086--221 Swatercooled panel, motor end 02250084--348 panel,cooler support 02250083--863 panel,acoustical insulation 02250081--399 panel,seal plate 02250091--256 panel,top end 02250091--236...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.10 CANOPY, ACOUSTICAL PANELS & PARTS...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.10 CANOPY, ACOUSTICAL PANELS AND PARTS (CONTINUED) part number description number quantity panel,roof--motor end 02250083--920 panel,roof--front side 02250083--864 panel,roof--rear side 02250083--865 panel,roof--top 02250083--919 grille,roof--left 02250084--537 grille,roof--right 02250078--578 panel,acoustical insulation 02250084--762 panel,acoustical insulation 02250081--398 panel,acoustical insulation 02250081--397 grommet,rubber--1/4”...
Section 9 ILLUSTRATIONS AND PARTS LIST 9.11 DECAL GROUP 02250077- -472...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.11 DECAL GROUP part number description number quantity sign, warning -- compressor fluid fill cap 049685 sign, danger electrocution 049850 decal, electrocution (50 hertz compressors) 02250077--472 sign, warning -- hot surfaces 407408 decal, warning auto start 041065 decal, danger breath air 250027--935...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.11 DECAL GROUP ...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.11 DECAL GROUP (CONTINUED) part number description number quantity decal, rotation direction 040745 decal, compressor fluid SRF 1/4000 (I) 02250069--391 decal, earth ground 02250075--046 Sdecal, protective earth ground (not shown) 02250075--045 Sdecal, PE designation (not shown) 02250075--540 decal, danger hi voltage 042218...
Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 WIRING DIAGRAM - - FULL VOLTAGE - - SUPERVISOR II...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.14 WIRING DIAGRAM - - WYE DELTA 50/60 HZ - - ELECTRO/MECHANICAL...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.15 WIRING DIAGRAM - - WYE DELTA 50/60 HZ - - SUPERVISOR II...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.16 WIRING DIAGRAM - - WYE DELTA 50 HZ (EUROPE) - - ELECTRO/MECHANICAL...
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Section 9 ILLUSTRATIONS AND PARTS LIST 9.17 WIRING DIAGRAM - - WYE DELTA 50 HZ (EUROPE) - - SUPERVISOR II...
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ISO 898--1 1988 (E) Thru 39 ISO 898--1 < = 16 1988 (E) > 16 Thru 39 ISO 898--1 12.9 12.9 1988 (E) 1220 Thru 39 12.9 ALL DATA AND INFORMATION ON THIS SHEET IS CONFIDENTIAL AND PROPRIETARY TO SULLAIR CORPORATION...
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