Sullair ES-6 Operators Manual And Parts Lists
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Sullair ES-6 Operators Manual And Parts Lists

Sullair ES-6 Operators Manual And Parts Lists

Flood-lubricated rotary screw air compressor special 4.1kw
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ROTARY SCREW

AIR COMPRESSOR

ES-6 6
SPECIAL
4.1KW
OPERATOR'S
MANUAL AND
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Part Number 02250144-579
©Sullair Corporation

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Summary of Contents for Sullair ES-6

  • Page 1: Air Compressor

    ROTARY SCREW AIR COMPRESSOR ES-6 6 SPECIAL 4.1KW OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250144-579 ©Sullair Corporation...
  • Page 2 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 com- pressor electrical systems are presented at regular intervals throughout the year at a dedicated training facility at Sullair’s corporate headquarters in Michigan City, Indiana.

  • Page 3: Table Of Contents

    FUNCTIONAL DESCRIPTION 2.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION 2.7 INSTRUMENTATION, FUNCTIONAL DESCRIPTION Section 3 SPECIFICATIONS 3.1 SPECIFICATIONS- ES-6 3.2 COMPRESSOR LUBRICATION GUIDE Table 3-1 Lubrication Guide Section 4 OPERATION 4.1 LOCATION OF COMPRESSOR 4.2 VENTILATION AND COOLING 4.3 SERVICE AIR PIPING...
  • Page 4 TABLE OF CONTENTS Section 5 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 AND ADJUSTMENT PROCEDURES FLUID FILTER REPLACEMENT AIR FILTER MAINTENANCE...

  • Page 5: General

    SAFETY 1.1 GENERAL the service air outlet and the shut-off (throttle) Sullair Corporation and its subsidiaries design and valve, either at the compressor or at any other point manufacture all of their products so they can be along the air line, when an air hose exceeding operated safely.

  • Page 6: Fire And Explosion

    Section 1 SAFETY death or serious injury may result. environment unless the compressor has been spe- cially designed and manufactured for that duty. 1.4 FIRE AND EXPLOSION A. Clean up spills of lubricant or other combustible 1.5 MOVING PARTS substances immediately, if such spills occur. A.

  • Page 7: Electrical Shock

    Section 1 SAFETY supplying respirators or other breathing air utiliza- or repairs with one hand only, so as to minimize the tion equipment and DO NOT discharge air from possibility of creating a current path through the these systems into unventilated or other confined heart.

  • Page 8: Entrapment

    Section 1 SAFETY pallet if provided. If neither fork pockets or pallet are cause the compressor to tumble off, possibly caus- provided, then make sure compressor is secure ing serious injury or property damage in the and well balanced on forks before attempting to process.

  • Page 9: Introduction

    Refer to Figure 2-1. The components and assem- vent element failure. blies of the ES-6 Series air compressor are clearly FLUID MANAGEMENT SYSTEM shown. The complete compressor consists of an The fluid management system consists of an encapsulated compressor system, inlet system, air/fluid separator, thermal valve and fluid filter.
  • Page 10 Section 2 DESCRIPTION Figure 2-1 Description of Components...

  • Page 11: Control System, Functional Description

    2.7 INSTRUMENTATION, FUNCTIONAL DESCRIP- TION Due to the simplicity of the ES-6 Series compres- sor, the only instrumentation necessary is a line pressure gauge which is located on the left side of the electrical control center and a discharge tem-...
  • Page 12 NOTES...

  • Page 13: Specifications

    Certain other plastic materials may also be affect- See Figure 3-1. For best value and longest uninter- rupted service, the ES-6 compressor is factory filled (I) Plastic Pipe Institute, Recommendation B, with Sullube, a long life lubricant, unless a different Adopted January 19, 1972.
  • Page 14 “extended" life lubricants analysis program. This could result in a fluid change contact Sullair for recommendation. interval that is different from those stated in this Sullair encourages the user to participate in a fluid manual. Table 3-1 Lubrication Guide AMBIENT...
  • Page 15 Section 3 SPECIFICATIONS Figure 3-3 Dimensions 02250141-135R00...
  • Page 16 NOTES...

  • Page 17: Location Of Compressor

    4.1 LOCATION OF COMPRESSOR (I) Plastic Pipe Institute, Recommendation B, Adopted January 19, 1972. The ES-6 Series compressor package may be placed on any level surface able to support its 4.4 FLUID LEVEL CHECK AND CHANGE PROCE- weight. The unit should be bolted to a fixed mount-...

  • Page 18: Motor Rotation Direction Check

    4.5 MOTOR ROTATION DIRECTION CHECK concerning isolation switches, fused disconnects, After the electrical wiring has been done, it is nec- etc. Sullair provides a wiring diagram for use by the essary to check the direction of motor rotation. installer. When looking at the motor from the cooler end of...

  • Page 19: Purpose Of Controls

    OPERATION 5.1 GENERAL beginning of a malfunction. Before starting your Sullair has built safety features into this compressor Sullair compressor, read this section thoroughly to assure you that it is operating properly. You will and familiarize yourself with the controls and indi- want to recognize and interpret the reading of the cators - their purpose, location and use.
  • Page 20 Section 5 OPERATION 5. Start the compressor. 8. Observe the operating temperature. If the oper- ating temperature exceeds 93ºC, the cooling 6. Check for possible leaks in piping. system and installation environment should be 7. Slowly close the shut-off valve and check that the checked.

  • Page 21: Daily Operation

    Section 6 MAINTENANCE 6.1 GENERAL ES-6 Inboard Motor Bearing 1. Remove 1/8 inch hex plug located at the one o'clock position as you face the bell housing, Before doing compressor maintenance, discon- and install grease zerk. nect compressor from power source and lock out 2.

  • Page 22: Parts Replacement And Adjustment

    Section 6 MAINTENANCE 2. Drain fluid by removing fluid drain cap at tee Figure 6-1 Fluid Filter (P/N 250026-982) located beneath compressor (for complete fluid change, drain fluid from cooler). 3. Using a strap wrench, remove the old element and gasket. 4.

  • Page 23: Minimum Pressure/Check Valve

    Section 6 MAINTENANCE Figure 6-2 Air Filter (P/N 02250110-591) 4. Insert and push the new element in place. 5. Reinstall the cap. Hand-tighten using a 10 cm maximum length, 8 mm diameter pin in the radi- ally drilled hole. MINIMUM PRESSURE/CHECK VALVE MAINTE- NANCE Refer to Figure 6-4.

  • Page 24: Thermostat Actuator Maintenance

    Section 6 MAINTENANCE Figure 6-4 Minimum Pressure/Check Valve\ CONTROL SYSTEM ADJUSTMENT (P/N 606058) Refer to Figure 6-6. Prior to adjusting the Control System, it is necessary to determine the desired operating pressure range and also the maximum pressure at which your compressor is to operate. The pressure must not exceed the maximum oper- ating pressure which is stamped on the compressor serial number nameplate.

  • Page 25: Inlet Control Valve

    Section 6 MAINTENANCE Figure 6-6 Pressure Switch (P/N 02250141-938) 7.9 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. After the control pressures have been adjusted, the "unloaded"...

  • Page 26: Motor Shaft Seal Replacement

    Should your problem persist after making the rec- 15. Replace gasket and reinstall the whole inlet ommended check, consult your nearest Sullair rep- control valve assembly. resentative or the Sullair Corporation factory. 16. Apply screw lock adhesive to inlet control hous-...
  • Page 27 Section 6 MAINTENANCE TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM CAUSE REMEDY COMPRESSOR SHUTS DOWN Low Incoming Voltage Consult power company. WITH AIR DEMAND PRESENT Discharge Temperature Switch Open Cooling air flow restricted; clean cooler and check for proper ventilation. Ambient temperature is too high; provide sufficient ventilation.
  • Page 28 Section 6 MAINTENANCE TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM CAUSE REMEDY LIQUID WATER IN COM- Water Vapor Condensation From Remove the water vapor from compressed PRESSED AIR LINES Cooling Occurs Naturally air prior and Compression to distribution through the air system. Check operation of aftercooler and moisture separator.

  • Page 29: Maintenance Record

    Section 6 MAINTENANCE 6.8 MAINTENANCE RECORD MODEL NO. ______________________________ SERIAL NO. _________________________________ MAINTENANCE WORK PERFORMED AUTHORIZED HOURMETER DATE RECORD...
  • 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 MAMAGEMENT 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...
  • 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...
  • 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 motor Consult Factory 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...
  • 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...
  • Page 43 Section 7 ILLUSTRATIONS AND PARTS LIST 7.7 COMPRESSOR SYSTEM (CONTINUED) part number description number quantity 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" tube OD 3/4"-16 250026-350 tee, tube 250041-956...

  • Page 44: Inlet Filter And Inlet Control

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.8 INLET FILTER AND INLET CONTROL...
  • 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...
  • Page 47 02250043-320 gauge, pressure air 0-300 2” 02250044-361 gauge, temp 100-250 deg 3/4” sae 02250100-096 es-6 encapsulated compressor elecctl box w/2-1/2 hrmtr 02250127-225 switch, pressure 2-300 psi type1,4 02250141-938 connector, cord .312 cable x 1/2” hu 241585 connector, tube-strt 1/8mnpt x1/4”t...

  • Page 48: Decal Group

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.10 DECAL GROUP...
  • 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...
  • Page 51 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 decal, warning mixing fluids 02250110-891 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 decal, ES-6 Model 02250060-045 decal, Sullair .75 x 6 blk 02250059-046 sign, warning - hot surfaces 407408 decal, rotation direction 040745 decal, warning mixing fluids 02250110-891 decal, "voltage" yellow & black glbl...

  • Page 54: Wiring Diagram

    Section 7 ILLUSTRATIONS AND PARTS LIST 7.12 WIRING DIAGRAM 02250142-073R00...
  • Page 55 WORLDWIDE SALES AND SERVICE SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A. Sullair Road, No. 1 Zone Des Granges BP 82 Chiwan, Shekou 42602 Montbrison Cedex, France Shenzhen, Guangdong PRV. Telephone: 33-477968470 PRC POST CODE 518068 Fax: 33-477968499 Telephone: 755-6851686 www.sullaireurope.com Fax: 755-6853473 www.sullair-asia.com...

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