Sullair 1107e User Manual
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Sullair 1107e User Manual

Industrial air compressor. 11, 15 & 18kw/15, 20 & 25hp. air-cooled standard & 24 kt. 1100e series;1500e series;1800e series; 1100ev series;1500ev series;1800ev series
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USER MANUAL
INDUSTRIAL AIR COMPRESSOR
1100E, 1500E, 1800E,
1100EV, 1500EV, 1800EV
11, 15 & 18KW/15, 20 & 25HP
A
-C
S
& 24 KT
IR
OOLED
TANDARD
PART NUMBER:
02250176-311 R01
KEEP FOR
FUTURE
WARRANTY NOTICE
REFERENCE
SULLAIR CORPORATION
©
Failure to follow the instructions
The information in this manual is current
and procedures in this manual or,
as of its publication date, and applies to
misuse of this equipment will
compressor serial number:
VOID its warranty!
200805120000
and all subsequent serial numbers.

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  • Page 1 PART NUMBER: 02250176-311 R01 KEEP FOR FUTURE WARRANTY NOTICE REFERENCE SULLAIR CORPORATION © Failure to follow the instructions The information in this manual is current and procedures in this manual or, as of its publication date, and applies to misuse of this equipment will...
  • Page 2 AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility located at Michigan City, Indiana.

  • Page 3: Table Of Contents

    ELECTRICAL SHOCK LIFTING 1.10 ENTRAPMENT SECTION 2—DESCRIPTION INTRODUCTION DESCRIPTION OF COMPONENTS SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION- AL DESCRIPTION COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION CONTROL SYSTEM, FUNCTIONAL DESCRIPTION AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION INTEGRAL DRYER OPTION SECTION 3—SPECIFICATIONS...
  • Page 4 TABLE OF CONTENTS WIRING DIAGRAM, MFV WIRING DIAGRAM, VSD PARALLEL WYE 3.10 WIRING DIAGRAM MFV WITH INTEGRAL DRYER SECTION 4—INSTALLATION MOUNTING OF COMPRESSOR VENTILATION AND COOLING SERVICE AIR PIPING COUPLING ALIGNMENT CHECK FLUID LEVEL CHECK ELECTRICAL PREPARATION MOTOR ROTATION DIRECTION CHECK FAN MOTOR ROTATION CHECK SECTION 5—WS CONTROLLER CONTROLLER LAYOUT...

  • Page 5: Section 1-Safety

    GENERAL tions relative to personal protective equipment, such as eye and face protective equipment, Sullair Corporation and its subsidiaries design and respiratory protective equipment, equipment manufacture all of their products so they can be intended to protect the extremities, protective operated safely.

  • Page 6: Fire And Explosion

    SECTION 1 inside diameter to reduce pressure in case of accumulate on, under or around acoustical mate- hose failure. rial, or on any external surfaces of the air com- pressor. Wipe down using an aqueous industrial D. Flow-limiting valves are listed by pipe size and cleaner or steam clean as required.

  • Page 7: Hot Surfaces, Sharp Edges And Sharp Corners

    SECTION 1 C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially DANGER when exposed to hot or moving parts. D. Keep access doors, if any, closed except when making repairs or adjustments. E. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or operate it.

  • Page 8: Electrical Shock

    SECTION 1 swallowed, induce vomiting by administering a tablespoon of salt, in each glass of clean, warm water until vomit is clear, then administer two DANGER teaspoons of baking soda in a glass of clean water. Have patient lay down and cover eyes to exclude light.

  • Page 9: 1.10 Entrapment

    SECTION 1 Keep lift operator in constant attendance when- N. Make sure pallet-mounted compressors are ever compressor is suspended. firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them. J. Set compressor down only on a level surface NEVER attempt to forklift a compressor that is capable of safely supporting at least its weight not secured to its pallet, as uneven floors or sud-...
  • Page 10 NOTES...

  • Page 11: Introduction

    Compared other types compressors, the Sullair rotary screw is unique in mechanical reliability, with “no wear” and “no inspection” required of the working parts within the compressor unit. Read Maintenance on page 51 to see how surprisingly easy it is to keep your air...

  • Page 12: Description Of Components

    1100E, 1500E, 1800E USER MANUAL SECTION 2 DESCRIPTION OF steel frame. On air-cooled models, a fan draws air COMPONENTS into the enclosure over the fan and main motors through the combined aftercooler and fluid cooler Refer Figure 2-1. components thereby removing the compression heat from the assemblies of the air compressor are clearly shown.

  • Page 13: Sullair Compressor Unit, Functional Description

    SECTION 2 1100E, 1500E, 1800E USER MANUAL SULLAIR COMPRESSOR Sullair recommends that a 24KT sample be taken at UNIT, FUNCTIONAL the first filter change and sent to the factory for DESCRIPTION analysis. This is a free service. The sample kit with...

  • Page 14: Compressor Cooling And Lubrication System, Function

    1100E, 1500E, 1800E USER MANUAL SECTION 2 COMPRESSOR COOLING lubricates, cools and seals the rotors and the AND LUBRICATION SYSTEM, compression chamber. FUNCTIONAL DESCRIPTION As the discharge temperature rises above 185˚F (85˚C), due to the heat of compression, the thermal Refer to Figure 2-2 The Cooling and Lubrication valve begins to adjust and a portion of the fluid then System consists of a fan, fan motor, radiator-type...

  • Page 15: Compressor Discharge System, Functional Description

    SECTION 2 1100E, 1500E, 1800E USER MANUAL COMPRESSOR DISCHARGE minimum pressure/check valve, located SYSTEM, FUNCTIONAL downstream from the separator, assures a minimum DESCRIPTION separator/sump pressure of 50 psig (3.4 bar) during loaded conditions. This pressure is necessary for Refer to Figure 2-3. The compressor unit discharges proper air/fluid separation...
  • Page 16 1100E, 1500E, 1800E USER MANUAL SECTION 2 Figure 2-3: Discharge System 1. Compressor 3. Moisture Separator 2. Cooler...

  • Page 17: Control System, Functional Description

    SECTION 2 1100E, 1500E, 1800E USER MANUAL CONTROL SYSTEM, —I 110 PSIG (7.6 BAR) NLOAD XCESS OF FUNCTIONAL DESCRIPTION When a relatively small amount or no air is being used, the service line pressure continues to rise. Refer to Figure 2-4. The purpose of the compressor When it exceeds 110 psig (7.6 bar), the WS control system is to regulate the amount of air being Controller control system de-energizes the solenoid...
  • Page 18 1100E, 1500E, 1800E USER MANUAL SECTION 2 Figure 2-4: Standard Control System 1. Solenoid Valve 6. Separator/Sump 2. Inlet Control Valve 7. Temperature Thermistor 3. Blowdown Valve 8. Sight Glass - Upper Level 4. Pressure Regulator 9. Sight Glass - Lower Level 5.

  • Page 19: Air Inlet System, Functional Description

    SECTION 2 1100E, 1500E, 1800E USER MANUAL AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION WARNING Refer to Figure 2-5. The compressor inlet system “The Plastic Pipe Institute recommends consists of a dry-type air filter, a restriction gauge against the use of thermoplastic pipe to and an air inlet valve.

  • Page 20: Integral Dryer Option

    This the compressor to run on dryer fault. If necessary, prevents condensate from initially being allowed into this can be reset by your authorized Sullair servicing the compressed air stream. It also delays the supply distributor. of compressed air from the compressor until the 5...

  • Page 21: Table Of Specifications

    07 - 100 psig (6.9 bar) 10 - 150 psig (10.3 bar) 09 - 125 psig (8.6 bar) 12 - 175 psig (12 bar) Maximum pressure is rated pressure plus 10 psig (0.7 bar). NOTE For latest sound test data, consult Sullair Factory.
  • Page 22 Speed - 15, 20, 25 HP: 1765 RPM (60 Hz) or 1455 RPM (50 Hz) (IV) Multi-frequency and voltage motors are used. The compressors must be used only with the specified electrical frequency and voltage. NOTE For latest sound test data, consult Sullair Factory.

  • Page 23: Lubrication Guide

    Sullair encourages the user to participate in a fluid analysis program with the fluid suppliers. This could result in a fluid change interval differing from that stated in the manual. Contact your Sullair dealer for...

  • Page 24: Lubrication Change Recommendations And Mainte

    1100E, 1500E, 1800E USER MANUAL SECTION 3 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE—FLUID FILTER AND SEPARATOR LUBRICANT FLUID CHANGE FLUID FILTER CHANGE SEPARATOR CHANGE Sullube (2.5 gal) SRF 1/4000 (2.5 gal) 24KT (2.5 gal) CP-4600-32-F (2.5 gal) A - 8,000 hours or once a year. B - 4,000 hours or more frequently if conditions so require.
  • Page 25 BLANK PAGE...

  • Page 26: Identification, Air-Cooled

    IDENTIFICATION, AIR-COOLED 02250161-035-R02...
  • Page 27 IDENTIFICATION, AIR-COOLED Main Motor HP Motor Type Weight CFM Cooling Air TEFC 1044 LBS/474 KG 2000 CFM TEFC 1098 LBS/498 KG 2000 CFM TEFC 1122 LBS/509 KG 2000 CFM NOTES: 1. Allow 4.00 ft. (1.25 meters) minimum clearance around machine for access and free circulation of air. 2.
  • Page 28 IDENTIFICATION, AIR-COOLED WITH INTEGRAL DRYER 02250172-372-R02...
  • Page 29 IDENTIFICATION, AIR-COOLED WITH INTEGRAL DRYER Main Motor HP Motor Type Weight CFM Cooling Air TEFC 1194 LBS/542 KG 2000 CFM TEFC 1248 LBS/566 KG 2000 CFM TEFC 1323 LBS/600 KG 2000 CFM NOTES: 1. Allow 4.00 ft. [1.25 Meters] minimum clearance around machine for access and free circulation of air.

  • Page 30: Piping And Instrumentation, Air-Cooled

    PIPING AND INSTRUMENTATION, AIR-COOLED 02250157-525-R05...
  • Page 31 PIPING AND INSTRUMENTATION, AIR-COOLED PART NO. DESCRIPTION PART NO. DESCRIPTION 02250125-365 FILTER,AIR INLET 6” (PLASTIC) 02250118-589 ORF, .125” .25FNPT .25 MNPT VALVE, GROUP INLET DXX102E 02250078-249 SW,VAC 22”WC N4 6FT CABLE 5A MTR_VAR MOTOR 02250050-154 SW, DIFF PRESS 20 PSID COMPRESSOR 02250144-842 VALVE, BALL/STNR COMB 1/2F X 1/2M...

  • Page 32: Piping And Instrumentation, Air-Cooled With Integral

    PIPING AND INSTRUMENTATION, AIR-COOLED WITH INTEGRAL DRYER 02250172-797-R01...
  • Page 33 PIPING AND INSTRUMENTATION, AIR-COOLED WITH INTEGRAL DRYER PART NO. DESCRIPTION PART NO. DESCRIPTION 02250125-365 FILTER,AIR INLET 6” (PLASTIC) 02250118-589 ORF, .125” .25FNPT .25 MNPT VALVE, GROUP INLET DXX102E 02250078-249 SW,VAC 22”WC N4 6FT CABLE 5A MTR_VAR MOTOR 02250050-154 SW, DIFF PRESS 20 PSID COMPRESSOR 02250169-612 GA,DIFF PRESS Z-PRG ASY BTM...

  • Page 34: Wiring Diagram, Mfv

    WIRING DIAGRAM, MFV 02250171-211-R01...
  • Page 35 WIRING DIAGRAM, MFV Notes COMP DESCRIPTION 1MOL COMPRESSOR OVERLOAD 1. Customer to furnish fused or circuit breaker disconnect per COMPRESSOR STARTER local codes. 2MOL FAN MOTOR OVERLOAD 2. Remove jumper for auxilliary e-stop string devices. WET SUMP PRESSURE SENSOR PACKAGE DISCHARGE PRESSURE SENSOR 3.

  • Page 36: Wiring Diagram, Vsd Parallel Wye

    WIRING DIAGRAM, VSD PARALLEL WYE 02250156-119-R08...
  • Page 37 WIRING DIAGRAM, VSD PARALLEL WYE Notes COMP DESCRIPTION COMPRESSOR MOTOR 1. Customer to furnish fused or circuit breaker disconnect per COOLER FAN MOTOR STARTER local codes. 2MOL FAN MOTOR OVERLOAD 2. Remove jumper for auxilliary e-stop string devices. FAN MOTOR BRANCH CIRCUIT FUSES SCD TRANSFORMER PRIMARY FUSES 3.

  • Page 38: Wiring Diagram Mfv With Integral Dryer

    3.10 WIRING DIAGRAM MFV WITH INTEGRAL DRYER 02250174-982-R01...
  • Page 39 3.10 WIRING DIAGRAM MFV WITH INTEGRAL DRYER Notes DRYER START RELAY COMP DESCRIPTION 1. Customer to furnish fused or circuit breaker disconnect per 1MOL COMPRESSOR OVERLOAD local codes. COMPRESSOR STARTER 2. Remove jumper for auxilliary e-stop string devices. 2MOL FAN MOTOR OVERLOAD WET SUMP PRESSURE SENSOR 3.
  • Page 40 BLANK PAGE...

  • Page 41: Section 4-Installation

    1100E, 1500E, 1800E USER MANUAL Section 4 INSTALLATION MOUNTING OF VENTILATION AND COMPRESSOR COOLING A suitable foundation or fabricated support must be OOLED OMPRESSORS established to support the compressor. It should be • An area with adequate space must be provided for rigid enough to keep the compressor frame level and the compressor and its components.

  • Page 42: Service Air Piping

    1100E, 1500E, 1800E USER MANUAL SECTION 4 SERVICE AIR PIPING UTDOOR NSTALLATION HELTERED Many times a compressor must be installed outside Review carefully the total air system before installing due to available space or other jobsite conditions. a new compressor. Items to consider for the total air When this is necessary, there are certain items that system include liquid carryover, pipe sizing, and the should be incorporated into the system to help...

  • Page 43: Coupling Alignment Check

    SECTION 4 1100E, 1500E, 1800E USER MANUAL Figure 4-1: Service Air Piping, Typical Installation 1. Sullair Compressor 5. Water Leg Drain Valve 2. Sullair Dryer 6. By-Pass Gate Valve 3. Shut-Off Gate Valve 7. Standard Gate Valve 4. Sullair Filter...
  • Page 44 1100E, 1500E, 1800E USER MANUAL SECTION 4 • Feeder cable connections to incoming terminals L1- L2-L3 should be tight and clean. The applied voltage must be compatible with the CAUTION motor and compressor data plate ratings. • A starter hole is provided for incoming power con- nection.

  • Page 45: Motor Rotation Direction Check

    SECTION 4 1100E, 1500E, 1800E USER MANUAL MOTOR ROTATION the motor drive housing to show proper motor/ DIRECTION CHECK compressor rotation. An alternative to this procedure is to set the WS Controller to display P1 separator/ Motor rotation check must be made at compressor sump pressure.
  • Page 46 1100E, 1500E, 1800E USER MANUAL SECTION 4 Figure 4-3: Fan Motor/Main Motor Rotational Direction 60HZ 15HP/11KW, 60HZ 20HP/15KW...

  • Page 47: Controller Layout

    1100E, 1500E, 1800E USER MANUAL Section 5 WS CONTROLLER CONTROLLER LAYOUT ® Figure 5-1: WS Controller 1. ON 6. Maintenance Indicator 2. OFF 7. Fault Indicator 3. LCD Display 8. Up Key 4. Power Indicator 9. Down Key 5. Run Mode Indicator 10.

  • Page 48: Lcd Display

    1100E, 1500E, 1800E USER MANUAL SECTION 5 LCD DISPLAY The display's normal view shows the compressor package's discharge pressure, internal temperature, and the operating mode. The modes are MANUAL, OFF, AUTOMATIC, or FAULTED. Figure 5-5: Refer to Figure 5-6. Press the Down arrow " " to display additional information about the compressor.

  • Page 49: Led Lights

    SECTION 5 1100E, 1500E, 1800E USER MANUAL LED LIGHTS The four LED lights indicate the general condition of the machine. The green Power indicator " " simply indicates that power is applied to the controller. It will blink very slowly if the WS Controller is set up to automatically Figure 5-8: restart after power failure.
  • Page 50 BLANK PAGE...

  • Page 51: General

    1100E, 1500E, 1800E USER MANUAL Section 6 MAINTENANCE GENERAL WARNING WARNING HIGH-PRESSURE HAZARD! • DO NOT remove caps, plugs, and/or other Before any repairs are attempted, refer to components when compressor is running or Section 1: Safety before proceeding. pressurized. Stop compressor and relieve all internal pressure before doing so.

  • Page 52: Fluid Filter Maintenance

    1100E, 1500E, 1800E USER MANUAL SECTION 6 FLUID FILTER AIR FILTER MAINTENANCE MAINTENANCE Refer to Figure 6-2. Air filter maintenance should be Refer to Figure 6-1. Replace your fluid filter element performed when the maintenance gauge shows red under any of the following conditions, whichever with the compressor running full load, or once a year, occurs first: whichever comes first.

  • Page 53: Separator Maintenance

    SECTION 6 1100E, 1500E, 1800E USER MANUAL SEPARATOR MAINTENANCE 4. Once the separator is removed, the separa- tor fluid return line can be accessed for Replace the separator element when indicated by removal and cleaning. the WS Controller or after one (1) year, whichever 5.

  • Page 54: Troubleshooting

    2. Check for damaged piping. 3. Check for parts damaged by heat or an elec- trical short circuit, usually apparent by discol- oration or a burnt odor. Should your problem persist after making the recommended check, consult your nearest Sullair representative.

  • Page 55: Troubleshooting Guide

    SECTION 6 1100E, 1500E, 1800E USER MANUAL TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE REMEDY Compressor will not start Main disconnect switch open Close switch. Line fuse blown Replace fuse. Motor starter overload tripped Reset. Should trouble persist, check whether motor starter contacts are functioning properly.
  • Page 56 1100E, 1500E, 1800E USER MANUAL SECTION 6 TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE REMEDY Compressor Will Not Build Full Air Demand is Too Great Check service lines for leaks or open valves Discharge Pressure Dirty Air Filter Check the filter indicator and inspect and/or change element if required.
  • Page 57 SECTION 6 1100E, 1500E, 1800E USER MANUAL TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE REMEDY Liquid Water In Compressed Air Plugged Strainer in Moisture Drain Clean and service strainer located in the Lines Line line off the bottom of the water separator. Water Vapor Condensation from Remove the water vapor from compressed Cooling and Compression Occurs...
  • Page 58 BLANK PAGE...
  • Page 59 NOTES...
  • Page 60 ORLDWIDE ALES AND ERVICE SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A. Sullair Road, No. 1 3700 East Michigan Boulevard Zone Des Granges BP 82 Chiwan, Shekuo Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France Shenzen, Gunagdong PRV. www.sullair.com Telephone: 33-477968470 PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A.

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