Sullair ShopTek ST400 User Manual
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Sullair ShopTek ST400 User Manual

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USER MANUAL
I
A
C
NDUSTRIAL
IR
OMPRESSOR
S
T
™
HOP
EK
ST400, ST500, ST700, ST1100, ST1500
4, 5, 7, 11 &15
: 5, 7.5, 10, 15 & 20
KW
HP
PART NUMBER:
02250180-090 R01
KEEP FOR
FUTURE
REFERENCE
WARRANTY NOTICE
SULLAIR CORPORATION
©
The information in this manual is current
as of its publication date, and applies to
Failure to follow the instructions
compressor serial number:
and procedures in this manual or,
Base Mount: C03-C20350
misuse of this equipment will
Tank Mount: 200811010000
VOID its warranty!
and all subsequent serial numbers.

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Summary of Contents for Sullair ShopTek ST400

  • Page 1 PART NUMBER: 02250180-090 R01 KEEP FOR FUTURE REFERENCE WARRANTY NOTICE SULLAIR CORPORATION © The information in this manual is current as of its publication date, and applies to Failure to follow the instructions compressor serial number: and procedures in this manual or,...
  • 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

    TABLE OF CONTENTS SECTION 1—SAFETY GENERAL PERSONAL PROTECTIVE EQUIPMENT PRESSURE RELEASE FIRE AND EXPLOSION MOVING PARTS HOT SURFACES, SHARP EDGES AND SHARP CORNERS TOXIC AND IRRITATING SUBSTANCES ELECTRICAL SHOCK LIFTING 1.10 ENTRAPMENT SECTION 2—DESCRIPTION INTRODUCTION COMPRESSOR COMPONENT DESCRIPTION COMPRESSOR COOLING AND LUBRICATION SYSTEM — FUNC- TIONAL DESCRIPTION COMPRESSOR DISCHARGE SYSTEM—FUNCTIONAL DESCRIPTION CONTROL SYSTEM —...
  • Page 4 TABLE OF CONTENTS SECTION 5—OPERATION ROUTINE OPERATION SECTION 6—MAINTENANCE GENERAL MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION MAINTENANCE EVERY 2000 HOURS FLUID MAINTENANCE FILTER MAINTENANCE AIR FILTER MAINTENANCE SEPARATOR MAINTENANCE BELT MAINTENANCE REPLACEMENT AND ALIGNMENT OF BELT PULLEYS 6.10 HOSE MAINTENANCE 6.11 TANK MOUNT PACKAGE MAINTENANCE 6.12...

  • 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

    DESCRIPTION INTRODUCTION External piping, connectors, and the enclosure should be inspected and maintained in accordance The design of the Sullair ShopTek line of compressor with the procedures and recommendations in this units is a single stage, positive displacement, flooded manual.
  • Page 12 USER MANUAL SECTION 2 ™ Figure 2-1: Main Components, ST400, ST500, ST 700, 5 -10 HP 1. Fluid Filter 7. E-Stop Button 2. Fluid Cooler 8. Controller 3. Air Inlet Filter 9. Main Motor 4. Separator Tube 10. Compressor Unit 5.
  • Page 13 SECTION 2 USER MANUAL ™ Figure 2-2: Main Components, ST1100, ST1500, 15-20 HP 1. Fluid Filter 7. E-Stop Button 2. Aftercooler/Fluid Cooler 8. Controller 3. Air Inlet Filter 9. Main Motor 4. Separator Tube 10. Compressor Unit 5. Fluid Fill Sight Glass 11.
  • Page 14 USER MANUAL SECTION 2 ™ COOLING/LUBRICATION SYSTEM DISCHARGE SYSTEM Figure 2-3: Cooling/Lubrication and Discharge System ST400, ST500 and ST700 5-10 HP 1. Separator Tube 5. Separator Element 2. Cooler 6. Air 3. Fluid Filter 7. Air/Fluid Mix 4. Compressor Unit 8.
  • Page 15 SECTION 2 USER MANUAL ™ COOLING/LUBRICATION SYSTEM DISCHARGE SYSTEM Figure 2-4: Cooling/Lubrication and Discharge System ST1100 and ST1500 15 & 20 HP 1. Separator Tube 5. Separator Element 2. Cooler 6. Air 3. Fluid Filter 7. Air/Fluid Mix 4. Compressor Unit 8.

  • Page 16: Compressor Cooling And Lubrication System - Func

    USER MANUAL SECTION 2 ™ COMPRESSOR COOLING separator element as the air flows through the AND LUBRICATION SYSTEM separator. — FUNCTIONAL A return line (or scavenge tube) leads from the dry DESCRIPTION side of the separator tube to the medium pressure region.
  • Page 17 SECTION 2 USER MANUAL ™ - 50 (3.4 PSIG Other pressure settings can be selected depending on compressor application or rating. When the compressed air pressure rises above 50 psig (3.4 bar), the minimum pressure valve opens allowing compressed air to flow into the service line. TART PSIG From this point on, the Controller continuously...
  • Page 18 USER MANUAL SECTION 2 ™ Figure 2-6: Control System, ST1100, ST1500, 15-20 HP 1. Air Outlet 5. Separator Tube 2. Unload Solenoid Valve 6. Pressure Transducer 3. Air Inlet 7. Controller 4. Minimum Pressure/Check Valve service line pressure will rise. The Controller de- When the pressure drops to the low setting: (cut-in energizes the solenoid valve when the pressure pressure) usually 112 psig (7.7 bar) for high pressure...

  • Page 19: Air Inlet System, Functional Description

    SECTION 2 USER MANUAL ™ AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figure 2-7 and Figure 2-8. The compressor inlet system consists of a dry-type air filter and an air inlet valve. Figure 2-8: Air Inet System-ST1100, ST1500, 15-20 HP 1.

  • Page 20: Controller/Keypad

    USER MANUAL SECTION 2 ™ ® Figure 2-9: Controller Panel 1. Run Mode Indicator Light (Green) 6. Start Button 2. Power On Indicator Light (Red) 7. Return/Reset Button 3. Fault Warning Indicator Light (Red) 8. Cursor/Confirm Button 4. Display Panel 9.

  • Page 21: Led Lights

    SECTION 2 USER MANUAL ™ The lower line will display the cause of the fault. Refer to service instructions to correct the cause. Press and hold the Return/Reset pad to reset LOAD PRESS: the controller. 0110PSI Refer to Figure 2-11. Press the Down arrow display additional information about the compressor.
  • Page 22 NOTES 02250180-090 R00...

  • Page 23: Table Of Specifications

    USER MANUAL ™ Section 3 SPECIFICATIONS TABLE OF SPECIFICATIONS DIMENSIONS Length Width Height Weight Model (I) ST400 Series ST410 32.5 21.5 ST410 32.5 21.5 ST500 Series ST510 32.5 21.5 ST510 32.5 21.5 ST700 Series ST709 32.5 21.5 ST712 32.5 21.5 ST708 32.5 21.5...

  • Page 24: Compressor Specifications

    Ambient Temperature (Max.) 104ºF (40ºC) LUBRICATION GUIDE Refer to Figure 3-1 for the fluid fill port location. Sullair’s ShopTek series compressors are filled and tested at the factory with Sullube lubricant. CAUTION Do not mix different types of lubricants. Mixing lubricants can cause malfunctions or compressor damage: will void the compressor’s warranty.

  • Page 25: Lubrication Change Recommendations And Maintenance

    SECTION 3 USER MANUAL ™ NOTE When performing a fluid change or topping off: With machine off, fill to the bottom of the fill port. Sight glass will be com- pletely full. Mixing, changing or add- ing other lubricants within the compressor unit may void the air-end warranty.
  • Page 26 Figure 3-2: Identification - ST400, ST500, ST700, 5-10HP 02250179-432 R00...
  • Page 27 Identification - ST400, ST500, ST700, 5-10HP SEE TABLE NOTES: 1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR. 2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.
  • Page 28 Figure 3-3: Identification - ST1100, ST1500, 15-20HP 02250179-435 R01...
  • Page 29 Identification - ST1100, ST1500, 15-20HP SEE TABLE NOTES: 1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR. 2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.
  • Page 30 Figure 3-4: Piping and Instrumentation - ST400, ST500, ST700, 5-10HP 02250179-804 R01...
  • Page 31 Piping and Instrumentation - ST400, ST500, ST700, 5-10HP PART NO. DESCRIPTION 88290014-486 1 FILTER,AIR 1 VALVE,INLET INTEGRAL VARIOUS 1 MOTOR,ELECTRIC 02250171-669 1 UNIT,COMPRESSOR 88290014-534 1 PROBE,TEMP 88290015-814 1 SEPARATOR TUBE 88290015-049 1 ELEMENT,OIL SEPARATOR 88290014-222 1 OIL SIGHT GLASS 02250046-338 1 VALVE,MINIMUM PRESSURE 88290014-514 1 SENSOR,PRESSURE...
  • Page 32 Figure 3-5: Piping and Instrumentation - ST1100 and ST1500, 15-20HP 02250179-805 R02...
  • Page 33 Piping and Instrumentation - ST1100 and ST1500, 15-20HP PART NO. DESCRIPTION 88290014-485 1 FILTER,AIR 1 VALVE,INLET INTEGRAL VARIOUS 1 MOTOR,ELECTRIC 88290015-893 1 UNIT,COMPRESSOR 88290014-534 1 PROBE,TEMP 88290014-226 1 SEPARATOR TUBE 88290015-567 1 ELEMENT,OIL SEPARATOR 88290014-222 1 OIL SIGHT GLASS 02250046-338 1 VALVE,MINIMUM PRESSURE 88290014-225 1 COMBINATION AIR/OIL COOLER...
  • Page 34 Figure 3-6: Wiring Diagram - ST400-ST1500 208V-460V Full Voltage 88290015-618 R0...
  • Page 35 Figure 3-7: Wiring Diagram - ST400-ST1500 575V Full Voltage 88290017-537 R03...
  • Page 36 Figure 3-8: Wiring Diagram - ST400, ST500, ST700 400V/50Hz CE Full Voltage 88290014-361 R07...
  • Page 37 Figure 3-9: Wiring Diagram - ST1100-ST1500 400V/50Hz CE Wye-Delta 88290014-360 R09...

  • Page 38: Tank Mount And Dryer Options

    USER MANUAL SECTION 3 ™ TANK MOUNT AND DRYER OPTIONS DIMENSIONS Length Width Height Weight Model (I)(II) WS400 Series ST400R 1616 1605 ST400RD 1748 1605 WS500 Series ST500R 1616 1605 ST500RD 1748 1605 954.5 WS700 Series ST700R 1616 1605 ST700RD 1748 1605 WS11100 Series...
  • Page 39 NOTES 02250180-090 R00...
  • Page 40 Figure 3-10: Identification - ST400, ST500, ST700, 5-10HP Tank Mount 02250179-433 R00...
  • Page 41 Identification - ST400, ST500, ST700, 5-10HP Tank Mount SEE TABLE NOTES: 1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR. 2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.
  • Page 42 Figure 3-11: Identification - ST400, ST500, ST700, 5-10HP Tank Mount with Dryer 02250179-434 R00...
  • Page 43 Identification - ST400, ST500, ST700, 5-10HP Tank Mount with Dryer SEE TABLE NOTES: 1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR. 2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.
  • Page 44 Figure 3-12: Identification - ST1100, ST1500, 15-20HP Tank Mount 02250179-436 R01...
  • Page 45 Identification - ST1100, ST1500, 15-20HP Tank Mount SEE TABLE NOTES: 1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR. 2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.
  • Page 46 Figure 3-13: Identification - ST1100, ST1500, 15-20HP Tank Mount with Dryer 02250179-437 R01...
  • Page 47 Identification - ST1100, ST1500, 15-20HP Tank Mount with Dryer SEE TABLE NOTES: 1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR. 2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.
  • Page 48 Figure 3-14: Wiring Diagram - SRS 25-100 115-230V/1/60...
  • Page 49 Figure 3-15: Wiring Diagram - SRS 9-18 220-240V/1/50...
  • Page 50 Figure 3-16: Wiring Diagram - SRS 24-30 220-240V/1/50...

  • Page 51: Compressor Mounting - Support And Location

    NOTE Do not install compressors where the machine will be exposed to temperatures lower than 32°F (0°C). Contact Sullair Customer Care regarding operation in sub-freezing temperatures. 02250180-090 R00...
  • Page 52 USER MANUAL SECTION 4 ™ Table 4-1: Ventilation Requirements Model Ventilation Air Required ST400 1040 ST500 1040 ST700 1040 ST1100 1471 2500 ST1500 1471 2500 UTDOOR NSTALLATION HELTERED ShopTek packages are equipped with TEFC motors and have water tight controls that are NEMA 4 rated and are suitable for sheltered outdoor installation.

  • Page 53: Service Air Piping

    SECTION 4 USER MANUAL ™ Figure 4-2: ST1100, ST1500 Shipping Studs 1. Belt Guard 3. Shipping Studs (2) 2. Nut (2) SERVICE AIR PIPING IZING Pipes should be sized as a minimum to match the Before installing the compressor, review the service dimensions compressor’s discharge...

  • Page 54: Belt Check

    Compressors not equipped with a FLUID LEVEL CHECK receiver tank may need to have their response times adjusted. Contact Sullair The compressor is shipped fully charged with the Customer Care for assistance. proper amount of fluid. However, it is necessary to...

  • Page 55: Electrical Preparation

    2. Check motor starter and overload heater disconnects, etc. Refer to Figure 3-2 and Figure 3-4. sizes. Sullair provides a wiring diagram for use by the installer. An electrical check should be made to 3. Check electrical connections ensure that the first start-up will be successful.
  • Page 56 USER MANUAL SECTION 4 ™ Figure 4-4: Fan Motor/Main Motor Rotational Direction ST400, ST500, ST700, 5-10HP 1. Main Motor Rotational Direction 2. Fan Motor Rotational Direction Figure 4-5: Fan Motor/Main Motor Rotational Direction ST1100, ST1500, 15-20HP 1. Main Motor Rotational Direction 2.

  • Page 57: Section 5-Operation

    USER MANUAL ™ Section 5 OPERATION ROUTINE OPERATION After a routine start, observe the controller display for the proper indications for this phase of operation. Before starting the compressor, check the fluid level After the compressor has warmed up, check all in the separator tube.
  • Page 58 NOTES 02250180-090 R00...

  • Page 59: Section 6-Maintenance

    USER MANUAL ™ Section 6 MAINTENANCE WARNING Before any repairs are attempted, refer to Section 1: Safety before proceeding. GENERAL This compressor requires a minimal amount of inspections and maintenance. The Controller and other indicators alert the operator to situations requiring maintenance, or fault conditions.

  • Page 60: Maintenance Every 2000 Hours

    USER MANUAL SECTION 6 ™ FILTER MAINTENANCE Refer to Figure 6-3. Replace the fluid filter under any of the following conditions, or whichever occurs first: 1. Every 2000 hours a display on the Controller indicates the need for replacement 2. Every fluid change. LUID ILTER EPLACEMENT...

  • Page 61: Air Filter Maintenance

    SECTION 6 USER MANUAL ™ AIR FILTER MAINTENANCE Refer to Figure 6-4 and Figure 6-5. Air filter maintenance should be performed every 2000 hours or sooner if necessary. ILTER LEMENT EPLACEMENT 1. Remove enclosure panels to gain access to filter. 2.

  • Page 62: Separator Maintenance

    USER MANUAL SECTION 6 ™ SEPARATOR MAINTENANCE Replace the separator elements every 2 years or 4000 hours, whichever occurs first. The separator elements must be replaced. DO NOT attempt to clean and reinstall the separator elements. EPARATOR LEMENT EPLACEMENT Refer to Figure 6-6. Use the following procedure below to change the separator: CAUTION Relieve all pressure from the separator/...

  • Page 63: Belt Maintenance

    SECTION 6 USER MANUAL ™ Belt tension must be re-adjusted 0.5 to 2 hours after a new set of belts are fitted. This will ensure that the belts have completed their initial stretch. Subsequent to this, belt tension needs to be checked and adjusted if necessary every 2000 hours for the duration of the belt life.
  • Page 64 USER MANUAL SECTION 6 ™ Figure 6-8: Optikrik Belt Tension Meter G. Repeat for remaining belts. ELT TENSION MEASUREMENT WITH FREQUENCY METER Refer to Figure 6-9. Follow instructions as follows: H. Compare the resuls to the belt tension specifica- tion in Table 6-1 and adjust if necessary. A.
  • Page 65 SECTION 6 USER MANUAL ™ Table 6-1: Belt Tension Requirements TT Mini Optikrik Model First Time First Time Re-tension Re-tension Frequency (Hz) Frequency (Hz) Force (N) Force (N) ST400 Series ST410 ST410 ST500 Series ST510 ST510 ST700 Series ST709 ST712 ST708 ST713 ST1100 Series...
  • Page 66 USER MANUAL SECTION 6 ™ Figure 6-10: Belt Tension Adjustment, ST400, ST500, ST700, 5-10HP 1. Belt Guard 5. Comp. Unit Mounting Plate Bolts (4) 2. Belt Tension Adjustment Screw 6. Comp. Unit Pulley 3. Locking Nut 7. Belts 4. Jacking Nut 8.

  • Page 67: Replacement And Alignment Of Belt Pulleys

    V belt form, considerably shortening the service life 2. Using a laser, ensure misalignment is no of both belts and pulleys. Due to Sullair’s innovative greater than 0.5°. design, only parallel alignment of the drive pulleys needs to be checked...

  • Page 68: 6.10 Hose Maintenance

    USER MANUAL SECTION 6 ™ To correct parallel misalignment, first check that the rear face of the compressor unit pulley is positioned 0.3in (7.5mm) off the mounting face. This is required to ensure that the belts clear all mounting bolt heads. With the compressor unit pulley correctly positioned, move the motor pulley on the shaft to achieve correct alignment.
  • Page 69 SECTION 6 USER MANUAL ™ Table 6-3: 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 - if fault persists, check motor contacts for proper function. Low incoming line voltage Check voltage - in the case of low voltage, check power source, or contact local power...
  • Page 70 USER MANUAL SECTION 6 ™ Table 6-3: Troubleshooting Guide SYMPTOM PROBABLE CAUSE REMEDY Compressor cannot produce Check service lines for leaks or open Air demand too high full discharge pressure valves. Dirty air filter Replace filter. Inlet valve bleed orifice Check the control line bleed orifice inside obstructed/plugged the inlet valve for blockage or obstructions.
  • Page 71 NOTES...
  • Page 72 Zone Des Granges BP 82 Chiwan, Shekou Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France Shenzen, Guangdong PRV. www.sullair.com Telephone: 33-477968470 PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A. only) Fax: 33-477968499 Telephone: 755-6851686 Fax: 219-874-1273 www.sullaireurope.com Fax: 755-6853473 CUSTOMER CARE www.sullair-asia.com...

This manual is also suitable for:

Shoptek st500Shoptek st1100Shoptek st1500Shoptek st700

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