Sullair ShopTek ST18 Operation & Maintenance Manual
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Sullair ShopTek ST18 Operation & Maintenance Manual

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OPERATION & MAINTENANCE MANUAL
SAFETY WARNING
Users are required to read the
entire Operation & Maintenance
Manual before handling or using
the product.
ST18 & ST22
U.S.A. & Mexico
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual,
or misuse of this equipment, will
void its warranty.
Subject to EAR, ECCN EAR99 and related export control restrictions.
PART NUMBER:
88291013-137 R05
The information in this manual is current as of its
publication date and applies to compressors with
serial number:
37215080087
and all subsequent serial numbers.
Publication date: 11/25/2015
Copyright © 2014 – 2015 Sullair, LLC. All rights reserved.

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  • Page 1 Manual before handling or using or misuse of this equipment, will Publication date: 11/25/2015 the product. void its warranty. Copyright © 2014 – 2015 Sullair, LLC. All rights reserved. Subject to EAR, ECCN EAR99 and related export control restrictions.
  • 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 Stationary compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair’s training facility located at Michigan City, Indiana.

  • Page 3: Table Of Contents

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual Table of Contents Table of Contents Section 1: Safety.......................1 General....................... 1 Personal protective equipment ..............1 Pressure release ..................1 Fire and explosion ..................2 Moving parts ....................2 Hot surfaces, sharp edges and sharp corners..........3 Toxic and irritating substances ..............
  • Page 4 Table of Contents ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual Fluid/air separation system ............... 14 2.6.1 General description of the fluid/air separation system ........14 2.6.2 Fluid/air separator tank ..................15 2.6.3 Fluid/air separator element ................. 15 Microprocessor control system ..............
  • Page 5 ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual Table of Contents Section 6: Maintenance..................27 General..................... 27 Daily maintenance ..................27 6.2.1 Before starting the compressor................27 6.2.2 After starting the compressor................27 Recommended maintenance schedule ............ 28 6.3.1 Service at 50 operating hours................28 6.3.2 Service every 1000 operating hours ..............28 6.3.3...
  • Page 6 Table of Contents ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 7.12 Enclosure ....................60 7.13 Decal locations..................62 Appendix A: System Diagrams ................65 ST18 & ST22 identification ............... 65 ST18 & ST22 piping and instrumentation ..........66 Appendix B: Metric &...

  • Page 7: Section 1: Safety

    1.1 General protective clothing, protective shields and barriers Sullair and its subsidiaries design and manufacture all of and electrical protective equipment, as well as noise their products so they can be operated safely. However,...

  • Page 8: Fire And Explosion

    1: Safety ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual accordance with their manufacturer's recommenda- material. Any acoustical material with a protective tions. covering that has been torn or punctured should be replaced immediately to prevent accumulation of liq- E.

  • Page 9: Hot Surfaces, Sharp Edges And Sharp Corners

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 1: Safety E. Make sure all personnel are out of and/or clear of the DANGER compressor prior to attempting to start or operate it. F. Disconnect and lock out all power at source and ver- ify at the compressor that all circuits are de-energized to minimize the possibility of accidental start-up, or operation, prior to attempting repairs or adjustments.

  • Page 10: Electrical Shock

    1: Safety ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual cover eyes to exclude light. Call a physician immedi- DANGER ately. All field equipment must be tested for electro- 1.8 Electrical shock static fields prior to servicing or making contact A.

  • Page 11: Entrapment

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 1: Safety J. Set compressor down only on a level surface capa- 1. Review the equipment or machine to be ble of safely supporting at least its weight and its locked and tagged out.

  • Page 12: Safety Warnings

    1: Safety ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual lockout hasps on power shall remove pad- WARNING lock and lockout hasps and restore power. However, when the authorized person who applied the lock is unavailable to remove it Ground the unit following the instructions in this his/her Supervisor may remove padlock/pad- manual.
  • Page 13 State, Federal, and Do not touch any components on the circuit local electrical codes concerning isolation boards. Static voltage discharge may damage switches, fused disconnects, etc. Sullair pro- the components. vides a wiring diagram for use by the installer. NOTE Customer must provide electrical supply power disconnect within sight of machine.
  • Page 14 1: Safety ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-137 R05 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 15: Section 2: Description

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 2: Description Section 2 Description the compressed air using a combination of centrifugal 2.1 The air compression cycle force, impingement, and gravity. Then the compressed The ShopTek™ air compressor uses a lubricated rotary air passes through the fluid/air separator element to screw air end and supporting components to create com- remove almost all of the remaining fluid.
  • Page 16 2: Description ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 1. Fluid piping system 5. Discharge system 2. Air inlet system 6. Electric control system 3. Motor & air end 7. Enclosure 4. Cooling fan system 8. Fluid/air separation system Figure 2-1: ST18 &...
  • Page 17 ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 2: Description Key Description Air filter Inlet valve Capacity control integrated system Oil cooler Pressure switch Indicator Aftercooler Minimum pressure valve Single-stage fluid/air separator element Strainer Moisture separator Pressure sensor Temperature sensor Compressor air end Relief valve...

  • Page 18: Air Inlet System

    2.2.3.1 Inlet modulation To lower the frequency of the compressor’s load/unload To minimize the number of starts and stops the compres- cycles and extend the life of the compressor, Sullair rec- sor makes, the inlet modulation system automatically 88291013-137 R05...

  • Page 19: Minimum Pressure Valve

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 2: Description ommends installing a wet air receiver after the service 2.3.6 Moisture separator connector. The moisture separator removes the moisture from the compressed air stream. Moisture collected by the mois- Additional information ture separator can then be safely disposed of according to local regulations.

  • Page 20: Fluid Filter

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 2.5.2 Ambient temperature Additional information Sullair ShopTek™ compressors are designed to operate • For the viscosity required for the compressor in ambient temperatures between 4°C and 40°C (40°F fluid to act as a sealant, see Section 3.2: Lubri- and 104°F), measured at the cooling air inlet.

  • Page 21: Fluid/Air Separator Tank

    For assistance in operating the compressor in very low ambient temperatures, please 2.6.2 Fluid/air separator tank contact your Sullair representative. In addition to separating the air from the fluid, the fluid/air separator tank acts as a fluid reservoir, storing most of 2.6.3 Fluid/air separator element the compressor fluid.
  • Page 22 2: Description ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-137 R05 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 23: Section 3: Specifications

    1460 × 910 × 1535 mm (57.5 × 35.8 × 60.4 in) 3.2 Lubricant specifications Table 3-2: Lubricant specifications The oil used as a lubricant in Sullair’s rotary screw com- Synthetic oils Ambient temperature pressors must have the following properties: ®...
  • Page 24 3: Specifications ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-137 R05 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 25: Section 4: Installation & Setup

    4.2 Guidelines for lifting and moving 4.3 Compressor installation the compressor The ShopTek™ compressor is not weatherproof. The Sullair recommends using a forklift to move the compres- compressor should be installed inside (or in a sheltered sor. A crane can also be used. position outside).

  • Page 26: Heat Rejection And Ventilation Requirements

    Aftermarket prior to installation) and must not apply • For the exact location of the service connector, any weight to the compressor cabinet. Sullair also recom- see Section A.1: ST18 & ST22 identification on mends a section of the ductwork be removable to allow page 65.

  • Page 27: Checking The Compressor Fluid Level

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 4: Installation & Setup 4.6.2 Checking the motor rotation direction 4.5.2.1 Checking the air end of a new machine Rotate the flexible drive coupling by hand through two For the motor to rotate in the correct direction, the power complete revolutions in the direction indicated by the supply must be correctly connected.
  • Page 28 4: Installation & Setup ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-137 R05 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 29: Section 5: Operation

    CAUTION NOTE The compressor should always run smoothly. If the compressor vibrates excessively while run- ning, shut it down and contact your Sullair repre- You should always use the Stop button to stop sentative immediately. the compressor under normal circumstances.

  • Page 30: Starting The Compressor

    In the event of a high operating temperature shutdown fault, do not attempt to restart the compressor without first finding and correcting the underlying cause. Contact your Sullair repre- sentative for assistance. 5.7 Motor overload protection Both the compressor main drive motor and the fan motor have overload protection.

  • Page 31: Run-On Timer

    The factory setting of the run-on time is 15 minutes. Con- In the event of a motor overload protection shut- tact your Sullair representative before making any adjust- down fault, do not attempt to restart the com- ments, since an incorrect setting may result in damage to pressor without first finding and correcting the the compressor.
  • Page 32 5: Operation ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-137 R05 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 33: Section 6: Maintenance

    WARRANTY NOTICE Normal operation of your compressor depends upon per- forming maintenance and service correctly and according Failure to use Sullair genuine parts when servic- to a consistent schedule. ing a Sullair compressor may void your warranty. To help you follow this schedule, the ShopTek™ micro- processor controller has a programmable service timer.

  • Page 34: Recommended Maintenance Schedule

    6.3.4 Service every 4000 operating hours Contact your Sullair representative for advice on (or semi-annually) the correct service intervals for your installation. Perform all checks listed for every 1000 and 2000 hours plus: 6.3.1...

  • Page 35: Compressor Fluid Levels

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance 6.3.6 Compressor fluid levels 6.4 Compressor maintenance Refer to Section 7: Parts List for the part numbers of al items mentioned in this section. WARNING Do not attempt any maintenance when the com- pressor is running or pressurized.

  • Page 36: Fluid Filter Maintenance

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual Clean the lubrication system before changing fluid. If the ambient temperature is outside of the allowed range for the fluid, please contact your Sullair representative. WARRANTY INFORMATION ® Mixing of fluids other than Sullube will void the compressor’s warranty.

  • Page 37: Purge Oil Return Line Filter Maintenance

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance • Do not strike the filter element against a hard surface to remove the dirt. You may damage the element. • Do not oil the filter element. 6.4.5 Purge oil return line filter maintenance Clean the purge oil return line filter after the first 50 hours...
  • Page 38 6: Maintenance ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 7. Install the new fluid/air separator element and gasket assembly. CAUTION Do not remove the staples incorporated into the gaskets.They maintain a ground contact with the separator. 8. Reassemble in reverse order, carefully adjusting the purge oil return line tube so it has the correct clearance from the separator element base (see Section 6.4.5: Purge oil...

  • Page 39: Minimum Pressure Valve Maintenance

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance 3. Unscrew the top cap of the valve and 6.4.7 Minimum pressure valve remove the piston assembly from the valve. maintenance 4. Clean the valve and piston assembly care- fully.

  • Page 40: Drive Coupling Maintenance

    6: Maintenance ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 6.4.11 Drive coupling maintenance WARNING Isolate the compressor from the power supply before making any repairs or adjustments to the drive coupling. 1. Motor end sleeve 2. Elastomer 1.

  • Page 41: Main Motor Operation

    ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance See the main motor nameplate and the other topics in motor will create significantly more noise and this section for additional information about operating vibration.) conditions. • After any motor faults occurs, contact your Sul- lair representative.

  • Page 42: Check And Clean The Windings

    For a thorough cleaning, or if the Sullair recommends using a petroleum-based solvent for winding is very dusty, the rotor needs to be removed from cleaning the insulation.
  • Page 43 ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance Table 6-2: Troubleshooting guide lists some compressor symptoms with their most probable causes and remedies Table 6-2: Troubleshooting guide Symptom Possible causes Remedy Low fluid level in fluid/air separator Check fluid level.
  • Page 44 6: Maintenance ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-137 R05 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 45: Section 7: Parts List

    The genuine Sullair service parts listed meet or exceed the demands of this compressor. Use of replacement parts other than those approved by Sullair will void the Sullair warranties specific to this product and may lead to hazardous conditions over which Sullair has no control.

  • Page 46: Recommended Spare Parts List

    7: Parts List ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 7.2 Recommended spare parts list Service kit part number Qty Description 250025-525 Element for compressor fluid filter 88291002-854 Element for heavy duty air filter 88291002-853 02250121-500 Element for fluid/air separator 02250138-090 Repair kit for inlet valve 02250145-097...
  • Page 47 ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 7: Parts List Notes: 88291013-137 R05 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 48: Motor And Air End System

    7.3 Motor and air end system 88291010-732 R01...
  • Page 49 7.3 Motor and air end system Key Part number Qty Description Notes 02250155-285 Shock absorber 250040-319 Shield 829106-150 Bolt 829705-075 Bolt 837806-094 Spring washer 88250160-680 Airend ST18 60Hz 88250159-996 Airend ST22 60Hz 88291012-524 Motor ST18 60Hz 230/460V IP23 88291012-523 Motor ST 22 60Hz 230/460V IP23 88290012-853 Supporting plate...

  • Page 50: Air Inlet System

    7.4 Air inlet system 88291002-755 R00...
  • Page 51 7.4 Air inlet system Key Part number Qty Description Notes 250018-550 Clamp 88291002-853 Air filter 88291002-856 Rubber elbow 88831110-020 Flat washer 88832110-026 Spring washer 88291002-855 Air filter holder 88831108-016 Flat washer 88832108-021 Spring washer 88821108-068 88812110-030 Bolt 88813108-020 Bolt...

  • Page 52: Fluid Piping System

    7.5 Fluid piping system 88291002-756 R02...
  • Page 53 7.5 Fluid piping system Key Part number Qty Description Notes 02250099-766 Joint 250025-525 Oil filter element 88290021-503 Oil filter thermal valve assembly 02250078-204 Thermal valve element <12bar model 88291002-968 Oil pipe 88291002-969 Oil pipe 883527-012 Straight joint 88811110-135 Bolt 88831110-020 Flat washer 88832110-026 Spring washer...

  • Page 54: Cooling Fan System

    7.6 Cooling fan system 88291010-728 R02...
  • Page 55 7.6 Cooling fan system Key Part number Qty Description Notes 88291002-944 Cooler 88292002-481 60Hz ST18/22 0.75KW 250022-436 Weatherstrip 88813108-020 Bolt...

  • Page 56: Fluid/Air Separation System

    7.7 Fluid/air separation system 88291010-729 R02...
  • Page 57 7.7 Fluid/air separation system Key Part number Qty Description Notes 88290012-879 Adjustable joint 88290012-880 Metal hose 02250055-015 Joint 88291011-662 Min pressure valve 02250121-500 Element 250042-646 O-ring 88290006-367 Sight glass 88291010-367 Oil/air separator 810204-025 Joint 810204-012 Joint 02250117-782 Return line filter 02250126-129 Sight glass 88871008-044...

  • Page 58: Air Discharge System

    7.8 Air discharge system 88291013-661 R01...
  • Page 59 7.8 Air discharge system Key Part number Qty Description Notes 88842035-038 O-ring 88290017-747 Straight joint 88842026-033 O-ring 88291002-991 Hose 88291002-990 Straight joint 88290021-484 Connection pipe 88291013-636 Connector 88292001-712 Water trap...

  • Page 60: Control System

    7.9 Control system 88291012-748 R01...
  • Page 61 7.9 Control system Key Part number Description Notes 02250054-861 Nylon conduit(FT) 241771 Strainer 02250099-626 Elbow 02250099-630 Nylon conduit 250003-869 Vacuum indicator 250018-428 Straight joint 250018-430 Elbow 88290002-119 Pressure gauge 88290010-794 joint 88290011-584 joint 88290011-143 Cable joint 88290011-142 Cable joint 88833108-022 Washer 88291011-444 Rubber Washer...

  • Page 62: Starter Assembly-460/230V Dual Voltage

    7.10 Starter assembly—460/230V dual voltage 88291013-383 R03...
  • Page 63 7.10 Starter assembly—460/230V dual voltage Part number Qty Description Notes 88291013-032 MPCB, Standard Magnetic Trip (Fixed at 13 x le), 1.0-1.6 A -QF1 88291012-865 Auxiliary Contact Block, Front Mounted, 1 N.O. 1 N.C. -TC1 88291012-840 200VA, 230/460V-110V/25V (50/60Hz) UL -KM2,-KM3 88291012-882 MCS-C Contactor, IEC,60A, 120V 50/60Hz -KM1 88291012-881...

  • Page 64: Starter Assembly-460V

    7.11 Starter assembly—460V 88291012-977 R02...
  • Page 65 7.11 Starter assembly—460V Part Number Qty Description Notes 88291013-032 MPCB, Standard Magnetic Trip (Fixed at 13 x le), 1.0-1.6 A -QF1 88291012-865 Auxiliary Contact Block, Front Mounted, 1 N.O. 1 N.C. -TC1 88291012-840 200VA, 230/460V -110V/25V(50/60Hz) UL -KM2,-KM3 88291013-033 MCS-C Contactor, IEC,30A, 120V 50/60Hz -KM1 88291013-034 MCS-C Contactor, IEC, 16A, 120V 50/60Hz...

  • Page 66: Enclosure

    7.12 Enclosure 88291010-678 R03...
  • Page 67 7.12 Enclosure Key Part number Qty Description Notes 02250151-635 Door gasket 88291002-785 Door A 88291002-786 Door B 88291002-787 Door C 88291010-690 Post D 88291010-688 Beam A 88291002-790 Beam B 88291010-687 Post A 88291002-795 Post B 88291002-796 Post C 88291002-799 Corner panel A 88291002-800 Corner panel B 88291002-801...

  • Page 68: Decal Locations

    7.13 Decal locations 88291011-492 R04...
  • Page 69 Tag,first start 250021-564 Decal,rotation 3.5"lg 407408 Hot Surface Warning 88291012-969 Safety decal 88290013-683 Npl,for export model 88290013-723 Rivet,busterpop dia3.2 l=8 88290016-067 Decal,voltage wan component 88291011-501 SULLAIR LOGO decal 88291011-508 Decal,shoptek18 For ST18 88291011-514 Decal,shoptek22 For ST22 88291011-601 SULLAIR LOGO decal...
  • Page 70 Notes:...

  • Page 71: Appendix A: System Diagrams

    Appendix A: System Diagrams A.1 ST18 & ST22 identification 88291013-663 R00...

  • Page 72: St18 & St22 Piping And Instrumentation

    A.2 ST18 & ST22 piping and instrumentation...
  • Page 73 A.2 ST18 & ST22 piping and instrumentation Key Description Air filter Inlet valve Capacity control integrated system Oil cooler Pressure switch Indicator Aftercooler Minimum pressure valve Single-stage fluid/air separator element Strainer Moisture separator Pressure sensor Temperature sensor Compressor air end Relief valve Fluid/air separator tank Sight glass...

  • Page 74: Appendix B: Metric & Imperial Nominal Sizes

    B: Metric & Imperial Nominal Sizes ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Appendix B: Metric & Imperial Nominal Sizes Metric nominal size (DN) is the nominal size for valves, Table B-1: Metric to Imperial nominal sizes flanges and fittings as defined by ISO 6708-1980. DN Metric DN Imperial NS designates the size of all components in a piping system...
  • Page 75 Subject to EAR, ECCN EAR99 and related export control restrictions.
  • Page 76 Sullair, LLC 3700 East Michigan Boulevard Michigan City, IN 46360 USA www.sullair.com 1-800-SULLAIR (USA only) 1-219-879-5451 (non-USA) Information and specifications are subject to change without prior notice. Subject to EAR, ECCN EAR99 and related export control restrictions.

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