Sullair ES-6 SERIES User Manual
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Sullair ES-6 SERIES User Manual

Standard & 24kt 5, 7.5 and 10 hp / 4, 5.5 and 7.5 kw
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5, 7.5 AND 10 HP / 4, 5.5 AND 7.5 KW
WARRANTY NOTICE
Failure to follow the instructions and
procedures in this manual or, misuse
of this equipment will VOID its
warranty!
USER MANUAL
ES-6 SERIES
STANDARD & 24KT
PART NUMBER:
02250173-918-R00
KEEP FOR
FUTURE
REFERENCE
©SULLAIR CORPORATION
The information in this manual is current as of its publication date, and
applies to compressor serial number:
200711050000
and all subsequent serial numbers

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  • Page 1 USER MANUAL ES-6 SERIES STANDARD & 24KT 5, 7.5 AND 10 HP / 4, 5.5 AND 7.5 KW PART NUMBER: 02250173-918-R00 KEEP FOR FUTURE REFERENCE WARRANTY NOTICE Failure to follow the instructions and ©SULLAIR CORPORATION procedures in this manual or, misuse...
  • 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 PAGE SECTION DESCRIPTION SECTION 1 - SAFETY GENERAL SAFETY 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 DESCRIPTION OF COMPONENTS ENCAPSULATED COMPRESSOR SYSTEM,...
  • Page 4 TABLE OF CONTENTS PAGE SECTION DESCRIPTION SECTION 3 - SPECIFICATIONS (CONTINUED) COMPRESSOR LUBRICATION GUIDE COMPRESSOR LUBRICATION GUIDE - 24KT COMPRESSORS LUBRICATION GUIDE - OPTIONAL FLUID Figure 3-2 Identification - ES-6 Standard without Enclosure Figure 3-3 Identification - ES-6 Standard with Enclosure Figure 3-4 Identification - ES-6 Open Tank Mount (80 Gallon) Figure 3-5 Identification - ES-6 Enclosed Tank Mount (80 Gallon) Figure 3-6 Identification - ES-6 Open Tank Mount (80 Gallon) with Dryer...
  • Page 5 TABLE OF CONTENTS PAGE SECTION DESCRIPTION SECTION 5 - OPERATION (CONTINUED) PURPOSE OF CONTROLS INITIAL START-UP PROCEURE SUBSEQUENT START-UP PROCEDURE SHUTDOWN PROCEDURE SECTION 6 - MAINTENANCE GENERAL DAILY OPERATION MOTOR BEARNING LUBRICATION FLUID FILTER MAINTENANCE COOLER MAINTENANCE PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES FLUID FILTER REPLACEMENT AIR FILTER MAINTENANCE SEPARATOR ELEMENT REPLACEMENT...

  • Page 7: Section 1 - Safety

    Section 1 - SAFETY 1.1 GENERAL administrative and/or engineering controls and/or personal hearing protective equipment. Sullair Corporation and its subsidiaries design and manufacture all of their products so they can be 1.3 PRESSURE RELEASE operated safely. However, the responsibility for safe operation rests with those who use and A.

  • Page 8: Fire And Explosion

    Section 1 - SAFETY ES-6 USER MANUAL I. Keep personnel out of line with and away from such as terminals to avoid arcing which might the discharge opening of hoses or tools or serve as a source of ignition. other points of compressed air discharge. G.

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

    ES-6 USER MANUAL Section 1 - SAFETY 1.6 HOT SURFACES, SHARP EDGES E. Coolants and lubricants used in this compressor are typical of the industry. Care should be AND SHARP CORNERS taken to avoid accidental ingestion and/or skin A. Avoid bodily contact with hot fluid, hot coolant, contact.

  • Page 10: Lifting

    Section 1 - SAFETY ES-6 USER MANUAL C. Attempt repairs in clean, dry and well lighted K. When moving the compressor by forklift truck, and ventilated areas only. utilize fork pockets if provided. Otherwise, uti- lize pallet if provided. If neither fork pockets or D.

  • Page 11: Introduction

    Should any is an idler. questions arise which cannot be answered in the following text, call your nearest Sullair office or the The air/fluid mixture discharges directly into the Sullair Corporation Service Department. fluid management system.
  • Page 12 Section 2 - DESCRIPTION ES-6 USER MANUAL Figure 2-1 Description of Components 1. Air Inlet System 7. Fluid Fill Plug 13. Drain Valve 2. Pressure Regulator 8. Fluid Filter Element 14. Air Pressure Switch 3. Pressure Gauge 9. Fluid Level Sight Glass 15.
  • Page 13 ES-6 USER MANUAL Section 2 - DESCRIPTION Figure 2-2 Encapsulated Compressor System 1. Aftercooler and Fluid Cooler 5. Fluid Level Sight Glass 9. Air 2. Compressor Unit 6. Air/Fluid Separator 10. Air/Fluid 3. Fluid Fill Plug 7. Pressure Relief Valve 11.
  • Page 14 When the air demand is less than the rated flow for DESCRIPTION the compressor, the service line pressure will rise Due to the simplicity of the ES-6 Series to the pressure switch cut-out setting. The system compressor, the only instrumentation necessary is...

  • Page 15: Section 3 - Specifications (Continued)

    ES-6 USER MANUAL Section 3 - SPECIFICATIONS 3.1 SPECIFICATIONS - ES-6 60 Hz HP/KW Capacity Maximum dBA (I) DIMENSIONS Model ACFM/ Pressure with Length (II) Width (III) Height (IV) Weight PSIG/BAR canopy/ /Min without canopy ES-6 5H 18/.51 125/8.6 68/80 29.5 21.4 22.11...
  • Page 16 Nominal 3/16" x 3/16" x 1 1/4" FLUID FILTER (Internal Bypass Valve Set at 25 psig) Type: Spin on, Sullair Proprietary Micron: 23 Microns Abs. FLUID SEPARATOR ELEMENT Type: Push In Cartridge, Sullair Proprietary Efficiency at Maximum Capacity: 3PPM Maximum...

  • Page 17: Compressor Lubrication Guide

    Sullair encourages the user to participate in a fluid (mayonnaise) may occur, the fluid change interval analysis program. This could result in a fluid must be reduced to 300 hours maximum. A non- change interval that is different from those stated in detergent fluid with rust, oxidation and foam this manual.

  • Page 18: Lubrication Guide - Optional Fluid

    Maintenance of all other components is still FLUID recommended as indicated in the Operator's Manual. Sullair compressors may use SRF 1/4000 fluid as an optional factory fill. CAUTION Mixing of other fluids within the com- pressor will void all warranties.
  • Page 19 ES-6 USER MANUAL Section 3 - SPECIFICATIONS NOTES...

  • Page 20: Figure 3-2 Identification - Es-6 Standard Without Enclosure

    Section 3 - SPECIFICATIONS ES-6 USER MANUAL Figure 3-2 Identification - ES-6 Standard without Enclosure 02250172-315R00...

  • Page 21: Figure 3-3 Identification - Es-6 Standard With Enclosure

    ES-6 USER MANUAL Section 3 - SPECIFICATIONS Figure 3-3 Identification - ES-6 Standard with Enclosure 02250172-316R00...

  • Page 22: Figure 3-4 Identification - Es-6 Open Tank Mount (80 Gallon

    Section 3 - SPECIFICATIONS ES-6 USER MANUAL Figure 3-4 Identification - ES-6 Open Tank Mount (80 Gallon) 02250170-490R00...

  • Page 23: Figure 3-5 Identification - Es-6 Enclosed Tank Mount (80 Gallon

    ES-6 USER MANUAL Section 3 - SPECIFICATIONS Figure 3-5 Identification - ES-6 Enclosed Tank Mount (80 Gallon) 02250170-491R00...

  • Page 24: Figure 3-6 Identification - Es-6 Open Tank Mount (80 Gallon) With Dryer

    Section 3 - SPECIFICATIONS ES-6 USER MANUAL Figure 3-6 Identification - ES-6 Open Tank Mount (80 Gallon) with Dryer 02250172-307R00...

  • Page 25: Figure 3-7 Identification - Es-6 Enclosed Tank Mount (80 Gallon) With Dryer

    ES-6 USER MANUAL Section 3 - SPECIFICATIONS Figure 3-7 Identification - ES-6 Enclosed Tank Mount (80 Gallon) with Dryer 02250172-308R00...

  • Page 26: Figure 3-8 Identification - Es-6 Open Tank Mount (120 Gallon

    Section 3 - SPECIFICATIONS ES-6 USER MANUAL Figure 3-8 Identification - ES-6 Open Tank Mount (120 Gallon) 02250172-309R00...

  • Page 27: Figure 3-9 Identification - Es-6 Enclosed Tank Mount (120 Gallon

    ES-6 USER MANUAL Section 3 - SPECIFICATIONS Figure 3-9 Identification - ES-6 Enclosed Tank Mount (120 Gallon) 02250172-310R00...

  • Page 28: Figure 3-10 Identification - Es-6 Open Tank Mount (120 Gallon) With Dryer

    Section 3 - SPECIFICATIONS ES-6 USER MANUAL Figure 3-10 Identification - ES-6 Open Tank Mount (120 Gallon) with Dryer 02250172-311R00...

  • Page 29: Figure 3-11 Identification - Es-6 Enclosed Tank Mount (120 Gallon) With Dryer

    ES-6 USER MANUAL Section 3 - SPECIFICATIONS Figure 3-11 Identification - ES-6 Enclosed Tank Mount (120 Gallon) with Dryer 02250172-312R00...

  • Page 30: Figure 3-12 Piping And Instrumentation Diagram - Standard And Wye-Delta

    Section 3 - SPECIFICATIONS ES-6 USER MANUAL Figure 3-12 Piping and Instrumentation Diagram - Standard and Wye-Delta 02250101-011R04...
  • Page 31 ES-6 USER MANUAL Section 3 - SPECIFICATIONS Figure 3-12 Piping and Instrumentation Diagram - Standard and Wye-Delta (continued) Item Description Part No. Note filter, air heavy duty es-6 02250111-679 valve, air intake sub-assy 606448 motor various valve, solenoid n.o. 500psi 02250125-655 cooler, oil aftercooler es-6 250026-066...

  • Page 32: Figure 3-13 Wiring Diagram - Dual Control Full Voltage 2-Wire

    Section 3 - SPECIFICATIONS ES-6 USER MANUAL Figure 3-13 Wiring Diagram - Dual Control Full Voltage 2-Wire 02250045-623R06...

  • Page 33: Figure 3-14 Wiring Diagram - Dual Control Full Voltage 3-Wire

    ES-6 USER MANUAL Section 3 - SPECIFICATIONS Figure 3-14 Wiring Diagram - Dual Control Full Voltage 3-Wire 02250062-643R04...

  • Page 34: Figure 3-15 Wiring Diagram - Dual Control 200-230/1/60 5Hp

    Section 3 - SPECIFICATIONS ES-6 USER MANUAL Figure 3-15 Wiring Diagram - Dual Control 200-230/1/60 5HP 606512-001R07...

  • Page 35: Figure 3-16 Wiring Diagram - Dual Control Wye-Delta

    ES-6 USER MANUAL Section 3 - SPECIFICATIONS Figure 3-16 Wiring Diagram - Dual Control Wye-Delta 02250058-093R04...

  • Page 36: Figure 3-17 Wiring Diagram - Srs 25-100 115-230V/1/60

    Section 3 - SPECIFICATIONS ES-6 USER MANUAL Figure 3-17 Wiring Diagram - SRS 25-100 115-230V/1/60 02250171-733R00...

  • Page 37: Figure 3-18 Wiring Diagram - Srs 9-18 220-240V/1/50

    ES-6 USER MANUAL Section 3 - SPECIFICATIONS Figure 3-18 Wiring Diagram - SRS 9-18 220-240V/1/50 02250171-738R00...

  • Page 38: Figure 3-19 Wiring Diagram - Srs 24-30 220-240V/1/50

    Section 3 - SPECIFICATIONS ES-6 USER MANUAL Figure 3-19 Wiring Diagram - SRS 24-30 220-240V/1/50 02250171-739R00...

  • Page 39: Section 4 - Installation

    ES-6 USER MANUAL Section 4 - INSTALLATION 4.1 LOCATION OF COMPRESSOR DO NOT OVERFILL. The ES-6 Series compressor package may be WARNING placed on any level surface able to support its weight. The unit should be bolted to a fixed...
  • Page 40 T1, T2, and T3 from the concerning isolation switches, fused disconnects, starter. Energize the control circuits by turning etc. Sullair provides a wiring diagram for use by the the selector switch to the manual and auto- installer.

  • Page 41: Section 5 - Operation

    Sullair compressor, read this section thoroughly and While Sullair has built into this compressor a familiarize yourself with the controls and indicators comprehensive array of controls and indicators to - their purpose, location and use. assure you that it is operating properly, you will...

  • Page 42: Subsequent Start-Up Procedure

    Section 5 - OPERATION ES-6 USER MANUAL PRESSURE REGULATOR VALVE Modulates the intake valve to control compressor output. Senses compressor output pressure, the regulator stays closed up to a pre-set pressure and then modulates open to provide a positive control signal as compressor pressure increases. BALL VALVE Isolates the pressure regulator valve from standard operation of the compressor.

  • Page 43: General

    ES-6 USER MANUAL Section 6 - MAINTENANCE 6.1 GENERAL 6.3 MOTOR BEARING LUBRICATION WARNING WARNING Before doing compressor mainte- Before doing compressor mainte- nance, disconnect compressor from nance, disconnect compressor from power source and lock out power power source and lock out power source.

  • Page 44: Parts Replacement And Adjustment Procedures

    ES-6 USER MANUAL Section 6 - MAINTENANCE 7. Motor is now ready for operation. Figure 6-1 Fluid Filter (P/N 250026-982) (I) Use Chevron SRI-2 grease when lubri- cating motor bearings. Fill the cavity 1/3 to 1/2 full by repacking or use a low pressure grease gun and fill through the lubricating provisions on the motor end bell housing.

  • Page 45: Air Filter Maintenance

    Section 6 - MAINTENANCE ES-6 USER MANUAL Figure 6-2 Air Filter (P/N 02250111-680) 4. Remove element and base. Clean base and interior of cover using a damp cloth. DO NOT use compressed air to clean cover and base. 5. At this time replace element. 6.

  • Page 46: Separator Element Replacement

    ES-6 USER MANUAL Section 6 - MAINTENANCE 5. Reinstall the cap. Hand-tighten using a 4" max- 1. Unscrew the minimum pressure valve from the imum length, 1/4" diameter pin in the radially drive housing. drilled hole. 2. Remove all parts. 3.

  • Page 47: Control System Adjustment

    Section 6 - MAINTENANCE ES-6 USER MANUAL 1. To prevent spillage and loss of re-usable fluid, PRESSURE SWITCH ADJUSTMENT place a contaminate-free fluid receptacle 1. lose ball valve to isolate the pressure regulator beneath fluid drain valve and fluid filter. valve and set selector switch to manual.

  • Page 48: For Differential Adjustment Of Air

    ES-6 USER MANUAL Section 6 - MAINTENANCE until the line pressure gauge reads a pressure It is not necessary to remove the valve from the of 5 psi/ 0.34 bar below the pressure switch pipe line for repairs. setting established in Table DISASSEMBLY AND REASSEMBLY 5.
  • Page 49 Section 6 - MAINTENANCE ES-6 USER MANUAL Figure 6-7 Inlet Control Valve 1. Nylok Screw 4. Intake Valve Head 7. Intake Valve Rod 10. Spring Washers 13. Retaining Ring 2. Piston Seal (I) 5. Spring Retainer 8. Gasket (I) 11. Intake Check Spring 3.

  • Page 50: Motor Shaft Seal Replacement

    6.7 TROUBLESHOOTING Should your problem persist after making the The information contained in the Troubleshooting recommended check, consult your nearest Sullair chart is based upon both the actual applied representative or the Sullair Corporation factory. situations and extensive testing at the factory. It contains symptoms and usual causes for the described problems.
  • Page 51 ES-6 USER MANUAL Section 6 - MAINTENANCE 6.8 TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE REMEDY Discharge Temperature Switch COMPRESSOR SHUTS Defective discharge temperature switch; check for Open (continued) DOWN WITH AIR DEMAND a short or open circuit to probe and correct wiring. PRESENT (CONTINUED) COMPRESSOR WILL NOT Air Demand Is Too Great...

  • Page 52: Maintenance Record

    Section 6 - MAINTENANCE ES-6 USER MANUAL 6.9 MAINTENANCE RECORD MODEL NO. ___________________ SERIAL NO.____________________________________ DATE HOURMETER MAINTENANCE RECORD WORK AUTHORIZED PERFORMED BY...
  • Page 53 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. Such conditions include, but are not limited to, bodily injury and compressor failure.
  • Page 54 ES-6 USER MANUAL Section 7 - MAINTENANCE PARTS LIST Figure 7-1 Serial Plate Serial Number Location 7.2 MAINTENANCE PARTS LIST DESCRIPTION................KIT NUMBER ELEMENTS: replacement element kit for fluid filter 250026-982......250028-032 replacement element kit for air/fluid separator 250025-264 ....250028-033 replacement element kit for air filter 02250111-680......02250111-804 filter, clean air inlet option es6 ............02250172-109 KITS: repair kit for motor shaft seal 02250100-823 ........250028-035...
  • Page 55 ES-6 USER MANUAL Section 7 - MAINTENANCE PARTS LIST 7.2 MAINTENANCE PARTS LIST (CONTINUED) DESCRIPTION................KIT NUMBER FLUIDS: fluid, Sullube (one gallon) ..............250009-396 fluid, Sullube (five gallons)..............250022-669 fluid, 24 KT (5 gallons)..............02250051-153 fluid, SRF 1/4000 (5 gallons) .............250019-662 (I) For proper amount of fluid fill, please consult Lubrication Guide in Section 3, Specifications.
  • Page 56 NOTES...
  • Page 58 ORLDWIDE ALES AND ERVICE SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A. SULLAIR CORPORATION Sullair Road, No. 1 Zone Des Granges BP 82 3700 East Michigan Boulevard Chiwan, Shekuo 42602 Montbrison, France Michigan City, Indiana 46360 U.S.A Shenzhen, Guangdong PRV. Telephone: 33-477968470 www.sullair.com...

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