Sullair 20/12 Series Operator's Manual
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Sullair 20/12 Series Operator's Manual

Industrial air compressor, 2 stage air-cooled and water cooled 500-750 cfm
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INDUSTRIAL
AIR COMPRESSOR
20/12 SERIES - 2 STAGE
AIR-COOLED AND WATER COOLED
500 - 750 CFM
OPERATOR'S
MANUAL
Part Number 250041-546
ESullair Corporation, 1993
Effective 5/93

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  • Page 1 INDUSTRIAL AIR COMPRESSOR 20/12 SERIES - 2 STAGE AIR-COOLED AND WATER COOLED 500 - 750 CFM OPERATOR’S MANUAL Part Number 250041-546 ESullair Corporation, 1993 Effective 5/93...
  • 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 compressor 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

    1.8 ELECTRICAL SHOCK 1.9 LIFTING 1.10 ENTRAPMENT Section 2 DESCRIPTION 2.1 INTRODUCTION 2.2 DESCRIPTION OF COMPONENTS 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION 2.6 CAPACITY CONTROL SYSTEM, FUNCTIONAL DESCRIPTION 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION...
  • Page 4 TABLE OF CONTENTS (CONTINUED) Section 5 OPERATION 5.1 GENERAL 5.2 PURPOSE OF CONTROLS 5.3 INITIAL START-UP PROCEDURE 5.4 SUBSEQUENT START-UP PROCEDURE 5.5 SHUTDOWN PROCEDURE Section 6 MAINTENANCE 6.1 GENERAL 6.2 DAILY OPERATION 6.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION 6.4 MAINTENANCE AS REQUIRED BY LUBRICATION GUIDE (SECTION 3) 6.5 FILTER MAINTENANCE...

  • Page 5: General

    SAFETY 1.1 GENERAL (13mm) inside diameter is to be connected to the Sullair Corporation and its subsidiaries design and shut-off (throttle) valve, to reduce pressure in case manufacture all of their products so they can be op- of hose failure, per OSHA Standard 29 CFR erated safely.

  • Page 6: Fire And Explosion

    Section 1 SAFETY 1.4 FIRE AND EXPLOSION 1.5 MOVING PARTS A. Clean up spills of lubricant or other combustible A. Keep hands, arms and other parts of the body substances immediately, if such spills occur. and also clothing away from couplings, fans and other moving parts.

  • Page 7: Electrical Shock

    Section 1 SAFETY D. Locate the compressor or provide a remote inlet machinery and prior to handling any ungrounded so that it is not likely to ingest exhaust fumes or other conductors. toxic, noxious or corrosive fumes or substances. 1.9 LIFTING A.

  • Page 8: Entrapment

    Section 1 SAFETY 1.10 ENTRAPMENT A. If the compressor enclosure is large enough to hold a man and if it is necessary to enter it to perform service adjustments, inform other personnel before doing so, or else secure and tag the access door in the open position to avoid the possibility of others closing and possibly latching the door with person- nel inside.

  • Page 9: Introduction

    The 2-stage Sullair compressor unit is driven by an Your compressor is equipped with a 2-stage Sullair electric motor designed to provide enough horse- rotary screw air compressor.

  • Page 10: Compressor Cooling And Lubrication System, Functional Description

    Section 2 DESCRIPTION Figure 2-2 Sullair 20/12 Rotary Screw Air Compressor (Water-cooled) As the rotors turn, air is drawn into the compressor line and the fluid is directed through the cooling and unit at the first stage inlet. At the outlet of the first lubrication system in preparation for reinjection.

  • Page 11: Compressor Discharge System, Functional Description

    TIONAL DESCRIPTION compressor unit. On shutdown, the compressor unit Refer to Figures 2-3, and 2-5. The Sullair com- pressure is reduced, causing the fluid stop valve to pressor unit discharges the compressed air/fluid close and isolate the unit from the cooling system.
  • Page 12 Fluid collected at the All Sullair compressor models are equipped with a bottom of the elements is returned to the compres- high pressure shutdown switch to shut down the sor unit by a pressure difference between the area compressor at 365 psig (25.2 bar).
  • Page 13 Section 2 DESCRIPTION Figure 2-5 Piping and Instrumentation RESTRICTION...

  • Page 14: Capacity Control System, Functional Description

    Section 2 DESCRIPTION pressure relief valve from opening under routine the cylinder to extend, opening the butterfly valve conditions, thereby preventing fluid loss through the fully and the compressor then pumps at full rated ca- pressure relief valve. pacity (start Mode B). The rising compressed air pressure is isolated from the service line in this Fluid is added to the sump via a capped fluid filler phase by the minimum pressure valve, set at ap-...

  • Page 15: Air Inlet System, Functional Description

    Section 2 DESCRIPTION reaching the Sullicon Control. Should the pressure to the operation of the Sullicon Control (Section 2.6). begin to rise, the pilot pressure regulator will resume The inlet actuator cylinder holds the butterfly valve its normal function as previously described. closed during the compressor start mode.
  • Page 16 Section 2 DESCRIPTION S The sump pressure gauge continually monitors Figure 2-8 Instrument Panel the sump pressure at the various load and/or unload conditions. S The discharge temperature gauge monitors the temperature of the air leaving the compressor unit. The normal reading for the compressor is 230ºF (110ºC).

  • Page 17: Lubrication Guide

    Sullube 32 fluid should be changed every 8000 hours when indicated by fluid analysis or once a Sullair encourages the user to participate in a fluid year, whichever comes first. The fluid should be analysis program with the fluid suppliers. This could...
  • Page 18 NOTES...

  • Page 19: Mounting Of Compressor

    Service air piping should be installed as shown in plicable local electrical code concerning isolation Figure 4-1. A shut-off valve should be installed to switches, fused disconnects, etc. Sullair provides a isolate the compressor from the service line. Also wiring diagram for use by the installer.
  • Page 20 NOTES...

  • Page 21: General

    Section 5 OPERATION 5.1 GENERAL beginning of a malfunction. Before starting your While Sullair has built into this compressor a com- Sullair compressor, read this section thoroughly prehensive array of controls, protective devices and familiarize yourself with the controls, protective...
  • Page 22 Section 5 OPERATION 5.2 PURPOSE OF CONTROLS CONTROL OR INDICATOR PURPOSE PRESSURE RELIEF VALVE (Interstage) Opens inner stage to atmosphere should the pressure become too high (140 psig [9.7 bar). NOTE Under certain conditions, it may be desirable to pipe the relief valves to the outside of the building for inside installation.

  • Page 23: Initial Start-Up Procedure

    Section 5 OPERATION 5.3 INITIAL START-UP PROCEDURE 7. Observe the operating temperature. If the operat- ing temperature exceeds 230ºF (110ºC), the The following procedure should be used to make the cooling system or installation environment initial start-up of the compressor: should be checked.
  • Page 24 NOTES...

  • Page 25: General

    Section 6 MAINTENANCE 6.1 GENERAL 6.6 PARTS REPLACEMENT AND ADJUSTMENT A good maintenance program is the key to long com- PROCEDURES pressor life. Below is a program that when adhered to SEPARATOR MAINTENANCE should keep your compressor in top running condi- Refer to Figure 6-1.
  • Page 26 Section 6 MAINTENANCE 6. Scrape the old gasket material from the cover and Figure 6-2 Bearing Filter (P/N 250019-296) flange on the sump being careful not to let the scraps fall in the sump. 7. Inspect the separator tank for rust, dirt, etc. 8.
  • Page 27 Section 6 MAINTENANCE Figure 6-3 Air Filter (P/N 409264) SECONDARY ELEMENT DUST PRIMARY EVACUATOR WASHER ELEMENT HEX NUT COVER WASHER WINGNUT WINGNUT Replacement element P/N 409853 Replacement element P/N 409854 2. Inspect all gaskets and gasket contact surfaces of 1. Remove the four (4) capscrews which secure the the housing.
  • Page 28 Section 6 MAINTENANCE FOR DIFFERENTIAL PRESSURE ADJUSTMENT: Figure 6-4 Main Fluid Filter (P/N 045111) Differential is the difference between the high and low pressure settings (10 psig [0.7 bar]) typical. Turn the differential adjusting screw to the lower (re- set) setting. Turning the screw counterclockwise widens the differential by lowering the reset (lower) setting only.
  • Page 29 Section 6 MAINTENANCE and tighten the nut. All of the these parts with the Figure 6-6 Sullicon Control (P/N 011682-003) exception of pressure plate are provided in the re- pair kit. 9. Replace the seat ring with the new seat ring pro- vided.
  • Page 30 Section 6 MAINTENANCE 12. Replace the retainer plate. Figure 6-8 Control Pressure Regulator 13. Screw the pusher post into the piston and replace (P/N 048354) them as shown in the body. 14. Replace the body plug. 15. Next, place these parts in their proper place on the body and replace the spring as it was prior to dis- assembly.
  • Page 31 Section 6 MAINTENANCE Figure 6-9 Fluid Stop Valve (P/N 250038-489) 19. Install the two (2) seals; one into the cover and the other onto the piston rod guide. 20. Place cylinder over pilot guide. 21. Replace the cover and the four (4) nuts onto the cover.
  • Page 32 Section 6 MAINTENANCE cone base lubricant such as Parker Super “O” Figure 6-11 Thermal Valve (P/N 250001-456) lube or an equivalent quality grease. 4. Place the new spring and poppet assembly in the valve body as shown. Then place the poppet guide (with the o-ring in position) over the poppet assembly.

  • Page 33: Motor Connection Instructions

    Should your problem persist after making the recom- mended check, consult your nearest Sullair repre- Extreme caution should be used when removing the sentative or the Sullair Corporation factory toll free at cap from the body because there is spring tension on 1-800-348-2722.

  • Page 34: Troubleshooting

    Section 6 MAINTENANCE TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY COMPRESSOR WILL NOT START Main Disconnect Switch Open Close switch. Line Fuse Blown Replace fuse. Control Transformer Fuse Blown Replace fuse. Motor Starter Overloads Tripped Reset. Should trouble persist, check whether motor starter contacts are functioning properly.
  • Page 35 Section 6 MAINTENANCE TROUBLESHOOTING (Continued) SYMPTOM PROBABLE CAUSE REMEDY COMPRESSOR WILL NOT BUILD UP FULL DISCHARGE PRESSURE Air Demand is Too Great Check service lines for leaks or open valves. Dirty Air Filter Check the filter indicator and change or clean element if required.
  • Page 36 Section 6 MAINTENANCE TROUBLESHOOTING (continued) SYMPTOM PROBABLE CAUSE REMEDY PRESSURE RELIEF VALVE OPENS REPEATEDLY (cont.) Defective Blowdown Valve Repair or replace. Defective Muffler Replace. Defective Pressure Switch Repair or replace. Defective Solenoid Valve Repair or replace. Defective Sullicon Diaphragm Replace diaphragm. Incorrect Unload Stop Screw Position Reposition and tighten.

  • Page 37: Recommended Spare Parts List

    7.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the com- pressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the address or phone numbers below.
  • Page 40 WORLDWIDE SALES AND SERVICE SULLAIR CORPORATION A SUBSIDIARY OF SUNDSTRAND CORPORATION 3700 E. Michigan Blvd. Michigan City, Indiana 46360-9990 Telephone (219) 879-5451 ® Printed in U.S.A. Specifications Subject To Change Without Prior Notice...

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