Sullair DR13 125H Operator's Manual And Parts List
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Sullair DR13 125H Operator's Manual And Parts List

Industrial air compressor, 100-200 hp
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INDUSTRIAL
AIR COMPRESSOR
100---200 HP
Preliminary
DR---13
OPERATOR'S
MANUAL AND
PARTS LIST
REFERENCE
Part Number
02250116---296
ESullair Corporation
Copy
2006
KEEP FOR
FUTURE

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Summary of Contents for Sullair DR13 125H

  • Page 1 Preliminary Copy 2006 INDUSTRIAL AIR COMPRESSOR DR---13 100---200 HP OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250116---296 ESullair Corporation...
  • 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

    2.3 SERVICE AIR CONDENSATE PIPING 2.4 SHAFT COUPLING ALIGNMENT CHECK 2.5 FLUID LEVEL CHECK 2.6 ELECTRICAL PREPARATION 2.7 MOTOR ROTATION CHECK Section 3 SPECIFICATIONS 3.1 SULLAIR DR--- 13 COMPRESSOR PACKAGE 3.2 LUBRICATION GUIDE Section 4 COMPRESSOR SYSTEMS 4.1 INTRODUCTION 4.2 DESCRIPTION OF COMPONENTS 4.3 COMPRESSOR UNIT,...
  • Page 4 TABLE OF CONTENTS (CONTINUED) Section 5 Page SUPERVISOR II 5.1 INTRODUCTION 5.2 KEYPAD 5.3 STATUS DISPLAYS 5.4 LAMP INDICATORS 5.5 OPERATING PARMETER SET--- UP 5.6 OPERATING THE COMPRESSOR 5.7 SUPERVISOR II OUTPUT RELAYS 5.8 SUPERVISOR II CONTROL PARAMETERS--- DR--- 13 Section 6 COMPRESSOR OPERATION...
  • Page 5 TABLE OF CONTENTS (CONTINUED) Section 7 Page MAINTENANCE 7.7.8 SUMP BREATHER FILTER MAINTENANCE (CONTINUED) 7.7.9 OIL SUMP STRAINER MAINTENANCE 7.7.10 BLOWDOWN VALVE MAINTENANCE 7.7.11 DRIVE COUPLING MAINTENANCE Section 8 TROUBLESHOOTING 8.1 INTRODUCTION 8.2 TROUBLESHOOTING 8.3 CALIBRATION Section 9 PARTS LIST 9.1 PROCEDURE FOR ORDERING PARTS 9.2 RECOMMENDED SPARE PARTS LIST 9.3 COMPRESSOR, MOTOR AND FRAME...
  • Page 6 NOTES...

  • Page 7: General

    SAFETY 1.1 GENERAL 1926.302(b)(7) and/or any applicable Federal, Sullair Corporation and its subsidiaries designs State and Local codes, standards and regulations. and manufactures all of its products so they can be B. When the hose is to be used to supply a mani- operated safely.

  • Page 8: Moving Parts

    Section 1 SAFETY C. DO NOT permit fluids, including air line anti--- E. Make sure all personnel are out of and/or clear of icer system antifreeze compound or fluid film to ac- the compressor prior to attempting to start or oper- cumulate on, under, or around acoustical material, ate it.

  • Page 9: Electrical Shock

    Section 1 SAFETY F. Wear goggles or a full face shield when adding helicopter must not be supported by the lifting bail antifreeze compound to air line anti---icer systems. but by slings instead. In any event, lift and/or han- dle only in full compliance with OSHA standards 29 G.

  • Page 10: Entrapment

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

  • Page 11: Mounting Of Compressor

    Section 2 INSTALLATION 2.1 MOUNTING OF COMPRESSOR because of the latent heat of condensation of the The compressor package should be placed on a moisture removed from the intake air and the heat surface or foundation that is capable of supporting from the motor inefficiency).

  • Page 12: Shaft Coupling Alignment Check

    Section 2 INSTALLATION drain traps is also recommended throughout. done by a qualified electrician, in compliance with OSHA, NEC, and any other applicable codes. A No piping loads or moments should be transmitted wiring diagram is provided with the package docu- to the air connections provided with the package.

  • Page 13: Sullair Dr

    3.2 LUBRICATION GUIDE fluid should be changed more frequently under se- vere operating conditions, such as high ambient Sullair DR---13 compressors are factory filled with temperatures coupled with high humidity or when Sullair lubricant (no. 02250057---198). high particulate level, corrosive gases or strong oxi- WARNING dizing gases are present in the air.
  • Page 14 NOTES...

  • Page 15: Introduction

    II assembly is easily accessible for servicing questions arise which cannot be answered in the behind a hinged and locked separate enclosure following text, call your nearest Sullair office or the panel door. Sullair Corporation Service Department. 4.3 COMPRESSOR UNIT, FUNCTIONAL DESCRIP-...

  • Page 16: Air Inlet System, Functional Description

    Section 4 COMPRESSOR SYSTEMS chosen. Figure 4 ---2 Compressor Inlet System A gear---type pump, coupled to the main drive shaft, supplies the required lubricating oil to the gears, anti---friction bearings and cooling to com- pressor jacket. A baseframe mounted, all---metal tank serves as the sump for the lubrication system.

  • Page 17: Load/Unload Capacity Control System, Functional Description

    Section 4 COMPRESSOR SYSTEMS 4 ---4 LP and HP Silencing/Discharge Air and Cooling Systems A decrease in compressor inlet pressure, caused START MODE -- 0 TO 5 PSIG (0 TO 0.34 BAR) by the collected airborne dirt, is sensed by the Su- When the “I”...
  • Page 18 Section 4 COMPRESSOR SYSTEMS Figure 4 ---5 Piping and Instrumentation Diagram (Air ---cooled)

  • Page 19: Cooling And Silencing System, Functional Description

    Section 4 COMPRESSOR SYSTEMS UNLOAD MODE -- 100+ PSIG (6.9+ BAR) 4.6 COOLING AND SILENCING SYSTEM, FUNC- If the demand of compressed air falls below that TIONAL DESCRIPTION supplied by the package, the line pressure (P2) in- Refer to Figure 4---4 and 4---5.

  • Page 20: Buffer Air System, Functional Description

    Section 4 COMPRESSOR SYSTEMS equal to approximately 45 psig (3.1 bar). An inte- All lubed points return the oil to the sump by gravity. gral bypass valve maintains the set flow, while pro- Vents on the compressor timing gear covers and tecting the pump against undesirable overpressur- the gear box are also piped into the sump, to avoid es.
  • Page 21 Section 5 SUPERVISOR II Figure 5 ---1 Supervisor II Panel...

  • Page 22: Introduction

    Section 5 SUPERVISOR II 5.1 INTRODUCTION mode to increment a value. Refer to Figure 5---1. The Supervisor II has a two line display to show temperature, pressure and sta- tus. It has a keypad for operating the compressor, programming the control points and selecting dis- plays.

  • Page 23: Lamp Indicators

    Section 5 SUPERVISOR II To view other status press the DSP key. All temper- the limit a T5 HI shutdown will occur. atures and pressures may be displayed as well as other status information. To scroll through the dis- T5 100 plays press the up arrow or down arrow keys.

  • Page 24: Operating Parmeter Set

    Section 5 SUPERVISOR II MOTOR --- If flashing, indicates the motor overload S Wye to delta transition timer --- For the contact has opened. full voltage starters and solid state starters supplied, this parameter is set to 0. INLET FILTER --- If flashing, indicates that inlet filter maintenance is needed.

  • Page 25: Operating The Compressor

    Section 5 SUPERVISOR II for slave or monitoring modes. Manual for details. CAPACITY BAUDRATE 9600 S Sequence Hours --- Used only for se- S Sequence method --- This parameter sets quencing, see Sequencing & Protocol the method used for sequencing. The Manual for details.

  • Page 26: Supervisor Ii Output Relays

    Section 5 SUPERVISOR II P2 > UNLD -- -- > load solenoid turned off S REMOTE --- Responds to status and pa- P2 < LOAD -- -- > load solenoid turned on rameter change messages but will not re- spond to start, stop, load or unload mes- POWER FAILURE RESTART sages.

  • Page 27: Supervisor Ii Control Parameters

    Section 5 SUPERVISOR II 5.8 SUPERVISOR II CONTROL PARAMETERS-- DS-- 13 SENSOR FUNCTION UNITS PREALARM SHUTDOWN FAILURE MODE Interstage Air Pressure psig/bar 49/ 3.4 52/ 3.6 Discharge Air Pressure psig/bar 50/ 3.4 Oil Filter Outlet Pressure psig/bar 25/ 1.7 Oil Filter Inlet Pressure psig/bar Inet Filter Vacuum inches H...
  • Page 28 NOTES...

  • Page 29: General

    Section 6 COMPRESSOR OPERATION 6.1 GENERAL WARNING While Sullair has built into the DR---13 compressor package a comprehensive array of controls and in- dicators to help assure proper operation, the user The minimum continuous operating pressure is should recognize and interpret readings which call 70 psig (4.8 bar).

  • Page 30: Supervisor Ii Operating Parameters

    S Unload the package by a suitable method. For S While modifying a setpoint, you may want to re- example, reprogram the Supervisor II to unload store the original value. To do so, press the Sullair at system line pressure, if such is available. If no logo.

  • Page 31: System Status Messages

    Section 6 COMPRESSOR OPERATION 13. Open service valve to air net system. Compres- T1 HI --- T1 was greater than 445_F (229_C). sor will run loaded or unloaded as the system T1 prealarm occurs at 435_F (224_C). demands. T2 HI --- T2 was greater than 445_F (229_C). T2 14.
  • Page 32 NOTES...

  • Page 33: General

    DO NOT remove caps, plugs, and/or other compo- 7.6 DIAGNOSTIC SERVICE (OPTIONAL) nents when compressor is running or pressurized. Sullair and its representatives offer a diagnostic ser- vice to check the condition of your compressor unit. Stop compressor and relieve all internal pressure The service, which is recommended at 8000 hour in- before doing so.

  • Page 34: Oil Filter Maintenance

    20 psig (1.4 barg). Your oil filter in- cludes a proprietary replaceable element (P/N 02250049--821) available solely from Sullair and its agents -- DO NOT substitute. 1. Using a strap wrench, remove the old element and gasket.

  • Page 35: Inlet Control Solenoid Valve Maintenance

    Section 7 MAINTENANCE Stop compressor and relieve all internal pressure Figure 7-3 Control Air Filter (P/N 02250112-032) before doing so. 1. Detach the body from the bowl by twisting the body about the bowl as far as it can go (approximately 1/8 turn), and pulling apart.
  • Page 36 Section 7 MAINTENANCE Figure 7-4 Solenoid Valve (P/N 250025-516) *Replacement Valve P/N 02250053-334 **Replacement Coil P/N 250031-431 circuit. Place an insulating washer at each end of CAUTION the non- - molded coil. When metal retaining clip disengages it will spring upward.
  • Page 37 Section 7 MAINTENANCE (cylinder) seat, end cap gasket or orifice gaskets. Figure 7-5 Solenoid Valve (P/N 02250119-220) Remove these only if replacement seats and gas- kets are available. 6. To remove body seat and seat gasket, insert an appropriate tool or a heavy gauge wire with a bent hook on the end through the center hole in the seat.
  • Page 38 Section 7 MAINTENANCE It is not necessary to remove the valve from the pipe Figure 7-6 Solenoid Valve (P/N 02250044-392) line for repairs. DISASSEMBLY Prior to performing this, be sure all pressure is re- moved from the system. 1. Remove the retaining cap. Push down on the coil while prying the nameplate/retainer cover in the direction of the arrow [ ] (See Figure 7-5).
  • Page 39 SPACER When replacing parts, always visually inspect those parts that are not included with the kit. If these parts show wear, consult Sullair factory. 1. Loosen the locknut and turn the adjusting screw counterclockwise until the inner spring tension is relieved.

  • Page 40: Sump Breather Filter Maintenance

    Section 7 MAINTENANCE 3. At this time, remove the diaphragm assembly, dia- Figure 7-10 Blowdown Valve (P/N 02250119-178) phragm gasket, adjusting spring and spring but- ton from the spring chamber. 4. Discard the brass diaphragm gasket, and replace it with the new gasket from the kit. 5.
  • Page 41 2. Loosen and remove all bolts securing each flexible element half to the shaft hubs. 3. Inspect each element body for signs of tears or separation away from the metal flanges -- if any faults are found, elements must be replaced and Sullair contacted for further assistance.
  • Page 42 Section 7 MAINTENANCE Table 1- Installation Data...

  • Page 43: Introduction

    Should your problem persist after making the of this would be the vibrations signature in- recommended check, consult your nearest Sull- crease of a damaged bearing or the efficiency air representative or the Sullair Corporation. 8.2 TROUBLESHOOTING SYMPTOM/MESSAGE PROBABLE CAUSE REMEDY COMPRESSOR WILL NOT START;...

  • Page 44: Solenoid Valve (02250119

    Blowdown Valve Failed to Open Refer to Component Manual for valve or Operated Sluggishly maintenance. P1 HI Defective HP Stage Consult Sullair Service Department. Pressure Transducer Failure Check connection from trans--- ducer. If adequate replace transducer. P2 HI Blowdown Valve Failed to Open Refer to Component Manual for valve maintenance.

  • Page 45: Solenoid Valve (02250044

    Limit Switch Controlling BVD Failed Check limit switch and cam adjuster to Operate on butterfly valve. Defective LP Stage Consult Sullair Service Department. LINE PRESSURE RISES ABOVE Blowdown Valve Failed to Refer to Component Manual for UNLOAD SETTING Activate valve maintenance.
  • Page 46 NOTES...

  • Page 47: Procedure For Ordering Parts

    9.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the ad- dress, fax or phone numbers below.

  • Page 48: Compressor, Motor And Frame

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.3 COMPRESSOR, MOTOR AND FRAME...
  • Page 49 Section 9 ILLUSTRATIONS AND PARTS LIST 9.3 COMPRESSOR, MOTOR AND FRAME part number description number quantity unit, compressor isolator, vibration 250042--757 guard, coupling 02250050--131 adaptor, motor/compressor 444/445 tsc 02250118--572 Sadaptor, motor/compressor 365/405 tsc 02250118--571 hub, coupling E--50 50mm 250042--754 element, coupling 406631 hub, coupling E--50 2.375 dia 407988...

  • Page 50: Air Inlet System

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.4 AIR INLET SYSTEM...
  • Page 51 Section 9 ILLUSTRATIONS AND PARTS LIST 9.4 AIR INLET SYSTEM part number description number quantity filter, air 150/200 HP (I) 048456 Selement, filter primary 150/200 HP 048462 Selement, filter secondary 150/200 HP 048463 band, mounting 044248 adapter, inlet 6” 02250105--687 clamp, hose 7”...

  • Page 52: Cooler Assembly

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.5 COOLER ASSEMBLY...
  • Page 53 Section 9 ILLUSTRATIONS AND PARTS LIST 9.5 COOLER ASSEMBLY part number description number quantity cooler, assembly 02250104--126 panel, LH fan box 02250105--470 plate, stiffener air box 02250107--842 panel, lower fan box 02250105--471 plate, venturi 40” 02250105--475 panel, RH fan box 02250105--472 panel, upper fan box 02250105--473...

  • Page 54: Lp Hot & Lp Cold

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.6 LP HOT & LP COLD...
  • Page 55 Section 9 ILLUSTRATIONS AND PARTS LIST 9.6 LP HOT & LP COLD part number description number quantity flange, 4” SAE 02250105--533 pipe, assembly LP hot flex 02250116--965 gasket, flange 240621--008 pipe, assembly LP hot 02250116--967 valve, relief 250042--766 u--bolt, 3” pipe 02250117--186 support, bracket “C”...

  • Page 56: Hp Discharge

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.7 HP DISCHARGE...
  • Page 57 Section 9 ILLUSTRATIONS AND PARTS LIST 9.7 HP DISCHARGE part number description number quantity flange, 3” SAE 02250105--534 pipe, assembly HP cold 2 1/2” 02250107--361 separator, water combo 2 1/2” 02250106--113 heater, condensate trap discharge 02250114--689 support, bracket turnbuckle 02250109--012 turnbuckle, 3/8”...

  • Page 58: Lube System

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 LUBE SYSTEM...
  • Page 59 Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 LUBE SYSTEM part number description number quantity filter, oil (I) 02250049--820 orifice, set screw 3/4”--10 x .203 02250115--992 02250110--549 hose, assembly flex 3/4” 02250108--308 hose, assembly flex 3/4” 02250107--874 valve, thermal 1” (II) 02250107--457 relief/bypass valve assembly 02250111--586...

  • Page 60: Electrical Box

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 ELECTRICAL BOX...
  • Page 61 Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 ELECTRICAL BOX part number description number quantity tape, heat 407403 60 ft box, junction heat trace 02250056--336 seal, heat trace end 02250056--337 sensor, temperature 02250118--769 receptacle, twistlock 02250116--384 socket, relay 250034--430 relay, phase monitor consult factory supply, power board, cam--lok...

  • Page 62: Control System/ Condensate Drain

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.10 CONTROL SYSTEM/ CONDENSATE DRAIN...
  • Page 63 Section 9 ILLUSTRATIONS AND PARTS LIST 9.10 CONTROL SYSTEM/ CONDENSATE DRAIN part number description number quantity valve, solenoid 2--way NC 1/4” (I) 02250044--392 strainer, V--type (II) 241771 valve, 3--way ball 044205 valve, check 1/4” 049905 support, bracket transducer 02250110--132 transducer, pressure (III) 02250078--933 switch, vacuum (IV) 02250078--249...

  • Page 64: Canopy

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.11 CANOPY...
  • Page 65 Section 9 ILLUSTRATIONS AND PARTS LIST 9.11 CANOPY part number description number quantity assembly, enclosure (I) 02250114--748 (I) For replacement enclosure parts, consult factory with drawing part number shown on page 54. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR...

  • Page 66: Decals

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 DECALS...
  • Page 67 Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 DECALS part number description number quantity sign, warning sever fan 049855 sign, warning sever fan port 049965 sign, danger electrocution 049850 decal, warning auto start 250017--903 decal, voltage 460/3/60 international (I) 02250069--399 decal, rotation 250021--286 decal, fluid Mobil DTE 02250069--390...
  • Page 68 Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 DECALS...
  • Page 69 Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 DECALS part number description number quantity sign, warning ground fault 049852 decal, danger high voltage 042218 decal, electrical component ID 250038--457 decal, ISO 9001 02250057--624 decal, water drain 250022--810 decal, water in 250019--107 decal, water out 250019--108 decal, fork lifting...
  • Page 70 Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 DECALS...
  • Page 71 Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 DECALS part number description number quantity sign, warning hot surfaces 407408 decal, electrocution hazard 02250077--472 decal, oil fill cap DS-13 02250115--652 decal, Supervisor II (I) 02250044--204 (I) For detailed view of decal no. 02250073-286, consult Section 5, Supervisor II, Figure 5-1. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR...

  • Page 72: Decal Locations

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 DECAL LOCATIONS...
  • Page 73 Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 DECAL LOCATIONS part number description number quantity decal, oil fill cap DS-13 02250115--652 decal, fluid Mobil DTE 02250069--390 decal, fork lifting 241814 sign, warning sever fan port 049965 sign, warning sever fan 049855 decal, rotation 250021--286 sign, warning hot surfaces...
  • Page 74 Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 DECAL LOCATIONS...
  • Page 75 Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 DECAL LOCATIONS part number description number quantity sign, warning sever fan 049855 sign, warning sever fan port 049965 decal, earth ground 02250075--046 decal, PE designation 02250075--540 decal, protective earth ground 02250075--045 sign, warning ground fault 049852 decal, danger high voltage 042218...
  • Page 76 Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 DECAL LOCATIONS...
  • Page 77 Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 DECAL LOCATIONS part number description number quantity sign, danger electrocution 049850 decal, warning auto start 250017--903 decal, ISO 9001 02250057--624 decal, electrocution hazard 02250077-472 decal, warning auto start 041065 sign, “food grade” lube 250003--144 sign, danger air breathing 250027--935...

  • Page 78: Wiring Diagram

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.14 WIRING DIAGRAM...
  • Page 79 NOTES...
  • Page 80 Fax: 755 -- 6853473 SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. Telephone: 1 -- 800 -- SULLAIR (U.S.A. Only) or 1-- 219-- 879-- 5451 Fax: (219) 874-- 1273 Fax: (219) 874-- 1835 (Parts) Fax: (219) 874-- 1205 (Service) Printed in U.S.A.

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