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Sullivan-Palatek 125G Operating And Parts Manual

Industrial electric air compressors
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OPERATING AND PARTS MANUAL
FOR
INDUSTRIAL ELECTRIC AIR COMPRESSORS
125, 150, 200 AND 250 HP-UD MODELS
WITH T1 MICRO PROCESSOR CONTROL
PALATEK, INC. dba SULLIVAN-PALATEK MICHIGAN CITY, IN 46360 ALL RIGHTS
RESERVED COPYRIGHT 2011
04/01/2011
P/N OPM125/250T1

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  • Page 1 OPERATING AND PARTS MANUAL INDUSTRIAL ELECTRIC AIR COMPRESSORS 125, 150, 200 AND 250 HP-UD MODELS WITH T1 MICRO PROCESSOR CONTROL PALATEK, INC. dba SULLIVAN-PALATEK MICHIGAN CITY, IN 46360 ALL RIGHTS RESERVED COPYRIGHT 2011 04/01/2011 P/N OPM125/250T1...

  • Page 2: Table Of Contents

    ______________________________SULLIVAN-PALATEK TABLE OF CONTENTS SECTION 1 - SAFETY ..................4   1.1  GENERAL ......................4  1.2  PRESSURE RELEASE ..................4  1.3  FIRES/EXPLOSIONS ..................5  1.4  MOVING PARTS ....................5  1.5  PHYSICAL DANGERS ..................6  1.6  TOXICITY ......................6  1.7  ELECTRIC SHOCK .................... 6  1.8 ...
  • Page 3 SULLIVAN-PALATEK______________________________ SECTION 6 - MAINTENANCE ................22   6.1  MAINTENANCE SCHEDULE ................22  6.2  OIL FILTER ....................... 23  6.3  AIR FILTER ...................... 23  6.4  AIR/OIL SEPARATOR ..................23  6.5  PRESSURE ADJUSTMENT ................24  6.6  SERVICE/MAINTENANCE PROCEDURES ............ 24  6.7  TROUBLESHOOTING ..................25  SCREW COMPRESSOR AIR - END EXCHANGE PROGRAM ......

  • Page 4: Section 1 - Safety

    SECTION 1 - SAFETY GENERAL SULLIVAN-PALATEK designs all its compressors so they can be operated safely despite the fact that operating a motor driven air compressor is inherently hazardous. Responsibility for continued safe operation rests with those who install, use and maintain the equipment.

  • Page 5: Fires/Explosions

    SULLIVAN-PALATEK______________________________ Do not use air pressure greater than 30 PSI (207 kPa) for blow-off or cleaning purposes, and then only with effective chip guarding and personal protective equipment as required by OSHA. Compressed air filters or lubricators with plastic bowls may be affected by lubricant and should not be used.

  • Page 6: Physical Dangers

    ______________________________SULLIVAN-PALATEK PHYSICAL DANGERS Wear OSHA approved personal protective gear including gloves, safety shoes, safety glasses, head covering, and ear protection when working on or around the compressor. Avoid bodily contact with hot oil, hot surfaces, sharp edges and corners. Keep all parts of the body away from all potential points of air discharge, including pressure relief valve ports.

  • Page 7: Lifting

    SULLIVAN-PALATEK______________________________ LIFTING Lift or move the compressor only with equipment of sufficient load capacity that has been inspected and is in good condition. Keep personnel out from under and away from the area when lifting or moving the compressor. Lift no higher than necessary. Carry as low as possible when moving. Keep lifting operator in attendance whenever compressor is suspended.

  • Page 8: Hazard Warning Signs

    ______________________________SULLIVAN-PALATEK 1.11 HAZARD WARNING SIGNS SULLIVAN-PALATEK compressors are all equipped with brightly colored, weather- resistant, pictorial/verbal self-adhesive decals. These are designed to warn the operator against potential hazards in order to minimize risk of property damage, bodily injury or death. All operators must be aware of the Warning Signs and follow the instructions thereon.

  • Page 9: Section 2 - Specifications

    NOTE: SEE INSTALLATION DRAWINGS ON PAGES 57-61 OF THIS MANUAL DATA AND DIMENSIONS SULLIVAN-PALATEK reserves the right to change the design or construction of the above compressors, or to offer them with options which will cause subject equipment to differ from the above specifications, without reference to any descriptions in this manual.

  • Page 10: Section 3 - Description Of Components

    MOTOR The electric motor used to power each SULLIVAN-PALATEK UD Series 125/250 horsepower compressor is a NEMA standard three phase 60 Hertz AC induction type, ODP motor, fitted with a C-face register at the compressor drive end to assure proper coupling alignment at all times.
  • Page 11 SULLIVAN-PALATEK______________________________ Control Operation - Starting: When the compressor start key is pressed, or starts automatically (signal from BLT or sequencer), it will run for approximately 10 seconds unloaded. After this interval, the pressure will rise quickly to 60 PSIG (415 KPA) which is the minimum pressure valve opening pressure.
  • Page 12 ______________________________SULLIVAN-PALATEK CONTROL SCHEMATIC...

  • Page 13: Compressor Lubrication/Cooling System

    SULLIVAN-PALATEK______________________________ COMPRESSOR LUBRICATION/COOLING SYSTEM The cooling system consists of a fan, fan motor, finned-tube radiator-type fluid cooler, thermovalve to accelerate warm-up, and to control operating temperature, a full-flow filter, a drain valve and interconnecting tubing. Pressure in the oil separation tank utilizes air pressure over oil which causes the lubricoolant to flow from this region of relatively high pressure through the system to an area of lower pressure at the compressor unit.
  • Page 14 ______________________________SULLIVAN-PALATEK A sight gauge is provided to monitor the lubricoolant level in the oil separation tank, and a capped oil fill port is provided to keep the oil the proper level and to refill the system after changing the lubricoolant. WARNING: Do not remove caps, plugs or other components or connections while the compressor is running or pressurized.

  • Page 15: Starter And Electrical Parts

    SULLIVAN-PALATEK______________________________ STARTER AND ELECTRICAL PARTS The three-phase electric motor starter supplied with the SULLIVAN-PALATEK Plant Air Compressor has a NEMA-1 rated enclosure. This is also the location of: the control power transformer, the control pressure transducer, the over-pressure shutdown switch ROP, the anti-restart pressure switch ASP, fan motor disconnect fuses, and fan overload.

  • Page 16: Section 4 - Installation

    It is possible to utilize this heat for space heating, combustion air pre-heating, product drying, etc., --providing that no additional restriction is imposed upon the compressor cooling fan. Consult the factory for assistance if heat recovery is desired. Model 125G 150G 200G 250G AIRFLOW (CFM)

  • Page 17: Wiring Diagram, Full Voltage Starter (Standard)

    SULLIVAN-PALATEK______________________________ 4.5a WIRING DIAGRAM, FULL VOLTAGE STARTER (STANDARD)

  • Page 18: Wiring Diagram Y - Delta Start (Optional)

    ______________________________SULLIVAN-PALATEK 4.5b WIRING DIAGRAM Y - DELTA START (OPTIONAL)

  • Page 19: Direction Of Rotation

    SULLIVAN-PALATEK______________________________ DIRECTION OF ROTATION Once the control circuit has been checked, all piping installed, and compressor is filled with lubricoolant, push the ‘run’ key (green) followed by the ‘stop’ button (red) and observe the direction of rotation. If rotation direction is incorrect, there may be a fault signal appear (ER0050).

  • Page 20: Section 5 - Operation

    ______________________________SULLIVAN-PALATEK SECTION 5 - OPERATION INTRODUCTION Read this entire Operator’s Manual to familiarize yourself with the SULLIVAN-PALATEK Plant Air Compressor, giving special attention to the Section 1 - SAFETY. INITIAL START Open main disconnect to be sure there is no power to the compressor.

  • Page 21: Normal Operation

    SULLIVAN-PALATEK______________________________ 6. Once the parameter has been selected, press “enter,” then use the “up” (+) or “down” (-) keys to change the setting. 7. Press “enter” to effect this change in setting. 8. Press “enter” again and then use the “up” (+) or “down” (-) key to select the next setting to be changed.

  • Page 22: Section 6 - Maintenance

    ______________________________SULLIVAN-PALATEK SECTION 6 - MAINTENANCE MAINTENANCE SCHEDULE Daily -1. Check lubricoolant level prior to start-up 2. Drain condensate from auxiliary tank. (If supplied) 3. Check micro processor for any fault or alarm codes (see 5.2 instructions). 4. Keeping a daily log of all operating parameters is recommended. First 50 hours - Change compressor lubricoolant filter elements.

  • Page 23: Oil Filter

    SULLIVAN-PALATEK______________________________ OIL FILTER Replace if differential pressure exceeds 15 psid, H6 fault signal is shown, or every 1000 Hrs. 1. Open and lock-out main disconnect. 2. Relieve all internal system pressure. 3. Using a strap wrench, remove spin-on oil filter element 4.

  • Page 24: Pressure Adjustment

    ______________________________SULLIVAN-PALATEK PRESSURE ADJUSTMENT Note: prior to making any control pressure adjustments, turn the adjusting screw on the modulating (or regulating) valve in several turns to get it out of the action. Once the control has been set, then the regulating (or modulating) valve is re-adjusted so that it starts operating (as determined by air coming out the vent hole in cap) at 5 PSIG lower pressure than the control set pressure.

  • Page 25: Troubleshooting

    SULLIVAN-PALATEK______________________________ TROUBLESHOOTING SYMPTOM PROBABLE CAUSES AND REMEDIES A. MACHINE WILL NOT START 1. Main disconnect open. Close switch. 2. Line fuse(s) blown. Replace Fuse(s). 3. Control circuit breaker tripped. Reset circuit breaker. 4. Motor starter overload tripped. Reset. Should trouble persist, check sizing and adjustment of overload.
  • Page 26 ______________________________SULLIVAN-PALATEK TROUBLESHOOTING, CON’T. SYMPTOM PROBABLE CAUSES AND REMEDIES B. MACHINE SHUTS DOWN WITH AIR 4. Monitor temperature at micro processor: DEMAND PRESENT normal discharge temperature should be 100-110° F (37-43° C) above ambient; control is set to trip at 235-245°F (112- 118°C).
  • Page 27 SULLIVAN-PALATEK______________________________ TROUBLESHOOTING, CON’T. SYMPTOM PROBABLE CAUSES AND REMEDIES D. LINE PRESSURE RISES ABOVE CUT- 1. Leak in control system causing loss of OUT PRESSURE pressure signal. Replace tubing/repair leak. 2. Improperly adjusted or defective regulator. Readjust or replace if necessary. 3.
  • Page 28 ______________________________SULLIVAN-PALATEK PARTS LISTING...

  • Page 29: Screw Compressor Air - End Exchange Program

    SULLIVAN-PALATEK______________________________ SCREW COMPRESSOR AIR - END EXCHANGE PROGRAM After the warranty period has expired a factory re-manufactured air-end can be purchased on an exchange basis. All bearings and seals have been replaced. All other parts not meeting our quality standards are also replaced. The air-end is then factory tested prior to shipment.

  • Page 30: Section 7 - Parts List

    PARTS ORDERING Parts should be ordered from the nearest full-service Distributor or Factory Authorized Compressor Center. If parts cannot be obtained locally, contact the factory directly. SULLIVAN-PALATEK 1201 W. U.S. Highway 20 Michigan City, IN 46360 Telephone: 219-874-2497 Fax: 219-872-5043 E-mail: info@palatek.com...
  • Page 31 SULLIVAN-PALATEK______________________________ DRIVE AND BASE ASSEMBLY...

  • Page 32: Drive And Base Assembly Parts List

    ______________________________SULLIVAN-PALATEK DRIVE AND BASE ASSEMBLY PARTS LIST...
  • Page 33 SULLIVAN-PALATEK______________________________ LUBRICATION AND COOLING SYSTEM - AIR COOLED...

  • Page 34: Lubrication And Cooling System - Air Cooled

    ______________________________SULLIVAN-PALATEK LUBRICATION AND COOLING SYSTEM - AIR COOLED...
  • Page 35 SULLIVAN-PALATEK______________________________ LUBRICATION AND COOLING SYSTEM-WATER COOLED 125/150...

  • Page 36: Lubrication And Cooling System - Water Cooled 125/150

    ______________________________SULLIVAN-PALATEK 7.5a LUBRICATION AND COOLING SYSTEM - WATER COOLED 125/150...
  • Page 37 SULLIVAN-PALATEK______________________________ LUBRICATION & COOLING SYSTEM W/C 200/250...

  • Page 38: Lubrication & Cooling System W/C 200/250

    ______________________________SULLIVAN-PALATEK 7.5b LUBRICATION & COOLING SYSTEM W/C 200/250...
  • Page 39 SULLIVAN-PALATEK______________________________ INLET AND CAPACITY CONTROL SYSTEM...

  • Page 40: Inlet And Capacity Control System

    ______________________________SULLIVAN-PALATEK INLET AND CAPACITY CONTROL SYSTEM *Item #14 – Recommend Rebuilding Inlet Valve with K09790-005 Kit every 2 Years.
  • Page 41 SULLIVAN-PALATEK______________________________ DISCHARGE SYSTEM - 125/150 HP...

  • Page 42: Discharge System - 125/150 Hp

    ______________________________SULLIVAN-PALATEK 7.7a DISCHARGE SYSTEM - 125/150 HP ITEM PART NUMBER DESCRIPTION 96363-252 CONNECTOR, 2.000 TUBE X 2.000 NPT 09632-205 TUBE, 2.000 MPV TO TV 99600-004 TUBING, STEEL .250 O.D. X .028 WALL 91557-042 ELBOW, 90° .250 NT X .125 NPT 96363-044 CONNECTOR, CFS .250 TUBE X .250 NPT 03286-003...
  • Page 43 SULLIVAN-PALATEK______________________________ DISCHARGE SYSTEM - 200/250 HP...

  • Page 44: Discharge System - 200/250 Hp

    ______________________________SULLIVAN-PALATEK 7.7b DISCHARGE SYSTEM - 200/250 HP ITEM PART NUMBER DESCRIPTION 09648-115 PIPE, ISOLATED 3.000 91177-048 NIPPLE, PIPE 3.000 NPT X CLOSE GALV 99600-004 TUBING, STEEL .250 O.D. X .028 WALL 91557-042 ELBOW, 90° .250 NT X .125 NPT 96363-044 CONNECTOR, CFS .250 TUBE X .250 NPT 03286-003 FITTING, SIPHON .250...
  • Page 45 SULLIVAN-PALATEK______________________________ OPEN COMPRESSOR ELECTRICAL & CONTROL PARTS...

  • Page 46: Open Compressor Electrical & Control Parts

    ______________________________SULLIVAN-PALATEK 7.8a OPEN COMPRESSOR ELECTRICAL & CONTROL PARTS...
  • Page 47 SULLIVAN-PALATEK______________________________ ENCLOSED COMPRESSOR CONTROL PARTS...

  • Page 48: Enclosed Compressor Control Parts

    ______________________________SULLIVAN-PALATEK 7.8b ENCLOSED COMPRESSOR CONTROL PARTS...
  • Page 49 SULLIVAN-PALATEK______________________________ AIR COOLED ENCLOSURE 125/250...

  • Page 50: Air Cooled Enclosure 125/150

    ______________________________SULLIVAN-PALATEK 7.10a AIR COOLED ENCLOSURE 125/150...
  • Page 51 SULLIVAN-PALATEK______________________________ AIR COOLED ENCLOSURE 200/250...

  • Page 52: Air Cooled Enclosure 200/250

    ______________________________SULLIVAN-PALATEK 7.10b AIR COOLED ENCLOSURE 200/250...
  • Page 53 SULLIVAN-PALATEK______________________________ WATER COOLED ENCLOSURE...

  • Page 54: Water Cooled Enclosure

    ______________________________SULLIVAN-PALATEK 7.11 WATER COOLED ENCLOSURE...

  • Page 55: Decal And Identification

    SULLIVAN-PALATEK______________________________ 7.12a DECAL AND IDENTIFICATION ITEM DESCRIPTION MODEL 125 MODEL 150 MODEL 200/250 PLATE, NAME/S.N. 03832-043 03832-043 03832-043 DECAL, VOLTAGE 460 08377-001 08377-001 08377-001 DECAL, WARNING 08377-043 08377-043 08377-043 DECAL, WARNING 08377-045 08377-045 08377-045 DECAL, WARNING 08377-046 08377-046 08377-046 DECAL, 3-POS. SWITCH 08378-048 08378-048 08378-048...

  • Page 56: Decal And Identification

    ______________________________SULLIVAN-PALATEK 7.12b DECAL AND IDENTIFICATION...

  • Page 57: Section 8 - General Arrangement Drawings

    SULLIVAN-PALATEK______________________________ SECTION 8 - GENERAL ARRANGEMENT DRAWINGS PIPING & INSTALLATION DIAGRAM 125/250 HP...

  • Page 58: General Arrangement - Open, Air Cooled 125/250

    ______________________________SULLIVAN-PALATEK GENERAL ARRANGEMENT - OPEN, AIR COOLED 125/250...

  • Page 59: General Arrangement - Open, Water Cooled 125/250

    SULLIVAN-PALATEK______________________________ GENERAL ARRANGEMENT - OPEN, WATER COOLED 125/250...

  • Page 60: General Arrangement - Enclosed, Air Cooled 125/150

    ______________________________SULLIVAN-PALATEK GENERAL ARRANGEMENT - ENCLOSED, AIR COOLED 125/150...

  • Page 61: General Arrangement - Enclosed, Air Cooled 200/250

    SULLIVAN-PALATEK______________________________ GENERAL ARRANGEMENT - ENCLOSED, AIR COOLED 200/250...

  • Page 62: General Arrangement - Enclosed, Water Cooled 125/250

    ______________________________SULLIVAN-PALATEK GENERAL ARRANGEMENT - ENCLOSED, WATER COOLED 125/250...

  • Page 63: Section 9 - Warranty

    Sullivan-Palatek; whichever is the first to occur. Compressor unit (excluding shaft seal) and Coupling Assembly (excluding elements): 24 months from the date of start-up by an authorized distributor or 30 months from date of shipment by Sullivan-Palatek; whichever is the first to occur.
  • Page 64 Platinum Extended Warranty is limited and applies to specific components as detailed below. The terms, conditions and limitations contained in the Sullivan-Palatek standard warranty, which is printed on the reverse, apply to the Platinum Warranty and that warranty is herein incorporated by reference.

  • Page 65: Sullivan - Palatek Compressor Maintenance Log

    SULLIVAN-PALATEK______________________________ SULLIVAN - PALATEK COMPRESSOR MAINTENANCE LOG S/N: SERVICE DIST: FILL OUT FOR EACH SERVICE OR REPAIR. MORE THAN ONE LINE MAY BE USED PER EACH SERVICE OR REPAIR. THIS FORM MAY BE PHOTOCOPIED AS NEEDED. SERVICE CHANGE CHANGED PART DATE HOURS NUMBER...
  • Page 66 ______________________________SULLIVAN-PALATEK SULLIVAN - PALATEK COMPRESSOR MAINTENANCE LOG S/N: SERVICE DIST: FILL OUT FOR EACH SERVICE OR REPAIR. MORE THAN ONE LINE MAY BE USED PER EACH SERVICE OR REPAIR. THIS FORM MAY BE PHOTOCOPIED AS NEEDED. SERVICE CHANGE CHANGED PART DATE HOURS NUMBER...

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