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Sullivan-Palatek 125UD Operating And Parts Manual

Industrial electric air compressors with t1 micro processor control and yaskawa drive
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OPERATING AND PARTS MANUAL
FOR
INDUSTRIAL ELECTRIC AIR COMPRESSORS
125, 150, 200 AND 250UD MODELS
WITH T1 MICRO PROCESSOR CONTROL
AND YASKAWA DRIVE
PALATEK, INC. dba SULLIVAN-PALATEK MICHIGAN CITY, IN 46360
ALL RIGHTS RESERVED
04/01/2011
P/N OPM-125250T1V-010

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  • Page 1 OPERATING AND PARTS MANUAL INDUSTRIAL ELECTRIC AIR COMPRESSORS 125, 150, 200 AND 250UD MODELS WITH T1 MICRO PROCESSOR CONTROL AND YASKAWA DRIVE PALATEK, INC. dba SULLIVAN-PALATEK MICHIGAN CITY, IN 46360 ALL RIGHTS RESERVED 04/01/2011 P/N OPM-125250T1V-010...

  • Page 3: Table Of Contents

    __________________________________SULLIVAN-PALATEK TABLE OF CONTENTS SECTION 1  SAFETY ....................... 5      GENERAL ..........................5     PRESSURE RELEASE ......................5     FIRES/EXPLOSIONS ........................ 6     MOVING PARTS ........................6     PHYSICAL DANGERS ......................6     TOXICITY ..........................6  ...
  • Page 4 SULLIVAN-PALATEK__________________________________ SECTION 6  MAINTENANCE ....................21      MAINTENANCE SCHEDULE ....................21     OIL FILTER ..........................22     AIR FILTER ..........................22     AIR/OIL SEPARATOR ......................22     PRESSURE ADJUSTMENT ....................23     SERVICE/MAINTENANCE PROCEDURES ................23  ...

  • Page 5: Safety

    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. The precautions offered in this section will minimize the inherent hazards and reduce the likelihood of accidental damage or injuries.

  • Page 6: Fires/Explosions

    SULLIVAN-PALATEK__________________________________ FIRES/EXPLOSIONS Clean up any spilled oil or oil leakage, and repair oil leaks as soon as they are discovered. Do not allow oil to accumulate on, in, or around acoustic noise material. Immediately replace any oil- soaked material after cleaning enclosure surface with nonflammable solvent. Do not operate compressor when there is a possibility of its ingesting flammable, toxic or explosive fumes, mists or particles.

  • Page 7: Electric Shock

    __________________________________SULLIVAN-PALATEK ELECTRIC SHOCK Remove watches & rings, and keep all parts of the body, tools, or other conductive objects away from exposed live parts of the electrical system. Maintain dry footing, stand on insulating surface and do not contact any other portion of the compressor when making adjustments. Turn compressor off, open main disconnect and lock it out and tag it prior to opening the Starter Enclosure or when testing or replacing any electrical component such as: switches, wiring, terminals, transformer, starter, timer, coil, relay, contact, interlock, fuse, overload heater, etc.

  • Page 8: Hazard Warning Signs

    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: Specifications

    SULLIVAN-PALATEK be the “lead” machine and the reciprocating the “lag” machine. That is, the SULLIVAN-PALATEK should be the first to start and the last to stop when being operated in the “automatic stop/start” mode, or the first to load and the last to unload, when in the “continuous run”...

  • Page 10: Description

    MOTOR The electric motor used to power each SULLIVAN-PALATEK UD Series 125/250 horsepower compressor is a NEMA special inverter duty 3 phase motor, fitted with a C-face register at the compressor drive end to assure proper coupling alignment at all times. The main compressor motor is connectable for 460 volts.
  • Page 11 __________________________________SULLIVAN-PALATEK VARIABLE SPEED OPERATION: The compressor will operate @ varying speeds depending on the signal from the line pressure transducer. This operating speed will vary from a maximum speed (set at the factory), and will try to maintain a constant line pressure (this is the control pressure setting on the T1 micro processor control). If air usage is very low, once the unload pressure setting is reached, the compressor will shut off.

  • Page 12: Compressor Lubrication/Cooling System

    SULLIVAN-PALATEK__________________________________ COMPRESSOR LUBRICATION/COOLING SYSTEM The cooling system consists of a fan, variable speed fan motor, finned-tube radiator-type fluid cooler, & thermovalve to accelerate warm-up, 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 13: Compressor Discharge System

    __________________________________SULLIVAN-PALATEK COMPRESSOR DISCHARGE SYSTEM The compressor unit discharges a mixture of compressed air and lubricoolant directly into the oil separation tank where it accomplishes the following three functions: A) Primary separation - by change of direction and reduction of velocity, this allows the heavier droplets of lubricoolant to drop out of the air stream.

  • Page 14: Variable Frequency Drive And Electrical Parts

    & cooler. VARIABLE FREQUENCY DRIVE AND ELECTRICAL PARTS The three-phase electric motor drive supplied with the SULLIVAN-PALATEK Plant Air Compressor has a NEMA-1 rated enclosure. A separate control box contains: the control power transformer, the 24 volt power supply for the micro processor control, the control pressure transducers, and fan motor disconnect fuses.

  • Page 15: 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 125UD 150UD 200UD 250UD MAX.

  • Page 16: Wiring Diagram, Yaskawa F7 Updraft Air Cooled

    SULLIVAN-PALATEK__________________________________ WIRING DIAGRAM, YASKAWA F7 UPDRAFT AIR COOLED VFD1 DISC101 YASKAWA F7 MAIN MOTOR DRIVE FUSIBLE DISCONNECT SWITCH BY CUSTOMER OPTIONAL E-Stop (2) THERMAL OVERLOAD OPTIONAL Line Reactor SN S6 SN S3 MC MB S1 SN POWER SUPPLY 32 31 3 phase To S1 X03 60 Hz...

  • Page 17: Wiring Diagram, Yaskawa F7 Updraft Water Cooled

    __________________________________SULLIVAN-PALATEK WIRING DIAGRAM, YASKAWA F7 UPDRAFT WATER COOLED VFD1 DISC101 YASKAWA F7 FUSIBLE DISCONNECT SWITCH MAIN MOTOR DRIVE BY CUSTOMER E-Stop (2) OPTIONAL THERMAL OVERLOAD OPTIONAL Line Reactor SN S6 SN S3 MC MB S1 SN POWER SUPPLY 3 phase To T1 X03 60 Hz M1 M2...

  • Page 18: Direction Of Rotation

    SULLIVAN-PALATEK__________________________________ DIRECTION OF ROTATION Once the control circuit has been checked, all piping installed, and compressors is filled with lubricoolant, push the ‘run’ key (green) and observe the direction of rotation. If rotation direction is incorrect, push the emergency stop button. Change two motor leads if rotation is incorrect. Incorrect rotation is only possible if the motor was disconnected.

  • Page 19: Operation

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

  • Page 20: Normal Operation

    SULLIVAN-PALATEK__________________________________ NORMAL OPERATION 1. Open and lock out main power disconnect. 2. Check lubricoolant level. Refill if necessary. 3. Re-close disconnect switch. Micro processor will illuminate indicating compressor is ready to start. Fully open service air valve. 5. Start machine by pressing ‘run’ button on micro processor. Observe pressure and temperature.

  • Page 21: Maintenance

    __________________________________SULLIVAN-PALATEK SECTION 6 MAINTENANCE MAINTENANCE SCHEDULE DAILY  Check lubricoolant level prior to start-up  Check micro processor for any fault or alarm codes (see 5.2 instructions).  Keeping a daily log of all operating parameters is recommended. FIRST 50 HOURS ...

  • Page 22: Oil Filter

    SULLIVAN-PALATEK__________________________________ OIL FILTER Replace if differential pressure exceeds 15psid (fault, H6 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 23: Pressure Adjustment

    __________________________________SULLIVAN-PALATEK PRESSURE ADJUSTMENT To change the load and unload pressures, or to see the fault history press the + and - keys simultaneously. Use the + or - keys to set the code to 0009. Use the ENTER key to move forward a digit and to enter when complete.

  • Page 24: 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. Fault condition. See microprocessor for fault. Press reset to clear faults. SYMPTOM PROBABLE CAUSES AND REMEDIES B.
  • Page 25 __________________________________SULLIVAN-PALATEK TROUBLESHOOTING (CONTINUED…) SYMPTOM PROBABLE CAUSES AND REMEDIES C. MACHINE WILL NOT BUILD UP FULL 1. Air demand too great. Repair system air leaks. DISCHARGE PRESSURE Add compressor capacity to satisfy demand. 2. Dirty air filter. Change or clean element if required.
  • Page 26 SULLIVAN-PALATEK__________________________________ NOTES:...
  • Page 27 __________________________________SULLIVAN-PALATEK PARTS LISTING...

  • Page 28: 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. A re-manufactured air- end has a warranty which is 12 months from start up date or 18 months from date of shipment in accordance with the terms set forth in the new air-end warranty found in SECTION 8.

  • Page 29: 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 West U.S. Highway 20 Michigan City, IN 46360 Telephone: 219-874-2497 Fax: 219-872-5043 E-mail: info@palatek.com...
  • Page 30 SULLIVAN-PALATEK__________________________________ DRIVE AND BASE ASSEMBLY – 125-250UD...

  • Page 31: Drive And Base Assembly - 125-250Ud

    __________________________________SULLIVAN-PALATEK DRIVE AND BASE ASSEMBLY – 125-250UD...
  • Page 32 SULLIVAN-PALATEK__________________________________ LUBRICATION AND COOLING SYSTEM – AIR COOLED – 125-250UD...

  • Page 33: Lubrication And Cooling System - Air Cooled - 125-250Ud

    __________________________________SULLIVAN-PALATEK LUBRICATION AND COOLING SYSTEM – AIR COOLED – 125-250UD ITEM 125/150UD 200/250UD DESCRIPTION 07711-016 07711-015 COOLER, OIL/AIR 90659-131 90659-131 O-RING, VITON 08207-009 08207-009 HOUSING, BY-PASS 09505-008 09505-008 VALVE, THERMOSTAT 165-185 90115-113 90115-113 BOLT, HEX 3/8 X 3.500 93115-013 93115-013 BOLT, WHIZ 3/8 X 1.000 00520-008 00520-008...
  • Page 34 SULLIVAN-PALATEK__________________________________ LUBRICATION AND COOLING SYSTEM – WATER COOLED – 125-150UD...

  • Page 35: Lubrication And Cooling System - Water Cooled - 125-150Ud

    __________________________________SULLIVAN-PALATEK LUBRICATION AND COOLING SYSTEM – WATER COOLED – 125-150UD ITEM PART NUMBER DESCRIPTION 18338-020 VALVE, WATER REGULATING 92469-133 NIPPLE, PIPE - 1-1/4 X 4" 91163-021 BUSHING, REDUCING GALV 1.5 X 1.25 95329-055 TEE, REDUCING 2 X 1/2 X 2 92466-153 NIPPLE, 2 X 4-1/2 94182-019...
  • Page 36 SULLIVAN-PALATEK__________________________________ LUBRICATION AND COOLING SYSTEM – WATER COOLED – 200-250UD...

  • Page 37: Lubrication And Cooling System - Water Cooled - 200-250Ud

    __________________________________SULLIVAN-PALATEK LUBRICATION AND COOLING SYSTEM – WATER COOLED – 200-250UD ITEM 200UD 250UD DESCRIPTION 18338-020 18338-020 VALVE, WATER REGULATING 92469-097 92469-097 NIPPLE, PIPE - 1-1/4 X 3" 91163-021 91163-021 BUSHING, REDUCING GALV 1.5 X 1.25 95329-055 95329-055 TEE, REDUCING 2 X 1/2 X 2 92466-153 92466-153 NIPPLE, 2 X 4-1/2...
  • Page 38 SULLIVAN-PALATEK__________________________________ INLET AND CAPACITY CONTROL SYSTEM – 125-250UD...

  • Page 39: Inlet And Capacity Control System - 125-250Ud

    __________________________________SULLIVAN-PALATEK INLET AND CAPACITY CONTROL SYSTEM – 125-250UD *Item #14 – Recommend Rebuilding Inlet Valve with K09790-005 Kit every 2 Years.
  • Page 40 SULLIVAN-PALATEK__________________________________ DISCHARGE SYSTEM – 125-150UD...

  • Page 41: Discharge System - 125-150Ud

    __________________________________SULLIVAN-PALATEK DISCHARGE SYSTEM – 125-150UD 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 FITTING, SIPHON .250 00547-001...
  • Page 42 SULLIVAN-PALATEK__________________________________ DISCHARGE SYSTEM – 200-250UD...

  • Page 43: Discharge System - 200-250Ud

    __________________________________SULLIVAN-PALATEK DISCHARGE SYSTEM – 200-250UD 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 00547-001...
  • Page 44 SULLIVAN-PALATEK__________________________________ MICROPROCESSOR CONTROL – OPEN – 125-250UD...

  • Page 45: Microprocessor Control - Open - 125-250Ud

    __________________________________SULLIVAN-PALATEK 7.10 MICROPROCESSOR CONTROL – OPEN – 125-250UD...
  • Page 46 SULLIVAN-PALATEK__________________________________ MICROPROCESSOR CONTROL – ENCLOSED – 125-250UD...

  • Page 47: Microprocessor Control - Enclosed - 125-250Ud

    __________________________________SULLIVAN-PALATEK 7.11 MICROPROCESSOR CONTROL – ENCLOSED – 125-250UD ITEM DESCRIPTION PART NUMBER MICROPROCESSOR, CONTROL T1 69671-010 CONNECTOR SET, MICROPROCESSOR 69674-006 BOLT, SERRATED HEAD 1/4 X .500 93115-387 DECAL, INSTRUCTION MICROPROCESSOR 08378-053 PANEL, INSTRUMENT 40-400UD NRM 00944-027 WEATHERSTRIP, 1.000 X .125 (UOM = FT) 09870-004 ENCLOSURE, 8 X 8 X 4 00543-088...
  • Page 48 SULLIVAN-PALATEK__________________________________ ENCLOSURE – AIR COOLED – 125-250UD...

  • Page 49: Enclosure - Air Cooled - 125-250Ud

    __________________________________SULLIVAN-PALATEK 7.12 ENCLOSURE – AIR COOLED – 125-250UD ITEM PART NUMBER DESCRIPTION 10947-044 PANEL, SUMP END RH 10947-046 PANEL, SUMP END CENTER 10947-043 PANEL, SUMP END LH 00488-026 DOOR, ENCL SIDE 10947-081 PANEL, SIDE SUPPORT/INST 00488-025 DOOR, ENCL SIDE 10947-041 PANEL, SIDE SUPPORT 10947-039 PANEL, CORNER MOTOR END...
  • Page 50 SULLIVAN-PALATEK__________________________________ ENCLOSURE – AIR COOLED – 200-250UD...

  • Page 51: Enclosure - Air Cooled - 200-250Ud

    __________________________________SULLIVAN-PALATEK 7.13 ENCLOSURE – AIR COOLED – 200-250UD ITEM PART NUMBER DESCRIPTION 10947-058 PANEL, SUMP END RH 10947-046 PANEL, SUMP END CENTER 10947-043 PANEL, SUMP END LH 00488-026 DOOR, ENCL SIDE 10947-081 PANEL, SIDE SUPPORT/INST 00488-025 DOOR, ENCL SIDE 10947-041 PANEL, SIDE SUPPORT 10947-039 PANEL, CORNER MOTOR END...
  • Page 52 SULLIVAN-PALATEK__________________________________ ENCLOSURE – WATER COOLED – 125-250UD...

  • Page 53: Enclosure - Water Cooled - 125-250Ud

    __________________________________SULLIVAN-PALATEK 7.14 ENCLOSURE – WATER COOLED – 125-250UD ITEM PART NUMBER DESCRIPTION 10947-044 PANEL, SUMP END RH 10947-052 PANEL, SUMP END CENTER 10947-043 PANEL, SUMP END LH 00488-026 DOOR, ENCL SIDE 10947-081 PANEL, SIDE SUPPORT/INST 00488-025 DOOR, ENCL SIDE 10947-041 PANEL, SIDE SUPPORT 10947-039 PANEL, CORNER MOTOR END...

  • Page 54: Decal, T1 Instructions Yaskawa

    SULLIVAN-PALATEK__________________________________ 7.15 DECAL, T1 INSTRUCTIONS YASKAWA...

  • Page 55: Warranty

    Purchaser’s Responsibility: Performance of proper maintenance as indicated in the Operation Manual furnished with the compressor, a copy of which is made a part of this contract. Provide any claim for warranty in writing to Sullivan-Palatek within the warranty period. The purchaser is also responsible for the following: the cost of normal maintenance and maintenance items, the...
  • Page 56 Extended Warranty requires that the purchaser use Sullivan-Palatek brand compressor lubricant, filters and service parts obtained from Sullivan-Palatek or one of its authorized distributors or service outlets. Proof of compliance with these terms must be available and rendered upon request in the event of a claim under this warranty. To facilitate and ensure purchaser’s compliance with the...

  • Page 57: General Arrangement Drawing

    __________________________________SULLIVAN-PALATEK SECTION 9 GENERAL ARRANGEMENT DRAWING PIPING AND INSTALLATION DIAGRAM – 125-150UD...

  • Page 58: Piping And Installation Diagram - 200-250Ud

    SULLIVAN-PALATEK__________________________________ PIPING AND INSTALLATION DIAGRAM – 200-250UD...

  • Page 59: General Arrangement - Air Cooled - Open - 125-250Ud

    __________________________________SULLIVAN-PALATEK GENERAL ARRANGEMENT – AIR COOLED – OPEN – 125-250UD...

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

    SULLIVAN-PALATEK__________________________________ GENERAL ARRANGEMENT – AIR COOLED – ENCLOSED – 125-150UD...

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

    __________________________________SULLIVAN-PALATEK GENERAL ARRANGEMENT – AIR COOLED – ENCLOSED – 200-250UD...

  • Page 62: General Arrangement - Water Cooled - Open - 125-250Ud

    SULLIVAN-PALATEK__________________________________ GENERAL ARRANGEMENT – WATER COOLED – OPEN – 125-250UD...

  • Page 63: General Arrangement - Water Cooled - Enclosed - 125-250Ud

    __________________________________SULLIVAN-PALATEK GENERAL ARRANGEMENT – WATER COOLED – ENCLOSED – 125-250UD...

  • Page 64: 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  AIR/OIL  SEP  NUMBER  FILTER                                             ...

This manual is also suitable for:

150ud200ud250ud

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