Related Manuals for Sullair DE-18 Series
Summary of Contents for Sullair DE-18 Series
- Page 1 OIL-FREE AIR COMPRESSOR DE-18 Series 1500 cfm OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250121-603 ©Sullair Corporation...
- Page 2 Sullair Air Care Seminars are 3-day courses that provide hands-on instruction in the proper operation, mainte- nance 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.
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Page 3: Table Of Contents
INSTALLATION 2.1 MOUNTING OF COMPRESSOR 2.2 VENTILATION AND COOLING 2.3 SERVICE AIR CONDENSATE PIPING 2.4 FLUID LEVEL CHECK Section 3 SPECIFICATIONS 3.1 DE-18 SERIES COMPRESSOR PACKAGE 3.2 LUBRICATION GUIDE Section 4 COMPRESSOR SYSTEMS 4.1 INTRODUCTION 4.2 DESCRIPTION OF COMPONENTS 4.3 COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION 4.4 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION... - Page 4 TABLE OF CONTENTS (CONT.) Section 5 CONTROLLER 5.3.1 EMS 547 (Continued) 5.3.2 MDDM 5.4 PARAMETER SET-UP TABLE 5-1 PROGRAM NUMBERS 5.5 WARNING/SHUTDOWN 5.6 COMMUNICATIONS TABLE 5-2 CONTROLLER RESPONSES Section 6 COMPRESSOR OPERATION 6.1 GENERAL 6.2 PURPOSE OF CONTROLS 6.3 STARTING SEQUENCE 6.4 WARM-UP CYCLE 6.5 RUNNING SEQUENCE 6.6 NORMAL STOPPING SEQUENCE...
- Page 5 TABLE OF CONTENTS (CONT.) Section 9 PARTS LIST 9.1 PROCEDURE FOR ORDERING PARTS 9.2 RECOMMENDED SPARE PARTS LIST...
- Page 6 NOTES...
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Page 7: General
Section 1 SAFETY 1.1 GENERAL equipment. Sullair Corporation and its subsidiaries designs and 1.3 PRESSURE RELEASE manufactures all of its products so they can be A. Install an appropriate flow-limiting valve between operated safely. However, the responsibility for the service air outlet and the shut-off (throttle) -
Page 8: Fire And Explosion
Section 1 SAFETY sible, ground the compressor to the dispenser prior J. Use air at pressures less than 30 psig (2.1 barg) to refueling. for cleaning purposes, and then only with effective chip guarding and personal protective equipment E. Clean up spills of fuel, fluid, battery electrolyte or per OSHA Standard 29 CFR 1910.242 (b) and/or coolant immediately if such spills occur. -
Page 9: Moving Parts
Section 1 SAFETY X. Store flammable fluids and materials away from O. Keep oily rags, trash, leaves, litter or other com- your work area. Know where fire extinguishers are bustibles out of and away from the compressor. and how to use them, and for what type of fire they are intended. -
Page 10: Toxic And Irritating Substances
Section 1 SAFETY tance promptly in case of injury. DO NOT ignore eyes, they should be washed with large quantities small cuts and burns as they may lead to infection. of clean water for 15 minutes. A physician, prefer- ably any eye specialist, should be contacted imme- 1.7 TOXIC AND IRRITATING SUBSTANCES diately. -
Page 11: Entrapment
Section 1 SAFETY standards 29 CFR 1910 subpart N and/or any appli- B. Batteries may contain hydrogen gas which is cable Federal, State, and Local codes, standards flammable and explosive. Keep flames, sparks and and regulations. other sources of ignition away. B. -
Page 12: Transport And Operations
Section 1 SAFETY M. Avoid accidental contact between jumper cable S. Connect the other end of this same jumper cable terminal clips or clamps and any metallic portion of to a clean portion of the compressor engine block either the compressor or the starting vehicle to min- away from fuel lines, the crank case breather open- imize the possibility of uncontrolled arcing which ing and the battery. -
Page 13: Mounting Of Compressor
Compressor and engine/intake is located next to The compressor lube circuit is supplied with the package controller. proper charge of Sullair AWF lube oil. Two sight glasses, located at the sump end, indicate the level Package discharge (cooling air) is located on top of lubricant in the sump. - Page 14 NOTES...
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Page 15: Series Compressor Package
Fuel Capacity: 245 Gallons 3.2 LUBRICATION GUIDE severe operating conditions, such as high ambient DE-18 Series compressors are factory filled with temperatures coupled with high humidity or when Sullair AWF oil. high particulate level, corrosive gases or strong oxi- dizing gases are present in the air. - Page 16 Section 3 SPECIFICATIONS Figure 3-1A, Part 1 of 2 Typical Identification (See Figure 3-1B for Part 2) 02250121-602R02...
- Page 17 Section 3 SPECIFICATIONS Figure 3-1B, Part 2 of 2 Typical Identification (See Figure 3-1A for Part 1) 02250121-602R02...
- Page 18 NOTES...
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Page 19: Introduction
COMPRESSOR SYSTEMS 4.1 INTRODUCTION or of the sound attenuating enclosure. The con- Your DE-18 Series, rotary screw air compressor will troller assembly is easily accessible for servicing provide you with improved reliability and reduced behind a hinged and locked separate enclosure maintenance. -
Page 20: Air Inlet System, Functional Description
Section 4 COMPRESSOR SYSTEMS rigid adapter which maintains the gear box and DEFAULT STATES engine shafts in optimum alignment and allows the Default states for the inlet valve and blowdown sub- driveline assembly to be supported by soft, vibra- systems are “mostly closed” and fully open respec- tion isolating rubberized mounts. - Page 21 Section 4 COMPRESSOR SYSTEMS down valve, and therefore the blowdown valve is the pneumatic blowdown valve staying open. open. The pneumatic blowdown valve uses a FULL LOAD MODE: ≅ ≅ 70 TO 135 PSIG (4.8-9.3 mechanical spring to keep the valve open if LP pilot air is not routed to the valve’s diaphragm chamber.
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Page 22: Cooling And Silencing System, Functional Description
4.7 LUBRICATION SYSTEM, FUNCTIONAL process air will be evacuated to the silencer. DESCRIPTION 4.6 COOLING AND SILENCING SYSTEM, FUNC- Refer to Figures 4-4 and 4-5. The DE-18 Series TIONAL DESCRIPTION Compressor delivers oil-free compressed air, but it Refer to Figure 4-3A, 4-3B and 4-4. - Page 23 Section 4 COMPRESSOR SYSTEMS Figure 4-4 Piping and Instrumentation Diagram...
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Page 24: Buffer Air System, Functional Description
Section 4 COMPRESSOR SYSTEMS Figure 4-5 Lubrication System efficiency, replaceable element filter, and a multi- to avoid releasing oil vapor. The sump is vented to port manifold, where the100°F (38°C) filtered out- atmosphere via a breather which includes an oil flow is distributed to bearing and gear lubrication vapor trap. - Page 25 NOTES...
- Page 26 Section 5 CONTROLLER Figure 5-1 Control Panel...
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Page 27: Ems
Section 5 CONTROLLER 5.1 DESCRIPTION of the package. The control system consists of a Murphy EMS 547 LAMP INDICATORS engine controller and an MDDM that receives data Embedded into the front of the panel are four from a CAT 3456E diesel engine. The panel also lamps. -
Page 28: Mddm
Section 5 CONTROLLER ·Sump Oil Temperature, T6 xxx ·Coolant Temperature, xxx °F ·Engine Speed, xxx RPM ·Oil Pressure , xxx psi ·Fuel Level, xxx % ·Engine Load, xxx % ·Battery, xxx VDC ·Fuel Pressure, xxx psi ·Engine Coolant, xxx °F ·Engine Load, xxx % ·Engine Oil, xxx psi ·System Volts, xx v... - Page 29 Section 5 CONTROLLER Table 5-1 Program Numbers PROGRAM NUMBER DESCRIPTION RANGE DEFAULT SETTING P4 OFFSET -100-300 PSI P2 OFFSET -100-300 PSI P1 OFFSET -100-300 PSI P3 OFFSET -100-300 PSI S-10 T4 OFFSET -100-300 °F S-12 T1 OFFSET -100-300 °F S-14 T5 OFFSET -100-300 °F S-16...
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Page 30: Warning/Shutdown
Section 5 CONTROLLER 5.5 WARNING/SHUTDOWN connection permits the identification of one pack- Consult Table 5-2, Controller Responses. This table age as a “master” and others as “slave”. The “mas- reflects the warnings and shutdowns that the con- ter” package will control the operation of all “slave” troller will respond to. - Page 31 Section 5 CONTROLLER Table 5-2 Controller Responses CLASS SD/WA EMS DISPLAY SET POINT CAT ECM DIAGNSTC CAT SD C267 COMM FAIL lost signal MDDM COMM FAIL lost signal LST ANLG P1 SD trip point fixed @<0.63V or 32 counts. Pressure transducer or connection failure LST ANLG P2 SD trip point fixed @<0.63V or 32 counts.
- Page 32 NOTES...
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Page 33: General
Section 6 COMPRESSOR OPERATION 6.1 GENERAL While Sullair has built into the DE-18 Series com- pressor package a comprehensive array of controls The minimum continuous operating pressure is 70 psig (4.8 barg). the compressor should not and indicators to help assure proper operation, the... -
Page 34: Starting Sequence
Section 6 COMPRESSOR OPERATION 6.2 PURPOSE OF CONTROLS CONTROL OR INDICATOR PURPOSE SUMP SIGHT GLASS (CONT.) Compressor operating: Oil level should be between the upper and lower sight glasses. The compressor should not be operated with an oil level below the lower sight glass. ENGINE OIL DIPSTICK Indicates the oil level in the engine. -
Page 35: Emergency Shutdown
Section 6 COMPRESSOR OPERATION 6.7 EMERGENCY SHUTDOWN line of the EMS. In addition, the “ENGINE SHUT- Pressing either E-Stop button will immediately stop DOWN” light located on the panel will flash a code. the unit and turn off the power. A decal describing certain flash codes is attached to the panel door. - Page 36 NOTES...
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Page 37: General
Section 7 MAINTENANCE 7.1 GENERAL Figure 7-1 Pillow Block Assembly As you proceed to study this section, it will be easy to see that maintenance for the air compressor is quite minimal. The controller monitors the status of the air and oil filters. When maintenance to either device is required, the controller will display the appropriate maintenance message. -
Page 38: Maintenance Every10000 Hours
Beware to maintain proper alignment and 7.8 DIAGNOSTIC SERVICE (OPTIONAL) height. Sullair and its representatives offer a diagnostic 7.7 MAINTENANCE EVERY 16000 HOURS OR TWO service to check the condition of your compressor YEARS OF OPERATION unit. The service, which is recommended at 8000... -
Page 39: Parts Replacement And Adjustment Procedures
- this corresponds to a pressure loss condi- tion across the unit of 20 psi (1.4 barg). Your oil fil- ter includes a proprietary replaceable element (P/N 02250049-821) available solely from Sullair and its agents - DO NOT substitute. *Replacement Element P/N 02250049-821 1. -
Page 40: Condensate Drain Solenoid Valve (P/N 02250125-805) Maintenance
Section 7 MAINTENANCE the repair kit, and reinstate into position on the body Figure 7-4 Control Line Filter (P/N 02250112-032) stem. Replace baffle and tighten. 5. Loosen and remove the nut on the bottom of the bowl. 6. Remove the float assembly and seals. 7. -
Page 41: Sump Breather Filter Maintenance
Section 7 MAINTENANCE Figure 7-5 Solenoid Valve (P/N 02250125-805) 4. Remove cover bolts, cover, (or plunger tube & cover assembly) and all internal parts. 5. All parts are now accessible for cleaning or replacement. Replace worn or damaged parts. Use all parts for best results. 6. -
Page 42: Oil Sump Strainer Maintenance
Section 7 MAINTENANCE Figure 7-7 Blowdown Valve (P/N 02250119-351) tank- some 1/4” control tubing may have to be removed to provide clearance. 4. Inspect, clean, and/or replace strainer. 5. Reassemble in reverse order. 7.9.7 BLOWDOWN VALVE MAINTENANCE Refer to Figure 7-7. -
Page 43: Introduction
An example of this would Should your problem persist after making the re be the vibrations signature increase of a damaged commended check, consult your nearest Sullair bearing or the efficiency decrease of a dirty heat representative or the Sullair Corporation. - Page 44 Operated Sluggishly maintenance. Low Fan Speed Re-tension fan belt or replace if damaged. HI P1 SD Defective HP Stage Consult Sullair Service Department. Pressure Transducer Failure Check connection from transducer. If ade- quate, replace transducer. HI T3 SD Temperature Transducer Failure Check connections from transducer.
- Page 45 Blowdown Valve Leaking or Sluggish Refer to Section 7.9.7 for blowdown valve maintenance. Defective LP Stage Consult Sullair Service Department. ENGINE OVERHEATING Loose or Broken Fan Belt Tighten or change belt. Refer to the Engine Operator’s Manual for details. Dirty Radiator Core Clean thoroughly.
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Page 46: Calibration
Section 8 TROUBLESHOOTING 8.2 TROUBLESHOOTING GUIDE SYMPTOM/MESSAGE PROBABLE CAUSE REMEDY ENGINE OVERHEATING (CONT.) Faulty Low Coolant Sensor Check for leaks in coolant system. Plugged Radiator Replace engine thermostat. Refer to the Engine Operator’s Manual for details. Defective Engine Thermostat Replace engine thermostat. NOTE ON TRANSDUCERS: Whenever a sensor is ture calculations. - Page 47 Section 8 TROUBLESHOOTING 8.4 INPUTS/OUTPUTS 547 PIN INPUT SIGNAL TYPE DESCRIPTION CAPABILITY ANALOG INPUT #4 ANALOG 1-5 VDC DISCHARGE PRESSURE P2 ANALOG INPUT #0 ANALOG INTERNAL TO S547 BATTERY VOLTAGE ANALOG INPUT #7 ANALOG 1-5 VDC OIL FILTER OUT PRESSURE ANALOG INPUT #1 ANALOG 1-5 VDC...
- Page 48 Section 8 TROUBLESHOOTING 8.5 C267 INPUTS/OUTPUTS 267 PIN INPUT SIGNAL TYPE DESCRIPTION CAPABILITY J1-1 OUTPUT #7 DIGITAL TRANSISTOR NOT USED J1-2 OUTPUT #5 DIGITAL TRANSISTOR COMPRESSOR FAULT LIGHT J1-3 OUTPUT #3 DIGITAL TRANSISTOR COMPRESSOR ALARM LIGHT J1-4 OUTPUT #1 DIGITAL TRANSISTOR OIL MAKE-UP SOLENOID J1-5...
- Page 49 RECOMMENDED SPARE PARTS LIST 9.1 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, fax or phone numbers below.
- Page 50 Section 9 RECOMMENDED SPARE PARTS LIST 9.2 RECOMMENDED SPARE PARTS LIST (CONT.) DESCRIPTION KIT NUMBER QUANTITY replacement probe, RTD 100 ohm plat 3.5” 02250044-985 replacement probe, RTD 100 ohm plat 3.5” 250039-909 replacement probe, RTD 100 ohm plat 6” 02250058-087 lubricant, AWF 250030-757 5 gal.
- Page 51 NOTES...
- Page 52 WORLDWIDE SALES AND SERVICE SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A. Sullair Road, No. 1 42602 Montbrison Cedex, France Chiwan, Shekou Shenzhen, Guangdong PRV. Shenzhen, Guangdong PRV. Telephone: 33-477968470 PRC POST CODE 518068 PRC POST CODE 518068 Telephone: 755-6851686 Fax: 33-477968499...