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Summary of Contents for Sullivan-Palatek 75G
- Page 1 OPERATING AND PARTS MANUAL INDUSTRIAL ELECTRIC AIR COMPRESSORS 75UDS AND 100UDS HP MODELS PALATEK, INC. dba SULLIVAN-PALATEK MICHIGAN CITY, IN 46360 ALL RIGHTS RESERVED COPYRIGHT 1994 10/03 Part Number: OPM7510-006S...
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Page 2: Table Of Contents
SULLIVAN-PALATEK_____________________________________ TABLE OF CONTENTS SECTION 1 - SAFETY ........................4 GENERAL ......................... 4 PRESSURE RELEASE ..................... 4 FIRES/EXPLOSIONS ....................... 5 MOVING PARTS ....................... 5 PHYSICAL DANGERS ...................... 6 TOXICITY .......................... 6 ELECTRIC SHOCK ......................6 LIFTING ..........................6 AUTOMATIC START ......................7 1.10 NOISE .......................... - Page 3 _____________________________________SULLIVAN-PALATEK SECTION 6 – MAINTENANCE ..................... 22 MAINTENANCE SCHEDULE ..................22 OIL FILTER ..22 1000 EPLACE ELEMENT IF DIFFERENTIAL PRESSURE EXCEEDS PSID OR EVERY HOURS AIR FILTER (I 1000 .) ..23 NSPECT EVERY HRS OR SOONER IN SEVERE DUST CONDITIONS AIR/OIL SEPARATOR ..
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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 can be 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 5: Fires/Explosions
_____________________________________SULLIVAN-PALATEK Compressed air filters or lubricators with plastic bowls should not be used. Steel bowls are recommended. Keep personnel out of line with, and away from, the discharge opening of air lines, or tools, or other areas of direct, or deflected, compressed air discharge. Do not allow anyone to engage in horseplay with air hoses as serious bodily injury or death may result. -
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: Automatic Start
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 to minimize risk of injury or death. All operators must be aware of the Warning Signs and follow the instructions thereon. -
Page 8: Section 2 - Specifications
SULLIVAN-PALATEK_____________________________________ SIGN LOCATION WARNING - HIGH VOLTAGE/MOVING PARTS MOTOR STARTER WARNING - COMPRESSED AIR INSTRUMENT PANEL WARNING - HOT OIL/PRESSURIZED AIR SEPARATOR TANK SECTION 2 - SPECIFICATIONS MODEL 100G 100D MOTOR SIZE (HP) AIR DELIVER (CFM) MAX. FULL LOAD PRESSURE MIN. -
Page 9: Data And Dimensions
_____________________________________SULLIVAN-PALATEK DATA AND DIMENSIONS SULLIVAN-PALATEK reserves the right to change the design or construction of the above compressor, 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
MOTOR The standard motor used to power the SULLIVAN-PALATEK 75 and 100 H.P. compressor is a C-face ODP E-pack premium efficiency motor. Other motors such as TEFC are available upon request. -
Page 11: Intake/Control System
_____________________________________SULLIVAN-PALATEK INTAKE/CONTROL SYSTEM The intake/control system consists of: an air filter, inlet control valve with a reverse flow check valve incorporated, a modulating or regulating signal pressure control valve, a control pressure switch, a combination unloading/blowdown solenoid valve, and a reverse rotation switch. - Page 12 SULLIVAN-PALATEK_____________________________________ CONTROL SCHEMATIC...
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Page 13: Compressor Lubrication/Cooling System
_____________________________________SULLIVAN-PALATEK COMPRESSOR LUBRICATION/COOLING SYSTEM The cooling system consists of a fan, finned-tubed radiator-type fluid cooler, cooler by-pass valve to accelerate warm-up, a full-flow fluid filter, a drain valve and interconnecting tubing. Pressure in the oil separation tank 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: 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, which allows the heavier droplets of lubricoolant to drop out. -
Page 15: Starter And Electrical Parts
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 enclosure is also the location of: the... - Page 16 SULLIVAN-PALATEK_____________________________________...
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Page 17: Instrumentation
INSTRUMENTATION Each SULLIVAN-PALATEK Plant Air Compressor is equipped with an hourmeter and five gauges. There is one pressure gauge to monitor the oil separation tank pressure, another to monitor line pressure, and a temperature gauge which senses compressor discharge temperature. -
Page 18: Section 4 - Installation
SULLIVAN-PALATEK_____________________________________ SECTION 4 - INSTALLATION RECEIVING Carefully inspect for any signs of possible shipping damage. 4.1a Welding Do not weld on compressor package. LOCATION The compressor is designed for indoor operation or protected outdoor site with an ambient temperature range of 35° to 104° F (1° to 40° C). It is important that there be sufficient unobstructed ventilating airflow to prevent re-circulation of hot fan air. -
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, connect the three motor leads, momentarily move the selector switch to “Run” then immediately back to “Off/Reset” to check for proper direction of rotation. Rotation should be clockwise when standing at the oil separation tank end, and counter-clockwise from the motor end. -
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 1. Open main disconnect to be sure there is no power to the compressor. -
Page 21: 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 4. Start machine in either “Run” or “Auto Start/Stop” mode. 5. Fully open service air valve. 6. Observe pressures and temperature. If temperature is incorrect, refer SECTION 6.8 - TROUBLE SHOOTING. -
Page 22: Section 6 - Maintenance
SULLIVAN-PALATEK_____________________________________ SECTION 6 – MAINTENANCE MAINTENANCE SCHEDULE Daily - 1. Check lubricoolant level prior to start-up. 2. Observe the instrument panel gauges. 3. Keeping a daily log of all operating parameters is recommended. First 50 hours 1. Change compressor lubricoolant filter element. Every 1000 hours - 1. -
Page 23: Air Filter (Inspect Every 1000 Hrs Or Sooner In Severe Dust Conditions.)
_____________________________________SULLIVAN-PALATEK AIR FILTER (Inspect every 1000 hrs or sooner in severe dust conditions.) Open and lock out main disconnect. Remove air filter element . Blow dust from inside towards outside with low pressure air (less than 30 psi/200 kPa). When reinstalling element be sure it is seated squarely so that dust cannot bypass the filter media. -
Page 24: Pressure Adjustment
SULLIVAN-PALATEK_____________________________________ PRESSURE ADJUSTMENT Only the throttling and unload or cut-out/automatic stop pressure can be adjusted. If the plant air service main pressure falls when the compressor is running at full load, more air is being used than the compressor can supply. To raise the pressure at which intake throttling occurs, loosen jam nut on control regulator valve and turn adjustment screw clockwise. - Page 25 _____________________________________SULLIVAN-PALATEK SYMPTON PROBABLE CAUSES AND REMEDY 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 overloads.
- Page 26 SULLIVAN-PALATEK_____________________________________ 100-110° F (55-61° C) above ambient; switch is set to trip at 235-245°F (112- 118°C). a. Cooling air flow restricted. Clean cooler and check for proper ventilation. b. Ambient temperature is too high. Provide sufficient ventilation. c. Low lubricoolant level. Add lubricoolant. d.
- Page 27 _____________________________________SULLIVAN-PALATEK 3. Improperly adjusted or defective regulator. Readjust or replace if necessary. 4. Defective blowdown valve. Check that sump pressure is exhausted to the atmosphere when unloader pilot valve opens. Replace if necessary. 5. High pressure shutdown switch is defective. Replace. 6.
- Page 28 SULLIVAN-PALATEK_____________________________________ PARTS LISTING...
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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, seals and substandard parts have been replaced. All other parts are inspected to meet our quality standards. The air- end is then factory tested prior to shipment. -
Page 30: Section 7 - Parts List
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 3501 W. DUNES HWY. MICHIGAN CITY, IN 46360 TELEPHONE: 219-874-2497 FAX: 219-872-5043 E-mail: jrissman@palatek.com... -
Page 31: 7.3 Lubrication And Cooling System Uds
_____________________________________SULLIVAN-PALATEK 7.3 LUBRICATION AND COOLING SYSTEM UDS *REQUIRED FOR ENCLOSED COMPRESSOR PACKAGE ONLY. Water Cooled Machines: 75 hp 100 hp Oil Cooler #00549-004 Oil Cooler #00549-005 After Cooler #00549-005 After Cooler #00549-008 Water Reg. Valve #18338-020 Water Reg. Valve #18338-020... - Page 32 SULLIVAN-PALATEK_____________________________________ LUBRICATION AND COOLING SYSTEM UDS...
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Page 33: 7.4 Motor, Compressor And Mounting Parts - Base Mounted Uds
_____________________________________SULLIVAN-PALATEK 7.4 MOTOR, COMPRESSOR AND MOUNTING PARTS - BASE MOUNTED UDS 75HP MOTOR 100HP MOTOR #08741-075 #08741-100 TEFC #08747-075 TEFC #08747-100... - Page 34 SULLIVAN-PALATEK_____________________________________ MOTOR, COMPRESSOR AND MOUNTING PARTS – BASE MOUNTED UDS...
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Page 35: 7.5 Intake And Capacity Control System Uds
_____________________________________SULLIVAN-PALATEK 7.5 INTAKE AND CAPACITY CONTROL SYSTEM UDS... - Page 36 SULLIVAN-PALATEK_____________________________________ INTAKE AND CAPACITY CONTROL SYSTEM UDS...
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Page 37: Discharge System Uds
_____________________________________SULLIVAN-PALATEK DISCHARGE SYSTEM UDS ~ Use Lithium Grease to Service MPC. - Page 38 SULLIVAN-PALATEK_____________________________________ DISCHARGE SYSTEM UDS...
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Page 39: Gauge Panel And Electrical Parts Uds
_____________________________________SULLIVAN-PALATEK GAUGE PANEL AND ELECTRICAL PARTS UDS * FOR HIGH PRESSURE MACHINES (OVER 150 PSIG., USE 09345-012) ** FOR LOW PRESSURE MACHINES (I.E.<75PSIG) 09344-000... - Page 40 SULLIVAN-PALATEK_____________________________________ GAUGE PANEL AND ELECTRICAL PARTS UDS...
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Page 41: Enclosure - Air Cooled Ud
_____________________________________SULLIVAN-PALATEK ENCLOSURE – AIR COOLED UDS... - Page 42 SULLIVAN-PALATEK_____________________________________ ENCLOSURE – AIR COOLED UDS...
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Page 43: Enclosure - Water Cooled Ud
_____________________________________SULLIVAN-PALATEK ENCLOSURE – WATER COOLED UDS *WATER COOLED VENT FAN P.N. 18080-016 1 QUANTITY NOT SHOWN ON DRAWING. - Page 44 SULLIVAN-PALATEK_____________________________________ ENCLOSURE – WATER COOLED UDS...
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Page 45: Decal And Identification
_____________________________________SULLIVAN-PALATEK 7.10 DECAL AND IDENTIFICATION ITEM DESCRIPTION MODEL 75 UD MODEL 100UD PLATE, NAME/S.N. 03832-043 03832-043 DECAL, VOLTAGE 460 08377-001 08377-001 DECAL, WARNING 08377-043 08377-043 DECAL, WARNING 08377-045 08377-045 DECAL, WARNING 08377-046 08377-046 DECAL, 3-POSITION SWITCH 08378-048 08378-048 DECAL, INSTRUCTIONS 08379-011 08379-011 DIAGRAM, WIRING... -
Page 46: Section 8 - Warranty
Sullivan-Palatek’s Obligations: Sullivan-Palatek’s exclusive obligations with respect to breach of warranty are (I) to repair or replace (at Sullivan-Palatek option and subject to return of defective parts) any defective part, (ii) to pay the reasonable cost of making the repair, or installing the replacement part (iii) to pay ground freight for the return of defective parts and shipment of replacement parts. -
Page 47: Maintenance Log
_____________________________________SULLIVAN-PALATEK MAINTENANCE LOG DATE HOURMETER AIR-OIL LINE SUMP RETURN AIR/OIL SERVICED READING TEMP. PRES. PRES. CLEAR FULL LEVEL FILTER SEP. FILTER... - Page 48 SULLIVAN-PALATEK_____________________________________ INSTALL – OPEN - DWG...
- Page 49 _____________________________________SULLIVAN-PALATEK INSTALL – ENCLOSED – DWG...
- Page 50 SULLIVAN-PALATEK_____________________________________...
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