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Summary of Contents for Sullivan-Palatek 75UDS
- 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 2/05 Part Number: OPM7510-006S...
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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 LIFTING .......................... - Page 3 _____________________________________SULLIVAN-PALATEK SECTION 6 - MAINTENANCE ...................... 22 6.1 MAINTENANCE SCHEDULE ....................22 6.2 OIL FILTER (R 1000 H .) .. 23 EPLACE IF DIFFERENTIAL PRESSURE EXCEEDS PSID OR EVERY 6.3 AIR FILTER (I 1000 ) ... 23 NSPECT EVERY HOURS OR SOONER IN SEVERE DUST CONDITIONS 6.4 AIR/OIL SEPARATOR (R ) 23 EPLACE ANNUALLY OR IF DIFFERENTIAL PRESSURE EXCEEDS...
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Page 4: Section 1 - Safety
SECTION 1 - SAFETY 1.1 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_____________________________________ 1.5 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 1.8 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. -
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
SEE INSTALLATION DRAWINGS ON PAGES 49 - 52 OF THIS MANUAL 2.1 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
For instrument-grade air, contact the factory for recommendations related to specialized compressed air preparation accessories. Whenever a SULLIVAN-PALATEK rotary screw compressor is installed in parallel with a reciprocating type of compressor, it is imperative that the SULLIVAN-PALATEK be the “lead”... -
Page 11: Intake/Control System
_____________________________________SULLIVAN-PALATEK 3.4 INTAKE/CONTROL SYSTEM The intake/control system consists of: an air filter, connecting rubber elbow, clamps, a combination compressor inlet valve/reverse-flow check valve, control signal regulator valve, blowdown valve, and control pressure switch. (See Intake Control Schematic.) The air filter is a multi-stage dry-type with a high efficiency cleanable/replaceable cellulose element. -
Page 12: Compressor Lubrication/Cooling System
SULLIVAN-PALATEK_____________________________________ With the selector switch in the “Run” position, the shutdown function of the control pressure switch is by-passed and the motor continues to run in an unloaded condition. With the resumption of plant air usage, the line pressure reduces to the “cut-in” setting of the control pressure switch where it closes. -
Page 13: Compressor Discharge System
_____________________________________SULLIVAN-PALATEK 3.6 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 fall. -
Page 14: Starter And Electrical Parts
SULLIVAN-PALATEK_____________________________________ 3.7 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 Run-Off/Reset-Auto Start selector switch, a control relay, the... -
Page 15: Instrumentation
_____________________________________SULLIVAN-PALATEK 3.8 INSTRUMENTATION Each SULLIVAN-PALATEK Plant Air Compressor is equipped with two pressure gauges, one to monitor the oil separation tank pressure and another to measure line pressure. There is a temperature gauge that senses compressor discharge temperature. In addition, there are two differential pressure gauges sensing the pressure drop across the oil filter and the separator element. -
Page 16: Section 4 - Installation
SULLIVAN-PALATEK_____________________________________ SECTION 4 - INSTALLATION 4.1 RECEIVING Carefully inspect for any signs of possible shipping damage 4.1a WELDING WARNING: Do not weld on compressor package. 4.2 LOCATION The standard compressor is designed for indoor operation or protected outdoor site with an ambient temperature range of 35°... -
Page 17: Wiring Diagram Y-Delta Start (Optional)
_____________________________________SULLIVAN-PALATEK 4.5a WIRING DIAGRAM Y-DELTA START (OPTIONAL) -
Page 18: Direction Of Rotation
SULLIVAN-PALATEK_____________________________________ 4.6 DIRECTION OF ROTATION Once the control circuit has been checked, all piping installed, and compressor is filled with lubricoolant, “jog” the motor by momentarily moving the selector switch to “Run”... -
Page 19: Compressed Air Piping
_____________________________________SULLIVAN-PALATEK then immediately back to “Off/Reset” to check for proper direction of rotation. Rotation should be as shown on the unit. In all cases, the fan air blows upwards. 4.7 COMPRESSED AIR PIPING Connect the compressor to the plant air system with a flexible connector rated for at least 200 psi (1380 kPa) and 275°... -
Page 20: Section 5 - Operation
SULLIVAN-PALATEK_____________________________________ SECTION 5 - OPERATION 5.1 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. 5.2 INITIAL START Open main disconnect to be sure there is no power to the compressor. -
Page 21: Normal Operation
_____________________________________SULLIVAN-PALATEK 5.3 NORMAL OPERATION Open and lock out main power disconnect. Check lubricoolant level. Refill if necessary. Re-close disconnect switch. Start machine in either “Run” or “Auto Start/Stop” mode. Fully open service air valve. Observe pressure and temperature. If temperature is incorrect, refer to SECTION 6.6 - TROUBLE SHOOTING. -
Page 22: Section 6 - Maintenance
SULLIVAN-PALATEK_____________________________________ SECTION 6 - MAINTENANCE 6.1 MAINTENANCE SCHEDULE Daily -1. Check lubricoolant level prior to start-up 2. Drain condensate from auxiliary tank. 3. Observe the instrument panel gauges. 4. Keeping a daily log of all operating parameters is recommended. First 50 hours - Change compressor lubricoolant filter element. Every 1,000 hours -1. -
Page 23: Oil Filter (Replace If Differential Pressure Exceeds 15Psid Or Every 1000 Hrs.)
_____________________________________SULLIVAN-PALATEK 6.2 OIL FILTER (Replace if differential pressure exceeds 15psid 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 elements. 4. Spread a thin film of grease on the gasket. 5. -
Page 24: Pressure Adjustment
SULLIVAN-PALATEK_____________________________________ 6.5 PRESSURE ADJUSTMENT Two capacity control features are incorporated in the Sullivan-Palatek compressors. The control pressure switch (CPS) will cycle the compressor between loaded and unloaded operation. This switch should be set so that the compressor loads when the... - Page 25 _____________________________________SULLIVAN-PALATEK 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_____________________________________ 6.6 TROUBLESHOOTING, CON’T. SYMPTOM PROBABLE CAUSES AND REMEDIES B. MACHINE SHUTS DOWN WITH AIR 4. Discharge temperature switch open. DEMAND PRESENT Monitor temperature gauge readings: normal discharge temperature should be 100-110° F (37-43° C) above ambient; switch is set to trip at 235-245°F (112- 118°C).
- Page 27 _____________________________________SULLIVAN-PALATEK 6.6 TROUBLESHOOTING, CON’T. SYMPTOM PROBABLE CAUSES AND REMEDIES D. LINE PRESSURE RISES ABOVE CUT- OUT PRESSURE 1. Leak in control system causing loss of pressure signal. Replace tubing/repair leak. 2. Defective pressure switch. Replace switch. 3. Improperly adjusted or defective regulator. Readjust or replace if necessary.
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Page 28: Parts Listing
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, 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
7.1 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: Lubrication And Cooling System Uds
_____________________________________SULLIVAN-PALATEK 7.3 LUBRICATION AND COOLING SYSTEM UDS 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: Motor, Compressor & Mounting Parts - Base Mounted Uds
_____________________________________SULLIVAN-PALATEK 7.4 MOTOR, COMPRESSOR & 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: 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 7.6 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 7.7 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 Uds
_____________________________________SULLIVAN-PALATEK 7.8 ENCLOSURE – AIR COOLED UDS... - Page 42 SULLIVAN-PALATEK_____________________________________ ENCLOSURE – AIR COOLED UDS...
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Page 43: Enclosure - Water Cooled Uds
_____________________________________SULLIVAN-PALATEK 7.9 ENCLOSURE – WATER COOLED UDS *WATER COOLED VENT FAN P.N. 18080-016 1 QUANTITY NOT SHOWN ON DRAWING. ENCLOSURE – WATER COOLED UDS... -
Page 44: Decal And Identification
SULLIVAN-PALATEK_____________________________________ 7.10 DECAL AND IDENTIFICATION ITEM DESCRIPTION MODEL 75 UD MODEL 100UD... -
Page 45: Section 8 - Warranty
SECTION 8 – WARRANTY Sullivan-Palatek New Industrial Compressors- 15 and greater Horsepower Sullivan-Palatek warrants its new stationary industrial air compressor products to be free from defects in material and workmanship and against loss of capacity due to wear, subject to the following provisions:... -
Page 46: Maintenance Log
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 _____________________________________SULLIVAN-PALATEK...
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