Sullair ShopTek ST30 Operation & Maintenance Manual
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Sullair ShopTek ST30 Operation & Maintenance Manual

Sullair ShopTek ST30 Operation & Maintenance Manual

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OPERATION & MAINTENANCE MANUAL
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual,
or misuse of this equipment,
will VOID its warranty!
ST30 & ST37
U.S.A. & Mexico
Subject to EAR, ECCN EAR99 and related export control restrictions.
PART NUMBER:
88291013-138 R02
The information in this manual is current as of its
publication date.
Publication date: 1/28/2015
Copyright © 2015 Sullair, LLC. All rights reserved.

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  • Page 1 The information in this manual is current as of its and procedures in this manual, publication date. or misuse of this equipment, will VOID its warranty! Publication date: 1/28/2015 Copyright © 2015 Sullair, LLC. All rights reserved. Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 2: Air Care Seminar Training

    Air Care Seminar Training Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on Stationary compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility located at Michigan City, Indiana.

  • Page 3: Table Of Contents

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual Table of Contents Table of Contents Section 1: Safety.......................1 General....................... 1 Personal protective equipment ..............1 Pressure release ..................1 Fire and explosion ..................2 Moving parts ....................2 Hot surfaces, sharp edges and sharp corners..........3 Toxic and irritating substances ..............
  • Page 4 Table of Contents ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual Fluid/air separation system ............... 14 2.6.1 General description of the fluid/air separation system ........14 2.6.2 Fluid/air separator tank ..................15 2.6.3 Fluid/air separator element ................. 15 Microprocessor control system ..............
  • Page 5 ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual Table of Contents Section 6: Maintenance..................27 General..................... 27 Daily maintenance ..................27 6.2.1 Before starting the compressor................27 6.2.2 After starting the compressor................27 Recommended maintenance schedule ............ 28 6.3.1 Service at 50 operating hours................28 6.3.2 Service every 1000 operating hours ..............28 6.3.3...
  • Page 6 Table of Contents ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 7.12 Starter assembly—460V ................62 7.13 Enclosure ....................64 7.14 Decal locations..................66 Appendix A: System Diagrams ................69 ST30 & ST37 identification ............... 69 ST30 & ST37 piping and instrumentation ..........70 Appendix B: Metric &...

  • Page 7: Section 1: Safety

    1.1 General protective clothing, protective shields and barriers Sullair and its subsidiaries design and manufacture all of and electrical protective equipment, as well as noise their products so they can be operated safely. However,...

  • Page 8: Fire And Explosion

    1: Safety ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual accordance with their manufacturer's recommenda- material. Any acoustical material with a protective tions. covering that has been torn or punctured should be replaced immediately to prevent accumulation of liq- E.

  • Page 9: Hot Surfaces, Sharp Edges And Sharp Corners

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 1: Safety E. Make sure all personnel are out of and/or clear of the DANGER compressor prior to attempting to start or operate it. F. Disconnect and lock out all power at source and ver- ify at the compressor that all circuits are de-energized to minimize the possibility of accidental start-up, or operation, prior to attempting repairs or adjustments.

  • Page 10: Electrical Shock

    1: Safety ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual cover eyes to exclude light. Call a physician immedi- DANGER ately. All field equipment must be tested for electro- 1.8 Electrical shock static fields prior to servicing or making contact A.

  • Page 11: Entrapment

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 1: Safety J. Set compressor down only on a level surface capa- 1. Review the equipment or machine to be ble of safely supporting at least its weight and its locked and tagged out.

  • Page 12: Safety Warnings

    1: Safety ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual lockout hasps on power shall remove pad- WARNING lock and lockout hasps and restore power. However, when the authorized person who applied the lock is unavailable to remove it Ground the unit following the instructions in this his/her Supervisor may remove padlock/pad- manual.
  • Page 13 State, Federal, and Do not touch any components on the circuit local electrical codes concerning isolation boards. Static voltage discharge may damage switches, fused disconnects, etc. Sullair pro- the components. vides a wiring diagram for use by the installer. NOTE Customer must provide electrical supply power disconnect within sight of machine.
  • Page 14 1: Safety ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-138 R02 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 15: Section 2: Description

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 2: Description Section 2 Description 2.1 The air compression cycle the compressed air using a combination of centrifugal force, impingement, and gravity. Then the compressed The ShopTek™ air compressor uses a lubricated rotary air passes through the fluid/air separator element to screw air end and supporting components to create com- remove almost all of the remaining fluid.
  • Page 16 2: Description ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 1. Fluid piping system 5. Discharge system 2. Air inlet system 6. Electric control system 3. Motor & air end 7. Enclosure 4. Cooling fan system 8. Fluid/air separation system Figure 2-1: ST30 &...
  • Page 17 ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 2: Description Key Description Air filter Inlet valve Capacity control integrated system Oil cooler Pressure switch Indicator Aftercooler Minimum pressure valve Single-stage fluid/air separator element Strainer Moisture separator Pressure sensor Temperature sensor Compressor air end Relief valve...

  • Page 18: Air Inlet System

    2.2.3.1 Inlet modulation To lower the frequency of the compressor’s load/unload To minimize the number of starts and stops the compres- cycles and extend the life of the compressor, Sullair rec- sor makes, the inlet modulation system automatically 88291013-138 R02...

  • Page 19: Minimum Pressure Valve

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 2: Description 2.3.6 Moisture separator ommends installing a wet air receiver after the service connector. The moisture separator removes the moisture from the compressed air stream. Moisture collected by the mois- Additional information ture separator can then be safely disposed of according to local regulations.

  • Page 20: Fluid Filter

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual Additional information 2.5.2 Ambient temperature Sullair ShopTek™ compressors are designed to operate • For the viscosity required for the compressor in ambient temperatures between 4°C and 40°C (40°F fluid to act as a sealant, see Section 3.2: Lubri- and 104°F), measured at the cooling air inlet.

  • Page 21: Fluid/Air Separator Tank

    For assistance in operating the compressor in very low ambient temperatures, please 2.6.2 Fluid/air separator tank contact your Sullair representative. In addition to separating the air from the fluid, the fluid/air separator tank acts as a fluid reservoir, storing most of 2.6.3 Fluid/air separator element the compressor fluid.
  • Page 22 2: Description ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-138 R02 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 23: Section 3: Specifications

    1820 × 1120 × 1625 mm (71.7 × 44.1 × 64.0 in) 3.2 Lubricant specifications Table 3-2: Lubricant specifications The oil used as a lubricant in Sullair’s rotary screw com- Synthetic oils Ambient temperature pressors must have the following properties: ®...
  • Page 24 3: Specifications ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-138 R02 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 25: Section 4: Installation & Setup

    4.2 Guidelines for lifting and moving 4.3 Compressor installation the compressor The ShopTek™ compressor is not weatherproof. The Sullair recommends using a forklift to move the compres- compressor should be installed inside (or in a sheltered sor. A crane can also be used. position outside).

  • Page 26: Heat Rejection And Ventilation Requirements

    Aftermarket prior to installation) and must not apply • For the exact location of the service connector, any weight to the compressor cabinet. Sullair also recom- see Section A.1: ST30 & ST37 identification on mends a section of the ductwork be removable to allow page 69.

  • Page 27: Checking The Compressor Fluid Level

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 4: Installation & Setup 4.5.2.1 Checking the air end of a new machine 4.6.2 Checking the motor rotation direction Rotate the flexible drive coupling by hand through two For the motor to rotate in the correct direction, the power complete revolutions in the direction indicated by the supply must be correctly connected.
  • Page 28 4: Installation & Setup ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-138 R02 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 29: Section 5: Operation

    CAUTION NOTE The compressor should always run smoothly. If the compressor vibrates excessively while run- ning, shut it down and contact your Sullair repre- You should always use the Stop button to stop sentative immediately. the compressor under normal circumstances.

  • Page 30: Starting The Compressor

    In the event of a high operating temperature shutdown fault, do not attempt to restart the compressor without first finding and correcting the underlying cause. Contact your Sullair repre- sentative for assistance. 5.7 Motor overload protection Both the compressor main drive motor and the fan motor have overload protection.

  • Page 31: Phase Failure/Reversal

    The fault mode may be cleared by pressing the Reset button on the controller. Keeping with Sullair’s philosophy of minimizing energy consumption, the electronic controller has a run-on timer. The run-on timer monitors how long the compressor has CAUTION run without compressing air.
  • Page 32 5: Operation ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-138 R02 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 33: Section 6: Maintenance

    WARRANTY NOTICE Normal operation of your compressor depends upon per- forming maintenance and service correctly and according Failure to use Sullair genuine parts when servic- to a consistent schedule. ing a Sullair compressor may void your warranty. To help you follow this schedule, the ShopTek™ micro- processor controller has a programmable service timer.

  • Page 34: Recommended Maintenance Schedule

    6.3.4 Service every 4000 operating hours Contact your Sullair representative for advice on (or semi-annually) the correct service intervals for your installation. Perform all checks listed for every 1000 and 2000 hours plus: 6.3.1...

  • Page 35: Compressor Fluid Levels

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance 6.4 Compressor maintenance 6.3.6 Compressor fluid levels Refer to Section 7: Parts List for the part numbers of al items mentioned in this section. WARNING Do not attempt any maintenance when the com- pressor is running or pressurized.

  • Page 36: Fluid Filter Maintenance

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual Clean the lubrication system before changing fluid. If the ambient temperature is outside of the allowed range for the fluid, please contact your Sullair representative. WARRANTY INFORMATION ® Mixing of fluids other than Sullube will void the compressor’s warranty.

  • Page 37: Purge Oil Return Line Filter Maintenance

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance • Do not strike the filter element against a hard surface to remove the dirt. You may damage the element. • Do not oil the filter element. 6.4.5 Purge oil return line filter maintenance Clean the purge oil return line filter after the first 50 hours...
  • Page 38 6: Maintenance ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 7. Install the new fluid/air separator element and gasket assembly. CAUTION Do not remove the staples incorporated into the gaskets.They maintain a ground contact with the separator. 8. Reassemble in reverse order, carefully adjusting the purge oil return line tube so it has the correct clearance from the separator element base (see Section 6.4.5: Purge oil...

  • Page 39: Minimum Pressure Valve Maintenance

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance 6.4.7 Minimum pressure valve 3. Unscrew the top cap of the valve and maintenance remove the piston assembly from the valve. 4. Clean the valve and piston assembly care- fully.

  • Page 40: Drive Coupling Maintenance

    6: Maintenance ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 6.4.11 Drive coupling maintenance WARNING Isolate the compressor from the power supply before making any repairs or adjustments to the drive coupling. 1. Motor end sleeve 2. Elastomer 1.

  • Page 41: Main Motor Operation

    ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance See the main motor nameplate and the other topics in motor will create significantly more noise and this section for additional information about operating vibration.) conditions. • After any motor faults occurs, contact your Sul- lair representative.

  • Page 42: Check And Clean The Windings

    For a thorough cleaning, or if the Sullair recommends using a petroleum-based solvent for winding is very dusty, the rotor needs to be removed from cleaning the insulation.
  • Page 43 ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance Table 6-2:Troubleshooting guide lists some compressor symptoms with their most probable causes and remedies Table 6-2: Troubleshooting guide Symptom Possible causes Remedy Low fluid level in fluid/air separator Check fluid level.
  • Page 44 6: Maintenance ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual Notes: 88291013-138 R02 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 45: Section 7: Parts List

    The genuine Sullair service parts listed meet or exceed the demands of this compressor. Use of replacement parts other than those approved by Sullair will void the Sullair warranties specific to this product and may lead to hazardous conditions over which Sullair has no control.

  • Page 46: Recommended Spare Parts List

    7: Parts List ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 7.2 Recommended spare parts list Service kit part number Qty Description 250025-526 Element for compressor fluid filter 88291002-854 Element for heavy duty air filter 88291002-853 (ST30) 88290006-013 Element for heavy duty air filter 88290006-012 (ST37) 250034-116 Element for fluid/air separator...
  • Page 47 ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Manual 7: Parts List Notes: 88291013-138 R02 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 48: Motor And Air End System (St3008)

    7.3 Motor and air end system (ST3008) 88291011-256 R02}...
  • Page 49 7.3 Motor and air end system (ST3008) Key Part number Description Notes 02250152-346 Shield 02250155-285 Shock absorber 829106-150 Bolt 837806-094 Washer 88250160-003 Compressor unit ST3008 60Hz 88290012-853 Supporting plate 88290019-861 Coupling 88291005-388 Adapter 88291013-508 Motor 30kW 60Hz 230/460V IP23 88291011-257 Base 88812110-025 Bolt...

  • Page 50: Motor And Air End System (St3708)

    7.4 Motor and air end system (ST3708) 88291010-682 R01...
  • Page 51 7.4 Motor and air end system (ST3708) Key Part number Description Notes 02250152-346 Shield 02250155-285 Shock absorber 88250152-539 Compressor unit ST3708 60Hz 88291010-693 Supporting plate 88290021-477 Adapter 60HZ 230/460V IP23 88290021-964 Coupling 88290012-637 Motor 37kW 60HZ 230/460V IP23 88291010-692 Base 88812110-025 Bolt 88812112-030...

  • Page 52: Air Inlet System (St3008)

    7.5 Air inlet system (ST3008) 88291005-385 R00...
  • Page 53 7.5 Air inlet system (ST3008) Key Part number Qty Description Notes 250018-550 Clamp 88291002-853 Air filter 88291005-386 Rubber elbow 88291005-389 Air filter holder 88812110-030 Bolt 88813108-020 Flange bolt 88821108-068 88831108-016 Flat washer 88831110-020 Flat washer 88832108-021 Spring washer 88832110-026 Spring washer...

  • Page 54: Air Inlet System (St3708)

    7.6 Air inlet system (ST3708) 88290021-460 R00...
  • Page 55 7.6 Air inlet system (ST3708) Key Part number Description Notes 040550 Rubber elbow 040642 Clamp 88290006-012 Air filter 88290006-144 Air filter anchor hoop 88290021-476 Air filter holder 88812108-020 Bolt 88812110-035 Bolt 88821108-068 88821110-084 88831108-016 Flat washer 88831110-020 Flat washer 88832108-021 Spring washer 88832110-026 Spring washer...

  • Page 56: Fluid Piping System

    7.7 Fluid piping system 88290021-461 R07...
  • Page 57 7.7 Fluid piping system Key Part number Description Notes 02250078-204 Thermal valve element <12bar model 02250099-766 Connector For ST30 02250141-104 Oil tube E For ST37 02250152-223 Joint For ST37 02250156-913 Oil pipe For ST30 02250164-115 Oil pipe 250025-526 Oil filter element 88290021-503 Oil filter thermal valve assembly 883527-012...

  • Page 58: Cooling Fan System

    7.8 Cooling fan system 88291010-684 R01...
  • Page 59 7.8 Cooling fan system Key Part number Description Notes 250018-330 Adapter,venturi 88290021-446 Oil cooler 88291013-109 Axial fan assembly 60Hz 230/460V 88290021-473 Supporting plate 88831108-016 Flange bolt 88821108-076 Flange nut 88811108-025 Flange bolt 88811108-020 Flange bolt 250022-436 Seal...

  • Page 60: Fluid/Air Separation System

    7.9 Fluid/air separation system 88291010-683 R02...
  • Page 61 7.9 Fluid/air separation system Key Part number Description Notes 88291010-368 Oil/air separator 88291010-842 Discharge pipe DN50 For ST37 88842035-058 O-ring 88290007-143 Half flange 040029 Plug 88290006-366 Sight glass 88832110-026 Spring washer 88821110-084 88812110-060 Bolt 88812110-025 Bolt 88290005-770 Adjustable rectangular joint 250006-938 Relief valve ASME US MODEL...

  • Page 62: Air Discharge System

    7.10 Air discharge system 88291010-846 R00...
  • Page 63 7.10 Air discharge system Key Part number Description Notes 88842035-045 O-ring 88290018-064 Straight 88842026-040 O-ring 88290021-609 Metal hose 88290021-608 Straight joint 88290021-484 Connector 88842035-038 O-ring 88291013-637 Connector 88291013-634 Water trap...

  • Page 64: Control System

    7.11 Control system 88291012-749 R02...
  • Page 65 7.11 Control system Key Part number Description Notes 02250054-861 Nylon conduit 02250099-626 Elbow 02250099-630 Nylon conduit 250003-869 Vacuum indicator 250018-430 Elbow 250018-427 Straight joint 807600-005 Connector 88291011-142 Nylon cable joint 88291011-143 Nylon cable joint 88813108-020 Flange bolt 250018-428 Straight joint 88833108-022 Large flat washer 88291011-444...
  • Page 66 7.11 Control system Key Part number Description Notes 88291011-908 0.8m Nylon conduit 88291011-450 1.2m Nylon conduit 88291013-456 Nylon joint 88291003-004 support FOR ST30 88831112-025 Flat washer FOR ST30 88832112-031 Spring washer FOR ST30 88811112-035 Bolt FOR ST30 88290010-794 joint FOR ST30 88842018-009 O-ring FOR ST30...
  • Page 67 Notes:...

  • Page 68: Starter Assembly-460V

    7.12 Starter assembly—460V 88291012-978 R02...
  • Page 69 7.12 Starter assembly—460V Part Number Description Notes 88291013-763 MPCB, Standard Magnetic Trip (Fixed at 13 x le), 4-6.3 A -QF1 88291012-865 Auxiliary Contact Block, Front Mounted, 1 N.O. 1 N.C. -TC1 88291012-840 200VA, 230/460V-110V/25V (50/60Hz) UL -KM2,-KM3 88291013-038 MCS-C Contactor, IEC, 43A, 120V 50/60Hz -KM1 88291013-033 MCS-C Contactor, IEC,30A, 120V 50/60Hz...

  • Page 70: Enclosure

    7.13 Enclosure 88291010-686 R01...
  • Page 71 7.13 Enclosure Key Part number Description Notes 02250048-520 Plastic cap 02250151-635 Door gasket 88290021-394 Post A 88291010-226 Corner panel A 88291010-227 Corner panel B 88291010-228 Corner panel C 88291010-232 Post B 88291010-716 Plate A 88291010-722 Post C 88291010-724 Beam A 88291010-725 Beam B 88291010-727...

  • Page 72: Decal Locations

    7.14 Decal locations 88291011-502 R02...
  • Page 73 7.14 Decal locations Key Part number Description Notes 88291011-503 SULLAIR LOGO decal 88291011-602 SULLAIR LOGO decal 241814 Decal, fork lifting 042218 Decal,danger hi voltage 250021-564 Decal,rotation 3.5" lg 049852 Sign,warning ground fault 250021-337 Tag,first start 250003-144 Sign,warn "food grade" lube...
  • Page 74 Notes:...

  • Page 75: Appendix A: System Diagrams

    Appendix A: System Diagrams A.1 ST30 & ST37 identification 88291013-664 R00...

  • Page 76: St30 & St37 Piping And Instrumentation

    A.2 ST30 & ST37 piping and instrumentation...
  • Page 77 A.2 ST30 & ST37 piping and instrumentation Key Description Air filter Inlet valve Capacity control integrated system Oil cooler Pressure switch Indicator Aftercooler Minimum pressure valve Single-stage fluid/air separator element Strainer Moisture separator Pressure sensor Temperature sensor Compressor air end Relief valve Fluid/air separator tank Sight glass...

  • Page 78: Appendix B: Metric & Imperial Nominal Sizes

    B: Metric & Imperial Nominal Sizes ST30 & ST37 (U.S.A. & Mexico) Operation & Maintenance Appendix B: Metric & Imperial Nominal Sizes Table B-1: Metric to Imperial nominal sizes Metric nominal size (DN) is the nominal size for valves, flanges and fittings as defined by ISO 6708-1980. DN Metric DN Imperial NS designates the size of all components in a piping system...
  • Page 79 Subject to EAR, ECCN EAR99 and related export control restrictions.
  • Page 80 Sullair, LLC 3700 East Michigan Boulevard Michigan City, IN 46360 USA www.sullair.com 1-800-SULLAIR (USA only) 1-219-879-5451 (non-USA) Information and specifications are subject to change without prior notice. Subject to EAR, ECCN EAR99 and related export control restrictions.

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