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18 months from shipment from Sullivan-Palatek to initiate the warranty. If the warranty registration is not initiated in this manner the warranty effective date will be deemed to be the date of shipment from Sullivan-Palatek. Service under this warranty is obtained by contacting the authorized Sullivan-Palatek distributor before the expiration of the warranty.
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Sullivan-Palatek’s Obligations: Sullivan-Palatek, Inc. will repair or replace, at Sullivan-Palatek’s option, any defective part. Sullivan-Palatek will pay the reasonable labor cost of making the repair or installing the replacement part when coverage includes labor, and will pay ground freight for the return of defective parts and shipment of replacement parts.
MANUAL ORGANIZATION Anyone operating or servicing the Sullivan-Palatek air compressor should read this entire manual and be familiar with its information. The following is a quick guide to the contents in this manual: SECTION 1: INTRODUCTION This section contains important basic information regarding the compressor, such as safety precautions and warranty information.
SAFETY DECALS Sullivan-Palatek compressors are all equipped with brightly colored, weather-resistant, pictorial/verbal decals. These are designed to warn the operator against potential hazards in order to minimize risk of property damage, bodily injury and/or death.
All bearings and seals in the factory-remanufactured air end are replaced. All other parts not meeting Sullivan-Palatek’s quality standards are also replaced. A remanufactured air end has a warranty period of 12 months from start-up date or 18 months from date of shipment.
AIR COMPRESSOR PACKAGE The air compressor package consists of a rotary screw compressor unit, air-cooled lubrication and cooling system, discharge system, intake and capacity control system, and monitoring system. COMPRESSION CYCLE During operation, two helically-grooved rotors mesh to compress air. Intake air is compressed as the male lobes roll down the female grooves, pushing trapped air along, compressing it until a female groove uncovers the discharge port in the end of the stator and delivers smooth-flowing, pulse-free air to the receiver.
3.4.2 PRESSURE RELIEF VALVE The pressure relief valve will open to relieve excess pressure in the sump tank if the pressure exceeds the set point. The valve will automatically reset to its reset pressure point after the excess pressure is relieved. The pressure relief valve is ASME compliant and rated at 200 psig to match the rating of the tank.
It is a sealant, sealing the rotors to reduce leakage paths between the rotors and between the stator housing. Rotary screw compressor units require specialized lubricant to maintain proper performance. Use of Sullivan-Palatek lubricants is recommended. Refer to 8.4 Compressor Lubricants on page 62. 3.6.2 TEMPERATURE CONTROL VALVE (THERMOSTATIC VALVE) The temperature control valve (also referred to as a thermostatic valve) regulates the flow of oil to the oil cooler based on temperature.
FIRST USED ON: SCALE: SHEET THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF SULLIVAN-PALATEK, INC. IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED. # COMPONENT # COMPONENT IT IS LOANED SUBJECT TO RETURN UPON DEMAND, IS NOT TO BE USED DIRECTLY OR INDIRECTLY IN ANYWAY DETRIMENTAL TO SULLIVAN-PALATEK'S INTEREST.
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START-UP LEGEND Line Pressure Dry Side SULLIVAN-PALATEK 12/10/13 Regulated Air 1201 West US Highway 20, Michigan City IN 46360 1-800-438-6203 108-127MM 15-60HP FIGURE 3-3. 15–60HP CONTROL SYSTEM (START-UP) NOTE! Image may not represent your exact model. When the compressor is started, a 20-second timer is energized to ensure the compressor is up to proper speed and minimum design pressure has been achieved.
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FULL-LOAD LEGEND Line Pressure Dry Side SULLIVAN-PALATEK 12/10/13 Regulated Air 1201 West US Highway 20, Michigan City IN 46360 1-800-438-6203 108-127MM 15-60HP FIGURE 3-4. 15–60HP CONTROL SYSTEM (FULL LOAD) NOTE! Image may not represent your exact model. After the initial start-up, the timer will force the electrical components controlling the low pressure control to drop out.
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MODULATION LEGEND Line Pressure Dry Side SULLIVAN-PALATEK 12/10/13 Regulated Air 1201 West US Highway 20, Michigan City IN 46360 1-800-438-6203 108-127MM 15-60HP FIGURE 3-5. 15–60HP CONTROL SYSTEM (MODULATION) NOTE! Image may not represent your exact model. Modulation will occur between the regulated set point and the setting of the pressure switch, which should be 10 psi (0.7 bar) over regulated set pressure to create a 10 psi (0.7 bar) modulating range.
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UNLOAD LEGEND Line Pressure Dry Side SULLIVAN-PALATEK 12/10/13 Regulated Air 1201 West US Highway 20, Michigan City IN 46360 1-800-438-6203 108-127MM 15-60HP FIGURE 3-6. 15–60HP CONTROL SYSTEM (UNLOAD) NOTE! Image may not represent your exact model. Unload status occurs when the customer’s demand pressure set point is achieved with an additional 10 psi (0.7 bar) overshoot.
3.7.2 INLET CONTROL VALVE The inlet control valve is the main control for air capacity within the air compressor. It is equipped with a poppet disc for inlet control as well as reverse flow check. The valve is initially opened at start-up by suction created by rotating screws in the compressor unit.
RECEIVING Every Sullivan-Palatek air compressor has been operated and tested at the Factory prior to shipment. The testing ensures that the air compressor is functioning properly and will deliver its rated pressure and capacity. Regardless of the care taken at the Factory, there is a possibility that the air compressor could be damaged during shipment.
The recommended water pressure range is 40–75 psig (2.8–5.2 bar). Refer to Technical Data on page 6 for cooling water flow rates. Water flow rates will vary by operating conditions. Consult the nearest Sullivan-Palatek representative for flow rates based on criteria other than what is listed.
COMPRESSED AIR SYSTEM Connect to plant air system with a flexible connector with a minimum rating of 200 psi (13.8 bar) and 245°F (118°C). Piping should be large enough in diameter to minimize pressure drop. Support piping so that stress is not transmitted to the compressor.
TABLE 5-1. E/M CONTROLS COMPONENTS ITEM COMPONENT DESCRIPTION Oil Filter Differential Displays pressure drop across the oil filter(s) for determining when to maintenance Separator Differential Displays pressure drop across the separator element for determining when to maintenance Temperature Displays temperature of air end oil leaving the air end for monitoring Line Pressure Displays the line pressure (air leaving the minimum pressure valve) for monitoring...
NORMAL STOP Close the service valve. Allow sump pressure to fall to 30-45 psig. Turn the selector switch to the OFF position. RESTARTS If the compressor shuts down unexpectedly, special procedures must be followed to safely restart the compressor. Below are the procedures for safely restarting the compressor, depending on the reason for the shutdown.
Sullivan-Palatek recommends oil sampling as the best guide for your fluid change interval. Changing fluid once a year may not be adequate or it can be excessive. For this reason an hourly service on lubricants is merely a guide. Please consult your factory-trained servicing distributor for questions concerning your lubricant life and Sullivan-Palatek’s lubricant sampling...
GENERAL MAINTENANCE SAFETY WARNING! Never assume a compressor is safe to work on just because it is not operating. It could restart at any time. WARNING! 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.
COMPRESSOR LUbRICANT Refer to Chapter 8.4 Compressor Lubricants on page 62 for additional information about lubricants offered by Sullivan-Palatek. CAUTION! Never mix synthetic lubricants with hydrocarbon lubricants. Never mix synthetic lubricants manufactured from different base products. Severe damage to the compressor system may result.
Remove any remaining oil by turning the compressor unit by hand. Remove oil filter element. FLUSH COMPRESSOR Pour as much flush lubricant into the inlet as was removed from the compressor. Add flush lubricant to the sump tank to maximum fill level. Install a new oil filter element and jog compressor.
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SAMPLE OIL FROM SUMP TANK Run the compressor long enough to reach normal operating temperatures. Follow 6.3 Stopping for Maintenance procedures. Remove the drain plug from the end of the drain line at the bottom of the sump tank. Open the drain valve and drain any water from the sump tank. Discard in an approved manner.
tooltip OIL FILTER The oil filter should be replaced after the first 50 hours of operation and then every 1,000 hours (or quarterly) or if the filter differential pressure gauge exceeds 15 psid. The oil filter element is mounted to the side of the compressor unit.
AIR/OIL SEPARATOR The separator element should be replaced every 4,000 hours (or once a year). Refer to Figure 6-5. Sump The separator element is located in the top side of Tank the sump tank under the tank lid. To replace the element, access panels have been supplied in the roof.
tooltip AIR FILTER The air filter should be replaced every 1,000 hours or more often in severe or outside conditions. The inlet filter is a critical filter, protecting the compressor from exterior foreign materials. Keeping the inlet filter element clean will help maintain proper capacity rating of the compressor. Filter Body Secondary Filter Element Primary Filter Element...
6.12 PRESSURE ADJUSTMENT The intervals at which the compressor loads, modulates and unloads are controlled by adjustable settings. The load and unload settings are adjusted on the control pressure switch (CPS). The modulating pressure is adjusted on the control pressure regulating valve. These settings are preset at the factory based on the original order.
INTRODUCTION This section contains instructions for troubleshooting the equipment following a malfunction. Each symptom of trouble for a component or system is followed by a list of probable causes of the trouble and suggested procedures to be followed to eliminate the cause. The procedures listed should be performed in the order in which they are listed, although the order may be varied if the need is indicated by conditions under which the trouble occurred.
LINE PRESSURE RISES AbOVE UNLOAD PRESSURE POSSIbLE CAUSE REMEDY Leak in control system tubing causing loss of Replace tubing. pressure signals Defective solenoid valve Repair or replace solenoid valve. Faulty inlet valve Repair or replace inlet valve. EXCESSIVE LUbRICANT CONSUMPTION POSSIbLE CAUSE REMEDY Clogged separator oil return line...
Use the space provided on the inside cover of the manual to record the model and serial number of the compressor for future reference. 8.1.1 CONTACT INFORMATION For replacement parts and manuals contact: Sullivan-Palatek, Inc. 1201 West US Highway 20 Michigan City, Indiana 46360 Phone: (219) 874-2497...
KIT, OIL ANALYSIS 00061-005 LUBRICANT, PALASYN 45 (5 GALLON) NOTE! Use only service parts supplied or recommended by Sullivan-Palatek. Use of substitutes may void warranty. See WARRANTY for details. 8.3.1 MAINTENANCE KITS Maintenance kits are available. Contact Distributor for more information.
For this reason an hourly service on lubricants is merely a guide. Please consult your factory-trained servicing distributor for questions concerning your lubricant life and Sullivan-Palatek’s lubricant sampling program. See 6.6 Oil Sample for Analysis on page 43 for additional information.
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FLUID LIFE Fluid life is maximum hours based on temperature only. Oil change interval to be based on oil per analysis findings. » 8,600 hours (or 1 year) ORDERING OPTIONS DESCRIPTION PART NUMbER LUBRICANT, PAL-EXTRA 44, 5 GALLON PAIL 00066-005 LUBRICANT, PAL-EXTRA 44, 55 GALLON DRUM 00066-055 8.4.4...
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8.4.6 PAL-32 LL (FOOD GRADE) PAL-32 LL is a full synthetic compressor lubricant formulated from the highest quality polyalphaolefin (PAO) base oils with a superior proprietary additive package to achieve long life. This long-life compressor lubricant provides significantly improved wear protection, oxidation stability and lubricity over the currently available H-1 food grade synthetic oils allowing the service life to increase by 50% to 100%.
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For this reason an hourly service on lubricants is merely a guide. Please consult your factory-trained servicing distributor for questions concerning your lubricant life and Sullivan-Palatek’s lubricant sampling program. See 6.6 Oil Sample For Analysis on page 49 for additional information.
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