SULLAIR ShopTek ST18 Operation & Maintenance Manual

Brand: SULLAIR

Model: ShopTek ST18

Category: Air compressors

Type: Operation & Maintenance Manual

This manual is also suitable for

ShopTek ST22

ST18 & ST22

U.S.A. & Mexico

PART NUMBER:

88291013-137 R05

The information in this manual is current as of its

publication date and applies to compressors with

serial number:

37215080087

and all subsequent serial numbers.

OPERATION & MAINTENANCE MANUAL

Publication date: 11/25/2015

Subject to EAR, ECCN EAR99 and related export control restrictions.

WARRANTY NOTICE

Failure to follow the instructions

and procedures in this manual,

or misuse of this equipment, will

void its warranty.

SAFETY WARNING

Users are required to read the

entire Operation & Maintenance

Manual before handling or using

the product.

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 training facility located at Michigan City, Indiana.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting common

faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,

contractor maintenance, and service personnel.

For detailed course outlines, schedule, and cost information contact:

Sullair Training Department

1-888-SULLAIR or

219-879-5451 (ext. 5623)

www.sullair.com

[email protected]

- Or Write -

Sullair, LLC

3700 E. Michigan Blvd.

Michigan City, IN 46360

Attn: Service Training Department.

Subject to EAR, ECCN EAR99 and related export control restrictions.

Table of Contents

ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual Table of Contents

88291013-137 R05

Subject to EAR, ECCN EAR99 and related export control restrictions. i

Section 1: Safety.......................................................................................................1

1.1 General....................................................................................................... 1

1.2 Personal protective equipment ................................................................... 1

1.3 Pressure release ........................................................................................ 1

1.4 Fire and explosion ...................................................................................... 2

1.5 Moving parts............................................................................................... 2

1.6 Hot surfaces, sharp edges and sharp corners............................................ 3

1.7 Toxic and irritating substances ................................................................... 3

1.8 Electrical shock........................................................................................... 4

1.9 Lifting.......................................................................................................... 4

1.10 Entrapment................................................................................................. 5

1.11 Implementation of lockout/tagout................................................................ 5

1.12 Safety warnings.......................................................................................... 6

Section 2: Description..............................................................................................9

2.1 The air compression cycle.......................................................................... 9

2.2 Air inlet system ......................................................................................... 12

2.2.1 General operation of the air inlet system .............................................................12

2.2.2 Air filter.................................................................................................................12

2.2.3 Inlet valve.............................................................................................................12

2.3 Discharge system..................................................................................... 12

2.3.1 General operation of the discharge system .........................................................12

2.3.2 Minimum pressure valve......................................................................................13

2.3.3 Automatic blowdown valve ..................................................................................13

2.3.4 Pressure relief valve ............................................................................................13

2.3.5 Aftercooler ...........................................................................................................13

2.3.6 Moisture separator...............................................................................................13

2.4 Lubrication system.................................................................................... 13

2.4.1 General description of the lubrication system......................................................13

2.4.2 Lubricating fluid....................................................................................................13

2.4.3 Fluid filter .............................................................................................................14

2.4.4 Purge oil return line..............................................................................................14

2.5 Cooling system......................................................................................... 14

2.5.1 General description of the cooling system...........................................................14

2.5.2 Ambient temperature ...........................................................................................14

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88291013-137 R05

ii Subject to EAR, ECCN EAR99 and related export control restrictions.

2.6 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

2.7 Microprocessor control system .................................................................15

Section 3: Specifications.......................................................................................17

3.1 Machine specifications..............................................................................17

3.2 Lubricant specifications.............................................................................17

Section 4: Installation & Setup .............................................................................19

4.1 Compressor pre-installation ......................................................................19

4.2 Guidelines for lifting and moving the compressor .....................................19

4.2.1 Guidelines for moving the compressor with a forklift........................................... 19

4.2.2 Guidelines for moving the compressor with a crane ........................................... 19

4.3 Compressor installation ............................................................................19

4.3.1 Physical installation requirements ....................................................................... 19

4.3.2 Heat rejection and ventilation requirements........................................................ 20

4.4 Connection to the air system ....................................................................20

4.5 Mechanical checks....................................................................................20

4.5.1 Checking the motor to air end coupling............................................................... 20

4.5.2 Checking the air end ........................................................................................... 20

4.5.3 Checking the compressor fluid level ................................................................... 21

4.5.4 Checking the isolation gate valve........................................................................ 21

4.6 Electrical checks .......................................................................................21

4.6.1 Power supply requirements................................................................................. 21

4.6.2 Checking the motor rotation direction ................................................................. 21

Section 5: Operation..............................................................................................23

5.1 Compressor protection features................................................................23

5.1.1 Stop run-on timer ................................................................................................ 23

5.1.2 Emergency stop .................................................................................................. 23

5.2 Starting the compressor for the first time..................................................23

5.3 Starting the compressor............................................................................24

5.4 Shutting down the compressor .................................................................24

5.5 Electronic controller ..................................................................................24

5.6 High temperature shutdown......................................................................24

5.7 Motor overload protection .........................................................................24

5.8 Run-on timer .............................................................................................25

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Subject to EAR, ECCN EAR99 and related export control restrictions. iii

Section 6: Maintenance..........................................................................................27

6.1 General..................................................................................................... 27

6.2 Daily maintenance.................................................................................... 27

6.2.1 Before starting the compressor............................................................................27

6.2.2 After starting the compressor...............................................................................27

6.3 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 Service every 2000 operating hours ....................................................................28

6.3.4 Service every 4000 operating hours (or semi-annually) ......................................28

6.3.5 Service every 10,000 hours (or yearly)................................................................28

6.3.6 Compressor fluid levels .......................................................................................29

6.4 Compressor maintenance ........................................................................ 29

6.4.1 Adding compressor fluid ......................................................................................29

6.4.2 Changing compressor fluid ..................................................................................29

6.4.3 Fluid filter maintenance........................................................................................30

6.4.4 Air filter maintenance ...........................................................................................30

6.4.5 Purge oil return line filter maintenance ................................................................31

6.4.6 Fluid/air separator maintenance ..........................................................................31

6.4.7 Minimum pressure valve maintenance ...............................................................33

6.4.8 Blowdown valve maintenance .............................................................................33

6.4.9 Solenoid valve maintenance................................................................................33

6.4.10 Pressure regulator maintenance..........................................................................33

6.4.11 Drive coupling maintenance ................................................................................34

6.5 Main motor operation and maintenance ................................................... 34

6.5.1 Main motor operation...........................................................................................35

6.5.2 Main motor maintenance and repair ....................................................................35

6.5.3 Periodic inspection of the main motor..................................................................35

6.5.4 Check and clean the windings .............................................................................36

6.6 Troubleshooting........................................................................................ 36

Section 7: Parts List...............................................................................................39

7.1 Procedure for ordering parts..................................................................... 39

7.2 Recommended spare parts list................................................................. 40

7.3 Motor and air end system......................................................................... 42

7.4 Air inlet system ......................................................................................... 44

7.5 Fluid piping system................................................................................... 46

7.6 Cooling fan system................................................................................... 48

7.7 Fluid/air separation system....................................................................... 50

7.8 Air discharge system ................................................................................ 52

7.9 Control system.......................................................................................... 54

7.10 Starter assembly—460/230V dual voltage ............................................... 56

7.11 Starter assembly—460V........................................................................... 58

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7.12 Enclosure ..................................................................................................60

7.13 Decal locations..........................................................................................62

Appendix A: System Diagrams.............................................................................65

A.1 ST18 & ST22 identification .......................................................................65

A.2 ST18 & ST22 piping and instrumentation .................................................66

Appendix B: Metric & Imperial Nominal Sizes.....................................................68

Section 1

ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 1: Safety

88291013-137 R05

Subject to EAR, ECCN EAR99 and related export control restrictions. 1

Safety

1.1 General

Sullair and its subsidiaries design and manufacture all of

their products so they can be operated safely. However,

the responsibility for safe operation rests with those who

use and maintain these products. The following safety

precautions are offered as a guide which, if conscien-

tiously followed, will minimize the possibility of accidents

throughout the useful life of this equipment.

The compressor should be operated only by those who

have been trained and delegated to do so, and who have

read and understood this Operator’s Manual. Failure to

follow the instructions, procedures and safety

precautions in this manual may result in accidents and

injuries. NEVER start the compressor unless it is safe to

do so. DO NOT attempt to operate the compressor with a

known unsafe condition. Tag the compressor and render

it inoperative by disconnecting and locking out all power

at source or otherwise disabling its prime mover so

others who may not know of the unsafe condition cannot

attempt to operate it until the condition is corrected.

Install, use and operate the compressor only in full

compliance with all pertinent OSHA regulations and/or

any applicable Federal, State, and Local codes,

standards and regulations. DO NOT modify the

compressor and/or controls in any way except with

written factory approval.

While not specifically applicable to all types of compres-

sors with all types of prime movers, most of the precau-

tionary statements contained herein are applicable to

most compressors and the concepts behind these state-

ments are generally applicable to all compressors.

1.2 Personal protective equipment

A. Prior to installing or operating the compressor, own-

ers, employers and users should become familiar

with, and comply with, all applicable OSHA regula-

tions and/or any applicable Federal, State and Local

codes, standards, and regulations relative to per-

sonal protective equipment, such as eye and face

protective equipment, respiratory protective equip-

ment, equipment intended to protect the extremities,

protective clothing, protective shields and barriers

and electrical protective equipment, as well as noise

exposure administrative and/or engineering controls

and/or personal hearing protective equipment.

1.3 Pressure release

A. Install an appropriate flow-limiting valve between the

service air outlet and the shut-off (throttle) valve,

either at the compressor or at any other point along

the air line, when an air hose exceeding ½″ (13 mm)

inside diameter is to be connected to the shut-off

(throttle) valve, to reduce pressure in case of hose

failure, per OSHA Standard 29 CFR 1926.302(b)(7)

and/or any applicable Federal, State and Local

codes, standards and regulations.

B. When the hose is to be used to supply a manifold,

install an additional appropriate flow-limiting valve

between the manifold and each air hose exceeding

½″ (13 mm) inside diameter that is to be connected

to the manifold to reduce pressure in case of hose

failure.

C. Provide an appropriate flow-limiting valve at the

beginning of each additional 75 feet (23 m) of hose in

runs of air hose exceeding ½″ (13 mm) inside diame-

ter to reduce pressure in case of hose failure.

D. Flow-limiting valves are listed by pipe size and flow-

rated. Select appropriate valves accordingly, in

NOTE

Operator is required to read

entire instruction manual.

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88291013-137 R05

2 Subject to EAR, ECCN EAR99 and related export control restrictions.

accordance with their manufacturer's recommenda-

tions.

E. DO NOT use air tools that are rated below the maxi-

mum rating of the compressor. Select air tools, air

hoses, pipes, valves, filters and other fittings accord-

ingly. DO NOT exceed manufacturer’s rated safe

operating pressures for these items.

F. Secure all hose connections by wire, chain or other

suitable retaining device to prevent tools or hose

ends from being accidentally disconnected and

expelled.

G. Open fluid filler cap only when compressor is not run-

ning and is not pressurized. Shut down the compres-

sor and bleed the receiver tank to zero internal

pressure before removing the cap.

H. Vent all internal pressure prior to opening any line, fit-

ting, hose, valve, drain plug, connection or other

component, such as filters and line oilers, and before

attempting to refill optional air line anti-icer systems

with antifreeze compound.

I. Keep personnel out of line with and away from the

discharge opening of hoses or tools or other points of

compressed air discharge.

J. DO NOT use air at pressures higher than 2.1 bar for

cleaning purposes, and then only with effective chip

guarding and personal protective equipment per

OSHA Standard 29 CFR 1910.242(b) and/or any

applicable Federal, State, and Local codes, stan-

dards and regulations.

K. DO NOT engage in horseplay with air hoses as

death or serious injury may result.

1.4 Fire and explosion

A. Clean up spills of lubricant or other combustible sub-

stances immediately, if such spills occur.

B. Shut off the compressor and allow it to cool. Then

keep sparks, flames and other sources of ignition

away and DO NOT permit smoking in the vicinity

when checking or adding lubricant or when refilling

air line anti-icer systems with antifreeze compound.

C. DO NOT permit fluids, including air line anti-icer sys-

tem antifreeze compound or fluid film, to accumulate

on, under or around acoustical material, or on any

external surfaces of the air compressor. Wipe down

using an aqueous industrial cleaner or steam clean

as required. If necessary, remove acoustical mate-

rial, clean all surfaces and then replace acoustical

material. Any acoustical material with a protective

covering that has been torn or punctured should be

replaced immediately to prevent accumulation of liq-

uids or fluid film within the material. DO NOT use

flammable solvents for cleaning purposes.

D. Disconnect and lock out all power at source prior to

attempting any repairs or cleaning of the compressor

or of the inside of the enclosure, if any.

E. Keep electrical wiring, including all terminals and

pressure connectors in good condition. Replace any

wiring that has cracked, cut, abraded or otherwise

degraded insulation, or terminals that are worn, dis-

colored or corroded. Keep all terminals and pressure

connectors clean and tight.

F. Keep grounded and/or conductive objects such as

tools away from exposed live electrical parts such as

terminals to avoid arcing which might serve as a

source of ignition.

G. Remove any acoustical material or other material

that may be damaged by heat or that may support

combustion and is in close proximity, prior to attempt-

ing weld repairs.

H. Keep suitable fully charged Class BC or ABC fire

extinguisher or extinguishers nearby when servicing

and operating the compressor.

I. Keep oily rags, trash, leaves, litter or other combusti-

bles out of and away from the compressor.

J. DO NOT operate the compressor without proper flow

of cooling air or water or with inadequate flow of lubri-

cant or with degraded lubricant.

K. DO NOT attempt to operate the compressor in any

classification of hazardous environment unless the

compressor has been specially designed and manu-

factured for that duty.

1.5 Moving parts

A. Keep hands, arms and other parts of the body and

clothing away from couplings, belts, pulleys, fans and

other moving parts.

B. DO NOT attempt to operate the compressor with the

fan, coupling or other guards removed.

C. Wear snug-fitting clothing and confine long hair when

working around this compressor, especially when

exposed to hot or moving parts.

D. Keep access doors, if any, closed except when mak-

ing repairs or adjustments.

ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 1: Safety

88291013-137 R05

Subject to EAR, ECCN EAR99 and related export control restrictions. 3

E. Make sure all personnel are out of and/or clear of the

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.

This is especially important when compressors are

remotely controlled.

G. Keep hands, feet, floors, controls and walking sur-

faces clean and free of fluid, water or other liquids to

minimize the possibility of slips and falls.

1.6 Hot surfaces, sharp edges and

sharp corners

A. Avoid bodily contact with hot fluid, hot coolant, hot

surfaces and sharp edges and corners.

B. Keep all parts of the body away from all points of air

discharge.

C. Wear personal protective equipment including gloves

and head covering when working in, on or around the

compressor.

D. Keep a first aid kit handy. Seek medical assistance

promptly in case of injury. DO NOT ignore small cuts

and burns as they may lead to infection

1.7 Toxic and irritating substances

A. DO NOT use air from this compressor for respiration

(breathing) except in full compliance with OSHA

Standards 29 CFR 1910 and/or any applicable Fed-

eral, State or Local codes or regulations.

B. DO NOT use air line anti-icer systems in air lines

supplying respirators or other breathing air utilization

equipment and DO NOT discharge air from these

systems into unventilated or other confined areas.

C. Operate the compressor only in open or adequately

ventilated areas.

D. Locate the compressor or provide a remote inlet so

that it is not likely to ingest exhaust fumes or other

toxic, noxious or corrosive fumes or substances.

E. Coolants and lubricants used in this compressor are

typical of the industry. Care should be taken to avoid

accidental ingestion and/or skin contact. In the event

of ingestion, seek medical treatment promptly. Wash

with soap and water in the event of skin contact.

Consult Material Safety Data Sheet for information

pertaining to fluid of fill.

F. Wear goggles or a full face shield when adding anti-

freeze compound to air line anti-icer systems.

G. If air line anti-icer system antifreeze compound

enters the eyes or if fumes irritate the eyes, they

should be washed with large quantities of clean

water for fifteen minutes. A physician, preferably an

eye specialist, should be contacted immediately.

H. DO NOT store air line anti-icer system antifreeze

compound in confined areas.

I. The antifreeze compound used in air line antifreeze

systems contains methanol and is toxic, harmful or

fatal if swallowed. Avoid contact with the skin or eyes

and avoid breathing the fumes. If swallowed, induce

vomiting by administering a tablespoon of salt, in

each glass of clean, warm water until vomit is clear,

then administer two teaspoons of baking soda in a

glass of clean water. Have patient lay down and

DANGER

Death or serious injury can result from inhaling

compressed air without using proper safety

equipment. See OSHA standards and/or any

applicable Federal, State, and Local codes, stan-

dards and regulations on safety equipment.

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88291013-137 R05

4 Subject to EAR, ECCN EAR99 and related export control restrictions.

cover eyes to exclude light. Call a physician immedi-

ately.

1.8 Electrical shock

A. This compressor should be installed and maintained

in full compliance with all applicable Federal, State

and Local codes, standards and regulations, includ-

ing those of the National Electrical Code, and also

including those relative to equipment grounding con-

ductors, and only by personnel that are trained, qual-

ified and delegated to do so.

B. Keep all parts of the body and any hand-held tools or

other conductive objects away from exposed live

parts of electrical system. Maintain dry footing, stand

on insulating surfaces and DO NOT contact any

other portion of the compressor when making adjust-

ments or repairs to exposed live parts of the electrical

system. Make all such adjustments or repairs with

one hand only, so as to minimize the possibility of

creating a current path through the heart.

C. Attempt repairs in clean, dry and well lighted and

ventilated areas only.

D. DO NOT leave the compressor unattended with open

electrical enclosures. If necessary to do so, then discon-

nect, lock out and tag all power at source so others will

not inadvertently restore power.

E. Disconnect, lock out, and tag all power at source

prior to attempting repairs or adjustments to rotating

machinery and prior to handling any ungrounded

conductors.

1.9 Lifting

A. If the compressor is provided with a lifting bail, then

lift by the bail provided. If no bail is provided, then lift

by sling. Compressors to be air-lifted by helicopter

must not be supported by the lifting bail but by slings

instead. In any event, lift and/or handle only in full

compliance with OSHA standards 29 CFR 1910 sub-

part N and/or any applicable Federal, State, and

Local codes, standards and regulations.

B. Inspect points of attachment for cracked welds and

for cracked, bent, corroded or otherwise degraded

members and for loose bolts or nuts prior to lifting.

C. Make sure entire lifting, rigging and supporting struc-

ture has been inspected, is in good condition and has

a rated capacity of at least the weight of the com-

pressor. If you are unsure of the weight, then weigh

compressor before lifting.

D. Make sure lifting hook has a functional safety latch or

equivalent, and is fully engaged and latched on the

bail or slings.

E. Use guide ropes or equivalent to prevent twisting or

swinging of the compressor once it has been lifted

clear of the ground.

F. DO NOT attempt to lift in high winds.

G. Keep all personnel out from under and away from the

compressor whenever it is suspended.

H. Lift compressor no higher than necessary.

I. Keep lift operator in constant attendance whenever

compressor is suspended.

DANGER

All field equipment must be tested for electro-

static fields prior to servicing or making contact

with the machine using the following or equiva-

lent test equipment:

• 90 – 600 VAC: Volt detector such as

Fluke Model 1AC-A

• 600 – 7000 VAC: Voltage detector such

as Fluke Networks Model C9970

It is the responsibility of each organization to

provide/arrange training for all their associates

expected to test for electrostatic fields.

ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 1: Safety

88291013-137 R05

Subject to EAR, ECCN EAR99 and related export control restrictions. 5

J. Set compressor down only on a level surface capa-

ble of safely supporting at least its weight and its

loading unit.

K. When moving the compressor by forklift truck, utilize

fork pockets if provided. Otherwise, utilize pallet if

provided. If neither fork pockets or pallet are pro-

vided, then make sure compressor is secure and well

balanced on forks before attempting to raise or trans-

port it any significant distance.

L. Make sure forklift truck forks are fully engaged and

tipped back prior to lifting or transporting the com-

pressor.

M. Forklift no higher than necessary to clear obstacles

at floor level and transport and corner at minimum

practical speeds.

N. Make sure pallet-mounted compressors are firmly

bolted or otherwise secured to the pallet prior to

attempting to forklift or transport them. NEVER

attempt to forklift a compressor that is not secured to

its pallet, as uneven floors or sudden stops may

cause the compressor to tumble off, possibly causing

serious injury or property damage in the process.

1.10 Entrapment

A. If the compressor enclosure, if any, is large enough

to hold a man and if it is necessary to enter it to per-

form service adjustments, inform other personnel

before doing so, or else secure and tag the access

door in the open position to avoid the possibility of

others closing and possibly latching the door with

personnel inside.

B. Make sure all personnel are out of compressor

before closing and latching enclosure doors.

1.11 Implementation of lockout/tagout

The energy control procedure defines actions necessary

to lockout a power source of any machine to be repaired,

serviced or set-up, where unexpected motion, or an

electrical or other energy source, would cause personal

injury or equipment damage. The power source on any

machine shall be locked out by each employee doing the

work except when motion is necessary during setup,

adjustment or trouble-shooting.

A. The established procedures for the application of

energy control shall cover the following elements and

actions and shall be initiated only by Authorized Per-

sons and done in the following sequence:

1. Review the equipment or machine to be

locked and tagged out.

2. Alert operator and supervisor of which

machine is to be worked on, and that power

and utilities will be turned off.

3. Check to make certain no one is operating

the machine before turning off the power.

4. Turn off the equipment using normal shut-

down procedure.

5. Disconnect the energy sources:

a. Air and hydraulic lines should be bled,

drained and cleaned out. There should

be no pressure in these lines or in the

reservoir tanks. Lockout or tag lines or

valves.

b. Any mechanism under tension or pres-

sure, such as springs, should be

released and locked out or tagged.

c. Block any load or machine part prior to

working under it.

d. Electrical circuits should be checked with

calibrated electrical testing equipment

and stored energy and electrical capaci-

tors should be safely discharged.

6. Lockout and/or Tagout each energy source

using the proper energy isolating devices

and tags. Place lockout hasp and padlock or

tag at the point of power disconnect where

lockout is required by each person perform-

ing work. Each person shall be provided with

their own padlock and have possession of

the only key. If more than one person is

working on a machine each person shall affix

personal lock and tag using a multi-lock

device.

7. Tagout devices shall be used only when

power sources are not capable of being

locked out by use of padlocks and lockout

hasp devices. The name of the person affix-

ing tag to power source must be on tag along

with date tag was placed on power source.

8. Release stored energy and bring the equip-

ment to a “zero mechanical state”.

9. Verify Isolation: Before work is started, test

equipment to ensure power is disconnected.

B. General Security

1. The lock shall be removed by the “Autho-

rized” person who put the lock on the

energy-isolating device. No one other than

the person/persons placing padlocks and

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88291013-137 R05

6 Subject to EAR, ECCN EAR99 and related export control restrictions.

lockout hasps on power shall remove pad-

lock and lockout hasps and restore power.

However, when the authorized person who

applied the lock is unavailable to remove it

his/her Supervisor may remove padlock/pad-

locks and lockout hasps and restore power

only if it is first:

a. verified that no person will be exposed to

danger.

b. verified that the “Authorized” person who

applied the device is not in the facility.

c. noted that all reasonable efforts to con-

tact the “Authorized” person have been

made to inform him or her that the lock-

out or tagout device has been removed.

d. ensured that the “Authorized” person is

notified of lock removal before returning

to work.

2. Tagout System—Tags are warning devices

affixed at points of power disconnect and are

not to be removed by anyone other that the

person placing tag on power lockout. Tags

shall never be by-passed, ignored, or other-

wise defeated.

1.12 Safety warnings

The following special instructions apply to VSD packages

provided with electronic adjustable speed motor drives.

These cautions that apply to VSD operation.

WARNING

Ground the unit following the instructions in this

manual. Ungrounded units may cause electric

shock and/or fire. The variable speed drive has a

large capacitive leakage current during opera-

tion, which can cause enclosure parts to be

above ground potential. Proper grounding, as

described in this manual, is required. Failure to

observe this precaution could result in death or

severe injury.

WARNING

Before applying power to the variable speed

drive, make sure that the front and cable covers

are closed and fastened to prevent exposure to

potential electrical fault conditions. Failure to

observe this precaution could result in death or

severe injury.

WARNING

Refer all drive service to trained technicians.

This equipment should be installed, adjusted,

and serviced by qualified electrical maintenance

personnel familiar with the construction and

operation of this type of equipment and the haz-

ards involved and in accordance with published

service manuals. Failure to observe this precau-

tion could result in death or severe injury.

WARNING

Line terminals (L1, L2, L3), motor terminals (U,

V, W) and the DC link/brake resistor terminals (-/

+) are live when the drive is connected to power,

even if the motor is not running. Contact with

this voltage is extremely dangerous and may

cause death or severe injury.

ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 1: Safety

88291013-137 R05

Subject to EAR, ECCN EAR99 and related export control restrictions. 7

WARNING

Before opening the variable speed drive covers:

• Disconnect all power to the variable

speed drive.

• Wait a minimum of 5 (five) minutes

after all the lights on the keypad are

off. This allows time for the DC bus

capacitors to discharge.

• A hazard voltage may still remain in

the DC bus capacitors even if the

power has been turned off. Confirm

that the capacitors have fully dis-

charged by measuring their voltage

using a multimeter set to measure DC

voltage. Failure to follow the above

precautions may cause death or

severe injury.

CAUTION

Do not perform any megger or voltage withstand

tests on any part of the variable speed drive or

its components. Improper testing may result in

damage. Prior to any tests or measurements of

the motor or the motor cable, disconnect the

motor cable at the variable speed drive output

terminals (U, VW) to avoid damaging the vari-

able speed drive during motor or cable testing.

CAUTION

Do not touch any components on the circuit

boards. Static voltage discharge may damage

the components.

CAUTION

Install the variable speed drive in a well venti-

lated room that is not subject to temperature

extremes, high humidity, or condensation, and

avoid locations that are directly exposed to sun-

light, or have high concentrations of dust, corro-

sive gas, explosive gas, inflammable gas,

grinding fluid mist, etc. Improper installation may

result in a fire hazard.

CAUTION

Make sure that no power correction capacitors

are connected to the variable speed drive output

or the motor terminals to prevent variable speed

drive malfunction and potential damage.

CAUTION

Make sure that the variable speed drive output

terminals (U, V, W) are not connected to the util-

ity line power as severe damage to the VSD may

occur.

NOTE

Interior electrical wiring is performed at the fac-

tory. Required customer wiring is minimal, but

should be done by a qualified electrician in com-

pliance with OSHA, National Electrical Code,

and/or any other applicable State, Federal, and

local electrical codes concerning isolation

switches, fused disconnects, etc. Sullair pro-

vides a wiring diagram for use by the installer.

NOTE

Customer must provide electrical supply power

disconnect within sight of machine.

1: Safety ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual

Notes:

88291013-137 R05

8 Subject to EAR, ECCN EAR99 and related export control restrictions.

Section 2

ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 2: Description

88291013-137 R05

Subject to EAR, ECCN EAR99 and related export control restrictions. 9

Description

2.1 The air compression cycle

The ShopTek™ air compressor uses a lubricated rotary

screw air end and supporting components to create com-

pressed air.

When the rotors inside the air end turn, they draw outside

air into the compressor through the air inlet system. As

the rotors compress this air from atmospheric pressure to

the target pressure, the lubrication system injects fluid

into the air end to cool the compressed air, lubricate the

rotors and bearings, and create a seal between the rotors

and the air end casing.

After leaving the air end, the compressed air/fluid mixture

flows into the fluid/air separation system. First, the fluid/

air separator tank separates the majority of the fluid from

the compressed air using a combination of centrifugal

force, impingement, and gravity. Then the compressed

air passes through the fluid/air separator element to

remove almost all of the remaining fluid.

Next, the compressed air flows through the aftercooler.

The aftercooler cools the compressed air to 8 – 12°C

(14 – 22°F) above the ambient temperature. The com-

pressed air then flows through the moisture separator (if

installed). The moisture separator collects the water

vapor that condensed when the compressed air was

cooled.

After leaving the aftercooler (or the moisture separator, if

installed), the compressed air flows through the service

connector of the compressor for downstream use.

2: Description ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual

88291013-137 R05

10 Subject to EAR, ECCN EAR99 and related export control restrictions.

Figure 2-1: ST18 & ST22 machine layout

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

ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 2: Description

88291013-137 R05

Subject to EAR, ECCN EAR99 and related export control restrictions. 11

Figure 2-2: ST18 & ST22 piping and instrumentation

Key Description

1Air filter

2 Inlet valve

3 Capacity control integrated system

4Oil cooler

5 Pressure switch

6 Indicator

7 Aftercooler

8 Minimum pressure valve

9 Single-stage fluid/air separator element

10 Strainer

11 Moisture separator

12 Pressure sensor

13 Temperature sensor

14 Compressor air end

15 Relief valve

16 Fluid/air separator tank

17 Sight glass

18 Oil plug

19 Fluid filter

20 Fluid filter pressure difference indicator

21 Strainer

22 Sight glass

23 Orifice

24 Thermal valve

2: Description ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual

88291013-137 R05

12 Subject to EAR, ECCN EAR99 and related export control restrictions.

2.2 Air inlet system

The air inlet system provides air for the compressor to

pressurize. The primary components of the air inlet sys-

tem are the air filter, inlet valve, and compressor air end.

2.2.1 General operation of the air inlet

system

The air end draws outside air through the air filter and

inlet valve into the air end compression chamber. Inside

the compression chamber, a male and female rotor pair

revolve at high speed, compressing the air and increas-

ing its pressure. When the compressed air/fluid mixture

reaches the end of the compression chamber, the mix-

ture flows through the air end discharge port into the

fluid/air separator.

2.2.2 Air filter

The air filter removes particulates from the intake air, pro-

viding clean air to the compressor. If these particulates

were not removed, they could wear down rotor surfaces

and contaminate the compressor fluid.

2.2.2.1 Air filter element

Because the air filter element traps the particulates it fil-

ters from the air on its surface, the air filter element must

be changed periodically to maintain the air filter’s effec-

tiveness.

Additional information

• For the recommended air filter maintenance

schedule, see Section 6.3: Recommended

maintenance schedule on page 28.

• For instructions on how to change the air filter

element, see Section 6.4.4: Air filter mainte-

nance on page 30.

2.2.3 Inlet valve

The inlet valve controls intake air volume using a modula-

tion control system.

2.2.3.1 Inlet modulation

To minimize the number of starts and stops the compres-

sor makes, the inlet modulation system automatically

adjusts the size of the inlet valve opening to match air

demand. The primary components of the inlet modulation

system are the solenoid valve, inlet valve, blowdown

valve, and control line.

When air demand is equal to or greater than the com-

pressors rating, the compressor will run at full load. The

solenoid valve is energized, closing the control line.

Because the control is not in use, the inlet valve of the air

end is fully open.

When air demand is lower than the compressor rating,

discharge pressure builds up slowly. Once the discharge

pressure reaches the unload setting of the controller, the

compressor will switch to unload mode. The solenoid

valve is de-energized, opening the control line. Because

the control line is in use and the discharge pressure is

high, the control line closes the inlet valve. At the same

time, the blowdown valve opens to release the pressure

in the fluid/air separator tank until the pressure stabilizes

at 15 – 25 psi.

Now the compressor will run with no load for a preset

time. Once the preset time is reached, the compressor

will stop. However, if the discharge pressure drops to the

load setting of the controller before the preset time is

reached, the compressor re-enters load mode. The sole-

noid valve is energized, closing the control line. Because

the control is not in use, the inlet valve of the air end is

fully open.

2.3 Discharge system

The discharge system pushes air from the compressor

air end to the service connector. The primary compo-

nents of the discharge system are the compressor air

end, fluid/air separator, minimum pressure valve, pres-

sure relief valve, automatic blowdown valve, aftercooler,

moisture separator (optional), and service connector.

2.3.1 General operation of the discharge

system

The compressed air/fluid mixture flows through the air

end discharge port into the fluid/air separator tank and

separator element. The separator tank and element

remove fluid from the air.

The compressed air then flows through the minimum

pressure valve, followed by the aftercooler, then the

moisture separator (if installed). Once the air is cooled

and the moisture removed (if the moisture separator is

installed), the air flows to the service connector for down-

stream use.

To lower the frequency of the compressor’s load/unload

cycles and extend the life of the compressor, Sullair rec-

WARRANTY NOTICE

Failure to follow the air filter maintenance sched-

ule or use Sullair genuine air filter elements can

cause early contamination of the compressor

fluid and the fluid/air separator element and may

void your warranty.

ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual 2: Description

88291013-137 R05

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ommends installing a wet air receiver after the service

connector.

Additional information

• For the size of the service connector, see Sec-

tion 3.1: Machine specifications on page 17.

2.3.2 Minimum pressure valve

The minimum pressure valve on the top cover of the fluid/

air separator ensures lubricant flow during both normal

operation and start-up by keeping pressure in the fluid/air

separator above 340 kPa (49.3 psi).

When pressure in the fluid/air separator is above 340 kPa

(49.3 psi) and higher than the downstream pipeline pres-

sure, the minimum pressure valve will be opened. Other-

wise, the minimum pressure valve will be closed to

maintain minimum tank pressure.

The minimum pressure valve also functions as a check

(non-return) valve, preventing compressed air down-

stream of the separator from flowing back into the sepa-

rator and air end during compressor blowdown.

2.3.3 Automatic blowdown valve

When the compressor is unloading or stopping, the blow-

down valve in the control line automatically opens to

release pressure. The blowdown valve routes the air to

the air inlet pipe (after the air filter) to prevent a com-

pressed air/fluid mixture from venting into the atmo-

sphere.

2.3.4 Pressure relief valve

To prevent damage to the fluid/air separator and other

compressor components the pressure relief valve located

on the fluid/air separator tank will open when the pres-

sure in the separator tank exceeds the pressure relief

valve setpoint.

Under normal operating conditions, the over pressure

stop switch will shut down the compressor before the

pressure relief valve setpoint is reached (see Section 3.1:

Machine specifications on page 17). However, the pres-

sure relief valve serves as an additional mechanical safe-

guard.

2.3.5 Aftercooler

The aftercooler cools the compressed air to 8 – 12°C

(14 – 22°F) above the ambient temperature. This cooling

causes water vapor to condense, which creates moisture

in the compressed air stream.

2.3.6 Moisture separator

The moisture separator removes the moisture from the

compressed air stream. Moisture collected by the mois-

ture separator can then be safely disposed of according

to local regulations.

2.4 Lubrication system

The lubrication system cools the compressor; lubricates

the rotors, bearings, and gears; and seals the air end

against leaks. The primary components of the lubrication

system are the compressor air end, fluid/air separator,

thermal valve, aftercooler, fluid filter, and interconnecting

piping.

2.4.1 General description of the lubrication

system

Fluid is injected into the air end compression chamber,

where it is compressed along with the intake air. The

compressed air/fluid mixture then flows into the fluid/air

separation system, which separates the fluid from the air

and collects the fluid for re-use. Depending on the fluid

temperature, the thermal valve routes none, some, or all

of the fluid to the aftercooler for cooling. Fluid that has

passed through the aftercooler, or that was not routed to

the aftercooler, flows through the fluid filter into the air

end to restart the lubrication cycle.

2.4.2 Lubricating fluid

The lubricating fluid provides three benefits.

•Cooling. The compressor fluid acts as a cool-

ant, absorbing the large amount of heat gener-

ated during compression.

•Lubricating. The compressor fluid forms a

layer between the rotors, preventing the male

and female rotors from making direct contact

and minimizing the surface wear of the rotors.

The compressor fluid also lubricates the bear-

ings and gears.

•Sealing. Compressor fluid with sufficient vis-

cosity can fill the gaps between rotors and

between the rotors and the casing. This

reduces air lost through leakage and increases

the efficiency of the compressor.

NOTE

The moisture separator ships loose for the cus-

tomer to install if needed for their installation. It is

not installed by the factory.

2: Description ST18 & ST22 (U.S.A. & Mexico) Operation & Maintenance Manual

88291013-137 R05

14 Subject to EAR, ECCN EAR99 and related export control restrictions.

Additional information

• For the viscosity required for the compressor

fluid to act as a sealant, see Section 3.2: Lubri-

cant specifications on page 17.

2.4.3 Fluid filter

The fluid filter collects any impurities in the compressor

fluid and ensures that only clean fluid enters the air end

compression chamber and internal lubrication feeds. If

these impurities in the fluid were not removed, they would

cause wear on the rotor and gear surfaces and bearings

and shorten the life of compressor.

2.4.3.1 Fluid filter element

Because the fluid filter element collects impurities on its

surface, the fluid filter element must be replaced regularly

to ensure good fluid circulation for proper lubrication and

cooling.

Additional information

• For the recommended fluid filter maintenance

schedule, see Section 6.3: Recommended

maintenance schedule on page 28.

• For instructions on how to change the fluid filter

element, see Section 6.4.3: Fluid filter mainte-

nance on page 30.

2.4.4 Purge oil return line

The purge oil return line located on the cover of the fluid/

air separator passes the compressor fluid collected by

the fluid/air separator element through the purge line fil-

ter, then returns the clean fluid to the compressor air end.

A small orifice in the purge oil return line limits return air

flow, minimizing the loss of compressed air. A sight glass

located in the purge line allows an operator to observe

the amount of fluid returning from the separator element.

2.5 Cooling system

The cooling system maintains a proper operating temper-

ature for the compressor.

2.5.1 General description of the cooling

system

Suction created by an axial flow cooling fan pulls cooling

air through louvers on both sides of the compressor. This

cooling air draws heat from the aftercooler before flowing

out of the machine.

2.5.2 Ambient temperature

Sullair ShopTek™ compressors are designed to operate

in ambient temperatures between 4°C and 40°C (40°F

and 104°F), measured at the cooling air inlet. If you need

to operate the compressor in a temperature outside this

range, contact your Sullair representative.

2.5.2.1 High ambient temperature and

overheating

If the ambient temperature is above 40°C (104°F), the air

drawn into the compressor may be too hot to adequately

cool the compressor fluid or the electric motor when the

compressor is operating at full load. If the compressor

load is less than 100%, operating the compressor in

higher ambient temperatures may be possible.

Regardless of the ambient temperature, the maximum

recommended operating temperature is 108°C (226°F).

2.6 Fluid/air separation system

The fluid/air separator system removes the fluid from the

compressed air stream. The primary components of the

fluid/air separation system are the fluid/air separator tank

and fluid/air separator element.

2.6.1 General description of the fluid/air

separation system

The compressed air/fluid mixture from the air end flows

into the fluid/air separator and strikes the wall of the sep-

arator tank, causing large drops of fluid to form because

of the lower air speed. Most of these fluid drops attach to

the wall of the tank, and gravity causes the drops to col-

lect at the bottom of the tank. The thermal valve then

routes this collected fluid back to the air end through the

aftercooler (if necessary) and the filter.

CAUTION

Continuously exceeding the maximum operating

temperature will damage the compressor.

CAUTION

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.

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SULLAIR ShopTek ST18 Operation & Maintenance Manual

Brand: SULLAIR

Model: ShopTek ST18

Category: Air compressors

Type: Operation & Maintenance Manual

This manual is also suitable for

ShopTek ST22

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SULLAIR ShopTek ST18 Operation & Maintenance Manual

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SULLAIR ShopTek ST18 Operation & Maintenance Manual

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