SULLAIR 02250179-685 User manual

Brand: SULLAIR

Model: 02250179-685

Category: Air compressors

Type: User manual

Failure to follow the instructions

and procedures in this manual or,

misuse of this equipment will

VOID its warranty!

WARRANTY NOTICE

PART NUMBER:

KEEP FOR

FUTURE

REFERENCE

USER MANUAL

SULLAIR CORPORATION

The information in this manual is current

as of its publication date, and applies to

compressor serial number:

and all subsequent serial numbers.

02250180-090 R01

Base Mount: C03-C20350

Tank Mount: 200811010000

INDUSTRIAL AIR COMPRESSOR

SHOPTEK

™

ST400, ST500, ST700, ST1100, ST1500

4, 5, 7, 11 &15

KW: 5, 7.5, 10, 15 & 20 HP

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 Industrial 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.

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 CUSTOMER CARE TRAINING DEPARTMENT

1-888-SULLAIR or

219-879-5451 (ext. 5623)

www.sullair.com

- Or Write -

Sullair Corporation

3700 E. Michigan Blvd.

Michigan City, IN 46360

Attn: Service Training Department.

TABLE OF CONTENTS

SECTION 1—SAFETY

3 1.1 GENERAL

3 1.2 PERSONAL PROTECTIVE EQUIPMENT

3 1.3 PRESSURE RELEASE

4 1.4 FIRE AND EXPLOSION

4 1.5 MOVING PARTS

5 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

5 1.7 TOXIC AND IRRITATING SUBSTANCES

6 1.8 ELECTRICAL SHOCK

6 1.9 LIFTING

7 1.10 ENTRAPMENT

SECTION 2—DESCRIPTION

9 2.1 INTRODUCTION

9 2.2 COMPRESSOR COMPONENT DESCRIPTION

14 2.3 COMPRESSOR COOLING AND LUBRICATION SYSTEM — FUNC-

TIONAL DESCRIPTION

14 2.4 COMPRESSOR DISCHARGE SYSTEM—FUNCTIONAL DESCRIPTION

14 2.5 CONTROL SYSTEM — FUNCTIONAL DESCRIPTION

17 2.6 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

18 2.7 CONTROLLER/KEYPAD

18 2.8 LCD DISPLAY

19 2.9 LED LIGHTS

SECTION 3—SPECIFICATIONS

21 3.1 TABLE OF SPECIFICATIONS

22 3.2 COMPRESSOR SPECIFICATIONS

22 3.3 LUBRICATION GUIDE

22 3.4 APPLICATION GUIDE

23 3.5 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE,

FLUID FILTER AND SEPARATOR

36 3.6 TANK MOUNT AND DRYER OPTIONS

SECTION 4—INSTALLATION

49 4.1 COMPRESSOR MOUNTING - SUPPORT AND LOCATION

49 4.2 VENTILATION AND COOLING

51 4.3 SERVICE AIR PIPING

52 4.4 BELT CHECK

52 4.5 FLUID LEVEL CHECK

53 4.6 ELECTRICAL PREPARATION

53 4.7 MOTOR ROTATION DIRECTION CHECK

TABLE OF CONTENTS

SECTION 5—OPERATION

55 5.1 ROUTINE OPERATION

SECTION 6—MAINTENANCE

57 6.1 GENERAL

57 6.2 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION

58 6.3 MAINTENANCE EVERY 2000 HOURS

58 6.4 FLUID MAINTENANCE

58 6.5 FILTER MAINTENANCE

59 6.6 AIR FILTER MAINTENANCE

60 6.7 SEPARATOR MAINTENANCE

61 6.8 BELT MAINTENANCE

65 6.9 REPLACEMENT AND ALIGNMENT OF BELT PULLEYS

66 6.10 HOSE MAINTENANCE

66 6.11 TANK MOUNT PACKAGE MAINTENANCE

66 6.12 TROUBLESHOOTING – INTRODUCTION

Section 1

SAFETY

1.1 GENERAL

Sullair Corporation 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 conscientiously 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

compressors with all types of prime movers, most of

the precautionary statements contained herein are

applicable to most compressors and the concepts

behind these statements are generally applicable to

all compressors.

1.2 PERSONAL PROTECTIVE

EQUIPMENT

A. Prior to installing or operating the compressor,

owners, employers and users should become

familiar with, and comply with, all applicable

OSHA regulations and/or any applicable Federal,

State and Local codes, standards, and regula-

tions relative to personal protective equipment,

such as eye and face protective equipment,

respiratory protective equipment, equipment

intended to protect the extremities, protective

clothing, protective shields and barriers and elec-

trical protective equipment, as well as noise

exposure administrative and/or engineering con-

trols and/or personal hearing protective equip-

ment.

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 exceed-

ing 1/2" (13mm) inside diameter is to be con-

nected to the shut-off (throttle) valve, to reduce

pressure in case of hose failure, per OSHA Stan-

dard 29 CFR 1926.302(b)(7) and/or any applica-

ble Federal, State and Local codes, standards

and regulations.

B. When the hose is to be used to supply a mani-

fold, install an additional appropriate flow-limiting

valve between the manifold and each air hose

exceeding 1/2" (13mm) 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 (23m) of

hose in runs of air hose exceeding 1/2" (13mm)

NOTE

OPERATOR IS REQUIRED TO READ

ENTIRE INSTRUCTION MANUAL.

SECTION 1

inside diameter 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 accordance with their manufacturer's recom-

mendations.

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

maximum rating of the compressor. Select air

tools, air hoses, pipes, valves, filters and other

fittings accordingly. DO NOT exceed manufac-

turer'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

running and is not pressurized. Shut down the

compressor and bleed the receiver tank to zero

internal pressure before removing the cap.

H. Vent all internal pressure prior to opening any

line, fitting, 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 effec-

tive chip guarding and personal protective equip-

ment per OSHA Standard 29 CFR 1910.242 (b)

and/or any applicable Federal, State, and Local

codes, standards 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

substances 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 anti-

freeze compound.

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

system antifreeze compound or fluid film, to

accumulate on, under or around acoustical mate-

rial, or on any external surfaces of the air com-

pressor. Wipe down using an aqueous industrial

cleaner or steam clean as required. If necessary,

remove acoustical material, clean all surfaces

and then replace acoustical material. Any acous-

tical material with a protective covering that has

been torn or punctured should be replaced

immediately to prevent accumulation of liquids or

fluid film within the material. DO NOT use flam-

mable solvents for cleaning purposes.

D. Disconnect and lock out all power at source prior

to attempting any repairs or cleaning of the com-

pressor 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 oth-

erwise degraded insulation, or terminals that are

worn, discolored 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 sup-

port combustion and is in close proximity, prior to

attempting weld repairs.

H. Keep suitable fully charged Class BC or ABC fire

extinguisher or extinguishers nearby when ser-

vicing and operating the compressor.

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

bustibles 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 lubricant 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 manufactured 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.

SECTION 1

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

making repairs or adjustments.

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

verify at the compressor that all circuits are de-

energized to minimize the possibility of acciden-

tal start-up, or operation, prior to attempting

repairs or adjustments. This is especially impor-

tant when compressors are remotely controlled.

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

surfaces 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 assis-

tance promptly in case of injury. DO NOT ignore

small cuts and burns as they may lead to infec-

tion

1.7 TOXIC AND IRRITATING

SUBSTANCES

A. DO NOT use air from this compressor for respi-

ration (breathing) except in full compliance with

OSHA Standards 29 CFR 1910 and/or any appli-

cable Federal, State or Local codes or regula-

tions.

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

supplying respirators or other breathing air utili-

zation equipment and DO NOT discharge air

from these systems into unventilated or other

confined areas.

C. Operate the compressor only in open or ade-

quately 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 sub-

stances.

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

antifreeze 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 immedi-

ately.

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

compound in confined areas.

I. The antifreeze compound used in air line anti-

freeze systems contains methanol and is toxic,

harmful or fatal if swallowed. Avoid contact with

the skin or eyes and avoid breathing the fumes. If

DANGER

Death or serious injury can result from

inhaling compressed air without using

proper safety equipment. See OSHA stan-

dards and/or any applicable Federal, State,

and Local codes, standards and regulations

on safety equipment.

SECTION 1

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 cover eyes to

exclude light. Call a physician immediately.

1.8 ELECTRICAL SHOCK

A. This compressor should be installed and main-

tained in full compliance with all applicable Fed-

eral, State and Local codes, standards and

regulations, including those of the National Elec-

trical Code, and also including those relative to

equipment grounding conductors, and only by

personnel that are trained, qualified and dele-

gated 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 adjustments 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 disconnect, 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 stan-

dards 29 CFR 1910 subpart N and/or any appli-

cable 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

structure has been inspected, is in good condi-

tion and has a rated capacity of at least the

weight of the compressor. 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.

DANGER

All field equipment must be tested for elec-

trostatic fields prior to servicing or making

contact with the machine using the follow-

ing or equivalent 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.

SECTION 1

I. Keep lift operator in constant attendance when-

ever compressor is suspended.

J. Set compressor down only on a level surface

capable 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 provided, then make sure compressor is

secure and well balanced on forks before

attempting to raise or transport it any significant

distance.

L. Make sure forklift truck forks are fully engaged

and tipped back prior to lifting or transporting the

compressor.

M. Forklift no higher than necessary to clear obsta-

cles 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 sud-

den 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 perform 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 possi-

bly latching the door with personnel inside.

B. Make sure all personnel are out of compressor

before closing and latching enclosure doors.

NOTES

Section 2

SHOPTEK

™

USER MANUAL

02250180-090 R00

DESCRIPTION

2.1 INTRODUCTION

The design of the Sullair ShopTek line of compressor

units is a single stage, positive displacement, flooded

rotary screw. A complete package includes the:

• Compressor unit

• Electric motor

•Starter

• Compressor inlet and discharge systems

• Compressor lubrication and cooling system

• Controller

• Aftercooler (ST1100 and ST1500 only)

• Heavy gauge steel mounting frame

New compressors are shipped from the factory fully

charged with Sullube lubrication fluid. The

SPECIFICATIONS Section 3.3 and Section 3.4

describe lubrication requirements and

recommendations for each compressor package.

External piping, connectors, and the enclosure

should be inspected and maintained in accordance

with the procedures and recommendations in this

manual.

2.2 COMPRESSOR

COMPONENT DESCRIPTION

The ShopTek compressor (Figure 2-1 and Figure 2-

2) uses a fan to draw outside air into the enclosure,

cooling the motors, the combined radiator fluid

cooler, and air aftercooler. This hot air is then vented

out of the top of the enclosure.

Fluid is injected into the compressor, and mixes

directly with the air as the rotors turn which

compresses the air. The fluid flow has three basic

functions:

1. As a coolant, it controls the air temperature

rise normally associated with the heat of

compression.

2. Seals the clearance paths between the

rotors and the stator, and also between the

two rotors.

3. Provides a lubricating film between the rotors

allowing one rotor to directly drive the other,

which is an idler, and also lubricates the

bearings.

After the air/fluid mixture is discharged from the

compressor unit, the fluid is separated from the air.

At this time, the air flows through an aftercooler and

separator, and then to the service line while the fluid

is cooled and filtered in preparation for reinjection.

CAUTION

Use only one type of a recommended com-

pressor lubricant. Adding a different one, or

mixing lubricants can cause damage and/or

malfunctions, and will void the compres-

sor’s warranty.

NOTE

The compressor requires no internal

inspections or maintenance actions. Open-

ing the compressor’s housing may void its

warranty. (This does not apply to the shaft

seal or inlet valve which are replaceable.)

SHOPTEK

™

USER MANUAL SECTION 2

02250180-090 R00

Figure 2-1: Main Components, ST400, ST500, ST 700, 5 -10 HP

1. Fluid Filter 7. E-Stop Button

2. Fluid Cooler 8. Controller

3. Air Inlet Filter 9. Main Motor

4. Separator Tube 10. Compressor Unit

5. Fluid Fill Sight Glass 11. Cooler Fan Motor

6. Fluid Fill

SECTION 2 SHOPTEK

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USER MANUAL

02250180-090 R00

Figure 2-2: Main Components, ST1100, ST1500, 15-20 HP

1. Fluid Filter 7. E-Stop Button

2. Aftercooler/Fluid Cooler 8. Controller

3. Air Inlet Filter 9. Main Motor

4. Separator Tube 10. Compressor Unit

5. Fluid Fill Sight Glass 11. Cooler Fan Motor

6. Fluid Fill

SHOPTEK

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USER MANUAL SECTION 2

02250180-090 R00

DISCHARGE SYSTEM

COOLING/LUBRICATION

SYSTEM

Figure 2-3: Cooling/Lubrication and Discharge System ST400, ST500 and ST700 5-10 HP

1. Separator Tube 5. Separator Element

2. Cooler 6. Air

3. Fluid Filter 7. Air/Fluid Mix

4. Compressor Unit 8. Fluid

SECTION 2 SHOPTEK

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USER MANUAL

02250180-090 R00

DISCHARGE SYSTEM

COOLING/LUBRICATION

SYSTEM

Figure 2-4: Cooling/Lubrication and Discharge System ST1100 and ST1500 15 & 20 HP

1. Separator Tube 5. Separator Element

2. Cooler 6. Air

3. Fluid Filter 7. Air/Fluid Mix

4. Compressor Unit 8. Fluid

SHOPTEK

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USER MANUAL SECTION 2

02250180-090 R00

2.3 COMPRESSOR COOLING

AND LUBRICATION SYSTEM

— FUNCTIONAL

DESCRIPTION

Refer to Figure 2-3 and Figure 2-4. The cooling and

lubrication system consists of a fan, fan motor,

aftercooler (ST1100/ST1500 15-20HP only) /fluid

cooler, full flow fluid filter, thermal valve,

interconnecting hoses and separator tube.

The pressure in the separator tube starts the fluid

flow by forcing the fluid from the high pressure area

of the tube to an area of lower pressure in the

compressor unit. Fluid flows from the bottom of the

separator/tube to the thermal valve that is fully open

when the fluid temperature is below 185°F (85°C)

[195°F (91°C) for pressures rated above 150 psig].

The fluid passes through the thermal valve, the fluid

filter, and directly to the compressor where it

lubricates, cools and seals the rotors, and the

compression chamber.

As the discharge temperature rises above 185°F

(85°C), due to the heat of compression, the thermal

valve begins to adjust and a portion of the fluid then

flows through the cooler. From the cooler the fluid

flows to the fluid filter and on to the compressor. A

portion of the fluid flow to the compressor is routed to

the anti-friction bearings which support the

compressor rotors.

The fluid filter must be replaced. Refer to Section 3.5:

Lubrication Change Recommendations and

Maintenance, Fluid Filter And Separator on page 23.

2.4 COMPRESSOR DISCHARGE

SYSTEM—FUNCTIONAL

DESCRIPTION

Refer to Figure 2-3 and Figure 2-4. The compressor

discharges the compressed air/fluid mixture into the

separator/tube. The separator/tube has three basic

functions:

1. It acts as a primary fluid separator.

2. Serves as the compressor fluid sump.

3. Houses the final fluid separator.

The compressed air/fluid mixture enters the

separator/tube and flows through an internal baffle

system that changes the flow’s direction and velocity,

which causes most of the fluid to fall to the bottom of

the separator tube. A small amount of fluid remaining

in the compressed air collects on the surface of the

separator element as the air flows through the

separator.

A return line (or scavenge tube) leads from the dry

side of the separator tube to the medium pressure

region. Scavanged fluid is returned by a pressure

differential between the separator tube and

compressor.

The separator system reduces the fluid carry-over to

less than 2 ppm at nominal rated pressures.

The Controller will shut down the compressor if the

discharge temperature reaches 235°F (113°C).

A minimum pressure/check valve located

downstream from the separator maintains the

separator tube pressure at 50 psig (3.4 bar) during

load conditions. This pressure level is necessary for

proper air/fluid separation and sufficient fluid

circulation.

A terminal check valve is a sub-component of the

minimum pressure/check valve that prevents

compressed air in the service line from back-flowing

into the separator tube on shutdown or when the

compressor is operating in an unload condition. Also,

a pressure relief valve on the compressor’s wet side

opens if the separator tube pressure exceeds its

rating.

Add fluid to the separator tube through the capped

fluid fill port. There is also a sight glass that enables

the user to check the separator tube fluid level. See

Fluid Level Check on page 52.

2.5 CONTROL SYSTEM —

FUNCTIONAL DESCRIPTION

Refer to Figure 2-5 and Figure 2-6. The compressor

control system regulates its output to match the

demand. This system consists of a solenoid valve

and an inlet valve that control the compressor’s

operational modes. The following descriptions of

operational modes apply to a compressor whose

operating range is 112 to 127 psig (7.7 to 8.8 bar)

WARNING

Stop the compressor and relieve all internal

pressure before removing caps, plugs, and/

or other components when the compressor

is running or pressurized.

SECTION 2 SHOPTEK

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USER MANUAL

02250180-090 R00

START MODE - 0 TO 50 PSIG (0 TO 3.5 BAR)

There is no load on the compressor at startup, the

solenoid valve is open and the inlet valve is closed.

When the compressor (START) pad is pressed,

the separator tube pressure rises from 0 to 50 psig (0

- 3.4 bar). When it reaches its full operating speed

(maximum rpm), the compressor switches to the Full

Load Mode.

FULL LOAD MODE - 50 TO 127 PSIG (3.4 TO

8.8 BAR)

When the compressed air pressure rises above 50

psig (3.4 bar), the minimum pressure valve opens

allowing compressed air to flow into the service line.

From this point on, the Controller continuously

monitors the line air pressure. The solenoid valve

remains closed in this mode. As long as the

compressor is running at 127 psig (8.8 bar) or lower,

the inlet valve is fully open.

UNLOAD MODE - GREATER THAN 127 PSIG

(8.8 BAR)

When there is no, or only a small demand, the

Other pressure settings can be selected depending

on compressor application or rating.

Figure 2-5: Control System, ST400, ST500, ST700, 5-10 HP

1. Air Outlet 5. Separator Tube

2. Unload Solenoid Valve 6. Pressure Transducer

3. Air Inlet 7. Controller

4. Minimum Pressure/Check Valve 8. Check Valve

SHOPTEK

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USER MANUAL SECTION 2

02250180-090 R00

service line pressure will rise. The Controller de-

energizes the solenoid valve when the pressure

exceeds 127 psig (8.8 bar) allowing the separator

tube air pressure to be supplied directly which closes

the inlet valve. At the same time the solenoid valve

exhausts the system pressure to the atmosphere and

lowers the separator tube pressure to approximately

29 psig (2.0 bar). A check valve in the air service line

prevents air from back-flowing to the separator tube.

When the pressure drops to the low setting: (cut-in

pressure) usually 112 psig (7.7 bar) for high pressure

(9 bar) compressors, 137 psig (9.4 bar) for (10 bar)

compressors, 161 psig (11.1 bar) for (12 bar)

compressors: the Controller energizes the solenoid

valve and prevents line pressure from reaching the

inlet control valve.

Figure 2-6: Control System, ST1100, ST1500, 15-20 HP

1. Air Outlet 5. Separator Tube

2. Unload Solenoid Valve 6. Pressure Transducer

3. Air Inlet 7. Controller

4. Minimum Pressure/Check Valve

SECTION 2 SHOPTEK

™

USER MANUAL

02250180-090 R00

2.6 AIR INLET SYSTEM,

FUNCTIONAL DESCRIPTION

Refer to Figure 2-7 and Figure 2-8. The compressor

inlet system consists of a dry-type air filter and an

air inlet valve.

The poppet-type air inlet valve controls the

compressor’s air intake volume. Refer to Full Load

Mode - 50 to 127 psig (3.4 to 8.8 bar) on page 15.

The air inlet valve also acts as a check valve to

prevent reverse rotation when the compressor is shut

down.

Figure 2-7: Air Inet System-ST400, ST500,

ST700, 5-10 HP

1. Air Inlet Filter 4. Clamp

2. Clamp 5. Compressor Unit

3. Inlet Tube

WARNING

"The Plastic Pipe Institute recommends

against the use of thermoplastic pipe to

transport compressed air or other com-

pressed gases in exposed above ground

locations, e.g. in exposed plant piping." (I)

Sullube should not be used with PVC piping

systems. It may affect the bond at cemented

joints. Certain other plastic materials may

also be affected.

(I) Plastic Pipe Institute, Recommendation

B, Adopted January 19, 1972.

Figure 2-8: Air Inet System-ST1100, ST1500,

15-20 HP

1. Air Inlet Filter 3. Inlet Adaptor

2. Clamp 4. Compressor Unit

SHOPTEK

™

USER MANUAL SECTION 2

02250180-090 R00

2.7 CONTROLLER/KEYPAD

Refer to Figure 2-9. The Controller keypad has two

main pads for compressor control. To start the

compressor operation, press the green Start pad

To stop compressor operation, press the red Stop

pad . The Run mode indicator lights up

whenever the control is in an operating mode.

2.8 LCD DISPLAY

The display's normal view shows the compressor

package's discharge pressure, internal temperature,

operating mode, and load status. The modes are

MANUAL, STOP, AUTOMATIC, or FAULT.

Refer to Figure 2-10. If a machine fault occurs, the

red fault indicator will light up, and the display will

indicate that a fault has occurred.

Figure 2-10

67891011

Figure 2-9: Controller Panel

1. Run Mode Indicator Light (Green) 6. Start Button

2. Power On Indicator Light (Red) 7. Return/Reset Button

3. Fault Warning Indicator Light (Red) 8. Cursor/Confirm Button

4. Display Panel 9. Up Button

5. Stop Button 10. Down Button

11. Set/Load/Unload Button

STOP:

RTD Fault

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SULLAIR 02250179-685 User manual

Brand: SULLAIR

Model: 02250179-685

Category: Air compressors

Type: User manual

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SULLAIR 02250179-685 User manual

SULLAIR 02250179-685 User manual

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