SULLAIR OWS-I700 User & Service Manual

Brand: SULLAIR

Model: OWS-I700

Type: User & Service Manual

This manual is also suitable for

SULLAIR OWS-I700 is an oil-water separator designed to remove oil from compressed air condensate. It has a maximum working pressure of 0 psi and a maximum working temperature of 95ºF. The OWS-I700 has a capacity of 1700 cfm for screw compressors with non-emulsifying oils. It has 4x 1/2" condensate inlets, a 1" water discharge, and a 1" oil discharge. The OWS-I700 is made of polyethylene and weighs 60 kg. It has dimensions of 33.5" width, 20.5" depth, and 45.7" height.

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/SERVICE MANUAL

©SULLAIR CORPORATION

02250194-770 R00

OIL WATER SEPARATOR FOR

COMPRESSED AIR CONDENSATE

WITH ACTIVATED CHARCOAL FILTERS FOR

CONDENSATE AND EXHAUSTED AIR

OWS-88 • OWS-2I0 • OWS-420

OWS-880 • OWS-I700 • OWS-2I00

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 TRAINING DEPARTMENT

1-888-SULLAIR or

219-879-5451 (ext. 5623)

www.sullair.com

[email protected]

- Or Write -

Sullair Corporation

3700 E. Michigan Blvd.

Michigan City, IN 46360

Attn: Service Training Department.

TABLE OF CONTENTS

SECTION 1—DESCRIPTION

6 1.1 OIL WATER SEPARATOR MODELS

SECTION 2—INSTALLATION & MAINTENANCE

11 2.1 PLACE OF INSTALLATION

11 2.2 FLOW OF CONDENSATE

11 2.3 CONNECTIONS

11 2.4 START-UP

11 2.5 CONDENSATE FLOW RATE

11 2.6 WASTE OIL

11 2.7 DISCHARGING CLEAN WATER

11 2.8 INSPECTIONS

13 2.9 FILTERING

13 2.10 FILTERS CHANGING

14 2.11 CHECKING OF DISCHARGING WATER

14 2.12 DISPOSAL

14 2.13 ENCLOSURES

15 2.14 TECHNICAL INFORMATION ON THE OIL-WATER SEPARATOR

15 2.15 OPERATING INSTRUCTION

15 2.16 INFLUENCE OF THE COMPRESSOR OIL ON THE EFFICIENCY

16 2.17 CONSEQUENCE

16 2.18 WHEN ARE THE FILTERS SATURATED?

16 2.19 CONCLUSION

17 2.20 OPTIONAL LEVEL CONTROL INSTALLATION

SECTION 3—TEST & SERVICE LOG

19 3.1 GENERAL INFORMATION

19 3.2 TESTING OF THE DISCHARGED CONDENSATE

19 3.3 TESTING THE CONDENSATE WITH OIL TEST PAPER

19 3.4 ASSESSMENT MEASUREMENT RESULTS WITH THE OIL TEST PA-

PER

TABLE OF CONTENTS

Section 1

OIL WATER SEPARATOR

DESCRIPTION

Compressed air holds water and oil vapor. Once that

vapor cools into a liquid (condensate), it is a dirty, oily

watery mixture that should not be simply dumped

down the drain. The condensate is approximately

95% water and 5%. therefore a Sullair OWS has

been specially developed to reduce or eliminate the

amount of oil in the condensate and reducing or

eliminating disposal costs and related issues.

Type Sullair

Part No. Body Material

Max.

Working

Temp

Max.

Working

Pressure

Max.

Compressor

Capacity

Dimensions (mm)

Wt.

Connections

Kit

Width Depth Height Condensate

-inlet

Water-

discharge

Oil-

discharge

OWS-88 02250193-619 Polyethylene 95ºF 0 88 11 8.3 21.7 7 3x1/2” 1” — 02250193-

641

OWS-210 02250193-620 Polyethylene 95ºF 0 210 17.2 12.8 35.8 18 4x1/2” 1” — 02250193-

642

OWS-420 02250193-621 Polyethylene 95ºF 0 420 24.4 20.5 38 25 4x1/2” 1” — 02250193-

643

OWS-880 02250193-622 Polyethylene 95ºF 0 880 24.4 20.5 45.7 40 4x1/2” 1” 1” 02250193-

644

OWS-1700 02250193-624 Polyethylene 95ºF 0 1700 33.5 20.5 45.7 60 4x1/2” 1” 1” 02250193-

645

OWS-2100 02250193-625 Polyethylene 95ºF 0 2100 33.5 20.5 45.7 65 4x1/2” 1” 1” 02250193-

646

Note:

ATF (Automatic Transmission Fluid) cannot be separated by the OWS oil/water separator

SCFM is at 102 psig and 95¡F inlet conditions with 65% relative humidity.

Capacity conditions can vary depending on compressor fluid used.

OIL WATER SEPARATOR SECTION 1

1.1 OIL WATER SEPARATOR MODELS

Figure 1-1: OWS-88

SECTION 1 OIL WATER SEPARATOR

Figure 1-2: OWS-210

NOTES

Figure 1-3: OWS-420

SECTION 1 OIL WATER SEPARATOR

Figure 1-4: OWS-880

OIL WATER SEPARATOR SECTION 1

Figure 1-5: OWS-1700/2100

Section 2

OIL WATER SEPARATOR

INSTALLATION & MAINTENANCE

2.1 PLACE OF INSTALLATION

The OWS shall be installed on a clean, smooth and

level surface. The OWS must be installed

horizontally and should not be installed in direct

sunlight.

2.2 FLOW OF CONDENSATE

The condensate can be fed with or without pressure.

2.3 CONNECTIONS

See Table 2-1.

2.4 START-UP

OWS - 88

Remove lid and filter. Fill the OWS with water until

the water runs out of the water discharge. Insert the

filter. Clean the tank and water inlet as needed. Re-

install the lid and filter, the device is now ready for

operation.

OWS - 2I0/420

Unscrew the dome. Fill the OWS with water until

water runs out of water discharge. Insert the filter.

Clean the tank and the water inlet as needed. Secure

the dome back on, the OWS is now ready for

operation.

OWS - 880-2I00

Unscrew the lid. Fill the OWS with water until water

runs out of water discharge. Insert the filter. Clean

the tank and the water inlet as needed. Secure the

dome back on, the OWS is now ready for operation.

2.5 CONDENSATE FLOW RATE

The condensation flow will depend on the

compressor and the type of oil used in the

compressor. For further information see Section 2.4:

Start-up on page 11. The condensate must be fed

continuously. Any sporadic input of large quantities

(e.g. when emptying the tank by hand) should be

avoided.

2.6 WASTE OIL

The waste oil flows out of the tube to which an oil

drain hose will be connected, leading to an oil-

container. The OWS-88-2I0-420 does not have an oil

discharge (oil-container). The separated oil will be

collected in the filter and will be discharged with

changing the filter.

2.7 DISCHARGING CLEAN

WATER

The clean condensate flows out through the tube

(R1") do not reduce the outlet connection.. The water

drain hose (R1” - 1”) must be connected with down

slope to the sewage system.

2.8 INSPECTIONS

A regular inspection of the running condensate and a

early change in filters (if needed) is helpful for a

flawless system. See Maintenance book provided

with your OWS.

See Section 2.20 for optional Level Control

instructions.

Table 2-1: CONNECTIONS OWS-88 OWS-210/420 OWS-880 OWS1700 OWS-2100

Condensate Inlet 3 x 1/2” 4 x 1/2” 4 x 1/2” 4 x 1/2” 4 x 1/2”

Water Discharge 1 x 1” 1 x 1” 1 x 1” 1 x 1” 1 x 1”

Oil Discharge - - 1 x 1” 1 x 1” 1 x 1”

OIL WATER SEPARATOR SECTION 2

SECTION 2 OIL WATER SEPARATOR

2.9 FILTERING

2.10 FILTERS CHANGING

Begin by draining the condensate from the OWS and

properly dispose of the oily condensate. Unscrew the

dome (OWS-2I0-420), and/or remove lid and filter

(OWS-88). Carefully remove the combined filter from

the filter chamber. Clean the entire OWS. Insert the

new filter. Fill the separator with clean water until

water runs out of the water discharge! Insert the filter

and close the device. The separator is ready for

operation. The activated charcoal filter inside the

expansion chamber (OWS-2I0-2I00) can be changed

after removing the lid from the dome.

NOTE

Only use recommended spare filters! Use

manufacturer's recommended filter ele-

ments and spare parts for optimal operation.

Table 2-2: TECHNICAL DATA

Model Sullair

Part No.

Compressor

-capacity Dimensions (mm) weight Connections

Kit

cfm width depth height kg Condensate

inlet

Water

outlet

Oil

outlet

OWS-88 02250193-619 88 280 210 550 5 3x 1/2” 1” - 02250193-641

OWS-210 02250193-620 210 437 325 908 17 4x 1/2” 1” - 02250193-642

OWS-420 02250193-621 420 300 260 870 25 4x 1/2” 1” - 02250193-643

OWS-880 02250193-622 880 620 520 1160 45 4x 1/2” 1” 1” 02250193-644

OWS-1700 02250193-624 1700 850 520 1160 65 4x 1/2” 1” 1” 02250193-645

OWS-2100 02250193-625 2100 850 520 1160 70 4x 1/2” 1” 1” 02250193-646

* Capacity for screw-compressors with non emulsifying oils in use.

For other compressor -types or other types of compressor oils, you have to reduce the max. capacity.

NOTE

It is recommended to soak the Charcoal

filter for 4 to 6 hours in clean water before

it is placed into the OWS.

By soaking the charcoal filter the air is

removed from the charcoal and there-

fore... the filter is immediately active.

Table 2-3: Kits—All required filters to refresh unit

02250193-641 Kit OWS-88 Kit, Service OWS-88

02250193-642 Kit OWS-210 Kit, Service OWS-210

02250193-643 Kit OWS-420 Kit, Service OWS-420

02250193-644 Kit OWS-880 Kit, Service OWS-880

02250193-645 Kit OWS-1700 Kit, Service OWS-1700

02250193-646 Kit OWS-2100 Kit, Service OWS-2100

OIL WATER SEPARATOR SECTION 2

2.11 CHECKING OF

DISCHARGING WATER

(see also Test & Service Log)

A test sample should be taken from the test valve (8).

The water must be clean and clear. If the water is

dirty the filters should be changed.

WEEKLY

Take a sample out of the test-valve

• Optical check (see also Test & Service

Log)

• Check with oil-test-paper (see also Test &

Service Log)

SEMIANNUAL

• Replace filters and clean tank as needed

ANNUAL

• Replace filters (min. once a year, if necces-

sary more often!)

• Send a sample of the filtered condensate

to a certified laboratory for evaluation.

The results from the laboratory should be noted in

your “Test & Service Log”. You should also note

when the filters were changed and when the

maintenance work was carried out.

2.12 DISPOSAL

The saturated filters have to be disposed of

according local EPA regulations. For details contact

a disposal company in your area.

2.13 ENCLOSURES

Test & Service Log

NOTE

After the initial operation we recommend the

maintenance intervals shown below.

SECTION 2 OIL WATER SEPARATOR

2.14 TECHNICAL INFORMATION

ON THE OIL-WATER

SEPARATOR

From time to time problems occur which require a

more detailed knowledge of the OWS. Below are

some information and rules which will help you.

2.15 OPERATING INSTRUCTION

Please read all instructions carefully , especially the

paragraph “condensate flow rate“, and be sure to

comply with it. The condensate should be fed

automatically, when possible; input under pressure is

possible by means of the expansion nozzle the

device is equipped with.

2.16 INFLUENCE OF THE

COMPRESSOR OIL ON THE

EFFICIENCY

In the past compressor oils were only chosen to suit

the compressor. The problem of the condensate

disposal was hardly considered or completely

neglected. This is why many companies still use

compressor oils which emulsify strongly with water

and some of which form stable emulsion.

Table 2-4: Capacity of OWS - Oil Water Separators in cfm of installed compressor-capacity

Type of Compressor Screw-Compressor

OWS Model OWS-88 OWS-210 OWS-420 OWS-880 OWS-1700 OWS-2100

non emulsified oils 88 210 420 880 1700 2100

Rotation-Compressor (oil-flooded)

OWS Model OWS-88 OWS-210 OWS-420 OWS-880 OWS-1700 OWS-2100

non emulsified oils 88 210 420 880 1700 2100

Piston Compressor (1 and 2 stage)

OWS Model OWS-88 OWS-210 OWS-420 OWS-880 OWS-1700 OWS-2100

non emulsified oils 44 100 200 440 800 1000

NOTE

1. The capacity above are maximum

figures.

2. Reduce the capacity when the

OWS is installed in difficult condi-

tions (e.g. hot dirty, dusty condi-

tions).

3. Divide capacity by 2 for conden-

sate delivered through timed sole-

noid drains.

OIL WATER SEPARATOR SECTION 2

2.17 CONSEQUENCE

The condensate is dirty and remains so even after

fairly long settling time. Under certain conditions it

builds up a solid foam, which floats on the water

surface and prevents the function of the separator

(outlet and coal choke up).

When the filters are unused, they are able to absorb

some of the oil from the emulsion. Sullair can not

guarantee that the OWS will work on all emulsion.

Nor can we guarantee that for all emulsion a 22ppm

can be maintained. It is possible, that the filters are

saturated within a few days or hours. If the filters are

saturated, the condensate level rises and the

condensate flows out through the oil outlet. It is

helpful and recommended to install the optional

available level-control, to recognize very early, when

the filters are saturated.

2.18 WHEN ARE THE FILTERS

SATURATED?

The service life of the filters depend on many factors

such as type of compressor, type of oil, amount of

condensate, tempearture of condensate etc. It

cannot be determined in advance for individual

applications. We recommmend to visually control the

discharging condensate regularly and to change the

filters if necessary.

2.19 CONCLUSION

Adequate conditions (type of oil, amount of

condensate, maintenance, etc.) are a must for a

proper functioning of the device. Therefore it is

extremely important to inform all users and

maintenance personnel of the importance

inspections and proper maintenance.

SECTION 2 OIL WATER SEPARATOR

2.20 OPTIONAL LEVEL CONTROL

INSTALLATION

The Level/Filter control, which can be field installed

on all OWS separators, except the OWS-88. The

level-switch is available in two versions:

A. The Single Pole Double Throw level switch. The

contacts are not energized. Customer would sup-

ply voltage to energize a customer supplied

alarm or light. (NS10P)

B. The second version (Art.No. NS10) is battery

charged and has an optical and acoustic alarm

signal.

NOTES

Section 3

OIL WATER SEPARATOR

TEST & SERVICE LOG

3.1 GENERAL INFORMATION

Environmental control officers may want to see proof

of the regular inspect and maintenance records of

the OWS.

The Test and Service Log is designed to help the

user keep records of the inspection and maintenance

performed on the OWS. There is a pocket on the side

of the OWS where this log can be kept.

After the first use, the following described

inspection should be completed once a week.

Therefore, you are able to determine your

maintenance intervals (filter changes, etc.) for

your particular application.

3.2 TESTING OF THE

DISCHARGED

CONDENSATE

1. Fill the test glass half with condensate taken

from the Test valve full.

2. Close the Test glass and hold the bottom up

against the light.

a. Compare the Condensate sample with the

frosted part of the Test glass.

b. If the condensate sample is clouded equal or

greater than the frosted part of the test glass,

the activated carbon filter must be replaced

(see instructions).

3. Record the test result and the maintenance

work in the adjacent table.

3.3 TESTING THE CONDENSATE

WITH OIL TEST PAPER

1. Dip the test strips into the condensate sam-

ple, move back and forth a few times.

2. Free the test strips of water droplets by

lightly shaking them.

3. Observe color changing of the strips: oil in

the condensate will turn the strip dark blue.

a. No color change or only a few blue spots

on the test strips: Oil content will be under

1-5 mg/ltr. condensate

b. A light blue coloring on the test strip: Oil

content about 5-20 mg/ltr. condensate

c. Dark blue coloration on the test strips: Oil

content more than 20 mg/ltr. condensate

4. Record the test result in the adjacent table.

3.4 ASSESSMENT

MEASUREMENT RESULTS

WITH THE OIL TEST PAPER

The detection of oil in water, especially if they are

finely dispersed oil droplets (dispersion) in milligrams

per liter of water, is possible with absolute certainty

only by chemical analysis. To that extent, the results

of the oil-paper test can only be used as an indication

of need for maintenance of the oil water separator.

The test result is also dependent on the the way the

the test is handled. It is recommended that for

consistency the same person or persons perform the

test each time.

The oil test paper responds only to non-

emulsified oil in the water.

To ensure the above test results a chemical analysis

shall be conducted once a year by a certified

laboratory

OIL WATER SEPARATOR SECTION 3

Test and Service Log (unit should be checked 1-4 times a month

Date Name

Filtrate Controls Service Completed

Optical Control Color Change of

Oil Test Paper Water Filter Air Filter

Clear Cloudy None

1-5 mg/ltr.

Few spots

5-20 mg/ltr.

Dark blue

>20 mg/ltr. Tested Changed Tested Changed

Chemical analysis of discharged condensate

If the above tests need confirmation by a chemical analysis, please note the test results below:

1st Test: Date: ______________ Test result: __________ mg oil/litre condensate

2nd Test: Date: ______________ Test result: __________ mg oil/litre condensate

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SULLAIR OWS-I700 User & Service Manual

Brand: SULLAIR

Model: OWS-I700

Type: User & Service Manual

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