SULLAIR ES 6 Air COMPRESSOR Parts Manual

ROTARY SCREW ES--6 Series 5, 7.5 and 10HP OPERATOR’S MANUAL AND Part Number 02250057--634 ©SullairCorporat ion PARTS LIST AIR COMPRESSOR 4, 5.5 and 7.5 kw KEEP FOR FUTURE REFERENCE

AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are 3--day courses that provide hands--on instruction in the proper operation, maintenance and service of Sullair equipment. Individual seminars on Industrial compressors and compressor electrical systems are presented at regular intervals throughout the year at a dedicated training facility at Sullair’s corporate headquarters in Michigan City, Indiana. Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of the most common problems, and actual equipment operation. The seminars are recommended for maintenance and service personnel. For detailed course outlines, schedule and cost information contact: Sullair Corporate Training Department 1--800--SULLAIR or 219--879--5451 (ext. 1816) -- OrWrite -- Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training Department

TABLE OF CONTENTS Section 1 PAGE SAFETY 1 1.1GENERAL 1 1.2PERSONAL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 2 1.7 TOXIC AND IRRITATING SUBSTANCES 3 1.8 ELECTRICAL SHOCK 3 1.9 LIFTING 4 1.10 ENTRAPMENT Section 2 DESCRIPTION 5 2.1 INTRODUCTION 5 2.2 DESCRIPTION OF COMPONENTS 5 2.3 ENCAPSULATED COMPRESSOR SYSTEM, FUNCTIONAL DESCRIPTION 5 2.4 COMPRESSOR COOLING SYSTEM, FUNCTIONAL DESCRIPTION 5 2.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION 7 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION 8 2.7 INSTRUMENTATION, FUNCTIONAL DESCRIPTION Section 3 SPECIFICATIONS 9 3.1 TABLE OF SPECIFICATIONS 10 3.2 COMPRESSOR LUBRICATION GUIDE Section 4 INSTALLATION 11 4.1 LOCATION OF COMPRESSOR 11 4.2 VENTILATION AND COOLING 11 4.3 SERVICE AIR PIPING 11 4.4 FLUID LEVEL CHECK AND CHANGE PROCEDURE 12 4.5 MOTOR ROTATION DIRECTION CHECK 12 4.6 ELECTRICAL PREPARATION

TABLE OF CONTENTS (CONTINUED) Section 5 PAGE OPERATION 13 5.1 GENERAL 13 5.2 PURPOSE OF CONTROLS 14 5.3 INITIAL START--UP PROCEDURE 14 5.4 SUBSEQUENT START--UP PROCEDURE 14 5.5 SHUTDOWN PROCEDURE Section 6 MAINTENANCE 15 6.1 GENERAL 15 6.2 DAILY OPERATION 15 6.3 MOTOR BEARING LUBRICATION 15 6.4 FLUID FILTER MAINTENANCE 15 6.5 COOLER MAINTENANCE 16 6.6 PARTS REPLACEMENT MAINTENANCE AND ADJUSTMENT PROCEDURES FLUID FILTER REPLACEMENT AIR FILTER MAINTENANCE SEPARATOR ELEMENT REPLACEMENT MINIMUM PRESSURE/CHECK VALVE MAINTENANCE THERMOSTAT ACTUATOR MAINTENANCE CONTROL SYSTEM ADJUSTMENT FOR DIFFERENTIAL ADJUSTMENT OF AIR PRESSURE SWITCH INLET CONTROL VALVE MOTOR SHAFT SEAL REPLACEMENT 21 6.7 TROUBLESHOOTING 23 6.8 MAINTENANCE RECORD Section 7 ILLUSTRATIONS AND PARTS LIST 25 7.1 PROCEDURE FOR ORDERING PARTS 25 7.2 RECOMMENDED SPARE PARTS LIST 26 7.3 FLUID MANAGEMENT SYSTEM 28 7.4 INLET FILTER 30 7.5 SEAL AND DRIVE GEAR 32 7.6 MOTOR, HOUSING AND PARTS 34 7.7 COMPRESSOR COOLER SYSTEM 36 7.8 COMPRESSOR SYSTEM 38 7.9 INLET CONTROL 40 7.10 CONTROL BOX 44 7.11 CANOPY AND PARTS 46 7.12 FRAME, CANOPY AND PARTS 48 7.13 WYE--DELTA ELECTRIC BOX ES--6

TABLE OF CONTENTS (CONTINUED) Section 7 PAGE ILLUSTRATIONS AND PARTS LIST (CONT) 50 7.14 WYE--DELTA ELECTRIC BOX ES--6 52 7.15 DECAL GROUP 56 7.16 WIRING DIAGRAM (SINGLE PHASE) (60 Hz) 57 7.17 WIRING DIAGRAM (THREE PHASE) (60 Hz) 58 7.18 WIRING DIAGRAM (50 Hz) 59 7.19 WIRING DIAGRAM (50 Hz) WYE--DELTA

Section 1 SAFETY 1 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 fol- lowed, 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 be- hind these statements are generally applicable to all compressors. 1.2 PERSONAL PROTECTIVE EQUIPMENT Prior to installing or operating the compressor, own- ers, 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 regulations relative to personal protective equipment, such as eye and face protective equipment, respiratory protective equipment, equipment intended to protect the extremi- ties, protective clothing, protective shields and barri- ers 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 1/2” (13mm) 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 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) inside diameter to reduce pressure in case of hose failure. D. Flow--limiting valves are listed by pipe size and rated CFM. Select appropriate valves accordingly, in accordance with their manufacturer’s recommen- dations. 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 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 ex- pelled. G. Open fluid filler cap only when compressor is not running and is not pressurized. Shut down the compressor and bleed the sump (receiver) 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. Use air at pressures less than 30 psig (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, 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 antifreeze compound. C. DO NOT permit fluids, including air line anti--icer system antifreeze compound or fluid film, to accu-

Section 1 SAFETY 2 mulate on, under or around acoustical material, or on any external surfaces of the air compressor or on internal surfaces of the enclosure. Wipe down using an aqueous industrial cleaner or steam clean as re- quired. If necessary, remove acoustical material, clean all surfaces and then replace acoustical material. Any acoustical material with a protective covering that has been torn or punctured should be re- placed 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 attempting 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 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 also clothing away from couplings, 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 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--en- ergized 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 surfaces clean and free of fluid, water or other liq- uids 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 infection. 1.7 TOXIC AND IRRITATING SUBSTANCES A. DO NOT use air from this compressor for respira- tion (breathing) except in full compliance with OSHA Standards 29 CFR 1910 and/or any applicable Fed- eral, State or Local codes or regulations. 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, standards and regulations on safety equipment. B. DO NOT use air line anti--icer systems in air lines supplying respirators or other breathing air utiliza- tion 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 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 antifreeze compound to air line anti--icer systems.

Section 1 SAFETY 3 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 table- spoon 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 Federal, State and Local codes, standards and regulations, including those of the National Electrical Code, and also including those relative to equipment grounding conductors, and only by personnel that are trained, qualified 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 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 he- licopter 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 subpart 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 structure has been inspected, is in good condition 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. I. Keep lift operator in constant attendance whenever compressor is suspended. J. Set compressor down only on a level surface ca- pable 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 ob- stacles 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 caus- ing serious injury or property damage in the process.

Section 1 SAFETY 4 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 possibly latching the door with personnel inside. B. Make sure all personnel are out of compressor before closing and latching enclosure doors.

SULLAIR ES 6 Air COMPRESSOR Parts Manual

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