Sullair 20/12 500 CFM, Operator'S Manual And Parts List

Page 1: ...Operator s Manual and Parts List Industrial Rotary Screw Air Compressor Part Number 253497 eSullair Corporation 20 12 200 400HP Air Cooled...

Page 2: ...t 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 ac...

Page 3: ...TIONAL DESCRIPTION 6 2 5 COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTION 9 2 6 CAPACITY CONTROL SYSTEM FUNCTIONAL DESCRIPTION 12 2 7 AIR INLET SYSTEM FUNCTIONAL DESCRIPTION 12 2 8 INSTRUMENT PANEL...

Page 4: ...NT 25 PRESSURE REGULATOR VALVE MAINTENANCE 26 FLUID STOP VALVE 26 CONTROL PRESSURE REGULATOR VALVE 27 RUNNING BLOWDOWN VALVE MAINTENANCE 28 THERMAL VALVE 28 MINIMUM PRESSURE CHECK VALVE MAINTENANCE 29...

Page 5: ...the compressor or at any other point along the air line when an air hose exceeding 1 2 inside diameter is to be connected to the shut off throttle valve to reduce pressure in case of hose failure per...

Page 6: ...und 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...

Page 7: ...onductors 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 heli copter must not...

Page 8: ...enter it to perform service adjustments inform other per sonnel before doing so or else secure and tag the access door in the open position to avoid the possi bility of others closing and possibly lat...

Page 9: ...erence to the guidelines and procedure operator s will be able to keep the compressor in top operational condition 2 2 DESCRIPTION OF COMPONENTS Refer to Figure 2 1 The components of the Sullair 2 sta...

Page 10: ...into the compres sion chambers This filter has a cleanable element and built in bypass which allow some fluid to flow even when the filter becomes plugged and requires changing or when the viscosity...

Page 11: ...the dis charge temperature reaches 265_F 130_C on first stage or 265_F 130_C on second stage All Sullair compressor models are equipped with a high pressure shutdown switch to shut down the compresso...

Page 12: ...Section 2 DESCRIPTION 8 Figure 2 3 Piping and Instrumentation...

Page 13: ...nation purposes this de scription will apply to compressors with an operating pressure range of 340 to 360 PSIG 2344 to 2482kPa A compressor with any other pressure range would operate in the same man...

Page 14: ...Section 2 DESCRIPTION 10 Figure 2 5 Capacity Control System Typical...

Page 15: ...rical power to the solenoid type pilot valve At this time the pilot valve allows dry sump tank air pressure to be ap plied directly to the Sullicon Control keeping the but terfly valve closed Simultan...

Page 16: ...wer and runindi cators an hourmeter plus various optional fault in dicator lights see Figure 2 7 Refer to Figure 2 3 for functional locations of the fol lowing indicators and controls S The line termi...

Page 17: ...0 Cycles Size See Model Series above Speed 1200 RPM and 1800 RPM 3 2 LUBRICATION GUIDE Sullair standard compressors are filled with Sullube 32 fluid as factory fill MIXING OF OTHER FLUIDS WITHIN THE C...

Page 18: ...14 NOTES...

Page 19: ...ION CHECK After the electrical wiring has been done it is neces sary to check the direction of the motor rotation This can be done by jogging the START and STOP but tons on the instrument panel When l...

Page 20: ...16 NOTES...

Page 21: ...ilter element change is INDICATOR required Shows red when the pressure drop through the filter is excessive SEPARATOR MAINTENANCE INDICATOR Indicates when separator element change is required Shows re...

Page 22: ...the inlet butterfly valve when the compressor reaches maximum operating pres sure BLOWDOWN VALVE Vents sump pressure to the atmosphere during unload conditions and shutdown PRESSURE SWITCH Senses ser...

Page 23: ...ts are nec essary see Control System Adjustments in the Maintenance Section of the manual 7 Observe the operating temperature If the operat ing temperature exceeds 230_F 129_C the cooling system or in...

Page 24: ...20 NOTES...

Page 25: ...owing mainte nance operations to prevent unnecessary problems 1 Clean the return line strainer 2 Clean the return line orifice 3 Clean the compressor unit gear housing bearing and shaft seal orifices...

Page 26: ...freely in canister 3 Remove filter element and gasket seal ring and discard 4 Install new fluid filter element in canister and install the gasket seal ring to the canister flange 5 Before reinstallin...

Page 27: ...resuming operation PRIMARY ELEMENT REPLACEMENT 1 Place the element in position on the cover and re place the lockring to secure the cover and ele ment 2 Install the cover element assembly and replace...

Page 28: ...hes the desired pressure the pres sure switch contacts should open If the pressure switch contacts do not open or they open prior to the desired pressure the pressure switch setting will re quire adju...

Page 29: ...ressure plate nut and disassemble the pressure plate diaphragm dia phragm gasket rubberized asbestos seat disc and seat gasket 6 Remove and discard the seat ring 7 The next step is to reassemble the r...

Page 30: ...replace the spring as it was prior to dis assembly 16 Place the spring over the spring button as shown 17 With all parts in order replace the spring chamber and tighten 18 Tighten the adjusting screw...

Page 31: ...all the two 2 seals one into the cover and the other onto the piston rod guide 20 Place cylinder over pilot guide 21 Replace the cover and the four 4 nuts onto the cover Tighten nuts alternately at op...

Page 32: ...50001 456 maintenance order the following Sull air parts one 1 quad ring P N 046425 one 1 gasket P N 049812 and if necessary thermal ele ment P N 250001 349 Follow the procedure ex plained below for i...

Page 33: ...ARNING Turn off all power relieve the pressure and discon nect coil lead wire to the valve before making re pairs It is necessary to remove the valve from the pipe line for repairs PILOT VALVE DISASSE...

Page 34: ...ing careful attention to exploded view provided for identification and placement of parts 2 Lubricate all gaskets with Dow Corning s Valve Seal silicone lubricant or equivalent high grade sil icone gr...

Page 35: ...systematically ana lyzed before undertaking any repairs or component replacement procedures A detailed visual inspection is worth performing for almost all problems and may avoid unnecessary addition...

Page 36: ...ring filter element COMPRESSOR WILL NOT BUILD UP FULL DISCHARGE PRESSURE Air Demand is Too Great Check service lines for leaks or open valves Dirty Air Filter Check the filter indicator and change or...

Page 37: ...ections and compo nents PRESSURE RELIEF VALVE OPENS REPEATEDLY High Pressure Shutdown Switch is Defective or Out of Adjustment Readjust below pressure relief valve setting or replace Defective Pressur...

Page 38: ...34 NOTES...

Page 39: ...630 CFM 046968 primary 1 replacement element for air filter 046956 500 630 CFM 046981 secondary 1 replacement element for air filter 046020 750 CFM 046299 primary 1 replacement element for air filter...

Page 40: ...Section 7 ILLUSTRATIONS AND PARTS LIST 36 7 3 MOTOR FRAME COMPRESSOR AND PARTS...

Page 41: ...1 6 hub compressor 200HP thru 350HP 047141 1 S hub compressor 400HP 250006 266 1 7 adapter 026974 1 8 compressor unit I 1 I There is an exchange program whereby a remanufactured compressor unit can be...

Page 42: ...Section 7 ILLUSTRATIONS AND PARTS LIST 38 7 4 AIR INLET SYSTEM...

Page 43: ...se hump 7 041917 1 13 capscrew hex gr5 5 16 18 x 11 2 828605 150 1 14 nut hex 3 8 16 824206 337 4 15 support air inlet filter 250000 826 1 16 capscrew hex gr5 3 8 16 x 1 828606 100 4 17 band mounting...

Page 44: ...Section 7 ILLUSTRATIONS AND PARTS LIST 40 7 5 COOLING AND LUBRICATION SYSTEM...

Page 45: ...22224 135 1 14 valve thermal I 250001 456 1 15 valve fluid stop II 250038 489 1 16 union pipe 2 805730 080 1 17 tee pipe 11 2 806630 060 1 18 nipple pipe 11 2 x 9 822224 090 1 19 nipple pipe 11 2 x 31...

Page 46: ...Section 7 ILLUSTRATIONS AND PARTS LIST 42 7 6 COOLER ASSEMBLY...

Page 47: ...1 6 aftercooler 200HP thru 300HP 250008 938 1 S aftercooler 350HP thru 400HP 406722 1 7 angle aftercooler support 250020 737 4 8 panel cooler side right hand 250020 739 1 9 panel Venturi 42 200HP thr...

Page 48: ...Section 7 ILLUSTRATIONS AND PARTS LIST 44 7 7 DISCHARGE SYSTEM...

Page 49: ...45626 1 18 elbow pipe 90_ 3 806530 120 2 19 nipple half 3 x 10 822448 100 1 20 coupling flexible 3 046817 1 21 nipple half 3 x 8 822448 080 1 22 nipple pipe 3 x 17 822248 170 1 23 valve disch check 21...

Page 50: ...Section 7 ILLUSTRATIONS AND PARTS LIST 46 7 7 DISCHARGE SYSTEM...

Page 51: ...o 3 4 250006 639 1 37 connector tube m 1 4 x 1 4 810204 025 4 38 glass sight 046559 1 39 orifice 022033 1 40 nipple pipe 1 4 x close 822204 000 2 41 strainer y line 1 4 IV 240686 1 42 rod threaded 3 4...

Page 52: ...Section 7 ILLUSTRATIONS AND PARTS LIST 48 7 8 INSTRUMENT PANEL AND PARTS...

Page 53: ...essure 042148 1 7 fastener suregrip 041516 4 8 nameplate Sullair 040052 1 9 capscrew hex gr5 3 8 16 x 11 2 828606 150 4 10 washer springlock 3 8 837606 125 8 11 isolator vibration 040091 4 12 nut hex...

Page 54: ...Section 7 ILLUSTRATIONS AND PARTS LIST 50 7 9 CONTROL SYSTEM...

Page 55: ...0038 666 1 19 valve solenoid 3 way V 407390 1 20 rod end spherical 5 16 left hand 042004 1 21 rod Sullicon Control 250028 170 1 22 cylinder air control VI 250016 990 1 23 rod end spherical 5 16 right...

Page 56: ...Section 7 ILLUSTRATIONS AND PARTS LIST 52 7 9 CONTROL SYSTEM...

Page 57: ...0094 1 35 seal cup 042538 1 36 diaphragm Sullicon 250020 028 1 37 spring control 250006 526 1 38 bolt adjusting Sullicon spring 250009 134 1 39 washer back up 021172 1 40 screw sealing 1 4 28 x 3 4 04...

Page 58: ...Section 7 ILLUSTRATIONS AND PARTS LIST 54 7 10 ELECTRIC CONTROL BOX...

Page 59: ...09 1 4 holder lamp 043383 1 S lens red 043384 1 S bulb 043386 1 S gasket lamp holder 241808 1 S gasket lens 241809 1 5 pushbutton START 041967 1 6 pushbutton STOP 042235 1 7 block terminal and track 0...

Page 60: ...Section 7 ILLUSTRATIONS AND PARTS LIST 56 7 11 UNIT TUBING...

Page 61: ...I 250019 296 1 17 nipple close 11 4 x 31 2 822220 035 1 18 hose hydraulic 1 2 x 13 249608 006 1 19 manifold injection 227239 1 20 elbow hose 45_ 1 2 x 1 2 860008 050 1 21 hose hydraulic 1 2 x 24 24960...

Page 62: ...Section 7 ILLUSTRATIONS AND PARTS LIST 58 7 11 UNIT TUBING...

Page 63: ...2 040356 1 39 gasket flexible 040771 2 40 plug pipe 1 807800 040 1 41 gasket air outlet 028077 1 42 capscrew ferry head gr8 3 8 x 1 2 828406 150 4 43 adapter air outlet 250022 747 1 44 elbow 45_ 8600...

Page 64: ...Section 7 ILLUSTRATIONS AND PARTS LIST 60 7 12 DECAL GROUP...

Page 65: ...luid stop valve P N 016742 410239 1 9 sign warning compressor fluid fill cap 049685 1 10 sign danger air breathing 250027 935 1 11 sign warning food grade lube 250003 144 1 12 sign warning ground faul...

Page 66: ...Boulevard Michigan City Indiana 46360 U S A Telephone 1 219 879 5451 Fax 219 874 1273 Fax 219 874 1835 Parts Fax 219 874 1288 Service SULLAIR ASIA LTD Sullair Road No 1 Chiwan Shekou Shenzhen Guangdo...