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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 mate-

rial. Any acoustical material with a protective cover-

ing 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 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 otherwise

degraded insulation, or terminals that are worn, dis-

colored or corroded. Keep all terminals and pres-

sure 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 at-

tempting 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 oth-

er 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 oper-

ate 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 ap-

plicable Federal, State, and Local codes, stan-

dards 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 an-

tifreeze compound to air line anti--icer systems.

Summary of Contents for ES-6 series

Page 1: ...ROTARY SCREW ES 6 Series 5 7 5 and 10HP OPERATOR S MANUAL AND Part Number 02250057 634 Sullair Corporation PARTS LIST AIR COMPRESSOR 4 5 5 and 7 5 kw KEEP FOR FUTURE REFERENCE...

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: ...NTS 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 DES...

Page 4: ...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...

Page 5: ...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...

Page 6: ...NOTES...

Page 7: ...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...

Page 8: ...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 oper ate it F Disc...

Page 9: ...ressor 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 bu...

Page 10: ...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 11: ...ng one rotor to directly drive the other which is an idler The air fluid mixture discharges directly into the fluid management system The fluid cooler bypass valve helps assure proper cooling by direc...

Page 12: ...Figure 2 1 Description of Components 4KW 5 5 7 5KW COMPRESSOR FLUID DRAIN CAP COMPRESSOR FLUID DRAIN CAP FLUID FILL PLUG FLUID FILL PLUG FLUID FILTER ELEMENT FLUID LEVEL SIGHT GLASS AIR FLUID SEPARAT...

Page 13: ...and the motor continues to run When the line pressure drops to the low setting of the pressure switch the pressure switch closes re energizing the normally open solenoid valve and al lowing the compr...

Page 14: ...is located on the left side of the electrical control center and a discharge temper ature gauge which is located on the right side of the electrical control center The line pressure gauge reads plant...

Page 15: ...495 325 150 ES 6 10XH 10 7 5 28 2 80 175 12 70 85 33 838 21 3 4 553 19 1 2 495 325 150 Model HP KW Capacity ACFM Maximum PSIG BAR Pressure Length in mm Width Height Weight lb kg 50Hz M3 MIN dBA I in m...

Page 16: ...lso be af fected I Plastic Pipe Institute Recommendation B Adopted January 19 1972 Maintenance of all other components is still recom mended as indicated in the Operator s Manual For light duty high h...

Page 17: ...d above ground locations e g in exposed plant piping I Sullube 32 should not be used with PVC piping systems It may affect the bond at cemented joints Certain other plastic materials may also be affec...

Page 18: ...stomer wiring is minimal but should be done by a qualified electrician in compliance with OSHA National Electrical Code and any other ap plicable State Federal and local electrical codes concerning is...

Page 19: ...erating temperature of 170qF 77qC Used for fast warm up and start up MINIMUM PRESSURE CHECK VALVE Maintains a minimum of 60 psig 4 1 bar in compres sor sump Valve piston restricts receiver air dischar...

Page 20: ...is set correctly If set correctly the compressor will unload at nameplate pres sure If adjustments are necessary see Control System Adjustment in Section 6 Maintenance of this manual 8 Observe the op...

Page 21: ...an ring to the cooler 2 Remove the 1 8 NPT plugs in the filler and drain connection for both bearings 3 Free drain hole of any hard grease use piece of wire if necessary 4 Add grease I using a low pre...

Page 22: ...so require WARNING Before doing compressor maintenance discon nect compressor from power source and lock out power source Isolate compressor from line pres sure by closing recommended discharge shut o...

Page 23: ...Figure 6 3 The separator should be changed once a year Follow the procedure ex plained below for element replacement WARNING Before doing compressor maintenance discon nect compressor from power sourc...

Page 24: ...all parts 4 Remove the screw holding the check valve seat Replace valve seat Reinstall securing with Loc titeR 222 5 Install new o ring Before reinstallation lubricate with Parker Super O ring seal or...

Page 25: ...OF AIR PRESSURE SWITCH Differential is the difference between the high and low pressure settings Turning the screw clockwise increases the differen tial and counterclockwise decreases the differential...

Page 26: ...crew washers and check spring from intake valve rod 7 Remove intake valve from valve housing Re move intake valve rod check spring spring re tainer and intake valve head 8 Remove intake piston from in...

Page 27: ...he Sullair Corporation factory TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY COMPRESSOR WILL NOT START Main Disconnect Switch Open Close switch Line Fuse Blown Replace fuse Control Transformer Fuse Bl...

Page 28: ...s Fluid Foaming Drain and change Fluid Level Too High Drain excess Shaft Seal Failure Replace shaft seal PRESSURE RELIEF VALVE Compressor Operating Pressure See Symptom Line Pressure Rises Above OPENS...

Page 29: ...Section 6 MAINTENANCE 23 MODEL NO SERIAL NO 6 8 MAINTENANCE RECORD DATE HOURMETER MAINTENANCE PERFORMED WORK PERFORMED BY AUTHORIZED BY...

Page 30: ...Section 7 ILLUSTRATIONS AND PARTS LIST 24 ES 6 COMPRESSOR ASSEMBLY EXPLODED VIEW 5 5 AND 7 5KW...

Page 31: ...hone 33 72232425 Fax 33 78907168 Fax 219 874 1835 Parts Fax 219 874 1805 Service 1 219 879 5451 SULLAIR ASIA LTD Chiwan Supply Base Bldg A5 1 Chiwan Shenzhen Guangdong PRV P R C Post Code 518068 Telep...

Page 32: ...Section 7 ILLUSTRATIONS AND PARTS LIST 26 7 3 FLUID MANAGEMENT SYSTEM...

Page 33: ...actuator thermostat III 250025 413 1 12 piston thermostat 250025 415 1 13 spring compression 250025 464 1 14 pin roll 1 4 x 1 1 2 827404 150 1 15 guide thermostat spring 250025 417 1 16 o ring IV 2500...

Page 34: ...Section 7 ILLUSTRATIONS AND PARTS LIST 28 7 4 INLET FILTER...

Page 35: ...ing 1 4 20 824815 004 1 3 washer seal 250025 661 1 4 hood air filter 250025 422 1 5 element air filter I 250025 421 1 6 plate air filter base 250025 423 1 7 rod threaded 1 4 x 5 843504 050 1 I For mai...

Page 36: ...Section 7 ILLUSTRATIONS AND PARTS LIST 30 7 5 SEAL AND DRIVE GEAR...

Page 37: ...wear 250025 412 1 5 seal shaft Teflon Viton I 250039 218 1 6 capscrew ferry head 1 4 20 x 3 4 828404 075 2 7 housing shaft seal 250025 312 1 8 o ring 2 7 8 x 3 32 826502 150 1 9 spacer gear 250039 600...

Page 38: ...Section 7 ILLUSTRATIONS AND PARTS LIST 32 7 6 MOTOR HOUSING AND PARTS 7 5 10HP 5 5 7 5KW ONLY...

Page 39: ...elief 1 2 175 psig 12 1 bar 409955 1 Svalve relief 1 2 200 psig 13 8 bar 250039 678 1 12 plug pipe hex soc 1 8 NPT 490046 001 2 13 motor 5HP 4KW Consult Factory 1 Smotor 7 5HP 5 5KW Consult Factory 1...

Page 40: ...Section 7 ILLUSTRATIONS AND PARTS LIST 34 7 7 COMPRESSOR COOLER SYSTEM 7 5 10HP 5 5 7 5KW COOLER...

Page 41: ...5 5 and 7 5KW 828405 200 2 10 washer flat 5 16 id x 1 1 4 od 5HP 4KW 250025 830 1 Swasher flat 5 16 id x 1 1 4 od 7 5 10HP 5 5 and 7 5KW 250025 830 2 11 connector tube straight threaded 1 2 x 3 4 8118...

Page 42: ...Section 7 ILLUSTRATIONS AND PARTS LIST 36 7 8 COMPRESSOR SYSTEM...

Page 43: ...be 90M 1 4 x 1 4 250025 850 2 19 bearing cylinder roll plain 499082 705 1 20 bearing needle roller steel 250023 213 1 21 retainer inlet bearing 250025 435 1 22 screw machine flat head 1 4 20 x 1 2 831...

Page 44: ...Section 7 ILLUSTRATIONS AND PARTS LIST 38 7 9 INLET CONTROL...

Page 45: ...02250044 811 1 8 seal ES 6 intake control piston II 02250044 671 1 9 washer Belleville spring I 250031 269 2 10 capscrew sch 10 32 x 1 2 Nylok 02250043 162 1 11 spring inlet control ES 6 02250042 966...

Page 46: ...Section 7 ILLUSTRATIONS AND PARTS LIST 40 7 10 CONTROL BOX...

Page 47: ...al reset 02250045 011 1 18 screw 1 4 20 x 1 2 long 250030 162 4 19 fastener suregrip 041516 2 20 nameplate Sullair 1 x 6 250035 063 1 21 joint compression phase 230V 3PH 250026 615 1 Sphase 3 460V not...

Page 48: ...Section 7 ILLUSTRATIONS AND PARTS LIST 42 7 10 CONTROL BOX...

Page 49: ...828604 550 1 37 capacitor run 5HP 4KW single phase 250031 734 2 38 capacitor start 5HP 4KW single phase 250031 733 2 39 nut hex flanged 1 4 20 single phase 825304 236 1 40 support lower control box ES...

Page 50: ...Section 7 ILLUSTRATIONS AND PARTS LIST 44 7 11 CANOPY AND PARTS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 51: ...et canopy ES 6 mounting right 250033 702 1 8 canopy stop ES 6 250033 096 2 9 decal Sullair logo not shown 02250059 052 1 10 decal ES 6 Model not shown 02250060 043 1 11 decal warning under pressure 02...

Page 52: ...Section 7 ILLUSTRATIONS AND PARTS LIST 46 7 12 FRAME CANOPY AND PARTS...

Page 53: ...2 hole 250034 583 1 36 screw hex serrated washer 1 4 x 1 2 829704 050 7 37 nut hex flange plated 1 4 20 825304 236 7 38 washer pl b regular plated 3 8 838206 071 8 39 bracket canopy adjustment 250025...

Page 54: ...Section 7 ILLUSTRATIONS AND PARTS LIST 48 7 13 WYE DELTA ELECTRIC BOX ES 6 LINE PRESSURE DISCHARGE TEMP MANUAL ON OFF RESET AUTO POWER ON 23 RE S ET 24...

Page 55: ...1 8 250025 849 3 14 tee male branch 1 8 250026 139 1 15 bushing reducing 3 8 x 1 8 807601 005 1 16 switch pressure range 40 150 250031 244 1 17 switch 3 position selector 250034 883 1 Sblock contact...

Page 56: ...Section 7 ILLUSTRATIONS AND PARTS LIST 50 7 14 WYE DELTA ELECTRIC BOX ES 6...

Page 57: ...ry Sfuse 4 amp Consult Factory Sfuse carrier Consult Factory 6 CPT with tamper proof cover Consult Factory 7 relay control Consult Factory 8 contactor Consult Factory Scontactor block Consult Factory...

Page 58: ...Section 7 ILLUSTRATIONS AND PARTS LIST 52 7 15 DECAL GROUP 7 8 9 11 12...

Page 59: ...direction 040745 1 8 decal compressor fluid Sullube 32 I 02250069 389 1 8B decal fluid SRF 1 4000 not shown I 02250069 391 1 9 decal earth ground 02250075 046 2 Sdecal protective earth ground not sho...

Page 60: ...Section 7 ILLUSTRATIONS AND PARTS LIST 54 7 15 DECAL GROUP 13...

Page 61: ...5 7 15 DECAL GROUP continued key part number description number quantity 13 decal ES 6 canopy bezel 02250061 884 1 14 decal mandatory read manual not shown 02250078 002 1 PLEASE NOTE WHEN ORDERING PAR...

Page 62: ...Section 7 ILLUSTRATIONS AND PARTS LIST 56 7 16 WIRING DIAGRAM SINGLE PHASE 60Hz...

Page 63: ...Section 7 ILLUSTRATIONS AND PARTS LIST 57 7 17 WIRING DIAGRAM THREE PHASE 60Hz...

Page 64: ...Section 7 ILLUSTRATIONS AND PARTS LIST 58 7 18 WIRING DIAGRAM 50 Hz...

Page 65: ...Section 7 ILLUSTRATIONS AND PARTS LIST 59 7 19 WIRING DIAGRAM 50 Hz WYE DELTA...

Page 66: ...NOTES...

Page 67: ...NOTES...

Page 68: ...33 72232425 Fax 33 78907168 SULLAIR CORPORATION Subsidiary of Sundstrand Corporation 3700 East Michigan Boulevard Michigan City Indiana 46360 U S A Telephone 1 800 SULLAIR U S A Only or 1 219 879 545...

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