Sullair ShopTek ST1100, User Manual

Page 1: ...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...

Page 2: ...cated 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 The...

Page 3: ...EM 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 SPECIFICAT...

Page 4: ...OURS 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 REPLA...

Page 5: ...rein 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 co...

Page 6: ...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 aqueo...

Page 7: ...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 unventi...

Page 8: ...andling 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...

Page 9: ...a 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 o...

Page 10: ...NOTES 8...

Page 11: ...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...

Page 12: ...0 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...

Page 13: ...0 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 F...

Page 14: ...R00 6 7 8 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 Fil...

Page 15: ...R00 6 7 8 DISCHARGE SYSTEM COOLING LUBRICATION SYSTEM 5 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 Filt...

Page 16: ...affle 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...

Page 17: ...g 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 remain...

Page 18: ...ely 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 h...

Page 19: ...hut 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 thermop...

Page 20: ...ressor 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 indica...

Page 21: ...s Press to accept changes Figure 2 13 Figure 2 14 Refer to Figure 2 14 If there is no keypad activity the display will return to normal view in about one minute If the Start Stop or Return Reset butto...

Page 22: ...NOTES 20 02250180 090 R00...

Page 23: ...ies ST1109 15 60 39 3 998 24 3 618 40 7 1035 772 350 ST1112 15 60 39 3 998 24 3 618 40 7 1035 772 350 ST1108 15 50 39 3 998 24 3 618 40 7 1035 772 350 ST1113 15 50 39 3 998 24 3 618 40 7 1035 772 350...

Page 24: ...ge interval which differs from the User Manual Contact a Sullair representative for details COMPRESSOR STANDARD MODELS Type Fluid Flooded Rotary Screw Standard Operating Pressure 115 psig 8 bar 125 ps...

Page 25: ...Hours C 4000 Hours I ST400 ST500 ST700 1 Gallon 4 Liters ST1100 ST1500 1 3 gallon 5 Liters Figure 3 1 Fluid Fill Location 1 Separator Tube 3 Fluid Fill Port 2 Sight Glass 4 TO DRAIN disconnect oil lin...

Page 26: ...S HOP T EK USER MANUAL SECTION 3 24 02250180 090 R00 Figure 3 2 Identification ST400 ST500 ST700 5 10HP 02250179 432 R00...

Page 27: ...COMPRESSSOR FRAME LEVEL IS REQUIRED 3 ALL DIMENSIONS ARE 50 12 7MM 4 RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING 5 DOORS ARE REMOVABLE USING LIFT OFF PINS 6 ALL DIMENSIONS SHOWN IN...

Page 28: ...S HOP T EK USER MANUAL SECTION 3 26 02250180 090 R00 Figure 3 3 Identification ST1100 ST1500 15 20HP 02250179 435 R01...

Page 29: ...TAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED 3 ALL DIMENSIONS ARE 50 12 7MM 4 RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING 5 DOORS ARE REMOVABLE USING LIFT OFF PINS 6 ALL DIMENSIONS...

Page 30: ...S HOP T EK USER MANUAL SECTION 3 28 02250180 090 R00 Figure 3 4 Piping and Instrumentation ST400 ST500 ST700 5 10HP 02250179 804 R01...

Page 31: ...R 8 88290014 222 1 OIL SIGHT GLASS 9 02250046 338 1 VALVE MINIMUM PRESSURE 10 88290014 514 1 SENSOR PRESSURE 11 VARIOUS 1 VALVE RELIEF 12 88290015 890 1 FILTER RETURN OIL 13 VARIOUS 1 VALVE THERMAL 14...

Page 32: ...S HOP T EK USER MANUAL SECTION 3 30 02250180 090 R00 Figure 3 5 Piping and Instrumentation ST1100 and ST1500 15 20HP 02250179 805 R02...

Page 33: ...EMENT OIL SEPARATOR 8 88290014 222 1 OIL SIGHT GLASS 9 02250046 338 1 VALVE MINIMUM PRESSURE 10 88290014 225 1 COMBINATION AIR OIL COOLER 11 88290014 514 1 SENSOR PRESSURE 12 VARIOUS 1 VALVE RELIEF 13...

Page 34: ...S HOP T EK USER MANUAL SECTION 3 32 02250180 090 R00 Figure 3 6 Wiring Diagram ST400 ST1500 208V 460V Full Voltage 88290015 618 R0...

Page 35: ...SECTION 3 S HOP T EK USER MANUAL 33 02250180 090 R00 Figure 3 7 Wiring Diagram ST400 ST1500 575V Full Voltage 88290017 537 R03...

Page 36: ...S HOP T EK USER MANUAL SECTION 3 34 02250180 090 R00 Figure 3 8 Wiring Diagram ST400 ST500 ST700 400V 50Hz CE Full Voltage 88290014 361 R07...

Page 37: ...SECTION 3 S HOP T EK USER MANUAL 35 02250180 090 R00 Figure 3 9 Wiring Diagram ST1100 ST1500 400V 50Hz CE Wye Delta 88290014 360 R09...

Page 38: ...5 876 398 ST500RD 7 5 69 1748 23 591 63 1605 954 5 434 WS700 Series ST700R 10 64 1616 23 591 63 1605 897 408 ST700RD 10 69 1748 23 591 63 1605 981 446 WS11100 Series ST1100R 15 66 1676 25 5 645 5 71 5...

Page 39: ...NOTES 37 02250180 090 R00...

Page 40: ...SECTION 3 S HOP T EK USER MANUAL 38 02250180 090 R00 Figure 3 10 Identification ST400 ST500 ST700 5 10HP Tank Mount 02250179 433 R00...

Page 41: ...VEL IS REQUIRED 3 ALL DIMENSIONS ARE 50 12 7MM 4 RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING 5 DOORS ARE REMOVABLE USING LIFT OFF PINS 6 ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMET...

Page 42: ...SECTION 3 S HOP T EK USER MANUAL 40 02250180 090 R00 Figure 3 11 Identification ST400 ST500 ST700 5 10HP Tank Mount with Dryer 02250179 434 R00...

Page 43: ...EVEL IS REQUIRED 3 ALL DIMENSIONS ARE 50 12 7MM 4 RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING 5 DOORS ARE REMOVABLE USING LIFT OFF PINS 6 ALL DIMENSIONS SHOWN IN INCHES WITH MILLIME...

Page 44: ...S HOP T EK USER MANUAL SECTION 3 42 02250180 090 R00 Figure 3 12 Identification ST1100 ST1500 15 20HP Tank Mount 02250179 436 R01...

Page 45: ...AME LEVEL IS REQUIRED 3 ALL DIMENSIONS ARE 50 12 7MM 4 RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING 5 DOORS ARE REMOVABLE USING LIFT OFF PINS 6 ALL DIMENSIONS SHOWN IN INCHES WITH MI...

Page 46: ...S HOP T EK USER MANUAL SECTION 3 44 02250180 090 R00 Figure 3 13 Identification ST1100 ST1500 15 20HP Tank Mount with Dryer 02250179 437 R01...

Page 47: ...SOR FRAME LEVEL IS REQUIRED 3 ALL DIMENSIONS ARE 50 12 7MM 4 RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING 5 DOORS ARE REMOVABLE USING LIFT OFF PINS 6 ALL DIMENSIONS SHOWN IN INCHES W...

Page 48: ...S HOP T EK USER MANUAL SECTION 3 46 02250180 090 R00 Figure 3 14 Wiring Diagram SRS 25 100 115 230V 1 60...

Page 49: ...SECTION 3 S HOP T EK USER MANUAL 47 02250180 090 R00 Figure 3 15 Wiring Diagram SRS 9 18 220 240V 1 50...

Page 50: ...S HOP T EK USER MANUAL SECTION 3 48 02250180 090 R00 Figure 3 16 Wiring Diagram SRS 24 30 220 240V 1 50...

Page 51: ...permit easy access to all compres sor components Walls and ceilings with soft or porous sur faces absorb sound and reduce ambient noise levels Hard surfaces reflect noise and have little effect on amb...

Page 52: ...should be housed in a covered four walled enclosure Sheltered air cooled machines must have their exhaust air vented outside of the enclosure Installations consisting of more than one compressor shoul...

Page 53: ...ischarge connection All piping and fittings should be rated for the discharge pressure AUXILIARY RECEIVER TANK An auxiliary receiver tank should be installed in systems where large demand fluctuations...

Page 54: ...ine 4 4 BELT CHECK Tension of drive belts should be checked upon installation and after 0 5 to 2 hours of run time This is essential to proper performance of the compressor unit as well as to ensure l...

Page 55: ...pressor data plate ratings A starter hole is provided for an incoming power connection If it is necessary to make a hole in the control box in a different location care should be taken to not allow me...

Page 56: ...or Main Motor Rotational Direction ST400 ST500 ST700 5 10HP Figure 4 5 Fan Motor Main Motor Rotational Direction ST1100 ST1500 15 20HP 1 Main Motor Rotational Direction 2 Fan Motor Rotational Directio...

Page 57: ...hooting Introduction on page 66 under EXCESSIVE COMPRESSOR FLUID CONSUMPTION for a probable cause and corrective action After a routine start observe the controller display for the proper indications...

Page 58: ...NOTES 56 02250180 090 R00...

Page 59: ...fault conditions 6 2 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION After the initial 50 hours of operation maintenance is required to clean the system of any foreign materials At this time the retu...

Page 60: ...Replace the fluid filter under any of the following conditions or whichever occurs first 1 Every 2000 hours a display on the Controller indicates the need for replacement 2 Every fluid change FLUID FI...

Page 61: ...every 2000 hours or sooner if necessary AIR FILTER ELEMENT REPLACEMENT 1 Remove enclosure panels to gain access to filter 2 Loosen hose clamp and remove filter 3 Install new filter and tighten hose c...

Page 62: ...spect the separator tube for rust contamination or damage 5 Reinsert the separator elements into the separator tube taking care not to dent the element against the tank opening 6 Install a new lubrica...

Page 63: ...A Ensure the indicator arm is pushed down prior to starting B Gently place the meter on the flat side of one belt at the midpoint between the motor and compres sor unit pulleys C Slowly press on the p...

Page 64: ...not to disturb any adjacent belts as this will give a false reading As the probe detects a vibration the meter will display the frequency Record data D Rotate the motor pulley through at least one com...

Page 65: ...g plate adjusting bolts I Ensure that the discharge hose is not kinked bent or has been placed under undue stress or strain J Replace the belt guard and the side panel Table 6 1 Belt Tension Requireme...

Page 66: ...64 02250180 090 R00 Figure 6 10 Belt Tension Adjustment ST400 ST500 ST700 5 10HP 1 Belt Guard 5 Comp Unit Mounting Plate Bolts 4 2 Belt Tension Adjustment Screw 6 Comp Unit Pulley 3 Locking Nut 7 Belt...

Page 67: ...ly parallel alignment of the drive pulleys needs to be checked PARALLEL ALIGNMENT CAN BE CHECKED BY TWO METHODS 1 Placing a straight edge against the pulleys near their centers For correct alignment t...

Page 68: ...y INSTRUCTIONS FOR REMOVING A PULLEY 1 Loosen and remove both grub screws 2 Install one grub screw into the jacking disas sembly hole Refer to Figure 6 12 3 Tighten grub screw to release taper lock hu...

Page 69: ...ressor shuts down under service load conditions High Pressure Fault Compressor pressure setting incorrect Change setting in Controller Control line strainer clogged Clean or replace strainer Minimum p...

Page 70: ...for leaks Inlet valve stuck open Remove the intake hose and check the inlet valve for proper operation Defective unload solenoid valve Check the valve for proper operation open when energized replace...

Page 71: ...NOTES 69...

Page 72: ...ors LTD 324 332 Frankston Dandenong Road Dandenong VIC Australia 3175 Ph 61397039000 Fx 61397039053 www championcompressors com au SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City Indian...