Sullair SN55, User Manual

Page 1: ...03 27 2020 Copyright 2020 Sullair LLC All rights reserved WARRANTY NOTICE Failure to follow the instructions and procedures in this manual or misuse of this equipment will void its warranty Subject to...

Page 2: ...ing on the function and installation of Sullair service parts troubleshooting common faults and malfunctions and actual equipment operation These courses are recommended for distributor service person...

Page 3: ...pressor unit functional description 14 2 4 Compressor cooling and lubrication system functional description 17 2 5 Compressor discharge system functional description 17 2 6 Control system functional d...

Page 4: ...ndations 56 4 2 5 1 Scale 56 4 2 5 2 Corrosion 56 4 2 5 3 Biological and organic fouling slime 56 4 2 6 Seawater cooled units 56 4 3 Outdoor installation sheltered 57 4 4 Service air piping 57 4 4 1 P...

Page 5: ...tions 4 6 7 Separator maintenance 72 6 7 1 Separator element replacement 72 6 8 Oil return sight glass maintenance 73 6 9 Pressure regulator adjustment 73 6 10 Water condensate drain maintenance 74 6...

Page 6: ...Table of Contents SN55 SN55S SN55V SN75 SN75S SN75V User Manual Notes 02250247 571 R04 5 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 7: ...plicable to most compressors and the concepts behind these state ments are generally applicable to all compressors 1 2 Personal protective equipment A Prior to installing or operating the compressor o...

Page 8: ...rial or on any external surfaces of the air compressor Wipe down using an aqueous industrial cleaner or steam clean as required If necessary remove acoustical mate rial clean all surfaces and then rep...

Page 9: ...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...

Page 10: ...ep 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 susp...

Page 11: ...ce using the proper energy isolating devices and tags Place lockout hasp and padlock or tag at the point of power disconnect where lockout is required by each person performing work Each person shall...

Page 12: ...published service manuals Failure to observe this precau tion could result in death or severe injury WARNING Line terminals L1 L2 L3 motor terminals U V W and the DC link brake resistor terminals are...

Page 13: ...to the util ity line power as severe damage to the VSD may occur NOTE Interior electrical wiring is performed at the fac tory Required customer wiring is minimal but should be done by a qualified elec...

Page 14: ...1 Safety SN55 SN55S SN55V SN75 SN75S SN75V User Manual Notes 02250247 571 R04 13 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 15: ...ed from the fluid Another similar heat exchanger cools the compressed air Both air cooled and water cooled versions have easily accessible items such as the fluid filter air oil separator and control...

Page 16: ...lated export control restrictions Figure 2 1 Overall component layout air cooled model 1 Compressor unit 8 Moisture separator 2 Motor 9 Fluid filter 3 Cooler fan motor 10 Fluid fill 4 Electrical enclo...

Page 17: ...control restrictions 16 Figure 2 2 Overall component layout water cooled model 1 Compressor unit 8 Moisture separator 2 Motor 9 Fluid filter 3 Oil cooler 10 Fluid fill 4 Electrical enclosure 11 Fluid...

Page 18: ...nal baffle system The direction of movement is changed and its velocity significantly reduced thus causing large droplets of fluid to form and fall to the bottom of the separator sump tank The fractio...

Page 19: ...Description 02250247 571 R04 Subject to EAR ECCN EAR99 and related export control restrictions 18 Figure 2 3 Air cooled cooling lubrication and discharge system 1 Compressor unit 4 Moisture separator...

Page 20: ...al 02250247 571 R04 19 Subject to EAR ECCN EAR99 and related export control restrictions Figure 2 4 Water cooled cooling lubrication and discharge system 1 Compressor unit 4 Moisture separator 2 Separ...

Page 21: ...e at the actuator expands the dia phragm The rack in turn engages with the pinion mounted on the spiral valve shaft assembly This results in a rotary motion As the spiral valve rotates it starts openi...

Page 22: ...and related export control restrictions Automatic operation For applications with varied periods of time when there are no air requirements the controller s AUTOMATIC mode allows the compressor to sh...

Page 23: ...bject to EAR ECCN EAR99 and related export control restrictions 22 Figure 2 5 Standard pneumatic control system 1 Air inlet 5 Air outlet 2 Minimum pressure check valve 6 Pressure regulator 3 Blowdown...

Page 24: ...response to the operation of the pressure regulator Refer to Full load mode 50 to 100 psig 3 4 to 6 9 bar on page 20 The inlet valve also acts as a check valve thus preventing reverse rotation when th...

Page 25: ...imum pressure valve opens allowing compressed air to flow into to the service line From this point on the controller monitors the line pressure which controls the VSD The pressure regulator and soleno...

Page 26: ...2 Description SN55 SN55S SN55V SN75 SN75S SN75V User Manual Notes 02250247 571 R04 25 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 27: ...55 87 6 2225 43 4 1103 68 5 1740 3455 1570 5510S 75 55 87 6 2225 43 4 1103 68 5 1740 3455 1570 5512S 75 55 87 6 2225 43 4 1103 68 5 1740 3455 1570 SN75 series 7507 100 75 87 6 2225 43 4 1103 68 5 1740...

Page 28: ...SN55V models 5507V through 5512V TEFC 460 60 72 87 6 2225 43 4 1103 68 5 1740 3411 1550 575 60 62 87 6 2225 43 4 1103 68 5 1740 3411 1550 VSD series SN75V models 7507V through 7512V TEFC 460 60 88 87...

Page 29: ...chscreen Controller 7 touchscreen 1 Special compressors are available for operation in higher ambient temperature Motor Standard models Size 75 100 hp 55 75 kW Type C flanged totally enclosed fan cool...

Page 30: ...gging When ambient conditions exceed those noted or if condi tions warrant use of extended life lubricants contact Sul lair for recommendation 3 6 Application guide Sullair encourages the user to part...

Page 31: ...Separator change Sullube 7 2 gal 27 3 L E G C I D PristineFG 7 2 gal 27 3 L H E G C B D B 4 000 hours or more frequently if conditions so require C When measured pressure loss exceeds 20 psig 1 3 bar...

Page 32: ...3 Specifications SN55 SN55S SN55V SN75 SN75S SN75V User Manual 02250247 571 R04 31 Subject to EAR ECCN EAR99 and related export control restrictions 3 8 Identification air cooled 02250242 484 R02...

Page 33: ...EE CIRCULATION OF AIR 2 A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE AND RIGID ENOUGH TO MAINTAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED A...

Page 34: ...3 Specifications SN55 SN55S SN55V SN75 SN75S SN75V User Manual 02250247 571 R04 33 Subject to EAR ECCN EAR99 and related export control restrictions 3 9 Identification water cooled 02250242 503 R02...

Page 35: ...REE CIRCULATION OF AIR 2 A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE AND RIGID ENOUGH TO MAINTAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED THE COMPRESSOR FRAME MUST BE LEVELLED...

Page 36: ...fications SN55 SN55S SN55V SN75 SN75S SN75V User Manual 02250247 571 R04 35 Subject to EAR ECCN EAR99 and related export control restrictions 3 10 Piping instrumentation air cooled SN55 SN75 02250218...

Page 37: ...VALVE COMBO 1 22 STRAINER VTYPE 1 23 VALVE SOLENOID 2 24 VALVE PRESSURE REG 1 25 TANK SEPARATOR 1 26 FILTER PNEUMATIC 1 27 VALVE CHECK 1 28 VALVE BALL STNR COMBO 1 29 DRAIN 1 30 VENTILATOR 1 31 GAUGE...

Page 38: ...ications SN55 SN55S SN55V SN75 SN75S SN75V User Manual 02250247 571 R04 37 Subject to EAR ECCN EAR99 and related export control restrictions 3 11 Piping instrumentation water cooled SN55 SN75 02250218...

Page 39: ...3 VALVE SOLENOID 3WNO 2 24 VALVE PRESSURE REG 1 25 TANK SEPARATOR 1 26 FILTER PNEUMATIC 1 27 VALVE CHECK 2 28 HEAT EXCHANGER 1 29 SWITCH PRESS 1 30 VALVE WATER REG 1 31 VALVE SOLENOID 2WNC 1 32 VALVE...

Page 40: ...ications SN55 SN55S SN55V SN75 SN75S SN75V User Manual 02250247 571 R04 39 Subject to EAR ECCN EAR99 and related export control restrictions 3 12 Piping instrumentation air cooled SN55S SN75S 02250243...

Page 41: ...1 21 VALVE SOLENOID 3WNO 2 22 VALVE BLOWDOWN 1 23 REGULATOR 1 24 TANK SEPARATOR 1 25 FILTER PNEUMATIC 1 26 VALVE CHECK 2 27 VALVE BALL STNR COMBO 1 28 DRAIN ZERO LOSS 1 29 VALVE SPRIAL 1 Drawing note...

Page 42: ...cations SN55 SN55S SN55V SN75 SN75S SN75V User Manual 02250247 571 R04 41 Subject to EAR ECCN EAR99 and related export control restrictions 3 13 Piping instrumentation water cooled SN55S SN75S 0225024...

Page 43: ...1 23 TANK SEPARATOR 1 24 FILTER PNEUMATIC 1 25 VALVE CHECK 2 26 VALVE THERMAL 1 27 SWITCH PRESS 1 28 VALVE WATER REGULATOR 1 29 VALVE SOLINOID 2WNC 1 30 VALVE BALL STRAINER COMBO 1 31 DRAIN ZERO LOSS...

Page 44: ...ications SN55 SN55S SN55V SN75 SN75S SN75V User Manual 02250247 571 R04 43 Subject to EAR ECCN EAR99 and related export control restrictions 3 14 Piping instrumentation air cooled SN55V SN75V 02250243...

Page 45: ...OR WATER 1 19 ELEMENT SEPARATOR 1 20 VALVE DRAIN 1 21 VALVE SOLINOID 3WNO 1 22 TANK SEPARATOR 1 23 FILTER PNEUMATIC 1 24 VALVE CHECK 2 25 VALVE BALL STRAINER COMBO 1 26 DRAIN ZERO LOSS 1 27 VALVE THER...

Page 46: ...cations SN55 SN55S SN55V SN75 SN75S SN75V User Manual 02250247 571 R04 45 Subject to EAR ECCN EAR99 and related export control restrictions 3 15 Piping instrumentation water cooled SN55V SN75V 0225024...

Page 47: ...ALVE DRAIN 1 21 VALVE SOLENOID 3WNO 1 22 TANK SEPARATOR 1 23 FILTER PNEUMATIC 1 24 VALVE CHECK 2 25 VALVE THERMAL 1 26 SWITCH PRESS 1 27 VALVE WATER REG 1 28 VALVE SOLENOID 2WNC 1 29 VALVE BALL STRAIN...

Page 48: ...3 Specifications SN55 SN55S SN55V SN75 SN75S SN75V User Manual 02250247 571 R04 47 Subject to EAR ECCN EAR99 and related export control restrictions 3 16 Wiring diagram wye delta 02250242 364 R04 sh1...

Page 49: ...SN55 SN55S SN55V SN75 SN75S SN75V User Manual 3 Specifications 02250247 571 R04 Subject to EAR ECCN EAR99 and related export control restrictions 48 3 16 Wiring diagram wye delta 02250242 364 R04 sh2...

Page 50: ...EE TRANSFORMER CONNECTION TABLE FOR PROPER VOLTAGE CONNECTION TRANSFORMER FUSING ON CLIPS LOCATED ON TRANSFORMER X1 XF INTERNALLY JUMPERED SEE TRANSFORMER FUSE CHART FOR SIZING 5 REFER TO SEQUENCING P...

Page 51: ...SN55 SN55S SN55V SN75 SN75S SN75V User Manual 3 Specifications Notes 02250247 571 R04 Subject to EAR ECCN EAR99 and related export control restrictions 50...

Page 52: ...cations SN55 SN55S SN55V SN75 SN75S SN75V User Manual 02250247 571 R04 51 Subject to EAR ECCN EAR99 and related export control restrictions 3 17 Wiring diagram VSD air cooled parallel wye 02250243 116...

Page 53: ...S SN55V SN75 SN75S SN75V User Manual 3 Specifications 02250247 571 R04 Subject to EAR ECCN EAR99 and related export control restrictions 52 3 17 Wiring diagram VSD air cooled parallel wye 02250243 116...

Page 54: ...CTION TABLE FOR PROPER VOLTAGE CONNECTION TRANSFORMER FUSING ON CLIPS LOCATED ON TRANSFORMER X1 XF INTERNALLY JUMPERED SEE TRANSFORMER FUSE CHART FOR SIZING 5 REFER TO SEQUENCING PROTOCOL MANUAL 6 SEP...

Page 55: ...equate space must be provided for the compressor and its components Air cooled compressors require a minimum of 4 feet 1 25 meters around the perimeter of the compressor The location should be free fr...

Page 56: ...utilizing this heat If ductwork is added the high static fan option is required Do not install a water cooled or an air cooled after cooled compressor where it will be exposed to tempera tures less t...

Page 57: ...levels of dissolved oxygen and low pH levels assist in the creation of corrosive scale A thin coating of lime scale is often beneficial in helping to prevent corrosion from form ing 4 2 5 3 Biologica...

Page 58: ...extreme such that direct rain or snow may fall on the unit it should be in a fully enclosed room or building If installed under a shelter air cooled machines must be positioned in a way that prevents...

Page 59: ...era ture below the dew point For most ambient conditions considerable water vapor is condensed To remove the condensation each compressor with built in aftercooler is supplied with a combination conde...

Page 60: ...e electrical feed point is critical as voltage drops may impair the performance of the com pressor Cable sizes may vary considerably so the mains terminals will accept up to 50 mm2 1 awg 37 4 Sk 50 60...

Page 61: ...the STS monitor to display the P1 separator sump tank pressure Pull out the EMERGENCY STOP button and press once quickly and in succession the Start and Stop buttons This action will bump start the mo...

Page 62: ...4 Installation SN55 SN55S SN55V SN75 SN75S SN75V User Manual Notes 02250247 571 R04 61 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 63: ...ontroller 5 1 Controller layout Figure 5 1 Controller layout and button functions Key Description Function 1 Start button Push to start the compressor Can also be used to reset maintenance and warning...

Page 64: ...ght may blink rapidly if a machine start is immi nent Maintenance or Warning Indicator Amber Lights when recommended maintenance or service warning is issued In most cases the machine will continue to...

Page 65: ...and run times starts and cycles and message related to the current status state and mode The gauge area below shows discharge tem perature discharge pressure and sump pres sure as analog gauges You ca...

Page 66: ...maintenance information Login in as an administrator And perform other administrative functions To view the complete menu hierarchy see Section 5 5 on page 67 You can reach the main menu by pressing t...

Page 67: ...nd Celsius C as the unit of measure for temperature Language The user can choose between English Spanish French Portuguese Russian and Chinese for the display language Note The display language change...

Page 68: ...r SN55 SN55S SN55V SN75 SN75S SN75V User Manual 02250247 571 R04 67 Subject to EAR ECCN EAR99 and related export control restrictions 5 5 Menu hierarchy Figure 5 5 Sullair touch screen controller menu...

Page 69: ...ts of an antenna installed on the outside of the compressor s enclosure and an M70 modem installed inside the compressor s control cabinet The LED lights on the modem indicate the current status of th...

Page 70: ...5 Controller SN55 SN55S SN55V SN75 SN75S SN75V User Manual Notes 02250247 571 R04 69 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 71: ...warmed up it is recommended that a general check on the overall compressor be made to assure that the compressor is running properly 6 3 Maintenance after initial 50 hours of operation After the init...

Page 72: ...Refer to Figure 6 2 Air filter maintenance should be per formed when the maintenance gauge shows red with the compressor running full load or once a year whichever comes first If the filter needs to...

Page 73: ...of the cover plate and the separator sump tank flange Do not let any scraps fall into the separator sump tank 6 Inspect the separator sump tank for rust dirt etc 7 Insert a new separator element into...

Page 74: ...assembly and replace with new assembly 4 Inspect and clean the orifice inside the sight glass blocks The orifice must be removed with an allen wrench 5 Coat lubricate the O rings with silicone grease...

Page 75: ...ng the coupling element 3 Unwrap the coupling element from the coupling jaws 4 Install the new element by wrapping it around the jaws engaging the cogs on the element into the jaws 5 Reinstall the out...

Page 76: ...ure to 85 F 29 4 C or less Water cooled only Cooling water flow insufficient Check water lines and valves water cooled only Cooler plugged Clean tubes If plugging persists install water conditioner wa...

Page 77: ...el too high Drain and change Check that the compressor temperature has not dropped below 170 F 76 7 C Pressure relief valve opens repeatedly Defective pressure relief valve Replace Plugged separator C...

Page 78: ...6 Maintenance SN55 SN55S SN55V SN75 SN75S SN75V User Manual Notes 02250247 571 R04 77 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 79: ...Subject to EAR ECCN EAR99 and related export control restrictions...

Page 80: ...ons are subject to change without prior notice Subject to EAR ECCN EAR99 and related export control restrictions Sullair LLC 1 Sullair Way Michigan City IN 46360 USA www sullair com 1 800 SULLAIR USA...