ROTARY SCREW AIR COMPRESSOR ES--6 · PDF fileROTARY SCREW ES--6 Series 5, 7.5 and 10HP...

ROTARY SCREW

ES--6 Series5, 7.5 and 10HP

OPERATOR’SMANUAL AND

Part Number 02250057--634©S ullair C or por at ion

PARTS LIST

AIR COMPRESSOR

4, 5.5 and 7.5 kw

KEEP FORFUTURE

REFERENCE

Sullair

NOTE: When performing a manual search for a Sullair part number (binocular icon on tool bar above), substitute a SPACE for the HYPHEN. EXAMPLE: To find: 02250057-696 Type: 02250057 696 For further information consult the 'Sullair Manual Navigation Guide' in the Bookmark section.

AIR CARESEMINAR TRAINING

Sullair Air Care Seminars are 3--day courses that provide hands--on instructionin the proper operation, maintenance and service of Sullair equipment.Individual seminars on Industrial compressors and compressor electricalsystems are presented at regular intervals throughout the year at a dedicatedtraining facility at Sullair’s corporate headquarters in Michigan City, Indiana.

Instruction includes discussion of the function and installation of Sullair serviceparts, troubleshooting of the most common problems, and actual equipmentoperation. The seminars are recommended for maintenance and servicepersonnel.

For detailed course outlines, schedule and cost information contact:

Sullair Corporate Training Department1--800--SULLAIR or 219--879--5451 (ext. 1816)

-- Or Write --Sullair Corporation3700 E. Michigan Blvd.Michigan City, IN 46360Attn: 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 2DESCRIPTION 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 3SPECIFICATIONS 9 3.1 TABLE OF SPECIFICATIONS

10 3.2 COMPRESSOR LUBRICATION GUIDE

Section 4INSTALLATION 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 6MAINTENANCE 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 ADJUSTMENTPROCEDURES

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 7ILLUSTRATIONS ANDPARTS 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 ANDPARTS 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 1SAFETY

1.1 GENERALSullair Corporation and its subsidiaries design andmanufacture all of their products so they can be op-erated safely. However, the responsibility for safeoperation rests with those who use and maintainthese products. The following safety precautionsare offered as a guide which, if conscientiously fol-lowed, will minimize the possibility of accidentsthroughout the useful life of this equipment.

The compressor should be operated only by thosewho have been trained and delegated to do so, andwho have read and understood this Operator’sManual. Failure to follow the instructions, proce-dures and safety precautions in this manual may re-sult in accidents and injuries.

NEVER start the compressor unless it is safe to doso.DONOT attempt to operate the compressorwitha known unsafe condition. Tag the compressor andrender it inoperative by disconnecting and lockingout all power at source or otherwise disabling itsprimemover so others whomay not know of the un-safe condition cannot attempt to operate it until thecondition is corrected.

Install, use and operate the compressor only in fullcompliance with all pertinent OSHA regulationsand/or any applicable Federal, State, and Localcodes, standards and regulations.

DO NOT modify the compressor and/or controls inany way except with written factory approval.

While not specifically applicable to all types of com-pressors with all types of prime movers, most of theprecautionary statements contained herein are ap-plicable to most compressors and the concepts be-hind these statements are generally applicable to allcompressors.

1

1.2 PERSONAL PROTECTIVE EQUIPMENTPrior to installing or operating the compressor, own-ers, employers and users should become familiarwith, and comply with, all applicable OSHA regula-tions and/or any applicable Federal, State andLocalcodes, standards, and regulations relative to per-sonal protective equipment, such as eye and faceprotective equipment, respiratory protective equip-ment, equipment intended to protect the extremi-ties, protective clothing, protective shields andbarri-ers and electrical protective equipment, as well asnoise exposure administrative and/or engineeringcontrols and/or personal hearing protective equip-ment.

1.3 PRESSURE RELEASEA. Install an appropriate flow--limiting valve betweenthe service air outlet and the shut--off (throttle)valve, either at the compressor or at any other pointalong the air line, when an air hose exceeding 1/2”(13mm) inside diameter is to be connected to theshut--off (throttle) valve, to reduce pressure in caseof 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 thehose is to beused to supply amanifold,install an additional appropriate flow--limiting valvebetween the manifold and each air hose exceeding1/2” (13mm) inside diameter that is to be connectedto the manifold to reduce pressure in case of hosefailure.

C. Provide an appropriate flow--limiting valve at thebeginningof eachadditional 75 feet (23m) of hose inruns of air hoseexceeding 1/2” (13mm) insidediam-eter to reduce pressure in case of hose failure.

D. Flow--limiting valves are listed by pipe size andrated CFM. Select appropriate valves accordingly,in accordancewith their manufacturer’s recommen-dations.

E. DO NOT use air tools that are rated below themaximum rating of the compressor. Select air tools,air hoses, pipes, valves, filters and other fittings ac-cordingly. DO NOT exceed manufacturer’s ratedsafe operating pressures for these items.

F.Secure all hose connections by wire, chain or oth-er suitable retaining device to prevent tools or hoseends from being accidentally disconnected and ex-pelled.

G.Open fluid filler cap only whencompressor is notrunning and is not pressurized. Shut down thecompressor and bleed the sump (receiver) to zerointernal pressure before removing the cap.

H. Vent all internal pressure prior to opening anyline, fitting, hose, valve, drain plug, connection orother component, such as filters and line oilers, andbefore attempting to refill optional air line anti--icersystems with antifreeze compound.

I. Keep personnel out of line with and away from thedischarge opening of hoses or tools or other pointsof compressed air discharge.

J.Use air at pressures less than30 psig (2.1 bar) forcleaning purposes, and then only with effective chipguarding and personal protective equipment perOSHA Standard 29 CFR 1910.242 (b) and/or anyapplicable Federal, State, and Local codes, stan-dards and regulations.

K. DO NOT engage in horseplay with air hoses asdeath or serious injury may result.

.4 FIRE AND EXPLOSIONA. Clean up spills of lubricant or other combustiblesubstances immediately, if such spills occur.

B.Shut off the compressor andallow it to cool. Thenkeep sparks, flames and other sources of ignitionaway and DO NOT permit smoking in the vicinitywhen checking or adding lubricant or when refillingair line anti--icer systemswith antifreeze compound.

C. DO NOT permit fluids, including air line anti--icersystem antifreeze compound or fluid film, to accu-

1

Section 1SAFETY

2

1

mulate on, under or around acoustical material, oron any external surfaces of the air compressor or oninternal surfaces of the enclosure.Wipe down usingan aqueous industrial cleaner or steam clean as re-quired. If necessary, remove acoustical material,clean all surfaces and then replace acousticalmate-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 useflammable solvents for cleaning purposes.

D. Disconnect and lock out all power at source priorto 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 andpressure connectors in good condition. Replaceanywiring that has cracked, cut, abraded or otherwisedegraded 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 suchas tools away from exposed live electrical partssuch as terminals to avoid arcing which might serveas a source of ignition.

G.Removeany acousticalmaterial or othermaterialthat may be damaged by heat or that may supportcombustion and is in close proximity, prior to at-tempting weld repairs.

H. Keep suitable fully charged Class BC or ABC fireextinguisher or extinguishers nearbywhenservicingand 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 properflow of cooling air or water or with inadequate flow oflubricant or with degraded lubricant.

K. DO NOT attempt to operate the compressor inany classification of hazardous environment unlessthe compressor has been specially designed andmanufactured for that duty.

.5 MOVING PARTSA. Keep hands, arms and other parts of the bodyandalso clothingaway fromcouplings, fans andoth-er moving parts.

B. DO NOT attempt to operate the compressor withthe fan, coupling or other guards removed.

C. Wear snug--fitting clothing and confine long hairwhen working around this compressor, especiallywhen exposed to hot or moving parts.

D. Keep access doors, if any, closed except whenmaking repairs or adjustments.

E.Make sure all personnel are out of and/or clear ofthe compressor prior to attempting to start or oper-ate it.

F. Disconnect and lock out all power at source andverify at the compressor that all circuits are de--en-ergized to minimize the possibility of accidentalstart--up, or operation, prior to attempting repairs oradjustments. This is especially important whencompressors are remotely controlled.

G. Keep hands, feet, floors, controls and walkingsurfaces 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 SHARPCORNERSA. 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 ofair discharge.

C. Wear personal protective equipment includinggloves and head covering when working in, on oraround the compressor.

D. Keep a first aid kit handy. Seek medical assis-tance promptly in case of injury. DO NOT ignoresmall cuts and burns as they may lead to infection.

1.7 TOXIC AND IRRITATING SUBSTANCESA.DONOT use air from this compressor for respira-tion (breathing) except in full compliancewithOSHAStandards 29 CFR1910 and/or any applicable Fed-eral, State or Local codes or regulations.

DANGER!

Death or serious injury can result from inhalingcompressed air without using proper safetyequipment. See OSHA standards and/or any ap-plicable Federal, State, and Local codes, stan-dards and regulations on safety equipment.

B. DONOT use air line anti--icer systems in air linessupplying respirators or other breathing air utiliza-tion equipment and DO NOT discharge air fromthese systems into unventilated or other confinedareas.

C. Operate the compressor only in open or ade-quately ventilated areas.

D. Locate the compressor or provide a remote inletso that it is not likely to ingest exhaust fumes or othertoxic, noxious or corrosive fumes or substances.

E. Coolants and lubricants used in this compressorare typical of the industry. Care should be taken toavoid accidental ingestion and/or skin contact. Inthe event of ingestion, seek medical treatmentpromptly. Wash with soap and water in the event ofskin contact. Consult Material Safety Data Sheet forinformation pertaining to fluid of fill.

F.Wear goggles or a full face shieldwhenaddingan-tifreeze compound to air line anti--icer systems.

Section 1SAFETY

1

1

G. If air line anti--icer system antifreeze compoundenters the eyes or if fumes irritate the eyes, theyshould be washed with large quantities of clean wa-ter for fifteen minutes. A physician, preferably aneye specialist, should be contacted immediately.

H. DONOT store air line anti--icer systemantifreezecompound in confined areas.

I. The antifreeze compound used in air line anti-freeze systems contains methanol and is toxic,harmful or fatal if swallowed. Avoid contact with theskin or eyes and avoid breathing the fumes. If swal-lowed, induce vomiting by administering a table-spoon of salt, in each glass of clean, warmwater un-til vomit is clear, then administer two teaspoons ofbaking soda in a glass of clean water. Have patientlay down and cover eyes to exclude light. Call a phy-sician immediately.

.8 ELECTRICAL SHOCKA. 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, andalso including those relative to equipment groundingconductors, and only by personnel that are trained,qualified and delegated to do so.

B. Keep all parts of the body and any hand--heldtools or other conductive objects away from ex-posed live parts of electrical system. Maintain dryfooting, stand on insulating surfaces and DO NOTcontact any other portion of the compressor whenmaking adjustments or repairs to exposed live partsof the electrical system. Make all such adjustmentsor repairs with one hand only, so as to minimize thepossibility of creating a current path through theheart.

C. Attempt repairs in clean, dry and well lighted andventilated areas only.

D. DO NOT leave the compressor unattended withopen electrical enclosures. If necessary to do so,thendisconnect, lock out and tag all power at sourceso others will not inadvertently restore power.

E. Disconnect, lock out, and tag all power at sourceprior to attempting repairs or adjustments to rotatingmachinery and prior to handling any ungroundedconductors.

.9 LIFTINGA. 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 handleonly in full compliance with OSHA standards 29CFR1910 subpart N and/or any applicable Federal,State, and Local codes, standards and regulations.

B. Inspect points of attachment for cracked weldsand for cracked, bent, corroded or otherwise de-graded members and for loose bolts or nuts prior tolifting.

C. Make sure entire lifting, rigging and supportingstructure has been inspected, is in good conditionand has a rated capacity of at least the weight of thecompressor. If you are unsure of the weight, thenweigh compressor before lifting.

D. Make sure lifting hook has a functional safetylatch or equivalent, and is fully engaged and latchedon the bail or slings.

E. Use guide ropes or equivalent to prevent twistingor swingingof the compressor once it has been liftedclear of the ground.

F. DO NOT attempt to lift in high winds.

G.Keep all personnel out from under and away fromthe compressor whenever it is suspended.

H. Lift compressor no higher than necessary.

I.Keep lift operator in constant attendancewhenev-er compressor is suspended.

J. Set compressor down only on a level surface ca-pable of safely supporting at least its weight and itsloading unit.

K. When moving the compressor by forklift truck,utilize fork pockets if provided. Otherwise, utilizepallet if provided. If neither fork pockets or pallet areprovided, thenmakesure compressor is secure andwell balanced on forks before attempting to raise ortransport it any significant distance.

L. Make sure forklift truck forks are fully engagedand tipped back prior to lifting or transporting thecompressor.

M. Forklift no higher than necessary to clear ob-stacles at floor level and transport and corner atminimum practical speeds.

N. Make sure pallet--mounted compressors arefirmly bolted or otherwise secured to the pallet priorto attempting to forklift or transport them. NEVERattempt to forklift a compressor that isnot secured toits pallet, as uneven floors or sudden stops maycause the compressor to tumble off, possibly caus-ing serious injury or property damage in theprocess.

3

Section 1SAFETY

4

1.10 ENTRAPMENTA. If the compressor enclosure, if any, is largeenough to hold aman and if it is necessary to enter itto perform service adjustments, inform other per-sonnel before doing so, or else secure and tag theaccess door in the open position to avoid the possi-bility of others closing and possibly latching the doorwith personnel inside.

B. Make sure all personnel are out of compressorbefore closing and latching enclosure doors.

Section 2DESCRIPTION

2.1 INTRODUCTIONYour new Sullair flood--lubricated rotary screw aircompressor will provide youwith improved reliabilityand greatly reduced maintenance.

Compared to other types of compressors, the Sull-air rotary screw is unique in mechanical reliability,with “no wear” and “no inspection” required of theworking parts within the compressor unit.

Read Section 6 (Maintenance) to keep your com-pressor in topoperating condition. Should any ques-tions arise which cannot be answered in the follow-ing text, call your nearest Sullair office or the SullairCorporation Service Department.

2.2 DESCRIPTION OF COMPONENTSRef er t o F igur e 2 -- 1. T he c om ponent s and as s em -blies of the ES--6 Series air compressor are clearlyshown. The complete compressor consists of anencapsulated compressor system, inlet sys-tem, cooling system and control system.

The compact design of the ES--6 Series air com-pressor provides easy access to all serviceablecomponents.

2.3 ENCAPSULATED COMPRESSOR SYSTEM,FUNCTIONAL DESCRIPTIONRef er t o F igur e 2 -- 2. T he enc aps ulat ed c om pr es s orincludes compressor unit, fluid management sys-tem, andmotor section. The Sullair compressor unitis a single--stage positive displacement lubricatedtype compressor. This unit is equipped with taperedroller bearings on the discharge, and cylindrical roll-er bearings on the inlet end for high load carrying ca-pacity. This unit provides continuous pulse--free aircompression to meet your needs. With a Sullaircompressor there will be nomaintenance or internalinspection of the compressor.

WARNING!

DONOT remove caps, plugs and/or other compo-nents when compressor is running or pressur-ized.

Stop compressor and relieve all internal pressurebefore doing so.

Fluid is injected into the compressor unit in largequantities and mixes directly with the air as the ro-tors turn, compressing the air. The fluid flow hasthree main functions:1. As coolant, it controls the rise of air temperature

normally associated with the heat of compres-sion.

2. It seals the leakage paths between the rotors andthe stator and also between the rotors them-selves.

3. It acts as a lubricating film between the rotors al-lowing one rotor to directly drive the other, whichis an idler.

The air/fluidmixture discharges directly into the fluidmanagement system.

The fluid cooler bypass valve helps assure propercooling by directing the fluid to the fluid cooler whendischarge temperature reaches the thermostat tem-perature setting.

During start--up in cool ambient conditions, the cool-er pressure drop will cause the filter bypass valve toopen up, assuring adequate fluid supply to the com-pressor.

All fluid entering the compressor unit passesthrough the replaceable fluid filter element. This re-placeable filter element contains a built--in bypassvalve. Under conditions of restricted flow throughthe element, the bypass valve helps ensure ade-quate compressor fluid flow, as well as helps pre-vent element failure.

FLUID MANAGEMENT SYSTEMThe fluid management system consists of a multi--chambered primary/secondary separator, the fi-nal air/fluid separator element, cooler bypassgroup and fluid filter.

As compressed air/fluid enters the sump, the firstfluid separation takes place due to a reduction offlow speed coupled with a change of direction of theflowwithin the sump housing. Then the compressedair reaches the separator, where the finest fluiddrops and mist are separated.

MOTOR/DRIVE SECTIONThe motor/drive section consists of a squirrel cageinduction motor and integrated drive gearing whichis separated from the motor by a replaceable shaftseal.

The minimum pressure/discharge check valve ismounted on the compressor drive housing. Its func-tions are as follows:1. Maintain a minimum sump pressure of 60 psig

(4.1 bar) under full load operation to help assureadequate fluid pressure.

2. Act as a check valve to isolate the compressorfrom the system at shutdown or unload.

2.4 COMPRESSOR COOLING SYSTEM, FUNC-TIONAL DESCRIPTIONThe compressor cooling system consists of a fluidcooler, fan and cooler shroud.

The fan is mounted on the motor’s shaft end oppo-site the compressor. Air is drawn over the motor aswell as through the cooler. The air provides motorcooling and removes compression heat from thefluid.

2.5 AIR INLET SYSTEM, FUNCTIONAL DE-SCRIPTIONThecompressor inlet systemconsists of adry--typeair filter and an air control valve. Reacting on apressure signal, the valve closes the intake for un-loaded operation. The valve also acts as a checkvalve upon shutdown.

5


Figure 2--1 Description of Components

(4KW)

(5.5 & 7.5KW)

COMPRESSOR FLUIDDRAIN CAP

COMPRESSOR FLUIDDRAIN CAP

FLUID FILLPLUG

FLUID FILLPLUG

FLUID FILTERELEMENT

FLUID LEVELSIGHT GLASS

AIR/FLUIDSEPARATOR

ELEMENT ACCESSCOVER

6


Figure 2--2 Encapsulated Compressor System

2.6 CONTROL SYSTEM, FUNCTIONAL DE-SCRIPTIONThe purpose of the compressor control system is tomaintain compressor capacity to meet the systemdemand.

It consists of an inlet valve, solenoid valve, con-trol lines and the motor start selector switch.

The selector switch has three settings: MANUAL/START, OFF/RESET and AUTOMATIC START/STOP.

MANUAL MODEThe compressor motor will start and the air controlsolenoid valve will be energized. The compressorwill start to deliver compressed air. When no air isbeing used, the service line pressure rises to thesetting (cut--out pressure) of the pressure switch.The system pressure switch opens, interrupting theelectrical power to the solenoid valve. The solenoidvalve allows control air to the inlet valve, unloadingthe compressor 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 compressor to load again.

OFF/RESET MODEThe compressor motor, if running, will stop if the off/reset position is selected. If the compressor duringnormal runninghas a fault causedby eitheroverloador high discharge temperature, the compressor willstop. After a fault has been cleared, the compressorcan not be restarted unless the Off/Reset mode isselected on the selector switch, prior to starting inany other mode of operation.

AUTOMATIC MODEIn the automatic mode of operation, the air systempressure switch opens, interrupting the electricalpower to theair control solenoid valve; the compres-sor unloads and the motor will stop. The motor willautomatically restart when the compressor sumppressure drops to the minimum setpoint on thesump pressure switch and the line pressure dropsbelow the setpoint of the air pressure switch.

7


8

2.7 INSTRUMENTATION, FUNCTIONAL DE-SCRIPTIONDue to the simplicity of the ES--6 Series compres-sor, the only instrumentation necessary is a linepressure gauge which is located on the left side oftheelectrical control center anda discharge temper-ature gauge which is located on the right side of theelectrical control center. The line pressure gaugereads plant air system pressure only.

NOTE

At compressor shutdown, the sump pressure isreleased to atmosphere through the solenoidvalve. The line pressure gauge will continue toread system pressure.

Section 3SPECIFICATIONS

3.1 SPECIFICATIONS -- ES--6

DIMENSIONS

ES--6 5H 5/4 18/.51 125/8.6 68/80 31 787 21 3/8 543 19 1/2 495 275 125ES--6 5XH 5/4 13/.37 175/12 68/80 31 787 21 3/8 543 19 1/2 495 275 125ES--6 7.5H 7.5/5.5 28/.79 125/8.6 69/82 33 838 21 3/4 553 19 1/2 495 300 136ES--6 7.5XH 7.5/5.5 20/.57 175/12 69/82 33 838 21 3/4 553 19 1/2 495 300 136ES--6 10H 10/7.5 38/1.08 125/8.6 70/85 33 838 21 3/4 553 19 1/2 495 325 150ES--6 10XH 10/7.5 30/.85 175/12 70/85 33 838 21 3/4 553 19 1/2 495 325 150

Model HP/KW

CapacityACFM/

Maximum

PSIG/BARPressure

Lengthin. mm

Width Height Weightlb. kg

60HzM3/MIN

dBA (I)

in. mm in. mmwith canopy/without canopy

ES--6 5L 5/4 21.2/.60 110/7.5 68/80 31 787 21 3/8 543 19 1/2 495 275 125ES--6 5HH 5/4 17.3/.49 150/10 68/80 31 787 21 3/8 543 19 1/2 495 275 125ES--6 50XH 5/4 13.4/.38 175/12 68/80 31 787 21 3/8 543 19 1/2 495 275 125ES--6 7.5L 7.5/5.5 30/.85 110/7.5 69/82 33 838 21 3/4 553 19 1/2 495 300 136ES--6 7.5HH 7.5/5.5 24.4/.69 150/10 69/82 33 838 21 3/4 553 19 1/2 495 300 136ES--6 7.5XH 7.5/5.5 20.5/.58 175/12 69/82 33 838 21 3/4 553 19 1/2 495 300 136ES--6 10L 10/7.5 39.2/1.11 110/7.5 70/85 33 838 21 3/4 553 19 1/2 495 325 150ES--6 10HH 10/7.5 33.9/.96 150/10 70/85 33 838 21 3/4 553 19 1/2 495 325 150ES--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

CapacityACFM/

Maximum

PSIG/BARPressure

Lengthin. mm

Width Height Weightlb. kg

50HzM3/MIN

dBA (I)

in. mm in. mmwith canopy/without canopy

DIMENSIONS

COMPRESSORType: Single Stage Fluid Injected Screen CompressorMinimum Full Load Operating Pressure: 60 psi (4.1 bar)Maximum Full Load Operating Pressure: Nameplate Pressure (I)Bearing Type: Anti--frictionCooling: Pressurized FluidLubr ic ant : S ee Lubr ic ant S pec if ic at ion ( S ec t ion 3. 2)Sump Capacity: 4.6 quarts (4.35 liters)

(I) Compressors are available for pressures up to 175 psi (12.1 bar).

MOTOR 60Hz 50HzType: 5, 7.5, 10HP/ 5, 7.5, 10HP/

4, 5.5 & 7.5 KW 1.15 S.F. 4, 5.5 & 7.5 KWSynchronous Speed: 1800 RPM 1500 RPM (5, 7.5HP/4, 5.5KW)

3000 RPM (10HP/7.5KW)Voltage:

Standard All Sizes 230/460V 3 Phase 380/415 3 PhaseOptional All Sizes 200V 3 Phase 380/415 3 PhaseOptional All Sizes 575V 3 Phase 380/415 3 PhaseOptional 5HP Only 230V Single Phase 380/415 3 Phase

Type: Totally Enclosed Air Over Totally Enclosed Air OverInsulation Class: “F” “F”Maximum Ambient Temp.: 40 C (104 F) 40 C (104 F)Shaft Diameter Fan: Nominal 5/8” Nominal 5/8”Key Size Fan: Nominal 3/16” x 3/16” x 1 1/4” Nominal 3/16” x 3/16” x 1 1/4”

FLUID FILTERType: Spin on, Sullair ProprietaryMicron: 23 Microns Abs.Internal Bypass Valve Set at 25 psig

FLUID SEPARATOR ELEMENTType: Push In Cartridge, Sullair ProprietaryEfficiency at Maximum Capacity: 5PPM Maximum

9

Section 3SPECIFICATIONS

10

3.2 COMPRESSOR LUBRICATION GUIDEFor best value and longest uninterrupted service,the ES--6 compressor is factory filled with Sullube32, a long life lubricant, unless adifferent lubricant isrequested.If, due to availability or other reasons, other fluidsar e r equir ed, f ollow Table 3 -- 1, Lubr ic at ion G uide.

WARNING!

“The Plastic Pipe Institute recommends againstthe use of thermoplastic pipe to transport com-pressed air or other compressedgases inexposedabove ground locations, e.g. in exposed plant pip-ing.” (I)

Sullube 32 should not be used with PVC pipingsystems. Itmay affect the bond at cemented joints.Certain other plastic materials may also 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--humidity service where con-densed moisture and emulsification (mayonnaise)

Figure 3--1 Center of Gravity

APPROX. 6” (15.2CM)CENTER OF GRAVITY

may occur, the fluid change interval must be re-duced to 300 hours maximum. A non--detergentfluid with rust, oxidation and foam inhibitors andgood water separation characteristics should beused.

DO NOT MIX DIFFERENT TYPES OF FLUIDS.Contamination of non--detergent mineral fluids withtraces of ATF or detergent motor fluids may lead tooperational problems such as foaming, filter plug-ging, orifice or line plugging. Flushing is required ifchanging to a different lubricant.

WARNING!

Mixing of other fluids within the compressor willvoid all warranties.

When ambient conditions exceed those noted or ifconditions warrant use of “extended” life lubricantscontact Sullair for recommendation.

Sullair encourages the user to participate in a fluidanalysis program. This could result in a fluid changeinterval that is different from those stated in thismanual.

AMBIENTTEMPERATURE LUBRICATION

FLUID CHANGEPERIOD (HRS.)

FILTER CHANGEPERIOD (HRS.)

--10 F to +90 F(--23 C to +32 C) Sullube 32 8000 * 8000 *

Sullair LLL--4--32 8000 * 8000 *SRF 1/4000 4000 4000D--A Torque Fluid 1000 1000Motor Oil MIL--2104ESPEC API SF CC,CD SAE 10W Class SE 600 600

* 8,000 Hours or once a year.

Table 3--1, Lubrication Guide

Section 4INSTALLATION

4.1 LOCATION OF COMPRESSORThe ES--6 Series compressor package may beplaced on any level surface able to support itsweight. Theunit should bebolted toa fixedmountingsurface to avoid the possibility of externally appliedforces or vibration which would disturb the piping orwiring.

4.2 VENTILATION AND COOLINGSelect a location to permit sufficient unobstructedair flow in and out of the compressor to keep the op-erating temperature stable. The minimum distancethat the machine should be from surrounding wallsis what is needed for service and three (3) feet(914mm) or more from the fan air discharge end ofthe compressor.

4.3 SERVICE AIR PIPINGService air piping should be installed as shown inF igur e 4 -- 1. A s hut -- off v alv e s hould be ins t alled t oisolate the compressor from the service line. Alsonotice that the service line should be equipped withwater legs and condensate drains throughout thesystem.

WARNING!

“The Plastic Pipe Institute recommends againstthe use of thermoplastic pipe to transport com-pressed air or other compressed gases in ex-posed above ground locations, e.g. in exposedplant piping.” (I)

Sullube 32 should not be used with PVC pipingsystems. It may affect the bond at cemented

joints. Certain other plasticmaterialsmay also beaffected.

(I) Plastic Pipe Institute, RecommendationB,AdoptedJanuary19, 1972.

4.4 FLUID LEVEL CHECK AND CHANGE PROCE-DUREThe Sullair air compressor is equipped with theproper amount of fluid. However, it is necessary tocheck the fluid level at installation. The level ischecked by looking at the fluid level sight glass lo-c at ed on t he end bell. S ee F igur e 2 -- 1.

If the sump is properly filled, the fluid level shouldcover 1/4 to 1/2 of the sight glass during operation.DO NOT OVERFILL.

WARNING!

Beforeattempting compressormaintenance,dis-connect compressor from power source and lockout power source. Isolate compressor from linepressure by closing recommended dischargeshutoff valve and releasing all internal pressurefrom compressor.

WARNING!

Assure that line pressure guage on compressorindicates “ZERO” pressure before any work isdone. Failure to comply may cause injury.

When the compressor fluid is ready to be changed,the compressor needs to be shutdownwith thepow-er to the compressor disconnected (see Warningabove). Drain the fluid from the compressor using

Figure 4--1 Service Air Piping

11

Section 4INSTALLATION

1

t he c om pr es s or f luid dr ain c ap ( S ee F igur e 2 -- 1) .

Fluid capacity for the compressor can be found inSection 3, Specifications of this manual. The com-pressor sump is properly filled when the level on thefluid level sight tube is 3/4 of the sight tube. Duringoperation, the fluid level should cover 1/4 to 1/2 ofthe sight glass. DO NOT OVERFILL.

4.5 MOTOR ROTATION DIRECTION CHECKAfter the electrical wiring has been done, it is neces-sary to check the direction of motor rotation. Thiscan be done by jogging the START selector switchon the sideof the control center. When looking at themotor from the cooler end of the compressor unit,the cooler fan should be turning clockwise. If themo-tor is not turning clockwise, disconnect power to thestarter and exchange any two of the three power in-put leads, then check rotation.

A direction of rotation decal is located on the motorshroud, next to the cooler to insure correct motor/compressor rotation.

4.6 ELECTRICAL PREPARATIONInterior electrical wiring is performed at the factory.Required customer wiring is minimal, but should bedone by a qualified electrician in compliance withOSHA, National Electrical Code, and any other ap-plicable State, Federal and local electrical codesconcerning isolation switches, fused disconnects,etc. Sullair provides a wiring diagram for use by the

2

installer.

A few electrical checks should be made to help as-sure that the first start--up will be trouble--free.

WARNING!

Lethal shock hazard inside. Disconnect all powerat source before opening or servicing.

1. Check incoming voltage. Be sure that compres-sor is wired for the correct incoming voltage.

2. Check starter for correct size, proper overloadrelay and heaters.

3. Check all electrical connections for tightness.4. “Dry run” the electrical controls by disconnecting

the motor leads T1, T2, and T3 from the starter.Energize the control circuits by turning the selec-tor switch to themanual and automatic positions,and check all protection devices making surewhen activated, they will de--energize the startercontrol coil.

5. Reconnect the motor leads and jog the motor fora dir ec t ion of r ot at ion c hec k as ex plained in S ec -t ion 4. 5.

NOTE

Wiring diagram for standard compressors is sup-plied on the inside cover of the Control Center.Optional compressor wiring diagrams will vary.

Section 5OPERATION

5.1 GENERALWhile Sullair has built into this compressor a com-prehensive array of controls and indicators to as-sure you that it is operating properly, youwill want torecognizeand interpret the readingwhichwill call for

service or indicate the beginning of a malfunction.Before starting your Sullair compressor, read thissection thoroughly and familiarize yourself with thecontrols and indicators -- their purpose, location anduse.

5.2 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE

START SELECTOR SWITCH The three--position switch provides selection betweenMANUAL/START, OFF/RESET and AUTO--MATIC/START (for further description, see Section 2).

LINE PRESSURE GAUGE Continually monitors service line air pressure.

FLUID LEVEL SIGHT GLASS Indicates fluid level. The level is checked by looking atthe fluid level sight glass on the end bell. The fluid levelshould cover 1/2 to1/4 of the sight glass during opera-tion. With the compressor shut down, the level shouldbe 3/4 of the sight glass. DO NOT OVERFILL.

COOLER BYPASS VALVE Regulates fluid flow to and around the cooler. De-signed to maintain a minimum operating temperatureof 170 F (77 C). 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 dischargefrom receiver/sumpwhen pressure falls to 60 psig (4.1bar). Also incorporated in this valve is a terminal checkvalve which prevents line pressure backflow into thesump during unload conditions and after shutdown.

DISCHARGE TEMPERATURE SWITCH Shuts the compressor downwhen the compressor dis-charge temperature exceeds 240 F (116 C).

PRESSURE RELIEF VALVE Opens sump pressure to the atmosphere should pres-sure inside the sump become too high. Operation ofthis valve indicates that theair pressure switch is eitherfaulty or out of adjustment.

AIR PRESSURE SWITCH Senses service line pressure. When line pressurereaches maximum setting, the pressure switch openssolenoid valve circuit to unload the compressor.

SOLENOID VALVE Vents sump pressure through inlet control valve to theatmosphere during unload conditions and shutdown.

SUMP PRESSURE SWITCH Senses sump pressure and prevents compressor from(Not used on current models except starting until sump pressure has fallen below presetwith Wye--Delta starter). pressure of 10 psig (0.7bar).

DISCHARGE TEMPERATURE GAUGE Continually monitors discharge temperature of thecompressor.

13

Section 5OPERATION

14

5.3 INITIAL START--UP PROCEDUREThe followingprocedure should beused tomake theinitial start--up of the compressor.

1. Read the preceding pages of this manual thor-oughly.

2. Jog motor to check for correct rotation of fan (re-f er t o S ec t ion 4. 5) .

3. Be sure that all preparations and checks de-scribed in the Installation Section have beenmade.

4. Open the shut--off valve to the service line.5. Start the compressor by turning the selector

switch to “manual” or “automatic”.6. Check for possible leaks in piping.7. Slowly close the shut--off valve and check that the

pressure switch is set correctly. If set correctly,the compressor will unload at nameplate pres-sure. If adjustments are necessary, see Control

SystemAdjustment in Section 6, Maintenance ofthis manual.

8. Observe theoperating temperature. If the operat-ing temperature exceeds 200 F (93 C), the cool-ing system and installation environment shouldbe checked.

9. Open shut--off valve to the service line.10. Reinspect the compressor for temperature and

leaks the following day.
5.4 SUBSEQUENT START--UP PROCEDURE
Onsubsequent start--ups, check that the proper lev-el is visible in the fluid level sight glass and simplyturn selector switch to desired control. When thecompressor is running, observe the instrumenta-tion.

5.5 SHUTDOWN PROCEDURETo shut the compressor down, simply turn selectorswitch to OFF/RESET position.

Section 6MAINTENANCE

6.1 GENERAL

WARNING!

Before doing compressor maintenance, discon-nect compressor frompower source and lockoutpower source. Isolate compressor from line pres-sure by closing recommended discharge shut--off valve and releasing all internal pressure fromcompressor.

As youproceed in reading this section, it will be easyto see that the Maintenance Program for the aircompressor is quite minimal yet important. See in-structions for each item in Section 6.6, Parts Re-placement and Adjustment Procedures.

6.2 DAILY OPERATIONPrior to starting the compressor, it is necessary tocheck the fluid level in the sump. Should the level below, simply add the necessary amount. If the addi-tion of fluid becomes too frequent, a minor problemhas developed which is causing this excessive loss.S ee t he Tr oubles hoot ing S ec t ion ( 6. 7) under E x c es -s iv e F luid Cons um pt ion f or a pr obable c aus e andremedy.

After a routine start has beenmade, a general checkof the overall compressor should bemade to assurethat the compressor is running properly.

6.3 MOTOR BEARING LUBRICATION

WARNING!


S ee Table 1, M ot or B ear ing Lubr ic at ion S c hedule. I flubrication instructions are shown on themotor or ina separately provided manual, they will supercedethis general instruction.

1. Remove the fan guard by removing the four (4)self--tapping screws holding the guard and fanring to the cooler.

2. Remove the 1/8” NPT plugs in the filler and drainconnection for both bearings.

3. Free drain hole of any hard grease (use piece ofwire if necessary).

4. Add grease (I) using a low pressure grease gun.5. Wipe off any drained grease, and replace filler

and drain plugs.6. Replace fan guard.7. Motor is now ready for operation.

(I) Use Chevron SRI--2 grease when lubricatingmotor bearings. Fill the cavity 1/3 to 1/2 full byrepacking or use a low pressure grease gun andfill through the lubricating provisions on the mo-tor end bell housing.

6.4 FLUID FILTER MAINTENANCE

WARNING!

Fluid filter has internal bypass. DO NOT SUBSTI-TUTE.

Replace the fluid filter element under any of the fol-lowing conditions:1. A s r ec om m ended in t he Lubr ic at ion G uide in

Section 3.2. Every year.3. Every fluid change.

6.5 COOLER MAINTENANCEIf cooler becomes restricted, use standard spray de-greaser/cleaner and brush to clean cooler. Use airpressure to blow cooler clean. Care must be takenas not to damage cooler fins.

WARNING!


STANDARDCONDITIONS (I)

SEVERECONDITIONS (II)

EXTREMECONDITIONS (III)

5HP (4KW) 3 Years 1 Year 6 Months7.5 and 10HP 2.5 Years 10 1/2Months 5 1/2 Months(5.5 & 7.5KW)All MotorsOver 1800 RPM 6 Months 3 Months 3 Months

MODEL

(I) Eight hours per day, normal or light loading, clean 100 F (38 C) maximum ambient.(II) Twenty--four hours per day operation or shock loadings, vibration, or in dirt or dust at

100 F to 150 F (38 C to 66 C) ambient.(III) Heavy shock or vibration, dirt or dust at 100 F to 150 F (38 C to 66 C) ambient.

TABLE 1 -- MOTOR BEARING LUBRICATION SCHEDULE

15


16

CO

AMTEM--10(--23

* 8** 4

6.6 PARTS REPLACEMENT AND ADJUSTMENTPROCEDURES

WARNING!


FLUID FILTER REPLACEMENTRef er t o F igur e 6 -- 1.1. To prevent spillage and loss of reusable fluid,

place a contaminate--free fluid receptacle be-neath fluid drain valve and fluid filter.

2. Drain fluid by removing fluid drain valve cap at teelocated beneath compressor (for complete fluidchange, drain fluid from cooler).

3. Using a strap wrench, remove the old elementand gasket.

4. Clean gasket seating surface.5. Apply a light film of fluid to the new gasket.6. Hand tighten new element until gasket is seated.7. Continue tightening element an additional 1/2 to

3/4 turn.8. Replace fluid. DO NOT OVERFILL.9. Restart compressor and check for leaks.

MPRESSOR LUBRICATION GUIDE AND MAINTENANCE SCHEDULE

BIENTPERATURE LUBRICATION

FLUID & FILTER CHAPERIOD (HRS.)

F to +90 F Sullube 32 8000 *C to +32 C) Sullair LLL--4--32 8000 *

SRF 1/4000 4000ATF as per Dextron II 1000Motor Oil MIL--2104E,SPEC API SF CC,CD SAE 10W Class SE 600

,000 Hours or once a year.,000 Hours or more frequently if conditions so require.

Figure 6-1 Fluid Filter (P/N 250026-982)

* Replacement Element Kit P/N 250028--032

FLUID DRAINCAP

TEMPERATUREGAUGE

FLUID FILLPLUG

*FLUID FILTERELEMENT

AIR FILTER MAINTENANCERef er t o F igur e 6 -- 2. A ir f ilt er ( P / N 250025 -- 421)maintenance should be performedevery sixmonthsor more frequent if conditions so require.

WARNING!


AIR FILTER ELEMENT MAINTENANCE1. When performing maintenance, care must be

taken that no dirt or foreign matter enters intakehousing.

2. Clean exterior of air filter cover.3. Remove the air filter cover by loosening thewing-

nut securing the cover.4. Remove element and base. Clean base and inte-

rior of cover using a damp cloth. DO NOT usecompressed air to clean cover and base.

5. At this time replace element.6. Replace cover.

NGE

8000 * 4000 **8000 * 4000 **4000 4000 **1000 4000 **

600 4000 **

SEPARATOR CHANGEPERIOD (HRS.)

AIR FILTER CHANGEPERIOD (HRS.)


ELEMENT INSPECTION1. Place a bright light inside the element to inspect

for damage or leak holes. Concentrated light willshine through the element and locate any holes.

2. Inspect all gaskets and gasket contact surfacesof the housing. Should faulty gaskets be evident,correct the condition immediately.

3. If the clean element is to be stored for later use, itmust be stored in a clean container.

4. After the element has been installed, inspect andtighten (if necessary) all air inlet connectionsprior to resuming operation.

Figure 6--2 Air Filter (P/N 250025--421)


SEPARATOR ELEMENT REPLACEMENTRef er t o F igur e 6 -- 3. T he s epar at or s hould bechanged once a year. Follow the procedure ex-plained below for element replacement.

WARNING!


1. Insert a 4”maximum length, 1/4”diameter pin intothe radially drilled hole in the separator cap.Loosen, unscrew counterclockwise and removethe cap.

2. Pull out the old element by gripping the end of theelement with channel lock pliers or a similar tool.

3. Install new o--rings on separator cap and separa-tor element filter and oil lightly to make installa-tion easier.

4. Insert and push the new element in place.

Figure 6--3 Separator Element (P/N 250025--264)


17


18

5. Reinstall the cap. Hand--tighten using a 4” maxi-mum length, 1/4” diameter pin in the radiallydrilled hole.

MINIMUM PRESSURE/CHECK VALVE MAINTE-NANCERef er t o F igur e 6 -- 4. M inim um pr es s ur e/ c hec k v alv emaintenance is minimal. The only parts which nor-mally require replacement are the o--ring sealaround the piston and the valve seat on the checkvalve. To replaceany of the two parts, follow thepro-cedure explained below.

WARNING!


WARNING!

Assure that line pressure gauge on compressorindicates “ZERO” pressure before any work isdone. Failure to comply can cause injury.

1. Unscrew the minimum pressure valve from thedrive housing.

2. Remove all parts.3. Clean and inspect 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, lubricatewith Parker Super “O” ring seal or an equivalentgrease.

6. Reinstall the whole valve assembly. Tighten andsecure.

Figure 6--4 Minimum Pressure/Check Valve(P/N 606058)

* Repair Kit P/N 250030--226

THERMOSTAT ACTUATOR MAINTENANCERef er t o F igur e 6 -- 5. T he only par t whic h would ev erneed replacement is the thermostat valve actuator.For replacement, follow the procedure explainedbelow.

WARNING!


1. To prevent spillage and loss of re--usable fluid,place a contaminate--free fluid receptacle be-neath fluid drain valve and fluid filter.

2. Drain fluid by removing fluid drain cap at tee lo-cated beneath compressor.

3. Unscrew and remove hollow hex plug.4. Remove spring and piston.5. By using long nosed pliers, pull the actuator out.6. Install new actuator.7. Install piston and spring with centering guide.8. Re--install plug.

Figure 6--5 Thermostat Actuator(P/N 250025--413)

* Repair Kit P/N 250028--036


CONTROL SYSTEM ADJUSTMENTRef er t o F igur e 6 -- 6. A ll c om ponent s in t he Cont r olSystemaredesignedandmanufactured to close tol-erances to eliminate any need for adjustments. Theonly adjustment required is to set the air pressureswitch. This is done by following the instructions be-low.

1. Remove the pressure switch cover.2. With the shut--off valve closed or slightly cracked

open, start the compressor.3. Observe the line pressure gauge and pressure

switch contacts. When the line pressure reachesnameplate pressure, the pressure switch con-tacts should open.

4. If the pressure switch contacts do not open orthey open prior to the desired pressure, the pres-sure switch setting will require adjustment (referto Figure 6--6). To adjust the pressure switch,turn the range--adjusting screw to the high pres-sure setting. Turning the screwcounterclockwiselowers both the high and low pressure settingequally.

Figure 6--6 Air Pressure Switch (P/N 250025--299)

FOR DIFFERENTIAL ADJUSTMENT OF AIRPRESSURE SWITCH:Differential is the difference between the high andlow pressure settings.

Turning the screw clockwise increases the differen-tial, and counterclockwisedecreases thedifferentialpressure.

DANGER!

DO NOT touch the electrical contacts, terminal orleadswith anypart of the bodyor anyuninsulatedmetallic object. Severe electrical shock may oc-cur.

UNLOADER SOLENOID VALVE MAINTENANCEUnloader valve maintenance is minimal, but a peri-odic cleaning is desirable. The time between clean-ings will vary depending on operating conditions. Ingeneral, if the voltage to the coils is correct, sluggishvalve operation or excessive leakage will indicatethat cleaning is required.

WARNING!

Turn off all power, relieve sumppressure, anddis-connect coil lead wires to the solenoid valve be-fore making repairs.

It is not necessary to remove the valve from thepipeline for repairs.

DISASSEMBLY AND REASSEMBLY1. Remove the retaining capand slip the entire sole-

noid off the solenoid base subassembly.2. Unscrew the solenoid base assembly. Remove

the core assembly, core spring and body gasket.3. All parts are now accessible for cleaning or re-

placement.4. Reassemble in reverse order of disassembly.

19


20

COIL REPLACEMENT1. Remove the retaining cap, nameplate and cover.2. Slip the yoke containing the coil and sleeves off

the solenoid base subassembly.3. Reassemble in reverse order of disassembly.

WARNING!


INLET CONTROL VALVERef er t o F igur e 6 -- 7. T he only par t s whic h nor m allyrequire replacement are the piston seal on the in-take valve piston and gasket. Follow this procedurefor inlet control maintenance.1. Remove the inlet filter assembly.2. Disconnect tubing from intake control housing at

90 elbow.3. Remove the two (2) 3/8” ferry head capscrews

securing the intake control housing to the inletplate.

4. Remove intake control housing assembly andgasket.

5. Remove retaining ring, cap and intake checkspring from intake housing bore.

6. Remove socket head capscrew, washers, andcheck 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 intake/inlet controlhousing. Remove and discard old piston sealfrom intake piston.

9. Clean intake housing gasket surface and internalpiston bore.

10. Lubricate internal piston bore using lubricant sup-plied with kit.

11. Install new piston seal onto piston.12. Reinstall intake valve rod, check spring, spring re-

tainer and intake valve head into intake controlhousing. Install assembled intake piston into in-take control bore and onto intake valve rod.

13. Install washers. Apply screw lock adhesive pro-vided in kit to socket head capscrew. Replacesocket head capscrew into the valve rod andtorque socket head capscrew to 18 to 24 in.--lbs.(2.0 to 2.7Nm).

14. Install intake check spring, cap and retaining ring.15. Replace gasket and reinstall the whole inlet con-

trol valve assembly.

16. Apply screw lock adhesive to inlet control housingassembly ferry head capscrews and install.Torque to 30 ft.--lbs. (40.7Nm).

17. Reconnect tubing to inlet control valve housing at90 elbow.

Figure 6--7 Inlet Control Valve

* Repair Kit P/N 02250045--287

*

*


18. Reinstall air inlet filter assembly.

MOTOR SHAFT SEAL REPLACEMENTReplacement of motor shaft seal requires that thecompressor be separated from the drive housing.This operation requires qualified personnel.

Detailed instructions and a list of needed tooling areincluded in each motor shaft seal replacement kitno. 250028--035.

6.7 TROUBLESHOOTINGThe information contained in the Troubleshootingchart is based upon both the actual applied situa-tions and extensive testing at the factory. It containssymptoms and usual causes for the describedprob-lems. However DO NOT assume that these are theonly problems that may occur. All available data

concerning the trouble should be systematicallyanalyzed before undertaking any repair or compo-nent replacement procedures.

A detailed visual inspection is worth performing foralmost any problems which may prevent unneces-sary damage to the compressor. Always rememberto:

a. Check for loose wiring.b. Check for damaged piping.c. Check for parts damaged by heat or an electrical

short circuit, usually apparent by discoloration ora burnt odor.

Should your problem persist after making the rec-ommended check, consult your nearest Sullair rep-resentative or the 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 Blown Replace fuse.

Motor Starter Overloads Tripped Reset. Should trouble persist, checkwhether motor starter contacts arefunctioning properly.

Low Incoming Line Voltage Check voltage. Should voltage check low,consult power company.

COMPRESSOR SHUTS DOWN Low Incoming Voltage Consult power companyWITH AIR DEMAND PRESENT .

Excessive Operating Pressure Defect in pressure switch; check pressureat which contact points open.

Discharge Temperature Switch Open Cooling air flow restricted; clean cooler andcheck for proper ventilation.

Ambient temperature is too high; providesufficient ventilation.

Low fluid level; add fluid.

Clogged filter; change the fluid filterelement.

Thermal valve not functioning; replaceelement.

Defective discharge temperature switch;check for a short or open circuit to probeand correct wiring.

COMPRESSOR WILL NOT BUILD Air Demand Is Too Great Check service lines for leaks or openUP FULL DISCHARGE PRESSURE valves.

Dirty Air Filter Check filter and change element ifrequired.

Pressure Regulator Out Of Adjust regulator according to controlAdjustment adjustment instructions in Section 6,

Maintenance.

Defective Solenoid Valve A normally open solenoid must energize toload compressor; check for properoperation.

21


22

TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE REMEDY

LI N E P R E S S U R E R I S E S A B O V E D ef ec t iv e S olenoid Valv e R epair s olenoid v alv e ( s ee S ec t ion 6) .CUT--OUT PRESSURE SETTINGON PRESSURE SWITCH

Leak In Control System Causing Check for leaks.Loss Of Pressure Signals

Defective Pressure Switch Check that diaphragm and contacts are notdamaged. Replace if necessary.

Inlet Valve Stuck Open Inspect inlet valve and insure free operation(s ee Sec tion 6).

EXCESSIVE COMPRESSOR Clogged Return Line Remove element cover and clean orifice.FLUID CONSUMPTION

Separator Element Damaged Or Change separator element.Not Functioning Properly

Leak In The Lubrication System Check all pipes, connections andcomponents.

Excess 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 AboveOPENS REPEATEDLY

Too High Cut--out Pressure Setting on PressureSwitch” above

Defective Pressure Relief Valve Replace pressure relief valve.

LIQUID WATER IN COMPRESSED Water Vapor Condensation From Cooling Remove the water vapor from compressed air priorAIR LINES and Compression Occurs Naturally to distribution through the air system. Check

operation of aftercooler and moisture separator.Install a compressed air dryer sized for the flow anddryness level required. (Note: Filters may also berequired to remove particulates, liquid oil aerosolsor for oil vapor removal. Change cartridges asrecommended by the filter manufacturer.) Check alldrain traps routinely to insure their properoperation. Maintain them regularly.


MODEL NO. SERIAL NO.

6.8 MAINTENANCE RECORD

DATE HOURMETERMAINTENANCEPERFORMED

WORK PERFORMEDBY

AUTHORIZEDBY

23

Section 7ILLUSTRATIONS AND PARTS LIST

24

ES--6 COMPRESSOR ASSEMBLY, EXPLODED VIEW

(5.5 AND 7.5KW)


7.1 PROCEDURE FOR ORDERING PARTSParts should be ordered from the nearest Sullair Representative or the Representative from whom the com-pressorwas purchased. If for any reason parts cannot beobtained in this manner, contact the factory directly atthe address, phone numbers or fax numbers below.

Whenorderingparts always indicate theSerial Numberof the compressor. This canbeobtained from theBill ofLading for the compressor or from the Serial Number Plate located on the compressor.

The genuine Sullair service parts listed meet or exceed the demands of this compressor. Use of replacementparts other than those approved by Sullair Corporation may lead to hazardous conditions over which SullairCorporation has no control. Such conditions include, but are not limited to, bodily injury and compressor failure.

SULLAIR CORPORATIONSubsidiary of Sundstrand Corporation

3700 East Michigan BoulevardMichigan City, Indiana 46360 U.S.A.

Telephone: 1--800--SULLAIR (U.S. Only) or

Fax: (219) 874 -- 1273

SULLAIR EUROPE, S.A.Chemin de Genas BP 63969800 Saint Priest, FranceTelephone: 33--72232425

Fax: 33 -- 78907168

Fax: (219) 874 -- 1835 (Parts)Fax (219) 874 -- 1805 (Service)

1--219--879--5451

SULLAIR ASIA, LTD.Chiwan Supply BaseBldg A5--1 Chiwan

Shenzhen, Guangdong PRV.P.R.C. Post Code 518068Telephone: 755--6694982

FAX: 755--6694313

7.2 RECOMMENDED SPARE PARTS LIST

DESCRIPTION KIT NUMBER QUANTITY

replacement element kit for fluid filter 250026--982 250028--032 1replacement element kit for air/fluid separator 250025--264 250028--033 1replacement element kit for air filter 250025--421 250028--034 1repair kit for motor shaft seal 250039--218 250028--035 1repair kit, shaft seal installation 250034--267 1repair kit for thermostat actuator 250025--413 250028--036 1replacement kit for coil 250028--809 250028--387 1repair kit for solenoid valve 250030--164 250038--849 1replacement coil for solenoid valve 250030--164 250035--292 1repair kit for minimum pressure/check valve 606058 250030--226 1replacement piston seal kit for air inlet control valve 02250045--287 1replacement piston for inlet control valve 02250044--811 1replacement washer for inlet control valve 02250045--287 1fluid, Sullube 32 (one gallon) 250009--396 1fluid, Sullube 32 (five gallons) 250022--669 1repair kit for ES--6 1/2” npt service connection 250026--066 250030--103 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

25

Section 7

ILLUSTRATIONS AND PARTS LIST

7.3 FLUID MANAGEMENT SYSTEM

26


7.3 FLUID MANAGEMENT SYSTEM

key partnumber description number quantity

1 element, fluid filter (I) 250026--982 12 adapter, fluid filter 250025--914 13 cap, separator element 250026--038 14 o--ring, 2 3/16” x 3/32” 826502--139 15 element, separator air/fluid (II) 250025--264 16 o--ring, 1 7/16” x 1/16” 826502--127 17 plug, hex head 1 1/16”--12 SAE 250039--359 18 glass, sight 250025--420 19 housing, bell 250025--309 110 capscrew, ferry head 1/2”--13 x 3” 828408--300 12

Sscrew, socket ISO4762 m12 x 20 (metric) 829312--080 1211 actuator, thermostat (III) 250025--413 112 piston, thermostat 250025--415 113 spring, compression 250025--464 114 pin, roll 1/4” x 1 1/2” 827404--150 115 guide, thermostat spring 250025--417 116 o--ring (IV) 250025--419 317 plug, thermostat 1 1/16”--12 250025--418 118 decal, fluid (V) -- 1

(I) For maintenance on fluid filter element no. 250026--982, order repair kit no. 250028--032.

(II) For maintenance on air/fluid separator element no. 250025--264, order repair kit no. 250028--033.

(III) For maintenance on thermostat actuator no. 250025--413, order repair kit no. 250028--036.

(IV) For replacement only.

(V) Decal will vary with compressor fluid fill requirement. Factory fill (Sullube 32) decal part no. is02250069--389.


27

Section 7


28

7.4 INLET FILTER


7.4 INLET FILTER


1 filter, air assembly 250025--265 12 nut, wing 1/4”--20 824815--004 13 washer, seal 250025--661 14 hood, air filter 250025--422 15 element, air filter (I) 250025--421 16 plate, air filter base 250025--423 17 rod, threaded 1/4” x 5” 843504--050 1

(I) For maintenance on air filter element no. 250025--421, order repair kit no. 250028--034.


29

Section 7


7.5 SEAL AND DRIVE GEAR

30


7.5 SEAL AND DRIVE GEAR


1 plate, inlet 250028--339 12 gear, driven Consult Factory 13 gear, drive Consult Factory 14 sleeve, wear 250025--412 15 seal, shaft Teflon/Viton (I) 250039--218 16 capscrew, ferry head 1/4”--20 x 3/4” 828404--075 27 housing, shaft seal 250025--312 18 o--ring, 2 7/8” x 3/32” 826502--150 19 spacer, gear 250039--600 1

(I) For maintenance on motor shaft seal no. 250039--218, order repair kit no. 250028--035.

NOTE: Requires special tooling for removal/installation.


31

Section 7


7.6 MOTOR, HOUSING AND PARTS

7.5 & 10HP (5.5 & 7.5KW) ONLY

32


7.6 MOTOR, HOUSING AND PARTS


1 housing, drive 250026--839 1Shousing, drive (metric) 02250059--246 1

2 screw, machine round head #8--32 x 1/2” 250030--547 13 washer, pl--b #8 837201--045 14 seat, minimum pressure/check valve 250030--223 15 stem, minimum pressure/check valve 250030--502 16 spring, minimum pressure/check valve 250033--369 17 piston, minimum pressure/check valve 250025--428 18 o--ring, 3/32” x 3/4” 826502--116 19 spring, minimum pressure/check valve 250025--429 110 cap, minimum pressure/check valve 250025--430 111 valve, relief 1/2” 175 psig (12.1 bar) 409955 1

Svalve, relief 1/2” 200 psig (13.8 bar) 250039--678 112 plug, pipe hex soc. 1/8” NPT 490046--001 213 motor, 5HP/4KW Consult Factory 1

Smotor, 7.5HP/5.5KW Consult Factory 1Smotor, 10HP/7.5KW Consult Factory 1

14 switch, temperature 212 -- normally closed 250040--312 115 connector, tube--m 5/8” x 1/2”

(7.5 and 10HP/5.5 and 7.5 KW only) 810210--050 116 base, compressor 250026--469 117 capscrew, hex gr8 1/2”--13 x 1” 829108--100 218 valve, minimum pressure/check (I) 606058 119 washer, pl--b reg pltd 1/2” 838208--112 120 connector, tube--m 1/2” x 1/2” 810208--050 121 bail, lifting 250039--904 122 capscrew, hex 5/16”--18 x 7/8” 827905--088 1

(I) For maintenance on minimum pressure/check valve no. 606058, order repair kitno. 250030--226.


33

Section 7


7.7 COMPRESSOR COOLER SYSTEM

7.5 & 10HP (5.5 & 7.5KW)COOLER

34


7.7 COMPRESSOR COOLER SYSTEM


1 duct, cooler mount (5HP/4KW) 250026--472 1Sduct, cooler mount(7.5HP and 10HP/5.5 and 7.5KW) 250026--471 1

2 ring, cooler (5HP/4KW) 250034--535 1Sring, cooler(7.5HP and 10HP/5.5 and 7.5KW) 250034--536 1

3 screw, hex serrated washer 1/4”--20 x 1/2” 829704--050 84 screw, hex serrated washer 1/4” x 3/4” 829704--075 45 plate, cooler filler (5HP/4KW) 250025--829 1

Splate, cooler filler(7.5HP and 10HP/5.5 and 7.5KW) 250026--843 1

6 nut, hex 5/16”--18 (5HP/4KW) 825305--283 1Snut, hex 5/16”--18(7.5 and 10HP/5.5 and 7.5KW) 825305--283 2

7 cooler, fluid (5HP/4KW) 250028--961 1Scooler, fluid and aftercooler(7.5&10HP/5.5 and 7.5KW) (I) 250026--066 1

8 orifice, fan ring 12 3/8” id 250034--537 19 capscrew, ferry 5/16”--18 x 1 1/2” (5HP/4KW) 828405--150 1

capscrew, ferry 5/16”--18 x 2”(7.5HP &10HP/5.5 and 7.5KW) 828405--200 2

10 washer, flat 5/16”id x 1 1/4”od (5HP/4KW) 250025--830 1Swasher, 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” 811808--075 212 tube, 1/2”od (5HP/4KW) 250026--718 113 tube, 1/2”od 250030--040 114 cap, 1/2” tube 250026--350 115 tee, tube union 1/2” 811408--050 116 tube, 1/2”od (5HP/4KW) 250026--719 1

Stube, 1/2”od(7.5HP and 10HP/5.5 and 7.5KW) 250030--041 1

17 guard, 12” fan 250028--964 118 cap, fan guard 4” 250026--591 119 fan, 12” diameter (5HP/4KW) 250026--253 1

Sfan, 12” diameter(7.5HP and 10HP/5.5 and 7.5KW) 250026--254 1

20 elbow, 90 connector 7/8”--14 x 1/2”npt 250030--104 121 elbow, tube straight threaded 5/8” x 7/8”

(7.5 and 10HP/5.5 and 7.5KW) 811615--062 122 tubing, aftercooler in

(7.5 and 10HP/5.5 and 7.5KW) 250030--042 123 tubing, fluid cooler out

(7.5 and 10HP/5.5 and 7.5KW) 250030--043 124 screw, brass set 250031--014 125 insert, 1/4”--20 threaded blind 250034--538 8

(I) ES--6 1/2” npt service connection kit no. 250030--103.


35

Section 7


7.8 COMPRESSOR SYSTEM

36


7.8 COMPRESSOR SYSTEM


1 washer seal bolt bu ss 499065--007 22 locknut, male--M25 x 1 02250055--135 13 wavespring, male 02250047--887 14 bearing, taper 499080--203 25 housing, stator ES--6 “E” profile 250029--910 16 cover, outlet 250025--315 17 capscrew, ferry head 1/4”--20 x 11/4” 828404--125 58 locknut, female M17 x 1 02250055--136 19 wavespring, female 02250055--485 110 washer, pl b--reg pltd 3/8” 838206--071 211 bearing, taper 499025--005 212 capscrew, ferry head 5/16”--18 x 1” 828405--100 313 capscrew, ferry head 5/16”--18 x 2 1/4” 828405--225 214 rotor, female “E” profile (I) 02250055--489 115 rotor, male “E” profile (I) 02250055--490 116 capscrew, ferry head 3/8”--16 x 33/4” 828406--375 217 plate, inlet 250028--339 118 elbow, tube 90M 1/4” x 1/4” 250025--850 219 bearing, cylinder roll plain 499082--705 1
20 bearing, needle roller steel 250023--213 121 retainer, inlet bearing 250025--435 122 screw, machine flat head 1/4”--20 x 1/2” 831204--050 123 orifice, gear spray (mounting location) 250030--545 124 tube, separator fluid return 250025--865 125 tee, tube branch straight thread 1/2” x 3/4” 250041--956 126 valve, body thermostat 250025--414 127 capscrew, ferry head 5/16”--18 x 1 1/2” 828405--150 228 fitting, separator fluid return 250025--870 129 cap, 1/2” tube od 3/4”--16 250026--350 130 capscrew, socket head 1/4”--20 x 1/4” 828304--025 231 plate, ES--6 identification 250026--859 132 screw, drive rod plated #8 x 3/8” 839608--060 233 screw, set cup 5/8”--11 x 1/2” 250033--368 134 pin, dowel 3/8” x 1” 499045--032 435 capscrew, ferry 3/8”--16 x 3/4” 828406--075 236 hose, nylon 1/4” 842215--004 5 ft.
(I) Machine serial numbers below 006--93007285 consult factory for rotor part numbers.


37

Section 7


7.9 INLET CONTROL

38


7.9 INLET CONTROL


1 rod, ES--6 intake control valve 02250044--810 12 spring, PTO ES--6 intake check 250034--619 13 retainer, ES--6 intake control valve 02250044--809 14 gasket, inlet valve 250025--425 15 head, ES--6 intake control valve 02250044--808 16 housing, intake control 250025--310 17 piston, ES--6 intake control valve (I) 02250044--811 18 seal, ES--6 intake control piston (II) 02250044--671 19 washer, Belleville spring (I) 250031--269 210 capscrew, sch #10--32 x 1/2” Nylok 02250043--162 111 spring, inlet control ES--6 02250042--966 112 cap, air intake 250029--898 113 ring, retaining internal 1 3/8” 836150--137 114 elbow, 90 male 1/8” npt x 1/4” tube 250025--840 115 hose, nylon 1/4” 842215--004 5 ft.

(I) For maintenance on inlet control, order piston no. 02250044--811 and washer no. 250031--269.

(II) For maintenance on air intake valve piston seal, order repair kit no. 02250045--287.


39

Section 7


7.10 CONTROL BOX

40


7.10 CONTROL BOX


1 Consult factory for starter group, and refer to compressor serial number.3 bracket, top starter 250039--244 14 plate ES--6, access (Ref.) 250034--858 15 locknut, conduit 1/2” 847200--050 36 nipple, chase 1/2” npt 847815--050 27 decal, 3 position switch panel 250039--113 18 hose, nylon 1/4” 842215--004 5 ft.9 valve, solenoid 1/8” 110/120 (I) 250030--164 110 box, junction 250026--740 111 screw, hex serrated washer 1/4” x 1/2” 829704--050 913 lug 849215--004 114 nut, hex flanged 1/4”--20 825304--236 915 switch, selector 3 position 248168 116 elbow, 90 m swvl 1/8T x 1/8 NPT 250025--849 217 pushbutton, “manual/reset” 02250045--011 118 screw, 1/4”--20 x 1/2” long 250030--162 419 fastener, suregrip 041516 220 nameplate, Sullair 1” x 6” 250035--063 1
21 joint, compression phase 230V, 3PH 250026--615 1
Sphase 3 460V (not shown) 250026--615 322 insulator, splice phase 1 230V, 3PH 250006--110 1

Sphase 3, 460V (not shown) 250006--110 323 panel, circuit board 250025--863 124 Consult factory for starter group, and refer to compressor serial number.25 transformer 02250045--012 126 rivet, pop 1/8” x 3/8” 843102--038 427 nameplate, Sullair 02250059--318 128 gauge, pressure 0--200# bar/psi 250005--185 129 tee, male branch 1/8” 250026--139 130 connector, male tube straight 1/8” x 1/4” 250025--858 131 plug, hole 1/2” 045689 1

(Continued on page 43)

(I) For maintenance on solenoid valve no. 250030--164, order repair kit no. 250038--849, andreplacement coil no. 250035--292.


41

Section 7


7.10 CONTROL BOX

42


7.10 CONTROL BOX (continued)


32 bushing, reducing 1/4” x 1/8” 807600--005 133 switch, pressure 0--200# (air) 250025--299 134 connector, 1/2” 250026--153 135 plate ES--6, switch (Ref.) 250031--869 136 capscrew, hex 1/4”--20 x 5 1/2” 5HP

single phase 828604--550 137 capacitor, run 5HP/4KW single phase 250031--734 238 capacitor, start 5HP/4KW single phase 250031--733 239 nut, hex flanged 1/4”--20 (single phase) 825304--236 140 support, lower control box ES--6 250041--860 141 gauge, temperature 02250043--291 142 light, pilot assembly -- green 250000--104 143 hourmeter, rnd 2 1/2” 120V/60Hz (optional) 250042--224 144 gasket, hourmeter (optional) 02250056--423 145 panel, gauge temperature capillary 02250043--320 1


43

Section 7


7.11 CANOPY AND PARTS

1

2

3

4

5

6

7 89

1011

12

13

14

15

16

17

18

44


7.11 CANOPY AND PARTS


1 cover, ES--6 canopy 250031--542 12 foam, front ES--6 canopy sound 250041--300 13 soundcoat, ES--6 canopy -- right 250032--871 14 soundcoat, ES--6 canopy -- left 250032--872 15 louvers, ES--6 canopy 250032--309 16 bracket, ES--6 canopy mounting -- left 250033--701 17 bracket, canopy ES--6 mounting -- right 250033--702 18 canopy, stop ES--6 250033--096 29 decal, Sullair logo (not shown) 02250059--052 110 decal, ES--6 Model (not shown) 02250060--043 111 decal, warning--under pressure 02250078--001 112 decal, prohibit breath 02250078--007 113 trim, canopy edge 250034--157 214 screw, #14 x .625 hex 250034--158 1615 rivet, plastic 1/4” x 5/8” 250034--159 416 foam, ES--6 canopy sound -- top 250041--298 117 foam, ES--6 canopy sound -- rear 250041--299 118 decal, ISO 9001 (not shown) 02250059--288 1


45

Section 7


7.12 FRAME, CANOPY AND PARTS

46


7.12 FRAME, CANOPY AND PARTS


1 canopy, ES--6 250031--542 121 pan, ES--6 canopy base 250031--545 122 partition, ES--6 canopy 250031--546 123 rod, ES--6 canopy support 250032--223 124 footing, ES--6 canopy 250032--226 225 rod, ES--6 canopy hinge 250032--308 126 soundcoat, ES--6 canopy partition 250032--873 127 mounts, canopy vibration 250032--874 428 anchor, support rod 250032--878 129 retainer, ES--6 canopy partition 250034--582 330 retainer, shakeproof 843415--375 231 screw, hex serrated washer 3/8” x 1” 829706--100 432 nut, hex flange plated 3/8”--16 825306--347 433 isolator, 5/16”--18 x 1” diameter pad 250035--188 234 bracket, ES--6 canopy centering 250034--498 235 plug, 2” hole 250034--583 136 screw, hex serrated washer 1/4” x 1/2” 829704--050 737 nut, hex flange plated 1/4”--20 825304--236 738 washer, pl--b regular plated 3/8” 838206--071 839 bracket, canopy adjustment 250025--108 245 panel, ES--6 access (Retrofit kit only) 250034--858 1
46 plate, ES--6 switch (Retrofit kit only) 250031--869 147 plug, 1.2 diameter hole into pressure
switch 250032--881 149 light, pilot assembly -- green 250000--104 151 gauge, temperature capillary 1/2” x 4’

(not shown) 02250043--291 152 hourmeter, round 2 1/2” 120V/60Hz ES--6 250042--224 155 gauge, pressure 0--200# bar/psi

(not shown) 250038--243 158 rivet, plastic 1/4” x 5/8” 250034--159 460 bezel, ES--6 canopy control 250032--227 164 decal, warning auto start 02250077--473 165 decal, ES--6 canopy bezel switch 02250061--884 166 gasket, hourmeter 410353 167 nut, hex flanged plated 5/16”--18 825305--283 471 switch, pressure 250025--299 1


47

Section 7


7.13 WYE--DELTA ELECTRIC BOX ES--6

LINE PRESSUREDISCHARGE TEMP.

MANUAL

ON

OFF/RESET

AUTO

POWER ON

23

RE S ET

24

48




1 hose, nylon 1/4” 842215--004 5 ft.2 valve, solenoid 250030--164 13 nipple, chase 1/2” 847815--050 14 box, electric control (5.5 HP/4KW) 250031--242 1

Sbox, electric control (7.5&10HP/5.5&7.5KW) 250031--243 15 hourmeter 250042--010 111 locknut, conduit 1/2” 847200--050 712 nipple, pipe 1/2” x close 822208--000 113 elbow, 90 M swivel 1/4” x 1/8” 250025--849 314 tee, male branch 1/8” 250026--139 115 bushing, reducing 3/8” x 1/8” 807601--005 116 switch, pressure range 40--150# 250031--244 117 switch, 3 position selector 250034--883 1

Sblock, contact with mounting base 250025--181 1Sblock, contact without mounting base 250034--882 1

18 light, unit 250027--443 1Slens, clear 250026--998 1

19 gauge, pressure air 0--300# 2” 02250044--361 120 gauge, temperature 02250043--291 121 bezel, ES--6 canopy control 250032--227 122 rivets, plastic 1/4” x 5/8” 250034--159 423 decal, ES--6 canopy bezel 02250061--884 124 button, reset Consult Factory 1


49

Section 7



50




1 tee, tube 250028--270 12 connector, liquid tight 250041--988 13 connector, male 1/4” x 1/8” 250025--858 14 terminal, block Consult Factory5 fuse, 2 amp Consult Factory

Sfuse, carrier Consult FactorySfuse, 4 amp Consult FactorySfuse, carrier Consult Factory

6 CPT with tamper proof cover Consult Factory7 relay, control Consult Factory8 contactor Consult Factory

Scontactor, block Consult Factory9 interlock, mechanical Consult Factory10 contactor Consult Factory

Srelay, (7.5HP and 10HP/5.5 and 7.5KW) Consult FactorySrelay, (5.5HP/4KW) Consult Factory

11 contactor Consult FactoryStimer head Consult Factory

12 switch, pressure 250032--763 1


51

Section 7


7.15 DECAL GROUP

78

9

11

12

52


7.15 DECAL GROUP


1 decal, warning -- under pressure(not shown) 02250078--001 1

2 decal, 3 position switch panel(not shown) 250039--113 1

3 sign, warning -- hot surfaces(not shown) 02250077--999 1

4 decal, warning auto start(not shown) 02250077--473 1

5 decal, prohibition, breath/food(not shown) 02250078--998 1

6 decal, Sullair logo (not shown) 02250059--052 17 decal, rotation direction 040745 18 decal, compressor fluid Sullube 32 (I) 02250069--389 18B decal, fluid SRF 1/4000 (not shown) (I) 02250069--391 19 decal, earth ground 02250075--046 2

Sdecal, protective earth ground (not shown) 02250075--045 1Sdecal, PE designation (not shown) 02250075--540 1

10 decal, ES--6 Model (not shown) 02250060--043 111 decal, ISO 9001 02250059--288 112 decal, voltage international (II) 02250069--397 1

(Continued on page 55)

(I) Decal will change with fluid requirement.

(II) Decal will vary with machine voltage. If voltage is not known, consult factory with serial number of com-pressor.


53

Section 7


5

7.15 DECAL GROUP

13

4


7.15 DECAL GROUP (continued)


13 decal, ES--6 canopy bezel 02250061--884 114 decal, mandatory read manual (not shown) 02250078--002 1


55

Section 7


56

7.16 WIRING DIAGRAM (SINGLE PHASE) (60Hz)


7.17 WIRING DIAGRAM (THREE PHASE) (60Hz)

57

Section 7


7.18 WIRING DIAGRAM (50 Hz)

58


7.19 WIRING DIAGRAM (50 Hz) WYE--DELTA

59

Printed in U.S.A.

Specifications Subject ToChange Without Prior Notice

EN95EPS

WORLDWIDE SALES AND SERVICE

SULLAIR EUROPE, S.A.Chemin de Genas BP 63969800 Saint Priest, FranceTelephone: 33--72232425

Fax: 33 -- 78907168

SULLAIR CORPORATIONSubsidiary of Sundstrand Corporation

3700 East Michigan BoulevardMichigan City, Indiana 46360 U.S.A.

Telephone: 1--800--SULLAIR (U.S.A. Only) or1--219--879--5451

Fax: (219) 874 -- 1273

SULLAIR ASIA, LTD.ROOM 2304A

Shartex Plaza Ctr.No. 88 Zun Yi Nan Rd.

Shanghai, P.R.C.Telephone: 21--2192066

Fax: 21 -- 2196568

Fax: (219) 874 -- 1835 (Parts)Fax: (219) 874 -- 1805 (Service)

ROTARY SCREW AIR COMPRESSOR ES--6 · PDF fileROTARY SCREW ES--6 Series 5, 7.5 and 10HP...

Documents

Transcript of ROTARY SCREW AIR COMPRESSOR ES--6 · PDF fileROTARY SCREW ES--6 Series 5, 7.5 and 10HP...