Professional Documents
Culture Documents
Manual - EN - ES6 - User - 02250173-918 R00
Manual - EN - ES6 - User - 02250173-918 R00
ES-6 SERIES
STANDARD & 24KT
5, 7.5 AND 10 HP / 4, 5.5 AND 7.5 KW
PART NUMBER:
02250173-918-R00
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Instruction includes training on the function and installation of Sullair service parts, troubleshooting
common faults and malfunctions, and actual equipment operation. These seminars are recommended for
maintenance, contractor maintenance, and service personnel.
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
TABLE OF CONTENTS
PAGE SECTION DESCRIPTION
SECTION 1 - SAFETY
1 1.1 GENERAL SAFETY
1 1.2 PERSONAL PROTECTIVE EQUIPMENT
1 1.3 PRESSURE RELEASE
2 1.4 FIRE AND EXPLOSION
2 1.5 MOVING PARTS
3 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
3 1.7 TOXIC AND IRRITATING SUBSTANCES
3 1.8 ELECTRICAL SHOCK
4 1.9 LIFTING
4 1.10 ENTRAPMENT
SECTION 2 - DESCRIPTION
5 2.1 INTRODUCTION
5 2.2 DESCRIPTION OF COMPONENTS
5 2.3 ENCAPSULATED COMPRESSOR SYSTEM,
FUNCTIONAL DESCRIPTION
7 2.4 COMPRESSOR COOLING SYSTEM,
FUNCTIONAL DESCRIPTION
7 2.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
7 2.6 CONTROL, FUNCTIONAL DESCRIPTION
8 2.7 INSTRUMENTATION, FUNCTIONAL DESCRIPTION
SECTION 3 - SPECIFICATIONS
9 3.1 SPECIFICTIONS - ES-6
CONTINUED...
TABLE OF CONTENTS
SECTION 4 - INSTALLATION
33 4.1 LOCATION OF COMPRESSOR
33 4.2 VENTILATION AND COOLING
33 4.3 SERVICE AIR PIPING
33 4.4 FLUID LEVEL CHECK AND CHANGE PROCEDURE
33 4.5 MOTOR ROTATION DIRECTION CHECK
33 4.6 ELECTRICAL PREPARTATION
SECTION 5 - OPERATION
35 5.1 GENERAL
TABLE OF CONTENTS
SECTION 6 - MAINTENANCE
37 6.1 GENERAL
37 6.2 DAILY OPERATION
37 6.3 MOTOR BEARNING LUBRICATION
38 6.4 FLUID FILTER MAINTENANCE
38 6.5 COOLER MAINTENANCE
38 6.6 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
38 FLUID FILTER REPLACEMENT
39 AIR FILTER MAINTENANCE
39 SEPARATOR ELEMENT REPLACEMENT
40 MINIMUM PRESSURE/CHECK VALVE MAINTENANCE
40 THERMOSTAT ACTUATOR MAINTENANCE
41 CONTROL SYSTEM ADJUSTMENT
41 PRESSURE SWITCH ADJUSTMENT
41 PRESSURE REGULATOR ADJUSTMENT
42 FOR DIFFERENTIAL ADJUSTMENT OF AIR
PRESSURE SWITCH
42 UNLOADER SOLENOID VALVE MAINTENANCE
42 INLET CONTROL VALVE
44 MOTOR SHAFT SEAL REPLACEMENT
44 6.7 TROUBLESHOOTING
44 6.8 TROUBLESHOOTING GUIDE
46 6.9 MAINTENANCE RECORD
Prior to installing or operating the compressor, G. Open fluid filler cap only when compressor is not
owners, employers and users should become running and is not pressurized. Shut down the
familiar with, and comply with, all applicable OSHA compressor and bleed the sump (receiver) to
regulations and/or any applicable Federal, State zero internal pressure before removing the
and Local codes, standards, and regulations cap.
relative to personal protective equipment, such as H. Vent all internal pressure prior to opening any
eye and face protective equipment, respiratory line, fitting, hose, valve, drain plug, connection
protective equipment, equipment intended to or other component, such as filters and line oil-
protect the extremities, protective clothing, ers, and before attempting to refill optional air
protective shields and barriers and electrical line anti-icer systems with antifreeze com-
protective equipment, as well as noise exposure pound.
1
Section 1 - SAFETY ES-6 USER MANUAL
I. Keep personnel out of line with and away from such as terminals to avoid arcing which might
the discharge opening of hoses or tools or serve as a source of ignition.
other points of compressed air discharge.
G. Remove any acoustical material or other mate-
J. Use air at pressures less than 30 psig (2.1 bar) rial that may be damaged by heat or that may
for cleaning purposes, and then only with support combustion and is in close proximity,
effective chip guarding and personal protective prior to attempting weld repairs.
equipment per OSHA Standard 29 CFR
H. Keep suitable fully charged Class BC or ABC
1910.242 (b) and/or any applicable Federal,
fire extinguisher or extinguishers nearby when
State, and Local codes, standards and regula-
servicing and operating the compressor.
tions.
I. Keep oily rags, trash, leaves, litter or other com-
K. DO NOT engage in horseplay with air hoses as
bustibles out of and away from the compres-
death or serious injury may result.
sor.
1.4 FIRE AND EXPLOSION J. DO NOT operate the compressor without proper
flow of cooling air or water or with inadequate
A. Clean up spills of lubricant or other combustible flow of lubricant or with degraded lubricant.
substances immediately, if such spills occur.
K. DO NOT attempt to operate the compressor in
B. Shut off the compressor and allow it to cool. any classification of hazardous environment
Then keep sparks, flames and other sources of unless the compressor has been specially
ignition away and DO NOT permit smoking in designed and manufactured for that duty.
the vicinity when checking or adding lubricant
or when refilling air line anti-icer systems with
1.5 MOVING PARTS
antifreeze compound.
A. Keep hands, arms and other parts of the body
C. DO NOT permit fluids, including air line anti-icer
and also clothing away from couplings, fans
system antifreeze compound or fluid film, to
and other moving parts.
accumulate on, under or around acoustical
material, or on any external surfaces of the air B. DO NOT attempt to operate the compressor
compressor or on internal surfaces of the with the fan, coupling or other guards removed.
enclosure. Wipe down using an aqueous
C. Wear snug-fitting clothing and confine long hair
industrial cleaner or steam clean as required. If
when working around this compressor, espe-
necessary, remove acoustical material, clean
cially when exposed to hot or moving parts.
all surfaces and then replace acoustical mate-
rial. Any acoustical material with a protective D. Keep access doors, if any, closed except when
covering that has been torn or punctured making repairs or adjustments.
should be replaced immediately to prevent
E. Make sure all personnel are out of and/or clear
accumulation of liquids or fluid film within the
of the compressor prior to attempting to start or
material. DO NOT use flammable solvents for
operate it.
cleaning purposes.
F. Disconnect and lock out all power at source and
D. Disconnect and lock out all power at source
verify at the compressor that all circuits are de-
prior to attempting any repairs or cleaning of
energized to minimize the possibility of acci-
the compressor or of the inside of the enclo-
dental start-up, or operation, prior to attempting
sure, if any.
repairs or adjustments. This is especially
E. Keep electrical wiring, including all terminals important when compressors are remotely
and pressure connectors in good condition. controlled.
Replace any wiring that has cracked, cut,
G. Keep hands, feet, floors, controls and walking
abraded or otherwise degraded insulation, or
surfaces clean and free of fluid, water or other
terminals that are worn, discolored or cor-
liquids to minimize the possibility of slips and
roded. Keep all terminals and pressure con-
falls.
nectors clean and tight.
F. Keep grounded and/or conductive objects such
as tools away from exposed live electrical parts
2
ES-6 USER MANUAL Section 1 - SAFETY
1.6 HOT SURFACES, SHARP EDGES E. Coolants and lubricants used in this compressor
AND SHARP CORNERS are typical of the industry. Care should be
taken to avoid accidental ingestion and/or skin
A. Avoid bodily contact with hot fluid, hot coolant, contact. In the event of ingestion, seek medical
hot surfaces and sharp edges and corners. treatment promptly. Wash with soap and water
B. Keep all parts of the body away from all points of in the event of skin contact. Consult Material
air discharge. Safety Data Sheet for information pertaining to
fluid of fill.
C. Wear personal protective equipment including
gloves and head covering when working in, on F. Wear goggles or a full face shield when adding
or around the compressor. antifreeze compound to air line anti-icer sys-
tems.
D. Keep a first aid kit handy. Seek medical assis-
tance promptly in case of injury. DO NOT G. If air line anti-icer system antifreeze compound
ignore small cuts and burns as they may lead enters the eyes or if fumes irritate the eyes,
to infection. they should be washed with large quantities of
clean water for fifteen minutes. A physician,
preferably an eye specialist, should be con-
1.7 TOXIC AND IRRITATING SUB-
tacted immediately.
STANCES
H. DO NOT store air line anti-icer system anti-
A. DO NOT use air from this compressor for respi- freeze compound in confined areas.
ration (breathing) except in full compliance with
OSHA Standards 29 CFR 1910 and/or any I. The antifreeze compound used in air line anti-
applicable Federal, State or Local codes or freeze systems contains methanol and is toxic,
regulations. harmful or fatal if swallowed. Avoid contact
with the skin or eyes and avoid breathing the
fumes. If swallowed, induce vomiting by
WARNING administering a tablespoon of salt, in each
glass of clean, warm water until vomit is clear,
then administer two teaspoons of baking soda
in a glass of clean water. Have patient lay
down and cover eyes to exclude light. Call a
physician immediately.
3
Section 1 - SAFETY ES-6 USER MANUAL
C. Attempt repairs in clean, dry and well lighted K. When moving the compressor by forklift truck,
and ventilated areas only. utilize fork pockets if provided. Otherwise, uti-
lize pallet if provided. If neither fork pockets or
D. DO NOT leave the compressor unattended with
pallet are provided, then make sure compres-
open electrical enclosures. If necessary to do
sor is secure and well balanced on forks before
so, then disconnect, lock out and tag all power
attempting to raise or transport it any signifi-
at source so others will not inadvertently
cant distance.
restore power.
L. Make sure forklift truck forks are fully engaged
E. Disconnect, lock out, and tag all power at source
and tipped back prior to lifting or transporting
prior to attempting repairs or adjustments to
the compressor.
rotating machinery and prior to handling any
ungrounded conductors. M. Forklift no higher than necessary to clear obsta-
cles at floor level and transport and corner at
1.9 LIFTING minimum practical speeds.
A. If the compressor is provided with a lifting bail, N. Make sure pallet-mounted compressors are
then lift by the bail provided. If no bail is pro- firmly bolted or otherwise secured to the pallet
vided, then lift by sling. Compressors to be air- prior to attempting to forklift or transport them.
lifted by helicopter must not be supported by NEVER attempt to forklift a compressor that is
the lifting bail but by slings instead. In any not secured to its pallet, as uneven floors or
event, lift and/or handle only in full compliance sudden stops may cause the compressor to
with OSHA standards 29 CFR 1910 subpart N tumble off, possibly causing serious injury or
and/or any applicable Federal, State, and property damage in the process.
Local codes, standards and regulations.
1.10 ENTRAPMENT
B. Inspect points of attachment for cracked welds
and for cracked, bent, corroded or otherwise A. If the compressor enclosure, if any, is large
degraded members and for loose bolts or nuts enough to hold a man and if it is necessary to
prior to lifting. enter it to perform service adjustments, inform
other personnel before doing so, or else
C. Make sure entire lifting, rigging and supporting
secure and tag the access door in the open
structure has been inspected, is in good condi-
position to avoid the possibility of others clos-
tion and has a rated capacity of at least the
ing and possibly latching the door with person-
weight of the compressor. If you are unsure of
nel inside.
the weight, then weigh compressor before lift-
ing. B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.
D. Make sure lifting hook has a functional safety
latch or equivalent, and is fully engaged and
latched on the bail or slings.
E. Use guide ropes or equivalent to prevent twist-
ing or swinging of the compressor once it has
been lifted clear of the ground.
F. DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away
from the compressor whenever it is sus-
pended.
H. Lift compressor no higher than necessary.
I. Keep lift operator in constant attendance when-
ever compressor is suspended.
J. Set compressor down only on a level surface
capable of safely supporting at least its weight
and its loading unit.
4
ES-6 USER MANUAL Section 2 - DESCRIPTION
Read Section 6 (Maintenance) to keep your 3. It acts as a lubricating film between the rotors
compressor in top operating condition. Should any allowing one rotor to directly drive the other, which
questions arise which cannot be answered in the is an idler.
following text, call your nearest Sullair office or the The air/fluid mixture discharges directly into the
Sullair Corporation Service Department. fluid management system.
2.2 DESCRIPTION OF COMPONENTS The fluid cooler bypass valve helps assure proper
cooling by directing the fluid to the fluid cooler
Refer to Figure 2-1. The components and when discharge temperature reaches the
assemblies of the ES-6 Series air compressor are thermostat temperature setting.
clearly shown. The complete compressor consists
of an encapsulated compressor system, inlet During start-up in cool ambient conditions, the
system, cooling system and control system. cooler pressure drop will cause the filter bypass
valve to open up, assuring adequate fluid supply to
The compact design of the ES-6 Series air the compressor.
compressor provides easy access to all
serviceable components. All fluid entering the compressor unit passes
through the replaceable fluid filter element. This
replaceable filter element contains a built-in bypass
2.3 ENCAPSULATED COMPRESSOR
valve. Under conditions of restricted flow through
SYSTEM, FUNCTIONAL DESCRIPTION the element, the bypass valve helps ensure
Refer to Figure 2-2. The encapsulated compressor adequate compressor fluid flow, as well as helps
includes compressor unit, fluid management prevent element failure.
system, and motor section. The Sullair compressor
unit is a single-stage positive displacement FLUID MANAGEMENT SYSTEM
lubricated type compressor. This unit is equipped
The fluid management system consists of a multi-
with tapered roller bearings on the discharge, and
chambered primary/secondary separator, the final
cylindrical roller bearings on the inlet end for high
air/fluid separator element, cooler bypass group
load carrying capacity. This unit provides
and fluid filter.
continuous pulse-free air compression to meet
your needs. With a Sullair compressor there will be As compressed air/fluid enters the sump, the first
no maintenance or internal inspection of the fluid separation takes place due to a reduction of
compressor. flow speed coupled with a change of direction of
the flow within the sump housing. Then the
WARNING compressed air reaches the separator, where the
finest fluid drops and mist are separated.
MOTOR/DRIVE SECTION
DO NOT remove caps, plugs and/or The motor/drive section consists of a squirrel cage
other components when compres- induction motor and integrated drive gearing which
sor is running or pressurized. is separated from the motor by a replaceable shaft
seal.
Stop compressor and relieve all
internal pressure before doing so.
5
Section 2 - DESCRIPTION ES-6 USER MANUAL
7
12
11
8
9 10
13 3 4
15
16
14
17
4. Discharge Temperature Gauge 10. Encapsulated Compressor 16. Motor Start Selector Switch
System
5. Unload Solenoid Valve 11. Pressure Relief Valve 17. Motor Overload Reset Switch
6
ES-6 USER MANUAL Section 2 - DESCRIPTION
The minimum pressure/discharge check valve is motor as well as through the cooler. The air
mounted on the compressor drive housing. Its provides motor cooling and removes compression
functions are as follows: heat from the fluid.
1. Maintain a minimum sump pressure of 60 psig
(4.1 bar) under full load operation to help 2.5 AIR INLET SYSTEM, FUNCTIONAL
assure adequate fluid pressure. DESCRIPTION
2. Act as a check valve to isolate the compressor The compressor inlet system consists of a dry-type
from the system at shutdown or unload. air filter and an air control valve. Reacting on a
pressure signal, the valve closes the intake for
2.4 COMPRESSOR COOLING SYSTEM, unloaded operation. The valve also acts as a check
FUNCTIONAL DESCRIPTION valve upon shutdown.
The compressor cooling system consists of a fluid 2.6 CONTROL SYSTEM, FUNCTIONAL
cooler, fan and cooler shroud.
DESCRIPTION
The fan is mounted on the motor's shaft end
The purpose of the compressor control system is to
opposite the compressor. Air is drawn over the
maintain compressor capacity to meet the system
7
Section 2 - DESCRIPTION ES-6 USER MANUAL
OFF/RESET MODE
The compressor motor, if running, will stop if the
off/reset position is selected. If the compressor
during normal running has a fault caused by either
overload or high discharge temperature, the
compressor will stop. After a fault has been
cleared, the compressor can not be restarted
unless the Off/Reset mode is selected on the
selector switch, prior starting in any other mode of
operation.
8
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
Model
ACFM/ Pressure with Length (II) Width (III) Height (IV) Weight
M3/Min PSIG/BAR canopy/
without in mm in mm in mm lb. kg
canopy
ES-6 5H 5/4 18/.51 125/8.6 68/80 29.5 749 21.4 544 22.11 562 230 104
ES-6 5XH 5/4 13/.37 175/12 68/80 29.5 749 21.4 544 22.11 562 230 104
ES-6 7.5H 7.5/5.5 28/.79 125/8.6 69/82 31.5 800 21.4 544 22.11 562 270 122
ES-6 7.5/5.5 20/.57 175/12 69/82 31.5 800 21.4 544 22.11 562 270 122
7.5XH
ES-6 10H 10/7.5 38/1.08 125/8.6 70/85 31.5 800 21.4 544 22.11 562 280 127
ES-6 10/7.5 30/.85 175/12 70/85 31.5 800 21.4 544 22.11 562 280 127
10XH
(I) Ratings of dBA at one meter. (IV) Enclosure option height is 28 in. / 711 mm
(II) Enclosure option length is 44 in. / 1118 mm. (V) For enclosure models, add 170 lbs. / 77 kg to base
weight of machine.
(III) Enclosure option width is 28 in. / 711 mm.
9
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
COMPRESSOR
Type: Single Stage Fluid Injected Screw Compressor
Type: 5, 7.5, 10HP/ 4, 5.5 & 7.5 KW 1.15 S.F. 5, 7.5, 10HP/ 4, 5.5 & 7.5 KW
Voltage:
Key Size Fan: Nominal 3/16" x 3/16" x 1 1/4" Nominal 3/16" x 3/16" x 1 1/4"
10
Section 3 - SPECIFICATIONS ES-6 USER MANUAL
WARNING
“The Plastic Pipe Institute recom-
mends against the use of thermo-
plastic pipe to transport compressed
air or other compressed gases in
exposed above ground locations,
e.g. in exposed plant piping." (I)
NOTE
Sullube should not be used with PVC
piping systems. It may affect the Fluid fill level should
bond at cemented joints. Certain be at 1/4 to 1/2 of the
other plastic materials may also be sight glass when the
affected. 1. Fluid Fill Port compressor is
running.
(I) Plastic Pipe Institute, Recommen- 2. Sight Glass
dation B, Adopted January 19, 1972.
11
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
at the first filter change and sent to the factory for SRF 1/4000 fluid should be changed every 4000
analysis. This is a free service. A sample kit with hours or once a year, whichever comes first. The
instructions and self-addressed container is to be fluid should be changed more frequently under
supplied by your Sullair Representative at start-up. severe operating conditions, such as high ambient
The user will receive an analysis report with temperatures coupled with high humidity, or when
recommendations. high particulate level, corrosive gases or strong
oxidizing gases are present in the air.
3.4 LUBRICATION GUIDE - OPTIONAL Maintenance of all other components is still
FLUID recommended as indicated in the Operator's
Sullair compressors may use SRF 1/4000 fluid as Manual.
an optional factory fill.
CAUTION
Mixing of other fluids within the com-
pressor will void all warranties.
Sullube A C E A
SRF 1/4000 B C E B
24KT D C E A
12
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
NOTES
13
Section 3 - SPECIFICATIONS ES-6 USER MANUAL
02250172-315R00
14
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
02250172-316R00
15
Section 3 - SPECIFICATIONS ES-6 USER MANUAL
02250170-490R00
16
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
02250170-491R00
17
Section 3 - SPECIFICATIONS ES-6 USER MANUAL
Figure 3-6 Identification - ES-6 Open Tank Mount (80 Gallon) with Dryer
02250172-307R00
18
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
Figure 3-7 Identification - ES-6 Enclosed Tank Mount (80 Gallon) with Dryer
02250172-308R00
19
Section 3 - SPECIFICATIONS ES-6 USER MANUAL
02250172-309R00
20
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
02250172-310R00
21
Section 3 - SPECIFICATIONS ES-6 USER MANUAL
Figure 3-10 Identification - ES-6 Open Tank Mount (120 Gallon) with Dryer
02250172-311R00
22
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
Figure 3-11 Identification - ES-6 Enclosed Tank Mount (120 Gallon) with Dryer
02250172-312R00
23
Section 3 - SPECIFICATIONS ES-6 USER MANUAL
02250101-011R04
24
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
Figure 3-12 Piping and Instrumentation Diagram - Standard and Wye-Delta (continued)
25
Section 3 - SPECIFICATIONS ES-6 USER MANUAL
02250045-623R06
26
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
02250062-643R04
27
Section 3 - SPECIFICATIONS ES-6 USER MANUAL
606512-001R07
28
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
02250058-093R04
29
Section 3 - SPECIFICATIONS ES-6 USER MANUAL
02250171-733R00
30
ES-6 USER MANUAL Section 3 - SPECIFICATIONS
02250171-738R00
31
Section 3 - SPECIFICATIONS ES-6 USER MANUAL
02250171-739R00
32
ES-6 USER MANUAL Section 4 - INSTALLATION
33
Section 4 - INSTALLATION ES-6 USER MANUAL
OSHA, National Electrical Code, and any other 4. “Dry run" the electrical controls by disconnect-
applicable State, Federal and local electrical codes ing the motor leads T1, T2, and T3 from the
concerning isolation switches, fused disconnects, starter. Energize the control circuits by turning
etc. Sullair provides a wiring diagram for use by the the selector switch to the manual and auto-
installer. matic positions, and check all protection
devices making sure when activated, they will
A few electrical checks should be made to help
de-energize the starter control coil.
assure that the first start-up will be trouble-free.
5. Reconnect the motor leads and jog the motor
for a direction of rotation check as explained in
WARNING Section 4.5.
34
ES-6 USER MANUAL Section 5 - OPERATION
START SELECTOR SWITCH The three-position switch provides selection between MANUAL/
START, OFF/RESET and AUTOMATIC/START (for further
description, see Section 2).
FLUID LEVEL SIGHT GLASS Indicates fluid level. The level is checked by looking at the fluid
level sight glass on the end bell. The fluid level should cover 1/2
to1/4 of the sight glass during operation. With the compressor
shut down, the level should be 3/4 of the sight glass. DO NOT
OVERFILL.
COOLER BYPASS VALVE Regulates fluid flow to and around the cooler. Designed to main-
tain a minimum operating temperature of 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 compressor sump.
Valve piston restricts receiver air discharge from receiver/sump
when pressure falls to 60 psig (4.1 bar). Also incorporated in this
valve is a terminal check valve which prevents line pressure
backflow into the sump during unload conditions and after shut-
down.
DISCHARGE TEMPERATURE SWITCH Shuts the compressor down when the compressor discharge
temperature exceeds 240°F (116°C).
PRESSURE RELIEF VALVE Opens sump pressure to the atmosphere should pressure inside
the sump become too high. Operation of this valve indicates that
the air pressure switch is either faulty or out of adjustment.
AIR PRESSURE SWITCH Senses service line pressure. When line pressure reaches maxi-
mum setting, the pressure switch opens solenoid valve circuit to
unload the compressor.
SOLENOID VALVE Vents sump pressure through inlet control valve to the atmo-
sphere during unload conditions and shutdown.
SUMP PRESSURE SWITCH (Not used on cur- Senses sump pressure and prevents compressor from starting
rent models except with Wye-Delta starter). until sump pressure has fallen below preset pressure of 10 psig
(0.7 bar).
35
Section 5 - OPERATION ES-6 USER MANUAL
PRESSURE REGULATOR VALVE Modulates the intake valve to control compressor output. Senses
compressor output pressure, the regulator stays closed up to a
pre-set pressure and then modulates open to provide a positive
control signal as compressor pressure increases.
BALL VALVE Isolates the pressure regulator valve from standard operation of
the compressor. When the ball valve is in the closed position,
selector switch settings are utilized. Ball valve in the open posi-
tion will allow operation of the pressure regulator valve.
36
ES-6 USER MANUAL Section 6 - MAINTENANCE
WARNING WARNING
Before doing compressor mainte-
nance, disconnect compressor from Before doing compressor mainte-
power source and lock out power nance, disconnect compressor from
source. Isolate compressor from line power source and lock out power
pressure by closing recommended source. Isolate compressor from line
discharge shut-off valve and releas- pressure by closing recommended
ing all internal pressure from com- discharge shut-off valve and releas-
pressor. ing all internal pressure from com-
pressor.
As you proceed in reading this section, it will be
easy to see that the Maintenance Program for the See Table 6A - Motor Bearing Lubrication
air compressor is quite minimal yet important. See Schedule. If lubrication instructions are shown on
instructions for each item in Section 6.6, Parts the motor or in a separately provided manual, they
Replacement and Adjustment Procedures. will supersede this general instruction.
1. Remove the fan guard by removing the four (4)
6.2 DAILY OPERATION self-tapping screws holding the guard and fan
Prior to starting the compressor, it is necessary to ring to the cooler.
check the fluid level in the sump. Should the level 2. Remove the 1/8" NPT plugs in the filler and
be low, simply add the necessary amount. If the drain connection for both bearings.
addition of fluid becomes too frequent, a minor 3. Free drain hole of any hard grease (use piece
problem has developed which is causing this of wire if necessary).
excessive loss. See the Troubleshooting Section
4. Add grease (I) using a low pressure grease
(6.7) under Excessive Fluid Consumption for a
gun.
probable cause and remedy.
5. Wipe off any drained grease, and replace filler
After a routine start has been made, a general and drain plugs.
check of the overall compressor should be made to
assure that the compressor is running properly. 6. Replace fan guard.
STANDARD
CONDITIONS SEVERE
MODEL (I) CONDITIONS (II) EXTREME CONDITIONS (III)
(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 104°F
(38°C to 40°C) ambient.
(III) Heavy shock or vibration, dirt or dust at 100°F to 104°F (38°C to 40°C) ambient
37
ES-6 USER MANUAL Section 6 - MAINTENANCE
7. Motor is now ready for operation. Figure 6-1 Fluid Filter (P/N 250026-982)
(I) Use Chevron SRI-2 grease when lubri-
cating motor bearings. Fill the cavity 1/3 to
1/2 full by repacking or use a low pressure
grease gun and fill through the lubricating
provisions on the motor end bell housing.
WARNING
Fluid filter has internal bypass. DO
NOT SUBSTITUTE.
38
Section 6 - MAINTENANCE ES-6 USER MANUAL
Figure 6-2 Air Filter (P/N 02250111-680) 4. Remove element and base. Clean base and
interior of cover using a damp cloth. DO NOT
use compressed air to clean cover and base.
5. At this time replace element.
6. Replace cover.
ELEMENT INSPECTION
1. Place a bright light inside the element to
inspect for damage or leak holes. Concen-
trated light will shine through the element and
locate any holes.
2. Inspect all gaskets and gasket contact sur-
faces of the housing. Should faulty gaskets be
evident, correct the condition immediately.
3. If the clean element is to be stored for later
use, it must be stored in a clean container.
4. After the element has been installed, inspect
and tighten (if necessary) all air inlet connec-
tions prior to resuming operation.
39
ES-6 USER MANUAL Section 6 - MAINTENANCE
5. Reinstall the cap. Hand-tighten using a 4" max- 1. Unscrew the minimum pressure valve from the
imum length, 1/4" diameter pin in the radially drive housing.
drilled hole.
2. Remove all parts.
Figure 6-3 Separator Element (P/N 250025-264) 3. Clean and inspect all parts.
4. Remove the screw holding the check valve
seat. Replace valve seat. Reinstall securing
with Loctite® #222.
5. Install new o-ring. Before reinstallation, lubri-
cate with Parker Super "O" ring seal or an
equivalent grease.
6. Reinstall the whole valve assembly. Tighten
and secure.
WARNING
Assure that line pressure gauge on 1. Valve 3. Valve 5. Screw 7. Check
compressor indicates "ZERO" pres- Spring Stem Spring (I)
sure before any work is done. Failure 2. O-ring (I) 4. Washer 6. Valve 8. Cap
to comply can cause injury. Seat (I)
(I) Repair Kit P/N 250030-226
40
Section 6 - MAINTENANCE ES-6 USER MANUAL
41
ES-6 USER MANUAL Section 6 - MAINTENANCE
until the line pressure gauge reads a pressure It is not necessary to remove the valve from the
of 5 psi/ 0.34 bar below the pressure switch pipe line for repairs.
setting established in Table 6A.
5. Open shut-off valve and observe operation. DISASSEMBLY AND REASSEMBLY
1. Remove the retaining cap and slip the entire
FOR DIFFERENTIAL ADJUSTMENT OF solenoid off the solenoid base subassembly.
AIR PRESSURE SWITCH: 2. Unscrew the solenoid base assembly. Remove
Differential is the difference between the high and the core assembly, core spring and body gas-
low pressure settings. ket.
3. All parts are now accessible for cleaning or
Turning the screw clockwise increases the
replacement.
differential, and counterclockwise decreases the
4. Reassemble in reverse order of disassembly.
differential pressure.
COIL REPLACEMENT
DANGER 1. Remove the retaining cap, nameplate and
DO NOT touch the electrical con- cover.
tacts, terminal or leads with any part 2. Slip the yoke containing the coil and sleeves
of the body or any uninsulated metal- off the solenoid base subassembly.
lic object. Severe electrical shock
may occur. 3. Reassemble in reverse order of disassembly.
42
Section 6 - MAINTENANCE ES-6 USER MANUAL
1. Nylok Screw 4. Intake Valve Head 7. Intake Valve Rod 10. Spring Washers 13. Retaining Ring
2. Piston Seal (I) 5. Spring Retainer 8. Gasket (I) 11. Intake Check
Spring
3. Intake Piston 6. Check Spring 9. Inlet Valve Housing 12. Cap
(I) Repair Kit P/N 02250045-287
1. Remove the inlet filter assembly. 10. Lubricate internal piston bore using lubricant
supplied with kit.
2. Disconnect tubing from intake control housing
at 90° elbow. 11. Install new piston seal onto piston
3. Remove the two (2) 3/8" ferry head capscrews 12. Reinstall intake valve rod, check spring, spring
securing the intake control housing to the inlet retainer and intake valve head into intake con-
plate. trol housing. Install assembled intake piston
into intake control bore and onto intake valve
4. Remove intake control housing assembly and
rod.
gasket.
13. Install washers. Apply screw lock adhesive
5. Remove retaining ring, cap and intake check
provided in kit to socket head capscrew.
spring from intake housing bore.
Replace socket head capscrew into the valve
6. Remove socket head capscrew, washers, and rod and torque socket head capscrew to 18 to
check spring from intake valve rod. 24 in.-lbs. (2.0 to 2.7Nm).
7. Remove intake valve from valve housing. 14. Install intake check spring, cap and retaining
Remove intake valve rod, check spring, spring ring.
retainer and intake valve head.
15. Replace gasket and reinstall the whole inlet
8. Remove intake piston from intake/inlet control control valve assembly.
housing. Remove and discard old piston seal
16. Apply screw lock adhesive to inlet control
from intake piston.
housing assembly ferry head capscrews and
9. Clean intake housing gasket surface and inter- install. Torque to 30 ft.-lbs. (40.7Nm).
nal piston bore.
43
ES-6 USER MANUAL Section 6 - MAINTENANCE
17. Reconnect tubing to inlet control valve housing that these are the only problems that may occur.
at 90° elbow. All available data concerning the trouble should be
18. Reinstall air inlet filter assembly. systematically analyzed before undertaking any
repair or component replacement procedures.
MOTOR SHAFT SEAL REPLACEMENT A detailed visual inspection is worth performing for
Replacement of motor shaft seal requires that the almost any problems which may prevent
compressor be separated from the drive housing. unnecessary damage to the compressor. Always
This operation requires qualified personnel. remember to:
Detailed instructions and a list of needed tooling • Check for loose wiring.
are included in each motor shaft seal replacement • Check for damaged piping.
kit no. 250028-035. • Check for parts damaged by heat or an
electrical short circuit, usually apparent by
discoloration or a burnt odor.
6.7 TROUBLESHOOTING
Should your problem persist after making the
The information contained in the Troubleshooting
recommended check, consult your nearest Sullair
chart is based upon both the actual applied
representative or the Sullair Corporation factory.
situations and extensive testing at the factory. It
contains symptoms and usual causes for the
described problems. However DO NOT assume
Low Incoming Line Voltage Check voltage. Should voltage check low, consult
power company.
Discharge Temperature Switch Cooling air flow restricted; clean cooler and check
Open for proper ventilation.
44
ES-6 USER MANUAL Section 6 - MAINTENANCE
COMPRESSOR SHUTS Discharge Temperature Switch Defective discharge temperature switch; check for
DOWN WITH AIR DEMAND Open (continued) a short or open circuit to probe and correct wiring.
PRESENT (CONTINUED)
COMPRESSOR WILL NOT Air Demand Is Too Great Check service lines for leaks or open valves.
BUILD UP FULL DIS-
Dirty Air Filter Check filter and change element if required.
CHARGE PRESSURE
Pressure Regulator Out Of Adjust regulator according to control adjustment
Adjustment instructions in Maintenance Section.
LI NE PRESSURE RISES Defective Solenoid Valve Repair solenoid valve (see Section 6).
ABOVE CUT-OUT PRES-
Leak In Control System Caus- Check for leaks.
SURE SETTING ON PRES-
ing Loss of Pressure Signals
SURE SWITCH
Defective Pressure Switch Check that diaphragm and contacts are not dam-
aged. Replace if necessary.
Inlet Valve Stuck Open Inspect inlet valve and insure free operation (see
Section 6).
EXCESSIVE COMPRESSOR Clogged Return Line Remove element cover and clean orifice.
FLUID CONSUMPTION
Separator Element Damaged Change separator element.
Or Not Functioning Properly
Leak In The Lubrication System Check all pipes, connections and components.
PRESSURE RELIEF VALVE Compressor Operating Pres- See Symptom “Line Pressure Rises Above Cut-
OPENS REPEATEDLY sure Too High out Pressure Setting on Pressure Switch” above.
LIQUID WATER IN COM- Water Vapor Condensation Remove the water vapor from compressed air
PRESSED AIR LINES From Cooling and Compression prior to distribution through the air system. Check
Occurs Naturally operation of aftercooler and moisture separator.
Install a compressed air dryer sized for the flow
and dryness level required. (Note: Filters may also
be required to remove particulates, liquid oil aero-
sols or for oil vapor removal. Change cartridges as
recommended by the filter manufacturer.) Check
all drain traps routinely to insure their proper oper-
ation. Maintain them regularly.
45
Section 6 - MAINTENANCE ES-6 USER MANUAL
46
ES-6 USER MANUAL Section 7 - MAINTENANCE PARTS LIST
SULLAIR CORPORATION
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
www.sullair.com
Telephone: 1-800-SULLAIR (U.S.A. Only)
or 1-219-879-5451
Fax: (219) 874-1273
CHAMPION
COMPRESSORS, LTD.
Princes Highway
Hallam, Victoria 3803
Australia
Telephone: 1800-810-015 (for Australia
-wide Branch Network Only)
Telephone: 61-3-9796-4000
Fax: 61-3-9703-8053
www.championcompressors.com.au
47
Section 7 - MAINTENANCE PARTS LIST ES-6 USER MANUAL
ELEMENTS:
1 replacement element kit for fluid filter 250026-982............................250028-032 1
2 replacement element kit for air/fluid separator 250025-264 ..............250028-033 1
3 replacement element kit for air filter 02250111-680......................... 02250111-804 1
4 filter, clean air inlet option es6 .........................................................02250172-109 1
KITS:
5 repair kit for motor shaft seal 02250100-823 .....................................250028-035 1
6 repair kit, shaft seal installation..........................................................250034-267 1
7 repair kit for thermostat actuator 250025-413 ...................................250028-036 1
8 repair kit for solenoid valve 02250125-655......................................02250160-743 1
• replacement coil for solenoid valve 02250125-655 .......................02250125-856 1
9 repair kit for regulator valve 250017-280...........................................250019-453 1
10 repair kit for minimum pressure/check valve 604131 ........................250030-226 1
11 replacement piston seal kit for air inlet control valve ......................02250045-287 1
12 replacement piston for inlet control valve ........................................02250044-811 1
13 replacement washer for inlet control valve ......................................02250045-287 1
14 repair kit for ES-6 1/2" npt service connection 250026-066 ..............250030-103 1
15 kit, hose es6 dryer srs 25-35 ...........................................................02250172-758 1
16 kit, hose es6 dryer srs 50-75 ...........................................................02250172-759 1
17 pre-filter, replacement for dryer scf-40n/b .......................................02250153-289 1
18 pre-filter, replacement for dryer scf-65n/b........................................02250153-290 1
19 pre-filter, replacement for dryer scf-125n/b......................................02250153-291 1
...............................................................................Continued on page 49
48
ES-6 USER MANUAL Section 7 - MAINTENANCE PARTS LIST
FLUIDS:
20 fluid, Sullube (one gallon) ..................................................................250009-396 (I)
21 fluid, Sullube (five gallons).................................................................250022-669 (I)
22 fluid, 24 KT (5 gallons).....................................................................02250051-153 (I)
23 fluid, SRF 1/4000 (5 gallons) .............................................................250019-662 (I)
(I) For proper amount of fluid fill, please consult Lubrication Guide in Section 3, Specifications.
49
NOTES
WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A.
Sullair Road, No. 1 Zone Des Granges BP 82
Chiwan, Shekuo 3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A 42602 Montbrison, France
Shenzhen, Guangdong PRV. Telephone: 33-477968470
PRC POST CODE 518068 www.sullair.com
Telephone: 1-800-SULLAIR (U.S.A. only) Fax: 33-477968499
Telephone: 755-6851686 www.sullaireurope.com
Fax: 755-6853473 Fax: 219-874-1273
www.sullair-asia.com
CUSTOMER CARE
for PARTS and Service
1-888-SULLAIR (7855247)
219-874-1835