Manual St5508

OPERATION & MAINTENANCE MANUAL
ST45, ST55, ST75

U.S.A. & Mexico
PART NUMBER:
88292021-240 R01
SAFETY WARNING WARRANTY NOTICE The information in this manual is current as of its
publication date and applies to compressor models
indicated on this cover with serial number:
Users are required to read the Failure to follow the instructions
entire User Manual before han- and procedures in this manual,
37217040260
and all subsequent serial numbers until next revision of
dling or using the product. Keep or misuse of this equipment, will this manual or release of a replacement manual..
the User Manual in a safe place void its warranty.
for future reference. Publication date: 08/31/2018
Copyright © 2018 Sullair, LLC. All rights reserved.
Subject to EAR, ECCN EAR99 and related export control restrictions.

Service Training Courses
Sullair training courses provide hands-on and classroom instruction for the proper operation, maintenance, and
servicing of Sullair products. Individual courses on Stationary compressors, variable speed drives, compressor
electrical systems, and dryers are offered at regular intervals throughout the year at Sullair’s training facility located
in Michigan City, Indiana.
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These courses are recommended for distributor
service personnel. There is also a basic Stationary compressor course available for end-users.
For details on course offerings, outlines, schedules, and cost information contact:
Sullair Training Department

1-888-SULLAIR or
219-879-5451 (ext. 5623)
training@sullair.com
www.SullairTraining.com
- Or Write -
Sullair
1 Sullair Way
Michigan City, IN 46360
Attn: Training Department

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual Table of Contents
Table of Contents
Section 1: Safety.......................................................................................................7
1.1 General............................................................................................................................................ 7
1.2 Personal protective equipment ........................................................................................................ 7
1.3 Pressure release ............................................................................................................................. 7
1.4 Fire and explosion ........................................................................................................................... 8
1.5 Moving parts .................................................................................................................................... 8
1.6 Hot surfaces, sharp edges and sharp corners................................................................................. 9
1.7 Toxic and irritating substances ........................................................................................................ 9
1.8 Electrical shock................................................................................................................................ 9
1.9 Lifting ............................................................................................................................................. 10
1.10 Entrapment .................................................................................................................................... 10
1.11 Implementation of lockout/tagout................................................................................................... 11
1.12 Safety warnings ............................................................................................................................. 12
1.13 Safety decals ................................................................................................................................. 13
Section 2: Description............................................................................................15
2.1 The air compression cycle............................................................................................................. 15
2.2 Air inlet system .............................................................................................................................. 17
2.2.1 General operation of the air inlet system ............................................................................ 17
2.2.2 Air filter................................................................................................................................ 17
2.2.2.1 Air filter element ........................................................................................................ 17
2.2.3 Inlet valve............................................................................................................................ 17
2.2.3.1 Inlet modulation ......................................................................................................... 17
2.3 Discharge system .......................................................................................................................... 17
2.3.1 General operation of the discharge system ........................................................................ 17
2.3.2 Minimum pressure valve ..................................................................................................... 18
2.3.3 Automatic blowdown valve.................................................................................................. 18
2.3.4 Pressure relief valve ........................................................................................................... 18
2.3.5 Aftercooler .......................................................................................................................... 18
2.3.6 Moisture separator .............................................................................................................. 18
2.4 Lubrication system......................................................................................................................... 18
2.4.1 General description of the lubrication system ..................................................................... 18
2.4.2 Lubricating fluid................................................................................................................... 18
2.4.3 Fluid filter ............................................................................................................................ 19
2.4.3.1 Fluid filter element ..................................................................................................... 19
2.4.4 Purge oil return line............................................................................................................. 19
2.5 Cooling system .............................................................................................................................. 19
2.5.1 General description of the cooling system .......................................................................... 19
88292021-240 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 3
Table of Contents ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
2.5.2 Ambient temperature .......................................................................................................... 19

2.5.2.1 High ambient temperature and overheating .............................................................. 19
2.6 Fluid/air separation system ........................................................................................................... 19
2.6.1 General description of the fluid/air separation system........................................................ 19
2.6.2 Fluid/air separator tank ....................................................................................................... 20
2.6.2.1 Fluid filler port and sight glass................................................................................... 20
2.6.2.2 Separator tank condensation—low operating temperature ....................................... 20
2.6.3 Fluid/air separator element ................................................................................................. 20
2.7 Microprocessor control system...................................................................................................... 20
Section 3: Specifications....................................................................................... 21
3.1 Machine specifications .................................................................................................................. 21
3.2 Lubricant specifications ................................................................................................................. 21
3.3 Piping and instrumentation............................................................................................................ 22
Section 4: Installation ............................................................................................ 25

4.1 Compressor pre-installation .......................................................................................................... 25
4.2 Guidelines for lifting and moving the compressor ......................................................................... 25
4.2.1 Guidelines for moving the compressor with a forklift .......................................................... 25
4.2.2 Guidelines for moving the compressor with a crane........................................................... 25
4.3 Compressor installation................................................................................................................. 25
4.3.1 Physical installation requirements ...................................................................................... 25
4.3.2 Heat rejection and ventilation requirements ....................................................................... 26
4.3.2.1 Poorly ventilated areas.............................................................................................. 26
4.3.2.2 Additional considerations for multiple compressor installations ................................ 26
4.3.2.3 Ventilation and existing high ambient temperature ................................................... 26
4.4 Connection to the air system......................................................................................................... 26
4.5 Mechanical checks ........................................................................................................................ 26
4.5.1 Checking the motor to air end coupling .............................................................................. 26
4.5.2 Checking the air end........................................................................................................... 26
4.5.2.1 Checking the air end of a new machine .................................................................... 27
4.5.3 Checking the compressor fluid level ................................................................................... 27
4.5.4 Checking the isolation gate valve ....................................................................................... 27
4.6 Electrical checks............................................................................................................................ 27
4.6.1 Power supply requirements ................................................................................................ 27
4.6.2 Checking the motor rotation direction ................................................................................. 27
Section 5: Operation .............................................................................................. 29

5.1 Compressor protection features .................................................................................................... 29
5.1.1 Stop run-on timer ................................................................................................................ 29
5.1.2 Emergency stop.................................................................................................................. 29
5.2 Starting the compressor for the first time ...................................................................................... 29
5.3 Starting the compressor ................................................................................................................ 30
5.4 Shutting down the compressor...................................................................................................... 30
5.5 Electronic controller....................................................................................................................... 30
5.6 High temperature shutdown .......................................................................................................... 30
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ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual Table of Contents
5.7 Motor overload protection.............................................................................................................. 30

5.8 Phase failure/reversal.................................................................................................................... 31
5.9 Run-on timer.................................................................................................................................. 31
Section 6: Maintenance..........................................................................................33
6.1 General.......................................................................................................................................... 33
6.2 Daily maintenance ......................................................................................................................... 33
6.2.1 Before starting the compressor........................................................................................... 33
6.2.2 After starting the compressor.............................................................................................. 33
6.3 Recommended maintenance schedule ......................................................................................... 33
6.3.1 Service at 50 operating hours ............................................................................................. 33
6.3.2 Service every 1000 operating hours ................................................................................... 34
6.3.3 Service every 2000 operating hours ................................................................................... 34
6.3.4 Service every 2000 operating hours (or six months) .......................................................... 34
6.3.5 Service every 4000 operating hours (or semi-annually) ..................................................... 34
6.3.6 Service every 10,000 hours ................................................................................................ 34
6.3.7 Compressor fluid levels....................................................................................................... 34
6.4 Compressor maintenance ............................................................................................................. 35
6.4.1 Adding compressor fluid ..................................................................................................... 35
6.4.2 Changing compressor fluid ................................................................................................. 35
6.4.3 Fluid filter maintenance....................................................................................................... 36
6.4.3.1 Replacing the fluid filter element ............................................................................... 36
6.4.4 Air filter maintenance .......................................................................................................... 36
6.4.4.1 Replacing the air filter element .................................................................................. 37
6.4.4.2 Inspecting the air filter element ................................................................................. 37
6.4.5 Purge oil return line filter maintenance ............................................................................... 37
6.4.6 Fluid/air separator maintenance ......................................................................................... 37
6.4.6.1 Replacing the fluid/air separator element .................................................................. 37
6.4.7 Minimum pressure valve maintenance .............................................................................. 38
6.4.8 Solenoid valve maintenance ............................................................................................... 39
6.4.9 Drive coupling maintenance................................................................................................ 39
6.5 Main motor operation and maintenance ........................................................................................ 39
6.5.1 Main motor operation .......................................................................................................... 39
6.5.2 Main motor maintenance and repair ................................................................................... 40
6.5.3 Periodic inspection of the main motor................................................................................. 40
6.5.3.1 Periodic inspection checklist ..................................................................................... 40
6.5.4 Check and clean the windings ............................................................................................ 40
6.5.4.1 Dry cloth .................................................................................................................... 40
6.5.4.2 Brush and vacuum .................................................................................................... 41
6.5.4.3 Compressed air ......................................................................................................... 41
6.5.4.4 Solvent ...................................................................................................................... 41
6.6 Troubleshooting............................................................................................................................. 41
Section 7: Parts List ...............................................................................................43

7.1 Procedure for ordering parts.......................................................................................................... 43
7.2 Recommended spare parts list...................................................................................................... 44
88292021-240 R01
Table of Contents ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
7.3 Motor and air end system.............................................................................................................. 46

7.4 Air inlet system .............................................................................................................................. 50
7.5 Fluid piping system........................................................................................................................ 52
7.6 Cooling fan system........................................................................................................................ 54
7.7 Fluid/air separation system ........................................................................................................... 56
7.8 Air discharge system ..................................................................................................................... 60
7.9 Control system .............................................................................................................................. 62
7.10 Starter assembly ........................................................................................................................... 66
7.11 Enclosure ...................................................................................................................................... 70
7.12 Decal locations .............................................................................................................................. 72
Appendix A: Nominal Sizes................................................................................... 75
88292021-240 R01
ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 1: Safety
Section 1
Safety
most compressors and the concepts behind these state-
NOTE ments are generally applicable to all compressors.
1.2 Personal protective equipment

A. Prior to installing or operating the compressor, own-
ers, employers and users should become familiar
with, and comply with, all applicable OSHA regula-
Operator is required to read tions and/or any applicable Federal, State and Local
entire instruction manual. codes, standards, and regulations relative to per-
sonal protective equipment, such as eye and face
protective equipment, respiratory protective equip-
1.1 General ment, equipment intended to protect the extremities,
protective clothing, protective shields and barriers
Sullair and its subsidiaries design and manufacture all of
and electrical protective equipment, as well as noise
their products so they can be operated safely. However,
exposure administrative and/or engineering controls
the responsibility for safe operation rests with those who
and/or personal hearing protective equipment.
use and maintain these products. The following safety
precautions are offered as a guide which, if conscien-
tiously followed, will minimize the possibility of accidents
throughout the useful life of this equipment.
1.3 Pressure release
A. Install an appropriate flow-limiting valve between the
The compressor should be operated only by those who service air outlet and the shut-off (throttle) valve,
have been trained and delegated to do so, and who have either at the compressor or at any other point along
read and understood this Operator’s Manual. Failure to the air line, when an air hose exceeding ½″ (13 mm)
follow the instructions, procedures and safety inside diameter is to be connected to the shut-off
precautions in this manual may result in accidents and (throttle) valve, to reduce pressure in case of hose
injuries. NEVER start the compressor unless it is safe to failure, per OSHA Standard 29 CFR 1926.302(b)(7)
do so. DO NOT attempt to operate the compressor with a and/or any applicable Federal, State and Local
known unsafe condition. Tag the compressor and render codes, standards and regulations.
it inoperative by disconnecting and locking out all power
at source or otherwise disabling its prime mover so B. When the hose is to be used to supply a manifold,
others who may not know of the unsafe condition cannot install an additional appropriate flow-limiting valve
attempt to operate it until the condition is corrected. between the manifold and each air hose exceeding
½″ (13 mm) inside diameter that is to be connected
Install, use and operate the compressor only in full to the manifold to reduce pressure in case of hose
compliance with all pertinent OSHA regulations and/or failure.
any applicable Federal, State, and Local codes,
standards and regulations. DO NOT modify the C. Provide an appropriate flow-limiting valve at the
compressor and/or controls in any way except with beginning of each additional 75 feet (23 m) of hose in
written factory approval. runs of air hose exceeding ½″ (13 mm) inside diame-
ter to reduce pressure in case of hose failure.
While not specifically applicable to all types of compres-
sors with all types of prime movers, most of the precau- D. Flow-limiting valves are listed by pipe size and flow-
tionary statements contained herein are applicable to rated. Select appropriate valves accordingly, in
88292021-240 R01
1: Safety ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
accordance with their manufacturer's recommenda- material. Any acoustical material with a protective
tions. covering that has been torn or punctured should be
replaced immediately to prevent accumulation of liq-
E. DO NOT use air tools that are rated below the maxi-
uids or fluid film within the material. DO NOT use
mum rating of the compressor. Select air tools, air
flammable solvents for cleaning purposes.
hoses, pipes, valves, filters and other fittings accord-
ingly. DO NOT exceed manufacturer’s rated safe D. Disconnect and lock out all power at source prior to
operating pressures for these items. attempting any repairs or cleaning of the compressor
or of the inside of the enclosure, if any.
F. Secure all hose connections by wire, chain or other
suitable retaining device to prevent tools or hose E. Keep electrical wiring, including all terminals and
ends from being accidentally disconnected and pressure connectors in good condition. Replace any
expelled. wiring that has cracked, cut, abraded or otherwise
degraded insulation, or terminals that are worn, dis-
G. Open fluid filler cap only when compressor is not run-
colored or corroded. Keep all terminals and pressure
ning and is not pressurized. Shut down the compres-
connectors clean and tight.
sor and bleed the receiver tank to zero internal
pressure before removing the cap. F. Keep grounded and/or conductive objects such as
tools away from exposed live electrical parts such as
H. Vent all internal pressure prior to opening any line, fit-
terminals to avoid arcing which might serve as a
ting, hose, valve, drain plug, connection or other
source of ignition.
component, such as filters and line oilers, and before
attempting to refill optional air line anti-icer systems G. Remove any acoustical material or other material
with antifreeze compound. that may be damaged by heat or that may support
combustion and is in close proximity, prior to attempt-
I. Keep personnel out of line with and away from the
ing weld repairs.
discharge opening of hoses or tools or other points of
compressed air discharge. H. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when servicing
J. DO NOT use air at pressures higher than 2.1 bar for
and operating the compressor.
cleaning purposes, and then only with effective chip
guarding and personal protective equipment per I. Keep oily rags, trash, leaves, litter or other combusti-
OSHA Standard 29 CFR 1910.242(b) and/or any bles out of and away from the compressor.
applicable Federal, State, and Local codes, stan-
J. DO NOT operate the compressor without proper flow
dards and regulations.
of cooling air or water or with inadequate flow of lubri-
K. DO NOT engage in horseplay with air hoses as cant or with degraded lubricant.
death or serious injury may result.
K. DO NOT attempt to operate the compressor in any
classification of hazardous environment unless the
compressor has been specially designed and manu-
1.4 Fire and explosion factured for that duty.
A. Clean up spills of lubricant or other combustible sub-
stances immediately, if such spills occur.
B. Shut off the compressor and allow it to cool. Then
1.5 Moving parts
keep sparks, flames and other sources of ignition A. Keep hands, arms and other parts of the body and
away and DO NOT permit smoking in the vicinity clothing away from couplings, belts, pulleys, fans and
when checking or adding lubricant or when refilling other moving parts.
air line anti-icer systems with antifreeze compound.
B. DO NOT attempt to operate the compressor with the
C. DO NOT permit fluids, including air line anti-icer sys- fan, coupling or other guards removed.
tem antifreeze compound or fluid film, to accumulate
C. Wear snug-fitting clothing and confine long hair when
on, under or around acoustical material, or on any
working around this compressor, especially when
external surfaces of the air compressor. Wipe down
exposed to hot or moving parts.
using an aqueous industrial cleaner or steam clean
as required. If necessary, remove acoustical mate- D. Keep access doors, if any, closed except when mak-
rial, clean all surfaces and then replace acoustical ing repairs or adjustments.
88292021-240 R01
E. Make sure all personnel are out of and/or clear of the B. DO NOT use air line anti-icer systems in air lines
compressor prior to attempting to start or operate it. supplying respirators or other breathing air utilization
equipment and DO NOT discharge air from these
F. Disconnect and lock out all power at source and ver-
systems into unventilated or other confined areas.
ify at the compressor that all circuits are de-ener-
gized to minimize the possibility of accidental start- C. Operate the compressor only in open or adequately
up, or operation, prior to attempting repairs or adjust- ventilated areas.
ments. This is especially important when compres-
D. Locate the compressor or provide a remote inlet so
sors are remotely controlled.
that it is not likely to ingest exhaust fumes or other
G. Keep hands, feet, floors, controls and walking sur- toxic, noxious or corrosive fumes or substances.
faces clean and free of fluid, water or other liquids to
E. Coolants and lubricants used in this compressor are
minimize the possibility of slips and falls.
typical of the industry. Care should be taken to avoid
accidental ingestion and/or skin contact. In the event
of ingestion, seek medical treatment promptly. Wash
1.6 Hot surfaces, sharp edges and with soap and water in the event of skin contact.
sharp corners Consult Material Safety Data Sheet for information
A. Avoid bodily contact with hot fluid, hot coolant, hot pertaining to fluid of fill.
surfaces and sharp edges and corners. F. Wear goggles or a full face shield when adding anti-
B. Keep all parts of the body away from all points of air freeze compound to air line anti-icer systems.
discharge. G. If air line anti-icer system antifreeze compound
C. Wear personal protective equipment including gloves enters the eyes or if fumes irritate the eyes, they
and head covering when working in, on or around the should be washed with large quantities of clean
compressor. water for fifteen minutes. A physician, preferably an
eye specialist, should be contacted immediately.
D. Keep a first aid kit handy. Seek medical assistance
promptly in case of injury. DO NOT ignore small cuts H. DO NOT store air line anti-icer system antifreeze
and burns as they may lead to infection compound in confined areas.
I. The antifreeze compound used in air line antifreeze
systems contains methanol and is toxic, harmful or
1.7 Toxic and irritating substances fatal if swallowed. Avoid contact with the skin or eyes
A. DO NOT use air from this compressor for respiration and avoid breathing the fumes. If swallowed, induce
(breathing) except in full compliance with OSHA vomiting by administering a tablespoon of salt, in each
Standards 29 CFR 1910 and/or any applicable Fed- glass of clean, warm water until vomit is clear, then
eral, State or Local codes or regulations. 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.
DANGER
1.8 Electrical shock
A. This compressor should be installed and maintained
in full compliance with all applicable Federal, State
and Local codes, standards and regulations, includ-
ing those of the National Electrical Code, and also
including those relative to equipment grounding con-
ductors, and only by personnel that are trained, qual-
Death or serious injury can result from inhaling ified and delegated to do so.
compressed air without using proper safety
equipment. See OSHA standards and/or any B. Keep all parts of the body and any hand-held tools or
applicable Federal, State, and Local codes, stan- other conductive objects away from exposed live
dards and regulations on safety equipment. parts of electrical system. Maintain dry footing, stand
on insulating surfaces and DO NOT contact any
other portion of the compressor when making adjust-
88292021-240 R01
ments or repairs to exposed live parts of the electrical D. Make sure lifting hook has a functional safety latch or
system. Make all such adjustments or repairs with equivalent, and is fully engaged and latched on the
one hand only, so as to minimize the possibility of bail or slings.
creating a current path through the heart.
E. Use guide ropes or equivalent to prevent twisting or
C. Attempt repairs in clean, dry and well lighted and swinging of the compressor once it has been lifted
ventilated areas only. clear of the ground.
D. DO NOT leave the compressor unattended with open F. DO NOT attempt to lift in high winds.
electrical enclosures. If necessary to do so, then discon-
G. Keep all personnel out from under and away from the
nect, lock out and tag all power at source so others will
compressor whenever it is suspended.
not inadvertently restore power.
H. Lift compressor no higher than necessary.
E. Disconnect, lock out, and tag all power at source
prior to attempting repairs or adjustments to rotating I. Keep lift operator in constant attendance whenever
machinery and prior to handling any ungrounded compressor is suspended.
conductors.
J. Set compressor down only on a level surface capa-
ble of safely supporting at least its weight and its
loading unit.
DANGER
K. When moving the compressor by forklift truck, utilize
All field equipment must be tested for electro- fork pockets if provided. Otherwise, utilize pallet if
static fields prior to servicing or making contact provided. If neither fork pockets or pallet are pro-
with the machine using the following or equiva- vided, then make sure compressor is secure and well
lent test equipment: balanced on forks before attempting to raise or trans-
port it any significant distance.
• 90 – 600 VAC: Volt detector such as
Fluke Model 1AC-A L. Make sure forklift truck forks are fully engaged and
tipped back prior to lifting or transporting the com-
• 600 – 7000 VAC: Voltage detector such pressor.
as Fluke Networks Model C9970
It is the responsibility of each organization to M. Forklift no higher than necessary to clear obstacles
provide/arrange training for all their associates at floor level and transport and corner at minimum
expected to test for electrostatic fields. practical speeds.
N. Make sure pallet-mounted compressors are firmly
bolted or otherwise secured to the pallet prior to
attempting to forklift or transport them. NEVER
1.9 Lifting attempt to forklift a compressor that is not secured to
A. If the compressor is provided with a lifting bail, then its pallet, as uneven floors or sudden stops may
lift by the bail provided. If no bail is provided, then lift cause the compressor to tumble off, possibly causing
by sling. Compressors to be air-lifted by helicopter serious injury or property damage in the process.
must not be supported by the lifting bail but by slings
instead. In any event, lift and/or handle only in full
compliance with OSHA standards 29 CFR 1910 sub- 1.10 Entrapment
part N and/or any applicable Federal, State, and
A. If the compressor enclosure, if any, is large enough
Local codes, standards and regulations.
to hold a man and if it is necessary to enter it to per-
B. Inspect points of attachment for cracked welds and form service adjustments, inform other personnel
for cracked, bent, corroded or otherwise degraded before doing so, or else secure and tag the access
members and for loose bolts or nuts prior to lifting. door in the open position to avoid the possibility of
others closing and possibly latching the door with
C. Make sure entire lifting, rigging and supporting struc-
personnel inside.
ture has been inspected, is in good condition and has
a rated capacity of at least the weight of the com- B. Make sure all personnel are out of compressor
pressor. If you are unsure of the weight, then weigh before closing and latching enclosure doors.
compressor before lifting.
88292021-240 R01
1.11 Implementation of lockout/tagout their own padlock and have possession of

the only key. If more than one person is
The energy control procedure defines actions necessary working on a machine each person shall affix
to lockout a power source of any machine to be repaired, personal lock and tag using a multi-lock
serviced or set-up, where unexpected motion, or an device.
electrical or other energy source, would cause personal
injury or equipment damage. The power source on any 7. Tagout devices shall be used only when
machine shall be locked out by each employee doing the power sources are not capable of being
work except when motion is necessary during setup, locked out by use of padlocks and lockout
adjustment or trouble-shooting. hasp devices. The name of the person affix-
ing tag to power source must be on tag along
A. The established procedures for the application of with date tag was placed on power source.
energy control shall cover the following elements and 8. Release stored energy and bring the equip-
actions and shall be initiated only by Authorized Per- ment to a “zero mechanical state”.
sons and done in the following sequence:
9. Verify Isolation: Before work is started, test
1. Review the equipment or machine to be equipment to ensure power is disconnected.
locked and tagged out.
B. General Security
2. Alert operator and supervisor of which
machine is to be worked on, and that power 1. The lock shall be removed by the “Autho-
and utilities will be turned off. rized” person who put the lock on the
3. Check to make certain no one is operating energy-isolating device. No one other than
the machine before turning off the power. the person/persons placing padlocks and
lockout hasps on power shall remove pad-
4. Turn off the equipment using normal shut- lock and lockout hasps and restore power.
down procedure. However, when the authorized person who
5. Disconnect the energy sources: applied the lock is unavailable to remove it
a. Air and hydraulic lines should be bled, his/her Supervisor may remove padlock/pad-
drained and cleaned out. There should locks and lockout hasps and restore power
be no pressure in these lines or in the only if it is first:
reservoir tanks. Lockout or tag lines or a. verified that no person will be exposed to
valves. danger.
b. Any mechanism under tension or pres- b. verified that the “Authorized” person who
sure, such as springs, should be applied the device is not in the facility.
released and locked out or tagged. c. noted that all reasonable efforts to con-
c. Block any load or machine part prior to tact the “Authorized” person have been
working under it. made to inform him or her that the lock-
d. Electrical circuits should be checked with out or tagout device has been removed.
calibrated electrical testing equipment d. ensured that the “Authorized” person is
and stored energy and electrical capaci- notified of lock removal before returning
tors should be safely discharged. to work.
6. Lockout and/or Tagout each energy source 2. Tagout System—Tags are warning devices
using the proper energy isolating devices affixed at points of power disconnect and are
and tags. Place lockout hasp and padlock or not to be removed by anyone other that the
tag at the point of power disconnect where person placing tag on power lockout. Tags
lockout is required by each person perform- shall never be by-passed, ignored, or other-
ing work. Each person shall be provided with wise defeated.
88292021-240 R01
1.12 Safety warnings

The following special instructions apply to VSD packages WARNING
provided with electronic adjustable speed motor drives.
These cautions that apply to VSD operation. Before opening the variable speed drive covers:
• Disconnect all power to the variable
speed drive.
WARNING
• Wait a minimum of 15 minutes after all
the lights on the keypad are off. This
Ground the unit following the instructions in this
allows time for the DC bus capacitors
manual. Ungrounded units may cause electric
to discharge.
shock and/or fire. The variable speed drive has a
large capacitive leakage current during opera- • A hazard voltage may still remain in
tion, which can cause enclosure parts to be the DC bus capacitors even if the
above ground potential. Proper grounding, as power has been turned off. Confirm
described in this manual, is required. Failure to that the capacitors have fully dis-
observe this precaution could result in death or charged by measuring their voltage
severe injury. using a multimeter set to measure DC
voltage. Failure to follow the above
precautions may cause death or
severe injury.
WARNING
Before applying power to the variable speed
drive, make sure that the front and cable covers
CAUTION
are closed and fastened to prevent exposure to
potential electrical fault conditions. Failure to Do not perform any megger or voltage withstand
observe this precaution could result in death or tests on any part of the variable speed drive or
severe injury. its components. Improper testing may result in
damage. Prior to any tests or measurements of
the motor or the motor cable, disconnect the
motor cable at the variable speed drive output
WARNING terminals (U, V, W) to avoid damaging the vari-
able speed drive during motor or cable testing.
Refer all drive service to trained technicians.
This equipment should be installed, adjusted,
and serviced by qualified electrical maintenance
personnel familiar with the construction and
CAUTION
operation of this type of equipment and the haz-
ards involved and in accordance with published Do not touch any components on the circuit
service manuals. Failure to observe this precau- boards. Static voltage discharge may damage
tion could result in death or severe injury. the components.
WARNING
Line terminals (L1, L2, L3), motor terminals (U,
V, W) and the DC link/brake resistor terminals (-/
+) are live when the drive is connected to power,
even if the motor is not running. Contact with
this voltage is extremely dangerous and may
cause death or severe injury.
88292021-240 R01
CAUTION NOTE
Customer must provide electrical supply power
Install the variable speed drive in a well venti- disconnect within sight of machine.
lated room that is not subject to temperature
extremes, high humidity, or condensation, and
avoid locations that are directly exposed to sun-
light, or have high concentrations of dust, corro- 1.13 Safety decals
sive gas, explosive gas, inflammable gas,
grinding fluid mist, etc. Improper installation may
result in a fire hazard. WARNING
Auto start hazard
CAUTION This machine is equipped with an
auto start sequence that will start
Make sure that no power correction capacitors the unit when power is restored
are connected to the variable speed drive output after a power failure or as part of
or the motor terminals to prevent variable speed automatic operation, which can
drive malfunction and potential damage. result in serious injury or death.
Do not attempt to make any adjustments or per-
form any maintenance on this machine without
disconnecting both main line and control circuit
CAUTION electrical power and follow all of your company’s
prescribed safety practices for electrical equip-
Make sure that the variable speed drive output ment.
terminals (U, V, W) are not connected to the util-
ity line power as severe damage to the VSD may
occur.
NOTE
Interior electrical wiring is performed at the fac-
tory. Required customer wiring is minimal, but
should be done by a qualified electrician in com-
pliance with OSHA, National Electrical Code,
and/or any other applicable State, Federal, and
local electrical codes concerning isolation
switches, fused disconnects, etc. Sullair pro-
vides a wiring diagram for use by the installer.
88292021-240 R01
Notes:
88292021-240 R01
ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 2: Description
Section 2
Description
2.1 The air compression cycle force, impingement, and gravity. Then the compressed
air passes through the fluid/air separator element to
The ShopTek™ air compressor uses a lubricated rotary
remove almost all of the remaining fluid.
screw air end and supporting components to create com-
pressed air. Next, the compressed air flows through the aftercooler.
The aftercooler cools the compressed air to 8 – 12°C
When the rotors inside the air end turn, they draw outside
(14 – 22°F) above the ambient temperature. The com-
air into the compressor through the air inlet system. As
pressed air then flows through the moisture separator (if
the rotors compress this air from atmospheric pressure to
installed). The moisture separator collects the water
the target pressure, the lubrication system injects fluid
vapor that condensed when the compressed air was
into the air end to cool the compressed air, lubricate the
cooled.
rotors and bearings, and create a seal between the rotors
and the air end casing. After leaving the aftercooler (or the moisture separator, if
installed), the compressed air flows through the service
After leaving the air end, the compressed air/fluid mixture
connector of the compressor for downstream use.
flows into the fluid/air separation system. First, the fluid/
air separator tank separates the majority of the fluid from
the compressed air using a combination of centrifugal
88292021-240 R01
2: Description ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
1. Enclosure 5. Air inlet system

2. Electric control system 6. Motor & air end
3. Cooling fan system 7. Fluid/air separation system
4. Discharge system 8. Fluid piping system
Figure 2-1: ST45, ST55 & ST75 machine layout
88292021-240 R01
2.2 Air inlet system adjusts the size of the inlet valve opening to match air
demand. The primary components of the inlet modulation
The air inlet system provides air for the compressor to
system are the solenoid valve, inlet valve, blowdown
pressurize. The primary components of the air inlet sys-
valve, and control line.
tem are the air filter, inlet valve, and compressor air end.
When air demand is equal to or greater than the com-
2.2.1 General operation of the air inlet pressors rating, the compressor will run at full load. The
system solenoid valve is energized, closing the control line.
The air end draws outside air through the air filter and Because the control is not in use, the inlet valve of the air
inlet valve into the air end compression chamber. Inside end is fully open.
the compression chamber, a male and female rotor pair When air demand is lower than the compressor rating,
revolve at high speed, compressing the air and increas- discharge pressure builds up slowly. Once the discharge
ing its pressure. When the compressed air/fluid mixture pressure reaches the unload setting of the controller, the
reaches the end of the compression chamber, the mix- compressor will switch to unload mode. The solenoid
ture flows through the air end discharge port into the valve is de-energized, opening the control line. Because
fluid/air separator. the control line is in use and the discharge pressure is
high, the control line closes the inlet valve. At the same
2.2.2 Air filter time, the blowdown valve opens to release the pressure
The air filter removes particulates from the intake air, pro- in the fluid/air separator tank until the pressure stabilizes
viding clean air to the compressor. If these particulates at 15 – 25 psi.
were not removed, they could wear down rotor surfaces
and contaminate the compressor fluid. Now the compressor will run with no load for a preset
time. Once the preset time is reached, the compressor
2.2.2.1 Air filter element will stop. However, if the discharge pressure drops to the
load setting of the controller before the preset time is
Because the air filter element traps the particulates it fil-
reached, the compressor re-enters load mode. The sole-
ters from the air on its surface, the air filter element must
noid valve is energized, closing the control line. Because
be changed periodically to maintain the air filter’s effec-
the control is not in use, the inlet valve of the air end is
tiveness.
fully open.
Additional information
• For the recommended air filter maintenance 2.3 Discharge system
schedule, see Section 6.3: Recommended
The discharge system pushes air from the compressor
maintenance schedule on page 33.
air end to the service connector. The primary compo-
• For instructions on how to change the air filter nents of the discharge system are the compressor air
element, see Section 6.4.4: Air filter mainte- end, fluid/air separator, minimum pressure valve, pres-
nance on page 36. sure relief valve, automatic blowdown valve, aftercooler,
moisture separator (optional), and service connector.
WARRANTY NOTICE
2.3.1 General operation of the discharge
Failure to follow the air filter maintenance sched- system
ule or use Sullair genuine air filter elements can The compressed air/fluid mixture flows through the air
cause early contamination of the compressor end discharge port into the fluid/air separator tank and
fluid and the fluid/air separator element and may separator element. The separator tank and element
void your warranty. remove fluid from the air.
The compressed air then flows through the minimum
pressure valve, followed by the aftercooler, then the
2.2.3 Inlet valve moisture separator (if installed). Once the air is cooled
The inlet valve controls intake air volume using a modula- and the moisture removed (if the moisture separator is
tion control system. installed), the air flows to the service connector for down-
stream use.
2.2.3.1 Inlet modulation
To minimize the number of starts and stops the compres- To lower the frequency of the compressor’s load/unload
sor makes, the inlet modulation system automatically cycles and extend the life of the compressor, Sullair rec-
88292021-240 R01
ommends installing a wet air receiver after the service 2.3.6 Moisture separator
connector. The moisture separator removes the moisture from the
compressed air stream. Moisture collected by the mois-
Additional information ture separator can then be safely disposed of according
• For the size of the service connector, see Sec- to local regulations.
tion 3.1: Machine specifications on page 21.
2.3.2 Minimum pressure valve NOTE

The minimum pressure valve on the top cover of the fluid/
The moisture separator ships loose for the cus-
air separator ensures lubricant flow during both normal
tomer to install if needed for their installation. It is
operation and start-up by keeping pressure in the fluid/air
not installed by the factory.
separator above 340 kPa (49.3 psi).
When pressure in the fluid/air separator is above 340 kPa
(49.3 psi) and higher than the downstream pipeline pres-
sure, the minimum pressure valve will be opened. Other-
2.4 Lubrication system
wise, the minimum pressure valve will be closed to The lubrication system cools the compressor; lubricates
maintain minimum tank pressure. the rotors, bearings, and gears; and seals the air end
against leaks. The primary components of the lubrication
The minimum pressure valve also functions as a check system are the compressor air end, fluid/air separator,
(non-return) valve, preventing compressed air down- thermal valve, aftercooler, fluid filter, and interconnecting
stream of the separator from flowing back into the sep- piping.
arator and air end during compressor blowdown.
2.4.1 General description of the lubrication
2.3.3 Automatic blowdown valve system
When the compressor is unloading or stopping, the blow- Fluid is injected into the air end compression chamber,
down valve in the control line automatically opens to where it is compressed along with the intake air. The
release pressure. The blowdown valve routes the air to compressed air/fluid mixture then flows into the fluid/air
the air inlet pipe (after the air filter) to prevent a com- separation system, which separates the fluid from the air
pressed air/fluid mixture from venting into the atmo- and collects the fluid for re-use. Depending on the fluid
sphere. temperature, the thermal valve routes none, some, or all
of the fluid to the aftercooler for cooling. Fluid that has
2.3.4 Pressure relief valve passed through the aftercooler, or that was not routed to
To prevent damage to the fluid/air separator and other the aftercooler, flows through the fluid filter into the air
compressor components the pressure relief valve located end to restart the lubrication cycle.
on the fluid/air separator tank will open when the pres-
sure in the separator tank exceeds the pressure relief 2.4.2 Lubricating fluid
valve setpoint. The lubricating fluid provides three benefits.
Under normal operating conditions, the over pressure • Cooling. The compressor fluid acts as a cool-
stop switch will shut down the compressor before the ant, absorbing the large amount of heat gener-
pressure relief valve setpoint is reached (see Section 3.1: ated during compression.
Machine specifications on page 21). However, the pres-
• Lubricating. The compressor fluid forms a
sure relief valve serves as an additional mechanical safe-
layer between the rotors, preventing the male
guard.
and female rotors from making direct contact
and minimizing the surface wear of the rotors.
2.3.5 Aftercooler The compressor fluid also lubricates the bear-
The aftercooler cools the compressed air to 8 – 12°C ings and gears.
(14 – 22°F) above the ambient temperature. This cooling
• Sealing. Compressor fluid with sufficient vis-
causes water vapor to condense, which creates moisture
cosity can fill the gaps between rotors and
in the compressed air stream.
between the rotors and the casing. This
reduces air lost through leakage and increases
the efficiency of the compressor.
88292021-240 R01
Additional information 2.5.2 Ambient temperature

• Sullair ShopTek™ compressors are designed to operate
• For the viscosity required for the compressor in ambient temperatures between 4°C and 40°C (40°F
fluid to act as a sealant, see Section 3.2: Lubri- and 104°F), measured at the cooling air inlet. If you need
cant specifications on page 21. to operate the compressor in a temperature outside this
range, contact your Sullair representative.
2.4.3 Fluid filter
The fluid filter collects any impurities in the compressor
2.5.2.1 High ambient temperature and
fluid and ensures that only clean fluid enters the air end
overheating
compression chamber and internal lubrication feeds. If If the ambient temperature is above 40°C (104°F), the air
these impurities in the fluid were not removed, they would drawn into the compressor may be too hot to adequately
cause wear on the rotor and gear surfaces and bearings cool the compressor fluid or the electric motor when the
and shorten the life of compressor. compressor is operating at full load. If the compressor
load is less than 100%, operating the compressor in
2.4.3.1 Fluid filter element higher ambient temperatures may be possible.
Because the fluid filter element collects impurities on its Regardless of the ambient temperature, the maximum
surface, the fluid filter element must be replaced regularly recommended operating temperature is 108°C (226°F).
to ensure good fluid circulation for proper lubrication and
cooling.
CAUTION
Additional information
• For the recommended fluid filter maintenance Continuously exceeding the maximum operating
schedule, see Section 6.3: Recommended temperature will damage the compressor.
maintenance schedule on page 33.
• For instructions on how to change the fluid filter
element, see Section 6.4.3: Fluid filter mainte-
nance on page 36. CAUTION
2.4.4 Purge oil return line In the event of a high operating temperature
The purge oil return line located on the cover of the fluid/ shutdown fault, do not attempt to restart the
air separator passes the compressor fluid collected by compressor without first finding and correcting
the fluid/air separator element through the purge line fil- the underlying cause. Contact your Sullair repre-
ter, then returns the clean fluid to the compressor air end. sentative for assistance.
A small orifice in the purge oil return line limits return air
flow, minimizing the loss of compressed air. A sight glass
located in the purge line allows an operator to observe 2.6 Fluid/air separation system
the amount of fluid returning from the separator element. The fluid/air separator system removes the fluid from the
compressed air stream. The primary components of the
fluid/air separation system are the fluid/air separator tank
2.5 Cooling system and fluid/air separator elements.
The cooling system maintains a proper operating tem-
perature for the compressor. 2.6.1 General description of the fluid/air
separation system
2.5.1 General description of the cooling The compressed air/fluid mixture from the air end flows
system into the fluid/air separator and strikes the wall of the sep-
Suction created by an axial flow cooling fan pulls cooling arator tank, causing large drops of fluid to form because
air through louvers on both sides of the compressor. This of the lower air speed. Most of these fluid drops attach to
cooling air draws heat from the aftercooler before flowing the wall of the tank, and gravity causes the drops to col-
out of the machine. lect at the bottom of the tank. The thermal valve then
routes this collected fluid back to the air end through the
aftercooler (if necessary) and the filter.
88292021-240 R01
After hitting the wall of the separator tank, the com- thermal valve set at the temperature required to evapo-
pressed air/fluid mixture then flows through the separator rate water.
element. The separator element removes fine fluid parti-
In areas where the ambient temperature is less than 4°C
cles. These particles accumulate at the bottom of the ele-
(40°F), you may need to take steps to prevent condensa-
ment and return to the air end through the purge oil return
tion. This may include fitting anti-condensation heaters to
line.
the separator vessel. For assistance in operating the
compressor in very low ambient temperatures, please
2.6.2 Fluid/air separator tank contact your Sullair representative.
In addition to separating the air from the fluid, the fluid/air
separator tank acts as a fluid reservoir, storing most of
2.6.3 Fluid/air separator element
the compressor fluid.
The fluid/air separator element removes fine fluid parti-
cles from the compressed air stream.
2.6.2.1 Fluid filler port and sight glass
The fluid/air separator tank is equipped with a fluid filler Over time, impurities in the lubrication system will clog
port and sight glass. Since trace amounts of compressor the fluid/air separator element, increasing the resistance
fluid remain in the discharged compressed air even after of the separator to compressed air flow. Because the
separation, over time the fluid level of the compressor will increased resistance will compromise the compressor’s
drop. You will need to monitor the fluid level and periodi- operation, the separator element needs to be replaced
cally add additional fluid to the tank. periodically.
Additional information Additional information

• For an explanation of how determine the fluid • For the recommended fluid/air separator ele-
level of the compressor, see Section 6.3.7: ment maintenance schedule, see Section 6.3:
Compressor fluid levels on page 34. Recommended maintenance schedule on page
33.
• For instructions on how to add compressor
fluid, see Section 6.4.1: Adding compressor • For instructions on how to change the fluid/air
fluid on page 35. separator element, see Section 6.4.6: Fluid/air
separator maintenance on page 37.
2.6.2.2 Separator tank condensation—low
operating temperature
In conditions of high humidity and low operating tempera- 2.7 Microprocessor control system
ture, water formed by condensation may collect in the The ShopTek™ compressor is equipped with a micropro-
compressor fluid. To ensure trouble-free operation, Sul- cessor controller. For detailed information on this control-
lair ShopTek™ compressors are fitted with an oil bypass ler, see EC2000 Controller Operation Manual.
88292021-240 R01
ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 3: Specifications
Section 3
Specifications
3.1 Machine specifications
Table 3-1: Compressor specifications
Model ST45 9 bar ST55 9 bar ST75 9 bar
Rated pressure 9 bar (125 psi) 9 bar (125 psi) 9 bar (125 psi)
Maximum working pressure 9.3 bar (135 psi) 9.3 bar (135 psi) 9.3 bar (135 psi)
Relief valve setpoint 10 bar (145 psi) 10 bar (145 psi) 10 bar (145 psi)
Voltage & frequency 460 V / 60 Hz
Air end type Single stage, oil injected rotary screw
Configuration Gear driven with external inlet modulation
Motor type ODP (IP23)
Motor rating 45 kW (60 hp) 55 kw (75 hp) 75 kW (100 hp)
Motor nominal speed 1775 rpm 1775 rpm 1775 rpm
Starting mode Y-∆ (Y-delta)
Service factor 1.25
Ambient temperature Between 4° and 40°C (40° and 104°F)
Lubricant Sullube®
Lubricant volume 33 L (8.7 gal)
Service connector NPT 2″
Moisture drain connector NPT ½″ (moisture separator shipped loose)
Machine weight 1563 kg (3446 lbs) 1708 kg (3765 lbs) 1822 kg (4017 lbs)
Machine dimensions (L × W × H) 2200 × 1260 × 1760 mm (86.6 × 49.6 × 69.3 in)
Package dimensions (L × W × H) 2350 × 1345 × 1975 mm (92.5 × 53.0 × 77.8 in)
3.2 Lubricant specifications Table 3-2: Lubricant specifications

The oil used as a lubricant in Sullair’s rotary screw com- Synthetic oils Ambient temperature
pressors must have the following properties:
Sullube® (factory fill) Up to 40°C (104°F)
• Low foaming
• Good resistance to emulsification
WARRANTY INFORMATION
• High oxidation resistance
• Viscosity of 10.5 cSt at the compressor’s oper- Mixing of fluids other than Sullube will void the
ating temperature compressor’s warranty.
88292021-240 R01
3: Specifications ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
3.3 Piping and instrumentation
88292020-840 R02
88292021-240 R01
3.3 Piping and instrumentation
ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
Key Description
1 FILTER,AIR INLET
2 INDICATOR,RESTRICTION
3 VALVE,AIR INLET CONTROL
4 COMPRESSOR UNIT
5 PROBE,THERMISTER
6 GAUGE,PRESSURE
7 TANK,FLUID/AIR SEPARATOR
8 ELEMENT,FLUID/AIR SEPARATOR PRIMARY
9 ELEMENT,FLUID/AIR SEPARATOR SECONDARY

10 VALVE,MINIMUM PRESSURE
11 TRANSDUCER,PRESSURE
12 COOLER,FLUID/AIR
13 SEPARATOR,MOISTURE
88292021-240 R01
14 VALVE, BLOWDOWN
15 FILTER,GENISIS
16 GLASS,SIGHT
17 ORIFICE,1/16"
18 ORIFICE,3/32"
19 VALVE,RELIEF
20 PLUG,SIGHT GLASS
21 PLUG,FLUID
22 VALVE,BALL
23 VALVE,THERMAL
24 FILTER,FLUID
25 INDICATOR,PRESSURE
26 ORIFICE, 1/4"
3: Specifications
23
3: Specifications ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
Notes:
88292021-240 R01
ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 4: Installation
Section 4
Installation
4.2.2 Guidelines for moving the
WARNING compressor with a crane
If a crane is used to move the compressor, ensure that
Incorrect installation or setup may void warranty. it’s rating is sufficient to lift the compressor’s weight (see
Section 3.1: Machine specifications on page 21).
When moving the compressor with a crane, lift the com-
4.1 Compressor pre-installation pressor with slings and use guide ropes to prevent twist-
ing. You should also use spreader bars to prevent panel
Before installing your ShopTek™ compressor, check it
damage.
carefully for any transportation damage. If you find any
damage, contact your Sullair representative immediately. When the compressor has been set down, check for
cracked welds and loose bolts or nuts.
4.2 Guidelines for lifting and moving

the compressor 4.3 Compressor installation
Sullair recommends using a forklift to move the compres- The ShopTek™ compressor is not weatherproof. The
sor. A crane can also be used. compressor should be installed inside (or in a sheltered
position outside).
NOTE
NOTE
A site assessment must be carried out to ensure
forklift or crane access for removal and servicing A site assessment must be carried out to ensure
of major components and compressor transport. forklift or crane access for removal and servicing
of major components and compressor transport.
4.2.1 Guidelines for moving the

compressor with a forklift 4.3.1 Physical installation requirements
When using a forklift to move the compressor, follow all Because the compressor must remain level at all times
local regulations for operating a forklift. In addition, Sullair (not more than 6 mm or ¼″ unevenness allowed), you
has several guidelines that must be followed. should install the compressor on a flat surface rated to
hold the compressor’s weight (see Section 3.1: Machine
• The forklift’s load rating must be sufficient to lift specifications on page 21). If you must install the com-
the compressor’s weight (see Section 3.1: pressor on an uneven surface, you can use shims to
Machine specifications on page 21) level the compressor. You do not need to bolt the com-
• The forklift must lift the compressor from the pressor in place.
front.
You must position the compressor so it has sufficient
• The fork tines must be correctly spaced. clearance on all sides (for the minimum distances
• The fork lift tines must be long enough to cover required, see the compressor’s ID drawing). If you have
the full depth of the compressor. more than one compressor installed at the same location,
• The fork tines must be fully engaged and tipped you must have clear access to each compressor. If you
back prior to lifting the compressor. need help correctly positioning your compressor, contact
your Sullair representative for assistance.
88292021-240 R01
4: Installation ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
4.3.2 Heat rejection and ventilation 4.4 Connection to the air system
requirements Sullair recommends installing an isolation gate valve
The compressor rejects a considerable amount of heat, immediately after the service connector to make installa-
so you must install it in a well-ventilated area. tion, service, and removal of the compressor easier.
Hot air from the cooling air discharge must not recirculate You must install a flexible connection between the
into the cooling air inlet. This recirculation can be caused compressor and the external pipe work. Because the
by installing the compressor in a room with a low ceiling internal components of the compressor are mounted on
or in a location where the cooling air is discharged past anti-vibration pads and are not rigidly supported, no load
the compressor’s cooling air inlet. In these situations, you should ever be transferred to the service connector of the
should follow the guidelines in Section 4.3.2.1: Poorly compressor.
ventilated areas.
IMPORTANT
Failure to install a flexible connection may result
Do not install the compressor in an area where in damage to the compressor and void your war-
exhaust fumes or other toxic, noxious, or corro- ranty.
sive fumes, chemicals, or substances can be
drawn into the air inlet.
The plant air line should have an internal diameter at
least the size of the service connector (for service con-
4.3.2.1 Poorly ventilated areas nector size, see Section 3.1: Machine specifications on
In a poorly ventilated area, the heated cooling air dis- page 21). For longer pipe runs, the pipe sizes should be
charged from the compressor can cause the ambient increased by one size to minimize pressure drop. Con-
temperature to rise above 40°C (104°F), which will cause densate from the pipe work should never flow towards
the compressor to overheat. Sullair recommends adding the compressor. One way of achieving this is to install
ductwork to route the cooling air discharge away from the mains pipe work adjacent to the compressor and below
compressor, possibly to another area or room. Any the service connector.
ductwork added (including the outlet grill) should not
cause a pressure drop greater than 30 Pa (.004 psi) Additional information
(contact Sullair Aftermarket prior to installation) and must • For the exact location of the service connector,
not apply any weight to the compressor cabinet. Sullair see the compressor’s ID drawing.
also recommends a section of the ductwork be remov-
able to allow easy access for servicing.
4.5 Mechanical checks
4.3.2.2 Additional considerations for multiple
compressor installations
In a multiple compressor installation, the air discharged WARNING
from one compressor must never flow into the intake of
another compressor.
Ensure that the compressor is electrically iso-
lated before performing any mechanical checks.
4.3.2.3 Ventilation and existing high ambient
temperature
If the compressor is in a location where existing environ- 4.5.1 Checking the motor to air end
mental conditions will cause the ambient temperature to coupling
exceed 40°C (104°F) even if the cooling air is adequately Ensure that the flexible drive coupling connecting the
dissipated (for example, in a boiler room), Sullair recom- motor and air end is correctly fastened.
mends following the guidelines in Section 4.3.2.1: Poorly
ventilated areas. 4.5.2 Checking the air end
Before a new machine is started for the first time, you
must check that the air end is not hydraulically locked.
88292021-240 R01
ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 4: Installation
4.5.2.1 Checking the air end of a new machine 4.6.2 Checking the motor rotation direction
Rotate the flexible drive coupling by hand through two For the motor to rotate in the correct direction, the power
complete revolutions in the direction indicated by the supply must be correctly connected.
arrows located on the air end and motor.
4.5.3 Checking the compressor fluid level WARNING

Open the front access panel just enough to view the sight
glass located on the separator tank, then follow the Never run the motor with the rotation direction
instructions in Section 6.3.7: Compressor fluid levels on reversed!
page 34 for how to check the compressor’s fluid level.
Motor rotation in the wrong direction can dam-
• If the fluid level is below the minimum fluid age the air end and may void your warranty.
level, see Section 6.4.1: Adding compressor
fluid on page 35.
You should check the rotation of the motor before starting
4.5.4 Checking the isolation gate valve up the compressor for use. Before checking the motor
If an isolation gate valve is installed in your air system, rotation direction, you must familiarize yourself with Sec-
make sure the valve is open. tion 5: Operation.
1. Pull out emergency stop (E-stop) button from
the monitor’s control panel.
4.6 Electrical checks 2. Press the Start button.
When performing any electrical work, refer to the electri-
3. Immediately press the E-Stop button.
cal diagram supplied with your compressor.
• This will cause the motor and air end to
All the compressor’s internal wiring is factory fitted and rotate momentarily, but not long enough to
tested. The required connection wiring is minimal, but it damage the air end if the motor rotation
must be performed by a licensed electrician. A licensed direction is reversed.
electrician must also review the electrical system to see
• If the phase sequence is wrong, a com-
that it is adequate for starting and running the compres-
pressor with a phase sequence protector
sor.
will not start and the controller will display
an error message.
4.6.1 Power supply requirements
4. Check that the motor and air end rotate in
• 460 VAC, 3-phase, 60 Hz with ground
the direction indicated by the arrows on the
• Control voltage: 110 VAC air end to motor drive coupling.
• If the motor and air end do not rotate in the
direction indicated by the arrows, the
incoming mains power leads need to be
reversed by a licensed electrician.
• Do not reverse any motor or starter wir-
ing. This wiring must not be modified.
88292021-240 R01
4: Installation ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
Notes:
88292021-240 R01
ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 5: Operation
Section 5
Operation
5.1 Compressor protection features guidelines in Section 4.3: Compressor instal-
lation and Section 4.4: Connection to the air
Your ShopTek™ compressor controller optimizes the per-
system.
formance of your system by adding additional electronic
protection to the motor and air end. 3. Perform all mechanical checks described in
Section 4.5.
5.1.1 Stop run-on timer 4. Open the isolation gate valve if it is installed.
This stop run-on timer provides a soft stop function, 5. If you are installing the compressor, perform
reducing the load on the air end before stopping the com- the motor rotation direction check described
pressor. When you press the Stop button, the compres- in Section 4.6.2.
sor will unload and then run for a period of time pre-set 6. Switch on the mains power (if it is not
by the factory, reducing the pressure in the separator already on).
tank, before coming to a complete stop.
7. Press the Start button.
5.1.2 Emergency stop • The compressor will start and switch from
Pressing the emergency stop (E-stop) button will stop the the Y start configuration to the delta run-
compressor immediately. ning configuration as it reaches full speed.
You must pull out the E-stop button to release it before

the compressor can be restarted. CAUTION
NOTE The compressor should always run smoothly. If

the compressor vibrates excessively while run-
You should always use the Stop button to stop ning, shut it down and contact your Sullair repre-
the compressor under normal circumstances. sentative immediately.
You should only use the E-stop button to stop
the compressor in an emergency. 8. Monitor the status of the compressor on the
controller display.
• Rising discharge air pressure and rising
5.2 Starting the compressor for the operating temperature indicate correct
operation (see Section 2.1: The air com-
first time pression cycle on page 15).
• On reaching the preset operating pressure,
NOTE the controller will unload the compressor
and the discharge air pressure will stop ris-
Also follow this procedure if the compressor has ing. The compressor will continue to run,
been out of service for more than 60 days or you but it will run unloaded.
have installed the compressor in a new location. 9. Run the compressor through a number of
load/unload cycles (bleed air from the plant
1. Read the preceding pages of this manual air system, if necessary) and check for con-
thoroughly. sistent operation, leaks (air or fluid), and a
stable operating temperature (see Section
2. If you are installing the compressor, confirm
2.5: Cooling system on page 19).
you have followed all the requirements and
88292021-240 R01
5: Operation ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
5.3 Starting the compressor 5.5 Electronic controller

If the compressor has been out of service for more than The EC2000 Controller Operation Manual describes the
60 days or you have installed the compressor in a new layout and explains the features of the ShopTek™ elec-
location, follow the steps under Section 5.2: Starting the tronic controller.
compressor for the first time instead of this procedure.
1. Open the isolation gate valve if it is installed.
WARNING
2. Press the Start button.
For safety reasons, the electronic controller
5.4 Shutting down the compressor pressure settings should never be adjusted to
anything other than the required settings for the
1. Press the Stop button.
serial plate nominal operating pressure. If you
• The compressor will begin a delayed stop require different pressure settings, contact your
sequence and will stop automatically after Sullair representative.
the delayed stop sequence is complete.
Adjusting the nominal operating pressure above
• During the delayed stop sequence
the maximum working pressure of your com-
pressing the Start button will not restart
pressor as indicated on the serial number plate
the compressor. You can only restart
may damage your compressor and void your
the compressor after the delayed stop
warranty.
sequence is complete.
WARNING 5.6 High temperature shutdown

The electronic controller will shut down the compressor if
Never assume that the compressor has com- the fluid temperature sensor reports a separator tank
pletely stopped, even if the compressor does not temperature above 113°C (235°F). This shutdown tem-
appear to be running. The compressor may be in perature is set at the factory and should not be changed.
standby mode and restart at any time. Do not A high temperature shutdown places the electronic con-
remove any covers or panels or attempt any ser- troller into fault mode, which prevents the compressor
vice without first isolating the compressor from from restarting. After the compressor cools down, the
the mains power supply and tagging it. fault mode may be cleared by pressing the Reset button
on the controller.
CAUTION
In the event of a high operating temperature
shutdown fault, do not attempt to restart the
compressor without first finding and correcting
the underlying cause. Contact your Sullair repre-
sentative for assistance.
5.7 Motor overload protection

Both the compressor main drive motor and the fan motor
have overload protection. If either motor draws too much
current, its overload protection will shut down the com-
pressor.
A motor overload protection shutdown places the elec-
tronic controller into fault mode, which prevents the com-
88292021-240 R01
ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 5: Operation
pressor from restarting. The fault mode may be cleared 5.9 Run-on timer
by pressing the Reset button on the controller.
Keeping with Sullair’s philosophy of minimizing energy
consumption, the electronic controller has a run-on timer.
The run-on timer monitors how long the compressor has
CAUTION run without compressing air. If this length of time is
greater than the pre-set run-on time, the compressor will
In the event of a motor overload protection shut- enter standby mode. The compressor will automatically
down fault, do not attempt to restart the com- restart if a fall in system pressure is registered.
pressor without first finding and correcting the
The factory setting of the run-on time is 15 minutes. You
underlying cause that triggered the motor over-
can use the electronic controller to adjust the run-on time,
load protection.
but ensure that the compressor does not exceed six shut
You can contact your Sullair representative for downs per hour. Contact your Sullair representative
assistance in finding and correcting the underly- before making any adjustments, since an incorrect set-
ing cause of a motor overload protection shutting may result in damage to the compressor.
down condition.
WARNING
5.8 Phase failure/reversal
Never assume that the compressor has com-
The electronic controller includes a phase failure/reversal
pletely stopped, even if the compressor does not
monitor to protect against reverse motor rotation. The
appear to be running. The compressor may be in
monitor can detect an under voltage condition, the
standby mode and restart at any time. Do not
absence of a supply phase, or the incorrect phase
remove any covers or panels or attempt any ser-
sequence of the supply power. If the monitor detects any
vice without first isolating the compressor from
of these conditions, the electronic controller will shut
the mains power supply and tagging it.
down the compressor. A licensed electrician must exam-
ine the compressor to resolve the problem.
88292021-240 R01
5: Operation ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
Notes:
88292021-240 R01
ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance
Section 6
Maintenance
6.1 General 6.2.1 Before starting the compressor
Normal operation of your compressor depends upon per- • Check the compressor fluid level and add fluid
forming maintenance and service correctly and according if necessary.
to a consistent schedule.
To help you follow this schedule, the ShopTek™ micro-
processor controller has a programmable service timer.
WARNING
When the service timer reaches the programmed value,
the controller will display a service reminder message in If you need to open the fluid filler plug, wait for
the status column. (After service is performed, you must the fluid level to settle and the separator tank to
reset the service timer. For more information, see the depressurize.
EC2000 Controller Operation Manual.)
• Drain the water from the moisture separator.
WARNING 6.2.2 After starting the compressor

• Monitor the electronic controller display for any
Isolate the compressor from the power supply fault messages or abnormal readings (for
before performing any maintenance or service example, unusually high or low temperatures or
work. pressures).
• Check for fluid or air leaks, excessive vibration,
or unusual sounds.
WARNING
Do not disassemble any component of the com-
6.3 Recommended maintenance
pressor when the compressor is running or pres- schedule
surized. Before disassembling any compressor Table 6-1: Standard maintenance intervals
component, shut down the compressor, isolate
Change intervals1
the compressor from any sources of external (all hours are operating hours)
pressure, and bleed the compressor’s internal
Fluid/air
pressure to zero.
Fluid separator
Fluid Fluid2 filter3 element Air filter3
6 months or
Sullube® 10,000 hours 1000 hours 2000 hours
WARRANTY NOTICE 4000 hours
1
If multiple intervals are listed, change the item at whichever interval
Failure to use Sullair genuine parts when servic- is reached first.
ing a Sullair compressor may void your warranty. 2
Or when required by fluid analysis or known contamination.
3
If the compressor is in a dusty environment, you should service the
fluid and air filters more frequently.
6.2 Daily maintenance 6.3.1 Service at 50 operating hours

If the compressor is run 24 hours a day, perform the ser- • Replace the fluid filter element.
vices listed in Section 6.2.1 and Section 6.2.2 frequently.
• Check the condition of the purge oil return line
filter and replace the filter if necessary.
88292021-240 R01
6: Maintenance ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
• Tighten all electrical connections.

• Assess the condition of the air filter element. If
it is excessively dirty, you may need to replace
it more frequently than the normal schedule
(every 2000 hours).
6.3.2 Service every 1000 operating hours

• Replace the fluid filter element(s).
• Inspect the air filter element and replace it if
necessary.
• Check the condition of the purge oil return line
filter and replace the filter if necessary.
• Tighten all electrical connections.

Perform all checks listed for every 1000 hours plus:
• Replace the air filter element.
• Grease the main motor bearings.
• Refer to the motor nameplate for grease
filling volume and filling locations. 1. Fluid sample valve
2. Fluid filter
(or six months) Figure 6-1: Fluid filter assembly
• While the compressor is running, take a fluid
sample from the fluid sample valve for analysis.
Refer to Figure 6-1.
• Check that all safety devices are operating cor-
rectly.
WARNING
6.3.6 Service every 10,000 hours
Hot fluid under pressure Perform all checks listed for every 1000 and 2000 hours
plus:
Could cause burns or bodily injury.
• Change the compressor fluid (Sullube).
When taking a fluid sample, wear gloves that are • If fluid analysis indicates you should change
heat- and liquid-resistant. the fluid more frequently, change the fluid
per the schedule recommended by the anal-
• Change the compressor fluid (Sullube®) if ysis.
the analysis indicates it is necessary.
6.3.7 Compressor fluid levels
6.3.5 Service every 4000 operating hours Check the fluid level when the compressor is running.
(or semi-annually) The fluid level in the sight glass should normally be
Perform all checks listed for every 1000 and 2000 hours plus: between halfway and three-quarters of the way up the
sight glass.
• Replace the fluid/air separator element and
purge oil return line filter. • While the compressor is running, the fluid level
should never exceed the maximum fluid level
• Inspect the flexible drive coupling and service it
shown in Figure 6-2.
if necessary.
• Fluid should be added before the fluid level
• Tighten all nuts, bolts, pipe fittings and electri-
drops below the minimum fluid level shown in
cal connections.
Figure 6-2.
88292021-240 R01
6.4 Compressor maintenance

Refer to Section 7: Parts List for the part numbers of all
items mentioned in this section.
WARNING
Do not attempt any maintenance when the com-
pressor is running or pressurized. Stop the com-
pressor, relieve all internal pressure, and isolate
the power supply before performing mainte-
nance. Only a competent person, experienced in
compressor service, should perform any service,
including maintenance.
6.4.1 Adding compressor fluid

When adding compressor fluid, only use new fluid of the
same type that is already in the compressor. Using dirty
or used fluid may cause poor performance, foaming, and
clogging of the filter element, nozzle, or pipes.
Mixing of fluids other than Sullube® will void the
compressor’s warranty.
1. Fluid filler 1. Shut down the compressor, bleed pressure

2. Sight glass to zero, and allow the compressor to cool.
A. Maximum fluid level 2. Slowly loosen the fluid filler cap by turning it
to the left by hand to allow any trapped air to
B. Normal fluid level
vent, then remove the cap.
C. Minimum fluid level
3. Pour fluid into the fluid filler.
Figure 6-2: Compressor fluid levels 4. Replace the fluid filler cap by turning the cap
to the right by hand until it will not turn any
further. Ensure the O-ring is properly seated.
5. Run the compressor for a short period of
time and check the fluid level through the
sight glass, adding more fluid if necessary
(see Section 6.3.7: Compressor fluid levels).
6.4.2 Changing compressor fluid

When changing compressor fluid, only use new fluid of
the same type that is already in the compressor. Using
dirty or used fluid may cause poor performance, foaming,
and clogging of the filter element, nozzle, or pipes.
88292021-240 R01
Clean the lubrication system before changing fluid. If the

ambient temperature is outside of the allowed range for
the fluid, please contact your Sullair representative.
Mixing of fluids other than Sullube® will void the
compressor’s warranty.
1. Shut down the compressor, bleed pressure

to zero, and allow the compressor to cool.
2. Slowly remove the plug from the ball valve at
the bottom of the fluid/air separator tank.
3. Securely attach a drain hose to the valve.
• It may be convenient to run the waste fluid
directly into a waste fluid drum.
4. Slowly open the ball valve. Leave the valve
open until the fluid stops draining.
1. Top cover
CAUTION 2. Washer
3. Fluid filter element1
Assume the fluid is hot and under pressure. 1 Element
part number: 250025-526
Figure 6-3: Fluid filter

5. Close the valve and remove the drain hose.
6. Replace the plug.
7. Remove the fluid filler cap.
8. Pour fluid into the fluid filler. 2. Remove the old element and washer using a
9. Replace the fluid filler cap by turning the cap filter wrench.
to the right by hand until it will not turn any 3. Clean the washer seating surface.
further. Ensure the O-ring is properly seated. 4. Apply a light film of silicone grease to the
10. Run the compressor for a short period of new washer.
time and check the fluid level through the 5. Hand tighten the new element until the
sight glass, adding more fluid if necessary washer is seated.
(see Section 6.3.7: Compressor fluid levels).
6. Continue to tighten the element by hand an
additional ½ to ¾ turn.
6.4.3 Fluid filter maintenance
Replace the fluid filter element every 1000 hours of ser- 7. Restart the compressor and check for leaks.
vice. The fluid filter service indicator will display a warn-
ing when the fluid filter element has exceeded its useful 6.4.4 Air filter maintenance
service life. Inspect the air filter element every 1000 hours of service.
Replace the air filter element every 2000 hours of service
6.4.3.1 Replacing the fluid filter element or if the service indicator of the air filter is in the red zone
when running the compressor at full load.
1. Shut down the compressor and bleed pres-
sure to zero. • Internal element part number: 88290002-338
• External element part number: 88290002-337
88292021-240 R01
• If the filter element is excessively dirty, replace

it with a new element.
• Do not strike the filter element against a
hard surface to remove the dirt. You may
damage the element.
• Do not oil the filter element.
6.4.5 Purge oil return line filter

maintenance
Clean the purge oil return line filter after the first 50 hours
of service. Check the condition of the purge oil return line
filter every 1000 hours of service for blockages or other
problems. Replace the purge oil return line filter when
you replace the separator element.
When replacing the separator element, adjust the purge
oil return line tube so the tube is centered within the sep-
arator element with a clearance from the separator ele-
ment base of 1 to 3 mm.
1. Air filter service indicator
6.4.6 Fluid/air separator maintenance
Figure 6-4: Air filter service indicator Replace the fluid/air separator element every 4000 hours
or if the pressure drop is greater than 0.7 bar (10 psi).
You may need to replace the separator element more fre-
quently in dusty or hot conditions.
6.4.4.1 Replacing the air filter element
1. Shut down the compressor.
NOTE
2. Clean the outside of the canopy.
3. Unscrew the outer wing nut. The fluid/air separator element cannot be
4. Remove the canopy and pour out any dust. cleaned or re-used.
5. Unscrew the inner wing nut.
6. Remove the washer and the filter element. 6.4.6.1 Replacing the fluid/air separator
7. Clean the inside of the canopy. Do not use element
compressed air. 1. Shut down the compressor and bleed pres-
8. Install the new filter element. sure to zero.
9. Reassemble the air filter. 2. Loosen the swivel nut on the discharge hose
connecting the minimum pressure valve to
10. Reset the service indicator. the aftercooler.
3. Disconnect the fittings and pipes from the
6.4.4.2 Inspecting the air filter element
separator cover and minimum pressure
• Insert a bright light source into the air filter ele- valve. Mark the locations of the fittings and
ment and look for light shining through holes or pipes to ensure correct reassembly.
cracks.
4. Remove the separator cover retaining bolts.
• If you find any holes or cracks, the element
is damaged and should be discarded. 5. Remove the cover, complete with the mini-
mum pressure valve, carefully clearing the
• Check the condition of all washers. purge oil return line tube projecting into the
• If a washer is damaged, replace the center of the separator element.
washer. 6. Remove the separator elements.
88292021-240 R01
9. Evenly tighten the separator cover bolts to

138 N m (102 lbf ft).
10. Check the continuity of the separator ele-
ment to the ground.
11. Re-tension the separator cover bolts after
the compressor has reached operating tem-
perature.
6.4.7 Minimum pressure valve

maintenance
1. Primary fluid/air separator element1

2. Secondary fluid/air separator element2
1
Primary element part number: 250042-862
2
Secondary element part number: 02250061-137
Figure 6-5: Fluid/air separator tank
7. Install the new primary & secondary fluid/air 1. Valve body 6. Spring
separator elements and gasket assembly.
2. Check valve assembly 7. Piston
3. Hex head set screw 8. O-ring
CAUTION 4. Spring lock washer 9. Top cap
5. Gasket
Do not remove the staples incorporated into the Minimum pressure valve repair kit part number: 88290018-146
gaskets.They maintain a ground contact with the
separator. Figure 6-6: Minimum pressure valve
8. Reassemble in reverse order, carefully

adjusting the purge oil return line tube so it 1. Shut down the compressor and bleed pres-
has the correct clearance from the separator sure to zero.
element base (see Section 6.4.5: Purge oil
return line filter maintenance).
88292021-240 R01
2. Disconnect the pipe connected to the mini-

mum pressure valve and remove the valve
from the cover of the fluid/air separator.
3. Unscrew the top cap of the valve and
remove the piston from the valve.
4. Clean the valve and piston carefully.
5. Replace the O-ring, applying a layer of
grease to the O-ring and the piston.
6. Apply Loctite gasket maker to the top cap of
the valve and reassemble the valve.
7. Reinstall the valve on the cover of the fluid/
air separator tank and reconnect the pipe.
6.4.8 Solenoid valve maintenance

The solenoid valve needs little service. However, if the
solenoid is reacting slowly or is leaking and the working
voltage is correct, you should clean the valve or, if neces- 1. Motor spindle plate
sary, replace it (repair kit part number 88291010-180). 2. Elastomer
3. Fixing cap
6.4.9 Drive coupling maintenance
4. Compressor mounting plate
Figure 6-7: Flexible drive coupling

WARNING
Isolate the compressor from the power supply
before making any repairs or adjustments to the See the main motor nameplate and the other topics in
drive coupling. this section for additional information about operating
conditions.
1. Shut down the compressor.

6.5.1 Main motor operation
• The main motor must be grounded correctly.
2. Remove the shroud from the fixing cap.
The ground wire of the main motor is already
3. Remove the screws from the fixing cap. connected in the electric cabinet. You only
4. Slide the fixing cap to expose the elastomer. need to connect this connection point to your
5. Remove the elastomer and inspect it. ground.
• If the elastomer is worn out, deformed, or • The lead wires of the main motor are clearly
torn, replace it with a new elastomer and marked.
contact your Sullair representative. • The main motor connection diagram is on the
6. Reassemble the coupling assembly. motor nameplate.
• The coupling shall be mounted so that the • If the voltage and frequency of the power
gap between the ends of the two plates is source for the main motor match the require-
2 – 3 mm. ments on the motor’s nameplate, the motor can
operate continuously at the rated power × utility
7. Replace the screws on the fixing cap.
coefficient. If the power source’s frequency
8. Replace the shroud on the fixing cap. deviates from the value on the nameplate by
1%, or under voltage or over voltage exceeds
10%, the motor is not guaranteed to deliver that
6.5 Main motor operation and output power continuously.
maintenance • The compressor motor runs best when imbal-
• Ambient temperature ≤ 40°C (104°F) ance among the three phases does not exceed
• Altitude ≤ 1000 m (3280 ft) 1%.
88292021-240 R01
• A current detection device in the electrical cabi- • Radiant heat

net of the compressor provides motor overload • Pests or mold
protection.
You should also inspect the main motor every six months
• The motor should not make intermittent or
when the compressor runs under nonstandard condi-
unusual noises or vibrations when running
tions, such as:
(either at no load or load).
• The rated voltage and/or frequency often devi-
6.5.2 Main motor maintenance and repair ates from the limits set under Section 6.5.1:
• The operating environment should be dry, the Main motor operation.
motor surface should be clean, and the motor’s • The compressor is in a room with either poor
air inlet should not be blocked by dust or fibers. ventilation or an ambient temperature over
• When the motor overload protection device 40°C (104°F).
shuts down the compressor, do not restart the • The motor starts and stops often because of
compressor until you find and eliminate the frequent fluctuations in air demand.
cause of the overload.
• Make sure bearings are well lubricated. Grease 6.5.3.1 Periodic inspection checklist
should be added or replaced every 2000 hours. • Add or change the main motor bearing grease
If grease becomes too hot or deteriorates according to the maintenance schedule.
during operation, replace it. Before adding • Inspect the bearing seal and eliminate oil leaks
grease, clean the bearing and cap slot. Differ- you find.
ent motors use different types of grease. See
• Check the end cover and the shroud for con-
the motor nameplate for the type of grease
densation, deposited water, iron rust, or corro-
needed.
sion.
• Replace the bearings at the end of their service
• Check for excessive dust or other foreign mate-
life. (At the end of the bearings’ service life, the
rial.
motor will create significantly more noise and
vibration). • Check the main lead-out wiring for overheating
or a corona discharge.
• After any motor faults occurs, contact your Sul-
lair representative. • Tighten the non-insulated electric connections
and check them for overheating, corrosion, or
6.5.3 Periodic inspection of the main electrical arcing.
motor • Tighten all nuts and bolts.
You should inspect the main motor yearly to ensure that
the motor is operating correctly and in good condition. 6.5.4 Check and clean the windings
The best way to clean the motor windings depends on
both the accessibility of the surface and what you are try-
WARNING ing to remove from it. For a thorough cleaning, or if the
winding is very dusty, the rotor needs to be removed from
Isolate the compressor from the power supply of the stator.
before making any repairs or adjustments to the
drive coupling.
WARNING
You should inspect the motor every six months if the Isolate the compressor from the power supply
compressor is exposed to any of these conditions: before checking or cleaning the windings.
• Corrosive or conductive dust
• Excessive dirt or dust (the accumulated dust 6.5.4.1 Dry cloth
may interfere with the compressor’s ventilation)
You can clean easy-to-reach surfaces that are dusty with
• Chemical smoke, steam, salt mist, or oil mist a dry, clean, lint-free cloth.
• A very wet or very dry atmosphere
88292021-240 R01
6.5.4.2 Brush and vacuum bustible under normal conditions, partial ventilation is
You can clean easy-to-reach surfaces that are dirty or required when the smell of the solvent becomes strong.
very dusty by scrubbing them with a short, hard, non-
metal brush, and then vacuuming up the loosened dirt
and dust. (Vacuuming the dirt after loosening it prevents 6.6 Troubleshooting
the dirt from getting deposited on other components.) Because a compressor fault can have multiple causes,
you should carry out a systematic analysis of the fault to
6.5.4.3 Compressed air determine the specific cause before performing service
You can blow dry compressed air through gaps to clean or replacing parts.
hard-to-reach surfaces, but you must follow the guide-
lines for cleaning with compressed air.
• The pressure of the compressed air must not
CAUTION
exceed 0.2 MPa (29 psi). Air at pressures
above 0.2 MPa (29 psi) can damage the insula- Never disassemble the machine without a spe-
tion. cific purpose.
• The compressed air does not contain any con-
densed water so that the motor stays dry. To avoid damaging the compressor, always perform a
• The compressed air does not blow the dust visual check of it prior to attempting any repair, remem-
deeper inside the motor. This could make the bering to:
dust harder to clean or even block an air duct. • Check for loose or disconnected cable leads
• Check for damaged or disconnected pipelines,
6.5.4.4 Solvent
tubing, or hoses
For a surface covered in bitumen, grease, wax, or oil,
wipe the surface with a cloth soaked in a solvent and • Check for parts damaged by excessive heat or
then with a dry, clean, lint-free cloth. short circuits
Table 6-2: Troubleshooting guide lists some compressor
Sullair recommends using a petroleum-based solvent for
symptoms with their most probable causes and remedies
cleaning the insulation. In very flammable areas, methyl
chloroform can be used. Although this solvent is not com-
Table 6-2: Troubleshooting guide

Symptom Possible causes Remedy
Low fluid level in fluid/air separator Check fluid level. Add fluid if necessary.
Cooler fin dirty Clean cooler fin
Fluid filter clogged and bypass valve
Replace fluid filter element
failed
High discharge air High ambient temperature Improve ventilation
temperature • Enlarge exhaust duct
High resistance in exhaust duct
• Install fan in the duct
Thermal resistor temperature trans- Check RTD connector. If the connector
ducer RTD failure is good, replace RTD.
Fan motor damaged Check and repair fan motor
88292021-240 R01
Table 6-2: Troubleshooting guide

Symptom Possible causes Remedy
• Reduce air demand
Air demand higher than air supply
• Check piping for air leaks
Air filter clogged Replace air filter element
Air supply pressure
lower than pressure Check movement of inlet valve. Check
rating Inlet valve does not open completely settings of the pressure relief valve and
pressure regulator.
Check transducer’s contacts. Replace
Pressure transducer fault
transducer if contacts are normal.
Check transducer’s contacts. Replace
Pressure transducer fault
transducer if contacts are normal.
Pipeline pressure Unloading components (e.g. blow-
Check if unloading components are
higher than unloading down valve, inlet regulator valve) are
working normally
pressure not working properly
Solenoid valve unload failure Check solenoid valve
Control pipeline is leaking air Check if control pipeline is leaking air
Purge oil return line filter or nozzle Clean purge oil return line filter and noz-
blocked zle
Fluid/air separator element damaged Check fluid/air separator element and
Fluid consumption too or washer displaced washer. Replace if necessary.
high
System piping is leaking fluid Check if system piping is leaking fluid
Fluid level too high Discharge some fluid
Excessive fluid foam Change fluid
Vibration and noise Isolator damaged Replace isolator
increased Fan fault Check centrifugal fan
88292021-240 R01
ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 7: Parts List
Section 7
Parts List
7.1 Procedure for ordering parts
You should order parts from the nearest authorized Sul-
lair representative or the representative from whom the
compressor was purchased. If for any reason you cannot
obtain parts in this manner, contact the factory directly at
the address, phone number, or website listed below.
Sullair North America Operations

1 Sullair Way
Michigan City, IN 46360 USA
www.sullair.com
1-800-SULLAIR (USA only)
1-219-879-5451 (non-USA)
When ordering parts, always indicate the serial number

of the compressor. You can get the serial number from
the Bill of Lading for the compressor or from the Serial
Number Plate located on the compressor (see Figure 7-
1: Serial number plate and location).
The genuine Sullair service parts listed meet or exceed
the demands of this compressor. Use of replacement
parts other than those approved by Sullair will void the
Sullair warranties specific to this product and may lead to
hazardous conditions over which Sullair has no control.
Such conditions include, but are not limited to, bodily
injury and compressor failure.
Figure 7-1: Serial number plate and location
88292021-240 R01
44
7.2 Recommended spare parts list
7: Parts List
Service kit part number Qty Description
250025-526 1 Element for compressor fluid filter
88290002-337 1 Element for heavy duty primary air filter 88290002-207
88290002-338 1 Element for heavy duty secondary air filter 88290002-207
250042-862 1 Primary element for fluid/air separator
02250061-137 1 Secondary element for fluid/air separator
88292009-684 1 Maintenance kit for inlet valve 88292027-255
88292009-685 1 Repair kit for inlet valve 88292027-255
88291010-178 1 Repair kit for pneumatic control integrated block in the air inlet valve control component assembly (capacity adjustment) 88292027-255
88291010-180 1 Repair kit for solenoid valve in the air inlet valve control component assembly (capacity adjustment) 88292027-255
250017-280 1 Pressure regulator
88290018-146 1 Repair kit for minimum pressure valve 242405
049542 1 Thermal valve element
02250117-782 1 Repair kit for purge oil return line filter
88292021-240 R01
02250050-364 1 Repair kit for shaft seal

88290003-326 1 Element, coupling 88290003-311/88290007-806
88292020-371 1 Repair kit for the auto drain of water trap 88291013-632 in air discharge system
250022-669 1 Fluid, Sullube® (5 gallons)
250022-670 1 Fluid, Sullube® (55 gallons)
Notes:
88292021-240 R01
7: Parts List ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
7.3 Motor and air end system
88292019-151 R03
88292021-240 R01
Key Part number Qty Description Notes
1 829108-150 6 CAPSCREW,HEX GR5 1/2-13 X 1 1/2"
2 837808-125 6 WASHER, SPRLOCK REG PLTD 1/2"
3 88290002-205 1 ADAPTER,MTR-COMP LS16-100 CHNSZ
4 88290002-206 2 GUARD,COUPLING LS16-100 CHNSZ
88290003-311 1 COUPLING,SHAFT VULKAN LS16-75+ FOR 365TSC-4
5 88290003-312 1 COUPLING,FLEXOMAX-G128/GG VULKAN+ FOR 365TSC-2
88290007-806 1 COUPLING,SHAFT VULKAN LS16-100+ FOR 405TSC-4
6 ———— 1 COMPRESSOR SEE COMPRESSOR LIST
7 88290020-282 2 ISOLATOR,VIBRATION AIREND WS4500-7500

8 88290020-283 2 ISOLATOR,VIBRATION WS4500-7500
9 88290020-284 1 SUPPORT,AIREND WS45-75
10 88290021-292 1 SUPPORT,AIR END WS45-75 FOR MAINTENANCE USE
11 88291005-932 1 SUPPORT,MOTOR AS45-75 FOR 365TSC
88292021-240 R01
12 88292013-890 2 BOOT, GUARD FOR WIRE

13 ———— 1 MOTOR SEE MOTOR LIST
14 88292020-093 1 FRAME BSE,ST45/55/75 AC
88811112-050 2 SCREW,M12X50 GB5782-86GAV SSAI FOR 365TSC
15
88811112-055 2 SCREW,M12X55 GB5782-86GAV SSAI FOR 405TSC
16 88812110-025 4 SCREW,M10X25 GB5783 GAV SSAI FOR 365TSC
17 88812112-025 2 SCREW M12X25 GB5783 GAV SSAI
18 88812112-030 4 SCREW,M12X30 GB5783 GAV SSAI
20 88813108-020 10 SCREW,M8X20 GB5787-86 SSAI
21 88831110-020 4 WASHER,10 GB97.1-85 GAV SSAI FOR 365TSC
22 88831112-025 6 WASHER,12 GB97.1-85 GAV SSAI
24 88832110-026 4 WASHER,SPRG 10 GB93-87 GAVSSAI FOR 365TSC
25 88832112-031 8 WASHER,SPRG 12 GB93-87 GAVSSAI
7: Parts List
27 88833112-033 2 WASHER,BIG12 GB96-85 SSAI
28 88290020-389 2 BOOT,GUARD FOR MOTOR NOT FOR UL&CUL MOTOR
Drawing notes
47
48
7: Parts List
A1 FOR 365TSC FRAME MOTOR
A2 FOR 405TSC FRAME MOTOR
A3 FROM AIR INLET FILTER
A4 MAIN OIL CONNECTION
A5 OIL RETURN FROM SIGHT GLASS ON RECEIVER TANK
A6 TO RECEIVER TANK
Compressor list
Part number Qty Description Notes

88290009-321 1 COMPRESSOR & PARTS,DXX163167E146S47ACM ST4508 60Hz/ST4509 60Hz US
Motor list
88292021-240 R01

1 88292016-171 1 MOTOR,60HP1.25 440-480V/6 23 UL+ 365TSC-4
2 88292016-172 1 MOTOR,75HP1.25 460/6 23 UL&CUL+ 365TSC-4
3 88292016-176 1 MOTOR,100HP1.25 460/6 23 UL&CUL+ 405TSC-4
Notes:
88292021-240 R01
7.4 Air inlet system
88292019-152 R01
88292021-240 R01
7.4 Air inlet system
1 02250061-835 1 ELBOW, RUB 90DEG 5"ID
2 408153 2 CLAMP, HOSE 6"DIA WORM DRIVE
3 829108-150 4 CAPSCREW,HEX GR5 1/2-13 X 1 1/2"
5 88290002-207 1 FILTER,AIR LS16 100HP CHNSZ
6 88290002-208 1 BAND,MOUNTING AIR FLTR LS16-100
7 88290004-147 1 GASKET,INL VLV LS12-50 LF SSAI
88291006-018 1 VALVE,ASSY INLET&CTL GRP AS45-75 ON/OFF OTHERS
88291010-175 1 VALVE,ASSY INLET&CTL GRP AS45-75 REGULATING OTHERS

8
88292027-271 1 VALVE,ASSY AIRINLET ON/OFF ON/OFF US
88292027-255 1 VALVE,ASSY AIRINLET REGULATION REGULATING US
88291007-195 1 SUPPORT,AIR FILTER AS45-75 FOR 364/365/404/405TSC
9
88291011-145 1 SUPPORT,AIR FILTER AS75 AUS FOR 444/445TSC
88292021-240 R01
10 88811110-070 1 SCREW,M10X70 GB5782-86GAV SSAI

12 88821110-084 3 NUT,M10 GB6170-86 GAV SSAI
Drawing notes
A1 COMPRESSOR INLET
A2 ATTACH TO ADAPTER
7: Parts List
51
7.5 Fluid piping system
88292019-154 R01
88292021-240 R01
7.5 Fluid piping system
1 02250101-372 1 SEAL,U-CUP VITON THERM VLV
2 02250196-306 1 VALVE, KP18NV (1/8" NPTF, VITON)
3 49542 1 ELEMENT,THERMAL VALVE 175
4 250025-526 1 ELEMENT,FLUID FILTER
5 826502-144 1 O-RING,VITON 2 1/2 X 3/32
6 88290023-074 1 SWITCH,MANIFOLD OIL FILTER FRAME+
7 88291008-555 1 HOSE,OIL IN CLR AS45-75AC
8 88291012-564 1 HOSE,OIL INLET AIREND ST45-75 FIXED SPEED
9 88292010-002 1 CONNECTOR,OIL FLTR-THRMVLV 150SSAIC

10 88292017-554 2 CONNECTOR,M-M42X2 F-M42X2SAE PORT
11 88292019-147 1 HOSE,OIL AIREND ST45-75AC FIXED SPEED
12 88292019-225 1 ELBOW,90 END ADJUST M42-FACE M40
13 88818210-040 4 SCREW.SOCKET M10X40 GB/T70.1
88292021-240 R01

15 88842018-029 6 O-RING,VITON 29.0X1.80
16 88842029-386 10 O-RING,VITON 38.6X2.9 ISO6149
17 88892042-042 1 ADAPTER,END M42-FACE M42
18 88896042-042 4 ELBOW,90 END ADJUST M42-FACE M40
19 89250112-477 1 HOUSING,THRM VLV W/BYP CONN M42X2
20 87250009-396 9.2 LUBRICANT,SULLUBE 2G 1GA(BULK QTY) NO BALLOON
Drawing notes
A1 TO RECEIVER TANK
A2 TO COMPRESSOR
A3 TO OIL COOLER
A4 FROM OIL COOLER
7: Parts List
53
7.6 Cooling fan system
88292019-155 R02
88292021-240 R01
7.6 Cooling fan system
1 250022-436 13 WEATHERSTRIP,3/16 X 3/8 FT
2 88291010-006 1 ADAPTER,VENTURI/COOLER AS45-75
88292017-516 1 COOLER,FLUID&AFTER ST45/55 ASME ST45/55 ASME
88292017-517 1 COOLER,FLUID&AFTER ST75 ASME ST75 ASME
3
88292018-732 1 COOLER,FLUID&AFTER ST45/55 GB ST45/55 GB
88292018-733 1 COOLER,FLUID&AFTER ST75 GB ST75 GB
88292018-870 1 FAN,ST45/55 230/460/6 UL&CSA+ ST45/55 230/460V US
4
88292018-871 1 FAN,ST75 230/460/6 UL&CSA+ ST75 230/460V US
Drawing notes
A1 TO THERMAL BLOCK
A2 FROM THERMAL BLOCK
A3 TO WATER SEPARATOR
A4 FROM MINIMUM PRESSURE VALVE
88292021-240 R01
7: Parts List
55
7.7 Fluid/air separation system
88292019-153 R01
88292021-240 R01
1 20169 2 CONNECTOR, FLEX 1/4T X 1/4P
2 02250061-137 1 ELEMENT,AIR/OIL SEP SECONDARY
3 02250097-349 1 VALVE,RELIEF 3/4"200#550SCFM W/TEFL ASME
4 02250101-490 2 CONNECTOR,TUBE MALE BHD 1/4 X SAE
5 02250117-782 2 FILTER,ASSEMBLY GENISIS FILTR +
6 02250125-775 1 ORIFICE,PLUG 1/8"NPT .062
7 02250125-776 1 ORIFICE,PLUG BRASS 1/8"NPT X 3/32"
8 02250126-129 2 GLASS,SIGHT/ORF BLK-SAE
9 250042-862 1 ELEMENT,AIR/OIL SEP PRIMARY

10 810104-025 1 CONNECTOR, TUBE-F 1/4 X 1/4"
11 810504-025 1 ELBOW, TUBE-M 1/4 X 1/4"
12 828408-150 4 CAPSCREW,FERRY HEAD 1/2-13 X 1 1/2"
88292021-240 R01
14 841215-004 3 TUBING,STNLS STL 1/4" 20GA FT

15 860704-025 1 ELBOW, PIPE M/F 1/4 X 1/4"
16 869825-025 1 TEE,MALE PIPE 1/4" BRASS
17 88290001-031 1 PLUG,OIL TANK 25S-300 SSAIC
18 88290001-219 1 GLASS,SIGHT,FSF4525S-300 SSAIC
19 88290002-435 1 VALVE,BALLDN15 Q11MP-25P SSAIP
20 88290002-637 1 SUPPORT,BRKT-OIL LS16-100 SSAIC
21 88290002-688 1 FLANGE,HALF 2-1/2"" LS16-100 SSAI
22 88290002-836 1 PLUG,TANK DRAIN R1/2
23 88291006-621 1 HOSE,FLEX DN65 AS45-75 ST45/55 EUR/AUS?ST45-75 US
24 88291010-492 1 TANK,SEP AS45-75 ASME+ ASME
25 88292007-724 1 CONNECTOR,90DEG M33X2-RC2 FOR CE TANK
26 88292011-696 1 TERMINAL,SC16-8+16SQMM
88292019-142 1 CONNECTOR,G3/4"(M) TO NPT3/4"(F) FOR ASME TANK
27
88290005-474 1 CONNECTOR,G3/4X1 VALVE DN25 FOR ST7508 GB TANK
28 88811112-030 4 SCREW M12X30 GB5782-86GAV SSAI
7: Parts List
29 88811112-060 4 SCREW,M12X60 GB5782-86GAV SSAI
30 88813108-016 2 SCREW,M8X16 GB5787-86 SSAI
31 88813108-025 4 SCREW,M8X25 GB5787-86 SSAI
57
58
7: Parts List
33 88832108-021 4 WASHER,SPRG 8 GB93-87 GAV SSAI
35 88842026-051 1 O-RING,VITON 51.5X2.65GB3452.1
36 88842035-023 1 O-RING,VITON 23.6X3.55GB3452.1
37 88842035-028 1 O-RING,VITON 28X3.55 GB3452.1 FOR CE TANK
38 88842035-047 1 O-RING,VITON47.5X3.55GB3452.1
39 88842035-069 1 O-RING,VITON 69X3.55 GB3452.1
40 88842035-075 1 O-RING,VITON 75X3.55 GB3452.1

41 88871008-044 1 NIPPLE,R1/2 GB3287 SSAI
42 88834233-027 1 WASHER,SEG JB982 FOR ST7508 GB TANK
Drawing notes
A1 FROM COMPRESSOR DISCHARGE
88292021-240 R01
A2 ATTACH TO TEMPERATURE SENSOR

A3 TO MINIMUM PRESSURE VALVE
A4 TO AIRINLET CONTROL VALVE
A5 ATTACH TO PRESSURE GAUGE
A6 TO THERMAL BLOCK
A7 TO COMPRESSOR OIL RETURN PORT
A8 ATTACH TO THE FRAME
Notes:
88292021-240 R01
7.8 Air discharge system
88292019-156 R01
88292021-240 R01
7.8 Air discharge system
1 88290001-541 1 CONNECTOR,SEP-MIN VLV 150AC SSAIC
2 88290005-230 1 ADAPTER,ELBOW ADJUST LS16-75/100
3 88290005-231 1 ADAPTER, LS16-75/100 CHNZ
4 88291011-165 1 HOSE,FLEX DN40 ST45-75 AC
5 88291009-260 1 CONNECTOR,DISC SYS AS45-75AC VSD
6 88291011-118 1 CONNECTOR,DISC SYS ST45-75 AC
7 88291011-207 1 SUPPORT,AIROC AS75 AUS
88291013-209 1 SEPARATOR,TRAP WS250 AS132 R2"
8
88291013-632 1 SEPARATOR,TRAP WS250 FNPT 2" NPT2"
88291007-773 1 CONNECTOR,ADJUST M48X2 TO R2 R2"
9
88292020-318 1 CONNECTOR,ADJUST M48X2 TO NPT2" NPT2"
10 88813108-016 2 SCREW,M8X16 GB5787-86 SSAI
11 88813108-025 2 SCREW,M8X25 GB5787-86 SSAI
88292021-240 R01
12 88822108-076 2 NUT,M8 GB6177-86 SSAI

13 88842026-042 2 O-RING,VITON 42.5X2.65GB3452.1
14 88842035-045 4 O-RING,VITON 45X3.55 GB3452.1
15 88842035-065 1 O-RING,VITON 65X3.55 GB3452.1
16 88851045-075 1 CLIP,SGL45X75 JB/ZQ4492-86SSAI
17 89242405 1 VALVE,MINIMUM PRESSURE & CHECK-2 MPT
Drawing notes
A1 FROM MINIMUM PRESSURE VALVE
A2 PACKAGE OUT
A3 MOISTURE DRAIN
7: Parts List
61
7.9 Control system
88292019-157 R05
88292021-240 R01
7.9 Control system
1 02250052-841 6 INSERT,NYL TBG 1/4 OD X .035W
2 02250054-861 6 TUBE,NYL .25 OD X 040W BLK(FT)
3 250003-869 1 INDICATOR, RESTRICTION 20"H20
4 250018-427 1 CONNECTOR, 1/4"TUBE X 1/8"NPT
5 807600-005 1 BUSHING, RED 1/4 X 1/8" STL
6 823202-000 1 NIPPLE, GALV XS 1/8 X CLOSE
7 88290002-119 1 GAUGE,PRES D50 0-1.6MPA 50BD SSAI
8 88290014-514 1 SENSOR,PRESSURE 250PSI 4-20MA+
9 88290021-398 1 CONTROLLER,EC2000 AC110V HONGSAI

10 88290021-986 1 SENSOR,TEMP PT100 ONLY FOR AS
11 88291011-142 1 CONNECTOR,MG12A-05(3-6.5) IP68 PA6
12 88291011-143 1 CONNECTOR,MG16A-10(5-10) IP68 PA6
88291011-111 1 TUBE,&FTG GRP FGK--M64B 0.8M ST45-75AC US
13
88292021-240 R01
88291011-930 1 TUBE,&FTG N-MGQ75B OTHERS

14 88291012-012 1 CONNECTOR,ELBOW G1/4MXNPT 1/8F
15 88291012-013 1 CONNECTOR,G1/4FXG1/8F
16 88291012-014 1 CONNECTOR,M18X1.5
88292016-662 1 STARTER,ST45AC460/575V YD ULCUL+ ST45AC 460/575V US
17 88292016-661 1 STARTER,ST55AC460/575V YD ULCUL+ ST55AC 460/575V US
88292016-663 1 STARTER,ST75AC460/575V YD ULCUL+ ST75AC 460/575V US
19 88813108-016 6 SCREW,M8X16 GB5787-86 SSAI
20 88821104-032 4 NUT,M4 GB6170-86 GAV SSAI
22 88832104-011 4 WASHER,SPRG 4 GB93-87 GAV SSAI
24 88834218-027 2 WASHER, 18
25 868508-050 2 NIPPLE,PIPE HEX 1/2 X 1/2" PLT
26 804415-020 1 TEE,FEMALE PIPE GALV 1/2
7: Parts List
27 88291008-364 1 VALVE,2-WAY PNEUMATIC 1/2 NPT
28 250041-088 1 TEE, M RUN 1/4T PLSX 1/8NPT
29 860208-050 3 ELBOW, 37FL 90M 1/2 X 1/2"
63
64
7.9 Control system
7: Parts List
30 250018-428 2 CONNECTOR, 1/4"TUBE X 1/4"NPT
31 88290017-336 4 HOSE,HIGH PRESS 1/2X1200
32 860108-050 1 CONNECTOR, 37FL/MPT 1/2 X 1/2"
33 250018-430 1 ELBOW, 1/4"TUBE X 1/4"NPT
34 88292031-784 1 ORIFICE,6.35MM NPT1/2-NPT1/2
Drawing notes
A1 ATTACH TO FRAME
A2 ATTACH TO ENCLOSURE
A3 ATTACH TO ENCLOSURE
A4 MOTOR WIRING
88292021-240 R01
Notes:
88292021-240 R01
7.10 Starter assembly
88292017-767 R04 (Sh1)

88292021-240 R01
88292017-767 R04 (Sh2)

88292021-240 R01
68
7: Parts List
Key Mark Part number Qty Description Notes
1 / 88292018-174 1 CUBICLE
2 / 88292018-669 1 MOUNTING PLATE
88291012-882 2 CONTACTOR ST45
3 KM1,2 88291012-883 2 CONTACTOR ST55
88292018-173 2 CONTACTOR ST75
88291013-038 1 CONTACTOR ST45
4 KM3 88291012-882 1 CONTACTOR ST55
88291012-882 1 CONTACTOR ST75
5 KM4 88291012-880 1 CONTACTOR_FAN AB

QF1 88291012-879 1 BREAKER ST45-55
6
QF1 88291013-763 1 BREAKER ST75
7 XT0 88292017-775 1 TERMINAL BLOCK AB
8 XT1 88290016-045 10 TERMINAL BLOCK
9 FR1 88291012-902 1 OVERLOAD RELAY AB
88292021-240 R01
10 PE 88291011-071 1 PE BAR
11 88290016-046 3 TERMINAL END COVER AB
12 XT1 88290017-859 2 PE TERMINAL AB
13 EC2000 88290021-398 1 CONTROLLER SULLAIR INSTALL
14 SB1 88290018-650 1 E-STOP AB
15 SB1 88290018-651 1 E-STOP CONTACT AB
16 SB1 88290018-648 1 E-STOP WARNING INDICATOR AB
17 TC1 88292017-769 1 TRANSFORMER
18 / 88291007-580 3M WIRE DUCT
19 0 88292007-713 1 PHASE SEQUENCE RELAY EATON
20 FU4 88291013-669 3 FUSE BUSSMAN
21 XT1 88290016-047 2 TERMINAL GENERAL TYPE
22 FU4 88292031-308 1 FUSE HOLDER VOHNER
23 FU1,3 88292031-307 2 FUSE HOLDER VOHNER
24 FU2 88292031-306 1 FUSE HOLDER VOHNER
25 FU2,3 88291012-905 3 FUSE BUSSMAN
26 / 88290006-263 2 RAIL
27 / 88292017-463 1 WIRING DIAGRAM VER03
28 FU1 88292021-716 2 FUSE BUSSMAN
Notes:
88292021-240 R01
7.11 Enclosure
8829019-158 R00
88292021-240 R01
71
7.11 Enclosure
7: Parts List
1 02250048-520 18 PLUG, PLASTIC 1.0 DIA BLACK
2 02250151-635 3 BEARING,FLANGED 5MM 3700
3 250022-436 48 WEATHERSTRIP,3/16 X 3/8 FT
4 88292019-582 1 PANEL,A ST45-75 AC
5 88292019-583 1 BM,D ST45-75 AC
6 88292019-584 2 PANEL,A ACCESS ST45-75AC
7 88292019-585 1 BM,E ST45-75 AC
8 88292019-586 1 COVER,A ST75 AUS
88292019-587 2 ANGLE,D ROOF CLR ST45/55AC ST45/55

9
88292019-588 2 ANGLE,B ROOF CLR ST75AC ST75
10 88292019-589 2 PANEL,C CORNER ST45-75 AC
88292019-590 2 ANGLE,A ROOF CLR ST45/55AC ST45/55
11
88292019-591 2 ANGLE,C ROOF CLR ST75AC ST75
88292021-240 R01
12 88292019-592 2 DOOR,C ST45-75 AC

13 88292019-593 1 BM,C ST45/75 AUS
14 88292019-594 1 PANEL,D SUPPORT ST45-75AC
15 88292019-595 1 PANEL,B ACCESS ROOF ST45-75AC
16 88292019-596 1 DOOR,B ST45-75
17 88292019-597 1 BM,D ST45/75 AUS
18 88292019-598 1 PANEL,A CORNER ST45-75
19 88292019-599 1 BM,A ST45/75 AUS
20 88292019-600 1 BM,B ST45-75 AC
21 88292019-601 1 PANEL,E SUPT ST45-75 AC
22 88813108-016 101 SCREW,M8X16 GB5787-86 SSAI
7.12 Decal locations
88292019-159 R00
88292021-240 R01
7.12 Decal locations
1 02250069-389 1 DECAL,FLUID SULLUBE
2 02250110-891 1 DECAL,EN-WARNING MIXING FLUIDS
3 02250171-797 1 DECAL, DO NOT BREATH COMP AIR
4 02250229-398 1 DECAL,WRNG REMOTELY CONTROLLED
5 02250229-399 1 DECAL,WRNG ELECTRICAL SHOCK
6 042218 1 DECAL,DANGER HI VOLTAGE
7 049685 1 DECAL,WARNING-COMP OIL FIL CAP
8 049852 1 DECAL,WARNING GROUND FAULT
9 049855 2 DECAL,WARNING-SEVER-FAN-INDUS
10 241814 2 DECAL,FORK LIFTING
11 250021-337 1 TAG, FIRST START
12 250021-564 2 DECAL,ROTATION 3.5"LG
13 407408 1 DECAL,WARNING-HOT SURFACES
88292021-240 R01
14 88290013-723 4 RIVET,BUSTERPOP DIA3.2 L=8

15 88290016-067 1 DECAL,VOLTAGE WAN COMPONENT
16 88291011-503 1 DECAL,SULLAIR LOGO ST30/37
88290013-683 1 NAMEPLATE,FOR EXPORT MODEL UL
17
88292016-647 1 NAMEPLATE,CSA ST4-ST15 SERIES CSA
18 88292020-630 1 DECAL,SULLAIR ST45-75
88292020-694 1 DECAL,SULLAIR ST45 ST45
19 88292020-695 1 DECAL,SULLAIR ST55 ST55
88292020-631 1 DECAL,SULLAIR ST75 ST75
7: Parts List
73
Notes:
88292021-240 R01
ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual A: Nominal Sizes
Appendix A: Nominal Sizes

Metric nominal size (DN) is the nominal size for valves, Table A-1: Metric to Imperial nominal sizes
flanges and fittings as defined by ISO 6708-1980. DN
designates the size of all components in a piping system Metric DN Imperial NS
(Nominal Size) (Nominal Size)
other than components designated by outside diameters
or by thread size. For example, steel tubes are desig- Designated in inches
A dimensionless designation
sometimes as ND, NB or NPS
nated and ordered by outside diameter and thickness.
6 ⅛″
8 ¼″
NOTE
10 ⅜″
Because DN is a round number that cannot be 15 ½″
measured and is only loosely related to manu- 20 ¾″
facturing dimensions, you should only use the
25 1″
DN number for reference and never for calcula-
tions. 32 1¼″
40 1½″
50 2″
A metric nominal size is indicated by the letters “DN” fol-
lowed by a number without any unit of measure. For met- 65 2½″
ric to imperial nominal size equivalents, refer to Table A- 80 3″
1: Metric to Imperial nominal sizes.
88292021-240 R01
A: Nominal Sizes ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual
Notes:
88292021-240 R01
Sullair, LLC
1 Sullair Way
Michigan City, IN 46360 USA
www.sullair.com
1-800-SULLAIR (USA only)
1-219-879-5451 (non-USA)
Information and specifications are subject to change without prior notice.


Manual St5508

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Manual St5508

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OPERATION & MAINTENANCE MANUAL

ST45, ST55, ST75

Subject to EAR, ECCN EAR99 and related export control restrictions.

Sullair Training Department

Subject to EAR, ECCN EAR99 and related export control restrictions.

2.5.2 Ambient temperature .......................................................................................................... 19

Section 4: Installation ............................................................................................ 25

Section 5: Operation .............................................................................................. 29

5.7 Motor overload protection.............................................................................................................. 30

Section 7: Parts List ...............................................................................................43

7.3 Motor and air end system.............................................................................................................. 46

Appendix A: Nominal Sizes................................................................................... 75

1.2 Personal protective equipment

1.11 Implementation of lockout/tagout their own padlock and have possession of

1.12 Safety warnings

1. Enclosure 5. Air inlet system

Figure 2-1: ST45, ST55 & ST75 machine layout

2.3.2 Minimum pressure valve NOTE

Additional information 2.5.2 Ambient temperature

Additional information Additional information

3.2 Lubricant specifications Table 3-2: Lubricant specifications

9 ELEMENT,FLUID/AIR SEPARATOR SECONDARY

4.2 Guidelines for lifting and moving

4.2.1 Guidelines for moving the

4.5.3 Checking the compressor fluid level WARNING

You must pull out the E-stop button to release it before

NOTE The compressor should always run smoothly. If

5.3 Starting the compressor 5.5 Electronic controller

WARNING 5.6 High temperature shutdown

5.7 Motor overload protection

WARNING 6.2.2 After starting the compressor

6.2 Daily maintenance 6.3.1 Service at 50 operating hours

• Tighten all electrical connections.

6.3.2 Service every 1000 operating hours

6.3.3 Service every 2000 operating hours

6.4 Compressor maintenance

6.4.1 Adding compressor fluid

1. Fluid filler 1. Shut down the compressor, bleed pressure

6.4.2 Changing compressor fluid

Clean the lubrication system before changing fluid. If the

1. Shut down the compressor, bleed pressure

Figure 6-3: Fluid filter

• If the filter element is excessively dirty, replace

6.4.5 Purge oil return line filter

9. Evenly tighten the separator cover bolts to

6.4.7 Minimum pressure valve

1. Primary fluid/air separator element1

Figure 6-5: Fluid/air separator tank

8. Reassemble in reverse order, carefully

2. Disconnect the pipe connected to the mini-

6.4.8 Solenoid valve maintenance

Figure 6-7: Flexible drive coupling

1. Shut down the compressor.

• A current detection device in the electrical cabi- • Radiant heat

Table 6-2: Troubleshooting guide

Table 6-2: Troubleshooting guide

Sullair North America Operations

When ordering parts, always indicate the serial number

Figure 7-1: Serial number plate and location

02250050-364 1 Repair kit for shaft seal

7 88290020-282 2 ISOLATOR,VIBRATION AIREND WS4500-7500

12 88292013-890 2 BOOT, GUARD FOR WIRE

Part number Qty Description Notes

Key Part number Qty Description Notes