E900H User Manual en-US 02250203-986 R03

E900H User Manual en-US 02250203-986 R03
USER MANUAL
Portable Air Compressor
E900H
PART NUMBER:
02250203-986 R03
SAFETY WARNING
Users are required to read the
entire User Manual before handling or using the product.
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual,
or misuse of this equipment, will
void its warranty.
The information in this manual is current as of its
publication date and applies to compressors with
serial number:
201501010000
and all subsequent serial numbers.
Publication date: 11/9/2015
Copyright © 2012 – 2015 Sullair, LLC. All rights reserved.
Subject to EAR, ECCN EAR99 and related export control restrictions.
Air Care Seminar Training
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Portable compressors 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 seminars are recommended for maintenance,
contractor maintenance, and service personnel.
For detailed course outlines, schedule, and cost information contact:
Sullair Training Department
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
training@sullair.com
- Or Write Sullair, LLC
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
Subject to EAR, ECCN EAR99 and related export control restrictions.
E900H User Manual
Table of Contents
Table of Contents
Section 1: Safety.......................................................................................................1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
General....................................................................................................... 1
Personal protective equipment ................................................................... 1
Pressure release ........................................................................................ 1
Fire and explosion ...................................................................................... 2
Moving parts ............................................................................................... 3
Hot surfaces, sharp edges and sharp corners............................................ 4
Toxic and irritating substances ................................................................... 4
Electrical shock........................................................................................... 5
Lifting .......................................................................................................... 5
Entrapment ................................................................................................. 5
Implementation of lockout/tagout................................................................ 5
Jump starting .............................................................................................. 6
Towing1 ...................................................................................................... 8
1.13.1 Preparing to tow.....................................................................................................8
1.13.2 Towing ...................................................................................................................9
1.13.3 Parking or locating compressor .............................................................................9
1.14
1.15
California proposition 65........................................................................... 11
Symbols and references........................................................................... 12
Section 2: Description............................................................................................17
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
Introduction............................................................................................... 17
Description of components ....................................................................... 17
Sullair compressor unit, functional description ......................................... 17
Air inlet system, functional description ..................................................... 19
Compressor discharge system, functional description ............................. 19
Compressor cooling and lubrication system, functional description ......... 21
Control system, functional description...................................................... 21
Aftercooled air system, functional description .......................................... 22
Instrument panel...................................................................................... 23
Piping and instrumentation diagram ......................................................... 24
Wiring diagram ......................................................................................... 26
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Section 3: Specifications....................................................................................... 29
3.1
3.2
3.3
3.4
3.5
Tables of specifications............................................................................. 29
Lubrication guide—compressor ................................................................ 30
Application guide....................................................................................... 30
Identification—less running gear............................................................... 32
Identification—portable ............................................................................. 34
Section 4: Installation ............................................................................................ 37
4.1
4.2
Fluid level check ....................................................................................... 37
Electrical preparation ................................................................................ 37
Section 5: Operation .............................................................................................. 39
5.1
5.2
5.3
5.4
5.5
5.6
5.7
General ..................................................................................................... 39
Purpose of controls ...................................................................................39
Initial start-up procedure ........................................................................... 40
Normal start-up procedure ........................................................................ 41
Main motor heater.................................................................................... 41
Fan rotation switch.................................................................................... 41
Phase/voltage fault relay........................................................................... 41
Section 6: Maintenance ......................................................................................... 43
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
General ..................................................................................................... 43
Daily operation ..........................................................................................43
Maintenance after initial 50 hours of operation .........................................43
Maintenance every 250 hours................................................................... 43
Maintenance every 300 hours................................................................... 43
Maintenance every 600 hours................................................................... 43
Maintenance every 1000 hours................................................................. 43
Maintenance every 1500 hours................................................................. 44
Parts replacement and adjustment procedures ........................................ 44
6.9.1
6.9.2
6.9.3
6.9.4
6.9.5
6.9.6
6.10
6.11
6.12
6.13
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Compressor fluid change procedure ................................................................... 44
Running gear lubrication ..................................................................................... 44
Wheel bearing lubrication.................................................................................... 45
Main fluid filter servicing ...................................................................................... 46
Air filter maintenance .......................................................................................... 46
Separator element replacement .......................................................................... 47
Pressure relief valve ................................................................................. 48
Hose maintenance .................................................................................... 48
Motor maintenance ...................................................................................48
Control system adjustment ....................................................................... 48
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6.13.1
6.13.2
6.13.3
6.13.4
Differential pressure regulator adjustment...........................................................48
Shaft coupling maintenance ................................................................................49
Unload pressure setting.......................................................................................49
Differential setting ................................................................................................49
Section 7: Troubleshooting ...................................................................................51
7.1
Introduction............................................................................................... 51
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Notes:
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E900H User Manual
1: Safety
Section 1
Safety
factory approval.
NOTE
Each day, walk around the air compressor and inspect
for leaks, loose or missing parts, damaged parts or parts
out of adjustment. Perform all recommended daily
maintenance.
Inspect for torn, frayed, blistered or otherwise
deteriorated and degraded hoses. Replace as required.
Operator is required to read
entire instruction manual.
1.1 General
Sullair designs and manufactures all of its products so
they can be operated safely. However, the responsibility
for safe operation rests with those who use and maintain
these products. The following safety precautions are
offered as a guide which, if conscientiously followed, will
minimize the possibility of accidents throughout the
useful life of this equipment. Read the AEM Safety
Manual prior to compressor operation and towing, if
applicable in your area.
The air compressor should be operated only by those
who have been trained and delegated to do so, and who
have read and understood this Operator’s Manual.
Failure to follow the instructions, procedures and safety
precautions in this manual can result in accidents and
injuries.
1.2 Personal protective equipment
A. Prior to installing or operating the compressor, owners, employers and users should become familiar
with, and comply with, all applicable OSHA regulations and/or any applicable Federal, State and Local
codes, standards, and regulations relative to personal protective equipment, such as eye and face
protective equipment, respiratory protective equipment, equipment intended to protect the extremities,
protective clothing, protective shields and barriers
and electrical protective equipment, as well as noise
exposure administrative and/or engineering controls
and/or personal hearing protective equipment.
1.3 Pressure release
A. Open the pressure relief valve at least weekly to
make sure it is not blocked, closed, obstructed or
otherwise disabled.
NEVER start the air compressor unless it is safe to do so.
DO NOT attempt to operate the air compressor with a
known unsafe condition. Tag the air compressor and
render it inoperative by disconnecting and locking out all
power at source or otherwise disabling its prime mover
so others who may not know of the unsafe condition
cannot attempt to operate it until the condition is
corrected.
B. Install an appropriate flow-limiting valve between the
compressor service air outlet and the shutoff (throttle) valve, when an air hose exceeding 1/2″ (13 mm)
inside diameter is to be connected to the shutoff
(throttle) valve, to reduce pressure in case of hose
failure, per OSHA Standard 29 CFR 1926.302 (b) (7)
or any applicable Federal, State and Local codes,
standards and regulations.
Use and operate the air compressor only in full
compliance with all pertinent OSHA requirements and/or
all pertinent Federal, State and Local codes or
requirements.
C. When the hose is to be used to supply a manifold,
install an additional appropriate flow-limiting valve
between the manifold and each air hose exceeding
1/2″ (13 mm) inside diameter that is to be connected
to the manifold to reduce pressure in case of hose
failure.
DO NOT modify the compressor except with written
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D. Provide an appropriate flow-limiting valve for each
additional 75 feet (23 m) of hose in runs of air hose
exceeding 1/2″ (13 mm) inside diameter to reduce
pressure in case of hose failure.
E. Flow-limiting valves are listed by pipe size and rated
CFM. Select appropriate valve accordingly.
F.
DO NOT use tools that are rated below the maximum
rating of this compressor. Select tools, air hoses,
pipes, valves, filters and other fittings accordingly.
DO NOT exceed manufacturer’s rated safe operating
pressures for these items.
G. Secure all hose connections by wire, chain or other
suitable retaining device to prevent tools or hose
ends from being accidentally disconnected and
expelled.
H. Open fluid filler cap only when compressor is not running and is not pressurized. Shut down the compressor and bleed the sump (receiver) to zero internal
pressure before removing the cap.
I.
Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other
component, such as filters and line oilers, and before
attempting to refill optional air line anti-icer systems
with antifreeze compound.
J. Keep personnel out of line with and away from the
discharge opening of hoses, tools or other points of
compressed air discharge.
K. DO NOT use air at pressures higher than 30 psig
(2.1 bar) for cleaning purposes, and then only with
effective chip guarding and personal protective
equipment per OSHA Standard 29 CFR 1910.242 (b)
or any applicable Federal, State and Local codes,
standards and regulations.
L. DO NOT engage in horseplay with air hoses as
death or serious injury may result.
M. This equipment is supplied with an ASME designed
pressure vessel protected by an ASME rated relief
valve. Lift the handle once a week to make sure the
valve is functional. DO NOT lift the handle while
machine is under pressure.
N. If the machine is installed in an enclosed area it is
necessary to vent the relief valve to the outside of the
structure or to an area of non-exposure.
O. DO NOT remove radiator filler cap until the coolant
temperature is below its boiling point. Then loosen
cap slowly to its stop to relieve any excess pressure
and make sure coolant is not boiling before removing
2
cap completely. Remove radiator filler cap only when
cool enough to touch with a bare hand.
P. The ethyl ether in the replaceable cylinders used in
diesel ether starting aid systems (optional) is under
pressure. DO NOT puncture or incinerate those cylinders. DO NOT attempt to remove the center valve
core or side pressure relief valve from these cylinders regardless of whether they are full or empty.
Q. If a manual blowdown valve is provided on the
receiver, open the valve to ensure all internal pressure has been vented prior to servicing any pressurized component of the compressor air/fluid system.
1.4 Fire and explosion
WARNING
Do not attempt to operate the compressor in any
classification of hazardous environment or
potentially explosive atmosphere unless the
compressor has been specially designed and
manufactured for that duty.
A. Refuel at a service station or from a fuel tank
designed for its intended purpose. If this is not possible, ground the compressor to the dispenser prior to
refueling.
B. Clean up spills of lubricant or other combustible substances immediately, if such spills occur.
C. Shut off air compressor and allow it to cool. Then
keep sparks, flames and other sources of ignition
away and DO NOT permit smoking in the vicinity
when adding fuel, checking or adding electrolyte to
batteries, checking or adding fluid, checking diesel
engine ether starting aid systems, replacing cylinders, or when refilling air line anti-icer systems antifreeze compound.
D. DO NOT permit fluids, including air line anti-icer system antifreeze compound or fluid film, to accumulate
on, under or around acoustical material, or on any
external surfaces of the air compressor. Wipe down
using an aqueous industrial cleaner or steam clean
as required. If necessary, remove acoustical material, clean all surfaces and then replace acoustical
material. Any acoustical material with a protective
covering that has been torn or punctured should be
replaced immediately to prevent accumulation of liq-
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uids or fluid film within the material. DO NOT use
flammable solvents for cleaning purposes.
E. Disconnect and lock out all power at source prior to
attempting any repairs or cleaning of the compressor
or of the inside of the enclosure, if any.
F.
Keep electrical wiring, including all terminals and
pressure connectors in good condition. Replace any
wiring that has cracked, cut, abraded or otherwise
degraded insulation, or terminals that are worn, discolored or corroded. Keep all terminals and pressure
connectors clean and tight.
G. Turn off battery charger before making or breaking
connections to the battery.
H. Keep grounded and/or conductive objects such as
tools away from exposed live electrical parts such as
terminals to avoid arcing which might serve as a
source of ignition.
I.
Replace damaged fuel tanks or lines immediately
rather than attempt to weld or otherwise repair them.
DO NOT store or attempt to operate the compressor
with any known leaks in the fuel system. Tag the
compressor and render it inoperative until repair can
be made.
J. Remove any acoustical material or other material
that may be damaged by heat or that may support
combustion and is in close proximity, prior to attempting weld repairs.
K. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when servicing
and operating the compressor.
L. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.
P. DO NOT attempt to use ether as a starting aid in gasoline engines or diesel engines with glow plugs as
serious personnel injury or property damage may
result.
Q. DO NOT spray ether into compressor air filter or into
an air filter that serves both the engine and the compressor as serious damage to the compressor or personal injury may result.
R. Antifreeze compound used in air line anti-icer systems contains methanol which is flammable. Use
systems and refill with compound only in well-ventilated areas away from heat, open flames or sparks.
DO NOT expose any part of these systems or the
antifreeze compound to temperatures above 150 °F
(66 °C). Vapors from the antifreeze compound are
heavier than air. DO NOT store compound or discharge treated air in confined or unventilated areas.
DO NOT store containers of antifreeze compound in
direct sunlight.
S. Store flammable fluids and materials away from your
work area. Know where fire extinguishers are and
how to use them, and for what type of fire they are
intended. Check readiness of fire suppression systems and detectors if so equipped.
T.
DO NOT operate the compressor without proper flow
of cooling air or water or with inadequate flow of lubricant or with degraded lubricant.
U. DO NOT attempt to operate the compressor in any
classification of hazardous environment unless the
compressor has been specially designed and manufactured for that duty.
1.5 Moving parts
M. Open all access doors and allow the enclosure to
ventilate thoroughly prior to attempting to start the
engine.
N. DO NOT operate compressor under low overhanging
leaves or permit such leaves to contact hot exhaust
system surfaces when operating the compressor in
forested areas.
O. Ethyl ether used in diesel engine ether starting aid
systems is extremely flammable. Change cylinders,
or maintain or troubleshoot these systems only in
well-ventilated areas away from heat, open flame or
sparks. DO NOT install, store or otherwise expose
ether cylinders to temperatures above 160°F (71°C).
Remove ether cylinder from the compressor when
operating in ambient temperatures above 60°F
(16°C).
WARNING
Disconnect and lock out all power at source and
verify at the compressor that all circuits are deenergized to minimize the possibility of accidental start-up, or operation, prior to attempting
repairs or adjustments. This is especially important when compressors are remotely controlled.
A. Keep hands, arms and other parts of the body and
also clothing away from couplings, fans and other
moving parts.
B. DO NOT attempt to operate the compressor with the
fan, coupling or other guards removed.
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Standards 29 CFR 1920 and any other Federal, State
or Local codes or regulations.
C. Wear snug-fitting clothing and confine long hair when
working around this compressor, especially when
exposed to hot or moving parts.
D. Make sure all personnel are out of and/or clear of the
compressor prior to attempting to start or operate it.
DANGER
E. When adjusting the controls, it may require operation
of the equipment during adjustment. DO NOT come
in contact with any moving parts while adjusting the
control regulator and setting the engine RPM. Make
all other adjustments with the engine shut off. When
necessary, make adjustment, other than setting control regulator and engine RPM, with the engine shut
off. If necessary, start the engine and check adjustment. If adjustment is incorrect, shut engine off, readjust, then restart the engine to recheck adjustment.
F.
Death or serious injury can result from inhaling
compressed air without using proper safety
equipment. See OSHA standards and/or any
applicable Federal, State, and Local codes, standards and regulations on safety equipment.
Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water or other liquids to
minimize the possibility of slips and falls.
1.6 Hot surfaces, sharp edges and
sharp corners
B. DO NOT use air line anti-icer systems in air lines
supplying respirators or other breathing air utilization
equipment and DO NOT discharge air from these
systems into unventilated or other confined areas.
A. Avoid bodily contact with hot fluid, hot coolant, hot
surfaces and sharp edges and corners.
C. Operate the compressor only in open or adequately
ventilated areas.
B. Keep all parts of the body away from all points of air
discharge and away from hot exhaust gases.
D. Locate the compressor so that exhaust fumes are not
apt to be carried towards personnel, air intakes servicing personnel areas or towards the air intake of
any portable or stationary compressor.
C. Wear personal protective equipment including gloves
and head covering when working in, on or around the
compressor.
D. Keep a first aid kit handy. Seek medical assistance
promptly in case of injury. DO NOT ignore small cuts
and burns as they may lead to infection.
1.7 Toxic and irritating substances
A. DO NOT use air from this compressor for respiration
(breathing) except in full compliance with OSHA
E. Fuels, fluids and lubricants used in this compressor
are typical of the industry. Care should be taken to
avoid accidental ingestion and/or skin contact. In the
event of ingestion, seek medical treatment promptly.
Wash with soap and water in the event of skin contact. Consult Material Safety Data Sheet for information pertaining to the specific fluid.
F.
Wear goggles or a full face shield when adding antifreeze compound to air line anti-icer systems.
G. Wear an acid-resistant apron and a face shield or
goggles when servicing the battery. If electrolyte is
spilled on skin or clothing, immediately flush with
large quantities of water.
H. Ethyl ether used in diesel engine ether starting aid
systems is toxic, harmful or fatal if swallowed. Avoid
contact with the skin or eyes and avoid breathing the
fumes. If swallowed, DO NOT induce vomiting and
call a physician immediately.
I.
4
Wear goggles or a full face shield when testing ether
starting aid systems or when adding antifreeze com-
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pound to air line anti-icer systems. Keep openings of
valve or atomizer tube of ether starting aid system
pointed away from yourself and other personnel.
J. If air line anti-icer system antifreeze compound
enters the eyes or if fumes irritate the eyes, they
should be washed with large quantities of clean
water for fifteen minutes. A physician, preferably an
eye specialist, should be contacted immediately.
K. DO NOT store ether cylinders or air line anti-icer system antifreeze compound in operator’s cabs or in
other similar confined areas.
L. The antifreeze compound used in air line antifreeze
systems contains methanol and is toxic, harmful or
fatal if swallowed. Avoid contact with the skin or eyes
and avoid breathing the fumes. If swallowed, induce
vomiting by administering a tablespoon of salt, in
each glass of clean, warm water until vomit is clear,
then administer two teaspoons of baking soda in a
glass of clean water. Have patient lay down and
cover eyes to exclude light. Call a physician immediately.
B. Inspect lifting bail and points of attachment for
cracked welds and for cracked, bent, corroded or
otherwise degraded members and for loose bolts or
nuts prior to lifting.
C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has
a rated capacity of at least the net weight of the compressor plus an additional 10% allowance for weight
of water, snow, ice, mud, stored tools, and equipment. If your are unsure of the weight, then weigh
compressor before lifting.
D. Make sure lifting hook has a functional safety latch or
equivalent, and is fully engaged and latched on the
bail.
E. Use guide ropes or equivalent to prevent twisting or
swinging of the compressor once it has been lifted
clear of the ground.
F.
DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away from the
compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
1.8 Electrical shock
I.
A. Keep the towing vehicle or equipment carrier, compressor hoses, tools and all personnel at least 10
feet (3 m) from power lines and buried cables.
B. Stay clear of the compressor during electrical storms!
It can attract lightning.
Keep lift operator in constant attendance whenever
compressor is suspended.
J. Set compressor down only on a level surface capable of supporting at least its net weight plus an additional 10% allowance for the weight of water, snow,
ice, mud, stored tools, and/or equipment.
C. Keep all parts of the body and any hand-held tools or
other conductive objects away from exposed live
parts of electrical system. Maintain dry footing, stand
on insulating surfaces and DO NOT contact any
other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical
system.
K. If the compressor is provided with parking brakes,
make sure they are set, and in any event, block or
chock both sides of all running wheels before disengaging the lifting hook.
D. Attempt repairs in clean, dry and well lighted and
ventilated areas only.
A.
Make sure all personnel are out of compressor
before closing and engaging enclosure doors.
B.
If the compressor is large enough to hold a man and
if it is necessary to enter it to perform service adjustments, inform other personnel before doing so, or
else secure the access door in the open position to
avoid the possibility of others closing and possibly
latching the door with personnel inside.
1.9 Lifting
A. If the compressor is provided with a lifting bail, then
lift by the bail provided. If no bail is provided, then lift
by sling. Compressors to be air lifted by helicopter
must not be supported by the lifting bail, but by
slings instead. In any event, lift only in full compliance
with OSHA Standards 29 CFR 1910 subpart N or any
other Local, State, Military and Federal regulations
that may apply.
1.10 Entrapment
1.11 Implementation of lockout/tagout
The energy control procedure defines actions necessary
to lockout a power source of any machine to be repaired,
serviced or set-up, where unexpected motion, or an
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electrical or other energy source, would cause personal
injury or equipment damage. The power source on any
machine shall be locked out by each employee doing the
work except when motion is necessary during setup,
adjustment or trouble-shooting.
A. The established procedures for the application of
energy control shall cover the following elements and
actions and shall be initiated only by Authorized Persons and done in the following sequence:
9. Verify Isolation: Before work is started, test
equipment to ensure power is disconnected.
B. General Security
3. Check to make certain no one is operating
the machine before turning off the power.
1. The lock shall be removed by the “Authorized” person who put the lock on the
energy-isolating device. No one other than
the person/persons placing padlocks and
lockout hasps on power shall remove padlock and lockout hasps and restore power.
However, when the authorized person who
applied the lock is unavailable to remove it
his/her Supervisor may remove padlock/padlocks and lockout hasps and restore power
only if it is first:
4. Turn off the equipment using normal shutdown procedure.
a. verified that no person will be exposed to
danger.
5. Disconnect the energy sources:
b. verified that the “Authorized” person who
applied the device is not in the facility.
1. Review the equipment or machine to be
locked and tagged out.
2. Alert operator and supervisor of which
machine is to be worked on, and that power
and utilities will be turned off.
a. Air and hydraulic lines should be bled,
drained and cleaned out. There should
be no pressure in these lines or in the
reservoir tanks. Lockout or tag lines or
valves.
b. Any mechanism under tension or pressure, such as springs, should be
released and locked out or tagged.
c.
Block any load or machine part prior to
working under it.
d. Electrical circuits should be checked with
calibrated electrical testing equipment
and stored energy and electrical capacitors should be safely discharged.
6. Lockout and/or Tagout each energy source
using the proper energy isolating devices
and tags. Place lockout hasp and padlock or
tag at the point of power disconnect where
lockout is required by each person performing work. Each person shall be provided with
their own padlock and have possession of
the only key. If more than one person is
working on a machine each person shall affix
personal lock and tag using a multi-lock
device.
7. Tagout devices shall be used only when
power sources are not capable of being
locked out by use of padlocks and lockout
hasp devices. The name of the person affixing tag to power source must be on tag along
with date tag was placed on power source.
6
8. Release stored energy and bring the equipment to a “zero mechanical state”.
c.
noted that all reasonable efforts to contact the “Authorized” person have been
made to inform him or her that the lockout or tagout device has been removed.
d. ensured that the “Authorized” person is
notified of lock removal before returning
to work.
2. Tagout System—Tags are warning devices
affixed at points of power disconnect and are
not to be removed by anyone other that the
person placing tag on power lockout. Tags
shall never be by-passed, ignored, or otherwise defeated.
1.12 Jump starting
A. Observe all safety precautions mentioned elsewhere
in this manual.
B. Batteries may contain hydrogen gas which is flammable and explosive. Keep flames, sparks and other
sources of ignition away.
C. Batteries contain acid which is corrosive and poisonous. DO NOT allow battery acid to contact eyes, skin,
fabrics or painted surfaces as serious personal injury
or property damage could result. Flush any contacted areas thoroughly with water immediately.
Always wear an acid-resistant apron and face shield
when attempting to jump start the compressor.
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D. Remove all vent caps (if so equipped) from the battery or batteries in the compressor. DO NOT permit
dirt or foreign matter to enter the open cells.
E. Check fluid level. If low, bring fluid to proper level
before attempting to jump start (not applicable to
maintenance-free batteries).
F.
DO NOT attempt to jump start if fluid is frozen or
slushy. Bring batteries up to at least 60°F (16°C)
before attempting to jump start or it may explode.
G. Cover open cells of all compressor batteries with
clean dampened cloths before attempting to jump
start.
H. Attempt to jump start only with a vehicle having a
negative ground electrical system with the same voltage, and is also equipped with a battery or batteries
of comparable size or larger than supplied in the
compressor. DO NOT attempt to jump start using
motor generator sets, welders or other sources of DC
power as serious damage may result.
I.
Bring the starting vehicle alongside the compressor,
but DO NOT permit metal to metal contact between
the compressor and the starting vehicle.
J. Set the parking brakes of both the compressor (if provided) and the starting vehicle or otherwise block
both sides of all wheels.
K. Place the starting vehicle in neutral or park, turn off
all non-essential accessory electrical loads and start
its engine.
L. Use only jumper cables that are clean, in good condition and are heavy enough to handle the starting current.
M. Avoid accidental contact between jumper cable terminal clips or clamps and any metallic portion of
either the compressor or the starting vehicle to minimize the possibility of uncontrolled arcing which
might serve as a source of ignition.
N. Positive battery terminals are usually identified by a
plus (+) sign on the terminal and the letters POS
adjacent to the terminal. Negative battery terminals
are usually identified by the letters NEG adjacent to
the terminal or a negative (-) sign.
O. Connect one end of a jumper cable to the positive
(POS) (+) battery terminal in the starting vehicle.
When jump starting 24V compressors and if the start-
ing vehicle is provided with two (2) 12V batteries connected in series, connect the jumper cable to the
positive (POS) (+) terminal of the ungrounded battery.
P. Connect the other end of the same jumper cable to
the positive (POS) (+) terminal of the starter motor
battery in the compressor when jump starting 24V
compressors, to the positive (POS) (+) terminal of
the ungrounded battery in the compressor.
Q. Connect one end of the other jumper cable to the
grounded negative (NEG) (-) terminal of the battery
in the starting vehicle. When jump starting 24V compressors and if the starting vehicle is provided with
two (2) 12V batteries connected in series, connect
the jumper cable to the negative (NEG) (-) terminal of
the grounded battery.
R. Check your connections. DO NOT attempt to start a
24V compressor with one 12V battery in the starting
vehicle. DO NOT apply 24V to one 12V battery in the
compressor.
S. Connect the other end of this same jumper cable to a
clean portion of the compressor engine block away
from fuel lines, the crank case breather opening and
the battery.
T.
Start the compressor in accordance with normal procedure. Avoid prolonged cranking.
U. Allow the compressor to warm up. When the compressor is warm and operating smoothly at normal
idle RPM, disconnect the jumper cable from the
engine block in the compressor, then disconnect the
other end of this same cable from the grounded negative (NEG) (-) terminal of the battery in the starting
vehicle. Then disconnect the other jumper cable from
the positive (POS) (+) terminal of the battery in the
compressor, or if provided with two (2) 12V batteries
connected in series, from the ungrounded battery in
the compressor, and finally, disconnect the other end
of this same jumper cable from the positive (POS) (+)
terminal of the battery in the starting vehicle or from
the positive (POS) (+) terminal of the ungrounded
battery in the starting vehicle, if it is provided with two
(2) 12V batteries connected in series.
V. Remove and carefully dispose of the dampened
cloths, as they may now be contaminated with acid,
then replace all vent caps.
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1.13 Towing1
each chain to itself by passing the grab hook over
(not through) a link. Cross chains under the front of
drawbar before passing them through points of
attachment on towing vehicle to support the front of
drawbar in case it should accidentally become
uncoupled.
1.13.1 Preparing to tow
WARNING
F.
Do NOT tow the compressor should its weight
exceed the rated limit of the tow vehicle, as the
vehicle may not brake safely with excess weight.
See rated limit in tow vehicle Operator's Manual,
and review its instructions and other requirements for safe towing.
A. Prior to hitching the air compressor to the tow vehicle, inspect all attachment parts and equipment,
checking for (I) signs of excessive wear or corrosion,
(II) parts that are cracked, bent, dented or otherwise
deformed or degraded, and (III) loose nuts, bolts or
other fasteners. Should any such condition be present, DO NOT TOW until the problem is corrected.
B. Back the tow vehicle to the compressor and position
it in preparation for coupling the compressor.
C. If the compressor is provided with a drawbar latched
in the vertical upright position, carefully unlatch drawbar and lower it to engage the coupling device. If not,
raise drawbar with the jack to engage coupling
device or otherwise couple the compressor to the
towing vehicle.
WARNING
This equipment may be tongue heavy. DO NOT
attempt to raise or lower the drawbar by hand if
the weight is more than you can safely handle.
Use the screw jack provided or a chain fall if you
cannot lift or lower it without avoiding injury to
yourself or others. Keep hands and fingers clear
of the coupling device and all other pinch points.
Keep feet clear of drawbar to avoid injury in case
it should slip from your hands.
D. Make sure the coupling device is fully engaged,
closed and locked.
E. If chains are provided, pass each chain through its
point of attachment on the towing vehicle; then hook
8
Make sure that the coupling device and adjacent
structures on the towing vehicle (and also, if utilized,
chain adjustment, brake and/or electrical interconnections) DO NOT interfere with or restrict motion of
any part of the compressor, including its coupling
device, with respect to the towing vehicle when
maneuvering over any anticipated terrain.
G. If provided, make sure chain length, brake and electrical interconnections provide sufficient slack to prevent strain when cornering and maneuvering, yet are
supported so they cannot drag or rub on road, terrain
or towing vehicle surfaces which might cause wear
that could render them inoperative.
WARNING
This equipment may be tongue heavy. DO NOT
attempt to raise or lower the drawbar by hand if
the weight is more than you can safely handle.
CAUTION
Retract the front screw jack only after attaching
the compressor to the tow vehicle. Raise the
screw jack to its full up position and pull the pin
connecting the jack to the drawbar. Rotate the
screw jack to its stowed position, parallel to the
drawbar, and reinsert the pin. Make sure the jack
is secured in place prior to towing.
If a caster wheel is provided on the screw jack it
is part of the screw jack and can not be
removed. Follow the same procedure for stowing away the wheeled jack as you would for the
standard screw jack. Pull the pin connecting the
jack to the drawbar and raise the screw jack to
its full up position. Rotate the screw jack to its
stowed position, parallel to the drawbar, and
reinsert the pin. Make sure the jack is secured in
place prior to towing.
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H. On two-wheeled models, fully retract front screw jack
and any rear stabilizer legs. If a caster wheel is provided on the screw jack it is part of the screw jack,
and can not be removed. Follow the same procedure
for stowing away the wheeled jack as you would for
the standard screw jack. Pull the pin connecting the
jack to the drawbar and raise the screw jack to its full
upright position. Rotate the screw jack to its stowed
position, parallel to the drawbar, and reinsert the pin.
Make sure the jack is secured in place prior to towing.
I.
Make sure tires are in good condition and are the
size (load range) specified and are inflated to the
specified pressures. DO NOT change the tire size or
type. Also, make sure wheel bolts, lugs or nuts are
tightened to the specified torques.
J. If provided, make sure all dual stop, tail directional
and clearance lights are operating properly and that
their lenses are clean and functional. Also, make
sure all reflectors and reflecting surfaces, including
the slow moving vehicle emblem on compressors
provided with same, are clean and functional.
K. Make sure all service air hoses (not air brake hoses)
are disconnected or are fully stowed and secured on
hose reels, if provided.
L. Make sure all access doors and tool box covers are
closed and latched. If the compressor is large
enough to hold a man, make sure all personnel are
out before closing and latching access doors.
M. Make sure parking brakes in towing vehicle are set,
or that its wheels are chocked or blocked, or that it is
otherwise restrained from moving. Then, release the
compressor parking brakes, if provided.
N. Make sure the compressor wheels are not chocked
or blocked, and that all tie-downs, if any, are free.
O. Test running brake operation, including breakaway
switch operation if provided, before attempting to tow
the compressor at its rated speed or less when conditions prevail.
P. DO NOT carry loose or inappropriate tools, equipment or supplies on or in the compressor.
Q. DO NOT load this equipment with accessories or
tools such that it is unbalanced from side to side or
front to back. Such unbalance will reduce the towability of this equipment and may increase the possibility
of tipping, rolling over, jackknifing, etc. Loss of control
of the towing vehicle may result.
1.13.2 Towing
A. Observe all Federal, State, and Local laws while towing this equipment (including those specifying minimum speed).
B. DO NOT exceed the towing speeds listed below
under ideal conditions. Reduce your speed according
to posted speed limits, weather, traffic, road or terrain
conditions:
C. Two axle four-wheel or three axle six-wheel steerable
models: 15 mph (24 km/h).
D. All other models: 55 mph (88 km/h).
E. Remember that the portable air compressor may
approach or exceed the weight of the towing vehicle.
Maintain increased stopping distances accordingly.
DO NOT make sudden lane changes, U-turns or
other maneuvers. Such maneuvers can cause the
compressor to tip, roll over, jackknife or slide and
cause loss of control of the towing vehicle. Tipping,
rolling over, etc. can occur suddenly without warning.
U-turns especially should be made slowly and carefully.
F.
Avoid grades in excess of 15° (27%).
G. Avoid potholes, rocks and other obstructions, and
soft shoulders or unstable terrain.
H. Maneuver in a manner that will not exceed the freedom of motion of the compressor’s drawbar and/ or
coupling device, in or on the towing vehicle’s coupling device and/or adjacent structure whether towing forward or backing up, regardless of the terrain
being traversed.
I.
DO NOT permit personnel to ride in or on the compressor.
J. Make sure the area behind, in front of, and under the
compressor is clear of all personnel and obstructions
prior to towing in any direction.
K. DO NOT permit personnel to stand or ride on the
drawbar, or to stand or walk between the compressor
and the towing vehicle.
1.13.3 Parking or locating compressor
A. Park or locate compressor on a level surface, if possible. If not, park or locate compressor across grade
so the compressor does not tend to roll downhill. DO
NOT park or locate compressor on grades exceeding
15° (27%).
B. Make sure compressor is parked or located on a firm
surface that can support its weight.
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C. Park or locate compressor so the wind, if any, tends
to carry the exhaust fumes and radiator heat away
from the compressor air inlet openings, and also
where the compressor will not be exposed to excessive dust from the work site.
CAUTION
Retract the front screw jack only after attaching
the compressor to the tow vehicle. Raise the
screw jack to its full up position and pull the pin
connecting the jack to the drawbar. Rotate the
screw jack to its stowed position, parallel to the
drawbar, and reinsert the pin. Make sure the jack
is secured in place prior to towing.
D. On steerable models, park compressor with front
wheels in straight-ahead position.
E. Set parking brakes and disconnect breakaway switch
cable and all other interconnecting electrical and/or
brake connections, if provided.
F.
On two-wheeled models, fully retract front screw
jack and any rear stabilizer legs. If a caster wheel
is provided on the screw jack it is part of the
screw jack and can not be removed. Follow the
same procedure for stowing away the wheeled
jack as you would for the standard screw jack.
Pull the pin connecting the jack to the drawbar
and raise the screw jack to its full up position.
Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make
sure the jack is secured in place prior to towing.
Block or chock both sides of all wheels.
G. If provided, unhook chains and remove them from
the points of chain attachment on the towing vehicle,
then hook chains to bail on drawbar or wrap chains
around the drawbar and hook them to themselves to
keep chains off the ground which might accelerate
rusting.
H. Lower front screw jack and/or any front and rear stabilizer legs. Make sure the surface they contact has
sufficient load bearing capability to support the
weight of the compressor.
I.
WARNING
This equipment may be tongue heavy. DO NOT
attempt to raise or lower the drawbar by hand if
the weight is more than you can safely handle.
If a caster wheel is provided on the screw jack, it is
part of the screw jack and cannot be removed. Follow
the same procedure for stowing away the wheeled
jack as you would for the standard screw jack. Raise
the screw jack to its full upright position and pull the
pin connecting the jack to the drawbar. Rotate the
screw jack to its stowed position, parallel to the drawbar and reinsert the pin. Make sure the jack is
secured in place prior to towing.
J. Disconnect coupling device, keeping hands and fingers clear of all pinch points. If the compressor is
provided with a drawbar, DO NOT attempt to lift the
drawbar or if hinged, to raise it to the upright position
by hand, if the weight is more than you can safely
handle. Use a screwjack or chain fall if you cannot lift
or raise the drawbar without avoiding injury to yourself or others.
K. Move the towing vehicle well clear of the parked
compressor and erect hazard indicators, barricades
and/or flares (if at night) if compressor is parked on
or adjacent to public roads. Park so as not to interfere with traffic.
NOTE
While not towed in the usual sense of the word,
many of these instructions are directly applicable
to skidmounted portable air compressors as well.
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1.14 California proposition 65
WARNING
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and other compounds known to the
State of California to cause cancer and birth
defects and other reproductive harm. Wash
hands after handling.
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1.15 Symbols and references
The symbols below may or may not be used. Please refer to the decals set forth on the machine for applicable
symbols.
DIESEL FUEL
HEARING PROTECTION
ROTARY COMPRESSOR
HARD HAT
TEST RUN
DRAIN
SAFETY GLASSES
HIGH PRESSURE
HOOK HERE
SHUT-OFF VALVE
W/ SAFETY
DO NOT REMOVE
MANUAL
NO
ENGINE
DO NOT BREATHE
COMPRESSED AIR
COMPRESSOR
DO NOT STAND ON
SERV. VALVE
ENGINE OIL
DO NOT OPERATE
W/ DOORS OPEN
ENGINE COOLANT
WATER
DO NOT OPEN
OIL
DO NOT STACK
ELECTRICAL SHOCK
DO NOT
CLOSED MECHANICAL
AIR FLOW
FUSE
HOT SURFACE
LOW PRESSURE
PRESSURIZED VESSEL
READ MANUAL
BRAKES
12
PRESSURIZED
COMPONENT
SAFETY SYMBOLS 1
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ENGINE START
DANGEROUS OUTLET
ENGINE ECM
REMOTELY
CONTROLLED
READ/WRITE DATA
CORROSIVE
INTAKE AIR
EXHAUST GAS
WARNING
FAN GUARD
DO NOT
MAINTENANCE
BELOW TEMPERATURE
BELT GUARD
DO NOT TOW
SERVICE POINT
BAR/PSI
LOW TEMPERATURE
BATTERY
BATTERY DISCONNECT
STD AIR
OFF
A/C AIR
ON
24 HOURS
RESET
BELTS
FILTER
NO FORKLIFT
STRAINER
FORK LIFT HERE
SAFETY SYMBOLS 2
DIRECTION OF ROTATION
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RADIATOR
HOUR METER
AIR-CIRCULATING
FAN
COMPRESSOR AIR
PRESSURE
AIR-COOLED
OIL COOLER
START
CONTROL
LIQUID-COOLED
OIL COOLER
ENGINE PREHEAT
LOW TEMP AID
LUBRICATION
ENGINE WARNING
TRAILER TOWING
MODE
FUEL LEVEL
AXEL
ENGINE RPM
LUBRICANT GREASE
EXAMINE, CHECK
ENGINE OIL
PRESSURE
CRUSH/PINCH POINT
ENGINE COOLANT
TEMPERATURE
FUNCTIONAL ARROW
COMPRESSOR
TEMPERATURE
DO NOT MIX
COOLANTS
ENGINE INTAKE
AIR FILTER
AFTERCOOLER
BYPASS VALVE
PRESSURE CONTROL
INLET VALVE SPRING
DRAIN HEATER
INTERNAL FUEL
BATTERY HEATER
EXTERNAL FUEL
COMPRESSOR
OIL HEAT
SIDE DOOR T-LATCH
STACKING LIMIT
BY NUMBER
SAFETY SYMBOLS 3
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DO NOT OPERATE
WHILE STACKED
WATER DRAIN
PRESSURIZED SPRING
SEVER (FAN)
DO NOT MIX FLUIDS
DEF FLUID ONLY
AUTO START/STOP
RUN
FLUID DRAIN
LOW FUEL
DPF: DIESEL
PARTICULATE FILTER
HEST: HIGH EMISSIONS
SYSTEM TEMPERATURE
DPF REGEN. INHIBIT
EMISSIONS
MALFUNCTION
INDICATION
SAFETY SYMBOLS 4
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Notes:
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2: Description
Section 2
Description
2.1 Introduction
Sullair portable air compressor models offer superior performance and reliability while requiring only minimal
maintenance.
The compressor is equipped with a Sullair rotary screw
compressor unit. Compared to other compressors, the
Sullair is unique in mechanical reliability and compressor
durability. No inspection is required of the working parts
within the compressor unit.
As you continue reading this manual and come to learn
how the compressor operates and is cared for, you will
see how surprisingly easy it is to keep a Sullair compressor in top operating condition.
Read Section 6: Maintenance to keep your compressor
in top operating condition. Should any problem or question arise which cannot be answered in this text, contact
your nearest Sullair representative or the Sullair Service
Department.
2.2 Description of components
Refer to Figure 2-1. The components and assemblies of
the Sullair portable air compressor models are clearly
shown. The package includes a compressor, electric
motor, compressor inlet system, compressor cooling and
lubrication system, compressor discharge system,
capacity control system, instrument panel and electrical
system.
The electric motor is direct coupled to the compressor
unit via a flexible coupling. A separate electric motordriven fan forces air through the cooler/aftercooler
assembly, thereby removing the heat of compression
from the cooling fluid.
2.3 Sullair compressor unit,
functional description
Sullair compressors feature the Sullair compressor unit, a
single-stage, positive displacement, flood lubricated-type
compressor. This unit provides continuous compression
to meet your needs.
NOTE
With a Sullair compressor, there is no maintenance or inspection of the internal parts of the
compressor unit permitted in accordance with
the terms of the warranty.
Sullair compressors are factory-filled with Sullair AWF®
lubricant. For more information on fluid fill, refer to Section 3.3: Application guide on page 30.
Fluid is injected into the compressor unit hoses and
mixes directly with the air as the rotors turn, compressing
the air. The fluid flow has three basic functions:
• As coolant, it controls the rise of air temperature normally associated with the heat of compression.
• Seals the clearance paths between the rotors
and the stator and also between the rotors
themselves.
• Acts as a lubricating film between the rotors
allowing one rotor to directly drive the other,
which is an idler.
After the air/fluid mixture is discharged from the compressor unit, the fluid is separated from the air. At this time,
the air flows through an aftercooler and separator then to
your service line while the fluid is being cooled in preparation for reinjection.
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1. Cooler assembly
8. Afterfilters
2. Lifting bail
9. Minimum pressure valve
3. Air filter
10. E-Stop button
4. Main motor
11. Fluid filters
5. Cooling fan
12. Electrical cabinet
6. Sump tank
13. Control panel
7. Moisture separator
Figure 2-1: E900H compressor
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2: Description
2.4 Air inlet system, functional
description
2.5 Compressor discharge system,
functional description
Refer to Figure 2-3. The Sullair compressor unit discharges compressed air/fluid mixture into the receiver
tank.
The receiver tank has three functions:
• It acts as a primary fluid separator.
• Serves as the compressor fluid storage sump.
• Houses the final fluid separator.
1. Air filter
4. Compressor
2. Inlet valve
5. Restriction indicator
3. Inlet adapter
6. Air inlet elbow
Figure 2-2: Air inlet system
Refer to Figure 2-2. The compressor inlet system consists of one air filter, a compressor air inlet valve and
interconnecting piping to the compressor. Also, an air filter restriction indicator gauge is located next to the air filter housing.
The air filter is a 2-stage unit with a safety element dry
element-type filter. This filter is capable of cleaning
extremely dirty air. However, in such cases, frequent
checks of the air filter will be required. Referring to the air
filter restriction gauge will indicate when restriction of the
air passing through the filter becomes too high.
At this time, change the air filter element. Refer to Section 6.9.5: Air filter maintenance on page 46. This indicator should be checked daily, after start-up under normal
conditions.
The compressor air inlet valve controls the amount of air
intake of the compressor in response to the air demand.
The compressed air/fluid mixture enters the receiver tank
and is directed against the tank side wall. By change of
direction and reduction of velocity, large droplets of fluid
separate and fall to the bottom of the receiver tank. The
fractional percentage of fluid remaining in the compressed air collects on the surface of the final separator
element as the compressed air flows through the separator. As more and more fluid collects on the element’s surface, the fluid descends to the bottom of the separator. A
return line (or scavenge tube) leads from the bottom of
the separator element to the inlet region of the compressor unit. Fluid collecting on the bottom of the separator
element is returned to the compressor by the pressure
difference between the area surrounding the separator
element and the compressor inlet. An orifice (protected
by a strainer) is included in this return line to help assure
proper flow.
The receiver tank is code rated. A minimum pressure/
check valve, located downstream from the separator,
helps assure a minimum receiver pressure during all conditions. This pressure is necessary for proper air/fluid
separation and proper fluid circulation.
A minimum pressure/check valve at the outlet of the
receiver is installed to prevent compressed air in the service line from bleeding back into the receiver on shutdown when the compressor is being run in parallel with
other compressors tied to a large air system.
Fluid is added to the receiver tank via a capped fluid filler.
A fluid level gauge glass enables the operator to visually
monitor the receiver tank fluid level.
WARNING
Do not remove caps, plugs and/or other components when compressor is running or pressurized.
Stop compressor and relieve all internal pressure before doing so.
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1. Compressor air filter
11. Thermal valve/fluid filter assembly
2. Electric motor
12. Receiver tank
3. Compressor unit
13. Fluid level sight gauge
4. Service air (aftercooled)
14. Final fluid separator element
5. Discharge air filters
15. Ball valve
6. Air inlet valve
16. P3 pressure switch
7. Moisture separator
17. Service air (non-aftercooled)
8. Aftercooler
18. Minimum pressure check valve
9. Relief valve
19. Temperature shutdown switch
10. Fluid cooler
Figure 2-3: Compressor flow diagram
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2.6
2: Description
Compressor cooling and lubrication
system, functional description
that works in conjunction with a separate motor-driven
fan. The fan blows air through the cooler removing the
heat of compression from the fluid. From the cooler, the
fluid is routed back to the thermal valve.
Before the temperature of the fluid reaches the valve set
point, cooled fluid is mixed with warmer fluid. When the
temperature of the fluid reaches 190°F (88°C), the thermal element shifts completely causing all fluid to flow to
the cooler. After the fluid passes through the thermal
valve it is then directed through the main fluid filter.
There, the fluid is filtered in preparation for injection into
the compression chamber and bearings of the compressor unit. The filter has replaceable elements. After the
fluid is properly filtered, it then flows on to the compressor unit where it lubricates, seals and cools the compression chamber as well as lubricates the bearings and
gears.
2.7 Control system, functional
description
The purpose of the compressor control system is to regulate the amount of air being compressed to match the
amount of compressed air being used.
1. Hose from oil cooler
5. Hose to oil cooler
2. Fan enclosure
6. Hose to unit
3. Fan guard
7. Fluid filter
4. Fan motor
8. Hose from separator
tank
Figure 2-4: Cooling and lubrication system
Refer to Figure 2-4. The compressor cooling and lubrication system is designed to provide adequate lubrication
as well as maintain the proper operating temperature of
the compressor. In addition to the cooler and fan, the system consists of a main filter and thermal valve.
Fluid is used in the system as a coolant and a lubricant.
The fluid is housed in the receiver tank.
Upon start up, the fluid temperature is cool, and routing
to the cooler is not required. The fluid first enters the thermal valve and then flows on to the compressor unit,
bypassing the cooler. As the compressor continues to
operate, the temperature of the fluid rises and the thermal valve element begins to shift. This forces a portion of
the fluid to the fluid cooler. The cooler is a radiator-type
The capacity control system consists of a pneumatic inlet
valve. The functional description of the control system is
described below in four distinct phases of compressor
operation. For explanatory purposes, this description
applies to any compressor with an operating range of 150
to 165 psig (10.3 to 11.4 bar). A compressor with any
other pressure range would operate in the same manner
except for the stated pressures.
Start mode—0 to 50 psig (0 to 3.4 bar)
When the compressor <START> button is depressed, the
sump pressure will quickly rise from 0 to 50 psig (0 to
3.4 bar). During this period, both of the pressure regulators and the solenoid valve are closed and the pneumatic
inlet valve is inoperative. The internal spring holds the
inlet valve fully closed to reduce motor torque for starting.
After six (6) seconds the solenoid valve will open, opening the inlet valve, and the compressor will run at full
rated capacity. The rising compressor air pressure is isolated from the service line in this phase by the minimum
pressure valve set at approximately 50 psig (3.4 bar).
Full load mode—50 to 150 psig (3.4 to 10.3 bar)
When the compressed air pressure in the sump rises
above 50 psig (3.4 bar), the minimum pressure valve
opens, allowing compressed air to flow into the service
line. A load signal is provided through a pressure reducing regulator set at 70 psig (4.8 bar) to maintain the inlet
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valve in an open position. The inlet valve will remain in
the full load position as long as the compressor is running
at 150 psig (10.3 bar) or below.
from the unload chamber, opening the inlet valve. The
blowdown valve closes, and the inlet valve opens.
Modulation—150 to 165 psig (10.3 to 11.4 bar)
2.8 Aftercooled air system,
functional description
As air demand drops below the rated capacity of the
compressor, the line pressure will rise above 150 psig
(10.3 bar). As the air pressure exceeds 150 psig
(10.3 bar), the differential pressure regulator controlling
the inlet valve opens. This allows the air pressure into the
unload chamber of the inlet valve, which starts partially
closing the inlet valve, providing modulation. During this
period, the pressure rises approximately from 150 to
165 psig (10.3 to 11.4 bar).
Unload mode—in excess of 165 psig (11.4 bar)
When a relatively small amount or no air is being used,
the service line pressure continues to rise. When it
exceeds 165 psig (11.4 bar), the pressure switch energizes the solenoid, applying pressure to the unload
chamber of the inlet valve, which fully closes the valve.
Simultaneously, the solenoid valve sends a pneumatic
signal to the blowdown valve. The blowdown valve opens
the sump to the atmosphere. This reduces the sump
pressure to approximately 25 psig (1.7 bar), which results
in low horsepower consumption. The check valve in the
air service line prevents line pressure from returning to
sump while the compressor is running in the unloaded
mode. The inlet valve remains in the unload position.
When the line pressure drops back to 150 psig (10.3 bar)
due to an increase in the air demand, the pressure switch
de-energizes the solenoid valve removing air pressure
22
Refer to Figure 2-3 and Figure 2-4. The purpose of the
aftercooled air system is to operate the air compressor in
conditions when compressed air temperatures are
required to be 10 to 25°F (5 to 13°C) over ambient temperature. A 3-valve bypass is provided to switch between
standard and aftercooled air. The ambient air, which is
blown through the aftercooler by the motor-driven fan,
cools the compressed air as it passes through the aftercooler core. Cooled air enters the moisture separator
where condensation is removed from the cooler air and
discharged. This condensation does carry some oil and it
should be disposed of properly in accordance with local
regulations. A condensation drain port is located in the
frame on the front of the machine for convenience of condensate removal. This drain port should never be
plugged or closed off in any way. From the moisture separator the compressed air goes through the discharge filters and on to the service valve.
NOTE
Aftercooled system should not be operated in
ambient conditions below 32°F (0°C).
To operate in the non-aftercooled mode, open
and close the appropriate valves.
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2.9
2: Description
Instrument panel
See Figure 2-5. The compressor is provided with an
instrument panel to monitor and control key functions of
the compressor package. To ensure proper operation of
the machine, operators should be familiar with the function and use of each display and control. See Section
5.2: Purpose of controls on page 39 for the details.
Figure 2-5: Instrument panel
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2: Description
24
2.10 Piping and instrumentation diagram
Key Description
1
FILTER, AIR
Qty Notes
1
Key Description
Qty Notes
Drawing notes
2
GAUGE, AIR FILTER RESTRICTION
1
P1
DRY SIDE PRESSURE SWITCH
3
INLET VALVE
1
T1
UNIT DISCHARGE TEMPERATURE SWITCH
4
COMPRESSOR
1
T3
SUMP/SEPARATOR TANK TEMPERATURE SWITCH (RT)
5
VALVE, RELIEF
1
6
SWITCH, TEMPERATURE
1
7
SWITCH, TEMPERATURE
1
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SWITCH, PRESSURE
1
9
SILENCER
1
10
SUMP, AIR/OIL SEPARATOR
1
11
GLASS, SIGHT OIL LEVEL
1
12
VALVE, MINIMUM PRESSURE
1
13
VALVE, BALL
5
14
COOLER, AIR (OPTIONAL)
1
15
SEPARATOR, MOISTURE
1
VALVE, BLOWDOWN NC
1
17
ORIFICE
3
18
GAUGE, TEMPERATURE
1
19
STRAINER
2
20
SIGHT GLASS, BLOCK
1
21
VALVE, THERMAL BYPASS
1
22
COOLER, OIL
1
23
FILTER, OIL
1
24
VALVE, 3-WAY NC
1
25
VALVE, 3-WAY NO
1
26
VALVE, REGULATOR BACK PRESSURE
1
27
GAUGE, PRESSURE
2
28
VALVE, REDUCING REGULATOR
1
29
VALVE, CHECK
3
30
VALVE, RECIRCULATION
1
31
GAUGE, DIFFERENTIAL PRESSURE
2
32
FILTER, AIR
2
33
MOISTURE SEPARATOR
1
25
2: Description
16
E900H User Manual
2.10 Piping and instrumentation diagram
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2: Description
26
2.11 Wiring diagram
Key
Description
M2
Notes
Key
Description
FAN MOTOR
ST2
RECEIVER TANK TEMPERATURE SWITCH
KM4
FAN MOTOR CONTACTOR - FORWARD ROTATION
YV1
LOAD/UNLOAD SOLENOID VALVE
KM5
FAN MOTOR CONTACTOR - REVERSE ROTATION
YV2
RUN/STOP SOLENOID VALVE
YV3
MOISTURE DRAIN SOLENOID VALVE
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QF
CUSTOMER SUPPLIED CIRCUIT BREAKER
QF1
COMPRESSOR MAIN CIRCUIT BREAKER
QF2
FAN MOTOR CIRCUIT PROTECTOR
FU1
PHASE MONITOR RELAY FUSE
FU2
CONTROL TRANSFORMER PRIMARY FUSE
FU3
CONTROL TRANSFORMER SECONDARY FUSE
TC1
CONTROL VOLTAGE TRANSFORMER
EH
MOTOR HEATER
HL1
POWER INDICATOR
HL2
HEATER INDICATOR
HL3
RUN INDICATOR
Notes
E900H User Manual
2.11 Wiring diagram
HL101 HIGH TEMPERATURE WARNING INDICATOR
HL102 COMPRESSOR MOTOR OVERLOAD INDICATOR
HL103 FAN MOTOR OVERLOAD INDICATOR
HM
HOUR METER
KA0
READY RELAY
KA1
RUN RELAY CONTACT
KA2
HIGH TEMP RELAY CONTACT
KA6
PHASE MONITOR RELAY
KT0
STOP LAG TIMING RELAY CONTACT
KT1
WYE-DELTA TIMING RELAY CONTACT
KT2
MOISTURE DRAIN TIMING RELAY CONTACT
SA1
MOTOR HEATER SWITCH
SB1
EMERGENCY STOP CONTACT
RUN/STOP SWITCH
SB3
FAN ROTATION SWITCH
SP1
PRESSURE SWITCH
ST0
MAIN DISCONNECT SWITCH
ST1
COMPRESSOR DISCHARGE TEMPERATURE SWITCH
27
2: Description
SB2
2: Description
E900H User Manual
Notes:
28
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3: Specifications
Section 3
Specifications
3.1 Tables of specifications
Table 3-1: Overall specifications
Length1
Height2
Width
Weight (wet)
Model series
in
mm
in
mm
in
mm
lb
kg
ETQ (Tandem)
195.5
4966
83.3
2115
94.2
2392
11,780
5355
ELQ (LRG)
143.5
3646
78.8
2001
67.1
1705
10,030
4560
1Length
over drawbar where applicable.
2
Over lifting bail.
Table 3-2: Compressor specifications
Compressor
E900H
Type
Rotary screw
Delivery @ operating pressure
900 acfm (25.5 m3/min)
Maximum full load operating pressure
150 psig (10.3 bar)
Rated pressure
150 psig (10.3 bar)
Cooling
Pressurized compressor fluid
Lubricating compressor fluid
See Section 3: Lubrication guide—compressor on page 30
Receiver tank capacity
29 US gallons (110 L)
Operating tilt (maximum)
15°
Operating voltage
460V 60 Hz / 380V 50 Hz
Control voltage
110V 60 Hz / 110V 50 Hz
Sound level at 7 m
73 dB(A)
Spec of air service valve (qty)
NPT 2″ / NPT 1″
Table 3-3: Motor specifications
Item
Detail
Size
214 hp (160 kW)
Type
Totally enclosed fan cooled (TEFC) premium efficient, IP55 enclosure
Starter
Wye-delta
Speed
1780 rpm (60 Hz) / 1480 rpm (50 Hz)
Table 3-4: Trailer specifications
Trailer
DTQ
Track width
67 in (1701 mm)
Tire size (load range)
ST 235/80 R16 (E)
Tire pressure
80 psig (5.5 bar)
Wheel size
16 x 6
Wheel bolt/lugnut torque
85 to 110 ft. lbs. (115 to 149 Nm)
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3: Specifications
E900H User Manual
3.2 Lubrication guide—compressor
Fluid type
Sullair AWF
Change period/hours
Ambient temperature range °F (°C)
1500
-20 to 125 (-29 to 52)
®1
®
2
varies
Sullube
32 to 125 (0 to 52)
SAE 10W SE, SF, SG, CD
250
0 to 100 (-18 to 38)
MIL-L-2104E 10W
250
0 to 100 (-18 to 38)
1
2
Sullair part numbers for Sullair AWF are 250030-757 (5 gallons/18.9 liters) and 250030-758 (55 gallon drum/280 liters).
Models filled with long life Sullube lubricant should be changed under the following conditions, whichever occurs first:
• Every 8000 hours.
• Once a year.
• As indicated by fluid analysis. A fluid sample at every 1000 hours is recommended.
• For information about a free Sullube analysis, contact your Sullair representative.
3.3 Application guide
AWF®
Sullair air compressors are supplied with Sullair
which is a heavy duty multi-viscosity, all weather fluid
which provides an extended change interval when compared to other fluids. Detergent motor oils (SAE 10W
Class SE, SF, SG, or CD) can also be used. Any of these
oils are suitable under conditions where severe oil oxidation can occur.
Water must be drained from the separator tank periodically. In high ambient temperature and humidity conditions, condensed moisture can emulsify with the oil
forming a “milky” color. SAE 10W is especially prone to
this condition. The fluid should be changed if this condition develops.
30
Do not mix different fluids. Combinations of different fluids can lead to operational problems such as foaming,
plugged filters, blocked orifices or lines.
When ambient conditions exceed the recommended
ranges, or if other conditions warrant the use of other
extended life lubricants, contact your local Sullair representative for recommendations.
Sullair encourages users to participate in a fluid analysis
program. The analysis might indicate a need for change
intervals different from those recommended in this manual. Sullair offers a fluid analysis for Sullair AWF. Contact
Sullair for details.
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3: Specifications
Notes:
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3: Specifications
32
3.4 Identification—less running gear
Drawing notes
1
DIMENSIONS ARE IN INCHES BRACKET [ ] DIMENSIONS ARE IN MILLIMETERS.
2
ALLOW 4’ [1,219 MM] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
3
DOORS REQUIRE 4’ [1,219 MM] MAXIMUM OPENING CLEARANCE (SEE NOTE A15).
4
THIS FRAME CAN CONTAIN 100% OF ALL MACHINE FLUIDS.
5
ALL DIMENSIONS ARE +/- .50”.
6
APPROX. PACKAGE WEIGHT: 10,030 LBS [4,550 kg].
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A1
CONDENSATE DRAIN 1/2” NPT
A2
SUMP/SEPARATOR TANK DRAIN 1/2” NPT
A3
AFTERCOOLER DRAIN 1/2” NPT
A4
OIL COOLER DRAIN 1/2” NPT
A5
SEPARATOR/SUMP TANK ACCESS PANEL
A6
LIFTING BAIL ACCESS PANEL
A7
AIR OUT 2” NPT
A8
AIR OUT 1” NPT
A9
PARALLEL INCOMING POWER CIRCUIT BREAKER DISCONNECT MALE 4/0 BLACK L1, L2, L3
E900H User Manual
3.4 Identification—less running gear
A10 LIFTING FORK POCKETS
A11 INSTRUMENT PANEL ACCESS
A12 DRAIN PLUG
A13 AIR INLET
A14 AIR OUTLET
A15 DOOR
A16 E-STOP BUTTON
3: Specifications
33
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34
3.5 Identification—portable
Drawing notes
1
DIMENSIONS ARE IN INCHES. BRACKET [ ] DIMENSIONS ARE IN MILLIMETERS.
2
ALLOW 4’ [1,291 MM] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
3
DOORS REQUIRE 4’ [1,291 MM] MAXIMUM OPENING CLEARANCE (SEE NOTE A16).
4
THIS FRAME CAN CONTAIN 100% OF ALL MACHINE FLUIDS.
5
ALL DIMENSIONS ARE +/- .50”.
6
APPROX. PACKAGE WEIGHT: 11,780 LBS. [5343 kg].
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A1
CONDENSATE DRAIN 1/2” NPT
A2
SUMP/SEPARATOR TANK DRAIN 1/2” NPT
A3
AFTERCOOLER DRAIN 1/2” NPT
A4
OIL COOLER DRAIN 1/2” NPT
A5
SEPARATOR/SUMP TANK ACCESS PANEL
A6
LIFTING BAIL ACCESS PANEL
A7
AIR OUT 2” NPT
A8
AIR OUT 1” NPT
A9
PARALLEL INCOMING POWER CIRCUIT BREAKER DISCONNECT MALE 4/0 BLACK L1, L2, L3
E900H User Manual
3.5 Identification—portable
A10 LIFTING FORK POCKETS
A11 INSTRUMENT PANEL ACCESS
A12 DRAIN PLUG
A13 AIR INLET
A14 AIR OUTLET
A15 TRACKING WIDTH
A16 DOOR
A17 E-STOP BUTTON
3: Specifications
35
3: Specifications
E900H User Manual
Notes:
36
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E900H User Manual
4: Installation
Section 4
Installation
4.1 Fluid level check
The compressor is shipped fully charged with the proper
amount of fluid. However, it is necessary to check the
fluid level at the time of installation and during compressor operation. Check the fluid level when the compressor
is in the SHUT DOWN mode (fluid level may not be visible when operating), and by looking at the sight glass on
the receiver tank (see Figure 6-5 on page 47). The full
level is at half the sight glass. Add fluid if fluid level is not
visible in the sight glass when machine is shut down.
in accordance with applicable codes, regulations, and
requirements.
Feeder cables should be sized by the customer/electrical
contractor to ensure that the circuit is balanced and not
overloaded by other electrical equipment. The length of
wiring from a suitable electrical power source is critical
because voltage drops can adversely effect the performance of the compressor. Refer to Table 4-1: Incoming
conductor wiring.
Table 4-1: Incoming conductor wiring
hp (kW)
Conductor
size
GND
conductor
480V 45°C
214 (160)
4/0
2/0
380V 45°C
214 (160)
350 MCM
250 MCM
4.2 Electrical preparation
WARNING
Energized internal components are a potentially
fatal shock hazard. Disconnect all power
before performing any work on the compressor’s
electrical system.
Interior electrical wiring is installed at the factory.
Required customer wiring should be done by a qualified
electrician in compliance with OSHA, National Electric
Code and/or any applicable local electrical codes. Customer to supply power via cam-lock located on end of
enclosures. An electrical check should be made to
ensure that the first start-up will be successful. The compressor and drive should be properly grounded/earthed
Parallel feeder cable connections to incoming terminal
cam-locks L1-L2-L3 should be tight and clean. These are
located on end of package. Behind the access door
located above the cam-locks is the package circuit
breaker disconnect, supplied for additional safety.
The applied voltage must conform to the motor and compressor data plate ratings.
• Check incoming voltage. The incoming voltage
must match the compressor’s wire rating/specifications.
• Check motor starting device and overload
heater sizes.
• Check all electrical connections for tightness.
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4: Installation
E900H User Manual
Notes:
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5: Operation
Section 5
Operation
5.1 General
While Sullair has built into this compressor a comprehensive array of controls and indicators to assure you that it
is operating properly, you will want to recognize and interpret the readings which will call for service or indicate the
beginning of a malfunction. Before starting your Sullair
compressor, read this section thoroughly and familiarize
yourself with the controls and indicators—their purpose,
location and use.
5.2 Purpose of controls
Control or indicator
Purpose
START / STOP switch
Utilized to start and stop the compressor. Upon stopping, the compressor will continue to run for a short time in order to relieve sump pressure.
Sump pressure gauge
Displays receiver tank pressure of the compressor during all phases of
operation.
Hour meter
Displays accumulated run time of the compressor.
Discharge temperature gauge
Displays temperature at the compressor discharge.
Discharge temperature switch &
high discharge temperature lamp
If the high operating temperature limit of 250°F (121°C) is exceeded, the
compressor will be stopped and the High Discharge Temperature lamp
lit. After addressing the cause of the fault, it is reset by depressing and
re-setting the emergency stop button.
Separator differential pressure
gauge
Displays the pressure difference between the wet and high side of the
separator element. Refer to Section 6: Maintenance for recommended
service intervals.
Fluid filter differential pressure
gauge
Displays the pressure difference between the inlet and outlet of the fluid
filter. Refer to Section 6: Maintenance for recommended service intervals.
Emergency stop / reset switch
When depressed, the compressor is stopped. Additionally when
depressed and reset, the High Temperature Alarm is reset.
Power / run indicators
The power indicator is lit when power is connected to the machine and
the main disconnect is closed. The run indicator is lit once the compressor is started.
Main motor / fan motor overload
indicator
These indicators are lit if the motors are overloaded. Once the fault is
addressed and the motor overload relays are reset, the indicators will be
reset. Refer to Section 7: Troubleshooting for potential causes.
Phase / voltage fault light
This indicator is lit when the phase/voltage relay detects incorrect phasing or a voltage fault. See Section 5.7 for details.
Fan forward/reverse switch
This switch controls the rotation direction of the cooling fan. See Section
5.6 for details.
Motor heater switch
This switch activates the internal heaters in the main motor. See Section
5.5 for details.
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5: Operation
E900H User Manual
Control or indicator
Purpose
Phase monitor relay
Prevents the compressor from starting with incorrect phase order, loss of
phase and under or over voltage.
Phase / voltage fault indicator
This indicator is lit when the phase/voltage relay detects incorrect phasing or a voltage fault. See Section 5.7 for details.
Ground fault protector
The protector contact will trip on the 110V circuit if a ground fault is
detected. This will shut down the compressor or prevent it from starting.
Pressure regulator
(LOAD chamber)
Maintains a maximum pilot pressure of 60 psig (4.1 bar).
Pressure regulator
(UNLOAD chamber)
Opens a pressure line between the sump and the inlet unload chamber,
allowing the inlet valve to regulate air delivery according to air demand.
Solenoid valve
Electrically actuated 3-way solenoid valve used to open the blowdown
valve and pressurize the unload port/close the inlet valve during shutdown.
Start control valve
Opens when the wye-delta timer closes; closes when the wye-delta
timer is open. Opens a pressure line between the sump and inlet load
chamber allowing the inlet valve to deliver air.
Pneumatic inlet valve
Regulates the amount of air being delivered. Also blocks reverse flow
upon shutdown.
Minimum pressure/check valve
Maintains a minimum pressure in the receiver tank. Prevents backflow
from the system during shutdown or unload.
Blowdown assembly valve
Vents receiver tank pressure during unloading and shutdown.
Thermal valve
Regulates flow of fluid to the cooler in order to minimize warm up time
and maintain a minimum operating temperature to avoid condensation.
Fluid level sight glass
Used to monitor fluid level. Proper level is always visible in the sight
glass. Check the level when the compressor is shutdown.
Separator return line sight glass
Indicates fluid flow from the separator scavenge. Flow should be visible
during full load; little to no flow when unloaded. Sluggish full load flow
indicates a need to clean the strainers fitted to the return lines.
Pressure relief valve
Opens receiver tank pressure to atmosphere if receiver tank pressure
exceeds relief valve setting.
Recirculation valve
Provides limited air supply back to inlet valve during unload conditions to
prevent cavitation in unit.
5.3 Initial start-up procedure
1. Place machine in level, suitable area and
chock the wheels.
2. Ensure that red shipping studs are loosened
and not supporting the motor or compressor
unit.
3. Connect power to machine. See Section 4.2:
Electrical preparation on page 37.
4. Check compressor fluid level. See Section
4.1: Fluid level check on page 37.
5. Fully open the air service valve.
40
6. Turn on main power supply and disconnect
on machine. At this time, the power indicator
light shall be on and the machine is ready to
start.
7. Check Phase/Voltage Fault indicator. If lit,
disconnect power and switch two of the
phases. See Section 5.7 for more details.
8. Depress start button and observe. If machine
starts, the run indicator light will be on and
the electrical connection is correct. Verify
proper rotation of compressor and fan.
9. Once machine is started, verify that it
unloads at the rated pressure.
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5: Operation
10. Stop the compressor per shutdown procedure and check fluid level.
CAUTION
CAUTION
Allow 5 minutes between starts for oil foam to
subside and the motor to cool.
The main motor heater will be switched off once
the motor is started.
CAUTION
5.4 Normal start-up procedure
1. Place machine in level, suitable area and
chock the wheels.
2. Check the compressor fluid level. Reference
Section 4.1.
If the machine is energized and the motor heater
switch is ON, the heater will be energized as
long as the machine is not running and the EStop is not depressed.
3. Verify the electrical connections are secure.
4. Turn on disconnect at machine and press the
start button.
5. Monitor parameters on instrument panel.
CAUTION
The receiver tank should be drained of condensate on a regular basis. The control line filter
should be drained of condensate on a weekly
basis.
5.6 Fan rotation switch
This switch controls the direction of rotation o the cooling
fan. the direction should be set to FORWARD in warm
weather. In cold weather, below 32°F (0°C), the fan can
operate in REVERSE. This will help to prevent freezing of
control lines as well as help to maintain the proper operating temperature of the compressor. Operating the fan in
REVERSE during warm temperatures can cause high
operating temperatures and ultimately the shutdown of
the compressor.
5.7 Phase/voltage fault relay
5.5
Main motor heater
When the motor heater switch is in the ON position, the
motor heater will be activated until the switch is set to
OFF or the compressor starts.
In extremely wet environments, the motor heater should
be run for 2 hours prior to start of compressor.
The heater should run for 2 hours once a month when the
compressor is unused for an extended period of time.
Additionally, the heater should be run for 2 hours prior to
initial startup following an extended storage period.
This compressor is equipped with a phase/voltage relay
to detect incorrect phasing of incoming power or incorrect
supply voltage. Upon initial power-up, the indicator on the
control panel will be lit if the incoming power was connected out of phase. Swap two of the cables to correct
the phasing.
If the relay is tripped during operation, proper operating
voltage and connections should be checked prior to
restarting compressor.
Even with the fault indicator lit upon initial power up, the
machine will attempt to start for approximately 10 seconds. This is a delay feature provided to allow the compressor to overcome voltage drops upon starting. If after
10 seconds, the voltage or phase fault is still present, the
machine will shut down.
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5: Operation
E900H User Manual
Notes:
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E900H User Manual
6: Maintenance
Section 6
Maintenance
6.1 General
A good maintenance program is the key to long compressor life. Below is a program that when adhered to, should
keep the compressor in top operating condition.
WARNING
Before any repairs are attempted, refer to Section 1: Safety before proceeding.
CAUTION
Do not remove caps, plugs and/or other components when compressor is running or pressurized. Stop compressor and relieve all internal
pressure before doing so.
• Check the air filter restriction gauge. Should it
indicate restriction, replace the elements immediately. Refer to Section 6.9.5: Air filter maintenance on page 46.
6.3 Maintenance after initial
50 hours of operation
After the initial 50 hours of operation, a few simple maintenance routines can rid the system of any possible foreign materials, if any. Perform the following maintenance
operations to prevent unnecessary problems.
• Clean the return line orifice and strainer.
• Change compressor fluid filter
6.4 Maintenance every 250 hours
Perform after every 250 hours of operation:
• Clean the cooler exterior. Depending on how
contaminated the atmosphere may be, more
frequent cooler cleaning may be necessary.
6.2 Daily operation
Prior to starting the compressor, it is necessary to perform a daily inspection.
Check the fluid level in the compressor receiver tank. Should
the level be low, simply add the necessary amount. If the addition of fluid becomes too frequent, a simple problem has developed which is causing this excessive loss. Refer to Table 7-1:
Troubleshooting guide on page 51 under “Excessive fluid
consumption” for a probable cause and remedy.
After a routine start has been made, it is necessary to
perform an inspection to ensure all operations are performing correctly. Perform the following inspections to
prevent unnecessary problems.
• Observe the instrument panel gauges and be
sure they monitor the correct readings for their
particular phase of operation.
• After the compressor has warmed up, it is recommended that a general check on the overall
compressor and instrument panel be made to
assure that the compressor is running properly.
6.5 Maintenance every 300 hours
When not using Sullair AWF®, change the compressor
fluid and replace the fluid filter element. Refer to Section
6.9.4: Main fluid filter servicing on page 46.
6.6 Maintenance every 600 hours
When not using Sullair AWF, replace the fluid filter element only. Refer to Section 6.9.4: Main fluid filter servicing on page 46.
6.7 Maintenance every 1000 hours
Perform after every 1000 hours of operation:
• Clean the return line orifice and strainer.
• Repack the wheel bearings on wheel-mounted
units.
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6: Maintenance
E900H User Manual
6.8 Maintenance every 1500 hours
When using Sullair AWF®, change the compressor fluid
and replace the fluid filter element.
Refer to Section 6.9: Parts replacement and adjustment
procedures.
6.9 Parts replacement and
adjustment procedures
6.9.1
Compressor fluid change procedure
pressure before proceeding. Drain the fluid by opening
the appropriate drain valve located in the frame at the
front of the machine. Close the valve when draining is
complete. Change the compressor fluid and replace the
fluid filter element. For element replacement: See Section 6.9.4: Main fluid filter servicing on page 46. Fill the
receiver tank with fluid according to Section 3.2: Lubrication guide—compressor on page 30.
6.9.2
Running gear lubrication
Refer to Figure 6-1. An inspection of the running gear
should be made on a routine basis.
Warm-up the compressor for 5 to 10 minutes to warm the
fluid. Shut the compressor off and relieve all internal
Figure 6-1: Running gear lubrication
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6.9.3
6: Maintenance
Wheel bearing lubrication
1. Rubber plug
5. Grease fitting
2. Outer bearing
6. Metal end cap
3. Inner bearing
7. Spring-loaded double lip seal
4. Grease flow
Figure 6-2: Typical E-Z Lube axle
Refer to Figure 6-2. Proper lubrication is essential to the
proper functioning and reliability of your portable compressor axle. Wheel bearings should be lubricated at
least once every 12 months, or more frequently to help
insure proper performance. Use wheel bearing grease
that conforms to military specification MIL-G-10924 or a
high temperature wheel bearing grease such as lithium
complex NLGI Consistency #2.
If your axle is equipped with the E-Z Lube feature, the
bearings can be periodically lubricated without removing
the hubs from the axle. This feature consists of axle spindles that have been specially drilled and fitted with a
grease zerk in their ends. When grease is pumped into
the zerk, it is channeled to the inner bearing and then
flows back to the outer bearing and eventually back out
of the grease cap hole (refer to Figure 6-2). The procedure is as follows:
1. Remove the rubber plug from the end of the
grease cap.
2. With a standard grease gun filled with a quality wheel bearing grease, place the gun onto
the grease zerk located in the end of the
spindle. Make sure the grease gun nozzle is
fully engaged on the fitting.
3. Pump grease into the zerk. The old, displaced grease will flow back out of the cap
around the grease gun nozzle.
4. When new, clean grease is observed,
remove the grease gun, wipe off any excess,
and replace the rubber plug in the cap.
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6: Maintenance
6.9.4
E900H User Manual
Main fluid filter servicing
5. Remove element and discard. These elements are not cleanable.
6. Make certain that the mounting surfaces and
filter heads are clean.
7. Apply a light film of clean fluid to each element gasket surface.
8. Center the new elements on filter housing
heads and tighten until the filter gaskets
make contact with the filter housing. After
gaskets make contact, tighten ½ to ⅔ of a
turn.
9. Run compressor and check for leaks.
6.9.5
1. Capscrew
5. Thermostat element
2. Washer
6. O-ring
3. Upper housing
7. Lower housing
4. O-ring
8. Filter elements
Air filter maintenance
1. Primary element assembly
2. Rear cover
3. Housing
4. Evacuator
Figure 6-3: Main fluid filter assembly and thermostat
Figure 6-4: Air filter assembly
Refer to Figure 6-3. The main fluid filters are located
schematically in the coolant line between the receiver
tank and the compressor unit. The main filter elements
are replaceable. For installation of the filter elements, follow the procedure explained below:
Refer to Figure 6-4. Air filter maintenance should be performed when indicated on the restriction indicator. The air
filters are equipped with a primary element and secondary element.
1. The compressor must be shut off and system pressure must be relieved.
The secondary element must be replaced after every
third primary element change. Do not reconnect the secondary element once it is removed.
2. Position a suitable container beneath the
elements to catch fluid drainage.
3. Remove elements using a suitable tool.
4. Rotate each element counterclockwise to
remove.
46
6.9.5.1 Air filter element removal
1. Clean the exterior of the air filter housing.
2. Remove the rear cap by releasing retaining
clamps.
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E900H User Manual
6: Maintenance
3. Remove the element from the housing.
6.9.6
Separator element replacement
4. Clean the interior of the housing by using a
damp cloth. Do not blow out dirt with compressed air as this may introduce dust downstream of the filter.
5. When it becomes necessary to remove the
secondary element, pull the element out of
the housing.
6. Install the new secondary element.
7. With the secondary element in place, replace
the primary element.
6.9.5.2 Air filter element inspection
1. Place a bright light inside the element to
inspect for damage or leak holes. Concentrated light will shine through the element
and disclose any holes.
2. Inspect all gaskets and gasket contact surfaces of the housing. Should faulty gaskets
be evident, correct the condition immediately.
3. If the clean element is to be stored for later
use, it must be stored in a clean container.
4. After the element has been installed, inspect
and tighten all air inlet connections prior to
resuming operation.
6.9.5.3 Primary air filter element replacement
1. Place the element in position over the secondary element.
2. Install the cover with clean-out port pointing
down.
1. Bolt
4. Tank
2. Cover
5. Oiler fill port
3. Element
6. Sight glass
Figure 6-5: Fluid filter separator
Refer to Figure 6-5. When fluid carry-over is evident after
the fluid return-line strainer and orifice, as well as the
blowdown valve diaphragm, have been inspected and
found to be in satisfactory condition, or if the separator
restriction gauge reads in excess of 10 psig (0.7 bar),
separator element replacement is necessary. Follow the
procedure explained below:
1. Remove all piping connected to the receiver
tank cover to allow removal (return line, service line, etc.).
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6: Maintenance
E900H User Manual
2. Remove the fluid return line from the fitting in
the cover.
3. Remove the cover capscrews and lockwashers and lift the cover from the receiver tank
with the minimum pressure/check valve in
place.
• The motor surface should be kept dry and
clean for most efficient cooling. The fan inlet
should be kept free from obstructions.
4. Remove the separator element.
• Bearings shall be lubricated every 2000 hours
of operation with 45g UNIREX N2. If bearing
overheating or grease degradation is found, the
grease should be changed immediately.
5. Scrape the old gasket material from the
cover and the flange on the receiver tank. Be
sure to keep all scrapings from falling inside
the tank.
• The motor heater should be operated in
extremely damp environments or during long
periods of storage. Refer to Section 5.5: Main
motor heater for details.
6. Install the separator element.
7. Make sure grounding staples are attached to
separator gasket. Do not remove staples.
8. Replace the receiver tank cover. Install the
eight (8) capscrews and lockwashers in finger-tight, then gradually tighten in a crisscross pattern in 4 to 5 steps. Always tighten
the capscrews alternately at opposite sides
of the cover. Never tighten capscrews adjacent to each other. Torque capscrews to
206 ft.lbs (280 N·m).
6.13 Control system adjustment
Prior to adjusting the control system it is necessary to
determine the desired operating pressure range as well
as the maximum operating pressure. The maximum
operating pressure must not exceed the maximum operating pressure per the serial nameplate.
6.13.1 Differential pressure regulator
adjustment
9. Reconnect all piping. The fluid return line
should extend to the bottom of the separator
element or no more than 1/16 in (1.6 mm) up
from the bottom. This will assure the proper
fluid return flow.
10. Clean the fluid return line strainer and clear
the orifice prior to restarting the compressor.
6.10 Pressure relief valve
An inoperable relief valve may not open properly to protect the compressor from overpressure. A relief valve
unable to close can lead to a large loss of fluid. The function of the pressure relief valve should be checked on a
weekly basis.
6.11 Hose maintenance
Inspect and replace inlet, lubrication and control line
hoses every 600 hours or six months. Replace if any
damage or is present.
6.12 Motor maintenance
• The motor should be inspected periodically for
unusual noise or vibrations. This can be a sign
of bearing damage or failure.
48
Figure 6-6: Pressure regulator
Refer to Figure 6-6. The differential pressure regulators
are adjusted by loosening the jam nut on the end of the
cone shaped cover of the pressure regulator. When the
jam nut is loose, turn the adjusting screw clockwise to
increase or counterclockwise to decrease the setting.
1 psi above the full load rated pressure of the compressor, the inlet regulator should allow pressure to flow into
the unload chamber of the inlet valve. Cycle the control
system several times and recheck all pressure settings.
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E900H User Manual
6: Maintenance
6.13.1.1 Pressure reducing regulator
When running with the compressor loaded, adjust the
pressure reducing regulator to maintain 70 psig (4.8 bar)
signal to open the inlet valve.
6.13.2 Shaft coupling maintenance
The coupling is a jaw type in shear. If the elastomeric
(rubber) element requires replacement due to wear or
damage, order a replacement element and perform the
following steps:
1. Remove the coupling guard.
2. Loosen the retaining screw located on the
outer sleeve. Slide the sleeve to one side,
exposing the coupling.
6. Reinstall the coupling guard.
6.13.3 Unload pressure setting
1. Start compressor with service valve closed
or slightly open.
2. Observe the pressure at which the contacts
open and machine unloads.
3. Turn the range adjustment screw until
desired unload pressure setting is achieved.
6.13.4 Differential setting
1. Unload compressor and allow receiver pressure to reach its minimum.
3. Unwrap the coupling element from the coupling jaws.
2. Open service valve and observe the pressure at which the pressure switch contacts
close and the compressor loads.
4. Install the new element by wrapping it
around the jaws, engaging the cogs on the
element into the jaws.
3. Turn the differential adjustment screw until
the desired load pressure and differential is
achieved.
5. Reinstall the outer sleeve and secure by
tightening the two screws to 45 in-lbs
(5 Nm).
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6: Maintenance
E900H User Manual
Notes:
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E900H User Manual
7: Troubleshooting
Section 7
Troubleshooting
7.1 Introduction
The information contained in the Troubleshooting Guide
has been compiled from field report data and factory
experience. It contains symptoms and usual causes for
the described problems. However, do not assume that
these are the only problems that may occur. All available
data concerning a problem should be systematically analyzed before undertaking any repairs or component
replacement procedures.
A detailed visual inspection is worth performing for
almost all problems and may avoid unnecessary additional damage to the compressor. Always remember to:
• Check for loose wiring.
• Check for damaged piping.
• Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor.
Should your problem persist after making the recommended check, consult your nearest Sullair representative.
Table 7-1: Troubleshooting guide
Symptom
Compressor will not start
or shuts down after 10 seconds
Probable cause
Remedy
Main disconnect switch open
Close switch.
Line fuse blown
Replace fuse.
Motor starter overload tripped
Reset. Should trouble persist, check
whether motor starter contacts are
functioning properly.
Low incoming line voltage
Check voltage. Should voltage check
low, consult power company.
Incorrect phase order trips phase
monitor.
Switch any two phases of incoming
power and reset monitor
Ground fault protector tripped
Look for shorts or open circuits on control circuit, repair and reset protector. If
none found, ground fault protector
could require replacement.
Control transformer fuse blown
Replace fuse
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7: Troubleshooting
E900H User Manual
Table 7-1: Troubleshooting guide
Symptom
Probable cause
Remedy
Loss of control voltage
Check incoming power connections
and reset monitor.
Low incoming line voltage
Check control fuses and wiring. Consult power company.
Cooling air flow restricted; clean cooler
and check for proper ventilation.
Ambient temperature is too high—provide sufficient ventilation.
Low fluid level, add fluid
Compressor shuts down
with air demand present
Compressor discharge temperature switch open
Clogged filter, change fluid filter element
Thermal valve not functioning properly;
replace element
Defective discharge temperature
switch; check for a short or open circuit.
If none, replace switch
Cooling fan is being operated in
REVERSE direction. Turn switch to
FORWARD
Compressor will not build
full discharge pressure
Loss of phase trips phase monitor.
Check incoming power connections
and reset monitor.
Air demand is too great
Check service lines for leaks or open
valves up.
Dirty air filter
Check the filter indicator and inspect
and/or change element if required.
Inlet valve bleed orifice plugged
Ensure control line bleed orifice is not
plugged.
Pressure regulator out of adjustment
Adjust regulator according to control
adjustment instructions in Section 6:
Maintenance.
Defective pressure regulator
52
Check diaphragm and replace if necessary (kit available).
Check valve operation. Replace the
coil or the complete valve if defective.
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E900H User Manual
7: Troubleshooting
Table 7-1: Troubleshooting guide
Symptom
Probable cause
Leak in control system causing loss
of pressure signals
Inlet valve stuck
Defective unload solenoid valve
Improper unloading with an
excessive pressure buildup causing relief valve to
open.
Remedy
Worn seals in inlet valve. Replace
seals (kits available).
Defective pressure regulating valves;
repair valves (kits available).
Free or repair inlet valve
Check the valve operation. Replace if
necessary.
Clean strainer (screen and O-ring
replacement kit available).
Defective blowdown valve
Check that the sump pressure is
exhausted to the atmosphere when in
the unloaded mode. Repair or replace if
necessary (kit available).
Plugged control line filter
Clean or repair as necessary
Check all control lines and components.
Excessive fluid consumption
Pressure relief valve opens
repeatedly
Restriction in the control system
Ice in control line or components. Run
fan in REVERSE direction when operating below freezing.
Clogged return tube or orifice
Clean orifice or strainer.
Separator element damaged or not
functioning properly
Change separator.
Leak in the lubrication system
Check all pipes, connections and components.
Excess fluid foaming
Drain and change.
Fluid level too high
Drain and change.
Operating pressure lower than
rated pressure
Increase compressor operating pressure
Fluid level is too high
Drain excess fluid.
Defective pressure relief valve
Replace.
Unload pressure set too high
Adjust Pressure switch per Section
6.13.3: Unload pressure setting on
page 49.
Failure to unload solenoid valve
Replace or repair solenoid valve
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7: Troubleshooting
E900H User Manual
Table 7-1: Troubleshooting guide
Symptom
Liquid water in compressed air lines
54
Probable cause
Remedy
Plugged separator
Check separator differential.
Plugged strainer in moisture drain
line
Clean and service strainer located in
the line off the bottom of the water separator.
Water vapor condensation from
cooling and compression occurs
naturally
Remove the water vapor from compressed air prior to distribution through
the air system. Check operation of
aftercooler and moisture separator.
Install a compressed air dryer sized for
the flow and dryness level required.
(Note: Filters may also be required to
remove particulates, liquid oil aerosols
or for oil vapor removal. Change cartridges as recommended by the filter
manufacturer). Check all drain traps
routinely to insure their proper operation. Maintain them regularly.
Defective drain solenoid valve
Ensure valve opens and closes as signaled by timer.
Improper drain settings.
Check drain interval and drain time,
and adjust accordingly. High humidity
conditions require longer drain times or
more frequent openings.
02250203-986 R03
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Subject to EAR, ECCN EAR99 and related export control restrictions.
Sullair, LLC
3700 East Michigan Boulevard
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.
Subject to EAR, ECCN EAR99 and related export control restrictions.
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