ROTARY SCREW AIR COMPRESSOR ES- Series -6

5, 7.5 and 10HP 4, 5.5 and 7.5 kw

OPERATORS MANUAL AND PARTS LIST

KEEP FOR FUTURE REFERENCE
Part Number 02250057-634 Sullair Corporation

AIR CARE SEMINAR TRAINING

Sullair Air Care Seminars are 3--day courses that provide hands--on instruction in the proper operation, maintenance and service of Sullair equipment. Individual seminars on Industrial compressors and compressor electrical systems are presented at regular intervals throughout the year at a dedicated training facility at Sullairs corporate headquarters in Michigan City, Indiana. Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of the most common problems, and actual equipment operation. The seminars are recommended for maintenance and service personnel. For detailed course outlines, schedule and cost information contact: Sullair Corporate Training Department 1--800--SULLAIR or 219--879--5451 (ext. 1816) -- Or Write -Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training Department

TABLE OF CONTENTS Section 1

SAFETY

PAGE 1 1 1 1 2 2 2 3 3 4
1.1 GENERAL 1.2 PERSONAL PROTECTIVE EQUIPMENT 1.3 PRESSURE RELEASE 1.4 FIRE AND EXPLOSION 1.5 MOVING PARTS 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS 1.7 TOXIC AND IRRITATING SUBSTANCES 1.8 ELECTRICAL SHOCK 1.9 LIFTING 1.10 ENTRAPMENT

Section 2

DESCRIPTION

5 5 5 5 5 7 8

2.1 INTRODUCTION 2.2 DESCRIPTION OF COMPONENTS 2.3 ENCAPSULATED COMPRESSOR SYSTEM, FUNCTIONAL DESCRIPTION 2.4 COMPRESSOR COOLING SYSTEM, FUNCTIONAL DESCRIPTION 2.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION 2.7 INSTRUMENTATION, FUNCTIONAL DESCRIPTION

Section 3

SPECIFICATIONS
Section 4

9 10

3.1 TABLE OF SPECIFICATIONS 3.2 COMPRESSOR LUBRICATION GUIDE

INSTALLATION

11 11 11 11 12 12

4.1 LOCATION OF COMPRESSOR 4.2 VENTILATION AND COOLING 4.3 SERVICE AIR PIPING 4.4 FLUID LEVEL CHECK AND CHANGE PROCEDURE 4.5 MOTOR ROTATION DIRECTION CHECK 4.6 ELECTRICAL PREPARATION

TABLE OF CONTENTS
(CONTINUED)

Section 5

OPERATION

PAGE 13 13 14 14 14
5.1 GENERAL 5.2 PURPOSE OF CONTROLS 5.3 INITIAL START-UP PROCEDURE 5.4 SUBSEQUENT START-UP PROCEDURE 5.5 SHUTDOWN PROCEDURE

Section 6

MAINTENANCE

15 15 15 15 15 16

6.1 GENERAL 6.2 DAILY OPERATION 6.3 MOTOR BEARING LUBRICATION 6.4 FLUID FILTER MAINTENANCE 6.5 COOLER MAINTENANCE 6.6 PARTS REPLACEMENT MAINTENANCE AND ADJUSTMENT PROCEDURES FLUID FILTER REPLACEMENT AIR FILTER MAINTENANCE SEPARATOR ELEMENT REPLACEMENT MINIMUM PRESSURE/CHECK VALVE MAINTENANCE THERMOSTAT ACTUATOR MAINTENANCE CONTROL SYSTEM ADJUSTMENT FOR DIFFERENTIAL ADJUSTMENT OF AIR PRESSURE SWITCH INLET CONTROL VALVE MOTOR SHAFT SEAL REPLACEMENT

21 23

6.7 TROUBLESHOOTING 6.8 MAINTENANCE RECORD

Section 7

ILLUSTRATIONS AND PARTS LIST

25 25 26 28 30 32 34 36 38 40 44 46 48

7.1 PROCEDURE FOR ORDERING PARTS 7.2 RECOMMENDED SPARE PARTS LIST 7.3 FLUID MANAGEMENT SYSTEM 7.4 INLET FILTER 7.5 SEAL AND DRIVE GEAR 7.6 MOTOR, HOUSING AND PARTS 7.7 COMPRESSOR COOLER SYSTEM 7.8 COMPRESSOR SYSTEM 7.9 INLET CONTROL 7.10 CONTROL BOX 7.11 CANOPY AND PARTS 7.12 FRAME, CANOPY AND PARTS 7.13 WYE-DELTA ELECTRIC BOX ES-6

TABLE OF CONTENTS
(CONTINUED)

Section 7

ILLUSTRATIONS AND PARTS LIST (CONT)

PAGE 50 52 56 57 58 59
7.14 WYE-DELTA ELECTRIC BOX ES-6 7.15 DECAL GROUP 7.16 WIRING DIAGRAM (SINGLE PHASE) (60 Hz) 7.17 WIRING DIAGRAM (THREE PHASE) (60 Hz) 7.18 WIRING DIAGRAM (50 Hz) 7.19 WIRING DIAGRAM (50 Hz) WYE-DELTA

NOTES

SAFETY
1.1 GENERAL Sullair Corporation and its subsidiaries design and manufacture all of their 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. The compressor should be operated only by those who have been trained and delegated to do so, and who have read and understood this Operators Manual. Failure to follow the instructions, procedures and safety precautions in this manual may result in accidents and injuries. NEVER start the compressor unless it is safe to do so. DO NOT attempt to operate the compressor with a known unsafe condition. Tag the 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. Install, use and operate the compressor only in full compliance with all pertinent OSHA regulations and/or any applicable Federal, State, and Local codes, standards and regulations. DO NOT modify the compressor and/or controls in any way except with written factory approval. While not specifically applicable to all types of compressors with all types of prime movers, most of the precautionary statements contained herein are applicable to most compressors and the concepts behind these statements are generally applicable to all compressors. 1.2 PERSONAL PROTECTIVE EQUIPMENT 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. Install an appropriate flow--limiting valve between the service air outlet and the shut--off (throttle) valve, either at the compressor or at any other point along the air line, when an air hose exceeding 1/2 (13mm) inside diameter is to be connected to the shut--off (throttle) valve, to reduce pressure in case of hose failure, per OSHA Standard 29 CFR 1926.302(b)(7) and/or any applicable Federal, State and Local codes, standards and regulations. B. When 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 (13mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure. C. Provide an appropriate flow--limiting valve at the beginning of each additional 75 feet (23m) of hose in runs of air hose exceeding 1/2 (13mm) inside diameter to reduce pressure in case of hose failure. D. Flow--limiting valves are listed by pipe size and rated CFM. Select appropriate valves accordingly, in accordance with their manufacturers recommendations. E. DO NOT use air tools that are rated below the maximum rating of the compressor. Select air tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturers rated safe operating pressures for these items. F. Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled. G. 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. H. 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. I. Keep personnel out of line with and away from the discharge opening of hoses or tools or other points of compressed air discharge. J. Use air at pressures less 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) and/or any applicable Federal, State, and Local codes, standards and regulations. K. DO NOT engage in horseplay with air hoses as death or serious injury may result. 1.4 FIRE AND EXPLOSION A. Clean up spills of lubricant or other combustible substances immediately, if such spills occur. B. Shut off the 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 checking or adding lubricant or when refilling air line anti--icer systems with antifreeze compound. C. DO NOT permit fluids, including air line anti--icer system antifreeze compound or fluid film, to accu1

Section 1

Section 1

SAFETY
mulate on, under or around acoustical material, or on any external surfaces of the air compressor or on internal surfaces of the enclosure. 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 liquids or fluid film within the material. DO NOT use flammable solvents for cleaning purposes. D. 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. E. 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. F. 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. G. 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. H. Keep suitable fully charged Class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor. I. Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor. J. DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or with degraded lubricant. K. 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 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. C. Wear snug--fitting clothing and confine long hair when working around this compressor, especially when exposed to hot or moving parts. D. Keep access doors, if any, closed except when making repairs or adjustments. E. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or operate it. F. Disconnect and lock out all power at source and verify at the compressor that all circuits are de--energized 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. G. 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 A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners. B. Keep all parts of the body away from all points of air discharge. 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 Standards 29 CFR 1910 and/or any applicable Federal, State or Local codes or regulations.
!

DANGER

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.

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. C. Operate the compressor only in open or adequately ventilated areas. D. Locate the compressor or provide a remote inlet so that it is not likely to ingest exhaust fumes or other toxic, noxious or corrosive fumes or substances. E. Coolants 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 fluid of fill. F. Wear goggles or a full face shield when adding antifreeze compound to air line anti--icer systems.

SAFETY
G. 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. H. DO NOT store air line anti--icer system antifreeze compound in confined areas. I. 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. 1.8 ELECTRICAL SHOCK A. This compressor should be installed and maintained in full compliance with all applicable Federal, State and Local codes, standards and regulations, including those of the National Electrical Code, and also including those relative to equipment grounding conductors, and only by personnel that are trained, qualified and delegated to do so. B. 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. Make all such adjustments or repairs with one hand only, so as to minimize the possibility of creating a current path through the heart. C. Attempt repairs in clean, dry and well lighted and ventilated areas only. D. DO NOT leave the compressor unattended with open electrical enclosures. If necessary to do so, then disconnect, lock out and tag all power at source so others will not inadvertently restore power. E. Disconnect, lock out, and tag all power at source prior to attempting repairs or adjustments to rotating machinery and prior to handling any ungrounded conductors. 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 and/or handle only in full compliance with OSHA standards 29 CFR 1910 subpart N and/or any applicable Federal, State, and Local codes, standards and regulations. B. Inspect 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 weight of the compressor. If you 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 or slings. 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. I. Keep lift operator in constant attendance whenever compressor is suspended. J. Set compressor down only on a level surface capable of safely supporting at least its weight and its loading unit. K. When moving the compressor by forklift truck, utilize fork pockets if provided. Otherwise, utilize pallet if provided. If neither fork pockets or pallet are provided, then make sure compressor is secure and well balanced on forks before attempting to raise or transport it any significant distance. L. Make sure forklift truck forks are fully engaged and tipped back prior to lifting or transporting the compressor. M. Forklift no higher than necessary to clear obstacles at floor level and transport and corner at minimum practical speeds. N. Make sure pallet--mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them. NEVER attempt to forklift a compressor that is not secured to its pallet, as uneven floors or sudden stops may cause the compressor to tumble off, possibly causing serious injury or property damage in the process.

Section 1

Section 1

SAFETY
1.10 ENTRAPMENT A. If the compressor enclosure, if any, 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 and tag the access door in the open position to avoid the possibility of others closing and possibly latching the door with personnel inside. B. Make sure all personnel are out of compressor before closing and latching enclosure doors.

DESCRIPTION
2.1 INTRODUCTION Your new Sullair flood--lubricated rotary screw air compressor will provide you with improved reliability and greatly reduced maintenance. Compared to other types of compressors, the Sullair rotary screw is unique in mechanical reliability, with no wear and no inspection required of the working parts within the compressor unit. Read Section 6 (Maintenance) to keep your compressor in top operating condition. Should any questions arise which cannot be answered in the following text, call your nearest Sullair office or the Sullair Corporation Service Department. 2.2 DESCRIPTION OF COMPONENTS Refer to Figure 2-- 1. The components and assemblies of the ES--6 Series air compressor are clearly shown. The complete compressor consists of an encapsulated compressor system, inlet system, cooling system and control system. The compact design of the ES--6 Series air compressor provides easy access to all serviceable components. 2.3 ENCAPSULATED COMPRESSOR SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figure 2-- 2. The encapsulated compressor includes compressor unit, fluid management system, and motor section. The Sullair compressor unit is a single--stage positive displacement lubricated type compressor. This unit is equipped with tapered roller bearings on the discharge, and cylindrical roller bearings on the inlet end for high load carrying capacity. This unit provides continuous pulse--free air compression to meet your needs. With a Sullair compressor there will be no maintenance or internal inspection of the compressor.
!

Section 2

The fluid cooler bypass valve helps assure proper cooling by directing the fluid to the fluid cooler when discharge temperature reaches the thermostat temperature setting. During start--up in cool ambient conditions, the cooler pressure drop will cause the filter bypass valve to open up, assuring adequate fluid supply to the compressor. All fluid entering the compressor unit passes through the replaceable fluid filter element. This replaceable filter element contains a built--in bypass valve. Under conditions of restricted flow through the element, the bypass valve helps ensure adequate compressor fluid flow, as well as helps prevent element failure. FLUID MANAGEMENT SYSTEM The fluid management system consists of a multi-chambered primary/secondary separator, the final air/fluid separator element, cooler bypass group and fluid filter. As compressed air/fluid enters the sump, the first fluid separation takes place due to a reduction of flow speed coupled with a change of direction of the flow within the sump housing. Then the compressed air reaches the separator, where the finest fluid drops and mist are separated. MOTOR/DRIVE SECTION The motor/drive section consists of a squirrel cage induction motor and integrated drive gearing which is separated from the motor by a replaceable shaft seal. The minimum pressure/discharge check valve is mounted on the compressor drive housing. Its functions are as follows: 1. Maintain a minimum sump pressure of 60 psig (4.1 bar) under full load operation to help assure adequate fluid pressure. 2. Act as a check valve to isolate the compressor from the system at shutdown or unload. 2.4 COMPRESSOR COOLING SYSTEM, FUNCTIONAL DESCRIPTION The compressor cooling system consists of a fluid cooler, fan and cooler shroud. The fan is mounted on the motors shaft end opposite the compressor. Air is drawn over the motor as well as through the cooler. The air provides motor cooling and removes compression heat from the fluid. 2.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION -type The compressor inlet system consists of a dryair filter and an air control valve. Reacting on a pressure signal, the valve closes the intake for unloaded operation. The valve also acts as a check valve upon shutdown.

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.

Fluid is injected into the compressor unit in large quantities and mixes directly with the air as the rotors turn, compressing the air. The fluid flow has three main functions: 1. As coolant, it controls the rise of air temperature normally associated with the heat of compression. 2. It seals the leakage paths between the rotors and the stator and also between the rotors themselves. 3. It acts as a lubricating film between the rotors allowing one rotor to directly drive the other, which is an idler. The air/fluid mixture discharges directly into the fluid management system.

Section 2

DESCRIPTION
Figure 2- Description of Components -1

(4KW) (5.5 & 7.5KW)

AIR/FLUID SEPARATOR ELEMENT ACCESS COVER

FLUID FILL PLUG FLUID FILTER ELEMENT FLUID LEVEL SIGHT GLASS COMPRESSOR FLUID DRAIN CAP

FLUID FILL PLUG

COMPRESSOR FLUID DRAIN CAP

DESCRIPTION
Figure 2- Encapsulated Compressor System -2

Section 2

2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION The purpose of the compressor control system is to maintain compressor capacity to meet the system demand. It consists of an inlet valve, solenoid valve, control lines and the motor start selector switch. The selector switch has three settings: MANUAL/ START, OFF/RESET and AUTOMATIC START/ STOP. MANUAL MODE The compressor motor will start and the air control solenoid valve will be energized. The compressor will start to deliver compressed air. When no air is being used, the service line pressure rises to the setting (cut--out pressure) of the pressure switch. The system pressure switch opens, interrupting the electrical power to the solenoid valve. The solenoid valve allows control air to the inlet valve, unloading the compressor and the motor continues to run. When the line pressure drops to the low setting of

the pressure switch, the pressure switch closes, re-energizing the normally open solenoid valve and allowing the compressor to load again. OFF/RESET MODE The compressor motor, if running, will stop if the off/ reset position is selected. If the compressor during normal running has a fault caused by either overload or high discharge temperature, the compressor will stop. After a fault has been cleared, the compressor can not be restarted unless the Off/Reset mode is selected on the selector switch, prior to starting in any other mode of operation. AUTOMATIC MODE In the automatic mode of operation, the air system pressure switch opens, interrupting the electrical power to the air control solenoid valve; the compressor unloads and the motor will stop. The motor will automatically restart when the compressor sump pressure drops to the minimum setpoint on the sump pressure switch and the line pressure drops below the setpoint of the air pressure switch.

Section 2

DESCRIPTION
2.7 INSTRUMENTATION, FUNCTIONAL DESCRIPTION Due to the simplicity of the ES--6 Series compressor, the only instrumentation necessary is a line pressure gauge which is located on the left side of the electrical control center and a discharge temperature gauge which is located on the right side of the electrical control center. The line pressure gauge reads plant air system pressure only. NOTE
At compressor shutdown, the sump pressure is released to atmosphere through the solenoid valve. The line pressure gauge will continue to read system pressure.

SPECIFICATIONS
3.1 SPECIFICATIONS -- ES-- 6
DIMENSIONS 60Hz Model ES- 5H -6 ES- 5XH -6 ES- 7.5H -6 ES- 7.5XH -6 ES- 10H -6 ES- 10XH -6 HP/KW 5/4 5/4 7.5/5.5 7.5/5.5 10/7.5 10/7.5 Capacity ACFM/ M3/MIN 18/.51 13/.37 28/.79 20/.57 38/1.08 30/.85 Maximum Pressure PSIG/BAR 125/8.6 175/12 125/8.6 175/12 125/8.6 175/12 dBA (I) with canopy/ without canopy 68/80 68/80 69/82 69/82 70/85 70/85 Length in. mm 31 31 33 33 33 33 787 787 838 838 838 838 Width in. mm 21 3/8 21 3/8 21 3/4 21 3/4 21 3/4 21 3/4 543 543 553 553 553 553 Height in. mm 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 495 495 495 495 495 495 Weight lb. kg 275 275 300 300 325 325 125 125 136 136 150 150

Section 3

DIMENSIONS 50Hz Model ES- 5L -6 ES- 5HH -6 ES- 50XH -6 ES- 7.5L -6 ES- 7.5HH -6 ES- 7.5XH -6 ES- 10L -6 ES- 10HH -6 ES- 10XH -6 HP/KW 5/4 5/4 5/4 7.5/5.5 7.5/5.5 7.5/5.5 10/7.5 10/7.5 10/7.5 Capacity ACFM/ M3/MIN 21.2/.60 17.3/.49 13.4/.38 30/.85 24.4/.69 20.5/.58 39.2/1.11 33.9/.96 28.2/.80 Maximum Pressure PSIG/BAR 110/7.5 150/10 175/12 110/7.5 150/10 175/12 110/7.5 150/10 175/12 dBA (I) with canopy/ without canopy 68/80 68/80 68/80 69/82 69/82 69/82 70/85 70/85 70/85 Length in. mm 31 31 31 33 33 33 33 33 33 787 787 787 838 838 838 838 838 838 Width in. mm 21 3/8 21 3/8 21 3/8 21 3/4 21 3/4 21 3/4 21 3/4 21 3/4 21 3/4 543 543 543 553 553 553 553 553 553 Height in. mm 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 495 495 495 495 495 495 495 495 495 Weight lb. kg 275 275 275 300 300 300 325 325 325 125 125 125 136 136 136 150 150 150

COMPRESSOR Type: Minimum Full Load Operating Pressure: Maximum Full Load Operating Pressure: Bearing Type: Cooling: Lubricant: Sump Capacity: MOTOR Type: Synchronous Speed: Voltage: Standard All Sizes Optional All Sizes Optional All Sizes Optional 5HP Only Type: Insulation Class: Maximum Ambient Temp.: Shaft Diameter Fan: Key Size Fan:

Single Stage Fluid Injected Screen Compressor 60 psi (4.1 bar) Nameplate Pressure (I) Anti--friction Pressurized Fluid See Lubricant Specification (Section 3.2) 4.6 quarts (4.35 liters) 50Hz 5, 7.5, 10HP/ 4, 5.5 & 7.5 KW 1500 RPM (5, 7.5HP/4, 5.5KW) 3000 RPM (10HP/7.5KW) 380/415 3 Phase 380/415 3 Phase 380/415 3 Phase 380/415 3 Phase Totally Enclosed Air Over F 40 C (104 F) Nominal 5/8 Nominal 3/16 x 3/16 x 1 1/4

(I) Compressors are available for pressures up to 175 psi (12.1 bar). 60Hz 5, 7.5, 10HP/ 4, 5.5 & 7.5 KW 1.15 S.F. 1800 RPM 230/460V 3 Phase 200V 3 Phase 575V 3 Phase 230V Single Phase Totally Enclosed Air Over F 40 C (104 F) Nominal 5/8 Nominal 3/16 x 3/16 x 1 1/4

FLUID FILTER Type: Micron: Internal Bypass Valve Set at 25 psig FLUID SEPARATOR ELEMENT Type: Efficiency at Maximum Capacity:

Spin on, Sullair Proprietary 23 Microns Abs.

Push In Cartridge, Sullair Proprietary 5PPM Maximum

Section 3

SPECIFICATIONS
Table 3--1, Lubrication Guide AMBIENT TEMPERATURE --10 F to +90 F (--23 C to +32 C) LUBRICATION Sullube 32 Sullair LLL--4--32 SRF 1/4000 D--A Torque Fluid Motor Oil MIL--2104E SPEC API SF CC, CD SAE 10W Class SE FLUID CHANGE PERIOD (HRS.) 8000 * 8000 * 4000 1000 600 FILTER CHANGE PERIOD (HRS.) 8000 * 8000 * 4000 1000 600

* 8,000 Hours or once a year.

3.2 COMPRESSOR LUBRICATION GUIDE For best value and longest uninterrupted service, the ES--6 compressor is factory filled with Sullube 32, a long life lubricant, unless a different lubricant is requested. If, due to availability or other reasons, other fluids are required, follow Table 3-- 1, Lubrication Guide.
!

may occur, the fluid change interval must be reduced to 300 hours maximum. A non--detergent fluid with rust, oxidation and foam inhibitors and good water separation characteristics should be used. DO NOT MIX DIFFERENT TYPES OF FLUIDS. Contamination of non--detergent mineral fluids with traces of ATF or detergent motor fluids may lead to operational problems such as foaming, filter plugging, orifice or line plugging. Flushing is required if changing to a different lubricant.
!

WARNING

The Plastic Pipe Institute recommends against the use of thermoplastic pipe to transport compressed air or other compressed gases in exposed above ground locations, e.g. in exposed plant piping. (I) Sullube 32 should not be used with PVC piping systems. It may affect the bond at cemented joints. Certain other plastic materials may also be affected. (I) Plastic Pipe Institute, Recommendation B, Adopted January 19, 1972.

WARNING

Mixing of other fluids within the compressor will void all warranties.

When ambient conditions exceed those noted or if conditions warrant use of extended life lubricants contact Sullair for recommendation. Sullair encourages the user to participate in a fluid analysis program. This could result in a fluid change interval that is different from those stated in this manual.

Maintenance of all other components is still recommended as indicated in the Operators Manual. For light--duty high--humidity service where condensed moisture and emulsification (mayonnaise) Figure 3- Center of Gravity -1

APPROX. 6 (15.2CM) CENTER OF GRAVITY

10

INSTALLATION
4.1 LOCATION OF COMPRESSOR The ES--6 Series compressor package may be placed on any level surface able to support its weight. The unit should be bolted to a fixed mounting surface to avoid the possibility of externally applied forces or vibration which would disturb the piping or wiring. 4.2 VENTILATION AND COOLING Select a location to permit sufficient unobstructed air flow in and out of the compressor to keep the operating temperature stable. The minimum distance that the machine should be from surrounding walls is what is needed for service and three (3) feet (914mm) or more from the fan air discharge end of the compressor. 4.3 SERVICE AIR PIPING Service air piping should be installed as shown in Figure 4-- 1. A shut -- off valve should be installed to isolate the compressor from the service line. Also notice that the service line should be equipped with water legs and condensate drains throughout the system.
!

Section 4

joints. Certain other plastic materials may also be affected. (I) Plastic Pipe Institute, Recommendation B, Adopted January 19, 1972.

4.4 FLUID LEVEL CHECK AND CHANGE PROCEDURE The Sullair air compressor is equipped with the proper amount of fluid. However, it is necessary to check the fluid level at installation. The level is checked by looking at the fluid level sight glass located on the end bell. See Figure 2-- 1. If the sump is properly filled, the fluid level should cover 1/4 to 1/2 of the sight glass during operation. DO NOT OVERFILL.
!

WARNING

Before attempting compressor maintenance, disconnect compressor from power source and lock out power source. Isolate compressor from line pressure by closing recommended discharge shutoff valve and releasing all internal pressure from compressor. !

WARNING

WARNING

The Plastic Pipe Institute recommends against the use of thermoplastic pipe to transport compressed air or other compressed gases in exposed above ground locations, e.g. in exposed plant piping. (I) Sullube 32 should not be used with PVC piping systems. It may affect the bond at cemented

Assure that line pressure guage on compressor indicates ZERO pressure before any work is done. Failure to comply may cause injury.

When the compressor fluid is ready to be changed, the compressor needs to be shutdown with the power to the compressor disconnected (see Warning above). Drain the fluid from the compressor using

Figure 4- Service Air Piping -1

11

Section 4

INSTALLATION
the compressor fluid drain cap (See Figure 2-- 1). Fluid capacity for the compressor can be found in Section 3, Specifications of this manual. The compressor sump is properly filled when the level on the fluid level sight tube is 3/4 of the sight tube. During operation, the fluid level should cover 1/4 to 1/2 of the sight glass. DO NOT OVERFILL. 4.5 MOTOR ROTATION DIRECTION CHECK After the electrical wiring has been done, it is necessary to check the direction of motor rotation. This can be done by jogging the START selector switch on the side of the control center. When looking at the motor from the cooler end of the compressor unit, the cooler fan should be turning clockwise. If the motor is not turning clockwise, disconnect power to the starter and exchange any two of the three power input leads, then check rotation. A direction of rotation decal is located on the motor shroud, next to the cooler to insure correct motor/ compressor rotation. 4.6 ELECTRICAL PREPARATION Interior electrical wiring is performed at the factory. Required customer wiring is minimal, but should be done by a qualified electrician in compliance with OSHA, National Electrical Code, and any other applicable State, Federal and local electrical codes concerning isolation switches, fused disconnects, etc. Sullair provides a wiring diagram for use by the installer. A few electrical checks should be made to help assure that the first start--up will be trouble--free.
!

WARNING

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

1. Check incoming voltage. Be sure that compressor is wired for the correct incoming voltage. 2. Check starter for correct size, proper overload relay and heaters. 3. Check all electrical connections for tightness. 4. Dry run the electrical controls by disconnecting the motor leads T1, T2, and T3 from the starter. Energize the control circuits by turning the selector switch to the manual and automatic positions, and check all protection devices making sure when activated, they will de--energize the starter control coil. 5. Reconnect the motor leads and jog the motor for a direction of rotation check as explained in Section 4.5. NOTE
Wiring diagram for standard compressors is supplied on the inside cover of the Control Center. Optional compressor wiring diagrams will vary.

12

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 reading which will call for 5.2 PURPOSE OF CONTROLS CONTROL OR INDICATOR START SELECTOR SWITCH LINE PRESSURE GAUGE FLUID LEVEL SIGHT GLASS PURPOSE The three--position switch provides selection between MANUAL/START, OFF/RESET and AUTO--MATIC/ START (for further description, see Section 2). Continually monitors service line air pressure. Indicates fluid level. The level is checked by looking at the fluid level sight glass on the end bell. The fluid level should cover 1/2 to1/4 of the sight glass during operation. With the compressor shut down, the level should be 3/4 of the sight glass. DO NOT OVERFILL. Regulates fluid flow to and around the cooler. Designed to maintain a minimum operating temperature of 170 F (77 C). Used for fast warm--up and start--up. Maintains a minimum of 60 psig (4.1 bar) in compressor sump. Valve piston restricts receiver air discharge from receiver/sump when pressure falls to 60 psig (4.1 bar). Also incorporated in this valve is a terminal check valve which prevents line pressure backflow into the sump during unload conditions and after shutdown. Shuts the compressor down when the compressor discharge temperature exceeds 240 F (116 C). Opens sump pressure to the atmosphere should pressure inside the sump become too high. Operation of this valve indicates that the air pressure switch is either faulty or out of adjustment. Senses service line pressure. When line pressure reaches maximum setting, the pressure switch opens solenoid valve circuit to unload the compressor. Vents sump pressure through inlet control valve to the atmosphere during unload conditions and shutdown. Senses sump pressure and prevents compressor from starting until sump pressure has fallen below preset pressure of 10 psig (0.7bar). Continually monitors discharge temperature of the compressor.

Section 5

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.

COOLER BYPASS VALVE MINIMUM PRESSURE/CHECK VALVE

DISCHARGE TEMPERATURE SWITCH PRESSURE RELIEF VALVE

AIR PRESSURE SWITCH SOLENOID VALVE SUMP PRESSURE SWITCH (Not used on current models except with Wye--Delta starter). DISCHARGE TEMPERATURE GAUGE

13

OPERATION
5.3 INITIAL START-UP PROCEDURE The following procedure should be used to make the initial start--up of the compressor. 1. Read the preceding pages of this manual thoroughly. 2. Jog motor to check for correct rotation of fan (refer to Section 4.5). 3. Be sure that all preparations and checks described in the Installation Section have been made. 4. Open the shut--off valve to the service line. 5. Start the compressor by turning the selector switch to manual or automatic. 6. Check for possible leaks in piping. 7. Slowly close the shut--off valve and check that the pressure switch is set correctly. If set correctly, the compressor will unload at nameplate pressure. If adjustments are necessary, see Control System Adjustment in Section 6, Maintenance of this manual. 8. Observe the operating temperature. If the operating temperature exceeds 200 F (93 C), the cooling system and installation environment should be checked. 9. Open shut--off valve to the service line. 10. Reinspect the compressor for temperature and leaks the following day. 5.4 SUBSEQUENT START-UP PROCEDURE On subsequent start--ups, check that the proper level is visible in the fluid level sight glass and simply turn selector switch to desired control. When the compressor is running, observe the instrumentation. 5.5 SHUTDOWN PROCEDURE To shut the compressor down, simply turn selector switch to OFF/RESET position.

Section 5

14

MAINTENANCE
6.1 GENERAL
!

Section 6

WARNING

Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate compressor from line pressure by closing recommended discharge shutoff valve and releasing all internal pressure from compressor.

As you proceed in reading this section, it will be easy to see that the Maintenance Program for the air compressor is quite minimal yet important. See instructions for each item in Section 6.6, Parts Replacement and Adjustment Procedures. 6.2 DAILY OPERATION Prior to starting the compressor, it is necessary to check the fluid level in the sump. Should the level be low, simply add the necessary amount. If the addition of fluid becomes too frequent, a minor problem has developed which is causing this excessive loss. See the Troubleshooting Section (6.7) under Excessive Fluid Consumption for a probable cause and remedy. After a routine start has been made, a general check of the overall compressor should be made to assure that the compressor is running properly. 6.3 MOTOR BEARING LUBRICATION
!

1. Remove the fan guard by removing the four (4) self--tapping screws holding the guard and fan ring to the cooler. 2. Remove the 1/8 NPT plugs in the filler and drain connection for both bearings. 3. Free drain hole of any hard grease (use piece of wire if necessary). 4. Add grease (I) using a low pressure grease gun. 5. Wipe off any drained grease, and replace filler and drain plugs. 6. Replace fan guard. 7. Motor is now ready for operation. (I) Use Chevron SRI--2 grease when lubricating motor bearings. Fill the cavity 1/3 to 1/2 full by repacking or use a low pressure grease gun and fill through the lubricating provisions on the motor end bell housing. 6.4 FLUID FILTER MAINTENANCE
!

WARNING

Fluid filter has internal bypass. DO NOT SUBSTITUTE.

Replace the fluid filter element under any of the following conditions: 1. As recommended in the Lubrication Guide in Section 3. 2. Every year. 3. Every fluid change. 6.5 COOLER MAINTENANCE If cooler becomes restricted, use standard spray degreaser/cleaner and brush to clean cooler. Use air pressure to blow cooler clean. Care must be taken as not to damage cooler fins.
!

WARNING

Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate compressor from line pressure by closing recommended discharge shutoff valve and releasing all internal pressure from compressor.

WARNING

See Table 1, Motor Bearing Lubrication Schedule. If lubrication instructions are shown on the motor or in a separately provided manual, they will supercede this general instruction. TABLE 1 - MOTOR BEARING LUBRICATION SCHEDULE MODEL 5HP (4KW) 7.5 and 10HP (5.5 & 7.5KW) All Motors Over 1800 RPM STANDARD CONDITIONS (I) 3 Years 2.5 Years 6 Months

Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate compressor from line pressure by closing recommended discharge shutoff valve and releasing all internal pressure from compressor.

SEVERE CONDITIONS (II) 1 Year 10 1/2Months 3 Months

EXTREME CONDITIONS (III) 6 Months 5 1/2 Months 3 Months

(I) Eight hours per day, normal or light loading, clean 100 F (38 C) maximum ambient. (II) Twenty--four hours per day operation or shock loadings, vibration, or in dirt or dust at 100 F to 150 F (38 C to 66 C) ambient. (III) Heavy shock or vibration, dirt or dust at 100 F to 150 F (38 C to 66 C) ambient.

15

Section 6

MAINTENANCE
6.6 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
!

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

WARNING

Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate compressor from line pressure by closing recommended discharge shutoff valve and releasing all internal pressure from compressor.

FLUID FILTER REPLACEMENT Refer to Figure 6-- 1. 1. To prevent spillage and loss of reusable fluid, place a contaminate--free fluid receptacle beneath fluid drain valve and fluid filter. 2. Drain fluid by removing fluid drain valve cap at tee located beneath compressor (for complete fluid change, drain fluid from cooler). 3. Using a strap wrench, remove the old element and gasket. 4. Clean gasket seating surface. 5. Apply a light film of fluid to the new gasket. 6. Hand tighten new element until gasket is seated. 7. Continue tightening element an additional 1/2 to 3/4 turn. 8. Replace fluid. DO NOT OVERFILL. 9. Restart compressor and check for leaks. AIR FILTER MAINTENANCE Refer to Figure 6-- 2. Air filter (P/N 250025-- 421) maintenance should be performed every six months or more frequent if conditions so require.
!

FLUID FILL PLUG *FLUID FILTER ELEMENT

WARNING

FLUID DRAIN CAP * Replacement Element Kit P/N 250028--032

Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate compressor from line pressure by closing recommended discharge shutoff valve and releasing all internal pressure from compressor.

AIR FILTER ELEMENT MAINTENANCE 1. When performing maintenance, care must be taken that no dirt or foreign matter enters intake housing.
COMPRESSOR LUBRICATION GUIDE AND MAINTENANCE SCHEDULE AMBIENT TEMPERATURE -10 F to +90 F (-23 C to +32 C) LUBRICATION Sullube 32 Sullair LLL- -32 -4SRF 1/4000 ATF as per Dextron II Motor Oil MIL-2104E, SPEC API SF CC, CD SAE 10W Class SE

2. Clean exterior of air filter cover. 3. Remove the air filter cover by loosening the wingnut securing the cover. 4. Remove element and base. Clean base and interior of cover using a damp cloth. DO NOT use compressed air to clean cover and base. 5. At this time replace element. 6. Replace cover.

FLUID & FILTER CHANGE PERIOD (HRS.) 8000 * 8000 * 4000 1000 600

SEPARATOR CHANGE PERIOD (HRS.) 8000 * 8000 * 4000 1000 600

AIR FILTER CHANGE PERIOD (HRS.) 4000 ** 4000 ** 4000 ** 4000 ** 4000 **

* 8,000 Hours or once a year. ** 4,000 Hours or more frequently if conditions so require.

16

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

Section 6

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 locate 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 (if necessary) all air inlet connections prior to resuming operation. SEPARATOR ELEMENT REPLACEMENT Refer to Figure 6-- 3. The separator should be changed once a year. Follow the procedure explained below for element replacement.
!

WARNING

Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate compressor from line pressure by closing recommended discharge shutoff valve and releasing all internal pressure from compressor.

* Replacement Element Kit P/N 250028--034 Figure 6- Separator Element (P/N 250025-3 -264)

1. Insert a 4 maximum length, 1/4 diameter pin into the radially drilled hole in the separator cap. Loosen, unscrew counterclockwise and remove the cap. 2. Pull out the old element by gripping the end of the element with channel lock pliers or a similar tool. 3. Install new o--rings on separator cap and separator element filter and oil lightly to make installation easier. 4. Insert and push the new element in place.

* Replacement Element Kit P/N 250028--033

17

Section 6

MAINTENANCE
Figure 6- Minimum Pressure/Check Valve -4 (P/N 606058) 4. Remove the screw holding the check valve seat. Replace valve seat. Reinstall securing with LoctiteR #222. 5. Install new o--ring. Before reinstallation, lubricate with Parker Super O ring seal or an equivalent grease. 6. Reinstall the whole valve assembly. Tighten and secure. THERMOSTAT ACTUATOR MAINTENANCE Refer to Figure 6-- 5. The only part which would ever need replacement is the thermostat valve actuator. For replacement, follow the procedure explained below.
!

WARNING

Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate compressor from line pressure by closing recommended discharge shutoff valve and releasing all internal pressure from compressor.

* Repair Kit P/N 250030--226 5. Reinstall the cap. Hand--tighten using a 4 maximum length, 1/4 diameter pin in the radially drilled hole. MINIMUM PRESSURE/CHECK VALVE MAINTENANCE Refer to Figure 6-- 4. Minimum pressure/check valve maintenance is minimal. The only parts which normally require replacement are the o--ring seal around the piston and the valve seat on the check valve. To replace any of the two parts, follow the procedure explained below.
!

1. To prevent spillage and loss of re--usable fluid, place a contaminate--free fluid receptacle beneath fluid drain valve and fluid filter. 2. Drain fluid by removing fluid drain cap at tee located beneath compressor. 3. Unscrew and remove hollow hex plug. 4. Remove spring and piston. 5. By using long nosed pliers, pull the actuator out. 6. Install new actuator. 7. Install piston and spring with centering guide. 8. Re--install plug. Figure 6- Thermostat Actuator(P/N 250025-5 -413)

WARNING

Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate compressor from line pressure by closing recommended discharge shutoff valve and releasing all internal pressure from compressor.

WARNING

Assure that line pressure gauge on compressor indicates ZERO pressure before any work is done. Failure to comply can cause injury.

1. Unscrew the minimum pressure valve from the drive housing. 2. Remove all parts. 3. Clean and inspect all parts.

* Repair Kit P/N 250028--036

18

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

Section 6

CONTROL SYSTEM ADJUSTMENT Refer to Figure 6-- 6. All components in the Control System are designed and manufactured to close tolerances to eliminate any need for adjustments. The only adjustment required is to set the air pressure switch. This is done by following the instructions below. 1. Remove the pressure switch cover. 2. With the shut--off valve closed or slightly cracked open, start the compressor. 3. Observe the line pressure gauge and pressure switch contacts. When the line pressure reaches nameplate pressure, the pressure switch contacts should open. 4. If the pressure switch contacts do not open or they open prior to the desired pressure, the pressure switch setting will require adjustment (refer to Figure 6--6). To adjust the pressure switch, turn the range--adjusting screw to the high pressure setting. Turning the screw counterclockwise lowers both the high and low pressure setting equally. FOR DIFFERENTIAL ADJUSTMENT OF AIR PRESSURE SWITCH: Differential is the difference between the high and low pressure settings. Turning the screw clockwise increases the differential, and counterclockwise decreases the differential pressure.

DANGER

DO NOT touch the electrical contacts, terminal or leads with any part of the body or any uninsulated metallic object. Severe electrical shock may occur.

UNLOADER SOLENOID VALVE MAINTENANCE Unloader valve maintenance is minimal, but a periodic cleaning is desirable. The time between cleanings will vary depending on operating conditions. In general, if the voltage to the coils is correct, sluggish valve operation or excessive leakage will indicate that cleaning is required.
!

WARNING

Turn off all power, relieve sump pressure, and disconnect coil lead wires to the solenoid valve before making repairs.

It is not necessary to remove the valve from the pipe line for repairs. DISASSEMBLY AND REASSEMBLY 1. Remove the retaining cap and slip the entire solenoid off the solenoid base subassembly. 2. Unscrew the solenoid base assembly. Remove the core assembly, core spring and body gasket. 3. All parts are now accessible for cleaning or replacement. 4. Reassemble in reverse order of disassembly.

19

Section 6

MAINTENANCE
COIL REPLACEMENT 1. Remove the retaining cap, nameplate and cover. 2. Slip the yoke containing the coil and sleeves off the solenoid base subassembly. 3. Reassemble in reverse order of disassembly.
!

WARNING

Before doing compressor maintenance, disconnect compressor from power source and lock out power source. Isolate compressor from line pressure by closing recommended discharge shutoff valve and releasing all internal pressure from compressor.

INLET CONTROL VALVE Refer to Figure 6-- 7. The only parts which normally require replacement are the piston seal on the intake valve piston and gasket. Follow this procedure for inlet control maintenance. 1. Remove the inlet filter assembly. 2. Disconnect tubing from intake control housing at 90 elbow. 3. Remove the two (2) 3/8 ferry head capscrews securing the intake control housing to the inlet plate. 4. Remove intake control housing assembly and gasket. 5. Remove retaining ring, cap and intake check spring from intake housing bore. Figure 6- Inlet Control Valve -7

6. Remove socket head capscrew, washers, and check spring from intake valve rod. 7. Remove intake valve from valve housing. Remove intake valve rod, check spring, spring retainer and intake valve head. 8. Remove intake piston from intake/inlet control housing. Remove and discard old piston seal from intake piston. 9. Clean intake housing gasket surface and internal piston bore. 10. Lubricate internal piston bore using lubricant supplied with kit. 11. Install new piston seal onto piston. 12. Reinstall intake valve rod, check spring, spring retainer and intake valve head into intake control housing. Install assembled intake piston into intake control bore and onto intake valve rod. 13. Install washers. Apply screw lock adhesive provided in kit to socket head capscrew. Replace socket head capscrew into the valve rod and torque socket head capscrew to 18 to 24 in.--lbs. (2.0 to 2.7Nm). 14. Install intake check spring, cap and retaining ring. 15. Replace gasket and reinstall the whole inlet control valve assembly. 16. Apply screw lock adhesive to inlet control housing assembly ferry head capscrews and install. Torque to 30 ft.--lbs. (40.7Nm). 17. Reconnect tubing to inlet control valve housing at 90 elbow.

*
* Repair Kit P/N 02250045--287

20

MAINTENANCE
18. Reinstall air inlet filter assembly. MOTOR SHAFT SEAL REPLACEMENT Replacement of motor shaft seal requires that the compressor be separated from the drive housing. This operation requires qualified personnel. Detailed instructions and a list of needed tooling are included in each motor shaft seal replacement kit no. 250028--035. 6.7 TROUBLESHOOTING The information contained in the Troubleshooting chart is based upon both the actual applied situations and extensive testing at the factory. 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 TROUBLESHOOTING
SYMPTOM COMPRESSOR WILL NOT START PROBABLE CAUSE Main Disconnect Switch Open Line Fuse Blown Control Transformer Fuse Blown Motor Starter Overloads Tripped Close switch. Replace fuse. Replace fuse. Reset. Should trouble persist, check whether motor starter contacts are functioning properly. Check voltage. Should voltage check low, consult power company. Consult power company . REMEDY

Section 6

concerning the trouble should be systematically analyzed before undertaking any repair or component replacement procedures. A detailed visual inspection is worth performing for almost any problems which may prevent unnecessary damage to the compressor. Always remember to: a. Check for loose wiring. b. Check for damaged piping. c. Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor. Should your problem persist after making the recommended check, consult your nearest Sullair representative or the Sullair Corporation factory.

Low Incoming Line Voltage COMPRESSOR SHUTS DOWN WITH AIR DEMAND PRESENT Low Incoming Voltage Excessive Operating Pressure Discharge Temperature Switch Open

Defect in pressure switch; check pressure at which contact points open. Cooling air flow restricted; clean cooler and check for proper ventilation. Ambient temperature is too high; provide sufficient ventilation. Low fluid level; add fluid. Clogged filter; change the fluid filter element. Thermal valve not functioning; replace element. Defective discharge temperature switch; check for a short or open circuit to probe and correct wiring.

COMPRESSOR WILL NOT BUILD UP FULL DISCHARGE PRESSURE

Air Demand Is Too Great Dirty Air Filter Pressure Regulator Out Of Adjustment Defective Solenoid Valve

Check service lines for leaks or open valves. Check filter and change element if required. Adjust regulator according to control adjustment instructions in Section 6, Maintenance. A normally open solenoid must energize to load compressor; check for proper operation.

21

Section 6

MAINTENANCE
TROUBLESHOOTING
SYMPTOM LINE PRESSURE RISES ABOVE CUT-OUT PRESSURE SETTING ON PRESSURE SWITCH PROBABLE CAUSE Defective Solenoid Valve REMEDY Repair solenoid valve (see Section 6).

Leak In Control System Causing Loss Of Pressure Signals Defective Pressure Switch Inlet Valve Stuck Open EXCESSIVE COMPRESSOR FLUID CONSUMPTION Clogged Return Line Separator Element Damaged Or Not Functioning Properly Leak In The Lubrication System Excess Fluid Foaming Fluid Level Too High Shaft Seal Failure PRESSURE RELIEF VALVE OPENS REPEATEDLY Compressor Operating Pressure Too High Defective Pressure Relief Valve LIQUID WATER IN COMPRESSED AIR LINES Water Vapor Condensation From Cooling and Compression Occurs Naturally

Check for leaks. Check that diaphragm and contacts are not damaged. Replace if necessary. Inspect inlet valve and insure free operation (s ee Sec tion 6). Remove element cover and clean orifice. Change separator element. Check all pipes, connections and components. Drain and change. Drain excess. Replace shaft seal. See Symptom Line Pressure Rises Above Cut-out Pressure Setting on Pressure Switch above Replace pressure relief valve. 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.

22

MAINTENANCE
6.8 MAINTENANCE RECORD MODEL NO. SERIAL NO.
MAINTENANCE PERFORMED WORK PERFORMED BY

Section 6

DATE

HOURMETER

AUTHORIZED BY

23

ILLUSTRATIONS AND PARTS LIST

ES- COMPRESSOR ASSEMBLY, EXPLODED VIEW -6

Section 7

(5.5 AND 7.5KW)

24

ILLUSTRATIONS AND PARTS LIST

Section 7

7.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the address, phone numbers or fax numbers below. When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the Bill of Lading for the compressor or from the Serial Number Plate located on the compressor. The genuine Sullair service parts listed meet or exceed the demands of this compressor. Use of replacement parts other than those approved by Sullair Corporation may lead to hazardous conditions over which Sullair Corporation has no control. Such conditions include, but are not limited to, bodily injury and compressor failure. Subsidiary of Sundstrand Corporation 3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. Telephone: 1-800-SULLAIR (U.S. Only) or 1-219-879-5451 Fax: (219) 874 - 1273 Fax: (219) 874 - 1835 (Parts) Fax (219) 874 - 1805 (Service) Chiwan Supply Base Bldg A5- Chiwan -1 Shenzhen, Guangdong PRV. P.R.C. Post Code 518068 Telephone: 755-6694982 FAX: 755-6694313 7.2 RECOMMENDED SPARE PARTS LIST DESCRIPTION replacement element kit for fluid filter 250026--982 replacement element kit for air/fluid separator 250025--264 replacement element kit for air filter 250025--421 repair kit for motor shaft seal 250039--218 repair kit, shaft seal installation repair kit for thermostat actuator 250025--413 replacement kit for coil 250028--809 repair kit for solenoid valve 250030--164 replacement coil for solenoid valve 250030--164 repair kit for minimum pressure/check valve 606058 replacement piston seal kit for air inlet control valve replacement piston for inlet control valve replacement washer for inlet control valve fluid, Sullube 32 (one gallon) fluid, Sullube 32 (five gallons) repair kit for ES--6 1/2 npt service connection 250026--066 KIT NUMBER 250028-032 250028-033 250028-034 250028-035 250034-267 250028-036 250028-387 250038-849 250035-292 250030-226 02250045-287 02250044-811 02250045-287 250009-396 250022-669 250030-103 QUANTITY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

SULLAIR CORPORATION

SULLAIR ASIA, LTD.

SULLAIR EUROPE, S.A.

Chemin de Genas BP 639 69800 Saint Priest, France Telephone: 33-72232425 Fax: 33 - 78907168 -

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

25

Section 7

ILLUSTRATIONS AND PARTS LIST

7.3 FLUID MANAGEMENT SYSTEM

26

ILLUSTRATIONS AND PARTS LIST

7.3 FLUID MANAGEMENT SYSTEM key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 part number 250026--982 250025--914 250026--038 826502--139 250025--264 826502--127 250039--359 250025--420 250025--309 828408--300 829312--080 250025--413 250025--415 250025--464 827404--150 250025--417 250025--419 250025--418 --

Section 7

description element, fluid filter (I) adapter, fluid filter cap, separator element o--ring, 2 3/16 x 3/32 element, separator air/fluid (II) o--ring, 1 7/16 x 1/16 plug, hex head 1 1/16--12 SAE glass, sight housing, bell capscrew, ferry head 1/2--13 x 3 Sscrew, socket ISO4762 m12 x 20 (metric) actuator, thermostat (III) piston, thermostat spring, compression pin, roll 1/4 x 1 1/2 guide, thermostat spring o--ring (IV) plug, thermostat 1 1/16--12 decal, fluid (V)

quantity 1 1 1 1 1 1 1 1 1 12 12 1 1 1 1 1 3 1 1

(I) For maintenance on fluid filter element no. 250026--982, order repair kit no. 250028--032. (II) For maintenance on air/fluid separator element no. 250025--264, order repair kit no. 250028--033. (III) For maintenance on thermostat actuator no. 250025--413, order repair kit no. 250028--036. (IV) For replacement only. (V) Decal will vary with compressor fluid fill requirement. Factory fill (Sullube 32) decal part no. is 02250069--389. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

27

Section 7

ILLUSTRATIONS AND PARTS LIST

7.4 INLET FILTER

28

ILLUSTRATIONS AND PARTS LIST

7.4 INLET FILTER key number 1 2 3 4 5 6 7 part number 250025--265 824815--004 250025--661 250025--422 250025--421 250025--423 843504--050

Section 7

description filter, air assembly nut, wing 1/4--20 washer, seal hood, air filter element, air filter (I) plate, air filter base rod, threaded 1/4 x 5

quantity 1 1 1 1 1 1 1

(I) For maintenance on air filter element no. 250025--421, order repair kit no. 250028--034. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

29

Section 7

ILLUSTRATIONS AND PARTS LIST

7.5 SEAL AND DRIVE GEAR

30

ILLUSTRATIONS AND PARTS LIST

7.5 SEAL AND DRIVE GEAR key number 1 2 3 4 5 6 7 8 9 part number 250028--339 Consult Factory Consult Factory 250025--412 250039--218 828404--075 250025--312 826502--150 250039--600

Section 7

description plate, inlet gear, driven gear, drive sleeve, wear seal, shaft Teflon/Viton (I) capscrew, ferry head 1/4--20 x 3/4 housing, shaft seal o--ring, 2 7/8 x 3/32 spacer, gear

quantity 1 1 1 1 1 2 1 1 1

(I) For maintenance on motor shaft seal no. 250039--218, order repair kit no. 250028--035. NOTE: Requires special tooling for removal/installation. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

31

Section 7

ILLUSTRATIONS AND PARTS LIST

7.6 MOTOR, HOUSING AND PARTS

7.5 & 10HP (5.5 & 7.5KW) ONLY

32

ILLUSTRATIONS AND PARTS LIST

7.6 MOTOR, HOUSING AND PARTS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 part number 250026--839 02250059--246 250030--547 837201--045 250030--223 250030--502 250033--369 250025--428 826502--116 250025--429 250025--430 409955 250039--678 490046--001 Consult Factory Consult Factory Consult Factory 250040--312 810210--050 250026--469 829108--100 606058 838208--112 810208--050 250039--904 827905--088

Section 7

description housing, drive Shousing, drive (metric) screw, machine round head #8--32 x 1/2 washer, pl--b #8 seat, minimum pressure/check valve stem, minimum pressure/check valve spring, minimum pressure/check valve piston, minimum pressure/check valve o--ring, 3/32 x 3/4 spring, minimum pressure/check valve cap, minimum pressure/check valve valve, relief 1/2 175 psig (12.1 bar) Svalve, relief 1/2 200 psig (13.8 bar) plug, pipe hex soc. 1/8 NPT motor, 5HP/4KW Smotor, 7.5HP/5.5KW Smotor, 10HP/7.5KW switch, temperature 212 -- normally closed connector, tube--m 5/8 x 1/2 (7.5 and 10HP/5.5 and 7.5 KW only) base, compressor capscrew, hex gr8 1/2--13 x 1 valve, minimum pressure/check (I) washer, pl--b reg pltd 1/2 connector, tube--m 1/2 x 1/2 bail, lifting capscrew, hex 5/16--18 x 7/8

quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1

(I) For maintenance on minimum pressure/check valve no. 606058, order repair kit no. 250030--226. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

33

Section 7

ILLUSTRATIONS AND PARTS LIST

7.7 COMPRESSOR COOLER SYSTEM

7.5 & 10HP (5.5 & 7.5KW) COOLER

34

ILLUSTRATIONS AND PARTS LIST

7.7 COMPRESSOR COOLER SYSTEM key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 description duct, cooler mount (5HP/4KW) Sduct, cooler mount (7.5HP and 10HP/5.5 and 7.5KW) ring, cooler (5HP/4KW) Sring, cooler (7.5HP and 10HP/5.5 and 7.5KW) screw, hex serrated washer 1/4--20 x 1/2 screw, hex serrated washer 1/4 x 3/4 plate, cooler filler (5HP/4KW) Splate, cooler filler (7.5HP and 10HP/5.5 and 7.5KW) nut, hex 5/16--18 (5HP/4KW) Snut, hex 5/16--18 (7.5 and 10HP/5.5 and 7.5KW) cooler, fluid (5HP/4KW) Scooler, fluid and aftercooler (7.5&10HP/5.5 and 7.5KW) (I) orifice, fan ring 12 3/8 id capscrew, ferry 5/16--18 x 1 1/2 (5HP/4KW) capscrew, ferry 5/16--18 x 2 (7.5HP &10HP/5.5 and 7.5KW) washer, flat 5/16id x 1 1/4od (5HP/4KW) Swasher, flat 5/16id x 1 1/4od (7.5 & 10HP/5.5 and 7.5KW) connector, tube straight threaded 1/2 x 3/4 tube, 1/2od (5HP/4KW) tube, 1/2od cap, 1/2 tube tee, tube union 1/2 tube, 1/2od (5HP/4KW) Stube, 1/2od (7.5HP and 10HP/5.5 and 7.5KW) guard, 12 fan cap, fan guard 4 fan, 12 diameter (5HP/4KW) Sfan, 12 diameter (7.5HP and 10HP/5.5 and 7.5KW) elbow, 90 connector 7/8--14 x 1/2npt elbow, tube straight threaded 5/8 x 7/8 (7.5 and 10HP/5.5 and 7.5KW) tubing, aftercooler in (7.5 and 10HP/5.5 and 7.5KW) tubing, fluid cooler out (7.5 and 10HP/5.5 and 7.5KW) screw, brass set insert, 1/4--20 threaded blind part number 250026--472 250026--471 250034--535 250034--536 829704--050 829704--075 250025--829 250026--843 825305--283 825305--283 250028--961 250026--066 250034--537 828405--150 828405--200 250025--830 250025--830 811808--075 250026--718 250030--040 250026--350 811408--050 250026--719 250030--041 250028--964 250026--591 250026--253 250026--254 250030--104 811615--062 250030--042 250030--043 250031--014 250034--538 quantity 1 1 1 1 8 4 1 1 1 2 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8

Section 7

(I) ES--6 1/2 npt service connection kit no. 250030--103. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

35

Section 7

ILLUSTRATIONS AND PARTS LIST

7.8 COMPRESSOR SYSTEM

36

ILLUSTRATIONS AND PARTS LIST

7.8 COMPRESSOR SYSTEM key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 part number 499065--007 02250055--135 02250047--887 499080--203 250029--910 250025--315 828404--125 02250055--136 02250055--485 838206--071 499025--005 828405--100 828405--225 02250055--489 02250055--490 828406--375 250028--339 250025--850 499082--705 250023--213 250025--435 831204--050 250030--545 250025--865 250041--956 250025--414 828405--150 250025--870 250026--350 828304--025 250026--859 839608--060 250033--368 499045--032 828406--075 842215--004

Section 7

description washer seal bolt bu ss locknut, male--M25 x 1 wavespring, male bearing, taper housing, stator ES--6 E profile cover, outlet capscrew, ferry head 1/4--20 x 11/4 locknut, female M17 x 1 wavespring, female washer, pl b--reg pltd 3/8 bearing, taper capscrew, ferry head 5/16--18 x 1 capscrew, ferry head 5/16--18 x 2 1/4 rotor, female E profile (I) rotor, male E profile (I) capscrew, ferry head 3/8--16 x 33/4 plate, inlet elbow, tube 90M 1/4 x 1/4 bearing, cylinder roll plain bearing, needle roller steel retainer, inlet bearing screw, machine flat head 1/4--20 x 1/2 orifice, gear spray (mounting location) tube, separator fluid return tee, tube branch straight thread 1/2 x 3/4 valve, body thermostat capscrew, ferry head 5/16--18 x 1 1/2 fitting, separator fluid return cap, 1/2 tube od 3/4--16 capscrew, socket head 1/4--20 x 1/4 plate, ES--6 identification screw, drive rod plated #8 x 3/8 screw, set cup 5/8--11 x 1/2 pin, dowel 3/8 x 1 capscrew, ferry 3/8--16 x 3/4 hose, nylon 1/4

quantity 2 1 1 2 1 1 5 1 1 2 2 3 2 1 1 2 1 2 1 1 1 1 1 1 1 1 2 1 1 2 1 2 1 4 2 5 ft.

(I) Machine serial numbers below 006--93007285 consult factory for rotor part numbers. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

37

Section 7

ILLUSTRATIONS AND PARTS LIST

7.9 INLET CONTROL

38

ILLUSTRATIONS AND PARTS LIST

7.9 INLET CONTROL key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 part number 02250044--810 250034--619 02250044--809 250025--425 02250044--808 250025--310 02250044--811 02250044--671 250031--269 02250043--162 02250042--966 250029--898 836150--137 250025--840 842215--004

Section 7

description rod, ES--6 intake control valve spring, PTO ES--6 intake check retainer, ES--6 intake control valve gasket, inlet valve head, ES--6 intake control valve housing, intake control piston, ES--6 intake control valve (I) seal, ES--6 intake control piston (II) washer, Belleville spring (I) capscrew, sch #10--32 x 1/2 Nylok spring, inlet control ES--6 cap, air intake ring, retaining internal 1 3/8 elbow, 90 male 1/8 npt x 1/4 tube hose, nylon 1/4

quantity 1 1 1 1 1 1 1 1 2 1 1 1 1 1 5 ft.

(I) For maintenance on inlet control, order piston no. 02250044--811 and washer no. 250031--269. (II) For maintenance on air intake valve piston seal, order repair kit no. 02250045--287. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

39

Section 7

ILLUSTRATIONS AND PARTS LIST

7.10 CONTROL BOX

40

ILLUSTRATIONS AND PARTS LIST

7.10 CONTROL BOX key number 1 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 part number

Section 7

description

quantity

Consult factory for starter group, and refer to compressor serial number. bracket, top starter 250039--244 1 plate ES--6, access (Ref.) 250034--858 1 locknut, conduit 1/2 847200--050 3 nipple, chase 1/2 npt 847815--050 2 decal, 3 position switch panel 250039--113 1 hose, nylon 1/4 842215--004 5 ft. valve, solenoid 1/8 110/120 (I) 250030--164 1 box, junction 250026--740 1 screw, hex serrated washer 1/4 x 1/2 829704--050 9 lug 849215--004 1 nut, hex flanged 1/4--20 825304--236 9 switch, selector 3 position 248168 1 elbow, 90 m swvl 1/8T x 1/8 NPT 250025--849 2 pushbutton, manual/reset 02250045--011 1 screw, 1/4--20 x 1/2 long 250030--162 4 fastener, suregrip 041516 2 nameplate, Sullair 1 x 6 250035--063 1 joint, compression phase 230V, 3PH 250026--615 1 Sphase 3 460V (not shown) 250026--615 3 insulator, splice phase 1 230V, 3PH 250006--110 1 Sphase 3, 460V (not shown) 250006--110 3 panel, circuit board 250025--863 1 Consult factory for starter group, and refer to compressor serial number. transformer 02250045--012 1 rivet, pop 1/8 x 3/8 843102--038 4 nameplate, Sullair 02250059--318 1 gauge, pressure 0--200# bar/psi 250005--185 1 tee, male branch 1/8 250026--139 1 connector, male tube straight 1/8 x 1/4 250025--858 1 plug, hole 1/2 045689 1 (Continued on page 43)

(I) For maintenance on solenoid valve no. 250030--164, order repair kit no. 250038--849, and replacement coil no. 250035--292. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

41

Section 7

ILLUSTRATIONS AND PARTS LIST

7.10 CONTROL BOX

42

ILLUSTRATIONS AND PARTS LIST

7.10 CONTROL BOX (continued) key number 32 33 34 35 36 37 38 39 40 41 42 43 44 45 part number 807600--005 250025--299 250026--153 250031--869 828604--550 250031--734 250031--733 825304--236 250041--860 02250043--291 250000--104 250042--224 02250056--423 02250043--320

Section 7

description bushing, reducing 1/4 x 1/8 switch, pressure 0--200# (air) connector, 1/2 plate ES--6, switch (Ref.) capscrew, hex 1/4--20 x 5 1/2 5HP single phase capacitor, run 5HP/4KW single phase capacitor, start 5HP/4KW single phase nut, hex flanged 1/4--20 (single phase) support, lower control box ES--6 gauge, temperature light, pilot assembly -- green hourmeter, rnd 2 1/2 120V/60Hz (optional) gasket, hourmeter (optional) panel, gauge temperature capillary

quantity 1 1 1 1 1 2 2 1 1 1 1 1 1 1

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

43

Section 7

ILLUSTRATIONS AND PARTS LIST

7.11 CANOPY AND PARTS

15

1 13

18

10 14 7 6 9 12 8 16

11

17

44

ILLUSTRATIONS AND PARTS LIST

7.11 CANOPY AND PARTS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 part number 250031--542 250041--300 250032--871 250032--872 250032--309 250033--701 250033--702 250033--096 02250059--052 02250060--043 02250078--001 02250078--007 250034--157 250034--158 250034--159 250041--298 250041--299 02250059--288

Section 7

description cover, ES--6 canopy foam, front ES--6 canopy sound soundcoat, ES--6 canopy -- right soundcoat, ES--6 canopy -- left louvers, ES--6 canopy bracket, ES--6 canopy mounting -- left bracket, canopy ES--6 mounting -- right canopy, stop ES--6 decal, Sullair logo (not shown) decal, ES--6 Model (not shown) decal, warning--under pressure decal, prohibit breath trim, canopy edge screw, #14 x .625 hex rivet, plastic 1/4 x 5/8 foam, ES--6 canopy sound -- top foam, ES--6 canopy sound -- rear decal, ISO 9001 (not shown)

quantity 1 1 1 1 1 1 1 2 1 1 1 1 2 16 4 1 1 1

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

45

Section 7

ILLUSTRATIONS AND PARTS LIST

7.12 FRAME, CANOPY AND PARTS

46

ILLUSTRATIONS AND PARTS LIST

7.12 FRAME, CANOPY AND PARTS key number 1 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 45 46 47 49 51 52 55 58 60 64 65 66 67 71 part number 250031--542 250031--545 250031--546 250032--223 250032--226 250032--308 250032--873 250032--874 250032--878 250034--582 843415--375 829706--100 825306--347 250035--188 250034--498 250034--583 829704--050 825304--236 838206--071 250025--108 250034--858 250031--869 250032--881 250000--104 02250043--291 250042--224 250038--243 250034--159 250032--227 02250077--473 02250061--884 410353 825305--283 250025--299

Section 7

description canopy, ES--6 pan, ES--6 canopy base partition, ES--6 canopy rod, ES--6 canopy support footing, ES--6 canopy rod, ES--6 canopy hinge soundcoat, ES--6 canopy partition mounts, canopy vibration anchor, support rod retainer, ES--6 canopy partition retainer, shakeproof screw, hex serrated washer 3/8 x 1 nut, hex flange plated 3/8--16 isolator, 5/16--18 x 1 diameter pad bracket, ES--6 canopy centering plug, 2 hole screw, hex serrated washer 1/4 x 1/2 nut, hex flange plated 1/4--20 washer, pl--b regular plated 3/8 bracket, canopy adjustment panel, ES--6 access (Retrofit kit only) plate, ES--6 switch (Retrofit kit only) plug, 1.2 diameter hole into pressure switch light, pilot assembly -- green gauge, temperature capillary 1/2 x 4 (not shown) hourmeter, round 2 1/2 120V/60Hz ES--6 gauge, pressure 0--200# bar/psi (not shown) rivet, plastic 1/4 x 5/8 bezel, ES--6 canopy control decal, warning auto start decal, ES--6 canopy bezel switch gasket, hourmeter nut, hex flanged plated 5/16--18 switch, pressure

quantity 1 1 1 1 2 1 1 4 1 3 2 4 4 2 2 1 7 7 8 2 1 1 1 1 1 1 1 4 1 1 1 1 4 1

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

47

Section 7

ILLUSTRATIONS AND PARTS LIST

7.13 WYE-DELTA ELECTRIC BOX ES-6

23

LINE PRESSURE

DISCHARGE TEMP.

OFF/RESET ON MANUAL AUTO

POWER ON

RE S E T

24

48

ILLUSTRATIONS AND PARTS LIST

7.13 WYE-DELTA ELECTRIC BOX ES-6 key number 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22 23 24 description hose, nylon 1/4 valve, solenoid nipple, chase 1/2 box, electric control (5.5 HP/4KW) Sbox, electric control (7.5&10HP/5.5&7.5KW) hourmeter locknut, conduit 1/2 nipple, pipe 1/2 x close elbow, 90 M swivel 1/4 x 1/8 tee, male branch 1/8 bushing, reducing 3/8 x 1/8 switch, pressure range 40--150# switch, 3 position selector Sblock, contact with mounting base Sblock, contact without mounting base light, unit Slens, clear gauge, pressure air 0--300# 2 gauge, temperature bezel, ES--6 canopy control rivets, plastic 1/4 x 5/8 decal, ES--6 canopy bezel button, reset part number 842215--004 250030--164 847815--050 250031--242 250031--243 250042--010 847200--050 822208--000 250025--849 250026--139 807601--005 250031--244 250034--883 250025--181 250034--882 250027--443 250026--998 02250044--361 02250043--291 250032--227 250034--159 02250061--884 Consult Factory quantity 5 ft. 1 1 1 1 1 7 1 3 1 1 1 1 1 1 1 1 1 1 1 4 1 1

Section 7

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

49

Section 7

ILLUSTRATIONS AND PARTS LIST

7.14 WYE-DELTA ELECTRIC BOX ES-6

50

ILLUSTRATIONS AND PARTS LIST

7.14 WYE-DELTA ELECTRIC BOX ES-6 key number 1 2 3 4 5 description tee, tube connector, liquid tight connector, male 1/4 x 1/8 terminal, block fuse, 2 amp Sfuse, carrier Sfuse, 4 amp Sfuse, carrier CPT with tamper proof cover relay, control contactor Scontactor, block interlock, mechanical contactor Srelay, (7.5HP and 10HP/5.5 and 7.5KW) Srelay, (5.5HP/4KW) contactor Stimer head switch, pressure part number 250028--270 250041--988 250025--858 Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory Consult Factory 250032--763 quantity 1 1 1

Section 7

6 7 8 9 10 11 12

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

51

Section 7

ILLUSTRATIONS AND PARTS LIST

7.15 DECAL GROUP

12

11

52

ILLUSTRATIONS AND PARTS LIST

7.15 DECAL GROUP key number 1 2 3 4 5 6 7 8 8B 9 part number 02250078--001 250039--113 02250077--999 02250077--473 02250078--998 02250059--052 040745 02250069--389 02250069--391 02250075--046 02250075--045 02250075--540 02250060--043 02250059--288 02250069--397

Section 7

description decal, warning -- under pressure (not shown) decal, 3 position switch panel (not shown) sign, warning -- hot surfaces (not shown) decal, warning auto start (not shown) decal, prohibition, breath/food (not shown) decal, Sullair logo (not shown) decal, rotation direction decal, compressor fluid Sullube 32 (I) decal, fluid SRF 1/4000 (not shown) (I) decal, earth ground Sdecal, protective earth ground (not shown) Sdecal, PE designation (not shown) decal, ES--6 Model (not shown) decal, ISO 9001 decal, voltage international (II)

quantity 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1

10 11 12

(Continued on page 55)

(I) Decal will change with fluid requirement. (II) Decal will vary with machine voltage. If voltage is not known, consult factory with serial number of compressor. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

53

Section 7

ILLUSTRATIONS AND PARTS LIST

7.15 DECAL GROUP

13

54

ILLUSTRATIONS AND PARTS LIST

7.15 DECAL GROUP (continued) key number 13 14 part number 02250061--884 02250078--002

Section 7

description decal, ES--6 canopy bezel decal, mandatory read manual (not shown)

quantity 1 1

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

55

Section 7

ILLUSTRATIONS AND PARTS LIST

7.16 WIRING DIAGRAM (SINGLE PHASE) (60Hz)

56

ILLUSTRATIONS AND PARTS LIST

7.17 WIRING DIAGRAM (THREE PHASE) (60Hz)

Section 7

57

Section 7

ILLUSTRATIONS AND PARTS LIST

7.18 WIRING DIAGRAM (50 Hz)

58

ILLUSTRATIONS AND PARTS LIST

7.19 WIRING DIAGRAM (50 Hz) WYE-DELTA

Section 7

59

NOTES

NOTES

WORLDWIDE SALES AND SERVICE

SULLAIR ASIA, LTD.

ROOM 2304A Shartex Plaza Ctr. No. 88 Zun Yi Nan Rd. Shanghai, P.R.C. Telephone: 21-2192066 Fax: 21 - 2196568 -

SULLAIR EUROPE, S.A.

Chemin de Genas BP 639 69800 Saint Priest, France Telephone: 33-72232425 Fax: 33 - 78907168 -

Subsidiary of Sundstrand Corporation 3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. Telephone: 1-800-SULLAIR (U.S.A. Only) or 1-219-879-5451 Fax: (219) 874 - 1273 Fax: (219) 874 - 1835 (Parts) Fax: (219) 874 - 1805 (Service) -

SULLAIR CORPORATION

Printed in U.S.A.
Specifications Subject To Change Without Prior Notice EN95EPS