ROTARY SCREW
AIR COMPRESSOR
ES--6 Series
5, 7.5 and 10HP
4, 5.5 and 7.5 kw
OPERATOR’S
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 Sullair’s 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
5
5
5
2.1 INTRODUCTION
5
2.4 COMPRESSOR COOLING SYSTEM,
FUNCTIONAL DESCRIPTION
5
7
8
2.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
9
3.1 TABLE OF SPECIFICATIONS
10
3.2 COMPRESSOR LUBRICATION GUIDE
11
11
11
11
12
12
4.1 LOCATION OF COMPRESSOR
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
2.2 DESCRIPTION OF COMPONENTS
2.3 ENCAPSULATED COMPRESSOR SYSTEM,
FUNCTIONAL DESCRIPTION
2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
2.7 INSTRUMENTATION, FUNCTIONAL DESCRIPTION
Section 3
SPECIFICATIONS
Section 4
INSTALLATION
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
15
15
15
15
15
16
6.1 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
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
25
25
26
28
30
32
34
36
38
40
44
46
48
7.1 PROCEDURE FOR ORDERING PARTS
6.8 MAINTENANCE RECORD
Section 7
ILLUSTRATIONS AND
PARTS LIST
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
Section 1
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 Operator’s
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 manufacturer’s 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 manufacturer’s 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
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.
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.
C. Wear snug--fitting clothing and confine long hair
when working around this compressor, especially
when exposed to hot or moving parts.
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.
D. Keep access doors, if any, closed except when
making repairs or adjustments.
F. Wear goggles or a full face shield when adding antifreeze compound to air line anti--icer systems.
B. DO NOT attempt to operate the compressor with
the fan, coupling or other guards removed.
2
E. Make sure all personnel are out of and/or clear of
the compressor prior to attempting to start or operate it.
Section 1
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.
3
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.
4
Section 2
DESCRIPTION
2.1 INTRODUCTION
Your new Sullair flood--lubricated rotary screw air
compressor will provide you with improved reliability
and greatly reduced maintenance.
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.
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.
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.
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.
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.
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.
!
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.
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 motor’s 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
The compressor inlet system consists of a dry--type
air 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.
5
Section 2
DESCRIPTION
Figure 2--1 Description of Components
(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
6
Section 2
DESCRIPTION
Figure 2--2 Encapsulated Compressor System
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.
7
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.
8
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.
Section 3
SPECIFICATIONS
3.1 SPECIFICATIONS -- ES-- 6
DIMENSIONS
60Hz
Model
ES--6 5H
ES--6 5XH
ES--6 7.5H
ES--6 7.5XH
ES--6 10H
ES--6 10XH
HP/KW
Capacity
ACFM/
M3/MIN
5/4
5/4
7.5/5.5
7.5/5.5
10/7.5
10/7.5
18/.51
13/.37
28/.79
20/.57
38/1.08
30/.85
HP/KW
Capacity
ACFM/
M3/MIN
Maximum
Pressure
PSIG/BAR
dBA (I)
with canopy/
without canopy
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
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
110/7.5
150/10
175/12
110/7.5
150/10
175/12
110/7.5
150/10
175/12
68/80
68/80
68/80
69/82
69/82
69/82
70/85
70/85
70/85
Maximum
Pressure
PSIG/BAR
dBA (I)
with canopy/
without canopy
125/8.6
175/12
125/8.6
175/12
125/8.6
175/12
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
DIMENSIONS
50Hz
Model
ES--6 5L
ES--6 5HH
ES--6 50XH
ES--6 7.5L
ES--6 7.5HH
ES--6 7.5XH
ES--6 10L
ES--6 10HH
ES--6 10XH
COMPRESSOR
Type:
Minimum Full Load Operating Pressure:
Maximum Full Load Operating Pressure:
Bearing Type:
Cooling:
Lubricant:
Sump Capacity:
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
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)
(I) Compressors are available for pressures up to 175 psi (12.1 bar).
MOTOR
Type:
Synchronous Speed:
60Hz
5, 7.5, 10HP/
4, 5.5 & 7.5 KW 1.15 S.F.
1800 RPM
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:
50Hz
5, 7.5, 10HP/
4, 5.5 & 7.5 KW
1500 RPM (5, 7.5HP/4, 5.5KW)
3000 RPM (10HP/7.5KW)
230/460V 3 Phase
200V 3 Phase
575V 3 Phase
230V Single Phase
Totally Enclosed Air Over
“F”
40qC (104qF)
Nominal 5/8”
Nominal 3/16” x 3/16” x 1 1/4”
380/415 3 Phase
380/415 3 Phase
380/415 3 Phase
380/415 3 Phase
Totally Enclosed Air Over
“F”
40qC (104qF)
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
9
Section 3
SPECIFICATIONS
Table 3--1, Lubrication Guide
AMBIENT
TEMPERATURE
--10qF to +90qF
(--23qC to +32qC)
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.)
FILTER CHANGE
PERIOD (HRS.)
8000 *
8000 *
4000
1000
8000 *
8000 *
4000
1000
600
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.
!
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)
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
Mixing of other fluids within the compressor will
void all warranties.
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.
When ambient conditions exceed those noted or if
conditions warrant use of “extended” life lubricants
contact Sullair for recommendation.
Maintenance of all other components is still recommended as indicated in the Operator’s Manual.
For light--duty high--humidity service where condensed moisture and emulsification (mayonnaise)
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.
Figure 3--1 Center of Gravity
APPROX. 6” (15.2CM)
CENTER OF GRAVITY
10
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.
Section 4
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.
!
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.
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
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--1 Service Air Piping
11
Section 4
INSTALLATION
the compressor fluid drain cap (See Figure 2-- 1).
installer.
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.
A few electrical checks should be made to help assure that the first start--up will be trouble--free.
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
12
!
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.
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 reading 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 SELECTOR SWITCH
The three--position switch provides selection between
MANUAL/START, OFF/RESET and AUTO--MATIC/
START (for further description, see Section 2).
LINE PRESSURE GAUGE
Continually monitors service line air pressure.
FLUID LEVEL SIGHT GLASS
Indicates fluid level. The level is checked by looking at
the fluid level sight glass on the end bell. The fluid level
should cover 1/2 to1/4 of the sight glass during operation. With the compressor shut down, the level should
be 3/4 of the sight glass. DO NOT OVERFILL.
COOLER BYPASS VALVE
Regulates fluid flow to and around the cooler. Designed to maintain a minimum operating temperature
of 170qF (77qC). Used for fast warm--up and start--up.
MINIMUM PRESSURE/CHECK VALVE
Maintains a minimum of 60 psig (4.1 bar) in compressor sump. Valve piston restricts receiver air discharge
from receiver/sump when pressure falls to 60 psig (4.1
bar). Also incorporated in this valve is a terminal check
valve which prevents line pressure backflow into the
sump during unload conditions and after shutdown.
DISCHARGE TEMPERATURE SWITCH
Shuts the compressor down when the compressor discharge temperature exceeds 240qF (116qC).
PRESSURE RELIEF VALVE
Opens sump pressure to the atmosphere should pressure inside the sump become too high. Operation of
this valve indicates that the air pressure switch is either
faulty or out of adjustment.
AIR PRESSURE SWITCH
Senses service line pressure. When line pressure
reaches maximum setting, the pressure switch opens
solenoid valve circuit to unload the compressor.
SOLENOID VALVE
SUMP PRESSURE SWITCH
(Not used on current models except
with Wye--Delta starter).
DISCHARGE TEMPERATURE GAUGE
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.
13
Section 5
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
14
System Adjustment in Section 6, Maintenance of
this manual.
8. Observe the operating temperature. If the operating temperature exceeds 200qF (93qC), 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 6
MAINTENANCE
6.1 GENERAL
!
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.
WARNING
Before doing compressor maintenance, disconnect compressor from power source and lock out
power source. Isolate compressor from line pressure by closing recommended discharge shut-off 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.
(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
!
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.
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
!
WARNING
Before doing compressor maintenance, disconnect compressor from power source and lock out
power source. Isolate compressor from line pressure by closing recommended discharge shut-off valve and releasing all internal pressure from
compressor.
WARNING
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 shut-off valve and releasing all internal pressure from
compressor.
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
STANDARD
CONDITIONS (I)
5HP (4KW)
7.5 and 10HP
(5.5 & 7.5KW)
All Motors
Over 1800 RPM
3 Years
2.5 Years
1 Year
10 1/2Months
6 Months
5 1/2 Months
6 Months
3 Months
3 Months
SEVERE
CONDITIONS (II)
EXTREME
CONDITIONS (III)
(I) Eight hours per day, normal or light loading, clean 100qF (38qC) maximum ambient.
(II) Twenty--four hours per day operation or shock loadings, vibration, or in dirt or dust at
100qF to 150qF (38qC to 66qC) ambient.
(III) Heavy shock or vibration, dirt or dust at 100qF to 150qF (38qC to 66qC) ambient.
15
Section 6
MAINTENANCE
6.6 PARTS REPLACEMENT AND ADJUSTMENT
PROCEDURES
!
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 shut-off 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.
!
Figure 6-1 Fluid Filter (P/N 250026-982)
WARNING
Before doing compressor maintenance, disconnect compressor from power source and lock out
power source. Isolate compressor from line pressure by closing recommended discharge shut-off 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.
FLUID FILL
PLUG
*FLUID FILTER
ELEMENT
FLUID DRAIN
CAP
* Replacement Element Kit P/N 250028--032
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.
COMPRESSOR LUBRICATION GUIDE AND MAINTENANCE SCHEDULE
AMBIENT
TEMPERATURE
--10qF to +90qF
(--23qC to +32qC)
LUBRICATION
Sullube 32
Sullair LLL--4--32
SRF 1/4000
ATF as per Dextron II
Motor Oil MIL--2104E,
SPEC API SF CC,
CD SAE 10W Class SE
FLUID & FILTER CHANGE
PERIOD (HRS.)
8000 *
8000 *
4000
1000
* 8,000 Hours or once a year.
** 4,000 Hours or more frequently if conditions so require.
16
600
SEPARATOR CHANGE
PERIOD (HRS.)
8000 *
8000 *
4000
1000
600
AIR FILTER CHANGE
PERIOD (HRS.)
4000 **
4000 **
4000 **
4000 **
4000 **
Section 6
MAINTENANCE
Figure 6--2 Air Filter (P/N 250025--421)
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 shut-off valve and releasing all internal pressure from
compressor.
* Replacement Element Kit P/N 250028--034
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.
Figure 6--3 Separator Element (P/N 250025--264)
* Replacement Element Kit P/N 250028--033
17
Section 6
MAINTENANCE
Figure 6--4 Minimum Pressure/Check Valve
(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 shut-off 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--5 Thermostat Actuator(P/N 250025--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 shut-off 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.
18
* Repair Kit P/N 250028--036
Section 6
MAINTENANCE
Figure 6--6 Air Pressure Switch (P/N 250025--299)
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.
!
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.
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.
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.
FOR DIFFERENTIAL ADJUSTMENT OF AIR
PRESSURE SWITCH:
Differential is the difference between the high and
low pressure settings.
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.
Turning the screw clockwise increases the differential, and counterclockwise decreases the differential
pressure.
!
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.
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 shut-off 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
90q 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.
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
90q elbow.
Figure 6--7 Inlet Control Valve
*
*
* Repair Kit P/N 02250045--287
20
Section 6
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
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.
TROUBLESHOOTING
SYMPTOM
PROBABLE CAUSE
COMPRESSOR WILL NOT START
Main Disconnect Switch Open
Close switch.
Line Fuse Blown
Replace fuse.
Control Transformer Fuse Blown
Replace fuse.
Motor Starter Overloads Tripped
Reset. Should trouble persist, check
whether motor starter contacts are
functioning properly.
Low Incoming Line Voltage
Check voltage. Should voltage check low,
consult power company.
Low Incoming Voltage
Consult power company
Excessive Operating Pressure
Defect in pressure switch; check pressure
at which contact points open.
Discharge Temperature Switch Open
Cooling air flow restricted; clean cooler and
check for proper ventilation.
COMPRESSOR SHUTS DOWN
WITH AIR DEMAND PRESENT
REMEDY
.
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
Check service lines for leaks or open
valves.
Dirty Air Filter
Check filter and change element if
required.
Pressure Regulator Out Of
Adjustment
Adjust regulator according to control
adjustment instructions in Section 6,
Maintenance.
Defective Solenoid Valve
A normally open solenoid must energize to
load compressor; check for proper
operation.
21
Section 6
MAINTENANCE
TROUBLESHOOTING
SYMPTOM
PROBABLE CAUSE
LINE PRESSURE RISES ABOVE
CUT--OUT PRESSURE SETTING
ON PRESSURE SWITCH
Defective Solenoid Valve
Repair solenoid valve (see Section 6).
Leak In Control System Causing
Loss Of Pressure Signals
Check for leaks.
Defective Pressure Switch
Check that diaphragm and contacts are not
damaged. Replace if necessary.
Inlet Valve Stuck Open
Inspect inlet valve and insure free operation
(s ee Sec tion 6).
Clogged Return Line
Remove element cover and clean orifice.
Separator Element Damaged Or
Not Functioning Properly
Change separator element.
Leak In The Lubrication System
Check all pipes, connections and
components.
Excess Fluid Foaming
Drain and change.
Fluid Level Too High
Shaft Seal Failure
Drain excess.
Replace shaft seal.
Compressor Operating Pressure
See Symptom “Line Pressure Rises Above
Too High
Cut--out Pressure Setting on Pressure
Switch” above
Defective Pressure Relief Valve
Replace pressure relief valve.
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.
EXCESSIVE COMPRESSOR
FLUID CONSUMPTION
PRESSURE RELIEF VALVE
OPENS REPEATEDLY
LIQUID WATER IN COMPRESSED
AIR LINES
22
REMEDY
Section 6
MAINTENANCE
6.8 MAINTENANCE RECORD
MODEL NO.
DATE
SERIAL NO.
HOURMETER
MAINTENANCE
PERFORMED
WORK PERFORMED
BY
AUTHORIZED
BY
23
Section 7
ILLUSTRATIONS AND PARTS LIST
ES--6 COMPRESSOR ASSEMBLY, EXPLODED VIEW
(5.5 AND 7.5KW)
24
Section 7
ILLUSTRATIONS AND PARTS LIST
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.
SULLAIR CORPORATION
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)
SULLAIR ASIA, LTD.
Chiwan Supply Base
Bldg A5--1 Chiwan
Shenzhen, Guangdong PRV.
P.R.C. Post Code 518068
Telephone: 755--6694982
FAX: 755--6694313
SULLAIR EUROPE, S.A.
Chemin de Genas BP 639
69800 Saint Priest, France
Telephone: 33--72232425
Fax: 33 -- 78907168
7.2 RECOMMENDED SPARE PARTS LIST
DESCRIPTION
KIT NUMBER
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
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
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
25
Section 7
ILLUSTRATIONS AND PARTS LIST
7.3 FLUID MANAGEMENT SYSTEM
26
Section 7
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
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)
part
number
quantity
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
--
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
Section 7
ILLUSTRATIONS AND PARTS LIST
7.4 INLET FILTER
key
number
1
2
3
4
5
6
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”
part
number
quantity
250025--265
824815--004
250025--661
250025--422
250025--421
250025--423
843504--050
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
Section 7
ILLUSTRATIONS AND PARTS LIST
7.5 SEAL AND DRIVE GEAR
key
number
1
2
3
4
5
6
7
8
9
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
part
number
quantity
250028--339
Consult Factory
Consult Factory
250025--412
250039--218
828404--075
250025--312
826502--150
250039--600
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
Section 7
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
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 212q -- 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”
part
number
quantity
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
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
810210--050
250026--469
829108--100
606058
838208--112
810208--050
250039--904
827905--088
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
Section 7
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 5/16”id x 1 1/4”od (5HP/4KW)
Swasher, flat 5/16”id x 1 1/4”od
(7.5 & 10HP/5.5 and 7.5KW)
connector, tube straight threaded 1/2” x 3/4”
tube, 1/2”od (5HP/4KW)
tube, 1/2”od
cap, 1/2” tube
tee, tube union 1/2”
tube, 1/2”od (5HP/4KW)
Stube, 1/2”od
(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, 90q connector 7/8”--14 x 1/2”npt
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
quantity
250026--472
1
250026--471
250034--535
1
1
250034--536
829704--050
829704--075
250025--829
1
8
4
1
250026--843
825305--283
1
1
825305--283
250028--961
2
1
250026--066
250034--537
828405--150
1
1
1
828405--200
250025--830
2
1
250025--830
811808--075
250026--718
250030--040
250026--350
811408--050
250026--719
2
2
1
1
1
1
1
250030--041
250028--964
250026--591
250026--253
1
1
1
1
250026--254
250030--104
1
1
811615--062
1
250030--042
1
250030--043
250031--014
250034--538
1
1
8
(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
Section 7
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
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”
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
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
Section 7
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
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, 90q male 1/8” npt x 1/4” tube
hose, nylon 1/4”
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
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
Section 7
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
description
part
number
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, 90q 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
Section 7
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
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
part
number
quantity
807600--005
250025--299
250026--153
250031--869
1
1
1
1
828604--550
250031--734
250031--733
825304--236
250041--860
02250043--291
250000--104
250042--224
02250056--423
02250043--320
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
5
1
13
18
10
11
14
6
7
12
9
8
16
4
17
3
2
44
Section 7
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
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)
part
number
quantity
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
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
Section 7
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
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
part
number
quantity
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
1
1
1
1
2
1
1
4
1
3
2
4
4
2
2
1
7
7
8
2
1
1
250032--881
250000--104
1
1
02250043--291
250042--224
1
1
250038--243
250034--159
250032--227
02250077--473
02250061--884
410353
825305--283
250025--299
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
DISCHARGE TEMP.
LINE PRESSURE
POWER ON
OFF/RESET
ON
AUTO
MANUAL
RE S E T
24
48
Section 7
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, 90qM 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
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
Section 7
ILLUSTRATIONS AND PARTS LIST
7.14 WYE--DELTA ELECTRIC BOX ES--6
key
number
1
2
3
4
5
6
7
8
9
10
11
12
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
1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
51
Section 7
ILLUSTRATIONS AND PARTS LIST
7.15 DECAL GROUP
£
8
7
12
9
11
52
Section 7
ILLUSTRATIONS AND PARTS LIST
7.15 DECAL GROUP
key
number
1
2
3
4
5
6
7
8
8B
9
10
11
12
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)
part
number
quantity
02250078--001
1
250039--113
1
02250077--999
1
02250077--473
1
02250078--998
02250059--052
040745
02250069--389
02250069--391
02250075--046
02250075--045
02250075--540
02250060--043
02250059--288
02250069--397
1
1
1
1
1
2
1
1
1
1
1
(Continued on page 55)
(I) Decal will change with fluid requirement.
(II) Decal will vary with machine voltage. If voltage is not known, consult factory with serial number of compressor.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
53
Section 7
ILLUSTRATIONS AND PARTS LIST
7.15 DECAL GROUP
13
54
Section 7
ILLUSTRATIONS AND PARTS LIST
7.15 DECAL GROUP (continued)
key
number
13
14
description
decal, ES--6 canopy bezel
decal, mandatory read manual (not shown)
part
number
quantity
02250061--884
02250078--002
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
Section 7
ILLUSTRATIONS AND PARTS LIST
7.17 WIRING DIAGRAM (THREE PHASE) (60Hz)
57
Section 7
ILLUSTRATIONS AND PARTS LIST
7.18 WIRING DIAGRAM (50 Hz)
58
Section 7
ILLUSTRATIONS AND PARTS LIST
7.19 WIRING DIAGRAM (50 Hz) WYE--DELTA
59
NOTES
NOTES
WORLDWIDE SALES AND SERVICE
£
SULLAIR EUROPE, S.A.
SULLAIR ASIA, LTD.
ROOM 2304A
Shartex Plaza Ctr.
No. 88 Zun Yi Nan Rd.
Shanghai, P.R.C.
Telephone: 21--2192066
Fax: 21 -- 2196568
Chemin de Genas BP 639
69800 Saint Priest, France
Telephone: 33--72232425
Fax: 33 -- 78907168
SULLAIR CORPORATION
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)
Printed in U.S.A.
Specifications Subject To
Change Without Prior Notice
EN95EPS