Sullair ST712 PDF
Sullair ST712 PDF
Sullair ST712 PDF
PART NUMBER:
02250180-090 R01
KEEP FOR
FUTURE
REFERENCE
WARRANTY NOTICE ©
SULLAIR CORPORATION
The information in this manual is current
as of its publication date, and applies to
Failure to follow the instructions compressor serial number:
and procedures in this manual or,
misuse of this equipment will Base Mount: C03-C20350
VOID its warranty! Tank Mount: 200811010000
and all subsequent serial numbers.
AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
TABLE OF CONTENTS
SECTION 1—SAFETY
3 1.1 GENERAL
3 1.2 PERSONAL PROTECTIVE EQUIPMENT
3 1.3 PRESSURE RELEASE
4 1.4 FIRE AND EXPLOSION
4 1.5 MOVING PARTS
5 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
5 1.7 TOXIC AND IRRITATING SUBSTANCES
6 1.8 ELECTRICAL SHOCK
6 1.9 LIFTING
7 1.10 ENTRAPMENT
SECTION 2—DESCRIPTION
9 2.1 INTRODUCTION
9 2.2 COMPRESSOR COMPONENT DESCRIPTION
14 2.3 COMPRESSOR COOLING AND LUBRICATION SYSTEM — FUNC-
TIONAL DESCRIPTION
14 2.4 COMPRESSOR DISCHARGE SYSTEM—FUNCTIONAL DESCRIPTION
14 2.5 CONTROL SYSTEM — FUNCTIONAL DESCRIPTION
17 2.6 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
18 2.7 CONTROLLER/KEYPAD
18 2.8 LCD DISPLAY
19 2.9 LED LIGHTS
SECTION 3—SPECIFICATIONS
21 3.1 TABLE OF SPECIFICATIONS
22 3.2 COMPRESSOR SPECIFICATIONS
22 3.3 LUBRICATION GUIDE
22 3.4 APPLICATION GUIDE
23 3.5 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE,
FLUID FILTER AND SEPARATOR
36 3.6 TANK MOUNT AND DRYER OPTIONS
SECTION 4—INSTALLATION
49 4.1 COMPRESSOR MOUNTING - SUPPORT AND LOCATION
49 4.2 VENTILATION AND COOLING
51 4.3 SERVICE AIR PIPING
52 4.4 BELT CHECK
52 4.5 FLUID LEVEL CHECK
53 4.6 ELECTRICAL PREPARATION
53 4.7 MOTOR ROTATION DIRECTION CHECK
TABLE OF CONTENTS
SECTION 5—OPERATION
55 5.1 ROUTINE OPERATION
SECTION 6—MAINTENANCE
57 6.1 GENERAL
57 6.2 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
58 6.3 MAINTENANCE EVERY 2000 HOURS
58 6.4 FLUID MAINTENANCE
58 6.5 FILTER MAINTENANCE
59 6.6 AIR FILTER MAINTENANCE
60 6.7 SEPARATOR MAINTENANCE
61 6.8 BELT MAINTENANCE
65 6.9 REPLACEMENT AND ALIGNMENT OF BELT PULLEYS
66 6.10 HOSE MAINTENANCE
66 6.11 TANK MOUNT PACKAGE MAINTENANCE
66 6.12 TROUBLESHOOTING – INTRODUCTION
Section 1
SAFETY
the precautionary statements contained herein are
NOTE applicable to most compressors and the concepts
behind these statements are generally applicable to
all compressors.
3
SECTION 1
inside diameter to reduce pressure in case of accumulate on, under or around acoustical mate-
hose failure. rial, or on any external surfaces of the air com-
pressor. Wipe down using an aqueous industrial
D. Flow-limiting valves are listed by pipe size and
cleaner or steam clean as required. If necessary,
flow-rated. Select appropriate valves accordingly,
remove acoustical material, clean all surfaces
in accordance with their manufacturer's recom-
and then replace acoustical material. Any acous-
mendations.
tical material with a protective covering that has
E. DO NOT use air tools that are rated below the been torn or punctured should be replaced
maximum rating of the compressor. Select air immediately to prevent accumulation of liquids or
tools, air hoses, pipes, valves, filters and other fluid film within the material. DO NOT use flam-
fittings accordingly. DO NOT exceed manufac- mable solvents for cleaning purposes.
turer's rated safe operating pressures for these
D. Disconnect and lock out all power at source prior
items.
to attempting any repairs or cleaning of the com-
F. Secure all hose connections by wire, chain or pressor or of the inside of the enclosure, if any.
other suitable retaining device to prevent tools or
E. Keep electrical wiring, including all terminals and
hose ends from being accidentally disconnected
pressure connectors in good condition. Replace
and expelled.
any wiring that has cracked, cut, abraded or oth-
G. Open fluid filler cap only when compressor is not erwise degraded insulation, or terminals that are
running and is not pressurized. Shut down the worn, discolored or corroded. Keep all terminals
compressor and bleed the receiver tank to zero and pressure connectors clean and tight.
internal pressure before removing the cap.
F. Keep grounded and/or conductive objects such
H. Vent all internal pressure prior to opening any as tools away from exposed live electrical parts
line, fitting, hose, valve, drain plug, connection or such as terminals to avoid arcing which might
other component, such as filters and line oilers, serve as a source of ignition.
and before attempting to refill optional air line
G. Remove any acoustical material or other material
anti-icer systems with antifreeze compound.
that may be damaged by heat or that may sup-
I. Keep personnel out of line with and away from port combustion and is in close proximity, prior to
the discharge opening of hoses or tools or other attempting weld repairs.
points of compressed air discharge.
H. Keep suitable fully charged Class BC or ABC fire
J. DO NOT use air at pressures higher than 2.1 bar extinguisher or extinguishers nearby when ser-
for cleaning purposes, and then only with effec- vicing and operating the compressor.
tive chip guarding and personal protective equip-
I. Keep oily rags, trash, leaves, litter or other com-
ment per OSHA Standard 29 CFR 1910.242 (b)
bustibles out of and away from the compressor.
and/or any applicable Federal, State, and Local
codes, standards and regulations. J. DO NOT operate the compressor without proper
flow of cooling air or water or with inadequate
K. DO NOT engage in horseplay with air hoses as
flow of lubricant or with degraded lubricant.
death or serious injury may result.
K. DO NOT attempt to operate the compressor in
1.4 FIRE AND EXPLOSION any classification of hazardous environment
unless the compressor has been specially
A. Clean up spills of lubricant or other combustible designed and manufactured for that duty.
substances immediately, if such spills occur.
B. Shut off the compressor and allow it to cool. 1.5 MOVING PARTS
Then keep sparks, flames and other sources of
A. Keep hands, arms and other parts of the body
ignition away and DO NOT permit smoking in the
and clothing away from couplings, belts, pulleys,
vicinity when checking or adding lubricant or
fans and other moving parts.
when refilling air line anti-icer systems with anti-
freeze compound. B. DO NOT attempt to operate the compressor with
the fan, coupling or other guards removed.
C. DO NOT permit fluids, including air line anti-icer
system antifreeze compound or fluid film, to
4
SECTION 1
5
SECTION 1
6
SECTION 1
I. Keep lift operator in constant attendance when- N. Make sure pallet-mounted compressors are
ever compressor is suspended. firmly bolted or otherwise secured to the pallet
prior to attempting to forklift or transport them.
J. Set compressor down only on a level surface
NEVER attempt to forklift a compressor that is
capable of safely supporting at least its weight
not secured to its pallet, as uneven floors or sud-
and its loading unit.
den stops may cause the compressor to tumble
K. When moving the compressor by forklift truck, off, possibly causing serious injury or property
utilize fork pockets if provided. Otherwise, utilize damage in the process.
pallet if provided. If neither fork pockets or pallet
are provided, then make sure compressor is 1.10 ENTRAPMENT
secure and well balanced on forks before
attempting to raise or transport it any significant A. If the compressor enclosure, if any, is large
distance. enough to hold a man and if it is necessary to
enter it to perform service adjustments, inform
L. Make sure forklift truck forks are fully engaged
other personnel before doing so, or else secure
and tipped back prior to lifting or transporting the
and tag the access door in the open position to
compressor.
avoid the possibility of others closing and possi-
M. Forklift no higher than necessary to clear obsta- bly latching the door with personnel inside.
cles at floor level and transport and corner at
B. Make sure all personnel are out of compressor
minimum practical speeds.
before closing and latching enclosure doors.
7
NOTES
8
SHOPTEK™ USER MANUAL
Section 2
DESCRIPTION
2.1 INTRODUCTION External piping, connectors, and the enclosure
should be inspected and maintained in accordance
The design of the Sullair ShopTek line of compressor with the procedures and recommendations in this
units is a single stage, positive displacement, flooded manual.
rotary screw. A complete package includes the:
• Compressor unit 2.2 COMPRESSOR
• Electric motor
COMPONENT DESCRIPTION
• Starter The ShopTek compressor (Figure 2-1 and Figure 2-
• Compressor inlet and discharge systems 2) uses a fan to draw outside air into the enclosure,
cooling the motors, the combined radiator fluid
• Compressor lubrication and cooling system
cooler, and air aftercooler. This hot air is then vented
• Controller out of the top of the enclosure.
• Aftercooler (ST1100 and ST1500 only)
Fluid is injected into the compressor, and mixes
• Heavy gauge steel mounting frame directly with the air as the rotors turn which
compresses the air. The fluid flow has three basic
functions:
1. As a coolant, it controls the air temperature
CAUTION rise normally associated with the heat of
compression.
Use only one type of a recommended com- 2. Seals the clearance paths between the
pressor lubricant. Adding a different one, or rotors and the stator, and also between the
mixing lubricants can cause damage and/or two rotors.
malfunctions, and will void the compres-
3. Provides a lubricating film between the rotors
sor’s warranty.
allowing one rotor to directly drive the other,
which is an idler, and also lubricates the
New compressors are shipped from the factory fully bearings.
charged with Sullube lubrication fluid. The
After the air/fluid mixture is discharged from the
SPECIFICATIONS Section 3.3 and Section 3.4
compressor unit, the fluid is separated from the air.
describe lubrication requirements and
At this time, the air flows through an aftercooler and
recommendations for each compressor package.
separator, and then to the service line while the fluid
is cooled and filtered in preparation for reinjection.
NOTE
The compressor requires no internal
inspections or maintenance actions. Open-
ing the compressor’s housing may void its
warranty. (This does not apply to the shaft
seal or inlet valve which are replaceable.)
02250180-090 R00 9
SHOPTEK™ USER MANUAL SECTION 2
10 02250180-090 R00
SECTION 2 SHOPTEK™ USER MANUAL
02250180-090 R00 11
SHOPTEK™ USER MANUAL SECTION 2
COOLING/LUBRICATION
SYSTEM
DISCHARGE SYSTEM
Figure 2-3: Cooling/Lubrication and Discharge System ST400, ST500 and ST700 5-10 HP
12 02250180-090 R00
SECTION 2 SHOPTEK™ USER MANUAL
COOLING/LUBRICATION
SYSTEM
7
DISCHARGE SYSTEM
5
Figure 2-4: Cooling/Lubrication and Discharge System ST1100 and ST1500 15 & 20 HP
02250180-090 R00 13
SHOPTEK™ USER MANUAL SECTION 2
2.3 COMPRESSOR COOLING separator element as the air flows through the
AND LUBRICATION SYSTEM separator.
— FUNCTIONAL A return line (or scavenge tube) leads from the dry
DESCRIPTION side of the separator tube to the medium pressure
region. Scavanged fluid is returned by a pressure
Refer to Figure 2-3 and Figure 2-4. The cooling and
differential between the separator tube and
lubrication system consists of a fan, fan motor,
compressor.
aftercooler (ST1100/ST1500 15-20HP only) /fluid
cooler, full flow fluid filter, thermal valve, The separator system reduces the fluid carry-over to
interconnecting hoses and separator tube. less than 2 ppm at nominal rated pressures.
The pressure in the separator tube starts the fluid The Controller will shut down the compressor if the
flow by forcing the fluid from the high pressure area discharge temperature reaches 235°F (113°C).
of the tube to an area of lower pressure in the
A minimum pressure/check valve located
compressor unit. Fluid flows from the bottom of the
downstream from the separator maintains the
separator/tube to the thermal valve that is fully open
separator tube pressure at 50 psig (3.4 bar) during
when the fluid temperature is below 185°F (85°C)
load conditions. This pressure level is necessary for
[195°F (91°C) for pressures rated above 150 psig].
proper air/fluid separation and sufficient fluid
The fluid passes through the thermal valve, the fluid
circulation.
filter, and directly to the compressor where it
lubricates, cools and seals the rotors, and the A terminal check valve is a sub-component of the
compression chamber. minimum pressure/check valve that prevents
compressed air in the service line from back-flowing
As the discharge temperature rises above 185°F
into the separator tube on shutdown or when the
(85°C), due to the heat of compression, the thermal
compressor is operating in an unload condition. Also,
valve begins to adjust and a portion of the fluid then
a pressure relief valve on the compressor’s wet side
flows through the cooler. From the cooler the fluid
opens if the separator tube pressure exceeds its
flows to the fluid filter and on to the compressor. A
portion of the fluid flow to the compressor is routed to rating.
the anti-friction bearings which support the
compressor rotors.
The fluid filter must be replaced. Refer to Section 3.5: WARNING
Lubrication Change Recommendations and
Maintenance, Fluid Filter And Separator on page 23. Stop the compressor and relieve all internal
pressure before removing caps, plugs, and/
or other components when the compressor
2.4 COMPRESSOR DISCHARGE is running or pressurized.
SYSTEM—FUNCTIONAL
DESCRIPTION
Add fluid to the separator tube through the capped
Refer to Figure 2-3 and Figure 2-4. The compressor fluid fill port. There is also a sight glass that enables
discharges the compressed air/fluid mixture into the the user to check the separator tube fluid level. See
separator/tube. The separator/tube has three basic Fluid Level Check on page 52.
functions:
1. It acts as a primary fluid separator. 2.5 CONTROL SYSTEM —
2. Serves as the compressor fluid sump.
FUNCTIONAL DESCRIPTION
3. Houses the final fluid separator. Refer to Figure 2-5 and Figure 2-6. The compressor
control system regulates its output to match the
The compressed air/fluid mixture enters the demand. This system consists of a solenoid valve
separator/tube and flows through an internal baffle and an inlet valve that control the compressor’s
system that changes the flow’s direction and velocity, operational modes. The following descriptions of
which causes most of the fluid to fall to the bottom of operational modes apply to a compressor whose
the separator tube. A small amount of fluid remaining operating range is 112 to 127 psig (7.7 to 8.8 bar)
in the compressed air collects on the surface of the
14 02250180-090 R00
SECTION 2 SHOPTEK™ USER MANUAL
02250180-090 R00 15
SHOPTEK™ USER MANUAL SECTION 2
service line pressure will rise. The Controller de- When the pressure drops to the low setting: (cut-in
energizes the solenoid valve when the pressure pressure) usually 112 psig (7.7 bar) for high pressure
exceeds 127 psig (8.8 bar) allowing the separator (9 bar) compressors, 137 psig (9.4 bar) for (10 bar)
tube air pressure to be supplied directly which closes compressors, 161 psig (11.1 bar) for (12 bar)
the inlet valve. At the same time the solenoid valve compressors: the Controller energizes the solenoid
exhausts the system pressure to the atmosphere and valve and prevents line pressure from reaching the
lowers the separator tube pressure to approximately inlet control valve.
29 psig (2.0 bar). A check valve in the air service line
prevents air from back-flowing to the separator tube.
16 02250180-090 R00
SECTION 2 SHOPTEK™ USER MANUAL
WARNING
"The Plastic Pipe Institute recommends
against the use of thermoplastic pipe to
transport compressed air or other com-
pressed gases in exposed above ground
locations, e.g. in exposed plant piping." (I)
Sullube should not be used with PVC piping
systems. It may affect the bond at cemented
joints. Certain other plastic materials may
also be affected.
02250180-090 R00 17
SHOPTEK™ USER MANUAL SECTION 2
X 1
2
3
S
4
11 10 9 8 7 6 5
18 02250180-090 R00
SECTION 2 SHOPTEK™ USER MANUAL
The lower line will display the cause of the fault.
Refer to service instructions to correct the cause.
Press and hold the Return/Reset pad to reset
the controller. LOAD PRESS:
0110PSI
Refer to Figure 2-11. Press the Down arrow to
display additional information about the compressor.
The upper line will indicate the name of the
temperature, pressure, or other measurement. The Figure 2-14
lower line indicates the present reading.
Refer to Figure 2-14. If there is no keypad activity,
the display will return to normal view in about one
minute. If the Start, Stop or Return/Reset buttons are
TOTAL RUN TIME: pressed, the display also returns to normal view. If
337H 20M any of these occur, the setting will not be altered.
If there are any warnings or recommended service
instructions, these will be periodically displayed on
Figure 2-11 the normal view.
Refer to Figure 2-12. When you continue beyond the The list of displays may be navigated from either
status information, the display will show a list of direction by using the Up or Down arrow
control settings. There are customer and factory keys.
settings. The upper line will indicate the name of the
setting. The lower line displays the present value. The Emergency Stop button located near the
controller overrides all electronic functions to turn off
the control devices. The controller senses this and
will display E-stop. To reset, twist and pull out the
LOAD PRESS: Emergency Stop button.
0110PSI
2.9 LED LIGHTS
The three LED lights indicate the general conditions
Figure 2-12
of the machine.
Refer to Figure 2-13 and 2-14. To change a selected The Power indicator indicates power is supplied
setting press and an interface will display where to the controller.
a password is needed. Use and to change
The Run mode indicator indicates compressor
values of each digit. Use to move to next digit. operation is enabled. It lights steadily if the motor is
After all digits of the password have been accepted, running.
press S . Upon acceptance of password, the The red Fault indicator indicates that a
setting can be modified. Use buttons as above to compressor fault has occurred and needs to be
change values. Press S to accept repaired before further operation. The text display
will indicate the cause of the fault.
changes.
PASSWORD ******
Figure 2-13
02250180-090 R00 19
NOTES
20 02250180-090 R00
SHOPTEK™ USER MANUAL
Section 3
SPECIFICATIONS
3.1 TABLE OF SPECIFICATIONS
DIMENSIONS
Length Width Height Weight
in mm in mm in mm lbs kg
Model (I) HP Hz
ST400 Series
ST410 5 60 32.5 826 21.5 546 37 940 524 238
ST410 5 50 32.5 826 21.5 546 37 940 524 238
ST500 Series
ST510 7.5 60 32.5 826 21.5 546 37 940 546 248
ST510 7.5 50 32.5 826 21.5 546 37 940 546 248
ST700 Series
ST709 10 60 32.5 826 21.5 546 37 940 567 258
ST712 10 60 32.5 826 21.5 546 37 940 567 258
ST708 10 50 32.5 826 21.5 546 37 940 567 258
ST713 10 50 32.5 826 21.5 546 37 940 567 258
ST1100 Series
ST1109 15 60 39.3 998 24.3 618 40.7 1035 772 350
ST1112 15 60 39.3 998 24.3 618 40.7 1035 772 350
ST1108 15 50 39.3 998 24.3 618 40.7 1035 772 350
ST1113 15 50 39.3 998 24.3 618 40.7 1035 772 350
ST1500 Series
ST1509 20 60 39.3 998 24.3 618 40.7 1035 805 365
ST1512 20 60 39.3 998 24.3 618 40.7 1035 805 365
ST1508 20 50 39.3 998 24.3 618 40.7 1035 805 365
ST1513 20 50 39.3 998 24.3 618 40.7 1035 805 365
(I) Rated pressure designations appearing after model number are as folllows:
08 - 115 psig (7.9 bar) 12 - 175 psig (12.0 bar)
09 - 125 psig (8.6 bar) 13 - 188 psig (13.0 bar)
10 - 150 psig (10.3 bar) 60HZ
10 - 145 psig (10 bar) 50HZ
Unload pressure is the same as rated pressure. Load pressure is rated pressure minus 15 psig (1 bar)
(II) For tankmount and dryer dimensions see Figure 3.6 on page 36.
02250180-090 R00 21
SHOPTEK™ USER MANUAL SECTION 3
CAUTION
Do not mix different types of lubricants. Mixing
lubricants can cause malfunctions or compressor
damage: will void the compressor’s warranty.
CAUTION
Contamination of compressor fluids with mineral
oil or other fluids can cause foaming, filter
plugging, or orifice line obstruction.
22 02250180-090 R00
SECTION 3 SHOPTEK™ USER MANUAL
NOTE
When performing a fluid
change or topping off:
With machine off, fill to
the bottom of the fill port.
Sight glass will be com-
pletely full.
Mixing, changing or add-
ing other lubricants within
the compressor unit may
void the air-end warranty.
02250180-090 R00 23
Figure 3-2: Identification - ST400, ST500, ST700, 5-10HP
SECTION 3
02250179-432 R00
Identification - ST400, ST500, ST700, 5-10HP
SECTION 3
SEE TABLE NOTES:
1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND
MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE
WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE
COMPRESSSOR FRAME LEVEL IS REQUIRED.
3. ALL DIMENSIONS ARE +/- .50” [12.7MM]
4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS
SHOWN ON DRAWING.
5. DOORS ARE REMOVABLE USING LIFT-OFF PINS.
6. ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER DIMEN-
SIONS IN BRACKETS.
SECTION 3
02250179-435 R01
Identification - ST1100, ST1500, 15-20HP
SECTION 3
SEE TABLE NOTES:
1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND
MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE
WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE
COMPRESSSOR FRAME LEVEL IS REQUIRED.
3. ALL DIMENSIONS ARE +/- .50” [12.7MM]
4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS
SHOWN ON DRAWING.
5. DOORS ARE REMOVABLE USING LIFT-OFF PINS.
6. ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER DIMEN-
SIONS IN BRACKETS.
SECTION 3
02250179-804 R01
Piping and Instrumentation - ST400, ST500, ST700, 5-10HP
SECTION 3
N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
1 88290014-486 1 FILTER,AIR
2 - 1 VALVE,INLET INTEGRAL
3 VARIOUS 1 MOTOR,ELECTRIC
4 02250171-669 1 UNIT,COMPRESSOR
5 88290014-534 1 PROBE,TEMP
6 88290015-814 1 SEPARATOR TUBE
7 88290015-049 1 ELEMENT,OIL SEPARATOR
8 88290014-222 1 OIL SIGHT GLASS
9 02250046-338 1 VALVE,MINIMUM PRESSURE
10 88290014-514 1 SENSOR,PRESSURE
11 VARIOUS 1 VALVE,RELIEF
02250180-090 R00
SECTION 3
02250179-805 R02
Piping and Instrumentation - ST1100 and ST1500, 15-20HP
SECTION 3
N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
1 88290014-485 1 FILTER,AIR
2 - 1 VALVE,INLET INTEGRAL
3 VARIOUS 1 MOTOR,ELECTRIC
4 88290015-893 1 UNIT,COMPRESSOR
5 88290014-534 1 PROBE,TEMP
6 88290014-226 1 SEPARATOR TUBE
7 88290015-567 1 ELEMENT,OIL SEPARATOR
8 88290014-222 1 OIL SIGHT GLASS
9 02250046-338 1 VALVE,MINIMUM PRESSURE
10 88290014-225 1 COMBINATION AIR/OIL COOLER
11 88290014-514 1 SENSOR,PRESSURE
02250180-090 R00
12 VARIOUS 1 VALVE,RELIEF
13 88290015-890 1 FILTER,RETURN OIL
14 VARIOUS 1 VALVE,THERMAL
15 88290014-484 1 FILTER,OIL
16 88290015-219 1 VALVE,SOLENOID
17 040127 1 ORIFICE, 0.062"
18 02250170-200 1 TANK,RECEIVER 120 GAL
19 250006-938 1 VALVE,PRESSURE RELIEF 200#
20 047115 1 VALVE,BALL 1/4"NPT
SECTION 3
88290015-618 R0
Figure 3-7: Wiring Diagram - ST400-ST1500 575V Full Voltage
SECTION 3
02250180-090 R00
SECTION 3
88290014-361 R07
Figure 3-9: Wiring Diagram - ST1100-ST1500 400V/50Hz CE Wye-Delta
SECTION 3
02250180-090 R00
88290014-360 R09
SHOPTEK™ USER MANUAL SECTION 3
DIMENSIONS
Length Width Height Weight
Model (I)(II) HP
in mm in mm in mm lbs kg
WS400 Series
ST400R 5 64 1616 23 591 63 1605 854 388
ST400RD 5 69 1748 23 591 63 1605 935 424
WS500 Series
ST500R 7.5 64 1616 23 591 63 1605 876 398
ST500RD 7.5 69 1748 23 591 63 1605 954.5 434
WS700 Series
ST700R 10 64 1616 23 591 63 1605 897 408
ST700RD 10 69 1748 23 591 63 1605 981 446
WS11100 Series
ST1100R 15 66 1676 25.5 645.5 71.5 1813.5 1192 541
ST1100RD 15 71 1797 25.5 645.5 71.5 1813.5 1288 584
WS1500 Series
ST1500R 20 66 1676 25.5 645.5 71.5 1813.5 1225 556
ST1500RD 20 71 1797 25.5 645.5 71.5 1813.5 1321 599
(I) R - Mounted on Reciever Tank
RD - Mounted on Reciever Tank with Dryer
(II) For package pressure ratings see Table 3-1
36 02250180-090 R00
NOTES
02250180-090 R00 37
Figure 3-10: Identification - ST400, ST500, ST700, 5-10HP Tank Mount
SECTION 3
02250180-090 R00
SECTION 3
SEE TABLE NOTES:
1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND
MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE
WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE
COMPRESSSOR FRAME LEVEL IS REQUIRED.
3. ALL DIMENSIONS ARE +/- .50” [12.7MM]
4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS
SHOWN ON DRAWING.
5. DOORS ARE REMOVABLE USING LIFT-OFF PINS.
6. ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER DIMEN-
SIONS IN BRACKETS.
MACHINE WEIGHTS
ST400 854LBS[388KG]
ST500 876LBS[398KG]
ST700 897LBS[408KG]
39
Figure 3-11: Identification - ST400, ST500, ST700, 5-10HP Tank Mount with Dryer
SECTION 3
02250180-090 R00
SECTION 3
SEE TABLE NOTES:
1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND
MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE
WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE
COMPRESSSOR FRAME LEVEL IS REQUIRED.
3. ALL DIMENSIONS ARE +/- .50” [12.7MM]
4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS
SHOWN ON DRAWING.
5. DOORS ARE REMOVABLE USING LIFT-OFF PINS.
6. ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER DIMEN-
SIONS IN BRACKETS.
MACHINE WEIGHTS
ST400 935.2LBS[423.7KG]
ST500 954.5LBS[433.7KG]
ST700 981.2LBS[446KG]
41
Figure 3-12: Identification - ST1100, ST1500, 15-20HP Tank Mount
SECTION 3
02250179-436 R01
Identification - ST1100, ST1500, 15-20HP Tank Mount
SECTION 3
SEE TABLE NOTES:
1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND
MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE
WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE
COMPRESSSOR FRAME LEVEL IS REQUIRED.
3. ALL DIMENSIONS ARE +/- .50” [12.7MM]
4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS
SHOWN ON DRAWING.
5. DOORS ARE REMOVABLE USING LIFT-OFF PINS.
6. ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER DIMEN-
SIONS IN BRACKETS.
MACHINE WEIGHTS
ST1100 1192LBS[541KG]
ST1500 1225LBS[556KG]
43
Figure 3-13: Identification - ST1100, ST1500, 15-20HP Tank Mount with Dryer
SECTION 3
02250179-437 R01
Identification - ST1100, ST1500, 15-20HP Tank Mount with Dryer
SECTION 3
SEE TABLE NOTES:
1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND
MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE
WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE
COMPRESSSOR FRAME LEVEL IS REQUIRED.
3. ALL DIMENSIONS ARE +/- .50” [12.7MM]
4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS
SHOWN ON DRAWING.
5. DOORS ARE REMOVABLE USING LIFT-OFF PINS.
6. ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER DIMEN-
SIONS IN BRACKETS.
MACHINE WEIGHTS
ST1100 1288LBS[584KG]
ST1500 1321LBS[599KG]
45
Figure 3-14: Wiring Diagram - SRS 25-100 115-230V/1/60
SECTION 3
Figure 3-15: Wiring Diagram - SRS 9-18 220-240V/1/50
SECTION 3
02250180-090 R00
SECTION 3
SHOPTEK™ USER MANUAL
Section 4
INSTALLATION
4.1 COMPRESSOR MOUNTING - 4.2 VENTILATION AND
SUPPORT AND LOCATION COOLING
The compressor must have a stable firm foundation, • ShopTek compressors require a three foot
or mounting structure that is rigid enough to keep the (one meter) clearance around their perime-
compressor frame level, and maintain the alignment ter.
of the compressor and motor. Tie-down bolts of • The location should be free from standing
sufficient size must be used to ensure that the water.
compressor frame is firmly anchored to its
• Clean air should be supplied to the com-
foundation. Rubber, cork, or other pliable materials
pressor, free from exhaust and paint
can be inserted between the foundation and
fumes, dust, metal particles, or caustic
compressor frame to provide a uniform contact
chemical vapors.
surface.
• Hot exhaust air should be vented out of the
• Use flex connectors to prevent piping loads area to prevent its recirculation back into
from being transmitted to the compressor. the compressor’s cooling system.
• National and local electrical codes specify- • Ducting or some other means must be
ing the required clearances for the area used to ensure that hot exhaust air is
around the electrical panel must be com- vented away from the compressor if the
plied with. compressor’s housing has minimal over-
• Ensure the lighting at the compressor’s head clearance..
location is sufficient for safe operation and
maintenance.
• The compressor’s location should be one NOTE
that allows access for maintenance vehi-
cles and lifting equipment. Remove the red shipping straps/shipping
studs before operating the drive assem-
• The clearances around the compressor
bly.See Figure 4-1 and Figure 4-2.
should permit easy access to all compres-
sor components.
• Walls and ceilings with soft or porous sur-
faces absorb sound and reduce ambient
NOTE
noise levels. Hard surfaces reflect noise
Housing the compressor in an inade-
and have little effect on ambient noise lev-
quately ventilated enclosure will cause
els. higher compressor operating tempera-
tures.
NOTE
Do not install compressors where the
machine will be exposed to temperatures
lower than 32°F (0°C). Contact Sullair
Customer Care regarding operation in
sub-freezing temperatures.
02250180-090 R00 49
SHOPTEK™ USER MANUAL SECTION 4
cfm m3/hr
50 02250180-090 R00
SECTION 4 SHOPTEK™ USER MANUAL
02250180-090 R00 51
SHOPTEK™ USER MANUAL SECTION 4
52 02250180-090 R00
SECTION 4 SHOPTEK™ USER MANUAL
during compressor operation. Check the fluid level by
looking at the sight glass on the separator tube when
the compressor is in the SHUT DOWN MODE (fluid
level may not be visible when operating). In this
condition the sight glass should be completely full. WARNING
Add fluid if the level is visible or if no fluid is visible at
all. Energized internal components are a poten-
tially FATAL SHOCK HAZARD. Disconnect
all power before performing any work on the
4.6 ELECTRICAL PREPARATION compressor’s electrical system.
Interior electrical wiring is installed at the factory.
Required customer wiring should be done by a 1. Check incoming voltage. The incoming
qualified electrician in compliance with OSHA, voltage must match the compressor’s wire
National Electric Code and/or any applicable local rating/specifications.
electrical codes applying to isolation switches, fused
disconnects, etc. Refer to Figure 3-2 and Figure 3-4. 2. Check motor starter and overload heater
Sullair provides a wiring diagram for use by the sizes.
installer. An electrical check should be made to 3. Check all electrical connections for
ensure that the first start-up will be successful. The tightness.
compressor and drive should be properly grounded/
earthed in accordance with applicable codes,
regulations, and requirements.
4.7 MOTOR ROTATION
DIRECTION CHECK
Feeder cables should be sized by the customer/
electrical contractor to ensure that the circuit is Motor rotation check must be done at compressor
balanced and not overloaded by other electrical start-up after the wiring has been installed. See
equipment. The length of wiring from a suitable Figure 4-4 and Figure 4-5. The compressor can be
electrical power source is critical because voltage
drops can adversely effect the performance of the damaged if it runs in the wrong direction for more
compressor. Cable sizes may vary considerably so than a few seconds. Motor rotation can be viewed
the mains terminals will accept up to 120 mm2 (4/0 through the openings in the belt guard. Pull out the
awg) (75kw) cable. EMERGENCY STOP button and press once, quickly
Feeder cable connections to incoming terminals L1- and in succession, the (START) pad and
L2-L3 should be tight and clean. (STOP) pad. This action will bump start the motor.
When looking at the motor from the compressor unit,
The applied voltage must conform to the motor and
the shaft should turn clockwise for ST400, ST500
compressor data plate ratings.
and ST700 and counterclockwise for ST1100 and
A starter hole is provided for an incoming power ST1500. If reverse rotation occurs, disconnect the
connection. If it is necessary to make a hole in the power to the starter and exchange any two of the
control box in a different location, care should be three power input leads, then re-check rotation. A
taken to not allow metal shavings to enter the starter "Direction of Rotation" decal is located on the motor
and other electrical components within the box. If drive housing to show proper motor/compressor
another hole is used, the original hole must be rotation.
blocked off with a sealed plug.
Fan motor rotation should also be checked. It should
rotate counter-clockwise when viewing the fan motor
from the backside of the motor.
02250180-090 R00 53
SHOPTEK™ USER MANUAL SECTION 4
Figure 4-4: Fan Motor/Main Motor Rotational Direction ST400, ST500, ST700, 5-10HP
Figure 4-5: Fan Motor/Main Motor Rotational Direction ST1100, ST1500, 15-20HP
54 02250180-090 R00
SHOPTEK™ USER MANUAL
Section 5
OPERATION
5.1 ROUTINE OPERATION After a routine start, observe the controller display for
the proper indications for this phase of operation.
Before starting the compressor, check the fluid level After the compressor has warmed up, check all
in the separator tube. If sight glass is not completely compressor operation indications to ensure that it is
full, add the required amount of fluid to bring it to its running properly.
proper level. Frequent addition of fluid indicates the
presence of a leak or a condition causing excessive
fluid consumption. See the Troubleshooting –
Introduction on page 66 under EXCESSIVE
COMPRESSOR FLUID CONSUMPTION for a
probable cause and corrective action.
WARNING
HIGH-PRESSURE HAZARD!
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.
Failure to comply could result in death or serious
injury.
02250180-090 R00 55
NOTES
56 02250180-090 R00
SHOPTEK™ USER MANUAL
Section 6
MAINTENANCE
WARNING
Before any repairs are attempted, refer to
Section 1: Safety before proceeding.
6.1 GENERAL
This compressor requires a minimal amount of
inspections and maintenance. The Controller and
other indicators alert the operator to situations
requiring maintenance, or fault conditions.
1. Strainer
2. Separator Tube
02250180-090 R00 57
SHOPTEK™ USER MANUAL SECTION 6
1. Strainer
2. Separator Tube
58 02250180-090 R00
SECTION 6 SHOPTEK™ USER MANUAL
02250180-090 R00 59
SHOPTEK™ USER MANUAL SECTION 6
CAUTION
Relieve all pressure from the separator/
sump tank and all compressor lines.
1. Cover
2. Cover Gasket
3. Separator Element
4. Separator Tube
60 02250180-090 R00
SECTION 6 SHOPTEK™ USER MANUAL
Belt tension must be re-adjusted 0.5 to 2 hours after
a new set of belts are fitted. This will ensure that the
belts have completed their initial stretch.
Subsequent to this, belt tension needs to be checked
and adjusted if necessary every 2000 hours for the
duration of the belt life.
There are two recommended methods for checking
the belt tension. The test methods will be detailed as
follows.
BELT TENSION MEASUREMENT WITH OPTIKRIK TENSION
METER.
02250180-090 R00 61
SHOPTEK™ USER MANUAL SECTION 6
BELT TENSION MEASUREMENT WITH FREQUENCY METER G. Repeat for remaining belts.
Refer to Figure 6-9. Follow instructions as follows: H. Compare the resuls to the belt tension specifica-
tion in Table 6-1 and adjust if necessary.
A. Turn on the meter.
B. Hold the meter so that the probe is >10mm (3/8”)
away from the belt being tested. Do not touch the
belt with tester probe.
C. Pluck a single belt at the midpoint between the
motor and compressor unit pulleys. Try not to
disturb any adjacent belts, as this will give a false
reading.As the probe detects a vibration, the
meter will display the frequency. Record data.
D. Rotate the motor pulley through at least one
complete revolution and measure the belts
again, recording the results.
E. Repeat D for a total of 3 measurements.
F. Average the three measurements to obtain the
true belt tension. Figure 6-9: Belt Tension Frequency Meter
62 02250180-090 R00
SECTION 6 SHOPTEK™ USER MANUAL
BELT TENSION ADJUSTMENT E. Adjust the belt tension by turning the jacking nut
clockwise to tighten or counterclockwise to
Refer to Figure 6-10 and Figure 6-11. loosen.
Adjust the belt tension according to the following F. Measure belt tension and ensure it meets the
procedure: specifications in Table 6-1.
A. Shut down the compressor and isolate all electric G. Tighten the locking nut.
power.
H. Tighten the four compressor unit mounting plate
B. Open the side panel and remove belt guard. adjusting bolts.
C. Loosen the locking nut. I. Ensure that the discharge hose is not kinked,
D. Loosen the four compressor unit mounting plate bent, or has been placed under undue stress or
bolts ¾ of a turn. strain.
J. Replace the belt guard and the side panel.
02250180-090 R00 63
SHOPTEK™ USER MANUAL SECTION 6
64 02250180-090 R00
SECTION 6 SHOPTEK™ USER MANUAL
02250180-090 R00 65
SHOPTEK™ USER MANUAL SECTION 6
NOTE
For additional troubleshooting guidelines,
consult the Controller manual.
66 02250180-090 R00
SECTION 6 SHOPTEK™ USER MANUAL
02250180-090 R00 67
SHOPTEK™ USER MANUAL SECTION 6
68 02250180-090 R00
NOTES
69
WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A.
Zuo Pao Tai Road, No. 1 3700 East Michigan Boulevard Zone Des Granges BP 82
Chiwan, Shekou Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France
Shenzen, Guangdong PRV. www.sullair.com Telephone: 33-477968470
PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A. only) Fax: 33-477968499
Telephone: 755-6851686 Fax: 219-874-1273 www.sullaireurope.com
Fax: 755-6853473
www.sullair-asia.com CUSTOMER CARE
for PARTS and Service
1-888-SULLAIR (7855247)
219-874-1835