Sullivan-Palatek 75UDG Manuel utilisateur

OPERATING AND PARTS MANUAL

FOR

INDUSTRIAL ELECTRIC AIR COMPRESSORS

75UDG AND 100UDG MODELS

WITH T1 MICRO PROCESSOR CONTROL

PALATEK, INC. dba SULLIVAN-PALATEK MICHIGAN CITY, IN 46360 ALL RIGHTS

10-26-2011

Part Number: OPM75100T1

_____________________________________SULLIVAN-PALATEK

TABLE OF CONTENTS

SECTION 1 - SAFETY..........................................................................................4

1.1GENERAL............................................................................................................4

1.2PRESSURE RELEASE........................................................................................4

1.3FIRES/EXPLOSIONS ..........................................................................................5

1.4MOVING PARTS..................................................................................................5

1.5PHYSICAL DANGERS.........................................................................................6

1.6TOXICITY ............................................................................................................6

1.7ELECTRIC SHOCK..............................................................................................6

1.8LIFTING...............................................................................................................7

1.9AUTOMATIC START AND/OR RESTART...........................................................7

1.10NOISE...............................................................................................................7

1.11HAZARD WARNING SIGNS.............................................................................8

SECTION 2 - SPECIFICATIONS..........................................................................9

2.1DATA AND DIMENSIONS....................................................................................9

2.2LUBRICATION GUIDE.........................................................................................9

2.3APPLICATION GUIDE.......................................................................................10

SECTION 3 - DESCRIPTION .............................................................................10

3.1INTRODUCTION................................................................................................10

3.2COMPRESSOR UNIT........................................................................................10

3.3MOTOR..............................................................................................................10

3.4INTAKE/CONTROL SYSTEM............................................................................11

3.5COMPRESSOR LUBRICATION/COOLING SYSTEM.......................................12

3.6COMPRESSOR DISCHARGE SYSTEM ...........................................................13

3.7STARTER AND ELECTRICAL PARTS..............................................................15

3.8INSTRUMENTATION.........................................................................................15

SECTION 4 - INSTALLATION............................................................................16

4.1RECEIVING .......................................................................................................16

4.1AWELDING.......................................................................................................16

4.2LOCATION.........................................................................................................16

4.3SUPPORT..........................................................................................................16

4.4ELECTRICAL.....................................................................................................16

4.5AWIRING DIAGRAM, FULL VOLTAGE STARTER (STANDARD)....................17

4.5BWIRING DIAGRAM Y-DELTA START (OPTIONAL) .....................................18

4.6DIRECTION OF ROTATION..............................................................................19

4.7COMPRESSED AIR PIPING..............................................................................19

4.8ADDITIONAL HELP ...........................................................................................19

SECTION 5 - OPERATION ................................................................................20

5.1INTRODUCTION................................................................................................20

5.2INITIAL START..................................................................................................20

5.3MICRO PROCESSOR PROGRAMMING; GENERAL INSTRUCTIONS............20

5.4NORMAL OPERATION......................................................................................21

5.5SHUTDOWN......................................................................................................21

5.6RESTARTS........................................................................................................21

SULLIVAN-PALATEK_____________________________________

SECTION 6 - MAINTENANCE ...........................................................................22

6.1MAINTENANCE SCHEDULE.............................................................................22

6.2OIL FILTER........................................................................................................23

6.3AIR FILTER........................................................................................................23

6.4AIR/OIL SEPARATOR .......................................................................................23

6.5PRESSURE ADJUSTMENT ..............................................................................24

6.6SERVICE/MAINTENANCE PROCEDURES......................................................24

6.7TROUBLESHOOTING.......................................................................................25

SCREW COMPRESSOR AIR-END EXCHANGE PROGRAM...........................29

SECTION 7 - PARTS LIST.................................................................................30

7.1PARTS ORDERING...........................................................................................30

7.2RECOMMENDED SPARE PARTS ....................................................................30

7.3MOTOR COMPRESSOR AND MOUNTING PARTS .........................................32

7.4LUBRICATION AND COOLING SYSTEM -AIR COOLED.................................34

7.5INTAKE AND CAPACITY CONTROL SYSTEM -75G &100G...........................36

7.7DISCHARGE SYSTEM -75 &100G ..................................................................38

7.8MICROPROCESSOR CONTROL &ELECTRICAL PARTS -OPEN..................40

7.9MICROPROCESSOR CONTROL -ENCLOSED...............................................42

7.10ENCLOSURE -AIR COOLED UD...................................................................44

7.11ENCLOSURE -WATER COOLED UD............................................................46

7.13ADECAL AND IDENTIFICATION......................................................................47

7.13BDECAL AND IDENTIFICATION......................................................................48

SECTION 8 - WARRANTY.................................................................................49

SECTION 9 - GENERAL ARRANGEMENT DRAWINGS ..................................51

9.1P&I DIAGRAM –AIR COOLED..........................................................................51

9.2GENERAL ARRANGEMENT -75-100HP UDAC, OPEN...................................52

9.3GENERAL ARRANGEMENT -75-100HP UDAC, ENCLOSED..........................53

9.4GENERAL ARRANGEMENT -75-100HP WC, OPEN .......................................54

9.5GENERAL ARRANGEMENT -75-100HP WC, ENCLOSED..............................55

SULLIVAN - PALATEK COMPRESSOR MAINTENANCE LOG.......................56

_____________________________________SULLIVAN-PALATEK

SECTION 1 - SAFETY

1.1 GENERAL

SULLIVAN-PALATEK designs all its compressors so they can be operated safely

despite the fact that operating a motor driven air compressor is inherently hazardous.

Responsibility for continued safe operation rests with those who install, use and maintain

the equipment. The precautions offered in this section will minimize the inherent

hazards and reduce the likelihood of accidental damage or injuries.

The operation of air compressors should be limited to personnel who have been so

trained and specifically assigned to do so, and who have read and understand this

Operator’s Manual. Failure to follow the instructions and safety precautions in this

manual may increase the possibility of accidents or injuries.

Never start this compressor unless it is safe to do so. Do not attempt to operate the air

compressor with an unsafe condition relative to the compressor, the electrical system or

the air piping, filtering, regulating, preparation, conditioning, valving, hosing or air-using

components. Open the main disconnect switch or circuit breaker, then lock it out and

tag it to prevent anyone else from starting the compressor until the unsafe condition has

been corrected.

Operate compressors only in full compliance with all applicable Federal, State and local

codes and requirements such as OSHA, NEC, NFPA, CSA, etc.

WARNING: Do not modify this compressor without specific written approval from

the factory.

1.2 PRESSURE RELEASE

Operate manually the pressure relief valve(s) periodically to be sure there is no

blockage, obstruction, or inability to operate.

Shut machine off by using stop button on Micro Processor. Open and lock-out

disconnect switch, and vent all pressure before opening or removing any filter element,

line, tube, fitting, valve, plug, cover, connection, or any other component on the air

compressor or in the plant’s compressed air system. Remove Oil Filler Cap, (Caution:

Hot oil is present.) only when compressor has been turned off, the disconnect switch

locked open, and there is no pressure in the oil separation tank. Bleed off any residual

pressure by opening the pressure relief valve. WARNING: compressors may re-start

AUTOMATICALLY if not properly taken off the power line!

Do not use accessories such as tools, valves, filters, hoses, piping, dryers, etc. that are

rated lower than the maximum pressure or temperature rating of this compressor. Do

not exceed the accessory component manufacturer’s rated safe, continuous working

pressure or temperature.

Install appropriate velocity-limiting valves (rated by pipe size and CFM) whenever air

hose larger than ½ inch (12.5 mm) inside diameter is used anywhere in the system.

This will reduce pressure in case of hose or connection failure. Install additional velocity

limiting valves, in series, whenever 75 feet (22.8m) of hose length is exceeded. These

valves must comply with pertinent OSHA requirements.

SULLIVAN-PALATEK_____________________________________

Do not use air pressure greater than 30 PSI (207 kPa) for blow-off or cleaning purposes,

and then only with effective chip guarding and personal protective equipment as required

by OSHA.

Compressed air filters or lubricators with plastic bowls may be affected by lubricant and

should not be used. Steel bowls are recommended.

Keep personnel out of line with, and away from, the discharge opening of airlines, or

tools, or other areas of direct, or deflected, compressed air discharge.

Do not allow anyone to engage in horseplay with air hoses, as serious bodily injury or

death may result.

Do not substitute bolts with material or marking different from original equipment.

Do not over-tighten any bolt, nut, fitting, connection, or spin-off filter element.

1.3 FIRES/EXPLOSIONS

Clean up any spilled oil or oil leakage, and repair oil leaks as soon as they are

discovered.

Do not allow oil to accumulate on, in, or around acoustic noise material. Immediately

replace any oil-soaked material after cleaning enclosure surface with nonflammable

solvent.

Do not operate compressor when there is a possibility of its ingesting flammable, toxic or

explosive fumes, mists or particles.

Do not operate compressor with the temperature sensor inoperative or any of its two

Pressure Switches inoperative or incorrectly connected.

Keep conductive objects away from exposed live electrical parts, such as terminals, to

avoid sparks that may serve as a source of ignition.

Replace the air/oil separator element only with factory original equipment replacement

parts to be certain that anti-static provisions are present.

Ground the machine in accordance with National Electrical Code (NEC) requirements.

Do not use plastic pipe for compressed air.

1.4 MOVING PARTS

WARNING: Do not operate the compressor with its Fan Guard removed.

Keep clothing, hands, arms, and other parts of the body, away from the fan and drive

coupling.

Wear snug-fitting protective clothing (no neckties) and confine long hair when working

around compressor.

_____________________________________SULLIVAN-PALATEK

1.5 PHYSICAL DANGERS

Wear OSHA approved personal protective gear including gloves, safety shoes, safety

glasses, head covering, and ear protection when working on or around the compressor.

Avoid bodily contact with hot oil, hot surfaces, sharp edges and corners.

Keep all parts of the body away from all potential points of air discharge, including

pressure relief valve ports.

Keep an adequate first-aid kit nearby. Obtain medical assistance promptly in case of

injury. Do not ignore small cuts, burns or minor eye injuries as they may lead to

infection.

Perform repairs and maintenance in well lighted conditions. Clean and dry components

prior to servicing.

1.6 TOXICITY

WARNING: Air from this compressor should not be used for breathing air, unless

you adhere to specific OSHA standards.

Operate the compressor only in open or well-ventilated areas.

Carefully analyze the compressor inlet conditions to be certain that the compressor is

ingesting no dangerous levels of contaminants.

Do not permit air from this compressor to contact foodstuff except in compliance with

FDA Standard 21 CFR 178.3570 and other applicable regulations. (Use food grade

lubricant for such applications.)

1.7 ELECTRIC SHOCK

Remove watches & rings, and keep all parts of the body, tools, or other conductive

objects away from exposed live parts of the electrical system. Maintain dry footing,

stand on insulating surface and do not contact any other portion of the compressor when

making adjustments.

Turn compressor off, open main disconnect and lock it out and tag it prior to opening the

Starter Enclosure or when testing or replacing any electrical component such as:

switches, wiring, terminals, transformer, starter, timer, coil, relay, contact, interlock, fuse,

overload heater, etc.

Be certain that the equipment is properly grounded in accordance with NEC and all other

applicable state & local codes.

Initial installation and wiring must be done by a trained and qualified electrician and be in

accordance with all Federal, State and local codes, standards, and regulations.

Improper installation or unsafe servicing could result in serious bodily injury or death.

Should a breaker trip for any reason, be sure to check for the cause that produced the

trip. Fix the root cause if possible prior to resetting and operating the compressor.

When restarting, check for maximum current being drawn by the circuit.

If a fuse should blow, for any reason, always replace it with one of the same size, type,

and ampere rating.

SULLIVAN-PALATEK_____________________________________

1.8 LIFTING

Lift or move the compressor only with equipment of sufficient load capacity that has

been inspected and is in good condition.

Keep personnel out from under and away from the area when lifting or moving the

compressor.

Lift no higher than necessary. Carry as low as possible when moving.

Keep lifting operator in attendance whenever compressor is suspended.

Set compressor down only on level surface capable of supporting several times the

machine weight.

Do not lift entire machine by motor lifting eyes, as they are intended only for lifting the

motor.

1.9 AUTOMATIC START AND/OR RESTART

Do not assume that any air compressor is ready for maintenance, service, or trouble-

shooting if it is not running. It may be in the “Automatic-Start” mode “Sleep” mode, or

was not shut down properly prior to power having been shut off, then when power is re-

applied the compressor may suddenly re-start, thereby creating a hazardous condition!

Also, compressor may be wired to BLT or sequencer which might call for a start.

Close discharge air valves and shut off machine. Open main disconnect; lock it out and

tag it to prevent others from inadvertently re-closing it.

1.10 NOISE

Working near an open-air compressor, or an enclosed machine with doors and/or

access panels open or removed, can prove hazardous even during short-term exposure.

The noise may interfere with hearing verbal warnings or other sounds of impending

dangers.

WARNING: For prolonged exposure to machinery noise, hearing protection is

recommended and may be required by OSHA.

_____________________________________SULLIVAN-PALATEK

1.11 HAZARD WARNING SIGNS

SULLIVAN-PALATEK compressors are all equipped with brightly colored, weather-

resistant, pictorial/verbal self-adhesive decals. These are designed to warn the operator

against potential hazards in order to minimize risk of property damage, bodily injury or

death. All operators must be aware of the Warning Signs and follow the instructions

thereon.

If any Warning Signs are missing, damaged or painted over, or located in such a position

as to be unreadable in a given installation, new Warning Signs must be ordered. Be

sure they are properly positioned and installed correctly.

WARNING: If any operators are not fully conversant with the English language

and/or cannot comprehend the intended pictorial warnings, it becomes incumbent

upon the owner, lesser or other responsible administrator to be sure the operator

is properly trained and also made aware of, and understands, the meaning of all

Warning Signs.

SIGN LOCATION

WARNING SIGN

HIGH VOLTAGE/MOVING PARTS MOTOR/STARTER

WARNING SIGN

COMPRESSED AIR INSTRUMENT PANEL

WARNING SIGN

HOT OIL/PRESSURIZED AIR SEPARATOR TANK

SULLIVAN-PALATEK_____________________________________

SECTION 2 - SPECIFICATIONS

MODEL 75UDG 100UDG

MOTOR SIZE (HP) 75 100

AIR DELIVERY (CFM @ 125 PSIG) 340 440

MAX. FULL LOAD PRESSURE 125 125

MIN. FULL LOAD PRESSURE 70 70

LUBRICOOLANT CAP’Y

GAL.SYST/SUMP 15/12 15/12

DIMENSIONS:

OPEN LENGTH 80

WIDTH 45

HEIGHT 57

ENCLOSED LENGTH 80

WIDTH 45

HEIGHT 64

NOTE: SEE INSTALLATION DRAWINGS ON PAGES 55-58 OF THIS MANUAL

2.1 DATA AND DIMENSIONS

SULLIVAN-PALATEK reserves the right to change the design or construction of the

above compressors, or to offer them with options which will cause subject equipment to

differ from the above specifications, without reference to any descriptions in this manual.

2.2 LUBRICATION GUIDE

SULLIVAN-PALATEK recommends using Palasyn 45 synthetic lubricoolant for normal

plant-air service. For compressors running two or three shift operations, extended life

lubricants such as Pallube 32p, or Pal-extra 44 are offered as factory fill. Also, where

incidental food contact may happen, we offer a Food Grade 32FLL.

For extreme environments (i.e. fine particulate, caustic, acidic, or oxidant atmospheres)

contact the factory for lubricant recommendations. Also, for such conditions we would

suggest oil analysis every 1000 hours.

Mixing of these or any other type of oil or synthetic fluid will void the 5-year compressor

unit warranty and could result in greatly increased maintenance and service expenses.

Ce manuel convient aux modèles suivants

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