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Sullivan-Palatek 15D - User Manual

Sullivan-Palatek 15D
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USER MANUAL
INDUSTRIAL ELECTRIC COMPRESSOR \ 1540 HP \ D-SERIES
15D, H15D, 20D, H20D, HH20D
25D, HH25D, 25D4, H25D4
30D7, H30D7, HH30D7
40D, H40D, HH40D
ELECTRO-MECHANICAL CONTROLS
Document: 18730-049 / 00
Issued: June 30, 2017

Table of Contents

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Summary

About This Manual

Safety Instructions

Instructions for safe operation and maintenance of the air compressor.

Manual Organization

Quick guide to the contents of the manual.

Supplemental Documents

Information on additional documents for specific compressor components.

Introduction

General Compressor Safety Precautions

Critical safety precautions for operating and maintaining the compressor.

Safety Decals

Information on the purpose and location of warning decals on the compressor.

Screw Compressor Air End Exchange Program

Details on purchasing factory-remanufactured air ends after the warranty period.

Specifications

Technical Data

Detailed technical specifications for various compressor models.

Dimensions - Open, Base Mount, Air-Cooled

Dimensional drawings for open, base mount, air-cooled compressor configurations.

Dimensions - Enclosed, Base Mount, Air-Cooled

Dimensional drawings for enclosed, base mount, air-cooled compressor configurations.

Dimensions - Open, Base Mount, Water-Cooled

Dimensional drawings for open, base mount, water-cooled compressor configurations.

Dimensions - Enclosed, Base-Mount, Water-Cooled

Dimensional drawings for enclosed, base mount, water-cooled compressor configurations.

Dimensions - Open, Platform Mount, Air-Cooled

Dimensional drawings for open, platform mount, air-cooled compressor configurations.

Dimensions - Enclosed, Platform Mount, Air-Cooled

Dimensional drawings for enclosed, platform mount, air-cooled compressor configurations.

Dimensions - Open, Platform Mount, Water-Cooled

Dimensional drawings for open, platform mount, water-cooled compressor configurations.

Dimensions - Horizontal Receiver (120 Gallon)

Dimensional drawings for a 120-gallon horizontal receiver tank.

Dimensions - Horizontal Receiver (200 Gallon)

Dimensional drawings for a 200-gallon horizontal receiver tank.

Dimensions - Horizontal Receiver (240 Gallon)

Dimensional drawings for a 240-gallon horizontal receiver tank.

Piping and Instrumentation (Air-Cooled)

P&ID diagram for air-cooled compressor systems.

Piping and Instrumentation (Water-Cooled)

P&ID diagram for water-cooled compressor systems.

Wiring Diagram, MFV (208;230;460 V)

Electrical wiring diagram for MFV models at 208/230/460V.

Wiring Diagram, MFV (575 V)

Electrical wiring diagram for MFV models at 575V.

Component Description

Air Compressor Package

Overview of the main components of the air compressor package.

Compression Cycle

Explanation of the rotary screw compression process and its components.

Drive System

Description of the motor, coupling, and starter assembly powering the compressor.

Protective Devices

Explanation of safety devices like pressure relief valves and switches.

Air;Oil Discharge System

Description of the system that separates and discharges air and oil.

Cooling and Lubricating System

Details on the oil circulation, cooling, and lubrication functions.

Air Inlet and Capacity Control System

How the system controls air intake and capacity based on demand.

Monitoring System

Description of the gauge panel for monitoring critical compressor outputs.

Installation

Receiving

Procedures for inspecting the compressor upon delivery.

Moving and Lifting

Guidelines for safely moving and lifting the compressor unit.

Location and Support

Recommendations for choosing a proper installation site and support.

Intake Air

Requirements for supplying clean and cool intake air to the compressor.

Ventilation and Cooling

Importance of adequate ventilation for maintaining operating temperature.

Electrical Connections

Instructions for making safe and compliant electrical connections.

Fluid Level Check

Procedure for verifying the oil level before initial start-up.

Direction of Rotation

How to check and correct motor rotation to prevent damage.

Compressed Air System

Guidelines for connecting the compressor to the plant air system.

Multiple Machine Installation

Considerations for installing compressors in sequence systems.

Storage

Procedures for safely storing the compressor for extended periods.

Operation

Electro-Mechanical Controls

Description and identification of the control panel components.

Modes of Operation

Explanation of the RUN and AUTO modes for compressor operation.

Prior to Starting

Essential checks and familiarization required before starting the compressor.

Normal Start

Step-by-step procedure for starting the compressor under normal conditions.

Normal Stop

Step-by-step procedure for safely stopping the compressor.

Restarts

Procedures for restarting the compressor after unexpected shutdowns.

Maintenance

Maintenance Schedule

A schedule of maintenance tasks based on operating hours.

Bolt Torque Guidelines

Torque specifications for fasteners based on size, grade, and plating.

Compressor Lubricant

Information on lubricant types, checking levels, filling, changing, and converting.

Oil Sample For Analysis

Procedure for taking and submitting oil samples for analysis.

Oil Filter

Instructions for removing and installing the oil filter element.

Air;Oil Separator

Procedures for replacing the air/oil separator element.

Air Filter

Instructions for removing and installing air filter elements.

Oil;After Cooler

Procedures for inspecting, cleaning, and replacing the oil/after cooler.

Minimum Pressure Valve

Instructions for inspecting and cleaning the minimum pressure valve.

Pressure Adjustment

How to adjust load, unload, and modulating pressure settings.

Troubleshooting

Troubleshooting Introduction

Introduction to troubleshooting procedures for compressor malfunctions.

Compressor Will Not Start

Common causes and remedies for a compressor that fails to start.

Machine Will Not Build Up Full Discharge Pressure

Possible causes and solutions when the compressor fails to reach discharge pressure.

Receiver Pressure Venting Through Blowdown

Troubleshooting issues related to receiver pressure venting during blowdown.

Machine Shuts Down With Air Demand Present

Reasons and solutions for compressor shutdown when air demand is present.

Line Pressure Rises Above Unload Pressure

Troubleshooting when line pressure exceeds the unload pressure setting.

Excessive Lubricant Consumption

Causes and remedies for high lubricant consumption.

Pressure Relief Valve Opens Repeatedly

Troubleshooting why the pressure relief valve may be opening repeatedly.

Parts Catalog

Ordering Parts

Information on how to order recommended spare parts and contact details.

Parts Drawings

Exploded drawings of various assemblies and sub-assemblies for parts identification.

Recommended Spare Parts List

A list of recommended spare parts to minimize downtime.

Compressor Lubricants

Detailed information on various lubricant types and their applications.

Compressor, Frame and Drive Assembly (15 hp)

Exploded view and parts list for the 15hp compressor frame and drive.

Compressor, Frame and Drive Assembly (20-30 hp)

Exploded view and parts list for the 20-30hp compressor frame and drive.

Compressor, Frame and Drive Assembly (40 hp)

Exploded view and parts list for the 40hp compressor frame and drive.

Pneumatic Controls Assembly (15-40 hp)

Exploded view and parts list for the pneumatic controls assembly.

Control Panel Assembly (15-40 hp)

Exploded view and parts list for the control panel assembly.

Air Inlet Assembly (15-30 hp)

Exploded view and parts list for the 15-30hp air inlet assembly.

Air Inlet Controls (15-30 hp)

Diagram and parts list for 15-30hp air inlet control system.

Air Inlet Assembly (40 hp)

Exploded view and parts list for the 40hp air inlet assembly.

Air Inlet Controls (40 hp)

Diagram and parts list for 40hp air inlet control system.

Discharge Assembly (15 hp)

Exploded view and parts list for the 15hp discharge assembly.

Discharge Assembly (20-30 hp)

Exploded view and parts list for the 20-30hp discharge assembly.

Discharge Assembly (40 hp)

Exploded view and parts list for the 40hp discharge assembly.

Cooling & Lubrication Assembly, Air-Cooled (15-25 hp)

Exploded view and parts list for air-cooled cooling/lubrication (15-25hp).

Cooling & Lubrication Assembly, Air-Cooled (30 hp)

Exploded view and parts list for air-cooled cooling/lubrication (30hp).

Cooling & Lubrication Assembly, Air-Cooled (40 hp)

Exploded view and parts list for air-cooled cooling/lubrication (40hp).

Cooling & Lubrication Assembly, Water-Cooled (15-40 hp)

Exploded view and parts list for water-cooled cooling/lubrication (15-40hp).

Enclosure Assembly, Horizontal Flow, Air-Cooled (15-40 hp)

Exploded view and parts list for horizontal flow air-cooled enclosures.

Enclosure Assembly, Updraft, Air-Cooled (15-30 hp)

Exploded view and parts list for updraft air-cooled enclosures.

Enclosure Assembly, Water-Cooled (15-40 hp)

Exploded view and parts list for water-cooled enclosures.

Summary

About This Manual

Safety Instructions

Instructions for safe operation and maintenance of the air compressor.

Manual Organization

Quick guide to the contents of the manual.

Supplemental Documents

Information on additional documents for specific compressor components.

Introduction

General Compressor Safety Precautions

Critical safety precautions for operating and maintaining the compressor.

Safety Decals

Information on the purpose and location of warning decals on the compressor.

Screw Compressor Air End Exchange Program

Details on purchasing factory-remanufactured air ends after the warranty period.

Specifications

Technical Data

Detailed technical specifications for various compressor models.

Dimensions - Open, Base Mount, Air-Cooled

Dimensional drawings for open, base mount, air-cooled compressor configurations.

Dimensions - Enclosed, Base Mount, Air-Cooled

Dimensional drawings for enclosed, base mount, air-cooled compressor configurations.

Dimensions - Open, Base Mount, Water-Cooled

Dimensional drawings for open, base mount, water-cooled compressor configurations.

Dimensions - Enclosed, Base-Mount, Water-Cooled

Dimensional drawings for enclosed, base mount, water-cooled compressor configurations.

Dimensions - Open, Platform Mount, Air-Cooled

Dimensional drawings for open, platform mount, air-cooled compressor configurations.

Dimensions - Enclosed, Platform Mount, Air-Cooled

Dimensional drawings for enclosed, platform mount, air-cooled compressor configurations.

Dimensions - Open, Platform Mount, Water-Cooled

Dimensional drawings for open, platform mount, water-cooled compressor configurations.

Dimensions - Horizontal Receiver (120 Gallon)

Dimensional drawings for a 120-gallon horizontal receiver tank.

Dimensions - Horizontal Receiver (200 Gallon)

Dimensional drawings for a 200-gallon horizontal receiver tank.

Dimensions - Horizontal Receiver (240 Gallon)

Dimensional drawings for a 240-gallon horizontal receiver tank.

Piping and Instrumentation (Air-Cooled)

P&ID diagram for air-cooled compressor systems.

Piping and Instrumentation (Water-Cooled)

P&ID diagram for water-cooled compressor systems.

Wiring Diagram, MFV (208;230;460 V)

Electrical wiring diagram for MFV models at 208/230/460V.

Wiring Diagram, MFV (575 V)

Electrical wiring diagram for MFV models at 575V.

Component Description

Air Compressor Package

Overview of the main components of the air compressor package.

Compression Cycle

Explanation of the rotary screw compression process and its components.

Drive System

Description of the motor, coupling, and starter assembly powering the compressor.

Protective Devices

Explanation of safety devices like pressure relief valves and switches.

Air;Oil Discharge System

Description of the system that separates and discharges air and oil.

Cooling and Lubricating System

Details on the oil circulation, cooling, and lubrication functions.

Air Inlet and Capacity Control System

How the system controls air intake and capacity based on demand.

Monitoring System

Description of the gauge panel for monitoring critical compressor outputs.

Installation

Receiving

Procedures for inspecting the compressor upon delivery.

Moving and Lifting

Guidelines for safely moving and lifting the compressor unit.

Location and Support

Recommendations for choosing a proper installation site and support.

Intake Air

Requirements for supplying clean and cool intake air to the compressor.

Ventilation and Cooling

Importance of adequate ventilation for maintaining operating temperature.

Electrical Connections

Instructions for making safe and compliant electrical connections.

Fluid Level Check

Procedure for verifying the oil level before initial start-up.

Direction of Rotation

How to check and correct motor rotation to prevent damage.

Compressed Air System

Guidelines for connecting the compressor to the plant air system.

Multiple Machine Installation

Considerations for installing compressors in sequence systems.

Storage

Procedures for safely storing the compressor for extended periods.

Operation

Electro-Mechanical Controls

Description and identification of the control panel components.

Modes of Operation

Explanation of the RUN and AUTO modes for compressor operation.

Prior to Starting

Essential checks and familiarization required before starting the compressor.

Normal Start

Step-by-step procedure for starting the compressor under normal conditions.

Normal Stop

Step-by-step procedure for safely stopping the compressor.

Restarts

Procedures for restarting the compressor after unexpected shutdowns.

Maintenance

Maintenance Schedule

A schedule of maintenance tasks based on operating hours.

Bolt Torque Guidelines

Torque specifications for fasteners based on size, grade, and plating.

Compressor Lubricant

Information on lubricant types, checking levels, filling, changing, and converting.

Oil Sample For Analysis

Procedure for taking and submitting oil samples for analysis.

Oil Filter

Instructions for removing and installing the oil filter element.

Air;Oil Separator

Procedures for replacing the air/oil separator element.

Air Filter

Instructions for removing and installing air filter elements.

Oil;After Cooler

Procedures for inspecting, cleaning, and replacing the oil/after cooler.

Minimum Pressure Valve

Instructions for inspecting and cleaning the minimum pressure valve.

Pressure Adjustment

How to adjust load, unload, and modulating pressure settings.

Troubleshooting

Troubleshooting Introduction

Introduction to troubleshooting procedures for compressor malfunctions.

Compressor Will Not Start

Common causes and remedies for a compressor that fails to start.

Machine Will Not Build Up Full Discharge Pressure

Possible causes and solutions when the compressor fails to reach discharge pressure.

Receiver Pressure Venting Through Blowdown

Troubleshooting issues related to receiver pressure venting during blowdown.

Machine Shuts Down With Air Demand Present

Reasons and solutions for compressor shutdown when air demand is present.

Line Pressure Rises Above Unload Pressure

Troubleshooting when line pressure exceeds the unload pressure setting.

Excessive Lubricant Consumption

Causes and remedies for high lubricant consumption.

Pressure Relief Valve Opens Repeatedly

Troubleshooting why the pressure relief valve may be opening repeatedly.

Parts Catalog

Ordering Parts

Information on how to order recommended spare parts and contact details.

Parts Drawings

Exploded drawings of various assemblies and sub-assemblies for parts identification.

Recommended Spare Parts List

A list of recommended spare parts to minimize downtime.

Compressor Lubricants

Detailed information on various lubricant types and their applications.

Compressor, Frame and Drive Assembly (15 hp)

Exploded view and parts list for the 15hp compressor frame and drive.

Compressor, Frame and Drive Assembly (20-30 hp)

Exploded view and parts list for the 20-30hp compressor frame and drive.

Compressor, Frame and Drive Assembly (40 hp)

Exploded view and parts list for the 40hp compressor frame and drive.

Pneumatic Controls Assembly (15-40 hp)

Exploded view and parts list for the pneumatic controls assembly.

Control Panel Assembly (15-40 hp)

Exploded view and parts list for the control panel assembly.

Air Inlet Assembly (15-30 hp)

Exploded view and parts list for the 15-30hp air inlet assembly.

Air Inlet Controls (15-30 hp)

Diagram and parts list for 15-30hp air inlet control system.

Air Inlet Assembly (40 hp)

Exploded view and parts list for the 40hp air inlet assembly.

Air Inlet Controls (40 hp)

Diagram and parts list for 40hp air inlet control system.

Discharge Assembly (15 hp)

Exploded view and parts list for the 15hp discharge assembly.

Discharge Assembly (20-30 hp)

Exploded view and parts list for the 20-30hp discharge assembly.

Discharge Assembly (40 hp)

Exploded view and parts list for the 40hp discharge assembly.

Cooling & Lubrication Assembly, Air-Cooled (15-25 hp)

Exploded view and parts list for air-cooled cooling/lubrication (15-25hp).

Cooling & Lubrication Assembly, Air-Cooled (30 hp)

Exploded view and parts list for air-cooled cooling/lubrication (30hp).

Cooling & Lubrication Assembly, Air-Cooled (40 hp)

Exploded view and parts list for air-cooled cooling/lubrication (40hp).

Cooling & Lubrication Assembly, Water-Cooled (15-40 hp)

Exploded view and parts list for water-cooled cooling/lubrication (15-40hp).

Enclosure Assembly, Horizontal Flow, Air-Cooled (15-40 hp)

Exploded view and parts list for horizontal flow air-cooled enclosures.

Enclosure Assembly, Updraft, Air-Cooled (15-30 hp)

Exploded view and parts list for updraft air-cooled enclosures.

Enclosure Assembly, Water-Cooled (15-40 hp)

Exploded view and parts list for water-cooled enclosures.

Sullivan-Palatek 15D Specifications

General IconGeneral
BrandSullivan-Palatek
Model15D
CategoryAir Compressor
LanguageEnglish

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