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Sullivan-Palatek VFD Series - User Manual

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User Manual
Industrial Air Compressors
2014
JULY
Document: 18730-020 / 00
Issued: July 07, 2014
VFD-Series
SP20 Models
T1 Microprocessor Control
Variable Frequency Drive

Table of Contents

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Summary

About This Manual

Foreward

Introduces the new line of Sullivan-Palatek rotary screw compressors and their capabilities.

Safety Instructions

Provides essential safety precautions for operating and maintaining the air compressor.

Manual Organization

Outlines the structure of the manual, detailing the content of each section for easy navigation.

Supplemental Documents

Indicates where to find additional detailed information on specific components or optional equipment.

Introduction

General Compressor Safety Precautions

Details critical safety guidelines for the proper operation and maintenance of air compressors.

Safety Decals

Explains the purpose and location of warning decals designed to identify potential hazards.

Screw Compressor Airend Exchange Program

Describes the availability and warranty of factory-remanufactured airends for screw compressors.

Specifications

Technical Data

Presents detailed technical specifications for various compressor models and configurations.

Dimensional Drawing, Air-Cooled (125-150 hp)

Provides a visual representation of the physical dimensions for air-cooled compressors.

Dimensional Drawing, Air-Cooled (200-250 hp)

Offers a visual overview of the physical dimensions for larger air-cooled compressor models.

Piping and Instrumentation Diagram, Air-Cooled

Illustrates the pneumatic and fluidic connections for air-cooled compressor systems.

Piping and Instrumentation Diagram, Water-Cooled

Details the pneumatic and fluidic connections specific to water-cooled compressor systems.

Wiring Diagram, 460 V (<10 hp Fan Motor)

Shows the electrical circuit layout for compressors with specific fan motor configurations.

Wiring Diagram, 460 V (≥ 10 hp Fan Motor)

Presents the electrical wiring schematic for compressors with larger fan motor sizes.

Component Description

Air Compressor Package

Details the main systems comprising the air compressor package.

Compression Cycle

Explains the process of air compression within the rotary screw unit.

Drive System

Describes the components responsible for powering and operating the compressor.

Protective Devices

Identifies and explains the function of various safety and protective components.

Air;Oil Discharge System

Details the system responsible for separating and discharging air and oil.

Cooling and Lubricating System

Explains the operation of the systems that manage oil circulation and heat dissipation.

Air Inlet and Capacity Control System

Describes how the compressor regulates air intake and adjusts capacity based on demand.

Installation

Receiving

Provides guidance on inspecting the compressor unit upon delivery for any shipping damage.

Moving and Lifting

Details safe procedures and equipment required for moving and lifting the compressor.

Location and Support

Offers recommendations for selecting a suitable installation site and ensuring proper support.

Intake Air

Specifies requirements for supplying clean and cool intake air to the compressor.

Ventilation and Cooling

Outlines ventilation requirements to maintain optimal operating temperatures for the compressor.

Electrical Connections

Provides instructions for making safe and compliant electrical connections to the compressor.

Fluid Level Check

Explains how to verify the correct fluid level before initial compressor startup.

Direction of Rotation

Details how to check and ensure the correct motor rotation to prevent damage.

Compressed Air System

Guides on connecting the compressor to the plant air system and related components.

Multiple Machine Installation

Addresses considerations for installing and sequencing multiple compressors.

Storage

Provides procedures for safely storing the compressor for extended periods.

Operation

T1 User Interface

Describes the T1 microprocessor interface, including keypad and LED indicators.

Access Codes

Explains how to use access codes to navigate restricted menu pages on the controller.

Prior to Starting

Lists essential checks and preparations required before starting the compressor.

Normal Start

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

Normal Stop

Provides the correct procedure for safely shutting down the air compressor.

Restarts

Outlines procedures for safely restarting the compressor after unexpected shutdowns.

Maintenance

Maintenance Schedule

Presents a comprehensive schedule of required maintenance tasks based on operating hours.

General Maintenance Safety

Covers fundamental safety rules and precautions for performing maintenance.

Stopping for Maintenance

Details the critical lockout/tagout and isolation procedures before maintenance.

Bolt Torque Guidelines

Provides recommended torque values for various fasteners based on size and grade.

Compressor Lubricant

Details lubricant types, checking levels, filling, changing, and conversion procedures.

Oil Filter

Explains the procedure for replacing the oil filter element at recommended intervals.

Air;Oil Separator

Provides instructions for replacing the air/oil separator element.

Oil;After Cooler

Describes inspection, cleaning, and installation procedures for the oil/after cooler.

Minimum Pressure Valve

Details inspection and cleaning procedures for the minimum pressure valve.

Pressure Adjustment

Explains how to adjust pressure settings for load, unload, and modulation.

Troubleshooting

Compressor Will Not Start

Lists common causes and remedies for a compressor failing to start.

Machine Will Not Build Up Full Discharge Pressure

Identifies issues preventing the compressor from reaching its target discharge pressure.

Machine Shuts Down With Air Demand Present

Addresses reasons for the compressor shutting down while air demand is present.

Line Pressure Rises Above Unload Pressure

Explains causes for line pressure exceeding the compressor's unload setting.

Excessive Lubricant Consumption

Details potential causes and solutions for high lubricant usage.

Pressure Relief Valve Opens Repeatedly

Troubleshoots scenarios where the pressure relief valve activates frequently.

Receiver Pressure Venting Through Blow-Down

Addresses issues related to receiver pressure venting during the blow-down process.

Parts Catalog

Ordering Parts

Provides information and contact details for ordering replacement parts and manuals.

Parts Drawings

Features exploded drawings of assemblies and sub-assemblies for part identification.

Spare Parts List

Lists recommended spare parts to maintain minimal downtime for common maintenance.

Compressor Lubricants

Details various compressor lubricant options, their properties, and ordering information.

Compressor, Frame and Drive Assembly

Exploded view and parts list for the main compressor unit, frame, and drive components.

Control Box Assemblies

Diagrams and parts lists for electrical control box assemblies for different motor configurations.

Electrical;Pneumatic Controls Assemblies

Parts breakdown for pneumatic and electrical control systems for various HP ranges.

Remote Controls Assemblies

Parts lists for remote electrical/pneumatic control assemblies in NEMA 1 and NEMA 4 enclosures.

Air Inlet Assemblies

Exploded views and parts lists for standard and remote air inlet assemblies.

Receiver Assembly

Diagram and parts list for the receiver tank and its associated components.

Air Piping Assemblies

Parts lists and diagrams for air piping configurations for various compressor models.

Air Cooler Assemblies

Parts lists for air cooler assemblies across different horsepower ratings.

Water Cooler Assembly

Details the components for the water cooler assembly.

Water Piping Assembly

Provides a parts list and diagram for the water piping system.

Fluid Piping Assemblies

Lists components for air-cooled and water-cooled fluid piping systems.

Enclosure Assemblies

Parts lists for air-cooled and water-cooled enclosure assemblies.

Summary

About This Manual

Foreward

Introduces the new line of Sullivan-Palatek rotary screw compressors and their capabilities.

Safety Instructions

Provides essential safety precautions for operating and maintaining the air compressor.

Manual Organization

Outlines the structure of the manual, detailing the content of each section for easy navigation.

Supplemental Documents

Indicates where to find additional detailed information on specific components or optional equipment.

Introduction

General Compressor Safety Precautions

Details critical safety guidelines for the proper operation and maintenance of air compressors.

Safety Decals

Explains the purpose and location of warning decals designed to identify potential hazards.

Screw Compressor Airend Exchange Program

Describes the availability and warranty of factory-remanufactured airends for screw compressors.

Specifications

Technical Data

Presents detailed technical specifications for various compressor models and configurations.

Dimensional Drawing, Air-Cooled (125-150 hp)

Provides a visual representation of the physical dimensions for air-cooled compressors.

Dimensional Drawing, Air-Cooled (200-250 hp)

Offers a visual overview of the physical dimensions for larger air-cooled compressor models.

Piping and Instrumentation Diagram, Air-Cooled

Illustrates the pneumatic and fluidic connections for air-cooled compressor systems.

Piping and Instrumentation Diagram, Water-Cooled

Details the pneumatic and fluidic connections specific to water-cooled compressor systems.

Wiring Diagram, 460 V (<10 hp Fan Motor)

Shows the electrical circuit layout for compressors with specific fan motor configurations.

Wiring Diagram, 460 V (≥ 10 hp Fan Motor)

Presents the electrical wiring schematic for compressors with larger fan motor sizes.

Component Description

Air Compressor Package

Details the main systems comprising the air compressor package.

Compression Cycle

Explains the process of air compression within the rotary screw unit.

Drive System

Describes the components responsible for powering and operating the compressor.

Protective Devices

Identifies and explains the function of various safety and protective components.

Air;Oil Discharge System

Details the system responsible for separating and discharging air and oil.

Cooling and Lubricating System

Explains the operation of the systems that manage oil circulation and heat dissipation.

Air Inlet and Capacity Control System

Describes how the compressor regulates air intake and adjusts capacity based on demand.

Installation

Receiving

Provides guidance on inspecting the compressor unit upon delivery for any shipping damage.

Moving and Lifting

Details safe procedures and equipment required for moving and lifting the compressor.

Location and Support

Offers recommendations for selecting a suitable installation site and ensuring proper support.

Intake Air

Specifies requirements for supplying clean and cool intake air to the compressor.

Ventilation and Cooling

Outlines ventilation requirements to maintain optimal operating temperatures for the compressor.

Electrical Connections

Provides instructions for making safe and compliant electrical connections to the compressor.

Fluid Level Check

Explains how to verify the correct fluid level before initial compressor startup.

Direction of Rotation

Details how to check and ensure the correct motor rotation to prevent damage.

Compressed Air System

Guides on connecting the compressor to the plant air system and related components.

Multiple Machine Installation

Addresses considerations for installing and sequencing multiple compressors.

Storage

Provides procedures for safely storing the compressor for extended periods.

Operation

T1 User Interface

Describes the T1 microprocessor interface, including keypad and LED indicators.

Access Codes

Explains how to use access codes to navigate restricted menu pages on the controller.

Prior to Starting

Lists essential checks and preparations required before starting the compressor.

Normal Start

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

Normal Stop

Provides the correct procedure for safely shutting down the air compressor.

Restarts

Outlines procedures for safely restarting the compressor after unexpected shutdowns.

Maintenance

Maintenance Schedule

Presents a comprehensive schedule of required maintenance tasks based on operating hours.

General Maintenance Safety

Covers fundamental safety rules and precautions for performing maintenance.

Stopping for Maintenance

Details the critical lockout/tagout and isolation procedures before maintenance.

Bolt Torque Guidelines

Provides recommended torque values for various fasteners based on size and grade.

Compressor Lubricant

Details lubricant types, checking levels, filling, changing, and conversion procedures.

Oil Filter

Explains the procedure for replacing the oil filter element at recommended intervals.

Air;Oil Separator

Provides instructions for replacing the air/oil separator element.

Oil;After Cooler

Describes inspection, cleaning, and installation procedures for the oil/after cooler.

Minimum Pressure Valve

Details inspection and cleaning procedures for the minimum pressure valve.

Pressure Adjustment

Explains how to adjust pressure settings for load, unload, and modulation.

Troubleshooting

Compressor Will Not Start

Lists common causes and remedies for a compressor failing to start.

Machine Will Not Build Up Full Discharge Pressure

Identifies issues preventing the compressor from reaching its target discharge pressure.

Machine Shuts Down With Air Demand Present

Addresses reasons for the compressor shutting down while air demand is present.

Line Pressure Rises Above Unload Pressure

Explains causes for line pressure exceeding the compressor's unload setting.

Excessive Lubricant Consumption

Details potential causes and solutions for high lubricant usage.

Pressure Relief Valve Opens Repeatedly

Troubleshoots scenarios where the pressure relief valve activates frequently.

Receiver Pressure Venting Through Blow-Down

Addresses issues related to receiver pressure venting during the blow-down process.

Parts Catalog

Ordering Parts

Provides information and contact details for ordering replacement parts and manuals.

Parts Drawings

Features exploded drawings of assemblies and sub-assemblies for part identification.

Spare Parts List

Lists recommended spare parts to maintain minimal downtime for common maintenance.

Compressor Lubricants

Details various compressor lubricant options, their properties, and ordering information.

Compressor, Frame and Drive Assembly

Exploded view and parts list for the main compressor unit, frame, and drive components.

Control Box Assemblies

Diagrams and parts lists for electrical control box assemblies for different motor configurations.

Electrical;Pneumatic Controls Assemblies

Parts breakdown for pneumatic and electrical control systems for various HP ranges.

Remote Controls Assemblies

Parts lists for remote electrical/pneumatic control assemblies in NEMA 1 and NEMA 4 enclosures.

Air Inlet Assemblies

Exploded views and parts lists for standard and remote air inlet assemblies.

Receiver Assembly

Diagram and parts list for the receiver tank and its associated components.

Air Piping Assemblies

Parts lists and diagrams for air piping configurations for various compressor models.

Air Cooler Assemblies

Parts lists for air cooler assemblies across different horsepower ratings.

Water Cooler Assembly

Details the components for the water cooler assembly.

Water Piping Assembly

Provides a parts list and diagram for the water piping system.

Fluid Piping Assemblies

Lists components for air-cooled and water-cooled fluid piping systems.

Enclosure Assemblies

Parts lists for air-cooled and water-cooled enclosure assemblies.

Sullivan-Palatek VFD Series Specifications

General IconGeneral
BrandSullivan-Palatek
ModelVFD Series
CategoryAir Compressor
LanguageEnglish

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