OPERATING AND PARTS MANUALINDUSTRIAL ELECTRIC AIR COMPRESSORS MODELS 30DG, 40DG, AND 50DG WITH A TEFC MOTOR PALATEK, INC. dba SULLIVAN-PALATEK, MICHIGAN CITY, IN 46360 ALL RIGHTS RESERVED COPYRIGHT 2001 3/17/08 MFP Part Number: OPM3060-004 _____________________________________SULLIVAN-PALATEK TABLE OF CONTENTS SECTION 1 - SAFETY ............................................................................................................. 4 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 2.1 2.2 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 GENERAL .................................................................................................................. 4 PRESSURE RELEASE .............................................................................................. 4 FIRES / EXPLOSIONS............................................................................................... 5 MOVING PARTS........................................................................................................ 5 PHYSICAL DANGERS............................................................................................... 6 TOXICITY .................................................................................................................. 6 ELECTRIC SHOCK.................................................................................................... 6 LIFTING ..................................................................................................................... 7 AUTOMATIC START ................................................................................................. 7 NOISE ........................................................................................................................ 7 HAZARD WARNING SIGNS ...................................................................................... 8 LUBRICATION GUIDE............................................................................................... 9 APPLICATION GUIDE ............................................................................................... 9 INTRODUCTION ..................................................................................................... 10 COMPRESSOR UNIT .............................................................................................. 10 MOTOR.................................................................................................................... 10 INTAKE/CONTROL SYSTEM .................................................................................. 12 COMPRESSOR LUBRICATION/COOLING SYSTEM ............................................. 13 COMPRESSOR DISCHARGE SYSTEM ................................................................. 14 STARTER AND ELECTRICAL PARTS .................................................................... 16 INSTRUMENTATION .............................................................................................. 16 RECEIVING ............................................................................................................. 17 WELDING ................................................................................................................ 17 LOCATION............................................................................................................... 17 SUPPORT................................................................................................................ 17 ELECTRICAL CONNECTIONS ............................................................................... 17 MAINTENANCE INDICATION-DIFFERENTIAL INDICATION ................................. 18 DIRECTION OF ROTATION .................................................................................... 18 COMPRESSED AIR PIPING .................................................................................... 18 ADDITIONAL HELP ................................................................................................. 18 SECTION 2 - SPECIFICATIONS ............................................................................................. 9 SECTION 3 - DESCRIPTION ................................................................................................. 10 SECTION 4 - INSTALLATION ............................................................................................... 17 2 SULLIVAN-PALATEK_____________________________________ SECTION 5 - OPERATION .................................................................................................... 19 5.1 5.2 5.3 5.4 5.5 6.1 6.2 6.3 6.4 6.5 6.6 6.7 INTRODUCTION ..................................................................................................... 19 INITIAL START ........................................................................................................ 19 NORMAL OPERATION ............................................................................................ 19 SHUTDOWN ............................................................................................................ 19 RESTARTS .............................................................................................................. 20 SCHEDULE ............................................................................................................. 21 OIL FILTER .............................................................................................................. 22 AIR FILTER .............................................................................................................. 22 AIR/OIL SEPARATOR ............................................................................................. 22 BOLT TORQUE SPECS .......................................................................................... 22 PRESSURE ADJUSTMENT .................................................................................... 23 TROUBLESHOOTING ............................................................................................. 24 SECTION 6 - MAINTENANCE ............................................................................................... 21 SCREW COMPRESSOR AIR-END EXCHANGE PROGRAM .............................................. 29 SECTION 7 - PARTS LISTING .............................................................................................. 30 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 PARTS ORDERING ................................................................................................. 30 RECOMMENDED SPARE PARTS .......................................................................... 30 MOTOR, COMPRESSOR AND MOUNTING PARTS - BASE MOUNTED ............... 32 LUBRICATION & COOLING SYSTEM ..................................................................... 34 INTAKE AND CAPACITY CONTROL SYSTEM ....................................................... 36 DISCHARGE SYSTEM ............................................................................................ 38 GAUGE PANEL & ELECTRICAL PARTS ................................................................ 40 DECAL & IDENTIFICATION .................................................................................... 41 SECTION 8 - WARRANTY .................................................................................................... 42 SULLIVAN - PALATEK COMPRESSOR MAINTENANCE LOG .......................................... 53 3 _____________________________________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 and 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, the air piping, filtering, regulating, preparation, conditioning, valving, hosing or 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. Do not modify this compressor without specific written approval from the factory. 1.2 PRESSURE RELEASE Open the pressure relief valve(s) periodically to be sure there is no blockage, obstruction, or inability to operate. Shut machine off, 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 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. REMEMBER, 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 manufacturers 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 (102.5 mm) inside diameter is used anywhere in the system to reduce pressure in case of hose or connection failure. Install additional velocity limiting valves, in series, whenever 75 feet (22.8 m) of hose length is exceeded. These valves must comply with pertinent OSHA requirements. 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 may be required by OSHA. 4 mists or particulates. arms. connection. Immediately replace any oil-soaked material after cleaning enclosure surface with nonflammable solvent. Do not allow oil to accumulate on. compressed air discharge. Do not use plastic pipe for compressed air. Do not allow anyone to engage in horseplay with air hoses as serious bodily injury or death may result. Keep clothing. Do not operate compressor with its temperature switch or any of three pressure switches inoperative or incorrectly connected. 1. Wear snug-fitting protective clothing (no neckties) and confine long hair when working around compressor. Keep personnel out of line with. 5 . away from the fan and drive coupling. Steel bowls are recommended. or deflected.SULLIVAN-PALATEK_____________________________________ Compressed air filters or lubricators with plastic bowls may be affected by the lubricant used. fitting. and other parts of the body. toxic or explosive fumes. or other areas of direct. 1. hands.4 MOVING PARTS Do not operate the compressor with its fan guard removed. Keep conductive objects away from explosive live electrical parts such as terminals to avoid sparks that might serve as a source of ignition. in. Do not substitute bolts with material or markings different from original equipment. or tools. or around acoustic noise material. and away from. or spin-on filter element. Do not over-tighten any bolt. Replace the air/oil separator element only with factory original equipment replacement parts to be certain that anti-static provisions are present. nut. the discharge opening of airlines. Do not operate compressor when there is a possibility of its ingesting flammable. Ground the machine in accordance with National Electrical Code (NEC) requirements.3 FIRES / EXPLOSIONS Clean up any spilled oil or oil leakage and repair oil leaks as soon as they are discovered. 1. If a fuse should blow for any reason. Operate the compressor only in open or well-ventilated areas. including pressure relief valve ports._____________________________________SULLIVAN-PALATEK 1. safety glasses. sharp edges and corners. Perform repairs and maintenance only in clean. Be certain that the equipment is properly grounded in accordance with NEC.5 PHYSICAL DANGERS Wear OSHA approved personal protective gear including gloves. Do not ignore small cuts.3570 and all other applicable regulations. head covering and ear protection when working on or around the compressor. stand on insulating surfaces and do not contact any other portion of the compressor when making adjustments. Improper installation or unsafe servicing could result in serious bodily injury or death.7 ELECTRIC SHOCK Keep all parts of the body as well as any tools or other conductive objects away from exposed live parts of the electrical system. Obtain medical assistance promptly in case of injury. 6 . Monitor the point-of-use location for adequate ventilation. burns or minor eye injuries as they may lead to infection. as it may contain colorless. hot surfaces. Severe injury or death may result within a few seconds. dry conditions in a well-lighted and ventilated area. odorless yet lethal gases. Do not use air from this compressor for breathing. State and Local codes.) 1. standards and regulations. Avoid bodily contact with hot oil.6 TOXICITY Carefully analyze the compressor inlet conditions to be certain that no dangerous levels of contaminants are being ingested by the compressor. Maintain dry footing. Keep an adequate first-aid kit nearby. Initial installation and wiring must be done by a trained and qualified electrician and be in accordance with all Federal. Doing otherwise may result in an unsafe condition. safety shoes. Keep all parts of the body away from all potential points of air discharge. type and ampere rating. (Use food grade lubricant for such applications. replace it with a fuse of the same size. Do not permit air from this compressor to contact foodstuff except in compliance with FDA Standard 21 CFM 178. can prove hazardous even during short-term exposure. It may be in the “Automatic-Start” mode of its dual-control system and suddenly re-start. Firmly restrain the compressor to prevent tipping or rolling. For prolonged exposure to machinery noise. 1. service. The noise may interfere with hearing verbal warnings or other sounds off impending dangers. 7 . Do not lift entire machine by motor lifting eyes. Keep personnel out from under and away from the area when lifting or moving the compressor. Carry as low as possible when moving. Drain condensate from Auxiliary Air Receiver prior to lifting.8 LIFTING Lift or move the compressor only with equipment of sufficient load capacity which has been inspected and is in good condition.SULLIVAN-PALATEK_____________________________________ 1.10 NOISE Working near an open-air compressor (or an enclosed machine with doors and/or access panels open or removed). thereby creating a hazardous condition! Close discharge air valves and shut machine off. Lift no higher than necessary. Set compressor down only on level surface capable of supporting several times the machine’s weight. Open main disconnect. 1.9 AUTOMATIC START Do not assume that any air compressor is ready for maintenance. Keep lifting operator in attendance whenever the compressor is suspended. or troubleshooting if it is not running. lock it out and tag it to prevent others from inadvertently re-closing it. as they are intended only for lifting the motor. hearing protection is recommended and may be required by OSHA. Use extreme care when moving tank-mounted compressors because of the high center of gravity. _____________________________________SULLIVAN-PALATEK 1.11 HAZARD WARNING SIGNS SULLIVAN-PALATEK compressors are all equipped with brightly colored. bodily injury or death. and understands. If any Warning Signs are missing. or to offer them with options which will cause the subject equipment to differ from the above specifications. it becomes incumbent upon the owner. without reference to any descriptions in this manual. 8 . If any operators are not fully conversant with the English language and/or cannot comprehend the intended pictorial warnings. pictorial/verbal self-adhesive decals. DECAL **WARNING SIGN** HIGH VOLTAGE/MOVING PARTS **WARNING SIGN** COMPRESSED AIR **WARNING SIGN** HOT OIL/PRESSURIZED AIR LOCATION MOTOR STARTER MOTOR STARTER INSTRUMENT PANEL INSTRUMENT PANEL SEPARATOR TANK SEPARATOR TANK SULLIVAN-PALATEK reserves the right to change the design or construction of the above compressors. Be sure they are properly positioned and installed correctly. All operators must be aware of the Warning Signs and follow the instructions thereon. These are designed to warn the operator against potential hazards in order to minimize risk of property damage. damaged or painted over. the meaning of all Warning Signs. lessor or other responsible administrator to be sure the operator is properly trained and also made aware of. weather-resistant. new Warning Signs must be ordered. or located in such a position as to be unreadable in a given installation. fine particulate. it is imperative that the SULLIVAN-PALATEK be the “lead” machine and the reciprocating the “lag” machine. That is.000 hours. or the first to load and the last to unload. caustic. or any other specialized compressor-related accessories. with no adverse effect on the life of the rotary. For extreme environments (i. For compressors running two or three shift operations extended life lubricants such as Pallube 32p or AFX 32 are offered as factory fill. For instrument-grade air.2 APPLICATION GUIDE Ambient Temperature Range: +35 to +104° F (+1 to 40° C). the SULLIVAN-PALATEK machine should be the first to start and the last to stop when being operated in the “automatic stop/start” mode. acidic.1 LUBRICATION GUIDE SULLIVAN-PALATEK recommends using Palasyn 45. Mixing of any other type of oil or synthetic fluid will void the 5year compressor unit warranty and could result in greatly increased maintenance and service expenses. 9 .SPECIFICATIONS 2.e. contact the factory for recommendations related to specialized compressed air preparation accessories. Contact the factory for heat-recovery equipment. It should also require the least electrical power consumption for the combination. 2. Whenever a SULLIVAN-PALATEK rotary screw air compressor is installed in parallel with a reciprocating type compressor. This will result in extending the life of the reciprocating machine. or oxidant atmospheres) contact the factory for lubricant recommendations. when in the “continuous run” mode. Also for such conditions we would suggest oil analysis every 1. a synthetic lubricoolant for normal plant-air service. The lower temperature limit is to prevent freeze-up of condensate in the aftercooler and/or control lines. contact the factory for a Lubricoolant that is FDA approved for “incidental contact with foodstuffs”.SULLIVAN-PALATEK_____________________________________ SECTION 2 . When operating these compressors for plant air in food or beverage processing industries. single stage. 3. flood lubricated rotary screw air compressor units with heavy duty long life tapered roller bearings. For outdoor operation. Maximum number of starts per hour: MOTOR HP STARTS/HR 30 4 40 4 50 4 10 . air intake capacity control system air cooled cooling system.3 MOTOR The electric motor used to power each SULLIVAN-PALATEK G-Series 30 40 and 50 horsepower compressor is a standard three phase 60 Hertz AC induction type motor. The compressor’s design and construction offer the greatest value and lowest life-cycle cost of operation. or protected outdoor operation in moderate climates. starter or wiring. reliable fan drive without an additional fan motor.DESCRIPTION 3. 3. They are available base mounted or tank mounted with or without enclosures. including a standard air cooled aftercooler. The standard motor is connectable for 230 or 460 volts and satisfactory for use at 208 volts. The lubricoolant lubricates the rotors. instrument panel and electrical system. bearings and shaft seal. fitted with a C-face register at the compressor drive end to assure proper coupling alignment at all times and double-extended to provide a simple. discharge system. These machines are intended for indoor installation. contact your nearest SULLIVAN-PALATEK distributor or the factory for specific options.2 COMPRESSOR UNIT SULLIVAN-PALATEK compressors feature direct connected. positive displacement. continuous-duty compressors. single-stage rotary screw type._____________________________________SULLIVAN-PALATEK SECTION 3 . cools the compressor by absorbing much of the heat of compression and acts to block slippage of compressed air through the compressor’s internal clearances. The compressor package includes a direct connected electric motor driven compressor. (200/400 volt motors available on request) Contact the factory for any other requirements. The lubricoolant fluid is injected directly into the compressor unit and mixes with the air as it is compressed by the rotors.1 INTRODUCTION SULLIVAN-PALATEK Plant Air Compressors are electric motor driven. SULLIVAN-PALATEK_____________________________________ 11 . connecting rubber sleeve. During periods of very low or zero air usage the inlet valve is held shut by an air signal from the solenoid control/blowdown valve. Selecting the “Auto” position on the selector switch allows the motor to shut off whenever the “cut-out” pressure setting of the control pressure switch is reached. solenoid control/blowdown valve.4 INTAKE/CONTROL SYSTEM The intake/control system consists of an air filter. and must not be restricted. but the air is held back by the minimum pressure valve. the service air pressure will continue to rise until the control regulator gradually opens. The inlet valve is held shut. Unloaded/Shutdown modes: When little or no air is being used. clamps. The control regulator has an orifice in the controller piston. which vents a small amount of control air whenever it is sending a pressure signal to the intake controller capacity control. therefore.start mode: When the compressor is turned on. Then control air signal to the inlet valve will be dissipated allowing the inlet valve to reopen. With the selector switch in the “Run” position. Upon shutdown the intake valve checks shut to eliminate blowback. cleaner air and/or for reduced noise level. or starts automatically. It remains in this “unloaded” mode for 10 minutes before shutting off. This applies pressure to the inlet valve piston. the compressor inlet valve is wide open. The control will function continually in this manner between the adjustable limits of 115 to 125 psi (750 to 860 kPa) in response to varying demands of the plant air system. With the resumption of plant air usage. Upon reaching 60 psig the minimum pressure valve opens allowing the compressor to deliver its full rated capacity to the plant air piping system. The intake valve controls the capacity or air delivery of the compressor in direct response to the plant air system demand via a varying signal from the control regulator valve. the compressor runs unloaded until air demand increases. This orifice is vital to the smoothness of the control operation. Control operation . (See Intake Control Schematic. The compressor returns to normal full load operation. The element should be cleaned periodically. a combination compressor inlet valve/reverse-flow check valve. This filter is adequate for areas of high air-borne dust concentrations and has a tubular intake to facilitate remote intake connection to cooler. the line pressure signal is reduced to the “cut-in” setting of the control pressure switch where it closes. This opens the control solenoid. 12 . thus partially closing the inlet valve disc reducing the amount of air entering the compressor air inlet until it matches the amount of air being used. control signal regulator valve. The control regulator and solenoid valve are both closed. which sends a pressure signal directly to the inlet valve piston.) The air filter is a multi-stage dry-type with a high efficiency cleanable/replaceable element. allowing the compressor to run unloaded with minimum power consumption. depending upon the amount of particulates in the air. and a control pressure switch._____________________________________SULLIVAN-PALATEK 3. while air is vented through an orifice fitting which reduces the pressure in the separation tank. the service line pressure will rise to the “cut-out” setting of the control pressure switch. Modulating mode: Whenever less than the rated capacity of the compressor is being used. The compressor will restart whenever the line pressure drops to the “cut-in” pressure. This air signal simultaneously reduces the pressure in the oil separation tank. which is the setting of the minimum pressure valve. the pressure will quickly rise to 60 psi (415 kPa). and replaced annually. The compressor is then drawing in its full rated capacity. A drain valve is provided to drain the lubricoolant at change-out time. the thermal valve is closed and all the lubricoolant flows through the cooler. through the system to an area of lower pressure at the compressor unit. While warming gradual change occurs where the fluid flow is split. finned-tube radiator-type fluid cooler. Pressure in the oil separation tank causes the lubricoolant to flow from this region of relatively high pressure. The element should be changed in accordance with the Maintenance Schedule on page 22. COOLING SYSTEM SCHEMATIC 13 . The fluid filter is of the spin-on replacement element type.5 COMPRESSOR LUBRICATION/COOLING SYSTEM The cooling system consists of a fan. During cold starts. thermal valve to accelerate warm-up. and from the filter to the compressor. Fluid flows from the oil separation tank to the cooler. When fully warmed up. the fluid will by-pass the oil cooler and go directly to the filter. from the cooler to the filter. partial flows being shared by both the oil cooler and by-pass through the thermal valve. a full-flow filter. an oil drain valve and interconnecting tubing.SULLIVAN-PALATEK_____________________________________ 3. which allow the heavier droplets of lubricoolant to fall.D. A sight gauge is provided to monitor the lubricoolant level in the oil separation tank.by collecting the hot lubricoolant. B) Serves as the lubricoolant sump . improved separation performance and extended service life. prior to re-circulation through the cooling system. a receiver over pressure switch has been installed to shut the motor off at 140 psig (190 psi on high pressure units. multi-layered. plugs or other components or connections while the compressor is running or pressurized. or about 100° F (55° C above ambient). and relieve all sump pressure before doing so. 14 . A capped oil fill port is provided to keep the oil at the proper level and to refill the system after changing the lubricoolant.a replaceable. The compressor discharge temperature gauge is also panel-mounted for ease of record keeping and trouble-shooting. (High-pressure units can be set to operate at control pressures from 175 to 190 psig. A pressure relief valve (located upstream.by change of direction and reduction of velocity. The reaction time of the switch is. not rapid enough to stop the compressor in the event of a sudden or complete loss of lubricoolant. C) Houses the final oil separation element . multi-media coalescing element with pleated initial stage for reduced velocity. A combination minimum. The panel-mounted pressure gauges show the pressure in the oil separation tank and line pressure. The oil separation tank is ASME rated for 200 psi (1379 kPa) maximum working pressure. differential pressure gauges showing the pressure drop across the oil filter and the separator element are supplied as an assist to proper maintenance of these elements. or scavenger tube. open and lock electrical disconnect. Normal discharge temperature should be approximately 180-220° F (82-105° C)._____________________________________SULLIVAN-PALATEK 3. WARNING: Do not remove caps. It prevents reverse flow of compressed air from the auxiliary air receiver and/or the plant air system back through the compressor at shutdown or during periods of unloaded operation. A C.6 COMPRESSOR DISCHARGE SYSTEM The compressor unit discharges a mixture of compressed air and lubricoolant directly into the oil separation tank where it accomplishes the following three functions: A) Primary Separation . Separated oil is returned to the compressor oil system via a small diameter return line. or on the “wet” side of the separator) is set to open if a control malfunction would allow the pressure to exceed 150 psig (1035 kPa). since the opening of this valve is noisy and results in hot oil being expelled.pressure/check valve in the separator cover assures a minimum pressure of 60 psig (415 kPa) for proper lubricoolant circulation and separation.T. however.).) However. Additionally. switch is provided to shut the motor off if the compressor discharge temperature exceeds 240° F (115° C) in the event of gradual reduction in cooling system efficiency coupled with unattended operation. Shut compressor off. FULL VOLTAGE STARTER 15 .SULLIVAN-PALATEK_____________________________________ WIRING DIAGRAM . initiating a 10-minute timer. the over-pressure shutdown switch and the anti-restart pressure switch. Overloads must be selected and set to match the motor voltage/full load amp rating for each voltage application. another reading line pressure._____________________________________SULLIVAN-PALATEK 3. This mode is generally used only if one wants to minimize motor starts. It is recommended that the separator is changed when 5psid is reached. to match air demand. The starter contactor is amp-rated to match the motor power. That is 230 volts for the 30 hp machine and 460 volts for the 40 and 50 hp machines.) The over-pressure shutdown switch acts to stop the compressor in the event of control malfunction or improper adjustment in order to prevent the pressure relief valve on the oil separation tank from suddenly opening. (This control mode saves power during periods of little or no air usage. The “Auto-Start” position allows the compressor to shut down automatically whenever the auxiliary air receiver or plant air system pressure reaches the top (“Cut-out”) setting of the control air pressure switch. The primary (high voltage) incoming power and the secondary (control voltage) circuits are both provided with breakers to minimize the potential for damage due to overloading or short-circuit faults. where the motor runs continuously while the compressor loads and unloads. the Run-On-Off-Reset. The compressor is prevented from starting under pressure by the anti-restart switch is in its normally closed mode. Auto Start selector switch. and the oil filter is changed when 15psid is reached. and a timer is utilized to limit motor starts.8 INSTRUMENTATION Each SULLIVAN-PALATEK Plant Air Compressor is equipped with two pressure gauges: one to monitor the sump tank pressure. The “Off-Reset” position is used to shut the compressor off and to reset the electrical control system following an automatic shutdown due to an over-temperature or over-pressure condition. a control relay. There is a temperature gauge which senses compressor discharge temperature. The selector switch allows the operator to select “Run” for continuous operation mode. In addition. provided that the oil separation tank pressure has been relieved via the blowdown valve. as required. This is also the location of: the control power transformer. which then releases the motor starter pull-in coil stopping the motor. 16 .7 STARTER AND ELECTRICAL PARTS The three-phase electric motor starter supplied with the SULLIVAN-PALATEK Plant Air Compressor has a NEMA-1 rated enclosure. This relays a signal to the control relay. The motor will restart as soon as the plant air pressure drops to the “cut-in” setting on the pressure switch. 3. The compressor hour meter is located in the electrical box or on its door. there are two differential pressure gauges sensing the pressure drop across the oil filter and the separator element. The control power transformer converts power from one phase of the incoming motor power to a lower voltage for activation of control features. the control pressure switch. ) Observing pressure build up on sump gauge. etc. short circuit protection. Duct the hot air outside if necessary to prevent excessively high ambient temperatures. It is recommended that the machine be mounted on isolation pads and secured to prevent movement.INSTALLATION 4. Consult the factory for assistance if heat recovery is desired. The compressor should be in a clean.392 50DG 5300 137. 4. This saves piping and reduces power requirements necessary to transmit compressed air long distances.providing that no additional restriction is imposed upon the compressor cooling fan. It is possible to utilize this heat for space heating.4 SUPPORT The compressor may be mounted on any level surface capable of supporting its weight. 4. Below is a listing of heat loads and fan air volumes that must be accommodated to keep machines operating normally.2 WELDING Do not weld on compressor package. Check all electrical connections for tightness! Check incoming voltage to be sure the motor is properly connected to match the starter and the overloads are properly set. If rotation is incorrect switch any two of the incoming lines after opening disconnect. State and Local codes concerning isolation switches. It is important that there be sufficient unobstructed ventilation airflow to prevent re-circulation of hot air. 4. . 17 .3 LOCATION The compressor is designed for indoor operation or protected outdoor site with an ambient temperature range of 35 to 104° F (1 to 40° C). product drying. MODEL AIR FLOW (CFM) HEAT REJECTION BTU/HR 30DG 4600 81. or if other ambient temperatures are present..408 40DG 5000 109. 4.” Check for compressor proper rotation by: a. When power wiring has been installed. engage disconnect and “bump” compressor by turning to “Run” and then back to “Off. etc.376 Locate compressor as close as practical to where the compressed air is to be utilized.SULLIVAN-PALATEK_____________________________________ SECTION 4 .1 RECEIVING Carefully inspect for any signs of possible shipping damage.) Observing coupling rotation. combustion air pre-heating.5 ELECTRICAL CONNECTIONS Electrical wiring to the motor starter must be done by a qualified electrician in accordance with all pertinent Federal. Once re-energized the compressor should be ready to turn on. dry and well-lighted area with ample space for maintenance and servicing. grounding. b. 4. 4.) Keep the piping as short and as straight as possible. (3” diameter.9 ADDITIONAL HELP By supplying the cleanest._____________________________________SULLIVAN-PALATEK 4. or preferably. Piping should be as large as possible to provide extra air storage capacity and minimize transmission losses. away from the motor.e.6 MAINTENANCE INDICATION-DIFFERENTIAL INDICATION The compressor package has differential pressure gauges for change out indication for the separator element and fluid filter. coalescers. all piping installed. the top of the pipe.reconnect the three motor leads by momentarily moving the selector switch to the “Run” position and then back to the “Off/Reset” position to check for correct compressor rotation.7 DIRECTION OF ROTATION Once the control circuit has been checked. or once per year. maintenance and power consumption will be minimized. Fan air ducted outside will reduce the machine noise somewhat. 4. to accommodate long runs and several bends. but care must be taken not to impose additional restriction to the fan airflow. whichever comes first. sloping to drain points. Fluid filter: 20 PSID. the fan air should blow out. Intake duct must be the same size as filter inlet. See Section 1. or larger. Support the piping to insure that no pipe stress is transmitted to any compressor component. For multiple machine installation. Rotation should be clockwise when viewed from the motor (i. Use a flexible connector at the filter inlet. The heavy-duty air filter is locally mounted with provision for remote connection. Air dryers and filters may be required. With proper attention to the ducting. this fan air can also be utilized for heating purposes. 18 . coolest air available to the compressor inlet. Change differentials are indicated as follows: Separator element: 10 PSID.8 COMPRESSED AIR PIPING Connect the compressor to the plant air system with a flexible connector rated for at least 200 psi (1400 kPa) and 275° F (135° C). regulators and/or lubricators are often required.) Inspect piping and air hoses frequently for leaks. Point-of-use filters. Support intake ducting properly to prevent its weight being transmitted to the compressor air filter. looking in at compressor shaft) Note: In all cases. contact the factory for special sequencing controls that can reduce power cost during part-load operation. and the compressor lubricant level has been checked . Piping should be in a “closed loop” configuration. with service air outlets taken from the side. (Note: never use plastic air piping or plastic bowls on filters or lubricators. SULLIVAN-PALATEK_____________________________________ SECTION 5 . Inspect for any visible signs of damage that could have occurred during installation. 11. 10. open main disconnect and then exchange any two of the three incoming leads L1.4 SHUTDOWN To stop compressor. 6.2 1. allow machine to pump up to normal operating pressures and observe operation of automatic controls. 8. 5. If unloaded pressure is incorrect.TROUBLE SHOOTING. be sure to relieve all oil separation tank pressure prior to removing fill cap.3 1. rotation should be as indicated on page 18. re-adjust pressure switch settings as required. refer to Section 6. move selector switch to “Off-Reset” position. 5. check operation throughout a range of pressures and observe operating temperatures. Jog motor (move selector switch to the “Run” position momentarily. INITIAL START Open main disconnect to be sure there is no power to the compressor. Close main disconnect. If it is necessary to add lubricoolant. If motor does not stop. or after any change or reconnection of the main electrical wiring. 2. If unloading pressure is incorrect. 7. close the main disconnect and start the compressor in either the “Run” or “Auto Start/Stop mode. Check lubricoolant level. Reclose disconnect switch. Fully open service air valve. Open service air valve. giving special attention to the SECTION 1 . then repair as necessary. 6. then immediately back to “Off/Reset”) to check direction of rotation . NORMAL OPERATION Open and lock out main power disconnect. CAUTION: Reverse rotation will cause damage that is not covered by warranty. If temperature is incorrect.looking at the fan from the tank end.1 INTRODUCTION Read this entire Operator’s Manual to familiarize yourself with the SULLIVAN-PALATEK Plant Air Compressor. open disconnect switch. L2 or L3. If rotation is wrong. Tighten oil-fill cap. Refill if necessary. 3. Check lubricoolant level. 5. 19 . 5. 5. 3. With service air valve closed.INSTALLATION to be certain all instructions have been complied with. 4.SAFETY. Observe pressures and temperature. and check for any possible leaks. Turn selector switch to “Off-Reset” and check lubricoolant level after it has been allowed to settle for a few minutes. 9. After closing the starter cover door.OPERATION 5. Rotation must be checked whenever the compressor has been moved to a new location. 2.7 . Review all the steps covered in Section 4 . 4. re-adjust pressure switch. Start machine in either “Run” or “Auto Start/Stop” mode. _____________________________________SULLIVAN-PALATEK 5. an unsafe operating condition will result! 20 . open and lock out the main disconnect. open and lock out the main disconnect switch.e. cdt. Then close the disconnect and follow Normal Operation start-up procedure. check all fuses and move selector switch to “Off-Reset” position. If the overload has tripped the motor off.5 RESTARTS After a power failure. first open and lock out the disconnect. Following a shutdown caused by either of the protective switches (i. NOTE: Never adjust the overload higher than indicated by starter manufacturer to match motor nameplate amperage rating. then push the starter overload reset button and check to be sure it is set properly and correctly adjusted. Close disconnect switch and follow Normal Operation start-up procedure. or rop). Correct the cause of shutdown and reset electrical controls. When using Pal Extra 44: Every 10. 4. fine dust) Inspect air filter element. as well as air and oil filter element. Clean and grease MPV with a Lithium Grease ex: Lubriplate 630-2 or Mobil SHCPM. Clean or replace air filter element (P/N 00521-060 for 30 and 00521-082 for 40 & 50 HP). Clean exterior surfaces of oil cooler/aftercooler. 2. Keeping a daily log of all operating parameters is recommended. oxidizing elements. As Required 1. Inspect interior of tank. Check lubricoolant level prior to start-up. (Ex: chemical fumes. When using Pallube 32p: Every 8. Drain condensate from auxiliary receiver. Every 1. SCHEDULE First 50 hoursChange compressor lubricoolant filter.MAINTENANCE 6. Clean tank if any build-up of deposits is present. whichever occurs first Drain lubricoolant and replace with a fresh charge. 3. 3. This may have to be done sooner depending upon results of lubricoolant analysis.000 hoursChange AFX 32 and inspect tank interior. When using Palasyn 45: Every 4. Replace air/oil separator. 2. Take sample of lubricoolant and submit for analysis if operating in severe environment.000 hours 1. Replace air and oil filter.000 hours Change Pallube 32p lubricoolant and inspect tank interior. 4.000 hours or once a year.1 Daily 1. if so equipped. Rebuild inlet valve every two years. Replace air/oil separator element. Observe the instrument panel gauges. Replace air/oil separator element and the air filter element.SULLIVAN-PALATEK_____________________________________ SECTION 6 . 3. Change compressor lubricoolant filter. 2. 21 . Disconnect oil return scavenge line. Using a strap wrench. lb. Open and lock out main disconnect. NOTE: To minimize downtime. No substitutions! 13. (If rusty. 6. Tighten 2/3 to one more turn.000 hours** 1. Remove cover and separator element. designated “SAE GRADE 8. Pick up line @ MVP. which has collected on the outer surface of the element from falling into the open compressor inlet. GRADE 8 BOLTS 1/2” 125 ft. 3. For fine dust conditions. 2. Wipe dust from inside of housing with a damp cloth. Replace cover. Replace element as needed. 10. Install element by hand until gasket touches the filter head. Tighten all cover bolts progressively in a diagonal criss-cross pattern until all bolts are properly torque to 50ft lbs for 3/8” bolts and125 ft-lbs for 1/2” bolts. 8. 2. These separator cover bolts are a special high-strength alloy. NOTE: An optional safety element is available. Spread a thin film of grease on the gasket.2 OIL FILTER **Replace element if differential pressure exceeds 15 psid or every 1. Remove end cover by operating snap-catch to release cover. Snap the end cover back on once the filter element has been replaced. (Check to make sure the metal flange is grounded to the tank via the clips on the separator) 11. 7. Disconnect control air. 22 . 2. 6. clean thoroughly and paint with high temperature paint. Drain lubricoolant and clean interior of oil separation tank if element appears dirty. 12. Check for leaks after compressor is up to temperature. Disconnect main air line to aftercooler._____________________________________SULLIVAN-PALATEK 6. Open and lock out main disconnect. Install new separator element.000 hours or sooner in severe dust conditions** 1. Unbolt cover in a diagonal criss-cross pattern. Clean flange and cover surfaces.4 AIR/OIL SEPARATOR **Replace annually or if differential pressure exceeds 8 psid** 1. 6. 5. 4. 3. 7. (P/N 00520-017) 4. 6. Open and lockout main disconnect. it is recommended that a spare element be kept on hand. 5.3 AIR FILTER **Inspect every 1. Remove air filter element. 4. a smaller micron element is also available.” Only grade 8 bolts are allowed. Check model and serial number for proper element number. Reconnect all tubing. taking care to prevent dirt. 3. Relieve all internal system pressure. 5. 6.5 BOLT TORQUE SPECS TORQUE SPECIFICATIONS: GRADE 8 BOLTS 3/8” 50 ft. lb. remove spin-on oil filter element. 9. Coat surfaces of gasket lightly with lithium grease. In the ‘Run’ mode the compressor motor is never shut off. 3. follow the following steps: 1. CCW to increase the cut-in pressure.SULLIVAN-PALATEK_____________________________________ 6. Adjust the cut-in pressure by turning the lower adjusting screw. and ‘Auto’. 2. “Off/Reset”. CW to decrease the cut-in. One the CPS has been set to the desired valves.) 23 . Loosen the adjusting screw until air is being vented from regulator at a pressure about 5 psi below the set cut-out pressure of the CPS. To set the compressor controls. the modulating valve must be reset. Note that the selector switch on the electrical box has three settings. This switch should be set so that the compressor loads when the line pressure falls to the lowest pressure required to operate plant equipment. The control pressure switch (CPS) will cycle the compressor between loaded and unloaded operation.) The other means of controlling compressor out-put is by means of the modulating or regulating valve. CCW to lower). Turn in on modulating valve adjusting screw about one turn (this is to remove this control while setting the CPS). 4. The modulating valve will proportionally pinch shut the inlet valve depending upon the existing line pressure. the pressure settings should have as large a differential as practical to allow the compressor to time out and shut off (consult factory for other optional energy saving options. ‘Run’.6 PRESSURE ADJUSTMENT Two capacity control features are incorporated in the Sullivan-Palatek compressors. and unloads the compressor at some higher pressure (normally about 10 psi above load pressure. In the ‘Auto’ position the compressor will shut off after running unloaded for 15 minutes. if it is intended to operate the compressor in the ‘Auto’ mode. For maximum efficiency of operation. Adjust the cut-out pressure by turning the top adjusting screw (CW to raise the pressure. Lock adjusting screw in place. SYMPTOM B. 3. Check restriction under full load conditions. d. 24 . Unit failure. Control Circuit breaker tripped. b. Replace. check transformer voltages. 9. Machine shuts down with air demand present. 6. Low incoming voltage. 10. PROBABLE CAUSE AND REMEDY 1. check sizing and adjustment of overloads. b. O.) a. Unit locked up: a. consult your power company._____________________________________SULLIVAN-PALATEK 6. Readjust or replace. Blowdown valve should exhaust when maximum operating pressure is reached. SYMPTOM A. Defective blowdown valve. Power failure. Motor starter overload tripped. 4. High-pressure shutdown switch (ROP) is set too Low.7 TROUBLESHOOTING PROBABLE CAUSES AND REMEDY 1. Separator requires maintenance. Replace inlet valve. 5.replace unit. Should trouble persist. If trouble persists. Reset. Improperly adjusted or defective pressure switch. 2. Check pressure at which pressure switch opens. Reset breakers. Loss of control voltage. 7. 8. see start-up. Replace. Check all voltages. Excessive operating pressure. ǻP should be < 10 psi. Replace or clean valve. See section B. c. Close switch. (trips. 2. Filled with oil: Inlet valve is leaking.L. Defective control relay. Adjust or replace switch. Line fuse(s) blown. Main disconnect switch open. Machine will not start. Faulty selector switch. Should voltage check low. Replace fuse(s). Reset breaker. Consult power company. 3. Open discharge temperature switch. Low incomiung line voltage. or be imbalanced. Also check motor starter contacts for fitting. Blowdown valve open. d. Ambient temperature is too high. Readjust or replace switch. 3. b. 5. Machine will not build up full discharge pressure. Defective solenoid valve. Switch is set to trip at 235-245° F a. 2. Adjust regulator by loosening lock nut and turning screw in 1/2 to 1 turn. Clean or change element as required. Clean cooler and check for proper ventilation. 1. 3. Low lubricoolant level.SULLIVAN-PALATEK_____________________________________ TROUBLESHOOTING. CONT SYMPTOM B. Discharge temperature switch open. Clogged oil filter. Add lubricoolant. 4. Repair system air leaks. f. 4. Faulty inlet valve. 25 . c. Replace. Repair or replace. Readjust or replace if necessary. Cooling airflow restricted. Provide sufficient ventilation. PROBABLE CAUSES AND REMEDY Air demand is too great. Machine shuts down with air demand present. Defective discharge temperature switch. Cooler thermostat not functioning properly. e. Replace. PROBABLE CAUSES AND REMEDY 4. Monitor temperature gauge readings: normal operating pressure discharge temperature should be 160-220° F (100 F above ambient). Control pressure regulator out of adjustment. 2. Repair or replace. Leak in control system tubing causing loss of pressure signals. Adjust or replace. 6. 5. Check diaphragm and replace if necessary. Line pressure rises above cut-out pressure. Dirty air filter. Faulty over pressure switch. Improperly adjusted or defective pressure switch. SYMPTOM D. Replace thermostat. Add compressor capacity to satisfy demand. High pressure shutdown switch is defective. SYMPTOM C. PROBABLE CAUSE AND REMEDY 1. Defective control regulator. Change the oil filter element. SYMPTOM F._____________________________________SULLIVAN-PALATEK TROUBLESHOOTING. Replace. PROBABLE CAUSE AND REMEDY Clogged separator oil return line. Adjust or replace. 2. 4. needs service. Incorrect control settings. 2. Pressure relief valve opens repeatedly. connections and components. Defective Check Valve portion of Minimum Pressure/Check Valve. Change separator. SYMPTOM G. CONT SYMPTOM E. Control pressure switch is misadjusted or faulty. Check for line blockage. Operating pressure below 60 psig. Readjust or replace modulating valve. Adjust or replace. PROBABLE CAUSE AND REMEDY 1. Excessive lubricoolant consumption 1. Receiver pressure venting through blowdown. Clean orifice and strainer located in oil return sight glass assembly. Faulty Pressure Relief Valve. Leak in lubrication system. Repair or replace check valve. 4. Check all pipes. Separator element damaged. 3. 26 . 3. Repair minimum pressure valve. PROBABLE CAUSE AND REMEDY 1. High pressure shutdown switch is defective. SULLIVAN-PALATEK_____________________________________ PIPING & INSTALLATION DRAWING 27 . _____________________________________SULLIVAN-PALATEK PARTS LISTING 28 . All bearings and seals have been replaced. The air end is then factory tested prior to shipment.SULLIVAN-PALATEK_____________________________________ SCREW COMPRESSOR AIR-END EXCHANGE PROGRAM After the warranty period has expired a factory re-manufactured air-end can be purchased on an exchange basis. All other parts not meeting our quality standards are also replaced. 29 . A re-manufactured air-end has a warranty which is 12 months from start up date or 18 months from date of shipment in accordance with the terms set forth in the new air-end warranty found on pages 42 & 43. Control Pressure † Switch. Blowdown Valve. IN 46360 Telephone: 219-874-2497 FAX: 219-872-5043 E-mail: info@palatek. contact the factory. 2 way. 30 .1 PARTS ORDERING Parts should be ordered from the nearest full-service Distributor or Factory Authorized Compressor Center. 115 vac 30hp (40/50hp) Regulator Control Valve ½” Pressure Relief Valve – 200 psi Gasket Inlet to Stator 30/40 hp Gasket Inlet to Slator 50/60hp MPV (Repair Kit) Switch.com When ordering parts. Solid State. Check (DBL. 1. Dunes Hwy. Standard commercial hardware items such as fasteners or fittings may not be listed since it is usually more convenient and economical to obtain such items locally. If parts cannot be obtained locally. be prepared to indicate the MODEL and SERIAL NUMBER of the machine(s). 10 minutes Element Thermostat (Higher Temp) Valve._____________________________________SULLIVAN-PALATEK SECTION 7 . Sol.PARTS LISTING 7. SULLIVAN-PALATEK 3501 W.2 RECOMMENDED SPARE PARTS PART NUMBER 00521-060 / 060S 00521-082 / 082S 00521-082 / 082S 00520-017 00520-015 KB08000-022 KB08000-022 KB08000-022 40529-010 (011) 09661-002 03100-008 00633-014 00633-127 K09610-001 00438-008 09344-001 09345-004 (006) 09344-003 K09147-127SV 69500-210 09505-004 (-006) 09660-012 09662-001 09791-001 00061-005 00064-005 00066-005 00062-005 QUANTITY 2 2 2 4 4 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 2 2 DESCRIPTION 30HP Air Filter Element 40HP Air Filter Element 50HP Air Filter Element Oil Filter 30-40 hp Oil Filter 50 hp 30DG Air/Oil Separator Element 40DG Air/Oil Separator Element 50DG Air/Oil Separator Element Valve. Michigan City.) ***Palasyn 45 Lubricoolant (5 Gal) ***Pallube 32 Lubricoolant (5 Gal) ***Pal-Extra 44 Lubricoolant (5 Gal) ***Food Grade Lubricant (5 Gal) † For High Pressure Use -006. This can be obtained from the Bill of Lading or the Serial Number Plate. Pressure Anti-Restart Switch. Compressor Temperature Switch. Compressor Overpressure Seal. Shaft Assembly Timer. Pilot Valve. SULLIVAN-PALATEK_____________________________________ MOTOR. AND MOUNTING PARTS 31 . COMPRESSOR. 32 .BASE MOUNTED DESCRIPTION AIR END SHAFT SEAL KIT SLEEVE. SHAFT BASE COUPLING GUARD MOTOR SUPPORT ISOLATOR QTY 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 10144-060 00697-016 18339-001 N/A 18516-060 08516-079 08747-430 08339-021 MODEL 30DG 80108-230 MODEL 40DG 80108-279 K09147-363 00371-200 00419-200 00633-032 01246-250 09148-200 10144-060 00697-016 18339-023 N/A 18516-060 08516-079 08747-044 18739-045 10144-060 00697-017 18339-043 08182-009 18516-060 08516-079 08747-054 18339-044 MODEL 50DG 80127-231 5 5A 6 7 COUPLING COUPLING ELEMENT MOTOR 230/460 AIR END SUPPORT FOR UNITS SOLD BEFORE 5/11/07 CALL SULLIVAN-PALATEK SERVICE FOR SHAFT SEAL KIT PART NUMBER. WEAR SPACER. PLEASE HAVE AIR END S/N AND MACHINE S/N READY WHEN YOU CALL.3 ITEM 1 1A A B C D E 2 3 4 MOTOR. WEAR SLEEVE GASKET. COMPRESSOR AND MOUNTING PARTS . SHAFT SEAL RING._____________________________________SULLIVAN-PALATEK 7. RETAINING SEAL. SULLIVAN-PALATEK_____________________________________ LUBRICATION & COOLING SYSTEM 33 . Valve 50 hp Model Oil Cooler After Cooler Water Reg.875M (a) TUBE CONN._____________________________________SULLIVAN-PALATEK 7..4 ITEM 1 2 3 4 5 6 7 8 10 11 12 14 19 20 21 22 23 LUBRICATION & COOLING SYSTEM DESCRIPTION COOLING FAN OIL COOLER/ AFTERCOOLER VITON O-RING THERMOSTAT * (Higher Temp.SUMP TO THERMOSTAT TUBE CONN.THERMOSTAT TO FILTER** TUBE ELBOW: 5/8 X 1/2 (a) TUBE ELBOW: 3/4 X 3/4 (b) OIL FILTER HEAD OIL FILTER ELEMENT FAN SPACER FAN HUB FAN KEY SHROUD FAN GUARD QTY 1 1 2 1 1 2 1 2 1 1 1 1 1 1 1 1 1 MODEL 30DG 08080-117 07711-202 90659-121 09505-006 08207-055 00660-010 09610-017 80120-010 (a) 09610-018 96391-108 (a) 08415-007 00520-017 N/A 00851-002 00858-001 13400-105 03216-105 MODEL 40DG 08080-046 07711-203 90659-121 09505-006 08207-054 00660-012 09600-322 80120-012 (b) 09600-324 96390-012 (b) 08415-007 00520-017 N/A 00851-003 00858-001 03400-018 03216-005 MODEL 50DG 08080-053 07711-011 90659-121 09505-004 08207-054 00660-012 09600-329 80120-012 (b) 09600-328 96390-012 (b) 08415-016* 00520-015* N/A 00851-003 90947-126 03400-018 03216-005 N/A NOT APPLICABLE *Prior to 10/01/04 Oil Filter Head was 08415-007 Oil Filter Element was 00520-017 Lower temp stat 165 ºF 09505-004. ** After 10/1/04 the line went to tube P/N 09612-067 due to larger oil filter head. Water Cooled Machines: 30 hp Model Oil Cooler After Cooler Water Reg.: 5/8 X . -180q F) BY-PASS HOUSING O-RING TUBE . Valve #00549-001 #00549-001 #18338-008 40 hp Model Oil Cooler After Cooler Water Reg.06M (b) TUBE . 3/4 X 1. Valve #00549-003 #00549-002 #18338-012 #00549-003 #00549-005 #18338-012 34 . SULLIVAN-PALATEK_____________________________________ INTAKE AND CAPACITY CONTROL SYSTEM 35 . REG.5 X 3 (a) RUBBER HOSE: 3. VALVE REPAIR KIT CNTL.I.5 ITEM 1 2 3 4 5 6 6A 7 9 10 10A 11 12 13 14 INTAKE AND CAPACITY CONTROL SYSTEM DESCRIPTION MOUNTING BAND RUBBER HOSE: 2.5 X 3 (b) RUBBER ELBOW: 5 X 3. PRESSURE SWITCH AIR FILTER ASSEMBLY HOSE CLAMP HOSE CLAMP AIR FILTER SUPPORT ORIFICE ROP SWITCH ANTI-START SWITCH QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 MODEL 30DG 00131-060 00077-253 (a) 00521-060 09790-006 40529-010 09661-002 K09661-002 09345-006 28174-060 92320-128 92320-080 08339-034 N/A 09344-003 09344-001 MODEL 40DG 00131-082 00077-353 (b) 00521-082 09790-006 40529-011 09661-002 K09661-002 09345-006 28174-082 92320-128 92320-144 08339-026 N/A 09344-003 09344-001 MODEL 50DG 00131-082 91411-535 (c) 00521-082 09790-012 40529-011 09661-002 K09661-002 09345-006 18174-088 92320-128 92320-208 08339-024 N/A 09344-003 09344-001 1 Recommend Rebuilding Inlet Valve with K09790-007 Kit for 30DG-40G every 2 years. Recommend Rebuilding Inlet Valve with K09790-009 Kit for 50DG every 2 years._____________________________________SULLIVAN-PALATEK 7. 36 .5 (c) AIR FILTER ELEMENT INTAKE VALVE1 BLOWDOWN VALVE REGULATOR VALVE N. SULLIVAN-PALATEK_____________________________________ DISCHARGE SYSTEM 37 . I. MINIMUM PRESSURE VALVE TO AFTERCOOLER CONNECTOR SIPHON FITTING GROMMET ELBOW.6 ITEM 1* 2 3 4 5 6 7 9 10 10A 10B 10C 10D 11 12 13 14 14A 15 16 17 19 20 DISCHARGE SYSTEM DESCRIPTION 1 ¼” MINIMUM PRESSURE VALVE SEPARATOR ELEMENT SUMP TANK VENTED CAP OIL FILL / SIGHT GLASS ELBOW ¼” MALE ELBOW ¼” X ¼” OIL DRAIN VALVE ½” 200 PSI RELIEF VALVE OIL RETURN SIGHT GLASS KIT OIL RETURN ORIFICE STRAINER SIGHT GLASS ADAPTER OIL RETURN TUBE TUBE.) BOLT._____________________________________SULLIVAN-PALATEK 7. AC (N. GRD 8 PIPE DISCHARGE FLANGE GASKET for 1½ FLNG. 38 . QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 1 2 1 MODEL 30DG 09610-001 KB08000022 03448-052 07255-016 17254-016 96399-004 95784-004 03100-008 29349-064 03001-064 18577-001 09349-001 00023-001 09062-033 09616-066 96363-161 03286-003 00547-001 96390-161 ½X1¾ 19600-035 91001-008 90708-005 MODEL 40DG 09610-001 KB08000022 03448-052 07255-016 17254-016 96399-004 95784-004 03100-008 29349-064 03001-064 18577-001 09349-001 00023-001 09062-033 09600-305 96363-202 03286-003 00547-001 96390-202 ½X1¾ 19600-035 91001-008 90708-005 MODEL 50DG 09610-001 KB08000022 03448-052 07255-016 17254-016 96399-004 95784-004 03100-008 29349-064 03001-064 18577-001 09349-001 00023-001 09062-033 09600-305 96363-202 03286-003 00547-001 96390-202 ½X1¾ 19600-034 91001-008 90708-005 *Use Lithium Grease to service MPV Valve. SULLIVAN-PALATEK_____________________________________ GAUGE PANEL & ELECTRICAL PARTS 39 . OVER PRESSURE SOLENOID VALVE LIGHT.AC 120V SWITCH. BULB ONLY 00347-007 40 . PRESS GAUGE. DELTA –P OIL FILTER SWITCH 3-POSITION HOURMETER. ††NEMA 4: KB00347-005.7 ITEM 1 2 3** 3A** 4 5 6 7 8* 9 10 11 12 †† NI GAUGE PANEL & ELECTRICAL PARTS DESCRIPTION GAUGE._____________________________________SULLIVAN-PALATEK 7. CONTROL PRESSURE † PANEL 15 GAUGE INDICATOR. ‘POWER ON’ SWITCH. TEMPERATURE GAUGE. FLUID FILTER 20 PSID † Prior to 8/01/01 switch 09345-007 was used. CDT QTY 1 2 1 1 1 1 1 1 1 1 1 1 1 1 MODEL 30DG 08312-025M 09174-325 09175-001 09175-030 00701-795 00735-120 09345-006 00944-007 07103-015 09344-001 09344-003 40529-010 00347-004 00438-008 MODEL 40DG 08312-025M 09174-325 09175-001 09175-030 00701-795 00735-120 09345-006 00944-007 07103-015 09344-001 09344-003 40529-011 00347-004 00438-008 MODEL 50DG 08312-025M 09174-325 09175-001 09175-030 00701-795 00735-120 09345-006 00944-007 07103-015 09344-001 09344-003 40529-011 00347-004 00438-008 + FOR 200 VOLT – 08312-026 IS REQUIRED * OPTIONAL GAUGES: #8 AIR FILTER INDICATOR (NOT SHOWN) **INDICATE CHANGE DIFFERENTIAL FOR SEPARATOR ELEMENT 10 PSID. PRESSURE ANTI-START SWITCH. AIR FILTER SWITCH. DELTA –P SEPARATOR GAUGE. 5X7 LOGO. WARNING DECAL. WARNING DECAL. SULLIVAN-PALATEK 3. 3 POSITION SWITCH DECAL.SULLIVAN-PALATEK_____________________________________ 7. VOLTAGE 460 DECAL.5X17. SULLIVAN-PALATEK 8. INSTRUCTIONS DIAGRAM. WARNING DECAL. NAME S/N DECAL. WARNING DECAL. VOLTAGE 208 DECAL. ROTATION ARROW LOGO.5 OPERATOR MANUAL AND PARTS LIST QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 MODEL 30DG 03832-043 08377-033 08377-022 08377-001 08377-043 08377-045 08377-046 08378-048 08379-020 12288-001 08378-065 08379-101 00447-001 00447-002 OMP3060-003 MODEL 40/50DG 03832-043 08377-033 08377-022 08377-001 08377-043 08377-045 08377-046 08378-048 08379-021 12288-001 08378-065 08379-101 00447-001 00447-002 OMP3060-003 41 .8 KEY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 DECAL & IDENTIFICATION DESCRIPTION PLATE. WIRING DECAL. VOLTAGE 230 DECAL. neglect. but not longer than 90 days after shipment from Sullivan-Palatek. LOSS OF USE OF PRODUCTIVE FACILITIES OR EQUIPMENT LOST PROFITS. STATUTORY OR OF FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED. In the event of any conflict between this warranty and earlier warranty statements. subject to the following provisions: Warranty Registration: The purchaser shall complete and return the warranty registration form within 10 days of start-up to validate the warranty. EXPRESS OR IMPLIED. These are defined as an escape of air or oil that only requires tightening to stop the leak.WARRANTY 2008 Sullivan-Palatek Warranty New Industrial Compressors . misuse.15 and greater Horsepower Sullivan-Palatek warrants its new stationary industrial air compressor products to be free from defects in material and workmanship and against loss of capacity due to wear. accident._____________________________________SULLIVAN-PALATEK SECTION 8 . LOSSES. the terms of this warranty will control. whichever expires first. LOST INCOME. failure to comply with Sullivan-Palatek’s product manual or failure to install product improvements provided by Sullivan-Palatek Attachment of accessories or service parts not supplied or recommended by Sullivan-Palatek may void the warranty of the product. THIS WARRANTY IS SULLIVAN-PALATEK’S ONLY WARRANTY OF ITS STATIONARY INDUSTRIAL AIR COMRESSOR PRODUCTS AND IS IN LIEU OF ANY OTHER WARRANTIES. Compressor Shaft Seal: Warranted for 12 months (1 year) from date of start-up or 18 months from date of shipment by Sullivan-Palatek. Warranty Period: The warranty period for applicable Sullivan-Palatek products is as follows (subject to the Exclusions and Limitations noted below): x x x x x x Total Package: 12 months (1 year) from the date of start-up by authorized distributor or 18 months from date of shipment by Sullivan-Palatek. except the motor after the first year. (iii) to pay ground freight for the return of defective parts and shipment of replacement parts. SullivanPalatek has no obligation for product failures or defects resulting from overload. or to the limit of the manufacturer’s warranty. THE TOTAL RESPONSIBILITY OF SULLIVAN PALATEK FOR CLAIMS. (ii) make the product available for repair. INDIRECT. WHETHER IN CONTRACT OR TORT ARISING OUT OF OR RELATED TO ITS PRODUCTS SHALL NOT EXCEED THE PURCHASE PRICE. (v) pay the costs of investigating performance complaints that are not covered by this warranty. or installing the replacement part. Components not manufactured by Sullivan-Palatek: Sullivan-Palatek’s warranty obligation with regard to equipment and components not of its own manufacture is limited to the warranty actually extended to the company by its supplier. Exclusions and Limitations: Disassembly of the air compressor unit will void this warranty and the unit exchange policy. whichever expires first. (ii) to pay the reasonable cost of making the repair. ANY IMPLIED WARRANTIES OF MERCHANTABILITY. except to the extent expressly superseded by a later warranty. 2008 superseding previous warranty policies. Customer Responsibility: As a condition to Sullivan-Palatek’s obligations under this warranty. Sullivan-Palatek’s Obligations: Sullivan-Palatek’s exclusive obligations with respect to breach of warranty are (i) to repair or replace (at Sullivan-Palatek option and subject to return of defective parts) any defective part. or a part or assembly error and are covered for one year due to defects in workmanship. PROPERTY DAMAGE. SULLIVANPALATEK HAS NO OBLIGATION UNDER THIS WARRANTY OR OTHERWISE (REGARDLESS OF THE FORM OF ACTION) FOR SPECIAL. LIABILITIES OR DAMAGES. This warranty applies to all Sullivan-Palatek stationary industrial air compressors of 15 horsepower or greater shipped after January 1. (iii) return defective parts to Sullivan-Palatek. Compressor unit and Coupling Assembly: 24 months (2 years) from the date of start-up by authorized distributor or 30 months from date of shipment by Sullivan-Palatek. Other leaks are considered a failure of sealant or application thereof. INCLUDING WITHOUT LIMITATION. 42 . whichever expires first. Failure to submit the warranty registration will cause the warranty effective date to be the Sullivan-Palatek ship date. (i) give Sullivan-Palatek written notice of warrantable failure of the Sullivan-Palatek product within the applicable warranty period. Warranty replacement parts: Remainder of the original warranty period for the replaced part. and (vi) pay costs of air freight or other expedited delivery made at customer’s request. Oil Leaks: Oil leaks will be covered under warranty for a period of 60 days from start up. Compressor Motor: 24 months (2 years) from the date of shipment by Sullivan-Palatek. EXPENSES INCURRED IN RELIANCE ON THE PERFORMANCE OF SULLIVAN PALATEK WHETHER SUFFERED BY THE BUYER OR ANY THIRD PARTY. (iv) pay reasonable travel expenses for field repairs performed at customer’s request. customer shall. CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY CHARTER. (i) give Sullivan-Palatek written notice of warrantable failure of the Sullivan-Palatek product within the applicable warranty period. Customer Responsibility: As a condition to Sullivan-Palatek’s obligations under this warranty. (ii) make the product available for repair. ANY IMPLIED WARRANTIES OF MERCHANTABILITY. Components not manufactured by Sullivan-Palatek: Sullivan-Palatek’s warranty obligation with regard to equipment and components not of its own manufacture is limited to the warranty actually extended to the company by its supplier. Other leaks are considered a failure of sealant or application thereof. EXPRESS OR IMPLIED. Exclusions and Limitations: Disassembly of the air compressor unit will void this warranty and the unit exchange policy. whichever expires first.palatek. SullivanPalatek has no obligation for product failures or defects resulting from overload. STATUTORY OR OF FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED. subject to the following provisions: Warranty Registration/Activation: The purchaser shall complete and return the platinum warranty registration/ startup card supplied with the machine within 10 days of start-up to validate the warranty. and Coupling Assembly (halves): 60 months (5 years) from the date of start-up by authorized distributor or 62 months from date of shipment by Sullivan-Palatek. LIABILITIES OR DAMAGES. (ii) to pay the reasonable cost of making the repair.15 and greater Horsepower Sullivan-Palatek warrants its new stationary industrial air compressor products to be free from defects in material and workmanship and against loss of capacity due to wear. Warranty replacement parts: Remainder of the original warranty period for the replaced part. LOST INCOME. customer shall. the terms of this warranty will control. This warranty applies to all Sullivan-Palatek Platinum stationary industrial air compressors of 15D horsepower or greater shipped after January 1. Oil Leaks: Oil leaks will be covered under warranty for a period of 60 days from start up. PROPERTY DAMAGE. 43 . 2008 superseding previous warranty policies. LOSS OF USE OF PRODUCTIVE FACILITIES OR EQUIPMENT LOST PROFITS. Compressor Shaft Seal and Coupling Element: Warranted for 12 months (1 year) from date of start-up or 18 months from date of shipment by Sullivan-Palatek. Compressor Motor: 60 months (5 years) from the date of shipment by Sullivan-Palatek. INCLUDING WITHOUT LIMITATION. except to the extent expressly superseded by a later warranty. SULLIVANPALATEK HAS NO OBLIGATION UNDER THIS WARRANTY OR OTHERWISE (REGARDLESS OF THE FORM OF ACTION) FOR SPECIAL. x Service must be maintained as stated in the operator’s manual and properly logged. accident. CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY CHARTER. misuse. All information required on the cards must be filled out along with the customer’s signature and date in order to activate. WHETHER IN CONTRACT OR TORT ARISING OUT OF OR RELATED TO ITS PRODUCTS SHALL NOT EXCEED THE PURCHASE PRICE. These are defined as an escape of air or oil that only requires tightening to stop the leak. EXPENSES INCURRED IN RELIANCE ON THE PERFORMANCE OF SULLIVAN PALATEK WHETHER SUFFERED BY THE BUYER OR ANY THIRD PARTY.com and it is required to be updated after each service. failure to comply with Sullivan-Palatek’s product manual or failure to install product improvements provided by Sullivan-Palatek Attachment of accessories or service parts not supplied or recommended by Sullivan-Palatek may void the warranty of the product. LOSSES. A maintenance log shall be available at www. Air/Oil Cooler. Sullivan-Palatek’s Obligations: Sullivan-Palatek’s exclusive obligations with respect to breach of warranty are (i) to repair or replace (at Sullivan-Palatek option and subject to return of defective parts) any defective part.SULLIVAN-PALATEK_____________________________________ 2008 Sullivan-Palatek Platinum Warranty New Industrial Compressors . whichever expires first. or to the limit of the manufacturer’s warranty. Copies of Invoices for service work and the log are required at time of warranty request) Use genuine Sullivan Palatek parts and fluids x Warranty Period: The warranty period for applicable Sullivan-Palatek products is as follows (subject to the Exclusions and Limitations noted below): x x x x x x Total Package: 12 months (1 year) from the date of start-up by authorized distributor or 18 months from date of shipment by Sullivan-Palatek. In the event of any conflict between this warranty and earlier warranty statements. whichever expires first. Compressor Unit. THIS WARRANTY IS SULLIVAN-PALATEK’S ONLY WARRANTY OF ITS STATIONARY INDUSTRIAL AIR COMRESSOR PRODUCTS AND IS IN LIEU OF ANY OTHER WARRANTIES. (v) pay the costs of investigating performance complaints that are not covered by this warranty. (Distributor is responsible for maintaining the records and keeping the service log required. neglect. but not longer than 90 days after shipment from Sullivan-Palatek. or installing the replacement part. (iii) to pay ground freight for the return of defective parts and shipment of replacement parts. (iii) return defective parts to Sullivan-Palatek. THE TOTAL RESPONSIBILITY OF SULLIVAN PALATEK FOR CLAIMS. Sump Tank. except the motor after the first year. and (vi) pay costs of air freight or other expedited delivery made at customer’s request. or a part or assembly error and are covered for one year due to defects in workmanship. INDIRECT. (iv) pay reasonable travel expenses for field repairs performed at customer’s request. _____________________________________SULLIVAN-PALATEK 44 . SULLIVAN-PALATEK_____________________________________ 45 . _____________________________________SULLIVAN-PALATEK 46 . SULLIVAN-PALATEK_____________________________________ 47 . _____________________________________SULLIVAN-PALATEK 48 . SULLIVAN-PALATEK_____________________________________ 49 . _____________________________________SULLIVAN-PALATEK 50 . SULLIVAN-PALATEK_____________________________________ 51 . _____________________________________SULLIVAN-PALATEK 52 . PALATEK COMPRESSOR MAINTENANCE LOG S/N: LINE PRESS SERVICE DIST: FILL OUT FOR EACH SERVICE OR REPAIR. SERVICE CHANGE CHANGED PART DATE HOURS NUMBER AIR/OIL SEP OIL FILTER ELE OIL LEVEL SERVICE BY OIL RET.SULLIVAN-PALATEK_____________________________________ SULLIVAN . MORE THAN ONE LINE MAY BE USED PER EACH SERVICE OR REPAIR. THIS FORM MAY BE PHOTOCOPIED AS NEEDED. CLEAR TEMP 53 .