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Section 7 MAINTENANCE ways showing the ol amount of ajustment Maxi turn aajustnaen i 7 ‘The DSP ey ex, wiping out changestotne curent Tem. wo daong changes tary previous Tema {The PRG key saves the curen fem an advances tole nest Al temperalres an pressures may be . Cale ndiualy 5 C c 45 3 dai = 7.1 GENERAL As youproceed in eading this section, twill be easy tosee that the Maintenance Program for the air com- x pressor is quite minimal. The use of the service indi- ad alors provided for the bearing fitter, air filter and fluid separator, will alert you when Service maintenance is required, When the maintenance gauge shows red, 3 maintenance for that specific item is required. See in: = structions for each item in Section 7.8, Parts Re- placement and Adjustment procedures. = 7.2 DAILY OPERATION Prior to starting the compressor, itis necessary to check the fluid level in the sump. ‘Should the level be low, simply add the necessary amount. If the addi- tion of fluid becomes too frequent, a simple problem has developed which is causing this excessive loss. ‘See the Troubleshooting Section under Excessive Fluid Consumption for a probable cause and remedy. Alter a routine start has been made, observe the in- strument panel gauges and be sure they monitor the correct readings for their particular phase of opera- tion. After the compressor has warmed up, itis rec- ‘ommended that a general check on the overall com- pressor and instrument panel be made to assure that the compressor is running properly, DONOT remove caps, plugs, andlor other compa. nents when compressor isrunming or pressurized. ‘Stop compressor and relieve al nternal pressure betbredalng 20 7.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION After the initial 50 hours of operation, @ few maint nance requirements are needed to clean the system of any foreign materials. Perform the following main- tenance operations to prevent unnecessary prob- lems. 1. Clean the return line strainer. 2, Clean the return line orifice. 7.4 MAINTENANCE EVERY 1000 HOURS ‘After 1000 hours of operation, it will be necessary to perform the following: 4. Clean the return line strainer, 2. Replace the fluid filter element and gasket. 7.5 FLUID MAINTENANCE Drain the sump and change the compressor fluid us- ing instructions shown in sections 3.2, 3.3, and 3.4 TIAA Section 7 MAINTENANCE Fi ure 7-1 Fluid Filter (P/N 02250096783) FILTER = Rlpair PIN 250025-525 7.6 FILTER MAINTENANCE Replace your fluid fiter element and the gasket un- ger any ofthe folowing concitions, whichever occurs first: 1. As indicated by the maintenance gauge. 2, Every 1000 hours. 3, Every 6 months. 7.7 SEPARATOR MAINTENANCE Replace the separator elements when your separa- tor maintenance gauges show red or after one (1) year, whichever comes first. The separator elements must be replaced, DO NOT clean the separator ele- ments. 7.8PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES FLUID FILTER ELEMENT REPLACEMENT Refer to Figure 7-1. 1. Using a strap wrench, remove the old element and asket 2, Giean gasket seating surface. 8: Aly aight fim of ful to thenew gasket 4; Hand fighten new element unit new gasket is Seated inte gasket groove. Avoid any nicks, cus or pinches to the gasket. 5. Continue tightening element by hand an additional 4/2 to 3/4 turn, 6. Restart compressor and check for leaks. “To minimize the porsoty of iter element rup- Teach import iat Sua rapier ters \enies itn Suir name, ogo Sn 37 STA eis Section 7 MAINTENANCE Figure 7-2 Ain Filter Replacement (PIN 02250107-327)- 25-3OHP/ 18-22KW (P/N 040595)- 4OHP/ SOKW use car PETANER ANG wwiscnew ea* * fplacementEloment PIN 043334 (25-30HP/18-22K) Replacement Element PIN 040586 (40HPISOKW) appropriate part number be usec {ted tlemente not be used, ‘Such ites may have nade ‘working pressure ratings. oF questionable AIR FILTER MAINTENANCE Refer to Figure 7-2. Air filter maintenance should be performed when the maintenance gauge shows red ‘with the compressor running full load, of once ayear, whichever comes first. If the filter needs to be re placed, order replacement elements. Below you will find procedures en how to replace the ai fiterele- ments. AIR FILTER ELEMENT REPLACEMENT 41, Clean exterior of air filter housing 2, Release tension on cover retaining ring 3, Remove the rubber baffle from the inside dust cup ‘and emply the dirt from the dust cap. 4. Remove air filter element by loosening the wingnut securing the element. 5. Remove element and clean interior of housing us- ing a damp clotn, DO NOT bow dit out wih com- pressed air 6. Al this time replace the element. 7, Reassemble in the reverse order ofthe cisasiem- iy. 38 8. Reset the air fiter restriction indicator i equipped (electro-mechanical medels only). ELEMENT INSPECTION 1, Place abright light inside the elemento inspect for damage Or leak holes. Concentrated light will shine through the element and disclose any holes. 2. Inspect all gaskets and gasket contact surfaces of the housing. Should faulty gaskets be evident, correct the condition immediately. 3. ifthe clean element is to be stored for later use, it ‘must be stored in a clean container. 4, Alter the element has been installed, inspect and tighten all air inlet connections prior to resuming operation. SEPARATOR ELEMENT REPLACEMENT Referto Figure 7-3. The separator elements must be changed when the maintenance gauge shows red with the compressor running fullload, or once a year, whichever occurs first, Follow the procedure ex: plained below for separator element replacement. 1, Relieve all pressure from the sump tank and all ‘compressor lines. Figure 7-3 Separator Element Replacement (PIN 250034-113) LOCK WASHER —— COVER SEPARATOR ELEMENT* RECEIVER/SUMP TANK + Replacement Kt oc Presary Element P/N 250034-114 Wi di MW TTT a TW de: Tw WM 5 a | 2 Disconnectall piping connected tothe sump cover to allow removal (return lines, service lines, etc) 3. Loosen and remove the eight (8) hex head cap: crews (1/2-13 x 1 1/2") from the cover plate. 4. Lift the cover plate frorn the sump. 5, Flemove the separator element. 6. Inspect the receiver/sump tank for rust, dit, ete. 7, Scrape the old gasket material from the cover and flange on the sump. Be careful not to let the seraps fallin the sump. 8, Reinsert the separator element into the sump tak- ing care not fo dent the element against the tank gpening. 9. Clean the underside of the recelver/sump tank over and remove any rust. 10, Replace the cover plate, washers and capscrews, Torque to 55 ft-lbs. (78 Nm). 11. Reconnect all piping making sure return line tubes. extend to the bottom or 1/4” (6mm) above the bot- tom of the separator element. This will assure pe id return flow to the compresscr. 12, Clean the return line strainers belore restarting the compressor. CONTROL SYSTEM ADJUSTMENT Refer to Figure 7-4. Prior to adjusting the Control System, itis necessary to determine the desired op- erating pressure range and also the maximum pres- ‘sure at which your Compressor is to operate. The Pressure must not exceed the maximum operating Figure 7-4 Pressure Switch PIN 040694- Standard PIN 407778- High Pressure ‘ADUUSTMENT SCREW Section 7 MAINTENANCE pressure which is stamped on the compressor serial umber namepiate. The following explanation ap- plies to a typical installation with a desired operating fange of 115to 125 psig (7.9t08.6bar). Thisinforma- tion will apply to a compressor with any other operat- ing range excepting the stated pressures. Remove the cover of the pressure switch. With the shut-off valve closed (or sightiy cracked open) start ihe compressor. Observe the line pressure gauge and pressure switch contacts. When ihe line pres- sure reaches 125 psig (.6 bat), the pressure switch contacts should open. If the pressure switch con- tacts do not open or they open prior to the desired pressure, the pressure switch setting wil require ad- Justment (refer to Figure 7-4) FOR PRESSURE RANGE ADJUSTMENT. 1, Remove cover to pressure switch. 2. Turn the range adjusting screw to the high pres- sure setting. Turning the screw counterclockwise lowers both the high and low pressure equally. FOR DIFFERENTIAL ADJUSTMENT: Diferental is tne citference between the high and fow pressure softings. 40 psig (07 bay) s ype 1. Turn the ferential agjusting serew to the ower (reset) seting. Turning the Screw counterciock- tnise widens the alferential by lowering tne reset (lower) setting only. 2. Whanthe pressure switch adjustmentis complet, the pressure regulator shouls be adjusted forthe pressure at which modulation of ar celvery Should begin. In this case that pressure wil be 118 psig (2 bar). The regulator asjusted by IGosening the jam nt on tne end of the cone Shaped cover othe pressure regulator When the Jamnut is loose, tun the adjusting screw clock: wise to increase or counterclockwise to decrease the seting. 3. To set the regulator, continue closing the service Valve unt the line pressure 6 118 psig (@ 2 bar. Aithis pot regulator should pass a signal othe init vaive to start closing ht Ithe line pressure eeps on rising ore adulation Goss not be- Gin, acjust tie reguletor vaive "es described Shove, After agjustnent tne pressure should Be approximately 118 psig (8.2 bar) and 1.00 in. Hg (288 cm Hg3 vacuum below the iiet, 4, Newt, close the service valve; line pressure wil Startsing, Wren ine pressure reaches 129 pig {GrS ar the init valve willbe Gosed to te max tnum position, The nit vacuum at his point wil Do argund 85 in. Hg (63.5.cm hg). The machine Should unioad at ths point. 5. Open the service vaive s0 the tine pressure is 115 Bag (9 ba). Machine 1s now set or operation jecheck the unload pressure by closing of the Service valve. Machine should ‘united wa the pressure switch at 125 psig (6 ba) After the control pressures have been adjusted, the “unloaded” sump pressure should be checked, It will 38 A EEE Whi dae Ta Pa ES Va Wa Wi Ma F Section 7 MAINTENANCE be necessary to shut the compressor down, remove the pressure switch cover, and disconnect one of the two lead wires that are ‘connected to the micro- switch (contact block). After disconnecting the lead, tape the exposed wire with electrician’s tape to make ssure that it does not come in contact with any metalic surface, 'DO NOT touch th tical contacts, terminal of feads with any metalie object. Severe eletrcal Shock may eceur With the lead taped, you may start the compressor again, Allow the sump pressure to stabilize. The sump pressure should read 30 to 85 psig (2.1 10 2.8 bar). ‘Once this is checked, shut the compressor down ‘once again and reconnect the taped lead and replace the pressure switch cover. Atthis time, start the com- pressor and cycle the Control System several times, and re-check all pressure settings and adjustments. PRESSURE REGULATOR ADJUSTMENT Start the compressor and adjust the service valve to maintain service ar pressure at rated pressure (115 psig for example). Turn the adjusting screw on the ‘egulator until ar just begins to escape from the con- {rol air orifice. The regulator is now property set, DRIVE COUPLING INSTALLATION AND MAIN- TENANCE Refer to Table 1 and Figure 7-5. For coupling instal- lation and maintenance the tovis required will be a measuring scale, one set of standard Allen ‘wrenches, and one set of standard socket wrenches, For installation and maintenance of the drive cou: pling, follow the steps explained below. EE Disconnect ll power at source, befor Maintenance or aclusiments STEP 1 - COUPLING GUARDS There are three 5/16" sorews from each of the wire guards located on each side of the unit/motor adap- {or for the 25/30 HP (18/22 KW) packages, orthe two 3/8" boll/nut/washer assemblies from the plate guard and adaptor located on the top side, 40 ‘TABLE 5 INSTALLATION DATA SERIES 10 (25-404 12-50KV) Couring _—_Couping Horsepower Element Hub Gap PeRSOuP! _o8seTe ia 2k £0, 75, 100, 250008659 0 Tons (65,85, 75 KM, 2aaznm (140M) Figure 7-5 Drive Coupling "Hub" Gap Check GAP ie STEP 2- MOUNTING HUBS/ELEMENT ‘The coupling halves have a unique bore for the motor and the air-end. The air-end half is to be located so that the hub is positioned against the shaft shoulder and secured in place by twa set-screws. The motor hal should remain free floating until the element isin its proper location. The motor half is then positioned within assembly maintaining an axial coupling gap as listed in Figure 7-5. There are two set-screws lo- ated on the motor coupiing haif also. Prior to start- ing of package, assure the set-screws are secure to eliminate potential movement of the hub. 7.8 TROUBLESHOOTING- STANDARD ELECTRO- MECHANICAL ‘The information contained in the Standard Electro Mechanical Troubleshooting chart has been com- piled from field report data and factory experience. It contains symptoms and usual causes for the de- scribed problems. However, DO NOT assume that these are the only problems that may occur. Allavail- able data concerning a problem should be systemati- cally analyzed before undertaking any repairs or component replacement procedures, A detailed visual inspection is worth performing for almost all problems and may avoid unnecessary additional damage to the compressor. Always re~ member to: 4. Check for loose wiring 2. Check for damaged piping, mT | = Section 7 = MAINTENANCE = 5. Check fr paris damaged by heat ora lesiel_ Shou your problem persist termaking tne recom Shor'creut, uevaly apparent by sscolration ot mended check, consul your nearest Sula repre- - burt odo Somatve, — ‘TROUBLESHOOTING~ STANDARD ELECTRO-MECHANICAL = Surrow PROBABLE CAUSE aEneov TOWPRESGORWILLNOTSTART Wan Dsconnest wich Open - tine ese Bown Fepace use Vem om) rom fn nso Contre Transtermer Fuse Biown Replace use Motor Stan Overloads Tipped eset. Shou Youble persist, check tether motor starter Contacts are {unetoning propery Low incoming Line Vatage Check voage, Should votage check low, consut power company COMPRESSOR SHUTS DOWN WITH Loss of Contel Vatage eset irauble poriss, chock hat ine Ki DEMAND PRESENT Prsbeure does not exceed maximum oper Sng result compressor Gest Sonsah power company, ces OpeaingPasaca bet ing or hs nck ene lea tng em ee Sunt nna aioe check Segui mains mince. = Mghpeeve stom ete ci seagate Reeders Dalia recon ane evar Slr ontaenvee: ners Severe fetes Beene oe cere ee “ cura Tengen Steno Coane gprs i Sa ee ey cssos toy snecre et oer Soars erento es Coo pang er ua oo Seer pageg can ues, upaona acer Ciga toe en eman conan Seog oer serena sts pve ‘sufficient ventilation, poh es ce a Spans an cen omer varet Copa eg trae atest ES ee creattcon aon Duar Mate to epi i tegen See er Ss at es Ma Wy My Section 7 MAINTENANCE TROUBLESHOOTING- STANDARD ELECTRO-MECHANICAL (CONTINUED) ‘SYMPTOM PROBABLE CAUSE REMEDY ‘COMPRESSOR Witt NOT BUILD ‘Air Damani Too Great FOLLOISCHARGE PRESSURE. ity Air Fitor Pressure Reguator Out of Acusiment Detective Pressure Ragustor LINE PRESSURE RISES ABOVE Leak in Gonval System Causing CUT-OUT PRESSURE SETTING Loss of Pressure Signals GN PRESSURE SWiTCH Detective Pressure Switch Detective Regulater Vatve lugged Contr Line Strainer Detective Blowconn Valve igh Pressure Stutdown Switch is DBatectve or Incowrecty Adjusted EXCESSIVE COMPRESSOR FLUID Clogged etum Line or Ones CONSUMPTION Seperator Element Damaged or Not Functoning Property Leak inthe Lubicaton System Excess Fis Fosring (Check servve ines fr leaks or open valves up Check the fer ingzator and inspect andlor henge element treqred ‘Ajuet regulator according to conte: austen insacions inthe Maiienance ‘ection ‘Check aaphragm and replace necessary (iitavalabie) aie, Check tat phragm and contacts ave act Samages, Aeplace fnecessary. (Check that air beads tram cont! once ‘when the pressure swich contacts oper Besant Rep oresiae ti neceasny tt aves (Clean strainer (sero and o-ring replacement kt evalable heck that sump pressures exhausted to ‘he atmosphere wien to pressure sich pen Repal or place races vale) Resaiust oc replace, ‘Gan strane (sereen and o-ang replace rent kt avaiable Grean ortee, ‘Change separator ‘Check a pipes, connections ana compo- ems Drain and change. Fie Level Teo High Drain and change. PRESSURE RELIEF VALVE OPEN Defecve Pressure Rell Valve Repace _ REPEATEDLY Plugged Separator Check seperator diteront UQUIDWATER IN COMPRESSED Water Vapor Condensation rom Gooing RUNES land Compression Octvee Nefraly 7.10 TROUBLESHOOTING- SUPERVISOR Il Remave the walor vapor fam compressed ab prior {p diavibuson trough the sr system. Check caera- fon of stercecler and moisture soparion nei @ Compressed Sr door sled torte tow and ares level requires: (Note Flters may also be requved to ‘emove paricuste,iquid ol seroscls oor Si vapor removal: Change cartdges as recorvvended by he {iter mandacture), Crock alldran bape routrly {o insure ther proper operation. Malta ther regu tory. contains symptoms and usual causes for the de- ‘The information contained in the Supervisor Il Trou- bleshooting chart is based upon both the actual ap- scribed problems, However, DO NOT assume that these are the only problems that may occur. All avail plied situations and extensive testing at the factory. It _able data concerning a problem should be systemati 42 me WW We cally analyzed before undertaking any repair or com= ponent replacement procedures. AA detailed visual inspection is worth performing for almost any problems which may prevent unneces- ‘sary damage to the compressor. Always remember to: fa, Check for loose wiring, ‘TROUBLESHOOTING - SUPERVISOR II Section 7 MAINTENANCE ’b, Check for damaged piping ©. Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor, ‘Should your problem persist after making the recom- mended check, consult your nearest Sullair repre sentative or the Sullair Corporation factory. SyuPTOM (CISPLAY) T+ Hi Message Hat PriMessage PROBABLE CAUSE Discharge Temperature Exceeded Bas GSr°Oj or Pe-Arm Dachage Temperate Exceudes 25S (hs"C) or Shtaown ‘Ambient Temperature Exceeded Torrens) Frid Levalin Sump Too Low Thecal Valve Maunconed Ceakr Fins are Diy (Acoli) Water Flows Low (Watr-coted Bastagesonyy” Water Temperate is High (ate Sete Beager oa Coolers Pugge (Water-Cooles Peotagee ong) ‘Temperature RTO Maitnetion Discharge Pressure Excoused Shutdown Level Beco Pt MAX-3psi (0.2 Bar Exceeded for Brecalarm 1 MAX Excendes for Shutdown Usloacing Device (e. Blowdown Valve) Faiod io Opersi Pressure Reguat Adjusted Inconectly ‘Solana Vale Fales to Operate, Control At Signal Leaks Control Air Signal Fiter Clogged REMEDY Improve local ventiaton (e fermote ake of process ane eeaing ai. Cheetdcorect ful level, CCheck/eplace termi valve CCesn cooler tin, Gack coving ater Supt Increase ws temparenre Clean tubes andlor shall = tube plug pert, woe caarar 5 How, lower water ‘Check connections ftom FTO. sonnet s goed, raplace RTO. ‘Check operation of unloading device. Check operation of prassure regulate. (Check operation of solencid vale, (Check tubework teeing cont Signal for lone ‘Service titer assemby. Pr. P2, Pa FAIL Patow ‘SEP MNTN Message Pressure Transducer Malfunction gare ener enon geen ed Prugges Separator AP 1 > 108.7881) ‘Check connections fom transducer Wonnections ave good, piace vansducer. Replace tte element Replenish ol evel Replace separator eloment. Cohack P1 & P2 pressure wansducers. 43 me PMT Te Tin Bo