Sullivan-Palatek 125G User manual

OPERATING AND PARTS MANUAL
FOR
INDUSTRIAL ELECTRIC AIR COMPRESSORS
125, 150, 200 AND 250 HP-UD MODELS
WITH T1 MICRO PROCESSOR CONTROL
PALATEK, INC. dba SULLIVAN-PALATEK MICHIGAN CITY, IN 46360 ALL RIGHTS
RESERVED COPYRIGHT 2011
04/01/2011
P/N OPM125/250T1

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TABLE OF CONTENTS
SECTION 1 - SAFETY..........................................................................................4
1.1GENERAL...........................................................................................................4
1.2PRESSURE RELEASE ......................................................................................4
1.3FIRES/EXPLOSIONS.........................................................................................5
1.4MOVING PARTS................................................................................................5
1.5PHYSICAL DANGERS.......................................................................................6
1.6TOXICITY...........................................................................................................6
1.7ELECTRIC SHOCK............................................................................................6
1.8LIFTING..............................................................................................................7
1.9AUTOMATIC START AND/OR RESTART.........................................................7
1.10NOISE.................................................................................................................7
1.11HAZARD WARNING SIGNS ..............................................................................8
SECTION 2 - SPECIFICATIONS..........................................................................9
2.1DATA AND DIMENSIONS..................................................................................9
2.2LUBRICATION GUIDE.......................................................................................9
2.3APPLICATION GUIDE........................................................................................9
SECTION 3 - DESCRIPTION OF COMPONENTS.............................................10
3.1INTRODUCTION..............................................................................................10
3.2COMPRESSOR UNIT ......................................................................................10
3.3MOTOR ............................................................................................................10
3.4INTAKE/CONTROL SYSTEM ..........................................................................10
3.5COMPRESSOR LUBRICATION/COOLING SYSTEM .....................................13
3.6COMPRESSOR DISCHARGE SYSTEM..........................................................13
3.7STARTER AND ELECTRICAL PARTS............................................................15
3.8INSTRUMENTATION.......................................................................................15
SECTION 4 - INSTALLATION............................................................................16
4.1RECEIVING......................................................................................................16
4.1aWELDING.........................................................................................................16
4.2LOCATION .......................................................................................................16
4.3SUPPORT ........................................................................................................16
4.4ELECTRICAL....................................................................................................16
4.5aWIRING DIAGRAM, FULL VOLTAGE STARTER (STANDARD).....................17
4.5bWIRING DIAGRAM Y - DELTA START (OPTIONAL)......................................18
4.6DIRECTION OF ROTATION ............................................................................19
4.7COMPRESSED AIR PIPING............................................................................19
4.8ADDITIONAL HELP..........................................................................................19
SECTION 5 - OPERATION ................................................................................20
5.1INTRODUCTION..............................................................................................20
5.2INITIAL START.................................................................................................20
5.3MICRO PROCESSOR PROGRAMMING; GENERAL INSTRUCTIONS..........20
5.4NORMAL OPERATION....................................................................................21
5.5SHUTDOWN.....................................................................................................21
5.6STARTS............................................................................................................21

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SECTION 6 - MAINTENANCE ...........................................................................22
6.1MAINTENANCE SCHEDULE...........................................................................22
6.2OIL FILTER.......................................................................................................23
6.3AIR FILTER ......................................................................................................23
6.4AIR/OIL SEPARATOR......................................................................................23
6.5PRESSURE ADJUSTMENT.............................................................................24
6.6SERVICE/MAINTENANCE PROCEDURES ....................................................24
6.7TROUBLESHOOTING......................................................................................25
SCREW COMPRESSOR AIR - END EXCHANGE PROGRAM.........................29
SECTION 7 - PARTS LIST.................................................................................30
7.1PARTS ORDERING .........................................................................................30
7.2RECOMMENDED SPARE PARTS...................................................................30
7.3DRIVE AND BASE ASSEMBLY PARTS LIST..................................................32
7.4LUBRICATION AND COOLING SYSTEM - AIR COOLED ..............................34
7.5aLUBRICATION AND COOLING SYSTEM - WATER COOLED 125/150 .........36
7.5bLUBRICATION & COOLING SYSTEM W/C 200/250.......................................38
7.6INLET AND CAPACITY CONTROL SYSTEM..................................................40
7.7aDISCHARGE SYSTEM - 125/150 HP ..............................................................42
7.7bDISCHARGE SYSTEM - 200/250 HP ..............................................................44
7.8aOPEN COMPRESSOR ELECTRICAL & CONTROL PARTS ..........................46
7.8bENCLOSED COMPRESSOR CONTROL PARTS ...........................................48
7.10aAIR COOLED ENCLOSURE 125/150...........................................................50
7.10bAIR COOLED ENCLOSURE 200/250...........................................................52
7.11WATER COOLED ENCLOSURE.....................................................................54
7.12aDECAL AND IDENTIFICATION....................................................................55
7.12bDECAL AND IDENTIFICATION....................................................................56
SECTION 8 - GENERAL ARRANGEMENT DRAWINGS ..................................57
8.1PIPING & INSTALLATION DIAGRAM 125/250 HP..........................................57
8.2GENERAL ARRANGEMENT - OPEN, AIR COOLED 125/250........................58
8.3GENERAL ARRANGEMENT - OPEN, WATER COOLED 125/250.................59
8.4GENERAL ARRANGEMENT - ENCLOSED, AIR COOLED 125/150 ..............60
8.5GENERAL ARRANGEMENT - ENCLOSED, AIR COOLED 200/250 ..............61
8.6GENERAL ARRANGEMENT - ENCLOSED, WATER COOLED 125/250 .......62
SECTION 9 - WARRANTY.................................................................................63
SULLIVAN - PALATEK COMPRESSOR MAINTENANCE LOG.......................65

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SECTION 1 - SAFETY
1.1 GENERAL
SULLIVAN-PALATEK designs all its compressors so they can be operated safely
despite the fact that operating a motor driven air compressor is inherently hazardous.
Responsibility for continued safe operation rests with those who install, use and maintain
the equipment. The precautions offered in this section will minimize the inherent
hazards and reduce the likelihood of accidental damage or injuries.
The operation of air compressors should be limited to personnel who have been so
trained and specifically assigned to do so, and who have read and understand this
Operator’s Manual. Failure to follow the instructions and safety precautions in this
manual may increase the possibility of accidents or injuries.
Never start this compressor unless it is safe to do so. Do not attempt to operate the air
compressor with an unsafe condition relative to the compressor, the electrical system or
the air piping, filtering, regulating, preparation, conditioning, valving, hosing or air-using
components. Open the main disconnect switch or circuit breaker, then lock it out and
tag it to prevent anyone else from starting the compressor until the unsafe condition has
been corrected.
Operate compressors only in full compliance with all applicable Federal, State and local
codes and requirements such as OSHA, NEC, NFPA, CSA, etc.
WARNING: Do not modify this compressor without specific written approval from
the factory.
1.2 PRESSURE RELEASE
Operate manually the pressure relief valve(s) periodically to be sure there is no
blockage, obstruction, or inability to operate.
Shut machine off by use of ‘stop’ button on micro processor. Open and lock-out
disconnect switch, and vent all pressure before opening or removing any filter element,
line, tube, fitting, valve, plug, cover, connection, or any other component on the air
compressor or in the plant’s compressed air system. Remove Oil Filler Cap, (Caution:
Hot oil is present.) only when compressor has been turned off, the disconnect switch
locked open, and there is no pressure in the oil separation tank. Bleed off any residual
pressure by opening the pressure relief valve.
WARNING: compressors may re-start AUTOMATICALLY if not properly taken off
the power line!
Do not use accessories such as tools, valves, filters, hoses, piping, dryers, etc. that are
rated lower than the maximum pressure or temperature rating of this compressor. Do
not exceed the accessory component 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 (12.5 mm) inside diameter is used anywhere in the system.
This will reduce pressure in case of hose or connection failure. Install additional velocity
limiting valves, in series, whenever 75 feet (22.8m) of hose length is exceeded. These
valves must comply with pertinent OSHA requirements.

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Do not use air pressure greater than 30 PSI (207 kPa) for blow-off or cleaning purposes,
and then only with effective chip guarding and personal protective equipment as required
by OSHA.
Compressed air filters or lubricators with plastic bowls may be affected by lubricant and
should not be used. Steel bowls are recommended.
Keep personnel out of line with, and away from, the discharge opening of airlines, or
tools, or other areas of direct, or deflected, compressed air discharge.
Do not allow anyone to engage in horseplay with air hoses, as serious bodily injury or
death may result.
Do not substitute bolts with material or marking different from original equipment.
Do not over-tighten any bolt, nut, fitting, connection, or spin-off filter element.
1.3 FIRES/EXPLOSIONS
Clean up any spilled oil or oil leakage, and repair oil leaks as soon as they are
discovered.
Do not allow oil to accumulate on, in, or around acoustic noise material. Immediately
replace any oil-soaked material after cleaning enclosure surface with nonflammable
solvent.
Do not operate compressor when there is a possibility of its ingesting flammable, toxic or
explosive fumes, mists or particles.
Do not operate compressor with the temperature sensor inoperative or any of its two
Pressure Switches inoperative or incorrectly connected.
Keep conductive objects away from exposed live electrical parts, such as terminals, to
avoid sparks that may serve as a source of ignition.
Replace the air/oil separator element only with factory original equipment replacement
parts to be certain that anti-static provisions are present.
Ground the machine in accordance with National Electrical Code (NEC) requirements.
Do not use plastic pipe for compressed air.
1.4 MOVING PARTS
WARNING: Do not operate the compressor with its Fan Guard removed.
Keep clothing, hands, arms, and other parts of the body, away from the fan and drive
coupling.
Wear snug-fitting protective clothing (no neckties) and confine long hair when working
around compressor.

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1.5 PHYSICAL DANGERS
Wear OSHA approved personal protective gear including gloves, safety shoes, safety
glasses, head covering, and ear protection when working on or around the compressor.
Avoid bodily contact with hot oil, hot surfaces, sharp edges and corners.
Keep all parts of the body away from all potential points of air discharge, including
pressure relief valve ports.
Keep an adequate first-aid kit nearby. Obtain medical assistance promptly in case of
injury. Do not ignore small cuts, burns or minor eye injuries as they may lead to
infection.
Perform repairs and maintenance in well lighted conditions. Clean and dry components
prior to servicing.
1.6 TOXICITY
WARNING: Air from this compressor should not be used for breathing air, unless
you adhere to specific OSHA standards.
Operate the compressor only in open or well-ventilated areas.
Carefully analyze the compressor inlet conditions to be certain that the compressor is
ingesting no dangerous levels of contaminants.
Do not permit air from this compressor to contact foodstuff except in compliance with
FDA Standard 21 CFR 178.3570 and other applicable regulations. (Use food grade
lubricant for such applications.)
1.7 ELECTRIC SHOCK
Remove watches & rings, and keep all parts of the body, tools, or other conductive
objects away from exposed live parts of the electrical system. Maintain dry footing,
stand on insulating surface and do not contact any other portion of the compressor when
making adjustments.
Turn compressor off, open main disconnect and lock it out and tag it prior to opening the
Starter Enclosure or when testing or replacing any electrical component such as:
switches, wiring, terminals, transformer, starter, timer, coil, relay, contact, interlock, fuse,
overload heater, etc.
Be certain that the equipment is properly grounded in accordance with NEC and all other
applicable state & local codes.
Initial installation and wiring must be done by a trained and qualified electrician and be in
accordance with all Federal, State and local codes, standards, and regulations.
Improper installation or unsafe servicing could result in serious bodily injury or death.
Should a breaker trip for any reason, be sure to check for the cause that produced the
trip. Fix the root cause if possible prior to resetting and operating the compressor.
When restarting, check for maximum current being drawn by the circuit.
If a fuse should blow, for any reason, always replace it with one of the same size, type,
and ampere rating.

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1.8 LIFTING
Lift or move the compressor only with equipment of sufficient load capacity that has
been inspected and is in good condition.
Keep personnel out from under and away from the area when lifting or moving the
compressor.
Lift no higher than necessary. Carry as low as possible when moving.
Keep lifting operator in attendance whenever compressor is suspended.
Set compressor down only on level surface capable of supporting several times the
machine weight.
Do not lift entire machine by motor lifting eyes, as they are intended only for lifting the
motor.
1.9 AUTOMATIC START AND/OR RESTART
Do not assume that any air compressor is ready for maintenance, service, or trouble-
shooting if it is not running. It may be in the “Automatic-Start” mode “Sleep” mode, or
was not shut down properly prior to power having been shut off, and then when power is
re-applied the compressor may suddenly re-start, thereby creating a hazardous
condition! Also, compressor may be wired to BLT or sequencer which might call for a
start.
Close discharge air valves and shut off machine. Open main disconnect; lock it out and
tag it to prevent others from inadvertently re-closing it.
1.10 NOISE
Working near an open-air compressor, or an enclosed machine with doors and/or
access panels open or removed, can prove hazardous even during short-term exposure.
The noise may interfere with hearing verbal warnings or other sounds of impending
dangers.
WARNING: For prolonged exposure to machinery noise, hearing protection is
recommended and may be required by OSHA.

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1.11 HAZARD WARNING SIGNS
SULLIVAN-PALATEK compressors are all equipped with brightly colored, weather-
resistant, pictorial/verbal self-adhesive decals. These are designed to warn the operator
against potential hazards in order to minimize risk of property damage, bodily injury or
death. All operators must be aware of the Warning Signs and follow the instructions
thereon.
If any Warning Signs are missing, damaged or painted over, or located in such a position
as to be unreadable in a given installation, new Warning Signs must be ordered. Be
sure they are properly positioned and installed correctly.
WARNING: If any operators are not fully conversant with the English language
and/or cannot comprehend the intended pictorial warnings, it becomes incumbent
upon the owner, lesser or other responsible administrator to be sure the operator
is properly trained and also made aware of, and understands, the meaning of all
Warning Signs.
SIGN LOCATION
WARNING SIGN
HIGH VOLTAGE/MOVING PARTS MOTOR/STARTER
WARNING SIGN
COMPRESSED AIR INSTRUMENT PANEL
WARNING SIGN
HOT OIL/PRESSURIZED AIR SEPARATOR TANK

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SECTION 2 - SPECIFICATIONS
MODEL 125G 150G 200G 250G
MOTOR SIZE (HP) 125 150 200 250
AIR DELIVER (CFM) 600 715 1000 1000
MAX. FULL LOAD PRESSURE 125 125 125 150
MIN. FULL LOAD PRESSURE 70 70 70 70
LUBRICOOLANT CAP GAL. SYS/TANK 33/25 33/25 33/25 33/25
DIMENSIONS: OPEN ENCLOSED
OPEN LENGTH 96 96
WIDTH 58 58
HEIGHT 66 3/8 67
NOTE: SEE INSTALLATION DRAWINGS ON PAGES 57-61 OF THIS MANUAL
2.1 DATA AND DIMENSIONS
SULLIVAN-PALATEK reserves the right to change the design or construction of the
above compressors, or to offer them with options which will cause subject equipment to
differ from the above specifications, without reference to any descriptions in this manual.
2.2 LUBRICATION GUIDE
SULLIVAN-PALATEK recommends using Palasyn 45 synthetic lubricoolant for normal
plant-air service. For compressors running two or three shift operations, extended life
lubricants such as Pallube 32p, or Pal-Extra 44 are offered as factory fill. Also, where
incidental food contact may happen, we offer a Food Grade 32FLL.
For extreme environments (i.e. fine particulate, caustic, acidic, or oxidant atmospheres)
contact the factory for lubricant recommendations. Also, for such conditions we would
suggest oil analysis every 1000 hours.
Mixing of these or any other type of oil or synthetic fluid will void the 5-year compressor
unit warranty and could result in greatly increased maintenance and service expenses.
2.3 APPLICATION GUIDE
Ambient Temperature Range: +35° to +104° F (+1° to +40° C). The lower temperature
limit is to prevent freeze-up of condensate in the aftercooler and/or control lines. When
operating these compressors for plant air in food or beverage processing industries,
contact the factory for a Lubricoolant that is FDA approved for “incidental contact with
foodstuffs." For instrument-grade air, contact the factory for recommendations related to
specialized compressed air preparation accessories.
Whenever a SULLIVAN-PALATEK rotary screw compressor is installed in parallel with a
reciprocating type of compressor, it is imperative that the SULLIVAN-PALATEK be the
“lead” machine and the reciprocating the “lag” machine. That is, the SULLIVAN-
PALATEK should be the first to start and the last to stop when being operated in the
“automatic stop/start” mode, or the first to load and the last to unload, when in the
“continuous run” mode. It should require the least electrical power consumption for the
combination. Maximum number of starts per hour:
Motor HP 125 150 200 250
Starts/Hr 4 4 4 4

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SECTION 3 - DESCRIPTION OF COMPONENTS
3.1 INTRODUCTION
SULLIVAN-PALATEK Plant Air Compressors are electric motor driven, single-stage
rotary screw type, and continuous-duty compressor. They are designed and constructed
to offer the greatest value and lowest life cycle cost of operation. The compressor
package includes: a direct-connected electric motor-driven compressor, air
intake/capacity control system, air-cooled cooling system (including a standard air-
cooled aftercooler), discharge system, instrument panel and electrical system. They are
available base mounted, with or without enclosures. These machines are intended for
indoor installation, or protected outdoor operation in moderate climates.
3.2 COMPRESSOR UNIT
All SULLIVAN-PALATEK compressors feature direct-connected, single-stage, positive
displacement, and flood-lubricated rotary screw compressor units with heavy-duty long-
life rolling element bearings. The lubricoolant fluid is injected directly into the
compressor unit and mixes with the air as the rotors compress it. The lubricoolant
lubricates the rotors, bearings and shaft seal, 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.
3.3 MOTOR
The electric motor used to power each SULLIVAN-PALATEK UD Series 125/250
horsepower compressor is a NEMA standard three phase 60 Hertz AC induction type,
ODP motor, fitted with a C-face register at the compressor drive end to assure proper
coupling alignment at all times. The main compressor motor is connectable for 230 or
460 volts. The 125/250 horsepower machines utilize a separate TEFC fan motor.
Contact the sales representative for any other requirements, such as TEFC or premium
efficiency main drive motor. It is recommended that these compressors be equipped
with either Y-D starting or a solid state soft start to limit in-rush current, rather than an
across the line starter.
3.4 INTAKE/CONTROL SYSTEM
The intake/control system consists of: an air filter, connecting rubber elbow, a
combination compressor inlet valve/reverse-flow check valve, control signal regulator
valve, blowdown valve, and control pressure transducer. (See Intake Control
Schematic.) The air filter is a multi-stage dry-type with a high efficiency
cleanable/replaceable cellulose element. The element should be cleaned periodically,
depending upon the amount of particles in the air, and replaced annually, of if a high
delta-p fault is shown. If remote air intake is desired, consult the factory for a special
intake option.
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, or an unload control signal. During periods of very low or zero air usage the inlet
valve is held shut by an air signal from the blowdown valve. This air signal
simultaneously reduces the pressure in the oil separation tank, allowing the compressor
to run unloaded with a minimum of power consumption. Upon shutdown the intake valve
checks shut to eliminate blowback.

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Control Operation - Starting:
When the compressor start key is pressed, or starts automatically (signal from BLT or
sequencer), it will run for approximately 10 seconds unloaded. After this interval, the
pressure will rise quickly to 60 PSIG (415 KPA) which is the minimum pressure valve
opening pressure. Until the controller pressure setting is reached, the compressor inlet
valve is wide open and the compressor will deliver its full rated capacity.
Normal Full Load Mode:
From 60 to 125 psi (415 to 863 kPa) the minimum pressure valve is open and the
compressor delivers its full rated capacity to the air receiver and/or the plant air piping
system.
Modulating Mode:
Whenever less than the rated capacity of the compressor is being used, the service air
pressure will continue to rise until the control regulator gradually opens. This applies
pressure to the inlet valve piston that partially closes the inlet valve disc thus reducing
the amount of air entering the compressor air inlet until it matches the amount of air
being used. The control will function continually in this manner between the adjustable
limits in response to varying demands from the plant air service line. The control
regulator has an orifice that vents a small amount of control air whenever it is sending a
pressure signal to the intake controller capacity control. This orifice is vital to the
smoothness of the control operation.
Unloaded and/or Shutdown Modes:
When little or no air is being used, the service line pressure will rise to the “unload”
setting of the micro processor which will interrupt the voltage to the control solenoid to
open and allow air pressure to close the inlet valve. This same air pressure which is
holding the inlet valve shut is also venting the pressure in the separator tank to reduce
the power required.
If the micro processor determines that the compressor has been unloaded for 3 minutes,
then the compressor goes into a “sleep” mode which shuts off the drive motor. When air
is being used again, the compressor will re-start (provided that it has been off for a least
a minute).
Note that the micro processor is programmed to limit the number of starts per hour
(depending on motor size) for motor protection. If the compressor is starting too often,
thus causing the compressor to be off when air is required; please contact the factory for
adjustments to be made to the controls to avoid this problem (i.e. adjust regulating valve,
lengthen run-on time, etc.).

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CONTROL SCHEMATIC

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3.5 COMPRESSOR LUBRICATION/COOLING SYSTEM
The cooling system consists of a fan, fan motor, finned-tube radiator-type fluid cooler,
thermovalve to accelerate warm-up, and to control operating temperature, a full-flow
filter, a drain valve and interconnecting tubing.
Pressure in the oil separation tank utilizes air pressure over oil which causes the
lubricoolant to flow from this region of relatively high pressure through the system to an
area of lower pressure at the compressor unit. Fluid flows from the oil separation tank to
the cooler; from the cooler to the filter, and from the filter to the compressor. During cold
starts, the thermovalve is open allowing the fluid to by-pass the oil cooler and go directly
to the filter. While warming up, a gradual change occurs where the fluid flow is split -
partial flows being shared by both the oil cooler and thermovalve. When fully warmed
up, the thermostat closes to maintain proper operating temperature.
The fluid filter is of the spin-on replacement element type. The element should be
changed in accordance with the Maintenance Schedule.
3.6 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 - by change of direction and reduction of velocity, which allows
the heavier droplets of lubricoolant to fall.
B) Serves as the lubricoolant sump - by collecting the hot lubricoolant prior to re-
circulation through the cooling system.
C) Houses the final oil separation element: a replaceable, multi-layered, multi-media
coalescing element with pleated initial stage for reduced velocity, improved
separation performance and extended service life. Separated oil is returned to the
compressor oil system via a small diameter return line, or scavenger tube.

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A sight gauge is provided to monitor the lubricoolant level in the oil separation tank, and
a capped oil fill port is provided to keep the oil the proper level and to refill the system
after changing the lubricoolant.
WARNING: Do not remove caps, plugs or other components or connections while
the compressor is running or pressurized. Shut the compressor off, open and
lock out the electrical disconnect switch, and relieve all sump pressure before
doing so.
The oil separation tank is ASME rated for 200 psig (1380 kPa) maximum working
pressure. A combination minimum-pressure/check valve in the separator cover assures
a minimum pressure of 60 psig (415 kPa) for proper lubricoolant circulation and
separation. At the same time it prevents a reverse flow of compressed air from an
auxiliary air receiver and/or the plant air-main back through the compressor at shutdown
or during periods of unloaded operation.
A pressure relief valve (located upstream, or on the “wet” side of the separator) is set to
open if a control malfunction would allow the pressure to exceed 200 psig (1380 kPa).
However, since the opening of this valve is noisy and results in hot oil being expelled,
the micro processor control has been set to shut the motor off @ 10 psi above the
control.
The panel-mounted micro processor shows the pressure at the discharge of the MPV.
(I.e. line pressure). Additionally, differential pressure switches which trip if the pressure
drop across the oil filter and the separator element are too high, and will indicate such by
a fault signal.
The compressor discharge temperature is also displayed on the micro processor screen.
Normal discharge temperature should be approximately 180-220° F (82-105° C), or
about 100° F (38° C) above ambient.
The micro processor is programmed to shut off the compressor should the discharge
temperature exceed 240° F. Should this occur, check for adequate lubricant, cooling fan
operation, dirty cooler, or varnish in oil & cooler.
DISCHARGE SYSTEM SCHEMATIC

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3.7 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 is also the location of: the control
power transformer, the control pressure transducer, the over-pressure shutdown switch
ROP, the anti-restart pressure switch ASP, fan motor disconnect fuses, and fan
overload.
The starter contactor is amp-rated to match the motor power at the customer’s voltage.
An overload relay is selected and set to match the motor voltage full load amp rating.
The sump-pressure sensor shutdown switch acts to stop the compressor in the event of
control malfunction or improper control adjustment, to prevent the pressure relief valve
on the oil separation tank from suddenly opening.
The control power transformer converts power from one phase of the incoming line
power to a 120v control voltage. This is to minimize the potential for arcing at the
contact points of switches, or relays. 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. In addition a 24 volt
output transformer is needed to supply the proper operating voltage for the micro
processor control.
3.8 INSTRUMENTATION
This SULLIVAN-PALATEK Plant Air
Compressor is equipped with a micro
processor control. This control
normally displays line pressure and
compressor discharge temperature. In
addition, the micro processor will
indicate faults due to motor overloads,
high differential pressures on; oil filter,
air/oil separator, and inlet filter. In
addition, the micro processor will
display a code signal for exceeding the
following maintenance service intervals;
oil filter change, oil change, air filter
change & air/oil separator change.
When this service is performed, the
appropriate service timer (meno PO4)
must be re-set using service access
code 0100.
MICRO PROCESSOR WITH REDUNDANT
GAUGES AND AIR FILTER INDICATOR
OPTIONS
(
ENCLOSED
)

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SECTION 4 - INSTALLATION
4.1 RECEIVING
Carefully inspect for any signs of possible shipping damage
4.1a WELDING
WARNING: Do not weld on compressor package.
4.2 LOCATION
The standard compressor is designed for indoor operation or protected outdoor site with
an ambient temperature range of 35° to 104° F (2° to 40° C). It is important that there be
sufficient unobstructed ventilating airflow to prevent re-circulation of hot air. The
compressor should be in a clean, dry, lighted area with ample space for maintenance
and servicing. Duct the hot air outside if necessary to prevent excessively high ambient
temperatures. Below is a listing of heat loads and fan air volumes that must be
accommodated to keep machines operating normally. It is possible to utilize this heat for
space heating, combustion air pre-heating, product drying, etc., --providing that no
additional restriction is imposed upon the compressor cooling fan. Consult the factory
for assistance if heat recovery is desired.
Model 125G 150G 200G 250G
AIRFLOW (CFM) 12,500 15,000 18,500 20,000
HEAT REJECTION (BTU/HR) 330,000 418,500 550,000 600,000
Locate compressor as close as practical to where the compressed air is to be utilized.
This saves piping and reduces power requirements necessary to transmit compressed
air long distances. The compressor should be piped into a receiver tank prior to any
filters or dryer. It is recommended that a moisture separator be placed between
compressor and receiver tank.
4.3 SUPPORT
The compressor may be mounted on any level surface capable of supporting its weight.
It is recommended that the machine be mounted on isolation pads and secured to
prevent movement.
4.4 ELECTRICAL
A trained qualified electrician must do electrical wiring to the motor starter with all
pertinent Federal, State and local codes concerning isolation switches, short circuit
protection, grounding, etc.
Check all electrical connections for tightness.
Check incoming voltage to be sure the motor is properly connected to match, and the
starter is properly sized and the overload relay is properly adjusted to match the motor
nameplate full load amps.

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4.5a WIRING DIAGRAM, FULL VOLTAGE STARTER (STANDARD)

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4.5b WIRING DIAGRAM Y - DELTA START (OPTIONAL)

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4.6 DIRECTION OF ROTATION
Once the control circuit has been checked, all piping installed, and compressor is filled
with lubricoolant, push the ‘run’ key (green) followed by the ‘stop’ button (red) and
observe the direction of rotation. If rotation direction is incorrect, there may be a fault
signal appear (ER0050). Change two power leads if rotation is incorrect.
4.7 COMPRESSED AIR PIPING
Connect the compressor to the plant air system with a flexible connector rated for at
least 200 psi (1380 kPa) and 275° F (135° C). Support the piping to insure that no pipe
stress is transmitted to any compressor component.
Compressor should be piped into a receiver tank prior to any filters or dryer. A moisture
separator may be placed between the compressor and receiver tank.
Piping should be as large as possible to minimize transmission losses. Piping should be
in a “closed loop” configuration, sloping to drain points, with service air outlets taken
from the side or, preferably, the top of the pipe. Point-of-use filters, coalescers,
regulators and/or lubricators are often required. (Note: Never use plastic air piping or
plastic bowls on filters or lubricators. See Section 1.) Inspect piping and air hoses
frequently for leaks.
4.8 ADDITIONAL HELP
By making the cleanest, coolest air available to the compressor inlet, maintenance and
power consumption will be minimized. The standard air filter is locally mounted. For a
remote inlet an optional filter must be fitted.
When connecting to a remote air inlet, use a flexible connector at the filter inlet. Keep
the piping as short and as straight as possible. Intake duct must be the same size as
filter inlet, or larger, to accommodate long runs and several bends creating no
restrictions to air flow.
Support intake ducting properly to prevent its weight being transmitted to the compressor
air filter.
For multiple machine installation, contact the factory for special sequencing controls that
can reduce power cost during part-load operation.
Fan air ducted outside will reduce the machine noise somewhat, but care must be taken
not to impose additional restriction to the fan air flow. With proper attention to the
ducting, this fan air can also be utilized for heating purposes.

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SECTION 5 - OPERATION
5.1 INTRODUCTION
Read this entire Operator’s Manual to familiarize yourself with the SULLIVAN-PALATEK
Plant Air Compressor, giving special attention to the Section 1 - SAFETY.
5.2 INITIAL START
Open main disconnect to be sure there is no power to the compressor.
Review all the steps covered in Section 4 - INSTALLATION to be certain all instructions
have been complied with.
Inspect for any visible signs of damage that could have occurred during installation.
Check lubricoolant level. Check if oil-fill cap is tight.
Close main disconnect. The micro processor display will illuminate and indicate line
pressure and discharge temperature.
Follow procedure in 4.6 to establish correct rotation.
WARNING: Reverse rotation will cause damage that is not covered by warranty.
Rotation must be checked whenever the compressor has been moved to a new
location, or after any change or reconnection of the main electrical wiring.
After closing and latching the starter cover door, close the main disconnect and start the
compressor by pushing green ‘run’ button.
With the service air valve closed, allow machine to pump up to normal operating
pressures and observe operation of automatic controls, and look for any possible leaks.
Open service air valve and check operation throughout the range of pressures,
observing operating temperatures.
Push red ‘stop’ button and check lubricoolant level after it has been allowed to settle for
a few minutes. If it is necessary to add lubricoolant, be sure to open main power
disconnect, lock it out, and be sure to relieve all oil separation tank pressure prior to
removing fill cap to top off tank.
If unloaded pressure is incorrect, readjust regulator and control pressure settings as
required.
5.3 MICRO PROCESSOR PROGRAMMING; GENERAL INSTRUCTIONS
The operational menus which normally have to be addressed are P01 (operations), P02
(fault history), and P04 (maintenance setting). Access codes which are required to
change settings are:
0009 for operational settings (P01)
0100 for faults and service (P02 & P04)
To get the access code, use the following procedure:
1. Simultaneously press the “up” (+) and “down” (-) keys.
2. Press “enter” to advance digits.
3. Use “up” (+) or “down (-) keys to select the correct numeral.
4. When the appropriate access code is shown, press “enter.”
5. After the access code has been selected, use the “up” (+) or “down” (-) keys to
change the corresponding parameter menu (i.e. P01, P02, or P04).