Sullivan-Palatek 125UD User manual

OPERATING AND PARTS MANUAL
FOR
INDUSTRIAL ELECTRIC AIR COMPRESSORS
125, 150, 200 AND 250UD MODELS
WITH T1 MICRO PROCESSOR CONTROL
AND YASKAWA DRIVE
PALATEK, INC. dba SULLIVAN-PALATEK MICHIGAN CITY, IN 46360
ALL RIGHTS RESERVED
04/01/2011
P/N OPM-125250T1V-010

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iii
TABLE OF CONTENTS
SECTION 1SAFETY...............................................................................................................5
1.1GENERAL..................................................................................................................................5
1.2PRESSURE RELEASE.............................................................................................................5
1.3FIRES/EXPLOSIONS................................................................................................................6
1.4MOVING PARTS.......................................................................................................................6
1.5PHYSICAL DANGERS..............................................................................................................6
1.6TOXICITY..................................................................................................................................6
1.7ELECTRIC SHOCK...................................................................................................................7
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 ..................................................................................................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............................................................12
3.6COMPRESSOR DISCHARGE SYSTEM................................................................................13
3.7VARIABLE FREQUENCY DRIVE AND ELECTRICAL PARTS..............................................14
3.8INSTRUMENTATION..............................................................................................................14
SECTION 4INSTALLATION ................................................................................................15
4.1RECEIVING.............................................................................................................................15
4.2WELDING................................................................................................................................15
4.3LOCATION ..............................................................................................................................15
4.4SUPPORT ...............................................................................................................................15
4.5ELECTRICAL...........................................................................................................................15
4.6WIRING DIAGRAM, YASKAWA F7 UPDRAFT AIR COOLED...............................................16
4.7WIRING DIAGRAM, YASKAWA F7 UPDRAFT WATER COOLED........................................17
4.8DIRECTION OF ROTATION...................................................................................................18
4.9COMPRESSED AIR PIPING...................................................................................................18
4.10ADDITIONAL HELP.................................................................................................................18
SECTION 5OPERATION .....................................................................................................19
5.1INTRODUCTION.....................................................................................................................19
5.2INITIAL START........................................................................................................................19
5.3MICRO-PROCESSOR PROGRAMMING; GENERAL INSTRUCTIONS................................19
5.4NORMAL OPERATION...........................................................................................................20
5.5SHUTDOWN............................................................................................................................20
5.6RESTARTS..............................................................................................................................20

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SECTION 6MAINTENANCE ................................................................................................21
6.1MAINTENANCE SCHEDULE..................................................................................................21
6.2OIL FILTER..............................................................................................................................22
6.3AIR FILTER .............................................................................................................................22
6.4AIR/OIL SEPARATOR.............................................................................................................22
6.5PRESSURE ADJUSTMENT....................................................................................................23
6.6SERVICE/MAINTENANCE PROCEDURES...........................................................................23
6.7TROUBLESHOOTING ............................................................................................................24
SCREW COMPRESSOR AIR-END EXCHANGE PROGRAM...................................................28
SECTION 7PARTS LIST......................................................................................................29
7.1PARTS ORDERING................................................................................................................29
7.2RECOMMENDED SPARE PARTS .........................................................................................29
7.3DRIVE AND BASE ASSEMBLY – 125-250UD .......................................................................31
7.4LUBRICATION AND COOLING SYSTEM – AIR COOLED – 125-250UD .............................33
7.5LUBRICATION AND COOLING SYSTEM – WATER COOLED – 125-150UD......................35
7.6LUBRICATION AND COOLING SYSTEM – WATER COOLED – 200-250UD......................37
7.7INLET AND CAPACITY CONTROL SYSTEM – 125-250UD..................................................39
7.8DISCHARGE SYSTEM – 125-150UD.....................................................................................41
7.9DISCHARGE SYSTEM – 200-250UD.....................................................................................43
7.10MICROPROCESSOR CONTROL – OPEN – 125-250UD......................................................45
7.11MICROPROCESSOR CONTROL – ENCLOSED – 125-250UD ............................................47
7.12ENCLOSURE – AIR COOLED – 125-250UD .........................................................................49
7.13ENCLOSURE – AIR COOLED – 200-250UD .........................................................................51
7.14ENCLOSURE – WATER COOLED – 125-250UD ..................................................................53
7.15DECAL, T1 INSTRUCTIONS YASKAWA ...............................................................................54
SECTION 8WARRANTY......................................................................................................55
SECTION 9GENERAL ARRANGEMENT DRAWING .........................................................57
9.1PIPING AND INSTALLATION DIAGRAM – 125-150UD.........................................................57
9.2PIPING AND INSTALLATION DIAGRAM – 200-250UD.........................................................58
9.3GENERAL ARRANGEMENT – AIR COOLED – OPEN – 125-250UD...................................59
9.4GENERAL ARRANGEMENT – AIR COOLED – ENCLOSED – 125-150UD .........................60
9.5GENERAL ARRANGEMENT – AIR COOLED – ENCLOSED – 200-250UD .........................61
9.6GENERAL ARRANGEMENT – WATER COOLED – OPEN – 125-250UD............................62
9.7GENERAL ARRANGEMENT – WATER COOLED – ENCLOSED – 125-250UD ..................63
SULLIVAN - PALATEK COMPRESSOR MAINTENANCE LOG...............................................64

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5
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.
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.

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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 its Pressure Switch 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.
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.)

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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.
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, then when power is re-applied the compressor may suddenly re-start,
thereby creating a hazardous condition!
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.
WARNING SIGN LOCATION
HIGH VOLTAGE/MOVING PARTS VFD
COMPRESSED AIR INSTRUMENT PANEL
HOT OIL/PRESSURIZED AIR SEPARATOR TANK

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SECTION 2 SPECIFICATIONS
MODEL 125UD 150UD 200UD 250UD
MOTOR SIZE (HP) 125 150 200 250
CFM AIR DELIVERY @ 100PSI 600 730 935 1130
CFM AIR DELIVERY @ 115PSI 575 685 880 1065
CFM AIR DELIVERY @ 125PSI 550 680 825 1010
CFM AIR DELIVERY @ 150PSI 505 590 765 970
COOLANT CAP.–GAL. SYST/TANK 33/25 33/25 33/25 33/25
MIN. FULL LOAD PRESSURE 70 70 70 70
DIMENSIONS: OPEN ENCLOSED
LENGTH 96 96
WIDTH 58 58
HEIGHT 66 3/8 67
NOTE: SEE INSTALLATION DRAWINGS IN SECTION 9 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 lubricant 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. The variable frequency drive will allow up to 20 starts per hour for all models.

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SECTION 3 DESCRIPTION
3.1 INTRODUCTION
SULLIVAN-PALATEK Plant Air Compressors are electric motor driven, single-stage rotary screw type,
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,
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 special inverter duty 3 phase 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 460 volts.
All air cooled compressors utilize a separate TEFC fan motor. Contact the factory for any other
requirements, such as TEFC main drive motor.
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, blow-down 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 VFD controls the capacity or air delivery of the compressor in direct response to the plant air system
demand via a varying signal from the line pressure transducer, 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 blow-down 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.
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 psi to the control pressure setting 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.

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VARIABLE SPEED OPERATION:
The compressor will operate @ varying speeds depending on the signal from the line pressure
transducer. This operating speed will vary from a maximum speed (set at the factory), and will try to
maintain a constant line pressure (this is the control pressure setting on the T1 micro processor control).
If air usage is very low, once the unload pressure setting is reached, the compressor will shut off. When
the line pressure drops again, the compressor will re-start after a specified set time interval.
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.

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3.5 COMPRESSOR LUBRICATION/COOLING SYSTEM
The cooling system consists of a fan, variable speed fan motor, finned-tube radiator-type fluid cooler, &
thermovalve to accelerate warm-up, 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, fan motor will
operate at a speed to control the sensed compressor discharge temperature.
The fluid filter is of the spin-on replacement element type. The element should be changed in accordance
with the Maintenance Schedule.

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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, this allows the heavier droplets
of lubricoolant to drop out of the air stream.
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.
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.

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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, a sensor which reads sump pressure will shut the
motor off at its set point (normally set at factory.
The panel-mounted micro processor shows the pressure at the discharge of the MPV. (i.e. line pressure).
Additionally, a differential pressure switch across the oil filter will indicate too high fault signal. The
difference between the sump pressure signal and the line pressure signal will indicate a separator fault.
A vacuum switch will indicate an air filter fault.
The compressor discharge temperature is also displayed on the micro processor screen. Normal
discharge temperature should be approximately 170-190° F, 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.
3.7 VARIABLE FREQUENCY DRIVE AND ELECTRICAL PARTS
The three-phase electric motor drive supplied with the SULLIVAN-PALATEK Plant Air Compressor has a
NEMA-1 rated enclosure. A separate control box contains: the control power transformer, the 24 volt
power supply for the micro processor control, the control pressure transducers, and fan motor disconnect
fuses.
The variable speed drive is amp-rated to match the motor amp draw at the customer’s voltage. The drive
is programmed to shut down if excessive amperage is drawn.
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
Each 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 (menu PO4) must be re-set using
service access code 0100.

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15
SECTION 4 INSTALLATION
4.1 RECEIVING
Carefully inspect for any signs of possible shipping damage.
4.2 WELDING
WARNING: Do not weld on compressor package.
4.3 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 125UD 150UD 200UD 250UD
MAX. AIRFLOW (CFM) 12,500 15,000 18,500 20,000
MAX. 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.
4.4 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.
4.5 ELECTRICAL
A trained qualified electrician must do electrical wiring to the VFD with all pertinent Federal, State and
local codes concerning isolation switches, short circuit protection, grounding, etc.
Check all electrical connections for tightness.
Check for proper incoming voltage!
Insure proper grounding has been made.

SULLIVAN-PALATEK__________________________________
16
4.6 WIRING DIAGRAM, YASKAWA F7 UPDRAFT AIR COOLED
[X1]
POWER
SUPPLY
60 Hz
BY CUSTOMER
[X2]
[H4]
1
CB111
2A
X1 460/120 VAC
T110
120/24 VAC
50VA XFMR
[H1]
GND
+ -
E-STOP
See Below
3 phase
VFD 2
S-
S+
VFD 1
AIR FILTER DP
+ -
Remote Load
Remote Load Enable
Remote Start
OIL FILTER DP
T1 MICROPROCESSOR
ASP
See Below
Auxillary Input
VFD1
Line Reactor
B2
A2
C2
A1
C1
B1
OPTIONAL
1L1
1L2
1L3
FUSIBLE DISCONNECT SWITCH
DISC101
T13 PALAYA E-XX Software
SHLD
GND
CB109
1A
GND
M1
YASKAWA F7
L3
L1
L2
T3
T2
T1
1T2
COMPRESSOR
MOTOR
MC MB S1 SN
32 31
To S1 X03
WHT
BLK
WHT
BLK
To line 18
M1 M2
36 5
1T1
1T3
R-
S- S+
R+
SN S6 SN S3
OPTIONAL E-Stop (2)
S4
To S1 X08
SHLD
IG
L1+
L2-
BLK
WHT
I
ON
-
+1
SW2
SW1
V
OFF
A2A1
AC
MAIN MOTOR DRIVE
THERMAL OVERLOAD
GND
M1
1T3
1T2
1T1
S1 SC
S4
MC
MA
BLK
WHT
MOTOR
FAN
AC
AM
T1
T2
T3
AC A2
VI
SW1
FAN MOTOR DRIVE
YASKAWA V1000
VFD 2
2A
2A
SV
EXTERNAL
VFD1VFD1
M1 M2
36
35 5
From S1 X03
2
UNLOAD
SOLENOID VALVE
81
L1 L2
T111
ASP
VFD 1
E-STOP
X04-C+
X04-C1
To VFD 1 (above)
VFD 1
S3
SN
2
T1 T1
100VA XFMR
L1
L2
L3
-
+2
DWG NO.
DATE:
MATL:
DRAWN BY:
0
DO NOT SCALE DRAWING
TOLERANCES
UNLESS OTHERWISE NOTED
DIMENSIONS ARE IN INCHES
ANGLES....... ±1/2 °
MACHINED......±1/64"
STRUCTURAL....±1/16"
DECIMAL:
0" TO 12"....030"
12" TO 36"....060"
36" TO........125"
A
SULLIVAN PALATEK
MRA
none
none
SHEET:
1 OF 1
REV
1
23
1
22
1
21
1
20
1
19
1
18
1
17
1
16
1
15
1
14
1
13
1
12
1
11
1
10
1
09
1
08
1
07
1
06
1
05
1
04
1
03
1
02
1
01
1
24
1
2
3
4
...
DESCRIPTION BEFORE CHANGEDATE BY:
NO.
SIZE
SCALE:
CONFIDENTIAL INFORMATION. IT MUST BE USED STRICTLY FOR THE LIMITED PURPOSE
SUBMITTED AND IS SUBJECT TO RETURN UPON DEMAND. ANY DISCLOSURE, REPRODUCTION
OR OTHER USE IS EXPRESSLY PROHIBITED EXCEPT AS OTHERWISE AGREED UPON IN WRITING.
THIS DOCUMENT IS THE PROPERTY OF PALATEK INC. AND CONTAINS PROPRIETARY AND
PALATEK, INC. - VFD UPDRAFT with F7 and V1000
ELECTRICAL SCHEMATIC T13PALYA
WD 50-250 UD-VFD
Size determined by HP
SHLD
Do not
ground
this side
A2
AC
82
8-26-2008
Removed 0080 alarm from drive
MRA
GND
Wire colors are typical
C+
C1
C2
C3 C4 C5
C6
C7
C8
BLU
ORG
BLK
GRN
WHT
RED
ORG/BLK
BLU/BLK
GRN/BLK
X04
L1+
L2- L2-
L1+
82
81
BLK
WHT
X07
BLU
ORG
WHT
GRN
X08 X06
54
55
53
52
51
56
WHT or BLU
BLK or BRN
WHT
BLK
WHT or BLU
BLK or BRN
X05
DISCHARGE
SUMP
PRESSURE TRANSDUCER
PRESSURE TRANSDUCER
TEMP SENSOR
S1 SN
VFD 1
To Unload relay
line 18 below
X02 X03
31
32
33
34
35
36 21
22
23
24
11
12
ORG
BLU
BLK
GRN
X01
WHT
RED
WHT
RED
BRN
BLK
37
BLK/WHT
RED/BLK
WHT/BLK
GRN/BLK
BLU/BLK
ORG/BLK
37 S1 To T1 (above)
VFD 1
32
T1
31 30
BLU
BLK
1201 Highway 20 West Michigan City, Indiana 46360
SN S7
BLK
WHT
M3 M4
5-15-2009

__________________________________SULLIVAN-PALATEK
17
4.7 WIRING DIAGRAM, YASKAWA F7 UPDRAFT WATER COOLED
[X1]
POWER
SUPPLY
60 Hz
FUSIBLE DISCONNECT SWITCH
BY CUSTOMER
DISC101
[X2]
[H4]
1CB111
2A
X1 460/120 VAC
100VA XFMR
T110
[H1]
GND
VFD1VFD1
M1 M2 SV
EXTERNAL UNLOAD
L3
L1
L2
T3
T2
T1
GND
M1
1T2
COMPRESSOR
MOTOR
MC MB S1 SN
31
BLK
+ -
E-STOP
Optional Remote Start
36
35 5
SOLENOID VALVE
2
VFD1
YASKAWA F7
1T1
1T3
See Below
3phase
S-
S+
VFD 1
AIR FILTER DP
TEMP SENSOR
+ -
Line Reactor
B2
A2
C2
A1
C1
B1
1L1
1L2
1L3
OPTIONAL
E-STOP
X04-C+
X04-C1
To S1 (above)
To VFD 1 (above)
VFD 1 VFD 1
S3
SN
2
SN S6 SN S3S4
Remote load Remote Enable
OIL FILTER DP
Auxillary Input
T13PALYA E-XX
T1 MICROPROCESSOR
From T1 X03
T1 T1
WHT
BLK
To line 18
M1 M2
36 5
R-
S- S+
R+
I
ON SW2
SW1
V
OFF L1+
L2-
IG
SN S7 AC A2
81 82
WHT
To S1 X06
MAIN MOTOR DRIVE
[X1] [X2]
[H1]
GND
F
460/120 VAC
CB112
FAN
ENCLOSURE
120/24 VAC
50VA XFMR M4 M3
AC
A2
DWG NO.
DATE: MATL:
DRAWN BY: 1
DO NOT SCALE DRAWING
TOLERANCES
UNLESS OTHERWISE NOTED
DIMENSIONS ARE IN INCHES
ANGLES....... ±1/2 °
MACHINED......±1/64"
STRUCTURAL....±1/16"
DECIMAL:
0" TO 12"....030"
12" TO 36"....060"
36" TO........125" A
SULLIVAN PALATEK
3501 W. Dunes Highway Michigan City, Indiana 46360
MRA
none none SHEET:1OF1
REV
1
23
1
22
1
21
1
20
1
19
1
18
1
17
1
16
1
15
1
14
1
13
1
12
1
11
1
10
1
09
1
08
1
07
1
06
1
05
1
04
1
03
1
02
1
01
1
24
1
2
3
4
...
DESCRIPTION BEFORE CHANGEDATENO.
SIZE
SCALE:
CONFIDENTIAL INFORMATION. IT MUST BE USED STRICTLY FOR THE LIMITED PURPOSE
SUBMITTED AND IS SUBJECT TO RETURN UPON DEMAND. ANY DI SCLOSURE, REPRODUCTION
OR OTHER USE IS EXPRESSLY PROHIBITED EXCEPT AS OTHERWISE AGREED UPON INWRITING.
THIS DOCUMENT IS THE PROPERTY OF PALATEK INC. AND CONTAINS PROPRIETARY AND
PALATEK, INC. - YASKAWA F7 INLINE
WD 15-50 VFD
WD 15-250 VFD WC
7-15-2008
SHLD
T111
2A
2A
VFD 1
ENCLOSED UNITS ONLY
SHLD
Do not
ground
this side
250VA XFMR
3A
6W
6B
GRN
37
BRN
OPTIONAL
THERMAL OVERLOAD
S1 SN
37
ASP
See Below
ASP
32
T1
37
CB109
3L1
2A
3L2
Wire colors are typical
C+ C1
C2
C3 C4 C5 C6 C7 C8
L1+
L2- L2-
L1+
82 81
BLK GRN
WHT
RED ORG/BLK
BLU/BLK GRN/BLK
X04
BLU
ORG
BLK
WHT
X07
BLU
ORG
X08
WHT
GRN
X06
51 52 53 54
55
56
BLK or BRN
WHT or BLU
BLK
WHT BLK or BRN WHT or BLU
X05
VFD 1
To Unloadrelay
line 18 below
31
32 33
34 35 36
21
22
23 24
ORG/BLK
BLU/BLK
GRN/BLK
WHT/BLK
RED/BLK
BLK/WHT
X03
BLK
GRN WHT
RED
X02
12
11
BLU
ORG
X01
BRN
RED
WHT
RED
ELECTRICAL SCHEMATIC T1 WC ENCLOSED
BY:
MRACorrected wire colors, 250 KVA enc. fan and wiring
10-3-08
WHT BLK
BLK
SUMP
DISCHARGE
Pressure Transducer
Pressure Transducer
SHLD
BLU
ORG
E-Stop (2)
30
BLK
BLU
30 BLU
31
BLK
31
To T1 X03
To T1 X08
BRN

SULLIVAN-PALATEK__________________________________
18
4.8 DIRECTION OF ROTATION
Once the control circuit has been checked, all piping installed, and compressors is filled with lubricoolant,
push the ‘run’ key (green) and observe the direction of rotation. If rotation direction is incorrect, push the
emergency stop button. Change two motor leads if rotation is incorrect. Incorrect rotation is only possible
if the motor was disconnected.
4.9 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.
4.10 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.

__________________________________SULLIVAN-PALATEK
19
SECTION 5 OPERATION
5.1 INTRODUCTION
Read this entire Operator’s Manual to be familiar with the SULLIVAN-PALATEK Plant Air Compressor,
giving special attention to the SECTION 1 - SAFETY.
5.2 INITIAL START
1. Open main disconnected to be sure there is no power to the compressor.
2. Review all the steps covered in SECTION 4 – INSTALLATION to be sure all instructions have been
complied with.
3. Inspect the compressor for any visible signs of damage that may have occurred during installation.
4. Check the compressor oil level. Check that the oil fill cap is tight.
5. Make sure the starter door is closed and latched.
WARNING: Do not power up the compressor starter with the starter door open!
6. Close the main disconnect; the compressor starter will now have power. The microprocessor will
boot, connect to the drive, then the display will illuminate and indicate line pressure.
WARNING: Reverse rotation will cause damage that is not covered by warranty. Rotation must be
checked whenever the motor has been disconnected.
7. Start the compressor by pushing the green “run” button.
8. With the service valve open, allow machine to pump up to normal operating pressures and observe
operation of automatic controls. Check for any possible leaks.
9. Check operation throughout the range of pressures, observing operating temperatures.
10. Push red “stop” button and check compressor oil level after it has been allowed to settle for a few
minutes. If it is necessary to add oil, be sure to open the main power disconnect, lock it out, and
relieve all oil separation tank pressure prior to removing fill cap to top off the tank.
11. If the control or unload pressures are incorrect, adjust the pressures in the microprocessor. Do NOT
raise the pressure without consulting the factory!
5.3 MICRO-PROCESSOR PROGRAMMING; GENERAL INSTRUCTIONS
The operational menus normally 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), fault history (P02), real-time clock and pressure schedule
(P11)
0100 for service (P04) and everything else a service technician would need
The general procedures for accessing and changing parameters in the microprocessor are:
1. Simultaneously press the ‘up’ (+) & ‘down’ (-) keys. The access code screen will appear.
2. Press ‘enter’ to move forward a digit. Use ‘clear’ (C) to move back a digit.
3. Use ‘up’ (+) or ‘down’ (-) keys to select the correct number.
4. Once the correct access code is shown press ‘enter’ to access the menu pages.
5. Use the ‘up’ (+) and ‘down’ (-) keys to move through the menu pages.
6. Press ‘enter’ to view the list of corresponding parameters for the selected menu page.
7. Use the ‘up’ (+) and ‘down’ (-) keys to scroll through the parameters.
8. Press ‘enter’ to select the parameter to change.
9. Use the ‘up’ (+) and ‘down’ (-) keys to change the value of the parameter.
10. Press ‘enter’ to save the new value.
11. Press ‘clear’ (C) to move back to the previous page, or press and hold ‘reset’ (//) to return to the main
screen.

SULLIVAN-PALATEK__________________________________
20
5.4 NORMAL OPERATION
1. Open and lock out main power disconnect.
2. Check lubricoolant level. Refill if necessary.
3. Re-close disconnect switch. Micro processor will illuminate indicating compressor is ready to start.
4. Fully open service air valve.
5. Start machine by pressing ‘run’ button on micro processor.
Observe pressure and temperature. If temperature is incorrect, refer to SECTION 6.7 – TROUBLE
SHOOTING. Observe pressure and temperature. If temperature is incorrect, refer to SECTION 6.7
– TROUBLE SHOOTING.
5.5 SHUTDOWN
To stop compressor, press ‘stop’ key on micro processor.
5.6 RESTARTS
After a power failure, open and lock out the main disconnect, check all fuses and breakers. Close
disconnect switch and follow Normal Operation start-up procedure.
Following a shutdown caused by either of the protective devices (i.e. temperature or R.O.P.), open and
lock out the main disconnect switch, correct the cause of shutdown, reset electrical controls, then close
the disconnect and follow Normal Operation start-up procedure.
Check lubricoolant level. Refill if necessary.
Re-close disconnect switch.
Start machine by pressing ‘run’ key on micro processor.
Fully open service air valve.
Observe pressure and temperature displayed by micro processor.