OPERATION & MAINTENANCE MANUAL · Sullair training courses provide hands-on and classroom instruction for the proper operation, maintenance, and servicing of Sullair products. Individual

PART NUMBER:88292021-240 R01

The information in this manual is current as of its publication date and applies to compressor models indicated on this cover with serial number:

37217040260and all subsequent serial numbers until next revision ofthis manual or release of a replacement manual..

Publication date: 08/31/2018Copyright © 2018 Sullair, LLC. All rights reserved.

WARRANTY NOTICE

Failure to follow the instructions and procedures in this manual, or misuse of this equipment, will void its warranty.

Subject to EAR, ECCN EAR99 and related export control restrictions.

SAFETY WARNING

Users are required to read the entire User Manual before han-dling or using the product. Keep the User Manual in a safe place for future reference.

OPERATION & MAINTENANCE MANUAL

ST45, ST55, ST75U.S.A. & Mexico

Service Training Courses

Sullair training courses provide hands-on and classroom instruction for the proper operation, maintenance, andservicing of Sullair products. Individual courses on Stationary compressors, variable speed drives, compressorelectrical systems, and dryers are offered at regular intervals throughout the year at Sullair’s training facility locatedin Michigan City, Indiana.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting commonfaults and malfunctions, and actual equipment operation. These courses are recommended for distributorservice personnel. There is also a basic Stationary compressor course available for end-users.

For details on course offerings, outlines, schedules, and cost information contact:

Sullair Training Department

1-888-SULLAIR or219-879-5451 (ext. 5623)

[email protected]

- Or Write -

Sullair1 Sullair Way

Michigan City, IN 46360Attn: Training Department


Table of Contents

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual Table of Contents

88292021-240 R01Subject to EAR, ECCN EAR99 and related export control restrictions. 3

Section 1: Safety.......................................................................................................71.1 General............................................................................................................................................ 71.2 Personal protective equipment ........................................................................................................ 71.3 Pressure release ............................................................................................................................. 71.4 Fire and explosion ........................................................................................................................... 81.5 Moving parts .................................................................................................................................... 81.6 Hot surfaces, sharp edges and sharp corners................................................................................. 91.7 Toxic and irritating substances........................................................................................................ 91.8 Electrical shock................................................................................................................................ 91.9 Lifting............................................................................................................................................. 101.10 Entrapment .................................................................................................................................... 101.11 Implementation of lockout/tagout................................................................................................... 111.12 Safety warnings............................................................................................................................. 121.13 Safety decals ................................................................................................................................. 13

Section 2: Description............................................................................................152.1 The air compression cycle............................................................................................................. 152.2 Air inlet system .............................................................................................................................. 17

2.2.1 General operation of the air inlet system ............................................................................ 172.2.2 Air filter................................................................................................................................ 17

2.2.2.1 Air filter element ........................................................................................................ 172.2.3 Inlet valve............................................................................................................................ 17

2.2.3.1 Inlet modulation ......................................................................................................... 172.3 Discharge system.......................................................................................................................... 17

2.3.1 General operation of the discharge system ........................................................................ 172.3.2 Minimum pressure valve ..................................................................................................... 182.3.3 Automatic blowdown valve.................................................................................................. 182.3.4 Pressure relief valve ........................................................................................................... 182.3.5 Aftercooler .......................................................................................................................... 182.3.6 Moisture separator .............................................................................................................. 18

2.4 Lubrication system......................................................................................................................... 182.4.1 General description of the lubrication system..................................................................... 182.4.2 Lubricating fluid................................................................................................................... 182.4.3 Fluid filter ............................................................................................................................ 19

2.4.3.1 Fluid filter element ..................................................................................................... 192.4.4 Purge oil return line............................................................................................................. 19

2.5 Cooling system.............................................................................................................................. 192.5.1 General description of the cooling system.......................................................................... 19

Table of Contents ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual

88292021-240 R014 Subject to EAR, ECCN EAR99 and related export control restrictions.

2.5.2 Ambient temperature .......................................................................................................... 192.5.2.1 High ambient temperature and overheating .............................................................. 19

2.6 Fluid/air separation system ........................................................................................................... 192.6.1 General description of the fluid/air separation system........................................................ 192.6.2 Fluid/air separator tank ....................................................................................................... 20

2.6.2.1 Fluid filler port and sight glass................................................................................... 202.6.2.2 Separator tank condensation—low operating temperature ....................................... 20

2.6.3 Fluid/air separator element ................................................................................................. 202.7 Microprocessor control system...................................................................................................... 20

Section 3: Specifications....................................................................................... 213.1 Machine specifications .................................................................................................................. 213.2 Lubricant specifications ................................................................................................................. 213.3 Piping and instrumentation............................................................................................................ 22

Section 4: Installation ............................................................................................ 254.1 Compressor pre-installation .......................................................................................................... 254.2 Guidelines for lifting and moving the compressor ......................................................................... 25

4.2.1 Guidelines for moving the compressor with a forklift .......................................................... 254.2.2 Guidelines for moving the compressor with a crane........................................................... 25

4.3 Compressor installation................................................................................................................. 254.3.1 Physical installation requirements ...................................................................................... 254.3.2 Heat rejection and ventilation requirements ....................................................................... 26

4.3.2.1 Poorly ventilated areas.............................................................................................. 264.3.2.2 Additional considerations for multiple compressor installations ................................ 264.3.2.3 Ventilation and existing high ambient temperature ................................................... 26

4.4 Connection to the air system......................................................................................................... 264.5 Mechanical checks ........................................................................................................................ 26

4.5.1 Checking the motor to air end coupling .............................................................................. 264.5.2 Checking the air end........................................................................................................... 26

4.5.2.1 Checking the air end of a new machine .................................................................... 274.5.3 Checking the compressor fluid level ................................................................................... 274.5.4 Checking the isolation gate valve ....................................................................................... 27

4.6 Electrical checks............................................................................................................................ 274.6.1 Power supply requirements ................................................................................................ 274.6.2 Checking the motor rotation direction ................................................................................. 27

Section 5: Operation .............................................................................................. 295.1 Compressor protection features .................................................................................................... 29

5.1.1 Stop run-on timer ................................................................................................................ 295.1.2 Emergency stop.................................................................................................................. 29

5.2 Starting the compressor for the first time ...................................................................................... 295.3 Starting the compressor ................................................................................................................ 305.4 Shutting down the compressor...................................................................................................... 305.5 Electronic controller....................................................................................................................... 305.6 High temperature shutdown .......................................................................................................... 30

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual Table of Contents


5.7 Motor overload protection.............................................................................................................. 305.8 Phase failure/reversal.................................................................................................................... 315.9 Run-on timer.................................................................................................................................. 31

Section 6: Maintenance..........................................................................................336.1 General.......................................................................................................................................... 336.2 Daily maintenance......................................................................................................................... 33

6.2.1 Before starting the compressor........................................................................................... 336.2.2 After starting the compressor.............................................................................................. 33

6.3 Recommended maintenance schedule ......................................................................................... 336.3.1 Service at 50 operating hours ............................................................................................. 336.3.2 Service every 1000 operating hours ................................................................................... 346.3.3 Service every 2000 operating hours ................................................................................... 346.3.4 Service every 2000 operating hours (or six months) .......................................................... 346.3.5 Service every 4000 operating hours (or semi-annually) ..................................................... 346.3.6 Service every 10,000 hours ................................................................................................ 346.3.7 Compressor fluid levels....................................................................................................... 34

6.4 Compressor maintenance ............................................................................................................. 356.4.1 Adding compressor fluid ..................................................................................................... 356.4.2 Changing compressor fluid ................................................................................................. 356.4.3 Fluid filter maintenance....................................................................................................... 36

6.4.3.1 Replacing the fluid filter element ............................................................................... 366.4.4 Air filter maintenance .......................................................................................................... 36

6.4.4.1 Replacing the air filter element.................................................................................. 376.4.4.2 Inspecting the air filter element ................................................................................. 37

6.4.5 Purge oil return line filter maintenance ............................................................................... 376.4.6 Fluid/air separator maintenance ......................................................................................... 37

6.4.6.1 Replacing the fluid/air separator element .................................................................. 376.4.7 Minimum pressure valve maintenance .............................................................................. 386.4.8 Solenoid valve maintenance............................................................................................... 396.4.9 Drive coupling maintenance................................................................................................ 39

6.5 Main motor operation and maintenance........................................................................................ 396.5.1 Main motor operation.......................................................................................................... 396.5.2 Main motor maintenance and repair ................................................................................... 406.5.3 Periodic inspection of the main motor................................................................................. 40

6.5.3.1 Periodic inspection checklist ..................................................................................... 406.5.4 Check and clean the windings ............................................................................................ 40

6.5.4.1 Dry cloth .................................................................................................................... 406.5.4.2 Brush and vacuum .................................................................................................... 416.5.4.3 Compressed air ......................................................................................................... 416.5.4.4 Solvent ...................................................................................................................... 41

6.6 Troubleshooting............................................................................................................................. 41

Section 7: Parts List ...............................................................................................437.1 Procedure for ordering parts.......................................................................................................... 437.2 Recommended spare parts list...................................................................................................... 44

Table of Contents ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual


7.3 Motor and air end system.............................................................................................................. 467.4 Air inlet system .............................................................................................................................. 507.5 Fluid piping system........................................................................................................................ 527.6 Cooling fan system........................................................................................................................ 547.7 Fluid/air separation system ........................................................................................................... 567.8 Air discharge system ..................................................................................................................... 607.9 Control system .............................................................................................................................. 627.10 Starter assembly ........................................................................................................................... 667.11 Enclosure ...................................................................................................................................... 707.12 Decal locations .............................................................................................................................. 72

Appendix A: Nominal Sizes................................................................................... 75

Section 1

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 1: Safety


Safety

1.1 GeneralSullair and its subsidiaries design and manufacture all oftheir products so they can be operated safely. However,the responsibility for safe operation rests with those whouse and maintain these products. The following safetyprecautions are offered as a guide which, if conscien-tiously followed, will minimize the possibility of accidentsthroughout the useful life of this equipment.

The compressor should be operated only by those whohave been trained and delegated to do so, and who haveread and understood this Operator’s Manual. Failure tofollow the instructions, procedures and safetyprecautions in this manual may result in accidents andinjuries. NEVER start the compressor unless it is safe todo so. DO NOT attempt to operate the compressor with aknown unsafe condition. Tag the compressor and renderit inoperative by disconnecting and locking out all powerat source or otherwise disabling its prime mover soothers who may not know of the unsafe condition cannotattempt to operate it until the condition is corrected.

Install, use and operate the compressor only in fullcompliance with all pertinent OSHA regulations and/orany applicable Federal, State, and Local codes,standards and regulations. DO NOT modify thecompressor and/or controls in any way except withwritten factory approval.

While not specifically applicable to all types of compres-sors with all types of prime movers, most of the precau-tionary statements contained herein are applicable to

most compressors and the concepts behind these state-ments are generally applicable to all compressors.

1.2 Personal protective equipmentA. Prior to installing or operating the compressor, own-

ers, employers and users should become familiarwith, and comply with, all applicable OSHA regula-tions and/or any applicable Federal, State and Localcodes, standards, and regulations relative to per-sonal protective equipment, such as eye and faceprotective equipment, respiratory protective equip-ment, equipment intended to protect the extremities,protective clothing, protective shields and barriersand electrical protective equipment, as well as noiseexposure administrative and/or engineering controlsand/or personal hearing protective equipment.

1.3 Pressure releaseA. Install an appropriate flow-limiting valve between the

service air outlet and the shut-off (throttle) valve,either at the compressor or at any other point alongthe air line, when an air hose exceeding ½″ (13 mm)inside diameter is to be connected to the shut-off(throttle) valve, to reduce pressure in case of hosefailure, per OSHA Standard 29 CFR 1926.302(b)(7)and/or any applicable Federal, State and Localcodes, standards and regulations.

B. When the hose is to be used to supply a manifold,install an additional appropriate flow-limiting valvebetween the manifold and each air hose exceeding½″ (13 mm) inside diameter that is to be connectedto the manifold to reduce pressure in case of hosefailure.

C. Provide an appropriate flow-limiting valve at thebeginning of each additional 75 feet (23 m) of hose inruns of air hose exceeding ½″ (13 mm) inside diame-ter to reduce pressure in case of hose failure.

D. Flow-limiting valves are listed by pipe size and flow-rated. Select appropriate valves accordingly, in

NOTE

Operator is required to readentire instruction manual.

1: Safety ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual


accordance with their manufacturer's recommenda-tions.

E. DO NOT use air tools that are rated below the maxi-mum rating of the compressor. Select air tools, airhoses, pipes, valves, filters and other fittings accord-ingly. DO NOT exceed manufacturer’s rated safeoperating pressures for these items.

F. Secure all hose connections by wire, chain or othersuitable retaining device to prevent tools or hoseends from being accidentally disconnected andexpelled.

G. Open fluid filler cap only when compressor is not run-ning and is not pressurized. Shut down the compres-sor and bleed the receiver tank to zero internalpressure before removing the cap.

H. Vent all internal pressure prior to opening any line, fit-ting, hose, valve, drain plug, connection or othercomponent, such as filters and line oilers, and beforeattempting to refill optional air line anti-icer systemswith antifreeze compound.

I. Keep personnel out of line with and away from thedischarge opening of hoses or tools or other points ofcompressed air discharge.

J. DO NOT use air at pressures higher than 2.1 bar forcleaning purposes, and then only with effective chipguarding and personal protective equipment perOSHA Standard 29 CFR 1910.242(b) and/or anyapplicable Federal, State, and Local codes, stan-dards and regulations.

K. DO NOT engage in horseplay with air hoses asdeath or serious injury may result.

1.4 Fire and explosionA. Clean up spills of lubricant or other combustible sub-

stances immediately, if such spills occur.

B. Shut off the compressor and allow it to cool. Thenkeep sparks, flames and other sources of ignitionaway and DO NOT permit smoking in the vicinitywhen checking or adding lubricant or when refillingair line anti-icer systems with antifreeze compound.

C. DO NOT permit fluids, including air line anti-icer sys-tem antifreeze compound or fluid film, to accumulateon, under or around acoustical material, or on anyexternal surfaces of the air compressor. Wipe downusing an aqueous industrial cleaner or steam cleanas required. If necessary, remove acoustical mate-rial, clean all surfaces and then replace acoustical

material. Any acoustical material with a protectivecovering that has been torn or punctured should bereplaced immediately to prevent accumulation of liq-uids or fluid film within the material. DO NOT useflammable solvents for cleaning purposes.

D. Disconnect and lock out all power at source prior toattempting any repairs or cleaning of the compressoror of the inside of the enclosure, if any.

E. Keep electrical wiring, including all terminals andpressure connectors in good condition. Replace anywiring that has cracked, cut, abraded or otherwisedegraded insulation, or terminals that are worn, dis-colored or corroded. Keep all terminals and pressureconnectors clean and tight.

F. Keep grounded and/or conductive objects such astools away from exposed live electrical parts such asterminals to avoid arcing which might serve as asource of ignition.

G. Remove any acoustical material or other materialthat may be damaged by heat or that may supportcombustion and is in close proximity, prior to attempt-ing weld repairs.

H. Keep suitable fully charged Class BC or ABC fireextinguisher or extinguishers nearby when servicingand operating the compressor.

I. Keep oily rags, trash, leaves, litter or other combusti-bles out of and away from the compressor.

J. DO NOT operate the compressor without proper flowof cooling air or water or with inadequate flow of lubri-cant or with degraded lubricant.

K. DO NOT attempt to operate the compressor in anyclassification of hazardous environment unless thecompressor has been specially designed and manu-factured for that duty.

1.5 Moving partsA. Keep hands, arms and other parts of the body and

clothing away from couplings, belts, pulleys, fans andother moving parts.

B. DO NOT attempt to operate the compressor with thefan, coupling or other guards removed.

C. Wear snug-fitting clothing and confine long hair whenworking around this compressor, especially whenexposed to hot or moving parts.

D. Keep access doors, if any, closed except when mak-ing repairs or adjustments.



E. Make sure all personnel are out of and/or clear of thecompressor prior to attempting to start or operate it.

F. Disconnect and lock out all power at source and ver-ify at the compressor that all circuits are de-ener-gized to minimize the possibility of accidental start-up, or operation, prior to attempting repairs or adjust-ments. This is especially important when compres-sors are remotely controlled.

G. Keep hands, feet, floors, controls and walking sur-faces clean and free of fluid, water or other liquids tominimize the possibility of slips and falls.

1.6 Hot surfaces, sharp edges and sharp corners

A. Avoid bodily contact with hot fluid, hot coolant, hotsurfaces and sharp edges and corners.

B. Keep all parts of the body away from all points of airdischarge.

C. Wear personal protective equipment including glovesand head covering when working in, on or around thecompressor.

D. Keep a first aid kit handy. Seek medical assistancepromptly in case of injury. DO NOT ignore small cutsand burns as they may lead to infection

1.7 Toxic and irritating substancesA. DO NOT use air from this compressor for respiration

(breathing) except in full compliance with OSHAStandards 29 CFR 1910 and/or any applicable Fed-eral, State or Local codes or regulations.

B. DO NOT use air line anti-icer systems in air linessupplying respirators or other breathing air utilizationequipment and DO NOT discharge air from thesesystems into unventilated or other confined areas.

C. Operate the compressor only in open or adequatelyventilated areas.

D. Locate the compressor or provide a remote inlet sothat it is not likely to ingest exhaust fumes or othertoxic, noxious or corrosive fumes or substances.

E. Coolants and lubricants used in this compressor aretypical of the industry. Care should be taken to avoidaccidental ingestion and/or skin contact. In the eventof ingestion, seek medical treatment promptly. Washwith soap and water in the event of skin contact.Consult Material Safety Data Sheet for informationpertaining to fluid of fill.

F. Wear goggles or a full face shield when adding anti-freeze compound to air line anti-icer systems.

G. If air line anti-icer system antifreeze compoundenters the eyes or if fumes irritate the eyes, theyshould be washed with large quantities of cleanwater for fifteen minutes. A physician, preferably aneye specialist, should be contacted immediately.

H. DO NOT store air line anti-icer system antifreezecompound in confined areas.

I. The antifreeze compound used in air line antifreezesystems contains methanol and is toxic, harmful orfatal if swallowed. Avoid contact with the skin or eyesand avoid breathing the fumes. If swallowed, inducevomiting by administering a tablespoon of salt, in eachglass of clean, warm water until vomit is clear, thenadminister two teaspoons of baking soda in a glass ofclean water. Have patient lay down and cover eyes toexclude light. Call a physician immediately.

1.8 Electrical shockA. This compressor should be installed and maintained

in full compliance with all applicable Federal, Stateand Local codes, standards and regulations, includ-ing those of the National Electrical Code, and alsoincluding those relative to equipment grounding con-ductors, and only by personnel that are trained, qual-ified and delegated to do so.

B. Keep all parts of the body and any hand-held tools orother conductive objects away from exposed liveparts of electrical system. Maintain dry footing, standon insulating surfaces and DO NOT contact anyother portion of the compressor when making adjust-

DANGER

Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA standards and/or any applicable Federal, State, and Local codes, stan-dards and regulations on safety equipment.



ments or repairs to exposed live parts of the electricalsystem. Make all such adjustments or repairs withone hand only, so as to minimize the possibility ofcreating a current path through the heart.

C. Attempt repairs in clean, dry and well lighted andventilated areas only.

D. DO NOT leave the compressor unattended with openelectrical enclosures. If necessary to do so, then discon-nect, lock out and tag all power at source so others willnot inadvertently restore power.

E. Disconnect, lock out, and tag all power at sourceprior to attempting repairs or adjustments to rotatingmachinery and prior to handling any ungroundedconductors.

1.9 LiftingA. If the compressor is provided with a lifting bail, then

lift by the bail provided. If no bail is provided, then liftby sling. Compressors to be air-lifted by helicoptermust not be supported by the lifting bail but by slingsinstead. In any event, lift and/or handle only in fullcompliance with OSHA standards 29 CFR 1910 sub-part N and/or any applicable Federal, State, andLocal codes, standards and regulations.

B. Inspect points of attachment for cracked welds andfor cracked, bent, corroded or otherwise degradedmembers and for loose bolts or nuts prior to lifting.

C. Make sure entire lifting, rigging and supporting struc-ture has been inspected, is in good condition and hasa rated capacity of at least the weight of the com-pressor. If you are unsure of the weight, then weighcompressor before lifting.

D. Make sure lifting hook has a functional safety latch orequivalent, and is fully engaged and latched on thebail or slings.

E. Use guide ropes or equivalent to prevent twisting orswinging of the compressor once it has been liftedclear of the ground.

F. DO NOT attempt to lift in high winds.

G. Keep all personnel out from under and away from thecompressor whenever it is suspended.

H. Lift compressor no higher than necessary.

I. Keep lift operator in constant attendance whenevercompressor is suspended.

J. Set compressor down only on a level surface capa-ble of safely supporting at least its weight and itsloading unit.

K. When moving the compressor by forklift truck, utilizefork pockets if provided. Otherwise, utilize pallet ifprovided. If neither fork pockets or pallet are pro-vided, then make sure compressor is secure and wellbalanced on forks before attempting to raise or trans-port it any significant distance.

L. Make sure forklift truck forks are fully engaged andtipped back prior to lifting or transporting the com-pressor.

M. Forklift no higher than necessary to clear obstaclesat floor level and transport and corner at minimumpractical speeds.

N. Make sure pallet-mounted compressors are firmlybolted or otherwise secured to the pallet prior toattempting to forklift or transport them. NEVERattempt to forklift a compressor that is not secured toits pallet, as uneven floors or sudden stops maycause the compressor to tumble off, possibly causingserious injury or property damage in the process.

1.10 EntrapmentA. If the compressor enclosure, if any, is large enough

to hold a man and if it is necessary to enter it to per-form service adjustments, inform other personnelbefore doing so, or else secure and tag the accessdoor in the open position to avoid the possibility ofothers closing and possibly latching the door withpersonnel inside.

B. Make sure all personnel are out of compressorbefore closing and latching enclosure doors.

DANGER

All field equipment must be tested for electro-static fields prior to servicing or making contact with the machine using the following or equiva-lent test equipment:

• 90 – 600 VAC: Volt detector such as Fluke Model 1AC-A

• 600 – 7000 VAC: Voltage detector such as Fluke Networks Model C9970

It is the responsibility of each organization to provide/arrange training for all their associates expected to test for electrostatic fields.



1.11 Implementation of lockout/tagoutThe energy control procedure defines actions necessaryto lockout a power source of any machine to be repaired,serviced or set-up, where unexpected motion, or anelectrical or other energy source, would cause personalinjury or equipment damage. The power source on anymachine shall be locked out by each employee doing thework except when motion is necessary during setup,adjustment or trouble-shooting.

A. The established procedures for the application ofenergy control shall cover the following elements andactions and shall be initiated only by Authorized Per-sons and done in the following sequence:

1. Review the equipment or machine to belocked and tagged out.

2. Alert operator and supervisor of whichmachine is to be worked on, and that powerand utilities will be turned off.

3. Check to make certain no one is operatingthe machine before turning off the power.

4. Turn off the equipment using normal shut-down procedure.

5. Disconnect the energy sources:

a. Air and hydraulic lines should be bled,drained and cleaned out. There shouldbe no pressure in these lines or in thereservoir tanks. Lockout or tag lines orvalves.

b. Any mechanism under tension or pres-sure, such as springs, should bereleased and locked out or tagged.

c. Block any load or machine part prior toworking under it.

d. Electrical circuits should be checked withcalibrated electrical testing equipmentand stored energy and electrical capaci-tors should be safely discharged.

6. Lockout and/or Tagout each energy sourceusing the proper energy isolating devicesand tags. Place lockout hasp and padlock ortag at the point of power disconnect wherelockout is required by each person perform-ing work. Each person shall be provided with

their own padlock and have possession ofthe only key. If more than one person isworking on a machine each person shall affixpersonal lock and tag using a multi-lockdevice.

7. Tagout devices shall be used only whenpower sources are not capable of beinglocked out by use of padlocks and lockouthasp devices. The name of the person affix-ing tag to power source must be on tag alongwith date tag was placed on power source.

8. Release stored energy and bring the equip-ment to a “zero mechanical state”.

9. Verify Isolation: Before work is started, testequipment to ensure power is disconnected.

B. General Security

1. The lock shall be removed by the “Autho-rized” person who put the lock on theenergy-isolating device. No one other thanthe person/persons placing padlocks andlockout hasps on power shall remove pad-lock and lockout hasps and restore power.However, when the authorized person whoapplied the lock is unavailable to remove ithis/her Supervisor may remove padlock/pad-locks and lockout hasps and restore poweronly if it is first:

a. verified that no person will be exposed todanger.

b. verified that the “Authorized” person whoapplied the device is not in the facility.

c. noted that all reasonable efforts to con-tact the “Authorized” person have beenmade to inform him or her that the lock-out or tagout device has been removed.

d. ensured that the “Authorized” person isnotified of lock removal before returningto work.

2. Tagout System—Tags are warning devicesaffixed at points of power disconnect and arenot to be removed by anyone other that theperson placing tag on power lockout. Tagsshall never be by-passed, ignored, or other-wise defeated.



1.12 Safety warningsThe following special instructions apply to VSD packagesprovided with electronic adjustable speed motor drives.These cautions that apply to VSD operation.

WARNING

Ground the unit following the instructions in this manual. Ungrounded units may cause electric shock and/or fire. The variable speed drive has a large capacitive leakage current during opera-tion, which can cause enclosure parts to be above ground potential. Proper grounding, as described in this manual, is required. Failure to observe this precaution could result in death or severe injury.

WARNING

Before applying power to the variable speed drive, make sure that the front and cable covers are closed and fastened to prevent exposure to potential electrical fault conditions. Failure to observe this precaution could result in death or severe injury.

WARNING

Refer all drive service to trained technicians. This equipment should be installed, adjusted, and serviced by qualified electrical maintenance personnel familiar with the construction and operation of this type of equipment and the haz-ards involved and in accordance with published service manuals. Failure to observe this precau-tion could result in death or severe injury.

WARNING

Line terminals (L1, L2, L3), motor terminals (U, V, W) and the DC link/brake resistor terminals (-/+) are live when the drive is connected to power, even if the motor is not running. Contact with this voltage is extremely dangerous and may cause death or severe injury.

WARNING

Before opening the variable speed drive covers:

• Disconnect all power to the variable speed drive.

• Wait a minimum of 15 minutes after all the lights on the keypad are off. This allows time for the DC bus capacitors to discharge.

• A hazard voltage may still remain in the DC bus capacitors even if the power has been turned off. Confirm that the capacitors have fully dis-charged by measuring their voltage using a multimeter set to measure DC voltage. Failure to follow the above precautions may cause death or severe injury.

CAUTION

Do not perform any megger or voltage withstand tests on any part of the variable speed drive or its components. Improper testing may result in damage. Prior to any tests or measurements of the motor or the motor cable, disconnect the motor cable at the variable speed drive output terminals (U, V, W) to avoid damaging the vari-able speed drive during motor or cable testing.

CAUTION

Do not touch any components on the circuit boards. Static voltage discharge may damage the components.



1.13 Safety decals

CAUTION

Install the variable speed drive in a well venti-lated room that is not subject to temperature extremes, high humidity, or condensation, and avoid locations that are directly exposed to sun-light, or have high concentrations of dust, corro-sive gas, explosive gas, inflammable gas, grinding fluid mist, etc. Improper installation may result in a fire hazard.

CAUTION

Make sure that no power correction capacitors are connected to the variable speed drive output or the motor terminals to prevent variable speed drive malfunction and potential damage.

CAUTION

Make sure that the variable speed drive output terminals (U, V, W) are not connected to the util-ity line power as severe damage to the VSD may occur.

NOTE

Interior electrical wiring is performed at the fac-tory. Required customer wiring is minimal, but should be done by a qualified electrician in com-pliance with OSHA, National Electrical Code, and/or any other applicable State, Federal, and local electrical codes concerning isolation switches, fused disconnects, etc. Sullair pro-vides a wiring diagram for use by the installer.

NOTE

Customer must provide electrical supply power disconnect within sight of machine.

WARNING

Auto start hazard

This machine is equipped with an auto start sequence that will start the unit when power is restored after a power failure or as part of automatic operation, which can result in serious injury or death.

Do not attempt to make any adjustments or per-form any maintenance on this machine without disconnecting both main line and control circuit electrical power and follow all of your company’s prescribed safety practices for electrical equip-ment.


Notes:


Section 2

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 2: Description


Description2.1 The air compression cycleThe ShopTek™ air compressor uses a lubricated rotaryscrew air end and supporting components to create com-pressed air.

When the rotors inside the air end turn, they draw outsideair into the compressor through the air inlet system. Asthe rotors compress this air from atmospheric pressure tothe target pressure, the lubrication system injects fluidinto the air end to cool the compressed air, lubricate therotors and bearings, and create a seal between the rotorsand the air end casing.

After leaving the air end, the compressed air/fluid mixtureflows into the fluid/air separation system. First, the fluid/air separator tank separates the majority of the fluid fromthe compressed air using a combination of centrifugal

force, impingement, and gravity. Then the compressedair passes through the fluid/air separator element toremove almost all of the remaining fluid.

Next, the compressed air flows through the aftercooler.The aftercooler cools the compressed air to 8 – 12°C(14 – 22°F) above the ambient temperature. The com-pressed air then flows through the moisture separator (ifinstalled). The moisture separator collects the watervapor that condensed when the compressed air wascooled.

After leaving the aftercooler (or the moisture separator, ifinstalled), the compressed air flows through the serviceconnector of the compressor for downstream use.

2: Description ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual


Figure 2-1: ST45, ST55 & ST75 machine layout

1. Enclosure 5. Air inlet system

2. Electric control system 6. Motor & air end

3. Cooling fan system 7. Fluid/air separation system

4. Discharge system 8. Fluid piping system



2.2 Air inlet systemThe air inlet system provides air for the compressor topressurize. The primary components of the air inlet sys-tem are the air filter, inlet valve, and compressor air end.

2.2.1 General operation of the air inlet system

The air end draws outside air through the air filter andinlet valve into the air end compression chamber. Insidethe compression chamber, a male and female rotor pairrevolve at high speed, compressing the air and increas-ing its pressure. When the compressed air/fluid mixturereaches the end of the compression chamber, the mix-ture flows through the air end discharge port into thefluid/air separator.

2.2.2 Air filterThe air filter removes particulates from the intake air, pro-viding clean air to the compressor. If these particulateswere not removed, they could wear down rotor surfacesand contaminate the compressor fluid.

2.2.2.1 Air filter elementBecause the air filter element traps the particulates it fil-ters from the air on its surface, the air filter element mustbe changed periodically to maintain the air filter’s effec-tiveness.

Additional information• For the recommended air filter maintenance

schedule, see Section 6.3: Recommendedmaintenance schedule on page 33.

• For instructions on how to change the air filterelement, see Section 6.4.4: Air filter mainte-nance on page 36.

2.2.3 Inlet valveThe inlet valve controls intake air volume using a modula-tion control system.

2.2.3.1 Inlet modulationTo minimize the number of starts and stops the compres-sor makes, the inlet modulation system automatically

adjusts the size of the inlet valve opening to match airdemand. The primary components of the inlet modulationsystem are the solenoid valve, inlet valve, blowdownvalve, and control line.

When air demand is equal to or greater than the com-pressors rating, the compressor will run at full load. Thesolenoid valve is energized, closing the control line.Because the control is not in use, the inlet valve of the airend is fully open.

When air demand is lower than the compressor rating,discharge pressure builds up slowly. Once the dischargepressure reaches the unload setting of the controller, thecompressor will switch to unload mode. The solenoidvalve is de-energized, opening the control line. Becausethe control line is in use and the discharge pressure ishigh, the control line closes the inlet valve. At the sametime, the blowdown valve opens to release the pressurein the fluid/air separator tank until the pressure stabilizesat 15 – 25 psi.

Now the compressor will run with no load for a presettime. Once the preset time is reached, the compressorwill stop. However, if the discharge pressure drops to theload setting of the controller before the preset time isreached, the compressor re-enters load mode. The sole-noid valve is energized, closing the control line. Becausethe control is not in use, the inlet valve of the air end isfully open.

2.3 Discharge systemThe discharge system pushes air from the compressorair end to the service connector. The primary compo-nents of the discharge system are the compressor airend, fluid/air separator, minimum pressure valve, pres-sure relief valve, automatic blowdown valve, aftercooler,moisture separator (optional), and service connector.

2.3.1 General operation of the discharge system

The compressed air/fluid mixture flows through the airend discharge port into the fluid/air separator tank andseparator element. The separator tank and elementremove fluid from the air.

The compressed air then flows through the minimumpressure valve, followed by the aftercooler, then themoisture separator (if installed). Once the air is cooledand the moisture removed (if the moisture separator isinstalled), the air flows to the service connector for down-stream use.

To lower the frequency of the compressor’s load/unloadcycles and extend the life of the compressor, Sullair rec-

WARRANTY NOTICE

Failure to follow the air filter maintenance sched-ule or use Sullair genuine air filter elements can cause early contamination of the compressor fluid and the fluid/air separator element and may void your warranty.



ommends installing a wet air receiver after the serviceconnector.

Additional information• For the size of the service connector, see Sec-

tion 3.1: Machine specifications on page 21.

2.3.2 Minimum pressure valveThe minimum pressure valve on the top cover of the fluid/air separator ensures lubricant flow during both normaloperation and start-up by keeping pressure in the fluid/airseparator above 340 kPa (49.3 psi).

When pressure in the fluid/air separator is above 340 kPa(49.3 psi) and higher than the downstream pipeline pres-sure, the minimum pressure valve will be opened. Other-wise, the minimum pressure valve will be closed tomaintain minimum tank pressure.

The minimum pressure valve also functions as a check(non-return) valve, preventing compressed air down-stream of the separator from flowing back into the sep-arator and air end during compressor blowdown.

2.3.3 Automatic blowdown valveWhen the compressor is unloading or stopping, the blow-down valve in the control line automatically opens torelease pressure. The blowdown valve routes the air tothe air inlet pipe (after the air filter) to prevent a com-pressed air/fluid mixture from venting into the atmo-sphere.

2.3.4 Pressure relief valveTo prevent damage to the fluid/air separator and othercompressor components the pressure relief valve locatedon the fluid/air separator tank will open when the pres-sure in the separator tank exceeds the pressure reliefvalve setpoint.

Under normal operating conditions, the over pressurestop switch will shut down the compressor before thepressure relief valve setpoint is reached (see Section 3.1:Machine specifications on page 21). However, the pres-sure relief valve serves as an additional mechanical safe-guard.

2.3.5 AftercoolerThe aftercooler cools the compressed air to 8 – 12°C(14 – 22°F) above the ambient temperature. This coolingcauses water vapor to condense, which creates moisturein the compressed air stream.

2.3.6 Moisture separatorThe moisture separator removes the moisture from thecompressed air stream. Moisture collected by the mois-ture separator can then be safely disposed of accordingto local regulations.

2.4 Lubrication systemThe lubrication system cools the compressor; lubricatesthe rotors, bearings, and gears; and seals the air endagainst leaks. The primary components of the lubricationsystem are the compressor air end, fluid/air separator,thermal valve, aftercooler, fluid filter, and interconnectingpiping.

2.4.1 General description of the lubrication system

Fluid is injected into the air end compression chamber,where it is compressed along with the intake air. Thecompressed air/fluid mixture then flows into the fluid/airseparation system, which separates the fluid from the airand collects the fluid for re-use. Depending on the fluidtemperature, the thermal valve routes none, some, or allof the fluid to the aftercooler for cooling. Fluid that haspassed through the aftercooler, or that was not routed tothe aftercooler, flows through the fluid filter into the airend to restart the lubrication cycle.

2.4.2 Lubricating fluidThe lubricating fluid provides three benefits.

• Cooling. The compressor fluid acts as a cool-ant, absorbing the large amount of heat gener-ated during compression.

• Lubricating. The compressor fluid forms alayer between the rotors, preventing the maleand female rotors from making direct contactand minimizing the surface wear of the rotors.The compressor fluid also lubricates the bear-ings and gears.

• Sealing. Compressor fluid with sufficient vis-cosity can fill the gaps between rotors andbetween the rotors and the casing. Thisreduces air lost through leakage and increasesthe efficiency of the compressor.

NOTE

The moisture separator ships loose for the cus-tomer to install if needed for their installation. It is not installed by the factory.



Additional information•

• For the viscosity required for the compressor fluid to act as a sealant, see Section 3.2: Lubri-cant specifications on page 21.

2.4.3 Fluid filterThe fluid filter collects any impurities in the compressorfluid and ensures that only clean fluid enters the air endcompression chamber and internal lubrication feeds. Ifthese impurities in the fluid were not removed, they wouldcause wear on the rotor and gear surfaces and bearingsand shorten the life of compressor.

2.4.3.1 Fluid filter elementBecause the fluid filter element collects impurities on itssurface, the fluid filter element must be replaced regularlyto ensure good fluid circulation for proper lubrication andcooling.

Additional information• For the recommended fluid filter maintenance

schedule, see Section 6.3: Recommendedmaintenance schedule on page 33.

• For instructions on how to change the fluid filterelement, see Section 6.4.3: Fluid filter mainte-nance on page 36.

2.4.4 Purge oil return lineThe purge oil return line located on the cover of the fluid/air separator passes the compressor fluid collected bythe fluid/air separator element through the purge line fil-ter, then returns the clean fluid to the compressor air end.

A small orifice in the purge oil return line limits return airflow, minimizing the loss of compressed air. A sight glasslocated in the purge line allows an operator to observethe amount of fluid returning from the separator element.

2.5 Cooling systemThe cooling system maintains a proper operating tem-perature for the compressor.

2.5.1 General description of the cooling system

Suction created by an axial flow cooling fan pulls coolingair through louvers on both sides of the compressor. Thiscooling air draws heat from the aftercooler before flowingout of the machine.

2.5.2 Ambient temperatureSullair ShopTek™ compressors are designed to operatein ambient temperatures between 4°C and 40°C (40°Fand 104°F), measured at the cooling air inlet. If you needto operate the compressor in a temperature outside thisrange, contact your Sullair representative.

2.5.2.1 High ambient temperature and overheating

If the ambient temperature is above 40°C (104°F), the airdrawn into the compressor may be too hot to adequatelycool the compressor fluid or the electric motor when thecompressor is operating at full load. If the compressorload is less than 100%, operating the compressor inhigher ambient temperatures may be possible.

Regardless of the ambient temperature, the maximumrecommended operating temperature is 108°C (226°F).

2.6 Fluid/air separation systemThe fluid/air separator system removes the fluid from thecompressed air stream. The primary components of thefluid/air separation system are the fluid/air separator tankand fluid/air separator elements.

2.6.1 General description of the fluid/air separation system

The compressed air/fluid mixture from the air end flowsinto the fluid/air separator and strikes the wall of the sep-arator tank, causing large drops of fluid to form becauseof the lower air speed. Most of these fluid drops attach tothe wall of the tank, and gravity causes the drops to col-lect at the bottom of the tank. The thermal valve thenroutes this collected fluid back to the air end through theaftercooler (if necessary) and the filter.

CAUTION

Continuously exceeding the maximum operating temperature will damage the compressor.

CAUTION

In the event of a high operating temperature shutdown fault, do not attempt to restart the compressor without first finding and correcting the underlying cause. Contact your Sullair repre-sentative for assistance.



After hitting the wall of the separator tank, the com-pressed air/fluid mixture then flows through the separatorelement. The separator element removes fine fluid parti-cles. These particles accumulate at the bottom of the ele-ment and return to the air end through the purge oil returnline.

2.6.2 Fluid/air separator tankIn addition to separating the air from the fluid, the fluid/airseparator tank acts as a fluid reservoir, storing most ofthe compressor fluid.

2.6.2.1 Fluid filler port and sight glassThe fluid/air separator tank is equipped with a fluid fillerport and sight glass. Since trace amounts of compressorfluid remain in the discharged compressed air even afterseparation, over time the fluid level of the compressor willdrop. You will need to monitor the fluid level and periodi-cally add additional fluid to the tank.

Additional information• For an explanation of how determine the fluid

level of the compressor, see Section 6.3.7:Compressor fluid levels on page 34.

• For instructions on how to add compressorfluid, see Section 6.4.1: Adding compressorfluid on page 35.

2.6.2.2 Separator tank condensation—low operating temperature

In conditions of high humidity and low operating tempera-ture, water formed by condensation may collect in thecompressor fluid. To ensure trouble-free operation, Sul-lair ShopTek™ compressors are fitted with an oil bypass

thermal valve set at the temperature required to evapo-rate water.

In areas where the ambient temperature is less than 4°C(40°F), you may need to take steps to prevent condensa-tion. This may include fitting anti-condensation heaters tothe separator vessel. For assistance in operating thecompressor in very low ambient temperatures, pleasecontact your Sullair representative.

2.6.3 Fluid/air separator elementThe fluid/air separator element removes fine fluid parti-cles from the compressed air stream.

Over time, impurities in the lubrication system will clogthe fluid/air separator element, increasing the resistanceof the separator to compressed air flow. Because theincreased resistance will compromise the compressor’soperation, the separator element needs to be replacedperiodically.

Additional information• For the recommended fluid/air separator ele-

ment maintenance schedule, see Section 6.3:Recommended maintenance schedule on page33.

• For instructions on how to change the fluid/airseparator element, see Section 6.4.6: Fluid/airseparator maintenance on page 37.

2.7 Microprocessor control systemThe ShopTek™ compressor is equipped with a micropro-cessor controller. For detailed information on this control-ler, see EC2000 Controller Operation Manual.

Section 3

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 3: Specifications


Specifications3.1 Machine specifications

3.2 Lubricant specificationsThe oil used as a lubricant in Sullair’s rotary screw com-pressors must have the following properties:

• Low foaming

• Good resistance to emulsification

• High oxidation resistance

• Viscosity of 10.5 cSt at the compressor’s oper-ating temperature

Table 3-1: Compressor specifications

Model ST45 9 bar ST55 9 bar ST75 9 bar

Rated pressure 9 bar (125 psi) 9 bar (125 psi) 9 bar (125 psi)

Maximum working pressure 9.3 bar (135 psi) 9.3 bar (135 psi) 9.3 bar (135 psi)

Relief valve setpoint 10 bar (145 psi) 10 bar (145 psi) 10 bar (145 psi)

Voltage & frequency 460 V / 60 Hz

Air end type Single stage, oil injected rotary screw

Configuration Gear driven with external inlet modulation

Motor type ODP (IP23)

Motor rating 45 kW (60 hp) 55 kw (75 hp) 75 kW (100 hp)

Motor nominal speed 1775 rpm 1775 rpm 1775 rpm

Starting mode Y-∆ (Y-delta)

Service factor 1.25

Ambient temperature Between 4° and 40°C (40° and 104°F)

Lubricant Sullube®

Lubricant volume 33 L (8.7 gal)

Service connector NPT 2″

Moisture drain connector NPT ½″ (moisture separator shipped loose)

Machine weight 1563 kg (3446 lbs) 1708 kg (3765 lbs) 1822 kg (4017 lbs)

Machine dimensions (L × W × H) 2200 × 1260 × 1760 mm (86.6 × 49.6 × 69.3 in)

Package dimensions (L × W × H) 2350 × 1345 × 1975 mm (92.5 × 53.0 × 77.8 in)

Table 3-2: Lubricant specifications

Synthetic oils Ambient temperature

Sullube® (factory fill) Up to 40°C (104°F)

WARRANTY INFORMATION

Mixing of fluids other than Sullube will void the compressor’s warranty.

3: SpecificationsShopTek™

ST45, ST55, ST75 (U.S.A

. & M

exico) Operation &

Maintenance M

anual

88292021-240 R01

22Subject to EAR

, ECC

N EAR

99 and related export control restrictions.

3.3 Piping and instrumentation

88292020-840 R02

ShopTek™ ST45, ST55, ST75 (U

.S.A. &

Mexico) O

peration & M

aintenance Manual

3: Specifications

88292021-240 R01

Subject to EAR, EC

CN

EAR99 and related export control restrictions.

23

3.3 Piping and instrumentation

Key Description

1 FILTER,AIR INLET

2 INDICATOR,RESTRICTION

3 VALVE,AIR INLET CONTROL

4 COMPRESSOR UNIT

5 PROBE,THERMISTER

6 GAUGE,PRESSURE

7 TANK,FLUID/AIR SEPARATOR

8 ELEMENT,FLUID/AIR SEPARATOR PRIMARY

9 ELEMENT,FLUID/AIR SEPARATOR SECONDARY

10 VALVE,MINIMUM PRESSURE

11 TRANSDUCER,PRESSURE

12 COOLER,FLUID/AIR

13 SEPARATOR,MOISTURE

14 VALVE, BLOWDOWN

15 FILTER,GENISIS

16 GLASS,SIGHT

17 ORIFICE,1/16"

18 ORIFICE,3/32"

19 VALVE,RELIEF

20 PLUG,SIGHT GLASS

21 PLUG,FLUID

22 VALVE,BALL

23 VALVE,THERMAL

24 FILTER,FLUID

25 INDICATOR,PRESSURE

26 ORIFICE, 1/4"

3: Specifications ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual

Notes:


Section 4

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 4: Installation


Installation

4.1 Compressor pre-installationBefore installing your ShopTek™ compressor, check itcarefully for any transportation damage. If you find anydamage, contact your Sullair representative immediately.

4.2 Guidelines for lifting and moving the compressor

Sullair recommends using a forklift to move the compres-sor. A crane can also be used.

4.2.1 Guidelines for moving the compressor with a forklift

When using a forklift to move the compressor, follow alllocal regulations for operating a forklift. In addition, Sullairhas several guidelines that must be followed.

• The forklift’s load rating must be sufficient to liftthe compressor’s weight (see Section 3.1:Machine specifications on page 21)

• The forklift must lift the compressor from thefront.

• The fork tines must be correctly spaced.

• The fork lift tines must be long enough to coverthe full depth of the compressor.

• The fork tines must be fully engaged and tippedback prior to lifting the compressor.

4.2.2 Guidelines for moving the compressor with a crane

If a crane is used to move the compressor, ensure thatit’s rating is sufficient to lift the compressor’s weight (seeSection 3.1: Machine specifications on page 21).

When moving the compressor with a crane, lift the com-pressor with slings and use guide ropes to prevent twist-ing. You should also use spreader bars to prevent paneldamage.

When the compressor has been set down, check forcracked welds and loose bolts or nuts.

4.3 Compressor installationThe ShopTek™ compressor is not weatherproof. Thecompressor should be installed inside (or in a shelteredposition outside).

4.3.1 Physical installation requirementsBecause the compressor must remain level at all times(not more than 6 mm or ¼″ unevenness allowed), youshould install the compressor on a flat surface rated tohold the compressor’s weight (see Section 3.1: Machinespecifications on page 21). If you must install the com-pressor on an uneven surface, you can use shims tolevel the compressor. You do not need to bolt the com-pressor in place.

You must position the compressor so it has sufficientclearance on all sides (for the minimum distancesrequired, see the compressor’s ID drawing). If you havemore than one compressor installed at the same location,you must have clear access to each compressor. If youneed help correctly positioning your compressor, contactyour Sullair representative for assistance.

WARNING

Incorrect installation or setup may void warranty.

NOTE

A site assessment must be carried out to ensure forklift or crane access for removal and servicing of major components and compressor transport.

NOTE

A site assessment must be carried out to ensure forklift or crane access for removal and servicing of major components and compressor transport.

4: Installation ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual


4.3.2 Heat rejection and ventilation requirements

The compressor rejects a considerable amount of heat,so you must install it in a well-ventilated area.

Hot air from the cooling air discharge must not recirculateinto the cooling air inlet. This recirculation can be causedby installing the compressor in a room with a low ceilingor in a location where the cooling air is discharged pastthe compressor’s cooling air inlet. In these situations, youshould follow the guidelines in Section 4.3.2.1: Poorlyventilated areas.

4.3.2.1 Poorly ventilated areasIn a poorly ventilated area, the heated cooling air dis-charged from the compressor can cause the ambienttemperature to rise above 40°C (104°F), which will causethe compressor to overheat. Sullair recommends addingductwork to route the cooling air discharge away from thecompressor, possibly to another area or room. Anyductwork added (including the outlet grill) should notcause a pressure drop greater than 30 Pa (.004 psi)(contact Sullair Aftermarket prior to installation) and mustnot apply any weight to the compressor cabinet. Sullairalso recommends a section of the ductwork be remov-able to allow easy access for servicing.

4.3.2.2 Additional considerations for multiple compressor installations

In a multiple compressor installation, the air dischargedfrom one compressor must never flow into the intake ofanother compressor.

4.3.2.3 Ventilation and existing high ambient temperature

If the compressor is in a location where existing environ-mental conditions will cause the ambient temperature toexceed 40°C (104°F) even if the cooling air is adequatelydissipated (for example, in a boiler room), Sullair recom-mends following the guidelines in Section 4.3.2.1: Poorlyventilated areas.

4.4 Connection to the air systemSullair recommends installing an isolation gate valveimmediately after the service connector to make installa-tion, service, and removal of the compressor easier.

You must install a flexible connection between thecompressor and the external pipe work. Because theinternal components of the compressor are mounted onanti-vibration pads and are not rigidly supported, no loadshould ever be transferred to the service connector of thecompressor.

The plant air line should have an internal diameter atleast the size of the service connector (for service con-nector size, see Section 3.1: Machine specifications onpage 21). For longer pipe runs, the pipe sizes should beincreased by one size to minimize pressure drop. Con-densate from the pipe work should never flow towardsthe compressor. One way of achieving this is to installmains pipe work adjacent to the compressor and belowthe service connector.

Additional information• For the exact location of the service connector,

see the compressor’s ID drawing.

4.5 Mechanical checks

4.5.1 Checking the motor to air end coupling

Ensure that the flexible drive coupling connecting themotor and air end is correctly fastened.

4.5.2 Checking the air endBefore a new machine is started for the first time, youmust check that the air end is not hydraulically locked.

IMPORTANT

Do not install the compressor in an area where exhaust fumes or other toxic, noxious, or corro-sive fumes, chemicals, or substances can be drawn into the air inlet.


Failure to install a flexible connection may result in damage to the compressor and void your war-ranty.

WARNING

Ensure that the compressor is electrically iso-lated before performing any mechanical checks.

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 4: Installation


4.5.2.1 Checking the air end of a new machineRotate the flexible drive coupling by hand through twocomplete revolutions in the direction indicated by thearrows located on the air end and motor.

4.5.3 Checking the compressor fluid levelOpen the front access panel just enough to view the sightglass located on the separator tank, then follow theinstructions in Section 6.3.7: Compressor fluid levels onpage 34 for how to check the compressor’s fluid level.

• If the fluid level is below the minimum fluidlevel, see Section 6.4.1: Adding compressorfluid on page 35.

4.5.4 Checking the isolation gate valveIf an isolation gate valve is installed in your air system,make sure the valve is open.

4.6 Electrical checksWhen performing any electrical work, refer to the electri-cal diagram supplied with your compressor.

All the compressor’s internal wiring is factory fitted andtested. The required connection wiring is minimal, but itmust be performed by a licensed electrician. A licensedelectrician must also review the electrical system to seethat it is adequate for starting and running the compres-sor.

4.6.1 Power supply requirements• 460 VAC, 3-phase, 60 Hz with ground

• Control voltage: 110 VAC

4.6.2 Checking the motor rotation directionFor the motor to rotate in the correct direction, the powersupply must be correctly connected.

You should check the rotation of the motor before startingup the compressor for use. Before checking the motorrotation direction, you must familiarize yourself with Sec-tion 5: Operation.

1. Pull out emergency stop (E-stop) button fromthe monitor’s control panel.

2. Press the Start button.

3. Immediately press the E-Stop button.

• This will cause the motor and air end torotate momentarily, but not long enough todamage the air end if the motor rotationdirection is reversed.

• If the phase sequence is wrong, a com-pressor with a phase sequence protectorwill not start and the controller will displayan error message.

4. Check that the motor and air end rotate inthe direction indicated by the arrows on theair end to motor drive coupling.

• If the motor and air end do not rotate in thedirection indicated by the arrows, theincoming mains power leads need to bereversed by a licensed electrician.

• Do not reverse any motor or starter wir-ing. This wiring must not be modified.

WARNING

Never run the motor with the rotation direction reversed!

Motor rotation in the wrong direction can dam-age the air end and may void your warranty.

4: Installation ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual

Notes:


Section 5

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 5: Operation


Operation5.1 Compressor protection featuresYour ShopTek™ compressor controller optimizes the per-formance of your system by adding additional electronicprotection to the motor and air end.

5.1.1 Stop run-on timerThis stop run-on timer provides a soft stop function,reducing the load on the air end before stopping the com-pressor. When you press the Stop button, the compres-sor will unload and then run for a period of time pre-setby the factory, reducing the pressure in the separatortank, before coming to a complete stop.

5.1.2 Emergency stopPressing the emergency stop (E-stop) button will stop thecompressor immediately.

You must pull out the E-stop button to release it beforethe compressor can be restarted.

5.2 Starting the compressor for the first time

1. Read the preceding pages of this manualthoroughly.

2. If you are installing the compressor, confirmyou have followed all the requirements and

guidelines in Section 4.3: Compressor instal-lation and Section 4.4: Connection to the airsystem.

3. Perform all mechanical checks described inSection 4.5.

4. Open the isolation gate valve if it is installed.

5. If you are installing the compressor, performthe motor rotation direction check describedin Section 4.6.2.

6. Switch on the mains power (if it is notalready on).


• The compressor will start and switch fromthe Y start configuration to the delta run-ning configuration as it reaches full speed.

8. Monitor the status of the compressor on thecontroller display.

• Rising discharge air pressure and risingoperating temperature indicate correctoperation (see Section 2.1: The air com-pression cycle on page 15).

• On reaching the preset operating pressure,the controller will unload the compressorand the discharge air pressure will stop ris-ing. The compressor will continue to run,but it will run unloaded.

9. Run the compressor through a number ofload/unload cycles (bleed air from the plantair system, if necessary) and check for con-sistent operation, leaks (air or fluid), and astable operating temperature (see Section2.5: Cooling system on page 19).

NOTE

You should always use the Stop button to stop the compressor under normal circumstances.

You should only use the E-stop button to stop the compressor in an emergency.

NOTE

Also follow this procedure if the compressor has been out of service for more than 60 days or you have installed the compressor in a new location.

CAUTION

The compressor should always run smoothly. If the compressor vibrates excessively while run-ning, shut it down and contact your Sullair repre-sentative immediately.

5: Operation ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual


5.3 Starting the compressorIf the compressor has been out of service for more than60 days or you have installed the compressor in a newlocation, follow the steps under Section 5.2: Starting thecompressor for the first time instead of this procedure.

1. Open the isolation gate valve if it is installed.


5.4 Shutting down the compressor1. Press the Stop button.

• The compressor will begin a delayed stopsequence and will stop automatically afterthe delayed stop sequence is complete.

• During the delayed stop sequencepressing the Start button will not restartthe compressor. You can only restartthe compressor after the delayed stopsequence is complete.

5.5 Electronic controllerThe EC2000 Controller Operation Manual describes thelayout and explains the features of the ShopTek™ elec-tronic controller.

5.6 High temperature shutdownThe electronic controller will shut down the compressor ifthe fluid temperature sensor reports a separator tanktemperature above 113°C (235°F). This shutdown tem-perature is set at the factory and should not be changed.

A high temperature shutdown places the electronic con-troller into fault mode, which prevents the compressorfrom restarting. After the compressor cools down, thefault mode may be cleared by pressing the Reset buttonon the controller.

5.7 Motor overload protectionBoth the compressor main drive motor and the fan motorhave overload protection. If either motor draws too muchcurrent, its overload protection will shut down the com-pressor.

A motor overload protection shutdown places the elec-tronic controller into fault mode, which prevents the com-

WARNING

Never assume that the compressor has com-pletely stopped, even if the compressor does not appear to be running. The compressor may be in standby mode and restart at any time. Do not remove any covers or panels or attempt any ser-vice without first isolating the compressor from the mains power supply and tagging it.

WARNING

For safety reasons, the electronic controller pressure settings should never be adjusted to anything other than the required settings for the serial plate nominal operating pressure. If you require different pressure settings, contact your Sullair representative.

Adjusting the nominal operating pressure above the maximum working pressure of your com-pressor as indicated on the serial number plate may damage your compressor and void your warranty.

CAUTION

In the event of a high operating temperature shutdown fault, do not attempt to restart the compressor without first finding and correcting the underlying cause. Contact your Sullair repre-sentative for assistance.

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 5: Operation


pressor from restarting. The fault mode may be clearedby pressing the Reset button on the controller.

5.8 Phase failure/reversalThe electronic controller includes a phase failure/reversalmonitor to protect against reverse motor rotation. Themonitor can detect an under voltage condition, theabsence of a supply phase, or the incorrect phasesequence of the supply power. If the monitor detects anyof these conditions, the electronic controller will shutdown the compressor. A licensed electrician must exam-ine the compressor to resolve the problem.

5.9 Run-on timerKeeping with Sullair’s philosophy of minimizing energyconsumption, the electronic controller has a run-on timer.The run-on timer monitors how long the compressor hasrun without compressing air. If this length of time isgreater than the pre-set run-on time, the compressor willenter standby mode. The compressor will automaticallyrestart if a fall in system pressure is registered.

The factory setting of the run-on time is 15 minutes. Youcan use the electronic controller to adjust the run-on time,but ensure that the compressor does not exceed six shutdowns per hour. Contact your Sullair representativebefore making any adjustments, since an incorrect set-ting may result in damage to the compressor.

CAUTION

In the event of a motor overload protection shut-down fault, do not attempt to restart the com-pressor without first finding and correcting the underlying cause that triggered the motor over-load protection.

You can contact your Sullair representative for assistance in finding and correcting the underly-ing cause of a motor overload protection shut-down condition.

WARNING

Never assume that the compressor has com-pletely stopped, even if the compressor does not appear to be running. The compressor may be in standby mode and restart at any time. Do not remove any covers or panels or attempt any ser-vice without first isolating the compressor from the mains power supply and tagging it.

5: Operation ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual

Notes:


Section 6

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 6: Maintenance


Maintenance6.1 GeneralNormal operation of your compressor depends upon per-forming maintenance and service correctly and accordingto a consistent schedule.

To help you follow this schedule, the ShopTek™ micro-processor controller has a programmable service timer.When the service timer reaches the programmed value,the controller will display a service reminder message inthe status column. (After service is performed, you mustreset the service timer. For more information, see theEC2000 Controller Operation Manual.)

6.2 Daily maintenanceIf the compressor is run 24 hours a day, perform the ser-vices listed in Section 6.2.1 and Section 6.2.2 frequently.

6.2.1 Before starting the compressor• Check the compressor fluid level and add fluid

if necessary.

• Drain the water from the moisture separator.

6.2.2 After starting the compressor• Monitor the electronic controller display for any

fault messages or abnormal readings (forexample, unusually high or low temperatures orpressures).

• Check for fluid or air leaks, excessive vibration,or unusual sounds.

6.3 Recommended maintenance schedule

6.3.1 Service at 50 operating hours• Replace the fluid filter element.

• Check the condition of the purge oil return linefilter and replace the filter if necessary.

WARNING

Isolate the compressor from the power supply before performing any maintenance or service work.

WARNING

Do not disassemble any component of the com-pressor when the compressor is running or pres-surized. Before disassembling any compressor component, shut down the compressor, isolate the compressor from any sources of external pressure, and bleed the compressor’s internal pressure to zero.

WARRANTY NOTICE

Failure to use Sullair genuine parts when servic-ing a Sullair compressor may void your warranty.

WARNING

If you need to open the fluid filler plug, wait for the fluid level to settle and the separator tank to depressurize.

Table 6-1: Standard maintenance intervals

Fluid

Change intervals1

(all hours are operating hours)

Fluid2Fluid filter3

Fluid/air separator element Air filter3

Sullube® 10,000 hours 1000 hours6 months or 4000 hours 2000 hours

1If multiple intervals are listed, change the item at whichever interval is reached first.

2Or when required by fluid analysis or known contamination.3If the compressor is in a dusty environment, you should service the fluid and air filters more frequently.

6: Maintenance ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual


• Tighten all electrical connections.

• Assess the condition of the air filter element. Ifit is excessively dirty, you may need to replaceit more frequently than the normal schedule(every 2000 hours).

6.3.2 Service every 1000 operating hours• Replace the fluid filter element(s).

• Inspect the air filter element and replace it ifnecessary.

• Check the condition of the purge oil return linefilter and replace the filter if necessary.

• Tighten all electrical connections.

6.3.3 Service every 2000 operating hoursPerform all checks listed for every 1000 hours plus:

• Replace the air filter element.

• Grease the main motor bearings.

• Refer to the motor nameplate for greasefilling volume and filling locations.

6.3.4 Service every 2000 operating hours (or six months)

• While the compressor is running, take a fluidsample from the fluid sample valve for analysis.Refer to Figure 6-1.

• Change the compressor fluid (Sullube®) ifthe analysis indicates it is necessary.

6.3.5 Service every 4000 operating hours (or semi-annually)

Perform all checks listed for every 1000 and 2000 hours plus:

• Replace the fluid/air separator element andpurge oil return line filter.

• Inspect the flexible drive coupling and service itif necessary.

• Tighten all nuts, bolts, pipe fittings and electri-cal connections.

• Check that all safety devices are operating cor-rectly.

6.3.6 Service every 10,000 hoursPerform all checks listed for every 1000 and 2000 hoursplus:

• Change the compressor fluid (Sullube).

• If fluid analysis indicates you should changethe fluid more frequently, change the fluidper the schedule recommended by the anal-ysis.

6.3.7 Compressor fluid levelsCheck the fluid level when the compressor is running.The fluid level in the sight glass should normally bebetween halfway and three-quarters of the way up thesight glass.

• While the compressor is running, the fluid levelshould never exceed the maximum fluid levelshown in Figure 6-2.

• Fluid should be added before the fluid leveldrops below the minimum fluid level shown inFigure 6-2.

WARNING

Hot fluid under pressure

Could cause burns or bodily injury.

When taking a fluid sample, wear gloves that are heat- and liquid-resistant.

Figure 6-1: Fluid filter assembly

1. Fluid sample valve

2. Fluid filter



6.4 Compressor maintenanceRefer to Section 7: Parts List for the part numbers of allitems mentioned in this section.

6.4.1 Adding compressor fluidWhen adding compressor fluid, only use new fluid of thesame type that is already in the compressor. Using dirtyor used fluid may cause poor performance, foaming, andclogging of the filter element, nozzle, or pipes.

1. Shut down the compressor, bleed pressureto zero, and allow the compressor to cool.

2. Slowly loosen the fluid filler cap by turning itto the left by hand to allow any trapped air tovent, then remove the cap.

3. Pour fluid into the fluid filler.

4. Replace the fluid filler cap by turning the capto the right by hand until it will not turn anyfurther. Ensure the O-ring is properly seated.

5. Run the compressor for a short period oftime and check the fluid level through thesight glass, adding more fluid if necessary(see Section 6.3.7: Compressor fluid levels).

6.4.2 Changing compressor fluidWhen changing compressor fluid, only use new fluid ofthe same type that is already in the compressor. Usingdirty or used fluid may cause poor performance, foaming,and clogging of the filter element, nozzle, or pipes.

Figure 6-2: Compressor fluid levels

1. Fluid filler

2. Sight glass

A. Maximum fluid level

B. Normal fluid level

C. Minimum fluid level

WARNING

Do not attempt any maintenance when the com-pressor is running or pressurized. Stop the com-pressor, relieve all internal pressure, and isolate the power supply before performing mainte-nance. Only a competent person, experienced in compressor service, should perform any service, including maintenance.


Mixing of fluids other than Sullube® will void the compressor’s warranty.



Clean the lubrication system before changing fluid. If theambient temperature is outside of the allowed range forthe fluid, please contact your Sullair representative.

1. Shut down the compressor, bleed pressureto zero, and allow the compressor to cool.

2. Slowly remove the plug from the ball valve atthe bottom of the fluid/air separator tank.

3. Securely attach a drain hose to the valve.

• It may be convenient to run the waste fluiddirectly into a waste fluid drum.

4. Slowly open the ball valve. Leave the valveopen until the fluid stops draining.

5. Close the valve and remove the drain hose.

6. Replace the plug.

7. Remove the fluid filler cap.

8. Pour fluid into the fluid filler.

9. Replace the fluid filler cap by turning the capto the right by hand until it will not turn anyfurther. Ensure the O-ring is properly seated.

10. Run the compressor for a short period oftime and check the fluid level through thesight glass, adding more fluid if necessary(see Section 6.3.7: Compressor fluid levels).

6.4.3 Fluid filter maintenanceReplace the fluid filter element every 1000 hours of ser-vice. The fluid filter service indicator will display a warn-ing when the fluid filter element has exceeded its usefulservice life.

6.4.3.1 Replacing the fluid filter element1. Shut down the compressor and bleed pres-

sure to zero.

2. Remove the old element and washer using afilter wrench.

3. Clean the washer seating surface.

4. Apply a light film of silicone grease to thenew washer.

5. Hand tighten the new element until thewasher is seated.

6. Continue to tighten the element by hand anadditional ½ to ¾ turn.

7. Restart the compressor and check for leaks.

6.4.4 Air filter maintenanceInspect the air filter element every 1000 hours of service.Replace the air filter element every 2000 hours of serviceor if the service indicator of the air filter is in the red zonewhen running the compressor at full load.

• Internal element part number: 88290002-338

• External element part number: 88290002-337


Mixing of fluids other than Sullube® will void the compressor’s warranty.

CAUTION

Assume the fluid is hot and under pressure.

Figure 6-3: Fluid filter

1. Top cover

2. Washer

3. Fluid filter element1

1 Element part number: 250025-526



6.4.4.1 Replacing the air filter element1. Shut down the compressor.

2. Clean the outside of the canopy.

3. Unscrew the outer wing nut.

4. Remove the canopy and pour out any dust.

5. Unscrew the inner wing nut.

6. Remove the washer and the filter element.

7. Clean the inside of the canopy. Do not usecompressed air.

8. Install the new filter element.

9. Reassemble the air filter.

10. Reset the service indicator.

6.4.4.2 Inspecting the air filter element• Insert a bright light source into the air filter ele-

ment and look for light shining through holes orcracks.

• If you find any holes or cracks, the elementis damaged and should be discarded.

• Check the condition of all washers.

• If a washer is damaged, replace thewasher.

• If the filter element is excessively dirty, replaceit with a new element.

• Do not strike the filter element against ahard surface to remove the dirt. You maydamage the element.

• Do not oil the filter element.

6.4.5 Purge oil return line filter maintenance

Clean the purge oil return line filter after the first 50 hoursof service. Check the condition of the purge oil return linefilter every 1000 hours of service for blockages or otherproblems. Replace the purge oil return line filter whenyou replace the separator element.

When replacing the separator element, adjust the purgeoil return line tube so the tube is centered within the sep-arator element with a clearance from the separator ele-ment base of 1 to 3 mm.

6.4.6 Fluid/air separator maintenanceReplace the fluid/air separator element every 4000 hoursor if the pressure drop is greater than 0.7 bar (10 psi).You may need to replace the separator element more fre-quently in dusty or hot conditions.

6.4.6.1 Replacing the fluid/air separator element

1. Shut down the compressor and bleed pres-sure to zero.

2. Loosen the swivel nut on the discharge hoseconnecting the minimum pressure valve tothe aftercooler.

3. Disconnect the fittings and pipes from theseparator cover and minimum pressurevalve. Mark the locations of the fittings andpipes to ensure correct reassembly.

4. Remove the separator cover retaining bolts.

5. Remove the cover, complete with the mini-mum pressure valve, carefully clearing thepurge oil return line tube projecting into thecenter of the separator element.

6. Remove the separator elements.

Figure 6-4: Air filter service indicator

1. Air filter service indicator

NOTE

The fluid/air separator element cannot be cleaned or re-used.



7. Install the new primary & secondary fluid/airseparator elements and gasket assembly.

8. Reassemble in reverse order, carefullyadjusting the purge oil return line tube so ithas the correct clearance from the separatorelement base (see Section 6.4.5: Purge oilreturn line filter maintenance).

9. Evenly tighten the separator cover bolts to138 N m (102 lbf ft).

10. Check the continuity of the separator ele-ment to the ground.

11. Re-tension the separator cover bolts afterthe compressor has reached operating tem-perature.

6.4.7 Minimum pressure valve maintenance

1. Shut down the compressor and bleed pres-sure to zero.

CAUTION

Do not remove the staples incorporated into the gaskets.They maintain a ground contact with the separator.

Figure 6-5: Fluid/air separator tank

1. Primary fluid/air separator element1

2. Secondary fluid/air separator element2

1 Primary element part number: 250042-8622 Secondary element part number: 02250061-137

Figure 6-6: Minimum pressure valve

1. Valve body 6. Spring

2. Check valve assembly 7. Piston

3. Hex head set screw 8. O-ring

4. Spring lock washer 9. Top cap

5. Gasket

Minimum pressure valve repair kit part number: 88290018-146



2. Disconnect the pipe connected to the mini-mum pressure valve and remove the valvefrom the cover of the fluid/air separator.

3. Unscrew the top cap of the valve andremove the piston from the valve.

4. Clean the valve and piston carefully.

5. Replace the O-ring, applying a layer ofgrease to the O-ring and the piston.

6. Apply Loctite gasket maker to the top cap ofthe valve and reassemble the valve.

7. Reinstall the valve on the cover of the fluid/air separator tank and reconnect the pipe.

6.4.8 Solenoid valve maintenanceThe solenoid valve needs little service. However, if thesolenoid is reacting slowly or is leaking and the workingvoltage is correct, you should clean the valve or, if neces-sary, replace it (repair kit part number 88291010-180).

6.4.9 Drive coupling maintenance

1. Shut down the compressor.

2. Remove the shroud from the fixing cap.

3. Remove the screws from the fixing cap.

4. Slide the fixing cap to expose the elastomer.

5. Remove the elastomer and inspect it.

• If the elastomer is worn out, deformed, ortorn, replace it with a new elastomer andcontact your Sullair representative.

6. Reassemble the coupling assembly.

• The coupling shall be mounted so that thegap between the ends of the two plates is2 – 3 mm.

7. Replace the screws on the fixing cap.

8. Replace the shroud on the fixing cap.

6.5 Main motor operation and maintenance

• Ambient temperature ≤ 40°C (104°F)

• Altitude ≤ 1000 m (3280 ft)

See the main motor nameplate and the other topics inthis section for additional information about operatingconditions.

6.5.1 Main motor operation• The main motor must be grounded correctly.

The ground wire of the main motor is alreadyconnected in the electric cabinet. You onlyneed to connect this connection point to yourground.

• The lead wires of the main motor are clearlymarked.

• The main motor connection diagram is on themotor nameplate.

• If the voltage and frequency of the powersource for the main motor match the require-ments on the motor’s nameplate, the motor canoperate continuously at the rated power × utilitycoefficient. If the power source’s frequencydeviates from the value on the nameplate by1%, or under voltage or over voltage exceeds10%, the motor is not guaranteed to deliver thatoutput power continuously.

• The compressor motor runs best when imbal-ance among the three phases does not exceed1%.

WARNING

Isolate the compressor from the power supply before making any repairs or adjustments to the drive coupling.

Figure 6-7: Flexible drive coupling

1. Motor spindle plate

2. Elastomer

3. Fixing cap

4. Compressor mounting plate



• A current detection device in the electrical cabi-net of the compressor provides motor overloadprotection.

• The motor should not make intermittent orunusual noises or vibrations when running(either at no load or load).

6.5.2 Main motor maintenance and repair• The operating environment should be dry, the

motor surface should be clean, and the motor’sair inlet should not be blocked by dust or fibers.

• When the motor overload protection deviceshuts down the compressor, do not restart thecompressor until you find and eliminate thecause of the overload.

• Make sure bearings are well lubricated. Greaseshould be added or replaced every 2000 hours.If grease becomes too hot or deterioratesduring operation, replace it. Before addinggrease, clean the bearing and cap slot. Differ-ent motors use different types of grease. Seethe motor nameplate for the type of greaseneeded.

• Replace the bearings at the end of their servicelife. (At the end of the bearings’ service life, themotor will create significantly more noise andvibration).

• After any motor faults occurs, contact your Sul-lair representative.

6.5.3 Periodic inspection of the main motor

You should inspect the main motor yearly to ensure thatthe motor is operating correctly and in good condition.

You should inspect the motor every six months if thecompressor is exposed to any of these conditions:

• Corrosive or conductive dust

• Excessive dirt or dust (the accumulated dustmay interfere with the compressor’s ventilation)

• Chemical smoke, steam, salt mist, or oil mist

• A very wet or very dry atmosphere

• Radiant heat

• Pests or mold

You should also inspect the main motor every six monthswhen the compressor runs under nonstandard condi-tions, such as:

• The rated voltage and/or frequency often devi-ates from the limits set under Section 6.5.1:Main motor operation.

• The compressor is in a room with either poorventilation or an ambient temperature over40°C (104°F).

• The motor starts and stops often because offrequent fluctuations in air demand.

6.5.3.1 Periodic inspection checklist• Add or change the main motor bearing grease

according to the maintenance schedule.

• Inspect the bearing seal and eliminate oil leaksyou find.

• Check the end cover and the shroud for con-densation, deposited water, iron rust, or corro-sion.

• Check for excessive dust or other foreign mate-rial.

• Check the main lead-out wiring for overheatingor a corona discharge.

• Tighten the non-insulated electric connectionsand check them for overheating, corrosion, orelectrical arcing.

• Tighten all nuts and bolts.

6.5.4 Check and clean the windings The best way to clean the motor windings depends onboth the accessibility of the surface and what you are try-ing to remove from it. For a thorough cleaning, or if thewinding is very dusty, the rotor needs to be removed fromof the stator.

6.5.4.1 Dry clothYou can clean easy-to-reach surfaces that are dusty witha dry, clean, lint-free cloth.

WARNING

Isolate the compressor from the power supply before making any repairs or adjustments to the drive coupling.

WARNING

Isolate the compressor from the power supply before checking or cleaning the windings.



6.5.4.2 Brush and vacuumYou can clean easy-to-reach surfaces that are dirty orvery dusty by scrubbing them with a short, hard, non-metal brush, and then vacuuming up the loosened dirtand dust. (Vacuuming the dirt after loosening it preventsthe dirt from getting deposited on other components.)

6.5.4.3 Compressed airYou can blow dry compressed air through gaps to cleanhard-to-reach surfaces, but you must follow the guide-lines for cleaning with compressed air.

• The pressure of the compressed air must notexceed 0.2 MPa (29 psi). Air at pressuresabove 0.2 MPa (29 psi) can damage the insula-tion.

• The compressed air does not contain any con-densed water so that the motor stays dry.

• The compressed air does not blow the dustdeeper inside the motor. This could make thedust harder to clean or even block an air duct.

6.5.4.4 SolventFor a surface covered in bitumen, grease, wax, or oil,wipe the surface with a cloth soaked in a solvent andthen with a dry, clean, lint-free cloth.

Sullair recommends using a petroleum-based solvent forcleaning the insulation. In very flammable areas, methylchloroform can be used. Although this solvent is not com-

bustible under normal conditions, partial ventilation isrequired when the smell of the solvent becomes strong.

6.6 TroubleshootingBecause a compressor fault can have multiple causes,you should carry out a systematic analysis of the fault todetermine the specific cause before performing serviceor replacing parts.

To avoid damaging the compressor, always perform avisual check of it prior to attempting any repair, remem-bering to:

• Check for loose or disconnected cable leads

• Check for damaged or disconnected pipelines,tubing, or hoses

• Check for parts damaged by excessive heat orshort circuits

Table 6-2: Troubleshooting guide lists some compressorsymptoms with their most probable causes and remedies

CAUTION

Never disassemble the machine without a spe-cific purpose.

Table 6-2: Troubleshooting guide

Symptom Possible causes Remedy

High discharge air temperature

Low fluid level in fluid/air separator Check fluid level. Add fluid if necessary.

Cooler fin dirty Clean cooler fin

Fluid filter clogged and bypass valve failed

Replace fluid filter element

High ambient temperature Improve ventilation

High resistance in exhaust duct• Enlarge exhaust duct

• Install fan in the duct

Thermal resistor temperature trans-ducer RTD failure

Check RTD connector. If the connector is good, replace RTD.

Fan motor damaged Check and repair fan motor



Air supply pressure lower than pressure rating

Air demand higher than air supply• Reduce air demand

• Check piping for air leaks

Air filter clogged Replace air filter element

Inlet valve does not open completelyCheck movement of inlet valve. Check settings of the pressure relief valve and pressure regulator.

Pressure transducer faultCheck transducer’s contacts. Replace transducer if contacts are normal.

Pipeline pressure higher than unloading pressure

Pressure transducer faultCheck transducer’s contacts. Replace transducer if contacts are normal.

Unloading components (e.g. blow-down valve, inlet regulator valve) are not working properly

Check if unloading components are working normally

Solenoid valve unload failure Check solenoid valve

Control pipeline is leaking air Check if control pipeline is leaking air

Fluid consumption too high

Purge oil return line filter or nozzle blocked

Clean purge oil return line filter and noz-zle

Fluid/air separator element damaged or washer displaced

Check fluid/air separator element and washer. Replace if necessary.

System piping is leaking fluid Check if system piping is leaking fluid

Fluid level too high Discharge some fluid

Excessive fluid foam Change fluid

Vibration and noise increased

Isolator damaged Replace isolator

Fan fault Check centrifugal fan

Table 6-2: Troubleshooting guide

Symptom Possible causes Remedy

Section 7

ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual 7: Parts List


Parts List7.1 Procedure for ordering partsYou should order parts from the nearest authorized Sul-lair representative or the representative from whom thecompressor was purchased. If for any reason you cannotobtain parts in this manner, contact the factory directly atthe address, phone number, or website listed below.

When ordering parts, always indicate the serial numberof the compressor. You can get the serial number fromthe Bill of Lading for the compressor or from the SerialNumber Plate located on the compressor (see Figure 7-1: Serial number plate and location).

The genuine Sullair service parts listed meet or exceedthe demands of this compressor. Use of replacementparts other than those approved by Sullair will void theSullair warranties specific to this product and may lead tohazardous conditions over which Sullair has no control.Such conditions include, but are not limited to, bodilyinjury and compressor failure.

Sullair North America Operations1 Sullair Way

Michigan City, IN 46360 USAwww.sullair.com

1-800-SULLAIR (USA only)1-219-879-5451 (non-USA)

Figure 7-1: Serial number plate and location

7: Parts ListShopTek™

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7.2 Recommended spare parts list

Service kit part number Qty Description

250025-526 1 Element for compressor fluid filter

88290002-337 1 Element for heavy duty primary air filter 88290002-207

88290002-338 1 Element for heavy duty secondary air filter 88290002-207

250042-862 1 Primary element for fluid/air separator

02250061-137 1 Secondary element for fluid/air separator

88292009-684 1 Maintenance kit for inlet valve 88292027-255

88292009-685 1 Repair kit for inlet valve 88292027-255

88291010-178 1 Repair kit for pneumatic control integrated block in the air inlet valve control component assembly (capacity adjustment) 88292027-255

88291010-180 1 Repair kit for solenoid valve in the air inlet valve control component assembly (capacity adjustment) 88292027-255

250017-280 1 Pressure regulator

88290018-146 1 Repair kit for minimum pressure valve 242405

049542 1 Thermal valve element

02250117-782 1 Repair kit for purge oil return line filter

02250050-364 1 Repair kit for shaft seal

88290003-326 1 Element, coupling 88290003-311/88290007-806

88292020-371 1 Repair kit for the auto drain of water trap 88291013-632 in air discharge system

250022-669 1 Fluid, Sullube® (5 gallons)

250022-670 1 Fluid, Sullube® (55 gallons)


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7.3 Motor and air end system

Key Part number Qty Description Notes

1 829108-150 6 CAPSCREW,HEX GR5 1/2-13 X 1 1/2"

2 837808-125 6 WASHER, SPRLOCK REG PLTD 1/2"

3 88290002-205 1 ADAPTER,MTR-COMP LS16-100 CHNSZ

4 88290002-206 2 GUARD,COUPLING LS16-100 CHNSZ

5

88290003-311 1 COUPLING,SHAFT VULKAN LS16-75+ FOR 365TSC-4

88290003-312 1 COUPLING,FLEXOMAX-G128/GG VULKAN+ FOR 365TSC-2

88290007-806 1 COUPLING,SHAFT VULKAN LS16-100+ FOR 405TSC-4

6 ———— 1 COMPRESSOR SEE COMPRESSOR LIST

7 88290020-282 2 ISOLATOR,VIBRATION AIREND WS4500-7500

8 88290020-283 2 ISOLATOR,VIBRATION WS4500-7500

9 88290020-284 1 SUPPORT,AIREND WS45-75

10 88290021-292 1 SUPPORT,AIR END WS45-75 FOR MAINTENANCE USE

11 88291005-932 1 SUPPORT,MOTOR AS45-75 FOR 365TSC

12 88292013-890 2 BOOT, GUARD FOR WIRE

13 ———— 1 MOTOR SEE MOTOR LIST

14 88292020-093 1 FRAME BSE,ST45/55/75 AC

1588811112-050 2 SCREW,M12X50 GB5782-86GAV SSAI FOR 365TSC

88811112-055 2 SCREW,M12X55 GB5782-86GAV SSAI FOR 405TSC

16 88812110-025 4 SCREW,M10X25 GB5783 GAV SSAI FOR 365TSC

17 88812112-025 2 SCREW M12X25 GB5783 GAV SSAI

18 88812112-030 4 SCREW,M12X30 GB5783 GAV SSAI


20 88813108-020 10 SCREW,M8X20 GB5787-86 SSAI

21 88831110-020 4 WASHER,10 GB97.1-85 GAV SSAI FOR 365TSC

22 88831112-025 6 WASHER,12 GB97.1-85 GAV SSAI


24 88832110-026 4 WASHER,SPRG 10 GB93-87 GAVSSAI FOR 365TSC

25 88832112-031 8 WASHER,SPRG 12 GB93-87 GAVSSAI


27 88833112-033 2 WASHER,BIG12 GB96-85 SSAI

28 88290020-389 2 BOOT,GUARD FOR MOTOR NOT FOR UL&CUL MOTOR

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Compressor list

Motor list

A1 FOR 365TSC FRAME MOTOR

A2 FOR 405TSC FRAME MOTOR

A3 FROM AIR INLET FILTER

A4 MAIN OIL CONNECTION

A5 OIL RETURN FROM SIGHT GLASS ON RECEIVER TANK

A6 TO RECEIVER TANK

Part number Qty Description Notes

88290009-321 1 COMPRESSOR & PARTS,DXX163167E146S47ACM ST4508 60Hz/ST4509 60Hz US




1 88292016-171 1 MOTOR,60HP1.25 440-480V/6 23 UL+ 365TSC-4

2 88292016-172 1 MOTOR,75HP1.25 460/6 23 UL&CUL+ 365TSC-4

3 88292016-176 1 MOTOR,100HP1.25 460/6 23 UL&CUL+ 405TSC-4



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7.4 Air inlet system


1 02250061-835 1 ELBOW, RUB 90DEG 5"ID

2 408153 2 CLAMP, HOSE 6"DIA WORM DRIVE

3 829108-150 4 CAPSCREW,HEX GR5 1/2-13 X 1 1/2"


5 88290002-207 1 FILTER,AIR LS16 100HP CHNSZ

6 88290002-208 1 BAND,MOUNTING AIR FLTR LS16-100

7 88290004-147 1 GASKET,INL VLV LS12-50 LF SSAI

8

88291006-018 1 VALVE,ASSY INLET&CTL GRP AS45-75 ON/OFF OTHERS

88291010-175 1 VALVE,ASSY INLET&CTL GRP AS45-75 REGULATING OTHERS

88292027-271 1 VALVE,ASSY AIRINLET ON/OFF ON/OFF US

88292027-255 1 VALVE,ASSY AIRINLET REGULATION REGULATING US

988291007-195 1 SUPPORT,AIR FILTER AS45-75 FOR 364/365/404/405TSC

88291011-145 1 SUPPORT,AIR FILTER AS75 AUS FOR 444/445TSC

10 88811110-070 1 SCREW,M10X70 GB5782-86GAV SSAI


12 88821110-084 3 NUT,M10 GB6170-86 GAV SSAI



Drawing notes

A1 COMPRESSOR INLET

A2 ATTACH TO ADAPTER


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7.5 Fluid piping system


1 02250101-372 1 SEAL,U-CUP VITON THERM VLV

2 02250196-306 1 VALVE, KP18NV (1/8" NPTF, VITON)

3 49542 1 ELEMENT,THERMAL VALVE 175

4 250025-526 1 ELEMENT,FLUID FILTER

5 826502-144 1 O-RING,VITON 2 1/2 X 3/32

6 88290023-074 1 SWITCH,MANIFOLD OIL FILTER FRAME+

7 88291008-555 1 HOSE,OIL IN CLR AS45-75AC

8 88291012-564 1 HOSE,OIL INLET AIREND ST45-75 FIXED SPEED

9 88292010-002 1 CONNECTOR,OIL FLTR-THRMVLV 150SSAIC

10 88292017-554 2 CONNECTOR,M-M42X2 F-M42X2SAE PORT

11 88292019-147 1 HOSE,OIL AIREND ST45-75AC FIXED SPEED

12 88292019-225 1 ELBOW,90 END ADJUST M42-FACE M40

13 88818210-040 4 SCREW.SOCKET M10X40 GB/T70.1


15 88842018-029 6 O-RING,VITON 29.0X1.80

16 88842029-386 10 O-RING,VITON 38.6X2.9 ISO6149

17 88892042-042 1 ADAPTER,END M42-FACE M42

18 88896042-042 4 ELBOW,90 END ADJUST M42-FACE M40

19 89250112-477 1 HOUSING,THRM VLV W/BYP CONN M42X2

20 87250009-396 9.2 LUBRICANT,SULLUBE 2G 1GA(BULK QTY) NO BALLOON

Drawing notes

A1 TO RECEIVER TANK

A2 TO COMPRESSOR

A3 TO OIL COOLER

A4 FROM OIL COOLER


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7.6 Cooling fan system

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7.6 Cooling fan system


1 250022-436 13 WEATHERSTRIP,3/16 X 3/8 FT

2 88291010-006 1 ADAPTER,VENTURI/COOLER AS45-75

3

88292017-516 1 COOLER,FLUID&AFTER ST45/55 ASME ST45/55 ASME

88292017-517 1 COOLER,FLUID&AFTER ST75 ASME ST75 ASME

88292018-732 1 COOLER,FLUID&AFTER ST45/55 GB ST45/55 GB

88292018-733 1 COOLER,FLUID&AFTER ST75 GB ST75 GB

488292018-870 1 FAN,ST45/55 230/460/6 UL&CSA+ ST45/55 230/460V US

88292018-871 1 FAN,ST75 230/460/6 UL&CSA+ ST75 230/460V US

Drawing notes

A1 TO THERMAL BLOCK

A2 FROM THERMAL BLOCK

A3 TO WATER SEPARATOR

A4 FROM MINIMUM PRESSURE VALVE


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7.7 Fluid/air separation system


1 20169 2 CONNECTOR, FLEX 1/4T X 1/4P

2 02250061-137 1 ELEMENT,AIR/OIL SEP SECONDARY

3 02250097-349 1 VALVE,RELIEF 3/4"200#550SCFM W/TEFL ASME

4 02250101-490 2 CONNECTOR,TUBE MALE BHD 1/4 X SAE

5 02250117-782 2 FILTER,ASSEMBLY GENISIS FILTR +

6 02250125-775 1 ORIFICE,PLUG 1/8"NPT .062

7 02250125-776 1 ORIFICE,PLUG BRASS 1/8"NPT X 3/32"

8 02250126-129 2 GLASS,SIGHT/ORF BLK-SAE

9 250042-862 1 ELEMENT,AIR/OIL SEP PRIMARY

10 810104-025 1 CONNECTOR, TUBE-F 1/4 X 1/4"

11 810504-025 1 ELBOW, TUBE-M 1/4 X 1/4"

12 828408-150 4 CAPSCREW,FERRY HEAD 1/2-13 X 1 1/2"


14 841215-004 3 TUBING,STNLS STL 1/4" 20GA FT

15 860704-025 1 ELBOW, PIPE M/F 1/4 X 1/4"

16 869825-025 1 TEE,MALE PIPE 1/4" BRASS

17 88290001-031 1 PLUG,OIL TANK 25S-300 SSAIC

18 88290001-219 1 GLASS,SIGHT,FSF4525S-300 SSAIC

19 88290002-435 1 VALVE,BALLDN15 Q11MP-25P SSAIP

20 88290002-637 1 SUPPORT,BRKT-OIL LS16-100 SSAIC

21 88290002-688 1 FLANGE,HALF 2-1/2"" LS16-100 SSAI

22 88290002-836 1 PLUG,TANK DRAIN R1/2

23 88291006-621 1 HOSE,FLEX DN65 AS45-75 ST45/55 EUR/AUS?ST45-75 US

24 88291010-492 1 TANK,SEP AS45-75 ASME+ ASME

25 88292007-724 1 CONNECTOR,90DEG M33X2-RC2 FOR CE TANK

26 88292011-696 1 TERMINAL,SC16-8+16SQMM

2788292019-142 1 CONNECTOR,G3/4"(M) TO NPT3/4"(F) FOR ASME TANK

88290005-474 1 CONNECTOR,G3/4X1 VALVE DN25 FOR ST7508 GB TANK

28 88811112-030 4 SCREW M12X30 GB5782-86GAV SSAI

29 88811112-060 4 SCREW,M12X60 GB5782-86GAV SSAI

30 88813108-016 2 SCREW,M8X16 GB5787-86 SSAI

31 88813108-025 4 SCREW,M8X25 GB5787-86 SSAI


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33 88832108-021 4 WASHER,SPRG 8 GB93-87 GAV SSAI


35 88842026-051 1 O-RING,VITON 51.5X2.65GB3452.1

36 88842035-023 1 O-RING,VITON 23.6X3.55GB3452.1

37 88842035-028 1 O-RING,VITON 28X3.55 GB3452.1 FOR CE TANK

38 88842035-047 1 O-RING,VITON47.5X3.55GB3452.1

39 88842035-069 1 O-RING,VITON 69X3.55 GB3452.1

40 88842035-075 1 O-RING,VITON 75X3.55 GB3452.1

41 88871008-044 1 NIPPLE,R1/2 GB3287 SSAI

42 88834233-027 1 WASHER,SEG JB982 FOR ST7508 GB TANK

Drawing notes

A1 FROM COMPRESSOR DISCHARGE

A2 ATTACH TO TEMPERATURE SENSOR

A3 TO MINIMUM PRESSURE VALVE

A4 TO AIRINLET CONTROL VALVE

A5 ATTACH TO PRESSURE GAUGE

A6 TO THERMAL BLOCK

A7 TO COMPRESSOR OIL RETURN PORT

A8 ATTACH TO THE FRAME



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7.8 Air discharge system

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7.8 Air discharge system


1 88290001-541 1 CONNECTOR,SEP-MIN VLV 150AC SSAIC

2 88290005-230 1 ADAPTER,ELBOW ADJUST LS16-75/100

3 88290005-231 1 ADAPTER, LS16-75/100 CHNZ

4 88291011-165 1 HOSE,FLEX DN40 ST45-75 AC

5 88291009-260 1 CONNECTOR,DISC SYS AS45-75AC VSD

6 88291011-118 1 CONNECTOR,DISC SYS ST45-75 AC

7 88291011-207 1 SUPPORT,AIROC AS75 AUS

888291013-209 1 SEPARATOR,TRAP WS250 AS132 R2"

88291013-632 1 SEPARATOR,TRAP WS250 FNPT 2" NPT2"

988291007-773 1 CONNECTOR,ADJUST M48X2 TO R2 R2"

88292020-318 1 CONNECTOR,ADJUST M48X2 TO NPT2" NPT2"

10 88813108-016 2 SCREW,M8X16 GB5787-86 SSAI

11 88813108-025 2 SCREW,M8X25 GB5787-86 SSAI

12 88822108-076 2 NUT,M8 GB6177-86 SSAI

13 88842026-042 2 O-RING,VITON 42.5X2.65GB3452.1

14 88842035-045 4 O-RING,VITON 45X3.55 GB3452.1

15 88842035-065 1 O-RING,VITON 65X3.55 GB3452.1

16 88851045-075 1 CLIP,SGL45X75 JB/ZQ4492-86SSAI

17 89242405 1 VALVE,MINIMUM PRESSURE & CHECK-2 MPT

Drawing notes

A1 FROM MINIMUM PRESSURE VALVE

A2 PACKAGE OUT

A3 MOISTURE DRAIN


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7.9 Control system

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7.9 Control system


1 02250052-841 6 INSERT,NYL TBG 1/4 OD X .035W

2 02250054-861 6 TUBE,NYL .25 OD X 040W BLK(FT)

3 250003-869 1 INDICATOR, RESTRICTION 20"H20

4 250018-427 1 CONNECTOR, 1/4"TUBE X 1/8"NPT

5 807600-005 1 BUSHING, RED 1/4 X 1/8" STL

6 823202-000 1 NIPPLE, GALV XS 1/8 X CLOSE

7 88290002-119 1 GAUGE,PRES D50 0-1.6MPA 50BD SSAI

8 88290014-514 1 SENSOR,PRESSURE 250PSI 4-20MA+

9 88290021-398 1 CONTROLLER,EC2000 AC110V HONGSAI

10 88290021-986 1 SENSOR,TEMP PT100 ONLY FOR AS

11 88291011-142 1 CONNECTOR,MG12A-05(3-6.5) IP68 PA6

12 88291011-143 1 CONNECTOR,MG16A-10(5-10) IP68 PA6

1388291011-111 1 TUBE,&FTG GRP FGK--M64B 0.8M ST45-75AC US

88291011-930 1 TUBE,&FTG N-MGQ75B OTHERS

14 88291012-012 1 CONNECTOR,ELBOW G1/4MXNPT 1/8F

15 88291012-013 1 CONNECTOR,G1/4FXG1/8F

16 88291012-014 1 CONNECTOR,M18X1.5


17

88292016-662 1 STARTER,ST45AC460/575V YD ULCUL+ ST45AC 460/575V US



19 88813108-016 6 SCREW,M8X16 GB5787-86 SSAI

20 88821104-032 4 NUT,M4 GB6170-86 GAV SSAI


22 88832104-011 4 WASHER,SPRG 4 GB93-87 GAV SSAI


24 88834218-027 2 WASHER, 18

25 868508-050 2 NIPPLE,PIPE HEX 1/2 X 1/2" PLT

26 804415-020 1 TEE,FEMALE PIPE GALV 1/2

27 88291008-364 1 VALVE,2-WAY PNEUMATIC 1/2 NPT

28 250041-088 1 TEE, M RUN 1/4T PLSX 1/8NPT

29 860208-050 3 ELBOW, 37FL 90M 1/2 X 1/2"


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30 250018-428 2 CONNECTOR, 1/4"TUBE X 1/4"NPT

31 88290017-336 4 HOSE,HIGH PRESS 1/2X1200

32 860108-050 1 CONNECTOR, 37FL/MPT 1/2 X 1/2"

33 250018-430 1 ELBOW, 1/4"TUBE X 1/4"NPT

34 88292031-784 1 ORIFICE,6.35MM NPT1/2-NPT1/2

Drawing notes

A1 ATTACH TO FRAME

A2 ATTACH TO ENCLOSURE

A3 ATTACH TO ENCLOSURE

A4 MOTOR WIRING



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7.10 Starter assembly

88292017-767 R04 (Sh1)


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7.10 Starter assembly

88292017-767 R04 (Sh2)


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Key Mark Part number Qty Description Notes

1 / 88292018-174 1 CUBICLE

2 / 88292018-669 1 MOUNTING PLATE

3 KM1,2

88291012-882 2 CONTACTOR ST45

88291012-883 2 CONTACTOR ST55

88292018-173 2 CONTACTOR ST75

4 KM3

88291013-038 1 CONTACTOR ST45

88291012-882 1 CONTACTOR ST55

88291012-882 1 CONTACTOR ST75

5 KM4 88291012-880 1 CONTACTOR_FAN AB

6QF1 88291012-879 1 BREAKER ST45-55

QF1 88291013-763 1 BREAKER ST75

7 XT0 88292017-775 1 TERMINAL BLOCK AB

8 XT1 88290016-045 10 TERMINAL BLOCK

9 FR1 88291012-902 1 OVERLOAD RELAY AB

10 PE 88291011-071 1 PE BAR

11 88290016-046 3 TERMINAL END COVER AB

12 XT1 88290017-859 2 PE TERMINAL AB

13 EC2000 88290021-398 1 CONTROLLER SULLAIR INSTALL

14 SB1 88290018-650 1 E-STOP AB

15 SB1 88290018-651 1 E-STOP CONTACT AB

16 SB1 88290018-648 1 E-STOP WARNING INDICATOR AB

17 TC1 88292017-769 1 TRANSFORMER

18 / 88291007-580 3M WIRE DUCT

19 0 88292007-713 1 PHASE SEQUENCE RELAY EATON

20 FU4 88291013-669 3 FUSE BUSSMAN

21 XT1 88290016-047 2 TERMINAL GENERAL TYPE

22 FU4 88292031-308 1 FUSE HOLDER VOHNER

23 FU1,3 88292031-307 2 FUSE HOLDER VOHNER

24 FU2 88292031-306 1 FUSE HOLDER VOHNER

25 FU2,3 88291012-905 3 FUSE BUSSMAN

26 / 88290006-263 2 RAIL

27 / 88292017-463 1 WIRING DIAGRAM VER03

28 FU1 88292021-716 2 FUSE BUSSMAN


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7.11 Enclosure

8829019-158 R00


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1 02250048-520 18 PLUG, PLASTIC 1.0 DIA BLACK

2 02250151-635 3 BEARING,FLANGED 5MM 3700

3 250022-436 48 WEATHERSTRIP,3/16 X 3/8 FT

4 88292019-582 1 PANEL,A ST45-75 AC

5 88292019-583 1 BM,D ST45-75 AC

6 88292019-584 2 PANEL,A ACCESS ST45-75AC

7 88292019-585 1 BM,E ST45-75 AC

8 88292019-586 1 COVER,A ST75 AUS

988292019-587 2 ANGLE,D ROOF CLR ST45/55AC ST45/55

88292019-588 2 ANGLE,B ROOF CLR ST75AC ST75

10 88292019-589 2 PANEL,C CORNER ST45-75 AC

1188292019-590 2 ANGLE,A ROOF CLR ST45/55AC ST45/55

88292019-591 2 ANGLE,C ROOF CLR ST75AC ST75

12 88292019-592 2 DOOR,C ST45-75 AC

13 88292019-593 1 BM,C ST45/75 AUS

14 88292019-594 1 PANEL,D SUPPORT ST45-75AC

15 88292019-595 1 PANEL,B ACCESS ROOF ST45-75AC

16 88292019-596 1 DOOR,B ST45-75

17 88292019-597 1 BM,D ST45/75 AUS

18 88292019-598 1 PANEL,A CORNER ST45-75

19 88292019-599 1 BM,A ST45/75 AUS

20 88292019-600 1 BM,B ST45-75 AC

21 88292019-601 1 PANEL,E SUPT ST45-75 AC

22 88813108-016 101 SCREW,M8X16 GB5787-86 SSAI


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7.12 Decal locations

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7.12 Decal locations


1 02250069-389 1 DECAL,FLUID SULLUBE

2 02250110-891 1 DECAL,EN-WARNING MIXING FLUIDS

3 02250171-797 1 DECAL, DO NOT BREATH COMP AIR

4 02250229-398 1 DECAL,WRNG REMOTELY CONTROLLED

5 02250229-399 1 DECAL,WRNG ELECTRICAL SHOCK

6 042218 1 DECAL,DANGER HI VOLTAGE

7 049685 1 DECAL,WARNING-COMP OIL FIL CAP

8 049852 1 DECAL,WARNING GROUND FAULT

9 049855 2 DECAL,WARNING-SEVER-FAN-INDUS

10 241814 2 DECAL,FORK LIFTING

11 250021-337 1 TAG, FIRST START

12 250021-564 2 DECAL,ROTATION 3.5"LG

13 407408 1 DECAL,WARNING-HOT SURFACES

14 88290013-723 4 RIVET,BUSTERPOP DIA3.2 L=8

15 88290016-067 1 DECAL,VOLTAGE WAN COMPONENT

16 88291011-503 1 DECAL,SULLAIR LOGO ST30/37

1788290013-683 1 NAMEPLATE,FOR EXPORT MODEL UL

88292016-647 1 NAMEPLATE,CSA ST4-ST15 SERIES CSA

18 88292020-630 1 DECAL,SULLAIR ST45-75

19

88292020-694 1 DECAL,SULLAIR ST45 ST45



7: Parts List ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual

Notes:


ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual A: Nominal Sizes

Appendix A:


Nominal Sizes

Metric nominal size (DN) is the nominal size for valves,flanges and fittings as defined by ISO 6708-1980. DNdesignates the size of all components in a piping systemother than components designated by outside diametersor by thread size. For example, steel tubes are desig-nated and ordered by outside diameter and thickness.

A metric nominal size is indicated by the letters “DN” fol-lowed by a number without any unit of measure. For met-ric to imperial nominal size equivalents, refer to Table A-1: Metric to Imperial nominal sizes.

NOTE

Because DN is a round number that cannot be measured and is only loosely related to manu-facturing dimensions, you should only use the DN number for reference and never for calcula-tions.

Table A-1: Metric to Imperial nominal sizes

Metric DN(Nominal Size)

Imperial NS(Nominal Size)

A dimensionless designation Designated in inches sometimes as ND, NB or NPS

6 ⅛″

8 ¼″

10 ⅜″

15 ½″

20 ¾″

25 1″

32 1¼″

40 1½″

50 2″

65 2½″

80 3″

A: Nominal Sizes ShopTek™ ST45, ST55, ST75 (U.S.A. & Mexico) Operation & Maintenance Manual

Notes:



Information and specifications are subject to change without prior notice.Subject to EAR, ECCN EAR99 and related export control restrictions.

Sullair, LLC1 Sullair Way

Michigan City, IN 46360 USAwww.sullair.com

1-800-SULLAIR (USA only)1-219-879-5451 (non-USA)

Documents

OPERATION & MAINTENANCE MANUAL · Sullair training courses provide hands-on and classroom instruction for the proper operation, maintenance, and servicing of Sullair products. Individual