User Manual: ST4, ST5, ST7, ST11, ST15
User Manual: ST4, ST5, ST7, ST11, ST15
PART NUMBER:
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SAFETY WARNING WARRANTY NOTICE The information in this manual is current as of its
publication date and applies to compressor models
indicated on this cover with serial number:
Users are required to read the Failure to follow the instructions
entire User Manual before han- and procedures in this manual,
37216100224
and all subsequent serial numbers until next revision of
dling or using the product. Keep or misuse of this equipment, will this manual or release of a replacement manual.
the User Manual in a safe place void its warranty.
for future reference. Publication date: 03/31/2017
Copyright © 2017 Sullair, LLC. All rights reserved.
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.
- Or Write -
Sullair, LLC
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
Table of Contents
Section 1: Safety.......................................................................................................1
1.1 General....................................................................................................... 1
1.2 Personal protective equipment ................................................................... 1
1.3 Pressure release ........................................................................................ 1
1.4 Fire and explosion ...................................................................................... 2
1.5 Moving parts ............................................................................................... 2
1.6 Hot surfaces, sharp edges and sharp corners............................................ 3
1.7 Toxic and irritating substances ................................................................... 3
1.8 Electrical shock........................................................................................... 4
1.9 Lifting .......................................................................................................... 4
1.10 Entrapment ................................................................................................. 5
1.11 Implementation of lockout/tagout................................................................ 5
1.12 Safety warnings .......................................................................................... 6
Section 2: Description..............................................................................................9
2.1 Introduction................................................................................................. 9
2.2 Compressor component description........................................................... 9
2.3 Compressor cooling and lubrication system—functional description ....... 14
2.4 Compressor discharge system—functional description............................ 14
2.5 Control system—functional description .................................................... 15
2.6 Air inlet system, functional description ..................................................... 18
2.7 Controller/keypad ..................................................................................... 19
2.8 LCD display .............................................................................................. 19
2.9 LED lights ................................................................................................. 20
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Table of Contents ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual Table of Contents
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Table of Contents ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
Notes:
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 1: Safety
Section 1
Safety
most compressors and the concepts behind these state-
NOTE ments are generally applicable to all compressors.
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1: Safety ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
accordance with their manufacturer's recommenda- material. Any acoustical material with a protective
tions. covering that has been torn or punctured should be
replaced immediately to prevent accumulation of liq-
E. DO NOT use air tools that are rated below the maxi-
uids or fluid film within the material. DO NOT use
mum rating of the compressor. Select air tools, air
flammable solvents for cleaning purposes.
hoses, pipes, valves, filters and other fittings accord-
ingly. DO NOT exceed manufacturer’s rated safe D. Disconnect and lock out all power at source prior to
operating pressures for these items. attempting any repairs or cleaning of the compressor
or of the inside of the enclosure, if any.
F. Secure all hose connections by wire, chain or other
suitable retaining device to prevent tools or hose E. Keep electrical wiring, including all terminals and
ends from being accidentally disconnected and pressure connectors in good condition. Replace any
expelled. wiring that has cracked, cut, abraded or otherwise
degraded insulation, or terminals that are worn, dis-
G. Open fluid filler cap only when compressor is not run-
colored or corroded. Keep all terminals and pressure
ning and is not pressurized. Shut down the compres-
connectors clean and tight.
sor and bleed the receiver tank to zero internal
pressure before removing the cap. F. Keep grounded and/or conductive objects such as
tools away from exposed live electrical parts such as
H. Vent all internal pressure prior to opening any line, fit-
terminals to avoid arcing which might serve as a
ting, hose, valve, drain plug, connection or other
source of ignition.
component, such as filters and line oilers, and before
attempting to refill optional air line anti-icer systems G. Remove any acoustical material or other material
with antifreeze compound. that may be damaged by heat or that may support
combustion and is in close proximity, prior to attempt-
I. Keep personnel out of line with and away from the
ing weld repairs.
discharge opening of hoses or tools or other points of
compressed air discharge. H. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when servicing
J. DO NOT use air at pressures higher than 2.1 bar for
and operating the compressor.
cleaning purposes, and then only with effective chip
guarding and personal protective equipment per I. Keep oily rags, trash, leaves, litter or other combusti-
OSHA Standard 29 CFR 1910.242(b) and/or any bles out of and away from the compressor.
applicable Federal, State, and Local codes, stan-
J. DO NOT operate the compressor without proper flow
dards and regulations.
of cooling air or water or with inadequate flow of lubri-
K. DO NOT engage in horseplay with air hoses as cant or with degraded lubricant.
death or serious injury may result.
K. DO NOT attempt to operate the compressor in any
classification of hazardous environment unless the
compressor has been specially designed and manu-
1.4 Fire and explosion factured for that duty.
A. 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. Then
1.5 Moving parts
keep sparks, flames and other sources of ignition A. Keep hands, arms and other parts of the body and
away and DO NOT permit smoking in the vicinity clothing away from couplings, belts, pulleys, fans and
when checking or adding lubricant or when refilling other moving parts.
air line anti-icer systems with antifreeze compound.
B. DO NOT attempt to operate the compressor with the
C. DO NOT permit fluids, including air line anti-icer sys- fan, coupling or other guards removed.
tem antifreeze compound or fluid film, to accumulate
C. Wear snug-fitting clothing and confine long hair when
on, under or around acoustical material, or on any
working around this compressor, especially when
external surfaces of the air compressor. Wipe down
exposed to hot or moving parts.
using an aqueous industrial cleaner or steam clean
as required. If necessary, remove acoustical mate- D. Keep access doors, if any, closed except when mak-
rial, clean all surfaces and then replace acoustical ing repairs or adjustments.
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 1: Safety
C. Wear personal protective equipment including gloves C. Operate the compressor only in open or adequately
and head covering when working in, on or around the ventilated areas.
compressor. D. Locate the compressor or provide a remote inlet so
D. Keep a first aid kit handy. Seek medical assistance that it is not likely to ingest exhaust fumes or other
promptly in case of injury. DO NOT ignore small cuts toxic, noxious or corrosive fumes or substances.
and burns as they may lead to infection E. Coolants and lubricants used in this compressor are
typical of the industry. Care should be taken to avoid
accidental ingestion and/or skin contact. In the event
1.7 Toxic and irritating substances of ingestion, seek medical treatment promptly. Wash
A. DO NOT use air from this compressor for respiration with soap and water in the event of skin contact.
(breathing) except in full compliance with OSHA Consult Material Safety Data Sheet for information
Standards 29 CFR 1910 and/or any applicable Fed- pertaining to fluid of fill.
eral, State or Local codes or regulations. 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 compound
enters the eyes or if fumes irritate the eyes, they
should be washed with large quantities of clean
water for fifteen minutes. A physician, preferably an
eye specialist, should be contacted immediately.
H. DO NOT store air line anti-icer system antifreeze
compound in confined areas.
I. The antifreeze compound used in air line antifreeze
systems contains methanol and is toxic, harmful or
fatal if swallowed. Avoid contact with the skin or eyes
and avoid breathing the fumes. If swallowed, induce
vomiting by administering a tablespoon of salt, in
each glass of clean, warm water until vomit is clear,
then administer two teaspoons of baking soda in a
glass of clean water. Have patient lay down and
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 1: Safety
J. Set compressor down only on a level surface capa- 1. Review the equipment or machine to be
ble of safely supporting at least its weight and its locked and tagged out.
loading unit. 2. Alert operator and supervisor of which
K. When moving the compressor by forklift truck, utilize machine is to be worked on, and that power
fork pockets if provided. Otherwise, utilize pallet if and utilities will be turned off.
provided. If neither fork pockets or pallet are pro- 3. Check to make certain no one is operating
vided, then make sure compressor is secure and well the machine before turning off the power.
balanced on forks before attempting to raise or trans- 4. Turn off the equipment using normal shut-
port it any significant distance. down procedure.
L. Make sure forklift truck forks are fully engaged and 5. Disconnect the energy sources:
tipped back prior to lifting or transporting the com- a. Air and hydraulic lines should be bled,
pressor. drained and cleaned out. There should
M. Forklift no higher than necessary to clear obstacles be no pressure in these lines or in the
at floor level and transport and corner at minimum reservoir tanks. Lockout or tag lines or
practical speeds. valves.
b. Any mechanism under tension or pres-
N. Make sure pallet-mounted compressors are firmly
sure, such as springs, should be
bolted or otherwise secured to the pallet prior to
released and locked out or tagged.
attempting to forklift or transport them. NEVER
attempt to forklift a compressor that is not secured to c. Block any load or machine part prior to
its pallet, as uneven floors or sudden stops may working under it.
cause the compressor to tumble off, possibly causing d. Electrical circuits should be checked with
serious injury or property damage in the process. calibrated electrical testing equipment
and stored energy and electrical capaci-
tors should be safely discharged.
1.10 Entrapment 6. Lockout and/or Tagout each energy source
A. If the compressor enclosure, if any, is large enough using the proper energy isolating devices
to hold a man and if it is necessary to enter it to per- and tags. Place lockout hasp and padlock or
form service adjustments, inform other personnel tag at the point of power disconnect where
before doing so, or else secure and tag the access lockout is required by each person perform-
door in the open position to avoid the possibility of ing work. Each person shall be provided with
others closing and possibly latching the door with their own padlock and have possession of
personnel inside. the only key. If more than one person is
working on a machine each person shall affix
B. Make sure all personnel are out of compressor personal lock and tag using a multi-lock
before closing and latching enclosure doors. device.
7. Tagout devices shall be used only when
1.11 Implementation of lockout/tagout power sources are not capable of being
locked out by use of padlocks and lockout
The energy control procedure defines actions necessary hasp devices. The name of the person affix-
to lockout a power source of any machine to be repaired, ing tag to power source must be on tag along
serviced or set-up, where unexpected motion, or an with date tag was placed on power source.
electrical or other energy source, would cause personal
8. Release stored energy and bring the equip-
injury or equipment damage. The power source on any
ment to a “zero mechanical state”.
machine shall be locked out by each employee doing the
work except when motion is necessary during setup, 9. Verify Isolation: Before work is started, test
adjustment or trouble-shooting. equipment to ensure power is disconnected.
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WARNING
1.12 Safety warnings
The following special instructions apply to VSD packages Refer all drive service to trained technicians.
provided with electronic adjustable speed motor drives. This equipment should be installed, adjusted,
These cautions that apply to VSD operation. 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.
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 1: Safety
WARNING CAUTION
Before opening the variable speed drive covers: Install the variable speed drive in a well venti-
lated room that is not subject to temperature
• Disconnect all power to the variable
extremes, high humidity, or condensation, and
speed drive.
avoid locations that are directly exposed to sun-
• Wait a minimum of 5 (five) minutes light, or have high concentrations of dust, corro-
after all the lights on the keypad are sive gas, explosive gas, inflammable gas,
off. This allows time for the DC bus grinding fluid mist, etc. Improper installation may
capacitors to discharge. result in a fire hazard.
• 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- CAUTION
charged by measuring their voltage
using a multimeter set to measure DC Make sure that no power correction capacitors
voltage. Failure to follow the above are connected to the variable speed drive output
precautions may cause death or or the motor terminals to prevent variable speed
severe injury. drive malfunction and potential damage.
CAUTION CAUTION
Do not perform any megger or voltage withstand Make sure that the variable speed drive output
tests on any part of the variable speed drive or terminals (U, V, W) are not connected to the util-
its components. Improper testing may result in ity line power as severe damage to the VSD may
damage. Prior to any tests or measurements of occur.
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- NOTE
able speed drive during motor or cable testing.
Interior electrical wiring is performed at the fac-
tory. Required customer wiring is minimal, but
should be done by a qualified electrician in com-
CAUTION pliance with OSHA, National Electrical Code,
and/or any other applicable State, Federal, and
Do not touch any components on the circuit local electrical codes concerning isolation
boards. Static voltage discharge may damage switches, fused disconnects, etc. Sullair pro-
the components. vides a wiring diagram for use by the installer.
NOTE
Customer must provide electrical supply power
disconnect within sight of machine.
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 2: Description
Section 2
Description
2.1 Introduction External piping, connectors, and the enclosure should be
The design of the Sullair ShopTek line of compressor inspected and maintained in accordance with the proce-
units is a single stage, positive displacement, flooded dures and recommendations in this manual.
rotary screw. A complete package includes the:
• Compressor unit 2.2 Compressor component
• Electric motor description
• Starter The ShopTek compressor (Figure 2-1 and Figure 2-2)
• Compressor inlet and discharge systems uses a fan to draw outside air into the enclosure, cooling
the motors, the combined radiator fluid cooler, and air
• Compressor lubrication and cooling system
aftercooler. This hot air is then vented out of the top of
• Controller the enclosure.
• Aftercooler (ST11 and ST15 only)
Fluid is injected into the compressor, and mixes directly
• Heavy gauge steel mounting frame with the air as the rotors turn which compresses the air.
The fluid flow has three basic functions:
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2: Description ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
2.3 Compressor cooling and The compressed air/fluid mixture enters the separator/
lubrication system—functional tube and flows through an internal baffle system that
changes the flow’s direction and velocity, which causes
description most of the fluid to fall to the bottom of the separator
Refer to Figure 2-3 and Figure 2-4. The cooling and lubri- tube. A small amount of fluid remaining in the com-
cation system consists of a fan, fan motor, aftercooler pressed air collects on the surface of the separator ele-
(ST11/ST15 only) / fluid cooler, full flow fluid filter, thermal ment as the air flows through the separator.
valve, interconnecting hoses and separator tube.
A return line (or scavenge tube) leads from the dry side of
The pressure in the separator tube starts the fluid flow by the separator tube to the medium pressure region. Scav-
forcing the fluid from the high pressure area of the tube to enged fluid is returned by a pressure differential between
an area of lower pressure in the compressor unit. Fluid the separator tube and compressor.
flows from the bottom of the separator/tube to the thermal
valve that is fully open when the fluid temperature is The separator system reduces the fluid carry-over to less
below 185°F (85°C) [195°F (91°C) for pressures rated than 2 ppm at nominal rated pressures.
above 150 psig]. The fluid passes through the thermal The controller will shut down the compressor if the dis-
valve, the fluid filter, and directly to the compressor where charge temperature reaches 235°F (113°C).
it lubricates, cools and seals the rotors, and the compres-
sion chamber. A minimum pressure/check valve located downstream
from the separator maintains the separator tube pressure
As the discharge temperature rises above 185°F (85°C) at 50 psig (3.4 bar) during load conditions. This pressure
[195°F (91°C) for pressures rated above 150 psig], due level is necessary for proper air/fluid separation and suffi-
to the heat of compression, the thermal valve begins to cient fluid circulation.
adjust and a portion of the fluid then flows through the
cooler. From the cooler the fluid flows to the fluid filter A terminal check valve is a sub-component of the mini-
and on to the compressor. A portion of the fluid flow to mum pressure/check valve that prevents compressed air
the compressor is routed to the anti-friction bearings in the service line from back-flowing into the separator
which support the compressor rotors. tube on shutdown or when the compressor is operating in
an unload condition. Also, a pressure relief valve on the
The fluid filter must be replaced. Refer to Section 3.4: compressor’s wet side opens if the separator tube pres-
Lubrication change recommendations and fluid filter and sure exceeds its rating.
separator maintenance on page 22.
WARNING
2.4 Compressor discharge system—
functional description Stop the compressor and relieve all internal
Refer to Figure 2-3 and Figure 2-4. The compressor dis- pressure before removing caps, plugs, and/or
charges the compressed air/fluid mixture into the separa- other components when the compressor is run-
tor/tube. The separator/tube has three basic functions: ning or pressurized.
• It acts as a primary fluid separator.
• Serves as the compressor fluid sump. Add fluid to the separator tube through the capped fluid
• Houses the final fluid separator. fill port. There is also a sight glass that enables the user
to check the separator tube fluid level. See Section 4.5:
Fluid level check on page 37.
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 2: Description
2.5 Control system—functional Full load mode—50 to 127 psig (3.4 to 8.8 bar)
description When the compressed air pressure rises above 50 psig
(3.4 bar), the minimum pressure valve opens allowing
Refer to Figure 2-5 and Figure 2-6. The compressor con-
compressed air to flow into the service line. From this
trol system regulates its output to match the demand.
point on, the Controller continuously monitors the line air
This system consists of a solenoid valve and an inlet
pressure. The solenoid valve remains closed in this
valve that control the compressor’s operational modes.
mode. As long as the compressor is running at 127 psig
The following descriptions of operational modes apply to
(8.8 bar) or lower, the inlet valve is fully open.
a compressor whose rated operating pressure is
125 psig (8.6 bar).
Unload mode—greater than 127 psig (8.8 bar)
When there is no, or only a small demand, the service
NOTE line pressure will rise. The controller de-energizes the
solenoid valve when the pressure exceeds 127 psig
Other pressure settings can be selected (8.8 bar) allowing the separator tube air pressure to be
depending on compressor application or rating. supplied directly which closes the inlet valve. At the same
time the solenoid valve exhausts the system pressure to
the atmosphere and lowers the separator tube pressure
Start mode—0 to 50 psig (0 to 3.5 bar) to approximately 29 psig (2.0 bar). A check valve in the
There is no load on the compressor at startup, the sole- air service line prevents air from back-flowing to the sep-
noid valve is open and the inlet valve is closed. When the arator tube.
compressor (START) pad is pressed, the separator
tube pressure rises from 0 to 50 psig (0 to 3.4 bar). When When the pressure drops to the low setting: (cut-in pres-
it reaches its full operating speed (maximum rpm), the sure) usually 112 psig (7.7 bar) for high pressure (9 bar)
compressor switches to the full load mode. compressors, 137 psig (9.4 bar) for (10 bar) compres-
sors, 161 psig (11.1 bar) for (12 bar) compressors: the
controller energizes the solenoid valve and prevents line
pressure from reaching the inlet control valve.
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 2: Description
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 2: Description
X 1
2
3
S
4
11 10 9 8 7 6 5
2.7 Controller/keypad Refer to Figure 2-10. If a machine fault occurs, the red
fault indicator will light up, and the display will indi-
Refer to Figure 2-9. The controller keypad has two main
cate that a fault has occurred.
pads for compressor control. To start the compressor
operation, press the green Start pad .
To stop compressor operation, press the red Stop pad
. The Run mode indicator lights up whenever the STOP:
control is in an operating mode.
RTD Fault
2.8 LCD display Figure 2-10: RTD fault
The display's normal view shows the compressor pack-
age's discharge pressure, internal temperature, operat-
ing mode, and load status. The modes are MANUAL, The lower line will display the cause of the fault. Refer to
STOP, AUTOMATIC, or FAULT. service instructions to correct the cause. Press and hold
the Return/Reset pad to reset the controller.
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2: Description ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
PASSWORD ******
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 3: Specifications
Section 3
Specifications
3.1 Tables of specifications—ShopTek 5 – 20 hp three-phase
Table 3-1: Compressor specifications—60 Hz
Model ST4 ST5 ST7 ST11 ST15
8.6 bar (125 psi)/ 8.6 bar (125 psi)/ 8.6 bar (125 psi)/
Rated pressure 10.3 bar (150 psi) 10.3 bar (150 psi)
12 bar (175 psi) 12 bar (175 psi) 12 bar (175 psi)
8.6 bar (125 psi)/ 8.6 bar (125 psi)/ 8.6 bar (125 psi)/
Maximum working pressure 10.3 bar (150 psi) 10.3 bar (150 psi)
12 bar (175 psi) 12 bar (175 psi) 12 bar (175 psi)
Relief valve setpoint 14.8 bar (215 psi)
Voltage & frequency 208/230/460V 60 Hz or 575V 60 Hz
Air end type Single stage, oil injected rotary screw
Configuration Belt driven
Motor type TEFC (IP55)
Motor rating 3.7 kW (5 hp) 5.5 kW (7.5 hp) 7.5 kW (10 hp) 11 kW (15 hp) 15 kW (20 hp)
Motor nominal speed 3520 rpm
Starting mode Full voltage
Service factor 1.25
Ambient temperature Between 4° and 40°C (40° and 104°F)
Lubricant Sullube®
Lubricant volume 4 L (1 gal) 5 L (1.3 gal)
Service connector NPT ¾″ NPT 1″
238 kg 248 kg 258 kg 298 kg 308 kg
Machine weight
(524 lbs) (546 lbs) (567 lbs) (657 lbs) (679 lbs)
826 × 546 × 938 mm 998 × 618 × 1035 mm
Machine dimensions (L × W × H)
(32.5 × 21.5 × 36.9 in) (39.2 × 24.3 × 40.7 in)
1100 × 630 × 1105 mm 1130 × 700 × 1215 mm
Package dimensions (L × W × H)
(43.3 × 24.8 × 43.5 in) (44.5 × 27.6 × 47.8 in)
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CAUTION
3.5 Installation drawings (ID), piping
Do not mix different types of lubricants. Mixing & instrumentation diagrams
lubricants can cause malfunctions or compres- (P&I), and wiring diagrams (WD)
sor damage and will void the compressor’s war- Printed copies of your installation drawings (ID), piping &
ranty.
instrumentation diagrams (P&I), and wiring diagrams
(WDs) for your compressor are included in the packet of
printed documentation included with your compressor.
CAUTION PDFs of these drawings are included on the documenta-
tion CD included with our compressor.
Contamination of compressor fluids with mineral
oil or other fluids can cause foaming, filter plug-
ging, or orifice line obstruction.
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 3: Specifications
Notes:
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3: Specifications ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
3.6 ID—ST4, ST5, ST7
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3.6 ID—ST4, ST5, ST7
A9 CONTROLLER
1 ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
A FOUNDATION OR MOUNTING PACKAGE CAPABLE OF SUPPORTING THE WEIGHT OF THE PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE
2 COMPRESSOR FRAME LEVEL IS REQUIRED.
3 ALL DIMENSIONS ARE +/-.50"[12.7MM]
4 RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.
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3: Specifications ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
3.7 ID—ST11, ST15
88290017-300 R01
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3.7 ID—ST11, ST15
A9 CONTROLLER
1 ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
A FOUNDATION OR MOUNTING PACKAGE CAPABLE OF SUPPORTING THE WEIGHT OF THE PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE
2 COMPRESSOR FRAME LEVEL IS REQUIRED.
3 ALL DIMENSIONS ARE +/-.50"[12.7MM]
4 RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.
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3: Specifications ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
3.8 Piping and instrumentation—ST4, ST5, ST7
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3.8 Piping and instrumentation—ST4, ST5, ST7
3: Specifications
29
3: Specifications ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
3.9 Piping and instrumentation—ST11, ST15
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3.9 Piping and instrumentation—ST11, ST15
3: Specifications
31
3: Specifications ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
Notes:
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 4: Installation
Section 4
Installation
4.1 Compressor mounting—support
and location NOTE
The compressor must have a stable firm foundation, or
mounting structure that is rigid enough to keep the com- Do not install compressors where the machine
pressor frame level, and maintain the alignment of the will be exposed to temperatures lower than 32°F
compressor and motor. Tie-down bolts of sufficient size (0°C). Contact Sullair Customer Care regarding
must be used to ensure that the compressor frame is operation in sub-freezing temperatures.
firmly anchored to its foundation. Rubber, cork, or other
pliable materials can be inserted between the foundation
4.1.1 Outdoor installation (sheltered)
and compressor frame to provide a uniform contact sur-
ShopTek packages are equipped with TEFC motors and
face.
have water tight controls that are IP54 rated and are suit-
• Use flex connectors to prevent piping loads able for sheltered outdoor installation.
from being transmitted to the compressor.
The compressor should be mounted on a concrete pad. If
• National and local electrical codes specifying the pad is not level, the compressor must be mounted in
the required clearances for the area around the such a manner that its base or skid is level in relation to
electrical panel must be complied with. the pad’s surface and fully supported.
• Ensure the lighting at the compressor’s location
If the compressor will be exposed to blowing rain or
is sufficient for safe operation and mainte-
snow, it should be housed in a covered, four-walled
nance.
enclosure.
• The compressor’s location should be one that
allows access for maintenance vehicles and lift- • Sheltered air-cooled machines must have their
ing equipment. exhaust air vented outside of the enclosure.
• The clearances around the compressor should • Installations consisting of more than one com-
permit easy access to all compressor compo- pressor should be done in such a manner that
nents. each compressor’s exhaust is directed away
from the air intakes of other compressors or air
• Walls and ceilings with soft or porous surfaces
dryers.
absorb sound and reduce ambient noise levels.
Hard surfaces reflect noise and have little effect • A standard compressor should not be started if
on ambient noise levels. the ambient temperature is 35°F (1.7°C) or
lower.
Compressor must not be operated in sub-freezing
conditions.
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4: Installation ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
NOTE
Remove the red shipping straps/shipping studs
before operating the drive assembly. See Figure 1. Shipping strap
4-1 and Figure 4-2.
Figure 4-1: Shipping strap—ST4, ST5, ST7
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 4: Installation
4.3.1 Pipe sizing ing). In this condition the sight glass should be completely
Pipes should be sized as a minimum to match the dimen- full. Add fluid if the level is visible or if no fluid is visible at all.
sions of the compressor’s discharge connection. All piping
and fittings should be rated for the discharge pressure.
4.6 Electrical preparation
4.3.2 Auxiliary receiver tank Interior electrical wiring is installed at the factory.
An auxiliary receiver tank should be installed in systems Required customer wiring should be done by a qualified
where large demand fluctuations will occur. electrician in compliance with OSHA, National Electric
Code and/or any applicable local electrical codes apply-
4.3.3 Isolation valves ing to isolation switches, fused disconnects, etc. Sullair
Install isolation valves where isolation of the compressor provides a wiring diagram for use by the installer. An
from the service lines is required. These valves should electrical check should be made to ensure that the first
have drip legs that drain at an angle downward from the start-up will be successful. The compressor and drive
base. A vent to the piping should be installed down- should be properly grounded/earthed in accordance with
stream of the compressor outlet connection. applicable codes, regulations, and requirements.
When two compressors are installed to operate in parallel Feeder cables should be sized by the customer/electrical
with a common receiver tank, an isolation valve and drain contractor to ensure that the circuit is balanced and not
trap for each compressor should be installed before the overloaded by other electrical equipment. The length of
common separator/sump. wiring from a suitable electrical power source is critical
because voltage drops can adversely effect the perfor-
mance of the compressor. Cable sizes may vary consid-
NOTE erably so the mains terminals will accept up to 120 mm2
(4/0 awg) (75 kw) cable.
Compressors not equipped with a receiver tank
Feeder cable connections to incoming terminals L1-L2-
may need to have their response times adjusted.
L3 should be tight and clean.
Contact Sullair Customer Care for assistance.
The applied voltage must conform to the motor and com-
pressor data plate ratings.
4.3.4 Fluid containment
Compressors have a fluid containment pan to collect fluid A starter hole is provided for an incoming power connec-
leaks or spills. The pan has a drain located on the front tion. If it is necessary to make a hole in the control box in
side of the machine. a different location, care should be taken to not allow
metal shavings to enter the starter and other electrical
components within the box. If another hole is used, the
4.4 Belt check original hole must be blocked off with a sealed plug.
Tension of drive belts should be checked upon installa-
tion and after ½ to 2 hours of run time. This is essential to
proper performance of the compressor unit as well as to WARNING
ensure long belt life. In addition, belt tension should be
checked every 2000 hours and adjusted if necessary. Energized internal components are a potentially
fatal shock hazard. Disconnect all power before
Refer to Section 6.8: Belt maintenance on page 45 for performing any work on the compressor’s elec-
detailed instructions. trical system.
4.5 Fluid level check 1. Check incoming voltage. The incoming volt-
The compressor is shipped fully charged with the proper age must match the compressor’s wire rat-
amount of fluid. However, it is necessary to check the fluid ing/specifications.
level at the time of installation and during compressor oper- 2. Check motor starter and overload heater sizes.
ation. Check the fluid level by looking at the sight glass on 3. Check all electrical connections for tightness.
the separator tube when the compressor is in the SHUT
DOWN MODE (fluid level may not be visible when operat-
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4: Installation ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
Figure 4-4: Main motor/fan motor direction of motor. When looking at the motor from the compressor
rotation—ST4, ST5, ST7 unit, the shaft should turn clockwise for ST4, ST5 and
ST7 and counterclockwise for ST11 and ST15. If reverse
rotation occurs, disconnect the power to the starter and
exchange any two of the three power input leads, then
Motor rotation check must be done at compressor start- re-check rotation. A “Direction of Rotation” decal is
up after the wiring has been installed. See Figure 4-4 and located on the motor drive housing to show proper motor/
Figure 4-5. The compressor can be damaged if it runs in compressor rotation.
the wrong direction for more than a few seconds. Motor
Fan motor rotation should also be checked. It should
rotation can be viewed through the openings in the belt
rotate counter-clockwise when viewing the fan motor
guard. Pull out the EMERGENCY STOP button and
from the backside of the motor.
press once, quickly and in succession, the (START)
pad and (STOP) pad. This action will bump start the
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 5: Operation
Section 5
Operation
5.1 Routine operation
Before starting the compressor, check the fluid level in
the separator tube. If sight glass is not completely full,
WARNING
add the required amount of fluid to bring it to its proper
level. Frequent addition of fluid indicates the presence of High pressure hazard
a leak or a condition causing excessive fluid consump- Removing caps, plugs, and/or other components
tion. See the Section 6.12: Troubleshooting on page 51 when compressor is running or pressurized
under “Excessive compressor fluid consumption” for a could result in death or serious injury.
probable cause and corrective action.
Do not remove caps, plugs, and/or other com-
ponents when compressor is running or pressur-
ized. Stop compressor and relieve all internal
pressure before removing caps, plugs, and/or
other components.
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5: Operation ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
Notes:
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 6: Maintenance
Section 6
Maintenance
WARNING
Before any repairs are attempted, refer to Sec-
tion 1: Safety before proceeding.
6.1 General
This compressor requires a minimal amount of inspec-
tions and maintenance. The controller and other indica-
tors alert the operator to situations requiring
maintenance, or fault conditions.
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6: Maintenance ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
1. Fluid filter
2. Fluid sample valve
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 6: Maintenance
Refer to Figure 6-4 and Figure 6-5. Air filter maintenance 1. Air filter element
should be performed every 2000 hours or sooner if nec- 2. Clamp
essary.
3. Hose
6.6.1 Air filter element replacement Figure 6-5: Air filter assembly—ST11, ST15
1. Remove enclosure panels to gain access to
filter.
2. Loosen hose clamp and remove filter.
3. Install new filter and tighten hose clamp.
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 6: Maintenance
6.7.1 Separator element replacement The belt tension is achieved by raising the compressor
Refer to Figure 6-6 and Figure 6-7. Use the following pro- unit which has the effect of increasing belt tension. Refer
cedure below to change the separator: to Figure 6-10 and Figure 6-11.
Belt tension must be re-adjusted ½ to 2 hours after a new
set of belts are fitted. This will ensure that the belts have
CAUTION completed their initial stretch. Subsequent to this, belt
tension needs to be checked and adjusted if necessary
Relieve all pressure from the separator/sump every 2000 hours for the duration of the belt life.
tank and all compressor lines.
There are two recommended methods for checking the
belt tension. The test methods will be detailed as follows.
1. Loosen and remove the six (6) hex head
capscrews (M12 x 45 mm) from the cover 6.8.1 Belt tension measurement with
plate. Optikrik tension meter
2. Lift the cover plate from the separator tube. Refer to Figure 6-8. Follow instructions as follows:
3. Remove the separator element. 1. Ensure the indicator arm is pushed down
4. Inspect the separator tube for rust, contami- prior to starting.
nation, or damage. 2. Gently place the meter on the flat side of one
5. Reinsert the separator elements into the belt at the midpoint between the motor and
separator tube taking care not to dent the compressor unit pulleys.
element against the tank opening. 3. Slowly press on the push pad. Avoid contact-
6. Install a new lubricated O-ring in the O-ring ing the meter with other fingers as this may
groove on the underside of the separator/ affect the reading.
tube cover. 4. Once a definite click is detected, immediately
7. Replace the cover plate, washers and cap- release pressure and the indication arm will
screws. Torque to 28 ft·lbs. (38 N·m). remain in the measuring position.
8. Clean the return line strainer before restart- 5. Carefully lift the meter without moving indi-
ing the compressor. Refer to Figure 6-1 and cating arm.
Figure 6-2. 6. Read the measurement at the exact point
9. Check condition of grounding spring on lid, where the top surface of the indicator arm
ensure it is clean and provides good contact. crosses the scale.
7. Rotate the motor pulley through at least one
complete revolution and measure the ten-
6.8 Belt maintenance sion again, recording the results.
The correct drive belt tension is essential to ensure that 8. Repeat step 7 for a total of 3 measurements.
full motor power is transmitted to the compressor unit.
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6: Maintenance ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual
9. Average the three measurements to obtain give a false reading. As the probe detects a
the true belt tension. vibration, the meter will display the fre-
10. Repeat for remaining belts. quency. Record data.
11. Compare the results to the belt tension spec- 4. Rotate the motor pulley through at least one
ification in Table 6-1 and adjust if necessary. complete revolution and measure the belts
again, recording the results.
6.8.2 Belt tension measurement with 5. Repeat step 4 for a total of 3 measurements.
frequency meter 6. Average the three measurements to obtain
the true belt tension.
7. Repeat for remaining belts.
8. Compare the results to the belt tension spec-
ification in Table 6-1 and adjust if necessary.
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6.9 Replacement and alignment of 8. Run machine for ½ to 1 hour and check the
belt pulleys tightening torque of the grub screws. Tighten
if necessary;
In the event of the motor or compressor unit having been
removed and replaced, pulley alignment will have to be
checked and adjusted.
6.9.2 Instructions for removing a pulley
Misalignment of pulleys can cause rapid wear of the V-belt
form, considerably shortening the service life of both belts
and pulleys. Due to Sullair’s innovative design, only paral-
lel alignment of the drive pulleys needs to be checked.
Parallel alignment can be checked by two methods.
1. Placing a straight edge against the pulleys
near their centers. For correct alignment, the
straight edge must be sitting flat against both
pulleys, i.e. full face contact. There should be
no more than 0.5 mm misalignment.
2. Using a laser, ensure misalignment is no
greater than 0.5°.
To correct parallel misalignment, first check that the rear
face of the compressor unit pulley is positioned 0.3 in
(7.5 mm) off the mounting face. This is required to ensure
that the belts clear all mounting bolt heads. With the com- 1. Jacking/disassembly hole
pressor unit pulley correctly positioned, move the motor
2. Installation hole
pulley on the shaft to achieve correct alignment.
Figure 6-12: Diagram of belt pulley and taper lock
6.9.1 Instructions for installing a pulley bushing assembly
1. Clean all surfaces of shaft, pulley and taper
lock bushing.
2. Fit taper lock bushing inside pulley. 1. Loosen and remove both grub screws.
3. Spray oil or anti-seize compound on the grub 2. Install one grub screw into the jacking/disas-
screw threads and gently screw in. sembly hole. Refer to Figure 6-12.
4. Slide the pulley/bushing assembly on to the 3. Tighten grub screw to release taper lock hub
shaft to the correct position, aligning the key- from pulley.
way.
4. Slide pulley and bushing from shaft.
5. Tighten the grub screws in stages to the
specification in Table 6-2.
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ShopTek™ ST4, ST5, ST7, ST11, ST15 Three-phase 60 Hz User Manual 6: Maintenance
6.12 Troubleshooting
The information in the Troubleshooting Guide describes NOTE
symptoms and usual causes for the listed discrepancies.
However, do not assume that these are the only mal- For additional troubleshooting guidelines, con-
functions or fault conditions that may occur. sult the controller’s User Manual.
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Subject to EAR, ECCN EAR99 and related export control restrictions.
Sullair, LLC
3700 East Michigan Boulevard
Michigan City, IN 46360 USA
www.sullair.com
1-800-SULLAIR (USA only)
1-219-879-5451 (non-USA)