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Portable Air CompressorE900H

PART NUMBER:02250203-986 R03

The information in this manual is current as of its publication date and applies to compressors with serial number:

201501010000and all subsequent serial numbers.

USER MANUAL

Publication date: 11/9/2015Copyright © 2012 – 2015 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.

Air Care Seminar Training

Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on Portable compressors are offered at regular intervals throughout the year at Sullair’s training facility located in Michigan City, Indiana.

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.

For detailed course outlines, schedule, and cost information contact:

Sullair Training Department

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

[email protected]

- Or Write -

Sullair, LLC3700 E. Michigan Blvd.Michigan City, IN 46360

Attn: Service Training Department.


Table of Contents

E900H User Manual Table of Contents

Section 1: Safety.......................................................................................................1

1.1 General....................................................................................................... 11.2 Personal protective equipment ................................................................... 11.3 Pressure release ........................................................................................ 11.4 Fire and explosion ...................................................................................... 21.5 Moving parts ............................................................................................... 31.6 Hot surfaces, sharp edges and sharp corners............................................ 41.7 Toxic and irritating substances................................................................... 41.8 Electrical shock........................................................................................... 51.9 Lifting .......................................................................................................... 51.10 Entrapment ................................................................................................. 51.11 Implementation of lockout/tagout................................................................ 51.12 Jump starting.............................................................................................. 61.13 Towing1...................................................................................................... 8

1.13.1 Preparing to tow.....................................................................................................8

1.13.2 Towing ...................................................................................................................9

1.13.3 Parking or locating compressor .............................................................................9

1.14 California proposition 65........................................................................... 111.15 Symbols and references........................................................................... 12

Section 2: Description............................................................................................17

2.1 Introduction............................................................................................... 172.2 Description of components ....................................................................... 172.3 Sullair compressor unit, functional description ......................................... 172.4 Air inlet system, functional description ..................................................... 192.5 Compressor discharge system, functional description ............................. 192.6 Compressor cooling and lubrication system, functional description ......... 212.7 Control system, functional description...................................................... 212.8 Aftercooled air system, functional description .......................................... 222.9 Instrument panel...................................................................................... 232.10 Piping and instrumentation diagram......................................................... 242.11 Wiring diagram ......................................................................................... 26

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Table of Contents E900H User Manual

Section 3: Specifications....................................................................................... 29

3.1 Tables of specifications.............................................................................293.2 Lubrication guide—compressor ................................................................303.3 Application guide.......................................................................................303.4 Identification—less running gear...............................................................323.5 Identification—portable .............................................................................34

Section 4: Installation ............................................................................................ 37

4.1 Fluid level check .......................................................................................374.2 Electrical preparation ................................................................................37

Section 5: Operation .............................................................................................. 39

5.1 General .....................................................................................................395.2 Purpose of controls ...................................................................................395.3 Initial start-up procedure ...........................................................................405.4 Normal start-up procedure ........................................................................415.5 Main motor heater....................................................................................415.6 Fan rotation switch....................................................................................415.7 Phase/voltage fault relay...........................................................................41

Section 6: Maintenance ......................................................................................... 43

6.1 General .....................................................................................................436.2 Daily operation ..........................................................................................436.3 Maintenance after initial 50 hours of operation .........................................436.4 Maintenance every 250 hours...................................................................436.5 Maintenance every 300 hours...................................................................436.6 Maintenance every 600 hours...................................................................436.7 Maintenance every 1000 hours.................................................................436.8 Maintenance every 1500 hours.................................................................446.9 Parts replacement and adjustment procedures ........................................44

6.9.1 Compressor fluid change procedure ................................................................... 44

6.9.2 Running gear lubrication ..................................................................................... 44

6.9.3 Wheel bearing lubrication.................................................................................... 45

6.9.4 Main fluid filter servicing...................................................................................... 46

6.9.5 Air filter maintenance .......................................................................................... 46

6.9.6 Separator element replacement.......................................................................... 47

6.10 Pressure relief valve .................................................................................486.11 Hose maintenance....................................................................................486.12 Motor maintenance ...................................................................................486.13 Control system adjustment .......................................................................48

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E900H User Manual Table of Contents

6.13.1 Differential pressure regulator adjustment...........................................................48

6.13.2 Shaft coupling maintenance ................................................................................49

6.13.3 Unload pressure setting.......................................................................................49

6.13.4 Differential setting ................................................................................................49

Section 7: Troubleshooting ...................................................................................51

7.1 Introduction............................................................................................... 51

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Table of Contents E900H User Manual

Notes:

02250203-986 R03iv Subject to EAR, ECCN EAR99 and related export control restrictions.

Section 1

E900H User Manual 1: Safety

Safety

1.1 GeneralSullair designs and manufactures all of its products so they can be operated safely. However, the responsibility for safe operation rests with those who use and maintain these products. The following safety precautions are offered as a guide which, if conscientiously followed, will minimize the possibility of accidents throughout the useful life of this equipment. Read the AEM Safety Manual prior to compressor operation and towing, if applicable in your area.

The air compressor should be operated only by those who have been trained and delegated to do so, and who have read and understood this Operator’s Manual. Failure to follow the instructions, procedures and safety precautions in this manual can result in accidents and injuries.

NEVER start the air compressor unless it is safe to do so. DO NOT attempt to operate the air compressor with a known unsafe condition. Tag the air compressor and render it inoperative by disconnecting and locking out all power at source or otherwise disabling its prime mover so others who may not know of the unsafe condition cannot attempt to operate it until the condition is corrected.

Use and operate the air compressor only in full compliance with all pertinent OSHA requirements and/or all pertinent Federal, State and Local codes or requirements.

DO NOT modify the compressor except with written

factory approval.

Each day, walk around the air compressor and inspect for leaks, loose or missing parts, damaged parts or parts out of adjustment. Perform all recommended daily maintenance.

Inspect for torn, frayed, blistered or otherwise deteriorated and degraded hoses. Replace as required.

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

ers, employers and users should become familiar with, and comply with, all applicable OSHA regula-tions and/or any applicable Federal, State and Local codes, standards, and regulations relative to per-sonal protective equipment, such as eye and face protective equipment, respiratory protective equip-ment, equipment intended to protect the extremities, protective clothing, protective shields and barriers and electrical protective equipment, as well as noise exposure administrative and/or engineering controls and/or personal hearing protective equipment.

1.3 Pressure release A. Open the pressure relief valve at least weekly to

make sure it is not blocked, closed, obstructed or otherwise disabled.

B. Install an appropriate flow-limiting valve between the compressor service air outlet and the shutoff (throt-tle) valve, when an air hose exceeding 1/2″ (13 mm) inside diameter is to be connected to the shutoff (throttle) valve, to reduce pressure in case of hose failure, per OSHA Standard 29 CFR 1926.302 (b) (7) or any applicable Federal, State and Local codes, standards and regulations.

C. When the hose is to be used to supply a manifold, install an additional appropriate flow-limiting valve between the manifold and each air hose exceeding 1/2″ (13 mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure.

NOTE

Operator is required to readentire instruction manual.

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1: Safety E900H User Manual

D. Provide an appropriate flow-limiting valve for each additional 75 feet (23 m) of hose in runs of air hose exceeding 1/2″ (13 mm) inside diameter to reduce pressure in case of hose failure.

E. Flow-limiting valves are listed by pipe size and rated CFM. Select appropriate valve accordingly.

F. DO NOT use tools that are rated below the maximum rating of this compressor. Select tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturer’s rated safe operating pressures for these items.

G. Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled.

H. Open fluid filler cap only when compressor is not run-ning and is not pressurized. Shut down the compres-sor and bleed the sump (receiver) to zero internal pressure before removing the cap.

I. Vent all internal pressure prior to opening any line, fit-ting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before attempting to refill optional air line anti-icer systems with antifreeze compound.

J. Keep personnel out of line with and away from the discharge opening of hoses, tools or other points of compressed air discharge.

K. DO NOT use air at pressures higher than 30 psig (2.1 bar) for cleaning purposes, and then only with effective chip guarding and personal protective equipment per OSHA Standard 29 CFR 1910.242 (b) or any applicable Federal, State and Local codes, standards and regulations.

L. DO NOT engage in horseplay with air hoses as death or serious injury may result.

M. This equipment is supplied with an ASME designed pressure vessel protected by an ASME rated relief valve. Lift the handle once a week to make sure the valve is functional. DO NOT lift the handle while machine is under pressure.

N. If the machine is installed in an enclosed area it is necessary to vent the relief valve to the outside of the structure or to an area of non-exposure.

O. DO NOT remove radiator filler cap until the coolant temperature is below its boiling point. Then loosen cap slowly to its stop to relieve any excess pressure and make sure coolant is not boiling before removing

cap completely. Remove radiator filler cap only when cool enough to touch with a bare hand.

P. The ethyl ether in the replaceable cylinders used in diesel ether starting aid systems (optional) is under pressure. DO NOT puncture or incinerate those cyl-inders. DO NOT attempt to remove the center valve core or side pressure relief valve from these cylin-ders regardless of whether they are full or empty.

Q. If a manual blowdown valve is provided on the receiver, open the valve to ensure all internal pres-sure has been vented prior to servicing any pressur-ized component of the compressor air/fluid system.

1.4 Fire and explosion

A. Refuel at a service station or from a fuel tank designed for its intended purpose. If this is not possi-ble, ground the compressor to the dispenser prior to refueling.

B. Clean up spills of lubricant or other combustible sub-stances immediately, if such spills occur.

C. Shut off air compressor and allow it to cool. Then keep sparks, flames and other sources of ignition away and DO NOT permit smoking in the vicinity when adding fuel, checking or adding electrolyte to batteries, checking or adding fluid, checking diesel engine ether starting aid systems, replacing cylin-ders, or when refilling air line anti-icer systems anti-freeze compound.

D. DO NOT permit fluids, including air line anti-icer sys-tem antifreeze compound or fluid film, to accumulate on, under or around acoustical material, or on any external surfaces of the air compressor. Wipe down using an aqueous industrial cleaner or steam clean as required. If necessary, remove acoustical mate-rial, clean all surfaces and then replace acoustical material. Any acoustical material with a protective covering that has been torn or punctured should be replaced immediately to prevent accumulation of liq-

WARNING

Do not attempt to operate the compressor in any classification of hazardous environment or potentially explosive atmosphere unless the compressor has been specially designed and manufactured for that duty.

02250203-986 R032 Subject to EAR, ECCN EAR99 and related export control restrictions.


uids or fluid film within the material. DO NOT use flammable solvents for cleaning purposes.

E. Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the compressor or of the inside of the enclosure, if any.

F. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace any wiring that has cracked, cut, abraded or otherwise degraded insulation, or terminals that are worn, dis-colored or corroded. Keep all terminals and pressure connectors clean and tight.

G. Turn off battery charger before making or breaking connections to the battery.

H. Keep grounded and/or conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition.

I. Replace damaged fuel tanks or lines immediately rather than attempt to weld or otherwise repair them. DO NOT store or attempt to operate the compressor with any known leaks in the fuel system. Tag the compressor and render it inoperative until repair can be made.

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

K. Keep suitable fully charged Class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor.

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

M. Open all access doors and allow the enclosure to ventilate thoroughly prior to attempting to start the engine.

N. DO NOT operate compressor under low overhanging leaves or permit such leaves to contact hot exhaust system surfaces when operating the compressor in forested areas.

O. Ethyl ether used in diesel engine ether starting aid systems is extremely flammable. Change cylinders, or maintain or troubleshoot these systems only in well-ventilated areas away from heat, open flame or sparks. DO NOT install, store or otherwise expose ether cylinders to temperatures above 160°F (71°C). Remove ether cylinder from the compressor when operating in ambient temperatures above 60°F (16°C).

P. DO NOT attempt to use ether as a starting aid in gas-oline engines or diesel engines with glow plugs as serious personnel injury or property damage may result.

Q. DO NOT spray ether into compressor air filter or into an air filter that serves both the engine and the com-pressor as serious damage to the compressor or per-sonal injury may result.

R. Antifreeze compound used in air line anti-icer sys-tems contains methanol which is flammable. Use systems and refill with compound only in well-venti-lated areas away from heat, open flames or sparks. DO NOT expose any part of these systems or the antifreeze compound to temperatures above 150 °F (66 °C). Vapors from the antifreeze compound are heavier than air. DO NOT store compound or dis-charge treated air in confined or unventilated areas. DO NOT store containers of antifreeze compound in direct sunlight.

S. Store flammable fluids and materials away from your work area. Know where fire extinguishers are and how to use them, and for what type of fire they are intended. Check readiness of fire suppression sys-tems and detectors if so equipped.

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

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

1.5 Moving parts

A. Keep hands, arms and other parts of the body and also clothing away from couplings, fans and other moving parts.

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

WARNING

Disconnect and lock out all power at source and verify at the compressor that all circuits are de-energized to minimize the possibility of acciden-tal start-up, or operation, prior to attempting repairs or adjustments. This is especially impor-tant when compressors are remotely controlled.



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

D. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or operate it.

E. When adjusting the controls, it may require operation of the equipment during adjustment. DO NOT come in contact with any moving parts while adjusting the control regulator and setting the engine RPM. Make all other adjustments with the engine shut off. When necessary, make adjustment, other than setting con-trol regulator and engine RPM, with the engine shut off. If necessary, start the engine and check adjust-ment. If adjustment is incorrect, shut engine off, read-just, then restart the engine to recheck adjustment.

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

1.6 Hot surfaces, sharp edges and sharp corners

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

B. Keep all parts of the body away from all points of air discharge and away from hot exhaust gases.

C. Wear personal protective equipment including gloves and head covering when working in, on or around the compressor.

D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. DO NOT ignore small cuts and 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 OSHA

Standards 29 CFR 1920 and any other Federal, State or Local codes or regulations.

B. DO NOT use air line anti-icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems into unventilated or other confined areas.

C. Operate the compressor only in open or adequately ventilated areas.

D. Locate the compressor so that exhaust fumes are not apt to be carried towards personnel, air intakes ser-vicing personnel areas or towards the air intake of any portable or stationary compressor.

E. Fuels, fluids 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 of ingestion, seek medical treatment promptly. Wash with soap and water in the event of skin con-tact. Consult Material Safety Data Sheet for informa-tion pertaining to the specific fluid.

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

G. Wear an acid-resistant apron and a face shield or goggles when servicing the battery. If electrolyte is spilled on skin or clothing, immediately flush with large quantities of water.

H. Ethyl ether used in diesel engine ether starting aid systems is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swallowed, DO NOT induce vomiting and call a physician immediately.

I. Wear goggles or a full face shield when testing ether starting aid systems or when adding antifreeze com-

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.



pound to air line anti-icer systems. Keep openings of valve or atomizer tube of ether starting aid system pointed away from yourself and other personnel.

J. 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.

K. DO NOT store ether cylinders or air line anti-icer sys-tem antifreeze compound in operator’s cabs or in other similar confined areas.

L. 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 cover eyes to exclude light. Call a physician immedi-ately.

1.8 Electrical shockA. Keep the towing vehicle or equipment carrier, com-

pressor hoses, tools and all personnel at least 10 feet (3 m) from power lines and buried cables.

B. Stay clear of the compressor during electrical storms! It can attract lightning.

C. Keep all parts of the body and any hand-held tools or other conductive objects away from exposed live parts of electrical system. Maintain dry footing, stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjust-ments or repairs to exposed live parts of the electrical system.

D. Attempt repairs in clean, dry and well lighted and ventilated areas only.

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

lift by the bail provided. If no bail is provided, then lift by sling. Compressors to be air lifted by helicopter must not be supported by the lifting bail, but by slings instead. In any event, lift only in full compliance with OSHA Standards 29 CFR 1910 subpart N or any other Local, State, Military and Federal regulations that may apply.

B. Inspect lifting bail and points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members 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 has a rated capacity of at least the net weight of the com-pressor plus an additional 10% allowance for weight of water, snow, ice, mud, stored tools, and equip-ment. If your are unsure of the weight, then weigh compressor before lifting.

D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail.

E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground.

F. DO NOT attempt to lift in high winds.

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

H. Lift compressor no higher than necessary.

I. Keep lift operator in constant attendance whenever compressor is suspended.

J. Set compressor down only on a level surface capa-ble of supporting at least its net weight plus an addi-tional 10% allowance for the weight of water, snow, ice, mud, stored tools, and/or equipment.

K. If the compressor is provided with parking brakes, make sure they are set, and in any event, block or chock both sides of all running wheels before disen-gaging the lifting hook.

1.10 EntrapmentA. Make sure all personnel are out of compressor

before closing and engaging enclosure doors.

B. If the compressor is large enough to hold a man and if it is necessary to enter it to perform service adjust-ments, inform other personnel before doing so, or else secure the access door in the open position to avoid the possibility of others closing and possibly latching the door with personnel inside.

1.11 Implementation of lockout/tagoutThe energy control procedure defines actions necessary to lockout a power source of any machine to be repaired, serviced or set-up, where unexpected motion, or an



electrical or other energy source, would cause personal injury or equipment damage. The power source on any machine shall be locked out by each employee doing the work except when motion is necessary during setup, adjustment or trouble-shooting.

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

1. Review the equipment or machine to be locked and tagged out.

2. Alert operator and supervisor of which machine is to be worked on, and that power and utilities will be turned off.

3. Check to make certain no one is operating the 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 should be no pressure in these lines or in the reservoir tanks. Lockout or tag lines or valves.

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

c. Block any load or machine part prior to working under it.

d. Electrical circuits should be checked with calibrated electrical testing equipment and stored energy and electrical capaci-tors should be safely discharged.

6. Lockout and/or Tagout each energy source using the proper energy isolating devices and tags. Place lockout hasp and padlock or tag at the point of power disconnect where lockout is required by each person perform-ing work. Each person shall be provided with their own padlock and have possession of the only key. If more than one person is working on a machine each person shall affix personal lock and tag using a multi-lock device.

7. Tagout devices shall be used only when power sources are not capable of being locked out by use of padlocks and lockout hasp devices. The name of the person affix-ing tag to power source must be on tag along with 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, test equipment to ensure power is disconnected.

B. General Security

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

a. verified that no person will be exposed to danger.

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

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

d. ensured that the “Authorized” person is notified of lock removal before returning to work.

2. Tagout System—Tags are warning devices affixed at points of power disconnect and are not to be removed by anyone other that the person placing tag on power lockout. Tags shall never be by-passed, ignored, or other-wise defeated.

1.12 Jump startingA. Observe all safety precautions mentioned elsewhere

in this manual.

B. Batteries may contain hydrogen gas which is flam-mable and explosive. Keep flames, sparks and other sources of ignition away.

C. Batteries contain acid which is corrosive and poison-ous. DO NOT allow battery acid to contact eyes, skin, fabrics or painted surfaces as serious personal injury or property damage could result. Flush any con-tacted areas thoroughly with water immediately. Always wear an acid-resistant apron and face shield when attempting to jump start the compressor.



D. Remove all vent caps (if so equipped) from the bat-tery or batteries in the compressor. DO NOT permit dirt or foreign matter to enter the open cells.

E. Check fluid level. If low, bring fluid to proper level before attempting to jump start (not applicable to maintenance-free batteries).

F. DO NOT attempt to jump start if fluid is frozen or slushy. Bring batteries up to at least 60°F (16°C) before attempting to jump start or it may explode.

G. Cover open cells of all compressor batteries with clean dampened cloths before attempting to jump start.

H. Attempt to jump start only with a vehicle having a negative ground electrical system with the same volt-age, and is also equipped with a battery or batteries of comparable size or larger than supplied in the compressor. DO NOT attempt to jump start using motor generator sets, welders or other sources of DC power as serious damage may result.

I. Bring the starting vehicle alongside the compressor, but DO NOT permit metal to metal contact between the compressor and the starting vehicle.

J. Set the parking brakes of both the compressor (if pro-vided) and the starting vehicle or otherwise block both sides of all wheels.

K. Place the starting vehicle in neutral or park, turn off all non-essential accessory electrical loads and start its engine.

L. Use only jumper cables that are clean, in good condi-tion and are heavy enough to handle the starting cur-rent.

M. Avoid accidental contact between jumper cable ter-minal clips or clamps and any metallic portion of either the compressor or the starting vehicle to mini-mize the possibility of uncontrolled arcing which might serve as a source of ignition.

N. Positive battery terminals are usually identified by a plus (+) sign on the terminal and the letters POS adjacent to the terminal. Negative battery terminals are usually identified by the letters NEG adjacent to the terminal or a negative (-) sign.

O. Connect one end of a jumper cable to the positive (POS) (+) battery terminal in the starting vehicle. When jump starting 24V compressors and if the start-

ing vehicle is provided with two (2) 12V batteries con-nected in series, connect the jumper cable to the positive (POS) (+) terminal of the ungrounded bat-tery.

P. Connect the other end of the same jumper cable to the positive (POS) (+) terminal of the starter motor battery in the compressor when jump starting 24V compressors, to the positive (POS) (+) terminal of the ungrounded battery in the compressor.

Q. Connect one end of the other jumper cable to the grounded negative (NEG) (-) terminal of the battery in the starting vehicle. When jump starting 24V com-pressors and if the starting vehicle is provided with two (2) 12V batteries connected in series, connect the jumper cable to the negative (NEG) (-) terminal of the grounded battery.

R. Check your connections. DO NOT attempt to start a 24V compressor with one 12V battery in the starting vehicle. DO NOT apply 24V to one 12V battery in the compressor.

S. Connect the other end of this same jumper cable to a clean portion of the compressor engine block away from fuel lines, the crank case breather opening and the battery.

T. Start the compressor in accordance with normal pro-cedure. Avoid prolonged cranking.

U. Allow the compressor to warm up. When the com-pressor is warm and operating smoothly at normal idle RPM, disconnect the jumper cable from the engine block in the compressor, then disconnect the other end of this same cable from the grounded neg-ative (NEG) (-) terminal of the battery in the starting vehicle. Then disconnect the other jumper cable from the positive (POS) (+) terminal of the battery in the compressor, or if provided with two (2) 12V batteries connected in series, from the ungrounded battery in the compressor, and finally, disconnect the other end of this same jumper cable from the positive (POS) (+) terminal of the battery in the starting vehicle or from the positive (POS) (+) terminal of the ungrounded battery in the starting vehicle, if it is provided with two (2) 12V batteries connected in series.

V. Remove and carefully dispose of the dampened cloths, as they may now be contaminated with acid, then replace all vent caps.



1.13 Towing1

1.13.1 Preparing to tow

A. Prior to hitching the air compressor to the tow vehi-cle, inspect all attachment parts and equipment, checking for (I) signs of excessive wear or corrosion, (II) parts that are cracked, bent, dented or otherwise deformed or degraded, and (III) loose nuts, bolts or other fasteners. Should any such condition be pres-ent, DO NOT TOW until the problem is corrected.

B. Back the tow vehicle to the compressor and position it in preparation for coupling the compressor.

C. If the compressor is provided with a drawbar latched in the vertical upright position, carefully unlatch draw-bar and lower it to engage the coupling device. If not, raise drawbar with the jack to engage coupling device or otherwise couple the compressor to the towing vehicle.

D. Make sure the coupling device is fully engaged, closed and locked.

E. If chains are provided, pass each chain through its point of attachment on the towing vehicle; then hook

each chain to itself by passing the grab hook over (not through) a link. Cross chains under the front of drawbar before passing them through points of attachment on towing vehicle to support the front of drawbar in case it should accidentally become uncoupled.

F. Make sure that the coupling device and adjacent structures on the towing vehicle (and also, if utilized, chain adjustment, brake and/or electrical intercon-nections) DO NOT interfere with or restrict motion of any part of the compressor, including its coupling device, with respect to the towing vehicle when maneuvering over any anticipated terrain.

G. If provided, make sure chain length, brake and elec-trical interconnections provide sufficient slack to pre-vent strain when cornering and maneuvering, yet are supported so they cannot drag or rub on road, terrain or towing vehicle surfaces which might cause wear that could render them inoperative.

WARNING

Do NOT tow the compressor should its weight exceed the rated limit of the tow vehicle, as the vehicle may not brake safely with excess weight. See rated limit in tow vehicle Operator's Manual, and review its instructions and other require-ments for safe towing.

WARNING

This equipment may be tongue heavy. DO NOT attempt to raise or lower the drawbar by hand if the weight is more than you can safely handle.

Use the screw jack provided or a chain fall if you cannot lift or lower it without avoiding injury to yourself or others. Keep hands and fingers clear of the coupling device and all other pinch points. Keep feet clear of drawbar to avoid injury in case it should slip from your hands.

WARNING


CAUTION

Retract the front screw jack only after attaching the compressor to the tow vehicle. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stow-ing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.



H. On two-wheeled models, fully retract front screw jack and any rear stabilizer legs. If a caster wheel is pro-vided on the screw jack it is part of the screw jack, and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full upright position. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to tow-ing.

I. Make sure tires are in good condition and are the size (load range) specified and are inflated to the specified pressures. DO NOT change the tire size or type. Also, make sure wheel bolts, lugs or nuts are tightened to the specified torques.

J. If provided, make sure all dual stop, tail directional and clearance lights are operating properly and that their lenses are clean and functional. Also, make sure all reflectors and reflecting surfaces, including the slow moving vehicle emblem on compressors provided with same, are clean and functional.

K. Make sure all service air hoses (not air brake hoses) are disconnected or are fully stowed and secured on hose reels, if provided.

L. Make sure all access doors and tool box covers are closed and latched. If the compressor is large enough to hold a man, make sure all personnel are out before closing and latching access doors.

M. Make sure parking brakes in towing vehicle are set, or that its wheels are chocked or blocked, or that it is otherwise restrained from moving. Then, release the compressor parking brakes, if provided.

N. Make sure the compressor wheels are not chocked or blocked, and that all tie-downs, if any, are free.

O. Test running brake operation, including breakaway switch operation if provided, before attempting to tow the compressor at its rated speed or less when con-ditions prevail.

P. DO NOT carry loose or inappropriate tools, equip-ment or supplies on or in the compressor.

Q. DO NOT load this equipment with accessories or tools such that it is unbalanced from side to side or front to back. Such unbalance will reduce the towabil-ity of this equipment and may increase the possibility of tipping, rolling over, jackknifing, etc. Loss of control of the towing vehicle may result.

1.13.2 Towing A. Observe all Federal, State, and Local laws while tow-

ing this equipment (including those specifying mini-mum speed).

B. DO NOT exceed the towing speeds listed below under ideal conditions. Reduce your speed according to posted speed limits, weather, traffic, road or terrain conditions:

C. Two axle four-wheel or three axle six-wheel steerable models: 15 mph (24 km/h).

D. All other models: 55 mph (88 km/h).

E. Remember that the portable air compressor may approach or exceed the weight of the towing vehicle. Maintain increased stopping distances accordingly. DO NOT make sudden lane changes, U-turns or other maneuvers. Such maneuvers can cause the compressor to tip, roll over, jackknife or slide and cause loss of control of the towing vehicle. Tipping, rolling over, etc. can occur suddenly without warning. U-turns especially should be made slowly and care-fully.

F. Avoid grades in excess of 15° (27%).

G. Avoid potholes, rocks and other obstructions, and soft shoulders or unstable terrain.

H. Maneuver in a manner that will not exceed the free-dom of motion of the compressor’s drawbar and/ or coupling device, in or on the towing vehicle’s cou-pling device and/or adjacent structure whether tow-ing forward or backing up, regardless of the terrain being traversed.

I. DO NOT permit personnel to ride in or on the com-pressor.

J. Make sure the area behind, in front of, and under the compressor is clear of all personnel and obstructions prior to towing in any direction.

K. DO NOT permit personnel to stand or ride on the drawbar, or to stand or walk between the compressor and the towing vehicle.

1.13.3 Parking or locating compressorA. Park or locate compressor on a level surface, if pos-

sible. If not, park or locate compressor across grade so the compressor does not tend to roll downhill. DO NOT park or locate compressor on grades exceeding 15° (27%).

B. Make sure compressor is parked or located on a firm surface that can support its weight.



C. Park or locate compressor so the wind, if any, tends to carry the exhaust fumes and radiator heat away from the compressor air inlet openings, and also where the compressor will not be exposed to exces-sive dust from the work site.

D. On steerable models, park compressor with front wheels in straight-ahead position.

E. Set parking brakes and disconnect breakaway switch cable and all other interconnecting electrical and/or brake connections, if provided.

F. Block or chock both sides of all wheels.

G. If provided, unhook chains and remove them from the points of chain attachment on the towing vehicle, then hook chains to bail on drawbar or wrap chains around the drawbar and hook them to themselves to keep chains off the ground which might accelerate rusting.

H. Lower front screw jack and/or any front and rear sta-bilizer legs. Make sure the surface they contact has sufficient load bearing capability to support the weight of the compressor.

I. If a caster wheel is provided on the screw jack, it is part of the screw jack and cannot be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Raise the screw jack to its full upright position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the draw-bar and reinsert the pin. Make sure the jack is secured in place prior to towing.

J. Disconnect coupling device, keeping hands and fin-gers clear of all pinch points. If the compressor is provided with a drawbar, DO NOT attempt to lift the drawbar or if hinged, to raise it to the upright position by hand, if the weight is more than you can safely handle. Use a screwjack or chain fall if you cannot lift or raise the drawbar without avoiding injury to your-self or others.

K. Move the towing vehicle well clear of the parked compressor and erect hazard indicators, barricades and/or flares (if at night) if compressor is parked on or adjacent to public roads. Park so as not to inter-fere with traffic.

WARNING


CAUTION

Retract the front screw jack only after attaching the compressor to the tow vehicle. Raise the screw jack to its full up position and pull the pin connecting the jack to the drawbar. Rotate the screw jack to its stowed position, parallel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

On two-wheeled models, fully retract front screw jack and any rear stabilizer legs. If a caster wheel is provided on the screw jack it is part of the screw jack and can not be removed. Follow the same procedure for stowing away the wheeled jack as you would for the standard screw jack. Pull the pin connecting the jack to the drawbar and raise the screw jack to its full up position. Rotate the screw jack to its stowed position, par-allel to the drawbar, and reinsert the pin. Make sure the jack is secured in place prior to towing.

NOTE

While not towed in the usual sense of the word, many of these instructions are directly applicable to skidmounted portable air compressors as well.



1.14 California proposition 65

WARNING

California Proposition 65 Warning

Diesel engine exhaust and some of its constitu-ents are known to the State of California to cause cancer, birth defects and other reproduc-tive harm.

Battery posts, terminals and related accessories contain lead and other compounds known to the State of California to cause cancer and birth defects and other reproductive harm. Wash hands after handling.



1.15 Symbols and referencesThe symbols below may or may not be used. Please refer to the decals set forth on the machine for applicable symbols.

DIESEL FUEL HEARING PROTECTION

HARD HAT

SAFETY GLASSES

HOOK HERE

DO NOT REMOVE MANUAL

DO NOT BREATHECOMPRESSED AIR

DO NOT STAND ONSERV. VALVE

DO NOT OPERATEW/ DOORS OPEN

DO NOT OPEN

DO NOT STACK

ELECTRICAL SHOCK

AIR FLOW

HOT SURFACE

PRESSURIZED VESSEL

PRESSURIZED COMPONENT

CLOSED MECHANICAL

FUSE

LOW PRESSURE

READ MANUAL

BRAKES

ROTARY COMPRESSOR

TEST RUN

DRAIN

HIGH PRESSURE

NO

ENGINE

COMPRESSOR

ENGINE OIL

ENGINE COOLANT

WATER

OIL

DO NOT

SHUT-OFF VALVEW/ SAFETY

SAFETY SYMBOLS 1



DANGEROUS OUTLET

CORROSIVE

WARNING

BELOW TEMPERATURE

DO NOT TOW

BAR/PSI

BATTERY

BATTERY DISCONNECT

OFF

ON

RESET

REMOTELY CONTROLLED

DO NOT MAINTENANCE

ENGINE START

ENGINE ECM

READ/WRITE DATA

INTAKE AIR

EXHAUST GAS

FAN GUARD

BELT GUARD

SERVICE POINT

LOW TEMPERATURE

STD AIR

A/C AIR

24 HOURS

BELTS

FILTER

STRAINERFORK LIFT HERE

DIRECTION OF ROTATION

NO FORKLIFT

SAFETY SYMBOLS 2



RADIATOR

LUBRICATION

AXEL

HOUR METER

START

CONTROL

ENGINE WARNING

FUEL LEVEL

ENGINE RPM

ENGINE OILPRESSURE

ENGINE COOLANTTEMPERATURE

COMPRESSORTEMPERATURE

DO NOT MIXCOOLANTS

AFTERCOOLER BYPASS VALVE

COMPRESSOROIL HEAT

STACKING LIMITBY NUMBER

DRAIN HEATER

BATTERY HEATER

ENGINE PREHEATLOW TEMP AID

COMPRESSOR AIR PRESSURE

AIR-CIRCULATINGFAN

AIR-COOLEDOIL COOLER

LIQUID-COOLEDOIL COOLER

TRAILER TOWINGMODE

CRUSH/PINCH POINT

FUNCTIONAL ARROW

PRESSURE CONTROL

INTERNAL FUEL

EXTERNAL FUEL

SIDE DOOR T-LATCH

INLET VALVE SPRING

ENGINE INTAKE AIR FILTER

LUBRICANT GREASE

EXAMINE, CHECK

SAFETY SYMBOLS 3



DO NOT OPERATEWHILE STACKED

DO NOT MIX FLUIDS

AUTO START/STOP

DPF: DIESELPARTICULATE FILTER

DPF REGEN. INHIBIT

FLUID DRAIN

PRESSURIZED SPRING

WATER DRAIN

SEVER (FAN)

DEF FLUID ONLY

RUN

SAFETY SYMBOLS 4

LOW FUEL

HEST: HIGH EMISSIONS SYSTEM TEMPERATURE

EMISSIONSMALFUNCTIONINDICATION



Notes:


Section 2

E900H User Manual 2: Description

Description
2.1 IntroductionSullair portable air compressor models offer superior per-formance and reliability while requiring only minimal maintenance.
The compressor is equipped with a Sullair rotary screw compressor unit. Compared to other compressors, the Sullair is unique in mechanical reliability and compressor durability. No inspection is required of the working parts within the compressor unit.

As you continue reading this manual and come to learn how the compressor operates and is cared for, you will see how surprisingly easy it is to keep a Sullair compres-sor in top operating condition.

Read Section 6: Maintenance to keep your compressor in top operating condition. Should any problem or ques-tion arise which cannot be answered in this text, contact your nearest Sullair representative or the Sullair Service Department.

2.2 Description of componentsRefer to Figure 2-1. The components and assemblies of the Sullair portable air compressor models are clearly shown. The package includes a compressor, electric motor, compressor inlet system, compressor cooling and lubrication system, compressor discharge system, capacity control system, instrument panel and electrical system.

The electric motor is direct coupled to the compressor unit via a flexible coupling. A separate electric motor-driven fan forces air through the cooler/aftercooler assembly, thereby removing the heat of compression from the cooling fluid.

2.3 Sullair compressor unit, functional description

Sullair compressors feature the Sullair compressor unit, a single-stage, positive displacement, flood lubricated-type compressor. This unit provides continuous compression to meet your needs.

Sullair compressors are factory-filled with Sullair AWF®

lubricant. For more information on fluid fill, refer to Sec-tion 3.3: Application guide on page 30.

Fluid is injected into the compressor unit hoses and mixes directly with the air as the rotors turn, compressing the air. The fluid flow has three basic functions:

• As coolant, it controls the rise of air tempera-ture normally associated with the heat of com-pression.

• Seals the clearance paths between the rotors and the stator and also between the rotors themselves.

• Acts as a lubricating film between the rotors allowing one rotor to directly drive the other, which is an idler.

After the air/fluid mixture is discharged from the compres-sor unit, the fluid is separated from the air. At this time, the air flows through an aftercooler and separator then to your service line while the fluid is being cooled in prepa-ration for reinjection.

NOTE

With a Sullair compressor, there is no mainte-nance or inspection of the internal parts of the compressor unit permitted in accordance with the terms of the warranty.


2: Description E900H User Manual

Figure 2-1: E900H compressor

1. Cooler assembly 8. Afterfilters

2. Lifting bail 9. Minimum pressure valve

3. Air filter 10. E-Stop button

4. Main motor 11. Fluid filters

5. Cooling fan 12. Electrical cabinet

6. Sump tank 13. Control panel

7. Moisture separator



2.4 Air inlet system, functional description

Refer to Figure 2-2. The compressor inlet system con-sists of one air filter, a compressor air inlet valve and interconnecting piping to the compressor. Also, an air fil-ter restriction indicator gauge is located next to the air fil-ter housing.

The air filter is a 2-stage unit with a safety element dry element-type filter. This filter is capable of cleaning extremely dirty air. However, in such cases, frequent checks of the air filter will be required. Referring to the air filter restriction gauge will indicate when restriction of the air passing through the filter becomes too high.

At this time, change the air filter element. Refer to Sec-tion 6.9.5: Air filter maintenance on page 46. This indica-tor should be checked daily, after start-up under normal conditions.

The compressor air inlet valve controls the amount of air intake of the compressor in response to the air demand.

2.5 Compressor discharge system, functional description

Refer to Figure 2-3. The Sullair compressor unit dis-charges compressed air/fluid mixture into the receiver tank.

The receiver tank has three functions:

• It acts as a primary fluid separator.

• Serves as the compressor fluid storage sump.

• Houses the final fluid separator.

The compressed air/fluid mixture enters the receiver tank and is directed against the tank side wall. By change of direction and reduction of velocity, large droplets of fluid separate and fall to the bottom of the receiver tank. The fractional percentage of fluid remaining in the com-pressed air collects on the surface of the final separator element as the compressed air flows through the separa-tor. As more and more fluid collects on the element’s sur-face, the fluid descends to the bottom of the separator. A return line (or scavenge tube) leads from the bottom of the separator element to the inlet region of the compres-sor unit. Fluid collecting on the bottom of the separator element is returned to the compressor by the pressure difference between the area surrounding the separator element and the compressor inlet. An orifice (protected by a strainer) is included in this return line to help assure proper flow.

The receiver tank is code rated. A minimum pressure/ check valve, located downstream from the separator, helps assure a minimum receiver pressure during all con-ditions. This pressure is necessary for proper air/fluid separation and proper fluid circulation.

A minimum pressure/check valve at the outlet of the receiver is installed to prevent compressed air in the ser-vice line from bleeding back into the receiver on shut-down when the compressor is being run in parallel with other compressors tied to a large air system.

Fluid is added to the receiver tank via a capped fluid filler. A fluid level gauge glass enables the operator to visually monitor the receiver tank fluid level.

Figure 2-2: Air inlet system

1. Air filter 4. Compressor

2. Inlet valve 5. Restriction indicator

3. Inlet adapter 6. Air inlet elbow

WARNING

Do not remove caps, plugs and/or other compo-nents when compressor is running or pressur-ized.

Stop compressor and relieve all internal pres-sure before doing so.



Figure 2-3: Compressor flow diagram

1. Compressor air filter 11. Thermal valve/fluid filter assembly

2. Electric motor 12. Receiver tank

3. Compressor unit 13. Fluid level sight gauge

4. Service air (aftercooled) 14. Final fluid separator element

5. Discharge air filters 15. Ball valve

6. Air inlet valve 16. P3 pressure switch

7. Moisture separator 17. Service air (non-aftercooled)

8. Aftercooler 18. Minimum pressure check valve

9. Relief valve 19. Temperature shutdown switch

10. Fluid cooler



2.6 Compressor cooling and lubrication system, functional description

Refer to Figure 2-4. The compressor cooling and lubrica-tion system is designed to provide adequate lubrication as well as maintain the proper operating temperature of the compressor. In addition to the cooler and fan, the sys-tem consists of a main filter and thermal valve.

Fluid is used in the system as a coolant and a lubricant. The fluid is housed in the receiver tank.

Upon start up, the fluid temperature is cool, and routing to the cooler is not required. The fluid first enters the ther-mal valve and then flows on to the compressor unit, bypassing the cooler. As the compressor continues to operate, the temperature of the fluid rises and the ther-mal valve element begins to shift. This forces a portion of the fluid to the fluid cooler. The cooler is a radiator-type

that works in conjunction with a separate motor-driven fan. The fan blows air through the cooler removing the heat of compression from the fluid. From the cooler, the fluid is routed back to the thermal valve.

Before the temperature of the fluid reaches the valve set point, cooled fluid is mixed with warmer fluid. When the temperature of the fluid reaches 190°F (88°C), the ther-mal element shifts completely causing all fluid to flow to the cooler. After the fluid passes through the thermal valve it is then directed through the main fluid filter. There, the fluid is filtered in preparation for injection into the compression chamber and bearings of the compres-sor unit. The filter has replaceable elements. After the fluid is properly filtered, it then flows on to the compres-sor unit where it lubricates, seals and cools the compres-sion chamber as well as lubricates the bearings and gears.

2.7 Control system, functional description

The purpose of the compressor control system is to regu-late the amount of air being compressed to match the amount of compressed air being used.

The capacity control system consists of a pneumatic inlet valve. The functional description of the control system is described below in four distinct phases of compressor operation. For explanatory purposes, this description applies to any compressor with an operating range of 150 to 165 psig (10.3 to 11.4 bar). A compressor with any other pressure range would operate in the same manner except for the stated pressures.

Start mode—0 to 50 psig (0 to 3.4 bar)When the compressor <START> button is depressed, the sump pressure will quickly rise from 0 to 50 psig (0 to 3.4 bar). During this period, both of the pressure regula-tors and the solenoid valve are closed and the pneumatic inlet valve is inoperative. The internal spring holds the inlet valve fully closed to reduce motor torque for starting. After six (6) seconds the solenoid valve will open, open-ing the inlet valve, and the compressor will run at full rated capacity. The rising compressor air pressure is iso-lated from the service line in this phase by the minimum pressure valve set at approximately 50 psig (3.4 bar).

Full load mode—50 to 150 psig (3.4 to 10.3 bar)When the compressed air pressure in the sump rises above 50 psig (3.4 bar), the minimum pressure valve opens, allowing compressed air to flow into the service line. A load signal is provided through a pressure reduc-ing regulator set at 70 psig (4.8 bar) to maintain the inlet

Figure 2-4: Cooling and lubrication system

1. Hose from oil cooler 5. Hose to oil cooler

2. Fan enclosure 6. Hose to unit

3. Fan guard 7. Fluid filter

4. Fan motor 8. Hose from separator tank



valve in an open position. The inlet valve will remain in the full load position as long as the compressor is running at 150 psig (10.3 bar) or below.

Modulation—150 to 165 psig (10.3 to 11.4 bar)As air demand drops below the rated capacity of the compressor, the line pressure will rise above 150 psig (10.3 bar). As the air pressure exceeds 150 psig (10.3 bar), the differential pressure regulator controlling the inlet valve opens. This allows the air pressure into the unload chamber of the inlet valve, which starts partially closing the inlet valve, providing modulation. During this period, the pressure rises approximately from 150 to 165 psig (10.3 to 11.4 bar).

Unload mode—in excess of 165 psig (11.4 bar)When a relatively small amount or no air is being used, the service line pressure continues to rise. When it exceeds 165 psig (11.4 bar), the pressure switch ener-gizes the solenoid, applying pressure to the unload chamber of the inlet valve, which fully closes the valve. Simultaneously, the solenoid valve sends a pneumatic signal to the blowdown valve. The blowdown valve opens the sump to the atmosphere. This reduces the sump pressure to approximately 25 psig (1.7 bar), which results in low horsepower consumption. The check valve in the air service line prevents line pressure from returning to sump while the compressor is running in the unloaded mode. The inlet valve remains in the unload position. When the line pressure drops back to 150 psig (10.3 bar) due to an increase in the air demand, the pressure switch de-energizes the solenoid valve removing air pressure

from the unload chamber, opening the inlet valve. The blowdown valve closes, and the inlet valve opens.

2.8 Aftercooled air system, functional description

Refer to Figure 2-3 and Figure 2-4. The purpose of the aftercooled air system is to operate the air compressor in conditions when compressed air temperatures are required to be 10 to 25°F (5 to 13°C) over ambient tem-perature. A 3-valve bypass is provided to switch between standard and aftercooled air. The ambient air, which is blown through the aftercooler by the motor-driven fan, cools the compressed air as it passes through the after-cooler core. Cooled air enters the moisture separator where condensation is removed from the cooler air and discharged. This condensation does carry some oil and it should be disposed of properly in accordance with local regulations. A condensation drain port is located in the frame on the front of the machine for convenience of con-densate removal. This drain port should never be plugged or closed off in any way. From the moisture sep-arator the compressed air goes through the discharge fil-ters and on to the service valve.

NOTE

Aftercooled system should not be operated in ambient conditions below 32°F (0°C).

To operate in the non-aftercooled mode, open and close the appropriate valves.



2.9 Instrument panelSee Figure 2-5. The compressor is provided with an instrument panel to monitor and control key functions of the compressor package. To ensure proper operation of the machine, operators should be familiar with the func-tion and use of each display and control. See Section 5.2: Purpose of controls on page 39 for the details.

Figure 2-5: Instrument panel


2: Description

E900H U

ser Manual

24 2.10 Piping and instrumentation diagram

02250203-986 R03

Subject to EAR, EC

CN

EAR99 and related export control restrictions.

02250204-020 R00

E900H U

ser Manual

2: Description

02250203-986 R03

Subject to EAR, EC

CN


25

SWITCH

ATURE SWITCH (RT)

Qty Notes

2.10 Piping and instrumentation diagramKey Description Qty Notes

1 FILTER, AIR 1

2 GAUGE, AIR FILTER RESTRICTION 1

3 INLET VALVE 1

4 COMPRESSOR 1

5 VALVE, RELIEF 1

6 SWITCH, TEMPERATURE 1

7 SWITCH, TEMPERATURE 1

8 SWITCH, PRESSURE 1

9 SILENCER 1

10 SUMP, AIR/OIL SEPARATOR 1

11 GLASS, SIGHT OIL LEVEL 1

12 VALVE, MINIMUM PRESSURE 1

13 VALVE, BALL 5

14 COOLER, AIR (OPTIONAL) 1

15 SEPARATOR, MOISTURE 1

16 VALVE, BLOWDOWN NC 1

17 ORIFICE 3

18 GAUGE, TEMPERATURE 1

19 STRAINER 2

20 SIGHT GLASS, BLOCK 1

21 VALVE, THERMAL BYPASS 1

22 COOLER, OIL 1

23 FILTER, OIL 1

24 VALVE, 3-WAY NC 1

25 VALVE, 3-WAY NO 1

26 VALVE, REGULATOR BACK PRESSURE 1

27 GAUGE, PRESSURE 2

28 VALVE, REDUCING REGULATOR 1

29 VALVE, CHECK 3

30 VALVE, RECIRCULATION 1

31 GAUGE, DIFFERENTIAL PRESSURE 2

32 FILTER, AIR 2

33 MOISTURE SEPARATOR 1

Drawing notes

P1 DRY SIDE PRESSURE SWITCH

T1 UNIT DISCHARGE TEMPERATURE

T3 SUMP/SEPARATOR TANK TEMPER

Key Description

2: Description

E900H U

ser Manual

26 2.11 Wiring diagram

02250203-986 R03

Subject to EAR, EC

CN


88291006-945 R04

E900H U

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2: Description

02250203-986 R03

Subject to EAR, EC

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27

SWITCH

E

LVE

Notes

2.11 Wiring diagram

Key Description Notes

M2 FAN MOTOR

KM4 FAN MOTOR CONTACTOR - FORWARD ROTATION

KM5 FAN MOTOR CONTACTOR - REVERSE ROTATION

QF CUSTOMER SUPPLIED CIRCUIT BREAKER

QF1 COMPRESSOR MAIN CIRCUIT BREAKER

QF2 FAN MOTOR CIRCUIT PROTECTOR

FU1 PHASE MONITOR RELAY FUSE

FU2 CONTROL TRANSFORMER PRIMARY FUSE

FU3 CONTROL TRANSFORMER SECONDARY FUSE

TC1 CONTROL VOLTAGE TRANSFORMER

EH MOTOR HEATER

HL1 POWER INDICATOR

HL2 HEATER INDICATOR

HL3 RUN INDICATOR

HL101 HIGH TEMPERATURE WARNING INDICATOR

HL102 COMPRESSOR MOTOR OVERLOAD INDICATOR

HL103 FAN MOTOR OVERLOAD INDICATOR

HM HOUR METER

KA0 READY RELAY

KA1 RUN RELAY CONTACT

KA2 HIGH TEMP RELAY CONTACT

KA6 PHASE MONITOR RELAY

KT0 STOP LAG TIMING RELAY CONTACT

KT1 WYE-DELTA TIMING RELAY CONTACT

KT2 MOISTURE DRAIN TIMING RELAY CONTACT

SA1 MOTOR HEATER SWITCH

SB1 EMERGENCY STOP CONTACT

SB2 RUN/STOP SWITCH

SB3 FAN ROTATION SWITCH

SP1 PRESSURE SWITCH

ST0 MAIN DISCONNECT SWITCH

ST1 COMPRESSOR DISCHARGE TEMPERATURE SWITCH

ST2 RECEIVER TANK TEMPERATURE

YV1 LOAD/UNLOAD SOLENOID VALV

YV2 RUN/STOP SOLENOID VALVE

YV3 MOISTURE DRAIN SOLENOID VA

Key Description


Notes:


Section 3

E900H User Manual 3: Specifications

Specifications
3.1 Tables of specificationsTable 3-1: Overall specifications
Model series

Length1 Width Height2 Weight (wet)

in mm in mm in mm lb kg

ETQ (Tandem) 195.5 4966 83.3 2115 94.2 2392 11,780 5355

ELQ (LRG) 143.5 3646 78.8 2001 67.1 1705 10,030 45601Length over drawbar where applicable.2Over lifting bail.

Table 3-2: Compressor specifications

Compressor E900H

Type Rotary screw

Delivery @ operating pressure 900 acfm (25.5 m3/min)

Maximum full load operating pressure 150 psig (10.3 bar)

Rated pressure 150 psig (10.3 bar)

Cooling Pressurized compressor fluid

Lubricating compressor fluid See Section 3: Lubrication guide—compressor on page 30

Receiver tank capacity 29 US gallons (110 L)

Operating tilt (maximum) 15°

Operating voltage 460V 60 Hz / 380V 50 Hz

Control voltage 110V 60 Hz / 110V 50 Hz

Sound level at 7 m 73 dB(A)

Spec of air service valve (qty) NPT 2″ / NPT 1″

Table 3-3: Motor specifications

Item Detail

Size 214 hp (160 kW)

Type Totally enclosed fan cooled (TEFC) premium efficient, IP55 enclosure

Starter Wye-delta

Speed 1780 rpm (60 Hz) / 1480 rpm (50 Hz)

Table 3-4: Trailer specifications

Trailer DTQ

Track width 67 in (1701 mm)

Tire size (load range) ST 235/80 R16 (E)

Tire pressure 80 psig (5.5 bar)

Wheel size 16 x 6

Wheel bolt/lugnut torque 85 to 110 ft. lbs. (115 to 149 Nm)


3: Specifications E900H User Manual

3.2 Lubrication guide—compressor

3.3 Application guideSullair air compressors are supplied with Sullair AWF®

which is a heavy duty multi-viscosity, all weather fluid which provides an extended change interval when com-pared to other fluids. Detergent motor oils (SAE 10W Class SE, SF, SG, or CD) can also be used. Any of these oils are suitable under conditions where severe oil oxida-tion can occur.

Water must be drained from the separator tank periodi-cally. In high ambient temperature and humidity condi-tions, condensed moisture can emulsify with the oil forming a “milky” color. SAE 10W is especially prone to this condition. The fluid should be changed if this condi-tion develops.

Do not mix different fluids. Combinations of different flu-ids can lead to operational problems such as foaming, plugged filters, blocked orifices or lines.

When ambient conditions exceed the recommended ranges, or if other conditions warrant the use of other extended life lubricants, contact your local Sullair repre-sentative for recommendations.

Sullair encourages users to participate in a fluid analysis program. The analysis might indicate a need for change intervals different from those recommended in this man-ual. Sullair offers a fluid analysis for Sullair AWF. Contact Sullair for details.

Fluid type Change period/hours Ambient temperature range °F (°C)

Sullair AWF® 1 1500 -20 to 125 (-29 to 52)

Sullube® varies2 32 to 125 (0 to 52)

SAE 10W SE, SF, SG, CD 250 0 to 100 (-18 to 38)

MIL-L-2104E 10W 250 0 to 100 (-18 to 38)1 Sullair part numbers for Sullair AWF are 250030-757 (5 gallons/18.9 liters) and 250030-758 (55 gallon drum/280 liters).2 Models filled with long life Sullube lubricant should be changed under the following conditions, whichever occurs first:

• Every 8000 hours. • Once a year. • As indicated by fluid analysis. A fluid sample at every 1000 hours is recommended.

• For information about a free Sullube analysis, contact your Sullair representative.


E900H User Manual 3: Specifications

Notes:


3: SpecificationsE900H

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anual

32 3.4 Identification—less running gear

02250203-986 R03

Subject to EAR, EC

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02250204-110 R01

E900H U

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3: Specifications

02250203-986 R03

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33

3.4 Identification—less running gear

Drawing notes

1 DIMENSIONS ARE IN INCHES BRACKET [ ] DIMENSIONS ARE IN MILLIMETERS.

2 ALLOW 4’ [1,219 MM] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.

3 DOORS REQUIRE 4’ [1,219 MM] MAXIMUM OPENING CLEARANCE (SEE NOTE A15).

4 THIS FRAME CAN CONTAIN 100% OF ALL MACHINE FLUIDS.

5 ALL DIMENSIONS ARE +/- .50”.

6 APPROX. PACKAGE WEIGHT: 10,030 LBS [4,550 kg].

A1 CONDENSATE DRAIN 1/2” NPT

A2 SUMP/SEPARATOR TANK DRAIN 1/2” NPT

A3 AFTERCOOLER DRAIN 1/2” NPT

A4 OIL COOLER DRAIN 1/2” NPT

A5 SEPARATOR/SUMP TANK ACCESS PANEL

A6 LIFTING BAIL ACCESS PANEL

A7 AIR OUT 2” NPT

A8 AIR OUT 1” NPT

A9 PARALLEL INCOMING POWER CIRCUIT BREAKER DISCONNECT MALE 4/0 BLACK L1, L2, L3

A10 LIFTING FORK POCKETS

A11 INSTRUMENT PANEL ACCESS

A12 DRAIN PLUG

A13 AIR INLET

A14 AIR OUTLET

A15 DOOR

A16 E-STOP BUTTON

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34 3.5 Identification—portable

02250203-986 R03

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02250204-126 R01

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3: Specifications

02250203-986 R03

Subject to EAR, EC

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35

3.5 Identification—portable

Drawing notes

1 DIMENSIONS ARE IN INCHES. BRACKET [ ] DIMENSIONS ARE IN MILLIMETERS.

2 ALLOW 4’ [1,291 MM] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.

3 DOORS REQUIRE 4’ [1,291 MM] MAXIMUM OPENING CLEARANCE (SEE NOTE A16).

4 THIS FRAME CAN CONTAIN 100% OF ALL MACHINE FLUIDS.

5 ALL DIMENSIONS ARE +/- .50”.

6 APPROX. PACKAGE WEIGHT: 11,780 LBS. [5343 kg].

A1 CONDENSATE DRAIN 1/2” NPT

A2 SUMP/SEPARATOR TANK DRAIN 1/2” NPT

A3 AFTERCOOLER DRAIN 1/2” NPT

A4 OIL COOLER DRAIN 1/2” NPT

A5 SEPARATOR/SUMP TANK ACCESS PANEL

A6 LIFTING BAIL ACCESS PANEL

A7 AIR OUT 2” NPT

A8 AIR OUT 1” NPT

A9 PARALLEL INCOMING POWER CIRCUIT BREAKER DISCONNECT MALE 4/0 BLACK L1, L2, L3

A10 LIFTING FORK POCKETS

A11 INSTRUMENT PANEL ACCESS

A12 DRAIN PLUG

A13 AIR INLET

A14 AIR OUTLET

A15 TRACKING WIDTH

A16 DOOR

A17 E-STOP BUTTON

3: Specifications E900H User Manual

Notes:


Section 4

E900H User Manual 4: Installation

Installation
4.1 Fluid level checkThe compressor is shipped fully charged with the proper amount of fluid. However, it is necessary to check the fluid level at the time of installation and during compres-sor operation. Check the fluid level when the compressor is in the SHUT DOWN mode (fluid level may not be visi-ble when operating), and by looking at the sight glass on the receiver tank (see Figure 6-5 on page 47). The full level is at half the sight glass. Add fluid if fluid level is not visible in the sight glass when machine is shut down.
4.2 Electrical preparation

Interior electrical wiring is installed at the factory. Required customer wiring should be done by a qualified electrician in compliance with OSHA, National Electric Code and/or any applicable local electrical codes. Cus-tomer to supply power via cam-lock located on end of enclosures. An electrical check should be made to ensure that the first start-up will be successful. The com-pressor and drive should be properly grounded/earthed

in accordance with applicable codes, regulations, and requirements.

Feeder cables should be sized by the customer/electrical contractor to ensure that the circuit is balanced and not overloaded by other electrical equipment. The length of wiring from a suitable electrical power source is critical because voltage drops can adversely effect the perfor-mance of the compressor. Refer to Table 4-1: Incoming conductor wiring.

Parallel feeder cable connections to incoming terminal cam-locks L1-L2-L3 should be tight and clean. These are located on end of package. Behind the access door located above the cam-locks is the package circuit breaker disconnect, supplied for additional safety.

The applied voltage must conform to the motor and com-pressor data plate ratings.

• Check incoming voltage. The incoming voltage must match the compressor’s wire rating/speci-fications.

• Check motor starting device and overload heater sizes.

• Check all electrical connections for tightness.

WARNING

Energized internal components are a potentially fatal shock hazard. Disconnect all power before performing any work on the compressor’s electrical system.

Table 4-1: Incoming conductor wiring

hp (kW)Conductor

sizeGND

conductor

480V 45°C 214 (160) 4/0 2/0

380V 45°C 214 (160) 350 MCM 250 MCM


4: Installation E900H User Manual

Notes:


Section 5

E900H User Manual 5: Operation

Operation
5.1 GeneralWhile Sullair has built into this compressor a comprehen-sive array of controls and indicators to assure you that it is operating properly, you will want to recognize and inter-pret the readings which will call for service or indicate the
beginning of a malfunction. Before starting your Sullair compressor, read this section thoroughly and familiarize yourself with the controls and indicators—their purpose, location and use.

5.2 Purpose of controls

Control or indicator Purpose

START / STOP switchUtilized to start and stop the compressor. Upon stopping, the compres-sor will continue to run for a short time in order to relieve sump pressure.

Sump pressure gaugeDisplays receiver tank pressure of the compressor during all phases of operation.

Hour meter Displays accumulated run time of the compressor.

Discharge temperature gauge Displays temperature at the compressor discharge.

Discharge temperature switch & high discharge temperature lamp

If the high operating temperature limit of 250°F (121°C) is exceeded, the compressor will be stopped and the High Discharge Temperature lamp lit. After addressing the cause of the fault, it is reset by depressing and re-setting the emergency stop button.

Separator differential pressure gauge

Displays the pressure difference between the wet and high side of the separator element. Refer to Section 6: Maintenance for recommended service intervals.

Fluid filter differential pressure gauge

Displays the pressure difference between the inlet and outlet of the fluid filter. Refer to Section 6: Maintenance for recommended service inter-vals.

Emergency stop / reset switchWhen depressed, the compressor is stopped. Additionally when depressed and reset, the High Temperature Alarm is reset.

Power / run indicatorsThe power indicator is lit when power is connected to the machine and the main disconnect is closed. The run indicator is lit once the compres-sor is started.

Main motor / fan motor overload indicator

These indicators are lit if the motors are overloaded. Once the fault is addressed and the motor overload relays are reset, the indicators will be reset. Refer to Section 7: Troubleshooting for potential causes.

Phase / voltage fault lightThis indicator is lit when the phase/voltage relay detects incorrect phas-ing or a voltage fault. See Section 5.7 for details.

Fan forward/reverse switchThis switch controls the rotation direction of the cooling fan. See Section 5.6 for details.

Motor heater switchThis switch activates the internal heaters in the main motor. See Section 5.5 for details.


5: Operation E900H User Manual

5.3 Initial start-up procedure1. Place machine in level, suitable area and

chock the wheels.

2. Ensure that red shipping studs are loosened and not supporting the motor or compressor unit.

3. Connect power to machine. See Section 4.2: Electrical preparation on page 37.

4. Check compressor fluid level. See Section 4.1: Fluid level check on page 37.

5. Fully open the air service valve.

6. Turn on main power supply and disconnect on machine. At this time, the power indicator light shall be on and the machine is ready to start.

7. Check Phase/Voltage Fault indicator. If lit, disconnect power and switch two of the phases. See Section 5.7 for more details.

8. Depress start button and observe. If machine starts, the run indicator light will be on and the electrical connection is correct. Verify proper rotation of compressor and fan.

9. Once machine is started, verify that it unloads at the rated pressure.

Phase monitor relayPrevents the compressor from starting with incorrect phase order, loss of phase and under or over voltage.

Phase / voltage fault indicatorThis indicator is lit when the phase/voltage relay detects incorrect phas-ing or a voltage fault. See Section 5.7 for details.

Ground fault protectorThe protector contact will trip on the 110V circuit if a ground fault is detected. This will shut down the compressor or prevent it from starting.

Pressure regulator (LOAD chamber)

Maintains a maximum pilot pressure of 60 psig (4.1 bar).

Pressure regulator (UNLOAD chamber)

Opens a pressure line between the sump and the inlet unload chamber, allowing the inlet valve to regulate air delivery according to air demand.

Solenoid valveElectrically actuated 3-way solenoid valve used to open the blowdown valve and pressurize the unload port/close the inlet valve during shut-down.

Start control valveOpens when the wye-delta timer closes; closes when the wye-delta timer is open. Opens a pressure line between the sump and inlet load chamber allowing the inlet valve to deliver air.

Pneumatic inlet valveRegulates the amount of air being delivered. Also blocks reverse flow upon shutdown.

Minimum pressure/check valveMaintains a minimum pressure in the receiver tank. Prevents backflow from the system during shutdown or unload.

Blowdown assembly valve Vents receiver tank pressure during unloading and shutdown.

Thermal valveRegulates flow of fluid to the cooler in order to minimize warm up time and maintain a minimum operating temperature to avoid condensation.

Fluid level sight glassUsed to monitor fluid level. Proper level is always visible in the sight glass. Check the level when the compressor is shutdown.

Separator return line sight glassIndicates fluid flow from the separator scavenge. Flow should be visible during full load; little to no flow when unloaded. Sluggish full load flow indicates a need to clean the strainers fitted to the return lines.

Pressure relief valveOpens receiver tank pressure to atmosphere if receiver tank pressure exceeds relief valve setting.

Recirculation valveProvides limited air supply back to inlet valve during unload conditions to prevent cavitation in unit.

Control or indicator Purpose


E900H User Manual 5: Operation

10. Stop the compressor per shutdown proce-dure and check fluid level.

5.4 Normal start-up procedure1. Place machine in level, suitable area and

chock the wheels.

2. Check the compressor fluid level. Reference Section 4.1.

3. Verify the electrical connections are secure.

4. Turn on disconnect at machine and press the start button.

5. Monitor parameters on instrument panel.

5.5 Main motor heaterWhen the motor heater switch is in the ON position, the motor heater will be activated until the switch is set to OFF or the compressor starts.

In extremely wet environments, the motor heater should be run for 2 hours prior to start of compressor.

The heater should run for 2 hours once a month when the compressor is unused for an extended period of time. Additionally, the heater should be run for 2 hours prior to initial startup following an extended storage period.

5.6 Fan rotation switchThis switch controls the direction of rotation o the cooling fan. the direction should be set to FORWARD in warm weather. In cold weather, below 32°F (0°C), the fan can operate in REVERSE. This will help to prevent freezing of control lines as well as help to maintain the proper oper-ating temperature of the compressor. Operating the fan in REVERSE during warm temperatures can cause high operating temperatures and ultimately the shutdown of the compressor.

5.7 Phase/voltage fault relayThis compressor is equipped with a phase/voltage relay to detect incorrect phasing of incoming power or incorrect supply voltage. Upon initial power-up, the indicator on the control panel will be lit if the incoming power was con-nected out of phase. Swap two of the cables to correct the phasing.

If the relay is tripped during operation, proper operating voltage and connections should be checked prior to restarting compressor.

Even with the fault indicator lit upon initial power up, the machine will attempt to start for approximately 10 sec-onds. This is a delay feature provided to allow the com-pressor to overcome voltage drops upon starting. If after 10 seconds, the voltage or phase fault is still present, the machine will shut down.

CAUTION

Allow 5 minutes between starts for oil foam to subside and the motor to cool.

CAUTION

The receiver tank should be drained of conden-sate on a regular basis. The control line filter should be drained of condensate on a weekly basis.

CAUTION

The main motor heater will be switched off once the motor is started.

CAUTION

If the machine is energized and the motor heater switch is ON, the heater will be energized as long as the machine is not running and the E-Stop is not depressed.


5: Operation E900H User Manual

Notes:


Section 6

E900H User Manual 6: Maintenance

Maintenance
6.1 GeneralA good maintenance program is the key to long compres-sor life. Below is a program that when adhered to, should keep the compressor in top operating condition.
6.2 Daily operationPrior to starting the compressor, it is necessary to per-form a daily inspection.

Check the fluid level in the compressor receiver tank. Should the level be low, simply add the necessary amount. If the addi-tion of fluid becomes too frequent, a simple problem has devel-oped which is causing this excessive loss. Refer to Table 7-1: Troubleshooting guide on page 51 under “Excessive fluid consumption” for a probable cause and remedy.

After a routine start has been made, it is necessary to perform an inspection to ensure all operations are per-forming correctly. Perform the following inspections to prevent unnecessary problems.

• Observe the instrument panel gauges and be sure they monitor the correct readings for their particular phase of operation.

• After the compressor has warmed up, it is rec-ommended that a general check on the overall compressor and instrument panel be made to assure that the compressor is running properly.

• Check the air filter restriction gauge. Should it indicate restriction, replace the elements imme-diately. Refer to Section 6.9.5: Air filter mainte-nance on page 46.

6.3 Maintenance after initial 50 hours of operation

After the initial 50 hours of operation, a few simple main-tenance routines can rid the system of any possible for-eign materials, if any. Perform the following maintenance operations to prevent unnecessary problems.

• Clean the return line orifice and strainer.

• Change compressor fluid filter

6.4 Maintenance every 250 hoursPerform after every 250 hours of operation:

• Clean the cooler exterior. Depending on how contaminated the atmosphere may be, more frequent cooler cleaning may be necessary.

6.5 Maintenance every 300 hoursWhen not using Sullair AWF®, change the compressor fluid and replace the fluid filter element. Refer to Section 6.9.4: Main fluid filter servicing on page 46.

6.6 Maintenance every 600 hoursWhen not using Sullair AWF, replace the fluid filter ele-ment only. Refer to Section 6.9.4: Main fluid filter servic-ing on page 46.

6.7 Maintenance every 1000 hoursPerform after every 1000 hours of operation:

• Clean the return line orifice and strainer.

• Repack the wheel bearings on wheel-mounted units.

WARNING

Before any repairs are attempted, refer to Sec-tion 1: Safety before proceeding.

CAUTION

Do not remove caps, plugs and/or other compo-nents when compressor is running or pressur-ized. Stop compressor and relieve all internal pressure before doing so.


6: Maintenance E900H User Manual

6.8 Maintenance every 1500 hours When using Sullair AWF®, change the compressor fluid and replace the fluid filter element.

Refer to Section 6.9: Parts replacement and adjustment procedures.

6.9 Parts replacement and adjustment procedures

6.9.1 Compressor fluid change procedureWarm-up the compressor for 5 to 10 minutes to warm the fluid. Shut the compressor off and relieve all internal

pressure before proceeding. Drain the fluid by opening the appropriate drain valve located in the frame at the front of the machine. Close the valve when draining is complete. Change the compressor fluid and replace the fluid filter element. For element replacement: See Sec-tion 6.9.4: Main fluid filter servicing on page 46. Fill the receiver tank with fluid according to Section 3.2: Lubrica-tion guide—compressor on page 30.

6.9.2 Running gear lubricationRefer to Figure 6-1. An inspection of the running gear should be made on a routine basis.

Figure 6-1: Running gear lubrication



6.9.3 Wheel bearing lubrication

Refer to Figure 6-2. Proper lubrication is essential to the proper functioning and reliability of your portable com-pressor axle. Wheel bearings should be lubricated at least once every 12 months, or more frequently to help insure proper performance. Use wheel bearing grease that conforms to military specification MIL-G-10924 or a high temperature wheel bearing grease such as lithium complex NLGI Consistency #2.

If your axle is equipped with the E-Z Lube feature, the bearings can be periodically lubricated without removing the hubs from the axle. This feature consists of axle spin-dles that have been specially drilled and fitted with a grease zerk in their ends. When grease is pumped into the zerk, it is channeled to the inner bearing and then flows back to the outer bearing and eventually back out

of the grease cap hole (refer to Figure 6-2). The proce-dure is as follows:

1. Remove the rubber plug from the end of the grease cap.

2. With a standard grease gun filled with a qual-ity wheel bearing grease, place the gun onto the grease zerk located in the end of the spindle. Make sure the grease gun nozzle is fully engaged on the fitting.

3. Pump grease into the zerk. The old, dis-placed grease will flow back out of the cap around the grease gun nozzle.

4. When new, clean grease is observed, remove the grease gun, wipe off any excess, and replace the rubber plug in the cap.

Figure 6-2: Typical E-Z Lube axle

1. Rubber plug 5. Grease fitting

2. Outer bearing 6. Metal end cap

3. Inner bearing 7. Spring-loaded double lip seal

4. Grease flow



6.9.4 Main fluid filter servicing

Refer to Figure 6-3. The main fluid filters are located schematically in the coolant line between the receiver tank and the compressor unit. The main filter elements are replaceable. For installation of the filter elements, fol-low the procedure explained below:

1. The compressor must be shut off and sys-tem pressure must be relieved.

2. Position a suitable container beneath the elements to catch fluid drainage.

3. Remove elements using a suitable tool.

4. Rotate each element counterclockwise to remove.

5. Remove element and discard. These ele-ments are not cleanable.

6. Make certain that the mounting surfaces and filter heads are clean.

7. Apply a light film of clean fluid to each ele-ment gasket surface.

8. Center the new elements on filter housing heads and tighten until the filter gaskets make contact with the filter housing. After gaskets make contact, tighten ½ to ⅔ of a turn.

9. Run compressor and check for leaks.

6.9.5 Air filter maintenance

Refer to Figure 6-4. Air filter maintenance should be per-formed when indicated on the restriction indicator. The air filters are equipped with a primary element and second-ary element.

The secondary element must be replaced after every third primary element change. Do not reconnect the sec-ondary element once it is removed.

6.9.5.1 Air filter element removal1. Clean the exterior of the air filter housing.

2. Remove the rear cap by releasing retaining clamps.

Figure 6-3: Main fluid filter assembly and thermostat

1. Capscrew 5. Thermostat element

2. Washer 6. O-ring

3. Upper housing 7. Lower housing

4. O-ring 8. Filter elements

Figure 6-4: Air filter assembly

1. Primary element assembly

2. Rear cover

3. Housing

4. Evacuator



3. Remove the element from the housing.

4. Clean the interior of the housing by using a damp cloth. Do not blow out dirt with com-pressed air as this may introduce dust down-stream of the filter.

5. When it becomes necessary to remove the secondary element, pull the element out of the housing.

6. Install the new secondary element.

7. With the secondary element in place, replace the primary element.

6.9.5.2 Air filter element inspection1. Place a bright light inside the element to

inspect for damage or leak holes. Concen-trated light will shine through the element and disclose any holes.

2. Inspect all gaskets and gasket contact sur-faces of the housing. Should faulty gaskets be evident, correct the condition immedi-ately.

3. If the clean element is to be stored for later use, it must be stored in a clean container.

4. After the element has been installed, inspect and tighten all air inlet connections prior to resuming operation.

6.9.5.3 Primary air filter element replacement1. Place the element in position over the sec-

ondary element.

2. Install the cover with clean-out port pointing down.

6.9.6 Separator element replacement

Refer to Figure 6-5. When fluid carry-over is evident after the fluid return-line strainer and orifice, as well as the blowdown valve diaphragm, have been inspected and found to be in satisfactory condition, or if the separator restriction gauge reads in excess of 10 psig (0.7 bar), separator element replacement is necessary. Follow the procedure explained below:

1. Remove all piping connected to the receiver tank cover to allow removal (return line, ser-vice line, etc.).

Figure 6-5: Fluid filter separator

1. Bolt 4. Tank

2. Cover 5. Oiler fill port

3. Element 6. Sight glass



2. Remove the fluid return line from the fitting in the cover.

3. Remove the cover capscrews and lockwash-ers and lift the cover from the receiver tank with the minimum pressure/check valve in place.

4. Remove the separator element.

5. Scrape the old gasket material from the cover and the flange on the receiver tank. Be sure to keep all scrapings from falling inside the tank.

6. Install the separator element.

7. Make sure grounding staples are attached to separator gasket. Do not remove staples.

8. Replace the receiver tank cover. Install the eight (8) capscrews and lockwashers in fin-ger-tight, then gradually tighten in a criss-cross pattern in 4 to 5 steps. Always tighten the capscrews alternately at opposite sides of the cover. Never tighten capscrews adja-cent to each other. Torque capscrews to 206 ft.lbs (280 N·m).

9. Reconnect all piping. The fluid return line should extend to the bottom of the separator element or no more than 1/16 in (1.6 mm) up from the bottom. This will assure the proper fluid return flow.

10. Clean the fluid return line strainer and clear the orifice prior to restarting the compressor.

6.10 Pressure relief valveAn inoperable relief valve may not open properly to pro-tect the compressor from overpressure. A relief valve unable to close can lead to a large loss of fluid. The func-tion of the pressure relief valve should be checked on a weekly basis.

6.11 Hose maintenanceInspect and replace inlet, lubrication and control line hoses every 600 hours or six months. Replace if any damage or is present.

6.12 Motor maintenance• The motor should be inspected periodically for

unusual noise or vibrations. This can be a sign of bearing damage or failure.

• The motor surface should be kept dry and clean for most efficient cooling. The fan inlet should be kept free from obstructions.

• Bearings shall be lubricated every 2000 hours of operation with 45g UNIREX N2. If bearing overheating or grease degradation is found, the grease should be changed immediately.

• The motor heater should be operated in extremely damp environments or during long periods of storage. Refer to Section 5.5: Main motor heater for details.

6.13 Control system adjustmentPrior to adjusting the control system it is necessary to determine the desired operating pressure range as well as the maximum operating pressure. The maximum operating pressure must not exceed the maximum oper-ating pressure per the serial nameplate.

6.13.1 Differential pressure regulator adjustment

Refer to Figure 6-6. The differential pressure regulators are adjusted by loosening the jam nut on the end of the cone shaped cover of the pressure regulator. When the jam nut is loose, turn the adjusting screw clockwise to increase or counterclockwise to decrease the setting. 1 psi above the full load rated pressure of the compres-sor, the inlet regulator should allow pressure to flow into the unload chamber of the inlet valve. Cycle the control system several times and recheck all pressure settings.

Figure 6-6: Pressure regulator



6.13.1.1 Pressure reducing regulatorWhen running with the compressor loaded, adjust the pressure reducing regulator to maintain 70 psig (4.8 bar) signal to open the inlet valve.

6.13.2 Shaft coupling maintenanceThe coupling is a jaw type in shear. If the elastomeric (rubber) element requires replacement due to wear or damage, order a replacement element and perform the following steps:

1. Remove the coupling guard.

2. Loosen the retaining screw located on the outer sleeve. Slide the sleeve to one side, exposing the coupling.

3. Unwrap the coupling element from the cou-pling jaws.

4. Install the new element by wrapping it around the jaws, engaging the cogs on the element into the jaws.

5. Reinstall the outer sleeve and secure by tightening the two screws to 45 in-lbs (5 Nm).

6. Reinstall the coupling guard.

6.13.3 Unload pressure setting1. Start compressor with service valve closed

or slightly open.

2. Observe the pressure at which the contacts open and machine unloads.

3. Turn the range adjustment screw until desired unload pressure setting is achieved.

6.13.4 Differential setting1. Unload compressor and allow receiver pres-

sure to reach its minimum.

2. Open service valve and observe the pres-sure at which the pressure switch contacts close and the compressor loads.

3. Turn the differential adjustment screw until the desired load pressure and differential is achieved.



Notes:


Section 7

E900H User Manual 7: Troubleshooting

Troubleshooting
7.1 IntroductionThe information contained in the Troubleshooting Guide has been compiled from field report data and factory experience. It contains symptoms and usual causes for the described problems. However, do not assume that these are the only problems that may occur. All available data concerning a problem should be systematically ana-lyzed before undertaking any repairs or component replacement procedures.
A detailed visual inspection is worth performing for almost all problems and may avoid unnecessary addi-tional damage to the compressor. Always remember to:

• Check for loose wiring.

• Check for damaged piping.

• Check for parts damaged by heat or an electri-cal short circuit, usually apparent by discolor-ation or a burnt odor.

Should your problem persist after making the recom-mended check, consult your nearest Sullair representa-tive.

Table 7-1: Troubleshooting guide

Symptom Probable cause Remedy

Compressor will not start or shuts down after 10 sec-onds

Main disconnect switch open Close switch.

Line fuse blown Replace fuse.

Motor starter overload trippedReset. Should trouble persist, check whether motor starter contacts are functioning properly.

Low incoming line voltageCheck voltage. Should voltage check low, consult power company.

Incorrect phase order trips phase monitor.

Switch any two phases of incoming power and reset monitor

Ground fault protector tripped

Look for shorts or open circuits on con-trol circuit, repair and reset protector. If none found, ground fault protector could require replacement.

Control transformer fuse blown Replace fuse


7: Troubleshooting E900H User Manual

Compressor shuts down with air demand present

Loss of control voltageCheck incoming power connections and reset monitor.

Low incoming line voltageCheck control fuses and wiring. Con-sult power company.

Compressor discharge tempera-ture switch open

Cooling air flow restricted; clean cooler and check for proper ventilation.

Ambient temperature is too high—pro-vide sufficient ventilation.

Low fluid level, add fluid

Clogged filter, change fluid filter ele-ment

Thermal valve not functioning properly; replace element

Defective discharge temperature switch; check for a short or open circuit. If none, replace switch

Cooling fan is being operated in REVERSE direction. Turn switch to FORWARD

Loss of phase trips phase monitor.Check incoming power connections and reset monitor.

Compressor will not build full discharge pressure

Air demand is too greatCheck service lines for leaks or open valves up.

Dirty air filterCheck the filter indicator and inspect and/or change element if required.

Inlet valve bleed orifice pluggedEnsure control line bleed orifice is not plugged.

Pressure regulator out of adjust-ment

Adjust regulator according to control adjustment instructions in Section 6: Maintenance.

Defective pressure regulator

Check diaphragm and replace if neces-sary (kit available).

Check valve operation. Replace the coil or the complete valve if defective.




E900H User Manual 7: Troubleshooting

Improper unloading with an excessive pressure build-up causing relief valve to open.

Leak in control system causing loss of pressure signals

Worn seals in inlet valve. Replace seals (kits available).

Defective pressure regulating valves; repair valves (kits available).

Inlet valve stuck Free or repair inlet valve

Defective unload solenoid valve

Check the valve operation. Replace if necessary.

Clean strainer (screen and O-ring replacement kit available).

Defective blowdown valve

Check that the sump pressure is exhausted to the atmosphere when in the unloaded mode. Repair or replace if necessary (kit available).

Plugged control line filter Clean or repair as necessary

Restriction in the control system

Check all control lines and compo-nents.

Ice in control line or components. Run fan in REVERSE direction when oper-ating below freezing.

Excessive fluid consump-tion

Clogged return tube or orifice Clean orifice or strainer.

Separator element damaged or not functioning properly

Change separator.

Leak in the lubrication systemCheck all pipes, connections and com-ponents.

Excess fluid foaming Drain and change.

Fluid level too high Drain and change.

Operating pressure lower than rated pressure

Increase compressor operating pres-sure

Fluid level is too high Drain excess fluid.

Pressure relief valve opens repeatedly

Defective pressure relief valve Replace.

Unload pressure set too highAdjust Pressure switch per Section 6.13.3: Unload pressure setting on page 49.

Failure to unload solenoid valve Replace or repair solenoid valve




7: Troubleshooting E900H User Manual

Liquid water in com-pressed air lines

Plugged separator Check separator differential.

Plugged strainer in moisture drain line

Clean and service strainer located in the line off the bottom of the water sep-arator.

Water vapor condensation from cooling and compression occurs naturally

Remove the water vapor from com-pressed air prior to distribution through the air system. Check operation of aftercooler and moisture separator. Install a compressed air dryer sized for the flow and dryness level required. (Note: Filters may also be required to remove particulates, liquid oil aerosols or for oil vapor removal. Change car-tridges as recommended by the filter manufacturer). Check all drain traps routinely to insure their proper opera-tion. Maintain them regularly.

Defective drain solenoid valveEnsure valve opens and closes as sig-naled by timer.

Improper drain settings.

Check drain interval and drain time, and adjust accordingly. High humidity conditions require longer drain times or more frequent openings.




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

Sullair, LLC3700 East Michigan BoulevardMichigan City, IN 46360 USA

www.sullair.com1-800-SULLAIR (USA only)1-219-879-5451 (non-USA)

e900h user manual en-us 02250203-986 r03...1: safety e900h user manual 02250203-986 r03 2 subject to...

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