Sullair ES-8 Air Compressor Operation, Maintenance, Troubleshooting

Sullair ES-8 Air Compressor
Operation, Maintenance,
Troubleshooting
John LaDisa – Sr. Technical Instructor,
JoyGlobal Surface Mining
October 2015
Surface Mining
2 │ August 2015 │ Sullair ES-8 Air Compressor
Description
 Positive displacement rotary screw compressor.
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Description
Male Rotor
(Driven)
Helical Screw
Rotors
Female Rotor
(Follower)
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Description
 Oil flooded; oil mixes directly with air during compression stage.
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Description
Air Air/Oil Oil
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Description
 Very tight clearances (approx. .003” - .005”) between rotors.
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Description
Male Rotor
(Driven)
Female Rotor
(Follower)
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Description
 Very tight clearances (approx. .003”- .005”) between rotors.

– Clearance maintained by oil film between the rotors.
– No metal to metal contact.
– Cannot tolerate reverse rotation.
(Rotation is CW when viewing Compressor from Motor end).
Surface Mining
Description
 Very tight clearances (approx. .003”- .005”) between rotors.

– Clearance maintained by oil film between the rotors.
– No metal to metal contact.
– Cannot tolerate reverse rotation.
(Rotation is CW when viewing Compressor from Motor end).
 Oil has three main functions:

– Controls air temperature rise associated with heat of compression.
– Seals the leakage paths between the rotors.
– Provides a lubricating film between the rotors; allows male rotor to
drive the female rotor.
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Specifications
 Model: ES8MD-60-460
 Voltage: 460
 Horsepower: 30
 Max. Full Load Operating

Pressure: 175 psig (12.1 bar)
 90.4 CPM
Typical Nameplate
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Specifications
 Voltage: 460
 Horsepower: 30

 90.4 CPM
Typical Nameplate
 Serial #: Provide when reporting
problems
Surface Mining
Specifications
 Voltage: 460
 Horsepower: 30

 90.4 CPM

problems
 Nameplate location
Surface Mining
Specifications
 Voltage: 460
 Horsepower: 30

 90.4 CPM

problems
 Nameplate location
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Assembly Components
Moisture
Oil Cooler Separator
Air Filter
Air Cooler
Motor
Air/Oil Separator
Air Inlet Control

Valve
Pressure
Relief Valve Fan
Oil Filter
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Assembly Components
Inlet Control, Seal/Drive Gear and Parts
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Assembly Components
Motor, Coupling, Fan and Parts
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Assembly Components
Inlet Filter, Compressor Housing/Sump and Parts
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Assembly Components
Compressor Cooler System and Parts
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Assembly Components
Control Box and Parts
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Assembly Components
Thermal Valve
 Oil Cooler bypass valve.
 Directs oil to the Oil Cooler

when discharge temperature
reaches the thermostat
temperature setting.
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Assembly Components
Thermal Valve
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Assembly Components
Minimum Pressure/Discharge
Check Valve
 Maintains a minimum sump

pressure of 60 psig to assure
adequate oil pressure.
 Pressure build-up above 60

psig flexes the piston spring,
raising the piston, allowing
airflow to the service line.
 Acts as a check valve to isolate

compressor from the service
line pressure during shutdown
or unloading.
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Assembly Components
Minimum Pressure
Discharge/Check
Valve
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Operation
Representative Piping and Instrumentation Diagram
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Operation
Representative Piping and Instrumentation Diagram
Sequencing/Full
Shuttle Valve Pressure Load Solenoid Valve
Regulator Valve
Shuttle Valve
Load/Unload
Solenoid Valve P1 Pressure
Transducer
Relief Valve
Air Filter P2 Pressure
Oil Separator
Assy Load/Unload Water Transducer
Motor Tank
Solenoid Valve Separator
Air inlet
Valve Oil Separator Min. Pressure/
Air Cooler
Element Check Valve
Compressor Unit
Oil Filter
Thermal Valve
Drain Solenoid
Valve
Oil Cooler
Surface Mining
Operation
Motor Rotation Check
Note: This compressor cannot tolerate reverse rotation, even for a

short duration. Therefore, after performing maintenance on the
compressor it is imperative to check the direction of motor rotation.
Pull out the E-Stop button and press once, quickly and in succession,
the “Start” and “Stop” buttons. This will bump-start the motor for a very
short time.
When viewing the compressor from the motor end, the coupling
should be turning in a clockwise direction. If reverse rotation is noted,
disconnect power to the starter and interchange any two of the three
power input leads and recheck rotation. A “Direction of Rotation” decal
is located on the cooler shroud to show proper motor/compressor
rotation.
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Operation
Start Mode – 0 to 60 psig

Sump pressure will quickly rise to 60 psig.
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Operation

Pressure Regulator and Solenoid Valve closed (energized).
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Operation
Pressure
Regulator
Valve
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Operation
Pressure Regulator Valve Components
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Operation
Solenoid
Valve
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Operation

Air Inlet Control Valve is fully open.
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Operation
Inlet
Control
Valve
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Operation
Inlet Control Valve Components
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Operation

Compressor pumps at full rated capacity.
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Operation

Compressor pumps at full rated capacity.
Compressor air pressure is isolated from service line by the Minimum

Pressure Check Valve which is set at 60 psig.
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Operation
Minimum Pressure Check Valve
0 – 60 psig 60 – 160 psig > 170 psig
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Operation
Minimum
Pressure
Check Valve
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Operation
Minimum
Pressure
Check Valve
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Operation
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Operation
Full Load Mode – 60 to 160 psig

Minimum Pressure Check Valve opens allowing compressed air to
flow into the service line.
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Operation
0 – 60 psig 60 – 160 psig ≥ 175 psig
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Operation

Pressure Regulator and Solenoid Valve remain closed (energized).
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Operation

Pressure Regulator and Solenoid Valve remain closed (energized).
Air Inlet Control Valve is fully open as long as Compressor is running

at 160 psig or less.
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Operation
Modulating Mode – 160 to 170 psig

If less than the rated capacity of compressed air is being used, service
line pressure will rise above 160 psig.
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Operation

Pressure Regulator Valve gradually opens, directing air pressure to

the Air Inlet Control Valve.
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Operation


This reduces air entering the Compressor until it matches the amount
of air being used.
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Operation


of air being used.
Continues to operate in this manner between 160 to 170 psig.
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Operation


of air being used.
Continues to operate in this manner between 160 to 170 psig.
Pressure Regulator Valve has an orifice which vents a small amount

of air to atmosphere when Pressure Regulator controls the Air Inlet
Control Valve.
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Operation
Pressure
Regulator
Valve
Orifice Vent
Hole
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Operation
Unload Mode – above 170 psig

When small amount or no air is being used, service line pressure
continues to rise.
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Operation

continues to rise.
When pressure reaches 175 psig, control system de-energizes the

Solenoid Valve (opens) allowing sump air pressure to be supplied
directly to close the Inlet Control Valve.
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Operation

continues to rise.

Simultaneously, the Solenoid Valve sends a pneumatic signal to the

Blowdown Valve which opens the sump to the atmosphere. This
reduces the sump pressure to approximately 20 to 30 psig.
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Operation
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Operation

continues to rise.

Simultaneously, the Solenoid Valve sends a pneumatic signal to the

Blowdown Valve which opens the sump to the atmosphere. This
reduces the sump pressure to approximately 20 to 30 psig.
Check valve in air service line prevents line pressure from returning to
the sump.
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Operation
Unload Mode – continued
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Operation

When line pressure drops to the low setting (cut-in pressure, 145 psig)
the control system energizes the Solenoid Valve (closes) and allows
the Blowdown Valve to close.
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Operation

Re-energized Solenoid Valve again prevents line pressure from

reaching the Inlet Control Valve.
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Operation

Re-energized Solenoid Valve again prevents line pressure from

reaching the Inlet Control Valve.
If pressure begins to rise, Pressure Regulator Valve will resume its
normal function as previously described.
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AirMaster Q1 Controller
 Provides compressor
monitoring and
control.
Q1
Controller
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 Provides compressor
monitoring and
control.
 Several levels of user

access for monitoring
and/or adjustment of
parameters depending
on level of access.
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 Touchpad Buttons
Button Name
Start
Stop
Reset
Enter
Up
Down
Escape
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Q1 Controller Display
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 To date, two versions

of Q1 software.
 Version E13 is most

recent. Version E10
was initial release.
 Software version can

be found in Parameter
P06.04: Software
Version.
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Maintenance
Air Filter
Inspect Air Filter element.
Check cleanliness.
Check for damage or holes in

filter element.
Typical replacement interval is

every 6 months in normal
operation. More frequently if
conditions require.
Refer to Maintenance Manual

for Air Filter element removal
procedure.
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Maintenance
Lubrication
Change oil and oil filter every

8000 hours or once a year.
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Maintenance
Lubrication
Oil drain cap.
Oil fill cap.
Sump Capacity:
2.5 gallons
(9.46 liters)
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Maintenance
Compressor Lubrication Guide
AMBIENT FLUID & FILTER CHANGE

TEMPERATURE LUBRICATION PERIOD (HRS.)
-10 °F to +90 °F Sullube 8000 (I)
(-23 °C to +32°) Sullair LLL-4-32 8000 (I)
SRF 1/4000 4000
(I) 8000 Hours or once a year
Surface Mining
Maintenance
Lubrication
Check that proper oil level is

visible in oil level sight glass.
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Maintenance
Lubrication
Check that proper oil level is

visible in oil level sight glass.
Check oil level before starting

compressor.
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Maintenance
Lubrication
Change Separator Element

once a year.
Surface Mining
Troubleshooting
Surface Mining
Troubleshooting
Surface Mining

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Sullair ES-8 Air Compressor

Air Air/Oil Oil

 Very tight clearances (approx. .003” - .005”) between rotors.

 Very tight clearances (approx. .003”- .005”) between rotors.

 Very tight clearances (approx. .003”- .005”) between rotors.

 Oil has three main functions:

 Max. Full Load Operating

 Max. Full Load Operating

 Max. Full Load Operating

 Serial #: Provide when reporting

 Max. Full Load Operating

 Serial #: Provide when reporting

Air Inlet Control

 Oil Cooler bypass valve.

 Directs oil to the Oil Cooler

 Maintains a minimum sump

 Pressure build-up above 60

 Acts as a check valve to isolate

Note: This compressor cannot tolerate reverse rotation, even for a

Start Mode – 0 to 60 psig

Start Mode – 0 to 60 psig

Pressure Regulator and Solenoid Valve closed (energized).

Start Mode – 0 to 60 psig

Pressure Regulator and Solenoid Valve closed (energized).

Air Inlet Control Valve is fully open.

Start Mode – 0 to 60 psig

Pressure Regulator and Solenoid Valve closed (energized).

Air Inlet Control Valve is fully open.

Compressor pumps at full rated capacity.

Start Mode – 0 to 60 psig

Pressure Regulator and Solenoid Valve closed (energized).

Air Inlet Control Valve is fully open.

Compressor pumps at full rated capacity.

Compressor air pressure is isolated from service line by the Minimum

Minimum Pressure Check Valve

0 – 60 psig 60 – 160 psig > 170 psig

Minimum Pressure Check Valve

Full Load Mode – 60 to 160 psig

Minimum Pressure Check Valve

0 – 60 psig 60 – 160 psig ≥ 175 psig

Full Load Mode – 60 to 160 psig

Pressure Regulator and Solenoid Valve remain closed (energized).

Full Load Mode – 60 to 160 psig

Pressure Regulator and Solenoid Valve remain closed (energized).

Air Inlet Control Valve is fully open as long as Compressor is running

Modulating Mode – 160 to 170 psig

Modulating Mode – 160 to 170 psig

Pressure Regulator Valve gradually opens, directing air pressure to

Modulating Mode – 160 to 170 psig

Pressure Regulator Valve gradually opens, directing air pressure to

Modulating Mode – 160 to 170 psig

Pressure Regulator Valve gradually opens, directing air pressure to

Continues to operate in this manner between 160 to 170 psig.

Modulating Mode – 160 to 170 psig

Pressure Regulator Valve gradually opens, directing air pressure to

Continues to operate in this manner between 160 to 170 psig.

Pressure Regulator Valve has an orifice which vents a small amount