Sullair 1600H User manual
Portable Air Compressor
1600H
Tier 4 Final
Condensate Management System
Caterpillar/Perkins
PART NUMBER:
02250251-632 R01
The information in this manual is current as of its
publication date and applies to compressor models
indicated on this cover with serial number:
201612120000
and all subsequent serial numbers.
ADDENDUM
Publication date: 03/27/2020
Copyright © 2020 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.
Service Training Courses
Sullair training courses provide hands-on and classroom instruction for the proper operation, maintenance, and
servicing of Sullair products. Individual courses on Portable compressors are offered at regular intervals
throughout the year at Sullair’s training facility located in Michigan City, Indiana and on-site at Sullair distributor
locations.
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 distributor service personnel.
For more information contact:
Sullair Training Department
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.SullairTraining.com
- Or Write -
Sullair
1 Sullair Way
Michigan City, IN 46360
Attn: Training Department
Subject to EAR, ECCN EAR99 and related export control restrictions.
Table of Contents
1600H T4F CAT/Perkins Addendum Table of Contents
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 3
Section 1: Description..............................................................................................5
1.1 Introduction & functional description................................................................................................5
1.2 Piping and instrumentation - Condensate management system.....................................................6
Section 2: Operation ................................................................................................9
2.1 Overview..........................................................................................................................................9
2.2 Shutdown procedure .......................................................................................................................9
Section 3: Maintenance..........................................................................................11
3.1 Overview........................................................................................................................................11
3.2 Troubleshooting.............................................................................................................................11
Section 4: Drawings ...............................................................................................13
4.1 Exhaust system.............................................................................................................................14
4.2 Exhaust pipe, 5 inches..................................................................................................................22
4.3 Exhaust pipe tail, 5 inches.............................................................................................................24
4.4 Discharge system - aftercooled/filtered with CMS.........................................................................28
4.5 Drains - aftercooled/filtered with CMS...........................................................................................34
Table of Contents 1600H T4F CAT/Perkins Addendum
Notes:
02250251-632 R01
4 Subject to EAR, ECCN EAR99 and related export control restrictions.
Section 1
1600H T4F CAT/Perkins Addendum 1: Description
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 5
Description
1.1 Introduction & functional
description
This compressor is equipped with Sullair’s Condensate
Management System (CMS). This system utilizes the
waste heat from the engine exhaust to evaporate con-
densate produced when operating in after-cooled mode.
Using CMS eliminates the need to collect and dispose of
condensate.
When operating in after-cooled mode, condensate is pro-
duced by the aftercooler and separated from the air
stream in the moisture separator.Asmall amount of addi-
tional condensate is removed by the after filters. These
condensate streams are routed to the exhaust and driven
by system pressure. Once at the exhaust, an atomizing
nozzle is used to inject the condensate into the exhaust
stream where it is evaporated.
Figure 1-1: Discharge System with Condensate Management System
1. Aftercooler
2. After-filters
3. Moisture separator
4. Strainer
5. Blow-down valve
6. Exhaust pipe
7. Nozzle
1: Description 1600H T4F CAT/Perkins Addendum
02250251-632 R01
6 Subject to EAR, ECCN EAR99 and related export control restrictions.
1.2 Piping and instrumentation - Condensate management system
02250250-793 R01
1600H T4F CAT/Perkins Addendum 1: Description
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 7
1.2 Piping and instrumentation - Condensate management system
Components
Key Description
1FILTER,AIR
2 GAUGE,AIR FILTER RESTRICTION
3 VALVE,INLET
4 COMPRESSOR
5 VALVE,RELIEF
6 SWITCH,TEMPERATURE
7 SENSOR,TEMPERATURE
8 SENSOR,PRESSURE
9 VALVE,DISCHARGE CHECK
10 TANK,AIR OIL SEPARATOR
11 SIGHTGLASS,OIL LEVEL
12 VALVE,MINIMUM PRESSURE
13 VALVE,BALL
14 COOLER,AIR
15 SEPARATOR,MOISTURE
16 ORIFICE
17 VALVE,SOLENOID 3WNO
18 STRAINER
19 SIGHTGLASS,ORIFICE BLOCK
20 VALVE,THERMAL BYPASS
21 COOLER,OIL
22 FILTER,OIL
23 VALVE,OIL STOP
24 VALVE,BACKPRESSURE
25 VALVE,BLOWDOWN NC
26 VALVE,CHECK
27 ELEMENT,AIR/OIL SEPARATOR
28 FILTER,AFTERCOOLED AIR
29 VALVE,OIL FILTER RELIEF
30 VALVE,OIL COOLER RELIEF
31 VALVE,BLOWDOWN NO
32 SILENCER, BLOWDOWN
33 NOZZLE,SPRAY
Component Description
P1 DRY SIDE PRESSURE
P2 CONTROL PRESSURE
P3 WET SIDE PRESSURE
P4 AFTERCOOLER FILTER DISCHARGE PRESSURE
T1 COMPRESSOR DISCHARGE TEMPERATURE (CDT)
T2 RECEIVER TANK TEMPERATURE (RTT)
T3 AFTERCOOLER DISCHARGE TEMPERATURE
Key Description
1: Description 1600H T4F CAT/Perkins Addendum
Notes:
02250251-632 R01
8 Subject to EAR, ECCN EAR99 and related export control restrictions.
Section 2
1600H T4F CAT/Perkins Addendum 2: Operation
02250251-632 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. 9
Operation
2.1 Overview
Follow machine operation guidelines from 1600H T4F
CAT User Manual 02250225-985. The Condensate Man-
agement System is automatic and does not require addi-
tional inputs from the operator. It is important to slowly
close the service valve prior to a shutdown. This allows
the system to be purged of condensate during the cool
down period.
2.2 Shutdown procedure
WARNING
The E-Stop (emergency stop switch) should be
used only in the event of an emergency. Refrain
from using the E-Stop to shut the machine down
during normal operations or equipment damage
can occur. All usage of the E-Stop is logged in per-
manent memory for use by service technicians
when troubleshooting a machine. Non-emergency
use of E-Stop is considered equipment abuse and
could void the manufacturer’s warranty.
2: Operation 1600H T4F CAT/Perkins Addendum
Notes:
02250251-632 R01
10 Subject to EAR, ECCN EAR99 and related export control restrictions.
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