SULLAIR
®
INDUSTRIAL AIR COMPRESSOR
3000, 3000P, 3700, 4500,
3000V, 3000PV, 3700V, 4500V
30, 37 & 45 KW/40, 50 & 60HP
Air-Cooled and Water-Cooled
Standard & 24 KT
PART NUMBER:
02250155-601
KEEP FOR
FUTURE
REFERENCE
©
SULLAIR CORPORATION
The information in this document is
correct at the time of printing for utility
compressor serial number
20060701XXXX
and all subsequent serial numbers.
O PERATO R’S M ANU AL AND PARTS LIST
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SULLAIR
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AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction in the proper operation, maintenance
and service of Sullair equipment. Individual seminars on Industrial compressors and compressor electrical
systems are presented at regular intervals throughout the year at a dedicated training facility at Sullair's corporate
headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of the
most common problems, and actual equipment operation. The seminars are recommended for Maintenance
and Contractor Maintenance and Service Personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Customer Care Training Department
: 1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
- Or Write Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
®
SULLAIR
®
TABLE OF CONTENTS
1 - SAFETY...................................................................................................1
General...................................................................................................1
Personal Protective Equipment..................................................................1
Pressure Release.....................................................................................1
Fire and Explosion....................................................................................2
Moving Parts............................................................................................2
Hot Surfaces, Sharp Edges and Sharp Corners............................................3
Toxic and Irritating Substances..................................................................3
Electrical Shock.......................................................................................3
Lifting......................................................................................................4
Entrapment..............................................................................................4
2 - DESCRIPTION.........................................................................................5
Introduction..............................................................................................5
Description of Components.......................................................................8
Sullair Compressor Unit, Functional Description..........................................8
Compressor Cooling and Lubrication System, Functional
Description............................................................................................11
Compressor Discharge System, Functional Description..............................11
Control System, Functional Description.....................................................12
Start Mode - 0 to 50 PSIG (0 to 3.5 Bar)................................................12
Full Load Mode - 50 to 100 PSIG (3.4 to 6.9 BAR).................................13
Modulating Mode - 100 to 110 PSIG (6.9 to 7.6 BAR).............................13
Unload Mode- In Excess of 110 PSIG (7.6 BAR)...................................13
Load / No Load Control......................................................................13
Automatic Operation.........................................................................13
Air Inlet System, Functional Description....................................................14
3 - SPECIFICATIONS..................................................................................17
Table of Specifications - 3000, 3000P, 3700 and 4500 Series
Models..................................................................................................17
Table of Specifications - Variable Speed Drive Models................................18
Compressor Specifications......................................................................19
Lubrication Guide...................................................................................20
Application Guide...................................................................................20
Lubrication Change Recommendations and Maintenance, Fluid Filter and
Separator...............................................................................................21
Identification, Air-Cooled, Standard and VSD.............................................22
Identification, Water-Cooled....................................................................24
Piping and Instrumentation, Air-Cooled.....................................................26
Piping and Instrumentation, Water-Cooled................................................30
Wiring Diagram, MFV Air-Cooled.............................................................34
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3000-4500 Operator’s Manual and Parts List
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TABLE OF CONTENTS
Wiring Diagram, MFV Water-Cooled.........................................................36
Wiring Diagram, Wye-Delta Air-Cooled.....................................................38
Wiring Diagram, Wye-Delta Water-Cooled................................................40
Wiring Diagram, VSD Air-Cooled..............................................................42
Wiring Diagram, VSD Water-Cooled.........................................................44
Wiring Diagram, VSD Air-Cooled, 575V Series Delta..................................46
Wiring Diagram, VSD Water-Cooled, Series Delta 575V..............................48
4 - INSTALLATION......................................................................................51
Mounting of Compressor.........................................................................51
Ventilation and Cooling...........................................................................51
Air-Cooled Compressors...................................................................51
Water-Cooled Compressors..............................................................52
Service Air Piping...................................................................................55
Pipe Sizing.......................................................................................55
Use of Auxiliary Receiver Tank...........................................................55
Isolation Valve(s)..............................................................................55
Fluid Containment............................................................................55
Coupling Alignment Check......................................................................56
Fluid Level Check...................................................................................56
Electrical Preparation..............................................................................56
Motor Rotation Direction Check ...............................................................56
5 - WS CONTROLLER.................................................................................57
Controller Layout....................................................................................57
Controller Keypad...................................................................................57
LCD Display...........................................................................................58
LED Lights.............................................................................................59
6 - MAINTENANCE......................................................................................61
General.................................................................................................61
Daily Operation......................................................................................61
Maintenance After Initial 50 Hours of Operation..........................................61
Maintenance Every 2000 Hours...............................................................62
Fluid Maintenance .................................................................................62
Filter Maintenance..................................................................................62
Fluid Filter Element Replacement.......................................................62
Air Filter Maintenance .............................................................................62
Air Filter Element Replacement..........................................................63
Separator Maintenance ..........................................................................63
Separator Element Replacement........................................................63
Oil Return/Sight Glass Maintenance...................................................64
Pressure Regulator Adjustment..........................................................65
Water Condensate Drain Maintenance...............................................65
Control Line Strainer.........................................................................65
Shaft Coupling Maintenance..............................................................65
Troubleshooting - Introduction.................................................................65
Troubleshooting Guide............................................................................66
7 - VSD CONTROL OPERATION..................................................................69
Description of Components.....................................................................69
Control System, Functional Description.....................................................69
Start Mode- 0 to 50 PSIG (0 to 3.5 Bar)................................................69
Full Load Mode- 50 to 100 PSIG (3.4 to 6.9 Bar)....................................69
Variable Speed Drive Part Load Control..............................................69
Modulating Mode- 100 to 106 PSIG (7.3 to 6.9 Bar) ..............................69
Unload Mode- In Excess of 106 PSIG (7.3 Bar) ....................................70
8 - PARTS LISTS.........................................................................................71
Procedure For Ordering Parts..................................................................71
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TABLE OF CONTENTS
Recommended Spare Parts List...............................................................73
Compressor, Frame and Drive, 3000P and 3700 Models.............................74
Compressor, Frame and Drive, 3000 Model With 10 Series
Unit.......................................................................................................76
Compressor, Frame and Drive, 4500 Model...............................................78
Air Inlet System, Standard 3000P, 3700 And 4500 Series............................80
Air Inlet System, 10 Series 3000...............................................................82
Air Piping, Air-Cooled..............................................................................84
Air Piping, Water-Cooled.........................................................................86
Fluid Piping, Air-Cooled...........................................................................88
Fluid Piping, Water-Cooled......................................................................90
Cooling and Lubrication System, Air-Cooled 18"/60Hz Fan, Standard
Cooler................................................................................................... 92
Fluid Cooling System, Water-Cooled........................................................94
Discharge, Receiver and Piping System, 3000P, 3700 and
4500......................................................................................................96
Discharge, Receiver and Piping, 3000 With 10 Series
Unit.....................................................................................................100
Moisture Drain......................................................................................104
Pneumatic Control System, With Standard Sequencing............................106
Control System and Electric Parts, MFV..................................................108
Control System and Electric Parts, WYE-Delta.........................................112
Control System and Electric Parts, VSD..................................................116
Enclosure, Air-Cooled...........................................................................120
Enclosure, Water-Cooled......................................................................122
Decal Locations, Air-Cooled..................................................................124
Decal Locations, Water-Cooled..............................................................128
Decal Group.........................................................................................132
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Section 1
SAFETY
NOTE
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL.
1.1 GENERAL
Sullair Corporation and its subsidiaries design and
manufacture all of their 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.
The 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 may result in accidents and injuries.
NEVER start the compressor unless it is safe to do so. DO
NOT attempt to operate the compressor with a known
unsafe condition. Tag the 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.
Install, use and operate the compressor only in full
compliance with all pertinent OSHA regulations and/or any
applicable Federal, State, and Local codes, standards and
regulations.
DO NOT modify the compressor and/or controls in any
way except with written factory approval.
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SULLAIR
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While not specifically applicable to all types of
compressors with all types of prime movers, most of the
precautionary statements contained herein are applicable
to most compressors and the concepts behind these
statements are generally applicable to all compressors.
1.2 PERSONAL PROTECTIVE
EQUIPMENT
Prior to installing or operating the compressor, owners,
employers and users should become familiar with, and
comply with, all applicable OSHA regulations and/or any
applicable Federal, State and Local codes, standards, and
regulations relative to personal protective equipment,
such as eye and face protective equipment, respiratory
protective equipment, 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. Install an appropriate flow-limiting valve between the
service air outlet and the shut-off (throttle) valve, either
at the compressor or at any other point along the air
line, when an air hose exceeding 1/2" (13mm) inside
diameter is to be connected to the shut-off (throttle)
valve, to reduce pressure in case of hose failure, per
OSHA Standard 29 CFR 1926.302(b)(7) and/or any
applicable Federal, State and Local codes, standards
and regulations.
B. 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" (13mm) inside diameter that is to be connected
to the manifold to reduce pressure in case of hose
failure.
C. Provide an appropriate flow-limiting valve at the
beginning of each additional 75 feet (23m) of hose in
runs of air hose exceeding 1/2" (13mm) inside
diameter to reduce pressure in case of hose failure.
3000-4500 Operator’s Manual and Parts List
1
SECTION 1
D. Flow-limiting valves are listed by pipe size and flowrated. Select appropriate valves accordingly, in
accordance with their manufacturer's
recommendations.
E. DO NOT use air tools that are rated below the
maximum rating of the compressor. Select air tools,
air hoses, pipes, valves, filters and other fittings
accordingly. DO NOT exceed manufacturer's rated
safe operating pressures for these items.
F. Secure all hose connections by wire, chain or other
suitable retaining device to prevent tools or hose ends
from being accidentally disconnected and expelled.
G. Open fluid filler cap only when compressor is not
running and is not pressurized. Shut down the
compressor and bleed the receiver tank to zero
internal pressure before removing the cap.
H. Vent all internal pressure prior to opening any line,
fitting, 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.
I. Keep personnel out of line with and away from the
discharge opening of hoses or tools or other points of
compressed air discharge.
J. DO NOT use air at pressures higher than 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) and/or any
applicable Federal, State, and Local codes, standards
and regulations.
K. DO NOT engage in horseplay with air hoses as death
or serious injury may result.
1.4 FIRE AND EXPLOSION
A. Clean up spills of lubricant or other combustible
substances immediately, if such spills occur.
B. Shut off the 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 checking
or adding lubricant or when refilling air line anti-icer
systems with antifreeze compound.
C. DO NOT permit fluids, including air line anti-icer
system 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 material, 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 liquids or fluid film within the material.
DO NOT use flammable solvents for cleaning
purposes.
2
D. 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.
E. 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,
discolored or corroded. Keep all terminals and
pressure connectors clean and tight.
F. 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.
G. 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
attempting weld repairs.
H. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when servicing
and operating the compressor.
I. Keep oily rags, trash, leaves, litter or other
combustibles out of and away from the compressor.
J. DO NOT operate the compressor without proper flow
of cooling air or water or with inadequate flow of
lubricant or with degraded lubricant.
K. DO NOT attempt to operate the compressor in any
classification of hazardous environment unless the
compressor has been specially designed and
manufactured 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.
C. Wear snug-fitting clothing and confine long hair when
working around this compressor, especially when
exposed to hot or moving parts.
D. Keep access doors, if any, closed except when
making repairs or adjustments.
E. Make sure all personnel are out of and/or clear of the
compressor prior to attempting to start or operate it.
F. Disconnect and lock out all power at source and verify
at the compressor that all circuits are de-energized to
minimize the possibility of accidental start-up, or
operation, prior to attempting repairs or adjustments.
This is especially important when compressors are
remotely controlled.
G. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water or other liquids
to minimize the possibility of slips and falls.
3000-4500 Operator’s Manual and Parts List
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SAFETY
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.
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
SUBSTANCES
A. DO NOT use air from this compressor for
respiration (breathing) except in full compliance with
OSHA Standards 29 CFR 1910 and/or any applicable
Federal, State or Local codes or regulations.
DANGER
INHALATION HAZARD!
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, standards and regulations on
safety equipment.
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.
G. If air line anti-icer system antifreeze compound enters
the eyes or if fumes irritate the eyes, they should be
washed with large quantities of clean water for fifteen
minutes. A physician, preferably an eye specialist,
should be contacted immediately.
H. DO NOT store air line anti-icer system antifreeze
compound in confined areas.
I. The antifreeze compound used in air line antifreeze
systems contains methanol and is toxic, harmful or
fatal if swallowed. Avoid contact with the skin or eyes
and avoid breathing the fumes. If swallowed, induce
vomiting by administering a tablespoon of salt, in each
glass of clean, warm water until vomit is clear, then
administer two teaspoons of baking soda in a glass of
clean water. Have patient lay down and cover eyes to
exclude light. Call a physician immediately.
1.8 ELECTRICAL SHOCK
A. This compressor should be installed and maintained
in full compliance with all applicable Federal, State
and Local codes, standards and regulations, including
those of the National Electrical Code, and also
including those relative to equipment grounding
conductors, and only by personnel that are trained,
qualified and delegated to do so.
B. 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 adjustments
or repairs to exposed live parts of the electrical
system. Make all such adjustments or repairs with one
hand only, so as to minimize the possibility of creating
a current path through the heart.
C. Attempt repairs in clean, dry and well lighted and
ventilated areas only.
D. DO NOT leave the compressor unattended with open
electrical enclosures. If necessary to do so, then
disconnect, lock out and tag all power at source so
others will not inadvertently restore power.
C. Operate the compressor only in open or adequately
ventilated areas.
D. Locate the compressor or provide a remote inlet so
that it is not likely to ingest exhaust fumes or other
toxic, noxious or corrosive fumes or substances.
E. Coolants and lubricants used in this compressor are
typical of the industry. Care should be taken to avoid
accidental ingestion and/or skin contact. In the event
of ingestion, seek medical treatment promptly. Wash
with soap and water in the event of skin contact.
Consult Material Safety Data Sheet for information
pertaining to fluid of fill.
F. Wear goggles or a full face shield when adding
antifreeze compound to air line anti-icer systems.
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3000-4500 Operator’s Manual and Parts List
3
SECTION 1
E. Disconnect, lock out, and tag all power at source prior
to attempting repairs or adjustments to rotating
machinery and prior to handling any ungrounded
conductors.
DANGER
All field equipment must be tested for
electrostatic fields prior to servicing
or making contact with the machine
using the following or equivalent test
equipment:
• 90-600 VAC: Volt detector such as
Fluke Model 1AC-A
• 600-7000 VAC: Voltage detector
such as Fluke Networks Model
C9970
N. Make sure pallet-mounted compressors are firmly
bolted or otherwise secured to the pallet prior to
attempting to forklift or transport them. NEVER
attempt to forklift a compressor that is not secured to
its pallet, as uneven floors or sudden stops may cause
the compressor to tumble off, possibly causing
serious injury or property damage in the process.
It is the responsibility of each
organization to provide/arrange
training for all their associates
expected to test for electrostatic
fields.
1.10 ENTRAPMENT
1.9 LIFTING
A. 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 and/or handle only in full
compliance with OSHA standards 29 CFR 1910
subpart N and/or any applicable Federal, State, and
Local codes, standards and regulations.
B. Inspect 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
structure has been inspected, is in good condition and
has a rated capacity of at least the weight of the
compressor. If you 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 or slings.
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 capable
of safely supporting at least its weight and its loading
unit.
4
K. When moving the compressor by forklift truck, utilize
fork pockets if provided. Otherwise, utilize pallet if
provided. If neither fork pockets or pallet are provided,
then make sure compressor is secure and well
balanced on forks before attempting to raise or
transport it any significant distance.
L. Make sure forklift truck forks are fully engaged and
tipped back prior to lifting or transporting the
compressor.
M. Forklift no higher than necessary to clear obstacles at
floor level and transport and corner at minimum
practical speeds.
A. If the compressor enclosure, if any, is large enough to
hold a man and if it is necessary to enter it to perform
service adjustments, inform other personnel before
doing so, or else secure and tag the access door in
the open position to avoid the possibility of others
closing and possibly latching the door with personnel
inside.
B. Make sure all personnel are out of compressor before
closing and latching enclosure doors.
3000-4500 Operator’s Manual and Parts List
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Section 2
DESCRIPTION
2.1 INTRODUCTION
Your new Sullair flood-lubricated rotary screw air
compressor will provide you with a unique experience in
improved reliability and simplified maintenance.
Compared to other types of compressors, the Sullair rotary
screw is unique in mechanical reliability, with "no wear"
and "no inspection" required of the working parts within the
compressor unit.
Read MAINTENANCE on page 61 to see how
surprisingly easy it is to keep your air compressor in top
operating condition.
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3000-4500 Operator’s Manual and Parts List
5
SECTION 2
11
10
1
6
3
7
8
1
5
9
2
12
5
2
13
4
02250155-601 2_1
1.
2.
3.
4.
5.
6.
7.
Fluid Filter
Moisture Separator
Receiver Tank
Fluid Fill
Fluid Fill Sight Glass
Starter Box
WS Controller
8.
9.
10.
11.
12.
13.
E-Stop Button
Compressor Unit
Cooler Fan Motor
Cooler
Motor
Air Inlet Filter
Figure 2-1: Overall Component Layout, Air-Cooled Model
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3000-4500 Operator’s Manual and Parts List
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DESCRIPTION
14
11
11
14
2
10
10
10
6
2
7
1
8
12
9
3
4
5
12
13
3
4
5
02250155-601_2_2
1.
2.
3.
4.
5.
6.
7.
Moisture Separator
Fluid Filter
Receiver Tank
Fluid Fill
Fluid Fill Sight Glass
Starter Box
WS Controller
8.
9.
10.
11.
12.
13.
14.
E-Stop Button
Compressor Unit
Oil Cooler
Aftercooler
Motor
Air Inlet Filter
Canopy Vent Fan
Figure 2-2: Overall Component Layout, Water-Cooled Model
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3000-4500 Operator’s Manual and Parts List
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SECTION 2
2.2 DESCRIPTION OF COMPONENTS
Refer to Figure 2-1 and Figure 2-2. The components and
assemblies of the air compressor are clearly shown. The
complete package includes compressor, electric motor,
starter, compressor inlet system, compressor discharge
system, compressor lubrication and cooling system,
capacity control system, WS Controller, aftercooler, a
combination separator and trap, all mounted on a heavy
gauge steel frame.
On air-cooled models, a fan draws air into the enclosure
over the fan and main motors through the combined
aftercooler and fluid cooler thereby removing the
compression heat from the compressed air and the
cooling fluid, and forces it out the top of the machine.
On water-cooled models, a shell and tube heat exchanger
is mounted on the compressor frame. Fluid is piped into
the heat exchanger where compression heat is removed
from the fluid. Another similar heat exchanger cools the
compressed air.
Both air-cooled and water-cooled versions have easily
accessible items such as the fluid filter air/oil separator and
control valves. The inlet air filter is also easily accessible
for servicing.
2.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
Sullair air compressors feature the Sullair compressor unit,
a single-stage, positive displacement, flood lubricatedtype compressor. This unit provides continuous
compression to meet your needs.
NOTE
The 3000-4500 Series compressors are factory-filled with
Sullube lubricant. For more information on fluid fill, consult
SPECIFICATIONS on page 17.
Sullair 24KT compressors are filled with a fluid that rarely
needs to be changed. Use only Sullair 24KT fluid in the
event that a fluid change is required.
CAUTION
Mixing of other lubricants within the
compressor unit will void all
warranties.
Sullair recommends that a 24KT sample be taken at the
first filter change and sent to the factory for analysis. This
is a free service. The sample kit with instructions and selfaddressed container is to be supplied by your Sullair
dealer at start-up. The user will receive an analysis report
with recommendations.
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:
1. As coolant, it controls the rise of air temperature
normally associated with the heat of compression.
2. Seals the clearance paths between the rotors and the
stator and also between the rotors themselves.
3. 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
compressor 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 preparation for reinjection.
With a Sullair compressor, there is no
maintenance or inspection of the
internal parts of the compressor unit
permitted in accordance with the
terms of the warranty.
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3000-4500 Operator’s Manual and Parts List
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SULLAIR
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DESCRIPTION
COOLING / LUBRICATION
SYSTEM
Fluid line
Fluid line
AIR
FLUID/AIR
FLUID
DISCHARGE SYSTEM
02250155-601_2_3
Figure 2-3: Air-Cooled, Cooling / Lubrication and Discharge System
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3000-4500 Operator’s Manual and Parts List
9
SECTION 2
COOLING / LUBRICATION
SYSTEM
AIR
FLUID/AIR
FLUID
DISCHARGE SYSTEM
02250155-601 2_4
Figure 2-4: Water-Cooled, Cooling / Lubrication and Discharge System
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3000-4500 Operator’s Manual and Parts List
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DESCRIPTION
Fluid flows from the bottom of the receiver tank to the
thermal valve. The thermal valve is fully open when the
fluid temperature is below 185˚F (85˚C) [200˚F (93˚C) for
24KT] and pressures are rated above 150 psig. The fluid
passes through the thermal valve, the main filter and
directly to the compressor unit where it lubricates, cools
and seals the rotors and the compression chamber.
The compressed air/fluid mixture enters the receiver tank
and flows through an internal baffle system. The direction
of movement is changed and its velocity significantly
reduced, thus causing large droplets of fluid to form and
fall to the bottom of the receiver tank. The fractional
percentage of fluid remaining in the compressed air
collects on the surface of the separator element as the
compressed air flows through the separator. A return line
(or scavenge tube) leads from the bottom of the separator
element to a medium pressure region of the compressor
unit. Fluid collecting on the bottom of the separator is
returned to the compressor by a pressure differential
between the receiver and the compressor. A visual sight
glass is located on the return line to observe this fluid flow.
There is also an orifice in this return line (protected by a
strainer) to assure proper flow. The separator system
reduces the fluid carry-over to less than 1 ppm (parts per
million). A message on the WS Controller indicates if
abnormal pressure drop through the separator develops.
Refer to
Lubrication Change Recommendations and
Maintenance, Fluid Filter and Separator on page 21.
As the discharge temperature rises above 185˚F (85˚C),
due to the heat of compression, the thermal valve begins
to close and a portion of the fluid then flows through the
cooler. From the cooler the fluid flows to the fluid filter and
then on to the compressor unit.
A minimum pressure/check valve, located downstream
from the separator, assures a minimum receiver pressure
of 50 psig (3.4 bar) during loaded conditions. This
pressure is necessary for proper air/fluid separation and
proper fluid circulation.
A portion of the fluid flowing to the compressor is routed to
the anti-friction bearings which support the rotors inside
the compressor unit.
A terminal check valve is incorporated into the minimum
pressure/check valve to prevent compressed air in the
service line from bleeding back into the receiver on
shutdown and during operation of the compressor in an
unloaded condition.
2.4 COMPRESSOR COOLING AND
LUBRICATION SYSTEM,
FUNCTIONAL DESCRIPTION
Refer to Figure 2-3 or Figure 2-4. The Cooling and
Lubrication System (air-cooled version) consists of a fan,
fan motor, radiator-type aftercooler/fluid cooler, full flow
fluid filter, thermal valve, and interconnecting hoses. For
water-cooled models, two shell and tube heat exchangers
are substituted for the radiator-type cooler listed above.
The pressure in the receiver tank causes fluid flow by
forcing the fluid from the high pressure area of the receiver
tank to an area of lower pressure in the compressor unit.
The fluid filter has a replacement element and an integral
pressure bypass valve. Refer to
Lubrication Change Recommendations and
Maintenance, Fluid Filter and Separator on page 21.
Water-cooled models have a water pressure switch to
prevent operation with inadequate water pressure.
A pressure relief valve (located on the wet side of the
separator) is set to open if the receiver tank pressure
exceeds the receiver tank rating. The WS Controller will
shut down the compressor if the discharge temperature
reaches 235˚F (113˚C).
2.5 COMPRESSOR DISCHARGE
SYSTEM, FUNCTIONAL
DESCRIPTION
WARNING
DO NOT remove caps, plugs, and/or
other components when compressor
is running or pressurized.
Refer to Figure 2-3 or Figure 2-4. The compressor unit
discharges the compressed air/fluid mixture into the
combination receiver tank.
The receiver has three basic functions:
1. It acts as a primary fluid separator.
2. Serves as the compressor fluid sump.
3. Houses the final fluid separator.
®
SULLAIR
®
Stop compressor and relieve all
internal pressure before doing so.
Fluid is added to the receiver tank via a capped fluid filler
opening, placed low on the tank to prevent overfilling of the
receiver tank. A sight glass enables the operator to visually
monitor the receiver tank fluid level.
3000-4500 Operator’s Manual and Parts List
11
SECTION 2
2.6 CONTROL SYSTEM,
FUNCTIONAL DESCRIPTION
Start Mode - 0 to 50 PSIG (0 to 3.5 Bar)
Refer to Figure 2-5 and Figure 2-6. The purpose of the
compressor control system is to regulate the amount of air
being compressed to match the amount of compressed air
being used. The capacity control system consists of a
solenoid valve, regulator valve and an inlet valve. The
functional description of the control system is described
below in four distinct phases of operation. For explanatory
purposes, this description will apply to a compressor with
an operating range of 100 to 110 psig (6.9 to 7.6 bar). A
compressor with any other pressure range would operate
in the same manner except stated pressures.
When the compressor " " (START) pad is depressed,
the receiver tank pressure will quickly rise from 0 to 50 psig
(0 - 3.4 bar). The compressor initially starts unloaded with
the solenoid valve open and the inlet valve closed. It then
switches to full load when full rpm has been achieved.
During this period, both the pressure regulator and the
solenoid valve are closed, the inlet valve is fully open and
the compressor pumps at full rated capacity. The rising
compressor air pressure is isolated from the service line
in this phase by the minimum pressure valve set at
approximately 50 psig (3.4 bar).
2
8
9
1
6
5
7
4
3
SU_0000007
1.
2.
3.
4.
5.
Air Outlet
Unload Solenoid Valve
Pressure Regulator
Air Inlet
Blowdown Valve
6.
7.
8.
9.
Minimum Pressure/Check Valve
Receiver Tank
Sequencing Solenoid Valve
WS Controller
Figure 2-5: Standard Sequencing Control System
12
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
DESCRIPTION
Full Load Mode - 50 to 100
PSIG (3.4 to 6.9 BAR)
When the compressed air pressure rises above 50 psig
(3.4 bar), the minimum pressure valve opens allowing
compressed air to flow into the service line. From this point
on, the line air pressure is continually monitored by the WS
Controller. The pressure regulator and the solenoid valve
remain closed during this phase. The inlet valve is in the
fully open position as long as the compressor is running at
100 psig (6.9 bar) or below.
Modulating Mode - 100 to 110
PSIG (6.9 to 7.6 BAR)
If less than the rated capacity of compressed air is being
used, the service line pressure will rise above 100 psig
(6.9 bar). The pressure regulator valve gradually opens,
directing air pressure to the inlet control valve, reducing air
entering the compressor until it matches the amount of air
being used. The control system functions continually in
this manner between the limits of 100 to 110 psig (6.9 to
7.6 bar) in response to varying demands from the service
line.
The integrated inlet valve has an orifice which vents a small
amount of air to the compressor inlet when the pressure
regulator controls the inlet control valve. The orifice also
bleeds any accumulated moisture from the control lines.
Unload Mode- In Excess of 110
PSIG (7.6 BAR)
When a relatively small amount or no air is being used, the
service line pressure continues to rise. When it exceeds
110 psig (7.6 bar), the WS Controller control system deenergizes the solenoid valve allowing receiver tank air
pressure to be supplied directly to close the inlet valve.
Simultaneously, the solenoid valve sends a pneumatic
signal to the blowdown valve. The blowdown valve opens
®
SULLAIR
®
to the atmosphere, located in the compressor receiver
tank, reducing the receiver tank pressure to approximately
17 psig (1.2 bar). The check valve in the air service line
prevents line pressure from returning to the receiver tank.
When the line pressure drops to the low setting (cut-in
pressure; usually 100 psig (6.9 bar) on low pressure (7 bar)
compressors and 125 psig (8.6 bar) on high pressure (9
bar) compressors, 150 psig (10.3 bar) on (10 bar)
compressors, 175 psig (12.0 bar) on (12 bar)
compressors), the WS Controller energizes the solenoid
valve and allows the blowdown valve to close. The reenergized solenoid valve again prevents line pressure
from reaching the inlet control valve. Should the pressure
begin to rise, the pressure regulator will resume its normal
function as previously described.
Load / No Load Control
If desired by the customer, the compressor can be set to
operate load/no load without modulating control. This
control mode is often selected when a large amount of
compressed air storage (air tank) is available. Using the
WS Controller keypad, select "load/no load control" from
the menu. On a machine rated for 100 psig (7 bar) the
compressor will run in the full load mode up to 100 psig (7
bar). If less than the rated capacity is required, pressure
will rise above 100 psig and the WS Controller will deenergize the solenoid valve, causing the compressor to
run in the unload mode. When the system pressure falls to
90 psig (6.3 bar), the WS Controller energizes the solenoid
valve, causing the compressor to return to the full load
mode. The compressor will thus operate to keep the
system pressure in the range of 90-100 psig (6.3 - 6.9 bar).
Automatic Operation
For applications with varied periods of time when there are
no air requirements, the WS Controller's AUTOMATIC
mode allows the compressor to shutdown (time delayed)
when no compressed air requirement is present and
restart as compressed air is needed.
3000-4500 Operator’s Manual and Parts List
13
SECTION 2
2.7 AIR INLET SYSTEM,
FUNCTIONAL DESCRIPTION
WARNING
Refer to Figure 2-6. The compressor inlet system consists
of a dry-type air filter, a restriction gauge and an air inlet
valve.
The restriction gauge (located on the air filter) indicates the
condition of the air filter by showing red when filter
maintenance is required.
The poppet-type modulating air inlet valve directly controls
the amount of air intake to the compressor in response to
the operation of the pressure regulator. Refer to
Full Load Mode - 50 to 100 PSIG (3.4 to 6.9 BAR)
on page 13. The inlet valve also acts as a check valve, thus
preventing reverse rotation when the compressor is shut
down.
14
"The Plastic Pipe Institute
recommends against the use of
thermoplastic pipe to transport
compressed air or other compressed
gases in exposed above ground
locations, e.g. in exposed plant
piping." (I)
Sullube should not be used with PVC
piping systems. It may affect the bond
at cemented joints. Certain other
plastic materials may also be affected.
(I) Plastic Pipe Institute,
Recommendation B, Adopted
January 19, 1972.
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
DESCRIPTION
1
2
5
3
4
SU_0000008
1. Air Inlet Filter
2. Air Inlet
3. Compressor Unit
4. Receiver Tank
5. Restriction Indicator
Figure 2-6: Air Inlet System
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
15
SECTION 2
THIS PAGE INTENTIONALLY LEFT BLANK
16
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
®
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®
Section 3
SPECIFICATIONS
3.1 TABLE OF SPECIFICATIONS - 3000, 3000P, 3700 AND 4500 SERIES
MODELS
DIMENSIONS
MODEL (I)
Length
HP
in
Width
mm
in
Height
mm
in
mm
Weight
Weight
lbs
kg
ODP
TEFC
ODP
TEFC
3000 SERIES
3007
40
62.0
1575
34.5
876
61.5
1562
1818
1884
825
855
3009
40
62.0
1575
34.5
876
61.5
1562
1818
1884
825
855
3010
40
62.0
1575
34.5
876
61.5
1562
1818
1884
825
855
3007P
40
62.0
1575
34.5
876
61.5
1562
1993
2059
904
934
3009P
40
62.0
1575
34.5
876
61.5
1562
1993
2059
904
934
3010P
40
62.0
1575
34.5
876
61.5
1562
1993
2059
904
934
3707
50
62.0
1575
34.5
876
61.5
1562
2043
2127
927
965
3709
50
62.0
1575
34.5
876
61.5
1562
2043
2127
927
965
3710
50
62.0
1575
34.5
876
61.5
1562
2043
2127
927
965
3712
50
62.0
1575
34.5
876
61.5
1562
2043
2127
927
965
4509
60
62.0
1575
34.5
876
61.5
1562
2193
2270
995
1030
4510
60
62.0
1575
34.5
876
61.5
1562
2193
2270
995
1030
4512
60
62.0
1575
34.5
876
61.5
1562
2193
2270
995
1030
3000P SERIES
3700 SERIES
4500 SERIES
(I) Includes standard and 24KT. Rated pressure designations appearing after model number are as follows:
07 - 100 psig (6.9 bar)
10 - 150 psig (10.3 bar)
09 - 125 psig (8.6 bar)
12 - 175 psig (12 bar)
Maximum pressure is rated pressure plus 10 psig (0.7 bar).
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
17
SECTION 3
3.2 TABLE OF SPECIFICATIONS - VARIABLE SPEED DRIVE MODELS
VSD SERIES (I) - 3000 (MODELS 3007 THROUGH 3010)
MOTOR
HZ / VOLTAGE
DRIVE AMP RATING
ODP
TEFC
460/60
575/60
400/50
460/60
575/60
400/50
72
52
87
72
52
87
WEIGHT (lbs / kg)
1894 / 859
1894 / 859
1894 / 859
1960 / 889
1960 / 889
1960 / 889
LENGTH (in / mm)
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
WIDTH (in / mm)
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
HEIGHT (in / mm)
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
VSD SERIES (I) - 3000P (MODELS 3007 THROUGH 3010)
MOTOR
HZ / VOLTAGE
DRIVE AMP RATING
ODP
460/60
575/60
TEFC
400/50
460/60
575/60
400/50
72
52
87
72
52
87
WEIGHT (lbs / kg)
2069 / 938
2069 / 938
2069 / 938
2135 / 968
2135 / 968
2135 / 968
LENGTH (in / mm)
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
WIDTH (in / mm)
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
HEIGHT (in / mm)
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
VSD SERIES (I) - 3700 (MODELS 3707 THROUGH 3712)
MOTOR
HZ / VOLTAGE
DRIVE AMP RATING
ODP
460/60
575/60
TEFC
400/50
460/60
575/60
400/50
72
52
87
72
52
87
WEIGHT (lbs / kg)
2119 / 961
2171 / 984
2119 / 961
2203 / 999
2255 / 1023
2203 / 999
LENGTH (in / mm)
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
WIDTH (in / mm)
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
HEIGHT (in / mm)
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
VSD SERIES (I) - 4500 (MODELS 4509 THROUGH 4510)
MOTOR
HZ / VOLTAGE
ODP
TEFC
460/60
575/60
400/50
460/60
575/60
400/50
72
52
87
72
52
87
WEIGHT (lbs / kg)
2361 / 1071
2244 / 1018
2361 / 1071
2438 / 1106
2296 / 1041
2438 / 1106
LENGTH (in / mm)
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
62.0 / 1575
WIDTH (in / mm)
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
34.5 / 876
HEIGHT (in / mm)
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
61.5 / 1562
DRIVE AMP RATING
(I) Includes standard and 24KT. Rated pressure designations appearing after model number are as follows:
07 - 100 psig (6.9 bar)
10 - 150 psig (10.3 bar)
09 - 125 psig (8.6 bar)
12 - 175 psig (12 bar)
Maximum pressure is rated pressure plus 10 psig (0.7 bar).
18
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
3.3 COMPRESSOR SPECIFICATIONS
COMPRESSOR:
STANDARD MODELS:
Type:
Rotary Screw
Standard Operating Pressure:
100 psig (7 bar) 125 psig (9 bar)
Bearing Type:
Anti-friction
Ambient Temperature (Max.) (II):
104°F (40°C)
Cooling:
Pressurized fluid
Compressor Fluid:
Sullair Sullube; 24KT is optional
Receiver Capacity:
3.0 gallons (11.4 liters)
Control:
WS Controller
150 psig (10 bar) 175 psig (12 bar)
(ll) Special compressors are available for operation in higher ambient temperature.
MOTOR (III):
STANDARD MODELS:
Size:
40, 50, 60 HP / 30, 37, 45 KW
Type:
C-Flanged, Open Drip-proof, Epact Efficiency, Three Phase, 230/460
60Hz, 380-415 (400) 50 Hz
VSD Type:
C-Flanged, Open Drip-proof, Premium Efficiency, Three Phase, 460V
60Hz, 380-415V (400V) 50Hz
Maximum Ambient Temperature
104°F (40°C)
Options Available:
200V and 575V 60 Hz, 220 50 Hz TEFC also available: CE Approved
Starter:
Full Voltage Magnetic, Wye-Delta or VSD
Speed - 40, 50, 60 HP:
1780 RPM (60 Hz) or 1475 RPM (50 Hz)
(III) Multi-frequency and voltage motors are used. The compressors must be used only with the specified electrical frequency and voltage.
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
19
SECTION 3
3.4 LUBRICATION GUIDE
NOTE
Refer to Figure 3-1 for location of fluid fill port. For best
value and longest uninterrupted service, the 3000-4500
Series compressors are factory filled and tested with
Sullube lubricant.
CAUTION
Mixing of other lubricants within the
compressor unit will void all
warranties.
Flush system when switching
lubricant brands.
When ambient conditions exceed those noted or if
conditions warrant use of "extended" life lubricants contact
Sullair for recommendation.
If fluid change is required, follow Section 3.6,
Lubrication Change Recommendations and
Maintenance, Fluid Filter and Separator on page 21.
4
WARNING
"The Plastic Pipe Institute
recommends against the use of
thermoplastic pipe to transport
compressed air or other compressed
gases in exposed above ground
locations, e.g. in exposed plant
piping." (I)
1
2
3
Sullube should not be used with PVC
piping systems. It may affect the bond
at cemented joints. Certain other
plastic materials may also be affected.
(I) Plastic Pipe Institute,
Recommendation B, Adopted
January 19, 1972.
SA_0000013
1.
2.
3.
4.
Figure 3-1: Fluid Fill Location
Maintenance of all other components is still recommended
as indicated in the Operator’s Manual.
DO NOT MIX DIFFERENT TYPES OF FLUIDS.
Contamination of compressor fluid with mineral oil or other
fluids may lead to operational problems such as foaming,
filter plugging, orifice or line plugging.
20
Fluid Fill Port
Sight Glass
Fluid Drain Valve
Receiver Tank
3.5 APPLICATION GUIDE
Sullair encourages the user to participate in a fluid analysis
program with the fluid suppliers. This could result in a fluid
change interval differing from that stated in the manual.
Contact your Sullair dealer for details.
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
3.6 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE, FLUID
FILTER AND SEPARATOR
LUBRICANT
FLUID CHANGE
FLUID FILTER CHANGE
SEPARATOR CHANGE
Sullube
A, E
G, C
A, D
SRF 1/4000
B, E
G, C
B, D
24KT
F, E
G, C
A, D
CP-4600-32-F
B, E
G, C
B, D
A - 8,000 hours or once a year.
B - 4,000 hours or more frequently if conditions so require.
C - When measured pressure loss exceeds 20 psig (1.3 bar).
D - When measured pressure loss exceeds 10 psig (0.7 bar).
E - When required by fluid analysis or known contamination.
F - Does not require replacement during normal service conditions.
G - Every 2,000 hours.
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
21
SECTION 3
3.7 IDENTIFICATION, AIR-COOLED, STANDARD AND VSD
2
3
1
02250156_213r03-2
22
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
5
6
4
10
9
8
7
02250156_213r03-1
1. Alternate Incoming Power Supply Location
Dia. 2.5 in. (63.5mm)
2. WS Controller
3. E-Stop
4. Oil Level Sight Glass
5. Air Exhaust
6. Air Inlet
7. Containment Pan Drain 1/2"-1/4" NPT
8. Incoming Customer Power Supply Location
2.5 in. (63.5mm)
9. Moisture Drain Connection 1/2"-1/4" NPT
10. Air Outlet Connection 1 1/2"-11 1/2" NPT
Figure 3-2: Identification, Air-Cooled, Standard and VSD
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
23
SECTION 3
3.8 IDENTIFICATION, WATER-COOLED
2
3
1
02250160_729r02-2
24
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
6
5
10
8
9
11
12
4
6
7
02250160_729r02-1
1. Alternate Incoming Power Supply Location
Dia. 2.5 in. (63.5mm)
2. WS Controller
3. E-Stop
4. Oil Level Sight Glass
5. Air Exhaust
6. Air Inlet
7. Containment Pan Drain 1/2"-1/4" NPT
8. Incoming Customer Power Supply Location
2.5 in. (63.5mm)
9. Moisture Drain Connection 1/2"-1/4" NPT
10. Air Outlet Connection 1 1/2"-11 1/2" NPT
11. Cooling Water Out 3/4"-14 NPT
12. Cooling Water In 3/4"-14 NPT
Figure 3-3: Identification, Water-Cooled
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3000-4500 Operator’s Manual and Parts List
25
SECTION 3
3.9 PIPING AND INSTRUMENTATION, AIR-COOLED
A1
A1
C5
A1
B3
A3
C1
A2
A3
B2
B1
C5
A3
A2
B7
C3
A4
C4
B5
B6
B4
02250156-203r07
Figure 3-4: Piping and Instrumentation, Air-Cooled
26
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
Key
®
Description
Part Number
Note
Quantity
1
filter, air 9" plastic
02250127-683
1
2
indicator, restriction
02250003-869
1
3
inlet
–
(I)
1
4
compressor unit
–
(I)
1
5
motor
–
(I)
1
6
filter, coreless 1-1/16 sae
02250155-708
1
7
cooler, air/oil 50 hp
02250151-493
(I)
1
cooler, air/oil 60hp
02250152-862
(I)
1
8
valve, thermal 195 deg 1-1/2"-18
02250092-081
(I)
1
valve, thermal 210 deg 1-1/2"-18
0250148-796
(I)
1
9
orifice, 1/8 x 1/32
02250125-774
1
10
gls, sight/orf sae
02250126-129
1
11
filter, assy genisis
02250117-782
1
12
plug, sightglass 1-5/16" sae
02250097-610
1
13
probe, thermister 3000 ohm
02250155-175
1
14
valve, relief 1/2"
250006-938
1
15
xducr, 1-250# radiometric
02250155-174
2
16
valve, shuttle 1/4" double chk
408893
1
17
vlv, min pressure 1-7/8 sae
02250097-598
1
18
valve, blowdown 1/2" 1.8;1
02250100-042
1
19
sep, wtr scws-235n 1-1/2" l/ad
02250166-734
1
20
elem, sep round 5.5d x 14.3lng
02250160-774
1
21
valve, ball 1/4"
47115
1
22
strainer, v-type 300psi x 1/4
241771
2
23
vlv, sol 3wno 1/4 250# 24vdc
02250155-714
(III)
1
24
valve, pressure reg
250017-280
1
25
tank, separator
02250149-624
1
26
orifice, .140 x 1/4m x 1/4f
02250161-433
1
27
vlv, sol 2wnc 1/4 200# 24vdc
02250155-715
1
28
vlv, chk 1/4" nptf brass viton
02250115-272
1
29
vlv, sol ees
02250125-673
(II)
1
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3000-4500 Operator’s Manual and Parts List
27
SECTION 3
3.9 PIPING AND INSTRUMENTATION, AIR-COOLED (CONTINUED)
A1
A1
C5
A1
B3
A3
C1
A2
A3
B2
B1
C5
A3
A2
B7
C3
A4
C4
B5
B6
B4
02250156-203r07
Figure 3-5: Piping and Instrumentation, Air-Cooled
28
3000-4500 Operator’s Manual and Parts List
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SPECIFICATIONS
Key
Part Number
Note
Quantity
(I)
Part varies by model.
(II)
Used with EES option.
(III)
Two solenoid valves are required with Sequencing option. Refer to B4.
A1
Tank pressure - blue color
A2
Reg pressure - yellow color
A3
Unload pressure - red color
A4
Water drain - clear color
B1
P1 - Wet sump pressure
B2
P2 - Line pressure
B3
SOL 1 - Load/unload solenoid valve
B4
SOL 4 - MEC/sequencing/full load solenoid valve
B5
SOL 5 - Electric drain/scd drain solenoid valve
B6
SOL 7 - EES solenoid valve (optional)
A to open inside EES damper (winter).
B to open outside EES damper (summer).
B7
T1 - Wet discharge temperature
C1
1/2" Hose.
C2
Control moisture drain lines are 1/4" tubing except as noted.
C3
1 1/2" - 11 1/2 npt air outlet.
C4
1/4"-18 npt moisture drain connection.
C5
Section between lettered points (A) and (B) are to be replaced with corresponding option pictured below, as
required by face of order. Refer to B4.
C6
Optional heat trace is applied only to control and moisture drain lines and used only with stainless steel tubing.
Refer to face of order for heat trace requirements.
®
Description
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
29
SECTION 3
3.10 PIPING AND INSTRUMENTATION, WATER-COOLED
A1
A1
C5
A1
A3
A2
A3
B2
B1
C5
B7
A3
A2
C3
B5
A4
C4
B8
C7
C5
C8
C5
B6
B9
D1
D2 C2 C6
B4
B11
D3 C2 C6
B5
D4
D5
D6
D7
B10
02250162-393R03
Figure 3-6: Piping and Instrumentation, Water-Cooled
30
3000-4500 Operator’s Manual and Parts List
®
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®
SPECIFICATIONS
Key
Description
Part Number
Note
Quantity
1
filter, air 9" plastic
02250127-683
1
2
indicator, restriction
250003-869
1
3
inlet
-
(I)
1
4
compressor unit
-
(I)
1
5
motor
-
(I)
1
6
filter, coreless 1-1/16" sae
02250155-708
1
7
clr, oil/water 5x36 1-5/16" sae
02250094-744
1
8
valve, thermal 210deg 1-1/2"-18 (24kt or 175 psig)
02250148-796
1
8
valve, thermal 195deg 1-1/2"-18 (sullube)
02250092-081
1
9
orifice, 1/8 x 1/32
02250125-774
1
10
gls, sight/orf sae
02250126-129
1
11
filter, assy genisis
02250117-782
1
12
plug, sightglass 1-5/16" sae
02250097-610
1
13
probe, thermister 3000 ohm
02250155-175
1
14
valve, relief 1/2"
250006-938
1
15
xducr, 1-250# radiometric
02250155-174
2
16
valve, shuttle 1/4" double chk
408893
1
17
vlv, min pressure 1-7/8" sae
02250097-598
1
18
valve, blowdown 1/2" 1.8:1
02250100-042
1
19
sep, wtr scws-235n 1 1/2" l/ad
02250166-734
1
20
elem, sep round 5.5d x 14.3lng
02250160-774
1
21
valve, ball 1/4"
47115
1
22
strainer, v-type 300psi x 1/4
241771
2
23
vlv, sol 3wno 1/4 250# 24vdc
02250155-714
2
24
valve, pressure reg
250017-280
1
25
tank, separator
02250149-624
1
26
orf, 140" .25 fnpt x .25
02250161-433
1
27
vlv, sol 2wnc 1/4 200# 24vdc
02250155-715
1
28
vlv, chk 1/4" nptf brass viton
02250115-272
1
29
ht exch
250017-527
1
30
switch, press no 10 psi
250017-992
1
31
valve, water reg 3/4" 160-230f
47398
1
32
vlv, sol 2wnc 3/4 250# n4
02250125-668
1
33
vlv, ball/stnr comb 1/2f x 1/2m
02250144-842
1
34
drn, electric condensate-scd400
02250130-866
1
Part varies by model.
(I)
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3000-4500 Operator’s Manual and Parts List
31
SECTION 3
3.10 PIPING AND INSTRUMENTATION, WATER-COOLED (CONTINUED)
A1
A1
C5
A1
A3
A2
A3
B2
B1
C5
B7
A3
A2
C3
B5
A4
C4
B8
C7
C5
C8
C5
B6
B9
D1
D2 C2 C6
B4
B11
D3 C2 C6
B5
D4
D5
D6
D7
B10
02250162-393R03
Figure 3-7: Piping and Instrumentation, Water-Cooled
32
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
Key
Part Number
Note
Quantity
A1
Tank pressure — blue color
A2
Regulator pressure – yellow color
A3
Unload pressure – red color
A4
Water drain – clear color
B1
P1 – wet sump pressure
B2
P2 – line pressure
B3
SOL 1 – load/unload solenoid valve
B4
SOL 4 – MEC/sequencing/full load solenoid valve
B5
SOL 5 – electric drain/SCD drain solenoid valve
B6
SOL 6 – water solenoid valve
B7
T1 – wet discharge temperature
B8
Water solenoid valve option
B9
Water regulating valve option
B10
Sequencing solenoid option
B11
SCD drain option
C1
½" hose
C2
Control/moisture drain lines are ¼" tubing except as noted
C3
1 ½" – 11 ½" npt air outlet
C4
¼"-18 npt moisture drain connection
C5
Sections between lettered points are to be replaced with corresponding option pictured below
C6
Optional head trace is applied only to control and moisture drain lines, and used only with stainless steel tubing
C7
Water inlet ¾"-14 npt
C8
Water outlet ¾"-14 npt
D1
Customer furnished line
D2
Water line
D3
Control line
D4
Fluid line
D5
Air/fluid line
D6
Temperature control probe
D7
Air line
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Description
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®
3000-4500 Operator’s Manual and Parts List
33
SECTION 3
3.11 WIRING DIAGRAM, MFV AIR-COOLED
02250156_577R04-1
34
3000-4500 Operator’s Manual and Parts List
®
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®
SPECIFICATIONS
02250156_577R04-2
Figure 3-8: Wiring Diagram, MFV Air-Cooled
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3000-4500 Operator’s Manual and Parts List
35
SECTION 3
3.12 WIRING DIAGRAM, MFV WATER-COOLED
02250161-763R03-1
36
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
02250161-763R03-2
Figure 3-9: Wiring Diagram, MFV Water-Cooled
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3000-4500 Operator’s Manual and Parts List
37
SECTION 3
3.13 WIRING DIAGRAM, WYE-DELTA AIR-COOLED
02250156_118R03-1
38
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
02250156_118R03-2
Figure 3-10: Wiring Diagram, Wye-Delta Air-Cooled
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3000-4500 Operator’s Manual and Parts List
39
SECTION 3
3.14 WIRING DIAGRAM, WYE-DELTA WATER-COOLED
02250161_761R02-1
40
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
02250161_761R02-2
Figure 3-11: Wiring Diagram, Wye-Delta Water-Cooled
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®
3000-4500 Operator’s Manual and Parts List
41
SECTION 3
3.15 WIRING DIAGRAM, VSD AIR-COOLED
02250156_119r04-2
42
3000-4500 Operator’s Manual and Parts List
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®
SPECIFICATIONS
02250156_119r04-2
Figure 3-12: Wiring Diagram, VSD Air-Cooled
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3000-4500 Operator’s Manual and Parts List
43
SECTION 3
3.16 WIRING DIAGRAM, VSD WATER-COOLED
02250161-762R02-1
44
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
02250161-762R02-2
Figure 3-13: Wiring Diagram, VSD Water-Cooled
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®
3000-4500 Operator’s Manual and Parts List
45
SECTION 3
3.17 WIRING DIAGRAM, VSD AIR-COOLED, 575V SERIES DELTA
02250164_731r01-1
46
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
02250164_731r01-2
Figure 3-14: Wiring Diagram, VSD Air-Cooled, 575V Series Delta
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3000-4500 Operator’s Manual and Parts List
47
SECTION 3
3.18 WIRING DIAGRAM, VSD WATER-COOLED, SERIES DELTA 575V
02250164_732r01-1
48
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
SPECIFICATIONS
02250164_732r01-2
Figure 3-15: Wiring Diagram, VSD Water-Cooled, Series Delta 575V
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3000-4500 Operator’s Manual and Parts List
49
SECTION 3
THIS PAGE INTENTIONALLY LEFT BLANK
50
3000-4500 Operator’s Manual and Parts List
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Section 4
INSTALLATION
4.1 MOUNTING OF COMPRESSOR
4.2 VENTILATION AND COOLING
A suitable foundation or fabricated support must be
established to support the compressor. It should be rigid
enough to keep the compressor frame level and maintain
alignment of the compressor and motor. Tie-down bolts of
sufficient size must be used to provide uniform contact
between the foundation and the compressor frame.
Materials such as rubber or cork can be used to provide
uniform contact between the foundation and compressor
frame.
Air-Cooled Compressors
•
•
•
•
•
•
Piping loads must be eliminated through the use of flex
connectors or other systems which prevent piping
loads from being transmitted to the compressor.
Special consideration should be made to meet
national and local electrical codes for the required
space around and in front of the electrical panel.
Lighting should be provided for future service
requirements.
Accessibility for fork lift trucks, overhead cranes and
maintenance vehicles should be given careful
consideration in order to provide any maintenance
that may be required. Adequate space around the unit
should be provided for access to all components of the
compressor.
•
•
•
Softer surfaces in walls or ceilings will absorb sound
and minimize ambient noise levels. Harder, reflective
surfaces will increase ambient noise levels.
Water-cooled compressors must have provisions for
cooling water supply and drainage available.
NOTE
Ambient temperatures above 104˚F
(40˚C) require that the high ambient
option is specified for the
compressor.
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SULLAIR
®
3000-4500 Operator’s Manual and Parts List
An area with adequate space must be provided for the
compressor and its components. Air-cooled
compressors require a minimum of 3 feet (1 meter)
around the perimeter of the compressor.
The location should be free from standing water and
allow access to clean air that is free from exhaust and
paint fumes, dust, metal filings or caustic chemicals.
Cooling air should be removed from the area in order
to prevent the re-introduction of heated exhaust air
back into the compressor’s cooling system.
Reduced headroom above the compressor will
require that cooling air be either ducted or in some way
deflected away from the compressor. Inadequate
ventilation will result in higher ambient operating
temperatures.
NOTE
Systems that employ both a
conventional reciprocating
compressor and a screw-type axial
compressor must be isolated from
each other by use of a common
receiver tank. Individual airlines from
each compressor should be piped to
the common receiver tank.
NOTE
Shipping straps are painted red in
order to help identify them for
removal. Be sure to remove them prior
to operation of the drive assembly.
51
SECTION 4
Water-Cooled Compressors
Adequate cooling water flow must be supplied to watercooled compressors. Water delivery must be verified to
assure constant delivery of the volumes outlined in Table
4-1 Water Flow Requirements on page 52. The figures
shown are for full-load operation utilizing an aftercooler.
Cooler water will reduce water-flow requirements and
warmer water will increase water-flow requirements.
Water piping to and from the compressor unit must be a
minimum of 1 inch diameter. Isolation valves with side
drains should be installed on both input and return lines.
Input water should have a 2 mm strainer installed in-line.
A normally closed solenoid valve should be connected to
the water outlet of the compressor. The compressor
control circuit switches this circuit. Consult the Sullair
Service Department for assistance in these setups.
Water quality is critical to proper cooling of the
compressor. Excessive build-up of lime, scale or other
deposits can restrict the flow of water to the compressor.
These deposits act as a thermal insulator and reduce the
efficiency of the water cooler.
The cleaning of piping and water coolers is the customer’s
responsibility. Inspect all piping for deposits and clean as
necessary. Refer to
Water Quality Recommendations on page 53.
TABLE 4-1 WATER FLOW REQUIREMENTS
Water Temp
˚F/˚C
Table 4-2 Ventilation Requirements on page 53
indicates the minimum ventilation requirements
necessary to keep the compressor running at its normal
operating temperature. The fan air requirement is the
amount of air, which must flow through the compressor for
proper ventilation. The heat rejection requirement is the
amount of heat that is radiated by the compressor. This
heat must be removed to assure a normal operating
temperature. With air-cooled compressors it is possible to
use this heat for space heating, providing additional
pressure drop across the fan does not exceed 0.2 in H2O.
Consult a Sullair office for assistance in utilizing this heat.
If ductwork is added, the high static fan option is required.
DO NOT install a water-cooled or an air-cooled/aftercooled compressor where it will be exposed to
temperatures less than 32˚F (0˚C). Consult factory for
machine operation in ambient temperature less than 32˚F
(0˚C).
If machine is equipped with water regulating valve, use the
water regulating valve to adjust compressor temperature
to maintain a minimum of 180°F (82.2°C); 190°F (87.8°C)
for 24KT.
Temperature and pressure gauges should be installed in
the water piping for use in troubleshooting of the water
system. Water pressure should ideally be between 25 and
75 psig (1.7 and 5.2 bar) but must not be above 145 psi
(10 bar).
Water Flow
Gallons Per Minute /Liters Per Minute (l)
40HP/30kW
50HP/37kW
60HP/45kW
70/21
5.6
7.0 (26.5)
9.0 (31.6)
80/27
8.4
10.5 (35.7)
11.5 (41.6)
(I) Water pressure should be maintained between 25 and 75
psig (1.7 and 5.2 bar), but not to exceed 145 psig (10 bar)
52
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
INSTALLATION
TABLE 4-2 VENTILATION REQUIREMENTS
Cooling Type
Air-Cooled with Aftercooler
Motor HP/kW
Water-Cooled
40 / 30
50 / 37
60 / 45
40 / 30
50 / 37
60 / 45
5,000 / 8,500
5,000 / 8,500
6,000 / 10,200
700 / 1,200
700 / 1,200
700 / 1,200
BTU/Hour
114,500
142,000
171,100
10,600
13,300
15,800
KCal/Hour
28,800
35,700
46,216
2,670
3,350
4,000
114,500
142,000
171,100
28,800
35,700
43,040
Fan Air cfm/m3/hr
Ventilating Air/Heat
Rejection
Cooling Water/Heat
Rejection
BTU/Hour
KCal/Hour
Water System Venting
Vent the system upon installation or after draining the
system on start-up:
1. Open the water valve(s) allowing water to flow to the
system.
2. Open the vent cocks (located on top of the aftercooler
and the lubricant cooler) and allow all air to escape
from the system. When water is observed at the vent
cocks, close them.
The system is now vented.
Draining The Water System
If the system needs to drained completely, follow the steps
outlined below:
1. At the rear of the unit. Disconnect both the inlets and
discharge water lines.
2. Remove the drain plugs located at the bottom of the
aftercooler and lubricant cooler.
3. Allow the system to drain completely.
Water Quality Recommendations
Water quality considerations are crucial to the effective
operation of a water-cooled compressor and yet are the
most often ignored. Premature failure of components can
often be traced to a reduction in heat-transfer rate that has
resulted from a reduced flow rate due to scale build-up in
water-cooling lines or the coolers themselves.
Scale
surface of lakes. A higher pH value will also assist in the
formation of lime scale. In all cases calcium will form scale
when water that has dissolved calcium is heated. It then
forms lime-scale on surfaces such as the inside of pipes
and the tubing that comprises water coolers. Scale
formation on the inside of pipes and inside of heat
exchangers acts as a thermal insulator. This causes
coolers to be less effective, and piping to have reduced
water flow, making them less effective. Over time lime
scale build-up can reduce water flow by 80% or greater.
This renders the cooling system ineffective and will
damage the system. Scale can be controlled with water
treatment.
Corrosion
As contrasted to lime scale build-up, corrosion eventually
causes a reduction in the wall thickness of pipes. High
levels of dissolved oxygen and low pH levels assist in the
creation of corrosive scale. A thin coating of lime scale is
often beneficial in helping to prevent corrosion from
forming.
Biological And Organic Fouling (Slime)
The heightened temperatures of compressor cooling
operations help to reduce the likelihood that organic
fouling will become a major concern. In the event of an
infestation, commercial chemical shock treatments are
available to control any outbreaks.
To ensure maximum life expectancy and best
performance of the compressor cooling system, refer to
Table 4-3 Water Tests on page 54.
Scale is formed from calcium carbonate, which
precipitates out of water. Calcium content tends to be
higher in water taken from wells than water taken from the
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3000-4500 Operator’s Manual and Parts List
53
SECTION 4
TABLE 4-3 WATER TESTS
Substances
Test Interval
Acceptable Concentration
Corrosivity Hardness, pH, Total Dissolved Monthly - if stable for 3 to 4 months, analyze
Solids, Temperature at inlet, Alkalinity
quarterly.
Langelier Index 0 to 1
Iron
Monthly
< 2 ppm
Sulphate
Monthly
< 50 ppm
Chloride
Monthly
< 50 ppm
Nitrate
Monthly
< 2 ppm
Silica
Monthly
< 100 ppm
Daily - if stable, analyze weekly
0 ppm (as low as possible)
Oil & Grease
Monthly
< 5 ppm
Ammonia
Monthly
< 1 ppm
Desolated Oxygen
Seawater-Cooled Units
NOTE
If seawater is to be used for cooling,
optional copper-nickel coolers must
be selected.
Water cleanliness is critical for operation of the
compressor. A strainer must be installed in the inlet piping
of the water system. It is also recommended that a
solenoid valve (normally closed) be installed into the water
outlet side of the compressor system. Consult the Sullair
Service Department for assistance in setting up these
recommended precautionary functions. In addition, be
aware that cleaning of coolers as a result of fouling is a
customer responsibility.
Isolation valves with side drains should be installed on
both the inlet and outlet lines.
The recommended flow rate cannot be exceeded. An
orifice plate must be installed in the pipe-work at least
3.3 ft (1 m) before the cooler. The orifice size must be
calculated to ensure that the maximum seawater flow rate
cannot be exceeded. Without these precautions, the
seawater flow rate through the cooler may be several times
the recommended maximum, which will lead to rapid
system failure.
54
Seawater pressure
psi (Bar)
Orifice diameter in inch
(mm) to give a maximum
seawater flow or 40 US gal/
min (152 l/min )
25 (1.7)
0.675 (17)
35 (2.4)
0.62 (16)
45 (3.1)
0.58 (15)
55 (3.8)
0.55 (14)
65 (4.5)
0.53 (13.5)
75 (5.2)
0.51 (13)
No oil cooler manufacturer can guarantee that its products
will have an indefinite life and for this reason, we suggest
that the cooling system be designed to minimize any
damage caused by oil cooler leaking. This can be
achieved as follows:
1. The oil pressure should be maintained at a pressure
higher than the seawater pressure. In the event of a
leak occurring, the oil will be prevented from becoming
contaminated.
2. When the hydraulic system is not in use, the coolers
should be isolated from incoming seawater under
pressure.
3. The seawater outlet pipe from the cooler should have
an open run to waste piping.
Outdoor Installation (Sheltered)
Many times a compressor must be installed outside due
to available space or other jobsite conditions. When this is
necessary, there are certain items that should be
incorporated into the system to help ensure trouble-free
operation. The unit must be purchased with a TEFC motor.
The standard machine has NEMA4 rated controls, which
are watertight.
NOTE
Variable speed drive compressors are
NEMA 12 rated and must not be
installed outside or exposed to the
elements.
The compressor should be on a concrete pad, which is
designed to drain water away from it. If the concrete pad
is sloped, then the compressor must be mounted so that
it is level. The base or skid must be fully supported where
it contacts the concrete pad.
A weatherhood option should be selected to prevent direct
rain and snow from falling on the unit. If local weather
conditions can be extreme such that direct rain or snow
may fall on the unit, it should be in a fully enclosed room
or building.
3000-4500 Operator’s Manual and Parts List
®
SULLAIR
®
INSTALLATION
If installed under a shelter, air-cooled machines must be
positioned in a way that prevents air recirculation (i.e., hot
exhaust being allowed back to the system air inlet).
In installations that include more than one compressor, hot
air exhaust should not be directed toward the fresh air
intake of the second unit or an air dryer.
A standard machine installed outside must not be started
or run if the ambient temperature in and around the
compressor drops or may drop below 35˚F (1.7˚C).
A built-in aftercooler reduces the discharge air
temperature below the dew point. For most ambient
conditions, considerable water vapor is condensed. To
remove the condensation, each compressor with built-in
aftercooler is supplied with a combination condensate
separator/trap. A drain line should be installed on the
condensate drain.
NOTE
For low-volume systems that do not
require an auxiliary receiver,
compressor response time may need
to be adjusted. Consult the Sullair
Service Department for assistance.
For installation in a below freezing climate, a low ambient
option with heat tracing and a receiver tank heater must
be installed.
4.3 SERVICE AIR PIPING
Review carefully the total air system before installing a new
compressor. Items to consider for the total air system
include liquid carryover, pipe sizing, and the use of an
auxiliary receiver. The installation of a drip leg or multiple
drip legs, installation of a line filter(s) and the installation
of isolation valve or valves. These considerations are
important to ensure a safe and effective system.
NOTE
Fluid Containment
Compressors are equipped with a fluid containment pan
to catch any fluid in the event of a leak or spill. The drain
for the pan is located on the air intake end of the machine.
For indoor installations, the drain should be plugged to
contain fluids. For outdoor applications, the drain must be
connected to a separate, customer supplied system to
allow rainwater or any accumulated compressor fluid to
drain out.
Discharged air contains a very small
amount of compressor lubricating oil,
and care should be taken to ensure
that this oil would not interfere with
downstream equipment. Downstream
filters and an air dryer can remove any
carryover.
Pipe Sizing
Pipe should be sized at least as large as the discharge
connection of the compressor. Piping and fittings should
all be suitably rated for the discharge pressure.
Use of Auxiliary Receiver Tank
An auxiliary receiver tank should be used in cases where
large demand swings are expected.
Isolation Valve(s)
If isolation of the compressor from the service lines is
required, isolation valves should be installed close to the
discharge of the compressor. They should be installed
with drip legs that drain sloping downward from the base
in order to drain properly. Install a vent to the piping
downstream of the compressor outlet connection.
When two compressors are operated in parallel, provide
an isolation valve and a drain trap for each compressor
before the common receiver.
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
CAUTION
The use of plastic bowls on line filters
and other plastic airline components
without metal guards can be
hazardous. Synthetic coolants or the
additives used in mineral oils can alter
their structural integrity and create
hazardous conditions. Metal bowls
should be used on any pressurized
system for safety concerns.
"The Plastic Pipe Institute
recommends against the use of
thermoplastic pipe to transport
compressed air or other compressed
gases in exposed above ground
locations, e.g. in exposed plant
piping." (I)
Sullube should not be used with PVC
piping systems. It may affect the bond
at cemented joints. Certain other
plastic materials may also be affected.
(I) Plastic Pipe Institute,
Recommendation B, Adopted
January 19, 1972.
55
SECTION 4
4.4 COUPLING ALIGNMENT CHECK
No coupling alignment is required.
Lethal shock hazard inside.
Disconnect all power at source before
opening or servicing.
4.5 FLUID LEVEL CHECK
The air compressor is shipped with the proper amount of
fluid installed. However, it is necessary to check the fluid
level at the time of installation and during continued
operation of the compressor. The fluid level is to be
checked when the compressor is in the SHUT DOWN
MODE (fluid level may not be visible when operating), and
by looking at the sight glass on the receiver tank. To be
able to see the fluid level it may be necessary to start the
machine and build the receiver tank pressure up to 10/20
psi and then shut down. If no fluid level is seen in the sight
glass add fluid to the center of the glass. Do not overfill in
any case. When a complete fluid change is performed, fill
the receiver tank to the maximum allowable fluid level,
which is center of the sight glass.
4.6 ELECTRICAL PREPARATION
Interior electrical wiring is performed 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 code
concerning isolation switches, fused disconnects, etc.
Sullair provides a wiring diagram for use by the installer.
An electrical check should be made to help assure that the
first start-up will be trouble-free. The compressor and drive
should be properly grounded/earthed in accordance with
Local and National Code requirements.
Installation of this compressor must be in accordance with
recognized electrical codes and any local Health and
Safety Codes.
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 feed point is critical as
voltage drops may impair the performance of the
compressor. Cable sizes may vary considerably so the
mains terminals will accept up to 50 mm2 (1 awg) (37/4 Sk
& 50/60 H) and up to 90 mm2 (3/0 awg) (55/75 k & 75/100
H) cable.
Feeder cable connections to incoming terminals L1‐L2‐L3
should be tight and clean.
The applied voltage must be compatible with the motor
and compressor data plate ratings.
A starter hole is provided for incoming power connection.
If it is necessary to make a hole in the control box in a
different location, care should be taken to not allow metal
shavings to enter the starter and other electrical
components within the box. If another hole is used, the
original hole must be blocked off:
56
DANGER
1. Check incoming voltage. Be sure that the incoming
voltage is the same voltage that the compressor was
wired for.
2. Check motor starter and overload heater sizes.
3. Check all electrical connections for tightness.
4. "DRY RUN" the electrical controls by disconnecting
the three (3) motor leads from the starter. Energize the
control circuits by pushing the " " (START) pad and
check all protective devices to be sure that they will
de-energize the starter coil when tripped.
5. Reconnect the three (3) motor leads and jog the motor
for a direction of rotation check, as explained in Motor
Rotation Direction Check on page 56.
4.7 MOTOR ROTATION DIRECTION
CHECK
Motor rotation check must be made at compressor startup. The compressor can be damaged if it runs in the wrong
direction for more than a few seconds. Motor rotation can
be viewed through the opening in the drive adapter
housing. After the electrical wiring has been done, it is
necessary to check the direction of the motor rotation. Pull
out the EMERGENCY STOP button and press once,
quickly and in succession, the " " (START) and
" " (STOP) pads. This action will bump start the motor
for a very short time. When looking at the motor from the
end opposite the compressor unit, the shaft should be
turning clockwise. If the reversed rotation is noted,
disconnect the power to the starter and exchange any two
of the three power input leads, then re-check rotation. A
"Direction of Rotation" decal is located on the motor drive
housing to show proper motor/compressor rotation. An
alternative to this procedure is to set the WS Controller to
display P1 receiver tank pressure. Pull out the
EMERGENCY STOP button and press once, quickly and
in succession, the " " (START) and " " (STOP) pads.
This action will bump start the motor for a very short time.
If motor rotation is correct there will be immediate pressure
shown. If no pressure is present, reverse rotation is
occurring. Disconnect the power to the starter and
exchange any two of the three power input leads. Recheck
rotation as outlined above.
Fan motor rotation should also be checked. It should rotate
counter-clockwise when viewing the fan motor from the
backside of the motor.
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Section 5
WS CONTROLLER
5.1 CONTROLLER LAYOUT
3
1
®
2
10
8
7
9
4
6
5
SU_0000021
1.
2.
3.
4.
5.
ON
OFF
LCD Display
Power Indicator
Run Mode Indicator
6.
7.
8.
9.
10.
Maintenance Indicator
Fault Indicator
Up Key
Down Key
Enter Key
Figure 5-1: WS Controller
5.2 CONTROLLER KEYPAD
•
The WS Controller keypad has two main pads for
compressor control.
• To start the compressor operation, press the green
Start pad " ".
To stop compressor operation, press the red Stop pad
" ".
•
The Run mode indicator " " lights up whenever the
control is in an operating mode.
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SECTION 5
5.3 LCD DISPLAY
The display's normal view shows the compressor
package's discharge pressure, internal temperature, and
the operating mode. The modes are MANUAL, OFF,
AUTOMATIC, or FAULTED.
Refer to Figure 5-6. Press the Down arrow " " to display
additional information about the compressor. The upper
line will indicate "Compressor Status" and the name of the
temperature, pressure, or other measurement. The lower
line indicates the present reading.
SA_0000003R01
SA_0000005R01
Figure 5-6:
Figure 5-2:
Refer to Figure 5-7. When you continue beyond the status
information, the display will show a list of control settings.
The upper line will indicate "Show Setting" and the name
of the setting. The lower line shows the present value.
Refer to Figure 5-2 and Figure 5-3. The lower line is
occasionally interrupted to describe the compressor
package's operating state.
SA_0000006R01
SA_0000004R01
Figure 5-3:
Figure 5-7:
Refer to Figure 5-4. If a machine fault occurs, the red fault
" " indicator will light up, and the display will indicate that
a fault has occurred.
Refer to Figure 5-8. To change the setting, press the Enter
pad " ". The display indicates that you are in a change
mode with reverse characters. Use the Up " " or Down
" " arrow keys to change the setting, and press Enter
again to save the new setting.
SA_0000001R01
Figure 5-4:
SA_0000007R01
Refer to Figure 5-5. The lower line periodically will display
the cause of the fault. Refer to service instructions to
correct the cause. Press the Stop pad " " to reset the
controller.
Figure 5-8:
Refer to Figure 5-8. If there is no keypad activity, the
display will return to normal view in about one minute. If
the Start or Stop buttons are pressed, the display also
returns to normal view. If either of these occur, the setting
will not be altered.
If there are any warnings or recommended service
instructions, these will be periodically displayed on the
normal view.
SA_0000002R01
Figure 5-5:
58
The list of displays may be navigated from either direction
by using the Up " " or Down " " arrow keys. For
example, to change language from normal view, press the
Up arrow pad once, press the Enter key " ", select your
language, and press Enter again. The number of displays
varies with compressor model, but will follow this pattern.
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WS CONTROLLER
The large Emergency Stop button located near the
controller overrides all electronic functions to turn off the
control devices. The controller senses this, and will display
E-stop. To reset, twist and pull out the Emergency Stop
button, then press the Stop pad to reset the WS Controller.
5.4 LED LIGHTS
The four LED lights indicate the general condition of the
machine.
The green Power indicator " " simply indicates that
power is applied to the controller. It will blink very slowly if
the WS Controller is set up to automatically restart after
power failure.
The green Run mode indicator " " indicates compressor
operation is enabled. It lights steadily if the motor is
running. If the motor stops while in Automatic mode, this
LED will blink to indicate that the motor may restart.
The yellow Maintenance indicator " " comes on
whenever there is recommended maintenance or a
warning. The text display will periodically indicate the
recommended actions or the cause of the warning.
The red Fault indicator "
" indicates that a compressor
fault has occurred and needs to be repaired before further
operation. The text display will indicate the cause of the
fault.
The PC support program for the WS controller provides
additional information about compressor operation and
advanced setup adjustments to optimize operation.
Software part numbers are shown in the display following
a power interruption or other interruption of
communication with the controller. The P/N remains on the
display until satisfactory communications are established
with the Input/Output module.
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SECTION 5
THIS PAGE INTENTIONALLY LEFT BLANK
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Section 6
MAINTENANCE
6.1 GENERAL
As you proceed in reading this section, it will be easy to
see that the Maintenance Program for the air compressor
is quite simple. The use of the service indicators provided
for the fluid filter, air filter and fluid separator will alert you
when service maintenance is required. When the WS
Controller display indicates service, maintenance for that
specific item is required. See instructions for each item in
Filter Maintenance, on page 62.
6.2 DAILY OPERATION
Prior to starting the compressor, it is necessary to check
the fluid level in the receiver tank . Should the level be low,
simply add the necessary amount. If the addition of fluid
becomes too frequent, a simple problem has developed
which is causing this excessive loss. See the
Troubleshooting Guide Section under EXCESSIVE
COMPRESSOR FLUID CONSUMPTION for a probable
cause and remedy.
After a routine start has been made, observe the controller
display and be sure it monitors the correct readings for
their particular phase of operation. After the compressor
has warmed up, it is recommended that a general check
on the overall compressor be made to assure that the
compressor is running properly.
6.3 MAINTENANCE AFTER INITIAL
50 HOURS OF OPERATION
After the initial 50 hours of operation, a few maintenance
requirements are needed to clean the system of any
foreign materials. Perform the following maintenance
operations to prevent unnecessary problems:
1. Clean the return line strainer. Refer to Maintenance
Every 2000 Hours on page 62 for location.
2. Clean the return line orifice.
WARNING
HIGH-PRESSURE HAZARD!
• DO NOT remove caps, plugs, and/or
other components when
compressor is running or
pressurized. Stop compressor and
relieve all internal pressure before
doing so.
• Failure to comply could result in
death or serious injury.
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61
SECTION 6
1. Using a wrench, remove the filter canister.
2. Remove and dispose of filter element. Observe all
laws and regulations for filter disposal.
6.4 MAINTENANCE EVERY 2000
HOURS
After 2000 hours of operation, it will be necessary to
perform the following:
1. Clean the return line strainer. Refer to Discharge,
Receiver and Piping System, 3000P, 3700 and 4500
on page 96.
2. Replace the fluid filter element.
3.
4.
5.
6.
Clean gasket seating surface.
Apply a light film of fluid to the element seal.
Install the element into the filter canister.
Screw the canister to the filter head. Tighten to 10 to
12 ft•lb (13.5 to 16.0 N·m).
7. Restart compressor and check for leaks.
6.7 AIR FILTER MAINTENANCE
1
3
2
2
1
SA_0000018
1. Housing
2. Element*
3. Cover
3
SA_0000017
1. Filter Head
2. Element*
3. Body
Fluid Filter Assembly:
P/N 02250155-708
*Fluid Filter
Replacement Kit:
P/N 02250155-709
Air Filter Assembly:
P/N 02250127-683
* Replacement Air
Filter Element Kit:
P/N 02250127-684
Figure 6-2: Air Filter Assembly
Refer to Figure 6-2. Air filter maintenance should be
performed when the maintenance gauge shows red with
the compressor running full load, or once a year,
whichever comes first. If the filter needs to be replaced,
order a replacement element. Below you will find
procedures on how to replace the air filter element.
Figure 6-1: Fluid Filter Assembly
6.5 FLUID MAINTENANCE
Drain the receiver tank and change the compressor fluid
using instructions shown in
Lubrication Guide on page 20.
6.6 FILTER MAINTENANCE
Refer to Figure 6-1. Replace your fluid filter element under
any of the following conditions, whichever occurs first:
1. As indicated by the WS Controller.
2. Every fluid change.
Fluid Filter Element Replacement
Refer to Figure 6-1.
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MAINTENANCE
Air Filter Element Replacement
1. Clean exterior of air filter housing.
2. Rotate end cover counterclockwise and remove
3. Remove air filter element by pulling it out of the
housing.
4. Clean interior of housing using a damp cloth. DO
NOT blow dirt out with compressed air.
5. At this time replace the element.
6. Reassemble in the reverse order of the disassembly.
6.8 SEPARATOR MAINTENANCE
Replace the separator element when indicated by the WS
Controller or after one (1) year, whichever comes first. The
separator element must be replaced. DO NOT attempt to
clean the separator element.
Separator Element Replacement
Refer to Figure 6-3. The separator element must be
changed when indicated by the WS Controller, or once a
year, whichever occurs first. Follow the procedure
explained below for separator element replacement:
NOTE
Relieve all pressure from the receiver
tank and all compressor lines.
1. Loosen and remove the eight (8) hex head capscrews
(M12 x 40mm) from the cover plate.
2. Lift the cover plate from the receiver tank.
3. Remove the separator element.
4. Inspect the receiver tank for rust, dirt, etc.
5. Reinsert the separator element into the receiver tank
taking care not to dent the element against the tank
opening.
6. Install a new lubricated O-ring in the O-ring groove on
the underside of the receiver tank cover.
7. Replace the cover plate, washers and capscrews.
Torque to 89 ft·lbs. (121 N·m).
8. Clean the return line strainer before restarting the
compressor.
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3000-4500 Operator’s Manual and Parts List
63
SECTION 6
Oil Return/Sight Glass Maintenance
1
2
3
Refer to Figure 6-4. The oil return/sight glass subassembly
is attached to the side of the separator tank. Oil return/sight
glass maintenance should be performed on a routine basis
parallel to that of the fluid filter, or as indicated in the
troubleshooting section of this manual. The maintenance
on an oil return/sight glass is mainly concerned with the
condition of the filter assembly. Order filter assembly No.
02250117-782, and use the following instructions as a
guide:
4
5
1
2
3
4
6
5
SA_0000019
1.
2.
3.
4.
5.
6.
6
Cover
Ground Spring*
Spring Fastener*
Cover Gasket*
Element*
Receiver Tank
7
Separator Element:
P/N 02250160-774
*Separator Element
Replacement Kit:
P/N 02250160-776
Figure 6-3: Separator Element Assembly
8
SU_0000032
1.
2.
3.
4.
5.
6.
7.
8.
To Receiver Tank
Male Tube Connector
90˚ Pipe Elbow
Filter Assembly*
Sight Glass/Orifice Block
Brass Plug Orifice
Female Tube Connector
To Unit
* Oil Return Filter
Replacment Kit:
P/N 02250117-782
Figure 6-4: Oil Return/Sight Glass
1. Disconnect the tube at bottom of sight glass.
2. Unscrew the sight glass assembly where the elbow
fitting joins the strainer/filter.
3. Remove used filter assembly, and replace with new
assembly.
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MAINTENANCE
4. Inspect and clean the orifice inside the sight glass
blocks. The orifice must be removed with an allen
wrench.
5. Coat/lubricate the O-rings with silicone grease.
6. Reattach the connectors to the sight glass/orifice
blocks.
Pressure Regulator Adjustment
Refer to Figure 6-5. Start the compressor and adjust the
service valve to maintain service air pressure
approximately at 1 psi over rated pressure. Turn the inlet
valve regulator adjusting screw until air just begins to
escape from the control air orifice, located at the bottom
of the regulator. Lock the adjusting screw in place with the
locknut. The regulator is now properly set.
from the strainer and remove the strainer screen. Clean
the screen and reinstall. If the screen is damaged, the
strainer assembly must be replaced (P/N 241772).
Shaft Coupling Maintenance
The compressor unit and motor are rigidly connected via
a mounting adapter housing. This arrangement makes
coupling alignment unnecessary. The coupling is a jaw
type in shear. If the elastomeric element requires
replacement due to wear or breakage, order replacement
element no. 02250152-670, and follow the following steps:
1. Remove the protective grill from the adapter housing.
2. Loosen the retaining screw located on the outer
sleeve. Slide the sleeve to one side, exposing the
coupling element.
3. Unwrap the coupling element from the coupling 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 the protective grill.
Secure the outer sleeve by tightening the two screws
to 45 in·lbs (5 N·m).
6.9 TROUBLESHOOTING INTRODUCTION
2
1
SU_0000033
1. Locking Nut
2. Adjustment Screw
Figure 6-5: Regulator Adjustment
Water Condensate Drain Maintenance
If your compressor is fitted with the standard solenoid
condensate drain valve, it is necessary to periodically
clean the strainer. Remove the hex cap from the strainer
and remove the strainer screen. Clean the screen and
reinstall. If the screen is damaged, the strainer assembly
must be replaced (P/N 241772).
The 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
analyzed before undertaking any repairs or component
replacement procedures.
A detailed visual inspection is worth performing for almost
all problems and may avoid unnecessary additional
damage to the compressor. Always remember to:
1. Check for loose wiring.
2. Check for damaged piping.
3. Check for parts damaged by heat or an electrical short
circuit, usually apparent by discoloration or a burnt
odor.
Should your problem persist after making the
recommended check, consult your nearest Sullair
representative.
Control Line Strainer
The regulator and solenoid valve(s), which control the
compressor, are protected by a strainer. Every 12 months
it is necessary to clean the strainer. Remove the hex cap
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65
SECTION 6
6.10 TROUBLESHOOTING GUIDE
SYMPTOM
PROBABLE CAUSE
REMEDY
Compressor Will Not Start
Main Disconnect Switch Open
Close switch.
Line Fuse Blown
Replace fuse.
Motor Starter Overload Tripped
Reset. Should trouble persist, check
whether motor starter contacts are
functioning properly.
Low Incoming Line Voltage
Check voltage. Should voltage check low,
consult power company.
Compressor Shuts Down With Air Demand Loss of Control Voltage
Present
Check power supply for 24V DC output.
Replace power supply if necessary.
Low Incoming Voltage
Consult power company.
Excessive Operating Pressure
Reset. If trouble persists, check that line
pressure does not exceed maximum
operating pressure of the compressor
(specified on nameplate).
Separator Requires Maintenance Indicated Replace separator.
by WS Controller
Machine Programmed for Wrong Pressure Reprogram with WSPC equipped laptop.
Setting
66
Defective Regulator Valve
Regulator valve should cause inlet valve to
close when the pressure switch contacts
open. Repair if defective.
Defective Blowdown Valve
Blowdown valve should exhaust receiver
tank pressure to 18 psig (1.2 bar) when
maximum operating pressure is reached.
Repair if defective.
Cooling Water Temperature Too High
Reduce water temperature to 85°F
(29.4°C) or less. Water-cooled only.
Cooling Water Flow Insufficient
Check water lines and valves
(water-cooled only).
Cooler Plugged
Clean tubes. If plugging persists, install
water conditioner (water-cooled only).
Cooling Air Flow Restricted
Clean cooler and check for proper
ventilation.
Ambient Temperature Is Too High
Provide sufficient ventilation.
Low Fluid Level
Add fluid.
Clogged Filter
Change the fluid filter element.
Thermal Valve Not Functioning Properly
Replace element.
Water Flow Regulating Valve Not
Functioning Properly
Change (water-cooled only).
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MAINTENANCE
6.10 TROUBLESHOOTING GUIDE (CONTINUED)
SYMPTOM
PROBABLE CAUSE
REMEDY
Compressor Will Not Build Full Discharge
Pressure
Air Demand is Too Great
Check service lines for leaks or open valves.
Dirty Air Filter
Check the filter indicator and inspect and/or
change element if required.
Inlet Valve Bleed Orifice Plugged
Ensure control line bleed orifice located
inside inlet valve is not plugged.
Pressure Regulator Out of Adjustment
Adjust regulator according to control
adjustment instructions in the Maintenance
section.
Defective Pressure Regulator
Replace regulator.
Defective Unload Solenoid Valve
Check that the valve closes when
energized. Replace the coil or the complete
valve if defective.
Leak in Control System Causing Loss of
Pressure Signals
Check for leaks.
Inlet Valve Stuck Open
Remove the intake hose and check for inlet
valve operation.
Defective Unload Solenoid Valve
Check that the valve is open when deenergized. Replace if necessary.
Plugged Control Line Strainer
Clean strainer (screen and O-ring
replacement kit available).
Defective Blowdown Valve
Check that receiver tank pressure is
exhausted to the atmosphere when the
solenoid valve opens. Repair or replace if
necessary (kit available).
Line Pressure Rises Above Unload
Pressure Set-Point
Excessive Compressor Fluid Consumption Clogged Return Line or Orifice
Clean strainer (screen and O-ring
replacement kit available).
Clean orifice.
Pressure Relief Valve Opens Repeatedly
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Separator Element Damaged or Not
Functioning Properly
Change separator.
Leak in the Lubrication System
Check all pipes, connections and
components.
Excess Fluid Foaming
Drain and change.
Fluid Level Too High
Drain and change. Check that the
compressor temperature has not dropped
below 170°F (76.7°C).
Defective Pressure Relief Valve
Replace.
Plugged Separator
Check separator differential.
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67
SECTION 6
6.10 TROUBLESHOOTING GUIDE (CONTINUED)
SYMPTOM
PROBABLE CAUSE
REMEDY
Liquid Water In Compressed Air Lines
Plugged Strainer in Moisture Drain Line
Clean and service strainer located in the line
off the bottom of the water separator.
Water Vapor Condensation from Cooling
and Compression Occurs Naturally
Remove the water vapor from compressed
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 cartridges as
recommended by the filter manufacturer).
Check all drain traps routinely to insure their
proper operation. Maintain them regularly.
Defective Drain Solenoid Valve
Ensure valve opens and closes as signaled
by the WS Controller.
Inadequate Drain Timer Settings
Check WS Controller control drain interval
and drain time, and adjust accordingly. High
humidity conditions require longer drain
times or more frequent openings.
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Section 7
VSD CONTROL
OPERATION
7.1 DESCRIPTION OF COMPONENTS
The variable speed drive unit is located in the machine
electrical enclosure. The heat sink for the drive extends
through the back of the enclosure, and is cooled by airflow
through the compressor enclosure.
7.2 CONTROL SYSTEM,
FUNCTIONAL DESCRIPTION
Refer to Figure 2-5. The purpose of the compressor control
system is to regulate the amount of the air being
compressed to match the amount of compressed air being
used. The Capacity Control System consist of variable
speed drive, solenoid valve, regulating valve, and the inlet
valve. The functional description of the control system is
described below in six distinct phases of operation. The
following description text applies to 3000V, 3000PV,
3700V and 4500V series variable speed drive
compressors with WS Controller. Depending on the
model, the compressor can be operated at a setpoint
pressure from 60 to 175 psig (4.1 to 12.1 bar). Refer to the
nameplate for operating pressure range. The WS
Controller will automatically set the frequency range based
on the selected pressure. For explanatory purposes, this
description will apply to a compressor with an operating
pressure of 100 psig (6.9 bar), and load delta setting of 6
psi (0.4 bar). The load delta has a default setting of 10 psi
(0.7 bar), but is recommended to set at 6 psi (0.4 bar) for
most efficient operation. A compressor with any other
pressure range would operate in the same manner except
stated pressures.
Start Mode- 0 to 50 PSIG (0 to 3.5 Bar)
When the WS Controller " " (START) button is
depressed, the VSD ramps the motor to full speed and the
receiver tank pressure will quickly rise from 0 to 50 psig
( 0-3.4 bar). During this period, both the regulator and
solenoid valves are closed, the inlet valve is fully open and
the air-end delivers full capacity to the receiver tank. The
rising compressor air pressure is isolated from the service
line in this phase by the minimum pressure valve set at
approximately 50 psig (3.4 bar).
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Full Load Mode- 50 to 100
PSIG (3.4 to 6.9 Bar)
When the compressed air pressure rises over 50 psig
(3.4 bar) the minimum pressure valve opens allowing
compressed air to flow into the service line. From this point
on the line pressure is continually monitored by the WS
Controller, which controls the variable speed drive. The
pressure regulator and solenoid valve remain closed with
the inlet valve fully open running at 100 psig (6.9 bar) or
below.
Variable Speed Drive Part Load Control
If less than rated capacity of compressed air is being used,
the service line pressure will rise above 100 psig
(6.9 bar). Consequently, the Variable Speed Drive will
begin to decelerate the motor, thereby reducing the output
capacity to match demand. The drive will continuously
adjust the motor speed (accelerate or decelerate) to
maintain a line pressure of 100 psig (6.9 bar). In this mode
the VSD will operate within the appropriate frequency
range determined by the WS Controller.
Modulating Mode- 100 to 106
PSIG (7.3 to 6.9 Bar)
During low demand periods and with the Variable Speed
Drive at minimum speed, the line pressure can continue to
rise. When the line pressure reaches 101-102 psig
(approximately 7 bar), the regulator valve (Figure 7-7)
gradually opens, directing air pressure to the inlet control
valve piston. This action causes the inlet valve to partially
close, thereby reducing the air entering the compressor
until it matches the amount of air being used. The control
system functions continually in this manner between the
limits of > 101 psig (7.0 bar) to 106 psig (7.3 bar), in
response to varying flow demand. The pressure regulator
has an orifice which vents a small amount of air to the
atmosphere when the pressure regulator controls the inlet
valve. The orifice also bleeds any accumulated moisture
from the control line. When the discharge pressure rises
above 106 psig (7.3 bar), or alternatively set unload
pressure the compressor unloads.
3000-4500 Operator’s Manual and Parts List
69
SECTION 7
NOTE
With a Sullair compressor, there is no
maintenance or inspection of the
internal parts of the compressor unit
permitted in accordance with the
terms of the warranty.
Unload Mode- In Excess of 106
PSIG (7.3 Bar)
When a relatively small amount or no air is being used, the
service line pressure continues to rise. When it exceeds
106 psig (7.3 bar), or alternatively set unload pressure, the
WS control system de-energizes the solenoid valve
allowing receiver tank air pressure to be supplied directly
to close the inlet valve. Simultaneously, the solenoid valve
sends a pneumatic signal to the blow down valve. The
blowdown valve opens to the atmosphere, reducing the
receiver tank pressure. The check valve in the air service
line prevents line pressure from returning to the receiver
tank . The compressor will shut down after the unload time
setting expires if programmed (the default setting is zero
[0] seconds for an immediate shutdown upon unload).
When the line pressure drops to the low setting pressure
of 100 psig (6.9 bar) The WS Controller starts the motor
and energizes the solenoid valve which closes the blow
down valve. The re-energized solenoid valve prevents line
pressure from reaching the inlet control valve, thereby
allowing it to fully open, and the compressor again delivers
compressed air to the system.
70
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®
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®
Section 8
PARTS LISTS
8.1 PROCEDURE FOR ORDERING PARTS
When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the Bill of Lading
for the compressor or from the Serial Number Plate located on the compressor. Refer to Figure 8-1.
SU_0000446
Figure 8-1: Serial Plate, Serial Number Location
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71
SECTION 8
Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was
purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the addresses, phone
and fax numbers listed below.
72
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PARTS LISTS
8.2 RECOMMENDED SPARE PARTS LIST
Key
Description
Part Number
Note
Quantity
ELEMENTS
1
element, compressor fluid filter 02250155-708
02250155-709
1
2
element, heavy duty air filter (3000P, 3700, 4500) 02250127-683
02250127-684
1
3
element, heavy duty air filter (3000) 02250125-369
02250125-372
1
4
element, replacement for separator 02250160-774
02250160-776
1
5
kit, repair for minimum pressure / check valve 02250097-598
02250110-727
1
6
kit, cap for minimum pressure check valve 02250097-598
02250046-396
1
7
kit, O-ring for minimum pressure check valve 02250097-598
02250048-363
1
8
kit, piston for minimum pressure check valve 02250097-598
02250051-337
1
9
kit, repair for thermal valve (Sullube) 02250092-081
02250144–327
1
10
kit, repair for thermal valve (24KT or 175 psig) 02250148-796
02250148–827
1
11
kit, repair for pressure regulator 250017-280
250019-453
1
12
kit, repair for blowdown valve 02250100-042
02250100-042
1
13
kit, repair for control solenoid valve 02250155-714
02250157-500
1
14
kit, coil replacement for control solenoid valve coil 02250155-714
02250157-502
1
15
kit, repair for condensate drain solenoid valve coil 02250155-715
02250157-501
1
16
kit, coil replacement for condensate drain solenoid valve coil
02250155-715
02250157-502
1
17
kit, repair inlet valve (integrated with compressor unit)
02250155-971
1
18
kit, rebuild inlet valve
02250155-970
1
19
kit, repair for v-type strainer 241771
241772
1
20
kit, repair for shaft seal (12 series)
02250050-363
1
21
kit, repair for shaft seal (10 series)
02250155-594
1
22
kit, tool for shaft seal installation (12 series)
602542-001
1
23
kit, repair for shaft seal installation (10 series)
001932–005
1
24
filter, scavenge line 02250117-782
02250117-782
2
25
kit, seal replacement for separator trap 02250144-635
02250144-735
1
26
fluid, SRF 1/4000 (5 gal/19 liter)
250019-662
(I)
27
lubricant, Sullube (Std.) (5 gal/19 liter)
250022-669
(I)
28
lubricant, 24 KT (5 gal/19 liter)
02250051-153
(I)
29
lubricant, Food Grade (5 gal/19 liter)
250029-008
(I)
KITS
LUBRICATION
(I)
For proper amount of fluid fill, please consult Lubrication Guide in Section 3, Specifications.
CAUTION
Mixing of other lubricants within the
compressor unit will void all
warranties.
®
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®
3000-4500 Operator’s Manual and Parts List
73
SECTION 8
8.3 COMPRESSOR, FRAME AND DRIVE, 3000P AND 3700 MODELS
02250152_458r01
74
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PARTS LISTS
8.3 COMPRESSOR, FRAME AND DRIVE, 3000P AND 3700 MODELS
(CONTINUED)
Key
Description
Part Number
Note
Quantity
1
frame, 37kw
02250151-176
1
2
isolator, vibration air end 50hp
02250151-500
2
3
adapter, compr/motor 50hp ma
02250151-630
1
4
grille, coupling guard 50hp
02250152-346
2
5
hub, coupling 1.75 bore falk 20r
02250152-624
1
hub, coupling 1.50 bore (3000)
02250152-662
6
hub, coupling 1.875 bore falk 20r
02250152-625
1
7
element, cplg falk 20r
02250152-670
1
8
cover, cplg element falk 20r
02250152-678
1
9
isolator, vibration motor 37kw
02250155-285
2
10
plate, motor seal 3000/3700/4500
02250156-393
2
11
nut, hex metric m12 x 1.75
825912-175
2
12
capscrew, hex 8.8 m12 x 40mm
828012-040
8
13
capscrew, hex 8.8 m12 x 50mm
828012-050
2
14
capscrew, hex gr5 5/8-11 x 1 3/4
829110-175
4
15
washer, spr lock reg pltd 5/8
837810-156
4
16
washer, spr lock-metric pltd m12
838812-250
8
17
washer, iso 7093-8-140hv
865708-240
8
18
elbow, pipe 90 deg plt 1/2"
866215-020
1
19
nipple, pipe-xs plt 1/2 x cl
866408-000
1
20
screw, hex serr washer m8 x 25
882608-025
8
21
washer, nord-lock pl m12 sp
883212-254
4
22
compressor
–
(I) (II)
1
23
motor
–
(I)
1
A1
From Air Inlet Filter
A2
Oil Return From Sightglass on Receiver Tank
A3
To Receiver Tank
A4
From Blowdown Valve
A5
Main Oil Connection
(I)
This part may vary per machine design. Consult factory with machine serial number to determine the proper part number.
(II)
Sullair offers an exchange program whereby a remanufactured compressor unit can be obtained from Sullair distributors
or the factory at a lower cost than it would cost for the owner to repair the unit. For information regarding the unit exchange
program, contact your nearest Sullair representative or the Sullair Corporation. The shaft seal is not considered part of the
compressor unit in regard to the two year warranty, but the normal Sullair parts warranty does apply. For shaft seal repairs,
order repair kit no. 02250050-363, and installation kit no. 602542-001.
®
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®
3000-4500 Operator’s Manual and Parts List
75
SECTION 8
8.4 COMPRESSOR, FRAME AND DRIVE, 3000 MODEL WITH 10 SERIES UNIT
A1
A5
A4
A2
A3
02250160-068R01
76
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PARTS LISTS
8.4 COMPRESSOR, FRAME AND DRIVE, 3000 MODEL WITH 10 SERIES UNIT
(CONTINUED)
Key
Description
Part Number
Note
Quantity
1
frame, 37kw
02250151-176
1
2
spacer,air end shaft height 60hp
02250151-499
2
3
hub, coupling 1.50 bore falk 20r
02250152-622
1
4
hub, coupling 1.875 bore falk 20r
02250152-625
1
5
element,cplg falk 20r
02250152-670
1
6
cover,cplg element falk 20r
02250152-678
1
7
isolator, vibration motor 37kw
02250155-285
4
8
plate, motor seal 3000/3700/4500
02250156-393
2
9
adapter, compressor 3700x w/10series
02250160-067
1
10
plate, motor/compr adapt cover 03
225980
1
11
adapter, motor compr 10/40 -
231977
1
12
adapter, sae 5 dxx10 gi ma -
250009-542
1
13
nut,hex pltd 3/8-16
825206-337
8
14
nut,hex metric m12 x 1.75
825912-175
2
15
capscrew,hex 8.8 m12 x 30mm
828012-030
2
16
capscrew,hex 8.8 m12 x 35mm
828012-035
2
17
capscrew,hex 8.8 m12 x 65mm
828012-065
2
18
capscrew,hex gr5 3/8-16 x 1 1/4
829106-125
7
19
capscrew,hex gr5 3/8-16 x 1 3/4
829106-175
8
20
capscrew,hex gr5 5/8-11 x 1 1/2
829110-150
4
21
washer, spr lock reg pltd 3/8
837806-094
15
22
washer, spr lock reg pltd 5/8
837810-156
4
23
elbow, pipe 90 deg plt 1/2"
866215-020
1
24
nipple,pipe-xs plt 1/2 x cl
866408-000
1
25
washer, nord-lock pl m12 sp
883212-254
8
26
compressor
–
(I) (II)
1
27
motor 40hp
–
(I)
1
A1
From Air Inlet Filter
A2
Oil Return From Sightglass on Receiver Tank
A3
To Receiver Tank
A4
From Blowdown Valve
A5
Main Oil Connection
(I)
This part may vary per machine design. Consult factory with machine serial number to determine the proper part number.
(II)
Sullair offers an exchange program whereby a remanufactured compressor unit can be obtained from Sullair distributors
or the factory at a lower cost than it would cost for the owner to repair the unit. For information regarding the unit exchange
program, contact your nearest Sullair representative or the Sullair Corporation.
The shaft seal is not considered part of the compressor unit in regard to the two year warranty, but the normal Sullair parts
warranty does apply. For shaft seal repairs, order repair kit no. 02250155-594, and installation kit no. 001932-005.
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
77
SECTION 8
8.5 COMPRESSOR, FRAME AND DRIVE, 4500 MODEL
02250153_265r01
78
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PARTS LISTS
8.5 COMPRESSOR, FRAME AND DRIVE, 4500 MODEL (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
frame, 37kw
02250151-176
1
2
isolator, vibration air end 50hp
02250151-499
2
3
adapter, compr/motor 50hp ma
02250151-630
1
4
isolator, vibration motor/airend 50/60hp
02250151-941
2
5
grille, coupling guard 50hp
02250152-346
2
6
hub, coupling 1.75 bore falk 20r
02250152-624
1
7
hub, coupling 1.875 bore falk 20r
02250152-625
1
8
element, cplg falk 20r
02250152-670
1
9
cover, cplg element falk 20r
02250152-678
1
10
isolator, vibration motor 37kw
02250155-285
2
11
plate, motor seal 3000/3700/4500
02250156-393
2
12
nut, hex metric m12 x 1.75
825912-175
2
13
capscrew, hex 8.8 m12 x 40mm
828012-040
8
14
capscrew, hex 8.8 m12 x 50mm
828012-050
2
15
capscrew, hex gr5 5/8-11 x 1 3/4
829110-175
8
16
washer, spr lock reg pltd 5/8
837810-156
8
17
washer, spr lock-metric pltd m12
838812-250
8
18
washer, iso 7093-8-140hv
865708-240
8
19
elbow, pipe 90 deg plt 1/2"
866215-020
1
20
nipple, pipe-xs plt 1/2 x cl
866408-000
1
21
screw, hex serr washer m8 x 25
882608-025
8
22
washer, nord-lock pl m12 sp
883212-254
4
23
compressor
–
(I) (II)
1
24
motor
–
(I)
1
A1
From Air Inlet Filter
A2
Oil Return From Sightglass on Receiver Tank
A3
To Receiver Tank
A4
From Blowdown Valve
A5
Main Oil Connection
(I)
This part may vary per machine design. Consult factory with machine serial number to determine the proper part number.
(II)
Sullair offers an exchange program whereby a remanufactured compressor unit can be obtained from Sullair distributors
or the factory at a lower cost than it would cost for the owner to repair the unit. For information regarding the unit exchange
program, contact your nearest Sullair representative or the Sullair Corporation.
The shaft seal is not considered part of the compressor unit in regard to the two year warranty, but the normal Sullair parts
warranty does apply. For shaft seal repairs, order repair kit no. 02250050-363, and installation kit no. 602542-001.
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
79
SECTION 8
8.6 AIR INLET SYSTEM, STANDARD 3000P, 3700 AND 4500 SERIES
02250152-457r01
A1
80
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PARTS LISTS
8.6 AIR INLET SYSTEM, STANDARD 3000P, 3700 AND 4500 SERIES
(CONTINUED)
Key
Description
Part Number
Note
Quantity
1
filter, air 9"
02250127-683
(I)
1
2
hose, rubber el 120deg 4"inl ws37
02250156-927
1
3
clamp, hose 4.25" — 5.12" i.d.
02250164–153
2
4
indicator, restriction 20" h20
250003-869
1
5
nut, serr flng m8x1.25
882508-125
2
6
screw, hex serr washer m8 x 25
882608-025
2
To Air Inlet on Compressor Unit
A1
(I)
For maintenance on air filter No. 02250127-683, order replacement element No. 02250127-684.
®
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®
3000-4500 Operator’s Manual and Parts List
81
SECTION 8
8.7 AIR INLET SYSTEM, 10 SERIES 3000
A1
02250160-069R02
82
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PARTS LISTS
8.7 AIR INLET SYSTEM, 10 SERIES 3000 (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
filter, air 8"(plastic) w/mtg & +
02250125-369
(I)
1
2
hose, rubber el 3-1/2"-3" 3000 w/+
02250160-073
1
3
support, air filter 3000 w/10series
02250160-721
1
4
indicator, restriction 20" h20
250003-869
1
5
clamp, hose 2-13/16 to 3-3/4"
250018-550
1
6
clamp, hose 4.25/3.31
250031-415
1
7
nut,serr flng m8 x 1.25
882508-125
4
8
screw, hex serr washer m8 x 16
882608-016
2
9
screw, hex serr washer m8 x 25
882608-025
2
To Air Inlet on Compressor Unit
A1
(I)
For maintenance on air filter No. 02250125-369, order replacement element No. 02250125-372.
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
83
SECTION 8
8.8 AIR PIPING, AIR-COOLED
A1
A3
A2
02250152_474r02
84
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®
PARTS LISTS
8.8 AIR PIPING, AIR-COOLED (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
tube, mpv/clr/moist sep ls12
02250121-707
1
2
separator, water 1-1/2" fnpt 1/4" drn
02250144-635
(I)
1
3
support, outlet conn 1-1/2npt
02250152-215
1
4
tube, mpv to a/c 1.5" orfs 3700
02250157-836
1
5
tube, a/c to trap 1.5" orfs 3700
02250157-837
1
6
connector, tube-m 1 1/2 x 1 1/2
810224-150
2
7
elbow, tube 90 deg m 1 1/2 x 1 1/2
810524-150
1
8
elbow, tube str thrd 1 1/2 x 1 7/8
811624-188
1
9
nut, serr flng m8 x 1.25
882508–125
2
10
screw, hex serr washer m8 x 16
883008-016
2
11
elbow, met st thd/orfs m48 x 1 1/2
883648-024
2
A1
To Aftercooler
A2
From Aftercooler
A3
From Minimum Pressure Valve
(I)
For maintenance on water separator No. 02250144-635, order seal replacement element No. 02250144-735.
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
85
SECTION 8
8.9 AIR PIPING, WATER-COOLED
A1
A2
A3
02250 155-292r05
86
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SULLAIR
®
PARTS LISTS
8.9 AIR PIPING, WATER-COOLED (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
separator, water d-h 1-1/2" fnpt 1/4" drn
02250144-635
(I)
1
2
support, outlet conn 1-1/2npt
02250152-215
1
3
tube, mpv to aftrclr 3700 wc
02250155-282
1
4
tube, aftrclr to outlet 3700 wc
02250155-283
1
5
connector, tube-m 1 1/2 x 1 1/2
810224-150
2
6
elbow, tube 90 deg m 1 1/2 x 1 1/2
810524-150
1
7
connector, tube str thd 1 1/2 x 1 7/8
811624-188
1
8
elbow, pipe 90 deg plt 1 1/2"
866215-060
1
9
nipple, pipe-xs plt 1 1/2 x cl
866424-000
1
10
nipple, pipe-xs plt 1 1/2 x 2
866424-020
1
11
nut, serr flng m8 x 1.25
882508–125
2
12
screw, tf-hex m8 x 16 blk zinc
883008-016
2
A1
To Aftercooler
A2
From Aftercooler
A3
From Minimum Pressure Valve
(I)
For maintenance on water separator no. 02250144-635, order replacement seal kit no. 02250144-735.
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
87
SECTION 8
8.10 FLUID PIPING, AIR-COOLED
13
8
3
10
7
9
12
6
11
2
1
5
4
02250152-488r00
88
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PARTS LISTS
8.10 FLUID PIPING, AIR-COOLED (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
hose, medium pressure orfs f-swvl 1" x 53"
02250141-104
1
2
hose, medium pressure orfs f-swvl 1" x 48"
02250143-476
1
3
block, thermal valve 50HP
02250151-498
1
4
connector, orfs x metr oring 3/4" 50HP
02250152-223
1
5
elbow, 90 1" sae x 3/4" orfs
02250152-544
1
6
filter, coreless m27 6"
02250155-708
(I)
1
7
o-ring, viton 13/16 x 1/8
826502-211
2
8
o-ring, viton 1 5/16 x 1/8
826502-219
1
9
screw, socket iso m10 x 85mm pc 12.9
874510-085
2
10
connector, metr str thd/orfs m27 x 3/4
883527-012
1
11
elbow, met st thd/orfs m27 x 3/4
883627-012
1
12
union, str thd iso 6149 m27 x 2
883727-012
1
13
element, thermal valve (Sullube)
02250092–081
(II)
1
element, thermal valve (24KT or 175 psig)
02250148–796
(III)
1
A1
To Cooler
A2
To Compressor Unit
A3
From Receiver Tank
(I)
For maintenance on coreless filter No. 02250155-708, order replacement element No. 02250155-709.
(II)
For maintenance on thermal valves on machines using Sullube, order repair kit no. 02250144-327.
(III)
For maintenance on thermal valves on machines using 24KT fluid, or rated 175 psig, order repair kit no. 02250148-827.
®
SULLAIR
®
3000-4500 Operator’s Manual and Parts List
89
SECTION 8
8.11 FLUID PIPING, WATER-COOLED
A1
A2
A5
A3
A4
02250 155-507r02
90
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®
SULLAIR
®
PARTS LISTS
8.11 FLUID PIPING, WATER-COOLED (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
adapter, sae 1 5/16 x 1 5/16-12
02250086-022
1
2
connector, sae x orfs .75"
02250135-568
1
3
hose, medium pressure orfs f-swvl 3/4"x 53"
02250141-104
1
4
elbow, 90 1"sae x 3/4"orfs
02250152-544
2
5
housing, thermal valve 50hp w/c
02250155-141
1
6
filter, coreless m27 6"l
02250155-708
1
7
hose, medium pressure orfs f-swvl 3/4" x 54"
02250156-913
1
8
tee, iso-6149/npt oil ret 3700
02250160-059
1
9
hose, medium pressure orfs f-swvl 3/4" x 60"
02250160-242
1
10
hose, medium pressure orfs f-swvl 3/4" x 29"
02250164-115
1
11
o-ring, viton 1 5/16 x 1/8"
826502-219
1
12
plug, pipe 1/4" 3000# stl plt
866900-010
1
13
connector, metr str thd/orfs m27 x 3/4
883527-012
2
14
elbow, met st thd/orfs m27 x 3/4
883627-012
2
15
union, str thd iso 6149 m27 x 2
883727-012
2
16
valve, thermal 195f 1 1/2-18 (Sullube)
02250092-081
(I)
1
element, thermal 210f (24kt, 175 psig)
02250148-796
(I)
1
A1
From Fluid Cooler Outlet
A2
To Fluid Cooler Inlet
A3
Fluid Return From Receiver Tank
A4
Fluid Injection To Compressor Unit
A5
To Water Regulator Valve
(I)
For maintenance on thermal valve no. 02250092-081, order repair kit No. 02250144-327.
For maintenance on thermal valve no. 02250148-796, order repair kit No. 02250148-827.
®
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®
3000-4500 Operator’s Manual and Parts List
91
SECTION 8
8.12 COOLING AND LUBRICATION SYSTEM, AIR-COOLED 18"/60HZ FAN,
STANDARD COOLER
A4
A3
A1
A2
02250158-442r02
92
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®
PARTS LISTS
8.12 COOLING AND LUBRICATION SYSTEM, AIR-COOLED 18"/60HZ FAN,
STANDARD COOLER (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
cooler, air/oil 50hp
02250151-493
1
2
duct, centrifugal fan 3700
02250151-496
1
3
support, fan motor 3700
02250151-501
1
4
panel, venturi 3700 18" fan
02250155-681
1
panel, venturi 4500 20" fan
02250155–680
1
5
adapter, venturi 3700 18" fan
02250155-682
1
adapter, venturi 4500 20" fan
02250155–683
1
6
fan, centrifugal hs 60hz 18"dia
02250155-684
1
fan, centrifugal 20" 50HP std
02250151-494
1
fan, centrifugal 18" 60HP hi static/60HP std
02250155-684
1
fan, centrifugal 20" 60HP hi static/50HZ
02250155-685
1
fan, centrifugal 18" 50HP 50HZ
02250151-495
1
7
guard, fan discharge 3700
02250158-544
1
8
weatherstrip, 3/16 x 3/8 ft
250022-436
6
9
nut, hex metric m8 x 1.25
825908-125
4
10
capscrew, hex 8.8 m8 x 20mm
828008-020
12
11
capscrew, hex 8.8 m8 x 30mm
828008-030
4
12
washer, iso 7093-8-140hv
865708-240
12
13
nut,serr flng m8 x 1.25
882508-125
8
14
screw, tf-hex m8 x 16 blk zinc
883008-016
22
15
washer, nord-lock pl m8 sp
883208-166
28
16
motor
-
(I)
1
A1
In From MPV
A2
Out To Water Separator
A3
Thermal Bypass Valve
A4
Cooler Pack Assembly Rest on Top Rails of Canopy. Thread Forming
Screws Attach Cooler Pack To Rails.
This part will vary by model.
(I)
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SECTION 8
8.13 FLUID COOLING SYSTEM, WATER-COOLED
A5
A5
A1
A2
A6
A7
A8
A4
A3
94
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PARTS LISTS
8.13 FLUID COOLING SYSTEM, WATER-COOLED (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
cooler, ls12v oil/wtr 5 x 36
02250094-744
1
2
valve, solenoid 2wnc 3/4 250# n4 +
02250125-668
(I) (III)
1
3
support, heat exchanger w/c 50hp
02250155-140
1
4
support, water conn 3/4" 3700 w/c
02250155-142
1
5
u-bolt, w/saddle 5.50"
02250155-250
2
6
elbow, tube 3/4"-plstc x 3/4"-npt
02250155-257
(II) (III)
4
7
spacer, stl tube .50 o.d. x .49
02250164-034
4
8
drainlock, 1/4"
40061
2
9
valve, water reg 3/4"160-230f
47398
(II)
1
10
clr, aftrclr 1-1/2" npt air/1" npt wtr port
250017-527
(IV)
1
clr, aftrclr 1-1/2" npt air/1" npt wtr port
250040-680
(V)
1
11
elbow, 90 1/4t pls x 1/4 npt m
250018-430
1
12
clamp, tubing 1-1/8" dia
250025-636
1
13
tubing, thermoplastic 3/4"(ft)
250039-353
7
14
connector, male plastic tubing 3/4x3/4
250039-357
4
15
elbow, pipe 90 deg plt 3/4"
866215-030
3
16
nipple, pipe pltd 3/4 x 2 1/2
866312-025
1
17
nipple, pipe-xs plt 3/4 x 3
866412-030
2
18
nipple, pipe-xs plt 3/4 x 4
866412-040
(II)
1
19
bushing, red hex pltd 3/8 x 1/4
868901-010
1
20
bushing, red hex pltd 1 x 3/4
868904-030
4
21
elbow, pipe 90f 1/4 x 1/4 brass
881104-025
2
22
nipple, pipe-hx brass 3/8 x 1/4
881306-025
2
23
nut,serr flng m8 x 1.25
882508-125
9
24
screw, hex serr washer m8 x 16
882608-016
11
A1
To Water Separator
A2
To Minimum Pressure Valve
A3
Water In
A4
Water Out
A5
Air Bleed Valve
A6
To PSW2 low Water Pressure Switch in Electrical Control Box
A7
To Fluid Cooler
A8
From Fluid Cooler
(I)
For maintenance on solenoid valve No. 02250125-668, order repair kit No. 02250160-751, and replacement coil No.
02250125-855.
(II)
Used on machines requiring water regulating valve option.
(III)
Used on machines requiring water solenoid valve option.
(IV)
3000, 3700 models only.
(V)
4500 model only.
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SECTION 8
8.14 DISCHARGE, RECEIVER AND PIPING SYSTEM, 3000P, 3700 AND 4500
A2
A1
A3
A7
A4
A6
A5
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PARTS LISTS
8.14 DISCHARGE, RECEIVER AND PIPING SYSTEM, 3000P, 3700 AND 4500
(CONTINUED)
Key
Description
Part Number
Note
Quantity
1
adapter, sae 1 7/8-12 x 1 7/8-12
02250055-014
1
2
vlv. min press chk 1-7/8 sae 0-ring
02250097-598
(I)
2
3
plug, sight glass 1 5/16" sae
02250097-610
1
4
elb, 90 deg 3/4 sae x 3/8 nptf
02250100-093
1
5
adapter, sae 7/16 x 7/16-20
02250101-783
1
6
filter, assembly screen filter
02250117-782
(II)
1
7
orifice, plug brass 1/8"npt x 1/32"
02250125-774
1
8
sightglass, orf block sae
02250126-129
1
9
valve, ball mini m x f 3/8"viton
02250146-870
1
10
tank, separator 3700
02250149-624
1
11
joint, expansion air end-separator
02250151-492
1
12
elbow, sae 1/4" (7/16-20) m x f
02250152-798
1
13
flange, kit sae split 2" m12 bolt
02250152-810
2
14
spring, conical oil sep ground
02250155-720
1
15
isolator, vibration 3700
02250156-379
4
16
wire,10 gage ground bond 12" m8
02250157-450
1
17
element, sep round 5.5d x 14.3lng
02250160-774
(III)
1
18
support, receiver 3700 shipping
02250162-937
1
19
plug, o-ring boss sae 1 1/4
40029
1
20
clamp, speed tube 1/4"
43357
1
21
valve, pressure relief 200 psig
250006-938
1
22
nut, hex metric m8 x 1.25
825908-125
4
23
o-ring, viton 7 3/4 x 3/16"
826502-368
1
24
capscrew, hex 8.8 m12 x 40mm
828012-040
8
25
washer, spr lock-metric pltd m12
838812-250
8
26
tubing, stnls stl 1/4 20ga ft
841215-004
4
27
screw, socket iso m5 x 8mm pc 12.9
874505-008
1
28
connector, tube-m 1/4 x 1/4 ss
876804-025
1
29
elbow, tube 90 deg m 1/4 x 1/4 ss
877004-025
1
30
nut,serr flng m8 x 1.25
882508-125
1
31
screw, hex serr washer m8 x 20
882608-020
1
32
screw, tf-hex m8 x 16 blk zinc
883008-016
2
33
washer, nord-lock pl m8 sp
883208-166
4
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SECTION 8
8.14 DISCHARGE, RECEIVER AND PIPING SYSTEM, 3000P, 3700 AND 4500
(CONTINUED)
A2
A1
A3
A7
A4
A6
A5
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PARTS LISTS
8.14 DISCHARGE, RECEIVER AND PIPING SYSTEM, 3000P, 3700 AND 4500
(CONTINUED)
Key
Part Number
Note
Quantity
A1
To Strainer on Solenoid Valve Assembly
A2
To Aftercooler In
A3
To Unit Oil Return Port
A4
From Unit Discharge
A5
To Grounding Location on Frame
A6
To Frame
A7
Sump Pressure
(I)
Description
For maintenance on minimum pressure valve no. 02250097-598, order:
kit, repair, No. 02250110-727
kit, cap, No. 02250046-396
kit, O-ring, No. 02250048-363
kit, piston , No. 02250051-337
(II)
For maintenance on return line strainer, order replacement strainer No. 02250117-782.
(III)
For maintenance on separator element No. 02250160-774, order replacement element No. 02250160-776.
®
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SECTION 8
8.15 DISCHARGE, RECEIVER AND PIPING, 3000 WITH 10 SERIES UNIT
A2
A1
A7
A3
A4
A5
A6
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PARTS LISTS
8.15 DISCHARGE, RECEIVER AND PIPING, 3000 WITH 10 SERIES UNIT
(CONTINUED)
Key
Description
Part Number
Note
Quantity
1
adapter, sae 1 7/8-12 x 1 7/8-12
02250055-014
1
2
vlv. min press chk 1-7/8 sae 0-ring por
02250097-598
(I)
1
3
plug, sight glass 1 5/16" sae
02250097-610
1
4
elb, 90 deg 3/4 sae x 3/8 np
02250100-093
1
5
adapter, sae 7/16 x 7/16-20
02250101-783
1
6
filter, assembly screen filter
02250117-782
(II)
1
7
orifice, plug brass 1/8"npt x 1/32"
02250125-774
1
8
sightglass, orf block sae
02250126-129
1
9
valve, ball mini m x f 3/8"viton
02250146-870
1
10
tank, separator ws37
02250149-624
1
11
elbow, sae 1/4" (7/16-20) m x f
02250152-798
1
12
flange, kit sae split 2" m12 bolt
02250152-810
1
13
spring, conical oil sep ground ws
02250155-720
1
14
isolator, vibration ws 30/37/45 rec tnk
02250156-379
4
15
wire, 10 gage ground bond 12" m8
02250157-450
1
16
joint, expansion 3700 w/10series unit
02250159-974
1
17
element, sep round 5.5d x 14.3lng+
02250160-774
(III)
1
18
support, receiver 3700 shipping
02250162-937
1
19
plug, o-ring boss sae 1 1/4
40029
1
20
clamp, speed tube 1/4"
43357
1
21
valve, pressure relief 200 psig
250006-938
1
22
nut, hex metric m8 x 1.25
825908-125
4
23
o-ring, viton 7 3/4 x 3/16"
826502-368
1
24
capscrew, hex 8.8 m12 x 40mm
828012-040
8
25
washer, spr lock-metric pltd m12
838812-250
8
26
tubing, stnls stl 1/4 20ga ft
841215-004
4
27
screw, socket iso m5 x 8mm pc 12.9
874505-008
1
28
connector, tube-m 1/4 x 1/4 ss
876804-025
1
29
elbow, tube 90 deg m 1/4 x 1/4 ss
877004-025
1
30
nut,serr flng m8 x 1.25
882508-125
1
31
screw, hex serr washer m8 x 20
882608-020
1
32
screw, tf-hex m8 x 16 blk zinc
883008-016
2
33
washer, nord-lock pl m8 sp
883208-166
4
34
connector, straight thd/orfs 1 7/8 x 1 1/2
884424-188
1
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SECTION 8
8.15 DISCHARGE, RECEIVER AND PIPING, 3000 WITH 10 SERIES UNIT
(CONTINUED)
A2
A1
A7
A3
A4
A5
A6
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PARTS LISTS
8.15 DISCHARGE, RECEIVER AND PIPING, 3000 WITH 10 SERIES UNIT
(CONTINUED)
Key
Part Number
Note
Quantity
A1
To Strainer on Solenoid Valve Assembly
A2
To Aftercooler In
A3
To Unit Oil Return Port
A4
From Unit Discharge
A5
To Grounding Location on Frame
A6
To Frame
A7
Sump Pressure
(I)
Description
For maintenance on minimum pressure valve no. 02250097-598, order:
kit, repair, No. 02250110-727
kit, cap, No. 02250046-396
kit, O-ring, No. 02250048-363
kit, piston , No. 02250051-337
(II)
For maintenance on return line strainer, order: strainer No. 02250117-782, (qty of 2 needed).
(III)
For maintenance on separator element No. 02250160-774, order: element No. 02250160-776.
®
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103
SECTION 8
8.16 MOISTURE DRAIN
02250152_494r01
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PARTS LISTS
8.16 MOISTURE DRAIN (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
locknut, n4 conduit sealing
02250071-362
4
2
valve, solenoid 2wnc 1/4 200# 24vdc
02250155-715
(I)
1
3
valve, ball 1/4" npt
047115
1
4
strainer, v-type 300psix1/4
241771
(II)
1
5
nipple, conduit 1/2 x 1.125"
250007-168
1
6
elbow, 90deg m swvl 1/4t x 1/4 npt
250025-850
1
7
connector, male1/4tube x 1/4
250025-859
1
8
hose,nylon 1/4(ft)
842215-004
5
9
conduit
846315-050
4
10
elbow, 45deg lq-tite 1/2
846500-050
1
11
elbow, 90deg lq-tite 1/2
846600-050
1
12
elbow, entrance 1/2
847715-050
1
13
elbow, pipe-90m 1/4 x 1/4 brass
881004-025
1
14
nipple, pipe-hx brass 1/4 x 1/4
881304-025
2
A1
To Air Bracket Out
A2
To Water Seperator
A3
To Bottom of Starter Box
A4
Port 1
A5
Port 2
(I)
For maintenance on solenoid valve no. 02250155-715, order repair kit no. 02250157-501, and replacement coil no.
02250157-502.
(II)
For maintenance on return line strainer no. 241771, order repair kit no. 241772.
®
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SECTION 8
8.17 PNEUMATIC CONTROL SYSTEM, WITH STANDARD SEQUENCING
A3
A4
A1
A3
A4
A2
A7
A1
A2
A8
A7
A5
A9
A6
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PARTS LISTS
8.17 PNEUMATIC CONTROL SYSTEM, WITH STANDARD SEQUENCING
(CONTINUED)
Key
Description
Part Number
Note
Quantity
1
locknut, n4 conduit sealing
02250071-362
2
2
valve, 1/2 bldwn 1.8:1 250 psig
02250100-042
(I)
1
3
valve, check 1/4" poppet style
02250115-272
1
4
valve, solenoid 3wno 1/4 250# 24vdc
02250155-714
(II)
2
5
tbg, nylon 1/4"-od red
02250155-961
3
6
tbg, nylon 1/4"-od blue
02250155-962
2
7
tbg, nylon 1/4"-od yellow
02250155-963
5
8
orifice,.140".25 fnpt x .25
02250161-433
1
9
strainer, v-type 300psix1/4
241771
(III)
1
10
hose, med press 0.50 x 015"
249608-019
1
11
valve, pressure regulator
250017-280
(IV)
1
12
elbow, 1/4" tube x 1/4" npt
250018-430
2
13
tee, male branch swiv 1/4 tube x 1/4 npt
250025-835
1
14
elbow, 90deg m swvl 1/4t x 1/8npt
250025-849
(V)
1
15
elbow, 90deg m swvl 1/4t x 1/4 npt
250025-850
8
16
connector, male1/4tube x 1/4
250025-859
1
17
connector, fem tube 1/4 x 1/4 nptf
250025-923
1
18
valve, shuttle 1/4" npt (dbl chk)
408893
1
19
adapter, fem pipe 1/4 x 7/16-20
811502-025
(V)
1
20
nipple, chase cond 1/2
847815-050
2
21
elbow, 37fl 90m 1/2 x 1/2
860208-050
1
22
elbow, pipe-90m 1/2 x 1/2
860508-050
1
23
tee, male pipe brass 1/4
869825-025
2
24
connector,37 fl 1/2 x 1/4" npt
873704-075
1
25
nipple, pipe-hx brass 1/4 x 1/4
881304-025
2
A1
Port 1
A2
Port 2
A3
Port 3
A4
To Starter Box
A5
To Inlet Valve
A6
To Inlet Adapter
A7
To Reciever Tank
A8
To Starter Below Inlet
A9
Flow Direction
(I)
For maintenance on blowdown valve no. 02250100-042, order: repair kit no. 02250100-042.
(II)
For maintenance on solenoid valve no. 02250155-714, order: repair kit no. 02250155-500, and replacement coil no.
02250157-502.
(III)
For maintenance on strainer no. 241771, order: repair kit no. 241772.
(IV)
For maintenance on pressure regulator valve no. 250017-280, order: repair kit no. 250019-453.
(V)
Use with 3000 machine only.
®
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SECTION 8
8.18 CONTROL SYSTEM AND ELECTRIC PARTS, MFV
A7
A6
A3
A4
A5
A2
A1
A8
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®
PARTS LISTS
8.18 CONTROL SYSTEM AND ELECTRIC PARTS, MFV (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
tube, nyl .25 x 040w blk (ft)
02250054-861
(I)
2
2
locknut, n4 conduit sealing
02250071-362
(I)
1
3
grip, cord n4 .125-.187 x 1/2"
02250071-379
1
4
grip, cord n4 .250-.375 x 1/2"
02250071-381
2
5
nameplate, e-stop 45mm yellow
02250081-473
1
6
transformer, control 150va univ w.pri fh
02250083-186
1
7
switch, push-button operator e22 40mm
02250085-504
1
8
bar, ground 5 post cutler hammer
02250101-721
2
9
control, display s4
02250154-051
1
10
control, i/o mod ws 24vdc supply
02250154-052
1
11
decal, microprocessor overlay
02250154-359
1
12
block, contact aux 1nc ch-it a-e
02250154-608
1
13
transducer, pressure 0-250# ratiometric
02250155-174
2
14
probe, rtd 100 ohm plat 3.5"x 6ft
02250155-175
1
15
specification, encl 3700 22"x36"x10"
02250155-936
1
16
wire, 10 gage ground bond 33" m8
02250157-449
1
17
receptacle,s4 program port nema 6p
02250159-547
1
18
cap, s4 program port nema 6p
02250159-549
1
19
spacer, p8/p12 ws mtg to encl
02250161-759
4
20
breaker, cir100a hmcp
250014-827
1
21
switch, pressure n.o. 10 psi
250017-992
(I)
1
22
elbow, 90 1/4"tube x 1/8"npt
250018-429
(I)
1
23
fuse, limitron ktk-r 2.00
250019-756
(I)
1
24
relay, overload 32a
250021-692
(II)
1
25
adapter, o.l.r. base mnt ch1
250021-694
(II)
1
26
weatherstrip, 3/16 x 3/8 ft
250022-436
1
27
block, contact 1nc
250027-125
1
28
fitting, compress adj
250028-635
1
29
plug, hole n4 1/2" cond
409918-002
2
30
nut, hex metric m8 x 1.25
825908-125
6
31
lug, scrulug kpa-25 4-1/0
849215-025
2
32
terminal, ring tng 3/8 x 8ga
849306-008
1
33
washer, nord-lock pl m8 sp
883208-166
6
34
starter, ac fan
-
(II) (III)
1
35
fuse
-
(I) (III)
2
36
block, power
-
(III)
1
37
supply, power
-
(III)
1
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SECTION 8
8.18 CONTROL SYSTEM AND ELECTRIC PARTS, MFV (CONTINUED)
A7
A6
A3
A4
A5
A2
A1
A8
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PARTS LISTS
8.18 CONTROL SYSTEM AND ELECTRIC PARTS, MFV (CONTINUED)
Key
Part Number
Note
Quantity
A1
P1 - Wet Receiver Pressure
A2
P2 - Line Pressure
A3
Solenoid 1
A4
Solenoid 4
A5
T1 - Wet Discharge Temp
A6
PSW2 - Low Water Pressure Switch
A7
Drill Hole for WC Machine
A8
To Frame
Description
(I)
Denotes water-cooled machines only.
(II)
Denotes air-cooled machines only.
(III)
This part may vary per machine specification. Consult the Sullair factory for details.
®
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SECTION 8
8.19 CONTROL SYSTEM AND ELECTRIC PARTS, WYE-DELTA
A7
A6
A3
A4
A2
A5
A1
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A8
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PARTS LISTS
8.19 CONTROL SYSTEM AND ELECTRIC PARTS, WYE-DELTA (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
tube, nyl .25 x 040w blk (ft)
02250054-861
(I)
2
2
locknut, n4 conduit sealing
02250071-362
(I)
1
3
grip, cord n4 .125-.187 x 1/2"
02250071-379
1
4
grip, cord n4 .250-.375 x 1/2"
02250071-381
2
5
nameplate, e-stop 45mm yellow
02250081-473
1
6
transformer, control 150va univ w.pri fh
02250083-186
(I)
1
7
switch, push-button operator e22 40mm
02250085-504
1
8
bar, ground 5 post cutler hammer
02250101-721
2
9
control, display s4
02250154-051
1
10
control, i/o mod ws 24vdc supply
02250154-052
1
11
decal, microprocessor overlay
02250154-359
1
12
block, contact aux 1no ch-it a-e
02250154-607
1
13
block, contact aux 1nc ch-it a-e
02250154-608
2
14
transducer, pressure 0-250# ratiometric
02250155-174
2
15
probe, rtd 100 ohm plat 3.5"x 6ft
02250155-175
1
16
link, mech intrlk ch it frm b-e
02250155-676
1
17
specification, encl 3700 22"x36"x10"
02250155-936
1
18
wire, 10 gage ground bond 33" m8
02250157-449
1
19
receptacle,s4 program port nema 6p
02250159-547
1
20
cap, s4 program port nema 6p
02250159-549
1
21
spacer, p8/p12 ws mtg to encl
02250161-759
4
22
switch, pressure n.o. 10 psi
250017-992
(I)
1
23
elbow, 90 1/4"tube x 1/8"npt
250018-429
(I)
1
24
relay, overload 32a
250021-692
(II)
1
25
adapter, o.l.r. base mnt ch1
250021-694
(II)
1
26
weatherstrip, 3/16 x 3/8 ft
250022-436
1
27
fuse, kldr 1.50 600v td
250026-643
(I)
2
28
block, contact 1nc
250027-125
1
29
fitting, compress adj
250028-635
1
30
plug, hole n4 1/2" cond
409918-002
2
31
nut, hex metric m8 x 1.25
825908-125
6
32
lug, scrulug kpa-25 4-1/0
849215-025
2
33
terminal, ring tng 3/8 x 8ga
849306-008
1
34
washer, nord-lock pl m8 sp
883208-166
6
35
starter, ac fan
-
(II) (III)
1
36
contactor
-
(III)
2
37
fuse
-
(I) (III)
1
38
block, power
-
(III)
1
39
supply, power
-
(III)
1
®
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8.19 CONTROL SYSTEM AND ELECTRIC PARTS, WYE-DELTA (CONTINUED)
A7
A6
A3
A4
A2
A5
A1
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8.19 CONTROL SYSTEM AND ELECTRIC PARTS, WYE-DELTA (CONTINUED)
Key
Part Number
Note
Quantity
A1
P1 - Wet Receiver Pressure
A2
P2 - Line Pressure
A3
Solenoid 1
A4
Solenoid 4
A5
T1 - Wet Discharge Temp
A6
PSW2 - Low Water Pressure Switch
A7
Drill Hole for WC Machine
A8
To Frame
Description
(I)
Denotes water-cooled machines only.
(II)
Denotes air-cooled machines only.
(III)
This part may vary per machine specification. Consult the Sullair factory for details.
®
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®
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SECTION 8
8.20 CONTROL SYSTEM AND ELECTRIC PARTS, VSD
A7
A6
A3
A4
A5
A2
A1
A8
116
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PARTS LISTS
8.20 CONTROL SYSTEM AND ELECTRIC PARTS, VSD (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
tube, nyl .25 x 040w blk (ft)
02250054-861
(I)
2
2
rail, din 35mm (meters)
02250060-705
(I)
1
3
locknut, n4 conduit sealing
02250071-362
(I)
1
4
grip, cord n4 .125-.187 x 1/2"
02250071-379
1
5
grip, cord n4 .250-.375 x 1/2"
02250071-381
2
6
nameplate, e-stop 45mm yellow
02250081-473
1
7
transformer, control 150va univ w.pri fh
02250083-186
(I)
1
8
switch, push-button operator e22 40mm
02250085-504
1
9
bar, ground 5 post cutler hammer
02250101-721
2
10
relay, sptd din 6a 24vdc coil
02250140-490
(I)
1
11
control, display s4
02250154-051
1
12
control, i/o mod ws 24vdc supply
02250154-052
1
13
decal, microprocessor overlay
02250154-359
1
14
transducer, pressure 0-250# ratiometric
02250155-174
2
15
probe, rtd 100 ohm plat 3.5"x 6ft
02250155-175
1
16
specification, encl 3700v 22" x 36" x 10
02250155-937
1
17
wire, 10 gage ground bond 33" m8
02250157-449
1
18
receptacle, s4 program port nema 6p
02250159-547
1
19
cap, s4 program port nema 6p
02250159-549
1
20
spacer, p8/p12 ws mtg to encl
02250161-759
4
21
switch, pressure n.o. 10 psi
250017-992
(I)
1
22
elbow, 90 1/4"tube x 1/8"npt
250018-429
(I)
1
23
fuse, limitron ktk-r 2.00
250019-756
(I)
1
24
holder, fuse ktk-r 3 pole
250019-773
(II)
1
25
weatherstrip, 3/16 x 3/8 ft
250022-436
2
26
block, contact 1nc
250027-125
1
27
fitting, compress adj
250028-635
1
28
fu, cc td 10a 600vac
250041-618
3
29
plug, hole n4 1/2" cond
409918-002
(II)
2
30
nut, hex metric m8 x 1.25
825908-125
6
31
lug, scrulug kpa-25 4-1/0
849215-025
1
32
terminal, ring tng 3/8 x 8ga
849306-008
1
33
washer, nord-lock pl m8 sp
883208-166
6
34
starter, ac fan
-
(II) (III)
1
35
fuse
-
(I) (III)
2
36
block, power
-
(III)
1
37
supply, power
-
(III)
1
38
vsd
-
(III)
1
®
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SECTION 8
8.20 CONTROL SYSTEM AND ELECTRIC PARTS, VSD (CONTINUED)
A7
A6
A3
A4
A5
A2
A1
A8
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PARTS LISTS
8.20 CONTROL SYSTEM AND ELECTRIC PARTS, VSD (CONTINUED)
Key
Part Number
Note
Quantity
A1
P1- Wet Receiver Pressure
A2
P2- Line Pressure
A3
Solenoid 1
A4
Solenoid 4
A5
T1-Wet Discharge Temperature
A6
PSW2- Low Water Pressure
A7
Drill Hole for WC machines
A8
To Frame
Description
(I)
Denotes water-cooled machines only.
(II)
Denotes air-cooled machines only.
(III)
This part may vary per machine specification. Consult the Sullair factory for details.
®
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®
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SECTION 8
8.21 ENCLOSURE, AIR-COOLED
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PARTS LISTS
8.21 ENCLOSURE, AIR-COOLED (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
cap, molded canopy corner
02250150-893
4
2
rail, vertical 3000,3700,4500
02250150-910
3
3
rail, roof air out end 37kw
02250150-912
1
4
gusset, str crnr square 37kw
02250151-177
1
5
panel, canopy door flanged w/cutout
02250151-178
1
6
panel, canopy door flanged 37kw
02250151-179
1
7
panel, starter end bottom 3700
02250151-180
1
8
panel, canopy door locking 37kw
02250151-181
2
9
panel, canopy assy intake end 37kw
02250151-182
1
10
panel, roof canopy 37kw
02250151-183
1
11
bearing, flanged 5mm 50hp
02250151-635
4
12
panel, starter end l/h 37kw
02250152-031
1
13
rail, roof starter end 37kw
02250152-040
1
14
insulation, foam 2" corner piece 50h
02250152-323
4
15
gusset, corner square 37kw
02250154-298
3
16
rail, vertical starter side 3700
02250154-393
1
17
cover, forkpocket 37kw
02250154-405
8
18
rail, side assy rh/lh 37kw
02250154-992
2
19
support, shipping mtr/unit 37kw
02250155-191
1
20
plug, hole 2 1/2" nylon black
02250155-284
1
21
pocket, drawing holder 3700
02250158-039
1
22
weatherstrip, 3/16 x 3/8 ft
250022-436
3
23
trim, canopy edge 7.5/10hp
250034-157
2
24
screw, tf-hex m8 x 16 blk zinc
883008-016
57
02250161-137
1
A1
®
Clean Air Inlet Filter 3700
SULLAIR
®
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SECTION 8
8.22 ENCLOSURE, WATER-COOLED
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PARTS LISTS
8.22 ENCLOSURE, WATER-COOLED (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
cap, molded canopy corner
02250150-893
4
2
rail, vertical 3000,3700,4500
02250150-910
3
3
rail, roof air out end 37kw
02250150-912
1
4
gusset, str crnr square 37kw
02250151-177
1
5
panel, canopy door flanged w/cutout
02250151-178
1
6
panel, canopy door flanged 37kw
02250151-179
1
7
panel, starter end bottom 3700
02250151-180
1
8
panel, canopy door locking 37kw
02250151-181
2
9
bearing, flanged 5mm 50hp
02250151-635
4
10
panel, starter end l/h 37kw
02250152-031
1
11
rail, roof starter end 37kw
02250152-040
1
12
insulation, foam 2" corner piece 50h
02250152-323
4
13
gusset, corner square 37kw
02250154-298
3
14
rail, vertical starter side 3700
02250154-393
1
15
cover, forkpocket 37kw
02250154-405
8
16
rail, side assy rh/lh 37kw
02250154-992
2
17
support, shipping mtr/unit 37kw
02250155-191
1
18
panel, roof canopy w/c
02250155-204
1
19
panel, baffle canopy w/c
02250155-205
1
20
panel, canopy assy intake 37kw w/c
02250155-260
1
21
plug, hole 2 1/2" nylon black
02250155-284
1
22
pocket, drawing holder 3700
02250158-039
1
23
guard, fan 13"dia
241579
1
24
fan, enclosure 10s wc
241580
1
25
weatherstrip, 3/16 x 3/8 ft
250022-436
3
26
trim, canopy edge 7.5/10hp
250034-157
2
27
nut, serr flng m8 x 1.25
882508-125
8
28
screw, hex serr washer m8 x 25
882608-025
8
29
screw, tf-hex m8 x 16 blk zinc
883008-016
62
A1
Cooling Fan Baffle
A2
Aftercooler Mounting Feet
A3
Oil Cooler Mounting Feet
A4
Clean Air Inlet Filter 3700
02250164-592
1
®
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®
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SECTION 8
8.23 DECAL LOCATIONS, AIR-COOLED
20
A1 A6
A1 A6
A4
20
A5
A7
A8
A3
A2
A2
A1
A4
A1
A8
A4
A1
A1
A7
02250152_489r05
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8.23 DECAL LOCATIONS, AIR-COOLED (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
decal, iso 9001 blk 3.44x5.75
02250057-624
1
2
decal, protective earth ground
02250075-045
(III)
2
3
decal, pe designation
02250075-540
(III)
1
4
decal, electrocution hazard international/global
02250077-472
1
5
decal, en-warning mixing fluids
02250110-891
1
6
decal, parallel wye motor conn.
02250146-385
2
7
decal, microprocessor overlay
02250154-359
1
8
decal, sullair side graphic 50hp
02250154-360
1
9
decal, sullair side graph 50hp
02250154-361
2
10
decal, black www.sullair.com
02250155-495
2
11
decal, maint kit eng 3700
02250156-300
1
12
decal, remove before start-up
02250158-358
(IV)
2
13
decal, vsd black p8/p10/p12
02250162-215
2
14
decal, warning n12 elec encl protc
02250164-823
1
15
decal, warning auto start
41065
1
16
decal, danger hi voltage
42218
(I)
1
17
sign, warning-comp oil fil cap
49685
1
18
decal, danger electrocution
49850
1
19
decal, warning elect. shock-ground fault
49852
(II)
1
20
sign, warning-sever-fan-indus
49855
3
21
decal, fork lifting
241814
4
22
decal, warn "food grade" lube
250003-144
1
23
decal, warning-autostart
250017-903
1
24
decal, water in
250019-107
1
25
decal, water out
250019-108
1
26
decal, rotation 3.5" lg
250021-564
2
27
decal, water drain 3 3/4 x 1"
250022-810
1
28
decal, danger inhaling comp air
250027-935
1
29
sign, warning-hot surfaces
407408
1
30
decal, fluid
–
(V)
1
31
nameplate
–
(V)
1
32
rivet
–
(V)
4
33
decal, series
–
(V)
2
34
decal, voltage
–
(I) (V)
1
®
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SECTION 8
8.23 DECAL LOCATIONS, AIR-COOLED (CONTINUED)
20
A1 A6
A1 A6
A4
20
A5
A7
A8
A3
A2
A2
A1
A4
A1
A8
A4
A1
A1
A7
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8.23 DECAL LOCATIONS, AIR-COOLED (CONTINUED)
Key
Description
Part Number
Note
Quantity
A1
Both Sides of Machine
A2
Center Stripes Vertically Based on Location of WS Controller Decal
A3
Locate Decals on both Sides of Machine by Using Location of End Stripe and WS Controller Location
A4
Used Only On VSD Machines
A5
Used On Parallel Wye Machines Only
A6
Air-cooled Only
A7
Water-cooled Only
A8
Not used on 575V VSD machines
(I)
Attach to the bottom on inside of starter box.
(II)
Attach to inside of starter door.
(III)
Attach to sub-panel inside starter box.
(IV)
Attach to top of shipping strap.
(V)
This part will vary by model. Consult factory with serial number.
®
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SECTION 8
8.24 DECAL LOCATIONS, WATER-COOLED
A5
A1
A3
A2
A1
A1
A4
A1
A1
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8.24 DECAL LOCATIONS, WATER-COOLED (CONTINUED)
Key
Description
Part Number
Note
Quantity
1
decal, iso 9001 blk 3.44x5 75
02250057-624
1
2
npl, sullair serial number
02250059-318
1
3
decal, protective earth ground
02250075-045
(III)
2
4
decal, pe designation
02250075-540
(III)
1
5
decal, electrocution hazard international/glbl
02250077-472
1
6
decal, en-warning mixing fluids
02250110-891
1
7
decal, parallel wye motor conn.
02250146-385
2
8
decal, microprocessor overlay
02250154-359
1
9
decal, sullair side graphic 50 hp
02250154-360
1
10
decal, sullair side graph 50hp
02250154-361
2
11
decal, black www.sullair.com
02250155-495
2
12
decal, maint kit eng 3700
02250156-300
1
13
decal, remove before start-up
02250158-358
(IV)
2
14
decal, vsd black p8/p10/p12
02250162-215
2
15
decal, warning auto start
41065
1
16
decal, danger hi voltage
42218
(I)
1
17
sign, warning-comp oil fil cap
49685
1
18
decal, danger electrocution
49850
1
19
decal, warning elect. shock-ground fault
49852
(II)
1
20
sign, warning-sever-fan-indus
49855
1
21
decal, fork lifting
241814
4
22
decal, warn "food grade" lube
250003-144
1
23
decal, warning-autostart
250017-903
1
24
decal, water in
250019-107
1
25
decal, water out
250019-108
1
26
decal, rotation 3.5" lg
250021-564
1
27
decal, water drain 3 3/4 x 1"
250022-810
1
28
decal, danger inhaling comp air
250027-935
1
29
sign, warning-hot surfaces
30
rivet, pop 1/8 x 1/2
31
decal, fluid
32
33
®
407408
1
843102-050
4
FLUID DECAL
1
decal, series
SERIES DECAL
2
decal, voltage
VOLTAGE DECAL
(I)
1
SULLAIR
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SECTION 8
8.24 DECAL LOCATIONS, WATER-COOLED (CONTINUED)
A5
A1
A3
A2
A1
A1
A4
A1
A1
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8.24 DECAL LOCATIONS, WATER-COOLED (CONTINUED)
Key
Description
Part Number
Note
Quantity
A1
Both Sides Of Machine
A2
Center Stripes Vertically Based On Location Of WS Controller Decal
A3
Locate Decals On Both Sides Of Machine By Using Location Of End Stripe And WS Controller Location
A4
Used On VSD Machines Only
A5
Used On Parallel Wye Machines Only
(I)
Attached to the bottom on inside of starter box.
(II)
Attached to inside of starter door.
(III)
Attached to sub-panel inside starter box.
(IV)
Attached to top of shipping strap.
(VIII)
This part may vary per machine specification. Consult the Sullair factory for details.
®
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®
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SECTION 8
8.25 DECAL GROUP
1
2
3
4
7
6
5
8
02250155_601_Decal_1
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PARTS LISTS
8.25 DECAL GROUP (CONTINUED)
Key
Part Number
Note
Quantity
1
sign, warning-comp oil fil cap
049685
1
2
decal, warn "food grade" lube
250003-144
1
3
sign, warning ground fault
049852
1
4
decal, warning-autostart
250017-903
1
5
decal, danger inhaling comp air
250027-935
1
6
sign, danger electrocution
049850
1
7
sign, warning-sever-fan-indus
049855
2
8
sign, warning-hot surfaces
407408
1
®
Description
SULLAIR
®
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SECTION 8
8.25 DECAL GROUP (CONTINUED)
9
10
11
12
13
14
16
17
15
18
02250155_601_Decal_2
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PARTS LISTS
8.25 DECAL GROUP (CONTINUED)
Key
Part Number
Note
Quantity
9
decal, caution auto start
041065
1
10
decal, danger hi voltage
042218
1
11
decal, en-warning mixing fluids
02250110-891
1
12
decal, electrocution hazard international/globa
02250077-472
1
13
decal, protective earth ground
02250075-045
2
14
decal, fluid Sullube
02250069-389
(I)
1
15
decal, maint kit eng 3700
02250156-300
1
16
decal, water drain 3 3/4 x 1"
250022-810
1
17
decal, rotation 3.5" lg
18
decal, ISO 9001 blk 3.44x5.75
Description
(I)
250021-564
1
02250057-624
1
Although Sullube fluid decal is shown, initial fluid fill may vary by machine. For correct corresponding fluid decal part number,
consult factory with serial numbers of your machine.
CAUTION
Mixing of other lubricants within the
compressor unit will void all
warranties.
®
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SECTION 8
8.25 DECAL GROUP (CONTINUED)
29
19
20
30
21
31
22
32
23
24
33
25
34
26
37
27
28
02250155_601_Decal_3
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PARTS LISTS
8.25 DECAL GROUP (CONTINUED)
Key
Description
Part Number
Note
Quantity
19
decal, microprocessor overlay
02250154-359
1
20
decal, black graphic
02250157-732
1
21
decal, side graphics
02250157-703
1
22
decal, black www.sullair.com
02250155-495
2
23
decal, fork lifting
241814
4
24
decal, VSD (variable speed drive)
02250162-215
1
25
decal, 3000 with stripe
02250157-029
1
26
decal, 3000P with stripe
02250166-030
1
27
decal, 3700 with stripe
02250157-030
1
28
decal, 4500 with stripe
02250157-031
1
29
decal, remove before start up
02250158-358
1
30
decal, voltage 460/3/60 international
02250569-399
(I)
1
31
decal, voltage 380-415/3/50 international
02250069-403
(I)
1
32
decal, voltage 230/3/60 international
02250069-397
(I)
1
33
decal, voltage 200/3/60 international
02250069-406
(I)
1
34
decal, voltage 575/3/60 international
02250069-400
(I)
1
35
nameplate, Sullair serial number
02250059-318
(II)
1
36
rivet, pop 1/8 x 1/2
843102-050
(III)
4
37
decal, warning n12 elec encl protection
02250164–823
1
(I)
This decal may vary per machine specification. Consult the Sullair factory for details.
(II)
See Figure 8-1 for features and location.
(III)
This part not shown.
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SULLAIR
®
3000-4500 Operator’s Manual and Parts List
137
SECTION 8
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138
3000-4500 Operator’s Manual and Parts List
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SULLAIR
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WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD.
Sullair Road, No. 1
Chiwan, Shekou
Shenzhen, Guangdong PRV.
PRC POST CODE 518068
Telephone: 755-6851686
Fax: 755-6853473
www.sullair-asia.com
SULLAIR CORPORATION
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
www.sullair.com
Telephone: 1-800-SULLAIR (U.S.A. Only)
or 1-219-879-5451
Fax: (219) 874-1273
CUSTOMER CARE
for PARTS and SERVICE
1-888-SULLAIR (7855247)
219-874-1835
CHAMPION COMPRESSORS, LTD.
Princess Highway
Hallam, Victoria 3803
Austrailia
Telephone: 61-3-9796-4000
Fax: 61-3-9703-8053
www.championcompressors.com.au
Printed in the U.S.A
Specifications subject to change
without prior notice
E07KCC
SULLAIR EUROPE, S.A.
Zone Des Granges BP 82
42602 Montbrison Cedex, France
Telephone: 33-477968470
Fax: 33-477968499
www.sullaireurope.com
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