USER MANUAL
INDUSTRIAL AIR COMPRESSOR
3000P, 3700, 4500
3000PV, 3700V, 4500V
30, 37 & 45 KW/40, 50 & 60HP
PART NUMBER:
02250176-182 R05
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual or,
misuse of this equipment will
VOID its warranty!
KEEP FOR
FUTURE
REFERENCE
COPYRIGHT 2012 SULLAIR
©
The information in this manual is current
as of its publication date, and applies to
compressor serial number:
201201120000
and all subsequent serial numbers.
AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Stationary compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.
For detailed course outlines, schedule, and cost information contact:
SULLAIR TRAINING DEPARTMENT
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
training@sullair.com
- Or Write Sullair
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
TABLE OF CONTENTS
SECTION 1—SAFETY
5
1.1
GENERAL
5
1.2
PERSONAL PROTECTIVE EQUIPMENT
5
1.3
PRESSURE RELEASE
6
1.4
FIRE AND EXPLOSION
7
1.5
MOVING PARTS
7
1.6
HOT SURFACES, SHARP EDGES AND SHARP CORNERS
7
1.7
TOXIC AND IRRITATING SUBSTANCES
8
1.8
ELECTRICAL SHOCK
8
1.9
LIFTING
9
1.10
ENTRAPMENT
9
1.11
SAFETY WARNINGS
SECTION 2—DESCRIPTION
11
2.1
INTRODUCTION
12
2.2
DESCRIPTION OF COMPONENTS
13
2.3
SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION
16
2.4
COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION
16
2.5
COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION
17
2.6
CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
19
2.7
AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
20
2.8
INTEGRAL DRYER OPTION
20
2.9
VARIABLE SPEED DRIVE (VSD) COMPONENTS
20
2.10
VSD CONTROL SYSTEM FUNCTIONAL DESCRIPTION
SECTION 3—SPECIFICATIONS
23
3.1
TABLE OF SPECIFICATIONS—3000P, 3700 & 4500 SERIES MODELS
24
3.2
TABLE OF SPECIFICATIONS—VARIABLE SPEED DRIVE MODELS
25
3.3
COMPRESSOR SPECIFICATIONS
26
3.4
LUBRICATION GUIDE
26
3.5
APPLICATION GUIDE
TABLE OF CONTENTS
27
3.6
LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE,
FLUID
28
3.7
IDENTIFICATION, AIR-COOLED
30
3.8
IDENTIFICATION, WATER-COOLED
32
3.9
IDENTIFICATION, AIR-COOLED W/ INTEGRAL DRYER
34
3.10
PIPING AND INSTRUMENTATION, AIR-COOLED
36
3.11
PIPING AND INSTRUMENTATION, WATER-COOLED
38
3.12
PIPING AND INSTRUMENTATION, AIR-COOLED WITH INTEGRAL
DRYER
40
3.13
WIRING DIAGRAM, VSD AIR-COOLED PARALLEL WYE SVX9000
42
3.14
WIRING DIAGRAM, AIR-COOLED PARALLEL WYE SVX9000
44
3.15
WIRING DIAGRAM, VSD AIR COOLED SERIES DELTA A1000
46
3.16
WIRING DIAGRAM, AIR COOLED MFV
48
3.17
WIRING DIAGRAM, YD CE
SECTION 4—INSTALLATION
51
4.1
MOUNTING OF COMPRESSOR
51
4.2
VENTILATION & COOLING
56
4.3
SERVICE AIR PIPING
57
4.4
COUPLING ALIGNMENT CHECK
57
4.5
FLUID LEVEL CHECK
57
4.6
ELECTRICAL PREPARATION
59
4.7
MOTOR ROTATION DIRECTION CHECK
SECTION 5—WS CONTROLLER
61
5.1
CONTROLLER LAYOUT
61
5.2
CONTROLLER KEYPAD
62
5.3
LCD DISPLAY
63
5.4
LED LIGHTS
SECTION 6—MAINTENANCE
65
6.1
GENERAL
65
6.2
DAILY OPERATION
65
6.3
MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
66
6.4
MAINTENANCE EVERY 2000 HOURS
66
6.5
FLUID MAINTENANCE
66
6.6
FILTER MAINTENANCE
66
6.7
AIR FILTER MAINTENANCE
67
6.8
SEPARATOR MAINTENANCE
69
6.9
TROUBLESHOOTING— INTRODUCTION
70
6.10
TROUBLESHOOTING GUIDE
Section 1
SAFETY
NOTE
the precautionary statements contained herein are
applicable to most compressors and the concepts
behind these statements are generally applicable to
all compressors.
1.2
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL.
1.1
GENERAL
Sullair 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.
While not specifically applicable to all types of
compressors with all types of prime movers, most of
PERSONAL PROTECTIVE
EQUIPMENT
A. 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)
5
SECTION 1
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.
inside diameter to reduce pressure in case of
hose failure.
D. Flow-limiting valves are listed by pipe size and
flow-rated. 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
6
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.
SECTION 1
1.5
MOVING PARTS
DANGER
A. Keep hands, arms and other parts of the body
and clothing away from couplings, belts, pulleys,
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.
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.
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 deenergized 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.
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.
B. DO NOT use air line anti-icer systems in air lines
supplying respirators or other breathing air utilization equipment and DO NOT discharge air
from these systems into unventilated or other
confined areas.
C. Operate the compressor only in open or adequately ventilated areas.
D. Locate the compressor 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.
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
7
SECTION 1
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.
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
It is the responsibility of each organization to
provide/arrange training for all their associates expected to test for electrostatic fields.
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.
8
SECTION 1
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.
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.
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.
1.10 ENTRAPMENT
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.
1.11 SAFETY WARNINGS
The following special instructions apply to VSD
packages provided with electronic adjustable speed
motor drives. These cautions that apply to VSD
operation.
WARNING
Ground the unit following the instructions in this
manual. Ungrounded units may cause electric
shock and/or fire. The variable speed drive has a
large capacitive leakage current during operation,
which can cause enclosure parts to be above
ground potential. Proper grounding, as described
in this manual, is required. Failure to observe this
precaution could result in death or severe injury.
WARNING
Before applying power to the variable speed
drive, make sure that the front and cable covers
are closed and fastened to prevent exposure to
potential electrical fault conditions. Failure to
observe this precaution could result in death or
severe injury.
WARNING
Refer all drive service to trained technicians. This
equipment should be installed, adjusted, and
serviced by qualified electrical maintenance
personnel familiar with the construction and
operation of this type of equipment and the
hazards involved and in accordance with
published service manuals. Failure to observe
this precaution could result in death or severe
injury.
WARNING
Line terminals (L1, L2, L3), motor terminals (U, V,
W) and the DClink/brake resistor terminals (-/+)
are live when the drive is connected to power,
even if the motor is not running. Contact with this
voltage is extremely dangerous and may cause
death or severe injury.
9
SECTION 1
WARNING
Before opening the variable speed drive covers:
• Disconnect all power to the variable speed drive.
• Wait a minimum of 5 (five) minutes after all the
lights on the keypad are off. This allows time for
the DC bus capacitors to discharge.
• A hazard voltage may still remain in the DC bus
capacitors even if the power has been turned off.
Confirm that the capacitors have fully discharged
by measuring their voltage using a multimeter set
to measure DC voltage. Failure to follow the above
precautions may cause death or severe injury.
CAUTION
Do not perform any meggar or voltage withstand
tests on any part of the variable speed drive or its
components. Improper testing may result in
damage. Prior to any tests or measurements of
the motor or the motor cable, disconnect the
motor cable at the variable speed drive output
terminals (U, VW) to avoid damaging the variable
speed drive during motor or cable testing.
CAUTION
Do not touch any components on the circuit
boards. Static voltage discharge may damage
the components.
CAUTION
Make sure that no power correction capacitors
are connected to the variable speed drive output or the motor terminals to prevent variable
speed drive malfunction and potential damage.
CAUTION
Make sure that the variable speed drive output
terminals (U, V, W) are not connected to the
utility line power as severe damage to the VSD
may occur.
NOTE
Interior electrical wiring is performed at the
factory. Required customer wiring is minimal,
but should be done by a qualified electrician
in compliance with OSHA, National Electrical
Code, and/or any other applicable State,
Federal, and local electrical codes concerning isolation switches, fused disconnects,
etc. Sullair provides a wiring diagram for use
by the installer.
NOTE
Customer must provide electrical supply
power disconnect within sight of machine.
CAUTION
Install the variable speed drive in a well ventilated room that is not subject to temperature
extremes, high humidity, or condensation, and
avoid locations that are directly exposed to
sunlight, or have high concentrations of dust,
corrosive gas, explosive gas, inflammable gas,
grinding fluid mist, etc. Improper installation
may result in a fire hazard.
10
3000P-4500 USER MANUAL
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 65 to
see how surprisingly easy it is to keep your air
compressor in top operating condition.
Figure 2-1: Overall Component Layout, Air-Cooled Model
1. Fluid Filter
8. E-Stop Button
2. Moisture Separator
9. Compressor Unit
3. Separator/Sump Tank
10. Cooler Fan Motor
4. Fluid Fill
11. Cooler
5. Fluid Fill Sight Glass
12. Motor
6. Starter Box
13. Air Inlet Filter
7. WS Controller
11
3000P-4500 USER MANUAL
SECTION 2
Figure 2-2: Overall Component Layout, Water-Cooled Model
2.2
1. Moisture Separator
8. E-Stop Button
2. Fluid Filter
9. Compressor Unit
3. Separator/Sump Tank
10. Oil Cooler
4. Fluid Fill
11. Aftercooler
5. Fluid Fill Sight Glass
12. Motor
6. Starter Box
13. Air Inlet Filter
7. WS Controller
14. Canopy Vent Fan
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
12
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.
SECTION 2
2.3
3000P-4500 USER MANUAL
SULLAIR COMPRESSOR
UNIT, FUNCTIONAL
DESCRIPTION
Sullair air compressors feature the Sullair
compressor
unit,
a
single-stage,
positive
displacement, flood lubricated- type compressor.
This unit provides continuous compression to meet
your needs.
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.
The 3000-4500 Series compressors are factory-filled
with Sullube lubricant. For more information on fluid
fill, consult Table of Specifications—3000p, 3700 &
4500 Series Models on page 23.
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.
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 self- addressed 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.
CAUTION
Mixing of other lubricants within the compressor unit will void all warranties.
13
3000P-4500 USER MANUAL
Figure 2-3: Air-Cooled, Cooling / Lubrication and Discharge System
14
SECTION 2
SECTION 2
3000P-4500 USER MANUAL
Figure 2-4: Water-Cooled, Cooling / Lubrication and Discharge System
15
3000P-4500 USER MANUAL
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 separator/
sump tank causes fluid flow by forcing the fluid from
the high pressure area of the separator/sump tank to
an area of lower pressure in the compressor unit.
Fluid flows from the bottom of the separator/sump
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.
As the discharge temperature rises above 185°F (85
°C), due to the heat of compression, the thermal
valve begins to adjust 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 portion of the fluid flowing to the compressor is
routed to the anti-friction bearings which support the
rotors inside the compressor unit.
The fluid filter has a replacement element and an
integral pressure bypass valve. Refer to Lubrication
Change Recommendations and Maintenance, Fluid
on page 27.
SECTION 2
The compressed air/fluid mixture enters the
separator/sump 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 separator/sump 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 dry side of the
separator/sump tank 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 separator/sump
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 at nominal rated
pressures 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 on page 27.
A
minimum
pressure/check
valve,
located
downstream from the separator, assures a minimum
separator/sump pressure of 50 psig (3.4 bar) during
loaded conditions. This pressure is necessary for
proper air/fluid separation and proper fluid
circulation.
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 separator/sump on shutdown and during
operation of the compressor in an unloaded
condition.
A pressure relief valve (located on the wet side of the
separator) is set to open if the separator/sump tank
pressure exceeds the separator/sump tank rating.
The WS Controller will shut down the compressor if
the discharge temperature reaches 235°F (113°C).
Water-cooled models have a water pressure switch
to prevent operation with inadequate water pressure.
2.5
COMPRESSOR DISCHARGE
SYSTEM, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-3 or Figure 2-4. The compressor
unit discharges the compressed air/fluid mixture into
the combination separator/sump tank.
The separator/sump has three basic functions:
1. 1. It acts as a primary fluid separator.
2. 2. Serves as the compressor fluid sump.
3. 3. Houses the final fluid separator.
16
WARNING
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.
Fluid is added to the separator/sump tank via a
capped fluid filler opening, placed low on the tank to
prevent overfilling of the separator/sump tank. A
sight glass enables the operator to visually monitor
the separator/sump tank fluid level.
SECTION 2
2.6
3000P-4500 USER MANUAL
CONTROL SYSTEM,
FUNCTIONAL DESCRIPTION
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.
START MODE - 0 TO 50 PSIG (0 TO 3.5 BAR)
When the compressor "
" (START) pad is
depressed, the separator/sump 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).
Figure 2-5: Standard Sequencing Control System
1. Air Outlet
6. Minimum Pressure/Check Valve
2. Unload Solenoid Valve
7. Separator/Sump Tank
3. Pressure Regulator
8. Sequencing Solenoid Valve
4. Air Inlet
9. WS Controller
5. Blowdown Valve
17
3000P-4500 USER MANUAL
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 de- energizes the solenoid
valve allowing separator/sump 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 to the atmosphere, located in
the compressor separator/sump tank, reducing the
separator/sump tank pressure to approximately 17
18
SECTION 2
psig (1.2 bar). The check valve in the air service line
prevents line pressure from returning to the
separator/sump tank.
When the line pressure drops to the low setting (cutin 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 re- energized 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.
SECTION 2
2.7
3000P-4500 USER MANUAL
AIR INLET SYSTEM,
FUNCTIONAL DESCRIPTION
Refer to Figure 2-6. The compressor inlet system
consists of a dry-type air filter, a restriction gauge
and an air inlet valve.
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)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.
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 18. The inlet valve also acts as a
check valve, thus preventing reverse rotation when
the compressor is shut down.
Figure 2-6: Air Inlet System
1. Air Inlet Filter
4. Separator/Sump Tank
2. Air Inlet
5.
Restriction Indicator
3. Compressor Unit
19
3000P-4500 USER MANUAL
2.8
INTEGRAL DRYER OPTION
An integral refrigerated dryer option is available. The
integral dryer is designed to work with the
compressor WS controller which controls dryer
starting and stopping, condensate drain valve
function and monitors dewpoint temperature and
dryer warnings and faults.
The dryer is fully
connected from the factory and is ready to run when
the compressor is installed.
Detail of dryer operation and spare parts can be
found in a supplement Manual 02250174-308 which
is provided with your machine.
Per the controller default settings, on initial start-up
the compressor will run unloaded for 5 minutes,
allowing the dryer to run and cool down. This
prevents condensate from initially being allowed into
the compressed air stream. It also delays the supply
of compressed air from the compressor until the 5
minute cool-down period is completed. When the
automatic control mode is selected, the compressor
will stop after running unloaded for a prescribed time,
but the dryer will continue to run to ensure there will
not be a surge of condensate when the compressor
re-starts. For other settings and control options, refer
to the WS controller manual 02250165-411, or to
your authorized Sullair servicing distributor.
In case the compressor needs to operate while the
dryer is being serviced, the dryer can be bypassed,
and removed if necessary for service. To bypass the
dryer, disconnect the inlet hose to the dryer,
disconnect the outlet hose at the main service
connection, and re-connect the dryer inlet hose to the
main service connection. Remove the fuses
powering the dryer and control wiring located in the
compressor electrical box. The WS controller must
be set-up for the compressor to run on dryer fault. If
necessary, this can be reset by your authorized
Sullair servicing distributor.
2.9
VARIABLE SPEED DRIVE
(VSD) COMPONENTS
The VSD, located in the machine’s electrical
enclosure, works in concert with the WS Controller to
allow the compressor to match its output to the
current demand of the system. The drive’s heat sink
extends through the back of the enclosure, and its
cooled by air flowing through the compressor
enclosure.
20
SECTION 2
2.10 VSD CONTROL SYSTEM
FUNCTIONAL DESCRIPTION
Refer to Figure 2-4. The controls consist of:
• a VSD
• a solenoid valve
• a regulating valve
• and an inlet valve.
Depending on the model, a compressor can be
operated at a setpoint pressure from 60 to 175 psig
(4.1 to 12.1 bar). The WS Controller automatically
sets the frequency range based on the selected
pressure. (The compressor's operating range is on
its nameplate.)
The following paragraphs apply to a compressor with
a 100 psig (6.9) operating pressure and a 6 psi (0.4
bar) load delta setting.
NOTE
The load delta default setting is 10 psi (0.7
bar). Sullair recommends a setting of 6
psi (0.4) for the most efficient operation.
Compressors with different pressure
ranges perform in the same manner.
operating
START MODE - 0 TO 50 PSIG (0 TO 3.5
BAR)
Pressing the WS Controller START button (1) signals
the VSD to accelerate the motor to full speed,
causing the separator/sump tank pressure to rise
from 0 to 50 psig (0 to 3.4 bar). At this time both the
pressure regulator and solenoid valves are closed;
the inlet valve is fully open and the air-end provides a
full flow to the separator/sump tank. A minimum
pressure valve set at approximately 50 psig (3.4 bar)
isolates the rising compressor air pressure from the
service line.
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 to the service
line. From this point on the WS Controller monitors
the line pressure which controls the VSD. The
pressure regulator and solenoid valves remain
closed with the inlet valve fully open, running at 100
psig (6.9 bar) or lower.
SECTION 2
VSD PART LOAD CONTROL
The service line pressure increases to a value above
100 psig (6.9) if the demand is less than the
compressor's rated capacity. In this condition, the
VSD slows the motor's rpm which reduces the output
to match the demand. The drive continuously adjusts
the motor's rpm to maintain a 100 psig (6.9 bar) line
pressure.The WS Controller maintains the correct
frequency when the VSD is operating in this mode.
MODULATING MODE-100 TO 106 PSIG
(7.3 TO 6.9 BAR)
During low demand periods and with the VSD
running 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 2-4) gradually opens, directing air
pressure to the inlet control valve piston. This action
causes the inlet valve to partially close, thereby
reducing the air flow entering the compressor until it
matches the demand. The control system functions
continuously in this manner between less than 101
psig (7.0 bar) to 106 psig (7.3 bar), in response to
varying system 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 off any
accumulated moisture from the control line. When
the discharge pressure rises above 106 psig (7.3
bar), or to a preset unload pressure, the compressor
unloads.
3000P-4500 USER MANUAL
UNLOAD MODE-IN EXCESS OF 106 PSIG
(7.3 BAR)
When there is no demand or it is at a minimal level,
the service line pressure continues to rise. When it
exceeds 106 psig (7.3 bar), or reaches a preset
unload pressure value, the WS control system de
energizes the solenoid valve allowing separator/
sump tank air pressure to be supplied directly which
closes the inlet valve. The solenoid valve
simultaneously sends a pneumatic signal to the blow
down valve which opens to the atmosphere, and
reduces the separator/sump tank pressure. The
check valve in the air service line prevents line
pressure from back-flowing to the separator/sump
tank. The compressor will shut down after the
programmed unload time setting expires (the default
setting is zero [0] minutes for an immediate shutdown
upon unload). When the line pressure drops to the
low pressure setting of 100 psig (6.9 bar) the WS
Controller starts the motor and energizes the
solenoid valve which closes the blowdown valve. The
re-energized solenoid valve prevents line pressure
from reaching the inlet control valve, thereby allowing
it to fully open, and the compressor supplies
compressed air to the system.
21
NOTES
22
3000P-4500 USER MANUAL
Section 3
SPECIFICATIONS
3.1
TABLE OF SPECIFICATIONS—3000P, 3700 & 4500 SERIES
MODELS
DIMENSIONS
MODEL (I)
HP
Length
in
mm
Width
in
mm
Height
in
mm
Weight
Weight
lbs
kg
ODP
TEFC
ODP
TEFC
3000P SERIES
3007P
40
62
1575
34.5
876
61.5
1562
1993
2059
904
934
3009P
40
62
1575
34.5
876
61.5
1562
1993
2059
904
934
3010P
40
62
1575
34.5
876
61.5
1562
1993
2059
904
934
3700 SERIES
3707
50
62
1575
34.5
876
61.5
1562
2043
2127
927
965
3709
50
62
1575
34.5
876
61.5
1562
2043
2127
927
965
3710
50
62
1575
34.5
876
61.5
1562
2043
2127
927
965
3712
50
62
1575
34.5
876
61.5
1562
2043
2127
927
965
4500 SERIES
4509
60
62
1575
34.5
876
61.5
1562
2193
2270
995
1030
4510
60
62
1575
34.5
876
61.5
1562
2193
2270
995
1030
4512
60
62
1575
34.5
876
61.5
1562
2193
2270
995
1030
(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).
Integral dryer Package adds: 284lbs (129kg) to total package weight and 10in (22mm) to package length.
23
3000P-4500 USER MANUAL
3.2
SECTION 3
TABLE OF SPECIFICATIONS—VARIABLE SPEED DRIVE MODELS
VSD SERIES (I) - 3000P (MODELS 3007 THROUGH 3010)
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)
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
DRIVE AMP RATING
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
ODP
TEFC
460/60
575/60
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
DRIVE AMP RATING
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
DRIVE AMP RATING
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
(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).
24
SECTION 3
3.3
3000P-4500 USER MANUAL
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
Separator/Sump 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.
COMPRESSOR:
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, 460
60Hz, 380-415V (400V) 50 Hz
Maximum Ambient Temperature
104°F (40°C)
Available Options:
200V and 575V 60Hz, 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)
(llI) Multi-frequency and voltage motors are used. The compressors must be used only with the specified electrical frequency and voltage
25
3000P-4500 USER MANUAL
3.4
SECTION 3
LUBRICATION GUIDE
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
NOTE
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.
Mixing of other lubricants within the compressor unit will void all warranties.
If fluid change is required, follow Section 3.6:
Lubrication
Change
Recommendations
and
Maintenance, Fluid on page 27.
4
1
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)
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.
2
3
Figure 3-1: Fluid Fill Location
1. Fluid Fill Port
2. Sight Glass
3. Fluid Drain Valve
4. Separator/Sump Tank
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.
26
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.
SECTION 3
3.6
3000P-4500 USER MANUAL
LUBRICATION CHANGE RECOMMENDATIONS AND
MAINTENANCE, FLUID
LUBRICANT
FLUID CHANGE
FLUID FILTER CHANGE
SEPARATOR CHANGE
Sullube (3.0 gal)
A, E
G, C
A, D
SRF 1/4000 (3.0 gal)
B, E
G, C
B, D
24KT (3.0 gal)
F, E
G, C
A, D
CP-4600-32-F (3.0 gal)
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.
27
IDENTIFICATION, AIR-COOLED
SECTION 3
02250156-213 R07
3000P-4500 USER MANUAL
28
3.7
KEY
NO.
1
2
IDENTIFICATION, AIR-COOLED
PART NO.
Q
T
Y
MACHINE WEIGHTS
DESCRIPTION
ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE
AROUND MACHINE FOR ACCESS AND FREE CIRCULATION
OF AIR.
A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING
THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED. THE
COMPRESSOR FRAME MUST BE LEVELLED AND SECURED
BETWEEN THE FRAME AND THE FOUNDATION. NO PIPING
LOADS ARE PERMITTED AT EXTERNAL CONNECTIONS.
3
ALL DIMENSIONS ARE +/- .50" [12.7MM].
4
RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS
SHOWN ON DRAWING.
5
IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR,
HIGH STATIC FAN MUST BE SELECTED. MAX ALLOWABLE
ADDITIONAL STATIC PRESSURE 0.4 IN WATER WITH HIGH
STATIC FAN.
6
DOORS ARE REMOVABLE USING LIFT-OFF HINGE PINS.
7
ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER
DIMENSIONS IN PARENTHESES.
Main Motor
HP
Motor Type
Weight
Cooling Air
(CFM)
3000P
40
odp
1993 lbs/904 kg
4800
3000P
40
tefc
2059 lbs/934 kg
4800
3700
50
odp
2043 lbs/927 kg
4800
3700
50
tefc
2127 lbs/ 965 kg
4800
4500
60
odp
2193 lbs/955 kg
5600
4500
60
tefc
2270 lbs/1030 kg
5600
SECTION 3
3.7
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
3000P-4500 USER MANUAL
29
IDENTIFICATION, WATER-COOLED
SECTION 3
02250160-729 R03
3000P-4500 USER MANUAL
30
3.8
KEY
NO.
1
2
IDENTIFICATION, WATER-COOLED
PART NO.
Q
T
Y
MACHINE WEIGHTS
DESCRIPTION
ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE
AROUND MACHINE FOR ACCESS AND FREE CIRCULATION
OF AIR.
A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING
THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED. THE
COMPRESSOR FRAME MUST BE LEVELLED AND SECURED
BETWEEN THE FRAME AND THE FOUNDATION. NO PIPING
LOADS ARE PERMITTED AT EXTERNAL CONNECTIONS.
3
ALL DIMENSIONS ARE +/- .50" [12.7MM].
4
RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS
SHOWN ON DRAWING.
5
IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR,
HIGH STATIC FAN MUST BE SELECTED. MAX ALLOWABLE
ADDITIONAL STATIC PRESSURE 0.4 IN WATER WITH HIGH
STATIC FAN.
6
DOORS ARE REMOVABLE USING LIFT-OFF HINGE PINS.
7
ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER
DIMENSIONS IN PARENTHESES.
Main Motor
HP
Motor Type
Weight
Cooling Air
(CFM)
3000P
40
odp
1993 lbs/904 kg
730
3000P
40
tefc
2059 lbs/934 kg
730
3700
50
odp
2043 lbs/927 kg
730
3700
50
tefc
2127 lbs/ 965 kg
730
4500
60
odp
2193 lbs/955 kg
730
4500
60
tefc
2270 lbs/1030 kg
730
SECTION 3
3.8
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
3000P-4500 USER MANUAL
31
IDENTIFICATION, AIR-COOLED W/ INTEGRAL DRYER
SECTION 3
02250169-069 R02
3000P-4500 USER MANUAL
32
3.9
KEY
NO.
1.
2.
IDENTIFICATION, AIR-COOLED W/ INTEGRAL DRYER
PART NO.
Q
T
Y
MACHINE WEIGHTS
DESCRIPTION
ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE
AROUND MACHINE FOR ACCESS AND FREE CIRCULATION
OF AIR.
A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING
THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSOR FRAME LEVEL IS REQUIRED. THE
COMPRESSOR FRAME MUST BE LEVELLED AND SECURED
BETWEEN THE FRAME AND THE FOUNDATION. NO PIPING
LOADS ARE PERMITTED AT EXTERNAL CONNECTIONS.
3.
ALL DIMENSIONS ARE +/- .50" [12.7MM].
4.
RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS
SHOWN ON DRAWING.
5.
IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR, HIGH
STATIC FAN MUST BE SELECTED. MAX ALLOWABLE ADDITIONAL STATIC PRESSURE 0.4 IN WATER WITH HIGH STATIC
FAN.
6.
DOORS ARE REMOVABLE USING LIFT-OFF HINGE PINS.
7.
ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER
DIMENSIONS IN PARENTHESES.
Main Motor
HP
Motor Type
Weight
(Lbs/Kg)
Cooling Air
(CFM)
3000P
40
odp
2277/1033
4800
3000P
40
tefc
2343/1063
4800
3700
50
odp
2327/1055
4800
3700
50
tefc
2411/1094
4800
4500
60
odp
2477/1124
5600
4500
60
tefc
2554/1158
5600
SECTION 3
3.9
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
3000P-4500 USER MANUAL
33
SECTION 3
02250156-203 R16
3000P-4500 USER MANUAL
34
3.10 PIPING AND INSTRUMENTATION, AIR-COOLED
KEY
NO.
PART NO.
Q
T
Y
DESCRIPTION
N
O
T
E
KEY
NO.
PART NO.
Q
T
Y
DESCRIPTION
N
O
T
E
1
02250127-683
1
FILTER, AIR 9” PLASTIC
29
02250182-548
1
VLV,BALL/STNR COMBO-1/2”NPT
2
250003-869
1
INDICATOR, RESTRICTION
30
02250182-545
1
DRN,ZERO LOSS 115V 1/2”NPT
3
-
1
INLET
31
02250112-881
1
VENT,ENCL PROT 1/2” SIDE MTG Z-PRG
4
-
1
COMPRESSOR UNIT
32
241771
1
STRAINER, V-TYPE 300PSIX1/4
5
-
1
MOTOR
33
02250140-865
1
VLV, BALL 1/8” MX 1/8”F 1/4 TURN
6
02250155-708
1
FILTER, CORELESS 1-1/16 SAE
NOTES:
7
02250151-493
1
COOLER, AIR/OIL 50HP
1
PART NUMBERS ARE FOR REFERENCE ONLY. REFER TO BILL OF MATERIAL AND OR FACE OF ORDER FOR ACTUAL PARTS.
2
SECTION BETWEEN LETTERED POINTS ARE TO BE REPLACED WITH CORRESPONDING OPTION PICTURED BELOW, AS REQUIRED BY FACE OF
ORDER.
7
02250152-862
1
COOLER, AIR/OIL 60HP
8
02250092-081
1
VALVE, THERMAL 195DEG 1-1/2”-18
8
02250148-796
1
VALVE, THERMAL 210DEG 1-1/2”-18
9
02250125-774
1
ORIFICE, 1/8 X 1/32
3
CONTROL/MOISTURE DRAIN LINES ARE 1/4” TUBING EXCEPT AS NOTED.
10
02250126-129
1
GLS, SIGHT/ORF SAE
4
11
02250117-782
1
FILTER, ASSY GENISIS
12
02250097-610
1
PLUG,SIGHTGLASS 1-5/16” SAE
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.
13
02250155-175
1
PROBE, THERMISTER 3000 OHM
5
PART VARIES BY MODEL.
14
250006-938
1
VALVE, RELIEF 1/2”
15
02250155-174
2
XDUCR, 1-250# RADIOMETRIC
16
408893
1
VALVE, SHUTTLE 1/4” DOUBLE CHK
17
02250097-598
1
VLV, MIN PRESSURE 1-7/8 SAE
18
02250100-042
1
VALVE, BLOWDOWN 1/2” 1.8:1
19
02250166-734
1
SEP,WTR SCWS-235N 1 1/2” L/AD
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
COMPONENT
P1
DESCRIPTION
WET SUMP PRESSURE
LINE PRESSURE
SOL1
LOAD/UNLOAD SOLENOID VALVE
02250160-774
1
ELEM,SEP ROUND 5.5D X 14.3LNG
SOL4
MEC/SEQUENCING/FULL LOAD SOLENOID VALVE
21
02250173-972
1
FLTR,PNEUMATIC 1/8”NPT 5MICRON
SOL5
COMBO DRAIN/JZL DRAIN SOLENOID VALVE
T1
WET DISCHARGE TEMPERATURE
22
02250170-783
1
VLV,DR COMBO 24 VDC
23
02250155-714
2
VLV,SOL 3WNO 1/4 250# 24VDC
24
250017-280
1
VALVE, PRESSURE REG
25
02250149-624
1
TANK, SEPARATOR
26
02250161-433
1
ORIFICE,.140 X 1/4M X 1/4F
Blue
TANK PRESSURE
27
02250078-976
1
GA,DIFF PRESS Z-PURGE ASY REGU
Yellow
REG PRESSURE
28
02250115-272
1
VLV,CHK 1/4”NPTF BRASS VITON
Red
UNLOAD PRESS
Clear
WATER DRAIN
TUBING
COLOR
PURPOSE
35
3000P-4500 USER MANUAL
P2
20
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
SECTION 3
3.10 PIPING AND INSTRUMENTATION, AIR-COOLED
SECTION 3
02250162-393 R08
3000P-4500 USER MANUAL
36
3.11 PIPING AND INSTRUMENTATION, WATER-COOLED
KEY
NO.
PART NO.
Q
T
Y
DESCRIPTION
KEY
NO.
PART NO.
Q
T
Y
DESCRIPTION
1
02250127-683
1
FILTER, AIR 9” PLASTIC
33
02250182-548
1
VLV,BALL/STNR COMBO-1/2”NPT
2
250003-869
1
INDICATOR, RESTRICTION
34
241771
1
STRAINER, V-TYPE 300PSIX1/4
3
-
1
INLET
NOTES:
4
-
1
COMPRESSOR UNIT
1
5
-
1
MOTOR
6
02250155-708
1
FILTER, CORELESS 1-1/16 SAE
PART NUMBERS ARE FOR REFERENCE ONLY.
REFER TO BILL OF MATERIAL AND OR FACE
OF ORDER FOR ACTUAL PARTS.
7
02250094-744
1
CLR,OIL/WATER 5X36 1-5/16”SAE
2
8
02250092-081
1
VALVE, THERMAL 195DEG 1-1/2”-18
8
02250148-796
1
VALVE, THERMAL 210DEG 1-1/2”-18
SECTION BETWEEN LETTERED POINTS ARE TO BE
REPLACED WITH CORRESPONDING OPTION PICTURED
BELOW, AS REQUIRED BY FACE OF ORDER.
9
02250125-774
1
ORIFICE, 1/8 X 1/32
3
CONTROL/MOISTURE DRAIN LINES ARE
1/4” TUBING EXCEPT AS NOTED.
10
02250126-129
1
GLS, SIGHT/ORF SAE
4
11
02250117-782
1
FILTER, ASSY GENISIS
12
02250097-610
1
PLUG,SIGHTGLASS 1-5/16” SAE
13
02250155-175
1
PROBE, THERMISTER 3000 OHM
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.
14
250006-938
1
VALVE, RELIEF 1/2”
5
PART VARIES BY MODEL.
15
02250155-174
2
XDUCR, 1-250# RADIOMETRIC
16
408893
1
VALVE, SHUTTLE 1/4” DOUBLE CHK
17
02250097-598
1
VLV, MIN PRESSURE 1-7/8 SAE
18
02250100-042
1
VALVE, BLOWDOWN 1/2” 1.8:1
19
02250166-734
1
SEP,WTR SCWS-235N 1 1/2” L/AD
P1
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
COMPONENT
DESCRIPTION
WET SUMP PRESSURE
20
02250160-774
1
ELEM,SEP ROUND 5.5D X 14.3LNG
P2
LINE PRESSURE
21
02250173-972
1
FLTR,PNEUMATIC 1/8”NPT 5MICRON
SOL1
LOAD/UNLOAD SOLENOID VALVE
02250170-783
2
VLV,DR COMBO 24 VDC
SOL4
MEC/SEQUENCING/FULL LOAD SOLENOID VALVE
23
02250155-714
2
VLV,SOL 3WNO 1/4 250# 24VDC
SOL5
COMBO DRAIN/JZL DRAIN SOLENOID VALVE
24
250017-280
1
VALVE, PRESSURE REG
SOL6
WATER SOLENOID VALVE
25
02250149-624
1
TANK, SEPARATOR
T1
WET DISCHARGE TEMPERATURE
26
02250161-433
1
ORF,.140”.25 FNPT X .25
27
02250182-545
1
DRN,ZERO LOSS 115V 1/2”NPT
28
02250115-272
1
VLV,CHK 1/4”NPTF BRASS VITON
29
250017-527
1
HT EXCH
BLUE
30
250017-992
1
SWITCH, PRESS NO 10 PSI
BLACK
SYS PRESSURE
31
47398
1
VALVE, WATER REG 3/4”160-230F
YELLOW
REG PRESSURE
32
02250125-668
1
VLV,SOL 2WNC 3/4 250# N4
RED
UNLOAD PRESS
CLEAR
WATER DRAIN
TUBING COLOR
PURPOSE
TANK PRESSURE
37
3000P-4500 USER MANUAL
22
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
SECTION 3
3.11 PIPING AND INSTRUMENTATION, WATER-COOLED
SECTION 3
02250171-773 R02
3000P-4500 USER MANUAL
38
3.12 PIPING AND INSTRUMENTATION, AIR-COOLED WITH INTEGRAL DRYER
KEY
NO.
PART NO.
Q
T
Y
DESCRIPTION
N
O
T
E
KEY
NO.
PART NO.
Q
T
Y
DESCRIPTION
1
02250125-369
1
FILTER,AIR INLET 8” (PLASTIC)
5
31
44905
2
VALVE,CHECK
1
02250127-683
1
FILTER,AIR INLET 9” (PLASTIC)
5
32
02250175-087
1
PROBE,THERMISTER 3000 OHM NTC 12’ L
2
250003-869
1
INDICATOR, RESTRICTION
33
02250173-972
1
FLTR,PNEUMATIC 1/8”NPT
3
-
1
INLET
NOTES:
4
-
1
COMPRESSOR UNIT
1
5
-
1
MOTOR
6
02250155-708
1
FILTER, CORELESS 1-1/16 SAE
PART NUMBERS ARE FOR REFERENCE ONLY.
REFER TO BILL OF MATERIAL AND OR FACE
OF ORDER FOR ACTUAL PARTS.
7
02250152-862
1
COOLER, AIR/OIL 60HP
2
7
02250151-493
1
COOLER, AIR/OIL 50HP
5
8
02250148-796
1
VALVE, THERMAL 210DEG 1-1/2”-18
5
SECTION BETWEEN LETTERED POINTS ARE TO BE
REPLACED WITH CORRESPONDING OPTION PICTURED
BELOW, AS REQUIRED BY FACE OF ORDER.
8
02250092-081
1
VALVE, THERMAL 195DEG 1-1/2”-18
5
3
CONTROL/MOISTURE DRAIN LINES ARE
1/4” TUBING EXCEPT AS NOTED.
4
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.
5
9
02250125-774
1
ORIFICE, 1/8 X 1/32
10
02250126-129
1
GLS, SIGHT/ORF SAE
11
02250117-782
1
FILTER, ASSY GENISIS
12
02250097-610
1
PLUG,SIGHTGLASS 1-5/16” SAE
13
02250155-175
1
PROBE, THERMISTER 3000 OHM
14
250006-938
1
VALVE, RELIEF 1/2”
15
02250155-174
2
XDUCR, 1-250# RADIOMETRIC
16
408893
1
VALVE, SHUTTLE 1/4” DOUBLE CHK
17
02250097-598
1
VLV, MIN PRESSURE 1-7/8 SAE
P1
18
02250100-042
1
VALVE, BLOWDOWN 1/2” 1.8:1
P2
LINE PRESSURE
19
02250166-734
1
SEP,WTR SCWS-235N 1 1/2” L/AD
SOL1
LOAD/UNLOAD SOLENOID VALVE
20
02250160-774
1
ELEM,SEP ROUND 5.5D X 14.3LNG
SOL4
MEC/SEQUENCING/FULL LOAD SOLENOID VALVE
21
02250170-783
1
VLV,DR COMBO 24 VDC
SOL5
ELECTRIC DRAIN
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
COMPONENT
DESCRIPTION
WET SUMP PRESSURE
241771
1
STRAINER, V-TYPE 300PSI X 1/4
T1
WET DISCHARGE TEMPERATURE
23
02250155-714
2
VLV,SOL 3WNO 1/4 250# 24VDC
T3
DRYER DEWPOINT TEMPERATURE PROBE
24
250017-280
1
VALVE, PRESSURE REG
25
02250149-624
1
TANK, SEPARATOR
26
02250161-433
1
ORIFICE,.140 X 1/4M X 1/4F
27
02250115-272
1
VLV,CHK 1/4”NPTF BRASS VITON
Blue
TANK PRESSURE
28
02250168-837
1
VENT,ENCL PROT 1/2” TOP
Yellow
REG PRESSURE
29
02250169-612
1
GA,DIFF PRESS Z-PRG ASY BTM
Red
UNLOAD PRESS
30
-
1
INTEGRAL REFRIGERANT DRYER
Clear
WATER DRAIN
TUBING COLOR
PURPOSE
39
3000P-4500 USER MANUAL
22
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
N
O
T
E
SECTION 3
3.12 PIPING AND INSTRUMENTATION, AIR-COOLED WITH INTEGRAL DRYER
SECTION 3
02250156-119 R09
3000P-4500 USER MANUAL
40
3.13 WIRING DIAGRAM, VSD AIR-COOLED PARALLEL WYE SVX9000
COMP
DESCRIPTION
1M
COMPRESSOR MOTOR
2M
COOLER FAN MOTOR STARTER
2MOL
COMP
HTR4
TH
XFMR1
FAN MOTOR OVERLOAD
SCD
DESCRIPTION
(OPT’L) CONTROL PANEL HEATER 50WATTS
THERMOSTAT FOR HEAT TRACE OPTION
CONTROL TRANSFORMER FOR SCD DRAIN
(OPT’L) SCD DRAIN
1FU
FAN MOTOR BRANCH CIRCUIT FUSES
2FU
SCD TRANSFORMER PRIMARY FUSES
3FU
SCD TRANSFORMER SCONDARY FUSE
NOTES
WET SUMP PRESSURE SENSOR
1
CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.
2
REMOVE JUMPER FOR AUXILLIARY E-STOP STRING
DEVICES.
3
USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY
OPTIONAL INPUTS TO THE WS CONTROLLER. MOUNT THE
RELAY LOCALLY IN THE STARTER BOX.
P1
P2
PACKAGE DISCHARGE PRESSURE SENSOR
T1
UNIT DISCHAGE TEMPERATURE PROBE
PSW1
(OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC
DPSW1
(OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID
INPUT 7
REMOTE RUN/UNLOAD
INPUT 8
CUSTOMER FURNISHED FAULT
INPUT 9
CUSTOMER FURNISHED WARNING
SOL1
LOAD CONTROL SOLENOID VALVE
SOL4
SEQUENCEING SOLENOID VALVE
SOL5
ELECTRIC CONDENSATE DRAIN VALVE
PS
24VDC POWER SUPPLY
K1
INTERNAL FAN RELAY CONTACT TEMP (T1) CONTROLLED
INTERNAL Y-DELTA START RELAY COMPRESSOR RUNNING
INTERNAL WYE-DELTA RUN RELAY COMPRESSOR
ENABLED
K4
INTERNAL LOAD CONTROL RELAY
K5
INTERNAL SEQUENCE RELAY
K6
INTERNAL ELECTRIC DRAIN RELAY
K7
INTERNAL COMMON FAULT RELAY
41
PMR
OPT’L POWER MONITOR RELAY
HTR1
(OPT’L) SUMP HEATER 800W
HTR2
(OPT’L) HEAT TRACE
HTR3
(OPT’L) TRAP HEATER 70WATTS
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
3000P-4500 USER MANUAL
K2
K3
SECTION 3
3.13 WIRING DIAGRAM, VSD AIR-COOLED PARALLEL WYE SVX9000
SECTION 3
02250171-938-R04
3000P-4500 USER MANUAL
42
3.14 WIRING DIAGRAM, AIR-COOLED PARALLEL WYE SVX9000
COMP
DR
1MOL
1M
DESCRIPTION
COMP
DESCRIPTION
DRYER START RELAY
TH
THERMOSTAT FOR HEAT TRACE OPTION
COMPRESSOR OVERLOAD
3FU
FAN MOTOR BRANCH FUSES
COMPRESSOR STARTER
6FU
INTEGRAL DRYER FUSES
FAN MOTOR OVERLOAD
7FU
INTEGRAL DRYER FUSES (575V)
P1
WET SUMP PRESSURE SENSOR
PPR
POWER PRESENT RELAY OPTION
P2
PACKAGE DISCHARGE PRESSURE SENSOR
T1
UNIT DISCHARGE TEMPERATURE PROBE
2MOL
T3
PSW1
(OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID
INPUT 7
REMOTE RUN/UNLOAD
INPUT 8
CUSTOMER FURNISHED FAULT
INPUT 9
CUSTOMER FURNISHED WARNING
SOL1
LOAD CONTROL SOLENOID VALVE
SOL4
SEQUENCEING SOLENOID VALVE
SOL5
ELECTRIC CONDENSATE DRAIN VALVE
PS
24VDC POWER SUPPLY
K1
INTERNAL RUN RELAY CONTACT
K2
INTERNAL Y-DELTA START RELAY
INTERNAL WYE-DELTA RUN RELAY
K4
INTERNAL LOAD CONTROL RELAY
K5
INTERNAL SEQUENCE RELAY
K6
INTERNAL ELECTRIC DRAIN RELAY
PF CAP
INTERNAL COMMON FAULT RELAY
OPT’L POWER MONITOR RELAY
POWER FACTOR CORRECTION CAPACITOR (OPT’L)
43
HTR1
(OPT’L) SUMP HEATER 800W
HTR2
(OPT’L) HEAT TRACE
HTR3
(OPT’L) TRAP HEATER 70WATTS
HTR4
(OPT’L) CONTROL PANEL HEATER 50WATTS
NOTES
1
CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.
2
REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.
3
1MOL SETTING TO BE 1M FLA. PLUS 2M FLA.
4
USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY
OPTIONAL INPUTS TO THE WS CONTROLLER. MOUNT THE
RELAY LOCALLY IN THE STARTER BOX.
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
3000P-4500 USER MANUAL
K3
K7
DRYER FAULT
DRYER DEWPOINT TEMPERATURE PROBE
(OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC
DPSW1
PMR
DF
SECTION 3
3.14 WIRING DIAGRAM, AIR COOLED MFV WITH INTEGRAL DRYER
SECTION 3
02250199-933-R00
3000P-4500 USER MANUAL
44
3.15 WIRING DIAGRAM, VSD AIR COOLED SERIES DELTA A1000
COMP
DESCRIPTION
1M
COMPRESSOR MOTOR
2M
COOLER FAN MOTOR STARTER
2MOL
FAN MOTOR OVERLOAD
1FU
FAN MOTOR BRANCH CIRCUIT FUSES
2FU
JZL TRANSFORMER PRIMARY FUSES (P12 ONLY)
3FU
JZL TRANSFORMER SECONDARY FUSE (P12 ONLY)
P1
TH
XFWR1
JZL
DESCRIPTION
THERMOSTAT FOR HEAT TRACE OPTION
CONTROL TRANSFORMER FOR JZL DRAIN (P12 ONLY)
OPTIONAL JZL DRAIN (P12 ONLY)
WET SUMP PRESSURE SENSOR
P2
PACKAGE DISCHARGE PRESSURE SENSOR
T1
UNIT DISCHARGE TEMPERATURE PROBE
PSW1
COMP
SECTION 3
3.15 WIRING DIAGRAM, VSD AIR COOLED SERIES DELTA A1000
(OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC
DPSW1
(OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID
INPUT 7
REMOTE RUN/UNLOAD
INPUT 8
CUSTOMER FURNISHED FAULT
INPUT 9
CUSTOMER FURNISHED WARNING
SOL1
LOAD CONTROL SOLENOID VALVE
SOL4
SEQUENCEING SOLENOID VALVE
SOL5
ELECTRIC CONDENSATE DRAIN VALVE
PS
24VDC POWER SUPPLY
K1
INTERNAL RUN RELAY CONTACT
INTERNAL Y-DELTA START RELAY
K3
INTERNAL WYE-DELTA RUN RELAY
K4
INTERNAL LOAD CONTROL RELAY
K5
INTERNAL SEQUENCE RELAY
K6
INTERNAL ELECTRIC DRAIN RELAY
K7
INTERNAL COMMON FAULT RELAY
45
PMR
OPT’L POWER MONITOR RELAY
HTR1
(OPT’L) SUMP HEATER 800W
HTR2
(OPT’L) HEAT TRACE
HTR3
(OPT’L) TRAP HEATER 70WATTS
HTR4
(OPT’L) CONTROL PANEL HEATER 50WATTS
3000P-4500 USER MANUAL
K2
SECTION 3
02250171-211 R04
3000P-4500 USER MANUAL
46
3.16 WIRING DIAGRAM, AIR COOLED MFV
COMP
DESCRIPTION
COMP
DESCRIPTION
COMPRESSOR OVERLOAD
2FU
JZL TRANSFORMER SECONDARY FUSE
1M
COMPRESSOR STARTER
3FU
FAN MOTOR BRANCH FUSES
2MOL
FAN MOTOR OVERLOAD
JZL
JZL DRAIN OPTION
P1
WET SUMP PRESSURE SENSOR
PPR
POWER PRESENT RELAY OPTION
P2
PACKAGE DISCHARGE PRESSURE SENSOR
T1
UNIT DISCHAGE TEMPERATURE PROBE
NOTES
(OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC
1
CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.
2
REMOVE JUMPER FOR AUXILLIARY E-STOP STRING
DEVICES.
3
1MOL SETTING TO BE 1M FLA. PLUS 2M FLA.
4
USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY
OPTIONAL INPUTS TO THE WS CONTROLLER. MOUNT THE
RELAY LOCALLY IN THE STARTER BOX.
1MOL
PSW1
DPSW1
(OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID
INPUT 7
REMOTE RUN/UNLOAD
INPUT 8
CUSTOMER FURNISHED FAULT
INPUT 9
CUSTOMER FURNISHED WARNING
SOL1
LOAD CONTROL SOLENOID VALVE
SOL4
SEQUENCEING SOLENOID VALVE
SOL5
ELECTRIC CONDENSATE DRAIN VALVE
PS
24VDC POWER SUPPLY
K1
INTERNAL RUN RELAY CONTACT
K2
INTERNAL Y-DELTA START RELAY
K3
INTERNAL WYE-DELTA RUN RELAY
K4
INTERNAL LOAD CONTROL RELAY
INTERNAL SEQUENCE RELAY
K6
INTERNAL ELECTRIC DRAIN RELAY
K7
INTERNAL COMMON FAULT RELAY
PMR
PF CAP
OPT’L POWER MONITOR RELAY
POWER FACTOR CORRECTION CAPACITOR (OPT’L)
HTR1
(OPT’L) SUMP HEATER 800W
HTR2
(OPT’L) HEAT TRACE
HTR3
(OPT’L) TRAP HEATER 70WATTS
HTR4
(OPT’L) CONTROL PANEL HEATER 50WATTS
47
TH
THERMOSTAT FOR HEAT TRACE OPTION
1FU
JZL TRANSFORMER PRIMARY FUSES
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
3000P-4500 USER MANUAL
K5
SECTION 3
3.16 WIRING DIAGRAM, AIR COOLED MFV
SECTION 3
02250178-718-R00
3000P-4500 USER MANUAL
48
3.17 WIRING DIAGRAM, YD CE
COMP
1MOL
1M
2M
S
3MOL
4M
DESCRIPTION
COMP
COMPRESSOR OVERLOAD
HTR4
WYE-DELTA STARTER
TH
DESCRIPTION
(OPT’L) CONTROL PANEL HEATER 50WATTS
THERMOSTAT FOR HEAT TRACE OPTION
WYE-DELTA RUN CONTACTOR
CB1
(OPT'L) TRANSFORMER PRIMARY CIRCUIT BREAKER
WYE-DELTA START CONTACTOR
CB2
(OPT'L) TRANSFORMER SECONDARY CIRCUIT BREAKER
FAN MOTOR OVERLOAD
SCD
SCD DRAIN OPTION
CONTACTOR FOR POWER FACTOR CAPACITOR OPT.
PPR
POWER PRESENT RELAY OPTION
P1
WET SUMP PRESSURE SENSOR
P2
PACKAGE DISCHARGE PRESSURE SENSOR
T1
UNIT DISCHAGE TEMPERATURE PROBE
NOTES
(OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC
1
CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.
2
REMOVE JUMPER FOR AUXILLIARY E-STOP STRING
DEVICES.
3
1MOL RELAY SET AT 58% OF 1M FULL LOAD PLUS 3M FULL
LOAD.
4
USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY
OPTIONAL INPUTS TO THE WS CONTROLLER. MOUNT THE
RELAY LOCALLY IN THE STARTER BOX.
PSW1
DPSW1
(OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID
INPUT 7
REMOTE RUN/UNLOAD
INPUT 8
CUSTOMER FURNISHED FAULT
INPUT 9
CUSTOMER FURNISHED WARNING
SOL1
LOAD CONTROL SOLENOID VALVE
SOL4
SEQUENCEING SOLENOID VALVE
SOL5
ELECTRIC CONDENSATE DRAIN VALVE
24VDC POWER SUPPLY
K1
INTERNAL RUN RELAY CONTACT
K2
INTERNAL Y-DELTA START RELAY
K3
INTERNAL WYE-DELTA RUN RELAY
K4
INTERNAL LOAD CONTROL RELAY
K5
INTERNAL SEQUENCE RELAY
K6
INTERNAL ELECTRIC DRAIN RELAY
K7
INTERNAL COMMON FAULT RELAY
PF CAP
POWER FACTOR CORRECTION CAPACITOR (OPT’L)
HTR1
(OPT’L) SUMP HEATER 800W
HTR2
(OPT’L) HEAT TRACE
HTR3
(OPT’L) TRAP HEATER 70WATTS
CONTROL TANSFORMER FOR OPTIONAL SCD DRAIN
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
49
3000P-4500 USER MANUAL
PS
XFMR
SECTION 3
3.17 WIRING DIAGRAM, YD CE
NOTES
50
3000P-4500 USER MANUAL
Section 4
INSTALLATION
4.1
MOUNTING OF
COMPRESSOR
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.
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.
4.2
VENTILATION & COOLING
AIR-COOLED COMPRESSORS
An area with adequate space must be provided for
the compressor and its components. Air-cooled
compressors require a minimum of 4 feet (1.25
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.
If discharge/inlet ductwork is added to the
compressor package, then remove the louvers from
the compressor package.
NOTE
Systems that employ both a conventional
reciprocating compressor and a screwtype 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
3000P-4500 USER MANUAL
SECTION 4
WATER-COOLED COMPRESSORS
(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)
Adequate cooling water flow must be supplied to
water- cooled compressors. Water delivery must be
verified to assure constant delivery of the volumes
outlined in Table : 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 54. 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.
Table 4-2:Ventilation Requirements 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.
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.
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).
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.
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).
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 54.
Table 4-1: WATER FLOW REQUIREMENTS
Water Temp
°F/°C
Water Flow
Gallons Per Minute/Liters Per Minute (I)
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)
Table 4-2: VENTILATION REQUIREMENTS
Cooling Type
Air-Cooled with Aftercooler
Water-Cooled
Motor HP/kW
40/30
50/37
60/45
40/30
50/37
60/45
Fan Air cfm/m3/hr
5,000/8,500
5,000/8,500
6,000/10,200
700/1,200
700/1,200
700/1,200
Ventilating Air/
Heat Rejection
BTU/Hour
114,500
142,000
171,000
10,600
13,300
15,800
KCal/Hour
28,800
35,700
46,216
2,670
3,350
4,000
52
SECTION 4
3000P-4500 USER MANUAL
Table 4-2: VENTILATION REQUIREMENTS
Cooling Type
Air-Cooled with Aftercooler
Water-Cooled
Cooling Water/
Heat Rejection
BTU/Hour
114,500
142,000
171,100
KCal/Hour
28,800
35,700
43,040
53
3000P-4500 USER MANUAL
SECTION 4
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.
precipitates out of water. Calcium content tends to be
higher in water taken from wells than water taken
from the 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
3. Allow the system to drain completely.
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.
WATER QUALITY RECOMMENDATIONS
BIOLOGICAL AND ORGANIC FOULING (SLIME)
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.
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.
2. Remove the drain plugs located at the bottom of the aftercooler and lubricant cooler.
SCALE
To ensure maximum life expectancy and best
performance of the compressor cooling system, refer
to Table 4-3:WATER TESTS.
Scale is formed from calcium carbonate, which
Table 4-3: WATER TESTS
Substances
Test Interval
Acceptable Concentration
Corrosivity Hardness, pH, Total DissolvedSolids, Temperature at inlet, Alkalinity
Monthly-if stable for 3 to 4 months,
analyze quarterly.
Langerlier Index 0 to 1
Iron
Monthly
<2ppm
Sulphate
Monthly
<50 ppm
Chloride
Monthly
<50 ppm
Nitrate
Monthly
<2 ppm
Silica
Monthly
<100 ppm
Desolated Oxygen
Daily-if stable, analyze weekly
0 ppm (as low as possible)
Oil & Grease
Monthly
<5 ppm
Ammonia
Monthly
<1 ppm
54
SECTION 4
3000P-4500 USER MANUAL
SEAWATER-COOLED UNITS
In the event of a leak occurring, the oil will be
prevented from becoming contaminated.
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.
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.
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 job site 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 NEMA 4 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.
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).
55
3000P-4500 USER MANUAL
SECTION 4
NOTE
Compressors with integral dryers can be
damaged by ambient temperatures below
freezing. The dryer electrical system is
Nema 12 rated and should not be installed
outdoors or in an unheated space, subject
to freezing temperatures.
For installation in a below freezing climate, a low
ambient option with heat tracing and a separator/
sump 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 tank. 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. See Figure 4-1.
NOTE
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.
Figure 4-1: Service Air Piping, Typical Installation
1.
2.
3.
4.
56
Sullair Compressor
Sullair Dryer
Shut-Off Gate Valve
Sullair Filter
5. Water Leg Drain Valve
6. By-Pass Gate Valve
7. Standard Gate Valve
SECTION 4
3000P-4500 USER MANUAL
When two compressors are operated in parallel,
provide an isolation valve and a drain trap for each
compressor before the common receiver.
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 separator/sump, compressor response time may need to be
adjusted. Consult the Sullair Service
Department for assistance.
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.
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.
4.4
COUPLING ALIGNMENT
CHECK
No coupling alignment is required.
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 separator/sump tank. To be able to see
the fluid level it may be necessary to start the
machine and build the separator/sump 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 separator/sump
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,
57
3000P-4500 USER MANUAL
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 L1L2-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
58
SECTION 4
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:
DANGER Lethal shock hazard inside. Disconnect all
power at source before opening or servicing.
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 59.
SECTION 4
4.7
MOTOR ROTATION
DIRECTION CHECK
Motor rotation check must be made at compressor
start- up. 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
3000P-4500 USER MANUAL
the motor drive housing to show proper motor/
compressor rotation. An alternative to this procedure
is to set the WS Controller to display P1 separator/
sump 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.
59
3000P-4500 USER MANUAL
60
SECTION 4
3000P-4500 USER MANUAL
Section 5
WS CONTROLLER
5.1
CONTROLLER LAYOUT
3
1
®
2
10
8
7
9
4
6
5
1. ON
6. Maintenance Indicator
2. OFF
7. Fault Indicator
3. LCD Display
8. Up Key
4. Power Indicator
9. Down Key
5. Run Mode Indicator
10. Enter Key
Figure 5-1: WS Controller
5.2
CONTROLLER KEYPAD
See WS Controller manual P/N 02250165-411 for
complete operation capabilities. 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.
61
3000P-4500 USER MANUAL
5.3
SECTION 5
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.
SA
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.
R
Figure 5-2:
Refer to Figure 5-2 and Figure 5-3. The lower line is
occasionally interrupted to describe the compressor
package's operating state.
Figure 5-6:
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.
Figure 5-3:
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.
SA 0000006R01
Figure 5-7:
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.
Figure 5-4:
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.
S
Figure 5-8:
Figure 5-5:
62
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.
SECTION 5
If there are any warnings or recommended service
instructions, these will be periodically displayed on
the normal view.
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.
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.
3000P-4500 USER MANUAL
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.
63
NOTES
64
3000-4500 USER MANUAL
Section 6
MAINTENANCE
6.1
GENERAL
WARNING
Before any repairs are attempted, refer to
Section 1: Safety before proceeding.
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 66.
6.2
DAILY OPERATION
Prior to starting the compressor, it is necessary to
check the fluid level in the separator/sump 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—
Introduction
Section
under
EXCESSIVE
COMPRESSOR FLUID CONSUMPTION for a
probable cause and remedy.
WARNING
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.
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 66 for
location.
2. Clean the return line orifice.
65
3000-4500 USER MANUAL
6.4
SECTION 6
MAINTENANCE EVERY 2000
HOURS
After 2000 hours of operation, it will be necessary to
perform the following:
FLUID FILTER ELEMENT REPLACEMENT
Refer to Figure 6-1.
1. Using a wrench, remove the filter canister.
1. Clean the return line strainer. Refer to Discharge, Separator/sump and Piping System,
3000P, 3700 and 4500 of the Parts Manual.
2. Remove and dispose of filter element.
Observe all laws and regulations for filter disposal.
2. Replace the fluid filter element.
3. Clean gasket seating surface.
3. Pull oil sample for analysis
4. Apply a light film of fluid to the element seal.
4. Check air filter. Change if necessary.
5. Install the element into the filter canister.
6. Screw the canister to the filter head. Tighten
to 30 to 35 ft•lb (40.5 to 47.3 N·m).
7.
1
Restart compressor and check for leaks.
6.7
AIR FILTER MAINTENANCE
2
3
3
2
1
Figure 6-1: Fluid Filter Assembly
1. Filter Head
2. Element*
1. Housing
3. Body
2. Element*
Fluid Filter Assembly: P/N 02250155-708
*Fluid Filter Replacement Kit: P/N 02250155-709
6.5
FLUID MAINTENANCE
Drain the separator/sump tank and change the
compressor fluid using instructions shown in
Lubrication Guide on page 26.
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.
66
Figure 6-2: Air Filter Assembly
3. Cover
Air Filter Assembly: P/N 02250127-683
* Replacement Air Filter Element Kit: P/N 02250127684
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.
SECTION 6
3000-4500 USER MANUAL
AIR FILTER ELEMENT REPLACEMENT
1. Clean exterior of air filter housing.
6. Install a new lubricated O-ring in the O-ring
groove on the underside of the separator/
sump tank cover.
2. Rotate end cover counterclockwise and
remove
7. Replace the cover plate, washers and capscrews. Torque to 49 ft·lbs. (68 N·m).
3. Remove air filter element by pulling it out of
the housing.
8. Clean the return line strainer before restarting the compressor.
4. Clean interior of housing using a damp cloth.
DO NOT blow dirt out with compressed air.
5. At this time replace the element.
1
6. Reassemble in the reverse order of the disassembly.
6.8
2
3
4
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.
5
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:
6
NOTE
Relieve all pressure from the separator/
sump tank and all compressor lines.
1. Loosen and remove the eight (8) hex head
capscrews (M12 x 40mm) from the cover
plate.
Figure 6-3: Separator Element Assembly
2. Lift the cover plate from the separator/sump
tank.
1. Cover
3. Remove the separator element.
2. Ground Spring*
4. Inspect the separator/sump tank for rust, dirt,
etc.
3. Spring Fastener*
5. Reinsert the separator element into the separator/sump tank taking care not to dent the
element against the tank opening.
5. Element*
4. Cover Gasket*
6. Separator/Sump Tank
Separator Element: P/N 02250160-774
*Separator Element Replacement
02250160-776
Kit:
P/N
67
3000-4500 USER MANUAL
SECTION 6
OIL RETURN/SIGHT GLASS MAINTENANCE
1. Disconnect the tube at bottom of sight glass.
Refer to Figure . 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:
2. Unscrew the sight glass assembly where the
elbow fitting joins the strainer/filter.
3. Remove used filter assembly, and replace
with new assembly.
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.
Figure 6-4: Oil Return/Sight Glass
1. To Separator/Sump Tank
2
1
2. Male Tube Connector
3. 90° Pipe Elbow
4. Filter Assembly*
5. Sight Glass/Orifice Block
6. Brass Plug Orifice
7. Female Tube Connector
8. To Unit
* Oil Return Filter Replacement Kit: P/N 02250117782
68
Figure 6-5: Regulator Adjustment
1. Locking Nut
2. Adjustment Screw
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).
SECTION 6
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 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. 02250152670, 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.
3000-4500 USER MANUAL
6.9
TROUBLESHOOTING—
INTRODUCTION
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.
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).
69
3000-4500 USER MANUAL
SECTION 6
6.10 TROUBLESHOOTING GUIDE
SYMPTOM
Compressor Will Not Start
Compressor Shuts Down With
Air Demand Present
70
PROBABLE CAUSE
REMEDY
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.
Loss of Control Voltage
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 by WS Controller
Replace separator.
Machine Programmed for Wrong
Pressure Setting
Reprogram with WSPC equipped laptop.
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 separator/
sump 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 85F (29.4C)
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).
SECTION 6
3000-4500 USER MANUAL
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 de-energized. Replace if necessary.
Plugged Control Line Strainer
Clean strainer (screen and O-ring replacement kit available).
Defective Blowdown Valve
Check that separator/sump tank pressure is
exhausted to the atmosphere when the
solenoid valve opens. Repair or replace if
necessary (kit available).
Clogged Return Line or Orifice
Clean strainer (screen and O-ring replacement kit available).
Line Pressure Rises Above
Unload Pressure Set-Point
Excessive Compressor Fluid
Consumption
Clean orifice.
Pressure Relief Valve Opens
Repeatedly
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
170F (76.7C).
Defective Pressure Relief Valve
Replace.
Plugged Separator
Check separator differential.
71
3000-4500 USER MANUAL
72
SECTION 6
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.
NOTES
Always air. Always there.
WWW.SULLAIR.COM
SULLAIR
3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A.
Telephone: 1-219-879-5451
Printed in the U.S.A.
Specifications subject to change
without prior notice.
E12EP