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USER MANUAL INDUSTRIAL AIR COMPRESSOR 1800, 2200, 3000, 1800V, 2200V, 3000V 18, 22 & 30KW/25 & 30 & 40HP

PART NUMBER:

02250176-180 R02 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 SULLAIR CORPORATION

©

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

201003010000 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 Industrial 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 CUSTOMER CARE TRAINING DEPARTMENT 1-888-SULLAIR or 219-879-5451 (ext. 5623) www.sullair.com

- Or Write Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training Department.

TABLE OF CONTENTS SECTION 1—SAFETY 3

1.1

GENERAL

3

1.2

PERSONAL PROTECTIVE EQUIPMENT

3

1.3

PRESSURE RELEASE

4

1.4

FIRE AND EXPLOSION

4

1.5

MOVING PARTS

5

1.6

HOT SURFACES, SHARP EDGES AND SHARP CORNERS

5

1.7

TOXIC AND IRRITATING SUBSTANCES

6

1.8

ELECTRICAL SHOCK

6

1.9

LIFTING

7

1.10

ENTRAPMENT

SECTION 2—DESCRIPTION 9

2.1

INTRODUCTION

9

2.2

DESCRIPTION OF COMPONENTS

10

2.3

SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION

11

2.4

COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION

13

2.5

COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION

15

2.6

CONTROL SYSTEM, FUNCTIONAL DESCRIPTION

17

2.7

AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

17

2.8

INTEGRAL DRYER OPTION

17

2.9

VARIABLE SPEED DRIVE (VSD) COMPONENTS

18

2.10

VSD CONTROL SYSTEM — FUNCTIONAL DESCRIPTION

SECTION 3—SPECIFICATIONS 21

3.1

TABLE OF SPECIFICATIONS

23

3.2

LUBRICATION GUIDE

24

3.3

APPLICATION GUIDE

24

3.4

LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE—FLUID FILTER AND SEPARATOR

26

3.5

AIR-COOLED, IDENTIFICATION 25-30HP

28

3.6

AIR-COOLED, IDENTIFICATION 40HP

TABLE OF CONTENTS 30 32

3.7 3.8

AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 25-30HP AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 40HP

34

3.9

PIPING AND INSTRUMENTATION, AIR-COOLED

36

3.10

PIPING AND INSTRUMENTATION, 1800-2200 W/INTEGRAL DRYER

38

3.11

WIRING DIAGRAM—MFV, AIR-COOLED

40

3.12

WIRING DIAGRAM—MFV, AIR-COOLED INTEGRAL DRYER

42

3.13

WIRING DIAGRAM—VSD, PARALLEL WYE

44

3.14

WIRING DIAGRAM—YD CE

SECTION 4—INSTALLATION 47

4.1

MOUNTING OF COMPRESSOR

47

4.2

VENTILATION AND COOLING

48

4.3

SERVICE AIR PIPING

50

4.4

COUPLING ALIGNMENT CHECK

50

4.5

FLUID LEVEL CHECK

50

4.6

ELECTRICAL PREPARATION

51

4.7

MOTOR ROTATION DIRECTION CHECK

51

4.8

FAN MOTOR ROTATION CHECK

SECTION 5—WS CONTROLLER 53 54

5.1 5.2

CONTROLLER KEYPAD LCD DISPLAY

55

5.3

LED LIGHTS

SECTION 6—MAINTENANCE 57

6.1

GENERAL

57

6.2

DAILY OPERATION

57

6.3

MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION

57

6.4

MAINTENANCE EVERY 2000 HOURS

58

6.5

FLUID MAINTENANCE

58

6.6

FILTER MAINTENANCE

59

6.7

AIR FILTER MAINTENANCE

59

6.8

SEPARATOR MAINTENANCE

61

6.9

TROUBLESHOOTING— INTRODUCTION

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 Corporation and its subsidiaries design and manufacture all of their products so they can be operated safely. However, the responsibility for safe operation rests with those who use and maintain these products. The following safety precautions are offered as a guide which, if conscientiously followed, will minimize the possibility of accidents throughout the useful life of this equipment. The compressor should be operated only by those who have been trained and delegated to do so, and who have read and understood this Operator's Manual. Failure to follow the instructions, procedures and safety precautions in this manual may result in accidents and injuries. NEVER start the compressor unless it is safe to do so. DO NOT attempt to operate the compressor with a known unsafe condition. Tag the compressor and render it inoperative by disconnecting and locking out all power at source or otherwise disabling its prime mover so others who may not know of the unsafe condition cannot attempt to operate it until the condition is corrected. Install, use and operate the compressor only in full compliance with all pertinent OSHA regulations and/ or any applicable Federal, State, and Local codes, standards and regulations. DO NOT modify the compressor and/or controls in any way except with written factory approval. 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)

3

SECTION 1 inside diameter to reduce pressure in case of hose failure.

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.

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

4

D. Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the compressor or of the inside of the enclosure, if any. E. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace any wiring that has cracked, cut, abraded or otherwise degraded insulation, or terminals that are worn, discolored or corroded. Keep all terminals and pressure connectors clean and tight. F.

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

G. Remove any acoustical material or other material that may be damaged by heat or that may support combustion and is in close proximity, prior to attempting weld repairs. H. Keep suitable fully charged Class BC or ABC fire extinguisher or extinguishers nearby when servicing and operating the compressor. I.

Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.

J. DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or with degraded lubricant. K. DO NOT attempt to operate the compressor in any classification of hazardous environment unless the compressor has been specially designed and manufactured for that duty.

1.5

MOVING PARTS

A. Keep hands, arms and other parts of the body and 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.

SECTION 1 C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially when exposed to hot or moving parts.

DANGER

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.

Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA standards and/or any applicable Federal, State, and Local codes, standards and regulations on safety equipment. B. DO NOT use air line anti-icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems into unventilated or other confined areas. 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

5

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

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.

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.

1.9

LIFTING

A. If the compressor is provided with a lifting bail, then lift by the bail provided. If no bail is provided, then lift by sling. Compressors to be air-lifted by helicopter must not be supported by the lifting bail but by slings instead. In any event, lift and/or handle only in full compliance with OSHA standards 29 CFR 1910 subpart N and/or any applicable Federal, State, and Local codes, standards and regulations. B. Inspect points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifting. C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has a rated capacity of at least the weight of the compressor. If you are unsure of the weight, then weigh compressor before lifting. D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail or slings. E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground. F.

DO NOT attempt to lift in high winds.

G. Keep all personnel out from under and away from the compressor whenever it is suspended. H. Lift compressor no higher than necessary.

6

SECTION 1 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.

7

NOTES

8

1800-3000 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 Section 6: Maintenance on page 57 to see how surprisingly easy it is to keep your air compressor in top operating condition.

2.2

DESCRIPTION OF COMPONENTS

Refer to Figure 2-1. The components and assemblies of the air compressor are clearly shown. The complete package includes compressor, electric motor, starter, compressor inlet system, compressor discharge system, compressor lubrication and cooling system, capacity control system, WS Controller, aftercooler, a combination separator and trap, all mounted on a heavy gauge steel frame. On air-cooled models, a fan draws air into the enclosure over the fan and main motors through the combined aftercooler and fluid cooler thereby removing the compression heat from the compressed air and the cooling fluid, and forces it out the top of the machine. This compressor model has easily accessible items such as the fluid filter air/oil separator and control valves. The inlet air filter is also easily accessible for servicing.

9

1800-3000 USER MANUAL

SECTION 2

Figure 2-1: Main Component Location 1. Moisture Separator

8. Starter Box

2. Sight Glass

9. Fan Motor

3. Fluid Port Fill

10. Air Filter

4. Separator/Sump Tank 11. Motor

2.3

5. Compressor Unit

12. Cooler

6. E-Stop

13. Fluid Filter

7. WS Controller

14. Variable Speed Drive (where equipped)

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 1800, 2200 & 3000f Series compressors are factory-filled with Sullube lubricant. For more

10

SECTION 2

1800-3000 USER MANUAL

information on fluid fill, Specifications on page 21.

refer

to

Section

3:

Sullair 24KT compressors are filled with a fluid that rarely needs to be changed. Use only Sullair 24KT fluid in the event that a fluid change is required.

CAUTION Mixing of other lubricants within the compressor unit will void all warranties. Sullair recommends that a 24KT sample be taken at the first filter change and sent to the factory for analysis. This is a free service. The sample kit with instructions and 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, and also lubricates the bearings. 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.

2.4

COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-2. The Cooling and Lubrication System consists of a fan, fan motor, radiator-type aftercooler/fluid cooler, full flow fluid filter, thermal valve, and interconnecting hoses. 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 185ûF (85ûC) [200ûF (93ûC) 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 185ûF (85ûC), 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. A message on the WS Controller indicates when the fluid filter needs to be changed.

11

1800-3000 USER MANUAL

Figure 2-2: Cooling and Lubrication System

12

SECTION 2

SECTION 2 2.5

COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-3. The compressor unit discharges the compressed air/fluid mixture into the combination separator/sump tank. The separator/sump tank has three basic functions: 1. It acts as a primary fluid separator. 2. Serves as the compressor fluid sump. 3. Houses the final fluid separator. 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 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 tank and the compressor. A visual sight glass is located on the return line to observe this fluid flow. There is also an orifice in this return line (protected by a strainer) to assure proper flow. The separator system reduces the fluid carry-over to less than 1 ppm (parts per million) for Sullube, or 2 ppm for 24KT at nominal rated pressures. A message on the controller indicates if abnormal pressure drop through the separator develops. At this time, separator element replacement is necessary.

1800-3000 USER MANUAL A minimum pressure/check valve, located downstream from the separator, assures a minimum separator/sump tank 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 tank 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 235ûF (113ûC).

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.

13

1800-3000 USER MANUAL

SECTION 2

Figure 2-3: Discharge System

14

SECTION 2 2.6

1800-3000 USER MANUAL

CONTROL SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-4. 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 are 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).

1. Air Outlet

5. Blowdown Valve

2. Solenoid Valve

6. Minimum Pressure/Check Valve

3. Regulator

7. Separator/Sump Tank

4. Air Inlet Figure 2-4: Standard Sequencing Control System

15

1800-3000 USER MANUAL

SECTION 2

Full Load Mode —50 to 100 PSIG (3.4 to 6.9 BAR)

check valve in the air service line prevents line pressure from returning to the separator/sump tank.

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.

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.

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 intake, reducing the separator/sump tank pressure to approximately 17 psig (1.2 bar). The

16

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 to 100 psig (6.3 to 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

1800-3000 USER MANUAL

AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-5. The compressor air inlet system consists of a dry-type air filter, a restriction gauge and an air inlet valve. The restriction gauge (located on the air filter) indicates the condition of the air filter by showing red when filter maintenance is required. The poppet-type modulating air inlet valve directly controls the amount of air intake to the compressor in response to the operation of the pressure regulator. Refer to Modulating Mode —100 to 110 PSIG (6.9 to 7.6 BAR) on page 16. The inlet valve also acts as a check valve, thus preventing reverse rotation when the compressor is shut down.

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.

2.8

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 on the system. The drive’s heat sink extends through the back of the enclosure, and is cooled by air flowing through the compressor enclosure.

17

1800-3000 USER MANUAL

SECTION 2

2.10 VSD CONTROL SYSTEM — FUNCTIONAL DESCRIPTION

FULL LOAD MODE - 50 TO 100 PSIG (3.4 TO 6.9 BAR)

Refer to Figure 2-4. The controls consist of:

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.

• 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.

18

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.

SECTION 2 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 deenergizes 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

1800-3000 USER MANUAL 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.

19

1800-3000 USER MANUAL

SECTION 2

Figure 2-5: Air Inlet System 1. Air FIlter

2. Inlet Valve 3. Compressor Unit

20

1800-3000 USER MANUAL

Section 3

SPECIFICATIONS 3.1

TABLE OF SPECIFICATIONS DIMENSIONS Length

Width

Height mm

in

Weight

MODEL

HP

in

mm

in

mm

lbs

kg

1807

25

53.2

1351

31.5

800

53.2

1351

1420

644

1809

25

53.2

1351

31.5

800

53.2

1351

1420

644

1810

25

53.2

1351

31.5

800

53.2

1351

1420

644

1812

25

53.2

1351

31.5

800

53.2

1351

1420

644

1800 Series

2200 Series 2207

30

53.2

1351

31.5

800

53.2

1351

1450

658

2209

30

53.2

1351

31.5

800

53.2

1351

1450

658

2210

30

53.2

1351

31.5

800

53.2

1351

1450

658

2212

30

53.2

1351

31.5

800

53.2

1351

1450

658

3009

40

53.2

1351

31.5

800

53.2

1351

1613

732

3010

40

53.2

1351

31.5

800

53.2

1351

1613

732

3012

40

53.2

1351

31.5

800

53.2

1351

1613

732

3000 Series

DIMENSIONS Length MODEL

HP

in

Width mm

in

Height mm

in

Weight mm

lbs

kg

1800 Series with Integral Dryer 1807

25

63.1

1603

31.5

800

53.2

1351

1621

735

1809

25

63.1

1603

31.5

800

53.2

1351

1621

735

1810

25

63.1

1603

31.5

800

53.2

1351

1621

735

1812

25

63.1

1603

31.5

800

53.2

1351

1621

735

2207

30

63.1

1603

31.5

800

53.2

1351

1651

749

2209

30

63.1

1603

31.5

800

53.2

1351

1651

749

2210

30

63.1

1603

31.5

800

53.2

1351

1651

749

2212

30

63.1

1603

31.5

800

53.2

1351

1651

749

2200 Series with Integral Dryer

3000 Series with Integral Dryer 3009

40

53.2

1351

31.5

800

53.2

1351

1814

823

3010

40

53.2

1351

31.5

800

53.2

1351

1814

823

3012

40

53.2

1351

31.5

800

53.2

1351

1814

823

21

1800-3000 USER MANUAL

SECTION 3

Table 3-1: Compressor Specifications COMPRESSOR:

STANDARD MODELS:

Type:

Rotary Screw

Standard Speed Operating Pressure (II):

100 psi (7 bar) 125 psig (9 bar)

Bearing Type:

Anti-friction

Ambient Temperature (Max.) (III):

104°(40°C)

Cooling:

Pressurized Fluid

Compressor Fluid:

Sullair Sullube

Separator/Sump Tank Capacity:

2.5 Gallons (9.5 liters)

Control:

WS Controller

150 psig (10 bar) 175 psig (12 bar)

(II) Special compressors are available for operation at higher pressures. (III) Special compressors are available for operation in higher ambient temperature.

MOTOR (IV):

STANDARD MODELS:

Size:

25,30,40HP / 18,22,30KW

Type:

C-Flanged, Open Drip proof, Epact Efficiency, Three Phase, 230/460 Hz, 380-515 (400) 50Hz

Maximum Ambient Temperature

104°(40°C)

Options Available:

200V and 575V 60 Hz, 220 50 Hz TEFC also available: CE Approved

Starter:

Full Voltage Magnetic, Wye-Delta

Options Available:

VSD Optional, 460V, 575V, 400V 50 Hz

Speed—25, 30 HP:

1765 RPM (60 Hz) or 1475 RPM (50 Hz)

(IV) Multi-frequency and voltage motors are used. The compressors msust be used only with the specified electrical frequency and voltage.

NOTE For latest sound test data, consult Sullair factory.

22

SECTION 3 3.2

1800-3000 USER MANUAL

LUBRICATION GUIDE

Refer to Figure 3-1 for location of fluid fill port. For best value and longest uninterrupted service, the 1800, 2200 & 3000 Series compressors are factory filled and tested with Sullube lubricant.

CAUTION Mixing of other lubricants within the compressor unit will void all warranties. If fluid change is required, follow 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. on page 24.

Contamination of non-detergent mineral fluids with traces of detergent motor fluids may lead to operational problems such as foaming, filter plugging, orifice or line plugging.

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.

To drain fluid, disconnect lubricant hose from the thermal valve and divert the open end into a suitable container below the separator/sump tank fluid level.

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. DO NOT MIX DIFFERENT TYPES OF FLUIDS.

1. Fluid Fill Port 2. Sight Glass 3. Separator/Sump Tank Figure 3-1: Fluid Fill Location

23

1800-3000 USER MANUAL 3.3

SECTION 3

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.

3.4

LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE—FLUID FILTER AND SEPARATOR FLUID CHANGE

FLUID FILTER CHANGE

SEPARATOR CHANGE

Sullube (2.5 gal)

A, E

G, C

A, D

SRF 1/4000 (2.5 gal)

B, E

G, C

B, D

24KT (2.5 gal)

F, E

G, C

A, D

CP-4600-32-F (2.5 gal)

B, E

G, C

B, D

LUBRICANT

A. B. C. D. E. F. G.

24

8,000 hours or once a year. 4,000 hours or more frequently if conditions so require. When measured pressure loss exceeds 20 psig (1.3 bar). When measured pressure loss exceeds 10 psig (0.7 bar). When required by fluid analysis or known contamination. Does not require replacement during normal service conditions. Every 2,000 hours.

NOTES

25

26

AIR-COOLED, IDENTIFICATION 25-30HP

02250159-354-R03

3.5

1800-3000 USER MANUAL SECTION 3

ODP TEFC

30 30

1450 LBS/658 KG

1383 LBS/627 KG

1420 LBS/644 KG

2000 CFM

2000 CFM

2000 CFM

2000 CFM

5. IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR, HIGH STATIC FAN MUST BE SELECTED. MAX ALLOWABLE ADDITIONAL STATIC PRESSURE 0.4 IN H20 WITH HIGH STATIC FAN.

4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.

3. ALL DIMENSIONS ARE ±1/2" [12.7MM].

2. 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 MUST BE PERMITTED AT EXTERNAL CONNECTIONS.

A10: AIR OUT CONNECTION 1-1/2" NPT

A9: MOISTURE DRAIN CONNECTION 1/4"-18 NPT

Ø2.50[63.5]

A8: INCOMING CUSTOMER POWER SUPPLY

A7: CONTAINMENT PAN DRAIN

A6: EXHAUST AIR OUT

A5: AIR INLET

A4: E-STOP

A3: CONTROLLER

A2: SPACE REQUIRED TO OPEN STARTER PANEL

TEFC

25

1374 LBS/623 KG

CFM Cooling Air

1. ALLOW 4.00 FT. [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.

ODP

25

Weight

A1: SPACE REQUIRED TO OPEN DOORS

Motor Type

Main Motor HP

AIR-COOLED, IDENTIFICATION 25-30HP

NOTES:

3.5

SECTION 3 1800-3000 USER MANUAL

27

28

AIR-COOLED, IDENTIFICATION 40HP

02250181-032 R00

3.6

1800-3000 USER MANUAL SECTION 3

1613 LBS/732 KG

2900 CFM

2900 CFM

5. IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR, HIGH STATIC FAN MUST BE SELECTED. MAX ALLOWABLE ADDITIONAL STATIC PRESSURE 0.4 IN H20 WITH HIGH STATIC FAN.

4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.

3. ALL DIMENSIONS ARE ±1/2" [12.7MM].

2. 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 MUST BE PERMITTED AT EXTERNAL CONNECTIONS.

A10: AIR OUT CONNECTION 1-1/2" NPT

A9: MOISTURE DRAIN CONNECTION 1/4"-18 NPT

Ø2.50[63.5]

A8: INCOMING CUSTOMER POWER SUPPLY

A7: CONTAINMENT PAN DRAIN

A6: EXHAUST AIR OUT

A5: AIR INLET

A4: E-STOP

A3: CONTROLLER

A2: SPACE REQUIRED TO OPEN STARTER PANEL

TEFC

40

1556 LBS/706 KG

CFM Cooling Air

1. ALLOW 4.00 FT. [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.

ODP

40

Weight

A1: SPACE REQUIRED TO OPEN DOORS

Motor Type

Main Motor HP

AIR-COOLED, IDENTIFICATION 40HP

NOTES:

3.6

SECTION 3 1800-3000 USER MANUAL

29

30

AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 25-30HP

02250168-699-R02

3.7

1800-3000 USER MANUAL SECTION 3

3.7

TEFC ODP TEFC

25 30 30

1651 LBS/749 KG

1584 LBS/718 KG

1621 LBS/735 KG

1575 LBS/714 KG

Weight

5. IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR, HIGH STATIC FAN MUST BE SELECTED. MAX ALLOWABLE ADDITIONAL STATIC PRESSURE 0.4 IN H20 WITH HIGH STATIC FAN.

4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.

3. ALL DIMENSIONS ARE ±1/2" [12.7MM].

2. 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 LEVELED AND SECURED BETWEEN THE FRAME AND THE FOUNDATION. NO PIPING LOADS MUST BE PERMITTED AT EXTERNAL CONNECTIONS.

1. ALLOW 4.00 FT. [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.

ODP

25

NOTES:

Motor Type

Main Motor HP

AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 25-30HP

2000 CFM

2000 CFM

2000 CFM

2000 CFM

CFM Cooling Air

SECTION 3 1800-3000 USER MANUAL

31

32

AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 40HP

02250180-784 R00

3.8

1800-3000 USER MANUAL SECTION 3

1814 LBS/823 KG

2900 CFM

2900 CFM

5. IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR, HIGH STATIC FAN MUST BE SELECTED. MAX ALLOWABLE ADDITIONAL STATIC PRESSURE 0.4 IN H20 WITH HIGH STATIC FAN.

4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.

3. ALL DIMENSIONS ARE ±1/2" [12.7MM].

2. 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 MUST BE PERMITTED AT EXTERNAL CONNECTIONS.

A10: AIR OUT CONNECTION 1-1/2" NPT

A9: MOISTURE DRAIN CONNECTION 1/4"-18 NPT

Ø2.72[69.0]

A8: INCOMING CUSTOMER POWER SUPPLY

A7: CONTAINMENT PAN DRAIN

A6: EXHAUST AIR OUT

A5: AIR INLET

A4: E-STOP

A3: CONTROLLER

A2: SPACE REQUIRED TO OPEN STARTER PANEL

TEFC

40

1757 LBS/797 KG

CFM Cooling Air

1. ALLOW 4.00 FT. [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.

ODP

40

Weight

A1: SPACE REQUIRED TO OPEN DOORS

Motor Type

Main Motor HP

AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 40HP

NOTES:

3.8

SECTION 3 1800-3000 USER MANUAL

33

34

PIPING AND INSTRUMENTATION, AIR-COOLED

02250156-114-R10

3.9

1800-3000 USER MANUAL SECTION 3

02250125-369

-

MTR_VAR

-

02250155-599

02250160-773

02250097-609

02250156-137

02250167-115

02250155-708

02250092-081

02250148-796

02250155-174

250006-938

02250155-175

02250049-634

02250170-783

02250155-714

250017-280

408893

250003-869

02250115-272

02250173-972

02250097-610

02250126-129

02250117-782

1

2

3

4

5

6

7

8

9

10

11

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

1

1

1

1

1

1

1

1

2

2

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

Q T Y

FILTER,ASSY GENESIS

GLASS,SIGHT SIGHT/ORIFICE BLK SAE

PLUG,SIGHT GLASS 1 5/16” SAE

FLTR,PNEUMATIC 1/8”NPT 5MICRON

VLV,CHK 1/4”-NPT

INDICATOR, RESTRICTION 20”H20

VALVE, SHUTTLE 1/4” (DBL CHK)

VALVE, PRESSURE REGULATOR

VALVE,SOL 3WNO 1/4 235# N4

VLV,DR COMBO 24 VDC

VLV,BLWDN 1/4 NPT HI PRS

PROBE,THERMISTER 3000 OHM NTC 6’L

VALVE, RELIEF 1/2” 200#

XDCR,PRESS 0-250PSI 1-5VDC N4

VLV,THERMAL 210 DEG

VLV,THERMAL 195 DEG

FLTR,CORELESS M27 6”L W/ BYPASS

SEP,WTR SCWS-235N 1” L/AD

COOLER, AIR/OIL 2200

VALVE, 1-5/8 SAE MIN PRESS CHK

ELEM,OIL SEP 1800/2200

TANK, SEP 2200

COMPRESSOR

MOTOR

VALVE, GROUP INLET DXX102E

FILTER, AIR 8”(PLASTIC) W/MTG BAND

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

02250144-841 02250182-548 02250182-545 02250168-837 02250169-612 241771

30 30 31 32 33 34

1

1

1

1

1

1

1

1

1

1

Q T Y

STRAINER, V-TYPE 300PSIX1/4

GA,DIFF PRESS Z-PRG ASY BTM

VENT,ENCL PROT 1/2” TOP

DRN,ZERO LOSS 115V 1/2”NPT

VLV,BALL/STNR COMBO-1/2”NPT

VLV,BALL/STNR COMB 1/2M X 1/2M

SW,DIFF PRESS 20 PSID

SW,VAC 22”WC N4 6FT CABLE 5A

ORF, .078” .25FNPT X.25MNPT

ORIFICE,PLUG BRASS 1/8NPT X 1/32”

DESCRIPTION

WET SUMP PRESSURE LINE PRESSURE FLUID FILTER DIFFERENTIAL SWITCH INLET AIR FILTER SWITCH 22"WC (558.9mm WC) LOAD/UNLOAD SOLENOID VALVE MEC/SEQUENCING/FULL LOAD SOLENOID VALVE COMBO DRAIN/JZL DRAIN SOLENOID VALVE WET DISCHARGE TEMPERATURE

P2 DPSW1 PSW1 SOL1 SOL4 SOL5 T1

DESCRIPTION

P1

COMPONENT

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250078-249 02250050-154

02250118-586

27 28

02250125-774

26

29

PART NO.

KEY NO.

PIPING AND INSTRUMENTATION, AIR-COOLED

KEY NO.

3.9

SECTION 3 1800-3000 USER MANUAL

35

36

02250172-798-R02

3.10 PIPING AND INSTRUMENTATION, 1800-2200 W/INTEGRAL DRYER

1800-3000 USER MANUAL SECTION 3

02250125-369 MTR_VAR 02250155-599 02250160-773 02250097-609 02250156-137 02250167-115 02250155-708 02250148-796 02250092-081 02250155-174 250006-938 02250155-175 02250049-634 241771 02250155-714 250017-280 408893 250003-869 02250115-272 02250170-783 02250097-610 02250126-129 02250117-782 02250125-774 02250118-586 02250078-249 02250050-154

1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1

Q T Y FILTER, AIR 8”(PLASTIC) W/MTG BAND VALVE, GROUP INLET DXX102E MOTOR COMPRESSOR TANK, SEP 2200 ELEM,OIL SEP 1800/2200 VALVE, 1-5/8 SAE MIN PRESS CHK COOLER, AIR/OIL 2200 SEP,WTR SCWS-235N 1” L/AD FLTR,CORELESS M27 6”L W/BYPASS VLV,THERMAL 210 DEG. VLV,THERMAL 195 DEG. XDCR,PRESS 0-250PSI 1-5VDC N4 VALVE, RELIEF 1/2” 200# PROBE,THERMISTER 3000 OHM NTC 6’L VLV,BLWDN 1/4 NPT HI PRS STRAINER, V TYPE 1/4” VALVE,SOL 3WNO 1/4 235# N4 VALVE, PRESSURE REGULATOR VALVE, SHUTTLE 1/4” (DBL CHK) INDICATOR, RESTRICTION 20”H20 VLV,CHK 1/4”-NPT VLV,DR COMBO 24 VDC PLUG,SIGHT GLASS 1 5/16” SAE GLASS,SIGHT SIGHT/ORIFICE BLK SAE FILTER,ASSY GENESIS ORIFICE,PLUG BRASS 1/8NPT X 1/32” ORF, .078” .25FNPT X.25MNPT SW,VAC 22”WC N4 6FT CABLE 5A SW,DIFF PRESS 20 PSID

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

KEY NO.

N O T E 02250168-837 02250169-612 049905 02250175-087

30 31 32 33 34

DESCRIPTION

N O T E

WET SUMP PRESSURE LINE PRESSURE FLUID FILTER DIFERENTIAL SWITCH INLET AIR FILTER SWITCH 22" WC (558.9 mm WC) LOAD/UNLOAD SOLENOID VALVE MEC/SEQUENCING/FULL LOAD SOLENOID VALVE ELECTRIC DRAIN SOLENOID VALVE WET DISCHARGE TEMPERATURE DRYER DEWPOINT TEMPERATURE PROBE

P2 DPSW1 PSW1 SOL1 SOL4 SOL5 T1 T3

DESCRIPTION P1

COMPONENT

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

1 1 1 2 1

Q T Y

VENT,ENCL PROT 1/2” TOP GA,DIFF PRESS Z-PRG ASY BTM INTEGRAL REFRIGERANT DRYER CHECK VALVE PROBE,THERMISTER 3000 OHM NTC 12’L 35 02250173-972 1 FLTR,PNEUMATIC 1/8”NPT 5MICRON 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. 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. PART VARIES BY MODEL.

PART NO.

KEY NO.

3.10 PIPING AND INSTRUMENTATION, 1800-2200 W/INTEGRAL DRYER

SECTION 3 1800-3000 USER MANUAL

37

38

02250171-211-R04

3.11 WIRING DIAGRAM—MFV, AIR-COOLED

1800-3000 USER MANUAL SECTION 3

UNIT DISCHAGE TEMPERATURE PROBE

T1

THERMOSTAT FOR HEAT TRACE OPTION

JZL TRANSFORMER PRIMARY FUSES

(OPT’L) CONTROL PANEL HEATER 50WATTS

HTR4

TH

(OPT’L) TRAP HEATER 70WATTS

HTR3

1FU

(OPT’L) HEAT TRACE

OPT’L POWER MONITOR RELAY

PMR

(OPT’L) SUMP HEATER 800W

INTERNAL COMMON FAULT RELAY

K7

HTR2

INTERNAL ELECTRIC DRAIN RELAY

K6

HTR1

INTERNAL SEQUENCE RELAY

K5

POWER FACTOR CORRECTION CAPACITOR (OPT’L)

INTERNAL LOAD CONTROL RELAY

K4

PF CAP

INTERNAL WYE-DELTA RUN RELAY

K3

ELECTRIC CONDENSATE DRAIN VALVE

SOL5

INTERNAL Y-DELTA START RELAY

SEQUENCEING SOLENOID VALVE

SOL4

INTERNAL RUN RELAY CONTACT

LOAD CONTROL SOLENOID VALVE

SOL1

K2

CUSTOMER FURNISHED WARNING

INPUT 9

K1

CUSTOMER FURNISHED FAULT

INPUT 8

24VDC POWER SUPPLY

REMOTE RUN/UNLOAD

PS

(OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID

DPSW1

INPUT 7

(OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC

PACKAGE DISCHARGE PRESSURE SENSOR

PSW1

WET SUMP PRESSURE SENSOR

P2

FAN MOTOR OVERLOAD

2MOL

P1

COMPRESSOR STARTER

1M

DESCRIPTION

COMPRESSOR OVERLOAD

1MOL

COMP

3.11 WIRING DIAGRAM—MFV, AIR COOLED

JZL DRAIN OPTION POWER PRESENT RELAY OPTION

JZL PPR

REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES. 1MOL SETTING TO BE 1M FLA. PLUS 2M FLA. USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY OPTIONAL INPUTS TO THE WS CONTROLLER. MOUNT THE RELAY LOCALLY IN THE STARTER BOX.

2 3 4

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.

1

NOTES

FAN MOTOR BRANCH FUSES

3FU

DESCRIPTION JZL TRANSFORMER SECONDARY FUSE

2FU

COMP

SECTION 3 1800-3000 USER MANUAL

39

40

02250174-982-R03

3.12 WIRING DIAGRAM—MFV, AIR-COOLED INTEGRAL DRYER

1800-3000 USER MANUAL SECTION 3

THERMOSTAT FOR HEAT TRACE OPTION

(OPT’L) CONTROL PANEL HEATER 50WATTS

TH

HTR4

OPT’L POWER MONITOR RELAY

PMR

(OPT’L) TRAP HEATER 70WATTS

INTERNAL COMMON FAULT RELAY

K7

HTR3

INTERNAL ELECTRIC DRAIN RELAY

K6

(OPT’L) HEAT TRACE

INTERNAL SEQUENCE RELAY

K5

HTR2

INTERNAL LOAD CONTROL RELAY

K4

(OPT’L) SUMP HEATER 800W

INTERNAL WYE-DELTA RUN RELAY

K3

POWER FACTOR CORRECTION CAPACITOR (OPT’L)

INTERNAL Y-DELTA START RELAY

K2

HTR1

INTERNAL RUN RELAY CONTACT

PF CAP

24VDC POWER SUPPLY

ELECTRIC CONDENSATE DRAIN VALVE

SOL5

K1

SEQUENCEING SOLENOID VALVE

SOL4

PS

CUSTOMER FURNISHED WARNING

LOAD CONTROL SOLENOID VALVE

CUSTOMER FURNISHED FAULT

INPUT 8

SOL1

REMOTE RUN/UNLOAD

INPUT 7

INPUT 9

(OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID

DRYER DEWPOINT TEMPERATURE PROBE

T3

DPSW1

UNIT DISCHARGE TEMPERATURE PROBE

T1

(OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC

PACKAGE DISCHARGE PRESSURE SENSOR

PSW1

WET SUMP PRESSURE SENSOR

P2

FAN MOTOR OVERLOAD

2MOL

P1

COMPRESSOR STARTER

1M

DESCRIPTION

COMPRESSOR OVERLOAD

1MOL

COMP

DRYER START RELAY

DR

REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES. 1MOL SETTING TO BE 1M FLA. PLUS 2M FLA. USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY OPTIONAL INPUTS TO THE WS CONTROLLER. MOUNT THE RELAY LOCALLY IN THE STARTER BOX.

2 3 4

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.

1

NOTES

POWER PRESENT RELAY OPTION DRYER FAULT

DF

INTEGRAL DRYER PRIMARY FUSES

7FU PPR

INTEGRAL DRYER SECONDARY FUSE

6FU

DESCRIPTION FAN MOTOR BRANCH FUSES

3FU

COMP

3.12 WIRING DIAGRAM—MFV, AIR-COOLED INTEGRAL DRYER

SECTION 3 1800-3000 USER MANUAL

41

42

02250156-119 R09

3.13 WIRING DIAGRAM—VSD, PARALLEL WYE

1800-3000 USER MANUAL SECTION 3

(OPT’L) HEAT TRACE

(OPT’L) TRAP HEATER 70WATTS

HTR3

INTERNAL COMMON FAULT RELAY

K7

HTR2

INTERNAL ELECTRIC DRAIN RELAY

K6

(OPT’L) SUMP HEATER 800W

INTERNAL SEQUENCE RELAY

K5

HTR1

INTERNAL LOAD CONTROL RELAY

K4

OPT’L POWER MONITOR RELAY

INTERNAL WYE-DELTA RUN RELAY COMPRESSOR ENABLED

PMR

INTERNAL Y-DELTA START RELAY COMPRESSOR RUNNING

K3

ELECTRIC CONDENSATE DRAIN VALVE

SOL5

K2

SEQUENCEING SOLENOID VALVE

SOL4

INTERNAL FAN RELAY CONTACT TEMP (T1) CONTROLLED

LOAD CONTROL SOLENOID VALVE

SOL1

K1

CUSTOMER FURNISHED WARNING

INPUT 9

24VDC POWER SUPPLY

CUSTOMER FURNISHED FAULT

PS

REMOTE RUN/UNLOAD

UNIT DISCHAGE TEMPERATURE PROBE

T1

INPUT 8

PACKAGE DISCHARGE PRESSURE SENSOR

P2

INPUT 7

WET SUMP PRESSURE SENSOR

P1

(OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID

SCD TRANSFORMER SCONDARY FUSE

3FU

DPSW1

SCD TRANSFORMER PRIMARY FUSES

2FU

(OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC

FAN MOTOR BRANCH CIRCUIT FUSES

1FU

PSW1

FAN MOTOR OVERLOAD

2MOL

COOLER FAN MOTOR STARTER

2M

DESCRIPTION

COMPRESSOR MOTOR

1M

COMP

3.13 WIRING DIAGRAM—VSD, PARALLEL WYE DESCRIPTION

REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES. USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY OPTIONAL INPUTS TO THE WS CONTROLLER. MOUNT THE RELAY LOCALLY IN THE STARTER BOX.

2 3

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.

(OPT’L) SCD DRAIN

CONTROL TRANSFORMER FOR SCD DRAIN

THERMOSTAT FOR HEAT TRACE OPTION

(OPT’L) CONTROL PANEL HEATER 50WATTS

1

NOTES

SCD

XFMR1

TH

HTR4

COMP

SECTION 3 1800-3000 USER MANUAL

43

44

02250178-718-R00

3.14 WIRING DIAGRAM—YD CE

1800-3000 USER MANUAL SECTION 3

COMPRESSOR STARTER

WYE-DELTA RUN CONTRACTOR

WYE-DELTA START CONTRACTOR

1M

2M

S

PACKAGE DISCHARGE PRESSURE SENSOR

UNIT DISCHAGE TEMPERATURE PROBE

P2

T1

CUSTOMER FURNISHED FAULT

CUSTOMER FURNISHED WARNING

LOAD CONTROL SOLENOID VALVE

SEQUENCEING SOLENOID VALVE

ELECTRIC CONDENSATE DRAIN VALVE

INPUT 8

INPUT 9

SOL1

SOL4

SOL5

(OPT’L) TRAP HEATER 70WATTS

(OPT’L) CONTROL PANEL HEATER 50WATTS

HTR3

HTR4

K7

(OPT’L) HEAT TRACE

INTERNAL COMMON FAULT RELAY

K6

(OPT’L) SUMP HEATER 800W

INTERNAL ELECTRIC DRAIN RELAY

K5

HTR2

INTERNAL SEQUENCE RELAY

K4

HTR1

INTERNAL LOAD CONTROL RELAY

K3

POWER FACTOR CORRECTION CAPACITOR (OPT’L)

INTERNAL WYE-DELTA RUN RELAY

K2

PF CAP

INTERNAL RUN RELAY CONTACT

INTERNAL Y-DELTA START RELAY

K1

24VDC POWER SUPPLY

REMOTE RUN/UNLOAD

PS

(OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID

DPSW1

INPUT 7

(OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC

WET SUMP PRESSURE SENSOR

P1

PSW1

CONTRACTOR FOR POWER FACTOR CAPACITOR OPT.

4M

FAN MOTOR OVERLOAD

COMPRESSOR OVERLOAD

1MOL

3MOL

DESCRIPTION

COMP

3.14 WIRING DIAGRAM—YD CE

(OPT'L) SCD DRAIN

PART NO.

Q T Y

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

4. USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY OPTIONAL INPUTS TO THE WS CONTROLLER. MOUNT THE RELAY LOCALLY IN THE STARTER BOX.

3. 1MOL RELAY SET AT 58% OF 1M FULL LOAD PLUS 3M FULL LOAD.

2. REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.

1. CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.

KEY NO.

N O T E

(OPT’L) TRANSFORMER SECONDARY CIRCUIT BREAKER

CB2 SCD

CONTROL TRANSFORMER FOR OPTIONAL SCD DRAIN

(OPT’L) TRANSFORMER PRIMARY CIRCUIT BREAKER

CB1

XFMR1

THERMOSTAT FOR HEAT TRACE OPTION

DESCRIPTION

TH

COMP

SECTION 3 1800-3000 USER MANUAL

45

NOTES

46

1800-3000 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.

NOTE Ambient temperatures above 104ûF (40ûC) require that the high ambient option is specified for the compressor.

4.2

VENTILATION AND 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.

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.

47

1800-3000 USER MANUAL OUTDOOR INSTALLATION (SHELTERED) Many times a compressor must be installed outside due to available space or other jobsite conditions. When this is necessary, there are certain items that should be incorporated into the system to help ensure trouble-free operation. The unit must be purchased with a TEFC motor. The standard machine has 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.

SECTION 4 35ûF (1.7ûC).

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 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 sealed 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

48

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 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.

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 (available from Sullair) can remove any liquid carryover.

SECTION 4

1800-3000 USER MANUAL

Figure 4-1: Service Air Piping, Typical Installation 1. Sullair Compressor

5. Water Leg Drain Valve

2. Sullair Dryer

6. By-Pass Gate Valve

3. Shut-Off Gate Valve

7. Standard Gate Valve

4. Sullair Filter

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. This is not necessary with a variable speed design. 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 connections, and upstream of the first isolation valve.

When two compressors are operated in parallel, provide an isolation valve and a drain trap for each compressor before the common receiver tank. A built-in after-cooler 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 after-cooler is supplied with a combination condensate separator/trap. A drain line should be installed on the condensate drain. 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.

49

1800-3000 USER MANUAL

SECTION 4 4.6

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 (up to the fill plug.)

50

ELECTRICAL PREPARATION

Interior electrical wiring is performed at the factory. Required customer wiring should be done by a qualified electrician in compliance with OSHA, National Electrical Code, and/or any other applicable state, federal and local electrical codes concerning isolation switches, fused disconnects, etc.

NOTE Customer must provide electrical supply power disconnect within sight of machine. The fuse protecting the circuit and the compressor must be selected in accordance with the data provided inside the starter enclosure. • The compressor and drive should be provided with a proper grounding conductor/ earthed in accordance with both local and National Electrical Code (NEC) 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 electrical circuit the system is connected to is balanced and not overloaded by any other electrical equipment. The length of wiring from a suitable electrical feed point is critical as voltage drop may impair the performance of the compressor. Cable sizes may vary so the mains terminals will accept from 8 ga. to 3/0 ga. cable. • Feeder cable connections to incoming terminals L1- L2-L3 should be tight and clean. The applied voltage must be compatible with the motor and compressor data plate ratings. • A starter hole is provided for incoming power connection. If it is necessary to make a hole in the control box in a different location, care should be taken to not allow metal shavings to enter the starter and other electrical components. If another hole is used, the original hole must be blocked off with a suitable knockout seal.

SECTION 4

1800-3000 USER MANUAL

• A few electrical checks should be made to help assure that the first start-up will be trouble-free.

DANGER Lethal shock hazards exist inside. Disconnect all power at source and lock out before opening or servicing. 1. Check incoming voltage. Be sure that the compressor is wired for the correct incoming voltage. 2. Check the motor starter for correct size, properly sized overload relay, and correct heaters for the load. 3. Check all electrical connections for tightness. Check all grounding connection for bond. 4. “DRY RUN” the electrical controls by disconnecting the three (3) motor leads from the starter. Energize the control circuits by pressing the “ ” (START) pad, and check all protective devices to be sure that they will de-energize the starter coil when tripped. 5. Reconnect the motor leads and jog the motor for a direction of rotation check as explained in Section 4.7. Wiring diagram for standard compressors is supplied with the machine.

4.7

MOTOR ROTATION DIRECTION CHECK

Motor rotation check must be made at compressor startup. See Figure 4-2 and Figure 4-3. The compressor will not operate correctly if it runs in the wrong direction. Open the compressor door to view the motor rotation. 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, ” (STOP) pads. This the “ ” (START) and “ action will bump start the motor for a very short time. When looking at the motor from the end opposite the compressor unit, the shaft should be turning clockwise. If the reversed rotation is noted, disconnect the power to the starter and exchange any two of the three power input leads, then re-check rotation. A “Direction of Rotation” decal is located on the motor 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.

4.8

FAN MOTOR ROTATION CHECK

On initial start-up check that the fan is rotating in the proper direction. The correct rotation is counterclockwise when viewing the fan motor from the driveshaft end.

51

1800-3000 USER MANUAL

Figure 4-2: Fan motor/main motor rotational direction 50Hz 25HP/18kw, 50Hz or 60Hz 30HP/22kw

Figure 4-3: Fan motor/main motor rotational direction 60Hz 25HP/18kw, 50Hz or 60Hz 40HP/30kw

52

SECTION 4

1800-3000 USER MANUAL

Section 5

WS CONTROLLER

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

5.1

CONTROLLER KEYPAD

For complete controller capabilities see WS Controller manual 02250165-411. 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.

53

1800-3000 USER MANUAL 5.2

LCD DISPLAY

SECTION 5

The display's normal view shows the compressor package's discharge pressure, internal temperature, and the operating mode. The modes are MANUAL, OFF, AUTOMATIC, or FAULTED.

Refer to Figure 5-6. Press the Down arrow " " to display additional information about the compressor. The upper line will indicate "Compressor Status" and the name of the temperature, pressure, or other measurement. The lower line indicates the present reading.

Figure 5-2:

Figure 5-6:

Refer to Figure 5-2 and Figure 5-3. The lower line is occasionally interrupted to describe the compressor package's operating state.

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.

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.

Figure 5-8: Refer to Figure 5-8. If there is no keypad activity, the display will return to normal view in about one minute. If the Start or Stop buttons are pressed, the display also returns to normal view. If either of these occur, the setting will not be altered.

Figure 5-5:

54

If there are any warnings or recommended service instructions, these will be periodically displayed on

SECTION 5 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.

5.3

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.

1800-3000 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.

55

NOTES

56

1800-3000 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. Refer to Filter Maintenance on page 58.

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 Section 6.9: Troubleshooting— Introduction on page 61 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 Discharge, Cooling and Lubrication System, AirCooled Centrifugal Fan, 50/60Hz 40HP on page 30 for location. 2. Clean the return line orifice.

6.4

MAINTENANCE EVERY 2000 HOURS

After 2000 hours of operation, it will be necessary to perform the following:

57

1800-3000 USER MANUAL 1. Clean the return line strainer. Refer to Discharge, Cooling and Lubrication System, AirCooled Centrifugal Fan, 50/60Hz 40HP on page 30 for location. 2. Replace the fluid filter element. 3. Pull oil sample for analysis 4. Check air filter. Change if necessary.

SECTION 6 6.5

FLUID MAINTENANCE

Drain the separator/sump tank and change the compressor fluid using instructions shown in Application Guide on page 24.

6.6

FILTER MAINTENANCE

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. Refer to Figure 6-1. Fluid Filter Element Replacement Refer to Figure 6-1. 1. Using a wrench, remove the filter canister. 2. Remove and dispose of filter element. Observe all laws and regulations for filter disposal. 3. Clean gasket seating surface. 4. Apply a light film of fluid to the element seal. 5. Install the element into the filter canister. 6. Screw the canister to the filter head. Tighten to 10 to 12 ft·lb (13.5 to 16.2 N·m). 7. Restart compressor and check for leaks. 6.7

1. Filter Head 2. Element* 3. Body * Fluid Filter Replacement Kit—P/N 02250155-709 Figure 6-1: Fluid Filter Assembly

58

SECTION 6 6.7

AIR FILTER MAINTENANCE

Refer to Figure 6-2. Air filter maintenance should be performed when the maintenance indicator 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.

1800-3000 USER MANUAL 6. Reassemble in the reverse order of the disassembly.

6.8

SEPARATOR MAINTENANCE

Replace the separator element when indicated by the WS Controller or after one (1) year, whichever comes first. The separator element must be replaced. DO NOT attempt to clean the separator element. Separator Element Replacement Refer to Figure 6-3. The separator element must be changed when indicated by the WS Controller, or once a year, whichever occurs first. Follow the procedure explained below for separator element replacement.

NOTE Relieve all pressure from the separator/ sump tank and all compressor lines. 1. Filter Head 2. Element* 3. Body * Air Filter Replacement Kit—P/N 02250125-372 Figure 6-2: Air Filter Assembly Air Filter Element Replacement 1. Clean exterior of air filter housing. 2. Rotate end cover counterclockwise and remove 3. Remove air filter element by pulling it out of the housing. 4. Clean interior of housing using a damp cloth. DO NOT blow dirt out with compressed air. 5. At this time replace the element.

1. Loosen and remove the six (6) hex head cap screws (8.8 M12 x 40 mm) from the cover plate. 2. Lift the cover plate from the separator/sump tank. 3. Remove the separator element. 4. Inspect the separator/sump tank for rust, dirt, etc. 5. Reinsert the separator element into the separator/sump tank taking care not to dent the element against the tank opening. 6. Install a new O-ring in the O-ring groove on the underside of the separator/sump tank cover. 7. Replace the cover plate, washers and cap screws. Torque to 70 ft·lbs (95 N·m). 8. Clean the return line strainer before restart-

59

1800-3000 USER MANUAL

1. Cover 2. Ground Spring* 3. Spring Fastener* 4. Cover Gasket* 5. Element* 6. Separator/Sump Tank

SECTION 6

1. To Separator/Sump Tank 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 * Fluid Return Filter Replacement Kit—P/N 02250117-782

Separator Element—P/N 02250185-533 * (Included in) Separator Element Replacement Kit—P/N 02250185-532

Figure 6-4: Separator Element Assembly

Figure 6-3: Separator Element Assembly

1. Disconnect the tube at bottom of sight glass.

Fluid Return/Sight Glass Maintenance Refer to Figure 6-4. The fluid return/sight glass subassembly is attached to the side of the separator tank. Fluid return/sight glass maintenance should be performed on a routine basis parallel to that of the fluid filter, or as indicated in Section 6.9: Troubleshooting— Introduction on page 61. The maintenance on a fluid 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.

60

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.

SECTION 6

1800-3000 USER MANUAL

Pressure Regulator Adjustment

Shaft Coupling Maintenance

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; refer to Figure 6-5). Lock the adjusting screw in place with the locknut. The regulator is now properly set.

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. 02250152669, and follow the following steps: 1. Remove the protective grill from the adapter housing. 2. Loosen the retaining screw located on the outer sleeve. Slide the sleeve to one side, exposing the coupling element. 3. Unwrap the coupling element from the coupling jaws. 4. Install the new element by wrapping it around the jaws, engaging the cogs on the element into the jaws. 5. Reinstall the outer sleeve and torque the securing screws to 10 in·lb (1.13 N·m). Install the protective grill.

6.9 1. Locking Nut 2. Adjustment Screw Figure 6-5: Separator Element Assembly 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 knurled 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).

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:

Control Line Strainer

1. Check for loose wiring.

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).

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.

61

1800-3000 USER MANUAL

SECTION 6

SYMPTOM

PROBABLY CAUSE

REMEDY

Compressor Will Not Start

Main Disconnect Switch Open

Close switch.

Line fuse blown

Replace fuse

Motor starter overload tripped

Reset. Should trouble persist, check whether motor starter contacts are functioning properly.

Low Incoming Line Voltage

Check voltage. Should voltage check low, consult power company.

Loss of Control Voltage

Reset. If trouble persists, check that line pressure does not exceed maximum operating pressure of the compressor (specified on nameplate).

Low Incoming Voltage

Consult power company.

Excessive Operating Pressure

—

Separator Requires Maintenance

Check maintenance indicator under full load conditions.

High Pressure Setting in WS Controller Set Wrong

Reset.

Defective Unload Solenoid Valve

WS Controller will energize valve to close. 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.

High Discharge Temperature

—

Cooling Air Flow Restricted

Clean cooler and check for proper ventilation.

Compressor Shuts Down With Air Demand Present

Ambient Temperature Is Too High

Provide sufficient ventilation.

Low Fluid Level

Add fluid.

Thermal Valve Not Functioning Properly

Replace element.

Compressor Will Not Build Full Dis- Air Demand Is Too Great charge Pressure

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 in assembly on top of air end is not plugged.

Pressure Regulator Out of Adjustment

Adjust regulator according to control adjustment instructions in the Maintenance .

62

Defective Pressure Regulator

Check diaphragm and replace if necessary (kit available).

Defective Unload Solenoid Valve

Check that the valve closes when energized. Replace the coil or the complete valve if defective.

Sheared Coupling Element

Replace coupling element. Refer to Shaft Coupling Maintenance on page 61.

SECTION 6 SYMPTOM

1800-3000 USER MANUAL PROBABLY CAUSE

Line Pressure Rises Above Unload Leak In Control System Causing Pressure Set-Point Loss of Pressure Signals

Excessive Compressor Fluid Consumption

REMEDY Check for leaks.

Inlet Valve Stuck Open

Remove the intake hose and check for inlet valve operation. Repair Valve (kit available).

Defective Unload Solenoid Valve

Check that the valve is open when deenergized. Replace if necessary.

Plugged Control Line Strainer

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

Defective Blowdown Valve

Check that 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). Clean orifice.

Separator Element Damaged or Not Change separator. Functioning Properly Leak in the Lubrication System

Check all hoses, connections and components.

Excess Fluid Foaming

Drain and change.

Fluid Level Too High

Drain and change.

Pressure Relief Valve Opens Repeatedly

Defective Pressure Relief Valve

Replace.

Plugged Separator

Check separator differential.

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.

63

NOTES

64

NOTES

65

WORLDWIDE SALES AND SERVICE SULLAIR ASIA, LTD.

SULLAIR CORPORATION

SULLAIR EUROPE, S.A.

Zuo Pao Tai Road, No. 1 Chiwan, Shekou Shenzen, Guangdong PRV. PRC POST CODE 518068 Telephone: 755-6851686 Fax: 755-6853473 www.sullair-asia.com

3700 East Michigan Boulevard Michigan City, Indiana, 46360 U.S.A. www.sullair.com Telephone: 1-800-SULLAIR (U.S.A. only) Fax: 219-874-1273

Zone Des Granges BP 82 42602 Montbrison, France Telephone: 33-477968470 Fax: 33-477968499 www.sullaireurope.com

CUSTOMER CARE for PARTS and Service 1-888-SULLAIR (7855247) 219-874-1835

Champion Compressors, LTD. 324-332 Frankston Dandenong Road Dandenong VIC Australia 3175 Ph: +61397039000 Fx: +61397039053 www.championcompressors.com.au

Printed in the U.S.A. Specifications subject to change without prior notice. E EP

PARTS LIST MANUAL INDUSTRIAL AIR COMPRESSOR 1800, 2200, 1800V, 2200V, 3000, 3000V 18, 22 & 30KW/25, 30 & 40HP

PART NUMBER:

02250176-181 R02 WARRANTY NOTICE Failure to follow the instructions and procedures in this manual or, misuse of this equipement will VOID its warranty!

KEEP FOR FUTURE REFERENCE SULLAIR CORPORATION

©

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

201003010000 and all subsequent serial numbers.

Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training Department.

- Or Write -

1-888-SULLAIR or 219-879-5451 (ext. 5623) www.sullair.com

SULLAIR CUSTOMER CARE TRAINING DEPARTMENT

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

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.

Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on Industrial 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.

AIR CARE SEMINAR TRAINING

SECTION

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

1.12

1.13

1.14

1.15

PAGE

5

6

8

10

12

14

16

18

20

22

24

26

28

30

32

DISCHARGE, SEPARATOR/SUMP TANK

COOLING AND LUBRICATION SYSTEM, AIR-COOLED CENTRIFUGAL FAN, 50/ 60HZ 40HP

COOLING AND LUBRICATION SYSTEM, AIR-COOLED AXIAL FAN, 60HZ/25HP

COOLING AND LUBRICATION SYSTEM, AIR-COOLED CENTRIFUGAL FAN, 50/ 60HZ/30HP, 50HZ/25HP

FLUID PIPING, AIR-COOLED 40HP

FLUID PIPING, AIR-COOLED 25/30HP

AIR PIPING WITH INTEGRAL DRYER 40HP

AIR PIPING WITH INTEGRAL DRYER 25/ 30HP

AIR PIPING, AIR-COOLED 40HP

AIR PIPING, AIR-COOLED 25/30HP

AIR INLET SYSTEM

COMPRESSOR, FRAME AND DRIVE 40HP

COMPRESSOR, FRAME AND DRIVE 25/ 30HP

RECOMMENDED SERVICE PARTS LIST

PROCEDURE FOR ORDERING PARTS

DESCRIPTION

1.23

48

1.27 1.28

58

1.26

1.25

56

54

52

1.24

1.22

46

50

1.21

1.20

1.19

1.18

1.17

1.16

SECTION

44

42

40

38

36

34

PAGE

TABLE OF CONTENTS

CONTROL SYSTEM AND ELECTRIC

CONTROL SYSTEM AND ELECTRIC PARTS, YD CE

CONTROL SYSTEM AND ELECTRIC PARTS, 230/460 WYE-DELTA

CONTROL SYSTEM AND ELECTICAL PARTS, VSD

CONTROL SYSTEM AND ELECTRICAL PARTS, MFV (CONTINUED)

CONTROL SYSTEM AND ELECTRICAL PARTS, MFV

PNEUMATIC CONTROL SYSTEM— STAINLESS STEEL

PNEUMATIC CONTROL SYSTEM— NYLON

MOISTURE DRAIN, AIR-COOLED WITH INTEGRAL DRYER

MOISTURE DRAIN—ZERO LOSS 40 HP

MOISTURE DRAIN—ZERO LOSS 25/30 HP

MOISTURE DRAIN—STANDARD

DISCHARGE, SEPARATOR/SUMP TANK AND PIPING SYSTEM

AND PIPING SYSTEM AIR-COOLED

DESCRIPTION

SECTION

1.29

1.30

1.31

1.32

1.33

1.34

1.35

PAGE

60

62

64

66

68

70

72

ENCLOSURE, AIR-COOLED 40HP

ENCLOSURE, AIR-COOLED 25/30HP

CONTROL STARTER—YD CE N4

CONTROL STARTER—VSD CE N12

CONTROL STARTER—VSD N12

CONTROL STARTER—WYE-DELTA

CONTROL STARTER—MFV

PARTS, VSD CE

DESCRIPTION

82

80

78

76

74

PAGE

1.40

1.39

1.38

1.37

1.36

SECTION

DESCRIPTION

DECAL GROUP

DECAL LOCATION SECTION, AIRCOOLED, INTEGRAL DRYER

DECAL LOCATION SECTION, AIRCOOLED

ENCLOSURE, AIR-COOLED INTEGRAL DRYER 40HP

ENCLOSURE, AIR-COOLED INTEGRAL DRYER 25/30HP

TABLE OF CONTENTS (CONTINUED)

Chiwan, Shekuo Shenzhen, Guangdong PRV. PRC POST CODE 518068 Telephone: 755-6851686

Michigan City, Indiana 46360 U.S.A

www.sullair.com

Telephone: 1-800-SULLAIR (U.S.A. only)

Fax: 219-874-1273

Hallam, Victoria 3803 Austrailia

Telephone: 33-477968470

Fax: 33-477968499

www.championcompressors.com.au

Fax: 61-3-9703-8053

When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the Bill of Lading for the compressor or from the Serial Number Plate located on the compressor. See Figure 1-1: Serial Plate / Serial Number Location.

Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the address, phone numbers or fax numbers below.

www.sullaireurope.com

Telephone: 61-3-9796-4000

Princess Highway

42602 Montbrison, France

Zone Des Granges BP 82

CHAMPION COMPRESSORS, LTD.

SULLAIR EUROPE, S.A.

219-874-1835

1-888-SULLAIR (785-5247)

www.sullair-asia.com

Fax: 755-6853473

Sullair Road, No. 1

3700 East Michigan Boulevard

CUSTOMER CARE for PARTS and SERVICE

SULLAIR ASIA, LTD.

PROCEDURE FOR ORDERING PARTS

SULLAIR CORPORATION

1.1

Figure 1-1: Serial Plate / Serial Number Location

5

The genuine Sullair service parts listed meet or exceed the demands of this compressor. Use of replacement parts other than those approved by Sullair Corporation may lead to hazardous conditions over which Sullair Corporation has no control. Such conditions include, but are not limited to, bodily injury and compressor failure.

PARTS LIST

02250155-709

02250125–372

02250185-532

02250110-988

02250046-397

826502-123

02250051-338

02250144-327

02250148-827

250019-453

02250157-500

02250157-502

02250157-501

02250157-502

02250164-606

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

ORDER PART NO.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

QTY

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

kit, repair inlet valve (integrated with compressor unit)

kit, coil replacement for condensate drain solenoid valve coil

kit, repair for condensate drain solenoid valve coil 02250155-715

kit, coil replacement for control solenoid valve coil 02250155-714

kit, repair for control solenoid valve 02250155-714

kit, repair for pressure regulator 250017-280

repair for thermal valve 210 deg 02250148-796

kit, repair for thermal valve 195deg 02250092-081

kit, piston for minimum pressure/check valve

kit, O-ring for minimum pressure/check valve

kit, cap for minimum pressure/check valve

kit, repair for minimum pressure/check valve 02250097-609

KITS

element, replacement for separator 02250185-533

element, heavy duty air filter 02250125–369

element, compressor fluid filter 02250155-708

ELEMENTS

RECOMMENDED SERVICE PARTS LIST

KEY NO.

1.2

RECOMMENDED SERVICE PARTS LIST

Continued on next page.

NOTE

6

(I)

241772

02250155–594

001932-005

02250117-782

02250144-735

250019-662

250022-669

02250051-053

250029-008

17

18

19

20

21

22

23

24

25

1

2

1

1

1

1

QTY

lubricant, Food Grade (5 gal/19 liter)

lubricant, 24 KT (5 gal/19 liter)

lubricant, Sullube (Std.) (5 gal/19 liter)

lubricant, Sullube (Std.) (5 gal/19 liter)

LUBRICATION

kit, seal replacement for separator/trap 02250144-635

filter, scavenge line 02250117-782

kit, repair for shaft seal installation

kit, repair for shaft seal

kit, repair for v-type strainer 241771

kit, rebuild inlet valve

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

Mixing of other lubricants within the compressor unit will void all warranties.

CAUTION

For proper amount of fluid fill, please consult Lubrication Guide in Section 3: Specifications in User Manual

02250164-607

16

ORDER PART NO.

RECOMMENDED SERVICE PARTS LIST

KEY NO.

1.2

(I)

(I)

(I)

(I)

NOTE

7

PARTS LIST

COMPRESSOR, FRAME AND DRIVE 25/30HP

02250175-288 R00

1.3

COMPRESSOR, FRAME AND DRIVE 25/30HP

8

828012-050

828012-065

829106-125

829108-125

829705-075

837806-094

837808-125

838812-250

17

18

19

20

21

22

23

5

4

7

6

4

7

2

1

2

1

2

1

1

1

2

4

4

1

1

1

1

2

1

Q T Y

WASHER, SPR LOCK-METRIC PLTD M12

WASHER, SPR LOCK REG PLTD 1/2

WASHER, SPR LOCK REG PLTD 3/8

SCREW, HEX SER WASHER 5/16-18 X 3/4

CAPSCR, HEX GR5 1/2-13 X 1 1/4

CAPSCR, HEX GR5 3/8-16 X 1 1/4

CAPSCR, HEX 8.8 M12 X 65MM

CAPSCR, HEX 8.8 M12 X 50MM

CAPSCR, HEX 8.8 M12 X 20MM

NUT, HEX METRIC M12 X 1.75

GRILLE,CPLG GUARD COMPR/MTR

ADAPTER,UNIT TO MOTOR

SUPT,SHIPPING MTR/UNIT P10-25/30

FRM,BSE P10

PLT,MTR SEAL 3000/3700/4500

ISOL, VIB MOTOR 37KW

CVR,FORKPOCKET 3700

COVER,CPLG ELEMENT 10R

ELEMENT,CPLG FALK 10R

HUB,CPLG 1.625 BORE 10R

HUB,CPLG 1.50 BORE 10R

SPCR,AIR END SHAFT HEIGHT 60HP

PLATE,ROTATION ARROW

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

828012-020

02250174-280

10

16

02250156-393

9

15

02250155-285

8

825912-175

02250154-405

7

14

02250152-677

6

250040-319

02250152-669

5

13

02250152-620

4

02250175-376

02250152-619

3

250038-448

02250151-499

2

12

02250057-737

1

11

PART NO.

30

29

28

27

26

25

24

KEY NO.

A1: A2: A3: A4: A5:

COMPRESSOR, FRAME AND DRIVE 25/30HP

KEY NO.

1.3

1

1

2

1

1

6

3

Q T Y

COMPR&PART, DXX102147E

MTR,25/30HP 4PYD ODP/TEFC EPACT

SCREW, TF-HEX M8 X 16 BLK ZINC

NIPPLE, PIPE-XS PLT 1/2 X 2 1/2

ELBOW, PIPE 90 DEG PLT 1/2”

WASHER, METRIC-ISO7089- 12

SCREW, DRIVE RD HD #8 X 3/8

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

FROM AIR INLET FILTER OIL RETURN FROM SIGHT-GLASS ON RECEIVER TANK TO RECEIVER TANK FROM BLOWDOWN VALVE (VSD DRIVE ONLY) MAIN OIL CONNECTION

SEE BOM

MAIN MOTOR

883008-016

866408-025

866215-020

865412-240

839608-060

PART NO.

9

PARTS LIST

COMPRESSOR, FRAME AND DRIVE 40HP

02250174-281 R00

1.4

COMPRESSOR, FRAME AND DRIVE 40HP

10

02250152-622

02250152-625

02250152-670

02250152-678

02250154-405

02250155-285

02250156-393

02250174-280

02250174-347

225980

231977

250009-542

821108-188

825206-337

825912-175

828012-020

828012-050

828012-065

829106-125

829106-175

829110-175

837806-094

837810-156

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

CAPSCR, HEX GR5 5/8-11 X 1 3/4

CAPSCR, HEX GR5 3/8-16 X 1 3/4

CAPSCR, HEX GR5 3/8-16 X 1 1/4

CAPSCR, HEX 8.8 M12 X 65MM

CAPSCR, HEX 8.8 M12 X 50MM

CAPSCR, HEX 8.8 M12 X 20MM

NUT, HEX METRIC M12 X 1.75

NUT, HEX PLTD 3/8-16

KEY, SQ CL1 1/2” X 1 7/8

ADAPTER, SAE 5 DXX10 GI MA

ADAPTER, MOTOR COMPR 10/40

PLATE, MOTOR/COMPR ADAPT COVER

SUPT,SHIPPING MTR/UNIT P10-40

FRM,BSE P10

PLT,MTR SEAL 3000/3700/4500

ISOL, VIB MOTOR 37KW

CVR,FORKPOCKET 3700

COVER,CPLG ELEMENT 20R

ELEMENT,CPLG 20R

HUB,CPLG 1.875 BORE 20R

HUB,CPLG 1.50 BORE 20R

DESCRIPTION

4

WASHER, SPR LOCK REG PLTD 5/8

15 WASHER, SPR LOCK REG PLTD 3/8

4

8

7

1

2

2

1

8

1

1

1

1

1

1

2

4

4

1

1

1

1

Q T Y

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

COMPRESSOR, FRAME AND DRIVE 40HP

KEY NO.

1.4

A1: A2: A3: A4: A5:

29

28

27

26

25

24

KEY NO.

1

1

2

2

4

3

Q T Y

VARIOUS 40HP

VARIOUS

WASHER, NORD-LOCK PL M12 SP

SCREW, TF-HEX M8 X 16 BLK ZINC

WASHER, METRIC-ISO7089- 12

WASHER, SPR LOCK-METRIC PLTD M12

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

FROM AIR INLET FILTER OIL RETURN FROM SIGHT-GLASS ON RECEIVER TANK TO RECEIVER TANK FROM BLOWDOWN VALVE (VSD DRIVE ONLY) MAIN OIL CONNECTION

MAIN MTR

COMPRESSOR

883212-254

883008-016

865412-240

838812-250

PART NO.

11

PARTS LIST

AIR INLET SYSTEM

02250174-282 R01

1.5

AIR INLET SYSTEM

12

02250125-369

02250162-347

02250163-999

02250174-283

02250185-865

040599

250003-869

250018-550

250031-415

866402-000

882508-125

882608-025

883008-016

1

2

3

4

5

6

7

8

9

10

11

12

13

2

2

2

1

1

3

1

1

1

1

1

1

1

Q T Y

screw, tf-hex m8 x 16 blk zinc

screw, hex serr washer m8 x 25

nut,serr flng m8 x 1.25

nipple,pipe-xs plt 1/8 x cl

clamp, hose 4.25/3.31

clamp, hose 2-13/16 to 3-3/4”

indicator, restriction 20” h20

elbow, rubber 90 deg i.d.

support, air tube inlet

tube,air inlet p10-40hp

hose, hump red str 3.50 x 3.00

clamp,hose o.d. 3.00

filter, air 8”(plastic)w/mtg&media

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

A2: TO UNIT

A1: TO SUPPORT BRACKET ON AIR DUCT

NOT USED WITH VACUUM SWITCH OPTION.

NOTES:

PART NO.

AIR INLET SYSTEM

KEY NO.

1.5

13

PARTS LIST

AIR PIPING, AIR-COOLED 25/30HP

02250156-633R05

1.6

AIR PIPING, AIR-COOLED 25/30HP

14

882508-125

882608-016

883633-016

883642-020

12

13

14

15

1

1

2

2

1

1

1

1

2

1

1

1

1

1

1

elbow,met st thd/orfs m42 x 1 1/4

elbow,met st thd/orfs m33 x 1

screw, hex serr washer m8 x 16

nut,serr flng m8 x 1.25

elbow, red 1 1/4 x 1 150# plt

bushing,red pltd 1 1/2 x 1 1/4

nipple,pipe-xs plt 1 x cl

elbow, tube str thrd 1 1/4 x 1 5/8

connector, tube-m 1 1/4 x 1 1/4

connector, tube-m 1 x 1

tube,1-1/4” discharge p10

separator, water scws-235n 1” l/ad

tube,orfs 1-1/4” mpv/aftrclr

tube,orfs 1” aftrclr to moist sep

support,outlet conn 1-1/2npt

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

867106-050

869205-040

866416-000

9

10

811620-162

8

11

810216-100

810220-125

02250167-608

5

6

02250167-115

4

7

02250159-493

02250166-561

2

02250152-215

1

3

PART NO.

Q T Y

AIR PIPING, AIR-COOLED 25/30HP

KEY NO.

1.6 N O T E

15

PARTS LIST

AIR PIPING, AIR-COOLED 40HP

02250174-302 R00

1.7

AIR PIPING, AIR-COOLED 40HP

16

02250152-215

02250166-734

02250174-303

02250175-265

810220-125

810520-150

811620-162

860220-150

867106-050

882508-125

882608-016

891120-020

1

2

3

4

5

6

7

8

9

10

11

12

1

2

2

1

1

2

1

1

1

1

1

1

Q T Y DESCRIPTION

connector,sw 37 deg 1 5/8 x 1 5/8 sae

screw, hex serr washer m8 x 16

nut,serr flng m8 x 1.25

bushing,red pltd 1 1/2 x 1 1/4

elbow, 37fl 90m 1 1/4 x 1 1/2

elbow, tube str thrd 1 1/4 x 1 5/8

elbow, tube 90 deg m 1 1/4 x 1 1/2

connector, tube-m 1 1/4 x 1 1/4

tube,1-1/4”-disch mpv/clr p10-40hp

tube,1-1/4”-discharge p10-40hp

separator, water scws-235n 1 1/2” l/ad

support,outlet conn 1-1/2npt

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

APPLY 3M 8898 4-WAY SPRAY LUBRICANT TO ALL O-RING CONNECTIONS.

NOTE:

A2: CUSTOMER AIR OUT CONNECTION

A1: FROM MINIMUM PRESSURE VALVE

PART NO.

AIR PIPING, AIR-COOLED 40HP

KEY NO.

1.7

17

PARTS LIST

AIR PIPING WITH INTEGRAL DRYER 25/30HP

02250168-701 R01

1.8

AIR PIPING WITH INTEGRAL DRYER 25/30HP

18

02250159-493

02250166-561

02250167-115

02250168-568

02250168-852

02250173-002

810216-100

811620-162

860116-100

860216-100

868906-040

875816-016

878416-131

882508-125

882608-016

883633-016

883642-020

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

1

1

2

2

1

1

1

2

1

1

1

1

1

1

1

1

1

Q T Y

elbow

elbow

screw

nut

union

elbow

bushing

elbow

connector

elbow

connector

hose

hose

support

separator

tube

tube

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

PART NO.

Q T Y DESCRIPTION

FROM MINIMUM PRESSURE VALVE

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

A8: COMPRESSOR AIR OUT FROM EVAPORATOR

A7: COMPRESSOR AIR IN TO EVAPORATOR

A6: CUSTOMER AIR OUT CONNECTION

A5: FROM MOISTURE DRAIN

A4: FROM AFTERCOOLER

A3:

A2: TO AFTERCOOLER

A1: PACKAGE DISCHARGE PRESSURE P2

KEY NO.

AIR PIPING WITH INTEGRAL DRYER 25/30HP

KEY NO.

1.8

19

PARTS LIST

AIR PIPING WITH INTEGRAL DRYER 40HP

02250183-886 R01

1.9

AIR PIPING WITH INTEGRAL DRYER 40HP

20

02250166-734

02250168-040

02250168-568

02250173-002

02250175-265

811620-162

860116-100

860116-150

860216-100

860220-150

868906-040

875816-016

878416-131

882508-125

882608-016

891120-020

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

1

2

2

1

1

1

1

1

1

1

2

1

1

1

1

1

Q T Y

connector

screw

nut

union

elbow

bushing

elbow

elbow

connector

connector

elbow

tube

hose

support

hose

separator

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

AIR PIPING WITH INTEGRAL DRYER 40HP

KEY NO.

1.9 PART NO.

Q T Y DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

APPLY 3M 8898 4-WAY SPRAY LUBRICANT TO ALL O-RING CONNECTIONS.

NOTE:

A4: COMPRESSOR AIR OUT FROM EVAPORATOR

A3: COMPRESSOR AIR IN TO EVAPORATOR

A2: CUSTOMER AIR OUT CONNECTION

A1: FROM MINIMUM PRESSURE VALVE

KEY NO.

21

PARTS LIST

02250156-634-R04

1.10 FLUID PIPING, AIR-COOLED 25/30HP

FLUID PIPING, AIR-COOLED 25/30HP

22

02250099-766

02250148-796

02250155-708

02250156-909

02250157-222

02250161-751

826502-211

826502-219

829310-080

883627-012

883727-012

884227-012

1

2

3

4

5

6

7

8

9

10

11

12

1

1

2

2

1

2

1

1

1

1

1

1

Q T Y

elbow,met st thd mxf m27

union,str thd iso 6149 m27 x 2

elbow,met st thd/orfs m27 x 3/4

screw, socket iso 4762 m10 x 80mm

o-ring, viton 1 5/16 x 1/8”

o-ring, viton 13/16 x 1/8”

hose, medium pressure orfs f-swvl 3/4” x 37”

housing, thrm vlv 2200

hose, medium pressure orfs f-swvl 3/4” x 33”

filter,coreless m27 6”l

valve,thermal 210f 1 1/2-18

elbow,90 sae x orfs .75”

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

KEY NO.

1.10 FLUID PIPING, AIR-COOLED 25/30HP N O T E

23

PARTS LIST

02250174-301 R01

1.11 FLUID PIPING, AIR-COOLED 40HP

FLUID PIPING, AIR-COOLED 40HP

24

884227-012

VARIOUS

11

12

1

1

1

2

2

1

2

1

1

1

1

2

Q T Y

valve,thermal 1 1/2-18

elbow,met st thd mxf m27

union,str thd iso 6149 m27 x 2

elbow,met st thd/orfs m27 x 3/4

screw, socket iso 4762 m10 x 80mm

o-ring, viton 1 5/16 x 1/8”

o-ring, viton 13/16 x 1/8”

housing,thrm valve 2200 40hp

hose, medium pressure orfs f-swvl 3/4” x 54”

hose, medium pressure orfs f-swvlend 33”long

filter,coreless m27 6”l

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

APPLY 3M 8898 4-WAY SPRAY LUBRICANT TO ALL O-RING CONNECTIONS.

NOTE:

A3: TO OIL COOLER

DESCRIPTION elbow,90 sae x orfs .75”

A2: TO BOTTOM OF SUMP TANK

A1: TO UNIT

883727-012

10

826502-211

6

883627-012

02250180-506

5

9

02250156-913

4

826502-219

02250156-909

3

829310-080

02250155-708

2

7

02250099-766

1

8

PART NO.

KEY NO.

1.11 FLUID PIPING, AIR-COOLED 40HP

25

PARTS LIST

02250173-352 R03

26

1.12 COOLING AND LUBRICATION SYSTEM, AIR-COOLED CENTRIFUGAL FAN, 50/60HZ/30HP, 50HZ/25HP

COOLING AND LUBRICATION SYSTEM, AIR-COOLED CENTRIFUGAL FAN, 50/60HZ/30HP, 50HZ/25HP

1 1

02250160-429

02250160-452

02250160-536

02250160-566

02250162-492

02250171-617

250018-497

850604-012

865408-170

865708-240

882508-125

882608-016

882608-030

883008-016

883306-030

884708-125

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

SCREW, HEX SERR WASHER M8 X 30

SCREW, HEX SERR WASHER M8 X 16

NUT, SERR FLNG M8 X 1.25

WASHER, ISO 7093-8-140HV

WASHER, METRIC-ISO7089- 8

WIRE, NEOPRENE #12-4 SO (FT)

GRIP, CORD FOR SO 12/4 ST 3/4”

PANEL, VENTURI P8/P10

INSUL,FOAM ACOUS LOUVER P8 P10

SUPT,AIROC ES8

DUCT,CENTRIFUGAL FAN P8 P10

GD,FAN DISCHARGE P8 P10

LOUVER,EXTRUDED 18KW 500.0 LNG

VENTURI, ES8 16”

SUPPORT, MOTOR FAN 1800/2200

STRIP, WEATHER 1” X 1/8” FOAM (FT)

FAN, CLG 16” 30HP 60HZ FAN, CLG 16” 25/30HP 50HZ

NUT, HEX LOCKING M8

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

4

16 SCREW, PLASTIC PILOT M6 X 30

22 SCREW, TF-HEX M8 X 16 BLK ZINC

4

8

4

3

4

8

2

1

4

2

4

1

1

7

02250154-721

02250058-345

4

1

02250156-639

02250156-637 02250156-638

3

CLR,AIR/OIL STD CLR, AIR/OIL CRN/CE

1

5

02250156-137 02250164-164

2

MTR,FAN

DESCRIPTION

1

Q T Y

6

-

PART NO.

1

KEY NO.

27

1.12 COOLING AND LUBRICATION SYSTEM, AIR-COOLED CENTRIFUGAL FAN, 50/60HZ/30HP, 50HZ/25HP

PARTS LIST

02250173-351-R02

1.13 COOLING AND LUBRICATION SYSTEM, AIR-COOLED AXIAL FAN, 60HZ/25HP

COOLING AND LUBRICATION SYSTEM, AIR-COOLED AXIAL FAN, 60HZ/25HP

28

882508-125

882608-016

882608-030

883008-016

19

20

21

22

nut,serr flng m8 x 1.25

screw, set cup 1/4 x 3/8 plt

washer, iso 7093-8-140hv

washer, metric-iso7089- 8

wire, neoprene #12-4 so (ft)

key, square cl1 3/16” x 1 1/2

grip,cord for so 12/4 st 3/4”

fan, 18” nylon 9-blade axial

panel, venturi p8/p10

drive,output shaft fan

insulation,foam acous louver p8 p10

support,airoc p8 p10

duct,centrifugal fan p8 p10

screw, hex serr washer m8 x 30

14 screw, tf-hex m8 x 16 blk zinc

4

16 screw, hex serr washer m8 x 16

4

2

3

4

8

1

2

1

1

1

1

guard, fan discharge p8 p10

louver,extruded 18kw 500.0 lng

support, motor fan 1800/2200

strip,weather 1” x 1/8” foam (ft)

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

865708-240

874904-038

865408-170

16

17

850604-012

15

18

250018-497

821103-150

13

02250173-084

12

14

02250171-617

11

4

02250162-492

02250167-452

9

02250160-566

8

10

2

02250160-536

7

1

4

1

02250160-429

02250154-721

4

7

02250160-452

02250058-345

3

cooler,air/oil p10 std cooler, air/oil crn/ce

1

5

02250156-137 02250164-164

2

motor, fan 1hp 4p teee

DESCRIPTION

1

Q T Y

6

-

PART NO.

1

KEY NO.

N O T E 24

23

KEY NO.

4

nut,hex locking m8

16 screw, plastic pilot m6 x 30

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

884708-125

883306-030

PART NO.

Q T Y

1.13 COOLING AND LUBRICATION SYSTEM, AIR-COOLED AXIAL FAN, 60HZ/25HP

29

N O T E

PARTS LIST

02250174-285 R00

1.14 COOLING AND LUBRICATION SYSTEM, AIR-COOLED CENTRIFUGAL FAN, 50/60HZ 40HP

COOLING AND LUBRICATION SYSTEM, AIR-COOLED CENTRIFUGAL FAN, 50/60HZ 40HP

30

screw, hex serr washer m8 x 30

screw, hex serr washer m8 x 16

nut,serr flng m8 x 1.25

washer, iso 7093-8-140hv

washer, metric-iso7089- 8

wire, neoprene #12-4 so (ft)

weatherstrip, 3/16 x 3/8 ft

grip,cord for so 12/4 st 3/4”

guard, fan discharge p10-40hp

22 screw, tf-hex m8 x 16 blk zinc

4

8

4

3

4

8

5

2

panel, venturi p10-40hp

duct,centrifugal fan p10-40hp

cooler,air/oil p10-40hp std cooler, air/oil 40ho crn

1 1

support,airoc es8

venturi,es8 16”

support, motor fan 1800/2200

2

1

1

fan, cooling 16” 60hz 40 hp fan, cooling 16” 50hz 40 hp

motor,1hp 4p

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

882608-030

883008-016

18

850604-012

12

17

250022-436

11

882608-016

250018-497

16

02250180-559

9

10

882508-125

02250174-300

8

15

02250174-294

7

865408-170

02250174-288 02250184-790

6

865708-240

02250160-566

5

14

1

02250156-639

4

13

1

02250154-721

3

1

02250174-423 02250174-424

2

1

Q T Y

-

PART NO.

1

KEY NO.

1.

PART NO.

Q T Y DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PLACE WEATHER STRIPPING ON DUCT MOUNTING FACE TO ELIMINATE AIR LEAKAGE.

NOTES:

KEY NO.

1.14 COOLING AND LUBRICATION SYSTEM, AIR-COOLED CENTRIFUGAL FAN, 50/60HZ 40HP

31

PARTS LIST

02250185-892 R00

1.15 DISCHARGE, SEPARATOR/SUMP TANK AND PIPING SYSTEM AIR-COOLED

DISCHARGE, SEPARATOR/SUMP TANK AND PIPING SYSTEM AIR-COOLED

32

02250055-015

02250097-609

02250156-379

02250157-450

02250157-596

02250159-433

02250185-891

825908-125

838808-200

865408-170

866900-005

870624-024

883008-016

1

2

3

4

5

6

7

8

9

10

11

12

13

1

2

1

3

3

3

1

3

1

1

3

1

1

Q T Y

screw

connector

plug

washer

washer

nut

tnk assy

gasket

hose

wire

isolator

valve

adapter

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

KEY NO.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

Q1: SEE ASSEMBLY DRAWING 02250185-891

A4: AIR OUT TO COOLER

A3: AIR IN FROM UNIT

A2: TO GRND LUG ON FRAME

A1: OIL RETURN SCAVANGE LINE

APPLY 3M 8898 4-WAY SPRAY LUBRICANT TO ALL O-RING CONNECTIONS

DESCRIPTION

2.

Q T Y

APPLY LOCTITE 567 PST PIPE SEALANT TO ALL NPT CONNECTIONS

PART NO.

1.

NOTES:

KEY NO.

1.15 DISCHARGE, SEPARATOR/SUMP TANK AND PIPING SYSTEM AIR-COOLED

33

PARTS LIST

02250185-891 R00

1.16 DISCHARGE, SEPARATOR/SUMP TANK AND PIPING SYSTEM

DISCHARGE, SEPARATOR/SUMP TANK AND PIPING SYSTEM

34

02250097-610

02250099-766

02250101-783

02250117-782

02250125-774

02250126-129

02250152-798

02250155-599

02250155-720

02250156-944

02250185-533

040029

250006-938

826502-369

828012-040

838812-250

874505-008

876804-025

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

1

1

6

6

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Q T Y

connector

screw

washer

capscrew

o-ring

valve

plug

element

decal

spring

tank

elbow

sightglass

orifice

filter

adapter

elbow

plug

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

KEY NO.

ALL FITTING SHOULD BE ORIENTED HORIZONTALLY OR VERTICALLY AS SHOWN TORQUE BOLTS TO 70 FT-LBS (LUBRICATED) MARK/TAG ASSEMBLY WITH SULLAIR P/N

5. 6. 7.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

ORIENT ELBOW (ITEM 2) 180° OPPOSITE RELIEF VALVE(ITEM 13)

CHECK ELECTRICAL CONTINUITY BETWEEN LID AND TANK AND APPLY VALIDATION DECAL

3. 4.

APPLY 3M 8898 4-WAY SPRAY LUBRICANT TO ALL O-RING CONNECTIONS

DESCRIPTION

2.

Q T Y

APPLY LOCTITE 567 PST PIPE SEALANT TO ALL NPT CONNECTIONS

PART NO.

1.

NOTES:

KEY NO.

1.16 DISCHARGE, SEPARATOR/SUMP TANK AND PIPING SYSTEM

35

PARTS LIST

02250171-765-R00

1.17 MOISTURE DRAIN—STANDARD

MOISTURE DRAIN—STANDARD

36

02250046-110

02250071-380

02250167-603

02250170-783

250025-859

842215-004

1

2

3

4

5

6

3

2

1

1

1

1

Q T Y DESCRIPTION

hose,nylon 1/4”

connector, male1/4tube x 1/4

valve, drain combo 24 vdc

adapter,1/2m bspp-1/2f npt brass

grip, cord n4 .187-.250 x 1/2”

bushing, red brs 1/2 x 1/4

KIT,DRAIN VALVE SERVICE

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250171-483 CABLE,PWR REPL DRN VLV

02250171-245

02250171-243 COIL,JCL 24 VDC 16W 50/60HZ

SERVICE KITS FOR 02250170-783

PART NO.

KEY NO.

1.17 MOISTURE DRAIN—STANDARD N O T E

37

PARTS LIST

02250182-810 R01

1.18 MOISTURE DRAIN—ZERO LOSS 25/30 HP

MOISTURE DRAIN—ZERO LOSS 25/30 HP

38

02250046-110

02250071-380

02250144-841

02250167-603

02250182-545

250024-685

842215-004

1

2

3

4

5

6

7

3

2

1

1

1

1

1

Q T Y

HOSE, NYLON 1/4(FT)

CONN,TUBE-STRT 1/4MNPT X1/4”T

DRN,ZERO LOSS 115V 1/2”NPT

ADPT,1/2M BSPP-1/2F NPT PLATED STEEL

VLV,BALL/STNR COMB 1/2M X 1/2M

GRIP,CD N4 .187-.250 X 1/2”

BSHG, RED BRS 1/2 X 1/4

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

KEY NO.

1.18 MOISTURE DRAIN—ZERO LOSS 25/30 HP

39

PARTS LIST

02250183-721 R01

1.19 MOISTURE DRAIN—ZERO LOSS 40 HP

MOISTURE DRAIN—ZERO LOSS 40 HP

40

02250046-110

02250071-380

02250140-865

02250144-841

02250167-603

02250182-545

250024-685

250025-849

250025-850

842215-004

866302-020

878212-012

881108-050

881308-050

1

2

3

4

5

6

7

8

9

10

11

12

13

14

1

1

1

1

6

1

1

2

1

1

1

1

1

2

Q T Y

NIPPLE, PIPE-HX BRASS 1/2 X 1/2

ELBOW, PIPE 90F 1/2 X 1/2 BRASS

TEE, FEMALE PIPE BRASS 1/8”

NIPPLE, PIPE PLTD 1/8 X 2

HOSE, NYLON 1/4(FT)

ELBOW, 90DEG M SWVL 1/4T X 1/4 NPT

ELBOW,90DEG M SWVL 1/4T X 1/8NPT

CONN,TUBE-STRT 1/4MNPT X1/4”T

DRN,ZERO LOSS 115V 1/2”NPT

ADPT,1/2M BSPP-1/2F NPT PLATED STEEL

VLV,BALL/SRNR 1/2M X 1/2M

VALVE,BALL 1/8M X 1/8F 1/4 TURN

GRIP,CD N4 .187-.250 X 1/2”

BSHG, RED BRS 1/2 X 1/4

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

KEY NO.

1.19 MOISTURE DRAIN—ZERO LOSS 40 HP PART NO.

Q T Y DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

A3: TO MOISTURE SEPARATOR

A2: TO P2 PACKAGE DISCHARGE PRESSURE

A1: TO STARTER BOX

02250182-571 KIT,VALVE SERVICE 115V ZLOSS

SERVICE KITS FOR 02250182-545

KEY NO.

41

PARTS LIST

02250170-758 R01

1.20 MOISTURE DRAIN, AIR-COOLED WITH INTEGRAL DRYER

MOISTURE DRAIN, AIR-COOLED WITH INTEGRAL DRYER

42

02250071-362

02250071-380

02250167-603

02250170-783

049905

250025-850

842215-004

866304-015

868902-010

868902-010

TO AIROUT BRACKET

FROM WATER SEPERATOR

TO BOTTOM OF STARTER BOX

FROM REFRIGERANT EVAPORATOR CONDENSATE HOSE

3

4

5

6

7

8

9

10

11

A1

A2

A3

A4

tee,male pipe brass 1/4

bushing,red hex pltd 1/2 x 1/4

nipple,pipe pltd 1/4 x 1 1/2

hose,nylon 1/4(ft)

elbow, 90deg m swvl 1/4t x 1/4 npt

valve, check 1/4"

valve, drain combo 24 vdc

adapter,1/2m bspp-1/2f npt plated steel

grip, cord n4 .187-.250 x 1/2"

locknut, n4 conduit sealing

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

1

1

1

5

3

1

1

1

1

1

bushing,red-brs-1/2"x1/4"

2

1

02250046-110

1

DESCRIPTION

PART NO.

KEY NO.

Q T Y

N O T E

1.20 MOISTURE DRAIN, AIR-COOLED WITH INTEGRAL DRYER

43

PARTS LIST

02250157-077-R07

1.21 PNEUMATIC CONTROL SYSTEM—NYLON

PNEUMATIC CONTROL SYSTEM—NYLON

44

02250155-962

02250155-963

8

9

250025-926

811502-025

847815-050

869825-025

20

21

22

23

2

2

1

1

1

1

1

1

1

7

1

2

1

1

3

3

3

2

1

1

3

2

1

Q T Y

tee, male pipe brass 1/4

adapter, fem pipe 1/4" x 7/16"-20

adapter, fem pipe 1/4" x 7/16"-20

valve, shuttle 1/4" npt (dbl chk)

connector, fem tube 3/8 x 1/4 nptf

connector, fem tube 1/4 x 1/4 nptf

connector, male1/4tube x 1/4

connector, male 1/4tube x 1/8

elbow, 90deg m swvl 3/8 t x1/4

elbow, 90deg m swvl 1/4t x 1/4 npt

tee, male branch swiv 1/4 tube x 1/4 npt

elbow, 90 1/4t pls x 1/4 npt m

valve, pressure regulator

strainer, v-type 300psix1/4

tbg, nylon 1/4"-od yellow

tbg, nylon 1/4"-od blue

tbg, nylon 1/4"-od red

valve, solenoid 3wno 1/4 250# 24vdc

orifice,.078 .25 fnpt x .25 mnpt

valve, check 1/4" poppet style

tube, nylon .375"od x .050w black (ft)

locknut, n4 conduit sealing

valve, blowdown 1/4 npt hi prs

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

250025-923

17

250025-926

250025-859

16

19

250025-858

15

18

250025-850

250025-852

14

250025-835

02250155-961

7

13

02250155-714

6

250018-430

02250118-586

5

12

02250115-272

4

241771

02250099-630

3

250017-280

02250071-362

2

10

02250049-634

1

11

PART NO.

KEY NO.

(III)

(II)

(I)

N O T E

1.21 PNEUMATIC CONTROL SYSTEM—NYLON

3

Blowdown subassembly

Sequencing subassembly Flow

DESCRIPTION nipple, pipe-hx brass 1/4 x 1/4

Load control subassembly

Port 3

Port 2

881304-025

PART NO.

Q T Y

N O T E

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

45

(I) For maintenance on solenoid valve no. 02250155-714, order repair kit no. 02250157-500 and replacement coil no. 02250157-502 (II) For maintenance on strainer no. 241771, order repair kit no. 241772 (III) For maintenance on pressure regulator no. 250017-280, order repair kit no. 250019-453

A6

A5

A4

A3

A2

A1

24

KEY NO.

PARTS LIST

02250158-319-R06

1.22 PNEUMATIC CONTROL SYSTEM—STAINLESS STEEL

PNEUMATIC CONTROL SYSTEM—STAINLESS STEEL

46

241771

250017-280

250018-760

250139-016

250139-024

250139-044

250139-053

250211-005

250211-017

250591-002

408893

811502-025

841215-004

841215-006

847815-050

869825-025

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

2

2

3

6

1

1

1

1

8

1

1

1

1

3

1

1

1

2

1

1

2

1

1

Q T Y

tee,male pipe brass 1/4

nipple,chase cond 1/2

tubing, stnls stl 3/8 20ga ft

tubing, stnls stl 1/4 20ga ft

adapter, fem pipe 1/4 x 7/16-20

valve, shuttle 1/4” npt (dbl chk)

tee,tube-m branch 1/4 swg ss

elbow, tube-m3/8t x1/4p swg ss

elbow,tube-m 1/4” swglk 316ss

connector, tube-f 3/8 x 1/4 316s

connector, tube-f 1/4 swglk 316s

connector, tube-m 1/4 x 1/8 316s

connector, tube-m 1/4 swglk 316s

nipple,hx tbe 316s 1/4”

valve, pressure regulator

strainer, v-type 300psix1/4

filter,pneumatic 1/8”npt 5micr

valve, solenoid 3wno 1/4 250# 24vdc

orifice,.078 .25 fnpt x .25 mnpt

valve,check 1/4” poppet style

locknut, n4 conduit sealing

valve, blowdown 1/4 npt hi prs

bushing, red brs 1/4 x 1/8

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250155-714

02250173-972

02250118-586

5

6

02250115-272

4

7

02250049-634

02250071-362

2

02250046-101

1

3

PART NO.

KEY NO.

N O T E PART NO.

Q T Y DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250157-500 KIT,SOL VLV 3WNO 24VDC

SERVICE KITS FOR 02250155-714

250019-453 KIT, REPAIR PRESS REG VALVE

SERVICE KITS FOR 250017-280

241772 KIT, REP STRAINER-V-TYPE

SERVICE KITS FOR 241771

A7- FLOW DIRECTION

A6- SUBASSEMBLY, BLOWDOWN

A5- SUBASSEMBLY, SEQUENCING

A4- SUBASSEMBLY, LOAD CONTROL

A3- PORT 1

A2- PORT 3

A1- PORT 2

KEY NO.

1.22 PNEUMATIC CONTROL SYSTEM—STAINLESS STEEL

47

N O T E

PARTS LIST

02250156-917-R05

1.23 CONTROL SYSTEM AND ELECTRICAL PARTS, MFV

CONTROL SYSTEM AND ELECTRICAL PARTS, MFV

48

250025-849

250025-858

250034-430

21

22

23

1

1

1

1

1

3

1

1

1

2

1

1

2

1

1

1

2

1

3

1

1

2

1

Q T Y

SOCKET, 8PIN 480V

CONNECTOR, MALE 1/4TUBE X 1/8

ELBOW,90DEG M SWVL 1/4T X 1/8NPT

CONN, CORD GRIP 0.09-0.26

HOLDER,FUSE 1P 30A 600V

ELBOW, 90 1/4”TUBE X 1/8”NPT

CONN, 1/4” TUBE X 1/8” NPT

HEATER, ENCLOSURE 50W

P,THERMISTER 3000 OHM NTC 12’L

RLY, SPTD DIN 10A 24VDC COIL

W, 10 GAGE GROUND BOND 12” M8

P,RTD 100 OHM PLAT 3.5”X 6FT

XDCR, PRESS 0-250# RATIOMETRIC

SW,DIFF PRESS 20PSID 12FT

XFMR,PT 50VA UNIV W/PRI FH

SW,VAC 22”WC N4 6FT CABLE 5A

GRIP,CD N4 .250-.375 X 1/2”

GRIP,CD N4 .187-.250 X 1/2”

GRIP,CD N4 .125-.187 X 1/2”

R,DIN 35MM (METERS)

STRIP, WEATHER 1” X 1/8” FOAM (FT)

BLK,TERM END STOP CH

TUBE,NYL .25 OD X 040W BLK(FT)

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

250019-771

250023-496

250018-429

18

20

250018-427

17

19

249008

16

02250100-363

10

02250175-087

02250083-182

9

15

02250078-249

8

02250158-377

02250071-381

7

14

02250071-380

6

02250157-450

02250071-379

5

13

02250060-705

4

02250155-174

02250058-345

3

02250155-175

02250057-245

2

11

02250054-861

1

12

PART NO.

KEY NO.

825908-125 838808-200

27 28

FUSE,PRI FUSE,SEC PHASE MNTR POWER SUPPLY RELAY,OVLD STARTER ASSY

32 33 34 35 36 37

DESCRIPTION

VARIOUS VARIOUS

1

VARIOUS 1

VARIOUS 1

VARIOUS

VARIOUS

VARIOUS

Continued on page 51

WASHER, METRIC-ISO7089- 8

TUBING, ST STL 1/4” 20GA

WASHER, SPR LOCK-METRIC PLTD M8

NUT, HEX METRIC M8 X 1.25

BLOCK,TERM ADAPTER KAD

BLOCK,TERMINAL KT3

BUTTON, PUSH NON-ILLUM BLK N4X

1

1

2

1

6

1

6

6

1

3

1

Q T Y

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

FUSE,DRYER

865408-170

31

30

841215-004

250041-103

26

29

250041-102

250034-627

PART NO.

25

24

KEY NO.

1.23 CONTROL SYSTEM AND ELECTRICAL PARTS, MFV

49

PARTS LIST

02250156-917-R05

1.24 CONTROL SYSTEM AND ELECTRICAL PARTS, MFV (CONTINUED)

CONTROL SYSTEM AND ELECTRICAL PARTS, MFV (CONTINUED)

50

PART NO.

Q T Y

P1-TO SUMP TANK WET SUMP PRESSURE

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

A20: DIFFERENTIAL PRESSURE SWITCH OPTION

A19: INLET PRESSURE SWITCH OPTION MOUNT TO FAN MOTOR SUPPORT

A18: TO AIR FILTER

A17: PHASE MONITOR OPTION

A16: DRYER COMPRESSOR MOTOR POWER

A15: DRYER CTL POWER - 24VDC

A14: ENCLOSURE HEATER MOUNTED INSIDE TOP OF STARTER BOX

A13: HEATER OPTIONS

A12: HOLE TO BE DRILLED IN BOX AS NEEDED

A11: DRYER OPTION

A10: SCD DRAIN OPTION

A9: MOTOR WIRING

A8: FAN MOTOR CONNECTION

A7: SOLENOID 5-ELECTRIC DRAIN

A6: SOLENOID 4

A5: SOLENOID 1

A4: T1-TO SUMP TANK WET DISCHARGE TEMPERATURE

A3:

A2: P2-PACKAGE DISCHARGE PRESSURE

A1: TO FRAME

KEY NO. PART NO.

Q T Y DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

Q1: SEE ASSY DRAWINGS: 02250169-624 DWG,START P8/10 MFV TAB

A23: OTHER OPTIONS

A22: CSA OPTION

A21: T3-TO INTEGRAL DRYER EVAPORATOR DRYER DEW POINT TEMPERATURE

KEY NO.

1.24 CONTROL SYSTEM AND ELECTRICAL PARTS, MFV

51

PARTS LIST

02250165-276-R03

1.25 CONTROL SYSTEM AND ELECTICAL PARTS, VSD

CONTROL SYSTEM AND ELECTICAL PARTS, VSD

52

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

KEY NO. 1 2 1 1 3 1 2 1 1 2 1 1 2 1 1 1 1 3 1 1 1 1 1 1 3 1 6 6 1 6 1

switch, defferential pressure 20psid 12ft or block, term end stop ch strip,weather 1” x 1/8” foam (ft) rail,din 35mm (meters) grip, cord n4 .125-.187 x 1/2” grip, cord n4 .187-.250 x 1/2” grip, cord n4 .250-.375 x 1/2” switch, vacuum 22”wc n4 6ft cable 5a transformer, control 50va univ w/pri fh transducer, pressure 0-250# ratiometric probe,rtd 100 ohm plat 3.5”x 6ft wire,10 gage ground bond 12” m8 relay,sptd din 10a 24vdc coil probe,thermister 3000 ohm ntc 12’l tube,nyl .25 od xx 040w blk(ft) heater, enclosure 50w connector,1/4” tube x 1/8” npt elbow, 90 1/4”tube x 1/8”npt holder,fuse 1p 30a 600v connector,cord grip 0.09-0.26 elbow,90deg m swvl 1/4t x 1/8npt connector, male 1/4tube x 1/8 socket, 8pin 480v button, push non-illum blk n4x block,terminal kt3 block,term adapter kad nut,hex metric m8 x 1.25 washer, spr lock-metric pltd m8 tubing, st stl 1/4” 20ga washer, metric-iso7089- 8 various

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250050-154 02250057-245 02250058-345 02250060-705 02250071-379 02250071-380 02250071-381 02250078-249 02250083-182 02250155-174 02250155-175 02250157-450 02250158-377 02250175-087 0225054-861 249008 250018-427 250018-429 250019-771 250023-496 250025-849 250025-858 250034-430 250034-627 250041-102 250041-103 825908-125 838808-200 841215-004 865408-170 FUSE,DRYER

PART NO.

Q T Y

N O T E PART NO.

Q T Y DESCRIPTION

N O T E

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

53

32 FUSE,FAN 3 various 33 FUSE,PRI 2 various 34 FUSE,SEC 1 various 35 PHASE MNTR 1 various 36 STARTER ASSY 1 various A1: TO FRAME A2: P2-PACKAGE DISCHARGE PRESSURE A3: P1-TO SUMP TANK WET SUMP PRESSURE A4: T1-TO SUMP TANK WET DISCHAGE TEMPERATURE A5: SOLENOID 1 A6: SOLENOID 4 A7: SOLENOID 5-ELECTRIC DRAIN A8: FAN MOTOR CONNECTION A9: MOTOR WIRING A10: SCD DRAIN OPTION A11: DRYER OPTION A12: HOLE TO BE DRILLED IN BOX AS NEEDED A13: HEATER OPTIONS A14: ENCLOSURE HEATER MOUNTED INSIDE TOP OF STARTER BOX A15: DRYER CTL POWER - 24VDC A16: DRYER COMPRESSOR MOTOR POWER A17: PHASE MONITOR OPTION A18: TO AIR FILTER A19: INLET PRESSURE SWITCH OPTION MOUNT TO FAN MOTOR SUPPORT A20: DIFFERENTIAL PRESSURE SWITCH OPTION A21: T3-TO INTEGRAL DRYER EVAPORATOR DRYER DEWPOINT TEMPERATURE A22: CSA OPTION A23: OTHER OPTIONS Q1: SEE ASSY DRAWINGS: 02250169-671 DWG,START P8/10 VSD TAB

KEY NO.

1.25 CONTROL SYSTEM AND ELECTICAL PARTS, VSD

PARTS LIST

02250165-275-R03

1.26 CONTROL SYSTEM AND ELECTRIC PARTS, 230/460 WYE-DELTA

CONTROL SYSTEM AND ELECTRIC PARTS, 230/460 WYE-DELTA

54

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

KEY NO. 1 1 2 1 1 3 1 2 1 1 2 1 1 2 1 1 1 3 1 1 1 1 1 1 3 1 6 6 1 6 1

switch, defferential pressure 20psid 12ft or tube,nyl .25 od xx 040w blk(ft) block, term end stop ch strip,weather 1” x 1/8” foam (ft) rail,din 35mm (meters) grip, cord n4 .125-.187 x 1/2” grip, cord n4 .187-.250 x 1/2” grip, cord n4 .250-.375 x 1/2” switch, vacuum 22”wc n4 6ft cable 5a transformer, control 50va univ w/pri fh transducer, pressure 0-250# ratiometric probe,rtd 100 ohm plat 3.5”x 6ft wire,10 gage ground bond 12” m8 relay,sptd din 10a 24vdc coil probe,thermister 3000 ohm ntc 12’l heater, enclosure 50w connector,1/4” tube x 1/8” npt elbow, 90 1/4”tube x 1/8”npt holder,fuse 1p 30a 600v connector,cord grip 0.09-0.26 elbow,90deg m swvl 1/4t x 1/8npt connector, male 1/4tube x 1/8 socket, 8pin 480v button, push non-illum blk n4x block,terminal kt3 block,term adapter kad nut,hex metric m8 x 1.25 washer, spr lock-metric pltd m8 tubing, st stl 1/4” 20ga washer, metric-iso7089- 8 various

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250050-154 02250054-861 02250057-245 02250058-345 02250060-705 02250071-379 02250071-380 02250071-381 02250078-249 02250083-182 02250155-174 02250155-175 02250157-450 02250158-377 02250175-087 249008 250018-427 250018-429 250019-771 250023-496 250025-849 250025-858 250034-430 250034-627 250041-102 250041-103 825908-125 838808-200 841215-004 865408-170 FUSE,DRYER

PART NO.

Q T Y

N O T E PART NO.

Q T Y DESCRIPTION

N O T E

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

55

32 FUSE,PRI 2 various 33 FUSE,SEC 1 various 34 PHASE MNTR 1 various 35 POWER SUPPLY 1 various 36 RELAY,OVLD 1 various 37 STARTER ASSY 1 various A1: TO FRAME A2: P2-PACKAGE DISCHARGE PRESSURE A3: P1-TO SUMP TANK WET SUMP PRESSURE A4: T1-TO SUMP TANK WET DISCHAGE TEMPERATURE A5: SOLENOID 1 A6: SOLENOID 4 A7: SOLENOID 5-ELECTRIC DRAIN A8: FAN MOTOR CONNECTION A9: MOTOR WIRING A10: SCD DRAIN OPTION A11: DRYER OPTION A12: HOLE TO BE DRILLED IN BOX AS NEEDED A13: HEATER OPTIONS A14: ENCLOSURE HEATER MOUNTED INSIDE TOP OF STARTER BOX A15: DRYER CTL POWER - 24VDC A16: DRYER COMPRESSOR MOTOR POWER A17: PHASE MONITOR OPTION A18: TO AIR FILTER A19: INLET PRESSURE SWITCH OPTION MOUNT TO FAN MOTOR SUPPORT A20: DIFFERENTIAL PRESSURE SWITCH OPTION A21: T3-TO INTEGRAL DRYER EVAPORATOR DRYER DEWPOINT TEMPERATURE A22: CSA OPTION A23: OTHER OPTIONS Q1: SEE ASSY DRAWINGS: 02250169-665 DWG,START P8/10 YD N4 TAB

KEY NO.

1.26 CONTROL SYSTEM AND ELECTRIC PARTS, 230/460 WYE-DELTA

PARTS LIST

02250179-957-R00

1.27 CONTROL SYSTEM AND ELECTRIC PARTS, YD CE

CONTROL SYSTEM AND ELECTRIC PARTS, YD CE

56

02250131-188

02250155-174

02250155-175

02250157-449

02250158-377

02250167-814

8

9

10

11

12

13

865408-170

RELAY OVERLOAD

STARTER

20

21

22

DESCRIPTION

various

various

1 2

washer, metric-iso7089- 8

terminal, ring tng 3/8 x 8ga

washer, spr lock-metric pltd m8

nut,hex metric m8 x 1.25

socket, 8pin 480v

heater, enclosure 50w

relay,phase monitor ce

relay,ovrld base for xt frame c

relay,sptd din 10a 24vdc coil

wire, ground bond 30” 10 ga

probe,rtd 100 ohm plat 3.5”x 6ft

transducer, pressure 0-250# ratiometric

breaker, circ-h high inrush

transformer, control 50va univ w/o pri fh

grip, cord n4 .250-.375 x 1/2”

grip, cord n4 .125-.187 x 1/2”

rail,din 35mm (meters)

strip,weather 1” x 1/8” foam

block, term end stop ch

6

1

6

6

1

1

1

1

2

1

1

2

3

1

2

1

3

1

6

12 block, term 45a 600v euro ch

Q T Y

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

838808-200

849306-008

18

19

825908-125

02250083-181

7

17

02250071-381

6

250034-430

02250071-379

5

16

02250060-705

4

02250179-970

02250058-345

3

249008

02250057-245

2

14

02250057-241

1

15

PART NO.

KEY NO.

N O T E PART NO.

Q T Y DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

SERVICE KITS FOR 02250178-681 02250178-681 DWG,START P10 CE YD N4 TAB

A11: OTHER OPTIONS

A10: STARTER BOX HEATER MOUNTED INSIDE TOP OF STARTER BOX

A9: PHASE MONITOR OPTION

A8: HEATER OPTIONS

A7: SCD DRAIN OPTION

A6: SOLENOID 4

A5: SOLENOID 1

A4: T1-TO SUMP TANK WET DISCHARGE TEMPERATURE

A3: P1-TO SUMP TANK WET SUMP PRESSURE

A2: P2-PACKAGE DISCHARGE PRESSURE

A1: TO FRAME

KEY NO.

1.27 CONTROL SYSTEM AND ELECTRIC PARTS, YD CE

57

N O T E

PARTS LIST

02250179-958-R00

1.28 CONTROL SYSTEM AND ELECTRIC PARTS, VSD CE

CONTROL SYSTEM AND ELECTRIC PARTS, VSD CE

58

02250155-174

02250155-175

02250157-449

02250158-377

02250162-392

02250179-970

249008

250034-430

10

11

12

13

14

15

16

17

DESCRIPTION

1

6

1

6

6

1

1

1

1

2

1

1

2

1

3

1

2

1

3

1

6

various

washer, metric-iso7089- 8

terminal, ring tng 3/8 x 8ga

washer, spr lock-metric pltd m8

nut,hex metric m8 x 1.25

socket, 8pin 480v

heater, enclosure 50w

relay,phase monitor ce

starter,1.9a fv ch-it

relay,sptd din 10a 24vdc coil

wire, ground bond 30” 10 ga

probe,rtd 100 ohm plat 3.5”x 6ft

transducer, pressure 0-250# ratiometric

block, contact aux 1no ch-it a-e

breaker, circ-h high inrush

transformer, control 50va univ w/o pri fh

grip, cord n4 .250-.375 x 1/2”

grip, cord n4 .125-.187 x 1/2”

rail,din 35mm (meters)

strip,weather 1” x 1/8” foam

block, term end stop ch

12 block, term 45a 600v euro ch

Q T Y

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

STARTER

02250154-607

9

22

02250131-188

8

865408-170

02250083-181

7

21

02250071-381

6

849306-008

02250071-379

5

20

02250060-705

4

825908-125

02250058-345

3

838808-200

02250057-245

2

18

02250057-241

1

19

PART NO.

KEY NO.

N O T E PART NO.

Q T Y DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

SERVICE KITS FOR 02250178-751 02250178-751 START,ASY P10 CE VSD N12

A11: OTHER OPTIONS

A10: STARTER BOX HEATER MOUNTED INSIDE TOP OF STARTER BOX

A9: PHASE MONITOR OPTION

A8: HEATER OPTIONS

A7: SCD DRAIN OPTION

A6: SOLENOID 4

A5: SOLENOID 1

A4: T1-TO SUMP TANK WET DISCHARGE TEMPERATURE

A3: P1-TO SUMP TANK WET SUMP PRESSURE

A2: P2-PACKAGE DISCHARGE PRESSURE

A1: TO FRAME

KEY NO.

1.28 CONTROL SYSTEM AND ELECTRIC PARTS, VSD CE

59

N O T E

PARTS LIST

02250169-587 R06

1.29 CONTROL STARTER—MFV

CONTROL STARTER—MFV

60

02250154-052

250021-694

-

-

250014-827

250014-127

02250154-359

6

7

8

9

10

11

12

CAP,S4 PROGRAM PORT NEMA 6P

RCPT,S4 PROGRAM PORT NEMA 6P

NPL,YELLOW RING 45MM E-STOP

BLOCK, CONTACT 1 N.C

SW,PB OPER RED40MM PUSH-TWIST

DECAL,MICROPROCESSOR OVERLAY

KIT, CIR BRKR DISCONNECT N4

CB, 100A HMCP

ADAPTER,O.L.R. BASE MNT

CTL,I/O MOD WS 24VDC

SPCR,.25DIA X .41 LONG - ALUM

CTL,DISPLAY WS

BAR, GROUND 5 POST

CNTOR,400A 3P 24VDC XT

CNTOR,225A 3P 24VDC XT

CNTOR,150A 3P 24VDC XT

CNTOR,115A 3P 24VDC XT

CNTOR,95A 3P 24VDC XT

CNTOR,80A 3P 24VDC XT

CNTOR,65A 3P 24VDC XT

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250159-549

02250161-759

5

17

02250154-051

4

02250159-547

02250101-721

3

16

02250167-822

2

02250081-473

02250167-821

2

15

02250167-820

2

02250085-504

02250170-760

2

250027-125

02250167-819

2

14

WASHER,LOCK EXTERNAL TOOTH 5/16”

02250170-761

2

13

LUG, GROUND

02250167-818

2

SPEC, ENCL P12/16 22” X 36” X 10”

02250169-621

1

DESCRIPTION

PART NO.

KEY NO.

Q T Y

1.29 CONTROL STARTER—MFV

02250145-195 250021-692 02250167-849 250019-773

18 19 20 21

Q T Y

HOLDER,FUSE KTK-R 3 POLE

BLK,AUX CONT 1NO 1NC FRONT

RELAY,OVERLOAD 32A

BLOCK, POWER DISTRIBUTION 175 AMP

BLOCK, POWER DISTRIBUTION 310 AMP

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

-ROUTE COMMUNICATION CABLE FROM I/O MODULE TO DISPLAY MODULE OFF OF THE SUB-PANEL.

-DO NOT ROUTE WIRING THROUGH OPTIONAL COMPONENT LOCATIONS.

-SULLAIR P/N 02250159-549 AND 02250159-547 SHOULD NOT BE INSTALLED AND WIRED BUT SHOULD BE SECURELY SHIPPED LOOSE INSIDE STARTER BOX.

-MANUFACTURER: CUTLER-HAMMER

-ALL COMPONENTS TO BE UL AND CSA APPROVED.

-GROUND WIRES ARE GREEN WITH YELLOW TRACER.

-ALL DC CONTROL WIRES TO BE DARK BLUE IF NOT IN A CABLE.

-SEPARATE DC CONTROL WIRING FROM AC CONTROL WIRING

NOTES:

02250145-194

PART NO.

18

KEY NO.

61

PARTS LIST

02250169-659 R07

1.30 CONTROL STARTER—WYE-DELTA

CONTROL STARTER—WYE-DELTA

62

02250145-195

19

Q T Y

BLOCK,POWER DISTRIBUTION 175 AMP

CAP,S4 PROGRAM PORT NEMA 6P

RCPT,S4 PROGRAM PORT NEMA 6P

ADAPTER,O.L.R. BASE MNT

NPL,YELLOW RING 45MM E-STOP

BLOCK, CONTACT 1 N.C

SW,PB OPER RED40MM PUSH-TWIST

KIT, CIR BKR DISCONNECT N4

CB, 100A HMCP

WASHER,LOCK EXTERNAL TOOTH 5/16”

LUG, GROUND

SPACER,6.35 DIA X 10.4 LONG ALUM

DECAL,MICROPROCESSOR OVERLAY

CTL,DISPLAY WS

BAR, GROUND 5 POST

CTL,I/O MOD WS 24VDC

RELAY,OVERLOAD 32A

CNTOR,225A 3P 24VDC XT

CNTOR,150A 3P 24VDC XT

CNTOR,95A 3P 24VDC XT

CNTOR,65A 3P 24VDC XT

CNTOR,32A 3P 24VDC XT

SPEC, ENCL P12/16 22” X 36” X 10”

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250159-549

18

-

10

02250159-547

-

9

17

02250161-759

8

250021-694

02250154-359

7

16

02250154-051

6

02250081-473

02250101-721

5

15

02250154-052

4

250027-125

250021-692

3

14

02250167-821

2

02250085-504

02250167-820

2

13

02250167-819

2

250014-827

02250167-818

2

250014-127

02250167-817

2

12

02250169-621

1

11

PART NO.

KEY NO.

1.30 CONTROL STARTER—WYE-DELTA

02250167-843 02250167-849 250019-773

20 20 21

Q T Y

HOLDER,FUSE KTK-R 3 POLE

BLK,AUX CONT 1NO 1NC FRONT

BLK,AUX CONT 1NO 1NC FRONT

BLOCK,POWER DISTRIBUTION 310 AMP

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

-ROUTE COMMUNICATION CABLE FROM I/O MODULE TO DISPLAY MODULE OFF OF THE SUB-PANEL.

-DO NOT ROUTE WIRING THROUGH OPTIONAL COMPONENT LOCATIONS.

-SULLAIR P/N 02250159-549 AND 02250159-547 SHOULD NOT BE INSTALLED AND WIRED BUT SHOULD BE SECURELY SHIPPED LOOSE INSIDE STARTER BOX.

-MANUFACTURER: CUTLER-HAMMER

-ALL COMPONENTS TO BE UL AND CSA APPROVED.

-GROUND WIRES ARE GREEN WITH YELLOW TRACER.

-ALL DC CONTROL WIRES TO BE DARK BLUE IF NOT IN A CABLE.

-SEPARATE DC CONTROL WIRING FROM AC CONTROL WIRING

NOTES:

02250145-194

PART NO.

19

KEY NO.

63

PARTS LIST

02250169-392R02

1.31 CONTROL STARTER—VSD N12

CONTROL STARTER—VSD N12

64

02250159-549

02250161-759

02250155-754

02250168-820

02250168-819

-

-

-

16

17

18

19

20

20

20

02250154-359

8

15

-

7

02250159-547

-

6

02250145-195

02250154-051

5

14

02250170-668

4

13

02250154-052

3

02250081-473

02250165-108

2

12

02250157-716

2

250027-125

02250157-717

2

11

1

02250157-718

2

250019-773

02250157-719

2

02250085-504

02250157-725

2

9

02250157-726

2

10

1

02250157-727

2

1

-

-

-

-

1

4

1

1

-

1

1

1

2

2

1

1

1

1

-

-

-

-

-

-

-

02250168-846

1

1

PART NO.

KEY NO.

1

-

-

-

-

1

4

1

1

-

1

1

1

1

1

2

2

1

1

1

-

-

-

-

-

-

-

1

1

1

-

-

-

-

1

4

1

1

-

1

1

1

1

1

2

2

1

1

1

-

-

-

-

-

-

1

-

1

-

1

-

-

1

1

4

1

1

1

1

1

1

1

1

2

2

1

1

1

-

-

-

-

-

1

-

-

1

-

1

-

-

1

-

4

1

1

1

1

1

1

1

1

2

2

1

1

1

-

-

-

-

1

-

-

-

1

-

1

-

-

1

-

4

1

1

1

1

1

1

1

1

2

2

1

1

1

-

-

-

1

-

-

-

-

1

-

1

-

-

1

-

4

1

1

1

1

1

1

1

1

2

2

1

1

1

-

-

1

-

-

-

-

-

1

-

-

1

1

-

-

4

1

1

1

1

1

1

1

1

2

2

1

1

1

-

1

-

-

-

-

-

-

1

KIT, VSD MOUNTING FLANGE FRAME 8

KIT, VSD MOUNTING FLANGE FRAME 7

KIT, VSD MOUNTING FLANGE FRAME 6

PLATE, FILLER FOR VSD FRAME 9

PLATE, FILLER FOR VSD FRAME 7

SPLY, PWR 575VAC/24VDC CH-IT

SPRC, .25DIA X .41 LONG-ALUM

CAP, S4 PROGRAM PORT NEMA 6P

RCPT, S4 PROGRAM PORT NEMA 6P

BLOCK, POWER DISTR 175A 2/0-#14AWG

NPL, YELLOW RING 45MM E-STOP

BLOCK, CONTACT 1 N.C.

SW, PB OPER RED 40MM PUSH-TWIST

HOLDER, FUSE KTK-R 3 POLE

DECAL, MICROPROCESSOR OVERLAY

WASHER LOCK EXTERNAL TOOTH 5/16”

LUG, GROUND

CTL, DISPLAY WS

BAR, GROUND 9 POST

CTL, I/O MOD WS 24VDC

DRIVE, VFD C-H 757V 100A NEMA 12

DRIVE, VFD C-H 380/460V 61A NEMA12

DRIVE, VFD C-H 380/460V 72A NEMA12

DRIVE, VFD C-H 380/460V 87A NEMA12

DRIVE, VFD C-H 380/460V 105A NEMA12

DRIVE, VFD C-H 575V 52A NEMA12

DRIVE, VFD C-H 575V 62A NEMA12

DRIVE, VFD C-H 575V 80A NEMA12

SPEC, ENCL P8/10 22” X 26” X 10”

DESCRIPTION

1.31 CONTROL STARTER—VSD N12 DESCRIPTION DRIVE, VFD C-H 575V 100A NEMA12 DRIVE, VFD C-H 380-460V 61A NEMA12 DRIVE, VFD C-H 380-460V 72A NEMA12 DRIVE, VFD C-H 380-460V 87A NEMA12 DRIVE, VFD C-H 380-460V 105 NEMA12 DRIVE, VFD C-H 575V 52A NEMA12 DRIVE, VFD C-H 575V 62A NEMA12 DRIVE, VFD C-H 575V 80A NEMA12

02250165-108 02250157-716 02250157-717 02250157-718 02250157-719 02250157-725 02250157-726 02250157-727

TORQUE VALUES (IN/LBS) SULLAIR P/N

65

340-187

340-187

85

85

85

85

35

340-187

LUG

PARTS LIST

02250178-751-R00

1.32 CONTROL STARTER—VSD CE N12

CONTROL STARTER—VSD CE N12

66

02250178-946

02250157-716

02250157-714

02250154-052

02250170-668

02250154-051

02250154-359

02250161-759

—

838405-034

02250145-195

02250085-504

250027-125

02250081-473

02250159-547

02250159-549

02250122-036

02250178-679

02250060-705

02250131-188

02250057-245

1

2

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

BLK, TERM END STOP C383CH

CB, 15A 1P HI INRUSH WMS1D15

R, DIN 35MM (METERS)

COVER, POWER BLOCK

SPLY, PWE 360-480VAC/24VDC CH-IT

CAP, S4 PROGRAM PORT NEMA 6P

RCPT, S4 PROGRAM PORT NEMA 6P

NPL, YELLOW RING 45MM E-STOP

BLOCK, CONTACT 1 N.C.

SW, PB OPER RED40MM PUSH-TWIST

BLOCK, POWER DISTRIBUTION 175 AMP

WASHER, LOCK EXTERNAL TOOTH 5/16"

LUG, GROUND

SPACER, 6.35 DIA X 10.4 LONG ALUM

DECAL, MICROPROCESSOR OVERLAY

CTL, DISPLAY WS

BAR, GROUND 9 POST

CTL, I/O MOD WS 24VDC

DRIVE, VSD CH 380/460V 38A N12

DRIVE, VSD, CH 380 460 61A N12

SPEC, ENCL CE P8/10 19" X 24.5" X 7

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

KEY NO.

1.32 CONTROL STARTER—VSD CE N12 DESCRIPTION CNTOR, 65A 3P 24VAC 1NO XT CNTOR, 32A 24VAC 1NO XT

SULLAIR P/N 02250167-818 02250167-817

TORQUE VALUES (IN/LBS)

26.6

29.2

LUG

10.6

10.6

67

TERMINALS

PARTS LIST

02250178-681-R00

1.33 CONTROL STARTER—YD CE N4

CONTROL STARTER—YD CE N4

68

02250081-473

02250159-547

02250159-549

02250145-195

02250167-843

02250178-679

02250122-036

12

13

14

15

16

17

18

SPLY, PWR 360-48AC/24DC CH-IT

CVR, POWER BLOCK CE

BLK, AUX CONT 1NO 1NC FRONT

BLK, POWER DISTRIBUTION 175A

CAP, S4 PROGRAM PORT NEMA 6P

RCPT, S4 PROGRAM PORT NEMA 6P

NPL, YELLOW RING 45MM E-STOP

BLOCK, CONTACT 1 N.C.

SW, PB OPER RED40MM PUSH-TWIST

WASHER, LOCK EXTERNAL TOOTH 5/16”

LUG, GROUND

SPACER, 6.35DIA X 10.4 LONG ALUM

DECAL, MICROPROCESSOR OVERLAY

CTL, DISPLAY WS

BAR, GROUND 5 POST

CTL, I/O MOD WS 24VDC

CNTOR, 32A 3P 24VDC 1NO XT

SPEC, ENCL CE YD P8/P10 19X24.5X7

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

250027-125

02250161-759

7

11

02250154-359

6

02250085-504

02250154-051

5

10

02250101-721

4

849215-025

02250154-052

3

838405-034

02250167-817

2

8

02250178-949

1

9

PART NO.

KEY NO.

1.33 CONTROL STARTER—YD CE N4

DESCRIPTION CNTOR, 65A 3P 24VAC 1NO XT CNTOR, 32A 24VAC 1NO XT

SULLAIR P/N 02250167-818 02250167-817

TORQUE VALUES (IN/LBS)

26.6

29.2

LUG

10.6

10.6

69

TERMINALS

PARTS LIST

02250155-649 R05

1.34 ENCLOSURE, AIR-COOLED 25/30HP

ENCLOSURE, AIR-COOLED 25/30HP

70

883008-016

20

trim, canopy edge 7.5/10hp

plug, plastic for 3/8" hole

panel, canopy door liftoff p8 p10

panel, louver rear p8 p10

panel, starter end bottom p10

panel, starter end bottom p8

rail, vertical p8 p10

rail, vertical starter side p8 p10

pocket, drawing holder 3700

rail, roof starter end p8 p10

panel, starter end p8 p10

plug, hole 2 1/2" nylon black

panel, roof various

trim, edge clip-on 185-260duq

gusset, corner p8 p10

rail, roof end p8 p10

rail, roof lh and rh

insulation, foam 2" corner piece

cap, molded canopy corner

DESCRIPTION

47 screw, tf-hex m8 x 16 blk zinc

2

2

2

1

1

1

3

1

1

1

1

1

1

7

4

1

2

4

4

Q T Y

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

250019-520

02250160-378

17

250034-157

02250160-377

16

19

02250160-375

18

02250160-374

15

02250155-824

9

14

02250155-284

8

02250160-373

02250154-667

7

13

02250154-659

6

02250160-372

02250152-336

5

12

02250152-335

4

02250155-825

02250152-334

3

02250158-039

02250152-323

2

11

02250150-893

1

10

PART NO.

KEY NO.

1.34 ENCLOSURE, AIR-COOLED 25/30HP N O T E

71

PARTS LIST

02250181-033 R01

1.35 ENCLOSURE, AIR-COOLED 40HP

ENCLOSURE, AIR-COOLED 40HP

72

02250150-893

02250152-323

02250152-334

02250152-335

02250152-336

02250155-284

02250155-824

02250155-825

02250158-039

02250160-372

02250160-373

02250160-375

02250160-377

02250160-378

02250180-756

250034-157

883008-016

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

TRIM,CANOPY EDGE 7.5/10HP

PANEL,ROOF VARIOUS

DOOR,ENCL LIFT OFF P8 P10

PNL,LOUVER REAR P8 P10

PNL,STARTER END BOTTOM P10

RAIL, VERTICAL P8 P10

R,VERTICAL STARTER SIDE P8 P10

PKT,DRAWING HOLDER 3700

R,ROOF STARTER END P8 P10

PNL,STARTER END P8 P10

PLUG, HOLE 2 1/2” NYLON BLACK

GUSSET, CORNER P8 P10

RAIL, ROOF END P8 P10

RAIL, ROOF LH AND RH

INSUL,FOAM 2” CORNER PIECE

CAP,MOLDED CANOPY CORNER

DESCRIPTION

47 SCREW, TF-HEX M8 X 16 BLK ZINC

2

1

2

1

1

3

1

1

1

1

1

4

1

2

4

4

Q T Y

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

KEY NO.

1.35 ENCLOSURE, AIR-COOLED 40HP

73

PARTS LIST

02250168-700-R01

1.36 ENCLOSURE, AIR-COOLED INTEGRAL DRYER 25/30HP

ENCLOSURE, AIR-COOLED INTEGRAL DRYER 25/30HP

74

250019-520

18

WASHER, METRIC-ISO7089- 8

CAPSCR, HEX 8.8 M8 X 25MM

TRIM,CANOPY EDGE 7.5/10HP

PLUG,PLASTIC FOR 3/8” HOLE

PNL,CAN ASSY INTAKE END 2200 W/DRYER

DOOR,ENCL LIFT OFF P8 P10

PNL,STARTER END BOTTOM P10

PNL,STARTER END BOTTOM P8

RAIL, VERTICAL P8 P10

R,VERTICAL STARTER SIDE P8 P10

PKT,DRAWING HOLDER 3700

R,ROOF STARTER END P8 P10

PNL,STARTER END P8 P10

PLUG, HOLE 2 1/2” NYLON BLACK

PANEL, ROOF ENCL ES8

TRIM,CLIP-ON GRIP 185-260DUQ

GUSSET, CORNER P8 P10

RAIL, ROOF END P8 P10

RAIL, ROOF LH AND RH

INSUL,FOAM 2” CORNER PIECE

CAP,MOLDED CANOPY CORNER

DESCRIPTION

47 SCREW, TF-HEX M8 X 16 BLK ZINC

2

2

2

2

1

2

1

1

3

1

1

1

1

1

1

7

4

1

2

4

4

Q T Y

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

883008-016

02250168-656

17

22

02250160-378

16

865408-170

02250160-375

15

21

02250160-374

14

250034-157

02250160-373

13

828008-025

02250160-372

12

20

02250158-039

11

19

02250155-825

10

02250154-659

6

02250155-824

02250152-336

5

9

02250152-335

4

02250154-667

02250152-334

3

02250155-284

02250152-323

2

7

02250150-893

1

8

PART NO.

KEY NO. PART NO.

Q T Y DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

A2 - USED ON 1100E/1500E/1800E

A1 - USED ON 1800/2200

KEY NO.

1.36 ENCLOSURE, AIR-COOLED INTEGRAL DRYER 25/30HP

75

PARTS LIST

02250182-890 R01

1.37 ENCLOSURE, AIR-COOLED INTEGRAL DRYER 40HP

ENCLOSURE, AIR-COOLED INTEGRAL DRYER 40HP

76

02250150-893

02250152-323

02250152-334

02250152-335

02250152-336

02250155-284

02250155-824

02250155-825

02250158-039

02250160-372

02250160-373

02250160-375

02250160-378

02250168-656

02250180-756

250034-157

828008-025

865408-170

883008-016

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

WASHER, METRIC-ISO7089- 8

CAPSCR, HEX 8.8 M8 X 25MM

TRIM,CANOPY EDGE 7.5/10HP

PANEL,ENCLOSURE ROOF - P10-40H

PNL,CAN ASSY INTAKE END 2200 W/DRYER

DOOR,ENCL LIFT OFF P8 P10

PNL,STARTER END BOTTOM P10

RAIL, VERTICAL P8 P10

R,VERTICAL STARTER SIDE P8 P10

PKT,DRAWING HOLDER 3700

R,ROOF STARTER END P8 P10

PNL,STARTER END P8 P10

PLUG, HOLE 2 1/2” NYLON BLACK

GUSSET, CORNER P8 P10

RAIL, ROOF END P8 P10

RAIL, ROOF LH AND RH

INSUL,FOAM 2” CORNER PIECE

CAP,MOLDED CANOPY CORNER

DESCRIPTION

47 SCREW, TF-HEX M8 X 16 BLK ZINC

2

2

2

1

1

2

1

3

1

1

1

1

1

4

1

2

4

4

Q T Y

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

PART NO.

KEY NO.

1.37 ENCLOSURE, AIR-COOLED INTEGRAL DRYER 40HP

77

PARTS LIST

02250157-700 R05

1.38 DECAL LOCATION SECTION, AIR-COOLED

DECAL LOCATION SECTION, AIR-COOLED

78

02250077-472

02250110-891

02250145-206

02250146-385

02250155-495

02250157-702

02250157-703

02250157-732

02250158-358

02250161-967

02250162-215

02250164-823

02250168-920

041065

042218

049685

049850

049852

049855

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

2

1

1

1

1

1

2

1

2

1

1

1

2

1

2

2

1

1

1

1

2

1

Q T Y

sign,warning-sever-fan-indus

decal,warning elect. shock-ground fault

decal,danger electrocution

sign,warning-comp oil fil cap

decal,danger hi voltage

decal,warning auto start

decal,s-energy black

decal, warning n12 elec encl protc

decal,vsd black p8/p10/p12

decal,sump fluid drain p8/p10

decal,remove before start-up

decal, sullair side graphic

decal, sullair side graphics

decal,maint kit eng

decal,black www.sullair.com

decal,parallel wye motor conn.

decal,24kt metalic gold

decal,en-warning mixing fluids

decal,electrocution hazard international/ global

decal,pe designation

decal,protective earth ground

decal,iso 9001 blk 3.44x5.75

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250075-045

02250075-540

2

02250057-624

1

3

PART NO.

KEY NO.

N O T E

1.38 DECAL LOCATION SECTION, AIR-COOLED

VOLTAGE

SERIES

RIVET

NAMEPLATE

FLUID

407408

1

2

4

1

1

1

1

1

1

1

1

2

Q T Y

decal,volts-various

decal,various black w/stripe

rivet,pop-various

nameplate, sullair serial number

decal,fluid-various

sign,warning-hot surfaces

decal,danger inhaling comp air

decal,water drain 3 3/4 x 1”

decal,rotation 3.5” lg

decal,warning-autostart

decal,warn “food grade” lube

decal,fork lifting

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

7-USE ON 24KT MACHINES ONLY

6-NOT USED ON 575V VSD MACHINES

5-ATTACH TO INSIDE OF STARTER BOX ON RIGHT HAND SIDE

4-USED ON VSD MACHINES ONLY

3-ATTACH TO SUB-PANEL INSIDE STARTER BOX

2-ATTACH TO INSIDE OF STARTER DOOR

1-ATTACH TO THE BOTTOM ON INSIDE OF STARTER BOX

34

33

32

31

30

29

250027-935

250022-810

27 28

250021-564

250017-903

250003-144

241814

PART NO.

26

25

24

23

KEY NO.

79

N O T E

PARTS LIST

02250172-255-R02

1.39 DECAL LOCATION SECTION, AIR-COOLED, INTEGRAL DRYER

DECAL LOCATION SECTION, AIR-COOLED, INTEGRAL DRYER

80

02250157-703

24

2

1

2

1

2

1

1

1

1

1

1

1

1

1

1

1

decal, sullair side graphics

decal,maint kit eng

decal,black www.sullair.com

decal,microprocessor overlay

decal,parallel wye motor conn.

decal,24kt metalic gold

decal,en-warning mixing fluids

decal,electrocution hazard international/ global

decal,protective earth ground

decal,iso 9001 blk 3.44x5.75

decal,danger inhaling comp air

decal,water drain 3 3/4 x 1”

decal,rotation 3.5” lg

decal,warning-autostart

decal,warn “food grade” lube

decal,fork lifting

sign,warning-sever-fan-indus

decal,warning elect. shock-ground fault

decal,danger electrocution

sign,warning-comp oil fil cap

decal,danger hi voltage

decal,warning auto start

decal,pe designation

decal,protective earth ground

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250155-495

02250154-359

21

02250157-702

02250146-385

20

22

02250145-206

19

23

02250110-891

18

*250027-935

14

02250077-472

*250022-810

13

17

*250021-564

12

02250057-624

*250017-903

11

02250075-045

*250003-144

15

2

*241814

9

10

16

2

*049852

*049855

7

8

1 1

*049685

1

1

*049850

*042218

4

5

*041065

3

1

1

Q T Y

6

*02250075-045

*02250075-540

1

2

PART NO.

KEY NO.

N O T E

RIVET SERIES VOLTAGE

35 36 37

1

2

4

1

1

1

1

2

1

2

1

1

1

Q T Y decal, sullair side graphic decal,sump fluid drain p8/p10

various

various

various

various

various

sign,warning-hot surfaces

decal,integral dryer

decal,s-energy black

decal, warning n12 elec encl protc

decal,vsd black p8/p10/p12

ATTACH TO INSIDE OF STARTER BOX DOOR

N O T E

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

81

Q1: A “*” PRECEEDING THE PART NUMBER INDICATES DECALS CONTAINED IN KIT 02250069-604

A8:

A7: 24KT MACHINES ONLY

A6: ATTACH TO SUB-PANEL INSIDE OF STARTER BOX

A5: ATTACH TO INSIDE OF STARTER BOX ON BOTTOM PANEL

A4: ATTACH TO INSIDE OF STARTER BOX ON RIGHT-HAND SIDE

A3: NOT USED ON 575V VSD MACHINES

A2: VSD MACHINES ONLY

DESCRIPTION

decal,remove before start-up

A1: BOTH SIDES OF MACHINES

FLUID NAMEPLATE

33

407408

02250170-899

02250168-920

02250164-823

02250162-215

02250161-967

02250158-358

02250157-732

PART NO.

34

32

31

30

29

28

27

26

25

KEY NO.

1.39 DECAL LOCATION SECTION, AIR-COOLED, INTEGRAL DRYER

PARTS LIST

ðîîëðïïðóèçï

ðìçèëð

Ô»¬¸¿´ ­¸±½µ ¸¿¦¿®¼ ·²­·¼»ò Ü·­½±²²»½¬ ¿´´ °±©»® ¿¬ ­±«®½»ô ¾»º±®» ±°»²·²¹ ±® ­»®ª·½·²¹ò

1.40 DECAL GROUP

DECAL GROUP

îëððïçÁðíîÎðï

ðìçèëë

ðìîîïè

îëððîéóçíî

Ü»¿¬¸ ±® ­»®·±«­ ·²¶«®§ ½¿² ±½½«® º®±³ ·²¸¿´·²¹ ½±³°®»­­»¼ ¿·® ©·¬¸±«¬ «­·²¹ °®±°»® ­¿º»¬§ »¯«·°³»²¬ò Í»» ÑÍØß ­¬¿²¼¿®¼­ ±² ­¿º»¬§ »¯«·°³»²¬ò

82

042218

02250110–891

049855

16

5

20

2

1

1

2

1

1

Q T Y

sign, warning–sever–fan–indus

decal, en–warning mixing fluids

decal, danger hi voltage

decal, parallel wye motor conn.

decal, danger electrocution

decal, danger inhaling comp air

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

049850

02250146–385

6

250027–935

26

18

PART NO.

KEY NO.

1.40 DECAL GROUP N O T E

83

PARTS LIST

ðîîëðððíÁïïì

ܱ ²±¬ °»®³·¬ ¿·® º®±³ ¬¸·­ »¯«·°ó ³» ²¬ ¬± ½±²¬¿ ½¬ º±±¼ ­¬«ºº »¨½»°¬ ·² º«´´ ½±³°·ó ¿²½» ©·¬¸ ÚÜß Í¬¿²¼¿ ®¼ îïÝÚÎïéèòíëéðô ¿²¼ ¿´´ ±¬¸»® ¿°°´·½¿¾´» º»¼» ®¿´ô ­¬¿¬» ¿²¼ ´±½¿´ô ½±¼» ­ô ­¬¿²¼¿ ®¼­ ¿²¼ ®»¹«´ ¿¬·±² ­ò

îëððïéóçðí

ɸ»² л®º±®³·²¹ Ó¿·²¬»²¿²½» Ú±´´±© DZ«® ݱ³°¿²§ù­ Ю»­½®·¾»¼ Í¿º»¬§ Ю¿½¬·½»­ º±® Û´»½¬®·½¿´ Û¯«·°³»²¬ò

̸·­ ˲·¬ ·­ Û¯«·°°»¼ É·¬¸ ß² ß«¬± ͬ¿®¬ Í»¯«»²½» ̸¿¬ É·´´ ͬ¿®¬ ̸» ˲·¬ ײ ̸» Ûª»²¬ Ѻ ß Ð±©»® Ú¿·´«®» ß«¬±³¿¬·½¿´´§ ߺ¬»® ̸» Í«³° Ю»­­«®» Ü®±°­ ̱ ïð ÐÍ×Ù ß²¼ ̸» б©»® ×Í Î»­¬±®»¼ò

ìïðêë

1.40 DECAL GROUP (CONTINUED)

DECAL GROUP

ðìçêèë

ܱ ²±¬ ®»³±ª» ½¿°­ô °´«¹­ô ±® ±¬¸»® ½±³°±ó ²»²¬­ ©¸»² ½±³°®»­­±® ·­ ®«²²·²¹ ±® °®»­­«®·¦»¼ò ͬ±° ½±³°®»­­±® ¿²¼ ®»´·»ª» ¿´´ ·²¬»®²¿´ °®»­­«®» ¾»º±®» ¼±·²¹ ­±ò

ðìçèëî

ìðéìðè

84

250017–903

049852

250003–144

407408

041065

23

19

22

27

15

1

1

1

1

1

1

Q T Y

decal, warning auto start

sign, warning–hot surfaces

decal, warning elec shock–ground fault

decal, warning elec shock–ground fault

decal, warning–autostart

sign, warning–comp oil fill cap

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

049685

PART NO.

17

KEY NO.

1.40 DECAL GROUP (CONTINUED) N O T E

85

PARTS LIST

ðîîëððéëóðìë

ðîîëðïëèÁíëèÎðð

ðîîëðïëéÁéðíÎðð

1.40 DECAL GROUP (CONTINUED)

DECAL GROUP

ðîîëðïêîÁîïëÎðï

ðîîëððéëóëìð

ðîîëðïêïóçêéÎðî

ðîîëðïëéÁéíîÎðï

ðîîëðïëëóìçë

86

2

1

2

1

2

2

1

2

Q T Y

decal, vsd black p8/p10/p12

decal, separator/sump tank fluid drain p8/p10

decal, remove before start–up

decal, sullair side graphic

decal, sullair side graphics

decal, black www.sullair.com

decal, pe designation

decal, protective earth ground

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250162–215

02250157–732

10

13

02250157–703

9

02250158–358

02250155–495

7

02250161–967

02250075–540

3

12

02250075–045

2

11

PART NO.

KEY NO.

1.40 DECAL GROUP (CONTINUED) N O T E

87

PARTS LIST

1.40 DECAL GROUP (CONTINUED)

DECAL GROUP

88

1 1

02250069–394

02250069–395

(I)

1

02250069–389 fluids, fluid decal

fluids, fluid decal

fluids, fluid decal

decal, water drain 3 3/4 x 1”

decal, rotation 3.5” lg

decal, fork lifting

decal, warning n12 elec encl protection

decal, maint kit eng

decal, electrocution hazard international/ global

DESCRIPTION

(I)

(I)

(I)

N O T E

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

This decal will vary with individual machine. Consult Sullair Corporation with serial number

1

1

2

28

241814

21

1

250021–564

02250164–823

14

1

250022–810

02250186-230

8

1

25

02250077–472

4

Q T Y

24

PART NO.

KEY NO.

1.40 DECAL GROUP (CONTINUED)

89

PARTS LIST

ðîîëððêçóíçé

ðîîëððêçóíçé

êð ئ Ø

îíðÊ

í

ðîîëððêçóìðí

ðîîëððêçóìðí

ëð ئ

íèðñìïëÊ

í

1.40 DECAL GROUP (CONTINUED)

DECAL GROUP

í

ðîîëðïéðóèçç

ðîîëððêçóíçç

êð ئ

ìêðÊ

ðîîëððëéóêîì

ðîîëððêçóìðð ðîîëððêçóìðê

ðîîëððêçóíçç

í

í

ðîîëððêçóìðê

êð ئ

îððÊ

ðîîëððêçóìðð

êð ئ

ëéëÊ

ðîîëðïëéóéíïÎðð

ðîîëðïëéóéíëÎðð

90

02250157–735

02250157–731

31

(I)

33

32

1 1

02250057–624

1

1 1 1

02250069–400

02250069–403

02250069–406 decal, integral dryer

voltage decal

voltage decal

voltage decal

voltage decal

voltage decal

series decal

series decal

decal, ISO 9001 blk 3.44 x 5.75

DESCRIPTION

(I)

(I)

(I)

(I)

(I)

(I)

(I)

N O T E

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

This decal will vary with individual machine. Consult Sullair Corporation with serial number

1

1

02250069–399

02250170-889

1

02250069–397

1

PART NO.

KEY NO.

Q T Y

1.40 DECAL GROUP (CONTINUED)

91

PARTS LIST

1.40 DECAL GROUP (CONTINUED)

DECAL GROUP

92

02250161-967

250019-107

250019-108

37

38

39

1

1

1

1

1

1

Q T Y

decal, water out

decal, water in

decal, sump fluid drain

decal, parallel wye motor conn.

decal, 24 kt gold metalic

decal, s-energy black

DESCRIPTION

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

02250145-206

02250146-385

36

02250168-920

34

35

PART NO.

KEY NO.

1.40 DECAL GROUP (CONTINUED) N O T E

93

PARTS LIST

NOTES

94

NOTES

WORLDWIDE SALES AND SERVICE SULLAIR ASIA, LTD.

SULLAIR CORPORATION

SULLAIR EUROPE, S.A.

Sullair Road, No. 1 Chiwan, Shekuo Shenzen, Gunagdong PRV. PRC POST CODE 518068 Telephone: 755-6851686 Fax: 755-6853473 www.sullair-asia.com

3700 East Michigan Boulevard Michigan City, Indiana, 46360 U.S.A. www.sullair.com Telephone: 1-800-SULLAIR (U.S.A. only) Fax: 219-874-1273

Zone Des Granges BP 82 42602 Montbrison, France Telephone: 33-477968470 Fax: 33-477968499 www.sullaireurope.com

CUSTOMER CARE for PARTS and Service 1-888-SULLAIR (7855247) 219-874-1835

Champion Compressors, LTD. 324-332 Frankston Dandenong Road Dandenong VIC Australia 3175 Ph: +61397039000 Fx: +61397039053 www.championcompressors.com.au

Printed in the U.S.A. Specifications subject to change without prior notice. E10EP

USER MANUAL WS CONTROLLER USER INTERFACE MANUAL

PART NUMBER:

02250202-046 R01 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 SULLAIR CORPORATION

©

The information in this manual is current as of its publication date, and applies to software part number:

02250201-216 and all subsequent software part 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 [email protected]

- Or Write Sullair Corporation 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

6

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—STARTUP PROCEDURES 11

2.1

INTRODUCTION

11

2.2

WS CONTROLLER PANEL LAYOUT

12

2.3

WS START UP PROCEDURES

13

2.4

SHUTDOWN PROCEDURE

SECTION 3—ADJUSTMENTS 15

3.1

INTRODUCTION

15

3.2

COMPRESSOR ADJUSTMENT PROCEDURES

16

3.3

USER ADJUSTABLE CONTROL PARAMETERS

18

3.4

CALIBRATION OF P2 PRESSURE TRANSDUCERS

18

3.5

REMOTE UNLOAD

SECTION 4—DESCRIPTION 19

4.1

INTRODUCTION

19

4.2

TOUCH PAD BUTTON DESCRIPTION

19

4.3

INDICATOR LED DESCRIPTION

20 21

4.4 4.5

DISPLAY SCREEN OPERATING MODES

TABLE OF CONTENTS 21 22

4.6 4.7

OPERATING STATES NORMAL VIEW SERVICE REMINDERS

23

4.8

WARNING MESSAGES

24

4.9

FAULT MESSAGES

25

4.10

DIAGNOSTIC VIEWS

SECTION 5—TROUBLESHOOTING 27

5.1

TROUBLESHOOTING INTRODUCTION

27

5.2

TROUBLESHOOTING GUIDE

32

5.3

WS CONTROLLER FAULTS AND WARNINGS

32

5.4

MACHINE BEHAVIOR AFTER A POWER INTERRUPTION

32

5.5

INTERNAL BATTERY

SECTION 6—VARIABLE SPEED DRIVE 35

6.1

OVERVIEW

35

6.2

INSTALLATION

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 Corporation and its subsidiaries design and manufacture all of their products so they can be operated safely. However, the responsibility for safe operation rests with those who use and maintain these products. The following safety precautions are offered as a guide which, if conscientiously followed, will minimize the possibility of accidents throughout the useful life of this equipment. The compressor should be operated only by those who have been trained and delegated to do so, and who have read and understood this Operator's Manual. Failure to follow the instructions, procedures and safety precautions in this manual may result in accidents and injuries. NEVER start the compressor unless it is safe to do so. DO NOT attempt to operate the compressor with a known unsafe condition. Tag the compressor and render it inoperative by disconnecting and locking out all power at source or otherwise disabling its prime mover so others who may not know of the unsafe condition cannot attempt to operate it until the condition is corrected. Install, use and operate the compressor only in full compliance with all pertinent OSHA regulations and/ or any applicable Federal, State, and Local codes, standards and regulations. DO NOT modify the compressor and/or controls in any way except with written factory approval. 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 inside diameter to reduce pressure in case of hose failure.

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.

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.

1.5

MOVING PARTS

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.

SECTION 1 C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially when exposed to hot or moving parts.

DANGER

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.

Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA standards and/or any applicable Federal, State, and Local codes, standards and regulations on safety equipment. B. DO NOT use air line anti-icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems into unventilated or other confined areas. 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

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.

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.

1.9

LIFTING

A. If the compressor is provided with a lifting bail, then lift by the bail provided. If no bail is provided, then lift by sling. Compressors to be air-lifted by helicopter must not be supported by the lifting bail but by slings instead. In any event, lift and/or handle only in full compliance with OSHA standards 29 CFR 1910 subpart N and/or any applicable Federal, State, and Local codes, standards and regulations. B. Inspect points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifting. C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has a rated capacity of at least the weight of the compressor. If you are unsure of the weight, then weigh compressor before lifting. D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail or slings. E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground. F.

DO NOT attempt to lift in high winds.

G. Keep all personnel out from under and away from the compressor whenever it is suspended. H. Lift compressor no higher than necessary.

8

SECTION 1 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 DC link/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

WS CONTROLLER USER INTERFACE MANUAL

Section 2

STARTUP PROCEDURES 2.1

INTRODUCTION

• Display Screen for displaying machine status

This compressor is equipped with an WS Controller for controlling the compressor system operation, setting the machine parameters and performing maintenance operations. The WS Controller is designed for the safe operation and protection of the compressor system. When fault conditions occur, the controller automatically shuts down the machine before the conditions can cause damage to the equipment. The WS Controller also contains features that enable sequential interface with other machines.

2.2

WS CONTROLLER PANEL LAYOUT

The WS Controller panel is shown in Figure 2-1. The controller panel consists of :

• START

pad for machine startup

• STOP pad for stopping machine operation and for clearing fault messages while the machine is stopped • UP arrow and DOWN arrow pads for navigation through the various panel displays and for changing parameter values • ENTER

pad for selecting and accessing vari-

ous screen displays and for entering values • • Machine status indicator lights for identifying the current machine operational status. Each of the controller components and functions is described in detail in Section 4.

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Figure 2-1: WS Controller Panel

11

WS CONTROLLER USER INTERFACE MANUAL 2.3

WS START UP PROCEDURES

COMPRESSOR MOTOR ROTATION DIRECTION CHECK (AT INSTALLATION) After the compressor has been installed and the electrical wiring is completed, perform following steps to verify the direction of the compressor motor rotation.

SECTION 2

FAN MOTOR ROTATION CHECK (AT INSTALLATION) The VSD fan direction is affected by installation. Verify the correct fan rotation using the following steps: 1. With the compressor running, visually check that the fan rotation is correct.

1. If the display screen shows AUTOMATIC,

2. If it is incorrect, change the direction of the fan motor by disconnecting power from the compressor.

press the UP arrow pad twice to navigate to the Mode parameter. Press the

3. Disconnect and lockout power according to lockout/tagout procedure.

ENTER

pad. The screen will display

reverse characters indicating change mode is active. Press the DOWN arrow pad to highlight the MANUAL selection (it will appear in reverse text in the display). Press the ENTER pad to accept the change and place the machine in the Manual operating mode. 2. Press the START and STOP pads in succession to “bump start” the compressor. 3. Observe the direction of rotation of the compressor motor shaft. Verify with Operators Manual for correct rotation. 4. Disconnect and lockout power according to lockout/tagout procedure. 5. If the motor shaft is not turning in the proper direction, disconnect the power to the starter and exchange any two of the three power input leads. Refer to the Compressor Operator’s Manual. 6. Perform above steps 1 - 3 again to confirm proper motor/compressor rotation.

NOTE Variable speed drive (VSD) packages do not require a main motor direction check sincethe variable speed motor is set at the time of manufacture.

4. Exchange any two of the three fan motor leads at the fan motor starter. Refer to the compressor Operator’s Manual. 5. Recheck the direction of the fan motor.

INITIAL START-UP AFTER INSTALLATION Perform the following procedure at the initial up of the compressor following installation.

START-

1. Verify that all preparations and checks necessary for proper installation have been made. Refer to the compressor Operator’s Manual. 2. Read the preceding pages of this manual thoroughly. 3. Slowly open the shut-off valve to the service line. 4. Press the START pad to START the compressor. Compressor will begin operating in the default mode (Automatic) set at the factory. 5. Check for possible leaks in piping. 6. Slowly close the service line shut-off valve to verify nameplate pressure unload setting is correct. The compressor should unload when nameplate pressure is achieved. If adjustments are necessary, see Compressor Adjustment Procedures on page 15. 7. Observe the operating temperature. Refer to compressor Operator’s Manual for acceptable operating range. If temperature exceeds this range, check the cooling system and installation environment. 8. Open the shut-off valve to the service line.

12

SECTION 2

WS CONTROLLER USER INTERFACE MANUAL

9. After operating the machine for 24 hours, inspect the compressor for fluid leaks and proper operating temperature.

SUBSEQUENT START-UP PROCEDURE 1. On subsequent start-ups, check the fluid sight glass for proper fluid level. Service if necessary. See compressor Operator’s Manual. 2. Press the START pad on the display screen. The machine will prepare to start up in the last operating mode existing at shutdown. The current Machine mode will appear on the display screen. 3. If a different operating mode is desired, use the arrow pads to navigate to the Mode parameter. Press the ENTER

the mode setting.

2.4

SHUTDOWN PROCEDURE

Shut down the compressor by pressing the STOP

pad on the WS Controller panel.

NOTE The system may require sump blowdown (typically below 10 psi) to be completed prior to restarting.

pad to

ENTER the Change Mode. Navigate to the desired mode (Automatic or Manual). Press the ENTER

4. When the compressor is running, observe the display panel and maintenance indicators to ensure the values displayed are within the proper ranges.

WARNING

pad to accept and save The compressor may restart automatically after a power failure or after the E-Stop button has been reset.

13

NOTES

14

WS CONTROLLER USER INTERFACE MANUAL

Section 3

ADJUSTMENTS 3.1

INTRODUCTION

This section describes steps for using the WS Controller to modify specific parameters that control the machine operation.

NOTE Control parameters described in this manual are those which can be adjusted via the WS controller. Additional parameters that control the operation of the compressor and sequencing of multiple machines can be viewed and edited using the WSPC Software program. See the WSPC User Interface Manual for more details. Typically, the top line of the Controller Display Screen will display the line pressure and compressor temperature; the bottom line will display the current operating mode. As the user presses the down navigation arrow, the screen will display various machine statistics appearing under the heading Compressor Status:. These values are not adjustable at the WS Controller. Navigating past these screens, the first line of the screen will display the words Show Setting -------. This indicates that the controller is in the Adjustment mode. When in Adjustment mode, control parameters will be described in the second line of the display screen. These control parameters can be modified by the user. The bottom line of the display will show the current value or setting of the control parameter.

3.2

COMPRESSOR ADJUSTMENT PROCEDURES

The following steps apply while Show Setting ------is indicated in the display. The control parameter described in the display can be modified by the user. Use these steps to modify a parameter value: 1. Press the UP arrow or DOWN arrow pad on the controller panel to navigate to the parameter to be change. 2. Press the ENTER

pad to select the

parameter and access the CHANGE mode. The change mode is indicated by the text Change Setting ----- appearing in reverse (negative) characters on the top line of the display. The parameter name will appear on the second line and the current parameter value or setting will appear in reverse characters on the bottom line. 3. Use the UP arrow or DOWN arrow pad to change the value or mode of the parameter. 4. When the desired value or mode name appears on the display, Press ENTER to accept and save this new value for the selected parameter. The display will return to the ADJUSTMENT view and the new value or mode will be displayed.

Section 3.2 provides general steps to modifying the compressor control parameters. A description of each user modifiable parameter is provided in Section 3.3.

15

WS CONTROLLER USER INTERFACE MANUAL 5. Press the START or STOP

pad when running

pad when stopped to return

the display to the NORMAL view.

NOTE If during the adjustment process, the START or STOP pad is pressed prior to pressing the ENTER pad, the display will return to the NORMAL view and the parameter value will not be changed.

3.3

USER ADJUSTABLE CONTROL PARAMETERS

Listed below are descriptions of the parameter that can be adjusted at the WS Controller: Unload Pressure - Set point (psi, bar, or kpa) at which the system pressure will begin unloading. For example if this parameter is set to 110 psi (7.6 bar) the machine will unload when the line pressure is above 110 psi (7.6 bar). Load Delta Pressure - The pressure differential (psi, bar, or kpa) below the unload pressure at which the machine will begin loading. For example if the unload pressure is set to 110 psi (7.6 bar) and the load differential is set to 10 psid (0.7 bar), the machine will load when the line pressure goes below 100 psi (6.9 bar). VSD Setpoint Press. - (VSD packages only) The targeted pressure (psi, bar, or kpa) for the variable speed controls. This is normally adjusted near the bottom of the load/unload delta. The speed will be adjusted to maintain this pressure. Unload Minutes - Set time that the machine will run unloaded in Automatic mode before shutting off. If the time is set less than 15 minutes (for example 5), there may be times when the machine will run

16

SECTION 3

unloaded for more than 15 minutes. This is because there is another timer that keeps the machine from being started more than four times an hour. This secondary timer is disabled when a machine is configured for VSD motor control. Drain Interval Mins. - Set interval in minutes between activation of the drain cycle for machines equipped with an electric solenoid drain. This does not apply to the Sullair SCD zero loss drain, which is not controlled or monitored by the WS Controller. Drain Time Seconds - Set time in seconds that the drain remains energized. Wye Delta Seconds - Set time for wye to delta starter transition. Also used to control the closed inlet start valve. Disable by setting to zero (0), standard for full voltage start. Requires approximately 4-6 seconds for wye-delta or solid state starting. Modulate - Manner in which the machine is set to regulate compressor flow. Default state is “YES” for proportional control. Select “NO” for Load/No Load operation. Operating Mode - The mode set for controlling the compressor motor operation (Manual / Automatic). Manual mode runs continuously. Automatic mode refer to “Unload Minutes”. Language - The choice of language for text that will appear on the display screen. The Diagram of Figure 3-1 shows the flow of the screens that appear on the WS Controller display screen for a typical standard compressor package. This diagram illustrates how adjustment parameters are accessed. Ethernet Address - (Models with Ethernet only) This selects the address for the service Ethernet connector of the control box. The default is “LAN” which is used for a local area network. The factory default address is 192.168.1.3, but may be modified as desired. The other selection is “Link Local” which may be used for simple connection to a PC. This puts the controller at address 169.254.250.249, port 502.

SECTION 3

WS CONTROLLER USER INTERFACE MANUAL

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Figure 3-1: Controller Display Flow Diagram

17

WS CONTROLLER USER INTERFACE MANUAL 3.4

CALIBRATION OF P2 PRESSURE TRANSDUCERS

The compressor is equipped with a pressure transducer that measures the output line (P2) pressure. Over time, the pressure transducer may vary slightly producing an inaccurate reading at the controller. Periodically and prior to operating multiple controllers in a sequence, the controller should be recalibrated to reflect the same measurement of P2 pressure through out the system. The re-calibration is best done when the system is at a stable pressure. Calibration of the WS Controller P2 pressure reading is accomplished using the WSPC User Interface Software Program. Refer to the WSPC User Interface Manual for details on calibrating the P2 system pressure measurement.

3.5

REMOTE UNLOAD

As a default configuration, the compressor is provided with one input to allow user-furnished external remote control. This may be wired to a remote switch, timer, or other controls to halt operation of the compressor as desired. To enable remote control of the compressor:

18

SECTION 3

1. Wire the remote contact to junction J4-7 and any vacant J3 terminal. 2. Access the PC User Interface software. At the User Adjustments display screen, select one of the following sequencing modes: Remote, Hours, or Com Number. Remote operation is disabled if the sequencing mode is Disabled or Slave. 3. Once enabled, the controller will respond to the wired input. • If the contact is closed, the compressor unloads and stops delivering air to the system. If the operating mode is AUTOMATIC, the compressor will stop after running unloaded for the period set in the Unload Minutes setting. When operating in a group of sequenced compressors, this removes only this compressor for service. • If the contact is open, the compressor operates normally. The WS Controller is field configurable for other remote functions with additional contacts or fieldbus commands. Refer to the WSPC manual for details.

WS CONTROLLER USER INTERFACE MANUAL

Section 4

DESCRIPTION 4.1

INTRODUCTION

This section describes the components of the WS Controller, the function of each component, and the various types of displays that may appear on the display screen. Descriptive lists of all messages appearing in the display are also provided.

4.2

TOUCH PAD BUTTON DESCRIPTION

The WS Controller Panel has five touch pads that allow the operator control of the compressor and enable adjustment of the machine operating parameters. Each touch pad and its functions are described below:

Start Pad —Large green pad button used to START the compressor operation. The pad is also pressed to reset warnings while the machine is running and to return the display to the Normal View. Stop Pad —Large red key pad used to stop the compressor operation. The STOP pad is also pressed to clear fault messages when the machine is stopped and to return the display to the Normal View.

Up Arrow Pad —Used to navigate “UP” the list of display messages and to increase or change parameter values for adjustments. Down Arrow Pad —Used to navigate “DOWN” the list of display messages and to decrease or change parameter values for adjustments. Enter Pad

4.3

INDICATOR LED DESCRIPTION

Four LED’s on the WS Controller Panel provide indication of the general state of the machine.

Power On Indicator

(GREEN LED)—Lights

whenever power is applied to the controller. This LED will blink very slowly if the compressor is set to automatically restart after power failure.

Automatic or Manual Run Mode Indicator (GREEN LED—Lights when the compressor operation is set to start and run automatically. This LED lights steadily when the motor is running. The LED will blink slowly if the compressor motor is stopped while in Automatic mode as a warning that the machine may restart at any time. The display screen will periodically indicate The compressor is Standing by. The Automatic Mode LED will blink rapidly if machine restart is imminent. The display screen will periodically display a message to indicate the state of the machine prior to restart (e.g., Waiting for Blowdown). Maintenance/Warning Indicator (AMBER LED)—Lights when recommended maintenance or service warning is issued. In most cases the machine will continue to operate normally. The display screen will periodically display the recommended maintenance actions or the cause of the warning. Refer to Section 5: Troubleshooting on page 27 to resolve maintenance conditions.

—Angled arrow key pad used to

select the parameter that is displayed on the screen. After adjusting the desired parameter value using the UP or DOWN arrow pads, the ENTER pad selects the parameter value displayed on the screen and saves it as the new value.

Fault Warning Indicator (RED LED)—Lights when a compressor fault has occurred. The indicator will remain lit and the compressor will remain inoperative until the fault condition is remedied. The controller display screen will indicate FAULTED and periodically a brief description of the cause of the fault. Refer to Section 5: Troubleshooting on page 27 to resolve fault conditions.

19

WS CONTROLLER USER INTERFACE MANUAL 4.4

DISPLAY SCREEN

Information relevant to the compressor operation is presented in three views on the controller display screen: Normal View, Compressor Status: and Compressor Adjustment: or Show Setting ------- .

NORMAL VIEW The Normal View is the default view for the display screen. When in Normal View, information regarding the compressor current operating conditions appears on the display screen. See Figure 4-1. The top line of the display screen in Normal View shows the discharge pressure and the internal temperature of the compressor package. The lower line of the Display Screen displays the current compressor operating mode.

SECTION 4

Listed below are compressor attributes that may be viewed in the Compressor Status View. This list will vary based on specific machine configurations. Temperature 1—Displays the current compressor temperature at temperature probe 1. Temperature 2—Displays the current compressor temperature at temperature probe 2. Temperature 3—Displays the current compressor temperature at temperature probe 3. Dewpoint Temperature—Displays the current dryer temperature at temperature probe 3. Sump Pressure—Displays pressure (P1).

the

current

sump

Line Pressure—Displays the current line output pressure (P2). Pressure 3—Displays the pressure (P3) at the specified transducer location. Separator Pressure ^ —Displays the current separator pressure differential. Run Hours—Displays the total time the compressor has been running loaded or unloaded.

Figure 4-1: Display Screen Normal View Example Under normal operating conditions, the lower line of the Controller Display Screen will alternately display the compressor operating state, warning messages, service reminders, and fault conditions when they occur.

COMPRESSOR STATUS VIEW The Compressor Status: View shows real-time machine measurement information. This information is quickly accessed using the Down navigational arrow. The top line of the display screen will indicate Compressor Status:. See Figure 4-2. The second line will show the name of the measurement (e.g., Line Pressure). The bottom line will display the current value of the measurement being viewed.

Figure 4-2: Display Screen Compressor Status View Example

20

Spiral Valve—Approximate percent of full capacity controlled by the compressor's spiral valve VSD Capacity—This is displayed as an approximate percentage (%) of the maximum capacity for the package. VSD Temperature—High temperatures usually indicate a need for cleaning of the VSD fan or heat sink by a trained service technician.

COMPRESSOR ADJUSTMENT VIEW – CONTROL PARAMETERS The Compressor Adjustment View shows current machine parameters which are conditions and limits that can be modified by the operator. This view is accessed using the navigational arrows and is indicated by the text Show Setting ------- appearing on the first line of the display screen. See Figure 4-3. Pressing ENTER

at the Show Setting screen

accesses the Change Mode. This mode is indicated by the text Change Setting----- appearing as reverse characters on the first line of the display screen and the change parameter appearing on the second line. See Figure 4-4. The value of the parameter is displayed as reverse characters on the bottom line. Refer to Section 3: Adjustments on page 15, for instructions on changing the compressor control parameters and a list of the control parameters that can be modified by the user.

SECTION 4

WS CONTROLLER USER INTERFACE MANUAL

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Figure 4-3: Adjustment View— Show Setting Example

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Figure 4-4: Adjustment View— Change Setting Example

4.5

OPERATING MODES

The Operating Mode is the manner in which the machine operation is being controlled. There are five Operating Modes: AUTOMATIC, MANUAL, OFF, FAULT and UI COMM. The active operating mode of the compressor appears on the lower line of the display screen’s Normal View. See Figure 4-5.

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Off mode—Indicated by the word OFF appearing in the lower line of the display window. This mode indicates that the compressor and motor have been turned off under normal conditions. When in this mode the machine will not operate until the START

ß«¬±³¿¬·½ Ó±¼» øÒ±®³¿´ Ê·»©÷

Figure 4-5: Compressor Operating Mode Display The compressor operating modes are described below: Automatic mode—Indicated by the word AUTOMATIC appearing in the lower line of the display window. This is a user selected mode that sets the compressor motor to automatically start when conditions necessitate and stop when motor operation is not required.

Fault mode—Indicated by the word FAULTED appearing in the lower line of the display window. This mode indicates that a machine problem has occurred causing the controller to shut down the machine until the condition is cleared. After a fault condition has been resolved, the fault indication can be cleared from the controller by pressing the STOP pad. Refer to Section 5: Troubleshooting on page 27, for information on resolving fault conditions. UI Comm mode—Indicated by the word UI COMM appearing in the lower line of the display window. This mode indicates that the User Interface has lost communication and, as a result, the machine operating mode or status is unknown.

4.6

OPERATING STATES

Operating States describe the state of the compressor operation in response to the current mode and current conditions. Essentially, the operating state is what the machine is doing at a particular moment. Most operating states occur automatically as normal functions of the compressor and require no direct action from the operator.

NOTE Machine operating states may vary depending on compressor model. Text descriptions of operating states appear periodically on the lower line of the display screen while in Normal View. See Figure 4-6. The leading line will read The compressor is below which the operating state description will be displayed.

Manual Mode—Indicated by the word MANUAL appearing in the lower line of the display window. This is a user selected mode that allows the operator to manually control the compressor motor operation. When the START pad is pressed while in Manual Mode the compressor motor will run continuously until the STOP pad is pressed. The compressor pump and all other machine parameters function the same in both Manual and Automatic modes.

Figure 4-6: Controller Display Normal View: Operating State The list below provides an explanation of each Operating State message that may appear in the

21

WS CONTROLLER USER INTERFACE MANUAL Normal View display. Some operating states occur instantaneously and may not be seen by the operator. Initializing—Displayed powered up.

as

the

compressor

is

Stopping—May be briefly displayed as the compressor is being stopped via the Controller Panel. Manually Stopped—Displayed compressor operation is stopped.

when

the

Remote Stopping—May be briefly displayed as the compressor is being stopped remotely. Remote Stopped—Displayed when the compressor operation is stopped but is armed to restart. The machine will start when the remote start contact is close. NOTE: The machine may start at any time when conditions are met. Standing by—Displayed when the compressor is stopped and waiting for proper conditions before restarting.

SECTION 4

Running Unloaded—Displayed when the system is running with the compressor unloaded. Remote Unloaded—Displayed when compressor has been unloaded remotely.

the

Restarting—Displayed during the restart waiting period after the starter has dropped out unexpectedly.

4.7

NORMAL VIEW SERVICE REMINDERS

Service reminders may alternately appear in the Normal View display. See Figure 4-7. The Service Reminder screen is indicated by the words Recommended Service: appearing on the second line of the display. The bottom line displays a brief description of the recommended service required. When a service reminder appears, the machine will continue to operate normally, however, the appropriate service should be scheduled and accomplished within a short period of time.

Faulting—Displayed as a fault condition is occurring. Faulted—Displayed after a fault condition has occurred. Waiting for Blowdown—Displayed when compressor is waiting for the sump to reach a minimum pressure prior to starting. After pressure has reduced to the set level, compressor will start automatically.

the set the the

Starting 1—Displayed as compressor initiates stage 1 startup processes. Starting 2—Displayed as compressor initiates stage 2 startup processes. Starting 3—Displayed as compressor initiates stage 3 startup processes. Precooling the Dryer—Displayed while initially cooling an integrated dryer with the compressor unloaded Loading—Displayed as the compressor begins delivering air. Loaded & Modulating—Displayed compressor is delivering air.

when

the

Figure 4-7: Controller Display Normal View: Service Reminder The list below provides an explanation of the Service Reminders that may appear in the Normal View display. Refer to Section 5: Troubleshooting on page 27, for additional instructions on actions to be taken when a service reminder appears. Change Fluid Filter—The compressor fluid filter should be changed within the time frame noted in the machine operation specifications. Change Separator—The compressor fluid separator should be changed within the time frame noted in the machine operation specifications. Change Air Filter—The compressor air filter should be changed within the time frame noted in the machine operation specifications.

Fully Loaded—Displayed when the compressor is delivering air at full rated capacity.

Analyze Fluid—A fluid analysis should be scheduled per machine operation specifications.

Unloading—Displayed as the compressor is being unloaded automatically.

Change Fluid—The compressor fluid should be changed within the time frame noted in the machine operation specifications.

Remote Unloading—Displayed as the compressor is being unloaded remotely.

22

Maintenance A—Periodic maintenance should be scheduled per machine operation specifications.

SECTION 4 4.8

WS CONTROLLER USER INTERFACE MANUAL

WARNING MESSAGES

When a Warning: condition occurs a warning message will alternately appear on the lower line of the Normal View display. See Figure 4-8. Under a Warning condition, the machine will continue to operate normally, however, appropriate maintenance action must be taken to remedy the warning condition. Refer to Section 5: Troubleshooting on page 27, for additional instructions on actions to be taken when warning conditions exists.

Figure 4-8: Controller Display Normal View: Warning Message The list below provides an explanation of the Warning Messages that may appear in the display when an error occurs.

High Dryer Dewpoint—Indicates that the integrated dryer is running with high dewpoint temperature. Consult the dryer manual and/or dryer manufacturer. Dryer High DP Fault—Indicates that the integrated dryer has stopped operation due to high dewpoint temperature. Consult the dryer manual and/or dryer manufacturer.

High Air Filter dP—Indicates the air filter pressure differential is high. The air filter unit needs to be checked or changed. High Oil Filter dP—Indicates the fluid filter pressure differential is high. The fluid filter needs to be checked or changed. High Separator dP—Indicates the fluid separator pressure differential is high. The separator unit needs to be checked or changed. High Temperature 1—Indicates that the compressor Temperature at temp probe location 1 is approaching the set high limit. High Temperature 2—Indicates that the compressor Temperature at temp probe location 2 is approaching the set high limit. High Temperature 3—Indicates that the compressor Temperature at temp probe location 3 is approaching the set high limit. Low Temperature 1—Indicates that the compressor Temperature at temp probe location 1 is approaching the set low limit. Low Temperature 2—Indicates that the compressor Temperature at temp probe location 2 is approaching the set low limit. Low Temperature 3—Indicates that the compressor Temperature at temp probe location 3 is approaching the set low limit.

Low Dryer Dewpoint—Indicates that the integrated dryer is running with low dewpoint temperature. Consult the dryer manual and/or dryer manufacturer.

Not Commissioned—A controller was replaced but has not been commissioned for a specific compressor model.

Dryer Low DP Fault—Indicates that the integrated dryer has stopped operation due to low dewpoint temperature. Consult the dryer manual and/or dryer manufacturer.

Power Interruption—Indicates interruption has occurred.

Dryer Overload Fault—Indicates that the integrated dryer has stopped operation due to a compressor motor overload. Consult the dryer manual and/or dryer manufacturer. Dryer Relay Fault—Indicates that the integrated dryer has stopped operation due to internal problems. Consult the dryer manual and/or dryer manufacturer. Dryer Service—Indicates a dryer is running while a malfunction is occurring. Consult the dryer manual and/or dryer manufacturer.

that

a

power

Replace Battery—Indicates the I/O backup battery is low. Sequence Comm Error—Indicates a communication problem exists between the compressor controllers set up for sequential operation. Starter—The main motor starter failed to operate, and was restarted. User Option Warning—Indicates a user furnished switch has been activated. VFD Overtemp—Operating approaching the VSD limits.

temperatures

are

Ethernet disabled—Ethernet was turned off due to excessive network traffic.

23

WS CONTROLLER USER INTERFACE MANUAL

SECTION 4

and the controller module has resulted in an open circuit.

WARNING The compressor may restart automatically after power has been restored following a power failure.

4.9

FAULT MESSAGES

When a Fault condition occurs, the machine will shut down and the display will indicate FAULTED on the lower line of the display window. A Fault Message will alternately appear in the lower line of the Normal View display briefly describing the nature of the fault. See Figure 4-9.

High Dryer Dewpoint—Indicates that the integrated dryer has stopped all package operation due to high dewpoint temperature. Consult the dryer manual and/or dryer manufacturer. High Interstage Pres—Interstage pressure is above the unit limits. High Package Press—Package Discharge pressure has exceeded the set high limit. High Plant Pressure—Plant line pressure has exceeded the set high limit. High Pressure A…B—Pressure at specified transducer (A or B) has exceeded the set high limit. High Separator dP—Separator pressure differential has exceeded the set high limit. High Spiral Valve Pr—Excessive pressure was applied to the spiral valve actuator.

̸» º¿«´¬ ½¿«­» ·­æ Ûóͬ±° Ы­¸ Þ«¬¬±²

High Sump Pressure—Compressor sump pressure has risen above the set limits.

Figure 4-9: Controller Display Normal View: Fault Message

High Temperature 1…3—The temperature at specified temp probe (1 through 3) has risen above the set high limit.

The list below provides an explanation of the Fault Messages that may appear when problems occur. Refer to Section 5: Troubleshooting on page 27, for instructions on actions to be taken when a FAULT condition occurs. Aux Motor Overload—The auxiliary motor overload relay has been tripped due to a power overload in the auxiliary motor.

CE Voltage too high / Low—The internal 24 volt supply is out of range. Controller Watchdog—Controller watchdog timer error. Dryer Fault—Indicates a dryer malfunction has occurred. Consult the dryer manual and/or dryer manufacturer. Dryer Overload—Indicates a dryer overload has occurred. Consult the dryer manual and/or dryer manufacturer. E-Stop Push Button—Emergency Stop button has been pressed. HIGH AN0 SENSOR (AN0-AN9)—Device assigned to sensor input AN0 through AN9 (temp probe, transducer unit, etc.) or wiring between the device

24

High Voltage Failed—No voltage is available at the high voltage motor starter. HIGH VOLT SENSOR—Indicates the system high voltage sensor has failed. Illegal State—Controller operating error. Internal Com Error—An error in communication between the controller and the compressor has occurred. LOW AN0 SENSOR (AN0 - AN9)—Device assigned to sensor input AN0 through AN9 (temp probe, transducer unit, etc.) or wiring between the device and the controller module has resulted in a short circuit. Low Dryer Dewpoint—Indicates that the integrated dryer has stopped all package operation due to low dewpoint temperature. Consult the dryer manual and/or dryer manufacturer. Low Line Pressure—The line pressure has fallen below the Low Fluid Pressure set low limit. Low Fluid Pressure—Compressor fluid pressure has fallen below the set low limit. Low Sump Pressure—Compressor sump pressure has fallen below the set limits.

SECTION 4

WS CONTROLLER USER INTERFACE MANUAL

Low Temperature 1 ... 3—Temperature at the specified temp probe (1 through 3) has fallen below the set low limit. LOW VOLT SENSOR—Indicates the system low voltage sensor has failed.

4.10 DIAGNOSTIC VIEWS While in the Normal View use the ENTER

Low Water Pressure—The water pressure switch has been tripped due to low water pressure.

Use the UP or DOWN the next Diagnostic view.

Main Motor Overload—The main motor overload relay has been tripped due to a power overload in the main motor.

Use the ENTER

Memory Error—The controller I/O board has failed. OPTION INPUT—User option error.

Ethernet Comm failed to a keypad.

arrow pads to access

Pad to return to the Normal

View. Figure 4-13 Illustrates how to navigate between the Normal View and the Diagnostic Views.

DIAGNOSTIC: ANALOG INPUT VIEW

OPTION INPUT RUN—User option error. Phase Protection.—Indicates protection relay has tripped.

Pad

to access the Diagnostic View.

external

phase

Error—Communications

have

The analog inputs are displayed in their order on the analog input terminal block in a left to right, top to bottom order. Inputs not used by the machine are not shown.

Power Interruption—A power interruption has occurred at the controller. Pump Motor Overload—The overload relay has tripped.

pump

motor's

Pump Starter Contact—The pump starter did not operate as expected. Starter—Starter auxiliary contact failed to connect power to the starter.

Figure 4-10: Typical Analog Input Status The analog values are typically displayed in the selected units of measure.

UI Voltage too high—The voltage to the User Interface has risen above the set limit.

The input labels typically refer to the pressure and temperature sensor references in the Piping and Instrumentation drawing.

UI Voltage too low—The voltage to the User Interface has fallen below the set limit.

DIAGNOSTIC: DIGITAL I/O VIEW

High Plant Pressure—The inlet valve failed to close as expected VSD1 Response—The A1000 responding to run commands

drive

is

The status of the digital inputs and relay outputs are shown from left to right in the order in which they are found on the terminal blocks.

not

VSD1 Comm Fault—An error in communication between the controller and the specified VSD compressor has occurred. VSD1 parameter error—An error has occurred during setup of the VSD adjustments.

Figure 4-11: Typical Digital I/O Status The values of one and zero refer to active or inactive states respectively. The labels refer to the controller input and output naming on the wiring diagram.

25

WS CONTROLLER USER INTERFACE MANUAL

SECTION 4

DIAGNOSTIC: ALARM VIEWS Any current fault, alarm or service reminder message will be available to view here. Multiple messages may be scrolled through using the UP and arrow pads. DOWN

λ½±³³»²¼»¼ Í»®ª·½»æ ݸ¿²¹» ß·® Ú·´¬»® Figure 4-12: Typical Alarm View

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òòò

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Figure 4-13: Navigation between the Normal and Diagnostic view

26

WS CONTROLLER USER INTERFACE MANUAL

Section 5

TROUBLESHOOTING 5.1

TROUBLESHOOTING INTRODUCTION

This Troubleshooting section is provided as a guide to aid in diagnosing and resolving compressor problems when they occur. The information contained in Table 5-1, Troubleshooting Guide, has been compiled from factory experience and contains symptoms and usual causes for the described problems. Each Service Reminder, Warning, or Fault Message is listed with conditions of when the problem may occur, a probable cause, and a suggested solution to the problem. DO NOT assume that these are the only problems that may occur. This document cannot address every possible adverse condition that may occur nor does it provide every solution for the potential troubles listed. All available data concerning the trouble should be systematically analyzed before undertaking any repairs or component replacement procedures. Always perform a detailed visual inspection when a machine problem occurs prior to attempting any repairs. Doing so may avoid unnecessary repair and/or additional damage to the compressor. Always remember to: a. Check for loose wiring. b. Check for damaged piping.

c. 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 Distributor or the Sullair Corporation factory Service Department.

NOTE Section 5.2 and Section 5.4 portray common systematic problems that can occur during controller operation. For a more thoroughly in-depth coverage of machine operation troubles, consult the Troubleshooting Section in the machine’s operator’s manual.

5.2

TROUBLESHOOTING GUIDE

Table 5-1 contains symptoms and usual causes for the problems that may occur throughout the compressor system. Each warning or fault message that may appear is listed along with conditions for the problem, a probable cause, and a suggested solution to the problem. DO NOT assume that these are the only troubles that may occur.

Table 5-1: WS Controller Troubleshooting Guide MESSAGE

PROBABLE CAUSE

REMEDY

Analyze Fluid

Service interval has expired. Maintenance due.

Select Maintenance from menu to see service due and part numbers.

Aux Motor Overload

Auxiliary Motor Tripped on Cooling Reset auxiliary overload after element cools. Verify correct motor amps. Fan, Fluid Pump or Other Motor. Check for loose connections. Check motor starter contact for proper operation. Check line voltage, if low consult power company.

27

WS CONTROLLER USER INTERFACE MANUAL

SECTION 5

Table 5-1: WS Controller Troubleshooting Guide MESSAGE

PROBABLE CAUSE

REMEDY

CE Voltage too high

Excessive voltage form power supply or transformer.

Check connections and adjustments.

CE Voltage too low

Inadequate voltage form power supply or transformer.

Check connections and adjustments.

Excessive load or short in 24v control devices.

Check wiring, coils, and solenoid valves.

Change Air Filter

Service interval has expired.

Change Fluid

Maintenance due.

Perform recommended maintenance and reset the reminder using WSPC.

Controller Watchdog

Controller fault.

Contact Sullair Factory Service.

Dryer Fault

Indicates a general dryer malfunction has occurred.

Consult the dryer manual and/or Sullair Factory Service.

High Dryer Dewpoint

The dryer is unable to cool below the high dewpoint temperature setting.

Consult the dryer manual and/or Sullair Factory Service.

Dryer Low DP Fault

The dryer is cooling below the low dewpoint temperature setting.

Consult the dryer manual and/or Sullair Factory Service.

Dryer Overload Dryer Overload Fault

Indicates a dryer overload has occurred.

Consult the dryer manual and/or Sullair Factory Service.

Dryer Relay Fault

Indicates a general dryer malfunction has occurred

Consult the dryer manual and/or Sullair Factory Service.

Dryer Service

Dryer malfunction is imminent.

Consult the dryer manual and/or Sullair Factory Service.

E-Stop Push Button

E-Stop Button Active.

Release button.

Faulty E-Stop Button.

Check wiring.

Ethernet disabled

Excessive Ethernet traffic

Install a router to reduce the traffic on the compressor's LAN.

High Air Filter dP

Differential Pressure Across Inlet Filter High.

Replace filter.

Sensor (Pressure Transducer, Temp Probe, etc.) or Wiring Failure.

Check sensor wiring.

High Dryer Dewpoint

The dryer is unable to cool below the high dewpoint temperature setting.

Consult the dryer manual and/or Sullair Factory Service.

High Oil Filter dP

Pressure across fluid filter above 20 psi (1.4 bar) while running.

Replace fluid filter.

Fluid filter clogged. Low ambient temperature.

Sump heater may be required in ambients below 40°F (4°C).

Sensor failure.

Check sensor, wiring and tubing.

Compressor Interstage Blockage or second stage failure

Inspect for: interstage flow restriction, or damaged air end and repair

Change Fluid Filter Change Separator

Dryer High DP Fault Low Dryer Dewpoint

HIGH AN0 SENSOR

High Interstage Pres

28

Check inlet filter pressure switch. Check sensor.

SECTION 5

WS CONTROLLER USER INTERFACE MANUAL

Table 5-1: WS Controller Troubleshooting Guide MESSAGE

PROBABLE CAUSE

REMEDY

High Package Press

High pressure.

Check operation of valves and controls.

High Pressure A

Faulty pressure sensor.

Check and replace pressure sensor if defective.

High Separator dP

High Separator pressure drop

Inspect separator and replace

High Spiral Valve Pr

Misadjustment

Check setting of the pressure regulator for the spiral valve actuator.

High Sump Pressure

Sump Pressure High (Poppet, Sullicon, Spiral, Blowdown or Pneumatic Valve Failed).

Check valves. Check Sullicon adjustment (see Control Adjustment section in the compressor operator’s manual).

Faulty solenoid valves.

Check solenoid valve operation and wiring.

Faulty pressure regulator.

Check pressure regulator adjustment and operation.

High Pressure B

Check minimum pressure check valve (not applicable to Fluid Free compressors). High Temp Fault.

Ambient above 105°F (41°C), improve local ventilation.

Fluid level low.

Replenish fluid to proper level.

Thermal valve fault.

Check thermal valve operation.

Cooler fins dirty.

Clean Cooler fins and fan blades.

Low water flow.

Check for valve closed, pump off or broken pipe.

High water temperature.

Increase water flow or lower water temperature.

Cooler plugged.

Clean cooler tubes and shell. If plugging persists, use cleaner water.

Temp probe or sensor failure.

Check sensor and wiring.

High Voltage Failed

No power to the high voltage starter

Close the disconnect switch Check main motor fuses or circuit breaker

Illegal State

Controller fault.

Contact Sullair Factory Service.

Ethernet Comm Error

Check wiring. Module Network Error; Communication has failed between the Display Module, I/O Module and other modules.

LOW AN0 SENSOR

Sensor (Pressure Transducer, Temp Probe, etc.) or Wiring Failure.

Check sensor wiring.

Low Dryer Dewpoint

The dryer is cooling below the low dewpoint temperature setting.

Consult the dryer manual and/or Sullair Factory Service.

Low Line Pressure

Demand exceeds capacity.

Reduce demands.

Leaks in supply lines.

Increase capacity.

High Temperature 1 High Temperature 2 High Temperature 3

Check sensor.

Check for leaks or open lines in air supply. Repair as necessary.

29

WS CONTROLLER USER INTERFACE MANUAL

SECTION 5

Table 5-1: WS Controller Troubleshooting Guide MESSAGE

PROBABLE CAUSE

REMEDY

Low Fluid Pressure

Fluid filter clogged.

Replace fluid filter.

Sump fluid level low.

Replenish fluid to proper level.

Low ambient temperature.

Sump heater may be required in ambients below 40°F (4°C). Fluid pump may be required for remote coolers.

Fluid pump failure.

Consult Sullair Factory Service.

Low Sump Pressure

Bad sensor or connections. Machine may have failed to start.

Check pressure sensor, wiring and tubing. Check machine operation.

Low Temperature 1

Low ambient air temperature

Sump heater may be required in ambients below 40°F (4°C).

Low Water Pressure

Cooling Water Pressure below 10 psi (0.7 bar).

Check for closed valves or broken pipes.

Low Water Pressure

Switch is shorted or open.

Replace switch. Check wiring for shorts, arcing or loose connections.

Main Motor Overload

Main Motor Overload Relay Tripped.

Reset overload after heater element cools down.

Low Temperature 2 Low Temperature 3

Check that compressor is properly configured. Ensure load pressure is set below limit of compressor. Check line voltage, if low consult power company. Maintenance A

Service interval has expired. Maintenance due.

Perform recommended maintenance and reset the reminder using WSPC.

Memory Error

The controller I/O board has failed. Board replacement required. Contact Sullair Factory Service.

Not Commissioned

Controller replacement

Follow commissioning procedures to set up for the specific compressor package.

Option Input Option Input Run

User furnished switch has operated.

Check operation of optional device.

User Option Warning

User furnished external phase relay protection relay has tripped.

Check operation of optional device. Refer to user supplied phase relay documentation and troubleshooting steps.

PortC Comm Error (C or E)

Wiring fault between the controller and keypad

Check the cable and connections

Power Interruption

Intermittent Control Power.

Check line voltage and connections.

Pump Motor Overload

Auxiliary Motor Tripped on Fluid Pump Motor

Reset auxiliary overload after element cools. Verify correct motor amps. Check for loose connections. Check motor starter contact for proper operation. Check line voltage, if low consult power company.

30

SECTION 5

WS CONTROLLER USER INTERFACE MANUAL

Table 5-1: WS Controller Troubleshooting Guide MESSAGE

PROBABLE CAUSE

REMEDY

Pump Starter Contact

Pump starter failed to operate. Faulty auxiliary contact.

Check starter and control wiring. Check contact and contact wiring.

Replace Battery

Controller I/O backup battery is low.

Replace battery.

Pressure Differential Across Separator High.

Replace separator.

Plugged separator elements.

Check sensor wiring.

High Separator dP

Pressure sensor failure. Cable or connection fault between compressors.

Check wiring.

Improper sequence adjustments.

Check sequence settings of all compressors in the sequence.

Starter

Main starter failed to operate. Faulty auxiliary contact. Momentary Line Power loss or brownout

Check starter and control wiring. Check contact and contact wiring. Check Line Power quality

UI Voltage too high

Controller fault.

Contact Sullair Factory Service.

UI Voltage too low

Controller fault.

Contact Sullair Factory Service.

High Plant Pressure

Compressor failed to unload

Check operation of the inlet valve and controls

User Option Warning

User furnished switch has operated.

Check function of optional device.

HIGH VOLT SENSOR

Controller fault.

Contact Sullair Factory Service.

LOW VOLT SENSOR

Controller fault.

Contact Sullair Factory Service.

VSD1 Comm Fault

Communications lost with the VSD Check connections to the VSD.

Sequence Comm Error

Check VSD control power and check for board faults. VFD Overtemp

Warns that the variable frequency drive is too hot

Ensure adequate ventilation Schedule cleaning before a High Temp fault occurs

VSD1 parameter error

Controller commissioned incorrectly.

Commission the controller per the machine nameplate

Incorrect VSD

Replace with proper drive rating

The A1000 drive is not responding to WS control.

Remove power for 1 minute Restore power for 1 minute Restart the machine

VSD1 Response

31

WS CONTROLLER USER INTERFACE MANUAL 5.3

SECTION 5

WS CONTROLLER FAULTS AND WARNINGS Parameter

High Limit

Low Limit

Comment

Type

Sensor

Separator Pressure ^

Warning

P2-P1+offset

10 psid

Sump Pressure

Fault

P1

135 psig

5 psig

100 psig machine

150 psig

5 psig

125 psig machine

175 psig

5 psig

150 psig machine

200 psig

5 psig

175 psig machine

165 psig

5 psig

100-140 psig VSD machine

200 psig

5 psig

150-175 psig VSD machine

125 psig

10 psig

100 psig machine

150 psig

10 psig

125 psig machine

175 psig

10 psig

150 psig machine

200 psig

10 psig

175 psig machine

155 psig

10 psig

100-140 psig VSD machine

200 psig

10 psig

150-175 psig VSD machine

Line Pressure

Air End Discharge Temperature

5.4

Fault

P2

Warning

T1

225 F

0F

Fault

T1

235/255F

0F

MACHINE BEHAVIOR AFTER A POWER INTERRUPTION

If the compressor was faulted prior to the power interruption, the controller will resume the FAULTED condition and display the reason for the fault. Repair the cause of the fault and press the STOP pad to reset the controller. If the compressor was manually stopped prior to the power interruption, the controller will return to the manually stopped mode. Press the START button to manually restart operation. If the restart timer is greater than zero AND the controller was in Automatic or Manual mode prior to the interruption, the controller will resume that mode after the restart timer expires. No key press is necessary to restart the compressor.

5.5

INTERNAL BATTERY

The WS Controller employs an internal battery that maintains the real-time clock and maintains the

32

offset for aftercooler or dryer

Time delayed/immediate

integrity of the controller memory records when power is disconnected from the controller. For best performance, ensure that the battery is functioning. If the controller is operated with a drained or dead battery, the time-of-day records will not work properly and loss of recent records could occur. If recent records are lost due to an inoperative battery (or other reason), the controller will revert to the last saved versions of settings and records. The internal battery is located inside the controller I/ O module and will operate for several years without requiring maintenance. When the battery voltage gets low, the controller will issue a “Replace Battery” warning. Perform the following steps to replace the battery. 1. Press the STOP pressor.

pad to stop the com-

2. Disconnect and lockout power according to lockout/tagout procedure. 3. Open the controller enclosure and locate the I/O Control Module.

SECTION 5

WS CONTROLLER USER INTERFACE MANUAL

4. Remove six screws from I/O Control Module cover and remove cover. 5. Locate the internal battery. The battery is located near one end of the I/O circuit board (usually oriented towards the top). 6. Remove the battery and replace with a battery type BR2330. 7. Replace the cover, close the enclosure, follow normal startup procedures.

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Large I/O Control Module Circuit Board

33

NOTES

34

WS CONTROLLER USER INTERFACE MANUAL

Section 6

VARIABLE SPEED DRIVE 6.1

OVERVIEW

The Sullair VSD drive application is custom designed for operation of air compressors. All necessary control functions are performed through the WS Controller keypad and WSPC software. The drive functions as a module on the WS Controller communications bus. WSPC provides detailed information about relevant drive status data and compressor performance. Drive controls are coordinated with internal compressor controls, and with other Supervisor or WS controlled compressors in sequenced systems. The WS Controller monitors drive performance to provide motor thermal and other protections in an easy-to-use, robust design.

6.2

INSTALLATION

Refer to the VSD Installation and Service manual that came with the compressor for installation information.

35

NOTES

36

NOTES

37

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WWW.SULLAIR.COM

SULLAIR CORPORATION 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