Industrial Air Compressor Sullair

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 Sullairs 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 1SAFETY
3
1.1
GENERAL
1.2
PERSONAL PROTECTIVE EQUIPMENT
1.3
PRESSURE RELEASE
1.4
FIRE AND EXPLOSION
1.5
MOVING PARTS
1.6
HOT SURFACES, SHARP EDGES AND SHARP CORNERS
1.7
TOXIC AND IRRITATING SUBSTANCES
1.8
ELECTRICAL SHOCK
1.9
LIFTING
1.10
ENTRAPMENT
SECTION 2DESCRIPTION
9
2.1
INTRODUCTION
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 3SPECIFICATIONS
21
3.1
TABLE OF SPECIFICATIONS
23
3.2
LUBRICATION GUIDE
24
3.3
APPLICATION GUIDE
24
3.4
LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCEFLUID 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 DIAGRAMMFV, AIR-COOLED
40
3.12
WIRING DIAGRAMMFV, AIR-COOLED INTEGRAL DRYER
42
3.13
WIRING DIAGRAMVSD, PARALLEL WYE
44
3.14
WIRING DIAGRAMYD CE
SECTION 4INSTALLATION
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 5WS CONTROLLER

53
54
5.1
5.2
CONTROLLER KEYPAD
LCD DISPLAY
55
5.3
LED LIGHTS
SECTION 6MAINTENANCE
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)
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
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
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.
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.
NOTES
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.
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
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 185F
(85C) [200F (93C) 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 185F
(85C), 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
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.

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 235F (113C).
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
SECTION 2
Figure 2-3: Discharge System
14
SECTION 2
2.6
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
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
AIR INLET SYSTEM,

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 machines 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 drives heat sink
extends through the back of the enclosure, and is
cooled by air flowing through the compressor
enclosure.
17
SECTION 2
2.10 VSD CONTROL SYSTEM

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 compressors 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
compressors rated capacity. In this condition, the
VSD slows the motors rpm which reduces the output
to match the demand. The drive continuously adjusts
the motors 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

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
SECTION 2
Figure 2-5: Air Inlet System

1. Air FIlter
2. Inlet Valve
3. Compressor Unit
20
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

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
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(40C)
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(40C)
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
Speed25, 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
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
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
locations, e.g. in exposed plant piping." (I)
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
Figure 3-1: Fluid Fill Location
23

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

MAINTENANCEFLUID 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
02250159-354-R03
3.5

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
2.50[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
NOTES:
3.5
SECTION 3
27
28
02250181-032 R00
3.6

SECTION 3
1613 LBS/732 KG
2900 CFM
2900 CFM

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.
2.50[63.5]
A6: EXHAUST AIR OUT
A5: AIR INLET
A4: E-STOP
A3: CONTROLLER
TEFC
40
1556 LBS/706 KG
CFM Cooling Air

ODP
40
Weight
Motor Type
Main Motor HP
NOTES:
3.6
SECTION 3
29
30
02250168-699-R02
3.7

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.
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
2000 CFM
2000 CFM
2000 CFM
2000 CFM
CFM Cooling Air
SECTION 3
31
32
02250180-784 R00
3.8

SECTION 3
1814 LBS/823 KG
2900 CFM
2900 CFM

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.
2.72[69.0]
A6: EXHAUST AIR OUT
A5: AIR INLET
A4: E-STOP
A3: CONTROLLER
TEFC
40
1757 LBS/797 KG
CFM Cooling Air

ODP
40
Weight
Motor Type
Main Motor HP
NOTES:
3.8
SECTION 3
33
34
02250156-114-R10
3.9

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
10
11
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Q
T
Y
FILTER,ASSY GENESIS
GLASS,SIGHT SIGHT/ORIFICE BLK SAE
PLUG,SIGHT GLASS 1 5/16 SAE
FLTR,PNEUMATIC 1/8NPT 5MICRON
VLV,CHK 1/4-NPT
INDICATOR, RESTRICTION 20H20
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 6L
VALVE, RELIEF 1/2 200#
XDCR,PRESS 0-250PSI 1-5VDC N4
VLV,THERMAL 210 DEG
VLV,THERMAL 195 DEG
FLTR,CORELESS M27 6L 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
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 1/2NPT
VLV,BALL/STNR COMBO-1/2NPT
VLV,BALL/STNR COMB 1/2M X 1/2M
SW,DIFF PRESS 20 PSID
SW,VAC 22WC 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

02250078-249
02250050-154
02250118-586
27
28
02250125-774
26
29
PART NO.
KEY
NO.
KEY
NO.
3.9
SECTION 3
35
36
02250172-798-R02
3.10 PIPING AND INSTRUMENTATION, 1800-2200 W/INTEGRAL DRYER

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 6L 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 6L
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 20H20
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,DIFF PRESS 20 PSID
DESCRIPTION

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
DRYER DEWPOINT TEMPERATURE PROBE
P2
DPSW1
PSW1
SOL1
SOL4
SOL5
T1
T3
DESCRIPTION
P1
COMPONENT

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
12L
35 02250173-972
1 FLTR,PNEUMATIC 1/8NPT 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
37
38
02250171-211-R04
3.11 WIRING DIAGRAMMFV, AIR-COOLED

SECTION 3
UNIT DISCHAGE TEMPERATURE PROBE
T1
THERMOSTAT FOR HEAT TRACE OPTION
JZL TRANSFORMER PRIMARY FUSES
(OPTL) CONTROL PANEL HEATER 50WATTS
HTR4
TH
(OPTL) TRAP HEATER 70WATTS
HTR3
1FU
(OPTL) HEAT TRACE
OPTL POWER MONITOR RELAY
PMR
(OPTL) SUMP HEATER 800W
INTERNAL COMMON FAULT RELAY
K7
HTR2
INTERNAL ELECTRIC DRAIN RELAY
K6
HTR1
INTERNAL SEQUENCE RELAY
K5
POWER FACTOR CORRECTION CAPACITOR (OPTL)
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
(OPTL)OIL FILTER DIFF PRESS SWITCH 20PSID
DPSW1
INPUT 7
(OPTL)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 DIAGRAMMFV, 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

CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.
NOTES
FAN MOTOR BRANCH FUSES
3FU
DESCRIPTION
JZL TRANSFORMER SECONDARY FUSE
2FU
COMP
SECTION 3
39
40
02250174-982-R03
3.12 WIRING DIAGRAMMFV, AIR-COOLED INTEGRAL DRYER

SECTION 3
TH
HTR4
PMR
K7
HTR3
K6
(OPTL) HEAT TRACE
K5
HTR2
K4
K3
K2
HTR1
PF CAP
24VDC POWER SUPPLY
SOL5
K1
SOL4
PS
INPUT 8
SOL1
REMOTE RUN/UNLOAD
INPUT 7
INPUT 9
DRYER DEWPOINT TEMPERATURE PROBE
T3
DPSW1
UNIT DISCHARGE TEMPERATURE PROBE
T1
PSW1
P2
FAN MOTOR OVERLOAD
2MOL
P1
COMPRESSOR STARTER
1M
DESCRIPTION
COMPRESSOR OVERLOAD
1MOL
COMP
DRYER START RELAY
DR

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

CUSTOMER TO FURNISH FUSED OR CIRCUIT

BREAKER DISCONNECT PER LOCAL CODES.
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 DIAGRAMMFV, AIR-COOLED INTEGRAL DRYER
SECTION 3
41
42
02250156-119 R09
3.13 WIRING DIAGRAMVSD, PARALLEL WYE

SECTION 3
(OPTL) HEAT TRACE
HTR3
K7
HTR2
K6
K5
HTR1
K4
INTERNAL WYE-DELTA RUN RELAY COMPRESSOR

ENABLED
PMR
INTERNAL Y-DELTA START RELAY COMPRESSOR RUNNING
K3
SOL5
K2
SOL4
INTERNAL FAN RELAY CONTACT TEMP (T1) CONTROLLED
SOL1
K1
INPUT 9
24VDC POWER SUPPLY
PS
REMOTE RUN/UNLOAD
T1
INPUT 8
P2
INPUT 7
P1
SCD TRANSFORMER SCONDARY FUSE
3FU
DPSW1
SCD TRANSFORMER PRIMARY FUSES
2FU
FAN MOTOR BRANCH CIRCUIT FUSES
1FU
PSW1
FAN MOTOR OVERLOAD
2MOL
COOLER FAN MOTOR STARTER
2M
DESCRIPTION
COMPRESSOR MOTOR
1M
COMP
3.13 WIRING DIAGRAMVSD, PARALLEL WYE

DESCRIPTION

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

CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.
(OPTL) SCD DRAIN
CONTROL TRANSFORMER FOR SCD DRAIN
NOTES
SCD
XFMR1
TH
HTR4
COMP
SECTION 3
43
44
02250178-718-R00
3.14 WIRING DIAGRAMYD CE

SECTION 3
COMPRESSOR STARTER
WYE-DELTA RUN CONTRACTOR
WYE-DELTA START CONTRACTOR
1M
2M
P2
T1
INPUT 8
INPUT 9
SOL1
SOL4
SOL5
HTR3
HTR4
K7
(OPTL) HEAT TRACE
K6
K5
HTR2
K4
HTR1
K3
K2
PF CAP
K1
24VDC POWER SUPPLY
REMOTE RUN/UNLOAD
PS
DPSW1
INPUT 7
P1
PSW1
CONTRACTOR FOR POWER FACTOR CAPACITOR OPT.
4M
FAN MOTOR OVERLOAD
COMPRESSOR OVERLOAD
1MOL
3MOL
DESCRIPTION
COMP
3.14 WIRING DIAGRAMYD CE
(OPT'L) SCD DRAIN
PART NO.
Q
T
Y
DESCRIPTION

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
(OPTL) TRANSFORMER SECONDARY CIRCUIT BREAKER
CB2
SCD
CONTROL TRANSFORMER FOR OPTIONAL SCD DRAIN
(OPTL) TRANSFORMER PRIMARY CIRCUIT BREAKER
CB1
XFMR1
DESCRIPTION
TH
COMP
SECTION 3
45
NOTES
46
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 104F (40C)
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 compressors 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

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
35F (1.7C).
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
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
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
locations, e.g. in exposed plant piping." (I)
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
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
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
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

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.

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
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

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 ftlb (13.5 to 16.2 Nm).
7. Restart compressor and check for leaks. 6.7
1. Filter Head
2. Element*
3. Body
* Fluid Filter Replacement KitP/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.

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 KitP/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 ftlbs (95 Nm).
8. Clean the return line strainer before restart-
59
1. Cover
2. Ground Spring*
3. Spring Fastener*
4. Cover Gasket*
5. Element*
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 KitP/N
02250117-782
Separator ElementP/N 02250185-533

* (Included in) Separator Element Replacement KitP/N 02250185-532
Figure 6-4: 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
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 inlb (1.13 Nm). Install
the protective grill.
6.9
1. Locking Nut
2. Adjustment Screw
Water Condensate Drain Maintenance
If your compressor is fitted with the standard solenoid
condensate drain valve, it is necessary to periodically
clean the strainer. Remove the 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
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).
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

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).
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
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
- Or Write -
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
SULLAIR CUSTOMER CARE TRAINING DEPARTMENT
and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical
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
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

AIR-COOLED AXIAL FAN, 60HZ/25HP

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

PARTS, YD CE

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 DRAINZERO LOSS 40 HP
MOISTURE DRAINZERO LOSS 25/30

HP
MOISTURE DRAINSTANDARD
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 STARTERYD CE N4
CONTROL STARTERVSD CE N12
CONTROL STARTERVSD N12
CONTROL STARTERWYE-DELTA
CONTROL STARTERMFV
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.
Michigan City, Indiana 46360 U.S.A
www.sullair.com
Fax: 219-874-1273
Hallam, Victoria 3803

Austrailia
Telephone: 33-477968470
Fax: 33-477968499
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.
Telephone: 61-3-9796-4000
Princess Highway
CHAMPION
COMPRESSORS, LTD.
219-874-1835
1-888-SULLAIR (785-5247)
Fax: 755-6853473
Sullair Road, No. 1
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
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
02250125372
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
10
11
12
13
14
15
ORDER PART NO.
QTY
DESCRIPTION

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 02250125369
element, compressor fluid filter 02250155-708
ELEMENTS
KEY NO.
1.2
Continued on next page.
NOTE
(I)
241772
02250155594
001932-005
02250117-782
02250144-735
250019-662
250022-669
02250051-053
250029-008
17
18
19
20
21
22
23
24
25
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

CAUTION
For proper amount of fluid fill, please consult Lubrication Guide in Section 3: Specifications in User Manual
02250164-607
16
ORDER PART NO.
KEY NO.
1.2
(I)
(I)
(I)
(I)
NOTE
PARTS LIST
COMPRESSOR, FRAME AND DRIVE 25/30HP
02250175-288 R00
1.3
828012-050
828012-065
829106-125
829108-125
829705-075
837806-094
837808-125
838812-250
17
18
19
20
21
22
23
Q
T
Y
WASHER, SPR LOCK-METRIC PLTD M12
WASHER, SPR LOCK REG PLTD 1/2
SCREW, HEX SER WASHER 5/16-18 X 3/4
CAPSCR, HEX GR5 1/2-13 X 1 1/4
CAPSCR, HEX 8.8 M12 X 65MM
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
SPCR,AIR END SHAFT HEIGHT 60HP
PLATE,ROTATION ARROW
DESCRIPTION

828012-020
02250174-280
10
16
02250156-393
15
02250155-285
825912-175
02250154-405
14
02250152-677
250040-319
02250152-669
13
02250152-620
02250175-376
02250152-619
250038-448
02250151-499
12
02250057-737
11
PART NO.
30
29
28
27
26
25
24
KEY
NO.
A1:
A2:
A3:
A4:
A5:
KEY
NO.
1.3
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

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.
PARTS LIST
COMPRESSOR, FRAME AND DRIVE 40HP
02250174-281 R00
1.4
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
10
11
12
13
14
15
16
17
18
19
20
21
22
23
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
DESCRIPTION
15 WASHER, SPR LOCK REG PLTD 3/8
Q
T
Y

PART NO.
KEY
NO.
1.4
A1:
A2:
A3:
A4:
A5:
29
28
27
26
25
24
KEY
NO.
Q
T
Y
VARIOUS 40HP
VARIOUS
WASHER, NORD-LOCK PL M12 SP
SCREW, TF-HEX M8 X 16 BLK ZINC
DESCRIPTION

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
10
11
12
13
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

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
02250156-633R05
1.6
14
882508-125
882608-016
883633-016
883642-020
12
13
14
15
elbow,met st thd/orfs m42 x 1 1/4
elbow,met st thd/orfs m33 x 1
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

867106-050
869205-040
866416-000
10
811620-162
11
810216-100
810220-125
02250167-608
02250167-115
02250159-493
02250166-561
02250152-215
PART NO.
Q
T
Y
KEY
NO.
1.6
N
O
T
E
15
PARTS LIST
02250174-302 R00
1.7
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
10
11
12
Q
T
Y
DESCRIPTION
connector,sw 37 deg 1 5/8 x 1 5/8 sae
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

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.
KEY
NO.
1.7
17
PARTS LIST
AIR PIPING WITH INTEGRAL DRYER 25/30HP
02250168-701 R01
1.8
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
10
11
12
13
14
15
16
17
Q
T
Y
elbow
elbow
screw
nut
union
elbow
bushing
elbow
connector
elbow
connector
hose
hose
support
separator
tube
tube
DESCRIPTION

PART NO.
PART NO.
Q
T
Y
DESCRIPTION
FROM MINIMUM PRESSURE VALVE

A8: COMPRESSOR AIR OUT FROM EVAPORATOR
A7: COMPRESSOR AIR IN TO EVAPORATOR
A5: FROM MOISTURE DRAIN
A4: FROM AFTERCOOLER
A3:
A2: TO AFTERCOOLER
A1: PACKAGE DISCHARGE PRESSURE P2
KEY
NO.
KEY
NO.
1.8
19
PARTS LIST
AIR PIPING WITH INTEGRAL DRYER 40HP
02250183-886 R01
1.9
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
10
11
12
13
14
15
16
Q
T
Y
connector
screw
nut
union
elbow
bushing
elbow
elbow
connector
connector
elbow
tube
hose
support
hose
separator
DESCRIPTION

PART NO.
KEY
NO.
1.9
PART NO.
Q
T
Y
DESCRIPTION

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
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
10
11
12
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 6l
valve,thermal 210f 1 1/2-18
elbow,90 sae x orfs .75
DESCRIPTION

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
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 33long
filter,coreless m27 6l

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
883627-012
02250180-506
02250156-913
826502-219
02250156-909
829310-080
02250155-708
02250099-766
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
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
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

16 SCREW, PLASTIC PILOT M6 X 30
22 SCREW, TF-HEX M8 X 16 BLK ZINC
02250154-721
02250058-345
02250156-639
02250156-637
02250156-638
CLR,AIR/OIL STD
CLR, AIR/OIL CRN/CE
02250156-137
02250164-164
MTR,FAN
DESCRIPTION
Q
T
Y
PART NO.
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
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
14 screw, tf-hex m8 x 16 blk zinc
16 screw, hex serr washer m8 x 16
guard, fan discharge p8 p10
louver,extruded 18kw 500.0 lng
support, motor fan 1800/2200
strip,weather 1 x 1/8 foam (ft)

865708-240
874904-038
865408-170
16
17
850604-012
15
18
250018-497
821103-150
13
02250173-084
12
14
02250171-617
11
02250162-492
02250167-452
02250160-566
10
02250160-536
02250160-429
02250154-721
02250160-452
02250058-345
cooler,air/oil p10 std

cooler, air/oil crn/ce
02250156-137
02250164-164
motor, fan 1hp 4p teee
DESCRIPTION
Q
T
Y
PART NO.
KEY
NO.
N
O
T
E
24
23
KEY
NO.
nut,hex locking m8
16 screw, plastic pilot m6 x 30
DESCRIPTION

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
washer, iso 7093-8-140hv
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
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
fan, cooling 16 60hz 40 hp

fan, cooling 16 50hz 40 hp
motor,1hp 4p
DESCRIPTION

882608-030
883008-016
18
850604-012
12
17
250022-436
11
882608-016
250018-497
16
02250180-559
10
882508-125
02250174-300
15
02250174-294
865408-170
02250174-288
02250184-790
865708-240
02250160-566
14
02250156-639
13
02250154-721
02250174-423
02250174-424
Q
T
Y
PART NO.
KEY
NO.
1.
PART NO.
Q
T
Y
DESCRIPTION

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
10
11
12
13
Q
T
Y
screw
connector
plug
washer
washer
nut
tnk assy
gasket
hose
wire
isolator
valve
adapter
DESCRIPTION

PART NO.
KEY
NO.

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

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
10
11
12
13
14
15
16
17
18
Q
T
Y
connector
screw
washer
capscrew
o-ring
valve
plug
element
decal
spring
tank
elbow
sightglass
orifice
filter
adapter
elbow
plug
DESCRIPTION

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.

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

13)
CHECK ELECTRICAL CONTINUITY BETWEEN LID AND TANK

AND APPLY VALIDATION DECAL
3.
4.

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 DRAINSTANDARD
MOISTURE DRAINSTANDARD
36
02250046-110
02250071-380
02250167-603
02250170-783
250025-859
842215-004
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

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 DRAINSTANDARD

N
O
T
E
37
PARTS LIST
02250182-810 R01
1.18 MOISTURE DRAINZERO LOSS 25/30 HP
MOISTURE DRAINZERO LOSS 25/30 HP
38
02250046-110
02250071-380
02250144-841
02250167-603
02250182-545
250024-685
842215-004
Q
T
Y
HOSE, NYLON 1/4(FT)
CONN,TUBE-STRT 1/4MNPT X1/4T
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

PART NO.
KEY
NO.
1.18 MOISTURE DRAINZERO LOSS 25/30 HP
39
PARTS LIST
02250183-721 R01
1.19 MOISTURE DRAINZERO LOSS 40 HP
MOISTURE DRAINZERO 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
10
11
12
13
14
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 X1/4T
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

PART NO.
KEY
NO.
1.19 MOISTURE DRAINZERO LOSS 40 HP

PART NO.
Q
T
Y
DESCRIPTION

A3: TO MOISTURE SEPARATOR
A2: TO P2 PACKAGE DISCHARGE PRESSURE
A1: TO STARTER BOX
02250182-571 KIT,VALVE SERVICE 115V ZLOSS
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
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

bushing,red-brs-1/2"x1/4"
02250046-110
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 SYSTEMNYLON
PNEUMATIC CONTROL SYSTEMNYLON
44
02250155-962
02250155-963
250025-926
811502-025
847815-050
869825-025
20
21
22
23
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)
valve, blowdown 1/4 npt hi prs
DESCRIPTION

250025-923
17
250025-926
250025-859
16
19
250025-858
15
18
250025-850
250025-852
14
250025-835
02250155-961
13
02250155-714
250018-430
02250118-586
12
02250115-272
241771
02250099-630
250017-280
02250071-362
10
02250049-634
11
PART NO.
KEY
NO.
(III)
(II)
(I)
N
O
T
E
1.21 PNEUMATIC CONTROL SYSTEMNYLON
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

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 SYSTEMSTAINLESS STEEL
PNEUMATIC CONTROL SYSTEMSTAINLESS 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
10
11
12
13
14
15
16
17
18
19
20
21
22
23
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 1/8npt 5micr
valve, solenoid 3wno 1/4 250# 24vdc
orifice,.078 .25 fnpt x .25 mnpt
valve,check 1/4 poppet style
valve, blowdown 1/4 npt hi prs
bushing, red brs 1/4 x 1/8
DESCRIPTION

02250155-714
02250173-972
02250118-586
02250115-272
02250049-634
02250071-362
02250046-101
PART NO.
KEY
NO.
N
O
T
E
PART NO.
Q
T
Y
DESCRIPTION

02250157-500 KIT,SOL VLV 3WNO 24VDC
250019-453 KIT, REPAIR PRESS REG VALVE
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 SYSTEMSTAINLESS 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
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 1/4TUBE X 1/8NPT
CONN, 1/4 TUBE X 1/8 NPT
HEATER, ENCLOSURE 50W
P,THERMISTER 3000 OHM NTC 12L
RLY, SPTD DIN 10A 24VDC COIL
W, 10 GAGE GROUND BOND 12 M8
P,RTD 100 OHM PLAT 3.5X 6FT
XDCR, PRESS 0-250# RATIOMETRIC
SW,DIFF PRESS 20PSID 12FT
XFMR,PT 50VA UNIV W/PRI FH
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

250019-771
250023-496
250018-429
18
20
250018-427
17
19
249008
16
02250100-363
10
02250175-087
02250083-182
15
02250078-249
02250158-377
02250071-381
14
02250071-380
02250157-450
02250071-379
13
02250060-705
02250155-174
02250058-345
02250155-175
02250057-245
11
02250054-861
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
VARIOUS
1
VARIOUS
1
VARIOUS
VARIOUS
VARIOUS
Continued on page 51
TUBING, ST STL 1/4 20GA
BLOCK,TERM ADAPTER KAD
BLOCK,TERMINAL KT3
BUTTON, PUSH NON-ILLUM BLK N4X
Q
T
Y

FUSE,DRYER
865408-170
31
30
841215-004
250041-103
26
29
250041-102
250034-627
PART NO.
25
24
KEY
NO.
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

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

A3:
A2: P2-PACKAGE DISCHARGE PRESSURE
A1: TO FRAME
KEY
NO.
PART NO.
Q
T
Y
DESCRIPTION

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.
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
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 22wc n4 6ft cable 5a
transformer, control 50va univ w/pri fh
transducer, pressure 0-250# ratiometric
probe,rtd 100 ohm plat 3.5x 6ft
wire,10 gage ground bond 12 m8
relay,sptd din 10a 24vdc coil
probe,thermister 3000 ohm ntc 12l
tube,nyl .25 od xx 040w blk(ft)
heater, enclosure 50w
connector,1/4 tube x 1/8 npt
elbow, 90 1/4tube x 1/8npt
holder,fuse 1p 30a 600v
connector,cord grip 0.09-0.26
elbow,90deg m swvl 1/4t x 1/8npt
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
various
DESCRIPTION

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

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
A3: P1-TO SUMP TANK WET SUMP PRESSURE
A4: T1-TO SUMP TANK WET DISCHAGE TEMPERATURE
A5: SOLENOID 1
A6: SOLENOID 4
A9: MOTOR WIRING
A11: DRYER OPTION
A13: HEATER OPTIONS
A18: TO AIR FILTER
A21: T3-TO INTEGRAL DRYER EVAPORATOR DRYER DEWPOINT TEMPERATURE
A22: CSA OPTION
A23: OTHER OPTIONS
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)
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 22wc n4 6ft cable 5a
transformer, control 50va univ w/pri fh
wire,10 gage ground bond 12 m8
probe,thermister 3000 ohm ntc 12l
connector,1/4 tube x 1/8 npt
elbow, 90 1/4tube x 1/8npt
holder,fuse 1p 30a 600v
connector,cord grip 0.09-0.26
elbow,90deg m swvl 1/4t x 1/8npt
socket, 8pin 480v
button, push non-illum blk n4x
block,terminal kt3
block,term adapter kad
tubing, st stl 1/4 20ga
various
DESCRIPTION

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

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
A3: P1-TO SUMP TANK WET SUMP PRESSURE
A4: T1-TO SUMP TANK WET DISCHAGE TEMPERATURE
A5: SOLENOID 1
A6: SOLENOID 4
A9: MOTOR WIRING
A11: DRYER OPTION
A13: HEATER OPTIONS
A18: TO AIR FILTER
A21: T3-TO INTEGRAL DRYER EVAPORATOR DRYER DEWPOINT TEMPERATURE
A22: CSA OPTION
A23: OTHER OPTIONS
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
10
11
12
13
865408-170
RELAY
OVERLOAD
STARTER
20
21
22
DESCRIPTION
various
various
1
2
terminal, ring tng 3/8 x 8ga
socket, 8pin 480v
relay,phase monitor ce
relay,ovrld base for xt frame c
wire, ground bond 30 10 ga
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
strip,weather 1 x 1/8 foam
12 block, term 45a 600v euro ch
Q
T
Y

838808-200
849306-008
18
19
825908-125
02250083-181
17
02250071-381
250034-430
02250071-379
16
02250060-705
02250179-970
02250058-345
249008
02250057-245
14
02250057-241
15
PART NO.
KEY
NO.
N
O
T
E
PART NO.
Q
T
Y
DESCRIPTION


02250178-681 DWG,START P10 CE YD N4 TAB
A11: OTHER OPTIONS
A10: STARTER BOX HEATER

MOUNTED INSIDE TOP OF STARTER BOX
A8: HEATER OPTIONS
A6: SOLENOID 4
A5: SOLENOID 1
A4: T1-TO SUMP TANK

A3: P1-TO SUMP TANK

WET SUMP 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
various
terminal, ring tng 3/8 x 8ga
socket, 8pin 480v
relay,phase monitor ce
starter,1.9a fv ch-it
wire, ground bond 30 10 ga
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
strip,weather 1 x 1/8 foam
12 block, term 45a 600v euro ch
Q
T
Y

STARTER
02250154-607
22
02250131-188
865408-170
02250083-181
21
02250071-381
849306-008
02250071-379
20
02250060-705
825908-125
02250058-345
838808-200
02250057-245
18
02250057-241
19
PART NO.
KEY
NO.
N
O
T
E
PART NO.
Q
T
Y
DESCRIPTION


02250178-751 START,ASY P10 CE VSD N12
A11: OTHER OPTIONS
A10: STARTER BOX HEATER

MOUNTED INSIDE TOP OF STARTER BOX
A8: HEATER OPTIONS
A6: SOLENOID 4
A5: SOLENOID 1
A4: T1-TO SUMP TANK

A3: P1-TO SUMP TANK

WET SUMP 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 STARTERMFV
CONTROL STARTERMFV
60
02250154-052
250021-694
250014-827
250014-127
02250154-359
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

02250159-549
02250161-759
17
02250154-051
02250159-547
02250101-721
16
02250167-822
02250081-473
02250167-821
15
02250167-820
02250085-504
02250170-760
250027-125
02250167-819
14
WASHER,LOCK EXTERNAL TOOTH 5/16
02250170-761
13
LUG, GROUND
02250167-818
SPEC, ENCL P12/16 22 X 36 X 10
02250169-621
DESCRIPTION
PART NO.
KEY
NO.
Q
T
Y
1.29 CONTROL STARTERMFV
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
DESCRIPTION

-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 STARTERWYE-DELTA
CONTROL STARTERWYE-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
SPEC, ENCL P12/16 22 X 36 X 10
DESCRIPTION

02250159-549
18
10
02250159-547
17
02250161-759
250021-694
02250154-359
16
02250154-051
02250081-473
02250101-721
15
02250154-052
250027-125
250021-692
14
02250167-821
02250085-504
02250167-820
13
02250167-819
250014-827
02250167-818
250014-127
02250167-817
12
02250169-621
11
PART NO.
KEY
NO.
1.30 CONTROL STARTERWYE-DELTA
02250167-843
02250167-849
250019-773
20
20
21
Q
T
Y
HOLDER,FUSE KTK-R 3 POLE
BLOCK,POWER DISTRIBUTION 310 AMP
DESCRIPTION

-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 STARTERVSD N12
CONTROL STARTERVSD N12
64
02250159-549
02250161-759
02250155-754
02250168-820
02250168-819
16
17
18
19
20
20
20
02250154-359
15
02250159-547
02250145-195
02250154-051
14
02250170-668
13
02250154-052
02250081-473
02250165-108
12
02250157-716
250027-125
02250157-717
11
02250157-718
250019-773
02250157-719
02250085-504
02250157-725
02250157-726
10
02250157-727
02250168-846
PART NO.
KEY
NO.
KIT, VSD MOUNTING FLANGE FRAME 8
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 575V 52A NEMA12
SPEC, ENCL P8/10 22 X 26 X 10
DESCRIPTION
1.31 CONTROL STARTERVSD N12

DESCRIPTION
DRIVE, VFD C-H 380-460V 61A NEMA12
DRIVE, VFD C-H 380-460V 105 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 STARTERVSD CE N12
CONTROL STARTERVSD 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
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
SW, PB OPER RED40MM PUSH-TWIST
WASHER, LOCK EXTERNAL TOOTH 5/16"
LUG, GROUND
SPACER, 6.35 DIA X 10.4 LONG ALUM
CTL, DISPLAY WS
BAR, GROUND 9 POST
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

PART NO.
KEY
NO.
1.32 CONTROL STARTERVSD CE N12

DESCRIPTION
CNTOR, 65A 3P 24VAC 1NO XT
CNTOR, 32A 24VAC 1NO XT
SULLAIR P/N
02250167-818
02250167-817
26.6
29.2
LUG
10.6
10.6
67
TERMINALS
PARTS LIST
02250178-681-R00
1.33 CONTROL STARTERYD CE N4
CONTROL STARTERYD 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
SW, PB OPER RED40MM PUSH-TWIST
WASHER, LOCK EXTERNAL TOOTH 5/16
LUG, GROUND
SPACER, 6.35DIA X 10.4 LONG ALUM
CTL, DISPLAY WS
BAR, GROUND 5 POST
CNTOR, 32A 3P 24VDC 1NO XT
SPEC, ENCL CE YD P8/P10 19X24.5X7
DESCRIPTION

250027-125
02250161-759
11
02250154-359
02250085-504
02250154-051
10
02250101-721
849215-025
02250154-052
838405-034
02250167-817
02250178-949
PART NO.
KEY
NO.
1.33 CONTROL STARTERYD CE N4
DESCRIPTION
CNTOR, 65A 3P 24VAC 1NO XT
CNTOR, 32A 24VAC 1NO XT
SULLAIR P/N
02250167-818
02250167-817
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
Q
T
Y

250019-520
02250160-378
17
250034-157
02250160-377
16
19
02250160-375
18
02250160-374
15
02250155-824
14
02250155-284
02250160-373
02250154-667
13
02250154-659
02250160-372
02250152-336
12
02250152-335
02250155-825
02250152-334
02250158-039
02250152-323
11
02250150-893
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
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
Q
T
Y

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
PLUG,PLASTIC FOR 3/8 HOLE
PNL,CAN ASSY INTAKE END 2200 W/DRYER
PANEL, ROOF ENCL ES8
TRIM,CLIP-ON GRIP 185-260DUQ
DESCRIPTION
Q
T
Y

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
02250155-824
02250152-336
02250152-335
02250154-667
02250152-334
02250155-284
02250152-323
02250150-893
PART NO.
KEY
NO.
PART NO.
Q
T
Y
DESCRIPTION

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
10
11
12
13
14
15
16
17
18
19
PANEL,ENCLOSURE ROOF - P10-40H
PNL,CAN ASSY INTAKE END 2200 W/DRYER
DESCRIPTION
Q
T
Y

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
10
11
12
13
14
15
16
17
18
19
20
21
22
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

02250075-045
02250075-540
02250057-624
PART NO.
KEY
NO.
N
O
T
E
1.38 DECAL LOCATION SECTION, AIR-COOLED
VOLTAGE
SERIES
RIVET
NAMEPLATE
FLUID
407408
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

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
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,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
DESCRIPTION

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
*241814
10
16
*049852
*049855
1
1
*049685
*049850
*042218
*041065
Q
T
Y
*02250075-045
*02250075-540
PART NO.
KEY
NO.
N
O
T
E
RIVET
SERIES
VOLTAGE
35
36
37
Q
T
Y
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

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
1.40 DECAL GROUP
DECAL GROUP
82
042218
02250110891
049855
16
20
Q
T
Y
sign, warningseverfanindus
decal, enwarning mixing fluids
decal, danger hi voltage
decal, parallel wye motor conn.
decal, danger electrocution
decal, danger inhaling comp air
DESCRIPTION

049850
02250146385
250027935
26
18
PART NO.
KEY
NO.
1.40 DECAL GROUP

N
O
T
E
83
PARTS LIST
1.40 DECAL GROUP (CONTINUED)
DECAL GROUP
84
250017903
049852
250003144
407408
041065
23
19
22
27
15
Q
T
Y
decal, warning auto start
sign, warninghot surfaces
decal, warning elec shockground fault
decal, warning elec shockground fault
decal, warningautostart
sign, warningcomp oil fill cap
DESCRIPTION

049685
PART NO.
17
KEY
NO.

N
O
T
E
85
PARTS LIST
DECAL GROUP
86
Q
T
Y
decal, vsd black p8/p10/p12
decal, separator/sump tank fluid drain

p8/p10
decal, remove before startup
decal, black www.sullair.com
decal, pe designation
decal, protective earth ground
DESCRIPTION

02250162215
02250157732
10
13
02250157703
02250158358
02250155495
02250161967
02250075540
12
02250075045
11
PART NO.
KEY
NO.

N
O
T
E
87
PARTS LIST
DECAL GROUP
88
1
1
02250069394
02250069395
(I)
02250069389
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

This decal will vary with individual machine. Consult Sullair Corporation
with serial number
28
241814
21
250021564
02250164823
14
250022810
02250186-230
25
02250077472
Q
T
Y
24
PART NO.
KEY
NO.
89
PARTS LIST
DECAL GROUP
90
02250157735
02250157731
31
(I)
33
32
1
1
02250057624
1
1
1
02250069400
02250069403
02250069406
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

This decal will vary with individual machine. Consult Sullair Corporation
with serial number
02250069399
02250170-889
02250069397
PART NO.
KEY
NO.
Q
T
Y
91
PARTS LIST
DECAL GROUP
92
02250161-967
250019-107
250019-108
37
38
39
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

02250145-206
02250146-385
36
02250168-920
34
35
PART NO.
KEY
NO.

N
O
T
E
93
PARTS LIST
NOTES
94
NOTES
WORLDWIDE SALES AND SERVICE

SULLAIR ASIA, LTD.
SULLAIR CORPORATION
Sullair Road, No. 1

Chiwan, Shekuo
Shenzen, Gunagdong PRV.
Fax: 755-6853473

Michigan City, Indiana, 46360 U.S.A.
www.sullair.com
Fax: 219-874-1273

Telephone: 33-477968470
Fax: 33-477968499
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

Specifications subject to
change without prior notice.
E10EP
USER MANUAL
WS CONTROLLER USER INTERFACE MANUAL
PART NUMBER:
02250202-046 R01
WARRANTY NOTICE
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.

and servicing of Sullair products. Individual seminars on Stationary compressors and compressor electrical
SULLAIR TRAINING DEPARTMENT

1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
training@sullair.com
- Or Write Sullair Corporation

TABLE OF CONTENTS
SECTION 1SAFETY
5
1.1
GENERAL
1.2
PERSONAL PROTECTIVE EQUIPMENT
1.3
PRESSURE RELEASE
1.4
FIRE AND EXPLOSION
1.5
MOVING PARTS
1.6
HOT SURFACES, SHARP EDGES AND SHARP CORNERS
1.7
TOXIC AND IRRITATING SUBSTANCES
1.8
ELECTRICAL SHOCK
1.9
LIFTING
1.10
ENTRAPMENT
1.11
SAFETY WARNINGS
SECTION 2STARTUP 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 3ADJUSTMENTS
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 4DESCRIPTION
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 5TROUBLESHOOTING
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 6VARIABLE 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)
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
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
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.
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.
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
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.
Figure 2-1: WS Controller Panel
11

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.
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 Operators 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 Operators 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 Operators
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 Operators 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
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 Operators
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
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

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
Figure 3-1: Controller Display Flow Diagram
17

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.
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 LEDs 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 LEDLights 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

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 1Displays the current compressor
temperature at temperature probe 1.
Dewpoint TemperatureDisplays the current dryer
Sump PressureDisplays
pressure (P1).
the
current
sump
Line PressureDisplays the current line output

pressure (P2).
Pressure 3Displays the pressure (P3) at the
specified transducer location.
Separator Pressure ^ Displays the current
separator pressure differential.
Run HoursDisplays 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 ValveApproximate percent of full capacity

controlled by the compressor's spiral valve
VSD CapacityThis is displayed as an approximate
percentage (%) of the maximum capacity for the
package.
VSD TemperatureHigh 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
pad is pressed.
Figure 4-3: Adjustment View

Show Setting Example
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 screens
Normal View. See Figure 4-5.
Off modeIndicated 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
Figure 4-5: Compressor Operating

Mode Display
The compressor operating modes are described
below:
Automatic
modeIndicated
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 modeIndicated 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 modeIndicated by the word UI COMM
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 ModeIndicated by the word MANUAL

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

Normal View display. Some operating states occur
instantaneously and may not be seen by the
operator.
InitializingDisplayed
powered up.
as
the
compressor
is
StoppingMay be briefly displayed as the

compressor is being stopped via the Controller
Panel.
Manually
StoppedDisplayed
compressor operation is stopped.
when
the
Remote StoppingMay be briefly displayed as the

compressor is being stopped remotely.
Remote StoppedDisplayed 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 byDisplayed when the compressor is
stopped and waiting for proper conditions before
restarting.
SECTION 4
Running UnloadedDisplayed when the system is

running with the compressor unloaded.
Remote
UnloadedDisplayed
when
compressor has been unloaded remotely.
the
RestartingDisplayed 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.
FaultingDisplayed as a fault condition is occurring.

FaultedDisplayed after a fault condition has
occurred.
Waiting for BlowdownDisplayed 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 1Displayed as compressor initiates stage

1 startup processes.
Precooling the DryerDisplayed while initially
cooling an integrated dryer with the compressor
unloaded
LoadingDisplayed as the compressor begins
delivering air.
Loaded & ModulatingDisplayed
compressor is delivering air.
when
the

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 FilterThe compressor fluid filter
should be changed within the time frame noted in the
machine operation specifications.
Change SeparatorThe compressor fluid separator
should be changed within the time frame noted in the
Change Air FilterThe compressor air filter should
be changed within the time frame noted in the
Fully LoadedDisplayed when the compressor is

delivering air at full rated capacity.
Analyze FluidA fluid analysis should be scheduled

per machine operation specifications.
UnloadingDisplayed as the compressor is being

unloaded automatically.
Change FluidThe compressor fluid should be

changed within the time frame noted in the machine
operation specifications.
Remote UnloadingDisplayed as the compressor

is being unloaded remotely.
22
Maintenance APeriodic maintenance should be

scheduled per machine operation specifications.
SECTION 4
4.8
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.

Warning Message
The list below provides an explanation of the
Warning Messages that may appear in the display
when an error occurs.
High Dryer DewpointIndicates that the integrated

dryer is running with high dewpoint temperature.
Consult the dryer manual and/or dryer manufacturer.
Dryer High DP FaultIndicates that the integrated
dryer has stopped operation due to high dewpoint
temperature. Consult the dryer manual and/or dryer
manufacturer.
High Air Filter dPIndicates the air filter pressure

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

dryer is running with low dewpoint temperature.
Consult the dryer manual and/or dryer manufacturer.
Not CommissionedA controller was replaced but

has not been commissioned for a specific
compressor model.
Dryer Low DP FaultIndicates that the integrated

dryer has stopped operation due to low dewpoint
temperature. Consult the dryer manual and/or dryer
manufacturer.
Power InterruptionIndicates
interruption has occurred.
Dryer Overload FaultIndicates that the integrated

dryer has stopped operation due to a compressor
motor overload. Consult the dryer manual and/or
dryer manufacturer.
Dryer Relay FaultIndicates that the integrated
dryer has stopped operation due to internal
problems. Consult the dryer manual and/or dryer
manufacturer.
Dryer ServiceIndicates a dryer is running while a
malfunction is occurring. Consult the dryer manual
and/or dryer manufacturer.
that
power
Replace BatteryIndicates the I/O backup battery

is low.
Sequence
Comm
ErrorIndicates
a
communication problem exists between the
compressor controllers set up for sequential
operation.
StarterThe main motor starter failed to operate,
and was restarted.
User Option WarningIndicates a user furnished
switch has been activated.
VFD OvertempOperating
approaching the VSD limits.
temperatures
are
Ethernet disabledEthernet was turned off due to

excessive network traffic.
23
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 DewpointIndicates that the integrated

dryer has stopped all package operation due to high
dewpoint temperature. Consult the dryer manual
High Interstage PresInterstage pressure is above
the unit limits.
High Package PressPackage Discharge pressure
has exceeded the set high limit.
High Plant PressurePlant line pressure has
exceeded the set high limit.
High Pressure ABPressure at specified
transducer (A or B) has exceeded the set high limit.
High Separator dPSeparator pressure differential
has exceeded the set high limit.
High Spiral Valve PrExcessive pressure was
applied to the spiral valve actuator.
High Sump PressureCompressor sump pressure

has risen above the set limits.

Fault Message
High Temperature 13The 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 OverloadThe auxiliary motor overload
relay has been tripped due to a power overload in the
auxiliary motor.
CE Voltage too high / LowThe internal 24 volt

supply is out of range.
Controller WatchdogController watchdog timer
error.
Dryer FaultIndicates a dryer malfunction has
occurred. Consult the dryer manual and/or dryer
manufacturer.
Dryer OverloadIndicates a dryer overload has
occurred. Consult the dryer manual and/or dryer
manufacturer.
E-Stop Push ButtonEmergency 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 FailedNo voltage is available at the

high voltage motor starter.
HIGH VOLT SENSORIndicates the system high
voltage sensor has failed.
Illegal StateController operating error.
Internal Com ErrorAn 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 DewpointIndicates that the integrated
dryer has stopped all package operation due to low
dewpoint temperature. Consult the dryer manual
Low Line PressureThe line pressure has fallen
below the Low Fluid Pressure set low limit.
Low Fluid PressureCompressor fluid pressure
has fallen below the set low limit.
Low Sump PressureCompressor sump pressure
has fallen below the set limits.
SECTION 4
Low Temperature 1 ... 3Temperature at the

specified temp probe (1 through 3) has fallen below
the set low limit.
LOW VOLT SENSORIndicates the system low
voltage sensor has failed.
4.10 DIAGNOSTIC VIEWS

While in the Normal View use the ENTER
Low Water PressureThe water pressure switch

has been tripped due to low water pressure.
Use the UP
or DOWN
the next Diagnostic view.
Main Motor OverloadThe main motor overload

relay has been tripped due to a power overload in the
main motor.
Use the ENTER
Memory ErrorThe controller I/O board has failed.

OPTION INPUTUser 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 RUNUser option error.

Phase Protection.Indicates
protection relay has tripped.
Pad
to access the Diagnostic View.
external
phase
ErrorCommunications
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 InterruptionA power interruption has

occurred at the controller.
Pump Motor OverloadThe
overload relay has tripped.
pump
motor's
Pump Starter ContactThe pump starter did not

operate as expected.
StarterStarter 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 highThe 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 lowThe voltage to the User

Interface has fallen below the set limit.
DIAGNOSTIC: DIGITAL I/O VIEW
High Plant PressureThe inlet valve failed to close

as expected
VSD1 ResponseThe 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 FaultAn error in communication

between the controller and the specified VSD
compressor has occurred.
VSD1 parameter errorAn 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
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

Figure 4-12: Typical Alarm View
Figure 4-13: Navigation between the

Normal and Diagnostic view
26
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 machines operators 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
SECTION 5

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
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.

Dryer Low DP Fault
The dryer is cooling below the low

dewpoint temperature setting.

Dryer Overload
Dryer Overload Fault
Indicates a dryer overload has

occurred.

Dryer Relay Fault
Indicates a general dryer

malfunction has occurred

Dryer Service
Dryer malfunction is imminent.

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.

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 40F (4C).
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

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 operators 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 105F (41C), 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.
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.
Low Dryer Dewpoint
The dryer is cooling below the low

dewpoint temperature setting.

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
SECTION 5

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.

below 40F (4C).
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

below 40F (4C).
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.
company.
Maintenance A

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.
company.
30
SECTION 5

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.
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.
UI Voltage too low
Controller fault.
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.
LOW VOLT SENSOR
Controller fault.
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

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
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
200 psig
10 psig
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-

3. Open the controller enclosure and locate the
I/O Control Module.
SECTION 5
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.
Large I/O Control Module

Circuit Board
33
NOTES
34
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
WWW.SULLAIR.COM
SULLAIR CORPORATION
3700 East Michigan Boulevard Michigan City, Indiana, 46360 U.S.A.
Telephone: 1-219-879-5451

Specifications subject to change
without prior notice.
E12EP

Industrial Air Compressor Sullair

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Industrial Air Compressor Sullair

Uploaded by

Copyright:

Available Formats

USER MANUAL

INDUSTRIAL AIR COMPRESSOR

The information in this manual is current

AIR CARE SEMINAR TRAINING

SULLAIR CUSTOMER CARE TRAINING DEPARTMENT

- Or Write Sullair Corporation

PERSONAL PROTECTIVE EQUIPMENT

FIRE AND EXPLOSION

HOT SURFACES, SHARP EDGES AND SHARP CORNERS

TOXIC AND IRRITATING SUBSTANCES

SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION

COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION

COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION

CONTROL SYSTEM, FUNCTIONAL DESCRIPTION

AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

INTEGRAL DRYER OPTION

VARIABLE SPEED DRIVE (VSD) COMPONENTS

VSD CONTROL SYSTEM FUNCTIONAL DESCRIPTION

LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCEFLUID FILTER AND SEPARATOR

AIR-COOLED, IDENTIFICATION 25-30HP

AIR-COOLED, IDENTIFICATION 40HP

AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 25-30HP

PIPING AND INSTRUMENTATION, AIR-COOLED

PIPING AND INSTRUMENTATION, 1800-2200 W/INTEGRAL DRYER

WIRING DIAGRAMMFV, AIR-COOLED

WIRING DIAGRAMMFV, AIR-COOLED INTEGRAL DRYER

WIRING DIAGRAMVSD, PARALLEL WYE

VENTILATION AND COOLING

SERVICE AIR PIPING

COUPLING ALIGNMENT CHECK

FLUID LEVEL CHECK

MOTOR ROTATION DIRECTION CHECK

FAN MOTOR ROTATION CHECK

SECTION 5WS CONTROLLER

MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION

MAINTENANCE EVERY 2000 HOURS

AIR FILTER MAINTENANCE

the precautionary statements contained herein are

Sullair Corporation and its subsidiaries design and

A. Prior to installing or operating the compressor,

A. Install an appropriate flow-limiting valve between

D. Flow-limiting valves are listed by pipe size and

Secure all hose connections by wire, chain or

G. Open fluid filler cap only when compressor is not

Keep personnel out of line with and away from

J. DO NOT use air at pressures higher than 2.1 bar

FIRE AND EXPLOSION

A. Clean up spills of lubricant or other combustible

D. Disconnect and lock out all power at source prior

Keep grounded and/or conductive objects such

G. Remove any acoustical material or other material

J. DO NOT operate the compressor without proper

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

D. Keep access doors, if any, closed except when

Disconnect and lock out all power at source and

G. Keep hands, feet, floors, controls and walking

HOT SURFACES, SHARP

A. Avoid bodily contact with hot fluid, hot coolant,

TOXIC AND IRRITATING

Death or serious injury can result from

Wear goggles or a full face shield when adding

G. If air line anti-icer system antifreeze compound

A. If the compressor is provided with a lifting bail,