Professional Documents
Culture Documents
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
201003010000
and all subsequent serial numbers.
TABLE OF CONTENTS
SECTION 1SAFETY
3
1.1
GENERAL
1.2
1.3
PRESSURE RELEASE
1.4
1.5
MOVING PARTS
1.6
1.7
1.8
ELECTRICAL SHOCK
1.9
LIFTING
1.10
ENTRAPMENT
SECTION 2DESCRIPTION
9
2.1
INTRODUCTION
2.2
DESCRIPTION OF COMPONENTS
10
2.3
11
2.4
13
2.5
15
2.6
17
2.7
17
2.8
17
2.9
18
2.10
SECTION 3SPECIFICATIONS
21
3.1
TABLE OF SPECIFICATIONS
23
3.2
LUBRICATION GUIDE
24
3.3
APPLICATION GUIDE
24
3.4
26
3.5
28
3.6
TABLE OF CONTENTS
30
32
3.7
3.8
34
3.9
36
3.10
38
3.11
40
3.12
42
3.13
44
3.14
WIRING DIAGRAMYD CE
SECTION 4INSTALLATION
47
4.1
MOUNTING OF COMPRESSOR
47
4.2
48
4.3
50
4.4
50
4.5
50
4.6
ELECTRICAL PREPARATION
51
4.7
51
4.8
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
57
6.4
58
6.5
FLUID MAINTENANCE
58
6.6
FILTER MAINTENANCE
59
6.7
59
6.8
SEPARATOR MAINTENANCE
61
6.9
TROUBLESHOOTING
INTRODUCTION
Section 1
SAFETY
NOTE
1.2
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL.
1.1
GENERAL
PERSONAL PROTECTIVE
EQUIPMENT
1.3
PRESSURE RELEASE
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.
1.4
Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.
1.5
MOVING PARTS
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
1.6
1.7
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.
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
SECTION 1
I.
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
Section 2
DESCRIPTION
2.1
INTRODUCTION
2.2
DESCRIPTION OF
COMPONENTS
SECTION 2
8. Starter Box
2. Sight Glass
9. Fan Motor
2.3
5. Compressor Unit
12. Cooler
6. E-Stop
7. WS Controller
SULLAIR COMPRESSOR
UNIT, FUNCTIONAL
DESCRIPTION
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
refer
to
Section
3:
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
2.4
COMPRESSOR COOLING
AND LUBRICATION
SYSTEM, FUNCTIONAL
DESCRIPTION
11
12
SECTION 2
SECTION 2
2.5
COMPRESSOR DISCHARGE
SYSTEM, FUNCTIONAL
DESCRIPTION
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
14
SECTION 2
2.6
CONTROL SYSTEM,
FUNCTIONAL DESCRIPTION
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
3. Regulator
7. Separator/Sump Tank
4. Air Inlet
Figure 2-4: Standard Sequencing Control System
15
SECTION 2
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
SECTION 2
2.7
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
2.9
17
SECTION 2
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
18
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
19
SECTION 2
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
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
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
STANDARD MODELS:
Type:
Rotary Screw
Bearing Type:
Anti-friction
104(40C)
Cooling:
Pressurized Fluid
Compressor Fluid:
Sullair Sullube
Control:
WS Controller
MOTOR (IV):
STANDARD MODELS:
Size:
25,30,40HP / 18,22,30KW
Type:
104(40C)
Options Available:
Starter:
Options Available:
Speed25, 30 HP:
(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
CAUTION
Mixing of other lubricants within the compressor unit will void all warranties.
If fluid change is required, follow Sullair encourages
the user to participate in a fluid analysis program with
the fluid suppliers. This could result in a fluid change
interval differing from that stated in the manual.
Contact your Sullair dealer for details. on page 24.
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.
WARNING
"The Plastic Pipe Institute recommends
against the use of thermoplastic pipe to
transport compressed air or other compressed gases in exposed above ground
locations, e.g. in exposed plant piping." (I)
Sullube should not be used with PVC piping
systems. It may affect the bond at
cemented joints. Certain other plastic materials may also be affected. (I) Plastic Pipe
Institute, Recommendation B, Adopted January 19, 1972.
DO NOT MIX DIFFERENT TYPES OF FLUIDS.
23
SECTION 3
APPLICATION GUIDE
3.4
SEPARATOR CHANGE
A, E
G, C
A, D
B, E
G, C
B, D
F, E
G, C
A, D
B, E
G, C
B, D
LUBRICANT
A.
B.
C.
D.
E.
F.
G.
24
NOTES
25
26
02250159-354-R03
3.5
ODP
TEFC
30
30
1450 LBS/658 KG
1383 LBS/627 KG
1420 LBS/644 KG
2000 CFM
2000 CFM
2000 CFM
2000 CFM
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.
2.50[63.5]
A4: E-STOP
A3: CONTROLLER
TEFC
25
1374 LBS/623 KG
ODP
25
Weight
Motor Type
Main Motor HP
NOTES:
3.5
SECTION 3
1800-3000 USER MANUAL
27
28
02250181-032 R00
3.6
1613 LBS/732 KG
2900 CFM
2900 CFM
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.
2.50[63.5]
A4: E-STOP
A3: CONTROLLER
TEFC
40
1556 LBS/706 KG
ODP
40
Weight
Motor Type
Main Motor HP
NOTES:
3.6
SECTION 3
1800-3000 USER MANUAL
29
30
02250168-699-R02
3.7
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.
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
SECTION 3
1800-3000 USER MANUAL
31
32
02250180-784 R00
3.8
1814 LBS/823 KG
2900 CFM
2900 CFM
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.
2.72[69.0]
A4: E-STOP
A3: CONTROLLER
TEFC
40
1757 LBS/797 KG
ODP
40
Weight
Motor Type
Main Motor HP
NOTES:
3.8
SECTION 3
1800-3000 USER MANUAL
33
34
02250156-114-R10
3.9
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
VLV,CHK 1/4-NPT
COMPRESSOR
MOTOR
DESCRIPTION
PART NO.
02250144-841
02250182-548
02250182-545
02250168-837
02250169-612
241771
30
30
31
32
33
34
Q
T
Y
VLV,BALL/STNR COMBO-1/2NPT
DESCRIPTION
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
1800-3000 USER MANUAL
35
36
02250172-798-R02
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,VAC 22WC N4 6FT CABLE 5A
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
P2
DPSW1
PSW1
SOL1
SOL4
SOL5
T1
T3
DESCRIPTION
P1
COMPONENT
1
1
1
2
1
Q
T
Y
PART NO.
KEY
NO.
SECTION 3
1800-3000 USER MANUAL
37
38
02250171-211-R04
T1
HTR4
TH
HTR3
1FU
PMR
K7
HTR2
K6
HTR1
K5
K4
PF CAP
K3
SOL5
SOL4
SOL1
K2
INPUT 9
K1
INPUT 8
REMOTE RUN/UNLOAD
PS
DPSW1
INPUT 7
PSW1
P2
2MOL
P1
COMPRESSOR STARTER
1M
DESCRIPTION
COMPRESSOR OVERLOAD
1MOL
COMP
JZL
PPR
2
3
4
NOTES
3FU
DESCRIPTION
JZL TRANSFORMER SECONDARY FUSE
2FU
COMP
SECTION 3
1800-3000 USER MANUAL
39
40
02250174-982-R03
TH
HTR4
PMR
K7
HTR3
K6
K5
HTR2
K4
K3
K2
HTR1
PF CAP
SOL5
K1
SOL4
PS
INPUT 8
SOL1
REMOTE RUN/UNLOAD
INPUT 7
INPUT 9
T3
DPSW1
T1
PSW1
P2
2MOL
P1
COMPRESSOR STARTER
1M
DESCRIPTION
COMPRESSOR OVERLOAD
1MOL
COMP
DR
2
3
4
NOTES
DF
7FU
PPR
6FU
DESCRIPTION
FAN MOTOR BRANCH FUSES
3FU
COMP
SECTION 3
1800-3000 USER MANUAL
41
42
02250156-119 R09
HTR3
K7
HTR2
K6
K5
HTR1
K4
PMR
K3
SOL5
K2
SOL4
SOL1
K1
INPUT 9
PS
REMOTE RUN/UNLOAD
T1
INPUT 8
P2
INPUT 7
P1
3FU
DPSW1
2FU
1FU
PSW1
2MOL
2M
DESCRIPTION
COMPRESSOR MOTOR
1M
COMP
2
3
NOTES
SCD
XFMR1
TH
HTR4
COMP
SECTION 3
1800-3000 USER MANUAL
43
44
02250178-718-R00
COMPRESSOR STARTER
1M
2M
P2
T1
INPUT 8
INPUT 9
SOL1
SOL4
SOL5
HTR3
HTR4
K7
K6
K5
HTR2
K4
HTR1
K3
K2
PF CAP
K1
REMOTE RUN/UNLOAD
PS
DPSW1
INPUT 7
P1
PSW1
4M
COMPRESSOR OVERLOAD
1MOL
3MOL
DESCRIPTION
COMP
PART NO.
Q
T
Y
DESCRIPTION
KEY
NO.
N
O
T
E
CB2
SCD
CB1
XFMR1
DESCRIPTION
TH
COMP
SECTION 3
1800-3000 USER MANUAL
45
NOTES
46
Section 4
INSTALLATION
4.1
MOUNTING OF
COMPRESSOR
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
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
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
2. Sullair Dryer
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.
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
against the use of thermoplastic pipe to
transport compressed air or other compressed gases in exposed above ground
locations, e.g. in exposed plant piping." (I)
Sullube should not be used with PVC piping
systems. It may affect the bond at
cemented joints. Certain other plastic materials may also be affected.
(I) Plastic Pipe Institute, Recommendation
B, Adopted January 19, 1972.
4.4
COUPLING ALIGNMENT
CHECK
4.5
50
ELECTRICAL PREPARATION
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
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
(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
51
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
5.1
CONTROLLER KEYPAD
53
LCD DISPLAY
SECTION 5
Figure 5-2:
Figure 5-6:
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
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
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
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.
6.3
MAINTENANCE AFTER
INITIAL 50 HOURS OF
OPERATION
6.4
57
SECTION 6
6.5
FLUID MAINTENANCE
6.6
FILTER MAINTENANCE
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
6.8
SEPARATOR MAINTENANCE
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.
59
1. Cover
2. Ground Spring*
3. Spring Fastener*
4. Cover Gasket*
5. Element*
6. Separator/Sump Tank
SECTION 6
1. To Separator/Sump Tank
2. Male Tube Connector
3. 90 Pipe Elbow
4. Filter Assembly*
5. Sight Glass/Orifice Block
6. Brass Plug Orifice
7. Female Tube Connector
8. To Unit
* Fluid Return Filter Replacement KitP/N
02250117-782
60
SECTION 6
6.9
1. Locking Nut
2. Adjustment Screw
Figure 6-5: Separator Element Assembly
Water Condensate Drain Maintenance
If your compressor is fitted with the standard solenoid
condensate drain valve, it is necessary to periodically
clean the strainer. Remove the knurled cap from the
strainer and remove the strainer screen. Clean the
screen and reinstall. If the screen is damaged, the
strainer assembly must be replaced (P/N 241772).
TROUBLESHOOTING
INTRODUCTION
61
SECTION 6
SYMPTOM
PROBABLY CAUSE
REMEDY
Close switch.
Replace fuse
Reset.
Add fluid.
Replace element.
Compressor Will Not Build Full Dis- Air Demand Is Too Great
charge Pressure
62
SECTION 6
SYMPTOM
REMEDY
Check for leaks.
Replace.
Plugged Separator
63
NOTES
64
NOTES
65
SULLAIR CORPORATION
CUSTOMER CARE
for PARTS and Service
1-888-SULLAIR (7855247)
219-874-1835
PART NUMBER:
02250176-181 R02
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual or,
misuse of this equipement will
VOID its warranty!
KEEP FOR
FUTURE
REFERENCE
SULLAIR CORPORATION
201003010000
and all subsequent serial numbers.
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
- Or Write -
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullairs corporate headquarters training facility
located at Michigan City, Indiana.
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
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
MOISTURE DRAINSTANDARD
DESCRIPTION
SECTION
1.29
1.30
1.31
1.32
1.33
1.34
1.35
PAGE
60
62
64
66
68
70
72
CONTROL STARTERYD CE N4
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
Chiwan, Shekuo
Shenzhen, Guangdong PRV.
PRC POST CODE 518068
Telephone: 755-6851686
www.sullair.com
Fax: 219-874-1273
Telephone: 33-477968470
Fax: 33-477968499
www.championcompressors.com.au
Fax: 61-3-9703-8053
www.sullaireurope.com
Telephone: 61-3-9796-4000
Princess Highway
CHAMPION
COMPRESSORS, LTD.
219-874-1835
1-888-SULLAIR (785-5247)
www.sullair-asia.com
Fax: 755-6853473
SULLAIR CORPORATION
1.1
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
QTY
DESCRIPTION
KITS
ELEMENTS
KEY NO.
1.2
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
LUBRICATION
DESCRIPTION
Mixing of other lubricants within the compressor unit will void all warranties.
CAUTION
For proper amount of fluid fill, please consult Lubrication Guide in Section 3: Specifications in User Manual
02250164-607
16
KEY NO.
1.2
(I)
(I)
(I)
(I)
NOTE
PARTS LIST
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
ADAPTER,UNIT TO MOTOR
FRM,BSE P10
CVR,FORKPOCKET 3700
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
WASHER, METRIC-ISO7089- 12
DESCRIPTION
SEE BOM
MAIN MOTOR
883008-016
866408-025
866215-020
865412-240
839608-060
PART NO.
PARTS LIST
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
FRM,BSE P10
CVR,FORKPOCKET 3700
ELEMENT,CPLG 20R
DESCRIPTION
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, METRIC-ISO7089- 12
DESCRIPTION
MAIN MTR
COMPRESSOR
883212-254
883008-016
865412-240
838812-250
PART NO.
11
PARTS LIST
02250174-282 R01
1.5
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
DESCRIPTION
A2: TO UNIT
NOTES:
PART NO.
KEY
NO.
1.5
13
PARTS LIST
02250156-633R05
1.6
14
882508-125
882608-016
883633-016
883642-020
12
13
14
15
nipple,pipe-xs plt 1 x cl
connector, tube-m 1 x 1
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
tube,1-1/4-discharge p10-40hp
NOTE:
PART NO.
KEY
NO.
1.7
17
PARTS LIST
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
A3:
A2: TO AFTERCOOLER
KEY
NO.
KEY
NO.
1.8
19
PARTS LIST
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
NOTE:
KEY
NO.
21
PARTS LIST
02250156-634-R04
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
filter,coreless m27 6l
DESCRIPTION
PART NO.
KEY
NO.
23
PARTS LIST
02250174-301 R01
24
884227-012
VARIOUS
11
12
Q
T
Y
valve,thermal 1 1/2-18
filter,coreless m27 6l
NOTE:
DESCRIPTION
elbow,90 sae x orfs .75
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.
25
PARTS LIST
02250173-352 R03
26
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
WASHER, METRIC-ISO7089- 8
SUPT,AIROC ES8
VENTURI, ES8 16
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
PARTS LIST
02250173-351-R02
28
882508-125
882608-016
882608-030
883008-016
19
20
21
22
washer, metric-iso7089- 8
support,airoc p8 p10
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
02250156-137
02250164-164
DESCRIPTION
Q
T
Y
PART NO.
KEY
NO.
N
O
T
E
24
23
KEY
NO.
nut,hex locking m8
DESCRIPTION
884708-125
883306-030
PART NO.
Q
T
Y
29
N
O
T
E
PARTS LIST
02250174-285 R00
1.14 COOLING AND LUBRICATION SYSTEM, AIR-COOLED CENTRIFUGAL FAN, 50/60HZ 40HP
30
washer, metric-iso7089- 8
1
1
support,airoc es8
venturi,es8 16
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
NOTES:
KEY
NO.
1.14 COOLING AND LUBRICATION SYSTEM, AIR-COOLED CENTRIFUGAL FAN, 50/60HZ 40HP
31
PARTS LIST
02250185-892 R00
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.
DESCRIPTION
2.
Q
T
Y
PART NO.
1.
NOTES:
KEY
NO.
33
PARTS LIST
02250185-891 R00
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.
5.
6.
7.
3.
4.
DESCRIPTION
2.
Q
T
Y
PART NO.
1.
NOTES:
KEY
NO.
35
PARTS LIST
02250171-765-R00
MOISTURE DRAINSTANDARD
36
02250046-110
02250071-380
02250167-603
02250170-783
250025-859
842215-004
Q
T
Y
DESCRIPTION
hose,nylon 1/4
02250171-245
PART NO.
KEY
NO.
37
PARTS LIST
02250182-810 R01
38
02250046-110
02250071-380
02250144-841
02250167-603
02250182-545
250024-685
842215-004
Q
T
Y
DESCRIPTION
PART NO.
KEY
NO.
39
PARTS LIST
02250183-721 R01
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
DESCRIPTION
PART NO.
KEY
NO.
Q
T
Y
DESCRIPTION
KEY
NO.
41
PARTS LIST
02250170-758 R01
42
02250071-362
02250071-380
02250167-603
02250170-783
049905
250025-850
842215-004
866304-015
868902-010
868902-010
TO AIROUT BRACKET
10
11
A1
A2
A3
A4
hose,nylon 1/4(ft)
bushing,red-brs-1/2"x1/4"
02250046-110
DESCRIPTION
PART NO.
KEY
NO.
Q
T
Y
N
O
T
E
43
PARTS LIST
02250157-077-R07
44
02250155-962
02250155-963
250025-926
811502-025
847815-050
869825-025
20
21
22
23
Q
T
Y
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
Blowdown subassembly
Sequencing subassembly
Flow
DESCRIPTION
nipple, pipe-hx brass 1/4 x 1/4
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
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
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
A3- PORT 1
A2- PORT 3
A1- PORT 2
KEY
NO.
47
N
O
T
E
PARTS LIST
02250156-917-R05
48
250025-849
250025-858
250034-430
21
22
23
Q
T
Y
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
WASHER, METRIC-ISO7089- 8
BLOCK,TERMINAL KT3
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
50
PART NO.
Q
T
Y
DESCRIPTION
A6: SOLENOID 4
A5: SOLENOID 1
A3:
A1: TO FRAME
KEY
NO.
PART NO.
Q
T
Y
DESCRIPTION
KEY
NO.
51
PARTS LIST
02250165-276-R03
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
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
A2: P2-PACKAGE DISCHARGE PRESSURE
A3: P1-TO SUMP TANK WET SUMP PRESSURE
A4: T1-TO SUMP TANK WET DISCHAGE TEMPERATURE
A5: SOLENOID 1
A6: SOLENOID 4
A7: SOLENOID 5-ELECTRIC DRAIN
A8: FAN MOTOR CONNECTION
A9: MOTOR WIRING
A10: SCD DRAIN OPTION
A11: DRYER OPTION
A12: HOLE TO BE DRILLED IN BOX AS NEEDED
A13: HEATER OPTIONS
A14: ENCLOSURE HEATER MOUNTED INSIDE TOP OF STARTER BOX
A15: DRYER CTL POWER - 24VDC
A16: DRYER COMPRESSOR MOTOR POWER
A17: PHASE MONITOR OPTION
A18: TO AIR FILTER
A19: INLET PRESSURE SWITCH OPTION MOUNT TO FAN MOTOR SUPPORT
A20: DIFFERENTIAL PRESSURE SWITCH OPTION
A21: T3-TO INTEGRAL DRYER EVAPORATOR DRYER DEWPOINT TEMPERATURE
A22: CSA OPTION
A23: OTHER OPTIONS
Q1: SEE ASSY DRAWINGS:
02250169-671 DWG,START P8/10 VSD TAB
KEY
NO.
PARTS LIST
02250165-275-R03
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
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
A2: P2-PACKAGE DISCHARGE PRESSURE
A3: P1-TO SUMP TANK WET SUMP PRESSURE
A4: T1-TO SUMP TANK WET DISCHAGE TEMPERATURE
A5: SOLENOID 1
A6: SOLENOID 4
A7: SOLENOID 5-ELECTRIC DRAIN
A8: FAN MOTOR CONNECTION
A9: MOTOR WIRING
A10: SCD DRAIN OPTION
A11: DRYER OPTION
A12: HOLE TO BE DRILLED IN BOX AS NEEDED
A13: HEATER OPTIONS
A14: ENCLOSURE HEATER MOUNTED INSIDE TOP OF STARTER BOX
A15: DRYER CTL POWER - 24VDC
A16: DRYER COMPRESSOR MOTOR POWER
A17: PHASE MONITOR OPTION
A18: TO AIR FILTER
A19: INLET PRESSURE SWITCH OPTION MOUNT TO FAN MOTOR SUPPORT
A20: DIFFERENTIAL PRESSURE SWITCH OPTION
A21: T3-TO INTEGRAL DRYER EVAPORATOR DRYER DEWPOINT TEMPERATURE
A22: CSA OPTION
A23: OTHER OPTIONS
Q1: SEE ASSY DRAWINGS:
02250169-665 DWG,START P8/10 YD N4 TAB
KEY
NO.
PARTS LIST
02250179-957-R00
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
washer, metric-iso7089- 8
relay,phase monitor ce
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
A6: SOLENOID 4
A5: SOLENOID 1
A1: TO FRAME
KEY
NO.
57
N
O
T
E
PARTS LIST
02250179-958-R00
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
washer, metric-iso7089- 8
relay,phase monitor ce
starter,1.9a fv ch-it
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
A6: SOLENOID 4
A5: SOLENOID 1
A1: TO FRAME
KEY
NO.
59
N
O
T
E
PARTS LIST
02250169-587 R06
CONTROL STARTERMFV
60
02250154-052
250021-694
250014-827
250014-127
02250154-359
10
11
12
DECAL,MICROPROCESSOR OVERLAY
CTL,DISPLAY WS
CNTOR,400A 3P 24VDC XT
CNTOR,225A 3P 24VDC XT
CNTOR,150A 3P 24VDC XT
CNTOR,115A 3P 24VDC XT
CNTOR,95A 3P 24VDC XT
CNTOR,80A 3P 24VDC XT
CNTOR,65A 3P 24VDC XT
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
02250170-761
13
LUG, GROUND
02250167-818
02250169-621
DESCRIPTION
PART NO.
KEY
NO.
Q
T
Y
02250145-195
250021-692
02250167-849
250019-773
18
19
20
21
Q
T
Y
RELAY,OVERLOAD 32A
DESCRIPTION
-MANUFACTURER: CUTLER-HAMMER
NOTES:
02250145-194
PART NO.
18
KEY
NO.
61
PARTS LIST
02250169-659 R07
CONTROL STARTERWYE-DELTA
62
02250145-195
19
Q
T
Y
LUG, GROUND
DECAL,MICROPROCESSOR OVERLAY
CTL,DISPLAY WS
RELAY,OVERLOAD 32A
CNTOR,225A 3P 24VDC XT
CNTOR,150A 3P 24VDC XT
CNTOR,95A 3P 24VDC XT
CNTOR,65A 3P 24VDC XT
CNTOR,32A 3P 24VDC XT
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.
02250167-843
02250167-849
250019-773
20
20
21
Q
T
Y
DESCRIPTION
-MANUFACTURER: CUTLER-HAMMER
NOTES:
02250145-194
PART NO.
19
KEY
NO.
63
PARTS LIST
02250169-392R02
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.
LUG, GROUND
CTL, DISPLAY WS
DESCRIPTION
02250165-108
02250157-716
02250157-717
02250157-718
02250157-719
02250157-725
02250157-726
02250157-727
65
340-187
340-187
85
85
85
85
35
340-187
LUG
PARTS LIST
02250178-751-R00
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
LUG, GROUND
CTL, DISPLAY WS
DESCRIPTION
PART NO.
KEY
NO.
SULLAIR P/N
02250167-818
02250167-817
26.6
29.2
LUG
10.6
10.6
67
TERMINALS
PARTS LIST
02250178-681-R00
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
LUG, GROUND
CTL, DISPLAY WS
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.
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
70
883008-016
20
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.
71
PARTS LIST
02250181-033 R01
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
PANEL,ROOF VARIOUS
DESCRIPTION
Q
T
Y
PART NO.
KEY
NO.
73
PARTS LIST
02250168-700-R01
74
250019-520
18
WASHER, METRIC-ISO7089- 8
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.
75
PARTS LIST
02250182-890 R01
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
WASHER, METRIC-ISO7089- 8
DESCRIPTION
Q
T
Y
PART NO.
KEY
NO.
77
PARTS LIST
02250157-700 R05
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,danger electrocution
decal,danger hi voltage
decal,s-energy black
decal,black www.sullair.com
decal,pe designation
DESCRIPTION
02250075-045
02250075-540
02250057-624
PART NO.
KEY
NO.
N
O
T
E
VOLTAGE
SERIES
RIVET
NAMEPLATE
FLUID
407408
Q
T
Y
decal,volts-various
rivet,pop-various
decal,fluid-various
sign,warning-hot surfaces
decal,rotation 3.5 lg
decal,warning-autostart
decal,fork lifting
DESCRIPTION
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
80
02250157-703
24
decal,black www.sullair.com
decal,microprocessor overlay
decal,rotation 3.5 lg
decal,warning-autostart
decal,fork lifting
sign,warning-sever-fan-indus
decal,danger electrocution
decal,danger hi voltage
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, sullair side graphic
decal,sump fluid drain p8/p10
various
various
various
various
various
sign,warning-hot surfaces
decal,integral dryer
decal,s-energy black
N
O
T
E
81
Q1: A * PRECEEDING THE PART NUMBER INDICATES DECALS CONTAINED IN KIT 02250069-604
A8:
DESCRIPTION
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.
PARTS LIST
DECAL GROUP
82
042218
02250110891
049855
16
20
Q
T
Y
sign, warningseverfanindus
DESCRIPTION
049850
02250146385
250027935
26
18
PART NO.
KEY
NO.
83
PARTS LIST
DECAL GROUP
84
250017903
049852
250003144
407408
041065
23
19
22
27
15
Q
T
Y
decal, warningautostart
DESCRIPTION
049685
PART NO.
17
KEY
NO.
85
PARTS LIST
DECAL GROUP
86
Q
T
Y
decal, pe designation
DESCRIPTION
02250162215
02250157732
10
13
02250157703
02250158358
02250155495
02250161967
02250075540
12
02250075045
11
PART NO.
KEY
NO.
87
PARTS LIST
DECAL GROUP
88
1
1
02250069394
02250069395
(I)
02250069389
fluids, fluid decal
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
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 in
DESCRIPTION
02250145-206
02250146-385
36
02250168-920
34
35
PART NO.
KEY
NO.
93
PARTS LIST
NOTES
94
NOTES
SULLAIR CORPORATION
CUSTOMER CARE
for PARTS and Service
1-888-SULLAIR (7855247)
219-874-1835
USER MANUAL
WS CONTROLLER USER INTERFACE MANUAL
PART NUMBER:
02250202-046 R01
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual or,
misuse of this equipment will
VOID its warranty!
KEEP FOR
FUTURE
REFERENCE
SULLAIR CORPORATION
02250201-216
and all subsequent software part numbers.
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:
TABLE OF CONTENTS
SECTION 1SAFETY
5
1.1
GENERAL
1.2
1.3
PRESSURE RELEASE
1.4
1.5
MOVING PARTS
1.6
1.7
1.8
ELECTRICAL SHOCK
1.9
LIFTING
1.10
ENTRAPMENT
1.11
SAFETY WARNINGS
2.1
INTRODUCTION
11
2.2
12
2.3
WS START UP PROCEDURES
13
2.4
SHUTDOWN PROCEDURE
SECTION 3ADJUSTMENTS
15
3.1
INTRODUCTION
15
3.2
16
3.3
18
3.4
18
3.5
REMOTE UNLOAD
SECTION 4DESCRIPTION
19
4.1
INTRODUCTION
19
4.2
19
4.3
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
32
5.4
32
5.5
INTERNAL BATTERY
6.1
OVERVIEW
35
6.2
INSTALLATION
Section 1
SAFETY
NOTE
1.2
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL.
1.1
GENERAL
PERSONAL PROTECTIVE
EQUIPMENT
1.3
PRESSURE RELEASE
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.
1.4
Keep oily rags, trash, leaves, litter or other combustibles out of and away from the compressor.
1.5
MOVING PARTS
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
1.6
1.7
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.
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
SECTION 1
I.
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.
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
2.2
WS CONTROLLER PANEL
LAYOUT
START
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
11
WS START UP PROCEDURES
SECTION 2
ENTER
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.
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
2.4
SHUTDOWN PROCEDURE
NOTE
The system may require sump blowdown
(typically below 10 psi) to be completed
prior to restarting.
pad to
WARNING
13
NOTES
14
Section 3
ADJUSTMENTS
3.1
INTRODUCTION
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
15
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
16
SECTION 3
SECTION 3
17
CALIBRATION OF P2
PRESSURE TRANSDUCERS
3.5
REMOTE UNLOAD
18
SECTION 3
Section 4
DESCRIPTION
4.1
INTRODUCTION
4.2
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
Power On Indicator
(GREEN LED)Lights
19
DISPLAY SCREEN
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
the
current
sump
20
SECTION 4
pad is pressed.
4.5
OPERATING MODES
4.6
OPERATING STATES
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.
21
as
the
compressor
is
when
the
SECTION 4
the
4.7
the
set
the
the
when
the
22
SECTION 4
4.8
WARNING MESSAGES
Power InterruptionIndicates
interruption has occurred.
that
power
temperatures
are
23
SECTION 4
WARNING
The compressor may restart automatically
after power has been restored following a
power failure.
4.9
FAULT MESSAGES
24
SECTION 4
Use the UP
or DOWN
the next Diagnostic view.
Ethernet Comm
failed to a keypad.
View.
Figure 4-13 Illustrates how to navigate between the
Normal View and the Diagnostic Views.
Pad
external
phase
ErrorCommunications
have
pump
motor's
drive
is
not
25
SECTION 4
Figure 4-12: Typical Alarm View
26
Section 5
TROUBLESHOOTING
5.1
TROUBLESHOOTING
INTRODUCTION
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
PROBABLE CAUSE
REMEDY
Analyze Fluid
27
SECTION 5
PROBABLE CAUSE
REMEDY
Change Fluid
Maintenance due.
Controller Watchdog
Controller fault.
Dryer Fault
Dryer Overload
Dryer Overload Fault
Dryer Service
Release button.
Check wiring.
Ethernet disabled
Replace filter.
Sensor failure.
28
SECTION 5
PROBABLE CAUSE
REMEDY
High pressure.
High Pressure A
High Separator dP
Misadjustment
High Pressure B
Cooler plugged.
Illegal State
Controller fault.
Check wiring.
Module Network Error;
Communication has failed between
the Display Module, I/O Module
and other modules.
Reduce demands.
Increase capacity.
High Temperature 1
High Temperature 2
High Temperature 3
Check sensor.
29
SECTION 5
PROBABLE CAUSE
REMEDY
Low Temperature 1
Low Temperature 2
Low Temperature 3
Memory Error
The controller I/O board has failed. Board replacement required. Contact Sullair
Factory Service.
Not Commissioned
Controller replacement
Option Input
Option Input Run
Power Interruption
30
SECTION 5
PROBABLE CAUSE
REMEDY
Replace Battery
Replace battery.
Replace separator.
High Separator dP
Check wiring.
Starter
Controller fault.
Controller fault.
Controller fault.
Controller fault.
Controller commissioned
incorrectly.
Incorrect VSD
VSD1 Response
31
SECTION 5
High
Limit
Low
Limit
Comment
Type
Sensor
Separator Pressure ^
Warning
P2-P1+offset
10 psid
Sump Pressure
Fault
P1
135 psig
5 psig
150 psig
5 psig
175 psig
5 psig
200 psig
5 psig
165 psig
5 psig
200 psig
5 psig
125 psig
10 psig
150 psig
10 psig
175 psig
10 psig
200 psig
10 psig
155 psig
10 psig
200 psig
10 psig
Line Pressure
5.4
Fault
P2
Warning
T1
225 F
0F
Fault
T1
235/255F
0F
5.5
INTERNAL BATTERY
32
Time delayed/immediate
SECTION 5
33
NOTES
34
Section 6
OVERVIEW
6.2
INSTALLATION
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