USER MANUAL

INDUSTRIAL AIR COMPRESSOR

1800, 2200, 3000, 1800V, 2200V, 3000V
18, 22 & 30KW/25 & 30 & 40HP

PART NUMBER:
02250176-180 R02
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions ©
SULLAIR CORPORATION
and procedures in this manual or, The information in this manual is current
as of its publication date, and applies to
misuse of this equipment will compressor serial number:
VOID its warranty!
201003010000
and all subsequent serial numbers.
 AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.

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

SULLAIR CUSTOMER CARE TRAINING DEPARTMENT

1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
 TABLE OF CONTENTS
SECTION 1—SAFETY
3 1.1 GENERAL
3 1.2 PERSONAL PROTECTIVE EQUIPMENT
3 1.3 PRESSURE RELEASE
4 1.4 FIRE AND EXPLOSION
4 1.5 MOVING PARTS
5 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
5 1.7 TOXIC AND IRRITATING SUBSTANCES
6 1.8 ELECTRICAL SHOCK
6 1.9 LIFTING
7 1.10 ENTRAPMENT

SECTION 2—DESCRIPTION
9 2.1 INTRODUCTION
9 2.2 DESCRIPTION OF COMPONENTS
10 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION
11 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION-
AL DESCRIPTION
13 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION
15 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
17 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
17 2.8 INTEGRAL DRYER OPTION
17 2.9 VARIABLE SPEED DRIVE (VSD) COMPONENTS
18 2.10 VSD CONTROL SYSTEM — FUNCTIONAL DESCRIPTION

SECTION 3—SPECIFICATIONS
21 3.1 TABLE OF SPECIFICATIONS
23 3.2 LUBRICATION GUIDE
24 3.3 APPLICATION GUIDE
24 3.4 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTE-
NANCE—FLUID FILTER AND SEPARATOR
26 3.5 AIR-COOLED, IDENTIFICATION 25-30HP
28 3.6 AIR-COOLED, IDENTIFICATION 40HP
TABLE OF CONTENTS

30 3.7 AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 25-30HP

32 3.8 AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 40HP
34 3.9 PIPING AND INSTRUMENTATION, AIR-COOLED
36 3.10 PIPING AND INSTRUMENTATION, 1800-2200 W/INTEGRAL DRYER
38 3.11 WIRING DIAGRAM—MFV, AIR-COOLED
40 3.12 WIRING DIAGRAM—MFV, AIR-COOLED INTEGRAL DRYER
42 3.13 WIRING DIAGRAM—VSD, PARALLEL WYE
44 3.14 WIRING DIAGRAM—YD CE

SECTION 4—INSTALLATION
47 4.1 MOUNTING OF COMPRESSOR
47 4.2 VENTILATION AND COOLING
48 4.3 SERVICE AIR PIPING
50 4.4 COUPLING ALIGNMENT CHECK
50 4.5 FLUID LEVEL CHECK
50 4.6 ELECTRICAL PREPARATION
51 4.7 MOTOR ROTATION DIRECTION CHECK
51 4.8 FAN MOTOR ROTATION CHECK

SECTION 5—WS CONTROLLER

53 5.1 CONTROLLER KEYPAD
54 5.2 LCD DISPLAY
55 5.3 LED LIGHTS

SECTION 6—MAINTENANCE
57 6.1 GENERAL
57 6.2 DAILY OPERATION
57 6.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
57 6.4 MAINTENANCE EVERY 2000 HOURS
58 6.5 FLUID MAINTENANCE
58 6.6 FILTER MAINTENANCE
59 6.7 AIR FILTER MAINTENANCE
59 6.8 SEPARATOR MAINTENANCE
61 6.9 TROUBLESHOOTING—
INTRODUCTION
 Section 1
SAFETY
NOTE
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
the precautionary statements contained herein are
applicable to most compressors and the concepts
behind these statements are generally applicable to
all compressors.
1.2 PERSONAL PROTECTIVE
EQUIPMENT
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 regula-
tions 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 elec-
trical protective equipment, as well as noise
exposure administrative and/or engineering con-
trols and/or personal hearing protective equip-
ment.
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 exceed-
ing 1/2" (13mm) inside diameter is to be con-
nected to the shut-off (throttle) valve, to reduce
pressure in case of hose failure, per OSHA Stan-
dard 29 CFR 1926.302(b)(7) and/or any applica-
ble Federal, State and Local codes, standards
and regulations.
B. When the hose is to be used to supply a mani-
fold, install an additional appropriate flow-limiting
valve between the manifold and each air hose
exceeding 1/2" (13mm) inside diameter that is to
be connected to the manifold to reduce pressure
in case of hose failure.
C. Provide an appropriate flow-limiting valve at the
beginning of each additional 75 feet (23m) of
hose in runs of air hose exceeding 1/2" (13mm)
3

inside diameter to reduce pressure in case of
hose failure.
D. Flow-limiting valves are listed by pipe size and
flow-rated. Select appropriate valves accordingly,
in accordance with their manufacturer's recom-
mendations.
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 manufac-
turer'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 effec-
tive chip guarding and personal protective equip-
ment 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 anti-
freeze compound.
C. DO NOT permit fluids, including air line anti-icer
system antifreeze compound or fluid film, to
4
SECTION 1
accumulate on, under or around acoustical mate-
rial, or on any external surfaces of the air com-
pressor. 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 acous-
tical 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 flam-
mable solvents for cleaning purposes.
D. Disconnect and lock out all power at source prior
to attempting any repairs or cleaning of the com-
pressor 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 oth-
erwise 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 sup-
port 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 ser-
vicing and operating the compressor.
I. Keep oily rags, trash, leaves, litter or other com-
bustibles 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.
D. Keep access doors, if any, closed except when
making repairs or adjustments.
E. Make sure all personnel are out of and/or clear of
the compressor prior to attempting to start or
operate it.
F. Disconnect and lock out all power at source and
verify at the compressor that all circuits are de-
energized to minimize the possibility of acciden-
tal start-up, or operation, prior to attempting
repairs or adjustments. This is especially impor-
tant 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 assis-
tance promptly in case of injury. DO NOT ignore
small cuts and burns as they may lead to infec-
tion
1.7 TOXIC AND IRRITATING
SUBSTANCES
A. DO NOT use air from this compressor for respi-
ration (breathing) except in full compliance with
OSHA Standards 29 CFR 1910 and/or any appli-
cable Federal, State or Local codes or regula-
tions.
DANGER
Death or serious injury can result from
inhaling compressed air without using
proper safety equipment. See OSHA stan-
dards 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 utili-
zation equipment and DO NOT discharge air
from these systems into unventilated or other
confined areas.
C. Operate the compressor only in open or ade-
quately 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 sub-
stances.
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 immedi-
ately.
H. DO NOT store air line anti-icer system antifreeze
compound in confined areas.
I. The antifreeze compound used in air line anti-
freeze systems contains methanol and is toxic,
harmful or fatal if swallowed. Avoid contact with
the skin or eyes and avoid breathing the fumes. If
5

swallowed, induce vomiting by administering a
tablespoon of salt, in each glass of clean, warm
water until vomit is clear, then administer two
teaspoons of baking soda in a glass of clean
water. Have patient lay down and cover eyes to
exclude light. Call a physician immediately.
1.8 ELECTRICAL SHOCK
A. This compressor should be installed and main-
tained in full compliance with all applicable Fed-
eral, State and Local codes, standards and
regulations, including those of the National Elec-
trical Code, and also including those relative to
equipment grounding conductors, and only by
personnel that are trained, qualified and dele-
gated 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.
6
SECTION 1
DANGER
All field equipment must be tested for elec-
trostatic fields prior to servicing or making
contact with the machine using the follow-
ing or equivalent test equipment:
• 90-600 VAC: Volt detector such as
Fluke Model 1AC-A
• 600-7000 VAC: Voltage detector
such as Fluke Networks Model
C9970
It is the responsibility of each organization
to provide/arrange training for all their
associates expected to test for electrostatic
fields.
1.9 LIFTING
A. If the compressor is provided with a lifting bail,
then lift by the bail provided. If no bail is provided,
then lift by sling. Compressors to be air-lifted by
helicopter must not be supported by the lifting
bail but by slings instead. In any event, lift and/or
handle only in full compliance with OSHA stan-
dards 29 CFR 1910 subpart N and/or any appli-
cable 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 condi-
tion 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 when-
ever 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 obsta-
cles 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 sud-
den 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 possi-
bly latching the door with personnel inside.
B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.
7
NOTES

8

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.
1800-3000 USER MANUAL
2.2 DESCRIPTION OF
COMPONENTS
Refer to Figure 2-1. The components and
assemblies of the air compressor are clearly shown.
The complete package includes compressor, electric
motor, starter, compressor inlet system, compressor
discharge system, compressor lubrication and
cooling system, capacity control system, WS
Controller, aftercooler, a combination separator and
trap, all mounted on a heavy gauge steel frame.
On air-cooled models, a fan draws air into the
enclosure over the fan and main motors through the
combined aftercooler and fluid cooler thereby
removing the compression heat from the
compressed air and the cooling fluid, and forces it
out the top of the machine.
This compressor model has easily accessible items
such as the fluid filter air/oil separator and control
valves. The inlet air filter is also easily accessible for
servicing.
9
1800-3000 USER MANUAL SECTION 2

Figure 2-1: Main Component Location

1. Moisture Separator 8. Starter Box

2. Sight Glass 9. Fan Motor
3. Fluid Port Fill 10. Air Filter
4. Separator/Sump Tank 11. Motor
5. Compressor Unit 12. Cooler
6. E-Stop 13. Fluid Filter
7. WS Controller 14. Variable Speed Drive
(where equipped)

2.3 SULLAIR COMPRESSOR

UNIT, FUNCTIONAL
DESCRIPTION
NOTE
Sullair air compressors feature the Sullair
compressor unit, a single-stage, positive With a Sullair compressor, there is no
displacement, flood lubricated type compressor. This maintenance or inspection of the internal
unit provides continuous compression to meet your parts of the compressor unit permitted in
needs. accordance with the terms of the war-
ranty.

The 1800, 2200 & 3000f Series compressors are

factory-filled with Sullube lubricant. For more

10
SECTION 2
information on fluid fill, refer to Section
Specifications on page 21.
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 com-
pressor 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 tempera-
ture 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
1800-3000 USER MANUAL
3: through an aftercooler and separator then to
your service line while the fluid is being
cooled in preparation for reinjection.
2.4 COMPRESSOR COOLING
AND LUBRICATION
SYSTEM, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-2. The Cooling and Lubrication
System consists of a fan, fan motor, radiator-type
aftercooler/fluid cooler, full flow fluid filter, thermal
valve, and interconnecting hoses. The pressure in
the separator/sump tank causes fluid flow by forcing
the fluid from the high pressure area of the separator/
sump tank to an area of lower pressure in the
compressor unit.
Fluid flows from the bottom of the separator/sump
tank to the thermal valve. The thermal valve is fully
open when the fluid temperature is below 185ûF
(85ûC) [200ûF (93ûC) for 24KT] and pressures are
rated above 150 psig. The fluid passes through the
thermal valve, the main filter and directly to the
compressor unit where it lubricates, cools and seals
the rotors and the compression chamber.
As the discharge temperature rises above 185ûF
(85ûC), due to the heat of compression, the thermal
valve begins to adjust and a portion of the fluid then
flows through the cooler. From the cooler the fluid
flows to the fluid filter and then on to the compressor
unit.
A portion of the fluid flowing to the compressor is
routed to the anti-friction bearings which support the
rotors inside the compressor unit.
The fluid filter has a replacement element and an
integral pressure bypass valve. A message on the
WS Controller indicates when the fluid filter needs to
be changed.
11
1800-3000 USER MANUAL SECTION 2

Figure 2-2: Cooling and Lubrication System

12
SECTION 2
2.5 COMPRESSOR DISCHARGE
SYSTEM, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-3. The compressor unit discharges
the compressed air/fluid mixture into the combination
separator/sump tank.
The separator/sump tank has three basic functions:
1. It acts as a primary fluid separator.
2. Serves as the compressor fluid sump.
3. Houses the final fluid separator.
The compressed air/fluid mixture enters the
separator/sump tank and flows through an internal
baffle system. The direction of movement is changed
and its velocity significantly reduced, thus causing
large droplets of fluid to form and fall to the bottom of
the separator/sump tank. The fractional percentage
of fluid remaining in the compressed air collects on
the surface of the separator element as the
compressed air flows through the separator. A return
line (or scavenge tube) leads from the dry side of the
separator/sump to a medium pressure region of the
compressor unit. Fluid collecting on the bottom of the
separator is returned to the compressor by a
pressure differential between the separator/sump
tank and the compressor. A visual sight glass is
located on the return line to observe this fluid flow.
There is also an orifice in this return line (protected
by a strainer) to assure proper flow. The separator
system reduces the fluid carry-over to less than 1
ppm (parts per million) for Sullube, or 2 ppm for 24KT
at nominal rated pressures. A message on the
controller indicates if abnormal pressure drop
through the separator develops. At this time,
separator element replacement is necessary.
1800-3000 USER MANUAL
A minimum pressure/check valve, located
downstream from the separator, assures a minimum
separator/sump tank pressure of 50 psig (3.4 bar)
during loaded conditions. This pressure is necessary
for proper air/fluid separation and proper fluid
circulation.
A terminal check valve is incorporated into the
minimum pressure/check valve to prevent
compressed air in the service line from bleeding back
into the separator/sump tank on shutdown and
during operation of the compressor in an unloaded
condition.
A pressure relief valve (located on the wet side of the
separator) is set to open if the separator/sump tank
pressure exceeds the separator/sump tank rating.
The WS Controller will shut down the compressor if
the discharge temperature reaches 235ûF (113ûC).
WARNING
DO NOT remove caps, plugs, and/or other
components when compressor is running
or pressurized.
Stop compressor and relieve all internal
pressure before doing so.
Fluid is added to the separator/sump tank via a
capped fluid filler opening, placed low on the tank to
prevent overfilling of the separator/sump tank. A
sight glass enables the operator to visually monitor
the separator/sump tank fluid level.
13
1800-3000 USER MANUAL SECTION 2

Figure 2-3: Discharge System

14
SECTION 2 1800-3000 USER MANUAL

2.6 CONTROL SYSTEM, Start Mode

FUNCTIONAL DESCRIPTION —0 TO 50 PSIG (0 TO 3.5 Bar)

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.
When the compressor “ ” (START) pad is
depressed, the separator/sump tank pressure will
quickly rise from 0 to 50 psig (0 - 3.4 bar). The
compressor initially starts unloaded with the solenoid
valve open and the inlet valve closed. It then
switches to full load when full rpm has been
achieved. During this period, both the pressure
regulator and the solenoid valve are closed, the inlet
valve is fully open and the compressor pumps are at
full rated capacity. The rising compressor air
pressure is isolated from the service line in this
phase by the minimum pressure valve set at
approximately 50 psig (3.4 bar).

1. Air Outlet 5. Blowdown Valve

2. Solenoid Valve 6. Minimum Pressure/Check Valve
3. Regulator 7. Separator/Sump Tank
4. Air Inlet
Figure 2-4: Standard Sequencing Control System

15
1800-3000 USER MANUAL
Full Load Mode
—50 to 100 PSIG (3.4 to 6.9 BAR)
When the compressed air pressure rises above 50
psig (3.4 bar), the minimum pressure valve opens
allowing compressed air to flow into the service line.
From this point on, the line air pressure is continually
monitored by the WS Controller. The pressure
regulator and the solenoid valve remain closed
during this phase. The inlet valve is in the fully open
position as long as the compressor is running at 100
psig (6.9 bar) or below.
Modulating Mode
—100 to 110 PSIG (6.9 to 7.6 BAR)
If less than the rated capacity of compressed air is
being used, the service line pressure will rise above
100 psig (6.9 bar). The pressure regulator valve
gradually opens, directing air pressure to the inlet
control valve, reducing air entering the compressor
until it matches the amount of air being used. The
control system functions continually in this manner
between the limits of 100 to 110 psig (6.9 to 7.6 bar)
in response to varying demands from the service
line.
The integrated inlet valve has an orifice which vents
a small amount of air to the compressor inlet when
the pressure regulator controls the inlet control valve.
The orifice also bleeds any accumulated moisture
from the control lines.
Unload Mode
—In Excess of 110 PSIG (7.6 BAR)
When a relatively small amount or no air is being
used, the service line pressure continues to rise.
When it exceeds 110 psig (7.6 bar), the WS
Controller control system de-energizes the solenoid
valve allowing separator/sump tank air pressure to
be supplied directly to close the inlet valve.
Simultaneously, the solenoid valve sends a
pneumatic signal to the blowdown valve. The
blowdown valve opens to the atmosphere, located in
the compressor intake, reducing the separator/sump
tank pressure to approximately 17 psig (1.2 bar). The
16
SECTION 2
check valve in the air service line prevents line
pressure from returning to the separator/sump tank.
When the line pressure drops to the low setting (cut-
in pressure; usually 100 psig (6.9 bar) on low
pressure (7 bar) compressors and 125 psig (8.6 bar)
on high pressure (9 bar) compressors, 150 psig (10.3
bar) on (10 bar) compressors, 175 psig (12.0 bar) on
(12 bar) compressors), the WS Controller energizes
the solenoid valve and allows the blowdown valve to
close. The re-energized solenoid valve again
prevents line pressure from reaching the inlet control
valve. Should the pressure begin to rise, the
pressure regulator will resume its normal function as
previously described.
Load/No Load Control
If desired by the customer, the compressor can be
set to operate load/no load without modulating
control. This control mode is often selected when a
large amount of compressed air storage (air tank) is
available. Using the WS Controller keypad, select
“load/no load control” from the menu. On a machine
rated for 100 psig (7 bar) the compressor will run in
the full load mode up to 100 psig (7 bar). If less than
the rated capacity is required, pressure will rise
above 100 psig and the WS Controller will de-
energize 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,
FUNCTIONAL DESCRIPTION
Refer to Figure 2-5. The compressor air inlet system
consists of a dry-type air filter, a restriction gauge
and an air inlet valve.
The restriction gauge (located on the air filter)
indicates the condition of the air filter by showing red
when filter maintenance is required.
The poppet-type modulating air inlet valve directly
controls the amount of air intake to the compressor in
response to the operation of the pressure regulator.
Refer to Modulating Mode —100 to 110 PSIG (6.9 to
7.6 BAR) on page 16. The inlet valve also acts as a
check valve, thus preventing reverse rotation when
the compressor is shut down.
WARNING
“The Plastic Pipe Institute recommends
against the use of thermoplastic pipe to
transport compressed air or other com-
pressed 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.
1800-3000 USER MANUAL
2.8 INTEGRAL DRYER OPTION
An integral refrigerated dryer option is available. The
integral dryer is designed to work with the
compressor WS controller which controls dryer
starting and stopping, condensate drain valve
function and monitors dewpoint temperature and
dryer warnings and faults. The dryer is fully
connected from the factory and is ready to run when
the compressor is installed.
Detail of dryer operation and spare parts can be
found in a supplement Manual 02250174-308 which
is provided with your machine.
Per the controller default settings, on initial start-up
the compressor will run unloaded for 5 minutes,
allowing the dryer to run and cool down. This
prevents condensate from initially being allowed into
the compressed air stream. It also delays the supply
of compressed air from the compressor until the 5
minute cool-down period is completed. When the
automatic control mode is selected, the compressor
will stop after running unloaded for a prescribed time,
but the dryer will continue to run to ensure there will
not be a surge of condensate when the compressor
re-starts. For other settings and control options, refer
to the WS controller manual 02250165-411, or to
your authorized Sullair servicing distributor.
In case the compressor needs to operate while the
dryer is being serviced, the dryer can be bypassed,
and removed if necessary for service. To bypass the
dryer, disconnect the inlet hose to the dryer,
disconnect the outlet hose at the main service
connection, and re-connect the dryer inlet hose to the
main service connection. Remove the fuses
powering the dryer and control wiring located in the
compressor electrical box. The WS controller must
be set-up for the compressor to run on dryer fault. If
necessary, this can be reset by your authorized
Sullair servicing distributor.
2.9 VARIABLE SPEED DRIVE
(VSD) COMPONENTS
The VSD, located in the machine’s electrical
enclosure, works in concert with the WS Controller to
allow the compressor to match its output to the
current demand on the system. The drive’s heat sink
extends through the back of the enclosure, and is
cooled by air flowing through the compressor
enclosure.
17
1800-3000 USER MANUAL
2.10 VSD CONTROL SYSTEM —
FUNCTIONAL DESCRIPTION
Refer to Figure 2-4. The controls consist of:
• a VSD
• a solenoid valve
• a regulating valve
• and an inlet valve.
Depending on the model, a compressor can be
operated at a setpoint pressure from 60 to 175 psig
(4.1 to 12.1 bar). The WS Controller automatically
sets the frequency range based on the selected
pressure. (The compressor’s operating range is on
its nameplate.)
The following paragraphs apply to a compressor with
a 100 psig (6.9) operating pressure and a 6 psi (0.4
bar) load delta setting.
NOTE
The load delta default setting is 10 psi (0.7
bar). Sullair recommends a setting of 6
psi (0.4) for the most efficient operation.
Compressors with different pressure operating
ranges perform in the same manner.
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
SECTION 2
FULL LOAD MODE - 50 TO 100 PSIG (3.4 TO
6.9 BAR)
When the compressed air pressure rises above 50
psig (3.4 bar) the minimum pressure valve opens
allowing compressed air to flow into to the service
line. From this point on the WS Controller monitors
the line pressure which controls the VSD. The
pressure regulator and solenoid valves remain
closed with the inlet valve fully open, running at 100
psig (6.9 bar) or lower.
VSD PART LOAD CONTROL—
The service line pressure increases to a value above
100 psig (6.9) if the demand is less than the
compressor’s rated capacity. In this condition, the
VSD slows the motor’s rpm which reduces the output
to match the demand. The drive continuously adjusts
the motor’s rpm to maintain a 100 psig (6.9 bar) line
pressure.The WS Controller maintains the correct
frequency when the VSD is operating in this mode.
MODULATING MODE- 100 TO 106 PSIG (7.3
TO 6.9 BAR)
During low demand periods and with the VSD
running at minimum speed, the line pressure can
continue to rise. When the line pressure reaches
101-102 psig (approximately 7 bar), the regulator
valve (Figure 2-4) gradually opens, directing air
pressure to the inlet control valve piston. This action
causes the inlet valve to partially close, thereby
reducing the air flow entering the compressor until it
matches the demand. The control system functions
continuously in this manner between less than 101
psig (7.0 bar) to 106 psig (7.3 bar), in response to
varying system demand. The pressure regulator has
an orifice which vents a small amount of air to the
atmosphere when the pressure regulator controls the
inlet valve. The orifice also bleeds off any
accumulated moisture from the control line. When
the discharge pressure rises above 106 psig (7.3
bar), or to a preset unload pressure, the compressor
unloads.
SECTION 2
UNLOAD MODE- IN EXCESS OF 106 PSIG (7.3
BAR)
When there is no demand or it is at a minimal level,
the service line pressure continues to rise. When it
exceeds 106 psig (7.3 bar), or reaches a preset
unload pressure value, the WS control system de-
energizes the solenoid valve allowing separator/
sump tank air pressure to be supplied directly which
closes the inlet valve. The solenoid valve
simultaneously sends a pneumatic signal to the blow
down valve which opens to the atmosphere, and
reduces the separator/sump tank pressure. The
check valve in the air service line prevents line
1800-3000 USER MANUAL
pressure from back-flowing to the separator/sump
tank. The compressor will shut down after the
programmed unload time setting expires (the default
setting is zero [0] minutes for an immediate shutdown
upon unload). When the line pressure drops to the
low pressure setting of 100 psig (6.9 bar) the WS
Controller starts the motor and energizes the
solenoid valve which closes the blowdown valve. The
re-energized solenoid valve prevents line pressure
from reaching the inlet control valve, thereby allowing
it to fully open, and the compressor supplies
compressed air to the system.
19
1800-3000 USER MANUAL SECTION 2

Figure 2-5: Air Inlet System

1. Air FIlter 2. Inlet Valve

3. Compressor Unit

20
 1800-3000 USER MANUAL

Section 3

SPECIFICATIONS
3.1 TABLE OF SPECIFICATIONS
DIMENSIONS
Length Width Height Weight
MODEL HP in mm in mm in mm lbs kg
1800 Series
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
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
3000 Series
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

DIMENSIONS
Length Width Height Weight
MODEL HP in mm in mm in 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
2200 Series with Integral Dryer
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
3000 Series with Integral Dryer
3009 40 53.2 1351 31.5 800 53.2 1351 1814 823
3010 40 53.2 1351 31.5 800 53.2 1351 1814 823
3012 40 53.2 1351 31.5 800 53.2 1351 1814 823

21
1800-3000 USER MANUAL SECTION 3

Table 3-1: Compressor Specifications

COMPRESSOR: STANDARD MODELS:

Type: Rotary Screw

Standard Speed Operating Pressure (II): 100 psi (7 bar) 125 psig (9 bar) 150 psig (10 bar) 175
psig (12 bar)

Bearing Type: Anti-friction

Ambient Temperature (Max.) (III): 104°(40°C)

Cooling: Pressurized Fluid

Compressor Fluid: Sullair Sullube

Separator/Sump Tank Capacity: 2.5 Gallons (9.5 liters)

Control: WS Controller

(II) Special compressors are available for operation at higher pressures.

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

MOTOR (IV): STANDARD MODELS:

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

Type: C-Flanged, Open Drip proof, Epact Efficiency, Three Phase,

230/460 Hz, 380-515 (400) 50Hz

Maximum Ambient Temperature 104°(40°C)

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

Starter: Full Voltage Magnetic, Wye-Delta

Options Available: VSD Optional, 460V, 575V, 400V 50 Hz

Speed—25, 30 HP: 1765 RPM (60 Hz) or 1475 RPM (50 Hz)

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

NOTE
For latest sound test data, consult Sullair
factory.

22
SECTION 3 1800-3000 USER MANUAL

3.2 LUBRICATION GUIDE Contamination of non-detergent mineral fluids with

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
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.

Mixing of other lubricants within the com-

pressor unit will void all warranties. When ambient conditions exceed those noted or if
conditions warrant use of “extended” life lubricants
contact Sullair for recommendation.
If fluid change is required, follow 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.
To drain fluid, disconnect lubricant hose from the
thermal valve and divert the open end into a suitable
container below the separator/sump tank fluid level.

WARNING
"The Plastic Pipe Institute recommends
against the use of thermoplastic pipe to
transport compressed air or other com-
pressed 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 mate-
rials may also be affected. (I) Plastic Pipe
Institute, Recommendation B, Adopted Jan-
uary 19, 1972.

DO NOT MIX DIFFERENT TYPES OF FLUIDS.

1. Fluid Fill Port

2. Sight Glass
3. Separator/Sump Tank

Figure 3-1: Fluid Fill Location

23
1800-3000 USER MANUAL SECTION 3

3.3 APPLICATION GUIDE

Sullair encourages the user to participate in a fluid
analysis program with the fluid suppliers. This could
result in a fluid change interval differing from that
stated in the manual. Contact your Sullair dealer for
details.

3.4 LUBRICATION CHANGE RECOMMENDATIONS AND

MAINTENANCE—FLUID FILTER AND SEPARATOR

LUBRICANT 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

A. 8,000 hours or once a year.

B. 4,000 hours or more frequently if conditions so require.
C. When measured pressure loss exceeds 20 psig (1.3 bar).
D. When measured pressure loss exceeds 10 psig (0.7 bar).
E. When required by fluid analysis or known contamination.
F. Does not require replacement during normal service conditions.
G. Every 2,000 hours.

24
NOTES

25
 3.5 AIR-COOLED, IDENTIFICATION 25-30HP

26
1800-3000 USER MANUAL

02250159-354-R03
SECTION 3
 3.5 AIR-COOLED, IDENTIFICATION 25-30HP
SECTION 3

Main Motor HP Motor Type Weight CFM Cooling Air

25 ODP 1374 LBS/623 KG 2000 CFM

25 TEFC 1420 LBS/644 KG 2000 CFM

30 ODP 1383 LBS/627 KG 2000 CFM

30 TEFC 1450 LBS/658 KG 2000 CFM

NOTES: A1: SPACE REQUIRED TO OPEN DOORS

1. ALLOW 4.00 FT. [1.25 METERS] MINIMUM CLEARANCE A2: SPACE REQUIRED TO OPEN STARTER PANEL
AROUND MACHINE FOR ACCESS AND FREE CIRCULA-
A3: CONTROLLER
TION OF AIR.
A4: E-STOP
2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORT-
ING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO A5: AIR INLET
MAINTAIN THE COMPRESSOR FRAME LEVEL IS
A6: EXHAUST AIR OUT
REQUIRED. THE COMPRESSOR FRAME MUST BE LEV-
ELLED AND SECURED BETWEEN THE FRAME AND THE A7: CONTAINMENT PAN DRAIN
FOUNDATION. NO PIPING LOADS MUST BE PERMITTED
A8: INCOMING CUSTOMER POWER SUPPLY
AT EXTERNAL CONNECTIONS.
Ø2.50[63.5]
3. ALL DIMENSIONS ARE ±1/2" [12.7MM].
A9: MOISTURE DRAIN CONNECTION 1/4"-18 NPT
4. RECOMMENDED INCOMING CUSTOMER POWER SUP-
PLY IS SHOWN ON DRAWING. A10: AIR OUT CONNECTION 1-1/2" NPT
5. IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR,
HIGH STATIC FAN MUST BE SELECTED. MAX ALLOW-
ABLE ADDITIONAL STATIC PRESSURE 0.4 IN H20 WITH
HIGH STATIC FAN.
1800-3000 USER MANUAL

27
 3.6 AIR-COOLED, IDENTIFICATION 40HP

28
1800-3000 USER MANUAL

02250181-032 R00
SECTION 3
 3.6 AIR-COOLED, IDENTIFICATION 40HP
SECTION 3

Main Motor HP Motor Type Weight CFM Cooling Air

40 ODP 1556 LBS/706 KG 2900 CFM

40 TEFC 1613 LBS/732 KG 2900 CFM

NOTES: A1: SPACE REQUIRED TO OPEN DOORS

1. ALLOW 4.00 FT. [1.25 METERS] MINIMUM CLEARANCE A2: SPACE REQUIRED TO OPEN STARTER PANEL
AROUND MACHINE FOR ACCESS AND FREE CIRCULA-
A3: CONTROLLER
TION OF AIR.
A4: E-STOP
2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORT-
ING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO A5: AIR INLET
MAINTAIN THE COMPRESSOR FRAME LEVEL IS
A6: EXHAUST AIR OUT
REQUIRED. THE COMPRESSOR FRAME MUST BE LEV-
ELLED AND SECURED BETWEEN THE FRAME AND THE A7: CONTAINMENT PAN DRAIN
FOUNDATION. NO PIPING LOADS MUST BE PERMITTED
A8: INCOMING CUSTOMER POWER SUPPLY
AT EXTERNAL CONNECTIONS.
Ø2.50[63.5]
3. ALL DIMENSIONS ARE ±1/2" [12.7MM].
A9: MOISTURE DRAIN CONNECTION 1/4"-18 NPT
4. RECOMMENDED INCOMING CUSTOMER POWER SUP-
PLY IS SHOWN ON DRAWING. A10: AIR OUT CONNECTION 1-1/2" NPT
5. IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR,
HIGH STATIC FAN MUST BE SELECTED. MAX ALLOW-
ABLE ADDITIONAL STATIC PRESSURE 0.4 IN H20 WITH
HIGH STATIC FAN.
1800-3000 USER MANUAL

29
 3.7 AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 25-30HP

30
1800-3000 USER MANUAL

02250168-699-R02
SECTION 3
 3.7 AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 25-30HP
SECTION 3

Main Motor HP Motor Type Weight CFM Cooling Air

25 ODP 1575 LBS/714 KG 2000 CFM

25 TEFC 1621 LBS/735 KG 2000 CFM

30 ODP 1584 LBS/718 KG 2000 CFM

30 TEFC 1651 LBS/749 KG 2000 CFM

NOTES:
1. ALLOW 4.00 FT. [1.25 METERS] MINIMUM CLEAR-
ANCE AROUND MACHINE FOR ACCESS AND
FREE CIRCULATION OF AIR.
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.
3. ALL DIMENSIONS ARE ±1/2" [12.7MM].
4. RECOMMENDED INCOMING CUSTOMER POWER
SUPPLY IS SHOWN ON DRAWING.
5. IF DUCTWORK IS TO BE INSTALLED FOR COOL-
ING AIR, HIGH STATIC FAN MUST BE SELECTED.
MAX ALLOWABLE ADDITIONAL STATIC PRES-
SURE 0.4 IN H20 WITH HIGH STATIC FAN.
1800-3000 USER MANUAL

31
 3.8 AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 40HP

32
1800-3000 USER MANUAL

02250180-784 R00
SECTION 3
 3.8 AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 40HP
SECTION 3

Main Motor HP Motor Type Weight CFM Cooling Air

40 ODP 1757 LBS/797 KG 2900 CFM

40 TEFC 1814 LBS/823 KG 2900 CFM

NOTES: A1: SPACE REQUIRED TO OPEN DOORS

1. ALLOW 4.00 FT. [1.25 METERS] MINIMUM CLEARANCE A2: SPACE REQUIRED TO OPEN STARTER PANEL
AROUND MACHINE FOR ACCESS AND FREE CIRCULA-
A3: CONTROLLER
TION OF AIR.
A4: E-STOP
2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORT-
ING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO A5: AIR INLET
MAINTAIN THE COMPRESSOR FRAME LEVEL IS
A6: EXHAUST AIR OUT
REQUIRED. THE COMPRESSOR FRAME MUST BE LEV-
ELLED AND SECURED BETWEEN THE FRAME AND THE A7: CONTAINMENT PAN DRAIN
FOUNDATION. NO PIPING LOADS MUST BE PERMITTED
A8: INCOMING CUSTOMER POWER SUPPLY
AT EXTERNAL CONNECTIONS.
Ø2.72[69.0]
3. ALL DIMENSIONS ARE ±1/2" [12.7MM].
A9: MOISTURE DRAIN CONNECTION 1/4"-18 NPT
4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY
IS SHOWN ON DRAWING. A10: AIR OUT CONNECTION 1-1/2" NPT
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.
1800-3000 USER MANUAL

33
 3.9 PIPING AND INSTRUMENTATION, AIR-COOLED

34
1800-3000 USER MANUAL

02250156-114-R10
SECTION 3
 3.9 PIPING AND INSTRUMENTATION, AIR-COOLED
Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
SECTION 3

1 02250125-369 1 FILTER, AIR 8”(PLASTIC) W/MTG BAND 26 02250125-774 1 ORIFICE,PLUG BRASS 1/8NPT X 1/32”
2 - 1 VALVE, GROUP INLET DXX102E 27 02250118-586 1 ORF, .078” .25FNPT X.25MNPT
3 MTR_VAR 1 MOTOR 28 02250078-249 1 SW,VAC 22”WC N4 6FT CABLE 5A
4 - 1 COMPRESSOR 29 02250050-154 1 SW,DIFF PRESS 20 PSID
5 02250155-599 1 TANK, SEP 2200 30 02250144-841 1 VLV,BALL/STNR COMB 1/2M X 1/2M
6 02250160-773 1 ELEM,OIL SEP 1800/2200 30 02250182-548 1 VLV,BALL/STNR COMBO-1/2”NPT
7 02250097-609 1 VALVE, 1-5/8 SAE MIN PRESS CHK 31 02250182-545 1 DRN,ZERO LOSS 115V 1/2”NPT
8 02250156-137 1 COOLER, AIR/OIL 2200 32 02250168-837 1 VENT,ENCL PROT 1/2” TOP
9 02250167-115 1 SEP,WTR SCWS-235N 1” L/AD 33 02250169-612 1 GA,DIFF PRESS Z-PRG ASY BTM
10 02250155-708 1 FLTR,CORELESS M27 6”L W/ BYPASS 34 241771 1 STRAINER, V-TYPE 300PSIX1/4
11 02250092-081 1 VLV,THERMAL 195 DEG PLEASE NOTE: WHEN ORDERING PARTS,
11 02250148-796 1 VLV,THERMAL 210 DEG INDICATE SERIAL NUMBER OF COMPRESSOR

12 02250155-174 2 XDCR,PRESS 0-250PSI 1-5VDC N4

COMPONENT DESCRIPTION
13 250006-938 1 VALVE, RELIEF 1/2” 200#
P1 WET SUMP PRESSURE
14 02250155-175 1 PROBE,THERMISTER 3000 OHM NTC 6’L
P2 LINE PRESSURE
15 02250049-634 1 VLV,BLWDN 1/4 NPT HI PRS
DPSW1 FLUID FILTER DIFFERENTIAL SWITCH
16 02250170-783 2 VLV,DR COMBO 24 VDC
PSW1 INLET AIR FILTER SWITCH 22"WC (558.9mm WC)
17 02250155-714 2 VALVE,SOL 3WNO 1/4 235# N4
SOL1 LOAD/UNLOAD SOLENOID VALVE
18 250017-280 1 VALVE, PRESSURE REGULATOR
SOL4 MEC/SEQUENCING/FULL LOAD SOLENOID VALVE
19 408893 1 VALVE, SHUTTLE 1/4” (DBL CHK)
SOL5 COMBO DRAIN/JZL DRAIN SOLENOID VALVE
20 250003-869 1 INDICATOR, RESTRICTION 20”H20
T1 WET DISCHARGE TEMPERATURE
21 02250115-272 1 VLV,CHK 1/4”-NPT
22 02250173-972 1 FLTR,PNEUMATIC 1/8”NPT 5MICRON
23 02250097-610 1 PLUG,SIGHT GLASS 1 5/16” SAE
24 02250126-129 1 GLASS,SIGHT SIGHT/ORIFICE BLK SAE
25 02250117-782 1 FILTER,ASSY GENESIS
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
1800-3000 USER MANUAL

35
 3.10 PIPING AND INSTRUMENTATION, 1800-2200 W/INTEGRAL DRYER

36
1800-3000 USER MANUAL

02250172-798-R02
SECTION 3
 3.10 PIPING AND INSTRUMENTATION, 1800-2200 W/INTEGRAL DRYER
N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
SECTION 3

E E
1 02250125-369 1 FILTER, AIR 8”(PLASTIC) W/MTG BAND 30 02250168-837 1
VENT,ENCL PROT 1/2” TOP
2 - 1 VALVE, GROUP INLET DXX102E 31 02250169-612 1
GA,DIFF PRESS Z-PRG ASY BTM
3 MTR_VAR 1 MOTOR 32 - 1
INTEGRAL REFRIGERANT DRYER
4 - 1 COMPRESSOR 33 049905 2
CHECK VALVE
5 02250155-599 1 TANK, SEP 2200 34 02250175-087 1
PROBE,THERMISTER 3000 OHM NTC
6 02250160-773 1 ELEM,OIL SEP 1800/2200 12’L
7 02250097-609 1 VALVE, 1-5/8 SAE MIN PRESS CHK 35 02250173-972 1 FLTR,PNEUMATIC 1/8”NPT 5MICRON
8 02250156-137 1 COOLER, AIR/OIL 2200 1. PART NUMBERS ARE FOR REFERENCE ONLY. REFER TO BILL OF
9 02250167-115 1 SEP,WTR SCWS-235N 1” L/AD MATERIAL AND OR FACE OF ORDER FOR ACTUAL PARTS.
10 02250155-708 1 FLTR,CORELESS M27 6”L W/BYPASS 2. SECTION BETWEEN LETTERED POINTS ARE TO BE REPLACED
WITH CORRESPONDING OPTION PICTURED BELOW, AS
11 02250148-796 1 VLV,THERMAL 210 DEG.
REQUIRED BY FACE OF ORDER.
11 02250092-081 1 VLV,THERMAL 195 DEG.
3, CONTROL/MOISTURE DRAIN LINES ARE 1/4" TUBING EXCEPT AS
12 02250155-174 2 XDCR,PRESS 0-250PSI 1-5VDC N4 NOTED.
13 250006-938 1 VALVE, RELIEF 1/2” 200# 4. OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND
14 02250155-175 1 PROBE,THERMISTER 3000 OHM NTC 6’L MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS
15 02250049-634 1 VLV,BLWDN 1/4 NPT HI PRS STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE
16 241771 1 STRAINER, V TYPE 1/4” REQUIREMENTS.
17 02250155-714 2 VALVE,SOL 3WNO 1/4 235# N4 5. PART VARIES BY MODEL.
18 250017-280 1 VALVE, PRESSURE REGULATOR PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
19 408893 1 VALVE, SHUTTLE 1/4” (DBL CHK)
20 250003-869 1 INDICATOR, RESTRICTION 20”H20
21 02250115-272 1 VLV,CHK 1/4”-NPT COMPONENT DESCRIPTION
22 02250170-783 1 VLV,DR COMBO 24 VDC P1 WET SUMP PRESSURE
23 02250097-610 1 PLUG,SIGHT GLASS 1 5/16” SAE P2 LINE PRESSURE
24 02250126-129 1 GLASS,SIGHT SIGHT/ORIFICE BLK SAE DPSW1 FLUID FILTER DIFERENTIAL SWITCH
25 02250117-782 1 FILTER,ASSY GENESIS
PSW1 INLET AIR FILTER SWITCH 22" WC (558.9 mm WC)
26 02250125-774 1 ORIFICE,PLUG BRASS 1/8NPT X 1/32”
SOL1 LOAD/UNLOAD SOLENOID VALVE
27 02250118-586 1 ORF, .078” .25FNPT X.25MNPT
28 02250078-249 1 SW,VAC 22”WC N4 6FT CABLE 5A SOL4 MEC/SEQUENCING/FULL LOAD SOLENOID VALVE
29 02250050-154 1 SW,DIFF PRESS 20 PSID SOL5 ELECTRIC DRAIN SOLENOID VALVE
PLEASE NOTE: WHEN ORDERING PARTS, T1 WET DISCHARGE TEMPERATURE
INDICATE SERIAL NUMBER OF COMPRESSOR T3 DRYER DEWPOINT TEMPERATURE PROBE
1800-3000 USER MANUAL

37
 3.11 WIRING DIAGRAM—MFV, AIR-COOLED

38
1800-3000 USER MANUAL

02250171-211-R04
SECTION 3
 3.11 WIRING DIAGRAM—MFV, AIR COOLED
COMP DESCRIPTION COMP DESCRIPTION
1MOL COMPRESSOR OVERLOAD 2FU JZL TRANSFORMER SECONDARY FUSE
SECTION 3

1M COMPRESSOR STARTER 3FU FAN MOTOR BRANCH FUSES

2MOL FAN MOTOR OVERLOAD JZL JZL DRAIN OPTION
P1 WET SUMP PRESSURE SENSOR PPR POWER PRESENT RELAY OPTION
P2 PACKAGE DISCHARGE PRESSURE SENSOR
T1 UNIT DISCHAGE TEMPERATURE PROBE NOTES
PSW1 (OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC 1 CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DIS-
DPSW1 (OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID CONNECT PER LOCAL CODES.

INPUT 7 REMOTE RUN/UNLOAD 2 REMOVE JUMPER FOR AUXILLIARY E-STOP STRING

DEVICES.
INPUT 8 CUSTOMER FURNISHED FAULT
3 1MOL SETTING TO BE 1M FLA. PLUS 2M FLA.
INPUT 9 CUSTOMER FURNISHED WARNING
4 USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY
SOL1 LOAD CONTROL SOLENOID VALVE OPTIONAL INPUTS TO THE WS CONTROLLER. MOUNT THE
SOL4 SEQUENCEING SOLENOID VALVE RELAY LOCALLY IN THE STARTER BOX.
SOL5 ELECTRIC CONDENSATE DRAIN VALVE PLEASE NOTE: WHEN ORDERING PARTS,
PS 24VDC POWER SUPPLY INDICATE SERIAL NUMBER OF COMPRESSOR

K1 INTERNAL RUN RELAY CONTACT

K2 INTERNAL Y-DELTA START RELAY
K3 INTERNAL WYE-DELTA RUN RELAY
K4 INTERNAL LOAD CONTROL RELAY
K5 INTERNAL SEQUENCE RELAY
K6 INTERNAL ELECTRIC DRAIN RELAY
K7 INTERNAL COMMON FAULT RELAY
PMR OPT’L POWER MONITOR RELAY
PF CAP POWER FACTOR CORRECTION CAPACITOR (OPT’L)
HTR1 (OPT’L) SUMP HEATER 800W
HTR2 (OPT’L) HEAT TRACE
HTR3 (OPT’L) TRAP HEATER 70WATTS
HTR4 (OPT’L) CONTROL PANEL HEATER 50WATTS
TH THERMOSTAT FOR HEAT TRACE OPTION
1FU JZL TRANSFORMER PRIMARY FUSES
1800-3000 USER MANUAL

39
 3.12 WIRING DIAGRAM—MFV, AIR-COOLED INTEGRAL DRYER

40
1800-3000 USER MANUAL

02250174-982-R03
SECTION 3
 3.12 WIRING DIAGRAM—MFV, AIR-COOLED INTEGRAL DRYER
COMP DESCRIPTION COMP DESCRIPTION
1MOL COMPRESSOR OVERLOAD 3FU FAN MOTOR BRANCH FUSES
SECTION 3

1M COMPRESSOR STARTER 6FU INTEGRAL DRYER SECONDARY FUSE

2MOL FAN MOTOR OVERLOAD 7FU INTEGRAL DRYER PRIMARY FUSES
P1 WET SUMP PRESSURE SENSOR PPR POWER PRESENT RELAY OPTION
P2 PACKAGE DISCHARGE PRESSURE SENSOR DF DRYER FAULT
T1 UNIT DISCHARGE TEMPERATURE PROBE DR DRYER START RELAY
T3 DRYER DEWPOINT TEMPERATURE PROBE
PSW1 (OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC NOTES
DPSW1 (OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID 1 CUSTOMER TO FURNISH FUSED OR CIRCUIT
INPUT 7 REMOTE RUN/UNLOAD BREAKER DISCONNECT PER LOCAL CODES.
INPUT 8 CUSTOMER FURNISHED FAULT 2 REMOVE JUMPER FOR AUXILLIARY E-STOP STRING
INPUT 9 CUSTOMER FURNISHED WARNING DEVICES.
SOL1 LOAD CONTROL SOLENOID VALVE 3 1MOL SETTING TO BE 1M FLA. PLUS 2M FLA.
SOL4 SEQUENCEING SOLENOID VALVE 4 USE ISOLATING RELAYS WITH DRY CONTACTS FOR
SOL5 ELECTRIC CONDENSATE DRAIN VALVE ANY OPTIONAL INPUTS TO THE WS CONTROLLER.
MOUNT THE RELAY LOCALLY IN THE STARTER BOX.
PS 24VDC POWER SUPPLY
PLEASE NOTE: WHEN ORDERING PARTS,
K1 INTERNAL RUN RELAY CONTACT INDICATE SERIAL NUMBER OF COMPRESSOR
K2 INTERNAL Y-DELTA START RELAY
K3 INTERNAL WYE-DELTA RUN RELAY
K4 INTERNAL LOAD CONTROL RELAY
K5 INTERNAL SEQUENCE RELAY
K6 INTERNAL ELECTRIC DRAIN RELAY
K7 INTERNAL COMMON FAULT RELAY
PMR OPT’L POWER MONITOR RELAY
PF CAP POWER FACTOR CORRECTION CAPACITOR (OPT’L)
HTR1 (OPT’L) SUMP HEATER 800W
HTR2 (OPT’L) HEAT TRACE
HTR3 (OPT’L) TRAP HEATER 70WATTS
HTR4 (OPT’L) CONTROL PANEL HEATER 50WATTS
TH THERMOSTAT FOR HEAT TRACE OPTION
1800-3000 USER MANUAL

41
 3.13 WIRING DIAGRAM—VSD, PARALLEL WYE

42
1800-3000 USER MANUAL

02250156-119 R09
SECTION 3
 3.13 WIRING DIAGRAM—VSD, PARALLEL WYE
COMP DESCRIPTION COMP DESCRIPTION
1M COMPRESSOR MOTOR HTR4 (OPT’L) CONTROL PANEL HEATER 50WATTS
SECTION 3

2M COOLER FAN MOTOR STARTER TH THERMOSTAT FOR HEAT TRACE OPTION

2MOL FAN MOTOR OVERLOAD XFMR1 CONTROL TRANSFORMER FOR SCD DRAIN
1FU FAN MOTOR BRANCH CIRCUIT FUSES SCD (OPT’L) SCD DRAIN
2FU SCD TRANSFORMER PRIMARY FUSES
3FU SCD TRANSFORMER SCONDARY FUSE NOTES
P1 WET SUMP PRESSURE SENSOR 1 CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DIS-
P2 PACKAGE DISCHARGE PRESSURE SENSOR CONNECT PER LOCAL CODES.

T1 UNIT DISCHAGE TEMPERATURE PROBE 2 REMOVE JUMPER FOR AUXILLIARY E-STOP STRING
DEVICES.
PSW1 (OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC
3 USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY
DPSW1 (OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID OPTIONAL INPUTS TO THE WS CONTROLLER. MOUNT THE
INPUT 7 REMOTE RUN/UNLOAD RELAY LOCALLY IN THE STARTER BOX.
INPUT 8 CUSTOMER FURNISHED FAULT PLEASE NOTE: WHEN ORDERING PARTS,
INPUT 9 CUSTOMER FURNISHED WARNING INDICATE SERIAL NUMBER OF COMPRESSOR

SOL1 LOAD CONTROL SOLENOID VALVE

SOL4 SEQUENCEING SOLENOID VALVE
SOL5 ELECTRIC CONDENSATE DRAIN VALVE
PS 24VDC POWER SUPPLY
K1 INTERNAL FAN RELAY CONTACT TEMP (T1) CONTROLLED
K2 INTERNAL Y-DELTA START RELAY COMPRESSOR RUNNING
K3 INTERNAL WYE-DELTA RUN RELAY COMPRESSOR
ENABLED
K4 INTERNAL LOAD CONTROL RELAY
K5 INTERNAL SEQUENCE RELAY
K6 INTERNAL ELECTRIC DRAIN RELAY
K7 INTERNAL COMMON FAULT RELAY
PMR OPT’L POWER MONITOR RELAY
HTR1 (OPT’L) SUMP HEATER 800W
HTR2 (OPT’L) HEAT TRACE
HTR3 (OPT’L) TRAP HEATER 70WATTS
1800-3000 USER MANUAL

43
 3.14 WIRING DIAGRAM—YD CE

44
1800-3000 USER MANUAL

02250178-718-R00
SECTION 3
 3.14 WIRING DIAGRAM—YD CE
COMP DESCRIPTION COMP DESCRIPTION
1MOL COMPRESSOR OVERLOAD TH THERMOSTAT FOR HEAT TRACE OPTION
1M COMPRESSOR STARTER CB1 (OPT’L) TRANSFORMER PRIMARY CIRCUIT BREAKER
SECTION 3

2M WYE-DELTA RUN CONTRACTOR CB2 (OPT’L) TRANSFORMER SECONDARY CIRCUIT BREAKER

S WYE-DELTA START CONTRACTOR SCD (OPT'L) SCD DRAIN
3MOL FAN MOTOR OVERLOAD XFMR1 CONTROL TRANSFORMER FOR OPTIONAL SCD DRAIN
4M CONTRACTOR FOR POWER FACTOR CAPACITOR OPT.
P1 WET SUMP PRESSURE SENSOR N
Q
KEY O
P2 PACKAGE DISCHARGE PRESSURE SENSOR PART NO. T DESCRIPTION
NO. T
T1 UNIT DISCHAGE TEMPERATURE PROBE Y
E
PSW1 (OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC 1. CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER
DPSW1 (OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID DISCONNECT PER LOCAL CODES.
INPUT 7 REMOTE RUN/UNLOAD 2. REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.
INPUT 8 CUSTOMER FURNISHED FAULT 3. 1MOL RELAY SET AT 58% OF 1M FULL LOAD PLUS 3M FULL LOAD.
INPUT 9 CUSTOMER FURNISHED WARNING 4. USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY OPTIONAL
INPUTS TO THE WS CONTROLLER. MOUNT THE RELAY LOCALLY IN
SOL1 LOAD CONTROL SOLENOID VALVE
THE STARTER BOX.
SOL4 SEQUENCEING SOLENOID VALVE
PLEASE NOTE: WHEN ORDERING PARTS,
SOL5 ELECTRIC CONDENSATE DRAIN VALVE INDICATE SERIAL NUMBER OF COMPRESSOR
PS 24VDC POWER SUPPLY
K1 INTERNAL RUN RELAY CONTACT
K2 INTERNAL Y-DELTA START RELAY
K3 INTERNAL WYE-DELTA RUN RELAY
K4 INTERNAL LOAD CONTROL RELAY
K5 INTERNAL SEQUENCE RELAY
K6 INTERNAL ELECTRIC DRAIN RELAY
K7 INTERNAL COMMON FAULT RELAY
PF CAP POWER FACTOR CORRECTION CAPACITOR (OPT’L)
HTR1 (OPT’L) SUMP HEATER 800W
HTR2 (OPT’L) HEAT TRACE
HTR3 (OPT’L) TRAP HEATER 70WATTS
HTR4 (OPT’L) CONTROL PANEL HEATER 50WATTS
1800-3000 USER MANUAL

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 pro-
vided 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 com-
ponents of the compressor.
• Softer surfaces in walls or ceilings will
absorb sound and minimize ambient noise
levels. Harder, reflective surfaces will
increase ambient noise levels.
NOTE
Ambient temperatures above 104ûF (40ûC)
require that the high ambient option is
specified for the compressor.
1800-3000 USER MANUAL
4.2 VENTILATION AND
COOLING
Air-Cooled Compressors
• An area with adequate space must be pro-
vided for the compressor and its compo-
nents. 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 com-
pressor’s cooling system.
• Reduced headroom above the compres-
sor 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 tempera-
tures.
NOTE
Systems that employ both a conventional
reciprocating compressor and a screw-
type axial compressor must be isolated
from each other by use of a common
receiver tank. Individual airlines from
each compressor should be piped to the
common receiver tank.
NOTE
Shipping straps are painted red in order
to help identify them for removal. Be sure
to remove them prior to operation of the
drive assembly.
47
1800-3000 USER MANUAL
OUTDOOR INSTALLATION (SHELTERED)
Many times a compressor must be installed outside
due to available space or other jobsite conditions.
When this is necessary, there are certain items that
should be incorporated into the system to help
ensure trouble-free operation. The unit must be
purchased with a TEFC motor. The standard
machine has NEMA 4 rated controls, which are
watertight.
NOTE
Variable speed drive compressors are
NEMA 12 rated and must not be installed
outside or exposed to the elements.
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
SECTION 4
35ûF (1.7ûC).
NOTE
Compressors with integral dryers can be
damaged by ambient temperatures below
freezing. The dryer electrical system is
Nema 12 rated and should not be installed
outdoors or in an unheated space, subject
to freezing temperatures.
For installation in a below freezing climate, a low
ambient option with heat tracing and a separator/
sump tank heater must be installed.
4.3 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 carry-
over.
SECTION 4 1800-3000 USER MANUAL

Figure 4-1: Service Air Piping, Typical Installation

1. Sullair Compressor 5. Water Leg Drain Valve

2. Sullair Dryer 6. By-Pass Gate Valve
3. Shut-Off Gate Valve 7. Standard Gate Valve
4. Sullair Filter
When two compressors are operated in parallel,
provide an isolation valve and a drain trap for each
Pipe Sizing
compressor before the common receiver tank.
Pipe should be sized at least as large as the
A built-in after-cooler reduces the discharge air
discharge connection of the compressor. Piping and
temperature below the dew point. For most ambient
fittings should all be suitably rated for the discharge
conditions, considerable water vapor is condensed.
pressure.
To remove the condensation, each compressor with
Use of Auxiliary Receiver Tank built-in after-cooler is supplied with a combination
condensate separator/trap. A drain line should be
An auxiliary receiver tank should be used in cases
installed on the condensate drain.
where large demand swings are expected. This is not
necessary with a variable speed design. Fluid Containment
Isolation Valve(s) Compressors are equipped with a fluid containment
pan to catch any fluid in the event of a leak or spill.
If isolation of the compressor from the service lines is
The drain for the pan is located on the air intake end
required, isolation valves should be installed close to
of the machine. For indoor installations, the drain
the discharge of the compressor. They should be
should be plugged to contain fluids. For outdoor
installed with drip legs that drain sloping downward
applications, the drain must be connected to a
from the base in order to drain properly. Install a vent
separate, customer supplied system to allow
to the piping downstream of the compressor outlet
rainwater or any accumulated compressor fluid to
connections, and upstream of the first isolation valve.
drain out.

49
1800-3000 USER MANUAL
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 com-
pressed 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 mate-
rials 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
SECTION 4
4.6 ELECTRICAL PREPARATION
Interior electrical wiring is performed at the factory.
Required customer wiring should be done by a
qualified electrician in compliance with OSHA,
National 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 pro-
vided with a proper grounding conductor/
earthed in accordance with both local and
National Electrical Code (NEC) require-
ments.
• 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 cus-
tomer/ electrical contractor to ensure that
the electrical circuit the system is con-
nected 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 termi-
nals will accept from 8 ga. to 3/0 ga. cable.
• Feeder cable connections to incoming ter-
minals 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. Discon-
nect 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 tight-
ness. Check all grounding connection for
bond.
4. “DRY RUN” the electrical controls by discon-
necting 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.
1800-3000 USER MANUAL
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,
the “ ” (START) and “ ” (STOP) pads. This
action will bump start the motor for a very short time.
When looking at the motor from the end opposite the
compressor unit, the shaft should be turning
clockwise. If the reversed rotation is noted,
disconnect the power to the starter and exchange
any two of the three power input leads, then re-check
rotation. A “Direction of Rotation” decal is located on
the motor to show proper motor/compressor rotation.
An alternative to this procedure is to set the WS
Controller to display P1 separator/sump tank
pressure. Pull out the EMERGENCY STOP button
and press once, quickly and in succession, the “ ”
(START) and “ ” (STOP) pads. This action will
bump start the motor for a very short time. If motor
rotation is correct there will be immediate pressure
shown. If no pressure is present, reverse rotation is
occurring. Disconnect the power to the starter and
exchange any two of the three power input leads.
Recheck rotation as outlined above.
4.8 FAN MOTOR ROTATION
CHECK
On initial start-up check that the fan is rotating in the
proper direction. The correct rotation is
counterclockwise when viewing the fan motor from
the driveshaft end.
51
1800-3000 USER MANUAL SECTION 4

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
 1800-3000 USER MANUAL

Section 5

WS CONTROLLER

1. ON 6. Maintenance Indicator
2. OFF 7. Fault Indicator
3. LCD Display 8. Up Key
4. Power Indicator 9. Down Key
5. Run Mode Indicator 10. Enter Key

Figure 5-1: WS Controller

5.1 CONTROLLER KEYPAD • To stop compressor operation, press the

red Stop pad " ".
For complete controller capabilities see WS
Controller manual 02250165-411. The WS Controller • The Run mode indicator " " lights up
keypad has two main pads for compressor control. whenever the control is in an operating
mode.
• To start the compressor operation, press
the green Start pad " ".

53
1800-3000 USER MANUAL
5.2 LCD DISPLAY
The display's normal view shows the compressor
package's discharge pressure, internal temperature,
and the operating mode. The modes are MANUAL,
OFF, AUTOMATIC, or FAULTED.
Figure 5-2:
Refer to Figure 5-2 and Figure 5-3. The lower line is
occasionally interrupted to describe the compressor
package's operating state.
Figure 5-3:
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 5-4:
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 5-5:
54
SECTION 5
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 5-6:
Refer to Figure 5-7. When you continue beyond the
status information, the display will show a list of
control settings. The upper line will indicate "Show
Setting" and the name of the setting. The lower line
shows the present value.
Figure 5-7:
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 5-8:
Refer to Figure 5-8. If there is no keypad activity, the
display will return to normal view in about one
minute. If the Start or Stop buttons are pressed, the
display also returns to normal view. If either of these
occur, the setting will not be altered.
If there are any warnings or recommended service
instructions, these will be periodically displayed on
SECTION 5
the normal view.
The list of displays may be navigated from either
direction by using the Up " " or Down " " arrow
keys. For example, to change language from normal
view, press the Up arrow pad once, press the Enter
key " ", select your language, and press Enter again.
The number of displays varies with compressor
model, but will follow this pattern.
The large Emergency Stop button located near the
controller overrides all electronic functions to turn off
the control devices. The controller senses this, and
will display E-stop. To reset, twist and pull out the
Emergency Stop button, then press the Stop pad to
reset the WS Controller.
5.3 LED LIGHTS
The four LED lights indicate the general condition of
the machine.
The green Power indicator " " simply indicates that
power is applied to the controller. It will blink very
slowly if the WS Controller is set up to automatically
restart after power failure.
1800-3000 USER MANUAL
The green Run mode indicator " " indicates
compressor operation is enabled. It lights steadily if
the motor is running. If the motor stops while in
Automatic mode, this LED will blink to indicate that
the motor may restart.
The yellow Maintenance indicator " " comes on
whenever there is recommended maintenance or a
warning. The text display will periodically indicate the
recommended actions or the cause of the warning.
The red Fault indicator " " indicates that a
compressor fault has occurred and needs to be
repaired before further operation. The text display
will indicate the cause of the fault.
The PC support program for the WS controller
provides additional information about compressor
operation and advanced setup adjustments to
optimize operation.
Software part numbers are shown in the display
following a power interruption or other interruption of
communication with the controller. The P/N remains
on the display until satisfactory communications are
established with the Input/Output module.
55
NOTES

56

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
1800-3000 USER MANUAL
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 Dis-
charge, Cooling and Lubrication System, Air-
Cooled Centrifugal Fan, 50/60Hz 40HP on
page 30 for location.
2. Clean the return line orifice.
6.4 MAINTENANCE EVERY 2000
HOURS
After 2000 hours of operation, it will be necessary to
perform the following:
57
1800-3000 USER MANUAL
1. Clean the return line strainer. Refer to Dis-
charge, Cooling and Lubrication System, Air-
Cooled 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.
1. Filter Head
2. Element*
3. Body
* Fluid Filter Replacement Kit—P/N
02250155-709
Figure 6-1: Fluid Filter Assembly
58
SECTION 6
6.5 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 dis-
posal.
3. Clean gasket seating surface.
4. Apply a light film of fluid to the element seal.
5. Install the element into the filter canister.
6. Screw the canister to the filter head. Tighten
to 10 to 12 ft·lb (13.5 to 16.2 N·m).
7. Restart compressor and check for leaks. 6.7
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.
1. Filter Head
2. Element*
3. Body
* Air Filter Replacement Kit—P/N
02250125-372
Figure 6-2: Air Filter Assembly
Air Filter Element Replacement
1. Clean exterior of air filter housing.
2. Rotate end cover counterclockwise and
remove
3. Remove air filter element by pulling it out of
the housing.
4. Clean interior of housing using a damp cloth.
DO NOT blow dirt out with compressed air.
5. At this time replace the element.
1800-3000 USER MANUAL
6. Reassemble in the reverse order of the dis-
assembly.
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. 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 sep-
arator/sump tank taking care not to dent the
element against the tank opening.
6. Install a new O-ring in the O-ring groove on
the underside of the separator/sump tank
cover.
7. Replace the cover plate, washers and cap
screws. Torque to 70 ft·lbs (95 N·m).
8. Clean the return line strainer before restart-
59
1800-3000 USER MANUAL SECTION 6

1. To Separator/Sump Tank
2. Male Tube Connector
3. 90° Pipe Elbow
1. Cover 4. Filter Assembly*
5. Sight Glass/Orifice Block
2. Ground Spring*
6. Brass Plug Orifice
3. Spring Fastener*
7. Female Tube Connector
4. Cover Gasket* 8. To Unit
5. Element* * Fluid Return Filter Replacement Kit—P/N
6. Separator/Sump Tank 02250117-782
Separator Element—P/N 02250185-533
* (Included in) Separator Element Replace-
ment Kit—P/N 02250185-532 Figure 6-4: Separator Element Assembly

Figure 6-3: Separator Element Assembly 1. Disconnect the tube at bottom of sight glass.

Fluid Return/Sight Glass Maintenance
Refer to Figure 6-4. The fluid return/sight glass
subassembly is attached to the side of the separator
tank. Fluid return/sight glass maintenance should be
performed on a routine basis parallel to that of the
fluid filter, or as indicated in Section 6.9:
Troubleshooting— Introduction on page 61. The
maintenance on a fluid return/sight glass is mainly
concerned with the condition of the filter assembly.
Order filter assembly No. 02250117-782, and use the
following instructions as a guide.
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.

60
SECTION 6
Pressure Regulator Adjustment
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.
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).
Control Line Strainer
The regulator and solenoid valve(s), which control
the compressor, are protected by a strainer. Every 12
months it is necessary to clean the strainer. Remove
the hex cap from the strainer and remove the strainer
screen. Clean the screen and reinstall. If the screen
is damaged, the strainer assembly must be replaced
(P/N 241772).
1800-3000 USER MANUAL
Shaft Coupling Maintenance
The compressor unit and motor are rigidly connected
via a mounting adapter housing. This arrangement
makes coupling alignment unnecessary. The
coupling is a jaw type in shear. If the elastomeric
element requires replacement due to wear or
breakage, order replacement element no. 02250152-
669, 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 cou-
pling jaws.
4. Install the new element by wrapping it
around the jaws, engaging the cogs on the
element into the jaws.
5. Reinstall the outer sleeve and torque the
securing screws to 10 in·lb (1.13 N·m). Install
the protective grill.
6.9 TROUBLESHOOTING—
INTRODUCTION
The information contained in the Troubleshooting
Guide has been compiled from field report data and
factory experience. It contains symptoms and usual
causes for the described problems. However, DO
NOT assume that these are the only problems that
may occur. All available data concerning a problem
should be systematically analyzed before
undertaking any repairs or component replacement
procedures.
A detailed visual inspection is worth performing for
almost all problems and may avoid unnecessary
additional damage to the compressor. Always
remember to:
1. Check for loose wiring.
2. Check for damaged piping.
3. Check for parts damaged by heat or an elec-
trical short circuit, usually apparent by discol-
oration or a burnt odor.
Should your problem persist after making the
recommended check, consult your nearest Sullair
representative.
61
1800-3000 USER MANUAL
SYMPTOM PROBABLY CAUSE
Compressor Will Not Start Main Disconnect Switch Open
Line fuse blown
Motor starter overload tripped
Low Incoming Line Voltage
Compressor Shuts Down With Air Loss of Control Voltage
Demand Present
Low Incoming Voltage
Excessive Operating Pressure
Separator Requires Maintenance
High Pressure Setting in WS Con-
troller Set Wrong
Defective Unload Solenoid Valve
Defective Blowdown Valve
High Discharge Temperature
Cooling Air Flow Restricted
Ambient Temperature Is Too High
Low Fluid Level
Thermal Valve Not Functioning
Properly
Compressor Will Not Build Full Dis- Air Demand Is Too Great
charge Pressure
Dirty Air Filter
Inlet Valve Bleed Orifice Plugged
Pressure Regulator Out of Adjust-
ment
Defective Pressure Regulator
Defective Unload Solenoid Valve
Sheared Coupling Element
62
SECTION 6
REMEDY
Close switch.
Replace fuse
Reset. Should trouble persist, check
whether motor starter contacts are function-
ing properly.
Check voltage. Should voltage check low,
consult power company.
Reset. If trouble persists, check that line
pressure does not exceed maximum oper-
ating pressure of the compressor (specified
on nameplate).
Consult power company.
—
Check maintenance indicator under full load
conditions.
Reset.
WS Controller will energize valve to close.
Repair if defective.
Blowdown valve should exhaust separator/
sump tank pressure to 18 psig (1.2 bar)
when maximum operating pressure is
reached. Repair if defective.
—
Clean cooler and check for proper ventila-
tion.
Provide sufficient ventilation.
Add fluid.
Replace element.
Check service lines for leaks or open
valves.
Check the filter indicator and inspect and/or
change element if required.
Ensure control line bleed orifice located in
assembly on top of air end is not plugged.
Adjust regulator according to control
adjustment instructions in the Maintenance
.
Check diaphragm and replace if necessary
(kit available).
Check that the valve closes when
energized. Replace the coil or the complete
valve if defective.
Replace coupling element. Refer to Shaft
Coupling Maintenance on page 61.
SECTION 6 1800-3000 USER MANUAL

SYMPTOM PROBABLY CAUSE REMEDY

Line Pressure Rises Above Unload Leak In Control System Causing
Pressure Set-Point
Excessive Compressor Fluid Con-
sumption
Pressure Relief Valve Opens
Repeatedly
Liquid Water In Compressed Air
Lines
Loss of Pressure Signals
Inlet Valve Stuck Open
Defective Unload Solenoid Valve
Plugged Control Line Strainer
Defective Blowdown Valve
Clogged Return Line or Orifice
Separator Element Damaged or Not Change separator.
Functioning Properly
Leak in the Lubrication System
Excess Fluid Foaming
Fluid Level Too High
Defective Pressure Relief Valve
Plugged Separator
Plugged Strainer in Moisture Drain
Line
Water Vapor Condensation From
Cooling And Compression Occurs
Naturally
Defective Drain Solenoid Valve
Inadequate Drain Timer Settings
Check for leaks.
Remove the intake hose and check for inlet
valve operation. Repair Valve (kit available).
Check that the valve is open when deener-
gized. Replace if necessary.
Clean strainer (screen and O-ring replace-
ment kit available).
Check that separator/sump tank pressure is
exhausted to the atmosphere when the
solenoid valve opens. Repair or replace if
necessary (kit available).
Clean strainer (screen and O-ring
replacement kit available).
Clean orifice.
Check all hoses, connections and
components.
Drain and change.
Drain and change.
Replace.
Check separator differential.
Clean and service strainer located in the
line off the bottom of the water separator.
Remove the water vapor from compressed
air prior to distribution through the air sys-
tem. 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 rou-
tinely to insure their proper operation. Main-
tain them regularly.
Ensure valve opens and closes as signaled
by the WS Controller.
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 3700 East Michigan Boulevard Zone Des Granges BP 82
Chiwan, Shekou Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France
Shenzen, Guangdong PRV. www.sullair.com Telephone: 33-477968470
PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A. only) Fax: 33-477968499
Telephone: 755-6851686 Fax: 219-874-1273 www.sullaireurope.com
Fax: 755-6853473
www.sullair-asia.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
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions ©
SULLAIR CORPORATION
and procedures in this manual or, The information in this manual is current
as of its publication date, and applies to
misuse of this equipement will compressor serial number:
VOID its warranty!
201003010000
and all subsequent serial numbers.
 AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.

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

SULLAIR CUSTOMER CARE TRAINING DEPARTMENT

1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
 TABLE OF CONTENTS
PAGE SECTION DESCRIPTION PAGE SECTION DESCRIPTION
5 1.1 PROCEDURE FOR ORDERING PARTS AND PIPING SYSTEM AIR-COOLED

6 1.2 RECOMMENDED SERVICE PARTS LIST 34 1.16 DISCHARGE, SEPARATOR/SUMP TANK

AND PIPING SYSTEM
8 1.3 COMPRESSOR, FRAME AND DRIVE 25/
30HP 36 1.17 MOISTURE DRAIN—STANDARD
10 1.4 COMPRESSOR, FRAME AND DRIVE 38 1.18 MOISTURE DRAIN—ZERO LOSS 25/30
40HP HP

12 1.5 AIR INLET SYSTEM 40 1.19 MOISTURE DRAIN—ZERO LOSS 40 HP

14 1.6 AIR PIPING, AIR-COOLED 25/30HP 42 1.20 MOISTURE DRAIN, AIR-COOLED WITH
INTEGRAL DRYER
16 1.7 AIR PIPING, AIR-COOLED 40HP
44 1.21 PNEUMATIC CONTROL SYSTEM—
18 1.8 AIR PIPING WITH INTEGRAL DRYER 25/ NYLON
30HP
46 1.22 PNEUMATIC CONTROL SYSTEM—
20 1.9 AIR PIPING WITH INTEGRAL DRYER STAINLESS STEEL
40HP
48 1.23 CONTROL SYSTEM AND ELECTRICAL
22 1.10 FLUID PIPING, AIR-COOLED 25/30HP PARTS, MFV
24 1.11 FLUID PIPING, AIR-COOLED 40HP 50 1.24 CONTROL SYSTEM AND ELECTRICAL
26 1.12 COOLING AND LUBRICATION SYSTEM, PARTS, MFV (CONTINUED)
AIR-COOLED CENTRIFUGAL FAN, 50/ 52 1.25 CONTROL SYSTEM AND ELECTICAL
60HZ/30HP, 50HZ/25HP PARTS, VSD
28 1.13 COOLING AND LUBRICATION SYSTEM, 54 1.26 CONTROL SYSTEM AND ELECTRIC
AIR-COOLED AXIAL FAN, 60HZ/25HP PARTS, 230/460 WYE-DELTA
30 1.14 COOLING AND LUBRICATION SYSTEM, 56 1.27 CONTROL SYSTEM AND ELECTRIC
AIR-COOLED CENTRIFUGAL FAN, 50/ PARTS, YD CE
60HZ 40HP
58 1.28 CONTROL SYSTEM AND ELECTRIC
32 1.15 DISCHARGE, SEPARATOR/SUMP TANK
 TABLE OF CONTENTS (CONTINUED)
PAGE SECTION DESCRIPTION PAGE SECTION DESCRIPTION
PARTS, VSD CE 74 1.36 ENCLOSURE, AIR-COOLED INTEGRAL
DRYER 25/30HP
60 1.29 CONTROL STARTER—MFV
76 1.37 ENCLOSURE, AIR-COOLED INTEGRAL
62 1.30 CONTROL STARTER—WYE-DELTA DRYER 40HP
64 1.31 CONTROL STARTER—VSD N12 78 1.38 DECAL LOCATION SECTION, AIR-
66 1.32 CONTROL STARTER—VSD CE N12 COOLED

68 1.33 CONTROL STARTER—YD CE N4 80 1.39 DECAL LOCATION SECTION, AIR-

COOLED, INTEGRAL DRYER
70 1.34 ENCLOSURE, AIR-COOLED 25/30HP
82 1.40 DECAL GROUP
72 1.35 ENCLOSURE, AIR-COOLED 40HP
 PARTS LIST

1.1 PROCEDURE FOR ORDERING PARTS
SULLAIR CORPORATION
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
CUSTOMER CARE for PARTS
and SERVICE
1-888-SULLAIR (785-5247)
219-874-1835
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.
SULLAIR ASIA, LTD.
Sullair Road, No. 1
Chiwan, Shekuo
Shenzhen, Guangdong PRV.
PRC POST CODE 518068
Telephone: 755-6851686
Fax: 755-6853473
www.sullair-asia.com

SULLAIR EUROPE, S.A. CHAMPION

Zone Des Granges BP 82 COMPRESSORS, LTD.
42602 Montbrison, France Princess Highway
Telephone: 33-477968470 Hallam, Victoria 3803
Fax: 33-477968499 Austrailia
www.sullaireurope.com Telephone: 61-3-9796-4000
Fax: 61-3-9703-8053

www.championcompressors.com.au

Parts should be ordered from the nearest Sullair Representative or the Figure 1-1: Serial Plate / Serial Number Location
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.
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.

5
RECOMMENDED SERVICE PARTS LIST

1.2 RECOMMENDED SERVICE PARTS LIST

KEY NO. ORDER PART NO. QTY DESCRIPTION NOTE

ELEMENTS

1 02250155-709 1 element, compressor fluid filter 02250155-708

2 02250125–372 1 element, heavy duty air filter 02250125–369

3 02250185-532 1 element, replacement for separator 02250185-533

KITS

4 02250110-988 1 kit, repair for minimum pressure/check valve 02250097-609

5 02250046-397 1 kit, cap for minimum pressure/check valve

6 826502-123 1 kit, O-ring for minimum pressure/check valve

7 02250051-338 1 kit, piston for minimum pressure/check valve

8 02250144-327 1 kit, repair for thermal valve 195deg 02250092-081

9 02250148-827 1 repair for thermal valve 210 deg 02250148-796

10 250019-453 1 kit, repair for pressure regulator 250017-280

11 02250157-500 1 kit, repair for control solenoid valve 02250155-714

12 02250157-502 1 kit, coil replacement for control solenoid valve coil 02250155-714

13 02250157-501 1 kit, repair for condensate drain solenoid valve coil 02250155-715

14 02250157-502 1 kit, coil replacement for condensate drain solenoid valve coil

15 02250164-606 1 kit, repair inlet valve (integrated with compressor unit)

Continued on next page.

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

6
 PARTS LIST

1.2 RECOMMENDED SERVICE PARTS LIST

KEY NO. ORDER PART NO. QTY DESCRIPTION NOTE

16 02250164-607 1 kit, rebuild inlet valve

17 241772 1 kit, repair for v-type strainer 241771

18 02250155–594 1 kit, repair for shaft seal

19 001932-005 1 kit, repair for shaft seal installation

20 02250117-782 2 filter, scavenge line 02250117-782

21 02250144-735 1 kit, seal replacement for separator/trap 02250144-635

LUBRICATION

22 250019-662 lubricant, Sullube (Std.) (5 gal/19 liter) (I)

23 250022-669 lubricant, Sullube (Std.) (5 gal/19 liter) (I)

24 02250051-053 lubricant, 24 KT (5 gal/19 liter) (I)

25 250029-008 lubricant, Food Grade (5 gal/19 liter) (I)

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

CAUTION
Mixing of other lubricants within the com-
pressor unit will void all warranties.

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

7
COMPRESSOR, FRAME AND DRIVE 25/30HP

1.3 COMPRESSOR, FRAME AND DRIVE 25/30HP

02250175-288 R00

8
 PARTS LIST

1.3 COMPRESSOR, FRAME AND DRIVE 25/30HP

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250057-737 1 PLATE,ROTATION ARROW 24 839608-060 3 SCREW, DRIVE RD HD #8 X 3/8
2 02250151-499 2 SPCR,AIR END SHAFT HEIGHT 60HP 25 865412-240 6 WASHER, METRIC-ISO7089- 12
3 02250152-619 1 HUB,CPLG 1.50 BORE 10R 26 866215-020 1 ELBOW, PIPE 90 DEG PLT 1/2”
4 02250152-620 1 HUB,CPLG 1.625 BORE 10R 27 866408-025 1 NIPPLE, PIPE-XS PLT 1/2 X 2 1/2
5 02250152-669 1 ELEMENT,CPLG FALK 10R 28 883008-016 2 SCREW, TF-HEX M8 X 16 BLK ZINC
6 02250152-677 1 COVER,CPLG ELEMENT 10R 29 MAIN MOTOR 1 MTR,25/30HP 4PYD ODP/TEFC EPACT
7 02250154-405 4 CVR,FORKPOCKET 3700 30 SEE BOM 1 COMPR&PART, DXX102147E
8 02250155-285 4 ISOL, VIB MOTOR 37KW
9 02250156-393 2 PLT,MTR SEAL 3000/3700/4500 A1: FROM AIR INLET FILTER
10 02250174-280 1 FRM,BSE P10 A2: OIL RETURN FROM SIGHT-GLASS ON RECEIVER TANK
A3: TO RECEIVER TANK
11 02250175-376 1 SUPT,SHIPPING MTR/UNIT P10-25/30 A4: FROM BLOWDOWN VALVE (VSD DRIVE ONLY)
12 250038-448 1 ADAPTER,UNIT TO MOTOR A5: MAIN OIL CONNECTION
13 250040-319 2 GRILLE,CPLG GUARD COMPR/MTR PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
14 825912-175 1 NUT, HEX METRIC M12 X 1.75
15 828012-020 2 CAPSCR, HEX 8.8 M12 X 20MM
16 828012-050 1 CAPSCR, HEX 8.8 M12 X 50MM
17 828012-065 2 CAPSCR, HEX 8.8 M12 X 65MM
18 829106-125 7 CAPSCR, HEX GR5 3/8-16 X 1 1/4
19 829108-125 4 CAPSCR, HEX GR5 1/2-13 X 1 1/4
20 829705-075 6 SCREW, HEX SER WASHER 5/16-18 X 3/4
21 837806-094 7 WASHER, SPR LOCK REG PLTD 3/8
22 837808-125 4 WASHER, SPR LOCK REG PLTD 1/2
23 838812-250 5 WASHER, SPR LOCK-METRIC PLTD M12
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

9
COMPRESSOR, FRAME AND DRIVE 40HP

1.4 COMPRESSOR, FRAME AND DRIVE 40HP

02250174-281 R00

10
 PARTS LIST

1.4 COMPRESSOR, FRAME AND DRIVE 40HP

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250152-622 1 HUB,CPLG 1.50 BORE 20R 24 838812-250 3 WASHER, SPR LOCK-METRIC PLTD M12
2 02250152-625 1 HUB,CPLG 1.875 BORE 20R 25 865412-240 4 WASHER, METRIC-ISO7089- 12
3 02250152-670 1 ELEMENT,CPLG 20R 26 883008-016 2 SCREW, TF-HEX M8 X 16 BLK ZINC
4 02250152-678 1 COVER,CPLG ELEMENT 20R 27 883212-254 2 WASHER, NORD-LOCK PL M12 SP
5 02250154-405 4 CVR,FORKPOCKET 3700 28 COMPRESSOR 1 VARIOUS
6 02250155-285 4 ISOL, VIB MOTOR 37KW 29 MAIN MTR 1 VARIOUS 40HP
7 02250156-393 2 PLT,MTR SEAL 3000/3700/4500
8 02250174-280 1 FRM,BSE P10 A1: FROM AIR INLET FILTER
9 02250174-347 1 SUPT,SHIPPING MTR/UNIT P10-40 A2: OIL RETURN FROM SIGHT-GLASS ON RECEIVER TANK
A3: TO RECEIVER TANK
10 225980 1 PLATE, MOTOR/COMPR ADAPT COVER A4: FROM BLOWDOWN VALVE (VSD DRIVE ONLY)
11 231977 1 ADAPTER, MOTOR COMPR 10/40 A5: MAIN OIL CONNECTION
12 250009-542 1 ADAPTER, SAE 5 DXX10 GI MA PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
13 821108-188 1 KEY, SQ CL1 1/2” X 1 7/8
14 825206-337 8 NUT, HEX PLTD 3/8-16
15 825912-175 1 NUT, HEX METRIC M12 X 1.75
16 828012-020 2 CAPSCR, HEX 8.8 M12 X 20MM
17 828012-050 2 CAPSCR, HEX 8.8 M12 X 50MM
18 828012-065 1 CAPSCR, HEX 8.8 M12 X 65MM
19 829106-125 7 CAPSCR, HEX GR5 3/8-16 X 1 1/4
20 829106-175 8 CAPSCR, HEX GR5 3/8-16 X 1 3/4
21 829110-175 4 CAPSCR, HEX GR5 5/8-11 X 1 3/4
22 837806-094 15 WASHER, SPR LOCK REG PLTD 3/8
23 837810-156 4 WASHER, SPR LOCK REG PLTD 5/8
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

11
AIR INLET SYSTEM

1.5 AIR INLET SYSTEM

02250174-282 R01

12
 PARTS LIST

1.5 AIR INLET SYSTEM

Q
KEY
PART NO. T DESCRIPTION
NO.
Y
1 02250125-369 1 filter, air 8”(plastic)w/mtg&media
2 02250162-347 1 clamp,hose o.d. 3.00
3 02250163-999 1 hose, hump red str 3.50 x 3.00
4 02250174-283 1 tube,air inlet p10-40hp
5 02250185-865 1 support, air tube inlet
6 040599 1 elbow, rubber 90 deg i.d.
7 250003-869 1 indicator, restriction 20” h20
8 250018-550 3 clamp, hose 2-13/16 to 3-3/4”
9 250031-415 1 clamp, hose 4.25/3.31
10 866402-000 1 nipple,pipe-xs plt 1/8 x cl
11 882508-125 2 nut,serr flng m8 x 1.25
12 882608-025 2 screw, hex serr washer m8 x 25
13 883008-016 2 screw, tf-hex m8 x 16 blk zinc

NOTES:
NOT USED WITH VACUUM SWITCH OPTION.

A1: TO SUPPORT BRACKET ON AIR DUCT

A2: TO UNIT
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

13
AIR PIPING, AIR-COOLED 25/30HP

1.6 AIR PIPING, AIR-COOLED 25/30HP

02250156-633R05

14
 PARTS LIST

1.6 AIR PIPING, AIR-COOLED 25/30HP

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
1 02250152-215 1 support,outlet conn 1-1/2npt
2 02250159-493 1 tube,orfs 1” aftrclr to moist sep
3 02250166-561 1 tube,orfs 1-1/4” mpv/aftrclr
4 02250167-115 1 separator, water scws-235n 1” l/ad
5 02250167-608 1 tube,1-1/4” discharge p10
6 810216-100 1 connector, tube-m 1 x 1
7 810220-125 2 connector, tube-m 1 1/4 x 1 1/4
8 811620-162 1 elbow, tube str thrd 1 1/4 x 1 5/8
9 866416-000 1 nipple,pipe-xs plt 1 x cl
10 867106-050 1 bushing,red pltd 1 1/2 x 1 1/4
11 869205-040 1 elbow, red 1 1/4 x 1 150# plt
12 882508-125 2 nut,serr flng m8 x 1.25
13 882608-016 2 screw, hex serr washer m8 x 16
14 883633-016 1 elbow,met st thd/orfs m33 x 1
15 883642-020 1 elbow,met st thd/orfs m42 x 1 1/4
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

15
AIR PIPING, AIR-COOLED 40HP

1.7 AIR PIPING, AIR-COOLED 40HP

02250174-302 R00

16
 PARTS LIST

1.7 AIR PIPING, AIR-COOLED 40HP

Q
KEY
PART NO. T DESCRIPTION
NO.
Y
1 02250152-215 1 support,outlet conn 1-1/2npt
2 02250166-734 1 separator, water scws-235n 1 1/2” l/ad
3 02250174-303 1 tube,1-1/4”-discharge p10-40hp
4 02250175-265 1 tube,1-1/4”-disch mpv/clr p10-40hp
5 810220-125 1 connector, tube-m 1 1/4 x 1 1/4
6 810520-150 1 elbow, tube 90 deg m 1 1/4 x 1 1/2
7 811620-162 2 elbow, tube str thrd 1 1/4 x 1 5/8
8 860220-150 1 elbow, 37fl 90m 1 1/4 x 1 1/2
9 867106-050 1 bushing,red pltd 1 1/2 x 1 1/4
10 882508-125 2 nut,serr flng m8 x 1.25
11 882608-016 2 screw, hex serr washer m8 x 16
12 891120-020 1 connector,sw 37 deg 1 5/8 x 1 5/8 sae

A1: FROM MINIMUM PRESSURE VALVE

A2: CUSTOMER AIR OUT CONNECTION

NOTE:
APPLY 3M 8898 4-WAY SPRAY LUBRICANT TO ALL O-RING
CONNECTIONS.
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

17
AIR PIPING WITH INTEGRAL DRYER 25/30HP

1.8 AIR PIPING WITH INTEGRAL DRYER 25/30HP

02250168-701 R01

18
 PARTS LIST

1.8 AIR PIPING WITH INTEGRAL DRYER 25/30HP

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250159-493 1 tube A1: PACKAGE DISCHARGE PRESSURE P2
2 02250166-561 1 tube A2: TO AFTERCOOLER
3 02250167-115 1 separator A3: FROM MINIMUM PRESSURE VALVE
4 02250168-568 1 support A4: FROM AFTERCOOLER
5 02250168-852 1 hose A5: FROM MOISTURE DRAIN
6 02250173-002 1 hose A6: CUSTOMER AIR OUT CONNECTION
7 810216-100 1 connector A7: COMPRESSOR AIR IN TO EVAPORATOR
8 811620-162 1 elbow A8: COMPRESSOR AIR OUT FROM EVAPORATOR
9 860116-100 1 connector PLEASE NOTE: WHEN ORDERING PARTS,
10 860216-100 2 elbow INDICATE SERIAL NUMBER OF COMPRESSOR

11 868906-040 1 bushing
12 875816-016 1 elbow
13 878416-131 1 union
14 882508-125 2 nut
15 882608-016 2 screw
16 883633-016 1 elbow
17 883642-020 1 elbow
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

19
AIR PIPING WITH INTEGRAL DRYER 40HP

1.9 AIR PIPING WITH INTEGRAL DRYER 40HP

02250183-886 R01

20
 PARTS LIST

1.9 AIR PIPING WITH INTEGRAL DRYER 40HP

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250166-734 1 separator A1: FROM MINIMUM PRESSURE VALVE
2 02250168-040 1 hose A2: CUSTOMER AIR OUT CONNECTION
3 02250168-568 1 support A3: COMPRESSOR AIR IN TO EVAPORATOR
4 02250173-002 1 hose A4: COMPRESSOR AIR OUT FROM EVAPORATOR
5 02250175-265 1 tube
6 811620-162 2 elbow NOTE:
7 860116-100 1 connector APPLY 3M 8898 4-WAY SPRAY LUBRICANT
8 860116-150 1 connector TO ALL O-RING CONNECTIONS.

9 860216-100 1 elbow PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR
10 860220-150 1 elbow
11 868906-040 1 bushing
12 875816-016 1 elbow
13 878416-131 1 union
14 882508-125 2 nut
15 882608-016 2 screw
16 891120-020 1 connector
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

21
FLUID PIPING, AIR-COOLED 25/30HP

1.10 FLUID PIPING, AIR-COOLED 25/30HP

02250156-634-R04

22
 PARTS LIST

1.10 FLUID PIPING, AIR-COOLED 25/30HP

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
1 02250099-766 1 elbow,90 sae x orfs .75”
2 02250148-796 1 valve,thermal 210f 1 1/2-18
3 02250155-708 1 filter,coreless m27 6”l
4 02250156-909 1 hose, medium pressure orfs f-swvl 3/4” x
33”
5 02250157-222 1 housing, thrm vlv 2200
6 02250161-751 1 hose, medium pressure orfs f-swvl 3/4” x
37”
7 826502-211 2 o-ring, viton 13/16 x 1/8”
8 826502-219 1 o-ring, viton 1 5/16 x 1/8”
9 829310-080 2 screw, socket iso 4762 m10 x 80mm
10 883627-012 2 elbow,met st thd/orfs m27 x 3/4
11 883727-012 1 union,str thd iso 6149 m27 x 2
12 884227-012 1 elbow,met st thd mxf m27
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

23
FLUID PIPING, AIR-COOLED 40HP

1.11 FLUID PIPING, AIR-COOLED 40HP

02250174-301 R01

24
 PARTS LIST

1.11 FLUID PIPING, AIR-COOLED 40HP

Q
KEY
PART NO. T DESCRIPTION
NO.
Y
1 02250099-766 2 elbow,90 sae x orfs .75”
2 02250155-708 1 filter,coreless m27 6”l
3 02250156-909 1 hose, medium pressure orfs f-swvlend 33”long
4 02250156-913 1 hose, medium pressure orfs f-swvl 3/4” x 54”
5 02250180-506 1 housing,thrm valve 2200 40hp
6 826502-211 2 o-ring, viton 13/16 x 1/8”
7 826502-219 1 o-ring, viton 1 5/16 x 1/8”
8 829310-080 2 screw, socket iso 4762 m10 x 80mm
9 883627-012 2 elbow,met st thd/orfs m27 x 3/4
10 883727-012 1 union,str thd iso 6149 m27 x 2
11 884227-012 1 elbow,met st thd mxf m27
12 VARIOUS 1 valve,thermal 1 1/2-18

A1: TO UNIT
A2: TO BOTTOM OF SUMP TANK
A3: TO OIL COOLER
NOTE:
APPLY 3M 8898 4-WAY SPRAY LUBRICANT TO ALL O-RING CON-
NECTIONS.
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

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

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

50HZ/25HP

02250173-352 R03

26
 PARTS LIST

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

50HZ/25HP
Q
KEY
PART NO. T DESCRIPTION
NO.
Y
1 - 1 MTR,FAN
2 02250156-137 1 CLR,AIR/OIL STD
02250164-164 CLR, AIR/OIL CRN/CE
3 02250156-637 1 FAN, CLG 16” 30HP 60HZ
02250156-638 FAN, CLG 16” 25/30HP 50HZ
4 02250058-345 7 STRIP, WEATHER 1” X 1/8” FOAM (FT)
5 02250154-721 1 SUPPORT, MOTOR FAN 1800/2200
6 02250156-639 1 VENTURI, ES8 16”
7 02250160-429 4 LOUVER,EXTRUDED 18KW 500.0 LNG
8 02250160-452 1 GD,FAN DISCHARGE P8 P10
9 02250160-536 1 DUCT,CENTRIFUGAL FAN P8 P10
10 02250160-566 2 SUPT,AIROC ES8
11 02250162-492 4 INSUL,FOAM ACOUS LOUVER P8 P10
12 02250171-617 1 PANEL, VENTURI P8/P10
13 250018-497 2 GRIP, CORD FOR SO 12/4 ST 3/4”
14 850604-012 8 WIRE, NEOPRENE #12-4 SO (FT)
15 865408-170 4 WASHER, METRIC-ISO7089- 8
16 865708-240 3 WASHER, ISO 7093-8-140HV
17 882508-125 4 NUT, SERR FLNG M8 X 1.25
18 882608-016 8 SCREW, HEX SERR WASHER M8 X 16
19 882608-030 4 SCREW, HEX SERR WASHER M8 X 30
20 883008-016 22 SCREW, TF-HEX M8 X 16 BLK ZINC
21 883306-030 16 SCREW, PLASTIC PILOT M6 X 30
22 884708-125 4 NUT, HEX LOCKING M8
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

27
COOLING AND LUBRICATION SYSTEM, AIR-COOLED AXIAL FAN, 60HZ/25HP

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

02250173-351-R02

28
 PARTS LIST

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

N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 - 1 motor, fan 1hp 4p teee 23 883306-030 16 screw, plastic pilot m6 x 30
2 02250156-137 1 cooler,air/oil p10 std 24 884708-125 4 nut,hex locking m8
02250164-164 cooler, air/oil crn/ce
PLEASE NOTE: WHEN ORDERING PARTS,
3 02250058-345 7 strip,weather 1” x 1/8” foam (ft) INDICATE SERIAL NUMBER OF COMPRESSOR
4 02250154-721 1 support, motor fan 1800/2200
5 02250160-429 4 louver,extruded 18kw 500.0 lng
6 02250160-452 1 guard, fan discharge p8 p10
7 02250160-536 1 duct,centrifugal fan p8 p10
8 02250160-566 2 support,airoc p8 p10
9 02250162-492 4 insulation,foam acous louver p8 p10
10 02250167-452 1 drive,output shaft fan
11 02250171-617 1 panel, venturi p8/p10
12 02250173-084 1 fan, 18” nylon 9-blade axial
13 250018-497 2 grip,cord for so 12/4 st 3/4”
14 821103-150 1 key, square cl1 3/16” x 1 1/2
15 850604-012 8 wire, neoprene #12-4 so (ft)
16 865408-170 4 washer, metric-iso7089- 8
17 865708-240 3 washer, iso 7093-8-140hv
18 874904-038 2 screw, set cup 1/4 x 3/8 plt
19 882508-125 4 nut,serr flng m8 x 1.25
20 882608-016 16 screw, hex serr washer m8 x 16
21 882608-030 4 screw, hex serr washer m8 x 30
22 883008-016 14 screw, tf-hex m8 x 16 blk zinc
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

29
COOLING AND LUBRICATION SYSTEM, AIR-COOLED CENTRIFUGAL FAN, 50/60HZ 40HP

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

02250174-285 R00

30
 PARTS LIST

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

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 - 1 motor,1hp 4p NOTES:
2 02250174-423 1 fan, cooling 16” 60hz 40 hp 1. PLACE WEATHER STRIPPING ON DUCT MOUNTING FACE TO
02250174-424 fan, cooling 16” 50hz 40 hp ELIMINATE AIR LEAKAGE.
3 02250154-721 1 support, motor fan 1800/2200 PLEASE NOTE: WHEN ORDERING PARTS,
4 02250156-639 1 venturi,es8 16” INDICATE SERIAL NUMBER OF COMPRESSOR

5 02250160-566 2 support,airoc es8

6 02250174-288 1 cooler,air/oil p10-40hp std
02250184-790 cooler, air/oil 40ho crn
7 02250174-294 1 duct,centrifugal fan p10-40hp
8 02250174-300 1 panel, venturi p10-40hp
9 02250180-559 1 guard, fan discharge p10-40hp
10 250018-497 2 grip,cord for so 12/4 st 3/4”
11 250022-436 5 weatherstrip, 3/16 x 3/8 ft
12 850604-012 8 wire, neoprene #12-4 so (ft)
13 865408-170 4 washer, metric-iso7089- 8
14 865708-240 3 washer, iso 7093-8-140hv
15 882508-125 4 nut,serr flng m8 x 1.25
16 882608-016 8 screw, hex serr washer m8 x 16
17 882608-030 4 screw, hex serr washer m8 x 30
18 883008-016 22 screw, tf-hex m8 x 16 blk zinc
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

31
DISCHARGE, SEPARATOR/SUMP TANK AND PIPING SYSTEM AIR-COOLED

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

02250185-892 R00

32
 PARTS LIST

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

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250055-015 1 adapter NOTES:
2 02250097-609 1 valve
3 02250156-379 3 isolator 1. APPLY LOCTITE 567 PST PIPE SEALANT TO ALL NPT CON-
4 02250157-450 1 wire NECTIONS

5 02250157-596 1 hose 2. APPLY 3M 8898 4-WAY SPRAY LUBRICANT TO ALL O-RING

CONNECTIONS
6 02250159-433 3 gasket
A1: OIL RETURN SCAVANGE LINE
7 02250185-891 1 tnk assy
A2: TO GRND LUG ON FRAME
8 825908-125 3 nut
A3: AIR IN FROM UNIT
9 838808-200 3 washer
A4: AIR OUT TO COOLER
10 865408-170 3 washer
Q1: SEE ASSEMBLY DRAWING 02250185-891
11 866900-005 1 plug
PLEASE NOTE: WHEN ORDERING PARTS,
12 870624-024 2 connector INDICATE SERIAL NUMBER OF COMPRESSOR
13 883008-016 1 screw
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

33
DISCHARGE, SEPARATOR/SUMP TANK AND PIPING SYSTEM

1.16 DISCHARGE, SEPARATOR/SUMP TANK AND PIPING SYSTEM

02250185-891 R00

34
 PARTS LIST

1.16 DISCHARGE, SEPARATOR/SUMP TANK AND PIPING SYSTEM

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250097-610 1 plug NOTES:
2 02250099-766 1 elbow
3 02250101-783 1 adapter 1. APPLY LOCTITE 567 PST PIPE SEALANT TO ALL NPT CON-
4 02250117-782 1 filter NECTIONS

5 02250125-774 1 orifice 2. APPLY 3M 8898 4-WAY SPRAY LUBRICANT TO ALL O-RING

CONNECTIONS
6 02250126-129 1 sightglass
3. CHECK ELECTRICAL CONTINUITY BETWEEN LID AND TANK
7 02250152-798 1 elbow AND APPLY VALIDATION DECAL
8 02250155-599 1 tank 4. ORIENT ELBOW (ITEM 2) 180° OPPOSITE RELIEF VALVE(ITEM
9 02250155-720 1 spring 13)
10 02250156-944 1 decal 5. ALL FITTING SHOULD BE ORIENTED HORIZONTALLY OR
VERTICALLY AS SHOWN
11 02250185-533 1 element
6. TORQUE BOLTS TO 70 FT-LBS (LUBRICATED)
12 040029 1 plug
7. MARK/TAG ASSEMBLY WITH SULLAIR P/N
13 250006-938 1 valve
14 826502-369 1 o-ring PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
15 828012-040 6 capscrew
16 838812-250 6 washer
17 874505-008 1 screw
18 876804-025 1 connector
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

35
MOISTURE DRAIN—STANDARD

1.17 MOISTURE DRAIN—STANDARD

02250171-765-R00

36
 PARTS LIST

1.17 MOISTURE DRAIN—STANDARD

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
1 02250046-110 1 bushing, red brs 1/2 x 1/4
2 02250071-380 1 grip, cord n4 .187-.250 x 1/2”
3 02250167-603 1 adapter,1/2m bspp-1/2f npt brass
4 02250170-783 1 valve, drain combo 24 vdc
5 250025-859 2 connector, male1/4tube x 1/4
6 842215-004 3 hose,nylon 1/4”
SERVICE KITS FOR 02250170-783

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

02250171-245 KIT,DRAIN VALVE SERVICE

02250171-483 CABLE,PWR REPL DRN VLV

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

37
MOISTURE DRAIN—ZERO LOSS 25/30 HP

1.18 MOISTURE DRAIN—ZERO LOSS 25/30 HP

02250182-810 R01

38
 PARTS LIST

1.18 MOISTURE DRAIN—ZERO LOSS 25/30 HP

Q
KEY
PART NO. T DESCRIPTION
NO.
Y
1 02250046-110 1 BSHG, RED BRS 1/2 X 1/4
2 02250071-380 1 GRIP,CD N4 .187-.250 X 1/2”
3 02250144-841 1 VLV,BALL/STNR COMB 1/2M X 1/2M
4 02250167-603 1 ADPT,1/2M BSPP-1/2F NPT PLATED STEEL
5 02250182-545 1 DRN,ZERO LOSS 115V 1/2”NPT
6 250024-685 2 CONN,TUBE-STRT 1/4MNPT X1/4”T
7 842215-004 3 HOSE, NYLON 1/4(FT)
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

39
MOISTURE DRAIN—ZERO LOSS 40 HP

1.19 MOISTURE DRAIN—ZERO LOSS 40 HP

02250183-721 R01

40
 PARTS LIST

1.19 MOISTURE DRAIN—ZERO LOSS 40 HP

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250046-110 2 BSHG, RED BRS 1/2 X 1/4 SERVICE KITS FOR 02250182-545
2 02250071-380 1 GRIP,CD N4 .187-.250 X 1/2” 02250182-571 KIT,VALVE SERVICE 115V ZLOSS
3 02250140-865 1 VALVE,BALL 1/8M X 1/8F 1/4 TURN
4 02250144-841 1 VLV,BALL/SRNR 1/2M X 1/2M A1: TO STARTER BOX
5 02250167-603 1 ADPT,1/2M BSPP-1/2F NPT PLATED A2: TO P2 PACKAGE DISCHARGE PRESSURE
STEEL A3: TO MOISTURE SEPARATOR
6 02250182-545 1 DRN,ZERO LOSS 115V 1/2”NPT
PLEASE NOTE: WHEN ORDERING PARTS,
7 250024-685 2 CONN,TUBE-STRT 1/4MNPT X1/4”T INDICATE SERIAL NUMBER OF COMPRESSOR
8 250025-849 1 ELBOW,90DEG M SWVL 1/4T X 1/8NPT
9 250025-850 1 ELBOW, 90DEG M SWVL 1/4T X 1/4
NPT
10 842215-004 6 HOSE, NYLON 1/4(FT)
11 866302-020 1 NIPPLE, PIPE PLTD 1/8 X 2
12 878212-012 1 TEE, FEMALE PIPE BRASS 1/8”
13 881108-050 1 ELBOW, PIPE 90F 1/2 X 1/2 BRASS
14 881308-050 1 NIPPLE, PIPE-HX BRASS 1/2 X 1/2
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

41
MOISTURE DRAIN, AIR-COOLED WITH INTEGRAL DRYER

1.20 MOISTURE DRAIN, AIR-COOLED WITH INTEGRAL DRYER

02250170-758 R01

42
 PARTS LIST

1.20 MOISTURE DRAIN, AIR-COOLED WITH INTEGRAL DRYER

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
1 02250046-110 1 bushing,red-brs-1/2"x1/4"
2 02250071-362 1 locknut, n4 conduit sealing
3 02250071-380 1 grip, cord n4 .187-.250 x 1/2"
4 02250167-603 1 adapter,1/2m bspp-1/2f npt plated steel
5 02250170-783 1 valve, drain combo 24 vdc
6 049905 1 valve, check 1/4"
7 250025-850 3 elbow, 90deg m swvl 1/4t x 1/4 npt
8 842215-004 5 hose,nylon 1/4(ft)
9 866304-015 1 nipple,pipe pltd 1/4 x 1 1/2
10 868902-010 1 bushing,red hex pltd 1/2 x 1/4
11 868902-010 1 tee,male pipe brass 1/4

A1 TO AIROUT BRACKET
A2 FROM WATER SEPERATOR
A3 TO BOTTOM OF STARTER BOX
A4 FROM REFRIGERANT EVAPORATOR CONDENSATE HOSE
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

43
PNEUMATIC CONTROL SYSTEM—NYLON

1.21 PNEUMATIC CONTROL SYSTEM—NYLON

02250157-077-R07

44
 PARTS LIST

1.21 PNEUMATIC CONTROL SYSTEM—NYLON

N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 02250049-634 1 valve, blowdown 1/4 npt hi prs 24 881304-025 3 nipple, pipe-hx brass 1/4 x 1/4
2 02250071-362 2 locknut, n4 conduit sealing
3 02250099-630 3 tube, nylon .375"od x .050w black (ft) A1 Port 2
4 02250115-272 1 valve, check 1/4" poppet style A2 Port 3
5 02250118-586 1 orifice,.078 .25 fnpt x .25 mnpt A3 Load control subassembly
6 02250155-714 2 valve, solenoid 3wno 1/4 250# 24vdc (I) A4 Sequencing subassembly
7 02250155-961 3 tbg, nylon 1/4"-od red A5 Blowdown subassembly
8 02250155-962 3 tbg, nylon 1/4"-od blue A6 Flow
9 02250155-963 3 tbg, nylon 1/4"-od yellow
10 241771 1 strainer, v-type 300psix1/4 (II) (I) For maintenance on solenoid valve no. 02250155-714, order repair kit no.
11 250017-280 1 valve, pressure regulator (III) 02250157-500 and replacement coil no. 02250157-502
(II) For maintenance on strainer no. 241771, order repair kit no. 241772
12 250018-430 2 elbow, 90 1/4t pls x 1/4 npt m (III) For maintenance on pressure regulator no. 250017-280, order repair kit
13 250025-835 1 tee, male branch swiv 1/4 tube x 1/4 npt no. 250019-453
14 250025-850 7 elbow, 90deg m swvl 1/4t x 1/4 npt PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
15 250025-852 1 elbow, 90deg m swvl 3/8 t x1/4
16 250025-858 1 connector, male 1/4tube x 1/8
17 250025-859 1 connector, male1/4tube x 1/4
18 250025-923 1 connector, fem tube 1/4 x 1/4 nptf
19 250025-926 1 connector, fem tube 3/8 x 1/4 nptf
20 250025-926 1 valve, shuttle 1/4" npt (dbl chk)
21 811502-025 1 adapter, fem pipe 1/4" x 7/16"-20
22 847815-050 2 adapter, fem pipe 1/4" x 7/16"-20
23 869825-025 2 tee, male pipe brass 1/4
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

45
PNEUMATIC CONTROL SYSTEM—STAINLESS STEEL

1.22 PNEUMATIC CONTROL SYSTEM—STAINLESS STEEL

02250158-319-R06

46
 PARTS LIST

1.22 PNEUMATIC CONTROL SYSTEM—STAINLESS STEEL

N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 02250046-101 1 bushing, red brs 1/4 x 1/8 A1- PORT 2
2 02250049-634 1 valve, blowdown 1/4 npt hi prs A2- PORT 3
3 02250071-362 2 locknut, n4 conduit sealing A3- PORT 1
4 02250115-272 1 valve,check 1/4” poppet style A4- SUBASSEMBLY, LOAD CONTROL
5 02250118-586 1 orifice,.078 .25 fnpt x .25 mnpt A5- SUBASSEMBLY, SEQUENCING
6 02250155-714 2 valve, solenoid 3wno 1/4 250# 24vdc A6- SUBASSEMBLY, BLOWDOWN
7 02250173-972 1 filter,pneumatic 1/8”npt 5micr A7- FLOW DIRECTION
8 241771 1 strainer, v-type 300psix1/4 SERVICE KITS FOR 241771
9 250017-280 1 valve, pressure regulator 241772 KIT, REP STRAINER-V-TYPE
10 250018-760 3 nipple,hx tbe 316s 1/4” SERVICE KITS FOR 250017-280
11 250139-016 1 connector, tube-m 1/4 swglk 316s 250019-453 KIT, REPAIR PRESS REG VALVE
12 250139-024 1 connector, tube-m 1/4 x 1/8 316s SERVICE KITS FOR 02250155-714
13 250139-044 1 connector, tube-f 1/4 swglk 316s 02250157-500 KIT,SOL VLV 3WNO 24VDC
14 250139-053 1 connector, tube-f 3/8 x 1/4 316s PLEASE NOTE: WHEN ORDERING PARTS,
15 250211-005 8 elbow,tube-m 1/4” swglk 316ss INDICATE SERIAL NUMBER OF COMPRESSOR

16 250211-017 1 elbow, tube-m3/8t x1/4p swg ss

17 250591-002 1 tee,tube-m branch 1/4 swg ss
18 408893 1 valve, shuttle 1/4” npt (dbl chk)
19 811502-025 1 adapter, fem pipe 1/4 x 7/16-20
20 841215-004 6 tubing, stnls stl 1/4 20ga ft
21 841215-006 3 tubing, stnls stl 3/8 20ga ft
22 847815-050 2 nipple,chase cond 1/2
23 869825-025 2 tee,male pipe brass 1/4
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

47
CONTROL SYSTEM AND ELECTRICAL PARTS, MFV

1.23 CONTROL SYSTEM AND ELECTRICAL PARTS, MFV

02250156-917-R05

48
 PARTS LIST

1.23 CONTROL SYSTEM AND ELECTRICAL PARTS, MFV

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250054-861 1 TUBE,NYL .25 OD X 040W BLK(FT) 24 250034-627 1 BUTTON, PUSH NON-ILLUM BLK N4X
2 02250057-245 2 BLK,TERM END STOP CH 25 250041-102 3 BLOCK,TERMINAL KT3
3 02250058-345 1 STRIP, WEATHER 1” X 1/8” FOAM (FT) 26 250041-103 1 BLOCK,TERM ADAPTER KAD
4 02250060-705 1 R,DIN 35MM (METERS) 27 825908-125 6 NUT, HEX METRIC M8 X 1.25
5 02250071-379 3 GRIP,CD N4 .125-.187 X 1/2” 28 838808-200 6 WASHER, SPR LOCK-METRIC PLTD M8
6 02250071-380 1 GRIP,CD N4 .187-.250 X 1/2” 29 841215-004 1 TUBING, ST STL 1/4” 20GA
7 02250071-381 2 GRIP,CD N4 .250-.375 X 1/2” 30 865408-170 6 WASHER, METRIC-ISO7089- 8
8 02250078-249 1 SW,VAC 22”WC N4 6FT CABLE 5A 31 FUSE,DRYER 1 VARIOUS
9 02250083-182 1 XFMR,PT 50VA UNIV W/PRI FH 32 FUSE,PRI 2 VARIOUS
10 02250100-363 1 SW,DIFF PRESS 20PSID 12FT 33 FUSE,SEC 1 VARIOUS
11 02250155-174 2 XDCR, PRESS 0-250# RATIOMETRIC 34 PHASE MNTR 1 VARIOUS
12 02250155-175 1 P,RTD 100 OHM PLAT 3.5”X 6FT 35 POWER 1 VARIOUS
13 02250157-450 1 W, 10 GAGE GROUND BOND 12” M8 SUPPLY

14 02250158-377 2 RLY, SPTD DIN 10A 24VDC COIL 36 RELAY,OVLD 1 VARIOUS

15 02250175-087 1 P,THERMISTER 3000 OHM NTC 12’L 37 STARTER 1 VARIOUS

ASSY
16 249008 1 HEATER, ENCLOSURE 50W
Continued on page 51
17 250018-427 1 CONN, 1/4” TUBE X 1/8” NPT
PLEASE NOTE: WHEN ORDERING PARTS,
18 250018-429 3 ELBOW, 90 1/4”TUBE X 1/8”NPT INDICATE SERIAL NUMBER OF COMPRESSOR
19 250019-771 1 HOLDER,FUSE 1P 30A 600V
20 250023-496 1 CONN, CORD GRIP 0.09-0.26
21 250025-849 1 ELBOW,90DEG M SWVL 1/4T X 1/8NPT
22 250025-858 1 CONNECTOR, MALE 1/4TUBE X 1/8
23 250034-430 1 SOCKET, 8PIN 480V
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

49
CONTROL SYSTEM AND ELECTRICAL PARTS, MFV (CONTINUED)

1.24 CONTROL SYSTEM AND ELECTRICAL PARTS, MFV (CONTINUED)

02250156-917-R05

50
 PARTS LIST

1.24 CONTROL SYSTEM AND ELECTRICAL PARTS, MFV

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
A1: TO FRAME A21: T3-TO INTEGRAL DRYER EVAPORATOR
A2: P2-PACKAGE DISCHARGE PRESSURE DRYER DEW POINT TEMPERATURE

A3: P1-TO SUMP TANK A22: CSA OPTION

WET SUMP PRESSURE A23: OTHER OPTIONS
A4: T1-TO SUMP TANK
WET DISCHARGE TEMPERATURE Q1: SEE ASSY DRAWINGS:
A5: SOLENOID 1 02250169-624 DWG,START P8/10 MFV TAB
A6: SOLENOID 4
A7: SOLENOID 5-ELECTRIC DRAIN PLEASE NOTE: WHEN ORDERING PARTS,
A8: FAN MOTOR CONNECTION INDICATE SERIAL NUMBER OF COMPRESSOR

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 SUP-
PORT
A20: DIFFERENTIAL PRESSURE SWITCH OPTION
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

51
CONTROL SYSTEM AND ELECTICAL PARTS, VSD

1.25 CONTROL SYSTEM AND ELECTICAL PARTS, VSD

02250165-276-R03

52
 PARTS LIST

1.25 CONTROL SYSTEM AND ELECTICAL PARTS, VSD

N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 02250050-154 1 switch, defferential pressure 20psid 12ft or 32 FUSE,FAN 3 various
2 02250057-245 2 block, term end stop ch 33 FUSE,PRI 2 various
3 02250058-345 1 strip,weather 1” x 1/8” foam (ft) 34 FUSE,SEC 1 various
4 02250060-705 1 rail,din 35mm (meters) 35 PHASE MNTR 1 various
5 02250071-379 3 grip, cord n4 .125-.187 x 1/2” 36 STARTER ASSY 1 various
6 02250071-380 1 grip, cord n4 .187-.250 x 1/2” A1: TO FRAME
7 02250071-381 2 grip, cord n4 .250-.375 x 1/2” A2: P2-PACKAGE DISCHARGE PRESSURE
8 02250078-249 1 switch, vacuum 22”wc n4 6ft cable 5a A3: P1-TO SUMP TANK WET SUMP PRESSURE
9 02250083-182 1 transformer, control 50va univ w/pri fh A4: T1-TO SUMP TANK WET DISCHAGE TEMPERATURE
10 02250155-174 2 transducer, pressure 0-250# ratiometric A5: SOLENOID 1
11 02250155-175 1 probe,rtd 100 ohm plat 3.5”x 6ft A6: SOLENOID 4
12 02250157-450 1 wire,10 gage ground bond 12” m8 A7: SOLENOID 5-ELECTRIC DRAIN
13 02250158-377 2 relay,sptd din 10a 24vdc coil A8: FAN MOTOR CONNECTION
14 02250175-087 1 probe,thermister 3000 ohm ntc 12’l A9: MOTOR WIRING
15 0225054-861 1 tube,nyl .25 od xx 040w blk(ft) A10: SCD DRAIN OPTION
16 249008 1 heater, enclosure 50w A11: DRYER OPTION
17 250018-427 1 connector,1/4” tube x 1/8” npt - A12: HOLE TO BE DRILLED IN BOX AS NEEDED
18 250018-429 3 elbow, 90 1/4”tube x 1/8”npt - A13: HEATER OPTIONS
19 250019-771 1 holder,fuse 1p 30a 600v A14: ENCLOSURE HEATER MOUNTED INSIDE TOP OF STARTER BOX
20 250023-496 1 connector,cord grip 0.09-0.26 A15: DRYER CTL POWER - 24VDC
21 250025-849 1 elbow,90deg m swvl 1/4t x 1/8npt A16: DRYER COMPRESSOR MOTOR POWER
22 250025-858 1 connector, male 1/4tube x 1/8 A17: PHASE MONITOR OPTION
23 250034-430 1 socket, 8pin 480v A18: TO AIR FILTER
24 250034-627 1 button, push non-illum blk n4x A19: INLET PRESSURE SWITCH OPTION MOUNT TO FAN MOTOR SUPPORT
25 250041-102 3 block,terminal kt3 A20: DIFFERENTIAL PRESSURE SWITCH OPTION
26 250041-103 1 block,term adapter kad A21: T3-TO INTEGRAL DRYER EVAPORATOR DRYER DEWPOINT TEMPERATURE
27 825908-125 6 nut,hex metric m8 x 1.25 A22: CSA OPTION
28 838808-200 6 washer, spr lock-metric pltd m8 A23: OTHER OPTIONS
29 841215-004 1 tubing, st stl 1/4” 20ga Q1: SEE ASSY DRAWINGS:
30 865408-170 6 washer, metric-iso7089- 8 02250169-671 DWG,START P8/10 VSD TAB
31 FUSE,DRYER 1 various PLEASE NOTE: WHEN ORDERING PARTS,
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
INDICATE SERIAL NUMBER OF COMPRESSOR

53
CONTROL SYSTEM AND ELECTRIC PARTS, 230/460 WYE-DELTA

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

02250165-275-R03

54
 PARTS LIST

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

N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 02250050-154 1 switch, defferential pressure 20psid 12ft or 32 FUSE,PRI 2 various
2 02250054-861 1 tube,nyl .25 od xx 040w blk(ft) 33 FUSE,SEC 1 various
3 02250057-245 2 block, term end stop ch 34 PHASE MNTR 1 various
4 02250058-345 1 strip,weather 1” x 1/8” foam (ft) 35 POWER SUPPLY 1 various
5 02250060-705 1 rail,din 35mm (meters) 36 RELAY,OVLD 1 various
6 02250071-379 3 grip, cord n4 .125-.187 x 1/2” 37 STARTER ASSY 1 various
7 02250071-380 1 grip, cord n4 .187-.250 x 1/2” A1: TO FRAME
8 02250071-381 2 grip, cord n4 .250-.375 x 1/2” A2: P2-PACKAGE DISCHARGE PRESSURE
9 02250078-249 1 switch, vacuum 22”wc n4 6ft cable 5a A3: P1-TO SUMP TANK WET SUMP PRESSURE
10 02250083-182 1 transformer, control 50va univ w/pri fh A4: T1-TO SUMP TANK WET DISCHAGE TEMPERATURE
11 02250155-174 2 transducer, pressure 0-250# ratiometric A5: SOLENOID 1
12 02250155-175 1 probe,rtd 100 ohm plat 3.5”x 6ft A6: SOLENOID 4
13 02250157-450 1 wire,10 gage ground bond 12” m8 A7: SOLENOID 5-ELECTRIC DRAIN
14 02250158-377 2 relay,sptd din 10a 24vdc coil A8: FAN MOTOR CONNECTION
15 02250175-087 1 probe,thermister 3000 ohm ntc 12’l A9: MOTOR WIRING
16 249008 1 heater, enclosure 50w A10: SCD DRAIN OPTION
17 250018-427 1 connector,1/4” tube x 1/8” npt A11: DRYER OPTION
18 250018-429 3 elbow, 90 1/4”tube x 1/8”npt A12: HOLE TO BE DRILLED IN BOX AS NEEDED
19 250019-771 1 holder,fuse 1p 30a 600v A13: HEATER OPTIONS
20 250023-496 1 connector,cord grip 0.09-0.26 A14: ENCLOSURE HEATER MOUNTED INSIDE TOP OF STARTER BOX
21 250025-849 1 elbow,90deg m swvl 1/4t x 1/8npt A15: DRYER CTL POWER - 24VDC
22 250025-858 1 connector, male 1/4tube x 1/8 A16: DRYER COMPRESSOR MOTOR POWER
23 250034-430 1 socket, 8pin 480v A17: PHASE MONITOR OPTION
24 250034-627 1 button, push non-illum blk n4x A18: TO AIR FILTER
25 250041-102 3 block,terminal kt3 A19: INLET PRESSURE SWITCH OPTION MOUNT TO FAN MOTOR SUPPORT
26 250041-103 1 block,term adapter kad A20: DIFFERENTIAL PRESSURE SWITCH OPTION
27 825908-125 6 nut,hex metric m8 x 1.25 A21: T3-TO INTEGRAL DRYER EVAPORATOR DRYER DEWPOINT TEMPERATURE
28 838808-200 6 washer, spr lock-metric pltd m8 A22: CSA OPTION
29 841215-004 1 tubing, st stl 1/4” 20ga A23: OTHER OPTIONS
30 865408-170 6 washer, metric-iso7089- 8 Q1: SEE ASSY DRAWINGS:
31 FUSE,DRYER 1 various 02250169-665 DWG,START P8/10 YD N4 TAB
PLEASE NOTE: WHEN ORDERING PARTS, PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR INDICATE SERIAL NUMBER OF COMPRESSOR

55
CONTROL SYSTEM AND ELECTRIC PARTS, YD CE

1.27 CONTROL SYSTEM AND ELECTRIC PARTS, YD CE

02250179-957-R00

56
 PARTS LIST

1.27 CONTROL SYSTEM AND ELECTRIC PARTS, YD CE

N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 02250057-241 12 block, term 45a 600v euro ch
2 02250057-245 6 block, term end stop ch A1: TO FRAME
3 02250058-345 1 strip,weather 1” x 1/8” foam A2: P2-PACKAGE DISCHARGE PRESSURE
4 02250060-705 3 rail,din 35mm (meters) A3: P1-TO SUMP TANK
5 02250071-379 1 grip, cord n4 .125-.187 x 1/2” WET SUMP PRESSURE

6 02250071-381 2 grip, cord n4 .250-.375 x 1/2” A4: T1-TO SUMP TANK

WET DISCHARGE TEMPERATURE
7 02250083-181 1 transformer, control 50va univ w/o pri fh
A5: SOLENOID 1
8 02250131-188 3 breaker, circ-h high inrush
A6: SOLENOID 4
9 02250155-174 2 transducer, pressure 0-250# ratiometric
A7: SCD DRAIN OPTION
10 02250155-175 1 probe,rtd 100 ohm plat 3.5”x 6ft
A8: HEATER OPTIONS
11 02250157-449 1 wire, ground bond 30” 10 ga
A9: PHASE MONITOR OPTION
12 02250158-377 2 relay,sptd din 10a 24vdc coil
A10: STARTER BOX HEATER
13 02250167-814 1 relay,ovrld base for xt frame c MOUNTED INSIDE TOP OF STARTER BOX
14 02250179-970 1 relay,phase monitor ce A11: OTHER OPTIONS
15 249008 1 heater, enclosure 50w
16 250034-430 1 socket, 8pin 480v SERVICE KITS FOR 02250178-681
17 825908-125 6 nut,hex metric m8 x 1.25 02250178-681 DWG,START P10 CE YD N4 TAB
18 838808-200 6 washer, spr lock-metric pltd m8 PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
19 849306-008 1 terminal, ring tng 3/8 x 8ga
20 865408-170 6 washer, metric-iso7089- 8
21 RELAY 1 various
OVERLOAD
22 STARTER 2 various
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

57
CONTROL SYSTEM AND ELECTRIC PARTS, VSD CE

1.28 CONTROL SYSTEM AND ELECTRIC PARTS, VSD CE

02250179-958-R00

58
 PARTS LIST

1.28 CONTROL SYSTEM AND ELECTRIC PARTS, VSD CE

N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 02250057-241 12 block, term 45a 600v euro ch A1: TO FRAME
2 02250057-245 6 block, term end stop ch A2: P2-PACKAGE DISCHARGE PRESSURE
3 02250058-345 1 strip,weather 1” x 1/8” foam A3: P1-TO SUMP TANK
4 02250060-705 3 rail,din 35mm (meters) WET SUMP PRESSURE

5 02250071-379 1 grip, cord n4 .125-.187 x 1/2” A4: T1-TO SUMP TANK

WET DISCHARGE TEMPERATURE
6 02250071-381 2 grip, cord n4 .250-.375 x 1/2”
A5: SOLENOID 1
7 02250083-181 1 transformer, control 50va univ w/o pri fh
A6: SOLENOID 4
8 02250131-188 3 breaker, circ-h high inrush
A7: SCD DRAIN OPTION
9 02250154-607 1 block, contact aux 1no ch-it a-e
A8: HEATER OPTIONS
10 02250155-174 2 transducer, pressure 0-250# ratiometric
A9: PHASE MONITOR OPTION
11 02250155-175 1 probe,rtd 100 ohm plat 3.5”x 6ft
A10: STARTER BOX HEATER
12 02250157-449 1 wire, ground bond 30” 10 ga MOUNTED INSIDE TOP OF STARTER BOX
13 02250158-377 2 relay,sptd din 10a 24vdc coil A11: OTHER OPTIONS
14 02250162-392 1 starter,1.9a fv ch-it
15 02250179-970 1 relay,phase monitor ce SERVICE KITS FOR 02250178-751
16 249008 1 heater, enclosure 50w 02250178-751 START,ASY P10 CE VSD N12
17 250034-430 1 socket, 8pin 480v PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
18 825908-125 6 nut,hex metric m8 x 1.25
19 838808-200 6 washer, spr lock-metric pltd m8
20 849306-008 1 terminal, ring tng 3/8 x 8ga
21 865408-170 6 washer, metric-iso7089- 8
22 STARTER 1 various

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

59
CONTROL STARTER—MFV

1.29 CONTROL STARTER—MFV

02250169-587 R06

60
 PARTS LIST

1.29 CONTROL STARTER—MFV

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250169-621 SPEC, ENCL P12/16 22” X 36” X 10” 18 02250145-194 BLOCK, POWER DISTRIBUTION 310 AMP
2 02250167-818 CNTOR,65A 3P 24VDC XT 18 02250145-195 BLOCK, POWER DISTRIBUTION 175 AMP
2 02250170-761 CNTOR,80A 3P 24VDC XT 19 250021-692 RELAY,OVERLOAD 32A
2 02250167-819 CNTOR,95A 3P 24VDC XT 20 02250167-849 BLK,AUX CONT 1NO 1NC FRONT
2 02250170-760 CNTOR,115A 3P 24VDC XT 21 250019-773 HOLDER,FUSE KTK-R 3 POLE
2 02250167-820 CNTOR,150A 3P 24VDC XT
2 02250167-821 CNTOR,225A 3P 24VDC XT NOTES:
2 02250167-822 CNTOR,400A 3P 24VDC XT -SEPARATE DC CONTROL WIRING FROM AC CONTROL WIRING
3 02250101-721 BAR, GROUND 5 POST -ALL DC CONTROL WIRES TO BE DARK BLUE IF NOT
4 02250154-051 CTL,DISPLAY WS IN A CABLE.

5 02250161-759 SPCR,.25DIA X .41 LONG - ALUM -GROUND WIRES ARE GREEN WITH YELLOW TRACER.

6 02250154-052 CTL,I/O MOD WS 24VDC -ALL COMPONENTS TO BE UL AND CSA APPROVED.

7 250021-694 ADAPTER,O.L.R. BASE MNT -MANUFACTURER: CUTLER-HAMMER

8 - LUG, GROUND -SULLAIR P/N 02250159-549 AND 02250159-547

SHOULD NOT BE INSTALLED AND WIRED BUT SHOULD
9 - WASHER,LOCK EXTERNAL TOOTH 5/16” BE SECURELY SHIPPED LOOSE INSIDE STARTER BOX.
10 250014-827 CB, 100A HMCP -DO NOT ROUTE WIRING THROUGH OPTIONAL COMPONENT
11 250014-127 KIT, CIR BRKR DISCONNECT N4 LOCATIONS.
12 02250154-359 DECAL,MICROPROCESSOR OVERLAY -ROUTE COMMUNICATION CABLE FROM I/O MODULE TO
DISPLAY MODULE OFF OF THE SUB-PANEL.
13 02250085-504 SW,PB OPER RED40MM PUSH-TWIST
14 250027-125 BLOCK, CONTACT 1 N.C PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
15 02250081-473 NPL,YELLOW RING 45MM E-STOP
16 02250159-547 RCPT,S4 PROGRAM PORT NEMA 6P
17 02250159-549 CAP,S4 PROGRAM PORT NEMA 6P
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

61
CONTROL STARTER—WYE-DELTA

1.30 CONTROL STARTER—WYE-DELTA

02250169-659 R07

62
 PARTS LIST

1.30 CONTROL STARTER—WYE-DELTA

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250169-621 SPEC, ENCL P12/16 22” X 36” X 10” 19 02250145-194 BLOCK,POWER DISTRIBUTION 310 AMP
2 02250167-817 CNTOR,32A 3P 24VDC XT 20 02250167-843 BLK,AUX CONT 1NO 1NC FRONT
2 02250167-818 CNTOR,65A 3P 24VDC XT 20 02250167-849 BLK,AUX CONT 1NO 1NC FRONT
2 02250167-819 CNTOR,95A 3P 24VDC XT 21 250019-773 HOLDER,FUSE KTK-R 3 POLE
2 02250167-820 CNTOR,150A 3P 24VDC XT
2 02250167-821 CNTOR,225A 3P 24VDC XT NOTES:
3 250021-692 RELAY,OVERLOAD 32A -SEPARATE DC CONTROL WIRING FROM AC CONTROL WIRING
4 02250154-052 CTL,I/O MOD WS 24VDC -ALL DC CONTROL WIRES TO BE DARK BLUE IF NOT
5 02250101-721 BAR, GROUND 5 POST IN A CABLE.

6 02250154-051 CTL,DISPLAY WS -GROUND WIRES ARE GREEN WITH YELLOW TRACER.

7 02250154-359 DECAL,MICROPROCESSOR OVERLAY -ALL COMPONENTS TO BE UL AND CSA APPROVED.

8 02250161-759 SPACER,6.35 DIA X 10.4 LONG ALUM -MANUFACTURER: CUTLER-HAMMER

9 - LUG, GROUND -SULLAIR P/N 02250159-549 AND 02250159-547

SHOULD NOT BE INSTALLED AND WIRED BUT SHOULD
10 - WASHER,LOCK EXTERNAL TOOTH 5/16” BE SECURELY SHIPPED LOOSE INSIDE STARTER BOX.
11 250014-827 CB, 100A HMCP -DO NOT ROUTE WIRING THROUGH OPTIONAL COMPONENT
12 250014-127 KIT, CIR BKR DISCONNECT N4 LOCATIONS.
13 02250085-504 SW,PB OPER RED40MM PUSH-TWIST -ROUTE COMMUNICATION CABLE FROM I/O MODULE TO
DISPLAY MODULE OFF OF THE SUB-PANEL.
14 250027-125 BLOCK, CONTACT 1 N.C
15 02250081-473 NPL,YELLOW RING 45MM E-STOP PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
16 250021-694 ADAPTER,O.L.R. BASE MNT
17 02250159-547 RCPT,S4 PROGRAM PORT NEMA 6P
18 02250159-549 CAP,S4 PROGRAM PORT NEMA 6P
19 02250145-195 BLOCK,POWER DISTRIBUTION 175 AMP
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

63
CONTROL STARTER—VSD N12

1.31 CONTROL STARTER—VSD N12

02250169-392R02

64
 PARTS LIST

1.31 CONTROL STARTER—VSD N12

KEY TORQUE VALUES (IN/LBS)

PART NO. DESCRIPTION
NO. SULLAIR P/N DESCRIPTION LUG
1 02250168-846 1 1 1 1 1 1 1 1 SPEC, ENCL P8/10 22” X 26” X 10” 02250165-108 DRIVE, VFD C-H 575V 100A NEMA12 340-187
2 02250157-727 - 1 - - - - - - DRIVE, VFD C-H 575V 80A NEMA12 02250157-716 DRIVE, VFD C-H 380-460V 61A NEMA12 35
2 02250157-726 - - 1 - - - - - DRIVE, VFD C-H 575V 62A NEMA12 02250157-717 DRIVE, VFD C-H 380-460V 72A NEMA12 85
2 02250157-725 - - - 1 - - - - DRIVE, VFD C-H 575V 52A NEMA12 02250157-718 DRIVE, VFD C-H 380-460V 87A NEMA12 85
02250157-719 DRIVE, VFD C-H 380-460V 105 NEMA12 85
2 02250157-719 - - - - 1 - - - DRIVE, VFD C-H 380/460V 105A NEMA12
02250157-725 DRIVE, VFD C-H 575V 52A NEMA12 85
2 02250157-718 - - - - - 1 - - DRIVE, VFD C-H 380/460V 87A NEMA12
02250157-726 DRIVE, VFD C-H 575V 62A NEMA12 340-187
2 02250157-717 - - - - - - 1 - DRIVE, VFD C-H 380/460V 72A NEMA12
02250157-727 DRIVE, VFD C-H 575V 80A NEMA12 340-187
2 02250157-716 - - - - - - - 1 DRIVE, VFD C-H 380/460V 61A NEMA12
2 02250165-108 1 - - - - - - - DRIVE, VFD C-H 757V 100A NEMA 12
3 02250154-052 1 1 1 1 1 1 1 1 CTL, I/O MOD WS 24VDC
4 02250170-668 1 1 1 1 1 1 1 1 BAR, GROUND 9 POST
5 02250154-051 1 1 1 1 1 1 1 1 CTL, DISPLAY WS
6 - 2 2 2 2 2 2 2 2 LUG, GROUND
7 - 2 2 2 2 2 2 2 2 WASHER LOCK EXTERNAL TOOTH 5/16”
8 02250154-359 1 1 1 1 1 1 1 1 DECAL, MICROPROCESSOR OVERLAY
9 250019-773 1 1 1 1 1 1 1 1 HOLDER, FUSE KTK-R 3 POLE
10 02250085-504 1 1 1 1 1 1 1 1 SW, PB OPER RED 40MM PUSH-TWIST
11 250027-125 1 1 1 1 1 1 1 1 BLOCK, CONTACT 1 N.C.
12 02250081-473 1 1 1 1 1 1 1 1 NPL, YELLOW RING 45MM E-STOP
13 02250145-195 - - - 1 1 1 1 1 BLOCK, POWER DISTR 175A 2/0-#14AWG
14 02250159-547 1 1 1 1 1 1 1 1 RCPT, S4 PROGRAM PORT NEMA 6P
15 02250159-549 1 1 1 1 1 1 1 1 CAP, S4 PROGRAM PORT NEMA 6P
16 02250161-759 4 4 4 4 4 4 4 4 SPRC, .25DIA X .41 LONG-ALUM
17 02250155-754 1 1 1 1 - - - - SPLY, PWR 575VAC/24VDC CH-IT
18 02250168-820 - - - 1 1 1 1 - PLATE, FILLER FOR VSD FRAME 7
19 02250168-819 - - - - - - - 1 PLATE, FILLER FOR VSD FRAME 9
20 - - - - - - - - 1 KIT, VSD MOUNTING FLANGE FRAME 6
20 - - - - 1 1 1 1 - KIT, VSD MOUNTING FLANGE FRAME 7
20 - 1 1 1 - - - - - KIT, VSD MOUNTING FLANGE FRAME 8

65
CONTROL STARTER—VSD CE N12

1.32 CONTROL STARTER—VSD CE N12

02250178-751-R00

66
 PARTS LIST

1.32 CONTROL STARTER—VSD CE N12

KEY TORQUE VALUES (IN/LBS)

PART NO. DESCRIPTION
NO. SULLAIR P/N DESCRIPTION LUG TERMINALS
1 02250178-946 SPEC, ENCL CE P8/10 19" X 24.5" X 7 02250167-818 CNTOR, 65A 3P 24VAC 1NO XT 29.2 10.6
02250167-817 CNTOR, 32A 24VAC 1NO XT 26.6 10.6
2 02250157-716 DRIVE, VSD, CH 380 460 61A N12
2 02250157-714 DRIVE, VSD CH 380/460V 38A N12
3 02250154-052 CTL, I/O MOD WS 24VDC
4 02250170-668 BAR, GROUND 9 POST
5 02250154-051 CTL, DISPLAY WS
6 02250154-359 DECAL, MICROPROCESSOR OVERLAY
7 02250161-759 SPACER, 6.35 DIA X 10.4 LONG ALUM
8 — LUG, GROUND
9 838405-034 WASHER, LOCK EXTERNAL TOOTH 5/16"
10 02250145-195 BLOCK, POWER DISTRIBUTION 175 AMP
11 02250085-504 SW, PB OPER RED40MM PUSH-TWIST
12 250027-125 BLOCK, CONTACT 1 N.C.
13 02250081-473 NPL, YELLOW RING 45MM E-STOP
14 02250159-547 RCPT, S4 PROGRAM PORT NEMA 6P
15 02250159-549 CAP, S4 PROGRAM PORT NEMA 6P
16 02250122-036 SPLY, PWE 360-480VAC/24VDC CH-IT
17 02250178-679 COVER, POWER BLOCK
18 02250060-705 R, DIN 35MM (METERS)
19 02250131-188 CB, 15A 1P HI INRUSH WMS1D15
20 02250057-245 BLK, TERM END STOP C383CH
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

67
CONTROL STARTER—YD CE N4

1.33 CONTROL STARTER—YD CE N4

02250178-681-R00

68
 PARTS LIST

1.33 CONTROL STARTER—YD CE N4

KEY TORQUE VALUES (IN/LBS)

PART NO. DESCRIPTION
NO.
SULLAIR P/N DESCRIPTION LUG TERMINALS
1 02250178-949 SPEC, ENCL CE YD P8/P10 19X24.5X7
02250167-818 CNTOR, 65A 3P 24VAC 1NO XT 29.2 10.6
2 02250167-817 CNTOR, 32A 3P 24VDC 1NO XT
02250167-817 CNTOR, 32A 24VAC 1NO XT 26.6 10.6
3 02250154-052 CTL, I/O MOD WS 24VDC
4 02250101-721 BAR, GROUND 5 POST
5 02250154-051 CTL, DISPLAY WS
6 02250154-359 DECAL, MICROPROCESSOR OVERLAY
7 02250161-759 SPACER, 6.35DIA X 10.4 LONG ALUM
8 849215-025 LUG, GROUND
9 838405-034 WASHER, LOCK EXTERNAL TOOTH 5/16”
10 02250085-504 SW, PB OPER RED40MM PUSH-TWIST
11 250027-125 BLOCK, CONTACT 1 N.C.
12 02250081-473 NPL, YELLOW RING 45MM E-STOP
13 02250159-547 RCPT, S4 PROGRAM PORT NEMA 6P
14 02250159-549 CAP, S4 PROGRAM PORT NEMA 6P
15 02250145-195 BLK, POWER DISTRIBUTION 175A
16 02250167-843 BLK, AUX CONT 1NO 1NC FRONT
17 02250178-679 CVR, POWER BLOCK CE
18 02250122-036 SPLY, PWR 360-48AC/24DC CH-IT
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

69
ENCLOSURE, AIR-COOLED 25/30HP

1.34 ENCLOSURE, AIR-COOLED 25/30HP

02250155-649 R05

70
 PARTS LIST

1.34 ENCLOSURE, AIR-COOLED 25/30HP

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
1 02250150-893 4 cap, molded canopy corner
2 02250152-323 4 insulation, foam 2" corner piece
3 02250152-334 2 rail, roof lh and rh
4 02250152-335 1 rail, roof end p8 p10
5 02250152-336 4 gusset, corner p8 p10
6 02250154-659 7 trim, edge clip-on 185-260duq
7 02250154-667 1 panel, roof various
8 02250155-284 1 plug, hole 2 1/2" nylon black
9 02250155-824 1 panel, starter end p8 p10
10 02250155-825 1 rail, roof starter end p8 p10
11 02250158-039 1 pocket, drawing holder 3700
12 02250160-372 1 rail, vertical starter side p8 p10
13 02250160-373 3 rail, vertical p8 p10
14 02250160-374 1 panel, starter end bottom p8
15 02250160-375 1 panel, starter end bottom p10
16 02250160-377 1 panel, louver rear p8 p10
17 02250160-378 2 panel, canopy door liftoff p8 p10
18 250019-520 2 plug, plastic for 3/8" hole
19 250034-157 2 trim, canopy edge 7.5/10hp
20 883008-016 47 screw, tf-hex m8 x 16 blk zinc
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

71
ENCLOSURE, AIR-COOLED 40HP

1.35 ENCLOSURE, AIR-COOLED 40HP

02250181-033 R01

72
 PARTS LIST

1.35 ENCLOSURE, AIR-COOLED 40HP

Q
KEY
PART NO. T DESCRIPTION
NO.
Y
1 02250150-893 4 CAP,MOLDED CANOPY CORNER
2 02250152-323 4 INSUL,FOAM 2” CORNER PIECE
3 02250152-334 2 RAIL, ROOF LH AND RH
4 02250152-335 1 RAIL, ROOF END P8 P10
5 02250152-336 4 GUSSET, CORNER P8 P10
6 02250155-284 1 PLUG, HOLE 2 1/2” NYLON BLACK
7 02250155-824 1 PNL,STARTER END P8 P10
8 02250155-825 1 R,ROOF STARTER END P8 P10
9 02250158-039 1 PKT,DRAWING HOLDER 3700
10 02250160-372 1 R,VERTICAL STARTER SIDE P8 P10
11 02250160-373 3 RAIL, VERTICAL P8 P10
12 02250160-375 1 PNL,STARTER END BOTTOM P10
13 02250160-377 1 PNL,LOUVER REAR P8 P10
14 02250160-378 2 DOOR,ENCL LIFT OFF P8 P10
15 02250180-756 1 PANEL,ROOF VARIOUS
16 250034-157 2 TRIM,CANOPY EDGE 7.5/10HP
17 883008-016 47 SCREW, TF-HEX M8 X 16 BLK ZINC
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

73
ENCLOSURE, AIR-COOLED INTEGRAL DRYER 25/30HP

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

02250168-700-R01

74
 PARTS LIST

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

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250150-893 4 CAP,MOLDED CANOPY CORNER A1 - USED ON 1800/2200
2 02250152-323 4 INSUL,FOAM 2” CORNER PIECE A2 - USED ON 1100E/1500E/1800E
3 02250152-334 2 RAIL, ROOF LH AND RH PLEASE NOTE: WHEN ORDERING PARTS,
4 02250152-335 1 RAIL, ROOF END P8 P10 INDICATE SERIAL NUMBER OF COMPRESSOR

5 02250152-336 4 GUSSET, CORNER P8 P10

6 02250154-659 7 TRIM,CLIP-ON GRIP 185-260DUQ
7 02250154-667 1 PANEL, ROOF ENCL ES8
8 02250155-284 1 PLUG, HOLE 2 1/2” NYLON BLACK
9 02250155-824 1 PNL,STARTER END P8 P10
10 02250155-825 1 R,ROOF STARTER END P8 P10
11 02250158-039 1 PKT,DRAWING HOLDER 3700
12 02250160-372 1 R,VERTICAL STARTER SIDE P8 P10
13 02250160-373 3 RAIL, VERTICAL P8 P10
14 02250160-374 1 PNL,STARTER END BOTTOM P8
15 02250160-375 1 PNL,STARTER END BOTTOM P10
16 02250160-378 2 DOOR,ENCL LIFT OFF P8 P10
17 02250168-656 1 PNL,CAN ASSY INTAKE END 2200 W/DRYER
18 250019-520 2 PLUG,PLASTIC FOR 3/8” HOLE
19 250034-157 2 TRIM,CANOPY EDGE 7.5/10HP
20 828008-025 2 CAPSCR, HEX 8.8 M8 X 25MM
21 865408-170 2 WASHER, METRIC-ISO7089- 8
22 883008-016 47 SCREW, TF-HEX M8 X 16 BLK ZINC
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

75
ENCLOSURE, AIR-COOLED INTEGRAL DRYER 40HP

1.37 ENCLOSURE, AIR-COOLED INTEGRAL DRYER 40HP

02250182-890 R01

76
 PARTS LIST

1.37 ENCLOSURE, AIR-COOLED INTEGRAL DRYER 40HP

Q
KEY
PART NO. T DESCRIPTION
NO.
Y
1 02250150-893 4 CAP,MOLDED CANOPY CORNER
2 02250152-323 4 INSUL,FOAM 2” CORNER PIECE
3 02250152-334 2 RAIL, ROOF LH AND RH
4 02250152-335 1 RAIL, ROOF END P8 P10
5 02250152-336 4 GUSSET, CORNER P8 P10
6 02250155-284 1 PLUG, HOLE 2 1/2” NYLON BLACK
7 02250155-824 1 PNL,STARTER END P8 P10
8 02250155-825 1 R,ROOF STARTER END P8 P10
9 02250158-039 1 PKT,DRAWING HOLDER 3700
10 02250160-372 1 R,VERTICAL STARTER SIDE P8 P10
11 02250160-373 3 RAIL, VERTICAL P8 P10
12 02250160-375 1 PNL,STARTER END BOTTOM P10
13 02250160-378 2 DOOR,ENCL LIFT OFF P8 P10
14 02250168-656 1 PNL,CAN ASSY INTAKE END 2200 W/DRYER
15 02250180-756 1 PANEL,ENCLOSURE ROOF - P10-40H
16 250034-157 2 TRIM,CANOPY EDGE 7.5/10HP
17 828008-025 2 CAPSCR, HEX 8.8 M8 X 25MM
18 865408-170 2 WASHER, METRIC-ISO7089- 8
19 883008-016 47 SCREW, TF-HEX M8 X 16 BLK ZINC
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

77
DECAL LOCATION SECTION, AIR-COOLED

1.38 DECAL LOCATION SECTION, AIR-COOLED

02250157-700 R05

78
 PARTS LIST

1.38 DECAL LOCATION SECTION, AIR-COOLED

N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 02250057-624 1 decal,iso 9001 blk 3.44x5.75 23 241814 2 decal,fork lifting
2 02250075-045 2 decal,protective earth ground 24 250003-144 1 decal,warn “food grade” lube
3 02250075-540 1 decal,pe designation 25 250017-903 1 decal,warning-autostart
4 02250077-472 1 decal,electrocution hazard international/ 26 250021-564 1 decal,rotation 3.5” lg
global 27 250022-810 1 decal,water drain 3 3/4 x 1”
5 02250110-891 1 decal,en-warning mixing fluids 28 250027-935 1 decal,danger inhaling comp air
6 02250145-206 1 decal,24kt metalic gold 29 407408 1 sign,warning-hot surfaces
7 02250146-385 2 decal,parallel wye motor conn. 30 FLUID 1 decal,fluid-various
8 02250155-495 2 decal,black www.sullair.com 31 NAMEPLATE 1 nameplate, sullair serial number
9 02250157-702 1 decal,maint kit eng 32 RIVET 4 rivet,pop-various
10 02250157-703 2 decal, sullair side graphics 33 SERIES 2 decal,various black w/stripe
11 02250157-732 1 decal, sullair side graphic 34 VOLTAGE 1 decal,volts-various
12 02250158-358 1 decal,remove before start-up 1-ATTACH TO THE BOTTOM ON INSIDE OF STARTER BOX
13 02250161-967 1 decal,sump fluid drain p8/p10 2-ATTACH TO INSIDE OF STARTER DOOR
14 02250162-215 2 decal,vsd black p8/p10/p12 3-ATTACH TO SUB-PANEL INSIDE STARTER BOX
15 02250164-823 1 decal, warning n12 elec encl protc 4-USED ON VSD MACHINES ONLY
16 02250168-920 2 decal,s-energy black 5-ATTACH TO INSIDE OF STARTER BOX ON RIGHT HAND SIDE
17 041065 1 decal,warning auto start 6-NOT USED ON 575V VSD MACHINES
18 042218 1 decal,danger hi voltage 7-USE ON 24KT MACHINES ONLY
19 049685 1 sign,warning-comp oil fil cap
PLEASE NOTE: WHEN ORDERING PARTS,
20 049850 1 decal,danger electrocution INDICATE SERIAL NUMBER OF COMPRESSOR
21 049852 1 decal,warning elect. shock-ground fault
22 049855 2 sign,warning-sever-fan-indus
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

79
DECAL LOCATION SECTION, AIR-COOLED, INTEGRAL DRYER

1.39 DECAL LOCATION SECTION, AIR-COOLED, INTEGRAL DRYER

02250172-255-R02

80
 PARTS LIST

1.39 DECAL LOCATION SECTION, AIR-COOLED, INTEGRAL DRYER

N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 *02250075-045 1 decal,protective earth ground 25 02250157-732 1 decal, sullair side graphic
2 *02250075-540 1 decal,pe designation 26 02250158-358 1 decal,remove before start-up
3 *041065 1 decal,warning auto start 27 02250161-967 1 decal,sump fluid drain p8/p10
4 *042218 1 decal,danger hi voltage 28 02250162-215 2 decal,vsd black p8/p10/p12
5 *049685 1 sign,warning-comp oil fil cap 29 02250164-823 1 decal, warning n12 elec encl protc
6 *049850 1 decal,danger electrocution 30 02250168-920 2 decal,s-energy black
7 *049852 1 decal,warning elect. shock-ground fault 31 02250170-899 1 decal,integral dryer
8 *049855 2 sign,warning-sever-fan-indus 32 407408 1 sign,warning-hot surfaces
9 *241814 2 decal,fork lifting 33 FLUID 1 various
10 *250003-144 1 decal,warn “food grade” lube 34 NAMEPLATE 1 various
11 *250017-903 1 decal,warning-autostart 35 RIVET 4 various
12 *250021-564 1 decal,rotation 3.5” lg 36 SERIES 2 various
13 *250022-810 1 decal,water drain 3 3/4 x 1” 37 VOLTAGE 1 various
14 *250027-935 1 decal,danger inhaling comp air A1: BOTH SIDES OF MACHINES
15 02250057-624 1 decal,iso 9001 blk 3.44x5.75 A2: VSD MACHINES ONLY
16 02250075-045 1 decal,protective earth ground A3: NOT USED ON 575V VSD MACHINES
17 02250077-472 1 decal,electrocution hazard international/ A4: ATTACH TO INSIDE OF STARTER BOX ON RIGHT-HAND SIDE
global A5: ATTACH TO INSIDE OF STARTER BOX ON BOTTOM PANEL
18 02250110-891 1 decal,en-warning mixing fluids A6: ATTACH TO SUB-PANEL INSIDE OF STARTER BOX
19 02250145-206 1 decal,24kt metalic gold A7: 24KT MACHINES ONLY
20 02250146-385 2 decal,parallel wye motor conn. A8: ATTACH TO INSIDE OF STARTER BOX DOOR
21 02250154-359 1 decal,microprocessor overlay Q1: A “*” PRECEEDING THE PART NUMBER INDICATES DECALS CON-
22 02250155-495 2 decal,black www.sullair.com TAINED IN KIT 02250069-604
23 02250157-702 1 decal,maint kit eng PLEASE NOTE: WHEN ORDERING PARTS,
24 02250157-703 2 decal, sullair side graphics INDICATE SERIAL NUMBER OF COMPRESSOR

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

81
DECAL GROUP

1.40 DECAL GROUP

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82
 PARTS LIST

1.40 DECAL GROUP

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
26 250027–935 1 decal, danger inhaling comp air
18 049850 1 decal, danger electrocution
6 02250146–385 2 decal, parallel wye motor conn.
16 042218 1 decal, danger hi voltage
5 02250110–891 1 decal, en–warning mixing fluids
20 049855 2 sign, warning–sever–fan–indus

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

83
DECAL GROUP

1.40 DECAL GROUP (CONTINUED)

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îëððïéóçðí

84
 PARTS LIST

1.40 DECAL GROUP (CONTINUED)

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
17 049685 1 sign, warning–comp oil fill cap
23 250017–903 1 decal, warning–autostart
19 049852 1 decal, warning elec shock–ground fault
22 250003–144 1 decal, warning elec shock–ground fault
27 407408 1 sign, warning–hot surfaces
15 041065 1 decal, warning auto start

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

85
DECAL GROUP

1.40 DECAL GROUP (CONTINUED)

ðîîëðïëëóìçë

ðîîëððéëóðìë ðîîëððéëóëìð

ðîîëðïëéÁéíîÎðï
ðîîëðïëéÁéðíÎðð

ðîîëðïêïóçêéÎðî

ðîîëðïëèÁíëèÎðð

ðîîëðïêîÁîïëÎðï

86
 PARTS LIST

1.40 DECAL GROUP (CONTINUED)

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
2 02250075–045 2 decal, protective earth ground
3 02250075–540 1 decal, pe designation
7 02250155–495 2 decal, black www.sullair.com
9 02250157–703 2 decal, sullair side graphics
10 02250157–732 1 decal, sullair side graphic
11 02250158–358 2 decal, remove before start–up
12 02250161–967 1 decal, separator/sump tank fluid drain
p8/p10
13 02250162–215 2 decal, vsd black p8/p10/p12

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

87
DECAL GROUP

1.40 DECAL GROUP (CONTINUED)

88
 PARTS LIST

1.40 DECAL GROUP (CONTINUED)

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
4 02250077–472 1 decal, electrocution hazard international/
global
8 02250186-230 1 decal, maint kit eng
14 02250164–823 1 decal, warning n12 elec encl protection
21 241814 2 decal, fork lifting
24 250021–564 1 decal, rotation 3.5” lg
25 250022–810 1 decal, water drain 3 3/4 x 1”
28 02250069–389 1 fluids, fluid decal (I)
02250069–394 1 fluids, fluid decal (I)
02250069–395 1 fluids, fluid decal (I)

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

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

89
DECAL GROUP

1.40 DECAL GROUP (CONTINUED)

ðîîëðïëéóéíëÎðð

ðîîëðïëéóéíïÎðð

ðîîëððëéóêîì

îíðÊ ìêðÊ ëéëÊ

ðîîëððêçóíçé
ðîîëððêçóíçç
ðîîëððêçóìðð
í êð ئ
Ø í êð ئ í êð ئ
ðîîëððêçóíçé ðîîëððêçóíçç ðîîëððêçóìðð

íèðñìïëÊ îððÊ

ðîîëððêçóìðí
ðîîëððêçóìðê

í ëð ئ í êð ئ
ðîîëððêçóìðí ðîîëððêçóìðê

ðîîëðïéðóèçç

90
 PARTS LIST

1.40 DECAL GROUP (CONTINUED)

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
1 02250057–624 1 decal, ISO 9001 blk 3.44 x 5.75
31 02250157–735 1 series decal (I)
02250157–731 1 series decal (I)
32 02250069–397 1 voltage decal (I)
02250069–399 1 voltage decal (I)
02250069–400 1 voltage decal (I)
02250069–403 1 voltage decal (I)
02250069–406 1 voltage decal (I)
33 02250170-889 1 decal, integral dryer
(I) This decal will vary with individual machine. Consult Sullair Corporation
with serial number

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

91
DECAL GROUP

1.40 DECAL GROUP (CONTINUED)

92
 PARTS LIST

1.40 DECAL GROUP (CONTINUED)

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
34 02250168-920 1 decal, s-energy black
35 02250145-206 1 decal, 24 kt gold metalic
36 02250146-385 1 decal, parallel wye motor conn.
37 02250161-967 1 decal, sump fluid drain
38 250019-107 1 decal, water in
39 250019-108 1 decal, water out

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

93
NOTES

94
NOTES
 WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A.
Sullair Road, No. 1 3700 East Michigan Boulevard Zone Des Granges BP 82
Chiwan, Shekuo Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France
Shenzen, Gunagdong PRV. www.sullair.com Telephone: 33-477968470
PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A. only) Fax: 33-477968499
Telephone: 755-6851686 Fax: 219-874-1273 www.sullaireurope.com
Fax: 755-6853473
www.sullair-asia.com CUSTOMER CARE
for PARTS and Service
1-888-SULLAIR (7855247)
219-874-1835

Champion Compressors, LTD.

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

Printed in the U.S.A.

Specifications subject to
change without prior notice.
E10EP
 USER MANUAL
WS CONTROLLER USER INTERFACE MANUAL

PART NUMBER:
02250202-046 R01
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions ©
SULLAIR CORPORATION
and procedures in this manual or, The information in this manual is current as
of its publication date, and applies to
misuse of this equipment will software part number:
VOID its warranty!
02250201-216
and all subsequent software part numbers.
 AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Stationary compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.

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

SULLAIR TRAINING DEPARTMENT

1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
training@sullair.com
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
 TABLE OF CONTENTS
SECTION 1—SAFETY
5 1.1 GENERAL
5 1.2 PERSONAL PROTECTIVE EQUIPMENT
5 1.3 PRESSURE RELEASE
6 1.4 FIRE AND EXPLOSION
6 1.5 MOVING PARTS
7 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
7 1.7 TOXIC AND IRRITATING SUBSTANCES
8 1.8 ELECTRICAL SHOCK
8 1.9 LIFTING
9 1.10 ENTRAPMENT
9 1.11 SAFETY WARNINGS

SECTION 2—STARTUP PROCEDURES

11 2.1 INTRODUCTION
11 2.2 WS CONTROLLER PANEL LAYOUT
12 2.3 WS START UP PROCEDURES
13 2.4 SHUTDOWN PROCEDURE

SECTION 3—ADJUSTMENTS
15 3.1 INTRODUCTION
15 3.2 COMPRESSOR ADJUSTMENT PROCEDURES
16 3.3 USER ADJUSTABLE CONTROL PARAMETERS
18 3.4 CALIBRATION OF P2 PRESSURE TRANSDUCERS
18 3.5 REMOTE UNLOAD

SECTION 4—DESCRIPTION
19 4.1 INTRODUCTION
19 4.2 TOUCH PAD BUTTON DESCRIPTION
19 4.3 INDICATOR LED DESCRIPTION
20 4.4 DISPLAY SCREEN
21 4.5 OPERATING MODES
TABLE OF CONTENTS

21 4.6 OPERATING STATES

22 4.7 NORMAL VIEW SERVICE REMINDERS
23 4.8 WARNING MESSAGES
24 4.9 FAULT MESSAGES
25 4.10 DIAGNOSTIC VIEWS

SECTION 5—TROUBLESHOOTING
27 5.1 TROUBLESHOOTING INTRODUCTION
27 5.2 TROUBLESHOOTING GUIDE
32 5.3 WS CONTROLLER FAULTS AND WARNINGS
32 5.4 MACHINE BEHAVIOR AFTER A POWER INTERRUPTION
32 5.5 INTERNAL BATTERY

SECTION 6—VARIABLE SPEED DRIVE

35 6.1 OVERVIEW
35 6.2 INSTALLATION
 Section 1
SAFETY
NOTE
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
the precautionary statements contained herein are
applicable to most compressors and the concepts
behind these statements are generally applicable to
all compressors.
1.2 PERSONAL PROTECTIVE
EQUIPMENT
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 regula-
tions 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 elec-
trical protective equipment, as well as noise
exposure administrative and/or engineering con-
trols and/or personal hearing protective equip-
ment.
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 exceed-
ing 1/2" (13mm) inside diameter is to be con-
nected to the shut-off (throttle) valve, to reduce
pressure in case of hose failure, per OSHA Stan-
dard 29 CFR 1926.302(b)(7) and/or any applica-
ble Federal, State and Local codes, standards
and regulations.
B. When the hose is to be used to supply a mani-
fold, install an additional appropriate flow-limiting
valve between the manifold and each air hose
exceeding 1/2" (13mm) inside diameter that is to
be connected to the manifold to reduce pressure
in case of hose failure.
C. Provide an appropriate flow-limiting valve at the
beginning of each additional 75 feet (23m) of
hose in runs of air hose exceeding 1/2" (13mm)
5

inside diameter to reduce pressure in case of
hose failure.
D. Flow-limiting valves are listed by pipe size and
flow-rated. Select appropriate valves accordingly,
in accordance with their manufacturer's recom-
mendations.
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 manufac-
turer'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 effec-
tive chip guarding and personal protective equip-
ment 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 anti-
freeze compound.
C. DO NOT permit fluids, including air line anti-icer
system antifreeze compound or fluid film, to
6
SECTION 1
accumulate on, under or around acoustical mate-
rial, or on any external surfaces of the air com-
pressor. 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 acous-
tical 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 flam-
mable solvents for cleaning purposes.
D. Disconnect and lock out all power at source prior
to attempting any repairs or cleaning of the com-
pressor 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 oth-
erwise 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 sup-
port 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 ser-
vicing and operating the compressor.
I. Keep oily rags, trash, leaves, litter or other com-
bustibles 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.
D. Keep access doors, if any, closed except when
making repairs or adjustments.
E. Make sure all personnel are out of and/or clear of
the compressor prior to attempting to start or
operate it.
F. Disconnect and lock out all power at source and
verify at the compressor that all circuits are de-
energized to minimize the possibility of acciden-
tal start-up, or operation, prior to attempting
repairs or adjustments. This is especially impor-
tant 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 assis-
tance promptly in case of injury. DO NOT ignore
small cuts and burns as they may lead to infec-
tion
1.7 TOXIC AND IRRITATING
SUBSTANCES
A. DO NOT use air from this compressor for respi-
ration (breathing) except in full compliance with
OSHA Standards 29 CFR 1910 and/or any appli-
cable Federal, State or Local codes or regula-
tions.
DANGER
Death or serious injury can result from
inhaling compressed air without using
proper safety equipment. See OSHA stan-
dards 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 utili-
zation equipment and DO NOT discharge air
from these systems into unventilated or other
confined areas.
C. Operate the compressor only in open or ade-
quately 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 sub-
stances.
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 immedi-
ately.
H. DO NOT store air line anti-icer system antifreeze
compound in confined areas.
I. The antifreeze compound used in air line anti-
freeze systems contains methanol and is toxic,
harmful or fatal if swallowed. Avoid contact with
the skin or eyes and avoid breathing the fumes. If
7

swallowed, induce vomiting by administering a
tablespoon of salt, in each glass of clean, warm
water until vomit is clear, then administer two
teaspoons of baking soda in a glass of clean
water. Have patient lay down and cover eyes to
exclude light. Call a physician immediately.
1.8 ELECTRICAL SHOCK
A. This compressor should be installed and main-
tained in full compliance with all applicable Fed-
eral, State and Local codes, standards and
regulations, including those of the National Elec-
trical Code, and also including those relative to
equipment grounding conductors, and only by
personnel that are trained, qualified and dele-
gated 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.
8
SECTION 1
DANGER
All field equipment must be tested for elec-
trostatic fields prior to servicing or making
contact with the machine using the follow-
ing or equivalent test equipment:
• 90-600 VAC: Volt detector such as
Fluke Model 1AC-A
• 600-7000 VAC: Voltage detector
such as Fluke Networks Model
C9970
It is the responsibility of each organization
to provide/arrange training for all their
associates expected to test for electrostatic
fields.
1.9 LIFTING
A. If the compressor is provided with a lifting bail,
then lift by the bail provided. If no bail is provided,
then lift by sling. Compressors to be air-lifted by
helicopter must not be supported by the lifting
bail but by slings instead. In any event, lift and/or
handle only in full compliance with OSHA stan-
dards 29 CFR 1910 subpart N and/or any appli-
cable 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 condi-
tion 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 when-
ever 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 obsta-
cles 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 sud-
den 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 possi-
bly latching the door with personnel inside.
B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.
1.11 SAFETY WARNINGS
The following special instructions apply to VSD
packages provided with electronic adjustable speed
motor drives. These cautions that apply to VSD
operation.
WARNING
Ground the unit following the instructions in this
manual. Ungrounded units may cause electric
shock and/or fire. The variable speed drive has a
large capacitive leakage current during operation,
which can cause enclosure parts to be above
ground potential. Proper grounding, as described
in this manual, is required. Failure to observe this
precaution could result in death or severe injury.
WARNING
Before applying power to the variable speed
drive, make sure that the front and cable covers
are closed and fastened to prevent exposure to
potential electrical fault conditions. Failure to
observe this precaution could result in death or
severe injury.
WARNING
Refer all drive service to trained technicians. This
equipment should be installed, adjusted, and
serviced by qualified electrical maintenance
personnel familiar with the construction and
operation of this type of equipment and the hazards
involved and in accordance with published service
manuals. Failure to observe this precaution could
result in death or severe injury.
WARNING
Line terminals (L1, L2, L3), motor terminals (U, V,
W) and the DC link/brake resistor terminals (-/+)
are live when the drive is connected to power,
even if the motor is not running. Contact with this
voltage is extremely dangerous and may cause
death or severe injury.
9
 SECTION 1

WARNING CAUTION
Before opening the variable speed drive covers:
Make sure that no power correction capacitors
• Disconnect all power to the variable speed drive.
are connected to the variable speed drive out-
• Wait a minimum of 5 (five) minutes after all the
put or the motor terminals to prevent variable
lights on the keypad are off. This allows time for
speed drive malfunction and potential damage.
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
CAUTION
to measure DC voltage. Failure to follow the above
Make sure that the variable speed drive output
precautions may cause death or severe injury.
terminals (U, V, W) are not connected to the
utility line power as severe damage to the VSD
may occur.
CAUTION
Do not perform any meggar or voltage withstand
tests on any part of the variable speed drive or its
NOTE
components. Improper testing may result in
Interior electrical wiring is performed at the
damage. Prior to any tests or measurements of
factory. Required customer wiring is minimal,
the motor or the motor cable, disconnect the
but should be done by a qualified electrician
motor cable at the variable speed drive output
in compliance with OSHA, National Electrical
terminals (U, VW) to avoid damaging the variable
Code, and/or any other applicable State,
speed drive during motor or cable testing.
Federal, and local electrical codes concern-
ing isolation switches, fused disconnects,
etc. Sullair provides a wiring diagram for use
CAUTION by the installer.

Do not touch any components on the circuit

boards. Static voltage discharge may damage NOTE
the components.
Customer must provide electrical supply
power disconnect within sight of machine.

CAUTION
Install the variable speed drive in a well venti-
lated room that is not subject to temperature
extremes, high humidity, or condensation, and
avoid locations that are directly exposed to
sunlight, or have high concentrations of dust,
corrosive gas, explosive gas, inflammable gas,
grinding fluid mist, etc. Improper installation
may result in a fire hazard.

10
 WS CONTROLLER USER INTERFACE MANUAL

Section 2

STARTUP PROCEDURES
2.1 INTRODUCTION • Display Screen for displaying machine status

This compressor is equipped with an WS Controller
for controlling the compressor system operation,
setting the machine parameters and performing
maintenance operations. The WS Controller is
designed for the safe operation and protection of the
compressor system. When fault conditions occur,
the controller automatically shuts down the machine
before the conditions can cause damage to the
equipment. The WS Controller also contains features
that enable sequential interface with other machines.
2.2 WS CONTROLLER PANEL
LAYOUT
The WS Controller panel is shown in Figure 2-1. The
controller panel consists of :
• START pad for machine startup
• STOP pad for stopping machine operation
and for clearing fault messages while the machine
is stopped
• UP arrow and DOWN arrow pads for
navigation through the various panel displays and
for changing parameter values
• ENTER pad for selecting and accessing vari-
ous screen displays and for entering values
• • Machine status indicator lights for identifying the
current machine operational status.
Each of the controller components and functions is
described in detail in Section 4.

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Figure 2-1: WS Controller Panel

11
WS CONTROLLER USER INTERFACE MANUAL
2.3 WS START UP PROCEDURES
COMPRESSOR MOTOR ROTATION
DIRECTION CHECK (AT
INSTALLATION)
After the compressor has been installed and the
electrical wiring is completed, perform following steps
to verify the direction of the compressor motor
rotation.
1. If the display screen shows AUTOMATIC,
press the UP arrow pad twice to navi-
gate to the Mode parameter. Press the
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 com-
pressor.
3. Observe the direction of rotation of the com-
pressor motor shaft. Verify with Operators
Manual for correct rotation.
4. Disconnect and lockout power according to
lockout/tagout procedure.
5. If the motor shaft is not turning in the proper
direction, disconnect the power to the starter
and exchange any two of the three power
input leads. Refer to the Compressor Oper-
ator’s Manual.
6. Perform above steps 1 - 3 again to confirm
proper motor/compressor rotation.
NOTE
Variable speed drive (VSD) packages do
not require a main motor direction check
sincethe variable speed motor is set at
the time of manufacture.
12
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.
2. If it is incorrect, change the direction of the
fan motor by disconnecting power from the
compressor.
3. Disconnect and lockout power according to
lockout/tagout procedure.
4. Exchange any two of the three fan motor
leads at the fan motor starter. Refer to the
compressor Operator’s Manual.
5. Recheck the direction of the fan motor.
INITIAL START-UP AFTER INSTALLATION
Perform the following procedure at the initial START-
up of the compressor following installation.
1. Verify that all preparations and checks nec-
essary for proper installation have been
made. Refer to the compressor Operator’s
Manual.
2. Read the preceding pages of this manual
thoroughly.
3. Slowly open the shut-off valve to the service
line.
4. Press the START pad to START the
compressor. Compressor will begin operat-
ing in the default mode (Automatic) set at the
factory.
5. Check for possible leaks in piping.
6. Slowly close the service line shut-off valve to
verify nameplate pressure unload setting is
correct. The compressor should unload
when nameplate pressure is achieved. If
adjustments are necessary, see Compressor
Adjustment Procedures on page 15.
7. Observe the operating temperature. Refer to
compressor Operator’s Manual for accept-
able operating range. If temperature
exceeds this range, check the cooling sys-
tem and installation environment.
8. Open the shut-off valve to the service line.
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 Operator’s
Manual.
2. Press the START pad on the display
screen. The machine will prepare to start up
in the last operating mode existing at shut-
down. 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 pad to
ENTER the Change Mode. Navigate to the
desired mode (Automatic or Manual). Press
the ENTER pad to accept and save
the mode setting.
WS CONTROLLER USER INTERFACE MANUAL
4. When the compressor is running, observe
the display panel and maintenance indica-
tors to ensure the values displayed are
within the proper ranges.
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.
WARNING
The compressor may restart automatically
after a power failure or after the E-Stop but-
ton has been reset.
13
NOTES

14
 WS CONTROLLER USER INTERFACE MANUAL
Section 3
ADJUSTMENTS
3.1 INTRODUCTION
This section describes steps for using the WS
Controller to modify specific parameters that control
the machine operation.
NOTE
Control parameters described in this
manual are those which can be adjusted
via the WS controller. Additional parame-
ters that control the operation of the com-
pressor 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.
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.
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.
15
WS CONTROLLER USER INTERFACE MANUAL
5. Press the START pad when running
or STOP pad when stopped to return
the display to the NORMAL view.
NOTE
If during the adjustment process, the
START or STOP pad is
pressed prior to pressing the ENTER
pad, the display will return to the
NORMAL view and the parameter value
will not be changed.
3.3 USER ADJUSTABLE
CONTROL PARAMETERS
Listed below are descriptions of the parameter that
can be adjusted at the WS Controller:
Unload Pressure - Set point (psi, bar, or kpa) at
which the system pressure will begin unloading. For
example if this parameter is set to 110 psi (7.6 bar)
the machine will unload when the line pressure is
above 110 psi (7.6 bar).
Load Delta Pressure - The pressure differential (psi,
bar, or kpa) below the unload pressure at which the
machine will begin loading. For example if the unload
pressure is set to 110 psi (7.6 bar) and the load
differential is set to 10 psid (0.7 bar), the machine will
load when the line pressure goes below 100 psi (6.9
bar).
VSD Setpoint Press. - (VSD packages only) The
targeted pressure (psi, bar, or kpa) for the variable
speed controls. This is normally adjusted near the
bottom of the load/unload delta. The speed will be
adjusted to maintain this pressure.
Unload Minutes - Set time that the machine will run
unloaded in Automatic mode before shutting off. If
the time is set less than 15 minutes (for example 5),
there may be times when the machine will run
16
SECTION 3
unloaded for more than 15 minutes. This is because
there is another timer that keeps the machine from
being started more than four times an hour. This
secondary timer is disabled when a machine is
configured for VSD motor control.
Drain Interval Mins. - Set interval in minutes
between activation of the drain cycle for machines
equipped with an electric solenoid drain. This does
not apply to the Sullair SCD zero loss drain, which is
not controlled or monitored by the WS Controller.
Drain Time Seconds - Set time in seconds that the
drain remains energized.
Wye Delta Seconds - Set time for wye to delta
starter transition. Also used to control the closed inlet
start valve. Disable by setting to zero (0), standard
for full voltage start. Requires approximately 4-6
seconds for wye-delta or solid state starting.
Modulate - Manner in which the machine is set to
regulate compressor flow. Default state is “YES” for
proportional control. Select “NO” for Load/No Load
operation.
Operating Mode - The mode set for controlling the
compressor motor operation (Manual / Automatic).
Manual mode runs continuously. Automatic mode
refer to “Unload Minutes”.
Language - The choice of language for text that will
appear on the display screen.
The Diagram of Figure 3-1 shows the flow of the
screens that appear on the WS Controller display
screen for a typical standard compressor package.
This diagram illustrates how adjustment parameters
are accessed.
Ethernet Address - (Models with Ethernet only) This
selects the address for the service Ethernet
connector of the control box. The default is “LAN”
which is used for a local area network. The factory
default address is 192.168.1.3, but may be modified
as desired. The other selection is “Link Local” which
may be used for simple connection to a PC. This puts
the controller at address 169.254.250.249, port 502.
SECTION 3 WS CONTROLLER USER INTERFACE MANUAL

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Figure 3-1: Controller Display Flow Diagram

17
WS CONTROLLER USER INTERFACE MANUAL
3.4 CALIBRATION OF P2
PRESSURE TRANSDUCERS
The compressor is equipped with a pressure
transducer that measures the output line (P2)
pressure. Over time, the pressure transducer may
vary slightly producing an inaccurate reading at the
controller. Periodically and prior to operating multiple
controllers in a sequence, the controller should be re-
calibrated 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 oper-
ating 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 nor-
mally.
The WS Controller is field configurable for other
remote functions with additional contacts or fieldbus
commands. Refer to the WSPC manual for details.
 WS CONTROLLER USER INTERFACE MANUAL
Section 4
DESCRIPTION
4.1 INTRODUCTION
This section describes the components of the WS
Controller, the function of each component, and the
various types of displays that may appear on the
display screen. Descriptive lists of all messages
appearing in the display are also provided.
4.2 TOUCH PAD BUTTON
DESCRIPTION
The WS Controller Panel has five touch pads that
allow the operator control of the compressor and
enable adjustment of the machine operating
parameters. Each touch pad and its functions are
described below:
Start Pad —Large green pad button used to
START the compressor operation. The pad is also
pressed to reset warnings while the machine is
running and to return the display to the Normal View.
Stop Pad —Large red key pad used to stop
the compressor operation. The STOP pad is also
pressed to clear fault messages when the machine is
stopped and to return the display to the Normal View.
Up Arrow Pad —Used to navigate “UP” the list
of display messages and to increase or change
parameter values for adjustments.
Down Arrow Pad —Used to navigate “DOWN”
the list of display messages and to decrease or
change parameter values for adjustments.
Enter Pad —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.
4.3 INDICATOR LED
DESCRIPTION
Four LED’s on the WS Controller Panel provide
indication of the general state of the machine.
Power On Indicator (GREEN LED)—Lights
whenever power is applied to the controller. This
LED will blink very slowly if the compressor is set to
automatically restart after power failure.
Automatic or Manual Run Mode Indicator
(GREEN LED—Lights when the compressor
operation is set to start and run automatically. This
LED lights steadily when the motor is running. The
LED will blink slowly if the compressor motor is
stopped while in Automatic mode as a warning that
the machine may restart at any time. The display
screen will periodically indicate The compressor is
Standing by. The Automatic Mode LED will blink
rapidly if machine restart is imminent. The display
screen will periodically display a message to indicate
the state of the machine prior to restart (e.g., Waiting
for Blowdown).
Maintenance/Warning Indicator (AMBER
LED)—Lights when recommended maintenance or
service warning is issued. In most cases the
machine will continue to operate normally. The
display screen will periodically display the
recommended maintenance actions or the cause of
the warning. Refer to Section 5: Troubleshooting on
page 27 to resolve maintenance conditions.
Fault Warning Indicator (RED LED)—Lights
when a compressor fault has occurred. The indicator
will remain lit and the compressor will remain
inoperative until the fault condition is remedied. The
controller display screen will indicate FAULTED and
periodically a brief description of the cause of the
fault. Refer to Section 5: Troubleshooting on page
27 to resolve fault conditions.
19
WS CONTROLLER USER INTERFACE MANUAL
4.4 DISPLAY SCREEN
Information relevant to the compressor operation is
presented in three views on the controller display
screen: Normal View, Compressor Status: and
Compressor Adjustment: or Show Setting ------- .
NORMAL VIEW
The Normal View is the default view for the display
screen. When in Normal View, information regarding
the compressor current operating conditions appears
on the display screen. See Figure 4-1. The top line
of the display screen in Normal View shows the
discharge pressure and the internal temperature of
the compressor package. The lower line of the
Display Screen displays the current compressor
operating mode.
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
SECTION 4
Listed below are compressor attributes that may be
viewed in the Compressor Status View. This list will
vary based on specific machine configurations.
Temperature 1—Displays the current compressor
temperature at temperature probe 1.
Temperature 2—Displays the current compressor
temperature at temperature probe 2.
Temperature 3—Displays the current compressor
temperature at temperature probe 3.
Dewpoint Temperature—Displays the current dryer
temperature at temperature probe 3.
Sump Pressure—Displays the current sump
pressure (P1).
Line Pressure—Displays the current line output
pressure (P2).
Pressure 3—Displays the pressure (P3) at the
specified transducer location.
Separator Pressure ^ —Displays the current
separator pressure differential.
Run Hours—Displays the total time the compressor
has been running loaded or unloaded.
Spiral Valve—Approximate percent of full capacity
controlled by the compressor's spiral valve
VSD Capacity—This is displayed as an approximate
percentage (%) of the maximum capacity for the
package.
VSD Temperature—High temperatures usually
indicate a need for cleaning of the VSD fan or heat
sink by a trained service technician.
COMPRESSOR ADJUSTMENT VIEW –
CONTROL PARAMETERS
The Compressor Adjustment View shows current
machine parameters which are conditions and limits
that can be modified by the operator. This view is
accessed using the navigational arrows and is
indicated by the text Show Setting ------- appearing
on the first line of the display screen. See Figure 4-3.
Pressing ENTER at the Show Setting screen
accesses the Change Mode. This mode is indicated
by the text Change Setting----- appearing as
reverse characters on the first line of the display
screen and the change parameter appearing on the
second line. See Figure 4-4. The value of the
parameter is displayed as reverse characters on
the bottom line. Refer to Section 3: Adjustments on
page 15, for instructions on changing the compressor
control parameters and a list of the control
parameters that can be modified by the user.
SECTION 4 WS CONTROLLER USER INTERFACE MANUAL

Off mode—Indicated by the word OFF appearing in

the lower line of the display window. This mode
͸±© Í»¬¬·²¹ ó ó ó ó ó ó ó indicates that the compressor and motor have been
˲´±¿¼ Ю»­­«®» turned off under normal conditions. When in this
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mode the machine will not operate until the START
ïïð °­·
pad is pressed.
Figure 4-3: Adjustment View—
Show Setting Example Fault mode—Indicated by the word FAULTED
appearing in the lower line of the display window.
This mode indicates that a machine problem has
ݸ¿²¹» Í»¬¬·²¹ ó ó ó ó ó ó ó occurred causing the controller to shut down the
˲´±¿¼ Ю»­­«®» machine until the condition is cleared. After a fault
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condition has been resolved, the fault indication can
ïïð °­· be cleared from the controller by pressing the STOP
Figure 4-4: Adjustment View— pad. Refer to Section 5: Troubleshooting on
Change Setting Example page 27, for information on resolving fault conditions.
UI Comm mode—Indicated by the word UI COMM
4.5 OPERATING MODES appearing in the lower line of the display window.
This mode indicates that the User Interface has lost
The Operating Mode is the manner in which the communication and, as a result, the machine
machine operation is being controlled. There are five operating mode or status is unknown.
Operating Modes: AUTOMATIC, MANUAL, OFF,
FAULT and UI COMM. 4.6 OPERATING STATES
The active operating mode of the compressor Operating States describe the state of the
appears on the lower line of the display screen’s compressor operation in response to the current
Normal View. See Figure 4-5. mode and current conditions. Essentially, the
operating state is what the machine is doing at a
particular moment. Most operating states occur
ïïè °­· éðpÚ automatically as normal functions of the compressor
ß«¬±³¿¬·½ Ó±¼» and require no direct action from the operator.
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Figure 4-5: Compressor Operating

Mode Display
NOTE
The compressor operating modes are described Machine operating states may vary
below: depending on compressor model.

Automatic mode—Indicated by the word

AUTOMATIC appearing in the lower line of the
display window. This is a user selected mode that
sets the compressor motor to automatically start
when conditions necessitate and stop when motor
operation is not required.
Manual Mode—Indicated by the word MANUAL
appearing in the lower line of the display window.
This is a user selected mode that allows the operator
to manually control the compressor motor operation.
When the START pad is pressed while in
Manual Mode the compressor motor will run
continuously until the STOP pad is pressed.
The compressor pump and all other machine
parameters function the same in both Manual and
Automatic modes.
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.
Figure 4-6: Controller Display Normal View:
Operating State
The list below provides an explanation of each
Operating State message that may appear in the

21
WS CONTROLLER USER INTERFACE MANUAL
Normal View display. Some operating states occur
instantaneously and may not be seen by the
operator.
Initializing—Displayed as the compressor
powered up.
Stopping—May be briefly displayed as the
compressor is being stopped via the Controller
Panel.
Manually Stopped—Displayed when
compressor operation is stopped.
Remote Stopping—May be briefly displayed as the
compressor is being stopped remotely.
Remote Stopped—Displayed when the compressor
operation is stopped but is armed to restart. The
machine will start when the remote start contact is
close. NOTE: The machine may start at any time
when conditions are met.
Standing by—Displayed when the compressor is
stopped and waiting for proper conditions before
restarting.
Faulting—Displayed as a fault condition is occurring.
Faulted—Displayed after a fault condition has
occurred.
Waiting for Blowdown—Displayed when
compressor is waiting for the sump to reach a
minimum pressure prior to starting. After
pressure has reduced to the set level,
compressor will start automatically.
Starting 1—Displayed as compressor initiates stage
1 startup processes.
Starting 2—Displayed as compressor initiates stage
2 startup processes.
Starting 3—Displayed as compressor initiates stage
3 startup processes.
Precooling the Dryer—Displayed while initially
cooling an integrated dryer with the compressor
unloaded
Loading—Displayed as the compressor begins
delivering air.
Loaded & Modulating—Displayed when
compressor is delivering air.
Fully Loaded—Displayed when the compressor is
delivering air at full rated capacity.
Unloading—Displayed as the compressor is being
unloaded automatically.
Remote Unloading—Displayed as the compressor
is being unloaded remotely.
22
SECTION 4
Running Unloaded—Displayed when the system is
running with the compressor unloaded.
Remote Unloaded—Displayed when the
is compressor has been unloaded remotely.
Restarting—Displayed during the restart waiting
period after the starter has dropped out
unexpectedly.
the 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.
the
set Figure 4-7: Controller Display Normal View:
the Service Reminder
the
The list below provides an explanation of the Service
Reminders that may appear in the Normal View
display. Refer to Section 5: Troubleshooting on page
27, for additional instructions on actions to be taken
when a service reminder appears.
Change Fluid Filter—The compressor fluid filter
should be changed within the time frame noted in the
machine operation specifications.
Change Separator—The compressor fluid separator
should be changed within the time frame noted in the
machine operation specifications.
Change Air Filter—The compressor air filter should
be changed within the time frame noted in the
the
machine operation specifications.
Analyze Fluid—A fluid analysis should be scheduled
per machine operation specifications.
Change Fluid—The compressor fluid should be
changed within the time frame noted in the machine
operation specifications.
Maintenance A—Periodic 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.
Figure 4-8: Controller Display Normal View:
Warning Message
The list below provides an explanation of the
Warning Messages that may appear in the display
when an error occurs.
High Dryer Dewpoint—Indicates that the integrated
dryer is running with high dewpoint temperature.
Consult the dryer manual and/or dryer manufacturer.
Dryer High DP Fault—Indicates that the integrated
dryer has stopped operation due to high dewpoint
temperature. Consult the dryer manual and/or dryer
manufacturer.
Low Dryer Dewpoint—Indicates that the integrated
dryer is running with low dewpoint temperature.
Consult the dryer manual and/or dryer manufacturer.
Dryer Low DP Fault—Indicates that the integrated
dryer has stopped operation due to low dewpoint
temperature. Consult the dryer manual and/or dryer
manufacturer.
Dryer Overload Fault—Indicates that the integrated
dryer has stopped operation due to a compressor
motor overload. Consult the dryer manual and/or
dryer manufacturer.
Dryer Relay Fault—Indicates that the integrated
dryer has stopped operation due to internal
problems. Consult the dryer manual and/or dryer
manufacturer.
Dryer Service—Indicates a dryer is running while a
malfunction is occurring. Consult the dryer manual
and/or dryer manufacturer.
Ethernet disabled—Ethernet was turned off due to
excessive network traffic.
WS CONTROLLER USER INTERFACE MANUAL
High Air Filter dP—Indicates the air filter pressure
differential is high. The air filter unit needs to be
checked or changed.
High Oil Filter dP—Indicates the fluid filter pressure
differential is high. The fluid filter needs to be
checked or changed.
High Separator dP—Indicates the fluid separator
pressure differential is high. The separator unit
needs to be checked or changed.
High Temperature 1—Indicates that the compressor
Temperature at temp probe location 1 is approaching
the set high limit.
High Temperature 2—Indicates that the compressor
Temperature at temp probe location 2 is approaching
the set high limit.
High Temperature 3—Indicates that the compressor
Temperature at temp probe location 3 is approaching
the set high limit.
Low Temperature 1—Indicates that the compressor
Temperature at temp probe location 1 is approaching
the set low limit.
Low Temperature 2—Indicates that the compressor
Temperature at temp probe location 2 is approaching
the set low limit.
Low Temperature 3—Indicates that the compressor
Temperature at temp probe location 3 is approaching
the set low limit.
Not Commissioned—A controller was replaced but
has not been commissioned for a specific
compressor model.
Power Interruption—Indicates that a power
interruption has occurred.
Replace Battery—Indicates the I/O backup battery
is low.
Sequence Comm Error—Indicates a
communication problem exists between the
compressor controllers set up for sequential
operation.
Starter—The main motor starter failed to operate,
and was restarted.
User Option Warning—Indicates a user furnished
switch has been activated.
VFD Overtemp—Operating temperatures are
approaching the VSD limits.
23
WS CONTROLLER USER INTERFACE MANUAL
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.
̸» º¿«´¬ ½¿«­» ·­æ
Ûóͬ±° Ы­¸ Þ«¬¬±²
Figure 4-9: Controller Display Normal View:
Fault Message
The list below provides an explanation of the Fault
Messages that may appear when problems occur.
Refer to Section 5: Troubleshooting on page 27, for
instructions on actions to be taken when a FAULT
condition occurs.
Aux Motor Overload—The auxiliary motor overload
relay has been tripped due to a power overload in the
auxiliary motor.
CE Voltage too high / Low—The internal 24 volt
supply is out of range.
Controller Watchdog—Controller watchdog timer
error.
Dryer Fault—Indicates a dryer malfunction has
occurred. Consult the dryer manual and/or dryer
manufacturer.
Dryer Overload—Indicates a dryer overload has
occurred. Consult the dryer manual and/or dryer
manufacturer.
E-Stop Push Button—Emergency Stop button has
been pressed.
HIGH AN0 SENSOR (AN0-AN9)—Device assigned
to sensor input AN0 through AN9 (temp probe,
transducer unit, etc.) or wiring between the device
24
SECTION 4
and the controller module has resulted in an open
circuit.
High Dryer Dewpoint—Indicates that the integrated
dryer has stopped all package operation due to high
dewpoint temperature. Consult the dryer manual
and/or dryer manufacturer.
High Interstage Pres—Interstage pressure is above
the unit limits.
High Package Press—Package Discharge pressure
has exceeded the set high limit.
High Plant Pressure—Plant line pressure has
exceeded the set high limit.
High Pressure A…B—Pressure at specified
transducer (A or B) has exceeded the set high limit.
High Separator dP—Separator pressure differential
has exceeded the set high limit.
High Spiral Valve Pr—Excessive pressure was
applied to the spiral valve actuator.
High Sump Pressure—Compressor sump pressure
has risen above the set limits.
High Temperature 1…3—The temperature at
specified temp probe (1 through 3) has risen above
the set high limit.
High Voltage Failed—No voltage is available at the
high voltage motor starter.
HIGH VOLT SENSOR—Indicates the system high
voltage sensor has failed.
Illegal State—Controller operating error.
Internal Com Error—An error in communication
between the controller and the compressor has
occurred.
LOW AN0 SENSOR (AN0 - AN9)—Device assigned
to sensor input AN0 through AN9 (temp probe,
transducer unit, etc.) or wiring between the device and
the controller module has resulted in a short circuit.
Low Dryer Dewpoint—Indicates that the integrated
dryer has stopped all package operation due to low
dewpoint temperature. Consult the dryer manual
and/or dryer manufacturer.
Low Line Pressure—The line pressure has fallen
below the Low Fluid Pressure set low limit.
Low Fluid Pressure—Compressor fluid pressure
has fallen below the set low limit.
Low Sump Pressure—Compressor sump pressure
has fallen below the set limits.
SECTION 4 WS CONTROLLER USER INTERFACE MANUAL

Low Temperature 1 ... 3—Temperature at the 4.10 DIAGNOSTIC VIEWS

specified temp probe (1 through 3) has fallen below
the set low limit.
While in the Normal View use the ENTER Pad
LOW VOLT SENSOR—Indicates the system low
voltage sensor has failed. to access the Diagnostic View.

Low Water Pressure—The water pressure switch Use the UP or DOWN arrow pads to access
has been tripped due to low water pressure. the next Diagnostic view.

Main Motor Overload—The main motor overload

relay has been tripped due to a power overload in the Use the ENTER Pad to return to the Normal
main motor. View.
Memory Error—The controller I/O board has failed. Figure 4-13 Illustrates how to navigate between the
Normal View and the Diagnostic Views.
OPTION INPUT—User option error.
OPTION INPUT RUN—User option error.
DIAGNOSTIC: ANALOG INPUT VIEW
The analog inputs are displayed in their order on the
Phase Protection.—Indicates external phase analog input terminal block in a left to right, top to
protection relay has tripped. bottom order. Inputs not used by the machine are not
Ethernet Comm Error—Communications have shown.
failed to a keypad.
Power Interruption—A power interruption has
occurred at the controller.
Pump Motor Overload—The pump motor's
overload relay has tripped.
Pump Starter Contact—The pump starter did not Figure 4-10: Typical Analog Input Status
operate as expected.
The analog values are typically displayed in the
Starter—Starter auxiliary contact failed to connect
selected units of measure.
power to the starter.
The input labels typically refer to the pressure and
UI Voltage too high—The voltage to the User
temperature sensor references in the Piping and
Interface has risen above the set limit.
Instrumentation drawing.
UI Voltage too low—The voltage to the User
Interface has fallen below the set limit.
DIAGNOSTIC: DIGITAL I/O VIEW
The status of the digital inputs and relay outputs are
High Plant Pressure—The inlet valve failed to close shown from left to right in the order in which they are
as expected found on the terminal blocks.
VSD1 Response—The A1000 drive is not
responding to run commands
VSD1 Comm Fault—An error in communication
between the controller and the specified VSD
compressor has occurred.
VSD1 parameter error—An error has occurred
during setup of the VSD adjustments. Figure 4-11: Typical Digital I/O Status

The values of one and zero refer to active or inactive

states respectively.
The labels refer to the controller input and output
naming on the wiring diagram.

25
WS CONTROLLER USER INTERFACE MANUAL SECTION 4

DIAGNOSTIC: ALARM VIEWS

Any current fault, alarm or service reminder message
will be available to view here. Multiple messages ÒÑÎÓßÔ Ê×ÛÉ ß²¿´±¹ ײ°«¬­ Ê·»©

may be scrolled through using the UP and

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Figure 4-13: Navigation between the

Normal and Diagnostic view

26
 WS CONTROLLER USER INTERFACE MANUAL

Section 5

TROUBLESHOOTING
5.1 TROUBLESHOOTING c. Check for parts damaged by heat or an elec-
INTRODUCTION trical short circuit, usually apparent by discol-
oration or a burnt odor.
This Troubleshooting section is provided as a guide
Should your problem persist after making the
to aid in diagnosing and resolving compressor
recommended check, consult your nearest Sullair
problems when they occur. The information
Distributor or the Sullair Corporation factory Service
contained in Table 5-1, Troubleshooting Guide, has
been compiled from factory experience and contains Department.
symptoms and usual causes for the described
problems. Each Service Reminder, Warning, or
Fault Message is listed with conditions of when the
NOTE
problem may occur, a probable cause, and a
Section 5.2 and Section 5.4 portray com-
suggested solution to the problem. DO NOT assume
mon systematic problems that can occur
that these are the only problems that may occur.
during controller operation. For a more
This document cannot address every possible thoroughly in-depth coverage of machine
adverse condition that may occur nor does it provide operation troubles, consult the Trouble-
every solution for the potential troubles listed. All shooting Section in the machine’s opera-
available data concerning the trouble should be tor’s manual.
systematically analyzed before undertaking any
repairs or component replacement procedures.
5.2 TROUBLESHOOTING GUIDE
Always perform a detailed visual inspection when a
machine problem occurs prior to attempting any Table 5-1 contains symptoms and usual causes for
repairs. Doing so may avoid unnecessary repair the problems that may occur throughout the
and/or additional damage to the compressor. compressor system. Each warning or fault message
that may appear is listed along with conditions for the
Always remember to:
problem, a probable cause, and a suggested solution
a. Check for loose wiring. to the problem. DO NOT assume that these are the
only troubles that may occur.
b. Check for damaged piping.

Table 5-1: WS Controller Troubleshooting Guide

MESSAGE PROBABLE CAUSE REMEDY
Analyze Fluid Service interval has expired. Select Maintenance from menu to see
Maintenance due. service due and part numbers.
Aux Motor Overload Auxiliary Motor Tripped on Cooling Reset auxiliary overload after element
Fan, Fluid Pump or Other Motor. cools. Verify correct motor amps.
Check for loose connections.
Check motor starter contact for proper
operation.
Check line voltage, if low consult power
company.

27
WS CONTROLLER USER INTERFACE MANUAL
Table 5-1: WS Controller Troubleshooting Guide
MESSAGE PROBABLE CAUSE
CE Voltage too high Excessive voltage form power
supply or transformer.
CE Voltage too low Inadequate voltage form power
supply or transformer.
Excessive load or short in 24v
control devices.
Change Air Filter Service interval has expired.
Change Fluid Maintenance due.
Change Fluid Filter
Change Separator
Controller Watchdog Controller fault.
Dryer Fault Indicates a general dryer
malfunction has occurred.
High Dryer Dewpoint The dryer is unable to cool below
Dryer High DP Fault the high dewpoint temperature
setting.
Low Dryer Dewpoint The dryer is cooling below the low
Dryer Low DP Fault dewpoint temperature setting.
Dryer Overload Indicates a dryer overload has
Dryer Overload Fault 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.
Faulty E-Stop Button.
Ethernet disabled Excessive Ethernet traffic
High Air Filter dP Differential Pressure Across Inlet
Filter High.
HIGH AN0 SENSOR Sensor (Pressure Transducer,
Temp Probe, etc.) or Wiring
Failure.
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.
Fluid filter clogged.
Low ambient temperature.
Sensor failure.
High Interstage Pres Compressor Interstage Blockage
or second stage failure
28
SECTION 5
REMEDY
Check connections and adjustments.
Check connections and adjustments.
Check wiring, coils, and solenoid valves.
Perform recommended maintenance and
reset the reminder using WSPC.
Contact Sullair Factory Service.
Consult the dryer manual and/or
Sullair Factory Service.
Consult the dryer manual and/or
Sullair Factory Service.
Consult the dryer manual and/or
Sullair Factory Service.
Consult the dryer manual and/or
Sullair Factory Service.
Consult the dryer manual and/or
Sullair Factory Service.
Consult the dryer manual and/or
Sullair Factory Service.
Release button.
Check wiring.
Install a router to reduce the traffic on the
compressor's LAN.
Replace filter.
Check inlet filter pressure switch.
Check sensor wiring.
Check sensor.
Consult the dryer manual and/or
Sullair Factory Service.
Replace fluid filter.
Sump heater may be required in ambients
below 40°F (4°C).
Check sensor, wiring and tubing.
Inspect for: interstage flow restriction, or
damaged air end and repair
SECTION 5 WS CONTROLLER USER INTERFACE MANUAL
Table 5-1: WS Controller Troubleshooting Guide
MESSAGE PROBABLE CAUSE
High Package Press High pressure.
High Pressure A Faulty pressure sensor.
High Pressure B
High Separator dP High Separator pressure drop
High Spiral Valve Pr Misadjustment
High Sump Pressure Sump Pressure High (Poppet,
Sullicon, Spiral, Blowdown or
Pneumatic Valve Failed).
Faulty solenoid valves.
Faulty pressure regulator.
High Temperature 1 High Temp Fault.
High Temperature 2
High Temperature 3 Fluid level low.
Thermal valve fault.
Cooler fins dirty.
Low water flow.
High water temperature.
Cooler plugged.
Temp probe or sensor failure.
High Voltage Failed No power to the high voltage
starter
Illegal State Controller fault.
Ethernet Comm Error 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.
Leaks in supply lines.
REMEDY
Check operation of valves and controls.
Check and replace pressure sensor if
defective.
Inspect separator and replace
Check setting of the pressure regulator for
the spiral valve actuator.
Check valves. Check Sullicon adjustment
(see Control Adjustment section in the
compressor operator’s manual).
Check solenoid valve operation and wiring.
Check pressure regulator adjustment and
operation.
Check minimum pressure check valve (not
applicable to Fluid Free compressors).
Ambient above 105°F (41°C), improve local
ventilation.
Replenish fluid to proper level.
Check thermal valve operation.
Clean Cooler fins and fan blades.
Check for valve closed, pump off or broken
pipe.
Increase water flow or lower water
temperature.
Clean cooler tubes and shell. If plugging
persists, use cleaner water.
Check sensor and wiring.
Close the disconnect switch
Check main motor fuses or circuit breaker
Contact Sullair Factory Service.
Check wiring.
Check sensor wiring.
Check sensor.
Consult the dryer manual and/or
Sullair Factory Service.
Reduce demands.
Increase capacity.
Check for leaks or open lines in air supply.
Repair as necessary.
29
WS CONTROLLER USER INTERFACE MANUAL
Table 5-1: WS Controller Troubleshooting Guide
MESSAGE PROBABLE CAUSE
Low Fluid Pressure Fluid filter clogged.
Sump fluid level low.
Low ambient temperature.
Fluid pump failure.
Low Sump Pressure Bad sensor or connections.
Machine may have failed to start.
Low Temperature 1 Low ambient air temperature
Low Temperature 2
Low Temperature 3
Low Water Pressure Cooling Water Pressure below 10
psi (0.7 bar).
Low Water Pressure Switch is shorted or open.
Main Motor Overload Main Motor Overload Relay
Tripped.
Maintenance A Service interval has expired.
Maintenance due.
Memory Error The controller I/O board has failed. Board replacement required. Contact Sullair
Factory Service.
Not Commissioned Controller replacement
Option Input User furnished switch has
Option Input Run operated.
User Option Warning User furnished external phase
relay protection relay has tripped.
PortC Comm Error (C or E) Wiring fault between the controller
and keypad
Power Interruption Intermittent Control Power.
Pump Motor Overload Auxiliary Motor Tripped on Fluid
Pump Motor
30
SECTION 5
REMEDY
Replace fluid filter.
Replenish fluid to proper level.
Sump heater may be required in ambients
below 40°F (4°C).
Fluid pump may be required for remote
coolers.
Consult Sullair Factory Service.
Check pressure sensor, wiring and tubing.
Check machine operation.
Sump heater may be required in ambients
below 40°F (4°C).
Check for closed valves or broken pipes.
Replace switch. Check wiring for shorts,
arcing or loose connections.
Reset overload after heater element cools
down.
Check that compressor is properly
configured.
Ensure load pressure is set below limit of
compressor.
Check line voltage, if low consult power
company.
Perform recommended maintenance and
reset the reminder using WSPC.
Follow commissioning procedures to set up
for the specific compressor package.
Check operation of optional device.
Check operation of optional device. Refer to
user supplied phase relay documentation
and troubleshooting steps.
Check the cable and connections
Check line voltage and connections.
Reset auxiliary overload after element
cools. Verify correct motor amps.
Check for loose connections.
Check motor starter contact for proper
operation.
Check line voltage, if low consult power
company.
SECTION 5 WS CONTROLLER USER INTERFACE MANUAL

Table 5-1: WS Controller Troubleshooting Guide

MESSAGE PROBABLE CAUSE REMEDY
Pump Starter Contact Pump starter failed to operate. Check starter and control wiring.
Faulty auxiliary contact. Check contact and contact wiring.
Replace Battery Controller I/O backup battery is Replace battery.
low.
Pressure Differential Across Replace separator.
High Separator dP Separator High.
Plugged separator elements. Check sensor wiring.
Pressure sensor failure.
Sequence Comm Error Cable or connection fault between Check wiring.
compressors.
Improper sequence adjustments. Check sequence settings of all
compressors in the sequence.
Starter Main starter failed to operate. Check starter and control wiring.
Faulty auxiliary contact. Check contact and contact wiring.
Momentary Line Power loss or Check Line Power quality
brownout
UI Voltage too high Controller fault. Contact Sullair Factory Service.
UI Voltage too low Controller fault. Contact Sullair Factory Service.
High Plant Pressure Compressor failed to unload Check operation of the inlet valve and
controls
User Option Warning User furnished switch has Check function of optional device.
operated.
HIGH VOLT SENSOR Controller fault. Contact Sullair Factory Service.
LOW VOLT SENSOR Controller fault. Contact Sullair Factory Service.
VSD1 Comm Fault Communications lost with the VSD Check connections to the VSD.
Check VSD control power and check for
board faults.
VFD Overtemp Warns that the variable frequency Ensure adequate ventilation
drive is too hot Schedule cleaning before a High Temp fault
occurs
VSD1 parameter error Controller commissioned Commission the controller per the machine
incorrectly. nameplate
Incorrect VSD Replace with proper drive rating
VSD1 Response The A1000 drive is not responding Remove power for 1 minute
to WS control. Restore power for 1 minute
Restart the machine

31
WS CONTROLLER USER INTERFACE MANUAL SECTION 5

5.3 WS CONTROLLER FAULTS AND WARNINGS

High Low
Parameter Type Sensor Comment
Limit Limit

Separator Pressure ^ Warning P2-P1+offset 10 psid offset for aftercooler or dryer

Sump Pressure Fault P1 135 psig 5 psig 100 psig machine

150 psig 5 psig 125 psig machine

175 psig 5 psig 150 psig machine

200 psig 5 psig 175 psig machine

165 psig 5 psig 100-140 psig VSD machine

200 psig 5 psig 150-175 psig VSD machine

Line Pressure Fault P2 125 psig 10 psig 100 psig machine

150 psig 10 psig 125 psig machine

175 psig 10 psig 150 psig machine

200 psig 10 psig 175 psig machine

155 psig 10 psig 100-140 psig VSD machine

200 psig 10 psig 150-175 psig VSD machine

Warning T1 225 F 0F
Air End Discharge Temperature
Fault T1 235/255F 0F Time delayed/immediate

5.4 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
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 pad to stop the com-
pressor.
2. Disconnect and lockout power according to
lockout/tagout procedure.
3. Open the controller enclosure and locate the
I/O Control Module.

32
SECTION 5 WS CONTROLLER USER INTERFACE MANUAL

4. Remove six screws from I/O Control Module

cover and remove cover.
5. Locate the internal battery. The battery is
located near one end of the I/O circuit board
(usually oriented towards the top).
6. Remove the battery and replace with a bat-
tery type BR2330.
7. Replace the cover, close the enclosure, fol-
low normal startup procedures.

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Large I/O Control Module

Circuit Board

33
NOTES

34
 WS CONTROLLER USER INTERFACE MANUAL

Section 6

VARIABLE SPEED DRIVE

6.1 OVERVIEW 6.2 INSTALLATION
The Sullair VSD drive application is custom designed Refer to the VSD Installation and Service manual
for operation of air compressors. All necessary that came with the compressor for installation
control functions are performed through the WS information.
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.

35
NOTES

36
NOTES

37
 ß´©¿§­ ¿·®ò ß´©¿§­ ¬¸»®»ò

WWW.SULLAIR.COM

SULLAIR CORPORATION
3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A.
Telephone: 1-219-879-5451

Printed in the U.S.A.

Specifications subject to change
without prior notice.
E12EP