WS4500 7500英文操作维护说明书88290021 328

We appreciate for both your purchasing and utilizing
this stationary screw compressor made by

Shenzhen Sullair Asia Industrial Co., Ltd.
This manual provides detailed functional and structural descriptions, operation, and
maintenance of WS4500&WS7500 stationary rotary screw compressors.
Prior to operation and maintenance of the compressor, read this manual carefully and
make sure the functional structure and safety precautions of this machine are fully
understood.
Special lubricant provided by Sullair must be used. Never mix lubricant of different
types.
Sullair reserves the right of research and improvement of its products, and is not
responsible for modifications and improvements on its previous products. Contents in
this manual may vary from actual condition after a period of time due to the ongoing
improvement of our products. Please be aware of such possibilities.
If you encounter any problem during operation that is not clearly described in this
manual, contact local Sullair dealer, or Sullair Asia After-sales Department directly.
―Editor
December 2009
Documents used together with this manual:

88290021-329 Stationary Screw Compressor Parts Manual
88290013-031 Standard Microprocessor Controller I – Operation Manual or
88290010-484 Deluxe Microprocessor Controller I – Operation Manual
Compressor Model:
Compressor Serial Number:
★:Unless otherwise stated expressly, “Sullair Asia” and “Sullair” shall mean
“Shenzhen Sullair Asia Industrial Co., Ltd.” or “Suzhou Sullair Air Equipment Co.,
Ltd.”, as the case may be.
Table of Contents
Chapter I Safety·················································································································································· 1
1.1 Overview ·················································································································································· 1
1.2 Safety Equipment ····································································································································· 1
1.3 Pressure Release ····································································································································· 1
1.4 Fire and Explosion Protection ··················································································································· 1
1.5 Moving Parts ············································································································································ 2
1.6 Hot Surfaces, Sharp Edges and Corners ··································································································· 2
1.7 Toxic and Irritative Substances ················································································································· 2
1.8 Electrical Safety ······································································································································· 2
1.9 Hoisting and Transportation ······················································································································ 3
1.10 Miscellaneous ·········································································································································· 3
1.11 Maintenance Precautions ························································································································· 3
Chapter II Compressor Structure························································································································ 4
2.1 Overview ·················································································································································· 4
2.2 Parts Description ······································································································································ 4
2.3 Air End ····················································································································································· 7
2.4 Inlet System ············································································································································· 7
2.5 Discharge System ···································································································································· 7
2.6 Lubrication System ··································································································································· 7
2.7 Cooling System ········································································································································ 8
2.8 Oil/air Separator System ··························································································································· 8
2.9 Air capacity Adjustment System ················································································································ 9
2.10 Microprocessor Controller ······················································································································· 12
Chapter III Specifications································································································································· 13
3.1 Specifications - WS4500 Line Frequency Models ···················································································· 13
3.2 Specifications – WS5500 Line Frequency Models ···················································································· 14
3.3 Specifications – WS7500 Line Frequency Models ···················································································· 15
3.4 Specifications - WS4500/5500 VSD Models ··························································································· 16
3.5 Specifications – WS7500 VSD Models ···································································································· 17
Chapter IV Installation of Compressor············································································································· 18
4.1 Foundation and Installation ····················································································································· 18
4.2 Cooling and Ventilation ··························································································································· 18
4.3 Cooling Water System – Water-cooled Model ·························································································· 18
4.4 Air Service Line ······································································································································ 19
4.5 Check Coupling ······································································································································ 19
4.6 Check Oil Level ······································································································································ 19
4.7 Remove Motor Support and Oil/air Separator Fixing Plate········································································ 19
4.8 Check Drain Plug of Cooler (Water-cooled Model only) ············································································ 20
4.9 Check Electric Circuit······························································································································ 20
4.10 Rotation Direction of Motor ····················································································································· 20
4.11 Dimension and Installation Diagram – Air-cooled Model ··········································································· 22
4.12 Dimension and Installation Diagram – Water-cooled Model ······································································ 23
Ⅱ
Chapter V Compressor Operation ···················································································································· 24
5.1 Safety Operation Procedure ···················································································································· 24
5.2 Preparation before Initial Starting ············································································································ 24
5.3 Normal Operation ··································································································································· 24
5.4 Stop ······················································································································································· 24
5.5 Loading/Unloading Setting and Adjustment of Pressure Regulator ··························································· 24
Chapter VI Maintenance and Service··············································································································· 26
6.1 Overview ················································································································································ 26
6.2 Daily Operation ······································································································································ 26
6.3 Service after 50 Operation Hours ············································································································ 26
6.4 Service after 1000 Operation Hours ········································································································ 26
6.5 Oil – Standard Compressor ····················································································································· 26
6.6 Oil – 24KT Compressor ·························································································································· 27
6.7 Maintenance of Oil Filter························································································································· 27
6.8 Maintenance of Air Filter ························································································································· 27
6.9 Maintenance of Inlet Valve ······················································································································ 28
6.10 Maintenance of Oil/air Separator Element ······························································································· 29
6.11 Maintenance of Pressure Regulator ········································································································ 30
6.13 Maintenance of Solenoid Valve ··············································································································· 31
6.14 Maintenance of Blowdown Valve ············································································································· 31
6.15 Maintenance of Coupling ························································································································ 32
6.16 Maintenance of the Motor for Sullair Compressor ···················································································· 33
6.17 Maintenance of Motor and Air End ·········································································································· 33
Chapter VII Schematics···································································································································· 36
7.1 System Flowchart ···································································································································· 36
7.2 Schematics·············································································································································· 39
Chapter VIII Troubleshooting ·························································································································· 42
8.1 Overview ················································································································································· 42
8.2 Possible compressor fault and actions are listed in the following table ······················································· 42
Chapter IX Spare Parts List······························································································································ 44
Ⅱ
WS4500&WS7500 Rotary Screw Compressor Operation Manual Chapter I Safety
Chapter I Safety
1.1 Overview
Sullair Asia designs and manufactures its products so that 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.
Only those who have been trained and delegated to do so, and who have read and understood this manual
should operate the air compressor. Failure to follow the instructions, procedures and safety precautions in
this manual can result in accidents and even injuries or death. Read this manual prior to start-up. Never
start the air 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 all source of power so
that others who may not know of the unsafe condition will not attempt to operate it until the condition is
corrected.
Installation and operation of the machine shall follow national and local laws and regulations. Do not
modify the devices and control unless approved by the manufacturer in writing.
1.2 Safety Equipment
Before installation and operation, all installers and operators shall be familiar with and follow the safety
regulations, national and local laws and standards. Safety equipment shall be provided, such gears to
protect eyes, faces and respiration, protection clothes, boards and electrician protection devices, noise
monitoring & control system, sound insulation equipment, etc.
1.3 Pressure Release
A.Make sure to shut down the compressor and bleed internal pipelines to zero before removing the
fluid cap.
B.Make sure to bleed internal pressures before disconnecting any part (including piping, connector, hose,
drain valve, filter, etc.).
1.4 Fire and Explosion Protection
A. Clean up spills of lubricant or inflammable substances immediately;
B. Avoid spark, flame or inflammable substance. Never smoke near the machine when observing or
filling lubricant. Service shall be carried out when the machine is stopped and compressor
completely cools down;
C. Do not permit lubricant to splash on acoustical material or accumulate on compressor, lower
surfaces and inside of fence. Wipe down using an aqueous industrial cleaner or steam – clean as
required. If necessary, replace acoustical material and clean all surfaces. Any acoustical material
with a protective covering that has been damaged should be replaced immediately to prevent
accumulation of fluid within the material. Do not use inflammable detergent;
D. Disconnect all power supplies prior to attempting any repairs or cleaning inside the enclosure;
E. Keep the electrical system (including terminals and contactors) in good condition. If the cable is
damaged, scratched, deteriorating in insulation performance, lead aging, fading in color or corroded,
replace immediate. Keep the wire lead and contactor clean;
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. In case welding is necessary when repairs, clear acoustical materials and other inflammables or heat
sensitive articles out of site;
H. Sufficient fire extinguishers shall be provided when servicing or operating the compressor;
I. Clean inflammable materials such as oil cloth or scrap of paper near the compressor in a timely
manner;
J. If the cooling system or lubrication/coolant system is not working property (poor circulation of
cooling air or lubricant, low water pressure, oil deterioration), do not start the machine;
1
K. Do not operate the compressor in a dangerous circumstance unless it is designed to do so.

1.5 Moving Parts
A. Keep hands, arms and other parts of the body and also clothing away from couplings, fans and other
moving parts;
B. Do not attempt to operate the compressor with the fan, coupling or other guards removed;
C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially
when exposed to hot or moving parts;
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 all power supplies and make sure all circuits are powered off when servicing or
adjusting the machine. This is especially important in remote control mode;
G. Keep hands, feet, floors, and 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 Corners
A. Do not contact hot oil, coolant, surface or sharp edge/corner;
B. Keep your body away from the air discharge outlet;
C. Wear safety equipment such as gloves or helmet, etc. when operating within or around the machine;
D. Keep a first-aid kit handy. Seek medical assistance promptly in case of injury. Do not ignore small
cuts and burns as they may lead to infection.
1.7 Toxic and Irritative Substances
A. Do not use discharged air for breathing purpose unless it meets the requirement of relevant laws;
B. Operate the compressor only in open or well-ventilated areas;
C. No toxic or caustic gas shall be present around the compressor;
D. The lubricant is unique in the industry. Avoid skin contact or swallow. In case of swallow, see a
doctor immediately. In case of skin contact, wash with soap and water.
E. Exhaust of air-cooled model shall be discharged into outdoor space with good ventilation.
1.8 Electrical Safety
A. Besides electrical regulations stipulated herein, the user shall also follow national and local laws,
regulations, orders and ordinances, etc. and shall formulated appropriate electrical safety procedures
and post accountability system.
B. Installation and maintenance of the compressor shall follow national and local laws, standards and
regulations (including national electric codes and other regulations on safety grounding), and shall
be down by qualified personnel.
C. The work site shall be clean, dry and well lighted. Insulation shoes, gloves and other gears must be
used and put a rubber carpet or insulation platform underneath.
D. Selection of incoming breaker provided by customer and determination of various current
protection coefficients shall be based on the actual capacity of machine. Sufficient insulation gap
shall be guaranteed between power supply terminals.
E. Wiring, service or maintenance may only be carried out with the power supply cut off. Meanwhile,
mark the machine with warning sign or take measures to avoid closing of breaker by accident. For
VSD models, service may only be carried out with the machine being power off for 5 minutes.
F. Ground line shall be provided for each machine. The ground line shall be firmly connected with
ground bar in electrical cabinet of the machine. There should be no split, damage or splice between
the user-side ground busbar and ground bar in the electrical cabinet. Ground line of each machine
shall be connected with user-side ground busbar independently with grounding resistance no greater
than 4ohm.
(Note: Inspection of grounding and insulation of VSD shall be as per the requirements of VSD
2
Operation Manual.)
G. Do not reach your hand or other objects into intake/exhaust port of motor to avoid electric shock.
H. Do not remove or damage the protection plate or electrical protection device within the electrical
cabinet.
I. Electrical components or devices to be replaced by user shall be supplied or approved by Sullair.
J. Once installation is completed, please dry and test all electrical circuits before starting the
compressor.
K. Fire extinguisher shall be suitable for electrical equipment (including electric motor) and oil
equipment. Corresponding personnel shall be familiar with the use and firefighting equipment and
practice for electrical fire.
1.9 Hoisting and Transportation
A. Use lifting chain when lug is not available. Be aware that governmental and local regulations and
laws shall always be complied with.
B. Inspect each connection point before hoisting to see if there is cracked weld, deformed or corroded
parts, and loose bolts/nuts.
C. Make sure entire hoisting, rigging and supporting structure has been inspected, is in good condition
and has a rated capacity of at least the weight of the compressor. If you are unsure of the weight,
then weigh compressor before hoisting.
D. The hook should be equipped with a safety buckle, which securely locks lugs or hoist chain during
hoisting.
E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been
lifted clear of the ground. Do not hoist in case of strong wind.
F. No person is allowed under the compressor or crane once the compressor has been lifted, and the
operator may not leave the site.
G. Lift the compressor no higher than necessary;
H. Set compressor down only on a level surface capable of safely supporting it.
I. If forklift is used, the forklift pocket or dedicated tray shall be used. If the forklift pocket or
dedicated tray is not available, make sure the compressor is balanced on the forklift. Make sure the
forklift is secure and leaning backward before moving.
J. If a plate support is used, secure the compressor with bolts or other means to prevent the
compressor from dropping in case of bumping road or sudden brake.
1.10 Miscellaneous
A. If it is necessary to enter the enclosure to perform service adjustments, inform other personnel
before doing so and setup notification. Block the door to avoid the possibility of others closing the
door;
B. Make sure all personnel are out of compressor before closing the door.
C. Do not alter the design or setting of air compressor without written approval of Sullair. Sullair is
not responsible for any consequences arising out of such modification.
1.11 Maintenance Precautions
Sullair genuine parts must be used when servicing Sullair compressor in accordance with the
requirements in Operation Manual.
Sullair genuine parts are specifically designed for Sullair compressor. Using parts of poor quality or
nonconforming parts will pose risk to the safety and quality of the machine. Therefore, it is hereby stated
that:
A. Sullair warranty will void if Sullair genuine parts is not used!
B. Sullair is not responsible for any failure caused by non-genuine Sullair parts!
C. Sullair is not responsible for any failure caused by maintenance or service not in compliance
with the Operation Manual!
3
WS4500&WS7500 Rotary Screw Compressor Operation Manual Chapter II Compressor Structure
Chapter II Compressor Structure

2.1 Overview
Presented to you is a low-noise, stationary VSD controlled screw compressor for power purpose. It has
single stage compressing unit, oil inject, air cooler and driving motor. The machine comprises the air end,
motor, oil/air separator, oil cooler, after-cooler, cooling fan assembly, chassis assembly, etc. enclosed in
a soundproof cover. An electric control cabinet is equipped on one side of the soundproof cover. The
machine is compact, elegant and easy to operate. Both air-cooled and water-cooled models are available
for user to choose from based on field operation.
Sullair rotary screw compressor not only features high efficiency and reliability, it also requires little
maintenance. Compared with compressors of other brands, Sullair product is unique in high reliability
and wear resistance. The internal parts of air end are “exempted from inspection”.
To keep your machine at top performance, please read Chapter 6 Maintenance carefully. For any
questions not explained in this Manual, you may contact local Sullair dealer or Sullair After-sales
Department.
2.2 Parts Description

See Figure 1 and Figure 2 for the layout of WS4500-WS7500 models. Parts and locations of air-cooled
and water-cooled models are shown on the figures. The machine comprises compressor motor assembly,
inlet system, oil/air separation system, cooling system, lubrication system, discharge system, control
system, etc.
4
Figure 1 WS4500-WS7500 air-cooled models layout

1.Control system 2.Cooling fan system 3.Enclosure assembly 4.Discharge system 5.Frame system
6.Inlet system 7.Oil/air separation system 8.Lubrication system 9.Decal system
5
Figure 2 WS4500-WS7500 water-cooled models layout
1. Control system 2. Discharge system 3.Decal system 4. Frame system 5.Inlet system
6. Enclosure assembly 7.Lubrication system 8.Oil/air separation system 9.Cooling system
6
2.3 Air End

Air end is an important component within the machine. Two pairs of rotors engaged together rotate at
high speed driven by motor. As the rotors intermesh, they reduce the volume of trapped air, so the air
sucked through the air filter is compressed and its pressure is increased. Meanwhile, fluid is continuously
injected into the working chamber of air end, mixing with air. The Fluid has three functions:
(1). It serves as coolant to effectively control temperature rise caused by compression heat;
(2). It seals the leak between rotors and casing, and between rotor and rotor;
(3). It forms a lubrication film between rotors so the driving screw may drive the slave screw.
When the groove space reaches the air outlet of the compressor, the oil/air mixture is discharged into the
oil/air separator.
2.4 Inlet System
Air inlet system is composed of air filter, inlet hose and inlet control valve. See the inlet diagram in Parts
List.
Air filter is used to remove impurities in air and provide clean air to compressor. Impurities in air will
cause wear on rotor surface and pollute the fluid.
Not following the air filter service requirement or not using original filter element will cause early
failure of fluid and oil/air separator element and warranty void.
The inlet valve may regulate inlet volume based on air demand level to maintain a balance between
supply and demand, saving energy consumption.
2.5 Discharge System
The discharge system comprises water trap, electronic drain valve and piping. See the discharge system
diagram in Parts List. Compressed air from oil/air separator goes through min pressure valve, aftercooler
and water trap before being discharged for customer use. Service port of the machine is Rp2”. User needs
to equip check valve on external air pipeline.
Water trap is used to extract condensate from compressed air and drain it outside of the machine.
A reliable electronic drain valve is used. User may observe the level through the sight glass of trap and
set draining duration and interval based on the condition of the machine. A manual drain valve is also
equipped to drain water in case that the electronic valve has failed. This is emergency procedure only.
Operator shall clean the electronic drain valve in a timely manner to restore the automatic drain function
of the trap. Once the compressor is stop, operator shall open the drain valve manually to discharge the
water, avoiding rust inside the trap.
(Note: Open the manual drain valve before servicing and disassembling the trap to release the pressure in
trap.)
Warning
Do not disassemble when the compressor is running or pressurized. Shut down the machine and
bleed internal pressure to zero before disassembling.
2.6 Lubrication System
Lubrication system is composed of thermal valve, fluid filter and piping. See the lubrication system
diagram in Parts List.
Fluid in oil/air separator flows into fluid cooler through thermal valve. Cooled fluid enters air end
working chamber through fluid filter. Then it is compressed along with inlet air and discharged into
oil/air separator for a complete cycle.
Thermal valve and fluid filter are integrated into one body and the valve element is in the top cap of filter.
Fluid serves for three roles:
(1). Coolant - Fluid injected into the machine absorbs large amount of heat generated during
compressing as a coolant.
7
(2). Lubricant - Fluid forms an oil layer between the rotors, avoiding direct contact between male and
female rotors. Therefore the wear between rotor surfaces is minimized. In addition, fluid flows to
lubrication positions through internal oil way to lubricate bearings and gears.
(3). Sealant - Fluid with appropriate viscosity can fill up the gaps between rotors and between rotor and
casing. It reduces leakage loss and enhances the volumetric efficiency of compressor.
(4). Fluid filter clears the impurity in fluid and ensure that clean fluid is transported to air end working
chamber and lubrication positions. Impurity in fluid will cause wear on rotor/gear engaging
surfaces and bearing, and reduces the life of compressor.
Fluid filter element should be replaced regularly to ensure good fluid circulation.
Pressure difference transducer is equipped at the top of fluid filter. If pressure difference between the two
sides of filter element exceeds threshold (0.14MPa), a service signal (OIL FILTER MAINT REQD) will
be displayed on the monitor to remind operator of filter element replacement.
2.7 Cooling System
The cooling system comprises fluid cooler and aftercooler. See the cooling system diagram in Parts List.
A. Water-cooled model: User shall be aware of the following when installing external coolant
system
(1). Coolant inlet pipe is connected with aftercooler, i.e. the air is cooled first and fluid is cooled later.
(2). To keep the cooler at good heat-exchanging performance and prolong lifespan of cooler,clean and
sufficient coolant must be used. See 4.3 Cooling System – Water-cooled model for requirements on
coolant quality and flow.
(3). To avoid frost crack to cooler in winter, discharge the water accumulated in cooler once the
machine is shut down. Drain the cooler if the machine is not to be used for a long period of time.
B. Air-cooled model:
The machine equips a centrifugal cooling fan with outer rotor. It features low noise, large air flow, high
pressure and compact structure. Cooling air enters the machine through rear louver and is driven into the
box of centrifugal fan under a negative pressure created by the blower, exchanging heat with cooler.
Then it is exhausts through top louver under centrifugal force.
A cover is used in the box of centrifugal fan to prevent large object or tool from dropping onto the leaf.
Note: The fan is accurately balanced. Do not disassemble the fan. Otherwise the blower may be
damaged.
2.8 Oil/air Separator System

Oil/air separation system comprises oil/air separator, filter element, check valve, min pressure valve,
relief valve, etc. See oil/air separator system diagram in Parts List.
Oil/air mixture from air end crashes on the wall of separator to lower its speed. Large oil drops are
formed due to lower speed. Most of the oil drops set to the bottom of separator under gravity. Oil/air
separator has the following functions:
(1) Prefilter – Oil/air mixture from air end enters the oil/air separator and crashes on the wall of
separator to lower its speed. Large oil drops are formed due to lower speed. Most of the oil drops set
to the bottom of separator under gravity.
(2) An oil reservoir of the compressor to store fluid.
(3) Filter element.
After collision separation, oil/air mixture flows through filter element for fine separation. Minor fluid
residue in compressed air is separated and accumulated on the bottom of filter element. Then the oil is
returned back to compressor's intake port and working chamber through the oil return pipe.
8
(1) Pressure regulation.

Certain amount of air inside the oil/air separator effectively stabilizes pipeline pressure.
The sump tank has two filter elements, primary element and secondary element. Oil/air mixture from
primary separation process is further separated by secondary filter element. Minor oil residual in the
compressed air is extracted and sets on the bottom of filter element. Then the oil goes to the inlet port of
air end through oil return line and is sucked into the working chamber. Sight glass is equipped on the
return line for operator to observe oil return condition. When the compressor is under full load, oil flow
should be significant. When the compressor is unloading, there should be little oil flow. In case the oil
flow is discontinuous or low when the machine is fully loaded, stop and unload the machine. Once the
system has cooled down, clean oil return filter.
Oil filling port and sight glass are equipped on the outer side of oil/air separator. Since discharged air
contains oil more or less, the oil level of separator will drop and need to be added. The normal oil level
shall be observable from the sight glass when the compressor is running at full load.
The min pressure valve is located on the top cap of oil/air separator. It is used to maintain pressure in
oil/air separator above 0.35MPa to ensure fluid flow in oil pipeline. When the compressor is unloading or
stopped, min pressure valve prevents compressed air from flowing back in the system.
An automatic blowdown valve is equipped on the oil/air separator. When the compressor is unloading or
being stopped, blowdown valve opens automatically to allow compressed air in oil/air separator into inlet
pipe, thus release pressure.
A relief valve is equipped on oil/air separator. When pressure in separator exceeds threshold, relief valve
will open to discharge pressure and make sure the machine is safe. The machine also features a high
pressure stop switch. When pressure in separator exceeds threshold, the machine will stop automatically.
Therefore relief valve will not open under normal circumstances.
2.9 Air capacity adjustment system
Air capacity adjustment system automatically adjusts the inlet volume of compressor based on air
demand to maintain the balance between supply and demand.
The control system adjusts compressor inlet volume based on demand for compressed air. The control
system comprises solenoid valve, pressure regulator, inlet valve and spiral valve (for models with spiral
valve only).
A. Line frequency model:
When air demand equals to rated capacity, the machine runs in full load mode and the inlet valve that
controls inlet volume is fully opened. If air demand is lower than rated capacity, the system will
automatically control the openness of spiral valve and inlet valve to reduce inlet volume. If there is no
demand, spiral valve and inlet valve will be closed automatically to stop air intake. In such a case the
machine runs on a lower back pressure in no-load mode.
Function of the control system is explained in the following four modes. To simplify the case, a
compressor with working pressure of 115-125 psig (8-8.6bar) is used. The working procedures applied to
all WS4500 & WS7500 series compressors except that they have different pressure range.
Starting up – 0 to 50 psig (0 to 3.5 bar)

Press start button to start the compressor. Pressure is instantly built in the oil/air separator. Compressed
air closes inlet valve through the control pipeline. The compressor starts at light load and automatically
enters full-load mode after a period of time (typically 6 sec), during which the pressure regulator and
solenoid valve are closed and inlet valve slightly opens under vacuum. The machine runs at no-load.
Pressure in separator builds up from 0 to 50 psig (0-3.5bar). During this period, min pressure valve is
closed and compressed air is disconnected from service pipe to maintain a pressure required for fluid to
flow. Pressure setting of the min pressure valve is typically around 50 psig (3.5 bar).
9
Normal operation – 50 to 115 psig (3.5 to 8 bar)

If system pressure exceeds 50 psig (3.5 bar), min pressure valve will open and compressed air will enter
supply pipe. Now the pressure of pipeline is monitored and controlled by microprocessor controller.
Pressure regulator and solenoid valve are still closed and inlet valve is fully opened till pressure of the
compressor reaches 115 psig (8 bar).
Air capacity adjustment (Standard model) – 115 to 125 psig (8 to 8.6 bar)
If air demand is less than rated capacity, discharge pressure will rise. When the pressure exceeds 115
psig (8 bar), pressure regulator will be activated, sending control air to inlet valve to reduce air intake and
keep the balance between supply and demand. Between 115 and 125 psig (8-8.6 bar), the control system
adjust according to line requirements. Volume regulation range is 100%~50%.
Air capacity adjustment (Spiral valve model) – 115 to 125 psig (8 to 8.6 bar)
When air demand is less than rated capacity, system pressure will build up. Once the pressure exceeds
115 psig (8 bar), pressure regulator that controls the spiral valve will send control air to the spiral valve,
pushing valve element by a rack. Thus, part of discharged air bypassed to inlet port to reduce supply. The
lower the air demand, the greater the openness of spiral valve. If air demand is 50% of the rated capacity,
system pressure will rise to 7.4 bar and the spiral valve will fully open. The guide of spiral valve will
point at MIN (minimum). Therefore, regulation range of spiral valve is 100% to 50%, corresponding to a
system pressure of 8.0~8.4bar. Guide of the spiral valve will turn from MAX to MIN.
If air demand is less than 50% of rated capacity, system pressure will exceed 8.4bar. Now the partial load
pressure regulator starts to work to output pressure to the closing air circuit, reducing the inlet valve and
air intake. When air demand drops to 40% of rated capacity, system pressure will rise to 8.6bar.
Therefore, partial load pressure regulator’s range is 50%~40% of rated capacity, corresponding to a
system pressure of 8.4~8.6bar.
During this process, guide of the spiral valve remains at MIN.
Unloading (Standard model)– Over 125 psig (8.6 bar)
When air demand continues to drop or there is no demand, pipeline pressure may exceed 125 psig (8.6
bar). In such a case, the controller will cut off power supply for loading/unloading solenoid valve, thus
opening the loading/unloading solenoid valve. Control air will enter inlet valve to close it and enter
blowdown valve to open it. In such a case the machine runs on a lower back pressure to reduce energy
consumption. Min pressure valve will prevent compressed air from flowing back to separator.
When pipeline pressure drops to minimum threshold, microprocessor board will power on the
loading/unloading solenoid valve and close blowdown valve. Now the solenoid valve releases inlet valve
to let it take air in again. Once the pressure is built up, pressure regulator will play its role again.
Unloading (Spiral valve model)– Over 125 psig (8.6 bar)
When air demand drops to 40% of rated capacity, system pressure will rise to 8.6bar. In such a case, the
controller will cut off power supply for loading/unloading solenoid valve, thus opening the
loading/unloading solenoid valve. Control air will enter inlet valve to close it and enter blowdown valve
to open it. In such a case the machine runs on a lower back pressure to reduce energy consumption. Min
pressure valve will prevent compressed air from flowing back to separator.
During this process, guide of the spiral valve remains at MIN.
If air demand increases, line pressure will drop. When pressure drops to 8.0bar, the controller will power
on the loading/unloading solenoid valve , meanwhile the inlet regulator and spiral valve returns to their
original places, and spiral valve guide will be point at MAX. The machine is running at full load mode
again.
10
B.VSD model:
Air capacity adjustment system of VSD model varies the speed of electric motor via frequency variation
to match the fluctuation of air demand, and keep the balance between supply and demand. Minimum
motor frequency of WS45-75 series VSD machines is 20Hz and the maximum frequency varies from
model to model. Reference frequency of electric motor is 75Hz. Each VSD model has its own maximum
output frequency for VSD and maximum speed for motor. When air demand equals to rated capacity, the
machine runs in full load mode and the frequency of motor VSD is at rated value. If air demand is lower
than rated capacity, motor frequency will be reduced to lower the speed or air end, thus reducing air
intake. If there is no demand, motor frequency will be reduced to minimum, meanwhile inlet valve will
be closed to stop air intake. In such a case the machine runs on a lower back pressure in no-load mode.
Air capacity adjustment system function is explained in the following four modes. To simplify the case, a
compressor with working pressure of 115-125 psig (8-8.6 bar) is used. The working procedures applied
to other VSD models except that the control pressure points of working pressure are different.
Starting up – 0 to 50 psig (0 to 3.5 bar)

Press start button to start the compressor with motor at lowest frequency. Pressure is instantly built in the
oil/air separator. Compressed air closes inlet valve through the control pipeline. The compressor starts at
light load and automatically enters full-load mode after a period of time (typically 6 sec), during which
the solenoid valve is closed and inlet valve slightly opens under vacuum. The machine runs at no-load.
Pressure in separator builds up from 0 to 50 psig (0-3.5bar). During this period, min pressure valve is
closed and compressed air is disconnected from discharge pipe to maintain a pressure required for fluid
to flow. Pressure setting of the min pressure valve is typically around 50 psig (3.5 bar).
Normal operation – 50 to 115 psig (3.5 to 8 bar)

If system pressure exceeds 50 psig (3.5 bar), min pressure valve will open and compressed air will enter
supply pipe. Now the pressure of pipeline is monitored and controlled by microprocessor controller.
Solenoid valve is still closed and inlet valve is fully opened till pressure of the compressor reaches
100psig (7bar). Now motor frequency reaches its rating.
Air capacity adjustment – 115 to 125 psig (8 to 8.6 bar)

If air demand is less than rated capacity, discharge pressure will rise. When the pressure exceeds 115
psig (8 bar), VSD motor will reduce its frequency, hence reducing intake air capacity to keep the balance
between intake and discharge. Between 115 and 125 psig (8-8.6 bar), frequency of VSD motor varies
according to the pressure in pipeline.
Unloading – Over 125 psig (8.6 bar)

When air demand continues to drop or there is no demand, pipeline pressure may exceed 125 psig (8.6
bar). In such a case the frequency of VSD motor is at minimum. Microprocessor board will send signal to
turn on the solenoid and control air will enter inlet valve to close it and enter blowdown valve to open it.
In such a case the machine runs on a lower back pressure to reduce energy consumption. If the
microprocessor board is in manual mode, the machine will keep running at unloading mode until line
pressure drops to 8bar, at which point the microprocessor board powers on the solenoid valve and closes
blowdown valve. Meanwhile, inlet valve opens to intake air again and the machine enters normal mode.
If the microprocessor board is in auto mode, the machine will keep running at unloading mode for a
preset period of time before it stops automatically. Once line pressure drops to 8bar, the compressor will
enter normal model again.
2.10 Microprocessor controller
11
The line frequency model is equipped with standard microprocessor controller. For detail information of the
controller, see 88290008-308 Standard Microprocessor Controller I – Operation Manual.
The line frequency model may have the option, and VSD model is equipped with deluxe microprocessor
controller. For detail information on controller, see 88290007-962 Deluxe Microprocessor Controller I –
Operation Manual.
12
WS4500&WS7500 Rotary Screw Compressor Operation Manual Chapter III Specifications
Chapter Ⅲ Specifications
3.1 Specifications - WS4500 Line Frequency Models
Model 4507 4507PS 4508 4508PS 4510 4512
8.5(300.2) 8.6(304) 7.8(275.5) 7.7(273) 6.9(243.7)

Nominal capacity 50Hz 50Hz 50Hz 50Hz 50Hz 5.65(199.5)
m3/min (CFM) 8.5(300) 8.8(310) 7.93(280) 7.8(276) 6.6(233) 50Hz
60Hz 60Hz 60Hz 60Hz 60Hz
Rated discharge pressure

7 (100) 7 (100) 8 (115) 8 (115) 10 (145) 12 (175)
bar (psi)
Max working pressure

7.6 (110) 7.6(110) 8.6 (126) 8.6(126) 10.6 (155) 12.6 (185)
bar (psi)
Relief valve opening

pressure 9(130) 9(130) 10(145) 10(145) 12(175) 14(200)
bar (psi)
Machine weight kg 1249
L× W× H mm 2300×1180×1750
Air end
Type Oil injection dual rotary screw compressor
Configuration Single-stage gear transmission/external inlet control valve
Bearing Wear-resistant
Fluid brand Sullube or 24KT
Fluid capacity, L 31
Electric motor
Type 364TSC-4(TEFC/ODP)
Rated power kW
(HP) 45(60)
Rated speed rpm 1470(50Hz)\1775(60Hz)
Voltage/frequency 380-415V 50Hz \ 380-420V/220-240V 440-480V 60Hz
Service factor 1.15
Ambient temperature
≤40
℃
Starting mode Y-△
Service connector
Rp 2
(internal thread)
Noise level dB (A) Air-cooled model: 71±3/Water-cooled model: 68±3
13
3.2 Specifications – WS5500 Line Frequency Models
Model 5507 5507PS 5508 5508PS 5510 5512
10.5(370.8) 10.9(387) 9.5(335.5) 9.9(349) 8.6(303.7) 7.6(268)

Nominal capacity 50Hz 50Hz 50Hz 50Hz 50Hz 50Hz
m3/min (CFM) 10.6(374) 10.9(387) 9.85(348) 9.9(349) 8.18(289) 7.73(273)
60Hz 60Hz 60Hz 60Hz 60Hz 60Hz
Rated discharge
pressure 7 (100) 7 (100) 8 (115) 8 (115) 10 (145) 12 (175)
bar (psi)

7.7 (110) 7.7(110) 8.7 (125) 8.7(125) 10.7 (155) 12.7 (185)
bar (psi)

pressure 9(130) 9(130) 10(145) 10(145) 12(175) 14(200)
bar (psi)
Machine weight kg 1297
L× W× H mm 2300×1180×1750
Air end
Electric motor
Type 365TSC-4 ODP/405TSC-4 TEFC
Rated power kW
(HP) 55(75)
Rated speed rpm 1470(50Hz)/1775(60Hz)

Service factor 1.15
Ambient temperature
≤40
℃
Starting mode Y-△
Service connector
Rp 2
(internal thread)
Noise level dB(A) Air-cooled model: 72±3/Water-cooled model: 69±3
14
3.3 Specifications – WS7500 Line Frequency Models
Model 7507 7507P&PS 7508 7508P&PS 7510 7510P&PS 7512P&PS
13.5(476.7) 13.9(491) 12.5(44) 12.9(457) 10.5(371) 11.5(405) 10.5(369)

Nominal capacity 50Hz 50Hz 50Hz 50Hz 50Hz 50Hz 50Hz
m3/min (CFM) 13.45(475) 14.1(500) 12.55(443) 12.9(457) 10.28(363) 11.8(418) 10.5(371)
60Hz 60Hz 60Hz 60Hz 60Hz 60Hz 60Hz
Rated discharge
pressure 7(100) 7(100) 8(116) 8(116) 10(145) 10(145) 12(175)
bar (psi)
Max working
pressure 7.7(110) 7.7(110) 8.7(126) 8.7(126) 10.7(155) 10.7(155) 12.7(185)
bar (psi)
Relief valve
opening pressure 9(130) 9(130) 10(145) 10(145) 12(175) 12(175) 14(200)
bar (psi)
Machine weight
1350
kg
L×W ×H mm 2300×1180×1750
Air end
Electric motor
Type 365TSC-2 /404TSC-4
Rated power kW
(HP) 55(75)
2940/50Hz 1470/50Hz 2940/50Hz 1470/50Hz 2940/50Hz 1470/50Hz 1470/50Hz

Rated speed rpm
1775/60Hz 1775/60Hz 1775/60Hz 1775/60Hz 1775/60Hz 1775/60Hz 1775/60Hz
Service factor 1.15
Ambient
temperature ≤40
℃
Starting mode Y-△
Service connector
Rp 2
(internal thread)
15
3.4 Specifications – WS4500/5500 VSD Models
Model 4507VSD 4508VSD 5507VSD 5508VSD 5510VSD 5512VSD
Nominal capacity 8.5 7.93 10.6 9.85 8.6 7.73

m3/min (CFM) (300) (280) (374) (348) (303.7) (273)
Capacity regulation range 1.93-8.5 1.91-7.93 2.52-10.6 2.52-9.85 2.12-8.6 2.09-7.73

m3/min(CFM) (68.2-300) (67.5-280) (89-374) (89-348) (75-303.7) (73.8-273)
Rated discharge pressure

7(100) 8(115) 7(100) 8(115) 10 (145) 12 (175)
bar (psi)

7.6(110) 8.6(126) 7.6(110) 8.6(126) 10.7 (155) 12.7 (185)
bar (psi)

pressure 9(130) 10(145) 9(130) 10(145) 12(175) 14(200)
bar (psi)
Machine weight kg 1249 1297

L × W× H mm 2300×1180×1750
Air end
Electric motor
364TSC-4 ODP
Type
365TSC-4 TEFC
Rated power kW (HP) 45(60) 55 (75)
Rated speed rpm As per model
Voltage/frequency 380-415V 50Hz \ 380-420V/440-480V 60Hz
Service factor 1.15
Ambient temperature℃ ≤40
Starting mode VSD starter
Service connector
Rp 2
(internal thread)
Air-cooled model: 71±3/

Water-cooled model: 68±3
16
3.5 Specifications – WS7500 VSD Models
7507 7507P&PS 7508 7508P&PS 7510 7510P&PS 7512P&PS

Model
VSD VSD VSD VSD VSD VSD VSD
Nominal capacity
13.5 (477) 14.1 (500) 12.55 (443) 12.9 (457) 10.5 (370.8) 11.8 (418) 10.5 (371)
m3/min (CFM)
Capacity
3.21-13.5 3.36-14.1 3.26-12.55 3.3-12.9 2.76-10.5 2.65-11.8 2.59-10.5
regulation range
(113-477) (119-500) (115-443) (117.2-457) (97.6-370.8) (94-418) (91.6-371)
m3/min(CFM)
Rated discharge
pressure 7(100) 7(100) 8(116) 8(116) 10(145) 10(145) 12(175)
bar (psi)
Max working
pressure 7.7(110) 7.7(110) 8.7(126) 8.7(126) 10.7(155) 10.7(155) 12.7(185)
bar (psi)
Relief valve
opening pressure 9(130) 9(130) 10(145) 10(145) 12(175) 12(175) 14(200)
bar (psi)
Machine weight
1350
kg
L ×W× H mm 2300×1180×1750
Air end
Electric motor
404TSC ODP
Type
405TSC TEFC
Rated power kW
55(75)
(HP)
Rated speed rpm As per model

Service factor 1.15
Ambient
temperature ≤40
℃
Starting mode VSD starter
Service connector
Rp 2
(internal thread)
17
WS4500&WS7500 Rotary Screw Compressor Operation Manual Chapter IV Installation of Compressor
Chapter IV Installation of Compressor

4.1 Foundation and Installation
The machine should be mounted on supporting ground or foundation with sufficient strength. To ensure
that the transmission and internal piping work properly, the machine should be level and firmly
contacting the ground. To control the vibration within technical range, suspended area between the
machine and ground shall be no greater than 15%. To avoid noise from leaking through the gap, a rubber
plate is suggested under the machine with thickness of 10~20mm and width of 80mm.
Elastomeric coupling is used for transmission. Note that the level error or large deflection could affect
the machine and reduce its lifespan.
No load from the piping shall be transferred to air/water connectors within the machine.
Air compressor shall be operated with ambient temperature of 0~40℃. Make sure the ambient
temperature is above 0℃ at all time.
4.2 Cooling and Ventilation

To provide reliable ambient temperature for air-cooled model, air should be able to flow in and out of the
compressor smoothly. Exhaust of the compressor should be at least 1m away from wall and top cover
should be at least 1.5m away from ceiling. Take measures to prevent hot exhaust being drawn back into
the compressor. Ventilation facility should be in place to avoid abrupt temperature rise. Air in/out
interface is ready on the enclosure. See Dimension and Installation Diagram for detailed size. Arrange
ductworks when designing the equipment room. Total pressure loss of all external ducts shall be no more
than 3mm water column. On the other hand, room design should also satisfy ambient temperature
requirement for starting in winter, which is 32°F (0℃) or above.
See the table below for ventilation and heat exchange of the machine:
Item Inlet temp. Ventilation Heat exchange

4500 air-cooled ≤32℃ 207M3/min 44.4x103 Kcal/Hr
5500 air-cooled ≤32℃ 207M3/min 54.2 x103 Kcal/Hr
7500 air-cooled ≤32℃ 207M3/min 73.9x103 Kcal/Hr
Water-cooled ≤32℃ 82 M3/min 4.8x103 Kcal/Hr
4.3 Cooling Water System – Water-cooled Model

According to the Code for Design of industrial circulating cooling Water Treatment GB50050 and Code
for Design of industrial circulating cooling Water GB/T50102-2003, as well as requirements for both
Sullair air compressor and water-cooled refrigerated dryer, requirements for cooling water quality are set
out below:
PH 6.5-9
Chloride, CL-- 20-50 mg/L Sulfate,
SO4- 50-100 mg/L
Free chlorine, CL2 0.5-1.0 mg/L
Calcium carbonate, CaCO3 70-100 mg/L
Total solid 25-50 mg/L
Iron Fe2+ <0.5 mg/L
Calcium, Ca2+ 30-200 mg/L
No ammonium or mercury
18
Ensure the supply of cooling water to water-ooled compressors. Specifications for cooling water system:
Water temp.℃ Water flow L/min
WS4500 WS5500 WS7500
27 39.7 48.7 66
30 47.6 58.4 79.2
35 55.6 68.2 92.4
(Inlet water temperature of 27℃ at rated condition. Water pressure drop through the machine is no more
than 0.3bar.)
4.4 Air Service Line

There is a Rp2 pipe on the outside of water trap. User may use the compressed air but using a sealed
thread pipe. User shall equip a check valve on external piping.
4.5 Check Coupling
Air end of compressor is connected with electric motor through elastomer coupling. Before
starting the machine for the first time, make sure each fastener is properly fastened according to
the procedures of coupling in the Manual.
4.6 Check Oil Level
Before leaving factory ,we have already added enough oil into compressor.
There is a oil glass on the oil separator .So you can view the level of oil by the oil glass , when the
machine is fully-loaded. Then it is normal. If not,you should stop the compressor and add the oil ,when
the level of oil reach between 1/2 and 3/4 of the oil glass ,then it is ok.
4.7 Remove Motor Support and Oil/air Separator Fixing Plate
A support below the seat of motor is connected with the frame to prevent damage to electric motor and
rubber isolator below the air end due to vibration during transportation. Remove this support in red color
before initial start-up. Customer is recommended to keep the support, which can be used to support the
motor when servicing the air end.
Motor support, to be removed Fixing plate of oil/air

before initial start-up. separator, to be removed
before initial start-up.
19
Similarly, a fixing plate below the oil/air separator tank is connected with the frame to prevent damage to
rubber isolator below the oil/air separator tank due to vibration during transportation. Remove this
support in red color before initial start-up.
4.8 Check Drain Plug of Cooler (Water-cooled Model only)
Drain plug of the cooler is already in place before the machine leaves factory. However, user shall check
each plug to make sure they are secured to avoid coolant leak upon start-up.
4.9 Check Electric Circuit
Internal circuits are wired at factory. There is little wiring work for user to carry out. When wiring the
machine, observe national and local regulations on insulation switch, fuse, etc. Sullair provides the
schematics.
Danger Danger
High-voltage inside. Be careful of electric shock.

Cut off all power supplies before servicing.
1. Check if input voltage is conforming.
2. Check the model of starter and overload heater.
3. Check if all electric terminals are securely fastened.
4. Re-wire the terminal of motor and check the rotation direction of motor according to 4.10.
4.10 Rotation Direction of Motor
Warning
Power breaker installed by user shall be near the machine
A．Line frequency model
User should check if motor rotation direction matches the mark as follows once the machine is powered
on.
Pull out emergency stop button from monitor's control panel and press "I" button (start) followed by "O"
button (stop) immediately. Let motor revolve for a moment. If motor rotates in the same direction of
marked arrow, it means wiring is correct. If not, cut off power and exchange any two power cables. Then
test again.
Never put the motor in reverse rotation direction!
B．VSD model
User should check rotation direction of main motor and fan motor separately once the wiring the
completed.
Check main motor rotation direction:
Pull out emergency stop button from monitor's control panel and press "I" button (start) followed by "O"
button (stop) immediately. Let motor revolve for a moment. Looking from the rear end of the motor, if
the spindle rotates clockwise, then it is correct. If not, cut off power and exchange the phase on the
output side of VSD and test again. There is a sign on the barrel between motor and compressor to
indicate rotation direction.
20
Check fan motor rotation direction:

Check the rotation direction of fan motor together with the main motor. Both motor and fan have
direction indicator. If the direction is wrong, adjust fan motor contactor or the phase on the output side of
fan VSD.
Warning
1. When testing the machine, press Stop or Emergency Stop button once the main motor starts to
run. NEVER let the machine operate with motor running at the wrong direction.
2. For VSD models, change the rotation direction of main motor only by switching phase on the
output side of VSD. Adjusting input power supply may not change the rotation direction of
main motor.
21
Emergency Control Air-out Ventilation 210m³/min
stop button panel
Air-in
Air Service
Port Rp2
Sight glass Condensate drain port

NPT 1/4 Forklift pocket
60 Cable inlet
16-M8 bolt hole Cable-in II: Bottom
for fan guide
installed by user
WS4500&WS7500 Rotary Screw Compressor Operation Manual
22
A-direction
Fixing hole on bottom
Figure 3
1.11 Dimension and Installation Diagram – Air-cooled Model
60×90 Cable inlet

knock down hole
Cable-in I: Top
Line Frequency and VSD Models

Installation Diagram – Air-cooled
Emergency Control Air-out
stop button panel
Ventilation 210m³/min
Air Service
Port Rp2
Air-in
Water-in
Water-out
Sight glass To external water

in/out pipes G1 1/4 Forklift pocket
Condensate drain port
NPT 1/4 60 Cable inlet
Cable-in II: Bottom
A-direction
Fixing hole on bottom
23
Ventilation fan
60×90 Cable inlet

knock down hole
4.12 Dimension and Installation Diagram – Water-cooled Model
Cable-in I: Top
Line Frequency and VSD Models

Figure 4 Installation Diagram – Water-cooled
WS4500&WS7500 Rotary Screw Compressor Operation Manual Chapter V Compressor Operation
Chapter V Compressor Operation

5.1 Safety Operation Procedure
To avoid injury and machine damage, customer shall make detailed safety operation procedure. Please
refer to the following:
(1) Operator must be well trained before operation, and has read and understood this manual.
(2) The installation and operation of machine shall comply with national and local laws and regulations,
as well as Chapter I – Safety of this Manual.
(3) Never modify machine structure and control mode, unless approved by manufacturer in written.
(4) If abnormal condition is encountered, stop the machine immediately and shut down all power supply.
(5) No inflammable, explosive, toxic and erosive gas shall be stored in the vicinity.
(6) Blowdown the compressor and shut down all power supply before maintenance or adjustment
operation.
5.2 Preparation before Initial Starting
(1) Check if electric connection is safe and reliable, and power supply is compliant;
(2) Set operation parameters according to the manual of accompanied computer controller;
(3) Firstly check the oil level .When the machine is stopped or the machine is fully-loaded ,you should
view the oil . you should stop the compressor and add the oil ,when the level of oil reach between 1/2
and 3/4 of the oil glass ,then it is ok.
(4) If ventilation tunnel is installed, make sure it is clean and clear;
(5) Connect water line (water-cooled model);
(6) Open discharge check valve;
(7) Check rotation direction of main motor and fan motor according to 4.10 of this Manual;
(8) Restart the compressor and close check valve gradually until the discharge pressure of compressor is
at its rated level;
(9) Check if all systems work properly. Check for oil, air and water leakage and abnormal sound;
(10) Close check valve. Check if unloading pressure coincides with settings. Reset the machine if not.
See 5.5 below for adjustment;
(11) Stop the machine.
5.3 Normal Operation
Once a new machine has been tested according to the first starting test procedures, it may be used for normal
operation. Check oil level before starting. Press "I" button (manual mode) or "" button (auto mode) to start
the compressor.
5.4 Stop
Press “O” button to stop the machine.
5.5 Loading/Unloading Setting and Adjustment of Pressure Regulator
Actual discharge pressure of the compressor can be adjusted according to field condition to meet
pressure/delivery requirements and save energy at the same time, provided that the discharge pressure at
maximum delivery is reduced, i.e. lower than rated discharge pressure. This is realized by adjusting the
24
loading/unloading setting and pressure regulator.
25
Warning
Loading/unloading setting and pressure regulator shall be adjusted by Sullair’s service engineer,
Sullair dealer’s service personnel or trained operator.
For VSD model, to make sure the VSD cabinet is cooled down, it is recommended to close the door
when the machine is running.
26
WS4500&WS7500 Rotary Screw Compressor Operation Manual Chapter VI Maintenance and Service
Chapter VI Maintenance and Service

6.1 Overview
The machine needs little maintenance. Air filter, oil filter and oil/air separator, etc. are monitored by the
controller. Once there is a problem, controller will give corresponding signal through the indicators on
panel schematics. Normal operation of the machine relies on good maintenance and service. Sullair
warranty is available only when you maintain and service the machine according to Sullair operation
manual. See the Warranty for details.
Warning
Do not disassemble any part when the compressor is running or pressurized. Shut down the machine
and bleed internal pressure to zero before disassembling.
6.2 Daily Operation

Check oil level before starting the machine. Add oil if level is low. The machine may consume a certain
amount of oil during operation. However, oil consumption above the limit indicates that there might may
fault condition within the system. See 6.10 Troubleshooting to find out causes and take corresponding
measures.
Once the machine is started, check the machine generally. Check if displayed parameters are correct to
make sure the machine is normal. Check operation condition of various systems after the machine is
warmed up, and check for leakage and abnormal sound.
6.3 Service after 50 Operation Hours

Clean foreign objects in the machine for safety after 50 operation hours and proceed with the following:
A. Clean oil return pipe filter;
B. Clean oil return pipe orifice;
C. Replace oil filter element;
D. Clean filter on control pipeline.
E. Clean the drain filter 。
6.4 Service after every 1000 Operation Hours
A. Clean oil return pipe filter;
B. Replace oil filter element as required;
C. Replace air filter element as required;
D. Clean electronic drain valve;
6.5 Oil – Standard Compressor

Sullair compressor has been filled with sufficient lubrication oil Sullube at factory. If users mix with
other oil, all warranty will void instantly.
In normal cases, Sullube has a long lifespan. However, the interval between oil changing may be shorter in
extreme environment (e.g. high temperature, high humidity, caustic or highly oxidative gas in the air).
Changing interval shall be based on oil sample analysis.
Replace some parts when changing oil. See corresponding chapters in this Manual.
27
Sullair encourages customers to attend the Sullair oil analyzing program. The program may indicate
differently than the changing interval stated in this Manual. Contact dealer for details. The analyzing
program is a service free of charge provided by Sullair to customers.
Change oil in case of either of the following:

(1) every 8000 operating hours;
(2) every year; or
(3) so indicated by the oil sample analyzing result.
6.6 Oil – 24KT Compressor
Sullair compressor has been filled with sufficient 24KT oil Sullube. The 24KT model normally does not
need oil change. If it is to be changed, use Sullair 24KT only. If users mix with other oil, all warranty
will void instantly.
Sullair hopes that customer may take some 24KT oil sample upon first time replacing oil filter element and
send the sample to manufacturer for analysis. A container is provided with the machine (with the address
of manufacturer and sample method). User will receive analyzing report and recommendation of the
company, which is a service free of charge.
6.7 Maintenance of Oil Filter Top cap
Replace oil filter element in case of:
1. Every 1000 operating hours;
2. Every six months;
3. Every time the oil is changed; or
4. Pressure drop of the element exceeds 20PSI,
Gasket
whichever comes first.
5. whichever comes first
Replacing the oil filter element

Filter element
See Figure 5. Replace as described below:
1. Remove old element and gasket with a belt wrench;
2. Clean the mounting surface of gasket;
3. Apply a layer of grease on the new gasket;
4. Tighten the new element and make sure the
gasket fall completely in the slot;
5. Screw it on firmly and tighten another 1/2-3/4 circle;
6. Restart the machine and check for leak.
Figure 5 Oil Filter Element
P/N 250025-526
6.8 Maintenance of Air Filter
See Figure 6 for air filter element. Surface of air filter will be covered by dust after a period and air flow
resistance will increase. Clean the inlet filter every 500 to 1000 hours (based on the environment condition).
If pressure difference between the two sides of filter element exceeds threshold, a "service needed" signal
will be displayed on the monitor. Should such signal occur, stop the machine and clean or replace the filter
element as described below:
A.Clean the external of filter;
B.Pull out the location handle and turn the back cap counterclockwise to remove it;
C.Remove filter element; clean the inner surface of hood and the seat;
28
D.Replace with new element;

E.Reinstall the top cap;
：P/N:
Air filter element
0225168-053
Figure6 Replacement of Inlet Air Filter Element

Check filter element
1. Put a light source in the filter element. Light will irradiate through the pore on the element. Check for
damage or leak;
2. Check all gaskets and mounting surface of the gasket. Replace damaged gasket immediately;
3. Spare filter element should be stored in a clean container;
4. With the element installed, check and tighten (if necessary) all connection parts of the inlet port before
starting the machine.
6.9 Maintenance of Inlet Valve

See Figure 7 Inlet Valve (P/N 02250166-128). *Piston spring
The inlet valve is suitable for 16-series air end *Piston Retainer ring
only. Inlet valve of 18-series air end is built-in.
Follow the procedure below when servicing: *O-ring PTFE
*O-ring
Warning (fluorous rubber)
Do not remove bolt, plug or other Valve body
Check valve
parts when the machine is pressurized.
Stop the machine and bleed internal Bolt
Retainer ring
pressure to zero before servicing.
Spring Plug
1. Remove all pipes connected with inlet valve;
washer
2. Remove the 4 bolts and spring washers *Check valve
Gasket spring
between inlet valve and air end, and move
the inlet valve away from air end;
3. Remove the retain ring and o-ring from inlet
valve;
4. Remove check valve assembly and spring Figure 7 Inlet Valve 02250166-128
from the valve; Seal service kit P/N 02250166-220
Repair service kit P/N 02250166-230
5. Remove piston spring and piston assembly;
6. Clean the valve and make sure internal channel is clean. Scrub off the old gasket from inlet valve flange;
7. Replace old parts with new parts and install then into the inlet valve;
29
Attention
Apply oil on parts to offer better sealing performance. Apply compressor fluid of the same type
on flange gasket for sealing purpose.
8. Install fluorine o-ring onto the piston. Apply oil and slide into the valve;
9. Install new piston spring;
10. Install new check valve spring into the piston and then install the check valve assembly;
11. Place new PTFE o-ring on the valve and tighten the nut. The bolt needs to be removed and tapped on
its head. Be aware of the sequence of each part when disassembling;
12. Clean air end inlet flange surface before installing the new flange gasket;
13. Tighten the 4 bolts and lock washers.
6.10 Maintenance of Oil/air Separator Element

Bolt
The maintenance of oil/air separator is the replacement of the
elements. See Figure 8. Washer
Replace separator element in case of the compressor has been Pressing cover
running for either:
(1). Pressure difference across the separator element exceeds
0.7bar, and controller displays “Alarm” signal.
(2). Every 8000 hours. ** Secondary
(3). Every year. filter element
Oil/air separator element should be replaced by the following
steps: * Primary
1.Release pressure in oil/air separator; filter element
2.Remove all pipes connected with the oil/air separator

(including oil return line and discharge pipe);
3.Remove separator element;
Oil/air
4.Check for dust, rust or other substances in the oil/air
Separation
separator; tank
5.Reinstall separator element. Do not collide with the housing;
6.Clean rust and dust on the shell of oil/air separator;
7.Install top cover and washer. Then tighten the screws with a
torque of 47ft.-1bs.(64Nm);
Figure 8 Replacement of Oil/air
8.Connect all pipes and stretch oil return line to the bottom of Separator Element
element to ensure oil return;
9.Clean oil return line filter.
Attention
Do not detach the gasket on the flange of filter element. Do not remove the metal
pressing stud on gasket. Metal pressing stud serves as grounding pole to prevent accident of
separator caused by static.
30
6.11 Maintenance of Pressure Regulator

See Figure 9. There are three types of pressure regulator.
Procedures:
1. Unscrew the locknut, and turn the adjusting
screw counterclockwise until the spring is Valve body
relaxed. Now the spring screw is not under Bolt*
pressure;
2. Screw off spring chamber; Retainer ring*
3. Take out the spring seat, spring and Membrane *
diaphragm assembly;
4. Remove the gasket; Valve plate*
5. Unscrew the nut on the valve disc, remove Locking washer*
the valve disc, diaphragm and bolts; Valve plate nut*
6. Remove retain ring and discard;
Gasket*
7. Replace with parts and reinstall;
8. Replace with new retain ring;
9. Replace with new gasket; Spring
chamber Plate nut
10. Replace with new spring if damaged;
11. Put in the spring seat;
12. Assemble other parts and install in the Locking nut Spring seat
spring chamber; Adjusting screw
13. Tighten adjusting screw until it is under
force from spring;
14. Readjust pressure regulator according to Figure 9 Pressure Regulator
control system procedures. Pressure regulator P/N Service kit P/N
Pressure regulator 250019-453
250017-280
Pressure regulator 408275 250028-693
6.12 Maintenance of Min Pressure Valve
Pressure regulator 045099 048409
See Figure 10 for the structure of the min
pressure valve. Generally, only the o-ring
needs to be replaced every half a year or Spring
2000 hours. The maintenance should proceed Top cap
as follows:
1. Remove the valve from the top of oil/air
separator tank;
2. Open top cover and remove main spring; Washer Spring
3. Reverse the valve and tap with screwdriver Locking washer
until piston and check valve come off;
4. Clean valve and undamaged parts; Allen bolt *O-ring
5. Apply a layer of oil on the new check valve
and put it into the valve gently. Install new Piston
check spring;
6.Apply a layer of oil on the new o-ring and
install piston and new piston ring. Reinstall the
top cap. Valve body
Figure 10 Min Pressure Valve 242405
Service kit P/N:001176
31
6.13 Maintenance of Solenoid Valve

See Figure 11 for the structure of the solenoid Retaining cap*
valve. The solenoid valve needs little
maintenance but it should be cleaned Cover
regularly. Generally, if correct operating
voltage is provided, cleaning is necessary
when the solenoid valve acts very slowly or Winding
leaks. The maintenance steps are as follows:
(1). Disconnect the connector on the
solenoid of the valve;
(2). Remove the fixing nut and
electromagnetic solenoid; Elastic pad
(3). Unscrew the screws on the valve body,
remove the valve core, core spring and
sealing ring; Valve stem
Valve body
(4). Unscrew the bottom cap completely.
Remove the sealing ring, spring and
valve needle; Guide ring Valve needle
(5). Clean all the parts;
(6). Replace the solenoid or valve core; Element spring
(7). Reassemble the solenoid valve. Spring
Element Gasket
6.14 Maintenance of Blowdown Washer

Bottom cap
Valve
See Figure 12 for the structure of blowdown
Figure 11 Solenoid Valve – Various Types
valve.
The valve is a pneumatic double pass valve,
which needs little maintenance. Normally if O-ring
Cap
P2 signal is displayed on the controller, or the
Piston
valve is acting slowly or leaking when the *Locking nut
*Polyethylene
machine is loading, it should be serviced. base
Washer*
Maintenance of blowdown valve mainly
Piston Washer*
includes the replacement of O-rings, and
*Polyethylene
should proceed as follows: base
(1). Remove four 1/4 〃×3/4 〃 bolts and Positioning
then remove the top cap; Bolt*
pole
(2). Remove the spring, piston and O-ring;
(3). Replace the fluorine rubber washer and
all the O-rings;
(4). Reassemble the blowdown valve. Cap
Valve body
Figure 12 Blowdown Valve 02250100-042

Service kit P/N02250045-132
32
6.15 Maintenance of Coupling

See Figure 14. Shaft of air end and spindle of motor are rigidly connected to their respective mounting
plates and the mounting plates are connected through an elastomer. P/N of the part is listed in the figure.
Customer may order from Sullair. Normally only the elastomer needs maintenance. Maintenance should be
carried out as follows:
1. Remove the cover on connection tube;
2. Loosen the set screw on the mounting plate of motor spindle (no need to remove);
3. Move the mounting plate of motor spindle in axial direction and leave as much service space as possible;
4. Remove elastomer and check for wear, deformation, rupture, etc. If the elastomer is to be replaced,
contact Sullair for more help;
5. Return the mounting plate of motor spindle to original place. Keep the clearance of 4~5mm in Figure 13
and fix the mounting plate.
Spare parts for coupling 88290003-312:
Part 1 Mounting plate of motor spindle: P/N: P/N 88290003-321
Part 2 Elastomer P/N: P/N 88290003-322
Part 3 Fixing cap P/N: P/N 88290003-323
Part 4 Mounting plate of air endP/N: P/N 88290003-324
Part 1 Mounting plate of motor spindle P/N: P/N 88290003-325
Part 4 Mounting plate of air end P/N: P/N 88290003-328
Part 1 Mounting plate of motor spindle P/N: P/N 88290007-817
Part 4 Mounting plate of air end P/N: P/N 88290003-328
Figure 13 Coupling
33
6.16 Maintenance of the Motor for Sullair Compressor
(1) Operating conditions of the motor for Sullair compressors (For exported units, they change with different
countries)
Ambient temperature ≤40℃
Altitude ≤1000m above sea level
Frequency 50Hz
Voltage 380V
Operation system S1
Insulation grade F
(2) Operation of the motor for Sullair compressors
1) Motor should be grounded correctly. Generally, the ground wire of the motor for Sullair compressors is
connected in the electric cabinet. Users only need to connect the earth ground wire securely to this point.
2) Clear markings are provided on the lead wires of the motor for Sullair compressors (the markings may vary
from motor to motor, please see the nameplate of motor):
Phase sequence A B C
Head T1 T2 T3
Tail T4 T5 T6
3) For connection of the motor for Sullair compressors, a connection diagram is provided on the nameplate.
4) If the voltage and frequency of power source for the motor for a Sullair compressor are as indicated on the
nameplate, the motor can operate continuously at the rated power × utility coefficient. If the frequency of
the power source deviates from the rating value indicated on the nameplate by 1% of this value or
undervoltage/overvoltage exceeds 5%, it cannot be guaranteed that the motor will deliver such output
power.
5) If the imbalance of three-phase power voltage does not exceed 1%, the motor can run normally.
6) Generally, a thermal relay is mounted in the electric cabinet of a Sullair compressor and it is used as motor
overload protection. (Not applicable to VSD models.)
7) There should be no intermittent or unusual noises or vibrations when the motor runs at no load or at loads.
(3) Maintenance and repair of the motor for Sullair compressors
1) Operating environment should be kept dry, the motor surface should be clean and its air inlet should not be
obstructed by dust or fibers.
2) When the thermal relay (line frequency model) or VSD (VSD model) is failure, check the fault cause. The
motor must not be put into operation until the fault is eliminated.
3) Ensure that the bearings are lubricated well during motor operation. Generally, for every about 2000 hours
of operation of the motor, the grease should be refilled or changed (for sealed bearing, the grease need not
be changed within its service life). If bearing overheating or grease deterioration is found during operation,
the grease should be changed immediately. The grease should be refilled. The grease brand differs for
different motors. For details, please refer to the motor nameplate or contact the Service Department of
Sullair.
4) When the service life of the bearing ends, shock and noises generated during motor operation will be
increased significantly, and in this case, the bearing should be replaced.
5) After motor faults occur, we recommend that the user contact Sullair or its agents.
6.17 Maintenance of Motor and Air End
During the lifetime of the machine, electric motor or air end may need service occasionally. To simplify the
work, only the door panel and post be the side of the air end and motor need to be removed. Since the air
end and motor are connected through a tube, there are two rubber isolators supporting the motor and
another two supporting the air end. The motor and air end need to be supported independently once there
are removed to ensure safety. Such supporting mechanism has been fully considered during design and
manufacturing. The details are described below.
34
Two types of air end are used for the compressors, i.e. 16-series and 18-series.
16-series air end model

Supporting for air end and motor and the operation are illustrated in the figure below.
Two bolts on inside and

outside are used to
support the air end. US
standard bots are from
the fastener for air end
and connection tube
Supporting plate for the motor

is equipped to safeguard the
machine during
transportation. Remove the
plate before initial startup and
reuse when supporting the
motor
35
18-series air end model

Supporting for air end and motor and the operation are illustrated in the figure below.
Supporting plate for the motor

is equipped to safeguard the
machine during
transportation. Remove the
plate before initial startup and
reuse when supporting the
motor.
Hex bolt M12x60 and nut

M12 are provided by customer
to support the air end.
36
1/4” Pipe
1/4” Pipe 7.1

As per sales order on
microprocessor board
1/4” Pipe
3/8” Pipe Air discharge Aftercooler
Electronic drain valve
Globe valve
Orifice
1/4” Pipe Shuttle valve
1/4” Pipe
1/4” Pipe
3/8” Pipe
Oil filter
System Flowchart
Thermal valve
Condensate drain Oil drain valve
Temperature
Oil plug
3/8” Pipe
set to 113°C Temperature
set to 113°C Water-cooled model Fluid sight glass
Oil/air Separation tank
Air in Oil cooler
Air end
Drain valve
Water-in Pressure sensor
InterfaceG1-1/4 Min pressure valve
Pressure: 560mm H2o Temperature probe
vacuum DN32 Pipe Separator tank relief valve
25 Pressure set to 0.07Mpa
Return line filter
Return line sight glass
Water-out Secondary oil return orifice

InterfaceG1-1/4 Separator relief valve
Pressure set to 0.14Mpa
37
Pressure regulator
Technical requirements:
1. Line section marked with letter is replaced by the option below. Use of option is POPPET valve
determined by sales order. Vacuum gauge
2. All P/Ns are for reference only. See BOM and system diagram for “-”. Air filter
3. Corresponding to drawing 88290021-135 in English. S/N P/N Name Qty. Remark
Sequence valve (option)

Oil/air mixture line
Oil line
Chapter VII Schematics
Air line
Control line
Water line
WS4500-WS7500 Line Frequency Model System Flowchart

Sequence valve (option)
Technical requirements:
1/4” Pipe 1. All P/Ns are for reference only. See BOM and system diagram for “-”.
3. Corresponding to drawing 88290021-136 in English.
31, 32 are only equipped
with models w/ spiral valve
Oil line
1/4” Pipe Air line
Spiral valve
Control line
Pressure regulator
Water line Pressure regulator
Aftercooler
1/4” Pipe
globe valve
Orifice
Shuttle valve
3/8” Pipe Air discharge
Pressure drop switch
Oil filter
Thermal valve
1/4” Pipe Oil drain valve
1/4” Pipe
1/4” Pipe Oil plug
3/8” Pipe
Fluid sight glass
Oil cooler
Condensate drain Air end
Temperature
Temperature Drain valve
set to 113°C
3/8” Pipe
set to 113°C Pressure sensor
Water-cooled model
Air in Min pressure valve
38
Temperature probe
Separator tank relief valve
Primary filter oil return orifice
Water-in Return line filter
InterfaceG1-1/4 Return line sight glass
Pressure: 560mm H2o Secondary oil return orifice
vacuum Separator relief valve
DN32 Pipe Pressure set to 0.07Mpa
Pressure regulator
Inlet Valve
Water-out Vacuum gauge
InterfaceG1-1/4 Air filter
Pressure set to 0.14Mpa S/N P/N Name Qty. Remark
WS4500P-WS7500P Line Frequency Model System Flowchart

1/4” Pipe
1/4” Pipe
Pressure regulator
Pressure regulator
1/4” Pipe
3/8” Pipe Air discharge
globe valve
Orifice
Shuttle valve
Pressure drop switch

Oil filter
1/4” Pipe Thermal valve
Oil drain valve
1/4” Pipe
1/4” Pipe
3/8” Pipe
w/ spiral valve
Oil plug
Fluid sight glass
Oil cooler
Condensate drain
Temperature Air end
set to 113°C Temperature Drain valve
3/8” Pipe
set to 113°C Pressure sensor
Air in Water-cooled model Min pressure valve
39
Temperature probe
Separator tank relief valve
Water-in
InterfaceG1-1/4 Primary filter oil return orifice
Return line filter
Pressure: 560mm H2o Return line sight glass
vacuum DN32 Pipe Pressure set to 0.07Mpa Secondary oil return orifice
Separator relief valve
Pressure regulator
Inlet Valve
Water-out
InterfaceG1-1/4 Vacuum gauge
Pressure set to 0.14Mpa Air filter
S/N P/N Name Qty. Remark
All P/Ns are for reference only. See BOM and system diagram

Oil line
Air line
Control line
Water line
WS4500P-WS7500P Line Frequency Model System Flowchart

To user’s power supply Note:
Components linked by dotted line are optional
User shall provide Remove jumper when using options
protection device See 88290002-027 (Sequence control wiring
diagram) for the sequencing of SMC RS485
For water-cooled model only
Dry-side discharge
air temperature Dry-side discharge Wet-side discharge
air pressure air pressure
7.2 Schematics
Wet-side discharge
air temperature
Remote Start/Stop
Water pressure switch

Power test
Modbus
Communication
Oil filter clogging
Use BELDEN 9842 Air filter clogging
shielded 3-core/2 twisted
pair or similar cable for Fan motor overload
communication To
Main motor overload Current transformer
Emergency stop button
Forced loading relay
Forced loading solenoid valve
Alarm relay
Loading signal relay
Loading/unloading
solenoid valve
Y Contactor
Emergency
stop button
40
Main contactor
Contactor
Fan motor contactor
From-XT1 Remote unit/local

Control selection signal relay
From-XT1
Discharge/fan
motor
To XT1
-M1
Motor moisture heater wiring diagram Main motor
To user’s AC220V grid User shall short-circuit
HT2 and HT4
Choose wiring method of heater according to user’s grid
WS4500P-WS7500 Line Frequency SMC Model Schematics

Machine Machine Machine
alarm operating
condition loading Remot
Start/Stop
Wiring on user’s side
To be provided by user
Note:
To user’s power supply

User shall provide
protection device
Dry-side discharge
air temperature Dry-side discharge Wet-side discharge
Wet-side discharge
air temperature
Equipment boundary
Water pressure switch
Section within the dotted line is

Power test
for remote mode only
Oil filter clogging
Air filter clogging
Fan motor overload
Main motor overload
Analog output Emergency stop button

Remote Start/Stop
To -XT1
Sequence control Current transformer
communication
Modbus communication
Remote mode / electronic drain

Alarm relay
41
Emergency
stop button Loading/unloading
solenoid valve
Y Contactor
Main contactor
Contactor
Fan motor contactor

Motor moisture heater wiring diagram
To user’s AC220V grid User shall short-circuit
HT2 and HT4 Remote unit/local
Control selection signal relay
From-XT1
Discharge/fan
Main motor motor
To -XT1
WS4500P-WS7500 Line Frequency SCN Model Schematics

Machine Machine Machine
alarm operating
condition loading
Remot
Wiring on user’s side Start/Stop
To be provided by user
To user’s power supply
User shall provide
protection device
Dry-side discharge
air temperature
Dry-side discharge Wet-side discharge
Wet-side discharge
Equipment boundary
air temperature
Note:
Option
Remove jumper when using options
See 88290008-680 Deluxe Microprocessor Controller I –
Sequencing and Communication Protocols Manual for the
wiring ofremote sequencing mode
See 88290007-919 Sequencing Control Wiring Diagram for
RS485 networking of Supper Microprocessor Controller
For water-cooled model only
For WS45/60/75 model only
Water pressure switch XT4 is for W818/22 model only
Section within the dotted line is

Power test
for remote mode only
Oil filter clogging
Air filter clogging
Fan motor overload

To XT1
VSD fault
Analog output Emergency stop button

Remote Start/Stop
Sequence control
communication
Modbus communication
42
Remote mode / electronic drain
Alarm relay
Loading/unloading
Emergency solenoid valve
stop button
VSD
Fan contactor
Remote unit/local
From-XT1 Control selection signal relay
From-XT1
Motor moisture heater wiring diagram

Discharge/fan
User shall short-circuit motor
To user’s AC220V grid
WS4500P-WS7500 VSD Model Schematics

HT2 and HT4
Air end

WS4500&WS7500 Rotary Screw Compressor Operation Manual Chapter VIII Troubleshooting
Chapter VIII Troubleshooting

8.1 Overview
Items listed in the troubleshooting table are based on vast experiments of actual application and
manufacturer. The table includes symptoms and normal causes.
Compressor's fault may be caused by multiple reasons. Therefore a systematic analysis on all causes of
the fault should be carried out before service or parts replacement. Do not disassemble the machine
without purpose. To avoid damage, visual check is necessary. Keep the following in mind:
a. Check if cable leads are loose or disconnected;
b. Check if pipeline is damaged;
c. Check if there is part damaged by over heat or short circuit. Normally phenomena are color changing
or scorch odor.
If the fault condition is unable to be removed by the recommended solution, contact local Sullair Dealer
or Sullair directly.
8.2 Possible compressor fault and actions are listed in the following table
Symptom Possible causes Actions

Low oil level in oil/air separator Check oil level, add oil if necessary
Check thermal valve and replace thermal
Thermal valve failure
components
High Cooler fin dirty (air-cooled model) Clean cooler fin
discharge air Oil filter clogged up and bypass valve
Replace oil filter
temperature failed
T1 Ambient temperature high Improve ventilation
High resistance in exhaust duct (air- 1. Enlarge exhaust duct
cooled model) 2. Install fan in the duct
Low cooling water flow (water-cooled
Check cooling water supply
model)
Increase cooling water flow and reduce
High cooling water temperature
temperature
Coolant clogged up (water-cooled model) Clean the pipeline and use clean cooling water
Thermal resistor temperature transducer Check RTD connector. If the connector is

RTD failure good, replace RTD
Direction of centrifugal blower reversed
Re-wire blower or repair
or blower damaged
Unloading components (e.g. blowdown
Check if unloading components are acting
valve, inlet valve, optional spiral valve)
High normally
are not working properly
discharge
pressure Pressure regulator failure Check pressure regulator
(tank Solenoid valve failure Check solenoid valve
pressure) P1
Control air pipe leak Check if control pipeline is leaking
Control pipeline filter clogged up Repair filter assembly
Oil/air separator element clogged up Replace oil/air separator element
Min pressure valve failure Check/repair min pressure valve
43
WS4500&WS7500 Rotary Screw Compressor Operation Manual Chapter VIII Troubleshooting
Possible compressor fault and actions are listed in the following table (continued)
Symptom Possible causes Actions
(1) Reduce air demand;

Air demand higher than air supply
(2) Check for leakage on pipeline.
Air filter clogged up Replace filter element
Line Inlet valve unable to open Check motion of inlet valve; check the setting of
completely pressure reducing valve and pressure regulator
pressure
lower than
discharge Check transducer's contacts. Replace transducer if
pressure Pressure transducer or contact fault contacts are normal.
rating
Min pressure valve failure Check/repair min pressure valve
Optional spiral valve open Check spiral valve pressure regulator
Oil/air separator element clogged

Check and replace oil/air separator element
up
Check transducer's contacts. Replace transducer if

Pressure transducer P2 fault contacts are normal.
Line Unloading components (e.g.

pressure blowdown valve, inlet valve,
higher than Check the operation of unloading components
optional spiral valve) are not
unloading working properly
pressure
setting Solenoid valve failure Check solenoid valve
Control air pipe leak Check if control pipeline is leaking
Control pipeline filter clogged up Repair filter assembly
Oil return line filter or orifice

Clean filter, sieve and orifice.Replace if necessary.
blocked
Oil Separator element or washer Check separator element and washer. Replace if
consumptio damaged damaged.
n too high
Fluid system is leaking Check if pipeline system
Fluid level too high Discharge some fluid
Too much oil froth Discharge and change fluid
Isolator damaged; Replace isolator;
Vibration Centrifugal fan or box fault; Check centrifugal fan; remove foreign object in fan
and noise box;
increased
Ventilation louver fell off Reinstall or replace louver
Time setting of electronic drain

Increase drain duration or reduce interval;
valve inappropriate;
Moisture in
compressed
Electronic drain valve clogged up; Clean or replace drain valve;
air
increased
Electronic drain valves coil failure Replace drain valve
44
WS4500&WS7500 Rotary Screw Compressor Operation Manual Chapter IX Spare Parts List
Chapter IX Spare Parts List

Name Service kit no. Quantity
Fluid filter 02250112－478 250025-526 1
Inlet air filter 02250164-930 02250168-053 1
Primary separator element 250042-862 1
Secondary separator element 02250061-137 1
Inlet valve 02250166-128 seal service kit (16-series) 02250166-220 1
Inlet valve 02250166-128 service kit (16-series) 02250166-230 1
Inlet valve seal service kit (18-series) 02250169-607 1
Inlet valve service kit (18-series) 02250169-608 1
Min pressure valve 242405 service kit 88290018-146 1
Thermal valve (170F) service kit (Sullube model) 049542 1
Thermal valve (190F) service kit (24KT model) 250028-762 1
Pressure regulator 250017-280 service kit 250019-453 1
Pressure regulator 408275 service kit 250028-693 1
Pressure regulator 045099 service kit 048409 1
Blowdown valve 02250100-042 service kit 02250045-132 1
Solenoid valve 250038-666 service kit 250038-672 1
Solenoid valve 250038-666 winding service kit 250038-730 1
Oil return line filter service kit 02250117-782 1
Shaft seal service kit(16-series) 02250050-364 1
Shaft seal service kit(18 -series) 02250169-605 1
Electromagnetic drain valve 88290022-934 88290022-934 1
Drain valve 88290022-936 88290022-936 1
Coupling 88290003-312 elastomer 88290003-322 1
Coupling 88290003-311/88290007-806 elastomer 88290003-326 1
Sullube32 oil (5gallon) 250022-669 1
Sullube32 oil (55 gallon) 250022-670 1
24KT oil (5 gallon) 02250051-153 1
24KT oil(55 gallon) 02250051-150 1
Note: please notify compressor model, series number and B.O.M number in ordering spare parts to
facilitate our service.
45
Global Sales and Service
US: SULLAIR CORPORATION

Subsidiary of Hamilton-Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 001-219-879-5451 or 1-800-Sullair (U.S.A. only) Fax: 001-219-874-1273
Asia: SULLAIR ASIA Website: http://www.sullair-asia.com Hotline: 800-830-3977

SULLAIR Singapore 74 Joo Koon Circle, Jurong Singapore 629093
Telephone：65-68611211 Fax：65-68612967
SULLAIR Taipei: 1, 3F, 248 Zhongshan Road, Linzhong Town, Taipei
Tel: 02-26013500 Fax: 02-26013032
Shenzhen Factory: Zuo Paotai Road, Chiwan, Shekou, Shenzhen, P. R. China 518068
Tel: 0755-26851686 Fax: 0755-26835157
Suzhou Factory: 266 Changyang Street, Singapore Industrial Park, Suzhou 215000
Tel: 0512-87162388 Fax: 0512-87162389, 87162387
Shanghai Branch: Room 1504, Ganglu Plaza, 18 Xizang Road Central, Shanghai 200001
Tel: 021-53852036, 53852038 Fax: 021-53852035
Beijing Branch: Room 1506, Block B, Xingfu Building, 3 Eastern Third Ring Road North, Beijing
100027
Tel: 010-64629770, 64629768 Fax: 010-64629773
Chengdu Branch: 28-H, Guancheng Plaza, 308 Shuncheng Street, Chengdu 610017
Tel: 028-86527506, 86527507 Fax: 028-86527505
Shenyang Branch: Room 1601, Gaodeng International Building, 355 Zhongshan Road, Shenhe
District, Shenyang 110014
Tel: 024-22818450, 22818550 Fax: 024-22818590
Xi’an Branch: Room 701A, Jinxin International Building, 99 Heping Road, Xi’an 710001
Tel: 029-87206201, 87206202 Fax: 029-87206204
Wuhan Branch: Room 2909, Block B, Zhongshang Plaza, 7 Zhongnan Road, Wuchang, Wuhan
430071
Tel: 027-87322745 Fax: 027-87322546
Xinjiang Branch: Unit J, 9F, National Development Bank Tower, 339 Zhongshan Road, Urumqi
830002
Tel: 0991-2308451, 2308452 Fax: 0991-2308450
P/N:88290021-328
E/N:01

WS4500 7500英文操作维护说明书88290021 328

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K. Do not operate the compressor in a dangerous circumstance unless it is designed to do so.

Chapter II Compressor Structure

2.2 Parts Description

Figure 1 WS4500-WS7500 air-cooled models layout

6.Inlet system 7.Oil/air separation system 8.Lubrication system 9.Decal system

Figure 2 WS4500-WS7500 water-cooled models layout

6. Enclosure assembly 7.Lubrication system 8.Oil/air separation system 9.Cooling system

2.3 Air End

2.6 Lubrication System

2.7 Cooling System

2.8 Oil/air Separator System

(1) Pressure regulation.

Starting up – 0 to 50 psig (0 to 3.5 bar)

Normal operation – 50 to 115 psig (3.5 to 8 bar)

Starting up – 0 to 50 psig (0 to 3.5 bar)

Normal operation – 50 to 115 psig (3.5 to 8 bar)

Air capacity adjustment – 115 to 125 psig (8 to 8.6 bar)

Unloading – Over 125 psig (8.6 bar)

2.10 Microprocessor controller

Model 4507 4507PS 4508 4508PS 4510 4512

8.5(300.2) 8.6(304) 7.8(275.5) 7.7(273) 6.9(243.7)

Rated discharge pressure

Max working pressure

Relief valve opening

Machine weight kg 1249

Rated speed rpm 1470(50Hz)\1775(60Hz)

Voltage/frequency 380-415V 50Hz \ 380-420V/220-240V 440-480V 60Hz

Service factor 1.15

Starting mode Y-△

Noise level dB (A) Air-cooled model: 71±3/Water-cooled model: 68±3

3.2 Specifications – WS5500 Line Frequency Models

Model 5507 5507PS 5508 5508PS 5510 5512

10.5(370.8) 10.9(387) 9.5(335.5) 9.9(349) 8.6(303.7) 7.6(268)

Max working pressure

Relief valve opening

Machine weight kg 1297

Rated speed rpm 1470(50Hz)/1775(60Hz)

Starting mode Y-△

Noise level dB(A) Air-cooled model: 72±3/Water-cooled model: 69±3

3.3 Specifications – WS7500 Line Frequency Models

Model 7507 7507P&PS 7508 7508P&PS 7510 7510P&PS 7512P&PS

13.5(476.7) 13.9(491) 12.5(44) 12.9(457) 10.5(371) 11.5(405) 10.5(369)

Configuration Single-stage gear transmission/external inlet control valve

Fluid brand Sullube or 24KT

2940/50Hz 1470/50Hz 2940/50Hz 1470/50Hz 2940/50Hz 1470/50Hz 1470/50Hz

Voltage/frequency 380-415V 50Hz \ 380-420V/220-240V 440-480V 60Hz

Service factor 1.15

Starting mode Y-△

Noise level dB(A) Air-cooled model: 73±3/Water-cooled model: 69±3

3.4 Specifications – WS4500/5500 VSD Models

Model 4507VSD 4508VSD 5507VSD 5508VSD 5510VSD 5512VSD

Nominal capacity 8.5 7.93 10.6 9.85 8.6 7.73

Capacity regulation range 1.93-8.5 1.91-7.93 2.52-10.6 2.52-9.85 2.12-8.6 2.09-7.73

Rated discharge pressure

Max working pressure

Relief valve opening

Machine weight kg 1249 1297

Configuration Single-stage gear transmission/external inlet control valve

Rated power kW (HP) 45(60) 55 (75)