02250176-184r02 Sullair User Manual

Failure to follow the instructions and procedures in this manual or,

misuse of this equipment will VOID its warranty!

WARRANTY NOTICE

PART NUMBER:

KEEP FORFUTURE REFERENCE

USER MANUAL

SULLAIR CORPORATIONThe information in this manual is currentas of its publication date, and applies tocompressor serial number:

and all subsequent serial numbers.

02250176-184 R02

201107010000

INDUSTRIAL AIR COMPRESSOR4500P, 5500, 7500, 4500PV,

5500V, 7500V, 4500PS, 5500PS, 7500P/PS, 7500PV, 45,55 & 75 KW:60, 75 & 100 HP

AIR CARE SEMINAR TRAININGSullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electricalsystems are offered at regular intervals throughout the year at Sullairs corporate headquarters training facilitylocated at Michigan City, Indiana.

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

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

SULLAIR TRAINING DEPARTMENT

1-888-SULLAIR or219-879-5451 (ext. 5623)

[email protected]

- Or Write -Sullair Corporation

3700 E. Michigan Blvd.Michigan City, IN 46360

Attn: Service Training Department.

TABLE OF CONTENTSSECTION 1SAFETY

5 1.1 GENERAL 5 1.2 PERSONAL PROTECTIVE EQUIPMENT 5 1.3 PRESSURE RELEASE 6 1.4 FIRE AND EXPLOSION 6 1.5 MOVING PARTS 7 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS 7 1.7 TOXIC AND IRRITATING SUBSTANCES 8 1.8 ELECTRICAL SHOCK 8 1.9 LIFTING 9 1.10 ENTRAPMENT

SECTION 2DESCRIPTION 11 2.1 INTRODUCTION 11 2.2 COMPRESSOR COMPONENT DESCRIPTION 15 2.3 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNC-

TIONAL DESCRIPTION 15 2.4 COMPRESSOR DISCHARGE SYSTEMFUNCTIONAL DESCRIPTION 17 2.5 CONTROL SYSTEM FUNCTIONAL DESCRIPTION 19 2.6 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION 20 2.7 WS CONTROLLER/KEYPAD 20 2.8 LCD DISPLAY 21 2.9 LED LIGHTS 22 2.10 VARIABLE SPEED DRIVE (VSD) COMPONENTS 22 2.11 VSD CONTROL SYSTEM FUNCTIONAL DESCRIPTION 23 2.12 INTEGRAL DRYER OPTION

SECTION 3SPECIFICATIONS 25 3.1 TABLE OF SPECIFICATIONS4500P, 5500 & 7500 SERIES MODELS 26 3.2 TABLE OF SPECIFICATIONSVARIABLE SPEED DRIVE 27 3.3 COMPRESSOR SPECIFICATIONS 27 3.4 LUBRICATION GUIDE 27 3.5 APPLICATION GUIDE

TABLE OF CONTENTS

27 3.6 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE, FLUID FILTER AND SEPARATOR

SECTION 4INSTALLATION 51 4.1 COMPRESSOR MOUNTING - SUPPORT AND LOCATION 51 4.2 VENTILATION AND COOLING 55 4.3 SERVICE AIR PIPING 57 4.4 COUPLING ALIGNMENT CHECK 57 4.5 FLUID LEVEL CHECK 57 4.6 ELECTRICAL PREPARATION 58 4.7 MOTOR ROTATION DIRECTION CHECK

SECTION 5OPERATION 61 5.1 ROUTINE OPERATION

SECTION 6MAINTENANCE 63 6.1 GENERAL 63 6.2 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION 63 6.3 MAINTENANCE EVERY 2000 HOURS 63 6.4 FLUID MAINTENANCE 63 6.5 FILTER MAINTENANCE 64 6.6 AIR FILTER MAINTENANCE 65 6.7 SEPARATOR MAINTENANCE 67 6.8 TROUBLESHOOTING INTRODUCTION

Section 1

5

SAFETY

1.1 GENERALSullair Corporation and its subsidiaries design andmanufacture all of their products so they can beoperated safely. However, the responsibility for safeoperation rests with those who use and maintainthese products. The following safety precautions areoffered as a guide which, if conscientiously followed,will minimize the possibility of accidents throughoutthe useful life of this equipment.

The compressor should be operated only by thosewho have been trained and delegated to do so, andwho have read and understood this Operator'sManual. Failure to follow the instructions, proceduresand safety precautions in this manual may result inaccidents and injuries. NEVER start the compressorunless it is safe to do so. DO NOT attempt to operatethe compressor with a known unsafe condition. Tagthe compressor and render it inoperative bydisconnecting and locking out all power at source orotherwise disabling its prime mover so others whomay not know of the unsafe condition cannot attemptto operate it until the condition is corrected.

Install, use and operate the compressor only in fullcompliance with all pertinent OSHA regulations and/or any applicable Federal, State, and Local codes,standards and regulations. DO NOT modify thecompressor and/or controls in any way except withwritten factory approval.

While not specifically applicable to all types ofcompressors with all types of prime movers, most of

the precautionary statements contained herein areapplicable to most compressors and the conceptsbehind these statements are generally applicable toall compressors.

1.2 PERSONAL PROTECTIVE EQUIPMENT

A. Prior to installing or operating the compressor,owners, employers and users should becomefamiliar with, and comply with, all applicableOSHA regulations and/or any applicable Federal,State and Local codes, standards, and regula-tions relative to personal protective equipment,such as eye and face protective equipment,respiratory protective equipment, equipmentintended to protect the extremities, protectiveclothing, protective shields and barriers and elec-trical protective equipment, as well as noiseexposure administrative and/or engineering con-trols and/or personal hearing protective equip-ment.

1.3 PRESSURE RELEASEA. Install an appropriate flow-limiting valve between

the service air outlet and the shut-off (throttle)valve, either at the compressor or at any otherpoint along the air line, when an air hose exceed-ing 1/2" (13mm) inside diameter is to be con-nected to the shut-off (throttle) valve, to reducepressure in case of hose failure, per OSHA Stan-dard 29 CFR 1926.302(b)(7) and/or any applica-ble Federal, State and Local codes, standardsand regulations.

B. When the hose is to be used to supply a mani-fold, install an additional appropriate flow-limitingvalve between the manifold and each air hoseexceeding 1/2" (13mm) inside diameter that is tobe connected to the manifold to reduce pressurein case of hose failure.

C. Provide an appropriate flow-limiting valve at thebeginning of each additional 75 feet (23m) ofhose in runs of air hose exceeding 1/2" (13mm)

NOTE

OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL.

SECTION 1

6

inside diameter to reduce pressure in case ofhose failure.

D. Flow-limiting valves are listed by pipe size andflow-rated. Select appropriate valves accordingly,in accordance with their manufacturer's recom-mendations.

E. DO NOT use air tools that are rated below themaximum rating of the compressor. Select airtools, air hoses, pipes, valves, filters and otherfittings accordingly. DO NOT exceed manufac-turer's rated safe operating pressures for theseitems.

F. Secure all hose connections by wire, chain orother suitable retaining device to prevent tools orhose ends from being accidentally disconnectedand expelled.

G. Open fluid filler cap only when compressor is notrunning and is not pressurized. Shut down thecompressor and bleed the receiver tank to zerointernal pressure before removing the cap.

H. Vent all internal pressure prior to opening anyline, fitting, hose, valve, drain plug, connection orother component, such as filters and line oilers,and before attempting to refill optional air lineanti-icer systems with antifreeze compound.

I. Keep personnel out of line with and away fromthe discharge opening of hoses or tools or otherpoints of compressed air discharge.

J. DO NOT use air at pressures higher than 2.1 barfor cleaning purposes, and then only with effec-tive chip guarding and personal protective equip-ment per OSHA Standard 29 CFR 1910.242 (b)and/or any applicable Federal, State, and Localcodes, standards and regulations.

K. DO NOT engage in horseplay with air hoses asdeath or serious injury may result.

1.4 FIRE AND EXPLOSIONA. Clean up spills of lubricant or other combustible

substances immediately, if such spills occur.

B. Shut off the compressor and allow it to cool.Then keep sparks, flames and other sources ofignition away and DO NOT permit smoking in thevicinity when checking or adding lubricant orwhen refilling air line anti-icer systems with anti-freeze compound.

C. DO NOT permit fluids, including air line anti-icersystem antifreeze compound or fluid film, to

accumulate on, under or around acoustical mate-rial, or on any external surfaces of the air com-pressor. Wipe down using an aqueous industrialcleaner or steam clean as required. If necessary,remove acoustical material, clean all surfacesand then replace acoustical material. Any acous-tical material with a protective covering that hasbeen torn or punctured should be replacedimmediately to prevent accumulation of liquids orfluid film within the material. DO NOT use flam-mable solvents for cleaning purposes.

D. Disconnect and lock out all power at source priorto attempting any repairs or cleaning of the com-pressor or of the inside of the enclosure, if any.

E. Keep electrical wiring, including all terminals andpressure connectors in good condition. Replaceany wiring that has cracked, cut, abraded or oth-erwise degraded insulation, or terminals that areworn, discolored or corroded. Keep all terminalsand pressure connectors clean and tight.

F. Keep grounded and/or conductive objects suchas tools away from exposed live electrical partssuch as terminals to avoid arcing which mightserve as a source of ignition.

G. Remove any acoustical material or other materialthat may be damaged by heat or that may sup-port combustion and is in close proximity, prior toattempting weld repairs.

H. Keep suitable fully charged Class BC or ABC fireextinguisher or extinguishers nearby when ser-vicing and operating the compressor.

I. Keep oily rags, trash, leaves, litter or other com-bustibles out of and away from the compressor.

J. DO NOT operate the compressor without properflow of cooling air or water or with inadequateflow of lubricant or with degraded lubricant.

K. DO NOT attempt to operate the compressor inany classification of hazardous environmentunless the compressor has been speciallydesigned and manufactured for that duty.

1.5 MOVING PARTSA. Keep hands, arms and other parts of the body

and clothing away from couplings, belts, pulleys,fans and other moving parts.

B. DO NOT attempt to operate the compressor withthe fan, coupling or other guards removed.

SECTION 1

7

C. Wear snug-fitting clothing and confine long hairwhen working around this compressor, especiallywhen exposed to hot or moving parts.

D. Keep access doors, if any, closed except whenmaking repairs or adjustments.

E. Make sure all personnel are out of and/or clear ofthe compressor prior to attempting to start oroperate it.

F. Disconnect and lock out all power at source andverify at the compressor that all circuits are de-energized to minimize the possibility of acciden-tal start-up, or operation, prior to attemptingrepairs or adjustments. This is especially impor-tant when compressors are remotely controlled.

G. Keep hands, feet, floors, controls and walkingsurfaces clean and free of fluid, water or otherliquids to minimize the possibility of slips andfalls.

1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

A. Avoid bodily contact with hot fluid, hot coolant,hot surfaces and sharp edges and corners.

B. Keep all parts of the body away from all points ofair discharge.

C. Wear personal protective equipment includinggloves and head covering when working in, on oraround the compressor.

D. Keep a first aid kit handy. Seek medical assis-tance promptly in case of injury. DO NOT ignoresmall cuts and burns as they may lead to infec-tion

1.7 TOXIC AND IRRITATING SUBSTANCES

A. DO NOT use air from this compressor for respi-ration (breathing) except in full compliance withOSHA Standards 29 CFR 1910 and/or any appli-cable Federal, State or Local codes or regula-tions.

B. DO NOT use air line anti-icer systems in air linessupplying respirators or other breathing air utili-zation equipment and DO NOT discharge airfrom these systems into unventilated or otherconfined areas.

C. Operate the compressor only in open or ade-quately ventilated areas.

D. Locate the compressor or provide a remote inletso that it is not likely to ingest exhaust fumes orother toxic, noxious or corrosive fumes or sub-stances.

E. Coolants and lubricants used in this compressorare typical of the industry. Care should be takento avoid accidental ingestion and/or skin contact.In the event of ingestion, seek medical treatmentpromptly. Wash with soap and water in the eventof skin contact. Consult Material Safety DataSheet for information pertaining to fluid of fill.

F. Wear goggles or a full face shield when addingantifreeze compound to air line anti-icer systems.

G. If air line anti-icer system antifreeze compoundenters the eyes or if fumes irritate the eyes, theyshould be washed with large quantities of cleanwater for fifteen minutes. A physician, preferablyan eye specialist, should be contacted immedi-ately.

H. DO NOT store air line anti-icer system antifreezecompound in confined areas.

I. The antifreeze compound used in air line anti-freeze systems contains methanol and is toxic,harmful or fatal if swallowed. Avoid contact withthe skin or eyes and avoid breathing the fumes. If

DANGER

Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA stan-dards and/or any applicable Federal, State, and Local codes, standards and regulations on safety equipment.

SECTION 1

8

swallowed, induce vomiting by administering atablespoon of salt, in each glass of clean, warmwater until vomit is clear, then administer twoteaspoons of baking soda in a glass of cleanwater. Have patient lay down and cover eyes toexclude light. Call a physician immediately.

1.8 ELECTRICAL SHOCKA. This compressor should be installed and main-

tained in full compliance with all applicable Fed-eral, State and Local codes, standards andregulations, including those of the National Elec-trical Code, and also including those relative toequipment grounding conductors, and only bypersonnel that are trained, qualified and dele-gated to do so.

B. Keep all parts of the body and any hand-heldtools or other conductive objects away fromexposed live parts of electrical system. Maintaindry footing, stand on insulating surfaces and DONOT contact any other portion of the compressorwhen making adjustments or repairs to exposedlive parts of the electrical system. Make all suchadjustments or repairs with one hand only, so asto minimize the possibility of creating a currentpath through the heart.

C. Attempt repairs in clean, dry and well lighted andventilated areas only.

D. DO NOT leave the compressor unattended withopen electrical enclosures. If necessary to do so,then disconnect, lock out and tag all power atsource so others will not inadvertently restorepower.

E. Disconnect, lock out, and tag all power at sourceprior to attempting repairs or adjustments torotating machinery and prior to handling anyungrounded conductors.

1.9 LIFTINGA. If the compressor is provided with a lifting bail,

then lift by the bail provided. If no bail is provided,then lift by sling. Compressors to be air-lifted byhelicopter must not be supported by the liftingbail but by slings instead. In any event, lift and/orhandle only in full compliance with OSHA stan-dards 29 CFR 1910 subpart N and/or any appli-cable Federal, State, and Local codes, standardsand regulations.

B. Inspect points of attachment for cracked weldsand for cracked, bent, corroded or otherwisedegraded members and for loose bolts or nutsprior to lifting.

C. Make sure entire lifting, rigging and supportingstructure has been inspected, is in good condi-tion and has a rated capacity of at least theweight of the compressor. If you are unsure ofthe weight, then weigh compressor before lifting.

D. Make sure lifting hook has a functional safetylatch or equivalent, and is fully engaged andlatched on the bail or slings.

E. Use guide ropes or equivalent to prevent twistingor swinging of the compressor once it has beenlifted clear of the ground.

F. DO NOT attempt to lift in high winds.

G. Keep all personnel out from under and awayfrom the compressor whenever it is suspended.

H. Lift compressor no higher than necessary.

DANGERAll field equipment must be tested for elec-trostatic fields prior to servicing or making contact with the machine using the follow-ing or equivalent test equipment:

90-600 VAC: Volt detector such as Fluke Model 1AC-A

600-7000 VAC: Voltage detector such as Fluke Networks Model C9970

It is the responsibility of each organization to provide/arrange training for all their associates expected to test for electrostatic fields.

SECTION 1

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I. Keep lift operator in constant attendance when-ever compressor is suspended.

J. Set compressor down only on a level surfacecapable of safely supporting at least its weightand its loading unit.

K. When moving the compressor by forklift truck,utilize fork pockets if provided. Otherwise, utilizepallet if provided. If neither fork pockets or palletare provided, then make sure compressor issecure and well balanced on forks beforeattempting to raise or transport it any significantdistance.

L. Make sure forklift truck forks are fully engagedand tipped back prior to lifting or transporting thecompressor.

M. Forklift no higher than necessary to clear obsta-cles at floor level and transport and corner atminimum practical speeds.

N. Make sure pallet-mounted compressors arefirmly bolted or otherwise secured to the palletprior to attempting to forklift or transport them.NEVER attempt to forklift a compressor that isnot secured to its pallet, as uneven floors or sud-den stops may cause the compressor to tumbleoff, possibly causing serious injury or propertydamage in the process.

1.10 ENTRAPMENTA. If the compressor enclosure, if any, is large

enough to hold a man and if it is necessary toenter it to perform service adjustments, informother personnel before doing so, or else secureand tag the access door in the open position toavoid the possibility of others closing and possi-bly latching the door with personnel inside.

B. Make sure all personnel are out of compressorbefore closing and latching enclosure doors.

NOTES

10

Section 2

11

4500-7500 USER MANUAL

DESCRIPTION2.1 INTRODUCTIONThe design of the Sullair 4500P, 5500, 7500,4500PV, 5500V, 7500V: 60, 75 and 100hp / 45, 55and 75kw line of compressor units is a single stage,positive displacement, flood lubricated one. Acomplete package includes the:

Compressor unit Electric motor Starter Compressor inlet and discharge systems Compressor lubrication and cooling system Capacity control system WS Controller Aftercooler Combination separator and trap Heavy gauge steel mounting frame

Some models also have a Variable Speed Drive(VSD) that is described in Section 2.10 and Section2.11. There are also optional components whichallow operation in environments where thecompressor is exposed to extreme temperatures, orif sea water is used as a coolant.

New compressors are shipped from the factory fullycharged with that particular models recommendedlubrication fluid. The SPECIFICATIONS Section 3.4and Section 3.5 describe lubrication requirementsand recommendations for each compressorpackage.

Sullair recommends that, in cases where 24KT

lubricant is used, users take a sample at the first filterchange and send it to the factory for a free analysisusing a sample kit provided by their Sullair dealer.The results will be sent back to the user in the form ofa report with recommendations.

Although both air and water-cooled models requireno inspection of the units internal components,external piping, connectors, and the enclosureshould be inspected and maintained in accordancewith the procedures and recommendations in thismanual.

2.2 COMPRESSOR COMPONENT DESCRIPTION

Air-cooled models (Figure 2-1) use a fan to drawoutside air into the enclosure, cooling the motors, thecombined radiator fluid cooler, and air aftercooler.This hot air is then vented out of the top of theenclosure.

Water-cooled models (Figure 2-2) use two shell andtube heat exchangers to transfer heat from thecoolant, and the compressed air. Both air-cooled andwater cooled models have a fluid filter, air/oilseparator, control valves, and an inlet air filter.

Fluid is injected into the compressor, and mixesdirectly with the air as the rotors turn whichcompresses the air. The fluid flow has three basicfunctions:

1. As a coolant, it controls the air temperaturerise normally associated with the heat ofcompression.

CAUTIONUse only one type of a recommended com-pressor lubricant. Adding a different one, or mixing lubricants can cause damage and/or malfunctions, and will void the compres-sors warranty.

NOTEThe compressor requires no internal inspections or maintenance actions. Open-ing the compressors housing may void its warranty. (This does not apply to the shaft seal which is replaceable.)

4500-7500 USER MANUAL SECTION 2

12

2. Seals the clearance paths between therotors and the stator, and also between thetwo rotors.

3. Provides a lubricating film between the rotorsallowing one rotor to directly drive the other,which is an idler, and also lubricates thebearings.

After the air/fluid mixture is discharged from thecompressor unit, the fluid is separated from the air.At this time, the air flows through an aftercooler andseparator, and then to the service line while the fluidis cooled and filtered in preparation for reinjection.

Figure 2-1: Main Components, Air-Cooled

1. Fluid Filter 8. Starter Box2. Cooler 9. E-Stop Button3. Moisture Separator 10. Compressor Unit4. Air Inlet Filter 11. Cooler Fan Motor5. separator/sump Tank 12. Motor6. Fluid Fill Sight Glass 13. Fluid Fill7. WS Controller

SECTION 2 4500-7500 USER MANUAL

13

Figure 2-2: Main Components, Water-Cooled

1. Fluid Filter 9. E-Stop Button2. Cooler 10. Compressor Unit3. Vent Fan 11. Moisture Separator4. Air Inlet Filter 12. Motor5. separator/sump Tank 13. Fluid Fill6. Fluid Fill Sight Glass 14. Water-Cooled Aftercooler7. WS Controller 15. Inlet Valve8. Starter Box


14

Figure 2-3: Air-Cooled, Cooling/Lubrication and Discharge System

1. Separator/Sump Tank 6. Separator Elements2. Cooler 7. Air3. Fluid Filter 8. Air/Fluid Mix4. Moisture Separator 9. Fluid5. Compressor Unit


15

2.3 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTIONAL DESCRIPTION

Refer to Figure 2-3 or Figure 2-4. The cooling andlubrication system (air-cooled models) consists of afan, fan motor, radiator aftercooler/fluid cooler,full flow fluid filter, thermal valve, andinterconnecting hoses. Water-cooled models havetwo shell and tube heat exchangers instead of aradiator cooler.

The pressure in the separator/sump tank starts thefluid flow by forcing the fluid from the high pressurearea of the tank to an area of lower pressure in thecompressor. Fluid flows from the bottom of theseparator/sump tank to the thermal valve that is fullyopen when the fluid temperature is below 185F(85C) [195F (91C) for 24KT and pressures ratedabove 150 psig]. The fluid passes through thethermal valve, the main filter, and directly to thecompressor where it lubricates, cools and seals therotors, and the compression chamber.

As the discharge temperature rises above 185F(85C), due to the heat of compression, the thermalvalve begins to adjust and a portion of the fluid thenflows through the cooler. From the cooler the fluidflows to the fluid filter and on to the compressor. Aportion of the fluid flow to the compressor is routed tothe anti-friction bearings which support thecompressor rotors.

The fluid filter has a replacement element and anintegral bypass valve. Refer to Section 3.6:Lubrication Change Recommendations andMaintenance, Fluid Filter And Separator on page 27.

Water-cooled models have a water pressure switchto prevent operation when the water pressure is toolow.

2.4 COMPRESSOR DISCHARGE SYSTEMFUNCTIONAL DESCRIPTION

Refer to Figure 2-3 or Figure 2-4. The compressordischarges the compressed air/fluid mixture into thecombination separator/sump tank. The separator/sump has three basic functions:

1. It acts as a primary fluid separator.

2. Serves as the compressor fluid sump.

3. Houses the final fluid separator.

The compressed air/fluid mixture enters theseparator/sump tank and flows through an internalbaffle system that changes the flows direction andvelocity, which causes most of the fluid to fall to thebottom of the separator/sump tank. A small amountof fluid remaining in the compressed air collects onthe surface of the separator element as the air flowsthrough the separator.

A return line (or scavenge tube) leads from the dryside of the separator/sump tank to the mediumpressure region. Scavanged fluid is returned by apressure differential between the separator/sumpand compressor.

A visual sight glass is located on the return line toobserve this flow. This return line also has an orifice(protected by a strainer) to ensure an unobstructedflow. The separator system reduces the fluid carry-over to less than 1ppm at nominal rated pressures.

The WS Controller will show an abnormal pressuredrop through the separator if the element becomesplugged. (Refer to Section 3.6: Lubrication ChangeRecommendations and Maintenance, Fluid FilterAnd Separator on page 27.) It will also shut down thecompressor if the discharge temperature reaches235F (113C).

A minimum pressure/check valve locateddownstream from the separator maintains theseparator/sump pressure at 50 psig (3.4 bar) duringload conditions. This pressure level is necessary forproper air/fluid separation and sufficient fluidcirculation.

A terminal check valve is a sub-component of theminimum pressure/check valve that preventscompressed air in the service line from back-flowinginto the separator/sump on shutdown or when thecompressor is operating in an unload condition. Also,a pressure relief valve on the compressors wet sideopens if the separator/sump tank pressure exceedsits rating.

WARNINGStop the compressor and relieve all internal pressure before removing caps, plugs, and/or other components when the compressor is running or pressurized.


16

Figure 2-4: Water-Cooled, Cooling/Lubrication and Discharge System

1. Separator/Sump Tank 6. Separator Elements2. Fluid Cooler 7. Air3. Fluid Filter 8. Air/Fluid Mix4. Moisture Separator 9. Fluid5. Compressor Unit 10. Aftercooler


17

Add fluid to the separator/sump tank through thecapped fluid filter port. There is also a sight glass thatenables the user to check the separator/sump tankfluid level. See Fluid Level Check on page 57.

2.5 CONTROL SYSTEM FUNCTIONAL DESCRIPTION

Refer to Figure 2-5. The compressor controlsystem regulates its output to match the demand.This system consists of a solenoid valve, aregulator and an inlet valve that control thecompressors four operational modes. The followingdescriptions of operational modes apply to acompressor whose operating range is 100 to 110psig (6.9 to 7.6 bar)

START MODE - 0 TO 50 PSIG (0 TO 3.5 BAR)There is no load on the compressor at startup, thesolenoid valve is open and the inlet valve is closed.When the compressor (START) pad is pressed,the separator/sump tank pressure rises from 0 to 50psig (0 - 3.4 bar). When it reaches its full operatingspeed (maximum rpm), the compressor switches tothe Full Load Mode.

Other pressure settings can be selected depending on compressor application or rating.

I

Figure 2-5: Standard Sequencing Control System

1. Air Outlet 6. Minimum Pressure / Check Valve2. Sequencing Solenoid Valve 7. Separator/sump Tank3. Pressure Regulator 8. Unload Solenoid Valve4. Air Inlet 9. WS Controller5. Blowdown Valve


18

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

When the compressed air pressure rises above 50psig (3.4 bar), the minimum pressure valve opensallowing compressed air to flow into the service line.From this point on, the WS Controller continuouslymonitors the line air pressure. The pressure regulatorand the solenoid valve remain closed in this mode.As long as the compressor is running at 100 psig (6.9bar or lower), the inlet valve is fully open.

MODULATING MODE - 100 TO 110 PSIG (6.9 TO 7.6 BAR) (STANDARD CONTROL)

If the rated capacity of compressed air is less thanthe demand, the service line pressure rises above100 psig (6.9) bar). The pressure regulator valvegradually opens, causing the air pressure to closethe inlet control valve at the same rate, reducing thevolume of air entering the compressor until itmatches the demand. The control system operatescontinuously in this mode to accommodate variationsin demand output.

The inlet valve has an orifice that directs a smallamount of air to the compressor inlet when the inletcontrol valve is under the pressure regulatorscontrol. The orifice also bleeds off any accumulatedmoisture from the control lines.

MODULATING MODE WITH SPIRAL VALVE - 100 TO 110 PSIG (6.9 TO 7.6 BAR)

As air demand drops below the rated capacity of thecompressor, the line pressure will rise above 100psig (6.9 bar). As a result, the differential pressureregulator for the spiral valve gradually opens, apply-ing air pressure to the spiral valve actuator. Air pres-sure at the actuator expands the diaphragm. Therack, in turn, engages with the pinion mounted on thespiral valve shaft assembly. This results in a rotarymotion. As the spiral valve rotates, it starts openingthe bypass ports gradually. Excess air is then beingreturned back internally to the suction end of thecompressor unit. Now the compressor is fullycompressing only that amount of air, which is beingused. As air demand keeps dropping further, thespiral valve keeps opening more and more until allthe bypass ports are fully open. At this point, thespiral valve has moved into the unload (minimum)position.

The spiral valve provides a modulation range from100 to 50%. During this period, the pressure rises

approximately from 100 to 105 psig (6.9 to 7.2 bar).As the air pressure exceeds 105 psig (7.2 bar), thedifferential pressure regulator controlling the inletpoppet valve starts opening and forcing the poppetclosed, thus throttling inlet air flow to the compres-sor. The inlet poppet valve provides a modulationrange from 50 to 40%. During this period, the pres-sure rises approximately from 106 to 110 psig (7.3 to7.6 bar). During this range, the spiral valve remainsin the unload position.

UNLOAD MODE - GREATER THAN 110 PSIG (7.6 BAR)

When there is no, or only a small demand, theservice line pressure will rise. The WS Controller de-energizes the solenoid valve when the pressureexceeds 110 psig (7.6 bar) allowing the separator/sump tank air pressure to be supplied directly whichcloses the inlet valve. At the same time the solenoidvalve sends a pneumatic signal to the blowdownvalve on the separator/sump tank. This componentexhausts the system pressure to the atmosphere andlowers the separator/sump tank pressure toapproximately 14 psig (1.2 bar). A check valve in theair service line prevents air from back-flowing to theseparator/sump tank.

When the pressure drops to the low setting: (cut-inpressure) usually 100 psig (6.9 bar) for low pressure(7 bar) compressors and 125 psig (8.6 bar) for highpressure (9 bar) compressors, 150 psig (10.3 bar) for(10 bar) compressors, 175 psig (12.0 bar) for (12bar) compressors: the WS Controller energizes thesolenoid valve and the blowdown valve closes. Thesolenoid valve now prevents line pressure fromreaching the inlet control valve. If the pressurebegins to rise, the pressure regulator resumes itsnormal function.

LOAD/NO LOAD CONTROLThe compressor can be set to operate withoutmodulation, operating in the load/no load condition.This mode is used most often with large air systemvolume, e.g., with a separator/sump or flowcontroller. This mode is selected using the WSController keypad and setting modulation to nofrom the menu. A machine rated for 100 psig (7bar)will run in the full load mode up to 100 psig (7 bar). Ifthe demand is less than the compressors ratedcapacity, the pressure will rise above 100 psig andthe WS Controller de-energizes the solenoid valvewhich causes the compressor to switch to the unloadmode. When the system pressure decreases to 90psig (6.3 bar), the WS Controller energizes the


19

solenoid valve and the compressor switches back tothe full load mode. The compressors WS Controllerkeeps the system pressure stabilized within a rangeof 90 to 100 psig (6.3 to 6.9 bar).

2.6 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-6. The compressor inlet systemconsists of a dry-type air filter, a restriction gaugeand an air inlet valve.

The restriction gauge (located on the air filter)indicates the condition of the air filter by showing redwhen filter maintenance is required.

The poppet-type modulating air inlet valve controlsthe compressors air intake volume. Refer to FullLoad Mode - 50 to 100 psig (3.4 to 6.9 bar) on page18. The air inlet valve also acts as a check valve toprevent reverse rotation when the compressor is shutdown.

Figure 2-6: Air Inet System

1. Air Inlet Filter 3. Compressor Unit2. Air Inlet Valve 4. Restriction Indicator

WARNING"The Plastic Pipe Institute recommends against the use of thermoplastic pipe to transport compressed air or other com-pressed gases in exposed above ground locations, e.g. in exposed plant piping." (I) Sullube should not be used with PVC piping systems. It may affect the bond at cemented joints. Certain other plastic materials may also be affected.

(I) Plastic Pipe Institute, Recommendation B, Adopted January 19, 1972.


20

2.7 WS CONTROLLER/KEYPADRefer to Figure 2-7. The WS Controller keypad hastwo main pads for compressor control. To start thecompressor operation, press the green Start pad

.

To stop compressor operation, press the red Stop

pad . The Run mode indicator lights upwhenever the control is in an operating mode.

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

Figure 2-8

Refer to Figure 2-8 and Figure 2-9. The lower line isoccasionally interrupted to describe the compressorpackage's operating state.

Figure 2-9

Figure 2-7: WS Controller Panel

1. Display Panel 6. Enter Pad2. Start Pad 7. Fault Warning Indicator Light (Red)3. Stop Pad 8. Maintenance Indicator Light (Amber)4. Arrow Up Pad 9. Auto Mode Indicator Light (Green)5. Arrow Down Pad 10. Power On (Green)


21

Refer to Figure 2-10. If a machine fault occurs, thered fault indicator will light up, and the display willindicate that a fault has occurred.

Figure 2-10

Refer to Figure 2-11. The lower line periodically willdisplay the cause of the fault. Refer to serviceinstructions to correct the cause. Press the Stop pad

to reset the controller.

Figure 2-11

Refer to Figure 2-12. Press the Down arrow todisplay additional information about the compressor.The upper line will indicate "Compressor Status" andthe name of the temperature, pressure, or othermeasurement. The lower line indicates the presentreading.

Figure 2-12

Refer to Figure 2-13. When you continue beyond thestatus information, the display will show a list ofcontrol settings. The upper line will indicate "ShowSetting" and the name of the setting. The lower lineshows the present value.

Figure 2-13

Refer to Figure 2-14. To change the setting, press

the Enter pad . The display indicates that youare in a change mode with reverse characters. Usethe Up or Down arrow keys to change thesetting, and press Enter again to save the newsetting.

Figure 2-14

Refer to Figure 2-14. If there is no keypad activity,the display will return to normal view in about oneminute. If the Start or Stop buttons are pressed, thedisplay also returns to normal view. If either of theseoccur, the setting will not be altered.

If there are any warnings or recommended serviceinstructions, these will be periodically displayed onthe normal view.

The list of displays may be navigated from either

direction by using the Up or Down arrowkeys. For example, to change language from normalview, press the Up arrow pad once, press the Enter

key , select your language, and press Enteragain. The number of displays varies withcompressor model, but will follow this pattern.

The Emergency Stop button located near thecontroller overrides all electronic functions to turn offthe control devices. The controller senses this, andwill display E-stop. To reset, twist and pull out theEmergency Stop button, then press the Stop pad toreset the WS Controller.

2.9 LED LIGHTSThe four LED lights indicate the general condition ofthe machine.

The green Power indicator indicates power isapplied to the controller. It will blink at a noticeablyslow rate if the WS Controller is set up toautomatically restart after power failure.

The green Run mode indicator indicatescompressor operation is enabled. It lights steadily ifthe motor is running. If the motor stops while in


22

Automatic mode, this LED will blink to indicate thatthe motor may restart.

The yellow Maintenance indicator comes onwhenever there is recommended maintenance or awarning. The text display will periodically indicate therecommended actions or the cause of the warning.

The red Fault indicator indicates that acompressor fault has occurred and needs to berepaired before further operation. The text displaywill indicate the cause of the fault.

The PC support program for the WS Controllerprovides additional information about compressoroperation and advanced setup adjustments tooptimize operation.

Software part numbers are shown in the displayfollowing a power interruption or other interruption ofcommunication with the controller. The P/N remainson the display until satisfactory communications areestablished with the Input/Output module.

2.10 VARIABLE SPEED DRIVE (VSD) COMPONENTS

The VSD, located in the machines electricalenclosure, works in concert with the WS Controller toallow the compressor to match its output to thecurrent demand on the system. The drives heat sinkextends through the back of the enclosure, and iscooled by air flowing through the compressorenclosure.

2.11 VSD CONTROL SYSTEM FUNCTIONAL DESCRIPTION

Refer to Figure 2-5. The controls consist of:

a VSD a solenoid valve a regulating valve and an inlet valve.

Depending on the model, a compressor can beoperated at a setpoint pressure from 60 to 175 psig

(4.1 to 12.1 bar). The WS Controller automaticallysets the frequency range based on the selectedpressure. (The compressors operating range is onits nameplate.)

The following paragraphs apply to a compressor witha 100 psig (6.9) operating pressure and a 6 psi (0.4bar) load delta setting.

Compressors with different pressure operatingranges perform in the same manner.

START MODE - 0 TO 50 PSIG (0 TO 3.5 BAR)Pressing the WS Controller START button (1) signalsthe VSD to accelerate the motor to full speed,causing the separator/sump tank pressure to risefrom 0 to 50 psig (0 to 3.4 bar). At this time both thepressure regulator and solenoid valves are closed;the inlet valve is fully open and the air-end provides afull flow to the separator/sump tank. A minimumpressure valve set at approximately 50 psig (3.4 bar)isolates the rising compressor air pressure from theservice line.

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

When the compressed air pressure rises above 50psig (3.4 bar) the minimum pressure valve opensallowing compressed air to flow into to the serviceline. From this point on the WS Controller monitorsthe line pressure which controls the VSD. Thepressure regulator and solenoid valves remainclosed with the inlet valve fully open, running at 100psig (6.9 bar) or lower.

VSD PART LOAD CONTROL4500PV, 5500V, 7500V (16 SERIES)

The service line pressure increases to a value above100 psig (6.9) if the demand is less than thecompressors rated capacity. In this condition, theVSD slows the motors rpm which reduces the outputto match the demand. The drive continuously adjuststhe motors rpm to maintain a 100 psig (6.9 bar) linepressure.The WS Controller maintains the correctfrequency when the VSD is operating in this mode.

NOTESection 2.10 and Section 2.11 apply only to compressors equipped with a Variable Speed Drive.

NOTEThe load delta default setting is 10 psi (0.7 bar). Sullair recommends a setting of 6 psi (0.4) for the most efficient operation.


23

MODULATING MODE WITH SPIRAL VALVE7500PV (18 SERIES) :

As demand decreases, the variable speed drivereduces motor speed to maintain the set point pres-sure. When the speed approaches the minimumsetting, a solenoid valve opens feeding air pressureto the spiral valve actuator. This in turn expands thediaphragm and engages the pinion mounted on thespiral valve shaft assembly, resulting in a rotarymotion and full opening of the spiral valve, effec-tively reducing the rotor length by 50%. Excess airwill be returned back internally to the suction side ofthe compressor unit. In this mode, the VSD willmodulate the motor speed within a specified range tomaintain the set point pressure as follows: Increasingdemand condition: If demand increases, the VSDincreases the motor speed until the set pointpressure is achieved. If set point pressure is notachieved while at maximum speed, the controller willclose the spiral valve, thereby eliminating internal airbypass. Consequently, the VSD will regulate themotor speed to achieve the set point pressure.Decreasing demand condition: While the spiral valveis open, if demand continues to decrease the VSDwill reduce the motor speed until the set pointpressure is achieved. This action will continue untilthe minimum speed is reached. When the systempressure reaches 106 psig (7.3 bar), or alternativelyset unload pressure, the compressor unloads, orturns off.

MODULATING MODE- 100 TO 106 PSIG (7.3 TO 6.9 BAR)

During low demand periods and with the VSDrunning at minimum speed, the line pressure cancontinue to rise. When the line pressure reaches101-102 psig (approximately 7 bar), the regulatorvalve (Figure 2-5) gradually opens, directing airpressure to the inlet control valve piston. This actioncauses the inlet valve to partially close, therebyreducing the air flow entering the compressor until itmatches the demand. The control system functionscontinuously in this manner between less than 101psig (7.0 bar) to 106 psig (7.3 bar), in response tovarying system demand. The pressure regulator hasan orifice which vents a small amount of air to theatmosphere when the pressure regulator controls theinlet valve. The orifice also bleeds off anyaccumulated moisture from the control line. Whenthe discharge pressure rises above 106 psig (7.3bar), or to a preset unload pressure, the compressorunloads.

UNLOAD MODE- IN EXCESS OF 106 PSIG (7.3 BAR)

When there is no demand or it is at a minimal level,the service line pressure continues to rise. When itexceeds 106 psig (7.3 bar), or reaches a presetunload pressure value, the WS control system de-energizes the solenoid valve allowing separator/sump tank air pressure to be supplied directly whichcloses the inlet valve. The solenoid valvesimultaneously sends a pneumatic signal to the blowdown valve which opens to the atmosphere, andreduces the separator/sump tank pressure. Thecheck valve in the air service line prevents linepressure from back-flowing to the separator/sumptank. The compressor will shut down after theprogrammed unload time setting expires (the defaultsetting is zero [0] minutes for an immediate shutdownupon unload). When the line pressure drops to thelow pressure setting of 100 psig (6.9 bar) the WSController starts the motor and energizes thesolenoid valve which closes the blowdown valve. There-energized solenoid valve prevents line pressurefrom reaching the inlet control valve, thereby allowingit to fully open, and the compressor suppliescompressed air to the system.

2.12 INTEGRAL DRYER OPTIONAn integral refrigerated dryer option is available. Theintegral dryer is designed to work with thecompressor WS controller which controls dryerstarting and stopping, condensate drain valvefunction and monitors dewpoint temperature anddryer warnings and faults. The dryer is fullyconnected from the factory and is ready to run whenthe compressor is installed.

Detail of dryer operation and spare parts can befound in a supplement Manual 02250174-308 whichis provided with your machine.

Per the controller default settings, on initial start-upthe compressor will run unloaded for 5 minutes,allowing the dryer to run and cool down. Thisprevents condensate from initially being allowed intothe compressed air stream. It also delays the supplyof compressed air from the compressor until the 5minute cool-down period is completed. When theautomatic control mode is selected, the compressorwill stop after running unloaded for a prescribed time,but the dryer will continue to run to ensure there willnot be a surge of condensate when the compressorre-starts. For other settings and control options, referto the WS controller manual 02250164-411, or to


24

your authorized Sullair servicing distributor.

In case the compressor needs to operate while thedryer is being serviced, the dryer can be bypassed,and removed if necessary for service. To bypass thedryer, disconnect the inlet hose to the dryer,disconnect the outlet hose at the main serviceconnection, and re-connect the dryer inlet hose to themain service connection. Remove the fusespowering the dryer located in the compressorelectrical box. The WS controller must be set-up forthe compressor to run on dryer fault. If necessary,this can be reset by your authorized Sullair servicingdistributor.

Section 3

25


SPECIFICATIONS3.1 TABLE OF SPECIFICATIONS4500P, 5500 & 7500 SERIES

MODELS

Model (I) HP

DIMENSIONSLength Width Height Weight Weight

in mm in mm in mmlbs kg

ODP TEFC ODP TEFC4500P SERIES

4507P 60 78.7 1999 43.3 1100 68.9 1750 2755 3121 1249 14154509P 60 78.7 1999 43.3 1100 68.9 1750 2755 3121 1249 14154510P 60 78.7 1999 43.3 1100 68.9 1750 2755 3121 1249 1415

5500 SERIES5507 75 78.7 1999 43.3 1100 68.9 1750 2826 3150 1281 14285509 75 78.7 1999 43.3 1100 68.9 1750 2826 3150 1281 14285510 75 78.7 1999 43.3 1100 68.9 1750 2826 3150 1281 14285512 75 78.7 1999 43.3 1100 68.9 1750 2826 3150 1281 1428

7500 SERIES7509 100 78.7 1999 43.3 1100 68.9 1750 3213 3432 1457 15567510 100 78.7 1999 43.3 1100 68.9 1750 3213 3432 1457 15567509 100 78.7 1999 43.3 1100 68.9 1750 3213 3432 1457 15567512 100 78.7 1999 43.3 1100 68.9 1750 3213 3432 1457 1556

4500PS SERIES4507PS 60 78.7 1999 43.3 1100 68.9 1750 3091 3369 1401 15284509PS 60 78.7 1999 43.3 1100 68.9 1750 3091 3369 1401 15284510PS 60 78.7 1999 43.3 1100 68.9 1750 3091 3369 1401 1528

5500PS SERIES5507PS 75 78.7 1999 43.3 1100 68.9 1750 3277 3391 1486 15375509PS 75 78.7 1999 43.3 1100 68.9 1750 3277 3391 1486 15375510PS 75 78.7 1999 43.3 1100 68.9 1750 3277 3391 1486 15375512PS 75 78.7 1999 43.3 1100 68.9 1750 3277 3391 1486 1537

7500P and 7500PS SERIES7507P/PS 100 78.7 1999 43.3 1100 68.9 1750 3419 3563 1550 16167509P/PS 100 78.7 1999 43.3 1100 68.9 1750 3419 3563 1550 16167510P/PS 100 78.7 1999 43.3 1100 68.9 1750 3419 3563 1550 16167512P/PS 100 78.7 1999 43.3 1100 68.9 1750 3419 3563 1550 1616

(I) Includes standard 24KT. Rated pressure designations appearing after model number are as follows:07 - 100 psig (6.9 bar) 10 - 150 psig (10.3 bar)09 - 125 psig (8.6 bar) 12 - 175 psig (12.0 bar)Maximum unload pressure is the rated pressure plus 10 psig (0.7 bar).


26

3.2 TABLE OF SPECIFICATIONSVARIABLE SPEED DRIVE

VSD SERIES (I) - 4500PV (MODELS 4507PV - 4509PV)MOTOR ODP TEFCHZ/VOLTAGE 460/60 575/60 400/50 460/60 575/60 400/50DRIVE AMP RATING 87 80 105 87 80 105

WEIGHT (lbs/kg) 2755/1250 3097/1404 3010/1365 3300/1497 3445/1503 3420/1551LENGTH (in/mm) 78.7/1999 78.7/1999 78.7/1999 78.7/1999 78.7/1999 78.7/1999WIDTH (in/mm) 43.3/1100 43.3/1100 43.3/1100 43.3/1100 43.3/1100 43.3/1100HEIGHT (in/mm) 68.9/1750 68.9/1750 68.9/1750 68.9/1750 68.9/1750 68.9/1750VSD SERIES (I) - 5500V (MODELS 5507V - 5512V)MOTOR ODP TEFCHZ/VOLTAGE 460/60 575/60 400/50 460/60 575/60 400/50DRIVE AMP RATING 105 100 140 105 100 140

WEIGHT (lbs/kg) 2963/1344 3168/1437 3014/1367 3281/1491 3492/1584 3338/1514LENGTH (in/mm) 78.7/1999 78.7/1999 78.7/1999 78.7/1999 78.7/1999 78.7/1999WIDTH (in/mm) 43.3/1100 43.3/1100 43.3/1100 43.3/1100 43.3/1100 43.3/1100HEIGHT (in/mm) 68.9/1750 68.9/1750 68.9/1750 68.9/1750 68.9/1750 68.9/1750VSD SERIES (I) - 7500V (MODELS 7509V - 7512V)MOTOR ODP TEFCHZ/VOLTAGE 460/60 575/60 400/50 460/60 575/60 400/50DRIVE AMP RATING 140 125 170 140 125 170

WEIGHT (lbs/kg) 3341/1515 3535/1603 3391/1515 3531/1601 3752/1690 3531/1601LENGTH (in/mm) 78.7/1999 78.7/1999 78.7/1999 78.7/1999 78.7/1999 78.7/1999WIDTH (in/mm) 43.3/1100 43.3/1100 43.3/1100 43.3/1100 43.3/1100 43.3/1100HEIGHT (in/mm) 68.9/1750 68.9/1750 68.9/1750 68.9/1750 68.9/1750 68.9/1750VSD SERIES (I) - 7500PV (MODELS 7507PV - 7512PV)MOTOR ODP TEFCHZ/VOLTAGE 460/60 575/60 400/50 460/60 575/60 400/50DRIVE AMP RATING 140 125 170 140 125 170

WEIGHT (lbs/kg) 3547/1608 3691/1674 3547/1608 3691/1674 3835/1739 3691/1674LENGTH (in/mm) 78.7/1999 78.7/1999 78.7/1999 78.7/1999 78.7/1999 78.7/1999WIDTH (in/mm) 43.3/1100 43.3/1100 43.3/1100 43.3/1100 43.3/1100 43.3/1100HEIGHT (in/mm) 68.9/1750 68.9/1750 68.9/1750 68.9/1750 68.9/1750 68.9/1750(I) Includes standard and 24KT. Rated pressure designations appearing after model number are as follows:07 - 100 psig (6.9 bar) 10 - 150 psig (10.3 bar)09 - 125 psig (8.6 bar) 12 - 175 psig (12.0 bar)Maximum unload pressure is the rated pressure plus 10 psig (0.7 bar).


27

3.3 COMPRESSOR SPECIFICATIONS

3.4 LUBRICATION GUIDERefer to Figure 3-1 for the fluid fill port location.Sullairs 4500P-7500 series compressors are filledand tested at the factory with Sullube lubricant.

3.5 APPLICATION GUIDESullair encourages its customers to participate in afluid analysis program with the fluid suppliers. Insome cases the analysis results suggest a fluidchange interval which differs from the User Manual.Contact a Sullair representative for details.

3.6 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE, FLUID FILTER AND SEPARATOR

COMPRESSOR: STANDARD MODELS:Type: Fluid Flooded Rotary Screw

Standard Operating Pressure: 100 psig (7 bar) 125 psig (9 bar) / 150 psig (10.0 bar) 175 psig (12.0 bar)Bearing Type: Anti-frictionAmbient Temperature (Max.) (II): 104F (40C)(II) Special compressors are available for operating in higher ambient temperature.

CAUTIONDo not mix different types of lubricants. Mixing

lubricants can cause malfunctions or compressor damage: will void the compressors warranty.

CAUTIONContamination of compressor fluids with mineral

oil or other fluids can cause foaming, filter plugging, or orifice line obstruction.

Figure 3-1: Fluid Fill Location

1. Fluid Fill Port 3. Fluid Drain Valve2. Sight Glass 4. Separator/sump Tank

NOTEWhen performing a fluidchange or topping off thefill, the proper levelshould be at half of thesight glass, with themachine off.

Mixing, changing or add-ing other lubricants withinthe compressor unit mayvoid the air-end warranty.

LUBRICANT FLUID CHANGE FLUID FILTER CHANGE SEPARATOR CHANGESullube (5 gallon cap.) A,E G,C A,DSRF 1/4000 (5 gallon cap.) B, E G, C B, D24kt (5 gallon cap.) F, E G, C A, DCP-4600-32-F (5 gallon cap.) B, E G, C A, DA - 8,000 hours or once per year.B - 4,000 hours or more frequntly if conditions require.C - When measured pressure loss exceeds 20 psig (1.3 bar).D - When measured pressure loss exceeeds 10 psig (0.7 bar).E - When required as the result of fluid analysis or known contamination.F - Does not require replacement under normal service conditions.G - Every 2,000 hours.

4500-7500 USER MANUALSECTION 3

28 Figure 3-2: Identification - 4500P, 5500 and 7500 Air-Cooled

02250161-702R00

SECTION 34500-7500 USER MANUAL 29

Identification - 4500P, 5500 and 7500 Air-Cooled

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE

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

2 A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.

3 ALL DIMENSIONS ARE +/-.50" [12.7MM]

4 RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.

5 IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR HIGH STATIC FAN MUST BE SELECTED. MAX ALLOWABLE ADDITIONAL STATIC PRESSURE 0.75 IN WATER WITH HIGH STATIC FAN.

6 DOORS ARE REMOVABLE USING LIFT-OFF HINGE PINS.

7 ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER DIMEN-SIONS IN PARENTHESES.

AN ADDITIONAL .75 IN/WG STATIC PRESSURE CAN BE ADDED WHEN USING HIGH STATIC FAN

A1: ALTERNATE INCOMING POWER SUPPLY LOCATION 2.50 DIA. [63.5]

A2: SPACE REQUIRED TO OPEN DOORS TYP. SEE NOTE #6

A3: SPACE REQUIRED TO OPEN STARTER PANEL

A4: CONTROLLER

A5: E-STOP

A6: OIL LEVEL SIGHTGLASS LOCATION

A7: AIR INLET

A8: EXHAUST AIR OUT

A9: CONTAINMENT PAN DRAIN

A10: INCOMING CUSTOMER POWER SUPPLY 3.0 DIA. (76.2)

A11: MOISTURE DRAIN CONNECTION 1/4"-18 NPT

A12: AIR OUT CONNECTION 2"-11 1/2 NPT

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

MACHINE WEIGHTS

MAIN MOTOR HP WEIGHT

COOLING AIR CFM

4500P 60 odp pe 2,815 lbs (1,276 kg) 8,100

4500P 60 tefc pe 3,181 lbs (1,442 kg) 8,100

5500 75 odp pe 2,886 lbs) 1,308 kg) 8,100

5500 75 tefc pe 3,210 lbs (1,455 kg) 8,100

7500 100 odp pe 3,213 lbs (1,457 kg) 8,400

7500 100 tefc pe 3,432 lbs (1,556 kg) 8,400

4500 60 odp pe 2,949 lbs (1,337 kg) 8,100

4500 60 tefc pe 3,227 lbs (1,463 kg) 8,100

5500 75 odp pe 3,135 lbs) 1,421 kg) 8,100

5500 75 tefc pe 3,249 lbs (1,473 kg) 8,100

7500 100 odp pe 3,277 lbs (1,463 kg) 8,400

7500 100 tefc pe 3,421 lbs (1,551 kg) 8,400


Figure 3-3: Identification - 4500P, 5500 and 7500 Water-Cooled

02250170-715-R00


Identification - 4500P, 5500 and 7500 Water-Cooled

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE

Notes:

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

2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.

3. ALL DIMENSIONS ARE +/- .50" [12.7]

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

5. DOORS ARE REMOVABLE USING LIFT-OFF HINGE PINS. 6. ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER DIMENSIONS IN PARENTHESES.




A4: CONTROLLER

A5: E-STOP


A7: AIR INLET

A8: EXHAUST AIR OUT 2,845 CFM



A11: MOISTURE DRAIN CONNECTION 1/4"-18 NPT

A12: AIR OUT CONNECTION 2"-11 1/2 NPT

A13: COOLING WATER OUT 1 1/2"-11 1/2 NPT

A14: COOLING WATER IN 1 1/2"-11 1/2 NPT


MACHINE WEIGHTS

MAIN MOTOR HP WEIGHT4500P 60 ODP EE 2,755 LBS (1,249 kg)

4500P 60 TEFC EE 3,121 LBS (1,415 kg)

5500 75 ODP EE 2,826 LBS (1.281 kg)

5500 75 TEFC EE 3,150 LBS (1,428 kg)

7500 100 ODP EE 3,178 LBS (1,441 kg)

7500 100 TEFC EE 3,427 LBS (1,554 kg)

4500P 60 ODP PE 2,889 LBS (1,310 kg)

4500P 60 TEFC PE 3,167 LBS (1,436 kg)

5500 75 ODP PE 3,075 LBS (1,394 kg)

5500 75 TEFC PE 3,189 LBS (1,446 kg)

7500 100 ODP PE 3,250 LBS (1,470 kg)

7500 100 TEFC PE 3,386 LBS (1,535 kg)


32 Figure 3-4: Identification - 4500P, 5500, and 7500 Air-Cooled with Integral Dryer

02250172-305-R01


Identification - 4500P, 5500, and 7500 Air-Cooled with Integral Dryer

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE

AN ADDITIONAL .75 IN/WG STATIC PRESSURE CAN BE ADDED WHEN USING HIGH STATIC FAN




A4: CONTROLLER

A5: E-STOP


A7: COMPRESSOR PACKAGE AIR INLET

A8: COMPRESSOR PACKAGE EXHAUST AIR OUT



A11: MOISTURE DRAIN CONNECTION 1/4-18 NPT

A12: AIR OUT CONNECTION 2-11 1/2 NPT

A13: DRYER AIR INLET

A14: DRYER EXHAUST AIR OUTLET

NOTES:

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

2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.

3. ALL DIMENSIONS ARE +/- .50 [12.7MM]

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


5. IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR HIGH STATIC FAN MUST BE SELECTED. MAX ALLOWABLE ADDITIONAL STATIC PRESSURE 0.75 IN WATER WITH HIGH STATIC FAN.

6. DOORS ARE REMOVABLE USING LIFT-OFF HINGE PINS.

7. ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER DIMENSIONS IN PARENTHESES.

MACHINE WEIGHTS

MAIN MOTOR HP WEIGHT

COOLING AIR CFM

4500P 60 ODP EE 3,188 LBS (1,446 kg) 8,100

4500P 60 TEFC EE 3,554 LBS (1,612 kg) 8,100

5500 75 ODP EE 3,259 LBS (1,478 kg) 8,100

5500 75 TEFC EE 3,583 LBS (1,625 kg) 8,100

7500 100 ODP EE 3,586 LBS (1,627 kg) 8,400

7500 100 TEFC EE 3,805 LBS (1,726 kg) 8,400

4500 60 ODP PE 3,322 LBS (1,507 kg) 8,100

4500 60 TEFC PE 3,600 LBS (1,633 kg) 8,100

5500 75 ODP PE 3,508 LBS (1,591 kg) 8,100

5500 75 TEFC PE 3,622 LBS (1,643 kg) 8,100

7500 100 ODP PE 3,650 LBS (1,656 kg) 8,400

7500 100 TEFC PE 3,794 LBS (1,721 kg) 8,400

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE



34 Figure 3-5: Piping and Instrumentation - Air-Cooled Models 16 Series

02250171-156-R03


Piping and Instrumentation - Air-Cooled Models 16 Series

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE

1 02250164-930 1 FLTR,AIR 5 2 STG P16/182 250003-869 1 INDICATOR, RESTRICTION3 02250166-128 1 VLV,INL 5 P16 LOW PILOT PRES4 - 1 COMPRESSOR UNIT5 - 1 MOTOR6 02250164-928 1 FILTER, CORELESS 1 SAE7 02250162-368 1 COOLER, AIR/OIL 100HP 57 02250163-627 1 COOLER, AIR/OIL 75HP 58 02250092-081 1 VALVE, THERMAL 195DEG 1-1/2-18 58 02250078-204 1 VALVE, THERMAL 185DEG 1-1/2-18 59 02250125-774 1 ORIFICE, 1/8 X 1/3210 02250126-129 1 GLS, SIGHT/ORF SAE11 02250117-782 1 PLUG,SIGHT GLASS 1 5/16 SAE12 02250097-610 1 PLUG,SIGHTGLASS 1-1/4 SAE13 02250155-175 1 PROBE, THERMISTER 3000 OHM14 02250097-349 1 VALVE, RELIEF 200#15 02250155-174 1 XDUCR, 1-250# RADIOMETRIC16 408893 1 VALVE, SHUTTLE 1/4 DOUBLE CHK17 02250109-817 1 VLV, MIN PRESSURE 100HP17 02250097-598 1 VLV, MIN PRESSURE 75HP18 02250100-042 1 VALVE, BLOWDOWN 1/2 1.8:119 02250166-736 1 SEP,WTR SCWS-235N 2 L/AD 519 02250166-735 1 SEP,WTR SCWS-235N 1 1/2 L/AD 520 02250160-774 2 ELEM,SEP ROUND 5.5D X 14.3LNG21 02250170-783 1 VLV,COMBO 24 VDC22 241771 1 STRAINER, V-TYPE 300PSI X 1/423 02250155-714 2 VLV,SOL 3WNO 1/4 250# 24VDC24 250017-280 1 VALVE, PRESSURE REG25 02250162-369 1 TANK, SEPARATOR26 02250172-323 1 ORF,.140 3/8 FNPT X 3/8 MNPT


27 02250172-320 1 VLV,CHK 3/8NPTF BRASS VITON28 02250144-842 1 VLV,BALL/STNR COMB 1/2F X 1/2M29 02250130-866 1 DRN,SCD400 115V NPT30 02250112-881 1 VENT,ENCL PROT 1/2 SIDE MTG Z-

PRG31 02250078-976 1 GA,DIFF PRESS Z-PURGE ASY REGU32 02250048-457 1 P,RTD 100OHM 90DEG BEND 12FT33 02250172-873 1 XDCR,PRESS 0-250# 12FT CORD34 02250173-972 1 FLTR,PNEUMATIC 1/8NPT 5MICRON

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE

1 PART NUMBERS ARE FOR REFERENCE ONLY. REFER TO BILL OF MATERIAL AND OR FACE OF ORDER FOR ACTUAL PARTS.

2 SECTION BETWEEN LETTERED POINTS ARE TO BE REPLACED WITH CORRESPONDING OPTION PICTURED BELOW, AS REQUIRED BY FACE OF ORDER.

3 CONTROL/MOISTURE DRAIN LINES ARE 1/4" TUBING EXCEPT AS NOTED.

4 OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE REQUIRE-MENTS.

5 PART VARIES BY MODEL.


KEY NO. PART NO.

QTY

DESCRIPTION

NOTE



36 Figure 3-6: Piping and Instrumentation - 16 Series Water-Cooled

02250171-157-R03


Piping and Instrumentation - 16 Series Water-Cooled

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE

1 02250164-930 FILTER, AIR 5 PLASTIC

2 250003-869 INDICATOR, RESTRICTION

3 02250166-128 VLV,INL 5 P16 LOW PILOT PRESSURE

4 - COMPRESSOR UNIT

5 - MOTOR

6 02250164-928 FILTER, CORELESS 1 SAE

7 02250172-501 CLR,OIL/WATER 6X36 1-5/8SAE

8 02250092-081 VALVE, THERMAL 195DEG 1-1/2-18 5

8 02250078-204 VALVE, THERMAL 185DEG 1-1/2-18 5

9 02250125-774 ORIFICE, 1/8 X 1/32

10 02250126-129 PLUG,SIGHT GLASS 1 5/16 SAE

11 02250117-782 FILTER, ASSY GENISIS

12 02250097-610 PLUG,SIGHTGLASS 1-1/4 SAE

13 02250155-175 PROBE, THERMISTER 3000 OHM

14 02250097-349 VALVE, RELIEF 200#

15 02250155-174 XDUCR, 1-250# RADIOMETRIC

16 408893 VALVE, SHUTTLE 1/4 DOUBLE CHK

17 02250109-817 VLV, MIN PRESSURE 100HP

18 02250100-042 VALVE, BLOWDOWN 1/2 1.8:1

19 02250166-736 SEP,WTR SCWS-235N 2 L/AD 5

19 02250166-735 SEP,WTR SCWS-235N 1 1/2 L/AD 5

20 02250160-774 ELEM,SEP ROUND 5.5D X 14.3LNG

21 02250170-783 VLV,COMBO 24VDC

22 241771 STRAINER, V-TYPE 300PSI X 1/4

23 02250155-714 VLV,SOL 3WNO 1/4 250# 24VDC

24 250017-280 VALVE, PRESSURE REG


25 02250162-369 TANK, SEPARATOR

26 02250172-323 ORF,.140 3/8 FNPT X 3/8 MNPT

27 02250172-320 VLV,CHK 3/8NPTF BRASS VITON

28 43008 HT EXCH

29 250017-992 SWITCH, PRESS NO 10 PSI

30 49474 VALVE, WATER REG 1-1/4160-230F

31 250035-291 VLV,SOL 2WNC 3/4 250# N4

32 02250144-842 VLV,BALL/STNR COMB 1/2F X 1/2M

33 02250130-866 DRN,SCD400 115V NPT

34 02250172-873 XDCR,PRESS 0-250# 12FT CORD

35 02250173-972 FLTR,PNEUMATIC 1/8NPT 5MICRON

5: Part number varies by model.

COMPONENT DSCRIPTIONP1 Wet Sump Pressure

P2 Line Pressure

SOL1 Load/Unload Solenoid Valve

SOL4 MEc/Sequencing/Full Load Solenoid Valve

SOL5 Electric Drain/SCD Drain Solenoid Valve

T1 Wet Discharge Temperature

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE



38 Figure 3-7: Piping and Instrumentation16 Series Air-Cooled with Integral Dryer

02250175-420-R00


Piping and Instrumentation16 Series Air-Cooled with Integral Dryer

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE

1 02250164-930 1 FLTR,AIR 5 2 STG P16/18

2 250003-869 1 INDICATOR, RESTRICTION

3 02250166-128 1 VLV,INL 5 P16 LOW PILOT PRES

4 - 1 COMPRESSOR UNIT

5 - 1 MOTOR

6 02250164-928 1 FILTER, CORELESS 1 SAE

7 02250162-368 1 COOLER, AIR/OIL 100HP 5

7 02250163-627 1 COOLER, AIR/OIL 75HP 5

8 02250092-081 1 VALVE, THERMAL 195DEG 1-1/2-18 5

8 02250078-204 1 VALVE, THERMAL 185DEG 1-1/2-18 5

9 02250125-774 1 ORIFICE, 1/8 X 1/32

10 02250126-129 1 GLS, SIGHT/ORF SAE

11 02250117-782 1 FILTER, ASSY GENISIS

12 02250097-610 1 PLUG,SIGHTGLASS 1-1/4 SAE

13 02250155-175 1 P,THERMISTER 3000 OHM NTC 6L

14 02250097-349 1 VALVE, RELIEF 200#

15 02250155-174 1 XDUCR, 1-250# RADIOMETRIC

16 408893 1 VALVE, SHUTTLE 1/4 DOUBLE CHK

17 02250109-817 1 VLV, MIN PRESSURE 100HP

17 02250097-598 1 VLV, MIN PRESSURE 75HP

18 02250100-042 1 VALVE, BLOWDOWN 1/2 1.8:1

19 02250166-736 1 SEP,WTR SCWS-235N 2 L/AD 5

19 02250166-735 1 SEP,WTR SCWS-235N 1 1/2 L/AD 5

20 02250160-774 2 ELEM,SEP ROUND 5.5D X 14.3LNG

21 02250170-783 1 VLV,COMBO 24 VDC

22 241771 1 STRAINER, V-TYPE 300PSI X 1/4


23 02250155-714 2 VLV,SOL 3WNO 1/4 250# 24VDC

24 250017-280 1 VALVE, PRESSURE REG

25 02250162-369 1 TANK, SEPARATOR

26 02250172-323 1 ORF,.140 3/8 FNPT X 3/8 MNPT

27 02250172-320 1 VLV,CHK 3/8NPTF BRASS VITON

28 02250112-881 1 VENT,ENCL PROT 1/2 SIDE MTG Z-PRG

29 02250078-976 1 GA,DIFF PRESS Z-PURGE ASY REGU

30 02250048-457 1 P,RTD 100OHM 90DEG BEND 12FT

31 02250172-873 1 XDCR,PRESS 0-250# 12FT CORD

32 - 1 INTEGRAL REFRIGERANT DRYER

33 49905 2 VALVE,CHECK

34 02250175-087 1 P,THERMISTER 3000 OHM NTC 12L

35 02250173-972 1 FLTR,PNEUMATIC 1/8NPT 5 MICRON



P2 Line Pressure





T3 Dryer Dewpoint Temperature Probe

T6 Cooler Fluid Out Temperature

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE



40 Figure 3-8: Piping and Instrumentation18 Series Air-Cooled w/ Spiral Valve

02250175-168-R01


Piping and Instrumentation18 Series Air-Cooled w/ Spiral Valve

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE

1 02250164-930 1 FLTR,AIR 5 2 STG P16/182 250003-869 1 INDICATOR, RESTRICTION3 - 1 INLET4 - 1 COMPRESSOR UNIT5 - 1 MOTOR6 02250164-928 1 FILTER, CORELESS 1 SAE7 02250162-368 1 COOLER, AIR/OIL 100HP 57 02250163-627 1 COOLER, AIR/OIL 75HP 58 02250092-081 1 VALVE, THERMAL 195DEG 1-1/2-18 58 02250078-204 1 VALVE, THERMAL 185DEG 1-1/2-18 59 02250125-774 1 ORIFICE, 1/8 X 1/3210 02250126-129 1 GLS, SIGHT/ORF SAE11 02250117-782 1 FILTER, ASSY GENISIS12 02250097-610 1 PLUG,SIGHT GLASS 1 5/16 SAE13 02250155-175 1 PROBE, THERMISTER 3000 OHM14 02250097-349 1 VALVE, RELIEF 200#15 02250155-174 1 XDUCR, 1-250# RADIOMETRIC16 408893 1 VALVE, SHUTTLE 1/4 DOUBLE CHK17 02250109-817 1 VLV, MIN PRESSURE 100HP 517 02250097-598 1 VLV, MIN PRESSURE 75HP 518 02250100-042 1 VALVE, BLOWDOWN 1/2 1.8:119 02250166-736 1 SEP,WTR SCWS-235N 2 L/AD 519 02250166-735 1 SEP,WTR SCWS-235N 1 1/2 L/AD 520 02250160-774 2 ELEM,SEP ROUND 5.5D X 14.3LNG21 02250170-783 1 VLV,COMBO 24 VDC22 241771 1 STRAINER, V-TYPE 300PSI X 1/423 02250155-714 2 VLV,SOL 3WNO 1/4 250# 24VDC24 250017-280 1 VALVE, PRESSURE REG25 02250162-369 1 TANK, SEPARATOR26 02250172-323 1 ORF,.140 3/8 FNPT X 3/8 MNPT



PRG31 02250078-976 1 GA,DIFF PRESS Z-PURGE ASY REGU32 02250048-457 1 P,RTD 100OHM 90DEG BEND 12FT33 02250172-873 1 XDCR,PRESS 0-250# 12FT CORD34 02250132-934 1 ORF,CAP 031 X 1/4NPT35 - 1 SPIRAL VALVE36 02250173-972 1 FLTR, PNEUMATIC 1/8NPT 5MICRON37 408275 1 VALVE, PRESSURE REG 100PSI38 02250176-101 1 XDCR,PRESS 0-50 PSI



P2 Line Pressure

P3 Spiral Valve Control Pressure




SOL6 Water Solenoid Valve


T6 Cooler Fluid Out Temperature

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE



42 Figure 3-9: Piping and Instrumentation18 Series Air-Cooled VSD

02250176-425-R00


Piping and Instrumentation18 Series Air-Cooled VSD

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE

1 02250164-930 1 FLTR,AIR 5 2 STG P16/182 250003-869 1 INDICATOR, RESTRICTION3 - 1 INLET4 - 1 COMPRESSOR UNIT5 - 1 MOTOR6 02250164-928 1 FILTER, CORELESS 1 SAE7 02250162-368 1 COOLER, AIR/OIL 100HP 57 02250163-627 1 COOLER, AIR/OIL 75HP 58 02250092-081 1 VALVE, THERMAL 195DEG 1-1/2-18 58 02250078-204 1 VALVE, THERMAL 185DEG 1-1/2-18 59 02250125-774 1 ORIFICE, 1/8 X 1/3210 02250126-129 1 GLS, SIGHT/ORF SAE11 02250117-782 1 FILTER, ASSY GENISIS12 02250097-610 1 PLUG,SIGHT GLASS 1 5/16 SAE13 02250155-175 1 PROBE, THERMISTER 3000 OHM14 02250097-349 1 VALVE, RELIEF 200#15 02250155-174 1 XDUCR, 1-250# RADIOMETRIC16 02250117-009 1 GA,PRESS LIQ FILL PSI/BAR 2.517 02250109-817 1 VLV, MIN PRESSURE 100HP 517 02250097-598 1 VLV, MIN PRESSURE 75HP 518 02250100-042 1 VALVE, BLOWDOWN 1/2 1.8:119 02250166-736 1 SEP,WTR SCWS-235N 2 L/AD 519 02250166-735 1 SEP,WTR SCWS-235N 1 1/2 L/AD 520 02250160-774 2 ELEM,SEP ROUND 5.5D X 14.3LNG21 02250170-783 1 VLV,COMBO 24 VDC22 241771 1 STRAINER, V-TYPE 300PSI X 1/423 02250155-714 2 VLV,SOL 3WNO 1/4 250# 24VDC24 02250046-568 1 REG,REDUCING 1/4NPT25 02250162-369 1 TANK, SEPARATOR26 02250172-323 1 ORF,.140 3/8 FNPT X 3/8 MNPT



PRG31 02250078-976 1 GA,DIFF PRESS Z-PURGE ASY REGU32 02250048-457 1 P,RTD 100OHM 90DEG BEND 12FT33 02250172-873 1 XDCR,PRESS 0-250# 12FT CORD34 02250132-934 1 ORF,CAP 031 X 1/4NPT35 - 1 SPIRAL VALVE36 02250173-972 1 FLTR, PNEUMATIC 1/8NPT 5MICRON



P2 Line Pressure






KEY NO. PART NO.

QTY

DESCRIPTION

NOTE



44 Figure 3-10: Wiring Diagram - Air-Cooled VSD Parallel WYE

02250176-126-R01


Wiring Diagram - Air-Cooled VSD Parallel WYE

KEY NO. DESCRIPTION2FU SCD TRANSFORMER PRIMARY FUSES

3FU SCD TRANSFORMER SECONDARY FUSES

P1 WET SUMP PRESSURE SENSOR

P2 PACKAGE DISCHARGE PRESSURE SENSOR

T1 UNIT DISCHAGE TEMPERATURE PROBE

PSW1 (OPTL)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC

DPSW1 (OPTL)OIL FILTER DIFF PRESS SWITCH 20PSID

INPUT 7 REMOTE RUN/UNLOAD

INPUT 8 CUSTOMER FURNISHED FAULT

INPUT 9 CUSTOMER FURNISHED WARNING

SOL1 LOAD CONTROL SOLENOID VALVE

SOL4 SEQUENCEING SOLENOID VALVE

SOL5 ELECTRIC CONDENSATE DRAIN VALVE

PS 24VDC POWER SUPPLY

K1 INTERNAL RUN RELAY CONTACT

K2 INTERNAL Y-DELTA START RELAY

K3 INTERNAL WYE-DELTA RUN RELAY

K4 INTERNAL LOAD CONTROL RELAY

K5 INTERNAL SEQUENCE RELAY

K6 INTERNAL ELECTRIC DRAIN RELAY

K7 INTERNAL COMMON FAULT RELAY

PMR OPTL POWER MONITOR RELAY

HTR1 (OPTL) SUMP HEATER 800W

HTR2 (OPTL) HEAT TRACE

HTR3 (OPTL) TRAP HEATER 70WATTS

HTR4 (OPTL) CONTROL PANEL HEATER 50WATTS

TH THERMOSTAT FOR HEAT TRACE OPTION

XFMR1 CONTROL TRANSFORMER FOR OPTIONAL SCD DRAIN


SCD (OPT/L) SCD DRAIN

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE

1 CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCON-NECT PER LOCAL CODES.

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

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


KEY NO. DESCRIPTION



46 Figure 3-11: Wiring Diagram - MFV AC with Integral Dryer

02250171-938-R02


Wiring Diagram - MFV AC with Integral Dryer

KEY NO. DESCRIPTIONDR DRYER START RELAY

COMP DESCRIPTION1MOL COMPRESSOR OVERLOAD

1M COMPRESSOR STARTER 2MOL FAN MOTOR OVERLOAD

P1 WET SUMP PRESSURE SENSORP2 PACKAGE DISCHARGE PRESSURE SENSOR T1 UNIT DISCHAGE TEMPERATURE PROBET3 DRYER DEWPOINT TEMPERATURE PROBE

PSW1 (OPTL)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WCDPSW1 (OPTL)OIL FILTER DIFF PRESS SWITCH 20PSID INPUT 7 REMOTE RUN/UNLOAD INPUT 8 CUSTOMER FURNISHED FAULT INPUT 9 CUSTOMER FURNISHED WARNING

SOL1 LOAD CONTROL SOLENOID VALVE SOL4 SEQUENCEING SOLENOID VALVE SOL5 ELECTRIC CONDENSATE DRAIN VALVE

PS 24VDC POWER SUPPLY K1 INTERNAL RUN RELAY CONTACT K2 INTERNAL Y-DELTA START RELAY K3 INTERNAL WYE-DELTA RUN RELAY K4 INTERNAL LOAD CONTROL RELAY K5 INTERNAL SEQUENCE RELAY K6 INTERNAL ELECTRIC DRAIN RELAY K7 INTERNAL COMMON FAULT RELAY

PMR OPTL POWER MONITOR RELAY PF CAP POWER FACTOR CORRECTION CAPACITOR (OPTL) HTR1 (OPTL) SUMP HEATER 800W HTR2 (OPTL) HEAT TRACE HTR3 (OPTL) TRAP HEATER 70WATTS HTR4 (OPTL) CONTROL PANEL HEATER 50WATTS

TH THERMOSTAT FOR HEAT TRACE OPTION 1FU SCD TRANSFORMER PRIMARY FUSES


2FU SCD TRANSFORMER SECONDARY FUSE 6FU INTEGRAL DRYER FUSES 7FU INTEGRAL DRYER FUSES (575V) SCD SCD DRAIN OPTION

XFMR1 CONTROL TRANSFORMER FOR OPTIONAL SCD DRAIN PPR POWER PRESENT RELAY OPTION DF DRYER FAULT

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE


2 REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.

3 1MOL SETTING TO BE 1M FLA. PLUS 2M FLA.




P2 Line Pressure






KEY NO. DESCRIPTION



48 Figure 3-12: Wiring Diagram - MFV Air-Cooled NC

02250171-211-R01


Wiring Diagram - MFV Air-Cooled NC

KEY NO. DESCRIPTIONPSW1 (OPTL)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC

DPSW1 (OPTL)OIL FILTER DIFF PRESS SWITCH 20PSID

INPUT 7 REMOTE RUN/UNLOAD

INPUT 8 CUSTOMER FURNISHED FAULT

INPUT 9 CUSTOMER FURNISHED WARNING

SOL1 LOAD CONTROL SOLENOID VALVE

SOL4 SEQUENCEING SOLENOID VALVE

SOL5 ELECTRIC CONDENSATE DRAIN VALVE

PS 24VDC POWER SUPPLY

K1 INTERNAL RUN RELAY CONTACT

K2 INTERNAL Y-DELTA START RELAY

K3 INTERNAL WYE-DELTA RUN RELAY

K4 INTERNAL LOAD CONTROL RELAY

K5 INTERNAL SEQUENCE RELAY

K6 INTERNAL ELECTRIC DRAIN RELAY

K7 INTERNAL COMMON FAULT RELAY

PMR OPTL POWER MONITOR RELAY

PF CAP POWER FACTOR CORRECTION CAPACITOR (OPTL)

HTR1 (OPTL) SUMP HEATER 800W

HTR2 (OPTL) HEAT TRACE

HTR3 (OPTL) TRAP HEATER 70WATTS

HTR4 (OPTL) CONTROL PANEL HEATER 50WATTS

TH THERMOSTAT FOR HEAT TRACE OPTION

1FU SCD TRANSFORMER PRIMARY FUSES

2FU SCD TRANSFORMER SECONDARY FUSE

6FU INTEGRAL DRYER FUSES

7FU INTEGRAL DRYER FUSES (575V)

SCD SCD DRAIN OPTION


XFMR1 CONTROL TRANSFORMER FOR OPTIONAL SCD DRAIN

PPR POWER PRESENT RELAY OPTION

DF DRYER FAULT

KEY NO. PART NO.

QTY

DESCRIPTION

NOTE


2 REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.

3 1MOL SETTING TO BE 1M FLA. PLUS 2M FLA.




P2 Line Pressure






KEY NO. DESCRIPTION


50

BLANK PAGE

Section 4

51


INSTALLATION4.1 COMPRESSOR MOUNTING -

SUPPORT AND LOCATIONThe compressor must have a stable firm foundation,or mounting structure that is rigid enough to keep thecompressor frame level, and maintain the alignmentof the compressor and motor. Tie-down bolts ofsufficient size must be used to ensure that thecompressor frame is firmly anchored to itsfoundation. Rubber, cork, or other pliable materialscan be inserted between the foundation andcompressor frame to provide a uniform contactsurface.

Use flex connectors to prevent piping loadsfrom being transmitted to the compressor.

National and local electrical codes specify-ing the required clearances for the areaaround the electrical panel must be com-plied with.

Ensure the lighting at the compressorslocation is sufficient for safe operation andmaintenance.

The compressors location should be onethat allows access for maintenance vehi-cles and lifting equipment.

The clearances around the compressorshould permit easy access to all compres-sor components.

Walls and ceilings with soft or porous sur-faces absorb sound and reduce ambientnoise levels. Hard surfaces reflect noiseand have little effect on ambient noise lev-els.

Water-cooled compressors must be locatedwhere a cooling water supply and drainageare available.

4.2 VENTILATION AND COOLING

AIR-COOLED COMPRESSORS Air-cooled compressors require a three foot

(one meter) clearance around their perime-ter.

The location should be free from standingwater.

Clean air should be supplied to the com-pressor, free from exhaust and paintfumes, dust, metal particles, or causticchemical vapors.

Hot exhaust air should be vented out of thearea to prevent its recirculation back intothe compressors cooling system.

Ducting or some other means must beused to ensure that hot exhaust air isvented away from the compressor if thecompressors housing has minimal over-head clearance.

. NOTE

Do not install compressors where the machine will be exposed to temperatures lower than 32F (0C). Contact Sullair Customer Care regarding operation in sub-freezing temperatures.

NOTECompressors operated in environments where ambient temperatures average above 104F (40C) must be equipped with the high-ambient option.

NOTERemove the red shipping straps before operating the drive assembly.


52

WATER-COOLED COMPRESSORS Water-cooled compressors require a cool-

ing water supply delivered at a constantrate and volume. (See Table 4-1:WaterFlow Requirements. The table data appliesto full load operation using an aftercooler.)

Compressor input and return lines must beone inch in diameter minimum, and haveisolation valves with side drains. The inputwater line should have a 2mm strainer

installed in-line. A solenoid valve (normallyclosed), controlled by the compressor con-trol circuit, should be connected to thecompressors water outlet. (Contact SullairCustomer Care for assistance.)

Cooling water quality is a critical factoreffecting proper machine cooling. Exces-sive deposit build-ups, such as lime orscale, restrict the water flow and act asthermal insulators. These deposits canincrease the compressors operating tem-perature by reducing the cooling systemsefficiency.

Regularly inspect and clean all water pipingand coolers.

Table 4-2:Ventilation Requirements speci-fies the minimum ventilation required forcompressor operation at normal tempera-tures. The fan air requirement applies tothe volume of air that must pass though thecompressor to ensure proper ventilation.The heat rejection requirement applies theamount of heat generated by the compres-sor which must be removed to maintain anormal operating temperature.

If the compressor has a water regulatingvalve, it can be used to adjust the compres-sor temperature to maintain a minimum of185F (82.2C); 195F (87.8C) for 24 KTmachines.

Temperature and pressure gauges shouldbe installed for water system troubleshoot-ing.

NOTEThe required flow rate depends upon the cooling waters temperature before it enters the cooling system. The higher the initial temperature, the higher the required flow rate: the lower the initial temperature, the lower the required flow rate.

NOTEThe waste heat from air-cooled com-pressors can be used for local space heating. If it is used for this purpose, the additional static pressure drop across the fan should not exceed 0.2 in. H20. The high static fan option is required if duct-work is added. Contact Sullair Custom Care for additional information.

NOTEHousing the compressor in an inade-quately ventilated enclosure will cause higher compressor operating tempera-tures.

NOTESystems using both reciprocating and rotary screw compressors must isolate the two types from each other through the use of a common receiver tank. Air lines from each individual compressor should be connected directly to the common receiver tank.

Table 4-1: Water Flow Requirements

Water Temp F/C

Water FlowGallons Per Minute /Liters Per Minute (I)

60hp/45kw 75hp/55kw 100hp/75kw

70/21 9.0 / 34.1 10.5 / 39.7 14 / 53.0

80/27 11.2 / 42.4 13 / 49.2 18.8 / 71.2

(I) Water pressure should be maintained between 25 and 75 psig (1.7 and 5.2 bar), but not to exceed 145 psig (10 bar).

NOTEWater pressure should normally range from 25 to 75 psig (1.7 to 5.2 bar), but must not go over 145 psig (10.0 bar).


53

WATER SYSTEM VENTINGVent the system a

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02250176-184r02 Sullair User Manual

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