PART NUMBER:
02250176-180 R05
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions ©
COPYRIGHT 2014 SULLAIR
and procedures in this manual or, The information in this manual is current
as of its publication date, and applies to
misuse of this equipment will compressor serial number:
VOID its warranty!
201403210000
and all subsequent serial numbers.
AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Stationary compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.
Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
training@sullair.com
- Or Write -
Sullair
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
TABLE OF CONTENTS
SECTION 1—SAFETY
5 1.1 GENERAL
5 1.2 PERSONAL PROTECTIVE EQUIPMENT
5 1.3 PRESSURE RELEASE
6 1.4 FIRE AND EXPLOSION
6 1.5 MOVING PARTS
7 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
7 1.7 TOXIC AND IRRITATING SUBSTANCES
8 1.8 ELECTRICAL SHOCK
8 1.9 LIFTING
9 1.10 ENTRAPMENT
9 1.11 SAFETY WARNINGS
SECTION 2—DESCRIPTION
11 2.1 INTRODUCTION
11 2.2 DESCRIPTION OF COMPONENTS
12 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION
13 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION-
AL DESCRIPTION
15 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION
17 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
19 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
19 2.8 INTEGRAL DRYER OPTION
19 2.9 VARIABLE SPEED DRIVE (VSD) COMPONENTS
20 2.10 VSD CONTROL SYSTEM — FUNCTIONAL DESCRIPTION
SECTION 3—SPECIFICATIONS
23 3.1 TABLE OF SPECIFICATIONS
25 3.2 LUBRICATION GUIDE
26 3.3 APPLICATION GUIDE
26 3.4 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTE-
NANCE—FLUID FILTER AND SEPARATOR
28 3.5 AIR-COOLED, IDENTIFICATION 25-30HP
TABLE OF CONTENTS
SECTION 4—INSTALLATION
51 4.1 MOUNTING OF COMPRESSOR
51 4.2 VENTILATION & COOLING
52 4.3 SERVICE AIR PIPING
54 4.4 COUPLING ALIGNMENT CHECK
54 4.5 FLUID LEVEL CHECK
54 4.6 ELECTRICAL PREPARATION
55 4.7 MOTOR ROTATION DIRECTION CHECK
55 4.8 FAN MOTOR ROTATION CHECK
SECTION 6—MAINTENANCE
61 6.1 GENERAL
61 6.2 DAILY OPERATION
61 6.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
61 6.4 MAINTENANCE EVERY 2000 HOURS
62 6.5 FLUID MAINTENANCE
62 6.6 FILTER MAINTENANCE
62 6.7 AIR FILTER MAINTENANCE
63 6.8 SEPARATOR MAINTENANCE
65 6.9 TROUBLESHOOTING—
INTRODUCTION
Section 1
SAFETY
the precautionary statements contained herein are
NOTE applicable to most compressors and the concepts
behind these statements are generally applicable to
all compressors.
5
SECTION 1
inside diameter to reduce pressure in case of accumulate on, under or around acoustical mate-
hose failure. rial, or on any external surfaces of the air com-
pressor. Wipe down using an aqueous industrial
D. Flow-limiting valves are listed by pipe size and
cleaner or steam clean as required. If necessary,
flow-rated. Select appropriate valves accordingly,
remove acoustical material, clean all surfaces
in accordance with their manufacturer's recom-
and then replace acoustical material. Any acous-
mendations.
tical material with a protective covering that has
E. DO NOT use air tools that are rated below the been torn or punctured should be replaced
maximum rating of the compressor. Select air immediately to prevent accumulation of liquids or
tools, air hoses, pipes, valves, filters and other fluid film within the material. DO NOT use flam-
fittings accordingly. DO NOT exceed manufac- mable solvents for cleaning purposes.
turer's rated safe operating pressures for these
D. Disconnect and lock out all power at source prior
items.
to attempting any repairs or cleaning of the com-
F. Secure all hose connections by wire, chain or pressor or of the inside of the enclosure, if any.
other suitable retaining device to prevent tools or
E. Keep electrical wiring, including all terminals and
hose ends from being accidentally disconnected
pressure connectors in good condition. Replace
and expelled.
any wiring that has cracked, cut, abraded or oth-
G. Open fluid filler cap only when compressor is not erwise degraded insulation, or terminals that are
running and is not pressurized. Shut down the worn, discolored or corroded. Keep all terminals
compressor and bleed the receiver tank to zero and pressure connectors clean and tight.
internal pressure before removing the cap.
F. Keep grounded and/or conductive objects such
H. Vent all internal pressure prior to opening any as tools away from exposed live electrical parts
line, fitting, hose, valve, drain plug, connection or such as terminals to avoid arcing which might
other component, such as filters and line oilers, serve as a source of ignition.
and before attempting to refill optional air line
G. Remove any acoustical material or other material
anti-icer systems with antifreeze compound.
that may be damaged by heat or that may sup-
I. Keep personnel out of line with and away from port combustion and is in close proximity, prior to
the discharge opening of hoses or tools or other attempting weld repairs.
points of compressed air discharge.
H. Keep suitable fully charged Class BC or ABC fire
J. DO NOT use air at pressures higher than 2.1 bar extinguisher or extinguishers nearby when ser-
for cleaning purposes, and then only with effec- vicing and operating the compressor.
tive chip guarding and personal protective equip-
I. Keep oily rags, trash, leaves, litter or other com-
ment per OSHA Standard 29 CFR 1910.242 (b)
bustibles out of and away from the compressor.
and/or any applicable Federal, State, and Local
codes, standards and regulations. J. DO NOT operate the compressor without proper
flow of cooling air or water or with inadequate
K. DO NOT engage in horseplay with air hoses as
flow of lubricant or with degraded lubricant.
death or serious injury may result.
K. DO NOT attempt to operate the compressor in
1.4 FIRE AND EXPLOSION any classification of hazardous environment
unless the compressor has been specially
A. Clean up spills of lubricant or other combustible designed and manufactured for that duty.
substances immediately, if such spills occur.
B. Shut off the compressor and allow it to cool. 1.5 MOVING PARTS
Then keep sparks, flames and other sources of
A. Keep hands, arms and other parts of the body
ignition away and DO NOT permit smoking in the
and clothing away from couplings, belts, pulleys,
vicinity when checking or adding lubricant or
fans and other moving parts.
when refilling air line anti-icer systems with anti-
freeze compound. B. DO NOT attempt to operate the compressor with
the fan, coupling or other guards removed.
C. DO NOT permit fluids, including air line anti-icer
system antifreeze compound or fluid film, to
6
SECTION 1
7
SECTION 1
8
SECTION 1
9
SECTION 1
WARNING CAUTION
Before opening the variable speed drive covers:
Make sure that no power correction capacitors
• Disconnect all power to the variable speed drive.
are connected to the variable speed drive out-
• Wait a minimum of 5 (five) minutes after all the
put or the motor terminals to prevent variable
lights on the keypad are off. This allows time for
speed drive malfunction and potential damage.
the DC bus capacitors to discharge.
• A hazard voltage may still remain in the DC bus
capacitors even if the power has been turned off.
Confirm that the capacitors have fully discharged
by measuring their voltage using a multimeter set
CAUTION
to measure DC voltage. Failure to follow the above
Make sure that the variable speed drive output
precautions may cause death or severe injury.
terminals (U, V, W) are not connected to the
utility line power as severe damage to the VSD
may occur.
CAUTION
Do not perform any meggar or voltage withstand
tests on any part of the variable speed drive or its
NOTE
components. Improper testing may result in
Interior electrical wiring is performed at the
damage. Prior to any tests or measurements of
factory. Required customer wiring is minimal,
the motor or the motor cable, disconnect the
but should be done by a qualified electrician
motor cable at the variable speed drive output
in compliance with OSHA, National Electrical
terminals (U, VW) to avoid damaging the variable
Code, and/or any other applicable State,
speed drive during motor or cable testing.
Federal, and local electrical codes concern-
ing isolation switches, fused disconnects,
etc. Sullair provides a wiring diagram for use
CAUTION by the installer.
CAUTION
Install the variable speed drive in a well venti-
lated room that is not subject to temperature
extremes, high humidity, or condensation, and
avoid locations that are directly exposed to
sunlight, or have high concentrations of dust,
corrosive gas, explosive gas, inflammable gas,
grinding fluid mist, etc. Improper installation
may result in a fire hazard.
10
1800-3000 USER MANUAL
Section 2
DESCRIPTION
2.1 INTRODUCTION 2.2 DESCRIPTION OF
COMPONENTS
Your new Sullair flood-lubricated rotary screw air
compressor will provide you with a unique Refer to Figure 2-1. The components and
experience in improved reliability and simplified assemblies of the air compressor are clearly shown.
maintenance. The complete package includes compressor, electric
motor, starter, compressor inlet system, compressor
Compared to other types of compressors, the Sullair
discharge system, compressor lubrication and
rotary screw is unique in mechanical reliability, with
cooling system, capacity control system, WS
“no wear” and “no inspection” required of the working
Controller, aftercooler, a combination separator and
parts within the compressor unit.
trap, all mounted on a heavy gauge steel frame.
Read Section 6: Maintenance on page 61 to see how
On air-cooled models, a fan draws air into the
surprisingly easy it is to keep your air compressor in
enclosure over the fan and main motors through the
top operating condition.
combined aftercooler and fluid cooler thereby
removing the compression heat from the
compressed air and the cooling fluid, and forces it
out the top of the machine.
This compressor model has easily accessible items
such as the fluid filter air/oil separator and control
valves. The inlet air filter is also easily accessible for
servicing.
11
1800-3000 USER MANUAL SECTION 2
12
SECTION 2 1800-3000 USER MANUAL
The 1800, 2200 & 3000 Series compressors are from the air. At this time, the air flows
factory-filled with Sullube lubricant. For more through an aftercooler and separator then to
information on fluid fill, refer to Section 3: Lubrication your service line while the fluid is being
Change Recommendations and Maintenance—Fluid cooled in preparation for reinjection.
Filter and Separator on page 26.
Sullair 24KT compressors are filled with a fluid that 2.4 COMPRESSOR COOLING
rarely needs to be changed. Use only Sullair 24KT AND LUBRICATION
fluid in the event that a fluid change is required. SYSTEM, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-2. The Cooling and Lubrication
CAUTION System consists of a fan, fan motor, radiator-type
aftercooler/fluid cooler, full flow fluid filter, thermal
Mixing of other lubricants within the com- valve, and interconnecting hoses. The pressure in
pressor unit will void all warranties. the separator/sump tank causes fluid flow by forcing
the fluid from the high pressure area of the separator/
sump tank to an area of lower pressure in the
Sullair recommends that a 24KT sample be taken at compressor unit.
the first filter change and sent to the factory for
analysis. This is a free service. The sample kit with Fluid flows from the bottom of the separator/sump
instructions and self addressed container is to be tank to the thermal valve. The thermal valve is fully
supplied by your Sullair dealer at start-up. The user open when the fluid temperature is below 185˚F
will receive an analysis report with (85˚C) [200˚F (93˚C) for 24KT] and pressures are
recommendations. rated above 150 psig. The fluid passes through the
thermal valve, the main filter and directly to the
Fluid is injected into the compressor unit hoses and compressor unit where it lubricates, cools and seals
mixes directly with the air as the rotors turn, the rotors and the compression chamber.
compressing the air. The fluid flow has three basic
functions: As the discharge temperature rises above 185˚F
(85˚C), due to the heat of compression, the thermal
1. As coolant, it controls the rise of air tempera- valve begins to adjust and a portion of the fluid then
ture normally associated with the heat of flows through the cooler. From the cooler the fluid
compression. flows to the fluid filter and then on to the compressor
2. Seals the clearance paths between the unit.
rotors and the stator and also between the A portion of the fluid flowing to the compressor is
rotors themselves. routed to the anti-friction bearings which support the
3. Acts as a lubricating film between the rotors rotors inside the compressor unit.
allowing one rotor to directly drive the other, The fluid filter has a replacement element and an
which is an idler, and also lubricates the integral pressure bypass valve. A message on the
bearings. WS Controller indicates when the fluid filter needs to
be changed.
After the air/fluid mixture is discharged from
the compressor unit, the fluid is separated
13
1800-3000 USER MANUAL SECTION 2
14
SECTION 2 1800-3000 USER MANUAL
15
1800-3000 USER MANUAL SECTION 2
16
SECTION 2 1800-3000 USER MANUAL
Refer to Figure 2-4. The purpose of the compressor When the compressor “ ” (START) pad is
control system is to regulate the amount of air being depressed, the separator/sump tank pressure will
compressed to match the amount of compressed air quickly rise from 0 to 50 psig (0 - 3.4 bar). The
being used. The capacity control system consists of compressor initially starts unloaded with the solenoid
a solenoid valve, regulator valve and an inlet valve. valve open and the inlet valve closed. It then
The functional description of the control system is switches to full load when full rpm has been
described below in four distinct phases of operation. achieved. During this period, both the pressure
For explanatory purposes, this description will apply regulator and the solenoid valve are closed, the inlet
to a compressor with an operating range of 100 to valve is fully open and the compressor pumps are at
110 psig (6.9 to 7.6 bar). A compressor with any full rated capacity. The rising compressor air
other pressure range would operate in the same pressure is isolated from the service line in this
manner except stated pressures. phase by the minimum pressure valve set at
approximately 50 psig (3.4 bar).
17
1800-3000 USER MANUAL SECTION 2
Full Load Mode check valve in the air service line prevents line
—50 to 100 PSIG (3.4 to 6.9 BAR) pressure from returning to the separator/sump tank.
When the compressed air pressure rises above 50 When the line pressure drops to the low setting (cut-
psig (3.4 bar), the minimum pressure valve opens in pressure; usually 100 psig (6.9 bar) on low
allowing compressed air to flow into the service line. pressure (7 bar) compressors and 125 psig (8.6 bar)
From this point on, the line air pressure is continually on high pressure (9 bar) compressors, 150 psig (10.3
monitored by the WS Controller. The pressure bar) on (10 bar) compressors, 175 psig (12.0 bar) on
regulator and the solenoid valve remain closed (12 bar) compressors), the WS Controller energizes
during this phase. The inlet valve is in the fully open the solenoid valve and allows the blowdown valve to
position as long as the compressor is running at 100 close. The re-energized solenoid valve again
psig (6.9 bar) or below. prevents line pressure from reaching the inlet control
valve. Should the pressure begin to rise, the
Modulating Mode
pressure regulator will resume its normal function as
—100 to 110 PSIG (6.9 to 7.6 BAR)
previously described.
If less than the rated capacity of compressed air is
Load/No Load Control
being used, the service line pressure will rise above
100 psig (6.9 bar). The pressure regulator valve If desired by the customer, the compressor can be
gradually opens, directing air pressure to the inlet set to operate load/no load without modulating
control valve, reducing air entering the compressor control. This control mode is often selected when a
until it matches the amount of air being used. The large amount of compressed air storage (air tank) is
control system functions continually in this manner available. Using the WS Controller keypad, select
between the limits of 100 to 110 psig (6.9 to 7.6 bar) “load/no load control” from the menu. On a machine
in response to varying demands from the service rated for 100 psig (7 bar) the compressor will run in
line. the full load mode up to 100 psig (7 bar). If less than
the rated capacity is required, pressure will rise
The integrated inlet valve has an orifice which vents
above 100 psig and the WS Controller will de-
a small amount of air to the compressor inlet when
energize the solenoid valve, causing the compressor
the pressure regulator controls the inlet control valve.
to run in the unload mode. When the system
The orifice also bleeds any accumulated moisture
pressure falls to 90 psig (6.3 bar), the WS Controller
from the control lines.
energizes the solenoid valve, causing the
Unload Mode compressor to return to the full load mode. The
—In Excess of 110 PSIG (7.6 BAR) compressor will thus operate to keep the system
pressure in the range of 90 to 100 psig (6.3 to 6.9
When a relatively small amount or no air is being
bar).
used, the service line pressure continues to rise.
When it exceeds 110 psig (7.6 bar), the WS Automatic Operation
Controller control system de-energizes the solenoid
For applications with varied periods of time when
valve allowing separator/sump tank air pressure to
there are no air requirements, the WS Controller's
be supplied directly to close the inlet valve.
AUTOMATIC mode allows the compressor to
Simultaneously, the solenoid valve sends a
shutdown (time delayed) when no compressed air
pneumatic signal to the blowdown valve. The
requirement is present and restart as compressed air
blowdown valve opens to the atmosphere, located in
is needed.
the compressor intake, reducing the separator/sump
tank pressure to approximately 17 psig (1.2 bar). The
18
SECTION 2 1800-3000 USER MANUAL
19
1800-3000 USER MANUAL SECTION 2
START MODE - 0 TO 50 PSIG (0 TO 3.5 BAR) UNLOAD MODE- IN EXCESS OF 106 PSIG (7.3
BAR)
Pressing the WS Controller START button (1) signals
the VSD to accelerate the motor to full speed, When there is no demand or it is at a minimal level,
causing the separator/sump tank pressure to rise the service line pressure continues to rise. When it
from 0 to 50 psig (0 to 3.4 bar). At this time both the exceeds 106 psig (7.3 bar), or reaches a preset
pressure regulator and solenoid valves are closed; unload pressure value, the WS control system de-
the inlet valve is fully open and the air-end provides a energizes the solenoid valve allowing separator/
full flow to the separator/sump tank. A minimum sump tank air pressure to be supplied directly which
pressure valve set at approximately 50 psig (3.4 bar) closes the inlet valve. The solenoid valve
isolates the rising compressor air pressure from the simultaneously sends a pneumatic signal to the blow
service line. down valve which opens to the atmosphere, and
reduces the separator/sump tank pressure. The
FULL LOAD MODE - 50 TO 100 PSIG (3.4 TO check valve in the air service line prevents line
6.9 BAR) pressure from back-flowing to the separator/sump
tank. The compressor will shut down after the
When the compressed air pressure rises above 50 programmed unload time setting expires (the default
psig (3.4 bar) the minimum pressure valve opens setting is zero [0] minutes for an immediate shutdown
allowing compressed air to flow into to the service upon unload). When the line pressure drops to the
line. From this point on the WS Controller monitors low pressure setting of 100 psig (6.9 bar) the WS
the line pressure which controls the VSD. The Controller starts the motor and energizes the
pressure regulator and solenoid valves remain solenoid valve which closes the blowdown valve. The
closed with the inlet valve fully open, running at 100 re-energized solenoid valve prevents line pressure
psig (6.9 bar) or lower. from reaching the inlet control valve, thereby allowing
it to fully open, and the compressor supplies
compressed air to the system.
20
SECTION 2 1800-3000 USER MANUAL
21
1800-3000 USER MANUAL SECTION 2
22
1800-3000 USER MANUAL
Section 3
SPECIFICATIONS
3.1 TABLE OF SPECIFICATIONS
DIMENSIONS
Length Width Height Weight
MODEL HP in mm in mm in mm lbs kg
1800 Series
1807 25 53.2 1351 31.5 800 53.2 1351 1420 644
1809 25 53.2 1351 31.5 800 53.2 1351 1420 644
1810 25 53.2 1351 31.5 800 53.2 1351 1420 644
1812 25 53.2 1351 31.5 800 53.2 1351 1420 644
2200 Series
2207 30 53.2 1351 31.5 800 53.2 1351 1450 658
2209 30 53.2 1351 31.5 800 53.2 1351 1450 658
2210 30 53.2 1351 31.5 800 53.2 1351 1450 658
2212 30 53.2 1351 31.5 800 53.2 1351 1450 658
3000 Series
3009 40 53.2 1351 31.5 800 53.2 1351 1613 732
3010 40 53.2 1351 31.5 800 53.2 1351 1613 732
3012 40 53.2 1351 31.5 800 53.2 1351 1613 732
DIMENSIONS
Length Width Height Weight
MODEL HP in mm in mm in mm lbs kg
1800 Series with Integral Dryer
1807 25 63.1 1603 31.5 800 53.2 1351 1621 735
1809 25 63.1 1603 31.5 800 53.2 1351 1621 735
1810 25 63.1 1603 31.5 800 53.2 1351 1621 735
1812 25 63.1 1603 31.5 800 53.2 1351 1621 735
2200 Series with Integral Dryer
2207 30 63.1 1603 31.5 800 53.2 1351 1651 749
2209 30 63.1 1603 31.5 800 53.2 1351 1651 749
2210 30 63.1 1603 31.5 800 53.2 1351 1651 749
2212 30 63.1 1603 31.5 800 53.2 1351 1651 749
3000 Series with Integral Dryer
3009 40 53.2 1351 31.5 800 53.2 1351 1814 823
3010 40 53.2 1351 31.5 800 53.2 1351 1814 823
3012 40 53.2 1351 31.5 800 53.2 1351 1814 823
23
1800-3000 USER MANUAL SECTION 3
Standard Speed Operating Pressure (II): 100 psi (7 bar) 125 psig (9 bar) 150 psig (10 bar) 175
psig (12 bar)
Control: WS Controller
Options Available: 200V and 575V 60 Hz, 220 50 Hz TEFC also available:
CE Approved
Speed—25, 30 HP: 1765 RPM (60 Hz) or 1475 RPM (50 Hz)
(IV) Multi-frequency and voltage motors are used. The compressors msust be used only with the specified
electrical frequency and voltage.
NOTE
For latest sound test data, consult Sullair
factory.
24
SECTION 3 1800-3000 USER MANUAL
WARNING 3
"The Plastic Pipe Institute recommends
against the use of thermoplastic pipe to
transport compressed air or other com- 2
pressed gases in exposed above ground
locations, e.g. in exposed plant piping." (I)
1
Sullube should not be used with PVC piping
systems. It may affect the bond at
cemented joints. Certain other plastic mate-
rials may also be affected. (I) Plastic Pipe
Institute, Recommendation B, Adopted Jan-
uary 19, 1972.
SU_0000062
25
1800-3000 USER MANUAL SECTION 3
26
NOTES
27
3.5 AIR-COOLED, IDENTIFICATION 25-30HP
28
SECTION 3
Main Motor HP Motor Type Weight CFM Cooling Air
SECTION 3
Main Motor HP Motor Type Weight CFM Cooling Air
SECTION 3
Main Motor HP Motor Type Weight CFM Cooling Air
SECTION 3
Main Motor HP Motor Type Weight CFM Cooling Air
SECTION 3
Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250125-369 1 FILTER, AIR 8”(PLASTIC) W/MTG BAND 26 02250125-774 1 ORIFICE,PLUG BRASS 1/8NPT X 1/32”
2 - 1 VALVE, GROUP INLET DXX102E 27 02250118-586 1 ORF, .078” .25FNPT X.25MNPT
3 MTR_VAR 1 MOTOR 28 02250078-249 1 SW,VAC 22”WC N4 6FT CABLE 5A
4 - 1 COMPRESSOR 29 02250050-154 1 SW,DIFF PRESS 20 PSID
5 02250155-599 1 TANK, SEP 2200 30 02250144-841 1 VLV,BALL/STNR COMB 1/2M X 1/2M
6 02250160-773 1 ELEM,OIL SEP 1800/2200 30 02250182-548 1 VLV,BALL/STNR COMBO-1/2”NPT
7 02250097-609 1 VALVE, 1-5/8 SAE MIN PRESS CHK 31 02250182-545 1 DRN,ZERO LOSS 115V 1/2”NPT
8 02250156-137 1 COOLER, AIR/OIL 2200 32 02250168-837 1 VENT,ENCL PROT 1/2” TOP
9 02250167-115 1 SEP,WTR SCWS-235N 1” L/AD 33 02250169-612 1 GA,DIFF PRESS Z-PRG ASY BTM
10 02250155-708 1 FLTR,CORELESS M27 6”L W/ BYPASS 34 241771 1 STRAINER, V-TYPE 300PSIX1/4
11 02250092-081 1 VLV,THERMAL 195 DEG PLEASE NOTE: WHEN ORDERING PARTS,
11 02250148-796 1 VLV,THERMAL 210 DEG INDICATE SERIAL NUMBER OF COMPRESSOR
SECTION 3
N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 02250125-369 1 FILTER, AIR 8”(PLASTIC) W/MTG BAND 30 02250168-837 1
VENT,ENCL PROT 1/2” TOP
2 - 1 VALVE, GROUP INLET DXX102E 31 02250169-612 1
GA,DIFF PRESS Z-PRG ASY BTM
3 MTR_VAR 1 MOTOR 32 - 1
INTEGRAL REFRIGERANT DRYER
4 - 1 COMPRESSOR 33 049905 2
CHECK VALVE
5 02250155-599 1 TANK, SEP 2200 34 02250175-087 1
PROBE,THERMISTER 3000 OHM NTC
6 02250160-773 1 ELEM,OIL SEP 1800/2200 12’L
7 02250097-609 1 VALVE, 1-5/8 SAE MIN PRESS CHK 35 02250173-972 1 FLTR,PNEUMATIC 1/8”NPT 5MICRON
8 02250156-137 1 COOLER, AIR/OIL 2200 1. PART NUMBERS ARE FOR REFERENCE ONLY. REFER TO BILL OF
9 02250167-115 1 SEP,WTR SCWS-235N 1” L/AD MATERIAL AND OR FACE OF ORDER FOR ACTUAL PARTS.
10 02250155-708 1 FLTR,CORELESS M27 6”L W/BYPASS 2. SECTION BETWEEN LETTERED POINTS ARE TO BE REPLACED
WITH CORRESPONDING OPTION PICTURED BELOW, AS
11 02250148-796 1 VLV,THERMAL 210 DEG.
REQUIRED BY FACE OF ORDER.
11 02250092-081 1 VLV,THERMAL 195 DEG.
3, CONTROL/MOISTURE DRAIN LINES ARE 1/4" TUBING EXCEPT AS
12 02250155-174 2 XDCR,PRESS 0-250PSI 1-5VDC N4 NOTED.
13 250006-938 1 VALVE, RELIEF 1/2” 200# 4. OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND
14 02250155-175 1 PROBE,THERMISTER 3000 OHM NTC 6’L MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS
15 02250049-634 1 VLV,BLWDN 1/4 NPT HI PRS STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE
16 241771 1 STRAINER, V TYPE 1/4” REQUIREMENTS.
17 02250155-714 2 VALVE,SOL 3WNO 1/4 235# N4 5. PART VARIES BY MODEL.
18 250017-280 1 VALVE, PRESSURE REGULATOR PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
19 408893 1 VALVE, SHUTTLE 1/4” (DBL CHK)
20 250003-869 1 INDICATOR, RESTRICTION 20”H20
21 02250115-272 1 VLV,CHK 1/4”-NPT COMPONENT DESCRIPTION
SECTION 3
COMP DESCRIPTION COMP DESCRIPTION
1MOL COMPRESSOR OVERLOAD 2FU JZL TRANSFORMER SECONDARY FUSE
1M COMPRESSOR STARTER 3FU FAN MOTOR BRANCH FUSES
2MOL FAN MOTOR OVERLOAD JZL JZL DRAIN OPTION
P1 WET SUMP PRESSURE SENSOR PPR POWER PRESENT RELAY OPTION
P2 PACKAGE DISCHARGE PRESSURE SENSOR
T1 UNIT DISCHAGE TEMPERATURE PROBE NOTES
PSW1 (OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC 1 CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DIS-
DPSW1 (OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID CONNECT PER LOCAL CODES.
SECTION 3
COMP DESCRIPTION COMP DESCRIPTION
1MOL COMPRESSOR OVERLOAD 3FU FAN MOTOR BRANCH FUSES
1M COMPRESSOR STARTER 6FU INTEGRAL DRYER SECONDARY FUSE
2MOL FAN MOTOR OVERLOAD 7FU INTEGRAL DRYER PRIMARY FUSES
P1 WET SUMP PRESSURE SENSOR PPR POWER PRESENT RELAY OPTION
P2 PACKAGE DISCHARGE PRESSURE SENSOR DF DRYER FAULT
T1 UNIT DISCHARGE TEMPERATURE PROBE DR DRYER START RELAY
T3 DRYER DEWPOINT TEMPERATURE PROBE
PSW1 (OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC NOTES
DPSW1 (OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID 1 CUSTOMER TO FURNISH FUSED OR CIRCUIT
INPUT 7 REMOTE RUN/UNLOAD BREAKER DISCONNECT PER LOCAL CODES.
INPUT 8 CUSTOMER FURNISHED FAULT 2 REMOVE JUMPER FOR AUXILLIARY E-STOP STRING
INPUT 9 CUSTOMER FURNISHED WARNING DEVICES.
SOL1 LOAD CONTROL SOLENOID VALVE 3 1MOL SETTING TO BE 1M FLA. PLUS 2M FLA.
SOL4 SEQUENCEING SOLENOID VALVE 4 USE ISOLATING RELAYS WITH DRY CONTACTS FOR
SOL5 ELECTRIC CONDENSATE DRAIN VALVE ANY OPTIONAL INPUTS TO THE WS CONTROLLER.
MOUNT THE RELAY LOCALLY IN THE STARTER BOX.
PS 24VDC POWER SUPPLY
PLEASE NOTE: WHEN ORDERING PARTS,
K1 INTERNAL RUN RELAY CONTACT INDICATE SERIAL NUMBER OF COMPRESSOR
K2 INTERNAL Y-DELTA START RELAY
K3 INTERNAL WYE-DELTA RUN RELAY
K4 INTERNAL LOAD CONTROL RELAY
K5 INTERNAL SEQUENCE RELAY
DISPLAY YELLOW
YELLOW GREEN
OPTIONAL BROWN
GREEN PINK
BROWN GRAY
WHITE
PINK
GRAY ETHERNET
WHITE
SEE CONNECTION TABLE
FOR PROPER VOLTAGE
CONNECTION
GREEN
COLD WEATHER OPTIONS BROWN
PINK
GRAY
WHITE
BROWN
GREEN
WHITE
GRAY
TO MATCH TERMINALS ON NEXT COMPRESSOR
PINK
TO CUSTOMER
SPEED DRIVE
GROUND
I/O
SHIELD
VARIABLE
120VAC SUPPLY
SULLAIR
MODULE 1M PARALLEL WYE
NOTE: CONNECTION
PROVIDE GROUND FAULT
PROTECTION ON SUPPLY OF
HEATING DEVICES PER NEC 427-22.
DC LINK REACTOR
EES OPTON
TERMINAL BLOCK
LINE VOLTAGE
SECTION 3
50/60 Hz
OPTIONAL POWER
PRESENT RELAY
02250207-214 R00
3.13 WIRING DIAGRAM—VSD, PARALLEL WYE SVX9000
SECTION 3
COMP DESCRIPTION COMP DESCRIPTION
1M COMPRESSOR MOTOR NOTES:
2M COOLER FAN MOTOR STARTER DELTA 1 CUSTOMER TO FURNISH FUSED
2MOL FAN MOTOR OVERLOAD OR CIRCUIT BREAKER DISCONNECT
1FU FAN MOTOR BRANCH CIRCUIT FUSES PER LOCAL CODES.
2FU JZL TRANSFORMER PRIMARY FUSES DELTA 2 REMOVE JUMPER FOR
3FU JZL TRANSFORMER SCONDARY FUSE AUXILLIARY E-STOP
P1 WET SUMP PRESSURE SENSOR STRING DEVICES.
P2 PACKAGE DISCHARGE PRESSURE SENSOR DELTA 3 USE ISOLATING RELAYS WITH DRY
T1 UNIT DISCHAGE TEMPERATURE PROBE CONTACTS FOR ANY OPTIONAL
PSW1 (OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC INPUTS TO THE WS CONTROLLER.
DPSW1 (OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID MOUNT THE RELAY LOCALLY IN
INPUT 7 REMOTE RUN/UNLOAD THE STARTER BOX.
INPUT 8 CUSTOMER FURNISHED FAULT DELTA 4 SHORTEN BAR IS STANDARD.
INPUT 9 CUSTOMER FURNISHED WARNING REMOVE IF ADDING EXTERNAL
SOL1 LOAD CONTROL SOLENOID VALVE DC LINK REACTOR
SOL4 SEQUENCEING SOLENOID VALVE
SOL5 ELECTRIC CONDENSATE DRAIN VALVE
PS 24VDC POWER SUPPLY
K1 INTERNAL FAN RELAY CONTACT TEMP (T1) CONTROLLED
K2 INTERNAL Y-DELTA START RELAY COMPRESSOR RUNNING
K3 INTERNAL WYE-DELTA RUN RELAY COMPRESSOR ENABLED
K4 INTERNAL LOAD CONTROL RELAY
K5 INTERNAL SEQUENCE RELAY
K6 INTERNAL ELECTRIC DRAIN RELAY
K7 INTERNAL COMMON FAULT RELAY
PMR OPT’L POWER MONITOR RELAY
HTR1 (OPT’L) SUMP HEATER 800W
SECTION 3
COMP DESCRIPTION NOTES:
1M COMPRESSOR MOTOR 1. CUSTOMER TO FURNISH FUSEDOR CIRCUIT BREAKER DIS-
2M COOLER FAN MOTOR STARTER CONNECT PER LOCAL CODES.
2MOL FAN MOTOR OVERLOAD
1FU FAN MOTOR BRANCH CIRCUIT FUSES 2. REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.
2FU SCD TRANSFORMER PRIMARY FUSES 3. USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY
3FU SCD TRANSFORMER SCONDARY FUSE OPTIONAL INPUTS TO THE WS CONTROLLER.
P1 WET SUMP PRESSURE SENSOR
4. MOUNT THE RELAY LOCALLY IN THE STARTER BOX.
P2 PACKAGE DISCHARGE PRESSURE SENSOR
T1 UNIT DISCHAGE TEMPERATURE PROBE 5. SHORTEN BAR IS STANDARD.
PSW1 (OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC 6. REMOVE IF ADDING EXTERNAL DC LINK REACTOR.
DPSW1 (OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID
7. JZL DRAIN OPTION AVAILABLE (FOR P12 ONLY)
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 FAN RELAY CONTACT TEMP (T1) CONTROLLED
K2 INTERNAL Y-DELTA START RELAY COMPRESSOR RUNNING
INTERNAL WYE-DELTA RUN RELAY COMPRESSOR
K3 ENABLED
K4 INTERNAL LOAD CONTROL RELAY
K5 INTERNAL SEQUENCE RELAY
K6 INTERNAL ELECTRIC DRAIN RELAY
K7 INTERNAL COMMON FAULT RELAY
PMR OPT’L POWER MONITOR RELAY
SECTION 3
COMP DESCRIPTION COMP DESCRIPTION
1MOL COMPRESSOR OVERLOAD TH THERMOSTAT FOR HEAT TRACE OPTION
1M COMPRESSOR STARTER CB1 (OPT’L) TRANSFORMER PRIMARY CIRCUIT BREAKER
2M WYE-DELTA RUN CONTRACTOR CB2 (OPT’L) TRANSFORMER SECONDARY CIRCUIT BREAKER
S WYE-DELTA START CONTRACTOR SCD (OPT'L) SCD DRAIN
3MOL FAN MOTOR OVERLOAD XFMR1 CONTROL TRANSFORMER FOR OPTIONAL SCD DRAIN
4M CONTRACTOR FOR POWER FACTOR CAPACITOR OPT.
P1 WET SUMP PRESSURE SENSOR N
Q
KEY O
P2 PACKAGE DISCHARGE PRESSURE SENSOR PART NO. T DESCRIPTION
NO. T
T1 UNIT DISCHAGE TEMPERATURE PROBE Y
E
PSW1 (OPT’L)INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC 1. CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER
DPSW1 (OPT’L)OIL FILTER DIFF PRESS SWITCH 20PSID DISCONNECT PER LOCAL CODES.
INPUT 7 REMOTE RUN/UNLOAD 2. REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.
INPUT 8 CUSTOMER FURNISHED FAULT 3. 1MOL RELAY SET AT 58% OF 1M FULL LOAD PLUS 3M FULL LOAD.
INPUT 9 CUSTOMER FURNISHED WARNING 4. USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY OPTIONAL
INPUTS TO THE WS CONTROLLER. MOUNT THE RELAY LOCALLY IN
SOL1 LOAD CONTROL SOLENOID VALVE
THE STARTER BOX.
SOL4 SEQUENCEING SOLENOID VALVE
PLEASE NOTE: WHEN ORDERING PARTS,
SOL5 ELECTRIC CONDENSATE DRAIN VALVE INDICATE SERIAL NUMBER OF COMPRESSOR
PS 24VDC POWER SUPPLY
K1 INTERNAL RUN RELAY CONTACT
K2 INTERNAL Y-DELTA START RELAY
K3 INTERNAL WYE-DELTA RUN RELAY
50
1800-3000 USER MANUAL
Section 4
INSTALLATION
4.1 MOUNTING OF 4.2 VENTILATION & COOLING
COMPRESSOR
Air-Cooled Compressors
A suitable foundation or fabricated support must be
• An area with adequate space must be pro-
established to support the compressor. It should be
vided for the compressor and its compo-
rigid enough to keep the compressor frame level and
nents. Air-cooled compressors require a
maintain alignment of the compressor and motor.
minimum of 4 feet (1.25 meter) around the
Tie-down bolts of sufficient size must be used to
perimeter of the compressor.
provide uniform contact between the foundation and
the compressor frame. Materials such as rubber or • The location should be free from standing
cork can be used to provide uniform contact between water and allow access to clean air that is
the foundation and compressor frame. free from exhaust and paint fumes, dust,
metal filings or caustic chemicals.
• Piping loads must be eliminated through
• Cooling air should be removed from the
the use of flex connectors or other systems
area in order to prevent the re-introduction
which prevent piping loads from being
of heated exhaust air back into the com-
transmitted to the compressor.
pressor’s cooling system.
• Special consideration should be made to
• Reduced headroom above the compressor
meet national and local electrical codes for
will require that cooling air be either ducted or
the required space around and in front of
in some way deflected away from the com-
the electrical panel. Lighting should be pro-
pressor. Inadequate ventilation will result in
vided for future service requirements.
higher ambient operating temperatures.
• Accessibility for fork lift trucks, overhead
• If discharge/inlet ductwork is added to the
cranes and maintenance vehicles should
compressor package, then remove the lou-
be given careful consideration in order to
vers from the compressor package.
provide any maintenance that may be
required. Adequate space around the unit
should be provided for access to all com- NOTE
ponents of the compressor.
• Softer surfaces in walls or ceilings will Systems that employ both a conventional
absorb sound and minimize ambient noise reciprocating compressor and a screw-
levels. Harder, reflective surfaces will type axial compressor must be isolated
increase ambient noise levels. from each other by use of a common
receiver tank. Individual airlines from
each compressor should be piped to the
NOTE common receiver tank.
51
1800-3000 USER MANUAL SECTION 4
52
SECTION 4 1800-3000 USER MANUAL
53
1800-3000 USER MANUAL SECTION 4
54
SECTION 4 1800-3000 USER MANUAL
55
1800-3000 USER MANUAL SECTION 4
56
1800-3000 USER MANUAL
Section 5
WS CONTROLLER
1. ON 6. Maintenance Indicator
2. OFF 7. Fault Indicator
3. LCD Display 8. Up Key
4. Power Indicator 9. Down Key
5. Run Mode Indicator 10. Enter Key
57
1800-3000 USER MANUAL SECTION 5
5.2 LCD DISPLAY Refer to Figure 5-6. Press the DOWN arrow " " to
display additional information about the compressor.
The display's normal view shows the compressor The upper line will indicate "Compressor Status" and
package's discharge pressure, internal temperature, the name of the temperature, pressure, or other
and the operating mode. The modes are MANUAL, measurement. The lower line indicates the present
OFF, AUTOMATIC, or FAULTED. reading.
SA_0000005R01 SA_0000003R01
Refer to Figure 5-2 and Figure 5-3. The lower line is Refer to Figure 5-7. When you continue beyond the
occasionally interrupted to describe the compressor status information, the display will show a list of
package's operating state. control settings. The upper line will indicate "Show
Setting" and the name of the setting. The lower line
shows the present value.
SA_0000004R01
Refer to Figure 5-4. If a machine fault occurs, the red Figure 5-7:
fault " " indicator will light up, and the display will
indicate that a fault has occurred. Refer to Figure 5-8. To change the setting, press the
ENTER pad " ". The display indicates that you are
in a change mode with reverse characters. Use the
UP " " or DOWN " " arrow keys to change the
setting, and press ENTER again to save the new
setting.
SA_0000001R01
Figure 5-4:
58
SECTION 5 1800-3000 USER MANUAL
the normal view. The green RUN mode indicator " " indicates
The list of displays may be navigated from either compressor operation is enabled. It lights steadily if
direction by using the UP " " or DOWN " " the motor is running. If the motor stops while in
arrow keys. For example, to change language from Automatic mode, this LED will blink to indicate that
normal view, press the Up arrow pad once, press the the motor may restart.
Enter key " ", select your language, and press
The yellow Maintenance indicator " " comes on
ENTER again. The number of displays varies with
whenever there is recommended maintenance or a
compressor model, but will follow this pattern.
warning. The text display will periodically indicate the
The large Emergency Stop button located near the recommended actions or the cause of the warning.
controller overrides all electronic functions to turn off
the control devices. The controller senses this, and The red FAULT indicator " " indicates that a
will display E-stop. To reset, twist and pull out the compressor FAULT has occurred and needs to be
Emergency STOP button, then press the STOP pad repaired before further operation. The text display
to reset the WS Controller. will indicate the cause of the fault.
The PC support program for the WS controller
5.3 LED LIGHTS provides additional information about compressor
operation and advanced setup adjustments to
The four LED lights indicate the general condition of optimize operation.
the machine.
Software part numbers are shown in the display
The green POWER indicator " " simply indicates following a power interruption or other interruption of
that power is applied to the controller. It will blink very communication with the controller. The P/N remains
slowly if the WS Controller is set up to automatically on the display until satisfactory communications are
restart after power failure. established with the Input/Output module.
59
NOTES
60
1800-3000 USER MANUAL
Section 6
MAINTENANCE
6.1 GENERAL
WARNING
WARNING HIGH-PRESSURE HAZARD!
• DO NOT remove caps, plugs, and/or other
Before any repairs are attempted, refer to components when compressor is running
Section 1: Safety before proceeding. or pressurized. Stop compressor and relieve
all internal pressure before doing so.
As you proceed in reading this section, it will be easy • Failure to comply could result in death or
to see that the Maintenance Program for the air serious injury.
compressor is quite simple. The use of the service
indicators provided for the fluid filter, air filter and
After a routine start has been made, observe the
fluid separator will alert you when service
controller display and be sure it monitors the correct
maintenance is required. When the WS Controller
readings for their particular phase of operation. After
display indicates service, maintenance for that
the compressor has warmed up, it is recommended
specific item is required. Refer to Filter Maintenance
that a general check on the overall compressor be
on page 62.
made to assure that the compressor is running
properly.
6.2 DAILY OPERATION
Prior to starting the compressor, it is necessary to 6.3 MAINTENANCE AFTER
check the fluid level in the separator/sump tank. INITIAL 50 HOURS OF
Should the level be low, simply add the necessary OPERATION
amount. If the addition of fluid becomes too frequent,
After the initial 50 hours of operation, a few
a simple problem has developed which is causing
maintenance requirements are needed to clean the
this excessive loss. See the Section 6.9:
system of any foreign materials. Perform the
Troubleshooting— Introduction on page 65 under
following maintenance operations to prevent
EXCESSIVE COMPRESSOR FLUID
unnecessary problems.
CONSUMPTION for a probable cause and remedy.
1. Clean the return line strainer. Refer to Com-
pressor Discharge System, Functional
Description on page 15 for location.
WARNING
2. Clean the return line orifice.
61
1800-3000 USER MANUAL SECTION 6
SU_0000071
Figure 6-1: Fluid Filter Assembly
1. Filter Head
4
2. Element* 3
3. Body
2
* Fluid Filter Replacement Kit—P/N
1 SU_0000072
02250155-709
62
SECTION 6 1800-3000 USER MANUAL
Air Filter Element Replacement 7. Replace the cover plate, washers and cap
screws. Torque to 70 ft·lbs (95 N·m).
1. Clean exterior of air filter housing.
8. Clean the return line strainer before restart-
2. Rotate end cover counterclockwise and
ing the compressor.
remove
3. Remove air filter element by pulling it out of
the housing.
4. Clean interior of housing using a damp cloth.
DO NOT blow dirt out with compressed air.
1
2
5. At this time replace the element.
6. Reassemble in the reverse order of the dis- 3
assembly.
4
6.8 SEPARATOR MAINTENANCE
5
Replace the separator element when indicated by
the WS Controller or after one (1) year, whichever
comes first. The separator element must be
replaced. DO NOT attempt to clean the separator
element.
Separator Element Replacement
Refer to Figure 6-3. The separator element must be
changed when indicated by the WS Controller, or
once a year, whichever occurs first. Follow the 6
procedure explained below for separator element
replacement.
NOTE
SU_0000073
Relieve all pressure from the separator/
sump tank and all compressor lines. 1. Cover
2. Ground Spring*
1. Loosen and remove the six (6) hex head cap 3. Spring Fastener*
screws (8.8 M12 x 40 mm) from the cover
4. Cover Gasket*
plate.
5. Element*
2. Lift the cover plate from the separator/sump
tank. 6. Separator/Sump Tank
Separator Element—P/N 02250185-533
3. Remove the separator element.
* (Included in) Separator Element Replace-
4. Inspect the separator/sump tank for rust, dirt, ment Kit—P/N 02250185-532
etc.
Figure 6-3: Separator Element Assembly
5. Reinsert the separator element into the sep-
arator/sump tank taking care not to dent the
element against the tank opening. Fluid Return/Sight Glass Maintenance
6. Install a new O-ring in the O-ring groove on Refer to Figure 6-4. The fluid return/sight glass
the underside of the separator/sump tank subassembly is attached to the side of the separator
cover. tank. Fluid return/sight glass maintenance should be
performed on a routine basis parallel to that of the
fluid filter, or as indicated in Section 6.9:
63
1800-3000 USER MANUAL SECTION 6
Troubleshooting— Introduction on page 65. The 4. Inspect and clean the orifice inside the sight
maintenance on a fluid return/sight glass is mainly glass blocks. The orifice must be removed
concerned with the condition of the filter assembly. with an allen wrench.
Order filter assembly No. 02250117-782, and use the 5. Coat/lubricate the O-rings with silicone
following instructions as a guide. grease.
6. Reattach the connectors to the sight glass/
orifice blocks.
1
Pressure Regulator Adjustment
SU_0000032
2
1. To Separator/Sump Tank 1
2. Male Tube Connector
3. 90° Pipe Elbow
SU_0000033
4. Filter Assembly*
5. Sight Glass/Orifice Block 1. Locking Nut
6. Brass Plug Orifice 2. Adjustment Screw
7. Female Tube Connector
8. To Unit Figure 6-5: Separator Element Assembly
* Fluid Return Filter Replacement Kit—P/N
Water Condensate Drain Maintenance
02250117-782
If your compressor is fitted with the standard solenoid
Figure 6-4: Separator Element Assembly condensate drain valve, it is necessary to periodically
clean the strainer. Remove the knurled cap from the
1. Disconnect the tube at bottom of sight glass. strainer and remove the strainer screen. Clean the
2. Unscrew the sight glass assembly where the screen and reinstall. If the screen is damaged, the
elbow fitting joins the strainer/filter. strainer assembly must be replaced (P/N 241772).
3. Remove used filter assembly, and replace
with new assembly.
64
SECTION 6 1800-3000 USER MANUAL
Control Line Strainer 5. Reinstall the outer sleeve and torque the
securing screws to 10 in·lb (1.13 N·m).
The regulator and solenoid valve(s), which control
Install the protective grill.
the compressor, are protected by a strainer. Every 12
months it is necessary to clean the strainer. Remove
the hex cap from the strainer and remove the strainer 6.9 TROUBLESHOOTING—
screen. Clean the screen and reinstall. If the screen INTRODUCTION
is damaged, the strainer assembly must be replaced
The information contained in the Troubleshooting
(P/N 241772).
Guide has been compiled from field report data and
Shaft Coupling Maintenance factory experience. It contains symptoms and usual
causes for the described problems. However, DO
The compressor unit and motor are rigidly connected
NOT assume that these are the only problems that
via a mounting adapter housing. This arrangement
may occur. All available data concerning a problem
makes coupling alignment unnecessary. The
should be systematically analyzed before
coupling is a jaw type in shear. If the elastomeric
undertaking any repairs or component replacement
element requires replacement due to wear or
procedures.
breakage, order replacement element no. 02250152-
669, and follow the following steps: A detailed visual inspection is worth performing for
almost all problems and may avoid unnecessary
1. Remove the protective grill from the adapter
additional damage to the compressor. Always
housing.
remember to:
2. Loosen the retaining screw located on the
1. Check for loose wiring.
outer sleeve. Slide the sleeve to one side,
exposing the coupling element. 2. Check for damaged piping.
3. Unwrap the coupling element from the cou- 3. Check for parts damaged by heat or an elec-
pling jaws. trical short circuit, usually apparent by discol-
oration or a burnt odor.
4. Install the new element by wrapping it
around the jaws, engaging the cogs on the Should your problem persist after making the
element into the jaws. recommended check, consult your nearest Sullair
representative.
65
1800-3000 USER MANUAL SECTION 6
.
Defective Pressure Regulator Check diaphragm and replace if necessary
(kit available).
Defective Unload Solenoid Valve Check that the valve closes when
energized. Replace the coil or the complete
valve if defective.
Sheared Coupling Element Replace coupling element. Refer to Shaft
Coupling Maintenance on page 65.
66
SECTION 6 1800-3000 USER MANUAL
67
NOTES
68
NOTES
Always air. Always there.
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SULLAIR
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Telephone: 1-219-879-5451