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AIR CARE SEMINAR TRAINING

Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.

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

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

S

ULLAIR

C

USTOMER

C

ARE

T

RAINING

D

EPARTMENT

1-888-SULLAIR or

219-879-5451 (ext. 5623)

www.sullair.com

- Or Write -

Sullair Corporation

3700 E. Michigan Blvd.

Michigan City, IN 46360

Attn: Service Training Department.

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Summary of Contents for 3000 EES

Page 1: ...y WARRANTY NOTICE PART NUMBER KEEP FOR FUTURE REFERENCE USER MANUAL SULLAIR CORPORATION The information in this manual is current as of its publication date and applies to compressor serial number and all subsequent serial numbers 02250175 332 R00 200710010000 INTEGRAL HEAT RECOVERY SYSTEM 3000 3000P 3700 4500 EES ...

Page 2: ...ocated at Michigan City Indiana Instruction includes training on the function and installation of Sullair service parts troubleshooting common faults and malfunctions and actual equipment operation These seminars are recommended for maintenance contractor maintenance and service personnel For detailed course outlines schedule and cost information contact SULLAIR CUSTOMER CARE TRAINING DEPARTMENT 1...

Page 3: ... 12 2 3 FUNCTIONAL DESCRIPTION MIXED AIR TEMPERATURE SENSOR 12 2 4 FUNCTIONAL DESCRIPTION OUTSIDE AIR TEMPERATURE SEN SOR 13 2 5 FUNCTIONAL DESCRIPTION ROOM THERMOSTAT 13 2 6 FUNCTIONAL DESCRIPTION INCOMING AND BYPASS AIR DAMP ERS AND ACTUATORS 13 2 7 FUNCTIONAL DESCRIPTION REJECTED AND RECOVERED AIR DAMPERS AND ACTUATORS 15 2 8 FUNCTIONAL DESCRIPTION POWER PRESENT RELAY SECTION 3 SPECIFICATIONS 1...

Page 4: ...WIRING SECTION 5 SETTINGS AND OPERATION 29 5 1 SETTINGS AND OPERATION 35 5 2 START UP TEST PROCEDURE SECTION 6 MAINTENANCE 37 6 1 MAINTENANCE SECTION 7 TROUBLESHOOTING 39 7 1 TROUBLESHOOTING TABLE SECTION 8 PARTS LISTS 46 8 1 EES ENCLOSURE ASSEMBLY 48 8 2 EES ELECTRICAL CONTROL ASSEMBLY 50 8 3 EES DISCHARGE ENCLOSURE ASSEMBLY 52 8 4 EES PACKAGE CLEAN AIR INLET OPTION ...

Page 5: ...erein are applicable to most compressors and the concepts behind these statements are generally applicable to all compressors 1 2 PERSONAL PROTECTIVE EQUIPMENT A Prior to installing or operating the compressor owners employers and users should become familiar with and comply with all applicable OSHA regulations and or any applicable Federal State and Local codes standards and regula tions relative...

Page 6: ...fluids including air line anti icer system 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 industrial cleaner or steam clean as required If necessary remove acoustical material clean all surfaces and then replace acoustical material Any acous tical material with a protective coveri...

Page 7: ...l codes or regula tions B DO NOT use air line anti icer systems in air lines supplying respirators or other breathing air utili zation equipment and DO NOT discharge air from these systems into unventilated or other confined areas C Operate the compressor only in open or ade quately ventilated areas D Locate the compressor or provide a remote inlet so that it is not likely to ingest exhaust fumes ...

Page 8: ...handling any ungrounded conductors 1 9 LIFTING A If the compressor is provided with a lifting bail then lift by the bail provided If no bail is provided then lift by sling Compressors to be air lifted by helicopter must not be supported by the lifting bail but by slings instead In any event lift and or handle only in full compliance with OSHA stan dards 29 CFR 1910 subpart N and or any appli cable...

Page 9: ...ta cles at floor level and transport and corner at minimum practical speeds N Make sure pallet mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them NEVER attempt to forklift a compressor that is not secured to its pallet as uneven floors or sud den stops may cause the compressor to tumble off possibly causing serious injury or p...

Page 10: ...NOTES 10 ...

Page 11: ...into the building at outside temperature will be eliminated The fuel savings result from the primary heating system of the facility not having to heat that cubic foot of air at outside temperature to the temperature of the heated space It is possible for the EES system to operate efficiently as a heating system that is where air is drawn and heated to some higher temperature say 90 F 32 C then dis...

Page 12: ...gure 2 1 The outdoor air temperature sensor is mounted in the incoming air stream outside of the compressor enclosure This sensor monitors the temperature of the incoming air When the temperature of the incoming air exceeds the set value on the outside air temperature controller Figure 2 2 all heat of compression is rejected outdoors In addition the incoming air damper is fully opened and the bypa...

Page 13: ... open Both actuators are spring return so when the compressor does not have power or is on standby the actuators return to their normal position When heat of compression is being rejected due to the outside air temperature setpoint being exceeded a signal is sent to control relay 2 Figure 2 2 which overrides the control signal and drives the incoming damper to fully open and the bypass damper to f...

Page 14: ...n The temperature of the heated space is higher than the set value of the room ther mostat Refer to Figure 2 4 Bypass Air Damper Incoming Air Damper Cooler Mixed Air Temperature Sensor Recovered Air Damper To Heated Space Rejected Air Damper Outside Air Temperature Sensor Figure 2 3 Low Room Temperature and Low Outside Temperature Bypass Air Damper To Outside Incoming Air Damper Outside Air Temper...

Page 15: ...f the EES components The EES system will only operate when the compressor is running When power is not provided to the compressor or when the compressor is in standby mode and not running there is no power to the EES controls or motor actuators Refer to Figure 2 6 Upon compressor startup a signal is sent from the WS controller to the power present relay located in the EES electrical enclosure Powe...

Page 16: ...16 BLANK PAGE ...

Page 17: ...5 876 98 3 2496 3000P 40 With 70 9 1801 34 5 876 98 3 2496 3700 50 Without 67 1 1703 34 5 876 98 3 2496 3700 50 With 70 9 1801 34 5 876 98 3 2496 4500 60 Without 67 1 1703 34 5 876 98 3 2496 4500 60 With 70 9 1801 34 5 876 98 3 2496 Standard Machines with EES Model Motor Type Main Motor HP Weight lbs kg 3000 ODP 40 2097 952 3000 TEFC 40 2163 982 3000P ODP 40 2272 1031 3000P TEFC 40 2338 1061 3700 ...

Page 18: ...ps Weight lbs kg 40 ODP 460 60 72 2348 1065 40 TEFC 460 60 72 2414 1095 40 ODP 575 60 52 2348 1065 40 TEFC 575 60 52 2414 1095 3700 VSD with EES MainMotor HP Motor Type Voltage Amps Weight lbs kg 50 ODP 460 60 72 2398 1088 50 TEFC 460 60 72 2482 1126 50 ODP 575 60 52 2450 1111 50 TEFC 575 60 52 2534 1150 4500 VSD with EES MainMotor HP Motor Type Voltage Amps Weight lbs kg 60 ODP 460 60 72 2640 119...

Page 19: ...0 Hz Class 2 Adjustment Range 30 to 130 F 35 to 55 C Outside Air Temperature Controller Voltage 24VAC DC 50 60 Hz Class 2 Adjustment Range 30 to 130 F 35 to 55 C Thermostat Voltage 24VAC Adjustment Range 40 to 90 F Heat Mode Proportional Actuator Voltage 24VAC 50 60 Hz Class 2 Power Consumption 13VA driving 5VA holding Enclosure Rating NEMA 2 2 Position Actuator Voltage 24VAC 50 60 Hz Class 2 Powe...

Page 20: ...EES USER MANUAL SECTION 3 20 Figure 3 1 Identification EES 02250175 281 R00 ...

Page 21: ...SECTION 3 EES USER MANUAL 21 Figure 3 2 Wiring Diagram EES 02250175 264 R01 ...

Page 22: ...22 BLANK PAGE ...

Page 23: ...external ductwork In certain applications a booster fan may be required If this is the case the following guidelines should be observed Booster fans should be selected based on air flow of 4 800 CFM for 3000P 40HP and 3700 50HP machines or 5600 CFM for 4500 60HP machines Fan rating should be based on the ductwork static pressure restriction minus 0 50 in w g If the fan discharge or inlet is shut o...

Page 24: ...the extended control rod to clear the opening 4 Reinstall the damper in the desired location and reattach the actuator Torque the nut on the actuator coupling to 120 180 lb in 13 6 20 3 N m Ensure the rejected and recovered dampers are at their normally closed positions before tightening the actuator coupling 5 Be sure to keep the actuators and dampers paired as they arrived from the factory 6 Whe...

Page 25: ...aining clip Refer to Fig ure 4 2 Be sure that the arrow on the coupling aligns with the 0 degree mark on the actuator housing Pay attention to the direction of rotation indicated on the actuator housing Reinstall the damper and actuator per step 4 above Figure 4 2 Movement of Coupling to Opposite Side of Actuator Figure 4 3 Actuator Installation and Orientation for Damper Location 1 and 3 ...

Page 26: ...SER MANUAL SECTION 4 26 Figure 4 4 Actuator Installation and Orientation for Damper Location 2 Figure 4 5 Actuator Attachment Damper Control Rod Actuator Coupling Coupling Nut Actuator Anti Rotation Bracket ...

Page 27: ...d provide sealing 3 Run wires along damper edge using wire clips as necessary 4 Each connector end is labeled Match connectors assemble and hand tighten 4 7 MIXED AIR TEMPERATURE SENSOR INSTALLATION Attach sensor holder to compressor roof panel using M6 nuts and lock washers Route mixed air temperature sensor from EES electrical enclosure Use wire clips and nylon ties to secure wires Route wire al...

Page 28: ...28 BLANK PAGE ...

Page 29: ... Figure 5 1 INCOMING AND BYPASS AIR ACTUATORS The incoming and bypass air actuators modulate to maintain the desired mixed air temperature Refer to Section 2 for a more detailed functional description Actuators are installed and set at factory The following information is for reference and troubleshooting DIRECTION OF ROTATION Indicated on actuator housing and set at the factory The incoming dampe...

Page 30: ...EES USER MANUAL SECTION 5 30 Figure 5 2 Actuator Installation and Orientation for Incoming Air Damper Figure 5 3 Actuator Installation and Orientation for Bypass Air Damper ...

Page 31: ... package some minimum output is desirable to maintain the intake of fresh air into building at all times In extreme cold lower or no minimum output may be desirable For most applications 10 minimum output is sufficient Setting of the minimum output is as follows 1 Turn setpoint dial to the lowest temperature possible 30 F 35 C 2 Remove cover of proportional controller 3 Start compressor and observ...

Page 32: ...ed air set temperature See Figure 5 5 for a chart of temperature rise of the cooling air across the cooler The recovered air temperature is the sum of the mixed air temperature and the temperature rise across the cooler The mixed air set temperature should never be set below 40 F 4 5 C to prevent problems with aftercooler freeze up Additionally the mixed air set temperature should not be set above...

Page 33: ...ve degrees OUTSIDE AIR CHANGEOVER TEMPERATURE This is the temperature of the incoming outside air at which it is desired to reject all heat of compression outdoors and use all outside air for compressor cooling This must be set higher than 40 F 4 5 C to prevent problems with aftercooler freeze up Adjusted by setpoint dial LED RELAY INDICATOR This light indicates when the integral relay is energize...

Page 34: ...n thermostat Set to desired maintained temperature for the space When heated space temperature reaches setpoint heat of compression will be rejected outdoors Digital Display Temperature Setting Button Raises Temperature Setting Temperature Setting Button Lowers Temperature Setting System Button Fan Button Not Used Figure 5 7 Room Thermostat ...

Page 35: ...r Lowest setting Room Thermostat Setting above display temperature Outside Air Temp Controller Lowest setting Compressor operating 1 1 LED lit on mixed air temp controller 2 Incoming damper fully open bypass damper fully closed 3 Rejected damper open 4 Recovered damper closed Mixed Air Temp Controller Lowest setting Room Thermostat Setting below display temperature Outside Air Temp Controller Lowe...

Page 36: ...36 BLANK PAGE ...

Page 37: ...Section 6 37 EES USER MANUAL MAINTENANCE 6 1 MAINTENANCE The EES system and components requires no regular maintenance Refer to the compressor manual for maintenance requirements of the compressor ...

Page 38: ...38 BLANK PAGE ...

Page 39: ...wiring 2 Check for damaged piping 3 Check for parts damaged by heat or an electrical short circuit usually apparent by discoloration or a burnt odor Should your problem persist after making the recommended check consult your nearest Sullair representative Symptom Probable Cause Remedy Operation of rejected and recovered air dampers is reversed Connectors from control box connected to incorrect act...

Page 40: ...ay 1 and or con trol relay 3 Replace relay Rejected air damper does not open with a rise in outside air temperature Thermostat set incorrectly Set to HEAT mode Confirm desired temperature setting Outside air temperature controller set incorrectly Set to HEAT mode Confirm desired temperature setting Wiring error in control enclosure Rewire Refer to wiring dia gram Wiring error in plug socket or act...

Page 41: ...ing on actuator Set to 3 0 10VDC Modulating Mixed air temperature sen sor failure Replace sensor Proportional controller fail ure Replace controller Control relay 2 failure Replace relay Loose actuator coupling Tighten to 120 180 lb in 13 6 20 3 N m Incoming or bypass damper does not operate Wiring error in plug socket or actuator Rewire Refer to wiring dia gram Incorrect control signal set ting o...

Page 42: ...t Acting DA operating mode Lower mixed air temperature setpoint Too much bypass air being used Confirm bypass damper is operational Insufficient cold air being drawn into compressor enclosure Confirm intake damper is operational Mixed air temperature sen sor failure Replace sensor Proportional controller fail ure Replace controller Control relay 2 failure Replace relay Incoming air damper does not...

Page 43: ...res sure Redesign or reinstall duct work Loose or slipped actuator coupling on bypass damper preventing damper from fully closing Adjust bypass damper to normally open with no power and tighten coupling to 120 180 lb in 13 6 20 3 N m Mixed air set temperature and outdoor air change over temperature set above maximum values Lower mixed air and outdoor air changeover tempera tures below 105 F 40 C m...

Page 44: ...44 BLANK PAGE ...

Page 45: ...Section 8 45 EES USER MANUAL PARTS LISTS ...

Page 46: ...EES USER MANUAL SECTION 8 46 8 1 EES ENCLOSURE ASSEMBLY 02250175 279 R00 ...

Page 47: ... 3700 16 02250154 393 1 R VERTICAL STARTER SIDE 3700 17 02250154 405 8 CVR FORKPOCKET 3700 18 02250154 992 2 R SIDE ASSY RH LH 37KW 19 02250155 191 1 SUPT SHIPPING MTR UNIT 37KW 20 02250155 284 1 PLUG HOLE 2 1 2 NYLON BLACK 21 02250158 039 1 PKT DRAWING HOLDER 3700 22 02250171 137 1 PANEL ENCL INTAKE EES P12 23 02250171 640 1 ACTUATOR PROPORTIONAL ESS 24 02250171 648 1 DWG ASSY CONTROL BOX EES 25 ...

Page 48: ...EES USER MANUAL SECTION 8 48 8 2 EES ELECTRICAL CONTROL ASSEMBLY 02250171 648 R00 ...

Page 49: ... 02250171 644 1 CONTROLLER ON OFF 11 02250171 645 4 RELAY 6A SPTD 24V COIL DIN MTG 12 02250171 649 1 DWG ENCL SPEC N4 EES 13 02250172 230 2 SNSR TEMP EES 14 02250174 932 1 DWG FUSE CLIP KIT 15 250041 102 4 BLOCK TERMINAL KT3 16 250041 103 2 BLOCK TERM ADAPTER KAD 17 250041 610 1 FU CCMR 5A 600VAC 18 825204 226 1 NUT HEX PLTD 1 4 20 19 835701 050 8 SCREW TC F RD HD 8 32 X 1 2 20 835701 075 2 SCREW ...

Page 50: ...EES USER MANUAL SECTION 8 50 8 3 EES DISCHARGE ENCLOSURE ASSEMBLY 02250171 646 R00 ...

Page 51: ...640 1 ACTUATOR PROPORTIONAL ESS 6 02250171 641 2 ACTUATOR 2 POSTION ESS 7 02250172 390 1 SA ESS ENCL P12 8 02250174 815 1 DMPR CONTROL RTN AIR ESS P12 9 250022 436 26 WEATHERSTRIP 3 16 X 3 8 FT 10 825201 130 6 NUT HEX PLTD 8 32 11 831601 050 6 SCREW MACH RD HD 8 32 X 1 2 12 835601 050 6 SCREW TC F PAN 8 32 X 1 2 13 837801 040 6 WASHER SPR LOCK REG PLTD 8 14 839105 112 4 EYEBOLT 5 16 18 X 1 1 8 PLT...

Page 52: ...EES USER MANUAL SECTION 8 52 8 4 EES PACKAGE CLEAN AIR INLET OPTION 02250176 044 R00 ...

Page 53: ...SECTION 8 EES USER MANUAL 53 KEY NO PART NO Q T Y DESCRIPTION N O T E 1 02250174 515 1 ADAPTER DUCT EES P12 2 02250175 421 1 FLTR CLEAN AIR EES P12 16 3 834504 075 8 SCREW SELF DRILL 1 4 X 3 4 ...

Page 54: ...54 BLANK PAGE ...

Page 55: ...NOTES 55 ...

Page 56: ...rs LTD Princess Highway Hallam Victoria 3803 Australia Telephone 61 3 9796 4000 Fax 61 3 9703 8053 www championcompressors com au SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City Indiana 46360 U S A www sullair com Telephone 1 800 SULLAIR U S A only Fax 219 874 1273 CUSTOMER CARE for PARTS and Service 1 888 SULLAIR 7855247 219 874 1835 SULLAIR EUROPE S A Zone Des Granges BP 82 42602 ...

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