Sullair 3000PB User Manual Download Page 70

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Information and specifications are subject to change without prior notice.

Subject to EAR, ECCN EAR99 and related export control restrictions.

Sullair, LLC

3700 East Michigan Boulevard

Michigan City, IN 46360 USA

www.sullair.com

1-800-SULLAIR (USA only)

1-219-879-5451 (non-USA)

Summary of Contents for 3000PB

Page 1: ...r 201505080000 and all subsequent serial numbers USER MANUAL Publication date 6 17 2015 Copyright 2015 Sullair LLC All rights reserved WARRANTY NOTICE Failure to follow the instructions and procedures...

Page 2: ...ncludes 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...

Page 3: ...n 9 2 1 Introduction 9 2 2 Description of components 9 2 3 Sullair compressor unit functional description 9 2 4 Compressor cooling and lubrication system functional description 12 2 5 Compressor disch...

Page 4: ...Air cooled compressors 43 4 2 2 Water cooled compressors 43 4 2 3 Water system venting 44 4 2 4 Draining the water system 44 4 2 5 Water quality recommendations 45 4 2 6 Seawater cooled units 45 4 3 O...

Page 5: ...nce 56 6 7 1 Air filter element replacement 56 6 8 Separator maintenance 57 6 8 1 Separator element replacement 57 6 9 Oil return sight glass maintenance 58 6 10 Pressure regulator adjustment 58 6 11...

Page 6: ...Table of Contents 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual Notes 02250216 786 R01 iv Subject to EAR ECCN EAR99 and related export control restrictions...

Page 7: ...e applicable to most compressors and the concepts behind these state ments are generally applicable to all compressors 1 2 Personal protective equipment A Prior to installing or operating the compress...

Page 8: ...aterial or on any external surfaces of the air compressor Wipe down using an aqueous industrial cleaner or steam clean as required If necessary remove acoustical mate rial clean all surfaces and then...

Page 9: ...DO NOT discharge air from these systems into unventilated or other confined areas C Operate the compressor only in open or adequately ventilated areas D Locate the compressor or provide a remote inle...

Page 10: ...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...

Page 11: ...e work except when motion is necessary during setup adjustment or trouble shooting A The established procedures for the application of energy control shall cover the following elements and actions and...

Page 12: ...motor drives These cautions that apply to VSD operation WARNING Ground the unit following the instructions in this manual Ungrounded units may cause electric shock and or fire The variable speed drive...

Page 13: ...o not touch any components on the circuit boards Static voltage discharge may damage the components CAUTION Install the variable speed drive in a well venti lated room that is not subject to temperatu...

Page 14: ...1 Safety 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual Notes 02250216 786 R01 8 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 15: ...cooled versions have easily accessible items such as the fluid filter air oil separator and control valves The inlet air filter is also easily acces sible for servicing 2 3 Sullair compressor unit fun...

Page 16: ...and related export control restrictions Figure 2 1 Overall component layout air cooled model 1 Fluid filter 8 E Stop button 2 Moisture separator 9 Compressor unit 3 Separator sump tank 10 Cooler fan...

Page 17: ...export control restrictions 11 Figure 2 2 Overall component layout water cooled model 1 Moisture separator 8 E Stop button 2 Fluid filter 9 Compressor unit 3 Separator sump tank 10 Oil cooler 4 Fluid...

Page 18: ...the com bination separator sump tank The separator sump has three basic functions It acts as a primary fluid separator Serves as the compressor fluid sump Houses the final fluid separator The compress...

Page 19: ...700B 4500B 3000PVB 3700VB 4500VB User Manual 2 Description 02250216 786 R01 Subject to EAR ECCN EAR99 and related export control restrictions 13 Figure 2 3 Air cooled cooling lubrication and discharge...

Page 20: ...tion 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual 02250216 786 R01 14 Subject to EAR ECCN EAR99 and related export control restrictions Figure 2 4 Water cooled cooling lubrication and discharg...

Page 21: ...ice line The integrated inlet valve has an orifice which vents a small amount of air to the compressor inlet when the pressure regulator controls the inlet control valve The orifice also bleeds any ac...

Page 22: ...16 Subject to EAR ECCN EAR99 and related export control restrictions Figure 2 5 Standard pneumatic control system 1 Air outlet 5 Blowdown valve 2 Unload solenoid valve 6 Minimum pressure check valve...

Page 23: ...to the compressor in response to the operation of the pressure regulator Refer to Section on page 15 The inlet valve also acts as a check valve thus preventing reverse rotation when the compressor is...

Page 24: ...essor s rated capacity In this condition the VSD slows the motor s rpm which reduces the output to match the demand The drive continuously adjusts the motor s rpm to maintain a 100 psig 6 9 bar line p...

Page 25: ...n 02250216 786 R01 Subject to EAR ECCN EAR99 and related export control restrictions 19 energized solenoid valve prevents line pressure from reaching the inlet control valve thereby allowing it to ful...

Page 26: ...2 Description 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual Notes 02250216 786 R01 20 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 27: ...1712 35 108 62 1564 2055 2079 932 943 3700B series 3707B 50 67 1712 35 108 62 1564 2080 2120 943 962 3709B 50 67 1712 35 108 62 1564 2080 2120 943 962 3710B 50 67 1712 35 108 62 1564 2080 2120 943 962...

Page 28: ...B through 3712VB 1 ODP 230 60 169 2030 921 67 1712 35 108 62 1564 460 60 72 2030 921 67 1712 35 108 62 1564 575 60 62 2030 921 67 1712 35 108 62 1564 TEFC 230 60 169 2070 939 67 1712 35 108 62 1564 46...

Page 29: ...ompressors are available for operation in higher ambient temperature Motor Standard models Size 40 50 60 hp 30 37 45 kW Type C flanged open drip proof premium efficiency three phase 230 460 60 Hz VSD...

Page 30: ...if condi tions warrant use of extended life lubricants contact Sul lair for recommendation 3 6 Application guide Sullair encourages the user to participate in a fluid analy sis program with the fluid...

Page 31: ...I D SRF 1 4000 3 5 gal 13 2 L B E G C B D 24KT 3 5 gal 13 2 L F E G C I D PristineFG 3 5 gal 13 2 L H E G C B D A 10 000 hours or once a year B 4 000 hours or more frequently if conditions so require...

Page 32: ...Specifications 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual 02250216 786 R01 26 Subject to EAR ECCN EAR99 and related export control restrictions 3 8 Identification air cooled 02250216 524 R0...

Page 33: ...S 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 COMPRESSOR FRAME LEVEL...

Page 34: ...Specifications 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual 02250216 786 R01 28 Subject to EAR ECCN EAR99 and related export control restrictions 3 9 Identification water cooled 02250216 528 R...

Page 35: ...kg 730 TEFC 2354 LBS 1068 kg 730 Drawing 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 T...

Page 36: ...ications 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual 02250216 786 R01 30 Subject to EAR ECCN EAR99 and related export control restrictions 3 10 Piping and instrumentation air cooled 02250216...

Page 37: ...LVE DR 1 23 VALVE SOLENOID 2 24 VALVE PRESSURE REG 1 25 ELEMENT SEPARATOR 1 26 GAUGE DIFF PRESS 1 27 VALVE CHECK 3 28 VALVE BALL STNR COMBO 1 29 DRAIN ZERO LOSS 1 30 VENTILATOR ENCL 1 31 STRAINER V TY...

Page 38: ...fications 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual 02250216 786 R01 32 Subject to EAR ECCN EAR99 and related export control restrictions 3 11 Piping instrumentation water cooled 02250216 6...

Page 39: ...RESSURE REG 1 25 TANK SEPARATOR 1 26 DRAIN ZERO LOSS 1 27 VALVE CHECK 2 28 HEAT EXCHANGER 1 29 SWITCH PRESS 1 30 VALVE WATER 1 31 VALVE SOLENOID 1 32 VALVE BALL STNR COMBO 1 33 STRAINER V TYPE 1 Drawi...

Page 40: ...ecifications 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual 02250216 786 R01 34 Subject to EAR ECCN EAR99 and related export control restrictions 3 12 Wiring diagram air cooled MFV 02250211 276...

Page 41: ...L 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...

Page 42: ...3 Specifications 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual 02250216 786 R01 36 Subject to EAR ECCN EAR99 and related export control restrictions 3 13 Wiring diagram YD 02250214 098 R03...

Page 43: ...INTERNAL WYE DELTA RUN RELAY K4 INTERNAL LOAD CONTROL RELAY K5 INTERNAL SEQUENCE RELAY K6 INTERNAL ELECTRIC DRAIN RELAY K7 INTERNAL COMMON FAULT RELAY PF CAP POWER FACTOR CORRECTION CAPACITOR OPT L H...

Page 44: ...000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual 02250216 786 R01 38 Subject to EAR ECCN EAR99 and related export control restrictions 3 14 Wiring diagram VSD air cooled parallel wye A1000 460V onl...

Page 45: ...L 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 COMMO...

Page 46: ...0PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual 02250216 786 R01 40 Subject to EAR ECCN EAR99 and related export control restrictions 3 15 Wiring diagram VSD air cooled series delta A1000 230 575V o...

Page 47: ...NAL 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 COM...

Page 48: ...3 Specifications 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual Notes 02250216 786 R01 42 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 49: ...h adequate space must be provided for the compressor and its components Air cooled compressors require a minimum of 4 feet 1 25 meters around the perimeter of the compressor The location should be fre...

Page 50: ...ce in utilizing this heat If ductwork is added the high static fan option is required Do not install a water cooled or an air cooled after cooled compressor where it will be exposed to tempera tures l...

Page 51: ...h water treatment 4 2 5 2 Corrosion As contrasted to lime scale build up corrosion eventually causes a reduction in the wall thickness of pipes High levels of dissolved oxygen and low pH levels assist...

Page 52: ...local weather conditions can be extreme such that direct rain or snow may fall on the unit it should be in a fully enclosed room or building If installed under a shelter air cooled machines must be po...

Page 53: ...tempera ture below the dew point For most ambient conditions considerable water vapor is condensed To remove the condensation each compressor with built in aftercooler is supplied with a combination c...

Page 54: ...d by other electrical equipment The length of wiring from a suitable electrical feed point is critical as voltage drops may impair the performance of the com pressor Cable sizes may vary considerably...

Page 55: ...r compressor rotation An alternative to this procedure is to set the WS Controller to display P1 separator sump tank pressure Pull out the EMERGENCY STOP button and press once quickly and in successio...

Page 56: ...4 Installation 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual Notes 02250216 786 R01 50 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 57: ...mplete operation capabilities The WS Controller key pad has two main pads for compressor control To start the compressor operation press the green Start pad To stop compressor operation press the red...

Page 58: ...ressor The upper line will indicate Compressor Status and the name of the temperature pressure or other measure ment The lower line indicates the present reading Refer to Figure 5 7 When you continue...

Page 59: ...ed to the controller It will blink very slowly if the WS Controller is set up to automatically restart after power failure The green Run mode indicator indicates compressor operation is enabled It lig...

Page 60: ...5 WS Controller 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual Notes 02250216 786 R01 54 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 61: ...s recommended that a general check on the overall compressor be made to assure that the compressor is running properly 6 3 Maintenance after initial 50 hours of operation After the initial 50 hours of...

Page 62: ...aintenance Refer to Figure 6 2 Air filter maintenance should be per formed when the maintenance gauge shows red with the compressor running full load or once a year whichever comes first If the filter...

Page 63: ...eight 8 hex head capscrews in 1 in from the cover plate 2 Lift the cover plate from the separator sump tank 3 Remove the separator element 4 Inspect the separator sump tank for rust dirt etc 5 Reinser...

Page 64: ...er assembly and replace with new assembly 4 Inspect and clean the orifice inside the sight glass blocks The orifice must be removed with an allen wrench 5 Coat lubricate the O rings with silicone grea...

Page 65: ...sing the coupling element 3 Unwrap the coupling element from the cou pling jaws 4 Install the new element by wrapping it around the jaws engaging the cogs on the element into the jaws 5 Reinstall the...

Page 66: ...perature to 85 F 29 4 C or less Water cooled only Cooling water flow insufficient Check water lines and valves water cooled only Cooler plugged Clean tubes If plugging persists install water condition...

Page 67: ...level too high Drain and change Check that the compressor temperature has not dropped below 170 F 76 7 C Pressure relief valve opens repeatedly Defective pressure relief valve Replace Plugged separat...

Page 68: ...6 Maintenance 3000PB 3700B 4500B 3000PVB 3700VB 4500VB User Manual Notes 02250216 786 R01 62 Subject to EAR ECCN EAR99 and related export control restrictions...

Page 69: ...Subject to EAR ECCN EAR99 and related export control restrictions...

Page 70: ...subject to change without prior notice Subject to EAR ECCN EAR99 and related export control restrictions Sullair LLC 3700 East Michigan Boulevard Michigan City IN 46360 USA www sullair com 1 800 SULLA...

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