Sullair 3000P 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 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.
02250176-182 R04
201107010000
INDUSTRIAL AIR COMPRESSOR
3000P, 3700, 4500
3000PV, 3700V, 4500V
30, 37 & 45 KW/40, 50 & 60HP

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:
SULLAIR TRAINING DEPARTMENT
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
[email protected]
- Or Write -
Sullair Corporation
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
SECTION 2—DESCRIPTION
11 2.1 INTRODUCTION
12 2.2 DESCRIPTION OF COMPONENTS
13 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION
16 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION-
AL DESCRIPTION
16 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION
17 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
19 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
20 2.8 INTEGRAL DRYER OPTION
20 2.9 VARIABLE SPEED DRIVE (VSD) COMPONENTS
20 2.10 VSD CONTROL SYSTEM FUNCTIONAL DESCRIPTION
SECTION 3—SPECIFICATIONS
23 3.1 TABLE OF SPECIFICATIONS—3000, 3000P, 3700 AND 4500 SERIES
MODELS
24 3.2 TABLE OF SPECIFICATIONS—VARIABLE SPEED DRIVE MODELS
25 3.3 COMPRESSOR SPECIFICATIONS
26 3.4 LUBRICATION GUIDE
26 3.5 APPLICATION GUIDE

TABLE OF CONTENTS
27 3.6 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE,
FLUID
28 3.7 IDENTIFICATION, AIR-COOLED
30 3.8 IDENTIFICATION, WATER-COOLED
32 3.9 IDENTIFICATION, AIR-COOLED W/ INTEGRAL DRYER
34 3.10 PIPING AND INSTRUMENTATION, AIR-COOLED
38 3.11 PIPING AND INSTRUMENTATION, WATER-COOLED
40 3.12 PIPING AND INSTRUMENTATION, AIR-COOLED WITH INTEGRAL
DRYER
42 3.13 WIRING DIAGRAM, VSD AIR-COOLED
44 3.14 WIRING DIAGRAM, AIR-COOLED MFV WITH INTEGRAL DRYER
46 3.15 WIRING DIAGRAM, AIR-COOLED MFV
48 3.16 WIRING DIAGRAM, YD CE
SECTION 4—INSTALLATION
51 4.1 MOUNTING OF COMPRESSOR
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 5—WS CONTROLLER
59 5.1 CONTROLLER LAYOUT
59 5.2 CONTROLLER KEYPAD
60 5.3 LCD DISPLAY
61 5.4 LED LIGHTS
SECTION 6—MAINTENANCE
63 6.1 GENERAL
63 6.2 DAILY OPERATION
63 6.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
64 6.4 MAINTENANCE EVERY 2000 HOURS
64 6.5 FLUID MAINTENANCE
64 6.6 FILTER MAINTENANCE
64 6.7 AIR FILTER MAINTENANCE
65 6.8 SEPARATOR MAINTENANCE
67 6.9 TROUBLESHOOTING— INTRODUCTION
68 6.10 TROUBLESHOOTING GUIDE

Section 1
5
SAFETY
1.1 GENERAL
Sullair Corporation and its subsidiaries design and
manufacture all of their products so they can be
operated safely. However, the responsibility for safe
operation rests with those who use and maintain
these products. The following safety precautions are
offered as a guide which, if conscientiously followed,
will minimize the possibility of accidents throughout
the useful life of this equipment.
The compressor should be operated only by those
who have been trained and delegated to do so, and
who have read and understood this Operator's
Manual. Failure to follow the instructions, procedures
and safety precautions in this manual may result in
accidents and injuries. NEVER start the compressor
unless it is safe to do so. DO NOT attempt to operate
the compressor with a known unsafe condition. Tag
the compressor and render it inoperative by
disconnecting and locking out all power at source or
otherwise disabling its prime mover so others who
may not know of the unsafe condition cannot attempt
to operate it until the condition is corrected.
Install, use and operate the compressor only in full
compliance with all pertinent OSHA regulations and/
or any applicable Federal, State, and Local codes,
standards and regulations. DO NOT modify the
compressor and/or controls in any way except with
written factory approval.
While not specifically applicable to all types of
compressors with all types of prime movers, most of
the precautionary statements contained herein 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 to personal protective equipment,
such as eye and face protective equipment,
respiratory protective equipment, equipment
intended to protect the extremities, protective
clothing, protective shields and barriers and elec-
trical protective equipment, as well as noise
exposure administrative and/or engineering con-
trols and/or personal hearing protective equip-
ment.
1.3 PRESSURE RELEASE
A. Install an appropriate flow-limiting valve between
the service air outlet and the shut-off (throttle)
valve, either at the compressor or at any other
point 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 reduce
pressure 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, standards
and regulations.
B. When the hose is to be used to supply a mani-
fold, install an additional appropriate flow-limiting
valve between the manifold and each air hose
exceeding 1/2" (13mm) inside diameter that is to
be connected to the manifold to reduce pressure
in case of hose failure.
C. Provide an appropriate flow-limiting valve at the
beginning of each additional 75 feet (23m) of
hose 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 of
hose failure.
D. Flow-limiting valves are listed by pipe size and
flow-rated. Select appropriate valves accordingly,
in accordance with their manufacturer's recom-
mendations.
E. DO NOT use air tools that are rated below the
maximum rating of the compressor. Select air
tools, air hoses, pipes, valves, filters and other
fittings accordingly. DO NOT exceed manufac-
turer's rated safe operating pressures for these
items.
F. Secure all hose connections by wire, chain or
other suitable retaining device to prevent tools or
hose ends from being accidentally disconnected
and expelled.
G. Open fluid filler cap only when compressor is not
running and is not pressurized. Shut down the
compressor and bleed the receiver tank to zero
internal pressure before removing the cap.
H. Vent all internal pressure prior to opening any
line, fitting, hose, valve, drain plug, connection or
other component, such as filters and line oilers,
and before attempting to refill optional air line
anti-icer systems with antifreeze compound.
I. Keep personnel out of line with and away from
the discharge opening of hoses or tools or other
points of compressed air discharge.
J. DO NOT use air at pressures higher than 2.1 bar
for 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 Local
codes, standards and regulations.
K. DO NOT engage in horseplay with air hoses as
death or serious injury may result.
1.4 FIRE AND EXPLOSION
A. 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 of
ignition away and DO NOT permit smoking in the
vicinity when checking or adding lubricant or
when refilling air line anti-icer systems with anti-
freeze compound.
C. DO NOT permit 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 covering that has
been torn or punctured should be replaced
immediately to prevent accumulation of liquids or
fluid film within the material. DO NOT use flam-
mable solvents for cleaning purposes.
D. Disconnect and lock out all power at source prior
to 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 and
pressure connectors in good condition. Replace
any wiring that has cracked, cut, abraded or oth-
erwise degraded insulation, or terminals that are
worn, discolored or corroded. Keep all terminals
and pressure connectors clean and tight.
F. Keep grounded and/or conductive objects such
as tools away from exposed live electrical parts
such as terminals to avoid arcing which might
serve as a source of ignition.
G. Remove any acoustical material or other material
that may be damaged by heat or that may sup-
port combustion and is in close proximity, prior to
attempting weld repairs.
H. Keep suitable fully charged Class BC or ABC fire
extinguisher 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 proper
flow of cooling air or water or with inadequate
flow of lubricant or with degraded lubricant.
K. DO NOT attempt to operate the compressor in
any classification of hazardous environment
unless the compressor has been specially
designed and manufactured for that duty.
1.5 MOVING PARTS
A. 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 with
the fan, coupling or other guards removed.

SECTION 1
7
C. Wear snug-fitting clothing and confine long hair
when working around this compressor, especially
when exposed to hot or moving parts.
D. Keep access doors, if any, closed except when
making repairs or adjustments.
E. Make sure all personnel are out of and/or clear of
the compressor prior to attempting to start or
operate it.
F. Disconnect and lock out all power at source and
verify at the compressor that all circuits are de-
energized to minimize the possibility of acciden-
tal start-up, or operation, prior to attempting
repairs or adjustments. This is especially impor-
tant when compressors are remotely controlled.
G. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water or other
liquids to minimize the possibility of slips and
falls.
1.6 HOT SURFACES, SHARP
EDGES AND 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 of
air discharge.
C. Wear personal protective equipment including
gloves and head covering when working in, on or
around the compressor.
D. Keep a first aid kit handy. Seek medical assis-
tance promptly in case of injury. DO NOT ignore
small 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 with
OSHA 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 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 or
other toxic, noxious or corrosive fumes or sub-
stances.
E. Coolants and lubricants used in this compressor
are typical of the industry. Care should be taken
to avoid accidental ingestion and/or skin contact.
In the event of ingestion, seek medical treatment
promptly. Wash with soap and water in the event
of skin contact. Consult Material Safety Data
Sheet for information pertaining to fluid of fill.
F. Wear goggles or a full face shield when adding
antifreeze compound to air line anti-icer systems.
G. If air line anti-icer system antifreeze compound
enters the eyes or if fumes irritate the eyes, they
should be washed with large quantities of clean
water for fifteen minutes. A physician, preferably
an eye specialist, should be contacted immedi-
ately.
H. DO NOT store air line anti-icer system antifreeze
compound 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 with
the 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 a
tablespoon of salt, in each glass of clean, warm
water until vomit is clear, then administer two
teaspoons of baking soda in a glass of clean
water. Have patient lay down and cover eyes to
exclude light. Call a physician immediately.
1.8 ELECTRICAL SHOCK
A. This compressor should be installed and main-
tained in full compliance with all applicable Fed-
eral, State and Local codes, standards and
regulations, including those of the National Elec-
trical Code, and also including those relative to
equipment grounding conductors, and only by
personnel that are trained, qualified and dele-
gated to do so.
B. Keep all parts of the body and any hand-held
tools or other conductive objects away from
exposed live parts of electrical system. Maintain
dry footing, stand on insulating surfaces and DO
NOT contact any other portion of the compressor
when making adjustments or repairs to exposed
live parts of the electrical system. Make all such
adjustments or repairs with one hand only, so as
to minimize the possibility of creating a current
path through the heart.
C. Attempt repairs in clean, dry and well lighted and
ventilated areas only.
D. DO NOT leave the compressor unattended with
open electrical enclosures. If necessary to do so,
then disconnect, lock out and tag all power at
source so others will not inadvertently restore
power.
E. Disconnect, lock out, and tag all power at source
prior to attempting repairs or adjustments to
rotating machinery and prior to 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 Federal, State, and Local codes, standards
and regulations.
B. Inspect points of attachment for cracked welds
and for cracked, bent, corroded or otherwise
degraded members and for loose bolts or nuts
prior to lifting.
C. Make sure entire lifting, rigging and supporting
structure has been inspected, is in good condi-
tion and has a rated capacity of at least the
weight of the compressor. If you are unsure of
the weight, then weigh compressor before lifting.
D. Make sure lifting hook has a functional safety
latch or equivalent, and is fully engaged and
latched on the bail or slings.
E. Use guide ropes or equivalent to prevent twisting
or swinging of the compressor once it has been
lifted clear of the ground.
F. DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away
from the compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
DANGER
All 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
9
I. Keep lift operator in constant attendance when-
ever compressor is suspended.
J. Set compressor down only on a level surface
capable of safely supporting at least its weight
and its loading unit.
K. When moving the compressor by forklift truck,
utilize fork pockets if provided. Otherwise, utilize
pallet if provided. If neither fork pockets or pallet
are provided, then make sure compressor is
secure and well balanced on forks before
attempting to raise or transport it any significant
distance.
L. Make sure forklift truck forks are fully engaged
and tipped back prior to lifting or transporting the
compressor.
M. Forklift no higher than necessary to clear obsta-
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 property
damage in the process.
1.10 ENTRAPMENT
A. If the compressor enclosure, if any, is large
enough to hold a man and if it is necessary to
enter it to perform service adjustments, inform
other personnel before doing so, or else secure
and tag the access door in the open position to
avoid the possibility of others closing and possi-
bly latching the door with personnel inside.
B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.

NOTES
10

Section 2
11
3000P-4500 USER MANUAL
DESCRIPTION
2.1 INTRODUCTION
Your new Sullair flood-lubricated rotary screw air
compressor will provide you with a unique
experience in improved reliability and simplified
maintenance. Compared to other types of
compressors, the Sullair rotary screw is unique in
mechanical reliability, with "no wear" and "no
inspection" required of the working parts within the
compressor unit. Read Maintenance on page 63 to
see how surprisingly easy it is to keep your air
compressor in top operating condition.
1. Fluid Filter
2. Moisture Separator
3. Separator/Sump Tank
4. Fluid Fill
5. Fluid Fill Sight Glass
6. Starter Box
7. WS Controller
8. E-Stop Button
9. Compressor Unit
10. Cooler Fan Motor
11. Cooler
12. Motor
13. Air Inlet Filter
Figure 2-1: Overall Component Layout, Air-Cooled Model

3000P-4500 USER MANUAL SECTION 2
12
2.2 DESCRIPTION OF
COMPONENTS
Refer to Figure 2-1 and Figure 2-2. The components
and assemblies of the air compressor are clearly
shown. The complete package includes compressor,
electric motor, starter, compressor inlet system,
compressor discharge system, compressor
lubrication and cooling system, capacity control
system, WS Controller, aftercooler, a combination
separator and trap, all mounted on a heavy gauge
steel frame.
On air-cooled models, a fan draws air into the
enclosure over the fan and main motors through the
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.
On water-cooled models, a shell and tube heat
exchanger is mounted on the compressor frame.
Fluid is piped into the heat exchanger where
compression heat is removed from the fluid. Another
similar heat exchanger cools the compressed air.
Both air-cooled and water-cooled versions have
easily accessible items such as the fluid filter air/oil
separator and control valves. The inlet air filter is also
easily accessible for servicing.
1. Moisture Separator
2. Fluid Filter
3. Separator/Sump Tank
4. Fluid Fill
5. Fluid Fill Sight Glass
6. Starter Box
7. WS Controller
8. E-Stop Button
9. Compressor Unit
10. Oil Cooler
11. Aftercooler
12. Motor
13. Air Inlet Filter
14. Canopy Vent Fan
Figure 2-2: Overall Component Layout, Water-Cooled Model

SECTION 2 3000P-4500 USER MANUAL
13
2.3 SULLAIR COMPRESSOR
UNIT, FUNCTIONAL
DESCRIPTION
Sullair air compressors feature the Sullair
compressor unit, a single-stage, positive
displacement, flood lubricated- type compressor.
This unit provides continuous compression to meet
your needs.
The 3000-4500 Series compressors are factory-filled
with Sullube lubricant. For more information on fluid
fill, consult Specifications on page 23.
Sullair 24KT compressors are filled with a fluid that
rarely needs to be changed. Use only Sullair 24KT
fluid in the event that a fluid change is required.
Sullair recommends that a 24KT sample be taken at
the first filter change and sent to the factory for
analysis. This is a free service. The sample kit with
instructions and self- addressed container is to be
supplied by your Sullair dealer at start-up. The user
will receive an analysis report with
recommendations.
Fluid is injected into the compressor unit hoses and
mixes directly with the air as the rotors turn,
compressing the air. The fluid flow has three basic
functions:
1. As coolant, it controls the rise of air tempera-
ture normally associated with the heat of
compression.
2. Seals the clearance paths between the
rotors and the stator and also between the
rotors themselves.
3. Acts as a lubricating film between the rotors
allowing one rotor to directly drive the other,
which is an idler.
After the air/fluid mixture is discharged from the
compressor unit, the fluid is separated from the air.
At this time, the air flows through an aftercooler and
separator then to your service line while the fluid is
being cooled in preparation for reinjection.
NOTE
With a Sullair compressor, there is no
maintenance or inspection of the internal
parts of the compressor unit permitted in
accordance with the terms of the war-
ranty.
CAUTION
Mixing of other lubricants within the com-
pressor unit will void all warranties.

3000P-4500 USER MANUAL SECTION 2
14
Figure 2-3: Air-Cooled, Cooling / Lubrication and Discharge System

SECTION 2 3000P-4500 USER MANUAL
15
Figure 2-4: Water-Cooled, Cooling / Lubrication and Discharge System

3000P-4500 USER MANUAL SECTION 2
16
2.4 COMPRESSOR COOLING
AND LUBRICATION
SYSTEM, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-3 or Figure 2-4. The Cooling and
Lubrication System (air-cooled version) consists of a
fan, fan motor, radiator-type aftercooler/fluid cooler,
full flow fluid filter, thermal valve, and interconnecting
hoses. For water-cooled models, two shell and tube
heat exchangers are substituted for the radiator-type
cooler listed above. The pressure in 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 compressor unit.
Fluid flows from the bottom of the separator/sump
tank to the thermal valve. The thermal valve is fully
open when the fluid temperature is below 185°F
(85°C) [200°F (93°C) for 24KT] and pressures are
rated above 150 psig. The fluid passes through the
thermal valve, the main filter and directly to the
compressor unit where it lubricates, cools and seals
the rotors and the compression chamber.
As the discharge temperature rises above 185°F (85
°C), due to the heat of compression, the thermal
valve begins to adjust and a portion of the fluid then
flows through the cooler. From the cooler the fluid
flows to the fluid filter and then on to the compressor
unit.
A portion of the fluid flowing to the compressor is
routed to the anti-friction bearings which support the
rotors inside the compressor unit.
The fluid filter has a replacement element and an
integral pressure bypass valve. Refer to Lubrication
Change Recommendations and Maintenance, Fluid
on page 27.
Water-cooled models have a water pressure switch
to prevent operation with inadequate water pressure.
2.5 COMPRESSOR DISCHARGE
SYSTEM, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-3 or Figure 2-4. The compressor
unit discharges the compressed air/fluid mixture into
the combination separator/sump tank.
The separator/sump has three basic functions:
1. 1. It acts as a primary fluid separator.
2. 2. Serves as the compressor fluid sump.
3. 3. Houses the final fluid separator.
The compressed air/fluid mixture enters the
separator/sump tank and flows through an internal
baffle system. The direction of movement is changed
and its velocity significantly reduced, thus causing
large droplets of fluid to form and fall to the bottom of
the separator/sump tank. The fractional percentage
of fluid remaining in the compressed air collects on
the surface of the separator element as the
compressed air flows through the separator. A return
line (or scavenge tube) leads from the dry side of the
separator/sump tank to a medium pressure region of
the compressor unit. Fluid collecting on the bottom of
the separator is returned to the compressor by a
pressure differential between the separator/sump
and the compressor. A visual sight glass is located
on the return line to observe this fluid flow. There is
also an orifice in this return line (protected by a
strainer) to assure proper flow. The separator system
reduces the fluid carry-over at nominal rated
pressures to less than 1 ppm (parts per million). A
message on the WS Controller indicates if abnormal
pressure drop through the separator develops. Refer
to Lubrication Change Recommendations and
Maintenance, Fluid on page 27.
A minimum pressure/check valve, located
downstream from the separator, assures a minimum
separator/sump pressure of 50 psig (3.4 bar) during
loaded conditions. This pressure is necessary for
proper air/fluid separation and proper fluid
circulation.
A terminal check valve is incorporated into the
minimum pressure/check valve to prevent
compressed air in the service line from bleeding back
into the separator/sump on shutdown and during
operation of the compressor in an unloaded
condition.
A pressure relief valve (located on the wet side of the
separator) is set to open if the separator/sump tank
pressure exceeds the separator/sump tank rating.
The WS Controller will shut down the compressor if
the discharge temperature reaches 235°F (113°C).
Fluid is added to the separator/sump tank via a
capped fluid filler opening, placed low on the tank to
prevent overfilling of the separator/sump tank. A
sight glass enables the operator to visually monitor
the separator/sump tank fluid level.
WARNING
DO NOT remove caps, plugs, and/or other
components when compressor is running
or pressurized. Stop compressor and
relieve all internal pressure before doing so.

SECTION 2 3000P-4500 USER MANUAL
17
2.6 CONTROL SYSTEM,
FUNCTIONAL DESCRIPTION
Refer to Figure 2-5 and Figure 2-6. The purpose of
the compressor control system is to regulate the
amount of air being compressed to match the
amount of compressed air being used. The capacity
control system consists of a solenoid valve, regulator
valve and an inlet valve. The functional description of
the control system is described below in four distinct
phases of operation. For explanatory purposes, this
description will apply to a compressor with an
operating range of 100 to 110 psig (6.9 to 7.6 bar). A
compressor with any other pressure range would
operate in the same manner except stated
pressures.
START MODE - 0 TO 50 PSIG (0 TO 3.5 BAR)
When the compressor " " (START) pad is
depressed, the separator/sump tank pressure will
quickly rise from 0 to 50 psig (0 - 3.4 bar). The
compressor initially starts unloaded with the solenoid
valve open and the inlet valve closed. It then
switches to full load when full rpm has been
achieved. During this period, both the pressure
regulator and the solenoid valve are closed, the inlet
valve is fully open and the compressor pumps at full
rated capacity. The rising compressor air pressure is
isolated from the service line in this phase by the
minimum pressure valve set at approximately 50 psig
(3.4 bar).
1. Air Outlet
2. Unload Solenoid Valve
3. Pressure Regulator
4. Air Inlet
5. Blowdown Valve
6. Minimum Pressure/Check Valve
7. Separator/Sump Tank
8. Sequencing Solenoid Valve
9. WS Controller
Figure 2-5: Standard Sequencing Control System

3000P-4500 USER MANUAL SECTION 2
18
FULL LOAD MODE - 50 TO 100 PSIG (3.4 TO
6.9 BAR)
When the compressed air pressure rises above 50
psig (3.4 bar), the minimum pressure valve opens
allowing compressed air to flow into the service line.
From this point on, the line air pressure is continually
monitored by the WS Controller. The pressure
regulator and the solenoid valve remain closed
during this phase. The inlet valve is in the fully open
position as long as the compressor is running at 100
psig (6.9 bar) or below.
MODULATING MODE - 100 TO 110 PSIG (6.9
TO 7.6 BAR)
If less than the rated capacity of compressed air is
being used, the service line pressure will rise above
100 psig (6.9 bar). The pressure regulator valve
gradually opens, directing air pressure to the inlet
control valve, reducing air entering the compressor
until it matches the amount of air being used. The
control system functions continually in this manner
between the limits of 100 to 110 psig (6.9 to 7.6 bar)
in response to varying demands from the service
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 accumulated
moisture from the control lines.
UNLOAD MODE- INEXCESS OF 110 PSIG (7.6
BAR)
When a relatively small amount or no air is being
used, the service line pressure continues to rise.
When it exceeds 110 psig (7.6 bar), the WS
Controller control system de- energizes the solenoid
valve allowing separator/sump tank air pressure to
be supplied directly to close the inlet valve.
Simultaneously, the solenoid valve sends a
pneumatic signal to the blowdown valve. The
blowdown valve opens to the atmosphere, located in
the compressor separator/sump tank, reducing the
separator/sump tank pressure to approximately 17
psig (1.2 bar). The check valve in the air service line
prevents line pressure from returning to the
separator/sump tank.
When the line pressure drops to the low setting (cut-
in pressure; usually 100 psig (6.9 bar) on low
pressure (7 bar) compressors and 125 psig (8.6 bar)
on high pressure (9 bar) compressors, 150 psig (10.3
bar) on (10 bar) compressors, 175 psig (12.0 bar) on
(12 bar) compressors), the WS Controller energizes
the solenoid valve and allows the blowdown valve to
close. The re- energized solenoid valve again
prevents line pressure from reaching the inlet control
valve. Should the pressure begin to rise, the
pressure regulator will resume its normal function as
previously described.
LOAD / NOLOAD CONTROL
If desired by the customer, the compressor can be
set to operate load/no load without modulating
control. This control mode is often selected when a
large amount of compressed air storage (air tank) is
available. Using the WS Controller keypad, select
"load/no load control" from the menu. On a machine
rated for 100 psig (7 bar) the compressor will run in
the full load mode up to 100 psig (7 bar). If less than
the rated capacity is required, pressure will rise
above 100 psig and the WS Controller will de-
energize the solenoid valve, causing the compressor
to run in the unload mode. When the system
pressure falls to 90 psig (6.3 bar), the WS Controller
energizes the solenoid valve, causing the
compressor to return to the full load mode. The
compressor will thus operate to keep the system
pressure in the range of 90-100 psig (6.3 - 6.9 bar).
AUTOMATIC OPERATION
For applications with varied periods of time when
there are no air requirements, the WS Controller's
AUTOMATIC mode allows the compressor to
shutdown (time delayed) when no compressed air
requirement is present and restart as compressed air
is needed.

SECTION 2 3000P-4500 USER MANUAL
19
2.7 AIR INLET SYSTEM,
FUNCTIONAL DESCRIPTION
Refer to Figure 2-6. The compressor inlet system
consists of a dry-type air filter, a restriction gauge
and an air inlet valve.
The restriction gauge (located on the air filter)
indicates the condition of the air filter by showing red
when filter maintenance is required.
The poppet-type modulating air inlet valve directly
controls the amount of air intake to the compressor in
response to the operation of the pressure regulator.
Refer to Full Load Mode - 50 to 100 PSIG (3.4 to 6.9
BAR) on page 18. The inlet valve also acts as a
check valve, thus preventing reverse rotation when
the compressor is shut down.
Figure 2-6: Air Inlet System
1. Air Inlet Filter
2. Air Inlet
3. Compressor Unit
4. Separator/Sump Tank
5. 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.

3000P-4500 USER MANUAL SECTION 2
20
2.8 INTEGRAL DRYER OPTION
An integral refrigerated dryer option is available. The
integral dryer is designed to work with the
compressor WS controller which controls dryer
starting and stopping, condensate drain valve
function and monitors dewpoint temperature and
dryer warnings and faults. The dryer is fully
connected from the factory and is ready to run when
the compressor is installed.
Detail of dryer operation and spare parts can be
found in a supplement Manual 02250174-308 which
is provided with your machine.
Per the controller default settings, on initial start-up
the compressor will run unloaded for 5 minutes,
allowing the dryer to run and cool down. This
prevents condensate from initially being allowed into
the compressed air stream. It also delays the supply
of compressed air from the compressor until the 5
minute cool-down period is completed. When the
automatic control mode is selected, the compressor
will stop after running unloaded for a prescribed time,
but the dryer will continue to run to ensure there will
not be a surge of condensate when the compressor
re-starts. For other settings and control options, refer
to the WS controller manual 02250165-411, or to
your authorized Sullair servicing distributor.
In case the compressor needs to operate while the
dryer is being serviced, the dryer can be bypassed,
and removed if necessary for service. To bypass the
dryer, disconnect the inlet hose to the dryer,
disconnect the outlet hose at the main service
connection, and re-connect the dryer inlet hose to the
main service connection. Remove the fuses
powering the dryer and control wiring located in the
compressor electrical box. The WS controller must
be set-up for the compressor to run on dryer fault. If
necessary, this can be reset by your authorized
Sullair servicing distributor.
2.9 VARIABLE SPEED DRIVE
(VSD) COMPONENTS
The VSD, located in the machine’s electrical
enclosure, works in concert with the WS Controller to
allow the compressor to match its output to the
current demand of the system. The drive’s heat sink
extends through the back of the enclosure, and its
cooled by aiir flowing through the compressor
enclosure.
2.10 VSD CONTROL SYSTEM
FUNCTIONAL DESCRIPTION
Refer to Figure 2-4. The controls consist of:
• a VSD
• a solenoid valve
• a regulating valve
• and an inlet valve.
Depending on the model, a compressor can be
operated at a setpoint pressure from 60 to 175 psig
(4.1 to 12.1 bar). The WS Controller automatically
sets the frequency range based on the selected
pressure. (The compressor's operating range is on
its nameplate.)
The following paragraphs apply to a compressor with
a 100 psig (6.9) operating pressure and a 6 psi (0.4
bar) load delta setting.
Compressors with different pressure operating
ranges perform in the same manner.
START MODE - 0 TO 50 PSIG (0 TO 3.5
BAR)
Pressing the WS Controller START button (1) signals
the VSD to accelerate the motor to full speed,
causing the separator/sump tank pressure to rise
from 0 to 50 psig (0 to 3.4 bar). At this time both the
pressure regulator and solenoid valves are closed;
the inlet valve is fully open and the air-end provides a
full flow to the separator/sump tank. A minimum
pressure valve set at approximately 50 psig (3.4 bar)
isolates the rising compressor air pressure from the
service line.
FULL LOAD MODE - 50 TO 100 PSIG (3.4
TO 6.9 BAR)
When the compressed air pressure rises above 50
psig (3.4 bar) the minimum pressure valve opens
allowing compressed air to flow into to the service
line. From this point on the WS Controller monitors
the line pressure which controls the VSD. The
pressure regulator and solenoid valves remain
closed with the inlet valve fully open, running at 100
psig (6.9 bar) or lower.
NOTE
The load delta default setting is 10 psi (0.7
bar). Sullair recommends a setting of 6
psi (0.4) for the most efficient operation.