Sullair 3000PB User manual

Industrial Air Compressor
3000PB, 3700B, 4500B,
3000PVB, 3700VB, 4500VB
40, 50 & 60 hp (30, 37 & 45 kW)
PART NUMBER:
02250216-786 R01
The information in this manual is current as of its
publication date and applies to compressors with
serial number:
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 in this manual,
or misuse of this equipment, will
void its warranty.
Subject to EAR, ECCN EAR99 and related export control restrictions.
SAFETY WARNING
Users are required to read the
entire User Manual before mov-
ing or using the product.

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 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, LLC
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
Subject to EAR, ECCN EAR99 and related export control restrictions.

Table of Contents
3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Table of Contents
02250216-786 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. i
Section 1: Safety.......................................................................................................1
1.1 General....................................................................................................... 1
1.2 Personal protective equipment ................................................................... 1
1.3 Pressure release ........................................................................................ 1
1.4 Fire and explosion ...................................................................................... 2
1.5 Moving parts ............................................................................................... 2
1.6 Hot surfaces, sharp edges and sharp corners............................................ 3
1.7 Toxic and irritating substances ................................................................... 3
1.8 Electrical shock........................................................................................... 4
1.9 Lifting.......................................................................................................... 4
1.10 Entrapment................................................................................................. 5
1.11 Implementation of lockout/tagout................................................................ 5
1.12 Safety warnings .......................................................................................... 6
Section 2: Description..............................................................................................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 discharge system, functional description ............................. 12
2.6 Control system, functional description...................................................... 15
2.7 Air inlet system, functional description ..................................................... 17
2.8 Variable speed drive (VSD) components ................................................. 18
2.9 VSD control system, functional description .............................................. 18
Section 3: Specifications.......................................................................................21
3.1 Table of specifications—3000PB, 3700B, 4500B models ........................ 21
3.2 Table of specifications—variable speed models ...................................... 22
3.3 Compressor specifications ....................................................................... 23
3.4 Motor specifications.................................................................................. 23
3.5 Lubrication guide ...................................................................................... 23
3.6 Application guide ...................................................................................... 24
3.7 Lubrication change recommendations and maintenance, fluid ................ 25

Table of Contents 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual
02250216-786 R01
ii Subject to EAR, ECCN EAR99 and related export control restrictions.
3.8 Identification, air-cooled ............................................................................26
3.9 Identification, water-cooled .......................................................................28
3.10 Piping and instrumentation, air-cooled......................................................30
3.11 Piping & instrumentation, water-cooled ....................................................32
3.12 Wiring diagram, air-cooled MFV ...............................................................34
3.13 Wiring diagram, YD...................................................................................36
3.14 Wiring diagram, VSD air-cooled parallel wye A1000 (460V only).............38
3.15 Wiring diagram, VSD air-cooled series delta A1000 (230/575V only) ......40
Section 4: Installation............................................................................................43
4.1 Mounting of compressor ...........................................................................43
4.2 Ventilation & cooling .................................................................................43
4.2.1 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 Outdoor installation (sheltered).................................................................46
4.4 Service air piping ......................................................................................46
4.4.1 Pipe sizing........................................................................................................... 47
4.4.2 Use of auxiliary receiver tank .............................................................................. 47
4.5 Coupling alignment check.........................................................................48
4.6 Fluid level check .......................................................................................48
4.7 Electrical preparation ................................................................................48
4.8 Motor rotation direction check...................................................................48
Section 5: WS Controller™ ...................................................................................51
5.1 Controller layout........................................................................................51
5.2 Controller keypad......................................................................................51
5.3 LCD display...............................................................................................52
5.4 LED lights..................................................................................................53
Section 6: Maintenance .........................................................................................55
6.1 General .....................................................................................................55
6.2 Daily operation ..........................................................................................55
6.3 Maintenance after initial 50 hours of operation .........................................55
6.4 Maintenance every 2000 hours.................................................................55
6.5 Fluid maintenance.....................................................................................55
6.6 Filter maintenance ....................................................................................56
6.6.1 Fluid filter element replacement .......................................................................... 56

3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Table of Contents
02250216-786 R01
Subject to EAR, ECCN EAR99 and related export control restrictions. iii
6.7 Air filter maintenance................................................................................ 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 Water condensate drain maintenance...................................................... 59
6.12 Control line strainer .................................................................................. 59
6.13 Shaft coupling maintenance ..................................................................... 59
6.14 Troubleshooting........................................................................................ 59
6.14.1 Introduction ..........................................................................................................59
6.14.2 Troubleshooting guide .........................................................................................59