Sullair ES-6 5H Guide

ROTARY SCREW
ES--6 Series
5, 7.5 and 10HP
OPERATOR’S
MANUAL AND
Part Number 02250123-285
eSullair Corporation
PARTS LIST
AIR COMPRESSOR
4, 5.5 and 7.5 kw
KEEP FOR
FUTURE
REFERENCE
Standard & 24KT

AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are 3--day courses that provide hands--on instruction
in the proper operation, maintenance and service of Sullair equipment.
Individual seminars on Industrial compressors and compressor electrical
systems are presented at regular intervals throughout the year at a dedicated
training facility at Sullair’s corporate headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service
parts, troubleshooting of the most common problems, and actual equipment
operation. The seminars are recommended for maintenance and service
personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1--888--SULLAIR or 219--879--5451 (ext. 5363)
-- Or Write --
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department

TABLE OF CONTENTS
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL
Section 1 PAGE
SAFETY 11.1 GENERAL
11.2 PERSONAL PROTECTIVE EQUIPMENT
11.3 PRESSURE RELEASE
11.4 FIRE AND EXPLOSION
21.5 MOVING PARTS
21.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
21.7 TOXIC AND IRRITATING SUBSTANCES
31.8 ELECTRICAL SHOCK
31.9 LIFTING
41.10 ENTRAPMENT
Section 2
DESCRIPTION 52.1 INTRODUCTION
52.2 DESCRIPTION OF COMPONENTS
52.3 ENCAPSULATED COMPRESSOR SYSTEM,
FUNCTIONAL DESCRIPTION
52.4 COMPRESSOR COOLING SYSTEM,
FUNCTIONAL DESCRIPTION
52.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
72.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
82.7 INSTRUMENTATION, FUNCTIONAL DESCRIPTION
Section 3
SPECIFICATIONS 93.1 SPECIFICATIONS-- ES--6
10 3.2 COMPRESSOR LUBRICATION GUIDE
10 3.3 LUBRICATION GUIDE--- 24KT COMPRESSORS
10 3.4 LUBRICATION GUIDE--- OPTIONAL FLUID
Section 4
INSTALLATION 13 4.1 LOCATION OF COMPRESSOR
13 4.2 VENTILATION AND COOLING
13 4.3 SERVICE AIR PIPING
13 4.4 FLUID LEVEL CHECK AND CHANGE PROCEDURE
14 4.5 MOTOR ROTATION DIRECTION CHECK
14 4.6 ELECTRICAL PREPARATION

TABLE OF CONTENTS
(CONTINUED)
Section 5 PAGE
OPERATION 15 5.1 GENERAL
15 5.2 PURPOSE OF CONTROLS
16 5.3 INITIAL START--UP PROCEDURE
16 5.4 SUBSEQUENT START--UP PROCEDURE
16 5.5 SHUTDOWN PROCEDURE
Section 6
MAINTENANCE 17 6.1 GENERAL
17 6.2 DAILY OPERATION
17 6.3 MOTOR BEARING LUBRICATION
17 6.4 FLUID FILTER MAINTENANCE
17 6.5 COOLER MAINTENANCE
18 6.6 PARTS REPLACEMENT MAINTENANCE AND ADJUSTMENT
PROCEDURES
18 FLUID FILTER REPLACEMENT
18 AIR FILTER ELEMENT MAINTENANCE
19 SEPARATOR ELEMENT REPLACEMENT
19 MINIMUM PRESSURE/CHECK VALVE MAINTENANCE
20 THERMOSTAT ACTUATOR MAINTENANCE
20 CONTROL SYSTEM ADJUSTMENT
21 PRESSURE SWITCH ADJUSTMENT
21 PRESSURE REGULATOR ADJUSTMENT
21 UNLOADER SOLENOID VALVE MAINTENANCE
22 INLET CONTROL VALVE
22 MOTOR SHAFT SEAL REPLACEMENT
23 6.7 TROUBLESHOOTING
23 6.8 TROUBLESHOOTING GUIDE
25 6.9 MAINTENANCE RECORD
Section 7
ILLUSTRATIONS AND
PARTS LIST 27 7.1 PROCEDURE FOR ORDERING PARTS
27 7.2 RECOMMENDED SPARE PARTS LIST
28 7.3 FLUID MANAGEMENT SYSTEM
30 7.4 INLET FILTER
32 7.5 SEAL AND DRIVE GEAR
34 7.6 MOTOR, HOUSING AND PARTS
36 7.7 COMPRESSOR COOLER SYSTEM
38 7.8 COMPRESSOR SYSTEM
42 7.9 INLET CONTROL

TABLE OF CONTENTS
(CONTINUED)
Section 7 PAGE
ILLUSTRATIONS AND
PARTS LIST (CONT) 44 7.10 CONTROL BOX
48 7.11 WYE--DELTA ELECTRIC BOX--- PART ONE
50 7.12 WYE--DELTA ELECTRIC BOX-- PART TWO
52 7.13 ENCLOSURE
56 7.14 DECAL GROUP
62 7.15 DECAL LOCATIONS
66 7.16 WIRING DIAGRAM-- DUAL CONTROL FULL VOLTAGE 2--WIRE
67 7.17 WIRING DIAGRAM-- DUAL CONTROL FULL VOLTAGE 3--WIRE
68 7.18 WIRING DIAGRAM-- DUAL CONTROL 200--230/1/60 5HP
69 7.19 WIRING DIAGRAM-- DUAL CONTROL WYE--DELTA

NOTES

Section 1
SAFETY
1
1.1 GENERAL
Sullair Corporation and its subsidiaries design and
manufacture all of their products so they can be op-
erated 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 fol-
lowed, 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
whohavereadandunderstoodthisOperator’sMan-
ual. 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.DONOT attempt tooperate thecompressorwith
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 notknowof the un-
safe 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 com-
pressors with alltypes of prime movers, most of the
precautionary statements contained herein are ap-
plicable to most compressors and the concepts be-
hindthesestatements aregenerallyapplicabletoall
compressors.
1.2 PERSONAL PROTECTIVE EQUIPMENT
Prior to installing or operatingthe compressor, own-
ers, employers and users should become familiar
with, and comply with, all applicable OSHA regula-
tionsand/or anyapplicable Federal,State andLocal
codes, standards, and regulations relative to per-
sonal protective equipment, such as eye and face
protective equipment, respiratory protective equip-
ment, equipment intended to protect the extremi-
ties,protectiveclothing, protectiveshieldsandbarri-
ers and electrical protective equipment, as well as
noise exposure administrative and/or engineering
controls and/or personal hearing protective equip-
ment.
1.3 PRESSURE RELEASE
A.Install anappropriateflow--limiting valvebetween
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 exceeding 1/2”
(13mm) inside diameter is to be connected to the
shut--off (throttle) valve, to reduce pressure in case
of hose failure, per OSHA Standard 29 CFR
1926.302(b)(7) and/or any applicable Federal,
State and Local codes, standards and regulations.
B. Whenthehoseisto beused tosupplyamanifold,
install an additional appropriate flow--limiting valve
between the manifold and each air hose exceeding
1/2” (13mm) inside diameter that is to beconnected
to the manifold to reduce pressure in case of hose
failure.
C. Provide an appropriate flow--limiting valve at the
beginningof eachadditional 75feet (23m)of hosein
runs of air hose exceeding 1/2” (13mm) inside di-
ameter to reduce pressure in case of hose failure.
D. Flow--limiting valves are listed by pipe size and
rated CFM. Select appropriate valves accordingly,
inaccordancewith their manufacturer’srecommen-
dations.
E. DO NOT use air tools that are rated below the
maximum rating of the compressor. Select airtools,
air hoses, pipes, valves, filters and other fittings ac-
cordingly. DO NOT exceed manufacturer’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 whencompressor isnot
running and is not pressurized. Shut down the
compressor and bleed the sump (receiver) 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 andaway from the
discharge opening of hoses or tools or other points
of compressed air discharge.
J. Useairatpressuresless than30psig(2.1bar)for
cleaning purposes, and then only with effective chip
guarding and personal protective equipment per
OSHA Standard 29 CFR 1910.242 (b) and/or any
applicable Federal, State, and Local codes, stan-
dards 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.Shutoffthecompressorandallowittocool. 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
airlineanti--icer systems with antifreezecompound.
C. DO NOT permit fluids, including air line anti--icer
system antifreeze compound or fluid film, to accu-

Section 1
SAFETY
2
mulate on, under or around acoustical material, or
on anyexternalsurfaces of the aircompressor oron
internal surfaces of the enclosure. Wipe downusing
an aqueous industrial cleaner or steam clean asre-
quired. If necessary, remove acoustical material,
clean allsurfaces andthen replaceacousticalmate-
rial. Any acoustical material with a protective cover-
ing that has been torn or punctured should be re-
placed immediately to prevent accumulation of liq-
uids or fluid film within the material. DO NOT use
flammable 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
pressureconnectors ingoodcondition. Replaceany
wiring that has cracked, cut, abraded or otherwise
degraded insulation, or terminals that are worn, dis-
colored or corroded. Keep all terminals and pres-
sure 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.Removeanyacousticalmaterialor othermaterial
that may be damaged by heat or that may support
combustion and is in close proximity, prior to at-
tempting weld repairs.
H. Keep suitable fully charged Class BC or ABC fire
extinguisherorextinguishersnearbywhenservicing
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
flowofcoolingairorwaterorwithinadequateflow 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 also clothing away from couplings, fans and
other moving parts.
B. DO NOT attempt to operatethe compressor with
the fan, coupling or other guards removed.
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 oper-
ate it.
F. Disconnect and lock out all power at source and
verify at the compressor that all circuits are de--en-
ergized to minimize the possibility of accidental
start--up, or operation, prior to attempting repairs or
adjustments. This is especially important when
compressors are remotely controlled.
G. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water or other liq-
uids 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 infection.
1.7 TOXIC AND IRRITATING SUBSTANCES
A.DONOTuseairfrom thiscompressor forrespira-
tion(breathing)exceptinfullcompliance withOSHA
Standards 29 CFR 1910 and/or any applicable Fed-
eral, State or Local codes or regulations.
DANGER
!
Death or serious injury can result from inhaling
compressed air without using proper safety
equipment. See OSHA standards and/or any ap-
plicable Federal, State, and Local codes, stan-
dards and regulations on safety equipment.
B. DO NOT useairlineanti--icer systems in airlines
supplying respirators or other breathing air utiliza-
tion 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
sothatitisnotlikelytoingestexhaustfumes orother
toxic, noxious or corrosive fumes or substances.
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. Weargogglesorafullfaceshieldwhenaddingan-
tifreeze compound to air line anti--icer systems.

Section 1
SAFETY
3
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 immediately.
H. DO NOT storeairlineanti--icersystemantifreeze
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 swal-
lowed, induce vomiting by administering a table-
spoon ofsalt, ineachglass ofclean,warm waterun-
til vomit is clear, then administer two teaspoons of
baking soda in a glass of clean water. Have patient
laydownand covereyesto excludelight. Callaphy-
sician immediately.
1.8 ELECTRICAL SHOCK
A. This compressor should be installed and main-
tained in full compliance with all applicableFederal,
State and Local codes, standards and regulations,
including those of the National Electrical Code, and
alsoincludingthoserelativetoequipmentgrounding
conductors, and only by personnel that are trained,
qualified and delegated to do so.
B. Keep all parts of the body and any hand--held
tools or other conductive objects away from ex-
posed 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 liveparts
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,
thendisconnect,lockoutandtag allpoweratsource
so others will not inadvertently restore power.
E. Disconnect, lock out, and tag all power at source
priortoattempting repairs oradjustments torotating
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 slingsinstead. In any event, lift and/or handle
only in full compliance with OSHA standards 29
CFR 1910 subpart N and/or any applicable Federal,
State, and Local codes, standards and regulations.
B. Inspect points of attachment for cracked welds
and for cracked, bent, corroded or otherwise de-
graded members and for loose bolts or nuts priorto
lifting.
C. Make sure entire lifting, rigging and supporting
structure has been inspected, is in good condition
and hasa rated capacity of at least the weight ofthe
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
orswingingofthecompressoronceithasbeenlifted
clear of the ground.
F. DO NOT attempt to lift in high winds.
G.Keep allpersonnel outfrom underand awayfrom
the compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
I. Keep lift operator in constant attendance when-
ever compressor is suspended.
J. Set compressor down only on a level surface ca-
pable 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 pocketsor palletare
provided, then makesurecompressorissecureand
well balanced on forks before attempting to raiseor
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 mini-
mum 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 toforklift acompressorthatisnotsecuredto
its pallet, as uneven floors or sudden stops may
cause the compressor to tumble off, possibly caus-
ingseriousinjuryorpropertydamageintheprocess.

Section 1
SAFETY
4
1.10 ENTRAPMENT
A. If the compressor enclosure, if any, is large
enoughto holda man andifitis necessaryto enterit
to perform service adjustments, inform other per-
sonnel before doing so, or else secure and tag the
access door in the open position to avoid the possi-
bility of others closing and possibly latching thedoor
with personnel inside.
B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.

Section 2
DESCRIPTION
5
2.1 INTRODUCTION
Your new Sullair flood--lubricated rotary screw air
compressor will provide youwith improvedreliability
and greatly reduced maintenance.
Compared to other types of compressors, the Sul-
lair rotary screw is unique in mechanical reliability,
with “no wear” and “no inspection” required of the
working parts within the compressor unit.
Read Section 6 (Maintenance) to keep your com-
pressorintopoperatingcondition.Should anyques-
tions arise which cannot be answered in the follow-
ing text, call your nearest Sullair office or the Sullair
Corporation Service Department.
2.2 DESCRIPTION OF COMPONENTS
Refer toFigure2--1.The components and assem-
blies of the ES--6 Series air compressor are clearly
shown. The complete compressor consists of an
encapsulated compressor system, inlet sys-
tem, cooling system and control system.
The compact design of the ES--6 Series air com-
pressor provides easy access to all serviceable
components.
2.3 ENCAPSULATED COMPRESSOR SYSTEM,
FUNCTIONAL DESCRIPTION
Refer toFigure2--2.The encapsulated compressor
includes compressor unit, fluid management sys-
tem, and motor section. The Sullair compressor unit
is a single--stage positive displacement lubricated
type compressor. This unit is equipped withtapered
roller bearings on the discharge, and cylindrical
roller bearings on the inlet end for high loadcarrying
capacity. This unit provides continuous pulse--free
air compression to meet your needs. With a Sullair
compressorthere willbeno maintenance or internal
inspection of the compressor.
WARNING
!
DONOT remove caps, plugs and/or other compo-
nents when compressor is running or pressur-
ized.
Stop compressor and relieve all internal pressure
before doing so.
Fluid is injected into the compressor unit in large
quantities and mixes directly with the air as the ro-
tors turn, compressing the air. The fluid flow has
three main functions:
1. As coolant, it controls the rise of air temperature
normally associated with the heat of compres-
sion.
2. It seals the leakage paths between the rotors and
the stator and also between the rotors them-
selves.
3. It acts as a lubricating film between the rotors al-
lowing one rotor to directly drive the other, which
is an idler.
The air/fluid mixture discharges directlyinto thefluid
management system.
The fluid cooler bypass valve helps assure proper
cooling by directing the fluid to the fluid cooler when
dischargetemperature reaches thethermostat tem-
perature setting.
During start--up in cool ambient conditions, the
cooler pressure drop will cause the filter bypass
valve to open up, assuring adequate fluid supply to
the compressor.
All fluid entering the compressor unit passes
through the replaceable fluid filter element. This re-
placeable filter element contains a built--in bypass
valve. Under conditions of restricted flow through
the element, the bypass valve helps ensure ade-
quate compressor fluid flow, as well as helps pre-
vent element failure.
FLUID MANAGEMENT SYSTEM
The fluid management system consists of a multi--
chambered primary/secondary separator, the fi-
nal air/fluid separator element, cooler bypass
group and fluid filter.
As compressed air/fluid enters the sump, the first
fluid separation takes place due to a reduction of
flow speed coupled with a change of direction of the
flowwithinthesumphousing.Then thecompressed
air reaches the separator, where the finest fluid
drops and mist are separated.
MOTOR/DRIVE SECTION
The motor/drive section consists of a squirrel cage
induction motor and integrated drive gearing which
is separated from the motor by a replaceable shaft
seal.
The minimum pressure/discharge check valve is
mounted on the compressor drivehousing. Its func-
tions are as follows:
1. Maintain a minimum sump pressure of 60 psig
(4.1 bar) under full load operation to help assure
adequate fluid pressure.
2. Act as a check valve to isolate the compressor
from the system at shutdown or unload.
2.4 COMPRESSOR COOLING SYSTEM, FUNC-
TIONAL DESCRIPTION
The compressor cooling system consists of a fluid
cooler, fan and cooler shroud.
The fan is mounted on the motor’s shaft end oppo-
site the compressor. Air is drawn over the motor as
well as through the cooler. The air provides motor
cooling and removes compression heat from the
fluid.
2.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIP-
TION
Thecompressorinletsystemconsistsofadry--type
air filter and an air control valve. Reacting on a
pressure signal, the valve closes the intake for un-
loaded operation. The valve also acts as a check
valve upon shutdown.

Section 2
DESCRIPTION
6
Figure 2-1 Description of Components

Section 2
DESCRIPTION
7
Figure 2-2 Encapsulated Compressor System
2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIP-
TION
The purpose of the compressor control system is to
maintain compressor capacity to meet the system
demand.
It consists of an inlet valve, pressure regulator
valve, solenoid valve, control lines and the mo-
tor start selector switch.
The selector switch has three settings: MANUAL/
START,OFF/RESET and AUTOMATIC START/
STOP.
MANUAL MODE
In the manual mode the ball valve should be closed
to isolate the pressure regulator. The compressor
motor will start and the air control solenoid will be
energized (closed.) During this time the inlet valve
is fully open due to inlet air flow, and the compres-
sorwill start todeliver compressed air. When the air
demand is less than the rated flowforthecompres-
sor, the service line pressure will rise to the pres-
sure switch cut---out setting. The system pressure
switch opens, interrupting the electrical power to
thesolenoid valve. Thesolenoidvalve opens allow-
ing pressure to be applied to the inlet valve causing
theinletvalvetofullyclose. Thecompressorwill
continue to run (unloaded) until the line pressure
drops to the low setting of the pressure switch --- ---
the pressure switch closes, reenergizing the nor-
mally open solenoid valve and allows the compres-
sor to load again.
MANUAL MODULATION CONTROL MODE
In the modulation control mode the ball valve
should be open to allow pressure to the pressure
regulator. The compressor motor will start and the
system pressure will rise until it reaches the set
point of the pressure regulator. The pressure regu-
lator will them begin to open allowing pressure to
be applied to the inlet valve. The pressure regula-
torwill modulate the inlet valve tomatch system de-
mand.
OFF/RESET MODE
The compressor motor, if running, willstop if theoff/
reset position is selected. If the compressor during
normalrunninghasafaultcausedbyeitheroverload
or high discharge temperature, the compressor will
stop. After a fault hasbeen cleared, the compressor

Section 2
DESCRIPTION
8
can not be restarted unless the Off/Reset mode is
selected on the selector switch, prior starting in any
other mode of operation.
AUTOMATIC MODE
In theautomatic mode of operation, the compressor
operates the same as in the manual mode except
that when the pressure switch unloads the machine
the compressor motor willstop. The motor willauto-
matically restart when the line pressuredrops to be-
low the set--point of the air pressure switch. If the
compressor is equipped with a wye--delta starter,
the compressor will not restart until the compressor
sump pressure drops to the minimum set--point on
thesump pressureswitch. It is notrecommendedto
open the pressure regulator ball valve for the auto-
matic mode of operation.
2.7 INSTRUMENTATION, FUNCTIONAL DESCRIP-
TION
Due to the simplicity of the ES--6 Series compres-
sor, the only instrumentation necessary is a line
pressure gauge which is located on the left side of
the electrical control center and a discharge tem-
perature gauge which is located on the right side of
the electrical control center. The line pressure
gauge reads plant air system pressure only.
NOTE
At compressor shutdown, the sump pressure is
released to atmosphere through the solenoid
valve. The line pressure gauge will continue to
read system pressure.

Section 3
SPECIFICATIONS
9
3.1 SPECIFICATIONS -- ES--6
DIMENSIONS
ES--6 5H 5/4 18/.51 125/8.6 68/80 29.5 749 21.4 544 22.11 562 230 104
ES--6 5XH 5/4 13/.37 175/12 68/80 29.5 749 21.4 544 22.11 562 230 104
ES--6 7.5H 7.5/5.5 28/.79 125/8.6 69/82 31.5 800 21.4 544 22.11 562 270 122
ES--6 7.5XH 7.5/5.5 20/.57 175/12 69/82 31.5 800 21.4 544 22.11 562 270 122
ES--6 10H 10/7.5 38/1.08 125/8.6 70/85 31.5 800 21.4 544 22.11 562 280 127
ES--6 10XH 10/7.5 30/.85 175/12 70/85 31.5 800 21.4 544 22.11 562 280 127
Model HP/KW
Capacity
ACFM/ Maximum
PSIG/BAR
Pressure Length (II)
in. mm Width (III) Height (IV) Weight (V)
lb. kg
60Hz
M3/MIN in. mm in. mm
ES--6 5L 5/4 21.2/.60 110/7.5 68/80 29.5 749 21.4 544 22.11 562 230 104
ES--6 5HH 5/4 17.3/.49 150/10 68/80 29.5 749 21.4 544 22.11 562 230 104
ES--6 5XH 5/4 13.4/.38 175/12 68/80 29.5 749 21.4 544 22.11 562 230 104
ES--6 7.5L 7.5/5.5 30/.85 110/7.5 69/82 31.5 800 21.4 544 22.11 562 270 122
ES--6 7.5HH 7.5/5.5 24.4/.69 150/10 69/82 31.5 800 21.4 544 22.11 562 270 122
ES--6 7.5XH 7.5/5.5 20.5/.58 175/12 69/82 31.5 800 21.4 544 22.11 562 270 122
ES--6 10L 10/7.5 39.2/1.11 110/7.5 70/85 31.5 800 21.4 544 22.11 562 280 127
ES--6 10HH 10/7.5 33.9/.96 150/10 70/85 31.5 800 21.4 544 22.11 562 280 127
ES--6 10XH 10/7.5 28.2/.80 175/12 70/85 31.5 800 21.4 544 22.11 562 280 127
Model HP/KW
Capacity
ACFM/ Maximum
PSIG/BAR
Pressure in. mm lb. kg
50Hz
M3/MIN
dBA (I)
in. mm in. mm
with canopy/
without canopy
DIMENSIONS
(II) Enclosure option length is 51.5 in/ 1308 mm.
(III) Enclosure option width is 31 in/ 787 mm.
(IV) Enclosure option height is 25.5 in/ 648 mm.
(I) Ratings of dBA at one meter.
Length (II) Width (III) Height (IV) Weight (V)
(V) For enclosure models, add 100 lbs/ 45.4 kg
to base weight of machine
dBA (I)
with canopy/
without canopy
COMPRESSOR
Type: Single Stage Fluid Injected Screw Compressor
Minimum Full Load Operating Pressure: 60 psi (4.1 bar)
Maximum Full Load Operating Pressure: Nameplate Pressure (VI)
Bearing Type: Anti--friction
Cooling: Pressurized Fluid
Lubricant: See Lubricant Specification (Section 3.2)
Sump Capacity: 4.6 quarts (4.35 liters)
(VI) Compressors are available for pressures up to 175 psi (12.1 bar).
MOTOR 60Hz 50Hz
Type: 5, 7.5, 10HP/ 5, 7.5, 10HP/
4, 5.5 & 7.5 KW 1.15 S.F. 4, 5.5 & 7.5 KW
Synchronous Speed: 1800 RPM 1500 RPM (5, 7.5HP/4, 5.5KW)
3000 RPM (10HP/7.5KW)
Voltage:
Standard All Sizes 230/460V 3 Phase 380/415 3 Phase
Optional All Sizes 200V 3 Phase 380/415 3 Phase
Optional All Sizes 575V 3 Phase 380/415 3 Phase
Optional 5HP Only 230V Single Phase 380/415 3 Phase
Type: Totally Enclosed Air Over Totally Enclosed Air Over
Insulation Class: “F” “F”
Maximum Ambient Temp.: 40_C (104_F) 40_C (104_F)
Shaft Diameter Fan: Nominal 5/8” Nominal 5/8”
Key Size Fan: Nominal 3/16” x 3/16” x 1 1/4” Nominal 3/16” x 3/16” x 1 1/4”
FLUID FILTER (Internal Bypass Valve Set at 25 psig)
Type: Spin on, Sullair Proprietary
Micron: 23 Microns Abs.
FLUID SEPARATOR ELEMENT
Type: Push In Cartridge, Sullair Proprietary
Efficiency at Maximum Capacity: 3PPM Maximum

Section 3
SPECIFICATIONS
10
3.2 COMPRESSOR LUBRICATION GUIDE
For best value and longest uninterrupted service,
the ES--6 compressor is factory filled with Sullube, a
long life lubricant, unless a different lubricant is re-
quested.
If, due to availability or other reasons, other fluids
arerequired, follow Sections 3.3,3.4and Table3--1,
Lubrication Guide.
WARNING
!
“The Plastic Pipe Institute recommends against
the use of thermoplastic pipe to transport com-
pressed air or other compressed gases inexposed
above ground locations, e.g. in exposed plant pip-
ing.” (I)
Sullube should not be used with PVC piping sys-
tems. It may affect the bond at cemented joints.
Certain other plastic materials may also be af-
fected.
(I) Plastic Pipe Institute, Recommendation B,
Adopted January 19, 1972.
Maintenance of all other components is still recom-
mended as indicated in the Operator’s Manual.
For light--duty high--humidity service where con-
densed moisture and emulsification (mayonnaise)
may occur, the fluid change interval must be re-
duced to 300 hours maximum. A non--detergent
fluid with rust, oxidation and foam inhibitors and
good water separation characteristics should be
used.
WARNING
!
Mixing of other fluids within the compressor will
void all warranties.
Contamination of non--detergent mineral fluids with
traces of ATF or detergent motor fluids may lead to
operational problems such as foaming, filter plug-
ging, orifice or line plugging. Flushing is required if
changing to a different lubricant.
When ambient conditions exceed those noted or if
conditions warrant use of “extended” life lubricants
contact Sullair for recommendation.
Sullair encourages the user to participate in a fluid
analysis program. This could result in a fluid change
interval that is different from those stated in this
manual.
3.3 LUBRICATION GUIDE--24KT COMPRESSORS
Sullair 24KT compressors are filled with a lubricant
which rarely needs to be changed. In the event a
change of fluid is required, use only Sullair 24KT
fluid.
WARNING
!
Mixing of other lubricants within the compressor
unit will void all warranties!
Sullair recommends that a 24KT sample betakenat
the first filter change andsent to the factory for anal-
ysis.This isafree service.A samplekit withinstruc-
tions and self--addressed container is tobesupplied
by your SullairRepresentative at start--up. The user
will receive an analysis report with recommenda-
tions.
3.4 LUBRICATION GUIDE--OPTIONAL FLUID
Sullair compressors may use SRF 1/4000 fluid as
an optional factory fill.
WARNING
!
Mixing of other fluids within the compressor will
void all warranties!
SRF 1/4000 fluid should be changed every 4000
hours or once a year, whichever comes first. The
fluid should be changed more frequently under se-
vere operating conditions, such as high ambient
temperatures coupled with high humidity, or when
high particulate level, corrosive gases or strong oxi-
dizing gases are present in the air.
Maintenance ofall other components is still recom-
mended as indicated in the Operator’s Manual.
LUBRICANT FLUID CHANGE SEPARATOR CHANGE
B--4,000 Hours or more frequently if conditions so require.
FLUID FILTER CHANGE
C--When measured pressure loss exceeds 20 psig (1.3 bar).
D--When measured pressure loss exceeds 10 psig (0.7 bar).
E--When required by fluid analysis or known contamination.
F--Does not require replacement during normal service conditions.
A--8,000 Hours or once a year.
G--Every 1000 hours.
Sullube A,E G,C A,D
SRF 1/4000 B,E G,C B,D
24KT F,E G,C A,D
Table 3-1 Lubrication Guide

Section 3
SPECIFICATIONS
11
Figure 3-1 Identification- ES-6

Section 3
SPECIFICATIONS
12
Figure 3-2 Identiification- ES-6 wiwth Canopy

Section 4
INSTALLATION
13
4.1 LOCATION OF COMPRESSOR
The ES--6 Series compressor package may be
placed on any level surface able to support its
weight.Theunitshouldbeboltedtoafixedmounting
surface to avoid the possibility of externally applied
forces or vibration which would disturb the pipingor
wiring.
4.2 VENTILATION AND COOLING
Select a location to permit sufficient unobstructed
air flow in and out of the compressor to keep the op-
erating temperature stable. The minimum distance
that the machine should be from surrounding walls
is what is needed for service and three (3) feet
(0.91m) or more from the fan air discharge end of
the compressor.
4.3 SERVICE AIR PIPING
Service air piping should be installed as shown in
Figure4--1.Ashut--off valveshould be installed to
isolate the compressor from the service line. Also
notice that the service line should be equipped with
water legs and condensate drains throughout the
system.
WARNING
!
“The Plastic Pipe Institute recommends against
the use of thermoplastic pipe to transport com-
pressed air or other compressed gases in ex-
posed above ground locations, e.g. in exposed
plant piping.” (I)
Sullube should not be used with PVC piping sys-
tems. It may affect the bond at cemented joints.
Certain other plastic materials may also be af-
fected.
(I) Plastic Pipe Institute, Recommendation B, Adopted January
19, 1972.
4.4 FLUID LEVEL CHECK AND CHANGE PROCE-
DURE
The Sullair air compressor is equipped with the
proper amount of fluid. However, it is necessary to
check the fluid level at installation. The level is
checked by looking at the fluid level sight glass lo-
cated on the end bell. See Figure2--1.
If the sump is properly filled, the fluid level should
cover 1/4 to 1/2 of the sight glass during operation.
DO NOT OVERFILL.
WARNING
!
Beforeattempting compressor maintenance, dis-
connect compressor from power source and lock
out power source. Isolate compressor from line
pressure by closing recommended discharge
shutoff valve and releasing all internal pressure
from compressor.
WARNING
!
Assure that line pressure guage on compressor
indicates “ZERO” pressure before any work is
done. Failure to comply may cause injury.
When the compressor fluid is ready to be changed,
thecompressorneedstobeshutdownwiththepow-
er to the compressor disconnected (see Warning
above). Drain the fluid from the compressor using
Figure 4---1 Service Air Piping

Section 4
INSTALLATION
14
the compressor fluid drain cap (See Figure2--1).
Fluid capacity for the compressor can be found in
Section 3,Specifications of this manual. The com-
pressor sump is properly filled when thelevel on the
fluid level sight glass is 3/4 of the sight tube. During
operation, the fluid level should cover 1/4 to 1/2 of
the sight glass. DO NOT OVERFILL.
4.5 MOTOR ROTATION DIRECTION CHECK
After theelectricalwiringhasbeendone,itisneces-
sary to check the direction of motor rotation. This
can be done by jogging the START selector switch
on the front of control center. When looking at the
motor from the cooler end of the compressor unit,
thecoolerfanshouldbeturningclockwise.Ifthemo-
tor is not turning clockwise, disconnect power to the
starter and exchange any two of the three power in-
put leads, then check rotation.
A direction of rotation decal is located on the motor
shroud, next to the cooler to insure correct motor/
compressor rotation.
4.6 ELECTRICAL PREPARATION
Interior electrical wiring is performed at the factory.
Required customer wiring is minimal, but should be
done by a qualified electrician in compliance with
OSHA, National Electrical Code, and any other
applicable State, Federal and local electrical codes
concerning isolation switches, fused disconnects,
etc. Sullair provides a wiring diagram for use by the
installer.
A few electrical checks should be made to help as-
sure that the first start--up will be trouble--free.
WARNING
!
Lethal shock hazard inside. Disconnect all power
at source before opening or servicing.
1. Check incoming voltage. Be sure that compres-
sor is wired for the correct incoming voltage.
2. Check starter for correct size, proper overload
relay and heaters.
3. Check all electrical connections for tightness.
4. “Dry run” the electrical controls by disconnecting
the motor leads T1, T2, and T3 from the starter.
Energize the control circuits by turning theselec-
torswitch tothemanualandautomatic positions,
and check all protection devices making sure
when activated, they will de--energize the starter
control coil.
5. Reconnect the motor leads and jog the motor for
a direction of rotation check as explained in Sec-
tion 4.5.
NOTE
Wiring diagram for standard compressors is
supplied on the inside cover of the Control Cen-
ter. Optional compressor wiring diagrams will
vary.