Sullair ES-6 series User manual

USER MANUAL
ES-6 SERIES
STANDARD & 24KT
5, 7.5 AND 10 HP / 4, 5.5 AND 7.5 KW
PART NUMBER:
02250173-918-R00
©SULLAIR CORPORATION
The information in this manual is current as of its publication date, and
applies to compressor serial number:
200711050000
and all subsequent serial numbers
WARRANTY NOTICE
Failure to follow the instructions and
procedures in this manual or, misuse
of this equipment will VOID its
warranty!
KEEP FOR
FUTURE
REFERENCE

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 Customer Care Training Department
1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.

TABLE OF CONTENTS
PAGE SECTION DESCRIPTION
SECTION 1 - SAFETY
11.1 GENERAL SAFETY
11.2 PERSONAL PROTECTIVE EQUIPMENT
11.3 PRESSURE RELEASE
21.4 FIRE AND EXPLOSION
21.5 MOVING PARTS
31.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
31.7 TOXIC AND IRRITATING SUBSTANCES
31.8 ELECTRICAL SHOCK
41.9 LIFTING
41.10 ENTRAPMENT
SECTION 2 - DESCRIPTION
52.1 INTRODUCTION
52.2 DESCRIPTION OF COMPONENTS
52.3 ENCAPSULATED COMPRESSOR SYSTEM,
FUNCTIONAL DESCRIPTION
72.4 COMPRESSOR COOLING SYSTEM,
FUNCTIONAL DESCRIPTION
72.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
72.6 CONTROL, FUNCTIONAL DESCRIPTION
82.7 INSTRUMENTATION, FUNCTIONAL DESCRIPTION
SECTION 3 - SPECIFICATIONS
93.1 SPECIFICTIONS - ES-6
CONTINUED...

TABLE OF CONTENTS
PAGE SECTION DESCRIPTION
SECTION 3 - SPECIFICATIONS (CONTINUED)
11 3.2 COMPRESSOR LUBRICATION GUIDE
11 3.3 COMPRESSOR LUBRICATION GUIDE -
24KT COMPRESSORS
12 3.4 LUBRICATION GUIDE - OPTIONAL FLUID
14 Figure 3-2 Identification - ES-6 Standard without Enclosure
15 Figure 3-3 Identification - ES-6 Standard with Enclosure
16 Figure 3-4 Identification - ES-6 Open Tank Mount (80 Gallon)
17 Figure 3-5 Identification - ES-6 Enclosed Tank Mount (80 Gallon)
18 Figure 3-6 Identification - ES-6 Open Tank Mount (80 Gallon) with Dryer
19 Figure 3-7 Identification - ES-6 Enclosed Tank Mount (80 Gallon) with Dryer
20 Figure 3-8 Identification - ES-6 Open Tank Mount (120 Gallon)
21 Figure 3-9 Identification - ES-6 Enclosed Tank Mount (120 Gallon)
22 Figure 3-10 Identification - ES-6 Open Tank Mount (120 Gallon) with Dryer
23 Figure 3-11 Identification - ES-6 Enclosed Tank Mount (120 Gallon) with Dryer
24 Figure 3-12 Piping and Instrumentation Diagram - Standard and Wye-Delta
26 Figure 3-13 Wiring Diagram - Dual Control Full Voltage 2-Wire
27 Figure 3-14 Wiring Diagram - Dual Control Full Voltage 3-Wire
28 Figure 3-15 Wiring Diagram - Dual Control 200-230/1/60 5HP
29 Figure 3-16 Wiring Diagram - Dual Control Wye-Delta
30 Figure 3-17 Wiring Diagram - SRS 25-100 115-230V/1/60
31 Figure 3-18 Wiring Diagram - SRS 9-18 220-240V/1/50
32 Figure 3-19 Wiring Diagram - SRS 24-30 220-240V/1/50
SECTION 4 - INSTALLATION
33 4.1 LOCATION OF COMPRESSOR
33 4.2 VENTILATION AND COOLING
33 4.3 SERVICE AIR PIPING
33 4.4 FLUID LEVEL CHECK AND CHANGE PROCEDURE
33 4.5 MOTOR ROTATION DIRECTION CHECK
33 4.6 ELECTRICAL PREPARTATION
SECTION 5 - OPERATION
35 5.1 GENERAL

TABLE OF CONTENTS
PAGE SECTION DESCRIPTION
SECTION 5 - OPERATION (CONTINUED)
35 5.2 PURPOSE OF CONTROLS
36 5.3 INITIAL START-UP PROCEURE
36 5.4 SUBSEQUENT START-UP PROCEDURE
36 5.5 SHUTDOWN PROCEDURE
SECTION 6 - MAINTENANCE
37 6.1 GENERAL
37 6.2 DAILY OPERATION
37 6.3 MOTOR BEARNING LUBRICATION
38 6.4 FLUID FILTER MAINTENANCE
38 6.5 COOLER MAINTENANCE
38 6.6 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
38 FLUID FILTER REPLACEMENT
39 AIR FILTER MAINTENANCE
39 SEPARATOR ELEMENT REPLACEMENT
40 MINIMUM PRESSURE/CHECK VALVE MAINTENANCE
40 THERMOSTAT ACTUATOR MAINTENANCE
41 CONTROL SYSTEM ADJUSTMENT
41 PRESSURE SWITCH ADJUSTMENT
41 PRESSURE REGULATOR ADJUSTMENT
42 FOR DIFFERENTIAL ADJUSTMENT OF AIR
PRESSURE SWITCH
42 UNLOADER SOLENOID VALVE MAINTENANCE
42 INLET CONTROL VALVE
44 MOTOR SHAFT SEAL REPLACEMENT
44 6.7 TROUBLESHOOTING
44 6.8 TROUBLESHOOTING GUIDE
46 6.9 MAINTENANCE RECORD
SECTION 7 - MAINTENANCE PARTS LIST
47 7.1 PROCUDURE FOR ORDERING PARTS
48 7.2 RECOMMENDED SPARE PARTS LIST

Section 1 - SAFETY
1
ES-6 USER MANUAL
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 EQUIP-
MENT
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 regulations
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 electrical
protective equipment, as well as noise exposure
administrative and/or engineering controls and/or
personal hearing protective equipment.
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 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. When the hose is to be used to supply a mani-
fold, install an additional appropriate flow-limit-
ing 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) inside diameter to reduce pressure in
case of hose failure.
D. Flow-limiting valves are listed by pipe size and
rated CFM. Select appropriate valves accord-
ingly, in accordance with their manufacturer's
recommendations.
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 discon-
nected and expelled.
G. Open fluid filler cap only when compressor is not
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 oil-
ers, and before attempting to refill optional air
line anti-icer systems with antifreeze com-
pound.

Section 1 - SAFETY
2
ES-6 USER MANUAL
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. Use air at pressures less than 30 psig (2.1 bar)
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, standards and regula-
tions.
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
antifreeze compound.
C. DO NOT permit fluids, including air line anti-icer
system antifreeze compound or fluid film, to
accumulate on, under or around acoustical
material, or on any external surfaces of the air
compressor or on internal surfaces of the
enclosure. Wipe down using an aqueous
industrial cleaner or steam clean as required. If
necessary, remove acoustical material, clean
all surfaces and then replace acoustical mate-
rial. Any acoustical 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 flammable solvents for
cleaning purposes.
D. Disconnect and lock out all power at source
prior to attempting any repairs or cleaning of
the compressor or of the inside of the enclo-
sure, if any.
E. Keep electrical wiring, including all terminals
and pressure connectors in good condition.
Replace any wiring that has cracked, cut,
abraded or otherwise degraded insulation, or
terminals that are worn, discolored or cor-
roded. Keep all terminals and pressure con-
nectors 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 mate-
rial that may be damaged by heat or that may
support 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
servicing and operating the compressor.
I. Keep oily rags, trash, leaves, litter or other com-
bustibles out of and away from the compres-
sor.
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 also clothing away from couplings, fans
and other moving parts.
B. DO NOT attempt to operate the compressor
with the fan, coupling or other guards removed.
C. Wear snug-fitting clothing and confine long hair
when working around this compressor, espe-
cially 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 acci-
dental 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
liquids to minimize the possibility of slips and
falls.

Section 1 - SAFETY
3
ES-6 USER MANUAL
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 SUB-
STANCES
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
applicable Federal, State or Local codes or
regulations.
B. DO NOT use air line anti-icer systems in air
lines supplying respirators or other breathing
air utilization equipment and DO NOT dis-
charge air from these systems into unventi-
lated 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 sys-
tems.
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 con-
tacted immediately.
H. DO NOT store air line anti-icer system anti-
freeze 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 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
Federal, State and Local codes, standards and
regulations, including those of the National
Electrical Code, and also including those rela-
tive to equipment grounding 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
exposed live parts of electrical system. Main-
tain 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 pos-
sibility of creating a current path through the
heart.
Death or serious injury can result
from inhaling compressed air with-
out using proper safety equipment.
See OSHA standards and/or any
applicable federal, state, and local
codes, standards and regulations on
safety equipment.
WARNING

Section 1 - SAFETY
4
ES-6 USER MANUAL
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 pro-
vided, 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 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
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 lift-
ing.
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 twist-
ing 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 sus-
pended.
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
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, uti-
lize pallet if provided. If neither fork pockets or
pallet are provided, then make sure compres-
sor is secure and well balanced on forks before
attempting to raise or transport it any signifi-
cant 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
sudden 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 clos-
ing and possibly latching the door with person-
nel inside.
B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.

Section 2 - DESCRIPTION
5
ES-6 USER MANUAL
2.1 INTRODUCTION
Your new Sullair flood-lubricated rotary screw air
compressor will provide you with improved
reliability and greatly reduced 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 Section 6 (Maintenance) to keep your
compressor in top operating condition. Should any
questions arise which cannot be answered in the
following text, call your nearest Sullair office or the
Sullair Corporation Service Department.
2.2 DESCRIPTION OF COMPONENTS
Refer to Figure 2-1. The components and
assemblies of the ES-6 Series air compressor are
clearly shown. The complete compressor consists
of an encapsulated compressor system, inlet
system, cooling system and control system.
The compact design of the ES-6 Series air
compressor provides easy access to all
serviceable components.
2.3 ENCAPSULATED COMPRESSOR
SYSTEM, FUNCTIONAL DESCRIPTION
Refer to Figure 2-2. The encapsulated compressor
includes compressor unit, fluid management
system, and motor section. The Sullair compressor
unit is a single-stage positive displacement
lubricated type compressor. This unit is equipped
with tapered roller bearings on the discharge, and
cylindrical roller bearings on the inlet end for high
load carrying capacity. This unit provides
continuous pulse-free air compression to meet
your needs. With a Sullair compressor there will be
no maintenance or internal inspection of the
compressor.
Fluid is injected into the compressor unit in large
quantities and mixes directly with the air as the
rotors 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 compression.
2. It seals the leakage paths between the rotors
and the stator and also between the rotors
themselves.
3. It acts as a lubricating film between the rotors
allowing one rotor to directly drive the other, which
is an idler.
The air/fluid mixture discharges directly into the
fluid management system.
The fluid cooler bypass valve helps assure proper
cooling by directing the fluid to the fluid cooler
when discharge temperature reaches the
thermostat temperature 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
replaceable filter element contains a built-in bypass
valve. Under conditions of restricted flow through
the element, the bypass valve helps ensure
adequate compressor fluid flow, as well as helps
prevent element failure.
FLUID MANAGEMENT SYSTEM
The fluid management system consists of a multi-
chambered primary/secondary separator, the final
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 flow within the sump housing. Then the
compressed 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.
DO NOT remove caps, plugs and/or
other components when compres-
sor is running or pressurized.
Stop compressor and relieve all
internal pressure before doing so.
WARNING

Section 2 - DESCRIPTION
6
ES-6 USER MANUAL
Figure 2-1 Description of Components
1. Air Inlet System 7. Fluid Fill Plug 13. Drain Valve
2. Pressure Regulator 8. Fluid Filter Element 14. Air Pressure Switch
3. Pressure Gauge 9. Fluid Level Sight Glass 15. Hourmeter
4. Discharge Temperature Gauge 10. Encapsulated Compressor
System 16. Motor Start Selector Switch
5. Unload Solenoid Valve 11. Pressure Relief Valve 17. Motor Overload Reset Switch
6. Air/Fluid Separator Element Access
Cover 12. Cooling System
1
2
4
3
5
34
6
7
9
8
10
12
11
13
16
14
15
17

Section 2 - DESCRIPTION
7
ES-6 USER MANUAL
Figure 2-2 Encapsulated Compressor System
The minimum pressure/discharge check valve is
mounted on the compressor drive housing. Its
functions 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,
FUNCTIONAL DESCRIPTION
The compressor cooling system consists of a fluid
cooler, fan and cooler shroud.
The fan is mounted on the motor's shaft end
opposite 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
DESCRIPTION
The compressor inlet system consists of a dry-type
air filter and an air control valve. Reacting on a
pressure signal, the valve closes the intake for
unloaded operation. The valve also acts as a check
valve upon shutdown.
2.6 CONTROL SYSTEM, FUNCTIONAL
DESCRIPTION
The purpose of the compressor control system is to
maintain compressor capacity to meet the system
1. Aftercooler and Fluid Cooler 5. Fluid Level Sight Glass 9. Air
2. Compressor Unit 6. Air/Fluid Separator 10. Air/Fluid
3. Fluid Fill Plug 7. Pressure Relief Valve 11. Fluid
4. Fluid Filter 8. Discharge Air

Section 2 - DESCRIPTION
8
ES-6 USER MANUAL
demand.
It consists of an inlet valve, pressure regulator
valve, solenoid valve, control lines and the motor
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
compressor will start to deliver compressed air.
When the air demand is less than the rated flow for
the compressor, the service line pressure will rise
to the pressure switch cut-out setting. The system
pressure switch opens, interrupting the electrical
power to the solenoid valve. The solenoid valve
opens allowing pressure to be applied to the inlet
valve causing the inlet valve to fully close. The
compressor will continue to run (unloaded) until the
line pressure drops to the low setting of the
pressure switch--the pressure switch closes,
reenergizing the normally open solenoid valve and
allows the compressor 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
regulator will them begin to open allowing pressure
to be applied to the inlet valve. The pressure
regulator will modulate the inlet valve to match
system demand.
OFF/RESET MODE
The compressor motor, if running, will stop if the
off/reset position is selected. If the compressor
during normal running has a fault caused by either
overload or high discharge temperature, the
compressor will stop. After a fault has been
cleared, the compressor 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 the automatic 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 will
stop. The motor will automatically restart when the
line pressure drops to below 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 the sump pressure switch. It
is not recommended to open the pressure
regulator ball valve for the automatic mode of
operation.
2.7 INSTRUMENTATION, FUNCTIONAL
DESCRIPTION
Due to the simplicity of the ES-6 Series
compressor, the only instrumentation necessary is
a line pressure gauge which is located on the left
side of the electrical control center and a discharge
temperature gauge which is located on the right
side of the electrical control center. The line
pressure gauge reads plant air system pressure
only.
At compressor shutdown, the sump
pressure is released to atmosphere
through the solenoid valve. The line
pressure gauge will continue to read
system pressure.
NOTE

Section 3 - SPECIFICATIONS
9
ES-6 USER MANUAL
3.1 SPECIFICATIONS - ES-6
60 Hz
Model HP/KW Capacity
ACFM/
M3/Min
Maximum
Pressure
PSIG/BAR
dBA (I)
with
canopy/
without
canopy
DIMENSIONS
Length (II) Width (III) Height (IV) Weight
in mm in mm in mm lb. kg
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
50 Hz
Model HP/KW Capacity
ACFM/M3/
Min
Maximum
Pressure
PSIG/BAR
dBA (I)
with
canopy/
without
canopy
DIMENSIONS
Length (II) Width (III) Height (IV) Weight
in mm in mm in mm lb. kg
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
(I) Ratings of dBA at one meter. (IV) Enclosure option height is 28 in. / 711 mm
(II) Enclosure option length is 44 in. / 1118 mm. (V) For enclosure models, add 170 lbs. / 77 kg to base
weight of machine.
(III) Enclosure option width is 28 in. / 711 mm.

Section 3 - SPECIFICATIONS
10
ES-6 USER MANUAL
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/ 4, 5.5 & 7.5 KW 1.15 S.F. 5, 7.5, 10HP/ 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 Optional All
Sizes 230/460V 3 Phase 200V 3 Phase 380/415 3 Phase 380/415 3 Phase
Optional All Sizes 575V 3 Phase 200V 3 Phase 380/415 3 Phase
Optional 5HP Only 230V Single 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
11
ES-6 USER MANUAL
3.2 COMPRESSOR LUBRICATION
GUIDE
Consult Figure 3-1 for fluid fill port location. 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
requested.
If, due to availability or other reasons, other fluids
are required, follow Sections 3.3, 3.4 and Table 3A
- Lubrication Guide.
Maintenance of all other components is still
recommended as indicated in the Operator's
Manual.
For light-duty high-humidity service where
condensed moisture and emulsification
(mayonnaise) may occur, the fluid change interval
must be reduced to 300 hours maximum. A non-
detergent fluid with rust, oxidation and foam
inhibitors and good water separation
characteristics should be used.
Contamination of non-detergent mineral fluids with
traces of ATF or detergent motor fluids may lead to
operational problems such as foaming, filter
plugging, 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 COM-
PRESSORS
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.
Sullair recommends that a 24KT sample be taken
“The Plastic Pipe Institute recom-
mends against the use of thermo-
plastic pipe to transport compressed
air or other compressed 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, Recommen-
dation B, Adopted January 19, 1972.
Mixing of other fluids within the com-
pressor will void all warranties.
WARNING
CAUTION
Mixing of other fluids within the com-
pressor will void all warranties.
Figure 3-1 Fluid Fill Location
Fluid fill level should
be at 1/4 to 1/2 of the
sight glass when the
compressor is
running.
NOTE
1. Fluid Fill Port
2. Sight Glass
CAUTION

Section 3 - SPECIFICATIONS
12
ES-6 USER MANUAL
at the first filter change and sent to the factory for
analysis. This is a free service. A sample kit with
instructions and self-addressed container is to be
supplied by your Sullair Representative at start-up.
The user will receive an analysis report with
recommendations.
3.4 LUBRICATION GUIDE - OPTIONAL
FLUID
Sullair compressors may use SRF 1/4000 fluid as
an optional factory fill.
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
severe operating conditions, such as high ambient
temperatures coupled with high humidity, or when
high particulate level, corrosive gases or strong
oxidizing gases are present in the air.
Maintenance of all other components is still
recommended as indicated in the Operator's
Manual.
Mixing of other fluids within the com-
pressor will void all warranties.
CAUTION
Table 3A - Lubrication Guide
LUBRICANT FLUID CHANGE FLUID FITER CHANGE SEPARATOR CHANGE
Sullube A C E A
SRF 1/4000 B C E B
24KT D C E A
A- 8,000 Hours or once a year.
B- 4,000 Hours or more frequently if conditions so require.
C- When required by fluid analysis or known contamination.
D- Does not require replacement during normal service condidtions.
E- Every 2000 hours.

Section 3 - SPECIFICATIONS
13
ES-6 USER MANUAL
NOTES

Section 3 - SPECIFICATIONS
14
ES-6 USER MANUAL
Figure 3-2 Identification - ES-6 Standard without Enclosure
02250172-315R00