Sullair ES-8 Installation and maintenance instructions

Part Number 02250061---282
ES --- 8 Integral
AirCompressor/Dryer&Filter
KEEP FOR
FUTURE
REFERENCE
OPERATOR’S
MANUAL AND
PARTS LIST
eSullair Corporation

AIR CARE
SEMINAR TRAINING
SullairAirCareSeminarsare2---daycoursesthatprovidehands---oninstruction
in the proper operation, maintenance and service of Sullair Dryers and Filters.
Seminars 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---800---SULLAIR or 219---879---5451 (ext. 1816)
--- Or Write ---
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department

TABLE OF CONTENTS
Section 1
SAFETY 11.1 GENERAL
11.2 PERSONAL PROTECTIVE EQUIPMENT
11.3 PRESSURE
21.4 FIRE AND EXPLOSION
21.5 MOVING PARTS
21.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
21.7 TOXIC AND IRRITATING SUBSTANCES
41.8 ELECTRICAL SHOCK
41.9 LIFTING
51.10 ENTRAPMENT
Section 2
DESCRIPTION 72.1 INTRODUCTION
72.2 IDENTIFICATION OF COMPONENTS
82.3 REFRIGERANT CIRCUIT, FUNCTIONAL DESCRIPTION
92.4 COMPRESSED AIR CIRCUIT, FUNCTIONAL DESCRIPTION
92.5 REFRIGERANT SYSTEM COMPONENT,
FUNCTIONAL DESCRIPTION
Section 3
SPECIFICATIONS 11 3.1 SPECIFICATIONS --- ES --- 8 INTEGRATED COMPRESSOR/
DRYER
13 3.2 LUBRICATION GUIDE
13 3.3 LUBRICATION CHANGE RECOMMENDATIONS
Section 4
INSTALLATION 15 4.1 GENERAL
15 4.2 MOUNTING OF INTEGRAL COMPRESSOR/DRYER
15 4.3 COMPRESSOR/DRYER PIPING
15 4.4 COMPRESSOR COUPLING ALIGNMENT CHECK
15 4.5 COMPRESSOR FLUID LEVEL CHECK
15 4.6 MOTOR ROTATION CHECK
16 4.7 ELECTRICAL PREPARATION
Section 5
COMPRESSOR
SYSTEMS 17 5.1 INTRODUCTION

TABLE OF CONTENTS
(CONTINUED)
Section 5
COMPRESSOR
SYSTEMS (cont.) 17 5.2 COMPRESSOR SYSTEM DESCRIPTION OF
COMPONENTS
17 5.3 COMPRESSOR SYSTEM, FUNCTIONAL DESCRIPTION
18 5.4 COMPRESSOR COOLING SYSTEM, FUNCTIONAL
DESCRIPTION
19 5.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
19 5.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
Section 6
SUPERVISOR II 21 6.1 INTRODUCTION
21 6.2 KEYPAD
21 6.3 STATUS DISPLAYS
22 6.4 LAMP INDICATORS
Section 7
COMPRESSOR
OPERATION 25 7.1 GENERAL
25 7.2 STANDARD PARAMETER SETUP
25 7.3 DELUXE PARAMETER SETUP
26 7.4 OPERATING THE COMPRESSOR
27 7.5 PURPOSE OF CONTROLS
28 7.6 SUPERVISOR II OUTPUT RELAYS
28 7.7 MOTOR ROTATION CHECK
28 7.8 INITIAL START---UP PROCEDURE
28 7.9 SUBSEQUENT TART---UP PROCEDURE
28 7.10 SHUTDOWN PROCEDURE
Section 8
DRYER
OPERATION 29 8.1 GENERAL
29 8.2 PURPOSE OF CONTROLS
29 8.3 INITIAL DRYER START---UP PROCEDURE
29 8.4 SUBSEQUENT START---UP PROCEDURE
30 8.5 NORMAL OPERATING CONDITIONS

TABLE OF CONTENTS
(CONTINUED)
Section 9
COMPRESSOR
MAINTENANCE AND
TROUBLESHOOTING 31 9.1 INTRODUCTION
31 9.2 DAILY OPERATION
31 9.3 MOTOR BEARING LUBRICATION
31 9.4 FLUID FILTER MAINTENANCE
31 9.5 COOLER MAINTENANCE
31 9.6 PARTS REPLACEMENT AND
ADJUSTMENT PROCEDURES
34 9.7 TROUBLESHOOTING INTRODUCTION
(COMPRESSOR)
34 9.8 TROUBLESHOOTING---COMPRESSOR
36 9.9 CALIBRATION
37 9.10 MAINTENANCE RECORD
Section 10
DRYER
MAINTENANCE AND
TROUBLESHOOTING 39 10.1 GENERAL
39 10.2 ROUTINE MAINTENANCE
39 10.3 TROUBLESHOOTING INTRODUCTION
DRYER
39 10.4 TROUBLESHOOTING---DRYER
Section 11
ILLUSTRATIONS
AND PARTS LIST 43 11.1 PROCEDURE FOR ORDERING PARTS
43 11.2A RECOMMENDED SPARE PARTS LIST---
ES---8 COMPRESSOR
44 11.2B RECOMMENDED SPARE PARTS LIST---
DRYER
44 11.2C RECOMMENDED SPARE PARTS LIST---
CONDENSING UNIT
46 11.3 INLET CONTROL, SEAL/DRIVE GEAR AND PARTS
(ES --- 8)
50 11.4 MOTOR, COUPLING, FAN AND PARTS (ES---8)
52 11.5 INLET FILTER, COMPRESSOR HOUSING/SUMP AND
PARTS (ES --- 8)

TABLE OF CONTENTS
(CONTINUED)
Section 11
ILLUSTRATIONS
AND PARTS LIST
(cont.) 56 11.6 COMPRESSOR COOLER SYSTEM
AND PARTS (ES---8)
58 11.7 REFRIGERANT SYSTEM (DRYER)
60 11.8 AIR SYSTEM (DRYER)
62 11.9 FRAME, CANOPY AND PARTS
64 11.10 DECAL GROUP
70 11.11 WIRING DIAGRAM---FULL VOLTAGE
(STANDARD)
71 11.12 WIRING DIAGRAM---FULL VOLTAGE
(DELUXE)
72 11.13 WIRING DIAGRAM---WYE DELTA 60 HZ

Section 1
SAFETY
1
1.1 GENERAL
Sullair Corporation and its subsidiaries design and
manufacture allof their products so they can beop-
erated safely. However, the responsibility for safe
operation rests with those who use and maintain
theseproducts.Thefollowingsafetyprecautions
are offered as a guide which, if conscientiously fol-
lowed, will minimize the possibility of accidents
throughout the useful life of this equipment.
The ES---8IntegralCompressor/AirDryer shouldbe
operated only by those who have been trained and
delegated to do so, and who have read and under-
stood this Operator’s Manual. Failure to follow the
instructions, procedures and safety precautions in
this manual can result in accidents and injuries.
Read this manual prior to startup.
NEVER start the compressor/dryer unless it is safe
to do so. DO NOT attempt to operate the compres-
sor/dryer with a known unsafe condition. Tag the
compressor/dryer and render it inoperative by dis-
connecting and locking out all power at the source
or otherwise disabling its prime mover so others,
who may not know of the unsafe condition, will not
attempt to operate it untilthecondition is corrected.
Install, use and operate the compressor/dryer only
in full compliance with all pertinent regulations and
allapplicableFederal, State, andLocalcodes,stan-
dards and regulations.
DO NOT modify the compressor/dryer and/or con-
trolsinanywayexceptwithwrittenfactoryapproval.
While not specifically applicable to all types of dry-
ers and/or compressors with alltypes of prime mov-
ers, most of the precautionary statements con-
tained herein are applicable to most dryers and/or
compressors and the concepts behind thesestate-
ments are generally applicable to all dryers and/or
compressors.
1.2 PERSONAL PROTECTIVE EQUIPMENT
Prior to installing or operating the compressor/dry-
er, owners, employers, and users should become
familiar with, and comply with, allapplicable regula-
tionsand/oranyapplicableFederal,StateandLocal
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, protective clothing, protective shields and bar-
riers and electrical protective equipment, as wellas
noise exposure administrative and/or engineering
controls and/or personal hearing protective equip-
ment.
1.3 PRESSURE
WARNING
!
DO NOT remove caps, plugs and/ or other compo-
nents when compressor/dryer is running or pres-
surized. Stop compressor/dryer and relieve all in-
ternal pressure before doing so.
A. Install an appropriate flow---limiting valve be-
tween 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 ex-
ceeding 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 all applicable
Federal, State and Localcodes, standardsandreg-
ulations.
B.Whenthehoseistobeusedtosupplyamanifold,
install an additional appropriate flow---limiting valve
between the manifold and each air hoseexceeding
1/2”(13mm)insidediameterthatistobeconnected
to the manifold to reduce pressure in case of hose
failure.
C. Provide an appropriate flow---limiting valve at the
beginningofeachadditional75feet(23m)ofhosein
runsofairhoseexceeding1/2”(13mm)insidediam-
eter to reduce pressure in case of hose failure.
D. Flow---limiting valves are listed by pipe size and
rated CFM. Select appropriate valves accordingly,
inaccordancewiththeirmanufacturer’srecommen-
dations.
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 ac-
cordingly. DO NOT exceed manufacturer’s rated
safe operating pressures for these items.
F. Secure all connections by wire, chain or other
suitable retaining devices to prevent tools or hose
ends from being accidentally disconnected and ex-
pelled.
G.Open fluid fillercaponlywhen compressor 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 air
line, fitting, hose, valve, drain plug, connection or
other components, such as filters and line oilers,
and before attempting torefill optional air line anti---
icer systems with anti---freeze compound.
I. Keeppersonneloutoflinewithandawayfromthe
discharge opening of hoses or tools or other points
of compressed air discharge.
J. Useairatpressureslessthan30 psig(2.1 bar)for
cleaningpurposes,and then onlywitheffectivechip
guarding and personal protective equipment.
K. DONOT tamperwithcompressorsumpandunit
(if provided) relief valves. Check the relief valve as
recommended in the Compressor Maintenance
Section of this manual or at a minimum of at least
weekly to make sure it is not blocked, clogged, ob-
structed or otherwise disabled. DO NOT change
the factory setting of the relief valve.
L. If the compressor/dryer is installed in an en-
closed area, it is necessary tovent therelief valveto

Section 1
SAFETY
2
the outside of the structure orto an area ofnon---ex-
posure.
M.DONOTengageinhorseplaywithairhoseasse-
rious injury or death may result.
N. DO NOT pass air through the compressor/dryer
while the compressor/dryer is in the OFF position.
O. DO NOT pass air through the compressor/dryer
untilthecompressor/dryerhasbeen stabilized.This
condition exists when the refrigeration suction and
discharge gauges read normal.
P. D O N O T operate a compressor/dryer at abnor-
malconditions.Consultthemanualfor normaloper-
ating conditions.
Q. Onlyqualifiedpersonnelshouldattempt torepair
leaksorproblemswiththerefrigerantsystemofthe
compressor/dryer.
R. For potential hazards of fluorocarbon refriger-
ants, see Table 1 (in this section).
1.4 FIRE AND EXPLOSION
WARNING
!
When installing a Base Load Transfer (BLT) Sys-
tem, remove jumpers between 16---17 & 18---19
(Dual Control Compressors) so the other com-
pressor does not backfeed defeating the shut-
down circuitry.
A. Clean up spills of lubricant or other combustible
substances immediately, if such spills occur.
B.Shutoffthecompressor/dryerandallowittocool.
Thenkeepsparks, flamesandothersourcesofigni-
tionaway,andDO NOTpermit smoking in the vicin-
ity when checking or adding lubricant or when refil-
lingairlineanti---icersystemswithanti---freezecom-
pound.
C.DO NOT permitfluids, includingair lineanti---icer
system antifreeze compound or fluid film to accu-
mulate on, under or around acoustical material, or
onanyexternalsurfacesoftheaircompressor/dryer
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 allsurfaces and then replaceacous-
tical material. Any acoustical material with a protec-
tivecoveringthathasbeentornorpuncturedshould
bereplacedimmediatelytopreventaccumulationof
liquids or fluid film within the material.DONOTuse
flammable solvents for cleaning purposes.
D. Disconnect andlock outall power at source prior
to attempting any repairs or cleaning of the com-
pressor/dryer or of the inside of the enclosure.
E. Keep electricalwiring, including all terminals and
pressure connectors in good condition. Replace
any wiring that has cracked, cut, abraded or other-
wise 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
astoolsawayfromexposedliveelectricalpartssuch
as terminals to avoid arcing which might serve as a
source of ignition.
G.Removeanyacousticalmaterialorothermaterial
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 fire extinguisher or
extinguishers nearby when servicing and operating
the compressor/dryer.
I. Keep oily rags, trash, leaves, litter or other com-
bustiblesoutofandawayfromthe compressor/dry-
er.
J. DO NOT operate the compressor/dryer without
properflowofcoolingairorwaterorwithinadequate
flow of lubricant or with degraded lubricant.
K.DONOTattempttooperatethecompressor/dry-
er in any classification of hazardous environment
unless the compressor/dryer has been specifically
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.DONOTattempt tooperate thecompressor/dry-
er with the fan, coupling or other guards removed.
C. Wear snug---fitting clothing and confine long hair
when working around this compressor/dryer, 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 allpersonnelare out of and/or clearof
the compressor/dryer prior to attempting to start or
operate it.
F. Disconnect and lock out all power at source and
verify at the compressor/dryer that all circuits are
de---energized to minimize the possibility of acci-
dental start---up or operation prior to attempting re-
pairs or adjustments. This is especially important
when compressors and dryers are remotely con-
trolled.
G. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water, or other
lquids 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 bodyaway from all pointsof
air discharge.

Section 1
SAFETY
3
Table 1 POTENTIAL HAZARDS OF FLUOROCARBON REFRIGERANTS
WARNING
!Dryers contain HCFC. This substance harms the public health and environment by
destroying the ozone in the upper atmosphere.
CONDITION POTENTIAL HAZARD SAFEGUARD
VAPORS MAY DECOMPOSE IN Inhalation of Toxic Good ventilation. Toxic decomposition products
FLAMES OR IN CONTACT WITH Decomposition Products. serve as warning agents.
HOT SURFACES. Avoid misuse.
Vent refrigerant outdoors.
VAPORS ARE 4 TO 5 TIMES HEAVIER Inhalation of Concentrated Vapors Avoid misuse.
THAN AIR. HIGH CONCENTRATIONS Can Be Fatal.
MAY TEND TO ACCUMULATE IN
LOW PLACES. Vent refrigerant outdoors.
Forced---air ventilation at the level of vapor
concentration.
Individual breathing devices with air supply.
Lifelines when entering tanks or other confined
areas.
DO NOT administer epinephrine or other
similar drugs.
DELIBERATE INHALATION TO Can Be Fatal. Avoid misuse.
PRODUCE INTOXICATION.
Vent refrigerant outdoors.
Forced---air ventilation at the level of vapor
concentration.
Individual breathing devices with air supply.
Lifelines when entering tanks or other confined
areas.
DO NOT administer epinephrine or other
similar drugs.
SOME FLUOROCARBON LIQUIDS Irritation of Dry, Sensitive Skin. Gloves and protective clothing.
TEND TO REMOVE NATURAL OILS
FROM THE SKIN.
LOWER BOILING LIQUIDS MAY BE Freezing of Skin. Gloves and protective clothing.
SPLASHED ON SKIN.
LIQUIDS MAY BE SPLASHED Lower Boiling Liquids May Cause Wear eye protection. Get medical attention.
INTO EYES. Freezing. Higher Boiling Liquids May Flush eyes for several minutes with running water.
Cause Temporary Irritation And If
Other Chemicals Are Dissolved, May
Cause Damage
.
CONTACT WITH HIGHLY REACTIVE Violent Explosion May Occur. Test the proposed system and take appropriate
METALS. . safety precautions
CRITICAL PROPERTIES OF REFRIGERANTS
REFRIGERANT CRITICAL TEMPERATURE CRITICAL PRESSURE
_F_CPsia kg/cm@
“Freon” 22 205 96 722 50.8

Section 1
SAFETY
4
C. Wear personal protective equipment including
gloves and head covering when working in, on or
around the compressor/dryer.
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. DO NOT use air from this compressor/dryer for
respiration (breathing) except in full compliance
withanyotherFederal,StateorLocalcodesorregu-
lations.
DANGER
!
Death or serious injury can result from inhaling
compressed air without using proper safety
equipment.
B. DONOTuseairlineanti---icersystemsinairlines
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/dryer only in open or
adequately ventilated areas.
D. Locate the compressor or provide a remote inlet
sothatitisnotlikelytoingestexhaustfumesorother
toxic, noxious or corrosive fumes or substances.
E. Coolants and lubricants usedin thiscompressor
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.Washwithsoapandwaterintheeventof
skin contact. Consult the Compressor Operator’s
Manual Lubrication Section for information pertain-
ing to compressor fluid fill.
F. Weargogglesorafullfaceshieldwhenaddingan-
tifreeze 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 quantitiesof clean wa-
terforfifteenminutes.Aphysician,preferablyaneye
specialist, should be contacted immediately.
H.DONOTstoreairlineanti---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, ineach glass of clean,warm waterun-
til vomit is clear. Then administer two teaspoons of
baking soda in a glass of clean water. Have patient
laydownandcovereyes toexclude light.Callaphy-
sician immediately.
1.8 ELECTRICAL SHOCK
A. This compressor/dryer should be installed and
maintained in full compliance with all applicable
Federal, State and Localcodes, standardsandreg-
ulations, including those of the National Electrical
Code, and also including those relative to equip-
mentgroundingconductors,andonlybypersonnel
who 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/dryer
whenmakingadjustmentsorrepairstoexposedlive
parts of the electrical system. Make all such adjust-
ments or repairs with one hand only, so as to mini-
mize 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 leavethecompressor/dryerunattended
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 pow-
er.
E. Disconnect, lock out and tag all power at the
source prior toattempting repairs or adjustmentsto
rotating machinery and prior to handling any un-
grounded conductors.
F. Dry test all shutdown circuits prior to starting the
compressor after installation.
1.9 LIFTING
A. If the compressor is provided with a lifting bail,
then lift by the bail provided. If no bail is provided,
thenliftbysling.Compressorstobeair---liftedbyhe-
licopter must not be supported by the lifting bail but
by slings instead. In any event, lift and/or handle
onlyinfullcompliancewithFederal,State,andLocal
codes.
B. Inspect points of attachment for cracked welds
and for cracked, bent, corroded or otherwise de-
graded members and for loosebolts or nuts prior to
lifting.
C. Make sure entire lifting, rigging and supporting
structure has been inspected, is in good condition
andhasaratedcapacityofatleastthe weightof the
compressor/dryer. If you are unsure of the weight,
then weigh compressor/dryer before lifting.
D. Make sure lifting hook has a functional safety
latch orequivalent, and is fullyengaged and latched
on the bail or slings.
E. Use guide ropes or equivalent to prevent twisting
or swinging of the compressor/dryer once it has
been lifted clear of the ground.
F. DO NOT attempt to lift in high winds.

Section 1
SAFETY
5
G. DO NOT lift compressor/dryer by motor---lifting
eye.
H.Keepallpersonneloutfromunderandawayfrom
the compressor/dryer whenever it is suspended.
I. Lift compressor/dryer no higher than necessary.
J.Keepliftoperatorinconstantattendancewhenev-
er compressor/dryer is suspended.
K. Set compressor/dryer down only on a level sur-
face capable ofsafely supporting at least its weight
and loading unit.
L.Whenmovingcompressor/dryersbyforklifttruck,
utilize fork pockets if provided. Otherwise, utilize
pallet if provided. If neither fork pocketsor pallet are
provided, then make sure compressor/dryer is se-
cure and well balanced on forks before attempting
to raise or transport it any significant distance.
M. Make sure forklift truck forks are fully engaged
and tipped back prior to lifting or transporting the
compressor/dryer.
N. Forklift no higher than necessary to clear ob-
stacles at floor level and transport and corner at
minimum practical speeds.
O. Make sure pallet---mounted compressor/dryers
are firmly bolted or otherwise secured to the pallet
prior toattemptingtoforkliftortransport them.NEV-
ER attempttoforkliftacompressor/dryerthatisnot
secured to its pallet, as uneven floors or sudden
stops may cause the compressor/dryer to tumble
off, possiblycausingseriousinjuryorpropertydam-
age in the process.
1.10 ENTRAPMENT
A. If the compressor/dryer enclosure is large
enoughtoholdamanandifitisnecessarytoenterit
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 the
door with personnel inside.
B. Make sure all personnel are out of compressor/
dryer before closing and latching enclosure doors.

6
NOTES

Section 2
DESCRIPTION
7
2.1 INTRODUCTION
This manual provides information and recommen-
dations for installing, operating and servicing the
ES---8IntegralCompressor/AirDryer.Theunitisde-
signed and manufactured to the highest quality
standards. Units have been fully tested and in-
spected by the manufacturer before shipment from
the factory.
The information, specifications and illustrations in
thismanualare inaccordance withinformation inef-
fectatthetimeofprinting.Themanufacturerre-
servestherighttochangedesignandspecifications
without notice and without incurring obligations.
Itisextremelyimportanttoanalyzecompletelyevery
system and understand the intended function of
each component before attempting to determine
the cause of a malfunction or failure.
The refrigerant (R---22) and air circuit can be easily
followed by referring to Figure 2---2.
A refrigerant suction pressure gauge is provided as
standard equipment for analyzing the system op-
eration and performance.
Any question or problem not covered herein can be
directed to the nearest Sullair representative. Al-
ways specify the model and serial number of the
compressor/dryeronallcorrespondenceregarding
service and parts.
2.2 IDENTIFICATION OF COMPONENTS
Refer toFigure 2---1.Parts can be ordered fromthe
nearestSullairrepresentative.Ifforanyreasonparts
cannot be obtained in this manner, contact the fac-
tory. Authorization and shipping instructions must
be obtained from the factory before returning the
parts to the factory. The manufacturer willnot be re-
sponsible for parts returned without proper authori-
zation or identification.
The ES---8 Integral Compressor/Air Dryer is de-
signed for the purpose of removing moisture from
compressed air by cooling to a temperature of 35_F
to 39_F(2_Cto4_C).
Figure 2---1 Identification of Components (Typical)
MPF FILTER
MPF FILTER
SEPARATOR
FILTER

Section 2
DESCRIPTION
8
2.3 REFRIGERANT CIRCUIT, FUNCTIONAL DE-
SCRIPTION
The ES---8 Integral Dryer cools the process air by
the use of a closed---loopvapor compression refrig-
erationcycle.Refer to Figure 2---2forthe flowsche-
matics.
Dry R---22 vapor enters the compressor inlet and its
pressure and temperature are raised at discharge.
The vapor continues through a condenser, where it
is cooled to its liquid state at near constant pres-
sure. A filter dryer then removes any water and im-
purities that may be carried by the refrigerant. A fur-
ther reduction of temperature and pressure takes
placeastheliquidR---22 is throttledthrough acapil-
lary tube. The resulting mixture of vapor and liquid
picksupheat(doescooling)asitmovesthroughthe
evaporator,whereitturnsbacktoitsvaporstateand
routes back to the compressor inlet port.
Topreventfeedingthe compressorwithliquidR---22
or evaporator icing during low heat load operation
(i.e., partial process air flow), a pressure operated
valve bypasses hot R---22 vapor to the evaporator
inlet, thus assuring thorough evaporation of the re-
frigerant.
To insure that adequate head pressure is main-
tained during periods of low ambient temperatures
or partial loads, a switch located at the compressor
discharge cycles the condenser fan on and off. If
theheadpressureistoolowtoinsureadequateflow
through the hot gas bypass valve, the condenser
fan is shut off.
Figure 2---2 Dryer Flow Schematic
AIR TO AIR HEAT EXCHANGER
MPF FILTER
DRY AIR OUTLET THROUGH
SEPARATOR FILTER
(NOT SHOWN)
WET, SATURATED AIR PASSES
THROUGH MPF FILTER (NOT
SHOWN) PRIOR TO ENTERING
HEAT EXCHANGER

Section 2
DESCRIPTION
9
2.4 COMPRESSED AIR CIRCUIT, FUNCTIONAL DE-
SCRIPTION
The compressed air drying circuit uses an air --- to ---
air heat exchanger which acts as a precooler/re---
heater, and an air---to---refrigerant heat exchanger
(evaporator).
Warm, saturated, compressed air first enters the
air---to---air heat exchanger, where it is precooled.
By precooling the incoming air, energy is saved
through the reduction of the heat load imposed on
the refrigerant compressor and condenser. From
the precooler, the air will enter into the evaporator
further reducing its temperature to 35_Fto39_F
(2_Cto4_C). Moisture is condensed, and it is then
separated by a cyclone separator and discharged
throughanautomaticfloat---typedraintrap.
The chilled air then re --- enters the air --- to --- air heat
exchanger,whereitisreheated.Reheatingoftheair
does not affect the air’s dewpoint. It prevents con-
densation of moisture on the outside of the air---dis-
tribution piping. The cold air flow through the air---
to---air heat exchanger is in a direction opposite to
the flow of the warm, saturated incoming air. This
counterflow assures high temperature differential
throughout the heat exchanger, resulting in a more
effective heat transfer.
The compressed air leaving the compressor/dryer
then passes through an MPF filter which removes
particles down to 1 micron diameter, including co-
alesced liquid water and oil. The coalesced oil/wa-
ter mixture is discharged through an automatic
float---type drain trap.
2.5 REFRIGERANT SYSTEM COMPONENT, FUNC-
TIONAL DESCRIPTION
The refrigerant compressor compresses low pres-
sure refrigerant gas into high pressure refrigerant
gas.
The air --- cooled condenser changes high pressure
refrigerant gas from compressor discharge into
high pressure liquid as the gas flows through.
The filter/dryer removes any contaminant and
moisture that may be in the system.
The capillary tube is a non---adjustable metering
device which separates the high pressure side of
thesystemfromthelowpressureside.Thecapillary
tube controls the flow of refrigerant to the evapora-
tor in order to maintain a non---adjustable tempera-
ture difference (superheat)between theevaporator
refrigerant inlet and outlet (see Figure 2---2).
The hot gas bypass valve (HGBV) is used to artifi-
cially load the evaporator during part---load condi-
tions. The HGBV accomplishes this task by divert-
ing high pressure gas from the compressor dis-
chargetotheinletoftheevaporator.TheHGBVsep-
aratesthehighpressuresideofthesystem fromthe
low pressure side. The HGBV will modulate from ful-
ly open to fully closed in response to its outlet pres-
sure setting. The HGBV is set to maintain the mini-
mum allowable suction line pressure.
The refrigerant--to--air heat exchanger chills the
compressed air to achieve a 35_Fto39_F(2_Cto
4_C) temperature. A low pressure liquid/gas mix-
ture enters the refrigerant side ofthe heat exchang-
erandremovesheatfromthewarmcompressedair.
The refrigerant changes phases as it passes
throughtheheatexchanger andexits as a low pres-
sure superheated gas.

10
NOTES

Section 3
SPECIFICATIONS
11
3.1 SPECIFICATIONS -- ES--8 INTEGRATED COMPRESSOR/DRYER
50 Hz KW M3/MIN BAR LENGTH WIDTH HEIGHT WEIGHT dBA (I)
MODEL (MM) (MM) (MM) (KG) w/ Encls.
w/o Encls.
15L 11 1.62 7.5 1321 813 813 424 70/80
15HH 11 1.34 10 1321 813 813 424 70/80
15XH 11 1.02 13 1321 813 813 424 70/80
20L 15 2.33 7.5 1321 813 813 455 73/83
20HH 15 1.87 10 1321 813 813 455 73/83
20XH 15 1.54 13 1321 813 813 455 73/83
25L 18.5 2.85 7.5 1321 813 813 479 75/85
25HH 18.5 2.22 10 1321 813 813 479 75/85
25XH 18.5 1.78 13 1321 813 813 479 75/85
30L 22 3.34 7.5 1321 813 813 483 76/85
30HH 22 2.81 10 1321 813 813 483 76/85
30XH 22 2.18 13 1321 813 813 483 76/85
60 Hz HP ACFM PSIG LENGTH WIDTH HEIGHT WEIGHT dBA (I)
MODEL (IN.) (IN.) (IN.) (LBS.) w/ Encls.
w/o Encls.
15L 15 65 110 52 32 32 935 70/80
15HH 15 58 135 52 32 32 935 70/80
15XH 15 44 185 52 32 32 935 70/80
20HH 20 77 185 52 32 32 1002 73/83
20XH 20 60 185 52 32 32 1002 73/83
25HH 25 96 135 52 32 32 1055 77/85
25XH 25 77 185 52 32 32 1055 77/85
30HH 30 114 135 52 32 32 1065 78/85
30XH 30 95 185 52 32 32 1065 78/85
(I) Ratings for dBA at one meter.
Figure 3 --- 1 ES --- 8 Compressor
COMPRESSOR
Type: Single Stage Fluid Injected Screw Compressor
Minimum Full Load Operating Pressure: 60 psig (4.2 bar)
Maximum Full Load Operating Pressure: Nameplate Pressure (II)
Bearing Type: Anti---friction
Cooling: Pressurized Fluid
Lubricant:SeeLubricantSpecification (Section 3.2)
Sump Capacity: 3 gallons (11.4 liters)
(II) Compressors are available for full load pressures up to 175 psig (12.1 bar) and unload pressure 185 psig
(12.8 bar).
MOTOR 60Hz 50Hz
Type: ODP, C --- Flange ODP, C --- Flange
Synchronous Speed: 15 & 20 HP = 1800 RPM 11KW = 1500 RPM
25 & 30 HP = 3600 RPM 18.5KW = 3000 RPM
Voltage:
Standard All Sizes: 230/460 380/415
Optional All Sizes: 208
Optional All Sizes: 575
Optional Only:
Type:
Insulation Class: B --- (Min.) B --- (Min.)

Section 3
SPECIFICATIONS
12
MODEL
Flow Capacity CFM at 39_F(4_C) Evaporator
M#/min. at 4_C Outlet Air Temperature
ES --- 8
Power Input (HP/KW)
Air Inlet/Outlet Connection (MPT)
DrainConnection(FPT)
Refrigerant Compressor HP/KW Rating
Maximum Heat of Rejection (BTU/HR /KCAL/HR)
Refrigerant/Charge (lbs/kg)
Standard Voltage (Optional)
(I) Flow Capacity rating is based on 118 psig (8.1 bar) air outlet pressure and 85_F(30_C)
ambient temperature.
(II) Voltage Code: A --- 115/1/60 B --- 230/1/60
Figure 3---2 Integral Refrigerant---Type Dryer Specifications
(I)
(II)
Total Power Input --- Amps/Coulombs
114 (60 Hz)
1.1 / .82
1”
1/4
1/2 / .5
8308 / 2094
331 / 9.4
.81 / .37
A/B
9.0 / 32400
Cooling Air Flow (CFM/M3/MIN)
Height (in./mm) 42/1067
Width (in./mm) 36/914
Length (in./mm) 60/1524
Weight (ES---8 30HP/22KW) lbs/kgs 1658/752
95 (50 Hz)
3.23 (60 Hz)
2.69 (50 Hz)
FLUID FILTER
Type: Spin on, Sullair Proprietary
Micron: 23 Microns Abs.
Internal Bypass Valve Set at 25 psig (1.7 bar)
FLUID SEPARATOR ELEMENT
Type: PushInCartridge,SullairProprietary
Efficiency at Maximum Capacity: 5PPM Maximum

Section 3
SPECIFICATIONS
13
3.2 LUBRICATION GUIDE
For best value and longest uninterrupted service,
theES---8compressorpartoftheIntegralCompres-
sor/Dryer package is factoryfilled and tested with a
long life lubricant.
WARNING
!
Mixing of other fluids within the compressor will
void all warranties.
If, due to unavailability or other reasons, other fluids
are required, follow Lubrication Guide below.
WARNING
!
“The Plastic Pipe Institute recommends against the
use of thermoplastic pipe to transport compressed
air or other compressed gases in exposed above
groundlocations, e.g. in exposed plant piping.” (I)
Sullube 32 shouldnotbe usedwith PVC piping sys-
tems.Itmayaffectthebondatcementedjoints.Cer-
tain other plastic materials may also be affected.
(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.
Contaminationofnon---detergentmineralfluidswith
traces of ATF or detergent motor fluids may lead to
operational problems such as foaming, filter plug-
ging, orifice or line plugging.
NOTE
Flush system when switching lubricant brands.
When ambient conditions exceed those noted or if
conditions warrant use of“extended” lifelubricants,
contact Sullair for recommendation.
Sullair encourages the user to participate in a fluid
analysisprogram.Thiscouldresultina fluidchange
interval that is different from those stated in this
manual.
3.3 LUBRICATION CHANGE RECOMMENDATIONS
AMBIENT
TEMPERATURE LUBRICATION FLUID CHANGE PERIOD (HRS.) FILTER CHANGE PERIOD (HRS.)
--- 10_Fto+90_F SRF 1/4000 (Std. Fill) 4000 4000
( --- 23_Cto+32_C) Sullube 32 8000 (I) 8000 (I)
Sullair LLL---4---32 8000 (I) 8000 (I)
Food Grade CP---4600---32---F 8000 (I) 8000 (I)
(I) 8000 hours or once a year.

14
NOTES