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Sullair 3000 EES User Manual

Integral heat recovery system
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USER MANUAL
I
H
S
NTEGRAL
EAT RECOVERY
YSTEM
3000/3000P/3700/4500 EES
PART NUMBER:
02250175-332 R00
KEEP FOR
FUTURE
WARRANTY NOTICE
REFERENCE
SULLAIR CORPORATION
©
Failure to follow the instructions
The information in this manual is current
and procedures in this manual or,
as of its publication date, and applies to
misuse of this equipment will
compressor serial number:
VOID its warranty!
200710010000
and all subsequent serial numbers.

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Summary of Contents for Sullair 3000 EES

  • Page 1 PART NUMBER: 02250175-332 R00 KEEP FOR FUTURE WARRANTY NOTICE REFERENCE SULLAIR CORPORATION © Failure to follow the instructions The information in this manual is current and procedures in this manual or, as of its publication date, and applies to misuse of this equipment will...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1—SAFETY GENERAL PERSONAL PROTECTIVE EQUIPMENT PRESSURE RELEASE FIRE AND EXPLOSION MOVING PARTS HOT SURFACES, SHARP EDGES AND SHARP CORNERS TOXIC AND IRRITATING SUBSTANCES ELECTRICAL SHOCK LIFTING 1.10 ENTRAPMENT SECTION 2—DESCRIPTION INTRODUCTION APPLICATION CONSIDERATIONS FUNCTIONAL DESCRIPTION —MIXED AIR TEMPERATURE SENSOR FUNCTIONAL DESCRIPTION —OUTSIDE AIR TEMPERATURE SEN- FUNCTIONAL DESCRIPTION —ROOM THERMOSTAT FUNCTIONAL DESCRIPTION —INCOMING AND BYPASS AIR DAMP-...
  • Page 4 TABLE OF CONTENTS EES ENCLOSURE ASSEMBLY ACTUATOR WIRING AND CONNECTION MIXED AIR TEMPERATURE SENSOR INSTALLATION THERMOSTAT PLACEMENT AND WIRING SECTION 5—SETTINGS AND OPERATION SETTINGS AND OPERATION START-UP TEST PROCEDURE SECTION 6—MAINTENANCE MAINTENANCE SECTION 7—TROUBLESHOOTING TROUBLESHOOTING TABLE SECTION 8—PARTS LISTS EES ENCLOSURE ASSEMBLY EES ELECTRICAL CONTROL ASSEMBLY EES DISCHARGE ENCLOSURE ASSEMBLY EES PACKAGE CLEAN AIR INLET OPTION...

  • Page 5: Section 1-Safety

    GENERAL tions relative to personal protective equipment, such as eye and face protective equipment, Sullair Corporation and its subsidiaries design and respiratory protective equipment, equipment manufacture all of their products so they can be intended to protect the extremities, protective operated safely.

  • Page 6: Fire And Explosion

    SECTION 1 inside diameter to reduce pressure in case of accumulate on, under or around acoustical mate- hose failure. rial, or on any external surfaces of the air com- pressor. Wipe down using an aqueous industrial D. Flow-limiting valves are listed by pipe size and cleaner or steam clean as required.

  • Page 7: Hot Surfaces, Sharp Edges And Sharp Corners

    SECTION 1 C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially DANGER 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.

  • Page 8: Electrical Shock

    SECTION 1 swallowed, induce vomiting by administering a tablespoon of salt, in each glass of clean, warm water until vomit is clear, then administer two DANGER teaspoons of baking soda in a glass of clean water. Have patient lay down and cover eyes to exclude light.

  • Page 9: 1.10 Entrapment

    SECTION 1 Keep lift operator in constant attendance when- N. Make sure pallet-mounted compressors are ever compressor is suspended. firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them. J. Set compressor down only on a level surface NEVER attempt to forklift a compressor that is capable of safely supporting at least its weight not secured to its pallet, as uneven floors or sud-...
  • Page 10 NOTES...

  • Page 11: Introduction

    ENERAL producing compressed air. This energy can be The Sullair EES is designed primarily to recover the converted into a useable source of heat. The heat is heat of compression in the form of heated makeup stored in the compressor cooling air as it passes over air.

  • Page 12: Functional Description -Mixed Air Temperature Sensor

    Actuator Mixed Air Sensor EES Control Enclosure Incoming Air Outside Air Damper Sensor Figure 2-1: Sullair Integral Heat Recovery System FUNCTIONAL DESCRIPTION FUNCTIONAL DESCRIPTION —MIXED AIR —OUTSIDE AIR TEMPERATURE SENSOR TEMPERATURE SENSOR Refer to Figure 2-1. The mixed air temperature Refer to Figure 2-1.

  • Page 13: Functional Description -Room Thermostat

    SECTION 2 EES USER MANUAL Proportional Controller Outside Air Temperature Controller Control Relay 3 Control Relay 2 Control Relay 1 Power Present Relay Fuse Transformer Figure 2-2: EES Control Enclosure FUNCTIONAL DESCRIPTION compressor does not have power or is on standby, —ROOM THERMOSTAT the actuators return to their normal position.
  • Page 14 EES USER MANUAL SECTION 2 Heat of compression is recovered when: Heat of compression is rejected when: • The temperature of the heated space is • The temperature of the heated space is less than the set value of room thermostat. higher than the set value of the room ther- mostat.

  • Page 15: Functional Description -Power Present Relay

    SECTION 2 EES USER MANUAL FUNCTIONAL DESCRIPTION —POWER PRESENT RELAY • The temperature of the incoming outside air is higher than the set value of the out- A power present relay (Figure 2-2) is used to prevent side air temperature controller. Refer to unnecessary operation of the EES components.
  • Page 16 BLANK PAGE...

  • Page 17: Table Of Specifications-Ees

    EES USER MANUAL Section 3 SPECIFICATIONS TABLE OF SPECIFICATIONS—EES Package Length Width Height Main Clean Air Model Motor HP Inlet Option 3000 Without 67.1 1703 34.5 98.3 2496 3000 With 70.9 1801 34.5 98.3 2496 3000P Without 67.1 1703 34.5 98.3 2496 3000P...
  • Page 18 EES USER MANUAL SECTION 3 Variable Speed Machines 3000 VSD with EES Weight Main Motor Motor Type Voltage Amps 460/60 2173 TEFC 460/60 2239 1016 575/60 2173 TEFC 575/60 2239 1016 3000P VSD with EES Weight Main Motor Motor Type Voltage Amps 460/60...
  • Page 19 SECTION 3 EES USER MANUAL Cooling Airflow Air Flow (CFM), max Main Motor Model 0.50 in w.g. duct restriction 3000 4800 3000P 4800 3700 4800 4500 5600 Electrical Ratings EES Electrical Enclosure NEMA 4 Proportional Controller 24VAC/DC Voltage 50/60 Hz Class 2 -30 to 130°F Adjustment Range...
  • Page 20 Figure 3-1: Identification—EES 02250175-281-R00...
  • Page 21 Figure 3-2: Wiring Diagram—EES 02250175-264-R01...
  • Page 22 BLANK PAGE...

  • Page 23: Compressor Installation

    Sullair provides a wiring diagram for use by the installer. An electrical check should be The Sullair EES is intended for installation in made to ensure that the first start-up will be enclosed spaces and should be protected from successful.
  • Page 24 EES USER MANUAL SECTION 4 Access Panel, No Damper Installation Rejected Air Damper Position 1 Position 2 Recovered Air Damper Position 3 Access Panel, No Damper Installation Incoming Air Damper Figure 4-1: Damper Locations Refer to Figure 4-1. The EES enclosure is shipped 4.
  • Page 25 SECTION 4 EES USER MANUAL • Direction of rotation is changed by moving the coupling to the opposite • Be sure that the arrow on the coupling side of the actuator. Remove the aligns with the 0 degree mark on the retaining clip, switch the coupling and actuator housing.
  • Page 26 EES USER MANUAL SECTION 4 Figure 4-4: Actuator Installation and Orientation for Damper Location 2 Damper Control Rod Actuator Coupling Coupling Actuator Anti-Rotation Bracket Figure 4-5: Actuator Attachment...
  • Page 27 SECTION 4 EES USER MANUAL MIXED AIR TEMPERATURE After preparation of the EES enclosure, it is now SENSOR INSTALLATION ready to install onto the compressor. The enclosure is shipped from the factory attached to the enclosure roof panel. Lift the EES enclosure assembly onto the Attach sensor holder to compressor roof panel using M6 nuts and lock washers.
  • Page 28 BLANK PAGE...

  • Page 29: Section 5-Settings And Operation

    EES USER MANUAL Section 5 SETTINGS AND OPERATION SETTINGS AND OPERATION INCOMING AND BYPASS AIR ACTUATORS REJECTED AND RECOVERED AIR The incoming and bypass air actuators modulate to ACTUATOR maintain the desired mixed air temperature. Refer to The rejected and recovered air actuators control Section 2 for a more detailed functional description.
  • Page 30 EES USER MANUAL SECTION 5 Figure 5-2: Actuator Installation and Orientation for Incoming Air Damper Figure 5-3: Actuator Installation and Orientation for Bypass Air Damper...
  • Page 31 SECTION 5 EES USER MANUAL PROPORTIONAL CONTROLLER times. In extreme cold, lower or no minimum output may be Based on the mixed air sensor value, the desirable. For most applications, 10% minimum proportional controller sends a control signal to the output is sufficient.
  • Page 32 EES USER MANUAL SECTION 5 Cooling Air Temperature Rise by HP 60 HP 50 HP 40 HP Compressor Capacity (%) Figure 5-5: Temperature Rise of Cooling Air The temperature of the recovered air can be IXED EMPERATURE ETPOINT controlled by adjusting the mixed air set temperature. This is adjusted on the proportional controller (Figure See Figure 5-5 for a chart of temperature rise of the 5-4).
  • Page 33 SECTION 5 EES USER MANUAL OUTSIDE AIR TEMPERATURE UTSIDE HANGEOVER EMPERATURE CONTROLLER This is the temperature of the incoming outside air at which it is desired to reject all heat of compression Based on the outside air sensor value, the outside air outdoors and use all outside air for compressor temperature controller, in conjunction with control cooling.
  • Page 34 EES USER MANUAL SECTION 5 THERMOSTAT PERATING Heat mode. Changed by pressing system button. EMPERATURE ETTING Adjusted by buttons on thermostat. Set to desired maintained temperature for the space. When heated space temperature reaches setpoint, heat compression will be rejected outdoors. Digital Display Temperature Setting Button - Raises Temperature Setting...
  • Page 35 SECTION 5 EES USER MANUAL START-UP TEST PROCEDURE After installation and adjustments are complete, the following test procedure can be performed to ensure proper operation of the EES. Settings Required Results 1. 1 LED lit on mixed air temp controller Mixed Air Temp Controller –...
  • Page 36 BLANK PAGE...

  • Page 37: Section 6-Maintenance

    EES USER MANUAL Section 6 MAINTENANCE MAINTENANCE The EES system and components requires no regular maintenance. Refer to the compressor manual for maintenance requirements of the compressor.
  • Page 38 BLANK PAGE...

  • Page 39: Section 7-Troubleshooting

    All available data concerning a problem your problem persist after making the recommended should systematically analyzed before check, consult your nearest Sullair representative. undertaking any repairs or component replacement Symptom Probable Cause Remedy Operation of rejected and recovered air...
  • Page 40 EES USER MANUAL SECTION 7 Symptom Probable Cause Remedy Rejected air damper does not open with a Thermostat set incorrectly. Set to HEAT mode rise in room temperature. Set thermostat to desired heated space temperature. Wiring error at thermostat Rewire. Refer to wiring dia- gram.
  • Page 41 SECTION 7 EES USER MANUAL Symptom Probable Cause Remedy Incoming Proportional controller set Set to Direct Acting (DA) and bypass air dampers do not incorrectly. operating mode maintain mixed air set temperature. Confirm desired temperature setting Wiring error at proportional Rewire.
  • Page 42 EES USER MANUAL SECTION 7 Symptom Probable Cause Remedy Recovered air temperature cooler than Proportional controller set Set to Direct Acting (DA) desired incorrectly. operating mode Raise mixed air temperature setpoint. Too much cold air being Adjust minimum position set- drawn into compressor ting.
  • Page 43 SECTION 7 EES USER MANUAL Symptom Probable Cause Remedy Dampers do not return to normally closed Wiring error at power pres- Rewire. Refer to wiring dia- or open positions when compressor is not ent relay. gram. running. Loose actuator coupling. Tighten to 120-180 lb-in (13.6 –...
  • Page 44 BLANK PAGE...

  • Page 45: Section 8-Parts Lists

    EES USER MANUAL Section 8 PARTS LISTS...

  • Page 46: Ees Enclosure Assembly

    EES ENCLOSURE ASSEMBLY 02250175-279-R00...
  • Page 47 PART NO. DESCRIPTION PART NO. DESCRIPTION 02250071-379 GRIP,CD N4 .125-.187 X 1/2" 02250171-648 DWG,ASSY CONTROL BOX EES 02250150-893 CAP,MOLDED CANOPY CORNER 02250171-652 SUPPORT, SENSOR EES 02250150-910 R,VERTICAL 3000,3700,4500 02250175-280 SUPT,SENSOR LONG EES 02250150-912 R,ROOF AIR OUT END 37KW 40125 GROMMET, RUBBER GUSSET,STR CRNR SQUARE 250022-436 WEATHERSTRIP, 3/16 X 3/8 FT...

  • Page 48: Ees Electrical Control Assembly

    EES ELECTRICAL CONTROL ASSEMBLY 02250171-648-R00...
  • Page 49 PART NO. DESCRIPTION PART NO. DESCRIPTION 02250057-245 BLK,TERM END STOP CH 849601-014 TERMINAL, RING TNG #8 X 10-12 02250060-705 R,DIN 35MM(METERS) 02250071-379 GRIP,CD N4 .125-.187 X 1/2" 02250071-381 GRIP,CD N4 .250-.375 X 1/2" BAR,GROUND 5 POST CUTLER 02250101-721 HAMMER 02250140-339 PLUG,4P POWER MONITOR 02250140-438 SOCKET,PLUG CONNECTOR...

  • Page 50: Ees Discharge Enclosure Assembly

    EES DISCHARGE ENCLOSURE ASSEMBLY 02250171-646-R00...
  • Page 51 PART NO. DESCRIPTION 02250047-178 GROMMET, 0.50 X 1.12 02250071-379 GRIP,CD N4 .125-.187 X 1/2" 02250152-693 DMPR,CONTROL EES 24.00 X 24.00 02250171-135 PANEL, ACCESS EES P12 02250171-640 ACTUATOR, PROPORTIONAL ESS 02250171-641 ACTUATOR, 2 POSTION ESS 02250172-390 SA, ESS ENCL P12 02250174-815 DMPR,CONTROL RTN AIR ESS P12 250022-436 WEATHERSTRIP, 3/16 X 3/8 FT...

  • Page 52: Ees Package Clean Air Inlet Option

    EES PACKAGE CLEAN AIR INLET OPTION 02250176-044-R00...
  • Page 53 PART NO. DESCRIPTION 02250174-515 ADAPTER,DUCT EES P12 02250175-421 FLTR,CLEAN AIR EES P12/16 834504-075 SCREW, SELF-DRILL 1/4 X 3/4...
  • Page 54 BLANK PAGE...
  • Page 55 NOTES...
  • Page 56 ORLDWIDE ALES AND ERVICE SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A. Sullair Road, No. 1 3700 East Michigan Boulevard Zone Des Granges BP 82 Chiwan, Shekuo Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France Shenzen, Gunagdong PRV. www.sullair.com Telephone: 33-477968470 PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A.

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