Sullair 3000P User Manual
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Sullair 3000P User Manual

Industrial air compressor
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USER MANUAL
I
A
C
NDUSTRIAL
IR
OMPRESSOR
3000P, 3700, 4500
3000PV, 3700V, 4500V
30, 37 & 45
/40, 50 & 60HP
KW
PART NUMBER:
02250176-182 R04
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!
201107010000
and all subsequent serial numbers.

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  • Page 1 USER MANUAL NDUSTRIAL OMPRESSOR 3000P, 3700, 4500 3000PV, 3700V, 4500V 30, 37 & 45 /40, 50 & 60HP PART NUMBER: 02250176-182 R04 KEEP FOR FUTURE WARRANTY NOTICE REFERENCE SULLAIR CORPORATION © Failure to follow the instructions The information in this manual is current...
  • 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 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION INTEGRAL DRYER OPTION VARIABLE SPEED DRIVE (VSD) COMPONENTS 2.10 VSD CONTROL SYSTEM FUNCTIONAL DESCRIPTION SECTION 3—SPECIFICATIONS TABLE OF SPECIFICATIONS—3000, 3000P, 3700 AND 4500 SERIES MODELS TABLE OF SPECIFICATIONS—VARIABLE SPEED DRIVE MODELS COMPRESSOR SPECIFICATIONS LUBRICATION GUIDE APPLICATION GUIDE...
  • Page 4 TABLE OF CONTENTS LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE, FLUID IDENTIFICATION, AIR-COOLED IDENTIFICATION, WATER-COOLED IDENTIFICATION, AIR-COOLED W/ INTEGRAL DRYER 3.10 PIPING AND INSTRUMENTATION, AIR-COOLED 3.11 PIPING AND INSTRUMENTATION, WATER-COOLED 3.12 PIPING AND INSTRUMENTATION, AIR-COOLED WITH INTEGRAL DRYER 3.13 WIRING DIAGRAM, VSD AIR-COOLED 3.14 WIRING DIAGRAM, AIR-COOLED MFV WITH INTEGRAL DRYER 3.15...

  • Page 5: General

    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: 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

    Compared other types compressors, the Sullair rotary screw is unique in 1. Fluid Filter 8. E-Stop Button 2. Moisture Separator 9. Compressor Unit 3. Separator/Sump Tank 10. Cooler Fan Motor 4.

  • Page 12: Description Of Components

    3000P-4500 USER MANUAL SECTION 2 1. Moisture Separator 8. E-Stop Button 2. Fluid Filter 9. Compressor Unit 3. Separator/Sump Tank 10. Oil Cooler 4. Fluid Fill 11. Aftercooler 5. Fluid Fill Sight Glass 12. Motor 6. Starter Box 13. Air Inlet Filter 7.

  • Page 13: Sullair Compressor Unit, Functional Description

    SECTION 2 3000P-4500 USER MANUAL SULLAIR COMPRESSOR Sullair recommends that a 24KT sample be taken at UNIT, FUNCTIONAL the first filter change and sent to the factory for DESCRIPTION analysis. This is a free service. The sample kit with instructions and self- addressed container is to be...
  • Page 14 3000P-4500 USER MANUAL SECTION 2 Figure 2-3: Air-Cooled, Cooling / Lubrication and Discharge System...
  • Page 15 SECTION 2 3000P-4500 USER MANUAL Figure 2-4: Water-Cooled, Cooling / Lubrication and Discharge System...

  • Page 16: Compressor Cooling And Lubrication System, Function

    3000P-4500 USER MANUAL SECTION 2 COMPRESSOR COOLING compressed air/fluid mixture enters separator/sump tank and flows through an internal AND LUBRICATION baffle system. The direction of movement is changed SYSTEM, FUNCTIONAL and its velocity significantly reduced, thus causing DESCRIPTION large droplets of fluid to form and fall to the bottom of the separator/sump tank.

  • Page 17: Control System, Functional Description

    SECTION 2 3000P-4500 USER MANUAL CONTROL SYSTEM, 50 PSIG (0 3.5 B TART FUNCTIONAL DESCRIPTION When the compressor " " (START) pad is Refer to Figure 2-5 and Figure 2-6. The purpose of depressed, the separator/sump tank pressure will the compressor control system is to regulate the quickly rise from 0 to 50 psig (0 - 3.4 bar).
  • Page 18 3000P-4500 USER MANUAL SECTION 2 - 50 100 PSIG (3.4 psig (1.2 bar). The check valve in the air service line prevents line pressure from returning to the 6.9 BAR) separator/sump tank. When the compressed air pressure rises above 50 When the line pressure drops to the low setting (cut- psig (3.4 bar), the minimum pressure valve opens...

  • Page 19: Air Inlet System, Functional Description

    SECTION 2 3000P-4500 USER MANUAL AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figure 2-6. The compressor inlet system WARNING consists of a dry-type air filter, a restriction gauge and an air inlet valve. "The Plastic Pipe Institute recommends The restriction gauge (located on the air filter)

  • Page 20: Integral Dryer Option

    The load delta default setting is 10 psi (0.7 not be a surge of condensate when the compressor bar). Sullair recommends a setting of 6 re-starts. For other settings and control options, refer psi (0.4) for the most efficient operation.
  • Page 21 SECTION 2 3000P-4500 USER MANUAL VSD PART LOAD CONTROL UNLOAD MODE-IN EXCESS OF 106 PSIG (7.3 BAR) The service line pressure increases to a value above 100 psig (6.9) if the demand is less than the When there is no demand or it is at a minimal level, compressor's rated capacity.
  • Page 22 NOTES...

  • Page 23: Table Of Specifications—3000, 3000P, 3700 And 4500 Series

    3000P-4500 USER MANUAL Section 3 SPECIFICATIONS TABLE OF SPECIFICATIONS—3000, 3000P, 3700 AND 4500 SERIES MODELS DIMENSIONS Length Width Height Weight Weight MODEL (I) TEFC TEFC 3000P SERIES 3007P 1575 34.5 61.5 1562 1993 2059 3009P 1575 34.5 61.5 1562 1993...
  • Page 24 3000P-4500 USER MANUAL SECTION 3 TABLE OF SPECIFICATIONS—VARIABLE SPEED DRIVE MODELS VSD SERIES (I) - 3000P (MODELS 3007 THROUGH 3010) MOTOR TEFC HZ / VOLTAGE 460/60 575/60 400/50 460/60 575/60 400/50 DRIVE AMP RATING WEIGHT (lbs / kg) 2069 / 938...

  • Page 25: Compressor Specifications

    Bearing Type: Anti-friction Ambient Temperature (Max.) (II): 104°F (40°C) Cooling: Pressurized fluid Compressor Fluid: Sullair Sullube; 24KT is optional Separator/Sump Capacity: 3.0 gallons (11.4 liters) Control: WS Controller (ll) Special compressors are available for operation in higher ambient temperature. COMPRESSOR:...

  • Page 26: Lubrication Guide

    Operator’s Manual. APPLICATION GUIDE DO NOT MIX DIFFERENT TYPES OF FLUIDS. Sullair encourages the user to participate in a fluid Contamination of compressor fluid with mineral oil or analysis program with the fluid suppliers. This could...

  • Page 27: Lubrication Change Recommendations And Maintenance

    SECTION 3 3000P-4500 USER MANUAL LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE, FLUID LUBRICANT FLUID CHANGE FLUID FILTER CHANGE SEPARATOR CHANGE Sullube (3.0 gal) A, E G, C A, D SRF 1/4000 (3.0 gal) B, E G, C B, D 24KT (3.0 gal)

  • Page 28: Identification, Air-Cooled

    IDENTIFICATION, AIR-COOLED 02250156-213 R04...
  • Page 29 MACHINE WEIGHTS PART NO. DESCRIPTION Main Motor Cooling Air Motor Type Weight (CFM) ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE 3000P 1993 lbs/904 kg 4800 AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR. 3000P tefc 2059 lbs/934 kg 4800...

  • Page 30: Identification, Water-Cooled

    IDENTIFICATION, WATER-COOLED 02250160-729 R03...
  • Page 31 DESCRIPTION Main Motor Cooling Air Motor Type Weight (CFM) ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE 3000P 1993 lbs/904 kg AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR. 3000P tefc 2059 lbs/934 kg A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING...

  • Page 32: Identification, Air-Cooled W/ Integral Dryer

    IDENTIFICATION, AIR-COOLED W/ INTEGRAL DRYER 02250169-069 R01...
  • Page 33 PART NO. DESCRIPTION Main Motor Weight Cooling Air Motor Type (Lbs/Kg) (CFM) ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE 3000P 2277/1033 4800 AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR. 3000P tefc 2343/1063 4800 A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING...

  • Page 34: Piping And Instrumentation, Air-Cooled

    3.10 PIPING AND INSTRUMENTATION, AIR-COOLED 02250156-203 R13...
  • Page 35 3.10 PIPING AND INSTRUMENTATION, AIR-COOLED PART NO. DESCRIPTION PART NO. DESCRIPTION 02250127-683 FILTER, AIR 9” PLASTIC 02250149-624 TANK, SEPARATOR 250003-869 INDICATOR, RESTRICTION 02250161-433 ORIFICE,.140 X 1/4M X 1/4F INLET 02250078-976 GA,DIFF PRESS Z-PURGE ASY REGU COMPRESSOR UNIT 02250115-272 VLV,CHK 1/4”NPTF BRASS VITON MOTOR 02250182-548 VLV,BALL/STNR COMBO-1/2”NPT...
  • Page 36 3.10 PIPING AND INSTRUMENTATION, AIR-COOLED (CONTINUED) 02250156-203 R13...
  • Page 37 3.10 PIPING AND INSTRUMENTATION, AIR-COOLED PART NO. DESCRIPTION PART NO. DESCRIPTION Part varies by model. Optional heat trace is applied only to control and moisture drain lines and used only with stainless steel tubing. Refer to face of (II) Used with EES option. order for heat trace requirements.

  • Page 38: Piping And Instrumentation, Water-Cooled

    3.11 PIPING AND INSTRUMENTATION, WATER-COOLED 02250162-393 R06...
  • Page 39 3.11 PIPING AND INSTRUMENTATION, WATER-COOLED PART NO. DESCRIPTION PART NO. DESCRIPTION 02250127-683 FILTER, AIR 9” PLASTIC 02250161-433 ORF,.140”.25 FNPT X .25 250003-869 INDICATOR, RESTRICTION 02250182-545 DRN,ZERO LOSS 115V 1/2”NPT INLET 02250115-272 VLV,CHK 1/4”NPTF BRASS VITON COMPRESSOR UNIT 250017-527 HT EXCH MOTOR 250017-992 SWITCH, PRESS NO 10 PSI...

  • Page 40: Piping And Instrumentation, Air-Cooled With Integral

    3.12 PIPING AND INSTRUMENTATION, AIR-COOLED WITH INTEGRAL DRYER 02250171-773 R01...

  • Page 41: Dryer

    3.12 PIPING AND INSTRUMENTATION, AIR-COOLED WITH INTEGRAL DRYER PART NO. DESCRIPTION PART NO. DESCRIPTION 02250125-369 FILTER,AIR INLET 8” (PLASTIC) 250017-280 VALVE, PRESSURE REG 02250127-683 FILTER,AIR INLET 9” (PLASTIC) 02250149-624 TANK, SEPARATOR 250003-869 INDICATOR, RESTRICTION 02250161-433 ORIFICE,.140 X 1/4M X 1/4F INLET 02250115-272 VLV,CHK 1/4”NPTF BRASS VITON...

  • Page 42: Wiring Diagram, Vsd Air-Cooled

    3.13 WIRING DIAGRAM, VSD AIR-COOLED 02250156-119 R09...
  • Page 43 3.13 WIRING DIAGRAM, VSD AIR-COOLED COMP DESCRIPTION COMP DESCRIPTION COMPRESSOR MOTOR HTR4 (OPT’L) CONTROL PANEL HEATER 50WATTS COOLER FAN MOTOR STARTER THERMOSTAT FOR HEAT TRACE OPTION 2MOL FAN MOTOR OVERLOAD XFMR1 CONTROL TRANSFORMER FOR SCD DRAIN FAN MOTOR BRANCH CIRCUIT FUSES (OPT’L) SCD DRAIN SCD TRANSFORMER PRIMARY FUSES NOTES...

  • Page 44: Wiring Diagram, Air-Cooled Mfv With Integral Dryer

    3.14 WIRING DIAGRAM, AIR-COOLED MFV WITH INTEGRAL DRYER 02250171-938-R04...
  • Page 45 3.14 WIRING DIAGRAM, AIR COOLED MFV WITH INTEGRAL DRYER COMP DESCRIPTION COMP DESCRIPTION DRYER START RELAY THERMOSTAT FOR HEAT TRACE OPTION 1MOL COMPRESSOR OVERLOAD FAN MOTOR BRANCH FUSES COMPRESSOR STARTER INTEGRAL DRYER FUSES 2MOL FAN MOTOR OVERLOAD INTEGRAL DRYER FUSES (575V) WET SUMP PRESSURE SENSOR POWER PRESENT RELAY OPTION PACKAGE DISCHARGE PRESSURE SENSOR...

  • Page 46: Wiring Diagram, Air-Cooled Mfv

    3.15 WIRING DIAGRAM, AIR-COOLED MFV 02250171-211-R04...
  • Page 47 3.15 WIRING DIAGRAM, AIR COOLED MFV COMP DESCRIPTION COMP DESCRIPTION 1MOL COMPRESSOR OVERLOAD JZL TRANSFORMER SECONDARY FUSE COMPRESSOR STARTER FAN MOTOR BRANCH FUSES 2MOL FAN MOTOR OVERLOAD JZL DRAIN OPTION WET SUMP PRESSURE SENSOR POWER PRESENT RELAY OPTION PACKAGE DISCHARGE PRESSURE SENSOR NOTES UNIT DISCHAGE TEMPERATURE PROBE PSW1...

  • Page 48: Wiring Diagram, Yd Ce

    3.16 WIRING DIAGRAM, YD CE 02250178-718-R00...
  • Page 49 3.16 WIRING DIAGRAM, YD CE COMP DESCRIPTION COMP DESCRIPTION 1MOL COMPRESSOR OVERLOAD HTR4 (OPT’L) CONTROL PANEL HEATER 50WATTS WYE-DELTA STARTER THERMOSTAT FOR HEAT TRACE OPTION WYE-DELTA RUN CONTACTOR (OPT'L) TRANSFORMER PRIMARY CIRCUIT BREAKER WYE-DELTA START CONTACTOR (OPT'L) TRANSFORMER SECONDARY CIRCUIT BREAKER 3MOL FAN MOTOR OVERLOAD SCD DRAIN OPTION...
  • Page 50 NOTES...

  • Page 51: Mounting Of Compressor

    3000P-4500 USER MANUAL Section 4 INSTALLATION MOUNTING OF VENTILATION AND COMPRESSOR COOLING A suitable foundation or fabricated support must be OOLED OMPRESSORS established to support the compressor. It should be An area with adequate space must be provided for rigid enough to keep the compressor frame level and the compressor and its components.
  • Page 52 0.2 in H2O. should be connected to the water outlet of the Consult a Sullair office for assistance in utilizing this compressor. The compressor control circuit switches heat. If ductwork is added, the high static fan option this circuit.
  • Page 53 SECTION 4 3000P-4500 USER MANUAL Table 4-2: VENTILATION REQUIREMENTS Cooling Type Air-Cooled with Aftercooler Water-Cooled Motor HP/kW 40/30 50/37 60/45 40/30 50/37 60/45 Fan Air cfm/m3/hr 5,000/8,500 5,000/8,500 6,000/10,200 700/1,200 700/1,200 700/1,200 Ventilating Air/Heat 114,500 142,000 171,000 10,600 13,300 15,800...
  • Page 54 3000P-4500 USER MANUAL SECTION 4 Table 4-3: WATER TESTS Substances Test Interval Acceptable Concentration Corrosivity Hardness, pH, Total Dissolved- Monthly-if stable for 3 to 4 months, Langerlier Index 0 to 1 Solids, Temperature at inlet, Alkalinity analyze quarterly. Iron Monthly <2ppm...

  • Page 55: Service Air Piping

    SECTION 4 3000P-4500 USER MANUAL A standard machine installed outside must not be started or run if the ambient temperature in and around the compressor drops or may drop below NOTE 35°F (1.7°C). Variable speed drive compressors are NOTE NEMA 12 rated and must not be installed outside or exposed to the elements.
  • Page 56 A drain line should be installed on the condensate drain. NOTE For low-volume systems that do not require an auxiliary separator/sump, com- pressor response time may need to be adjusted. Consult the Sullair Service Department for assistance.

  • Page 57: Coupling Alignment Check

    3. Check all electrical connections for tight- electrical code concerning isolation switches, fused ness. disconnects, etc. Sullair provides a wiring diagram for use by the installer. An electrical check should be 4. "DRY RUN" the electrical controls by discon- made to help assure that the first start-up will be necting the three (3) motor leads from the trouble-free.

  • Page 58: Motor Rotation Direction Check

    3000P-4500 USER MANUAL SECTION 4 MOTOR ROTATION sump tank pressure. Pull out the EMERGENCY DIRECTION CHECK STOP button and press once, quickly and in succession, the " " (START) and " " (STOP) Motor rotation check must be made at compressor pads.

  • Page 59: Controller Layout

    3000P-4500 USER MANUAL Section 5 WS CONTROLLER CONTROLLER LAYOUT ® 1. ON 6. Maintenance Indicator 2. OFF 7. Fault Indicator 3. LCD Display 8. Up Key 4. Power Indicator 9. Down Key 5. Run Mode Indicator 10. Enter Key Figure 5-1: WS Controller CONTROLLER KEYPAD •...

  • Page 60: Lcd Display

    3000P-4500 USER MANUAL SECTION 5 LCD DISPLAY Refer to Figure 5-6. Press the Down arrow " " to display additional information about the compressor. The display's normal view shows the compressor The upper line will indicate "Compressor Status" and package's discharge pressure, internal temperature, the name of the temperature, pressure, or other and the operating mode.

  • Page 61: Led Lights

    SECTION 5 3000P-4500 USER MANUAL If there are any warnings or recommended service The green Run mode indicator " " indicates instructions, these will be periodically displayed on compressor operation is enabled. It lights steadily if the normal view. the motor is running. If the motor stops while in...
  • Page 62 NOTES...

  • Page 63: General

    3000-4500 USER MANUAL Section 6 MAINTENANCE GENERAL WARNING WARNING HIGH-PRESSURE HAZARD! • DO NOT remove caps, plugs, and/or other components when compressor is running Before any repairs are attempted, refer to or pressurized. Stop compressor and Section 1: Safety before proceeding. relieve all internal pressure before doing so.

  • Page 64: Maintenance Every 2000 Hours

    1. Clean the return line strainer. Refer to Dis- Observe all laws and regulations for filter dis- charge, Separator/sump and Piping System, posal. 3000P, 3700 and 4500 on page 30 of the Parts Manual. 3. Clean gasket seating surface. 2. Replace the fluid filter element.

  • Page 65: Separator Maintenance

    SECTION 6 3000-4500 USER MANUAL 6. Install a new lubricated O-ring in the O-ring ILTER LEMENT EPLACEMENT groove on the underside of the separator/ 1. Clean exterior of air filter housing. sump tank cover. 2. Rotate end cover counterclockwise and 7.
  • Page 66 3000-4500 USER MANUAL SECTION 6 1. Disconnect the tube at bottom of sight glass. ETURN IGHT LASS AINTENANCE 2. Unscrew the sight glass assembly where the Refer to Figure 6-4. The oil return/sight glass elbow fitting joins the strainer/filter. subassembly is attached to the side of the separator tank.

  • Page 67: Troubleshooting— Introduction

    Should your problem persist after making the 3. Unwrap the coupling element from the cou- recommended check, consult your nearest Sullair pling jaws. representative. 4. Install the new element by wrapping it around the jaws, engaging the cogs on the element into the jaws.

  • Page 68: Troubleshooting Guide

    3000-4500 USER MANUAL SECTION 6 6.10 TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE REMEDY Compressor Will Not Start Main Disconnect Switch Open Close switch. Line Fuse Blown Replace fuse. Motor Starter Overload Tripped Reset. Should trouble persist, check whether motor starter contacts are function- ing properly.
  • Page 69 SECTION 6 3000-4500 USER MANUAL SYMPTOM PROBABLE CAUSE REMEDY Compressor Will Not Build Full Air Demand is Too Great Check service lines for leaks or open Discharge Pressure valves. Dirty Air Filter Check the filter indicator and inspect and/or change element if required. Inlet Valve Bleed Orifice Plugged Ensure control line bleed orifice located inside inlet valve is not plugged.
  • Page 70 3000-4500 USER MANUAL SECTION 6 SYMPTOM PROBABLE CAUSE REMEDY Liquid Water In Compressed Air Plugged Strainer in Moisture Drain Clean and service strainer located in the Lines Line line off the bottom of the water separator. Water Vapor Condensation from Remove the water vapor from compressed Cooling and Compression Occurs air prior to distribution through the air sys-...
  • Page 71 NOTES...
  • Page 72 Always air. Always there. WWW.SULLAIR.COM SULLAIR CORPORATION 3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A. Telephone: 1-219-879-5451 Printed in the U.S.A. Specifications subject to change without prior notice. E11EP...

This manual is also suitable for:

3700v4500v370045003000pv

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