Sullair 3000PB User Manual
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Sullair 3000PB User Manual

40, 50 & 60 hp (30, 37 & 45 kw)
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Industrial Air Compressor
3000PB, 3700B, 4500B,
3000PVB, 3700VB, 4500VB
40, 50 & 60 hp (30, 37 & 45 kW)
SAFETY WARNING
Users are required to read the
entire User Manual before mov-
ing or using the product.
USER MANUAL
WARRANTY NOTICE
Failure to follow the instructions
and procedures in this manual,
or misuse of this equipment, will
void its warranty.
Subject to EAR, ECCN EAR99 and related export control restrictions.
PART NUMBER:
02250216-786 R01
The information in this manual is current as of its
publication date and applies to compressors with
serial number:
201505080000
and all subsequent serial numbers.
Publication date: 6/17/2015
Copyright © 2015 Sullair, LLC. All rights reserved.

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Summary of Contents for Sullair 3000PB

  • Page 1 Publication date: 6/17/2015 void its warranty. Copyright © 2015 Sullair, LLC. All rights reserved. Subject to EAR, ECCN EAR99 and related export control restrictions.
  • 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 Stationary compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair’s training facility located at Michigan City, Indiana.

  • Page 3: Table Of Contents

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Table of Contents Table of Contents Section 1: Safety.......................1 General....................... 1 Personal protective equipment ..............1 Pressure release ..................1 Fire and explosion ..................2 Moving parts ....................2 Hot surfaces, sharp edges and sharp corners..........3 Toxic and irritating substances ..............
  • Page 4 Table of Contents 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Identification, air-cooled ................26 Identification, water-cooled ............... 28 3.10 Piping and instrumentation, air-cooled............30 3.11 Piping & instrumentation, water-cooled ............ 32 3.12 Wiring diagram, air-cooled MFV ............... 34 3.13 Wiring diagram, YD...................36 3.14...
  • Page 5 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Table of Contents Air filter maintenance................56 6.7.1 Air filter element replacement ................56 Separator maintenance ................57 6.8.1 Separator element replacement ................57 Oil return / sight glass maintenance ............58 6.10 Pressure regulator adjustment ..............58 6.11...
  • Page 6 Table of Contents 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Notes: 02250216-786 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 7: Section 1: Safety

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 1: Safety Section 1 Safety most compressors and the concepts behind these state- NOTE ments are generally applicable to all compressors. 1.2 Personal protective equipment A. Prior to installing or operating the compressor, own-...

  • Page 8: Fire And Explosion

    1: Safety 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual accordance with their manufacturer's recommenda- material. Any acoustical material with a protective tions. covering that has been torn or punctured should be replaced immediately to prevent accumulation of liq- E. DO NOT use air tools that are rated below the maxi- uids or fluid film within the material.

  • Page 9: Hot Surfaces, Sharp Edges And Sharp Corners

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 1: Safety E. Make sure all personnel are out of and/or clear of the DANGER compressor prior to attempting to start or operate it. F. Disconnect and lock out all power at source and ver-...

  • Page 10: Electrical Shock

    1: Safety 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual cover eyes to exclude light. Call a physician immedi- DANGER ately. All field equipment must be tested for electro- 1.8 Electrical shock static fields prior to servicing or making contact A.

  • Page 11: Entrapment

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 1: Safety J. Set compressor down only on a level surface capa- 1. Review the equipment or machine to be ble of safely supporting at least its weight and its locked and tagged out.

  • Page 12: Safety Warnings

    1: Safety 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual lockout hasps on power shall remove pad- WARNING lock and lockout hasps and restore power. However, when the authorized person who applied the lock is unavailable to remove it Ground the unit following the instructions in this his/her Supervisor may remove padlock/pad- manual.
  • Page 13 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 1: Safety WARNING CAUTION Before opening the variable speed drive covers: Install the variable speed drive in a well venti- lated room that is not subject to temperature • Disconnect all power to the variable extremes, high humidity, or condensation, and speed drive.
  • Page 14 1: Safety 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Notes: 02250216-786 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 15: Section 2: Description

    Sullair 24KT compressors are filled with a fluid that starter, compressor inlet system, compressor discharge rarely needs to be changed. Use only Sullair 24KT fluid in system, compressor lubrication and cooling system, the event that a fluid change is required.
  • Page 16 2: Description 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 1. Fluid filter 8. E-Stop button 2. Moisture separator 9. Compressor unit 3. Separator/sump tank 10. Cooler fan motor 4. Fluid fill 11. Cooler 5. Fluid fill sight glass 12. Motor 6.
  • Page 17 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 2: Description 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.

  • Page 18: Compressor Cooling And Lubrication System, Functional Description

    2: Description 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual After the air/fluid mixture is discharged from the compres- • Houses the final fluid separator. sor unit, the fluid is separated from the air. At this time, The compressed air/fluid mixture enters the separator/ the air flows through an aftercooler and separator then to sump tank and flows through an internal baffle system.
  • Page 19 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 2: Description Figure 2-3: Air-cooled, cooling / lubrication and discharge system 02250216-786 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.
  • Page 20 2: Description 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Figure 2-4: Water-cooled, cooling / lubrication and discharge system 02250216-786 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 21: Control System, Functional Description

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 2: Description 2.6 Control system, functional Unload mode—in excess of 110 psig (7.6 bar) When a relatively small amount or no air is being used, description the service line pressure continues to rise. When it Refer to Figure 2-5.
  • Page 22 2: Description 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 1. Air outlet 5. Blowdown valve 2. Unload solenoid valve 6. Minimum pressure/check valve 3. Pressure regulator 7. Separator/sump tank 4. Air inlet 8. Sequencing solenoid valve Figure 2-5: Standard pneumatic control system 02250216-786 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 23: Air Inlet System, Functional Description

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 2: Description 2.7 Air inlet system, functional description Refer to Figure 2-6. The compressor inlet system con- WARNING sists of a dry-type air filter, a restriction gauge and an air inlet valve.

  • Page 24: Variable Speed Drive (Vsd) Components

    2: Description 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual compressed air to flow into to the service line. From this 2.8 Variable speed drive (VSD) point on the controller monitors the line pressure which components controls the VSD. The pressure regulator and solenoid The VSD, located in the machine’s electrical enclosure,...
  • Page 25 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 2: Description energized solenoid valve prevents line pressure from open, and the compressor supplies compressed air to reaching the inlet control valve, thereby allowing it to fully the system. 02250216-786 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.
  • Page 26 2: Description 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Notes: 02250216-786 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 27: Section 3: Specifications

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 3: Specifications Section 3 Specifications 3.1 Table of specifications—3000PB, 3700B, 4500B models Dimensions Length Width Height Weight Model TEFC TEFC 3000PB series 3007PB 1712 1564 2055 2079 3009PB 1712 1564 2055 2079...

  • Page 28: Table Of Specifications-Variable Speed Models

    3: Specifications 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 3.2 Table of specifications—variable speed models Weight Length Width Height Drive amp Motor Hz / voltage rating VSD series—3000PVB (models 3007PVB through 3010PVB) 230/60 1996 1712 1564 460/60 1996 1712...

  • Page 29: Compressor Specifications

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 3: Specifications 3.3 Compressor specifications Compressor Standard models Type Rotary screw Standard operating pressure 100 psig (7 bar) 125 psig (9 bar) Bearing type Anti-friction 104°F (40°C) Maximum ambient temperature Minimum ambient temperature 40°F (4.4°C)

  • Page 30: Application Guide

    Sul- lair for recommendation. 3.6 Application guide Sullair encourages the user to participate in a fluid analy- sis program with the fluid suppliers. This could result in a fluid change interval differing from that stated in the man- ual.

  • Page 31: Lubrication Change Recommendations And Maintenance, Fluid

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 3: Specifications 3.7 Lubrication change recommendations and maintenance, fluid Lubricant Fluid change Fluid filter change Separator change ® Sullube (3.5 gal / 13,2 L) A, E G, C I, D ® SRF 1/4000 (3.5 gal / 13.2 L)

  • Page 32: Identification, Air-Cooled

    3.8 Identification, air-cooled 02250216-524 R01...
  • Page 33 3.8 Identification, air-cooled Machine weights Main motor Model Motor type Weight cooling air 2055 LBS/932 kg 4000 3000PB TEFC 2079 LBS/943 kg 4000 2080 LBS/943 kg 4000 3700B TEFC 2120 LBS/962 kg 4000 2366 LBS/1073 kg 5500 4500B TEFC 2444 LBS/1109 kg...

  • Page 34: Identification, Water-Cooled

    3.9 Identification, water-cooled 02250216-528 R01...
  • Page 35 3.9 Identification, water-cooled Machine weights Main motor Model Motor type Weight cooling air 1965 LBS/891 kg 3000PB TEFC 1989 LBS/902 kg 1990 LBS/903 kg 3700B TEFC 2030 LBS/921 kg 2276 LBS/1032 kg 4500B TEFC 2354 LBS/1068 kg Drawing notes ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.

  • Page 36: Piping And Instrumentation, Air-Cooled

    3.10 Piping and instrumentation, air-cooled 02250216-653 R02...
  • Page 37 3.10 Piping and instrumentation, air-cooled Description Description FILTER, AIR Drawing notes INDICATOR, RESTRICTION CONTROL/MOISTURE DRAIN LINES ARE 1/4" TUBING EXCEPT AS NOTED. INLET VALVE OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND COMPRESSOR UNIT MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS STEEL TUBING.

  • Page 38: Piping & Instrumentation, Water-Cooled

    3.11 Piping & instrumentation, water-cooled 02250216-655 R01...
  • Page 39 3.11 Piping & instrumentation, water-cooled Key Description Key Description FILTER, AIR Drawing notes INDICATOR, RESTRICTION CONTROL/MOISTURE DRAIN LINES ARE 1/4" TUBING EXCEPT AS NOTED. INLET VALVE OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND COMPRESSOR UNIT MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS MOTOR STEEL TUBING.

  • Page 40: Wiring Diagram, Air-Cooled Mfv

    3.12 Wiring diagram, air-cooled MFV 02250211-276 R03...
  • Page 41 3.12 Wiring diagram, air-cooled MFV Component Description Component Description 1MOL COMPRESSOR OVERLOAD JZL DRAIN OPTION COMPRESSOR STARTER XFMR UNIVERSAL TRANSFORMER 2MOL FAN MOTOR OVERLOAD 1MCR CONTROL RELAY FOR 300A CONTACTORS WET SUMP PRESSURE SENSOR Drawing notes PACKAGE DISCHARGE PRESSURE SENSOR CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.

  • Page 42: Wiring Diagram, Yd

    3.13 Wiring diagram, YD 02250214-098 R03...
  • Page 43 3.13 Wiring diagram, YD Component Description Component Description 1MOL COMPRESSOR OVERLOAD TRANSFORMER SECONDARY FUSE 115V WYE-DELTA STARTER TRANSFORMER SECONDARY FUSES 24V WYE-DELTA RUN CONTACTOR FAN MOTOR BRANCH FUSES WYE-DELTYA START CONTACTOR (OPT'L) JZL DRAIN 3MOL FAN MOTOR OVERLOAD XFMR UNIVERSAL TRANSFORMER CONTACTOR FOR POWER FACTOR CAPACITOR OPT.

  • Page 44: Wiring Diagram, Vsd Air-Cooled Parallel Wye A1000 (460V Only)

    3.14 Wiring diagram, VSD air-cooled parallel wye A1000 (460V only) 02250214-023 R03...
  • Page 45 3.14 Wiring diagram, VSD air-cooled parallel wye A1000 (460V only) Component Description Component Description COMPRESSOR MOTOR THERMOSTAT FOR HEAT TRACE OPTION COOLER FAN MOTOR STARTER (OPT'L) JZL DRAIN 2MOL FAN MOTOR OVERLOAD POWER PRESENT RELAY OPTION TRANSFORMER PRIMARY FUSES XFMR UNIVERSAL 250VAC TRANSFORMER TRANSFORMER SCONDARY FUSE 115V Drawing notes...

  • Page 46: Wiring Diagram, Vsd Air-Cooled Series Delta A1000 (230/575V Only)

    3.15 Wiring diagram, VSD air-cooled series delta A1000 (230/575V only) 02250216-829 R02...
  • Page 47 3.15 Wiring diagram, VSD air-cooled series delta A1000 (230/575V only) Component Description Component Description COMPRESSOR MOTOR THERMOSTAT FOR HEAT TRACE OPTION COOLER FAN MOTOR STARTER (OPT'L) JZL DRAIN 2MOL FAN MOTOR OVERLOAD POWER PRESENT RELAY OPTION TRANSFORMER PRIMARY FUSES XFMR UNIVERSAL 250VAC TRANSFORMER TRANSFORMER SCONDARY FUSE 115V Drawing notes...
  • Page 48 3: Specifications 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Notes: 02250216-786 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 49: Section 4: Installation

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 4: Installation Section 4 Installation require a minimum of 4 feet (1.25 meters) around the 4.1 Mounting of compressor perimeter of the compressor. A suitable foundation or fabricated support must be established to support the compressor. It should be rigid...

  • Page 50: Water System Venting

    4: Installation 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual utilizing an aftercooler. Cooler water will reduce water- heat rejection requirement is the amount of heat that is flow requirements and warmer water will increase water- radiated by the compressor. This heat must be removed flow requirements.

  • Page 51: Water Quality Recommendations

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 4: Installation 1. At the rear of the unit. Disconnect both the 4.2.5.2 Corrosion inlets and discharge water lines. As contrasted to lime scale build-up, corrosion eventually causes a reduction in the wall thickness of pipes. High 2.

  • Page 52: Outdoor Installation (Sheltered)

    4: Installation 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual (1 m) before the cooler. The orifice size must be calcu- is sloped, then the compressor must be mounted so that lated to ensure that the maximum seawater flow rate can- it is level.

  • Page 53: Pipe Sizing

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 4: Installation 4.4.1 Pipe sizing WARNING Pipe should be sized at least as large as the discharge connection of the compressor. Piping and fittings should all be suitably rated for the discharge pressure.

  • Page 54: Coupling Alignment Check

    4: Installation 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual trap. A drain line should be installed on the condensate voltage drops may impair the performance of the com- drain. pressor. Cable sizes may vary considerably so the mains terminals will accept up to 50 mm2 (1 awg) (37/4 Sk &...
  • Page 55 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 4: Installation (Stop) pads. This action will bump start the quickly succession, (Start) motor for a very short time. When looking at the motor (Stop) pads. This action will bump start the motor for from the end opposite the compressor unit, the shaft a very short time.
  • Page 56 4: Installation 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Notes: 02250216-786 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 57: Section 5: Ws Controller

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 5: WS Controller™ Section 5 WS Controller™ 5.1 Controller layout 1. Start pad 6. Down arrow pad 2. Stop pad 7. Run mode indicator 3. Up arrow pad 8. Power indicator 4. Fault indicator 9.

  • Page 58: Lcd Display

    5: WS Controller™ 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Refer to Figure 5-6. Press the (Down arrow) pad to 5.3 LCD display display additional information about the compressor. The The display’s normal view shows the compressor pack- upper line will indicate Compressor Status and the...

  • Page 59: Led Lights

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 5: WS Controller™ The list of displays may be navigated from either direc- The green Run mode indicator indicates compressor tion by using the (Up arrow) or Down arrow operation is enabled. It lights steadily if the motor is run- pads.
  • Page 60 5: WS Controller™ 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Notes: 02250216-786 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.

  • Page 61: Section 6: Maintenance

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 6: Maintenance Section 6 Maintenance Section 6.14.2: Troubleshooting guide on page 59 under 6.1 General “Excessive compressor fluid consumption” for a probable cause and remedy. WARNING After a routine start has been made, observe the control- ler display and be sure it monitors the correct readings for their particular phase of operation.

  • Page 62: Filter Maintenance

    6: Maintenance 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 6. Screw the canister to the filter head. Tighten 6.6 Filter maintenance to 30 to 35 ft•lb (40.5 to 47.3 N·m). Restart compressor and check for leaks. 6.7 Air filter maintenance 1.

  • Page 63: Separator Maintenance

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 6: Maintenance Refer to Figure 6-3. The separator element must be 6.8 Separator maintenance changed when indicated by the WS Controller, or once a Replace the separator element when indicated by the year, whichever occurs first.

  • Page 64: Oil Return / Sight Glass Maintenance

    6: Maintenance 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 1. Disconnect the tube at bottom of sight glass. 6.9 Oil return / sight glass 2. Unscrew the sight glass assembly where the maintenance elbow fitting joins the strainer/filter. 3. Remove used filter assembly, and replace with new assembly.

  • Page 65: Water Condensate Drain Maintenance

    3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 6: Maintenance coupling alignment unnecessary. The coupling is a jaw 6.11 Water condensate drain type in shear. If the elastomeric element requires maintenance replacement due to wear or breakage, order replacement If your compressor is fitted with the standard solenoid element no.
  • Page 66 6: Maintenance 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Symptom Probable cause Remedy Check power supply for 24V DC output. Loss of control voltage Replace power supply if necessary. Low incoming voltage Consult power company. Reset. If trouble persists, check that line pres-...
  • Page 67 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual 6: Maintenance Symptom Probable cause Remedy Leak in control system caus- Check for leaks. ing loss of pressure signals Remove the intake hose and check for inlet Inlet valve stuck open valve operation.
  • Page 68 6: Maintenance 3000PB, 3700B, 4500B, 3000PVB, 3700VB, 4500VB User Manual Notes: 02250216-786 R01 Subject to EAR, ECCN EAR99 and related export control restrictions.
  • Page 69 Subject to EAR, ECCN EAR99 and related export control restrictions.
  • Page 70 Sullair, LLC 3700 East Michigan Boulevard Michigan City, IN 46360 USA www.sullair.com 1-800-SULLAIR (USA only) 1-219-879-5451 (non-USA) Information and specifications are subject to change without prior notice. Subject to EAR, ECCN EAR99 and related export control restrictions.

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