Sullair 3000 User Manual

Integral heat recovery system

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USER MANUAL

NTEGRAL

EAT RECOVERY

YSTEM

3000, 3000P, 3700, 4500, 3000V, 3000PV, 3700V, 4500V, 4500P, 5500, 7500,

4500PV, 5500V, 7500V, 4500PS, 5500PS, 7500P/PS, 7500PV

30-75KW:40-100HP

PART NUMBER:

02250175-332 R01

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

Page 1 USER MANUAL NTEGRAL EAT RECOVERY YSTEM 3000, 3000P, 3700, 4500, 3000V, 3000PV, 3700V, 4500V, 4500P, 5500, 7500, 4500PV, 5500V, 7500V, 4500PS, 5500PS, 7500P/PS, 7500PV 30-75KW:40-100HP PART NUMBER: 02250175-332 R01 KEEP FOR FUTURE WARRANTY NOTICE REFERENCE SULLAIR CORPORATION © Failure to follow the instructions...
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 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 3000V, 3000PV, 3700V, 4500V EES DISCHARGE ENCLOSURE ASSEMBLY—MODELS:3000, 3000P, 3700, 4500, 3000V, 3000PV, 3700V, 4500V EES DECAL—ALL MODELS EES PACKAGE CLEAN AIR INLET OPTION—MODELS:3000, 3000P, 3700, 4500, 3000V, 3000PV, 3700V, 4500V EES ENCLOSURE ASSEMBLY—4500P, 5500, 7500, 4500PV, 5500V, 7500V, 4500PS, 5500PS, 7500P/PS, 7500PV EES DISCHARGE ENCLOSURE ASSEMBLY—4500P/PS, 5500, 7500,...
Page 5 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 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 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 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 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 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 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 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 Both actuators are spring return so when the —ROOM THERMOSTAT compressor does not have power or is on standby, the actuators return to their normal position.
Page 14 EES USER MANUAL SECTION 2 Heat of compression is recovered when: air temperature controller. Refer to Figure 2-3. • The temperature of the heated space is less than the set value of room thermostat. Rejected Air Damper Bypass Air Damper Recovered Air Damper •...
Page 15 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 NOTES...
Page 17 TABLE OF SPECIFICATIONS—EES Package Length Width Height Main Clean Air Model Motor HP Inlet Option 3000, 3000P, 3700, 4500, 3000V, 4500, 3000V, 3000PV, 40, 50, 60 Without 67.1 1703 34.5 98.3 2496 3700V, 4500V 3000, 3000P, 3700, 4500, 3000V, 4500, 3000V, 3000PV,...
Page 18 EES USER MANUAL SECTION 3 Variable Speed Machines 3000V with EES Main Motor Weight Motor Type Voltage 460/60 2173 575/60 460/60 TEFC 2239 1016 575/60 3000PV with EES Main Motor Weight Motor Type Voltage 460/60 2348 1065 575/60 460/60 TEFC 2414 1095 575/60...
Page 19 1724 TEFC 575/60 3667 1667 Cooling Airflow Air Flow (CFM), max 0.50 Model Main Motor HP in w.g. duct restriction 3000, 3000P, 3000V, 3000PV 4800 3700, 3700V 4800 4500, 4500V 5600 4500P, 4500PV, 4500PS 8100 5500, 5500V, 5500PS 8100 7500, 7500V, 7500P, 7500PS, 7500PV...
Page 20 Figure 3-1: Identification—3000, 3000P, 3700, 4500, 3000V, 3000PV, 3700V, 4500V with EES 02250175-281-R00...
Page 21 Figure 3-1: Identification—3000, 3000P, 3700, 4500, 3000V, 3000PV, 3700V, 4500V with EES NOTES Allow 4 feet (1.25 meters) minimum clearance around machine for access and free circulation of air. A foundation or mounting capable of supporting the weight of package, and rigid enough to maintain the compressor frame level is required.
Page 22 Figure 3-2: Identification—4500P, 4500PS, 4500PV, 5500, 5500PS, 5500V, 7500, 7500P/PS, 7500PV, 7500V with EES 02250178-392 R00...
Page 23 Figure 3-2: Identification—4500P, 4500PS, 4500PV, 5500, 5500PS, 5500V, 7500, 7500P/PS, 7500PV, 7500V with EES NOTES Allow 4 feet (1.25 meters) minimum clearance around machine for access and free circulation of air. A foundation or mounting capable of supporting the weight of package, and rigid enough to maintain the compressor frame level is required.
Page 24 Figure 3-3: Wiring Diagram—EES 02250175-264-R03...
Page 25 Figure 3-3: Wiring Diagram—EES NOTES Control relay, 24V coil spdt Control relay, 24V coil spdt Control relay, 24V coil spdt BYPS ACT Proportional actuator, bypass air IN ACT Proportional actuator, incoming air Connector, male Power present relay, 24V coil spdt PROP Proportional controller, direct acting operating mode RCVR...
Page 26 NOTES...
Page 27 0.50 in w.c. INSTALLATION • If the fan discharge or inlet is shut off, the fan drive motor should not overload. The Sullair EES is intended for installation in enclosed spaces and should be protected from ELECTRICAL PREPARATION blowing rain or snow.
Page 28 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 29 SECTION 4 EES USER MANUAL • Direction of rotation is changed by moving the coupling to the opposite side of the actuator. Remove the retaining clip, switch the coupling and reinstall the retaining clip. Refer to Fig- • Be sure that the arrow on the coupling ure 4-2.
Page 30 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 31 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 32 NOTES...
Page 33 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 34 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 35 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 36 7500(V), 7500P/PS(V) 60 HP - 4500(V) 50 HP - 3700(V) 75 HP 5500(V), 5500PS(V) 40 HP 3000(V), 3000P(V) 60 HP 4500P(V), 4500PS(V) Compressor Capacity (%) Figure 5-5: Temperature Rise of Cooling Air The temperature of the recovered air can be...
Page 37 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 38 EES USER MANUAL SECTION 5 Digital Display Temperature Setting Button - Raises Temperature Setting Temperature Setting Button - Lowers Temperature Setting Fan Button - Not Used System Button Figure 5-7: Room Thermostat THERMOSTAT PERATING Heat mode. Changed by pressing system button. EMPERATURE ETTING Adjusted by buttons on thermostat.
Page 39 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 40 NOTES...
Page 41 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 42 NOTES...
Page 43 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 44 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 45 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 46 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 47 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 48 NOTES...
Page 49 EES USER MANUAL Section 8 PARTS LISTS...
Page 50 EES ELECTRICAL CONTROL ASSEMBLY—ALL MODELS 02250171-648-R00...
Page 51 PART NO. DESCRIPTION 02250057-245 BLK,TERM END STOP CH 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" 02250101-721 BAR,GROUND 5 POST CUTLER HAMMER 02250140-339 PLUG,4P POWER MONITOR 02250140-438 SOCKET,PLUG CONNECTOR 02250171-636 XFMR,75VA 120/240-24AC 02250171-643 CONTROLLER, PROPORTIONAL 02250171-644 CONTROLLER, ON/OFF...
Page 52 EES ENCLOSURE ASSEMBLY— MODELS:3000, 3000P, 3700, 4500, 3000V, 3000PV, 3700V, 4500V 02250175-279-R00...
Page 53 GRIP,CD N4 .125-.187 X 1/2" 40125 GROMMET, RUBBER 02250150-893 CAP,MOLDED CANOPY CORNER 250022-436 WEATHERSTRIP, 3/16 X 3/8 FT 02250150-910 R,VERTICAL 3000,3700,4500 250034-157 TRIM,CANOPY EDGE 7.5/10HP 02250150-912 R,ROOF AIR OUT END 37KW 825201-130 NUT, HEX PLTD #8-32 02250151-177 GUSSET,STR CRNR SQUARE 3700 825906-100 NUT, HEX METRIC M6 X 1.0...
Page 54 EES DISCHARGE ENCLOSURE ASSEMBLY— MODELS:3000, 3000P, 3700, 4500, 3000V, 3000PV, 3700V, 4500V 02250171-646-R00...
Page 55 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 26 WEATHERSTRIP, 3/16 X 3/8 FT...
Page 56 EES DECAL—ALL MODELS 02250176-067-R00...
Page 57 PART NO. DESCRIPTION 02250176-065 DECAL,EES P12/P16...
Page 58 EES PACKAGE CLEAN AIR INLET OPTION— MODELS:3000, 3000P, 3700, 4500, 3000V, 3000PV, 3700V, 4500V 02250176-044-R00...
Page 59 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 60 EES ENCLOSURE ASSEMBLY— 4500P, 5500, 7500, 4500PV, 5500V, 7500V, 4500PS, 5500PS, 7500P/PS, 7500PV 02250176-276-R00...
Page 61 PART NO. DESCRIPTION PART NO. DESCRIPTION 02250071-379 GRIP,CD N4 .125-.187 X 1/2” 02250172-591 ANL,DR SUPT P16/18 AC/WC 02250150-893 CAP,MOLDED CANOPY CORNER 02250175-238 SUPT,ENCL BRACE P16/18 02250151-177 GUSSET,STR CRNR SQUARE 3700 02250175-280 SUPT,SENSOR LONG EES 02250151-635 BEARING,FLANGED 5MM 3700 02250176-277 DMPR, CONTROL EES 30.0” X 30.0” 02250152-323 INSUL,FOAM 2”...
Page 62 EES DISCHARGE ENCLOSURE ASSEMBLY— 4500P/PS, 5500, 7500, 4500PV, 5500V, 7500V/PV, 5500PS, 7500P/PS 02250176-281-R00...
Page 63 PART NO. DESCRIPTION 02250047-178 GROMMET, 0.50 X 1.12 02250071-379 GRIP,CD N4 .125-.187 X 1/2” 02250171-640 ACTUATOR, PROPORTIONAL ESS 02250171-641 ACTUATOR, 2 POSTION ESS 02250176-267 ENCL,SA EES P16/18 02250176-274 DMPR, CTL RETURN AIR EES P16/18 02250176-277 DMPR, CONTROL EES 30.0” X 30.0” 02250176-282 PNL, ACCESS EES P16/18 250022-436...
Page 64 EES PACKAGE CLEAN AIR INLET OPTION— 4500P/PS, 5500, 7500, 4500PV, 5500V, 7500V/PV, 5500PS, 7500P/PS 02250176-284-R00...
Page 65 PART NO. DESCRIPTION 02250176-285 ADPT,DUCT EES P16/18 02250176-286 FLTR,CLEAN AIR EES P16/18 834504-075 SCREW, SELF-DRILL 1/4 X 3/4...
Page 66 NOTES...
Page 67 NOTES...
Page 68 Zone Des Granges BP 82 Chiwan, Shekou Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France Shenzen, Guangdong PRV. www.sullair.com Telephone: 33-477968470 PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A. only) Fax: 33-477968499 Telephone: 755-6851686 Fax: 219-874-1273 www.sullaireurope.com Fax: 755-6853473 CUSTOMER CARE www.sullair-asia.com...

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3000p 3700 4500 3000v 3000pv 3700v ... Show all