Sullair 1800 User Manual

18, 22 & 30kw/25 & 30 & 40hp, industrial

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User manual (238 pages)

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Page 1 USER MANUAL NDUSTRIAL OMPRESSOR 1800, 2200, 3000, 1800 , 2200 , 3000 18, 22 & 30 /25 & 30 & 40HP PART NUMBER: 02250176-180 R05 KEEP FOR FUTURE WARRANTY NOTICE REFERENCE © COPYRIGHT 2014 SULLAIR 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 Stationary 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 ENTRAPMENT 1.11 SAFETY WARNINGS SECTION 2—DESCRIPTION INTRODUCTION DESCRIPTION OF COMPONENTS SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION- AL DESCRIPTION COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION CONTROL SYSTEM, FUNCTIONAL DESCRIPTION AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION INTEGRAL DRYER OPTION VARIABLE SPEED DRIVE (VSD) COMPONENTS 2.10...
Page 4 TABLE OF CONTENTS AIR-COOLED, IDENTIFICATION 40HP AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 25-30HP AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 40HP PIPING AND INSTRUMENTATION, AIR-COOLED 3.10 PIPING AND INSTRUMENTATION, 1800-2200 W/INTEGRAL DRYER 3.11 WIRING DIAGRAM—MFV, AIR-COOLED 3.12 WIRING DIAGRAM—MFV, AIR-COOLED INTEGRAL DRYER 3.13 WIRING DIAGRAM—VSD, PARALLEL WYE SVX9000 3.14...
Page 5: General
GENERAL tions relative to personal protective equipment, such as eye and face protective equipment, Sullair and its subsidiaries design and manufacture respiratory protective equipment, equipment all of their products so they can be operated safely. intended to protect the extremities, protective...
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 teaspoons of baking soda in a glass of clean DANGER water. Have patient lay down and cover eyes to exclude light.
Page 9: Entrapment
SECTION 1 Keep lift operator in constant attendance when- operation. ever compressor is suspended. J. Set compressor down only on a level surface WARNING capable of safely supporting at least its weight and its loading unit. Ground the unit following the instructions in this K.
Page 10 Code, and/or any other applicable State, speed drive during motor or cable testing. Federal, and local electrical codes concern- ing isolation switches, fused disconnects, etc. Sullair provides a wiring diagram for use CAUTION by the installer. Do not touch any components on the circuit NOTE boards.
Page 11: Introduction
The complete package includes compressor, electric motor, starter, compressor inlet system, compressor Compared to other types of compressors, the Sullair discharge system, compressor lubrication rotary screw is unique in mechanical reliability, with cooling system, capacity control system, WS “no wear”...
Page 12: Sullair Compressor Unit, Functional Description
7. WS Controller 14. Variable Speed Drive (where equipped) SULLAIR COMPRESSOR NOTE UNIT, FUNCTIONAL DESCRIPTION With a Sullair compressor, there is no maintenance or inspection of the internal Sullair compressors feature Sullair parts of the compressor unit permitted in compressor...
Page 13: Compressor Cooling And Lubrication System, Function
SECTION 2 1800-3000 USER MANUAL The 1800, 2200 & 3000 Series compressors are from the air. At this time, the air flows factory-filled with Sullube lubricant. For more through an aftercooler and separator then to information on fluid fill, refer to Section 3: Lubrication your service line while the fluid is being Change Recommendations and Maintenance—Fluid...
Page 14 1800-3000 USER MANUAL SECTION 2 Figure 2-2: Cooling and Lubrication System...
Page 15 SECTION 2 1800-3000 USER MANUAL COMPRESSOR DISCHARGE minimum pressure/check valve, located SYSTEM, FUNCTIONAL downstream from the separator, assures a minimum DESCRIPTION separator/sump tank pressure of 50 psig (3.4 bar) during loaded conditions. This pressure is necessary Refer to Figure 2-3. The compressor unit discharges...
Page 16 1800-3000 USER MANUAL SECTION 2 Figure 2-3: Discharge System...
Page 17: Control System, Functional Description
SECTION 2 1800-3000 USER MANUAL CONTROL SYSTEM, Start Mode FUNCTIONAL DESCRIPTION —0 TO 50 PSIG (0 TO 3.5 Bar) When the compressor “ ” (START) pad is Refer to Figure 2-4. The purpose of the compressor depressed, the separator/sump tank pressure will control system is to regulate the amount of air being quickly rise from 0 to 50 psig (0 - 3.4 bar).
Page 18 1800-3000 USER MANUAL SECTION 2 Full Load Mode check valve in the air service line prevents line —50 to 100 PSIG (3.4 to 6.9 BAR) pressure from returning to the 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
For other settings and control options, refer locations, e.g. in exposed plant piping.” (I) to the WS controller manual 02250165-411, or to your authorized Sullair servicing distributor. Sullube should not be used with PVC piping In case the compressor needs to operate while the systems.
Page 20: Vsd Control System — Functional Description
Sullair recommends a setting of 6 regulator controls the inlet valve. The orifice also bleeds psi (0.4) for the most efficient operation.
Page 21 SECTION 2 1800-3000 USER MANUAL Figure 2-5: Air Inlet System 1. Air FIlter 3. Compressor Unit 2. Inlet Valve 4. Fan Motor/Air Filter Mount...
Page 22 1800-3000 USER MANUAL SECTION 2...
Page 23: Table Of Specifications
1351 31.5 53.2 1351 1613 3012 53.2 1351 31.5 53.2 1351 1613 DIMENSIONS Length Width Height Weight MODEL 1800 Series with Integral Dryer 1807 63.1 1603 31.5 53.2 1351 1621 1809 63.1 1603 31.5 53.2 1351 1621 1810 63.1 1603 31.5...
Page 24 Speed—25, 30 HP: 1765 RPM (60 Hz) or 1475 RPM (50 Hz) (IV) Multi-frequency and voltage motors are used. The compressors msust be used only with the specified electrical frequency and voltage. NOTE For latest sound test data, consult Sullair factory.
Page 25: Lubrication Guide
Refer to Figure 3-1 for location of fluid fill port. For plugging, orifice or line plugging. best value and longest uninterrupted service, the 1800, 2200 & 3000 Series compressors are factory filled and tested with Sullube lubricant. NOTE Flush system when switching lubricant CAUTION brands.
Page 26: Application Guide
1800-3000 USER MANUAL SECTION 3 APPLICATION GUIDE Sullair encourages the user to participate in a fluid analysis program with the fluid suppliers. This could result in a fluid change interval differing from that stated in the manual. Contact your Sullair dealer for details.
Page 27 NOTES...
Page 28 AIR-COOLED, IDENTIFICATION 25-30HP 02250159-354-R04...
Page 29 AIR-COOLED, IDENTIFICATION 25-30HP Main Motor HP Motor Type Weight CFM Cooling Air 1374 LBS/623 KG 2000 CFM TEFC 1420 LBS/644 KG 2000 CFM 1383 LBS/627 KG 2000 CFM TEFC 1450 LBS/658 KG 2000 CFM NOTES: A1: SPACE REQUIRED TO OPEN DOORS 1.
Page 30: Air-Cooled, Identification 40Hp
AIR-COOLED, IDENTIFICATION 40HP 02250181-032 R02...
Page 31 AIR-COOLED, IDENTIFICATION 40HP Main Motor HP Motor Type Weight CFM Cooling Air 1556 LBS/706 KG 2900 CFM TEFC 1613 LBS/732 KG 2900 CFM NOTES: A1: SPACE REQUIRED TO OPEN DOORS 1. ALLOW 4.00 FT. [1.25 METERS] MINIMUM CLEARANCE A2: SPACE REQUIRED TO OPEN STARTER PANEL AROUND MACHINE FOR ACCESS AND FREE CIRCULA- A3: CONTROLLER TION OF AIR.
Page 32: Air-Cooled Integral Dryer, Identification 25-30Hp
AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 25-30HP 02250168-699-R03...
Page 33 AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 25-30H Main Motor HP Motor Type Weight CFM Cooling Air 1575 LBS/714 KG 2000 CFM TEFC 1621 LBS/735 KG 2000 CFM 1584 LBS/718 KG 2000 CFM TEFC 1651 LBS/749 KG 2000 CFM NOTES: A1: SPACE REQUIRED TO OPEN DOORS 1.
Page 34: Air-Cooled Integral Dryer, Identification 40Hp
AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 40HP 02250180-784 R01...
Page 35 AIR-COOLED INTEGRAL DRYER, IDENTIFICATION 40HP Main Motor HP Motor Type Weight CFM Cooling Air 1757 LBS/797 KG 2900 CFM TEFC 1814 LBS/823 KG 2900 CFM NOTES: A1: SPACE REQUIRED TO OPEN DOORS 1. ALLOW 4.00 FT. [1.25 METERS] MINIMUM CLEARANCE A2: SPACE REQUIRED TO OPEN STARTER PANEL AROUND MACHINE FOR ACCESS AND FREE CIRCULA- A3: CONTROLLER...
Page 36: Piping And Instrumentation, Air-Cooled
PIPING AND INSTRUMENTATION, AIR-COOLED 02250156-114-R10...
Page 37 SW,VAC 22”WC N4 6FT CABLE 5A COMPRESSOR 02250050-154 SW,DIFF PRESS 20 PSID 02250155-599 TANK, SEP 2200 02250144-841 VLV,BALL/STNR COMB 1/2M X 1/2M 02250160-773 ELEM,OIL SEP 1800/2200 02250182-548 VLV,BALL/STNR COMBO-1/2”NPT 02250097-609 VALVE, 1-5/8 SAE MIN PRESS CHK 02250182-545 DRN,ZERO LOSS 115V 1/2”NPT 02250156-137 COOLER, AIR/OIL 2200 02250168-837 VENT,ENCL PROT 1/2”...
Page 38: Piping And Instrumentation, 1800-2200 W/Integral Dryer
3.10 PIPING AND INSTRUMENTATION, 1800-2200 W/INTEGRAL DRYER 02250172-798-R02...
Page 39 3.10 PIPING AND INSTRUMENTATION, 1800-2200 W/INTEGRAL DRYER PART NO. DESCRIPTION PART NO. DESCRIPTION 02250125-369 FILTER, AIR 8”(PLASTIC) W/MTG BAND 02250168-837 VENT,ENCL PROT 1/2” TOP VALVE, GROUP INLET DXX102E 02250169-612 GA,DIFF PRESS Z-PRG ASY BTM MTR_VAR MOTOR INTEGRAL REFRIGERANT DRYER COMPRESSOR...
Page 40: Wiring Diagram—Mfv, Air-Cooled
3.11 WIRING DIAGRAM—MFV, AIR-COOLED 02250171-211-R04...
Page 41 3.11 WIRING DIAGRAM—MFV, AIR COOLED 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 42: Wiring Diagram—Mfv, Air-Cooled Integral Dryer
3.12 WIRING DIAGRAM—MFV, AIR-COOLED INTEGRAL DRYER 02250174-982-R03...
Page 43 3.12 WIRING DIAGRAM—MFV, AIR-COOLED INTEGRAL DRYER COMP DESCRIPTION COMP DESCRIPTION 1MOL COMPRESSOR OVERLOAD FAN MOTOR BRANCH FUSES COMPRESSOR STARTER INTEGRAL DRYER SECONDARY FUSE 2MOL FAN MOTOR OVERLOAD INTEGRAL DRYER PRIMARY FUSES WET SUMP PRESSURE SENSOR POWER PRESENT RELAY OPTION PACKAGE DISCHARGE PRESSURE SENSOR DRYER FAULT UNIT DISCHARGE TEMPERATURE PROBE DRYER START RELAY...
Page 44: Wiring Diagram—Vsd, Parallel Wye Svx9000
3.13 WIRING DIAGRAM—VSD, PARALLEL WYE SVX9000 E-STOP DISPLAY YELLOW GREEN YELLOW OPTIONAL BROWN GREEN PINK GRAY BROWN WHITE PINK ETHERNET GRAY WHITE SEE CONNECTION TABLE FOR PROPER VOLTAGE CONNECTION GREEN COLD WEATHER OPTIONS BROWN PINK GRAY WHITE TO MATCH TERMINALS ON NEXT COMPRESSOR TO CUSTOMER 120VAC SUPPLY MODULE...
Page 45 3.13 WIRING DIAGRAM—VSD, PARALLEL WYE SVX9000 COMP DESCRIPTION COMP DESCRIPTION COMPRESSOR MOTOR NOTES: COOLER FAN MOTOR STARTER DELTA 1 CUSTOMER TO FURNISH FUSED 2MOL FAN MOTOR OVERLOAD OR CIRCUIT BREAKER DISCONNECT FAN MOTOR BRANCH CIRCUIT FUSES PER LOCAL CODES. JZL TRANSFORMER PRIMARY FUSES DELTA 2 REMOVE JUMPER FOR JZL TRANSFORMER SCONDARY FUSE AUXILLIARY E-STOP...
Page 46: Wiring Diagram, Vsd Series Delta A1000
3.14 WIRING DIAGRAM, VSD SERIES DELTA A1000 02250199-933 r00...
Page 47 3.14 WIRING DIAGRAM, VSD SERIES DELTA A1000 NOTES: COMP DESCRIPTION COMPRESSOR MOTOR CUSTOMER TO FURNISH FUSEDOR CIRCUIT BREAKER DIS- COOLER FAN MOTOR STARTER CONNECT PER LOCAL CODES. 2MOL FAN MOTOR OVERLOAD REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES. FAN MOTOR BRANCH CIRCUIT FUSES SCD TRANSFORMER PRIMARY FUSES USE ISOLATING RELAYS WITH DRY CONTACTS FOR ANY SCD TRANSFORMER SCONDARY FUSE...
Page 48: Wiring Diagram—Yd Ce
3.15 WIRING DIAGRAM—YD CE 02250178-718-R00...
Page 49 3.15 WIRING DIAGRAM—YD CE COMP DESCRIPTION COMP DESCRIPTION 1MOL COMPRESSOR OVERLOAD THERMOSTAT FOR HEAT TRACE OPTION COMPRESSOR STARTER (OPT’L) TRANSFORMER PRIMARY CIRCUIT BREAKER WYE-DELTA RUN CONTRACTOR (OPT’L) TRANSFORMER SECONDARY CIRCUIT BREAKER WYE-DELTA START CONTRACTOR (OPT'L) SCD DRAIN 3MOL FAN MOTOR OVERLOAD XFMR1 CONTROL TRANSFORMER FOR OPTIONAL SCD DRAIN CONTRACTOR FOR POWER FACTOR CAPACITOR OPT.
Page 50 NOTES...
Page 51: Mounting Of Compressor
1800-3000 USER MANUAL Section 4 INSTALLATION MOUNTING OF VENTILATION & COOLING COMPRESSOR Air-Cooled Compressors A suitable foundation or fabricated support must be • An area with adequate space must be pro- established to support the compressor. It should be vided for the compressor and its compo- rigid enough to keep the compressor frame level and nents.
Page 52: Service Air Piping
Discharged air contains a very small 35˚F (1.7˚C) amount of compressor lubricating oil, and care should be taken to ensure that this oil would not interfere with downstream equipment. Downstream filters (available from Sullair) can remove any liquid carry- over.
Page 53 SECTION 4 1800-3000 USER MANUAL Figure 4-1: Service Air Piping, Typical Installation 1. Sullair Compressor 5. Water Leg Drain Valve 2. Sullair Dryer 6. By-Pass Gate Valve 3. Shut-Off Gate Valve 7. Standard Gate Valve 4. Sullair Filter When two compressors are operated in parallel,...
Page 54: Coupling Alignment Check
1800-3000 USER MANUAL SECTION 4 ELECTRICAL PREPARATION Interior electrical wiring is performed at the factory. Required customer wiring should be done by a CAUTION qualified electrician in compliance with OSHA, National Electrical Code, and/or any other applicable The use of plastic bowls on line filters and...
Page 55: Motor Rotation Direction Check
SECTION 4 1800-3000 USER MANUAL • A few electrical checks should be made to MOTOR ROTATION help assure that the first start-up will be DIRECTION CHECK trouble-free. Motor rotation check must be made at compressor startup. See Figure 4-2 and Figure 4-3. The...
Page 56 1800-3000 USER MANUAL SECTION 4 Figure 4-2: Fan motor/main motor rotational direction 50Hz 25HP/18kw, 50Hz or 60Hz 30HP/22kw Figure 4-3: Fan motor/main motor rotational direction 60Hz 25HP/18kw, 50Hz or 60Hz 40HP/30kw...
Page 57: Controller Keypad
1800-3000 USER MANUAL Section 5 WS CONTROLLER 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 58: Lcd Display
1800-3000 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 59: Led Lights
SECTION 5 1800-3000 USER MANUAL the normal view. The green RUN mode indicator " " indicates compressor operation is enabled. It lights steadily if The list of displays may be navigated from either the motor is running. If the motor stops while in direction by using the UP "...
Page 60 NOTES...
Page 61: General
1800-3000 USER MANUAL Section 6 MAINTENANCE GENERAL WARNING WARNING HIGH-PRESSURE HAZARD! • DO NOT remove caps, plugs, and/or other Before any repairs are attempted, refer to components when compressor is running Section 1: Safety before proceeding. or pressurized. Stop compressor and relieve all internal pressure before doing so.
Page 62: Fluid Maintenance
1800-3000 USER MANUAL SECTION 6 2. Replace the fluid filter element. 1. As indicated by the WS Controller. 3. Pull oil sample for analysis 2. Every fluid change. 4. Check air filter. Change if necessary. Refer to Figure 6-1. Fluid Filter Element Replacement Refer to Figure 6-1.
Page 63: Separator Maintenance
SECTION 6 1800-3000 USER MANUAL Air Filter Element Replacement 7. Replace the cover plate, washers and cap screws. Torque to 70 ft·lbs (95 N·m). 1. Clean exterior of air filter housing. 8. Clean the return line strainer before restart- 2. Rotate end cover counterclockwise and ing the compressor.
Page 64 1800-3000 USER MANUAL SECTION 6 Troubleshooting— Introduction on page 65. The 4. Inspect and clean the orifice inside the sight glass blocks. The orifice must be removed maintenance on a fluid return/sight glass is mainly with an allen wrench. concerned with the condition of the filter assembly.
Page 65: Troubleshooting
4. Install the new element by wrapping it around the jaws, engaging the cogs on the Should your problem persist after making the element into the jaws. recommended check, consult your nearest Sullair representative. SYMPTOM PROBABLY CAUSE REMEDY...
Page 66 1800-3000 USER MANUAL SECTION 6 SYMPTOM PROBABLY CAUSE REMEDY Compressor Shuts Down With Air Loss of Control Voltage Reset. If trouble persists, check that line Demand Present pressure does not exceed maximum oper- ating pressure of the compressor (specified on nameplate).
Page 67 SECTION 6 1800-3000 USER MANUAL SYMPTOM PROBABLY CAUSE REMEDY Line Pressure Rises Above Unload Leak In Control System Causing Check for leaks. Pressure Set-Point Loss of Pressure Signals Inlet Valve Stuck Open Remove the intake hose and check for inlet valve operation.
Page 68 NOTES...
Page 69 NOTES...
Page 70 Always air. Always there. WWW.SULLAIR.COM SULLAIR 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. E14EP...

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