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USER MANUAL I NDUSTRIAL A IR C OMPRESSOR 4500 P , 5500, 7500, 4500 PV

USER MANUAL

INDUSTRIAL AIR COMPRESSOR

4500P, 5500, 7500, 4500PV, 5500V, 7500V, 4500PS, 5500PS, 7500P/PS, 7500PV, 45,55 & 75 KW:60, 75 & 100 HP

P / PS , 7500 PV , 45,55 & 75 KW :60, 75 & 100 HP

WARRANTY NOTICE

Failure to follow the instructions and procedures in this manual or, misuse of this equipment will VOID its warranty!

PART NUMBER:

02250176-184 R02

KEEP FOR

FUTURE

REFERENCE

© SULLAIR CORPORATION

The information in this manual is current as of its publication date, and applies to compressor serial number:

201107010000

and all subsequent serial numbers.

AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are courses that provide hands-on instruction for

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.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting common faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance, contractor maintenance, and service personnel.

For detailed course outlines, schedule, and cost information contact:

SULLAIR TRAINING DEPARTMENT

1-888-SULLAIR or 219-879-5451 (ext. 5623) www.sullair.com training@sullair.com

- Or Write -

Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training Department.

TABLE OF CONTENTS SECTION 1—SAFETY 5 1.1 GENERAL 5 1.2 PERSONAL PROTECTIVE EQUIPMENT 5 1.3

TABLE OF CONTENTS

SECTION 1—SAFETY

5

1.1

GENERAL

5

1.2

PERSONAL PROTECTIVE EQUIPMENT

5

1.3

PRESSURE RELEASE

6

1.4

FIRE AND EXPLOSION

6

1.5

MOVING PARTS

7

1.6

HOT SURFACES, SHARP EDGES AND SHARP CORNERS

7

1.7

TOXIC AND IRRITATING SUBSTANCES

8

1.8

ELECTRICAL SHOCK

8

1.9

LIFTING

9

1.10

ENTRAPMENT

SECTION 2—DESCRIPTION

11

2.1

INTRODUCTION

11

2.2

COMPRESSOR COMPONENT DESCRIPTION

15

2.3

COMPRESSOR COOLING AND LUBRICATION SYSTEM — FUNC- TIONAL DESCRIPTION

15

2.4

COMPRESSOR DISCHARGE SYSTEM—FUNCTIONAL DESCRIPTION

17

2.5

CONTROL SYSTEM — FUNCTIONAL DESCRIPTION

19

2.6

AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

20

2.7

WS CONTROLLER/KEYPAD

20

2.8

LCD DISPLAY

21

2.9

LED LIGHTS

22

2.10

VARIABLE SPEED DRIVE (VSD) COMPONENTS

22

2.11

VSD CONTROL SYSTEM — FUNCTIONAL DESCRIPTION

23

2.12

INTEGRAL DRYER OPTION

SECTION 3—SPECIFICATIONS

25

3.1

TABLE OF SPECIFICATIONS—4500P, 5500 & 7500 SERIES MODELS

26

3.2

TABLE OF SPECIFICATIONS—VARIABLE SPEED DRIVE

27

3.3

COMPRESSOR SPECIFICATIONS

27

3.4

LUBRICATION GUIDE

27

3.5

APPLICATION GUIDE

TABLE OF CONTENTS

27 3.6

LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE, FLUID FILTER AND SEPARATOR

SECTION 4—INSTALLATION

51

4.1

COMPRESSOR MOUNTING - SUPPORT AND LOCATION

51

4.2

VENTILATION AND COOLING

55

4.3

SERVICE AIR PIPING

57

4.4

COUPLING ALIGNMENT CHECK

57

4.5

FLUID LEVEL CHECK

57

4.6

ELECTRICAL PREPARATION

58

4.7

MOTOR ROTATION DIRECTION CHECK

SECTION 5—OPERATION

61 5.1

ROUTINE OPERATION

SECTION 6—MAINTENANCE

63

6.1

GENERAL

63

6.2

MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION

63

6.3

MAINTENANCE EVERY 2000 HOURS

63

6.4

FLUID MAINTENANCE

63

6.5

FILTER MAINTENANCE

64

6.6

AIR FILTER MAINTENANCE

65

6.7

SEPARATOR MAINTENANCE

67

6.8

TROUBLESHOOTING – INTRODUCTION

6.6 AIR FILTER MAINTENANCE 65 6.7 SEPARATOR MAINTENANCE 67 6.8 TROUBLESHOOTING – INTRODUCTION

Section 1

SAFETY

NOTE

NOTE OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL.

OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL.

1.1

GENERAL

Sullair Corporation and its subsidiaries design and manufacture all of their products so they can be operated safely. However, the responsibility for safe operation rests with those who use and maintain these products. The following safety precautions are offered as a guide which, if conscientiously followed, will minimize the possibility of accidents throughout the useful life of this equipment.

The compressor should be operated only by those who have been trained and delegated to do so, and who have read and understood this Operator's Manual. Failure to follow the instructions, procedures and safety precautions in this manual may result in accidents and injuries. NEVER start the compressor unless it is safe to do so. DO NOT attempt to operate the compressor with a known unsafe condition. Tag the compressor and render it inoperative by disconnecting and locking out all power at source or otherwise disabling its prime mover so others who may not know of the unsafe condition cannot attempt to operate it until the condition is corrected.

Install, use and operate the compressor only in full compliance with all pertinent OSHA regulations and/ or any applicable Federal, State, and Local codes, standards and regulations. DO NOT modify the compressor and/or controls in any way except with written factory approval.

While not specifically applicable to all types of compressors with all types of prime movers, most of

types of compressors with all types of prime movers, most of the precautionary statements contained herein

the precautionary statements contained herein are applicable to most compressors and the concepts behind these statements are generally applicable to all compressors.

1.2 PERSONAL PROTECTIVE EQUIPMENT

A. Prior to installing or operating the compressor, owners, employers and users should become familiar with, and comply with, all applicable OSHA regulations and/or any applicable Federal, State and Local codes, standards, and regula- tions relative to personal protective equipment, such as eye and face protective equipment, respiratory protective equipment, equipment intended to protect the extremities, protective clothing, protective shields and barriers and elec- trical protective equipment, as well as noise exposure administrative and/or engineering con- trols and/or personal hearing protective equip- ment.

1.3 PRESSURE RELEASE

A. Install an appropriate flow-limiting valve between the service air outlet and the shut-off (throttle) valve, either at the compressor or at any other point along the air line, when an air hose exceed- ing 1/2" (13mm) inside diameter is to be con- nected to the shut-off (throttle) valve, to reduce pressure in case of hose failure, per OSHA Stan- dard 29 CFR 1926.302(b)(7) and/or any applica- ble Federal, State and Local codes, standards and regulations.

B. When the hose is to be used to supply a mani- fold, install an additional appropriate flow-limiting valve between the manifold and each air hose exceeding 1/2" (13mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure.

C. Provide an appropriate flow-limiting valve at the beginning of each additional 75 feet (23m) of hose in runs of air hose exceeding 1/2" (13mm)

5

SECTION 1

inside diameter to reduce pressure in case of hose failure.

D. Flow-limiting valves are listed by pipe size and flow-rated. Select appropriate valves accordingly, in accordance with their manufacturer's recom- mendations.

E. DO NOT use air tools that are rated below the maximum rating of the compressor. Select air tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufac- turer's rated safe operating pressures for these items.

F. Secure all hose connections by wire, chain or other suitable retaining device to prevent tools or hose ends from being accidentally disconnected and expelled.

G. Open fluid filler cap on ly when compressor is not running and is not pressurized. Shut down the compressor and bleed the receiver tank to zero internal pressure before removing the cap.

H. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before attempting to refill optional air line anti-icer systems with antifreeze compound.

I. Keep personnel out of line with and away from the discharge opening of hoses or tools or other points of compressed air discharge.

J. DO NOT use air at pressures higher than 2.1 bar for cleaning purposes, and then only with effec- tive chip guarding and personal protective equip- ment per OSHA Standard 29 CFR 1910.242 (b) and/or any applicable Federal, State, and Local codes, standards and regulations.

K. DO NOT engage in horseplay with air hoses as death or serious injury may result.

1.4 FIRE AND EXPLOSION

A. Clean up spills of lubricant or other combustible substances immediately, if such spills occur.

B. Shut off the compressor and allow it to cool. Then keep sparks, flames and other sources of ignition away and DO NOT permit smoking in the vicinity when checking or adding lubricant or when refilling air line anti-icer systems with anti- freeze compound.

C. DO NOT permit fluids, including air line anti-icer system antifreeze compound or fluid film, to

6

accumulate on, under or around acoustical mate- rial, or on any external surfaces of the air com- pressor. Wipe down using an aqueous industrial cleaner or steam clean as required. If necessary, remove acoustical material, clean all surfaces and then replace acoustical material. Any acous- tical material with a protective covering that has been torn or punctured should be replaced immediately to prevent accumulation of liquids or fluid film within the material. DO NOT use flam- mable solvents for cleaning purposes.

D. Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the com- pressor or of the inside of the enclosure, if any.

E. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace any wiring that has cracked, cut, abraded or oth- erwise degraded insulation, or terminals that are worn, discolored or corroded. Keep all terminals and pressure connectors clean and tight.

F. Keep grounded and/or conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition.

G. Remove any acoustical material or other material that may be damaged by heat or that may sup- port combustion and is in close proximity, prior to attempting weld repairs.

H. Keep suitable fully charged Class BC or ABC fire extinguisher or extinguishers nearby when ser- vicing and operating the compressor.

I. Keep oily rags, trash, leaves, litter or other com- bustibles out of and away from the compressor.

J. DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or with degraded lubricant.

K. DO NOT attempt to operate the compressor in any classification of hazardous environment unless the compressor has been specially designed and manufactured for that duty.

1.5 MOVING PARTS

A. Keep hands, arms and other parts of the body and clothing away from couplings, belts, pulleys, fans and other moving parts.

B. DO NOT attempt to operate the compressor with the fan, coupling or other guards removed.

fans and other moving parts. B. DO NOT attempt to operate the compressor with the fan,

SECTION 1

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

F. Disconnect and lock out all power at source and verify at the compressor that all circuits are de- energized to minimize the possibility of acciden- tal start-up, or operation, prior to attempting repairs or adjustments. This is especially impor- tant when compressors are remotely controlled.

G. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water or other liquids to minimize the possibility of slips and falls.

1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS

A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners.

B. Keep all parts of the body away from all points of air discharge.

C. Wear personal protective equipment including gloves and head covering when working in, on or around the compressor.

D. Keep a first aid kit handy. Seek medical assis- tance promptly in case of injury. DO NOT ignore small cuts and burns as they may lead to infec- tion

1.7 TOXIC AND IRRITATING SUBSTANCES

A. DO NOT use air from this compressor for respi- ration (breathing) except in full compliance with OSHA Standards 29 CFR 1910 and/or any appli- cable Federal, State or Local codes or regula- tions.

cable Federal, State or Local codes or regula- tions. DANGER Death or serious injury can result
DANGER Death or serious injury can result from inhaling compressed air without using proper safety

DANGER

DANGER Death or serious injury can result from inhaling compressed air without using proper safety equipment.
DANGER Death or serious injury can result from inhaling compressed air without using proper safety equipment.
Death or serious injury can result from inhaling compressed air without using proper safety equipment.

Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA stan- dards and/or any applicable Federal, State, and Local codes, standards and regulations on safety equipment.

B. DO NOT use air line anti-icer systems in air lines supplying respirators or other breathing air utili- zation equipment and DO NOT discharge air from these systems into unventilated or other confined areas.

C. Operate the compressor only in open or ade- quately ventilated areas.

D. Locate the compressor or provide a remote inlet so that it is not likely to ingest exhaust fumes or other toxic, noxious or corrosive fumes or sub- stances.

E. Coolants and lubricants used in this compressor are typical of the industry. Care should be taken to avoid accidental ingestion and/or skin contact. In the event of ingestion, seek medical treatment promptly. Wash with soap and water in the event of skin contact. Consult Material Safety Data Sheet for information pertaining to fluid of fill.

F. Wear goggles or a full face shield when adding antifreeze compound to air line anti-icer systems.

G. If air line anti-icer system antifreeze compound enters the eyes or if fumes irritate the eyes, they should be washed with large quantities of clean water for fifteen minutes. A physician, preferably an eye specialist, should be contacted immedi- ately.

H. DO NOT store air line anti-icer system antifreeze compound in confined areas.

I. The antifreeze compound used in air line anti- freeze systems contains methanol and is toxic, harmful or fatal if swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If

7

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 water. Have patient lay down and cover eyes to exclude light. Call a physician immediately.

1.8 ELECTRICAL SHOCK

A. This compressor should be installed and main- tained in full compliance with all applicable Fed- eral, State and Local codes, standards and regulations, including those of the National Elec- trical Code, and also including those relative to equipment grounding conductors, and only by personnel that are trained, qualified and dele- gated to do so.

B. Keep all parts of the body and any hand-held tools or other conductive objects away from exposed live parts of electrical system. Maintain dry footing, stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system. Make all such adjustments or repairs with one hand only, so as to minimize the possibility of creating a current path through the heart.

C. Attempt repairs in clean, dry and well lighted and ventilated areas only.

D. DO NOT leave the compressor unattended with open electrical enclosures. If necessary to do so, then disconnect, lock out and tag all power at source so others will not inadvertently restore power.

E. Disconnect, lock out, and tag all power at source prior to attempting repairs or adjustments to rotating machinery and prior to handling any ungrounded conductors.

8

DANGER

DANGER

All field equipment must be tested for elec- trostatic fields prior to servicing or making contact with the machine using the follow- ing or equivalent test equipment:

• 90-600 VAC: Volt detector such as Fluke Model 1AC-A

• 600-7000 VAC: Voltage detector such as Fluke Networks Model

C9970

It is the responsibility of each organization to provide/arrange training for all their associates expected to test for electrostatic fields.

1.9

LIFTING

A. If the compressor is provided with a lifting bail, then lift by the bail provided. If no bail is provided, then lift by sling. Compressors to be air-lifted by helicopter must not be supported by the lifting bail but by slings instead. In any event, lift and/or handle only in full compliance with OSHA stan- dards 29 CFR 1910 subpart N and/or any appli- cable Federal, State, and Local codes, standards and regulations.

B. Inspect points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifting.

C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condi- tion and has a rated capacity of at least the weight of the compressor. If you are unsure of the weight, then weigh compressor before lifting.

D. Make sure lifting hook has a functional safety latch or equivalent, and is fully engaged and latched on the bail or slings.

E. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground.

F. DO NOT attempt to lift in high winds.

G. Keep all personnel out from under and away from the compressor whenever it is suspended.

H. Lift compressor no higher than necessary.

out from under and away from the compressor whenever it is suspended. H. Lift compressor no

SECTION 1

I. Keep lift operator in constant attendance when- ever compressor is suspended.

J. Set compressor down only on a level surface capable of safely supporting at least its weight and its loading unit.

K. When moving the compressor by forklift truck, utilize fork pockets if provided. Otherwise, utilize pallet if provided. If neither fork pockets or pallet are provided, then make sure compressor is secure and well balanced on forks before attempting to raise or transport it any significant distance.

L. Make sure forklift truck forks are fully engaged and tipped back prior to lifting or transporting the compressor.

M. Forklift no higher than necessary to clear obsta- cles at floor level and transport and corner at minimum practical speeds.

level and transport and corner at minimum practical speeds. N. Make sure pallet-mounted compressors are firmly

N. Make sure pallet-mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them. NEVER attempt to forklift a compressor that is not secured to its pallet, as uneven floors or sud- den stops may cause the compressor to tumble off, possibly causing serious injury or property damage in the process.

1.10

ENTRAPMENT

A. If the compressor enclosure, if any, is large enough to hold a man and if it is necessary to enter it to perform service adjustments, inform other personnel before doing so, or else secure and tag the access door in the open position to avoid the possibility of others closing and possi- bly latching the door with personnel inside.

B. Make sure all personnel are out of compressor before closing and latching enclosure doors.

9

NOTES

10

NOTES 10

4500-7500 USER MANUAL

Section 2

DESCRIPTION

2.1

INTRODUCTION

The design of the Sullair 4500P, 5500, 7500, 4500PV, 5500V, 7500V: 60, 75 and 100hp / 45, 55 and 75kw line of compressor units is a single stage, positive displacement, flood lubricated one. A complete package includes the:

• Compressor unit

• Electric motor

• Starter

• Compressor inlet and discharge systems

• Compressor lubrication and cooling system

• Capacity control system

• WS Controller™

• Aftercooler

• Combination separator and trap

• Heavy gauge steel mounting frame

Some models also have a Variable Speed Drive (VSD) that is described in Section 2.10 and Section 2.11. There are also optional components which allow operation in environments where the compressor is exposed to extreme temperatures, or if sea water is used as a coolant.

CAUTION Use only one type of a recommended com- pressor lubricant. Adding a different one,

CAUTION

Use only one type of a recommended com- pressor lubricant. Adding a different one, or

Use only one type of a recommended com- pressor lubricant. Adding a different one, or mixing lubricants can cause damage and/or malfunctions, and will void the compres- sor’s warranty.

New compressors are shipped from the factory fully charged with that particular model’s recommended lubrication fluid. The SPECIFICATIONS Section 3.4 and Section 3.5 describe lubrication requirements and recommendations for each compressor package.

Sullair recommends that, in cases where 24KT

package. Sullair recommends that, in cases where 24KT lubricant is used, users take a sample at

lubricant is used, users take a sample at the first filter change and send it to the factory for a free analysis using a sample kit provided by their Sullair dealer. The results will be sent back to the user in the form of a report with recommendations.

NOTE

The compressor requires no internal inspections or maintenance actions. Open- ing the compressor’s housing may void its warranty. (This does not apply to the shaft seal which is replaceable.)

Although both air and water-cooled models require no inspection of the unit’s internal components, external piping, connectors, and the enclosure should be inspected and maintained in accordance with the procedures and recommendations in this manual.

2.2

COMPRESSOR COMPONENT DESCRIPTION

Air-cooled models (Figure 2-1) use a fan to draw outside air into the enclosure, cooling the motors, the combined radiator fluid cooler, and air aftercooler. This hot air is then vented out of the top of the enclosure.

Water-cooled models (Figure 2-2) use two shell and tube heat exchangers to transfer heat from the coolant, and the compressed air. Both air-cooled and water cooled models have a fluid filter, air/oil separator, control valves, and an inlet air filter.

Fluid is injected into the compressor, and mixes directly with the air as the rotors turn which compresses the air. The fluid flow has three basic functions:

1. As a coolant, it controls the air temperature rise normally associated with the heat of compression.

11

4500-7500 USER MANUAL

SECTION 2

2. Seals the clearance paths between the rotors and the stator, and also between the two rotors.

3. Provides a lubricating film between the rotors allowing one rotor to directly drive the other, which is an idler, and also lubricates the bearings.

After the air/fluid mixture is discharged from the compressor unit, the fluid is separated from the air. At this time, the air flows through an aftercooler and separator, and then to the service line while the fluid is cooled and filtered in preparation for reinjection.

is cooled and filtered in preparation for reinjection. Figure 2-1: Main Components, Air-Cooled 1. Fluid Filter

Figure 2-1: Main Components, Air-Cooled

1. Fluid Filter

8. Starter Box

2. Cooler

9. E-Stop Button

3. Moisture Separator

10. Compressor Unit

4. Air Inlet Filter

11. Cooler Fan Motor

5. separator/sump Tank

12. Motor

6. Fluid Fill Sight Glass

13. Fluid Fill

7. WS Controller

 

12

5. separator/sump Tank 12. Motor 6. Fluid Fill Sight Glass 13. Fluid Fill 7. WS Controller

SECTION 2

4500-7500 USER MANUAL

Figure 2-2: Main Components, Water-Cooled 1. Fluid Filter 9. E-Stop Button 2. Cooler 10. Compressor
Figure 2-2: Main Components, Water-Cooled
1. Fluid Filter
9.
E-Stop Button
2. Cooler
10.
Compressor Unit
3. Vent Fan
11.
Moisture Separator
4. Air Inlet Filter
12.
Motor
5. separator/sump Tank
13. Fluid Fill
6. Fluid Fill Sight Glass
14. Water-Cooled Aftercooler
7. WS Controller
15. Inlet Valve
8. Starter Box
Fluid Fill 6. Fluid Fill Sight Glass 14. Water-Cooled Aftercooler 7. WS Controller 15. Inlet Valve

13

4500-7500 USER MANUAL

SECTION 2

4500-7500 USER MANUAL SECTION 2 Figure 2-3: Air-Cooled, Cooling/Lubrication and Discharge System 1. Separator/Sump Tank

Figure 2-3: Air-Cooled, Cooling/Lubrication and Discharge System

1. Separator/Sump Tank

6.

Separator Elements

2. Cooler

7.

Air

3. Fluid Filter

8.

Air/Fluid Mix

4. Moisture Separator

9.

Fluid

14

5. Compressor Unit

7. Air 3. Fluid Filter 8. Air/Fluid Mix 4. Moisture Separator 9. Fluid 14 5. Compressor

SECTION 2

4500-7500 USER MANUAL

2.3 COMPRESSOR COOLING AND LUBRICATION SYSTEM — FUNCTIONAL DESCRIPTION

Refer to Figure 2-3 or Figure 2-4. The cooling and lubrication system (air-cooled models) consists of a fan, fan motor, radiator aftercooler/fluid cooler, full flow fluid filter, thermal valve, and interconnecting hoses. Water-cooled models have two shell and tube heat exchangers instead of a radiator cooler.

The pressure in the separator/sump tank starts the fluid flow by forcing the fluid from the high pressure area of the tank to an area of lower pressure in the compressor. Fluid flows from the bottom of the separator/sump tank to the thermal valve that is fully open when the fluid temperature is below 185°F (85°C) [195°F (91°C) for 24KT and pressures rated above 150 psig]. The fluid passes through the thermal valve, the main filter, and directly to the compressor where it lubricates, cools and seals the rotors, and the compression chamber.

As the discharge temperature rises above 185°F (85°C), due to the heat of compression, the thermal valve begins to adjust and a portion of the fluid then flows through the cooler. From the cooler the fluid flows to the fluid filter and on to the compressor. A portion of the fluid flow to the compressor is routed to the anti-friction bearings which support the compressor rotors.

The fluid filter has a replacement element and an integral bypass valve. Refer to Section 3.6:

Lubrication Change Recommendations and Maintenance, Fluid Filter And Separator on page 27.

Water-cooled models have a water pressure switch to prevent operation when the water pressure is too low.

2.4 COMPRESSOR DISCHARGE SYSTEM—FUNCTIONAL DESCRIPTION

Refer to Figure 2-3 or Figure 2-4. The compressor discharges the compressed air/fluid mixture into the combination separator/sump tank. The separator/ sump has three basic functions:

1. It acts as a primary fluid separator.

2. Serves as the compressor fluid sump.

3. Houses the final fluid separator.

compressor fluid sump. 3. Houses the final fluid separator. The compressed air/fluid mixture enters the separator/sump

The compressed air/fluid mixture enters the separator/sump tank and flows through an internal baffle system that changes the flow’s direction and

velocity, which causes most of the fluid to fall to the bottom of the separator/sump tank. A small amount

of fluid remaining in the compressed air collects on

the surface of the separator element as the air flows through the separator.

A return line (or scavenge tube) leads from the dry

side of the separator/sump tank to the medium pressure region. Scavanged fluid is returned by a pressure differential between the separator/sump and compressor.

A visual sight glass is located on the return line to

observe this flow. This return line also has an orifice (protected by a strainer) to ensure an unobstructed flow. The separator system reduces the fluid carry-

over

to less than 1ppm at nominal rated pressures.

The

WS Controller will show an abnormal pressure

drop

through the separator if the element becomes

plugged. (Refer to Section 3.6: Lubrication Change Recommendations and Maintenance, Fluid Filter And Separator on page 27.) It will also shut down the compressor if the discharge temperature reaches 235°F (113°C).

A minimum pressure/check valve located

downstream from the separator maintains the

separator/sump pressure at 50 psig (3.4 bar) during

load conditions. This pressure level is necessary for

proper air/fluid separation and sufficient fluid

circulation.

A terminal check valve is a sub-component of the

minimum pressure/check valve that prevents compressed air in the service line from back-flowing into the separator/sump on shutdown or when the

compressor is operating in an unload condition. Also,

a pressure relief valve on the compressor’s wet side opens if the separator/sump tank pressure exceeds its rating.

WARNING Stop the compressor and relieve all internal pressure before removing caps, plugs, and/ or

WARNING

Stop the compressor and relieve all internal pressure before removing caps, plugs, and/ or other

Stop the compressor and relieve all internal pressure before removing caps, plugs, and/ or other components when the compressor is running or pressurized.

15

4500-7500 USER MANUAL

SECTION 2

Figure 2-4: Water-Cooled, Cooling/Lubrication and Discharge System

1. Separator/Sump Tank

6.

Separator Elements

2. Fluid Cooler

7.

Air

3. Fluid Filter

8.

Air/Fluid Mix

4. Moisture Separator

9.

Fluid

16

5. Compressor Unit

10. Aftercooler

3. Fluid Filter 8. Air/Fluid Mix 4. Moisture Separator 9. Fluid 16 5. Compressor Unit 10.

SECTION 2

4500-7500 USER MANUAL

Add fluid to the separator/sump tank through the capped fluid filter port. There is also a sight glass that enables the user to check the separator/sump tank fluid level. See Fluid Level Check on page 57.

2.5 CONTROL SYSTEM — FUNCTIONAL DESCRIPTION

Refer to Figure 2-5. The compressor control system regulates its output to match the demand. This system consists of a solenoid valve, a regulator and an inlet valve that control the compressor’s four operational modes. The following descriptions of operational modes apply to a compressor whose operating range is 100 to 110 psig (6.9 to 7.6 bar)

Other pressure settings can be selected depending on compressor application or rating.

START MODE - 0 TO 50 PSIG (0 TO 3.5 BAR)

There is no load on the compressor at startup, the solenoid valve is open and the inlet valve is closed.

(START) pad is pressed,

the separator/sump tank pressure rises from 0 to 50 psig (0 - 3.4 bar). When it reaches its full operating speed (maximum rpm), the compressor switches to the Full Load Mode.

When the compressor

I
I
Figure 2-5: Standard Sequencing Control System 1. Air Outlet 6. Minimum Pressure / Check Valve
Figure 2-5: Standard Sequencing Control System
1. Air Outlet
6.
Minimum Pressure / Check Valve
2. Sequencing Solenoid Valve
7.
Separator/sump Tank
3. Pressure Regulator
8.
Unload Solenoid Valve
4. Air Inlet
9.
WS Controller
5. Blowdown Valve
17

4500-7500 USER MANUAL

SECTION 2

FULL LOAD MODE - 50 TO 100 PSIG (3.4 TO

6.9 BAR)

When the compressed air pressure rises above 50 psig (3.4 bar), the minimum pressure valve opens allowing compressed air to flow into the service line. From this point on, the WS Controller continuously monitors the line air pressure. The pressure regulator and the solenoid valve remain closed in this mode. As long as the compressor is running at 100 psig (6.9 bar or lower), the inlet valve is fully open.

MODULATING MODE - 100 TO 110 PSIG (6.9 TO

7.6 BAR) (STANDARD CONTROL)

If the rated capacity of compressed air is less than the demand, the service line pressure rises above

100 psig (6.9) bar). The pressure regulator valve

gradually opens, causing the air pressure to close the inlet control valve at the same rate, reducing the volume of air entering the compressor until it matches the demand. The control system operates continuously in this mode to accommodate variations in demand output.

The inlet valve has an orifice that directs a small amount of air to the compressor inlet when the inlet control valve is under the pressure regulator’s control. The orifice also bleeds off any accumulated moisture from the control lines.

MODULATING MODE WITH SPIRAL

VALVE - 100 TO 110 PSIG (6.9 TO

7.6 BAR)

As air demand drops below the rated capacity of the compressor, the line pressure will rise above 100 psig (6.9 bar). As a result, the differential pressure regulator for the spiral valve gradually opens, apply- ing air pressure to the spiral valve actuator. Air pres- sure at the actuator expands the diaphragm. The rack, in turn, engages with the pinion mounted on the spiral valve shaft assembly. This results in a rotary motion. As the spiral valve rotates, it starts opening the bypass ports gradually. Excess air is then being returned back internally to the suction end of the compressor unit. Now the compressor is fully compressing only that amount of air, which is being used. As air demand keeps dropping further, the spiral valve keeps opening more and more until all the bypass ports are fully open. At this point, the spiral valve has moved into the unload (minimum) position.

The spiral valve provides a modulation range from

100 to 50%. During this period, the pressure rises

18

approximately from 100 to 105 psig (6.9 to 7.2 bar). As the air pressure exceeds 105 psig (7.2 bar), the differential pressure regulator controlling the inlet poppet valve starts opening and forcing the poppet closed, thus throttling inlet air flow to the compres- sor. The inlet poppet valve provides a modulation range from 50 to 40%. During this period, the pres- sure rises approximately from 106 to 110 psig (7.3 to 7.6 bar). During this range, the spiral valve remains in the unload position.

UNLOAD MODE - GREATER THAN 110 PSIG

(7.6 BAR)

When there is no, or only a small demand, the service line pressure will rise. The WS Controller de- energizes the solenoid valve when the pressure exceeds 110 psig (7.6 bar) allowing the separator/ sump tank air pressure to be supplied directly which closes the inlet valve. At the same time the solenoid valve sends a pneumatic signal to the blowdown valve on the separator/sump tank. This component exhausts the system pressure to the atmosphere and lowers the separator/sump tank pressure to approximately 14 psig (1.2 bar). A check valve in the air service line prevents air from back-flowing to the separator/sump tank.

When the pressure drops to the low setting: (cut-in pressure) usually 100 psig (6.9 bar) for low pressure (7 bar) compressors and 125 psig (8.6 bar) for high pressure (9 bar) compressors, 150 psig (10.3 bar) for (10 bar) compressors, 175 psig (12.0 bar) for (12 bar) compressors: the WS Controller energizes the solenoid valve and the blowdown valve closes. The solenoid valve now prevents line pressure from reaching the inlet control valve. If the pressure begins to rise, the pressure regulator resumes its normal function.

LOAD/NO LOAD CONTROL

The compressor can be set to operate without modulation, operating in the load/no load condition. This mode is used most often with large air system volume, e.g., with a separator/sump or flow controller. This mode is selected using the WS Controller keypad and setting modulation to “no” from the menu. A machine rated for 100 psig (7bar) will run in the full load mode up to 100 psig (7 bar). If the demand is less than the compressor’s rated capacity, the pressure will rise above 100 psig and the WS Controller de-energizes the solenoid valve which causes the compressor to switch to the unload mode. When the system pressure decreases to 90 psig (6.3 bar), the WS Controller energizes the

to switch to the unload mode. When the system pressure decreases to 90 psig (6.3 bar),

SECTION 2

4500-7500 USER MANUAL

solenoid valve and the compressor switches back to the full load mode. The compressor’s WS Controller keeps the system pressure stabilized within a range of 90 to 100 psig (6.3 to 6.9 bar).

2.6 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

Refer to Figure 2-6. The compressor inlet system consists of a dry-type air filter, a restriction gauge and an air inlet valve.

air filter , a restriction gauge and an air inlet valve . Figure 2-6: Air Inet

Figure 2-6: Air Inet System

1. Air Inlet Filter

3. Compressor Unit

2. Air Inlet Valve

4. Restriction Indicator

The restriction gauge (located on the air filter) indicates the condition of the air filter by showing red when filter maintenance is required.

The poppet-type modulating air inlet valve controls the compressor’s air intake volume. Refer to Full Load Mode - 50 to 100 psig (3.4 to 6.9 bar) on page 18. The air inlet valve also acts as a check valve to prevent reverse rotation when the compressor is shut down.

prevent reverse rotation when the compressor is shut down. WARNING "The Plastic Pipe Institute recommends
WARNING

WARNING

"The Plastic Pipe Institute recommends against the use of thermoplastic pipe to transport compressed air or other com- pressed gases in exposed above ground locations, e.g. in exposed plant piping." (I) Sullube should not be used with PVC piping systems. It may affect the bond at cemented joints. Certain other plastic materials may also be affected.

(I) Plastic Pipe Institute, Recommendation

B, Adopted January 19, 1972.

19

4500-7500 USER MANUAL

SECTION 2

4500-7500 USER MANUAL SECTION 2 Figure 2-7: WS Controller Panel 1. Display Panel 6. Enter Pad

Figure 2-7: WS Controller Panel

1. Display Panel

6. Enter Pad

2. Start Pad

7. Fault Warning Indicator Light (Red)

3. Stop Pad

8. Maintenance Indicator Light (Amber)

4. Arrow Up Pad

9. Auto Mode Indicator Light (Green)

5. Arrow Down Pad

10. Power On (Green)

2.7 WS CONTROLLER/KEYPAD

Refer to Figure 2-7. The WS Controller keypad has two main pads for compressor control. To start the compressor operation, press the green Start pad

.
.

To stop compressor operation, press the red Stop

pad

whenever the control is in an operating mode.

lights up

pad whenever the control is in an operating mode. lights up . The Run mode indicator

. The Run mode indicator

is in an operating mode. lights up . The Run mode indicator 2.8 LCD DISPLAY The

2.8 LCD DISPLAY

The display's normal view shows the compressor package's discharge pressure, internal temperature, and the operating mode. The modes are MANUAL, OFF, AUTOMATIC, or FAULTED

20

mode. The modes are MANUAL, OFF, AUTOMATIC, or FAULTED 20 Figure 2-8 Refer to Figure 2-8
mode. The modes are MANUAL, OFF, AUTOMATIC, or FAULTED 20 Figure 2-8 Refer to Figure 2-8

Figure 2-8

Refer to Figure 2-8 and Figure 2-9. The lower line is occasionally interrupted to describe the compressor package's operating state.

2-9 . The lower line is occasionally interrupted to describe the compressor package's operating state. Figure
2-9 . The lower line is occasionally interrupted to describe the compressor package's operating state. Figure
Figure 2-9
Figure 2-9

SECTION 2

4500-7500 USER MANUAL

Refer to Figure 2-10. If a machine fault occurs, the

red fault

indicate that a fault has occurred.

indicator will light up, and the display willoccurs, the red fault indicate that a fault has occurred. Figure 2-10 Refer to Figure 2-11

has occurred. indicator will light up, and the display will Figure 2-10 Refer to Figure 2-11
has occurred. indicator will light up, and the display will Figure 2-10 Refer to Figure 2-11

Figure 2-10

Refer to Figure 2-11. The lower line periodically will display the cause of the fault. Refer to service instructions to correct the cause. Press the Stop pad

to reset the controller.instructions to correct the cause. Press the Stop pad Figure 2-11 Refer to Figure 2-12 .

the cause. Press the Stop pad to reset the controller. Figure 2-11 Refer to Figure 2-12

Figure 2-11

Press the Stop pad to reset the controller. Figure 2-11 Refer to Figure 2-12 . Press

Refer to Figure 2-12. Press the Down arrow to display additional information about the compressor. The upper line will indicate "Compressor Status" and the name of the temperature, pressure, or other measurement. The lower line indicates the present reading.

measurement. The lower line indicates the present reading. Figure 2-12 Refer to Figure 2-13 . When
measurement. The lower line indicates the present reading. Figure 2-12 Refer to Figure 2-13 . When

Figure 2-12

Refer to Figure 2-13. When you continue beyond the status information, the display will show a list of control settings. The upper line will indicate "Show Setting" and the name of the setting. The lower line shows the present value.

name of the setting. The lower line shows the present value. Figure 2-13 Refer to Figure
name of the setting. The lower line shows the present value. Figure 2-13 Refer to Figure
Figure 2-13
Figure 2-13

Refer to Figure 2-14. To change the setting, press

the Enter pad . The display indicates that you are in a change mode with reverse characters. Use

the Up

arrow keys to change the

setting, and press Enter again to save the new

setting.

the setting, and press Enter again to save the new setting. or Down Figure 2-14 Refer
the setting, and press Enter again to save the new setting. or Down Figure 2-14 Refer

or Down

and press Enter again to save the new setting. or Down Figure 2-14 Refer to Figure
and press Enter again to save the new setting. or Down Figure 2-14 Refer to Figure

Figure 2-14

Refer to Figure 2-14. If there is no keypad activity, the display will return to normal view in about one minute. If the Start or Stop buttons are pressed, the display also returns to normal view. If either of these occur, the setting will not be altered.

If there are any warnings or recommended service instructions, these will be periodically displayed on the normal view.

The list of displays may be navigated from either

arrow

direction by using the Up

keys. For example, to change language from normal view, press the Up arrow pad once, press the Enter

normal view, press the Up arrow pad once, press the Enter or Down key , select

or Down

view, press the Up arrow pad once, press the Enter or Down key , select your

key , select your language, and press Enter again. The number of displays varies with compressor model, but will follow this pattern.

The Emergency Stop button located near the controller overrides all electronic functions to turn off the control devices. The controller senses this, and will display E-stop. To reset, twist and pull out the Emergency Stop button, then press the Stop pad to reset the WS Controller.

2.9 LED LIGHTS

the Stop pad to reset the WS Controller. 2.9 LED LIGHTS The four LED lights indicate

The four LED lights indicate the general condition of the machine.

LED lights indicate the general condition of the machine. The green Power indicator indicates power is

The green Power indicator indicates power is applied to the controller. It will blink at a noticeably slow rate if the WS Controller is set up to automatically restart after power failure.

indicatesis set up to automatically restart after power failure. compressor operation is enabled. It lights steadily

compressor operation is enabled. It lights steadily if the motor is running. If the motor stops while in

The green Run mode indicator

21

4500-7500 USER MANUAL

SECTION 2

Automatic mode, this LED will blink to indicate that the motor may restart.

this LED will blink to indicate that the motor may restart. The yellow Maintenance indicator comes

The yellow Maintenance indicator comes on whenever there is recommended maintenance or a warning. The text display will periodically indicate the recommended actions or the cause of the warning.

the recommended actions or the cause of the warning. The compressor fault has occurred and needs

The

compressor fault has occurred and needs to be repaired before further operation. The text display will indicate the cause of the fault.

The PC support program for the WS Controller provides additional information about compressor operation and advanced setup adjustments to optimize operation.

Software part numbers are shown in the display following a power interruption or other interruption of communication with the controller. The P/N remains on the display until satisfactory communications are established with the Input/Output module.

a

red

Fault

indicator

indicates

that

NOTE

Section 2.10 and Section 2.11 apply only to compressors equipped with a Variable Speed Drive.

2.10 VARIABLE SPEED DRIVE (VSD) COMPONENTS

The VSD, located in the machine’s electrical enclosure, works in concert with the WS Controller to allow the compressor to match its output to the current demand on the system. The drive’s heat sink extends through the back of the enclosure, and is cooled by air flowing through the compressor enclosure.

2.11 VSD CONTROL SYSTEM — FUNCTIONAL DESCRIPTION

Refer to Figure 2-5. The controls consist of:

• a VSD

• a solenoid valve

• a regulating valve

• and an inlet valve.

Depending on the model, a compressor can be operated at a setpoint pressure from 60 to 175 psig

22

(4.1 to 12.1 bar). The WS Controller automatically sets the frequency range based on the selected pressure. (The compressor’s operating range is on its nameplate.)

The following paragraphs apply to a compressor with a 100 psig (6.9) operating pressure and a 6 psi (0.4 bar) load delta setting.

NOTE

The load delta default setting is 10 psi (0.7 bar). Sullair recommends a setting of 6 psi (0.4) for the most efficient operation.

Compressors with different pressure operating ranges perform in the same manner.

START MODE - 0 TO 50 PSIG (0 TO 3.5 BAR)

Pressing the WS Controller START button (1) signals the VSD to accelerate the motor to full speed, causing the separator/sump tank pressure to rise from 0 to 50 psig (0 to 3.4 bar). At this time both the pressure regulator and solenoid valves are closed; the inlet valve is fully open and the air-end provides a full flow to the separator/sump tank. A minimum pressure valve set at approximately 50 psig (3.4 bar) isolates the rising compressor air pressure from the service line.

FULL LOAD MODE - 50 TO 100 PSIG (3.4 TO

6.9 BAR)

When the compressed air pressure rises above 50 psig (3.4 bar) the minimum pressure valve opens allowing compressed air to flow into to the service line. From this point on the WS Controller monitors the line pressure which controls the VSD. The pressure regulator and solenoid valves remain closed with the inlet valve fully open, running at 100 psig (6.9 bar) or lower.

VSD PART LOAD CONTROL—4500PV, 5500V, 7500V (16 SERIES)

The service line pressure increases to a value above 100 psig (6.9) if the demand is less than the compressor’s rated capacity. In this condition, the VSD slows the motor’s rpm which reduces the output to match the demand. The drive continuously adjusts the motor’s rpm to maintain a 100 psig (6.9 bar) line pressure.The WS Controller maintains the correct frequency when the VSD is operating in this mode.

100 psig (6.9 bar) line pressure.The WS Controller maintains the correct frequency when the VSD is

SECTION 2

4500-7500 USER MANUAL

MODULATING MODE WITH SPIRAL VALVE—7500PV (18 SERIES) :

As demand decreases, the variable speed drive reduces motor speed to maintain the set point pres- sure. When the speed approaches the minimum setting, a solenoid valve opens feeding air pressure to the spiral valve actuator. This in turn expands the diaphragm and engages the pinion mounted on the spiral valve shaft assembly, resulting in a rotary motion and full opening of the spiral valve, effec- tively reducing the rotor length by 50%. Excess air will be returned back internally to the suction side of the compressor unit. In this mode, the VSD will modulate the motor speed within a specified range to maintain the set point pressure as follows: Increasing demand condition: If demand increases, the VSD increases the motor speed until the set point pressure is achieved. If set point pressure is not achieved while at maximum speed, the controller will close the spiral valve, thereby eliminating internal air bypass. Consequently, the VSD will regulate the motor speed to achieve the set point pressure. Decreasing demand condition: While the spiral valve is open, if demand continues to decrease the VSD will reduce the motor speed until the set point pressure is achieved. This action will continue until the minimum speed is reached. When the system pressure reaches 106 psig (7.3 bar), or alternatively set unload pressure, the com- pressor unloads, or turns off.

MODULATING MODE- 100 TO 106 PSIG (7.3 TO 6.9 BAR)

During low demand periods and with the VSD running at minimum speed, the line pressure can continue to rise. When the line pressure reaches 101-102 psig (approximately 7 bar), the regulator valve (Figure 2-5) gradually opens, directing air pressure to the inlet control valve piston. This action causes the inlet valve to partially close, thereby reducing the air flow entering the compressor until it matches the demand. The control system functions continuously in this manner between less than 101 psig (7.0 bar) to 106 psig (7.3 bar), in response to varying system demand. The pressure regulator has an orifice which vents a small amount of air to the atmosphere when the pressure regulator controls the inlet valve. The orifice also bleeds off any accumulated moisture from the control line. When the discharge pressure rises above 106 psig (7.3 bar), or to a preset unload pressure, the compressor unloads.

or to a preset unload pressure, the compressor unloads. U NLOAD M ODE - I N

UNLOAD MODE- IN EXCESS OF 106 PSIG (7.3 BAR)

When there is no demand or it is at a minimal level, the service line pressure continues to rise. When it exceeds 106 psig (7.3 bar), or reaches a preset unload pressure value, the WS control system de- energizes the solenoid valve allowing separator/ sump tank air pressure to be supplied directly which closes the inlet valve. The solenoid valve simultaneously sends a pneumatic signal to the blow down valve which opens to the atmosphere, and reduces the separator/sump tank pressure. The check valve in the air service line prevents line pressure from back-flowing to the separator/sump tank. The compressor will shut down after the programmed unload time setting expires (the default setting is zero [0] minutes for an immediate shutdown upon unload). When the line pressure drops to the low pressure setting of 100 psig (6.9 bar) the WS Controller starts the motor and energizes the solenoid valve which closes the blowdown valve. The re-energized solenoid valve prevents line pressure from reaching the inlet control valve, thereby allowing it to fully open, and the compressor supplies compressed air to the system.

2.12 INTEGRAL DRYER OPTION

An integral refrigerated dryer option is available. The integral dryer is designed to work with the compressor WS controller which controls dryer starting and stopping, condensate drain valve function and monitors dewpoint temperature and dryer warnings and faults. The dryer is fully connected from the factory and is ready to run when the compressor is installed.

Detail of dryer operation and spare parts can be found in a supplement Manual 02250174-308 which is provided with your machine.

Per the controller default settings, on initial start-up the compressor will run unloaded for 5 minutes, allowing the dryer to run and cool down. This prevents condensate from initially being allowed into the compressed air stream. It also delays the supply of compressed air from the compressor until the 5 minute cool-down period is completed. When the automatic control mode is selected, the compressor will stop after running unloaded for a prescribed time, but the dryer will continue to run to ensure there will not be a surge of condensate when the compressor re-starts. For other settings and control options, refer to the WS controller manual 02250164-411, or to

23

4500-7500 USER MANUAL

SECTION 2

your authorized Sullair servicing distributor.

In case the compressor needs to operate while the dryer is being serviced, the dryer can be bypassed, and removed if necessary for service. To bypass the dryer, disconnect the inlet hose to the dryer, disconnect the outlet hose at the main service connection, and re-connect the dryer inlet hose to the main service connection. Remove the fuses powering the dryer located in the compressor electrical box. The WS controller must be set-up for the compressor to run on dryer fault. If necessary, this can be reset by your authorized Sullair servicing distributor.

24

compressor to run on dr yer fault. If necessary, this can be reset by your authorized

4500-7500 USER MANUAL

Section 3

SPECIFICATIONS

3.1 TABLE OF SPECIFICATIONS—4500P, 5500 & 7500 SERIES MODELS

     

DIMENSIONS

 

Model (I)

HP

Length

Width

 

Height

Weight

Weight

in

mm

in

mm

in

mm

lbs

kg

 

ODP

TEFC

ODP

TEFC

4500P SERIES

 

4507P

60

78.7

1999

43.3

1100

68.9

1750

2755

3121

1249

1415

4509P

60

78.7

1999

43.3

1100

68.9

1750

2755

3121

1249

1415

4510P

60

78.7

1999

43.3

1100

68.9

1750

2755

3121

1249

1415

5500

SERIES

 

5507

75

78.7

1999

43.3

1100

68.9

1750

2826

3150

1281

1428

5509

75

78.7

1999

43.3

1100

68.9

1750

2826

3150

1281

1428

5510

75

78.7

1999

43.3

1100

68.9

1750

2826

3150

1281

1428

5512

75

78.7

1999

43.3

1100

68.9

1750

2826

3150

1281

1428

7500

SERIES

 

7509

100

78.7

1999

43.3

1100

68.9

1750

3213

3432

1457

1556

7510

100

78.7

1999

43.3

1100

68.9

1750

3213

3432

1457

1556

7509

100

78.7

1999

43.3

1100

68.9

1750

3213

3432

1457

1556

7512

100

78.7

1999

43.3

1100

68.9

1750

3213

3432

1457

1556

4500PS SERIES

 

4507PS

60

78.7

1999

43.3

1100

68.9

1750

3091

3369

1401

1528

4509PS

60

78.7

1999

43.3

1100

68.9

1750

3091

3369

1401

1528

4510PS

60

78.7

1999

43.3

1100

68.9

1750

3091

3369

1401

1528

5500PS SERIES

 

5507PS

75

78.7

1999

43.3

1100

68.9

1750

3277

3391

1486

1537

5509PS

75

78.7

1999

43.3

1100

68.9

1750

3277

3391

1486

1537

5510PS

75

78.7

1999

43.3

1100

68.9

1750

3277

3391

1486

1537

5512PS

75

78.7

1999

43.3

1100

68.9

1750

3277

3391

1486

1537

7500P and 7500PS SERIES

 

7507P/PS

100

78.7

1999

43.3

1100

68.9

1750

3419

3563

1550

1616

7509P/PS

100

78.7

1999

43.3

1100

68.9

1750

3419

3563

1550

1616

7510P/PS

100

78.7

1999

43.3

1100

68.9

1750

3419

3563

1550

1616

7512P/PS

100

78.7

1999

43.3

1100

68.9

1750

3419

3563

1550

1616

(I) Includes standard 24KT. Rated pressure designations appearing after model number are as follows:

 

07 - 100 psig (6.9 bar)

 

10

- 150 psig (10.3 bar)

 

09 - 125 psig (8.6 bar)

 

12

- 175 psig (12.0 bar)

 

Maximum unload pressure is the rated pressure plus 10 psig (0.7 bar).

 
12 - 175 psig (12.0 bar)   Maximum unload pressure is the rated pressure plus 10

25

4500-7500 USER MANUAL

SECTION 3

3.2 TABLE OF SPECIFICATIONS—VARIABLE SPEED DRIVE

VSD SERIES (I) - 4500PV (MODELS 4507PV - 4509PV)

 

MOTOR

 

ODP

 

TEFC

HZ/VOLTAGE

460/60

575/60

 

400/50

460/60

575/60

400/50

DRIVE AMP

           

RATING

87

80

 

105

87

80

105

WEIGHT (lbs/kg)

2755/1250

3097/1404

3010/1365

3300/1497

3445/1503

3420/1551

LENGTH (in/mm)

78.7/1999

78.7/1999

78.7/1999

78.7/1999

78.7/1999

78.7/1999

WIDTH (in/mm)

43.3/1100

43.3/1100

43.3/1100

43.3/1100

43.3/1100

43.3/1100

HEIGHT (in/mm)

68.9/1750

68.9/1750

68.9/1750

68.9/1750

68.9/1750

68.9/1750

VSD SERIES (I) - 5500V (MODELS 5507V - 5512V)

 

MOTOR

 

ODP

 

TEFC

HZ/VOLTAGE

460/60

575/60

 

400/50

460/60

575/60

400/50

DRIVE AMP

           

RATING

105

100

 

140

105

100

140

WEIGHT (lbs/kg)

2963/1344

3168/1437

3014/1367

3281/1491

3492/1584

3338/1514

LENGTH (in/mm)

78.7/1999

78.7/1999

78.7/1999

78.7/1999

78.7/1999

78.7/1999

WIDTH (in/mm)

43.3/1100

43.3/1100

43.3/1100

43.3/1100

43.3/1100

43.3/1100

HEIGHT (in/mm)

68.9/1750

68.9/1750

68.9/1750

68.9/1750

68.9/1750

68.9/1750

VSD SERIES (I) - 7500V (MODELS 7509V - 7512V)

 

MOTOR

 

ODP

 

TEFC

HZ/VOLTAGE

460/60

575/60

 

400/50

460/60

575/60

400/50

DRIVE AMP

           

RATING

140

125

 

170

140

125

170

WEIGHT (lbs/kg)

3341/1515

3535/1603

3391/1515

3531/1601

3752/1690

3531/1601

LENGTH (in/mm)

78.7/1999

78.7/1999

78.7/1999

78.7/1999

78.7/1999

78.7/1999

WIDTH (in/mm)

43.3/1100

43.3/1100

43.3/1100

43.3/1100

43.3/1100

43.3/1100

HEIGHT (in/mm)

68.9/1750

68.9/1750

68.9/1750

68.9/1750

68.9/1750

68.9/1750

VSD SERIES (I) - 7500PV (MODELS 7507PV - 7512PV)

 

MOTOR

 

ODP

 

TEFC

HZ/VOLTAGE

460/60

575/60

 

400/50

460/60

575/60

400/50

DRIVE AMP

           

RATING

140

125

 

170

140

125

170

WEIGHT (lbs/kg)

3547/1608

3691/1674

3547/1608

3691/1674

3835/1739

3691/1674

LENGTH (in/mm)

78.7/1999

78.7/1999

78.7/1999

78.7/1999

78.7/1999

78.7/1999

WIDTH (in/mm)

43.3/1100

43.3/1100

43.3/1100

43.3/1100

43.3/1100

43.3/1100

HEIGHT (in/mm)

68.9/1750

68.9/1750

68.9/1750

68.9/1750

68.9/1750

68.9/1750

(I) Includes standard and 24KT. Rated pressure designations appearing after model number are as follows:

07

- 100 psig (6.9 bar)

 

10

- 150 psig (10.3 bar)

 

09

- 125 psig (8.6 bar)

 

12

- 175 psig (12.0 bar)

 

Maximum unload pressure is the rated pressure plus 10 psig (0.7 bar).

 

26

12 - 175 psig (12.0 bar)   Maximum unload pressure is the rated pressure plus 10

SECTION 3

4500-7500 USER MANUAL

3.3 COMPRESSOR SPECIFICATIONS

COMPRESSOR:

STANDARD MODELS:

Type:

Fluid Flooded Rotary Screw

Standard Operating Pressure:

100 psig (7 bar) 125 psig (9 bar) / 150 psig (10.0 bar) 175 psig (12.0 bar)

Bearing Type:

Anti-friction

Ambient Temperature (Max.) (II):

104ºF (40ºC)

(II) Special compressors are available for operating in higher ambient temperature.

3.4 LUBRICATION GUIDE

Refer to Figure 3-1 for the fluid fill port location. Sullair’s 4500P-7500 series compressors are filled and tested at the factory with Sullube lubricant.

CAUTION Do not mix different types of lubricants. Mixing lubricants can cause malfunctions or compressor

CAUTION

Do not mix different types of lubricants. Mixing lubricants can cause malfunctions or compressor damage:

Do not mix different types of lubricants. Mixing lubricants can cause malfunctions or compressor damage: will void the compressor’s warranty.

CAUTION Contamination of compressor fluids with mineral oil or other fluids can cause foaming, filter

CAUTION

Contamination of compressor fluids with mineral oil or other fluids can cause foaming, filter plugging, or orifice line obstruction.

of compressor fluids with mineral oil or other fluids can cause foaming, filter plugging, or orifice
NOTE When performing a fluid change or topping off the fill, the proper level should
NOTE
When performing a fluid
change or topping off the
fill, the proper level
should be at half of the
sight glass, with the
machine off.
Mixing, changing or add-
ing other lubricants within
the compressor unit may
void the air-end warranty.

Figure 3-1: Fluid Fill Location

1. Fluid Fill Port

3.

Fluid Drain Valve

2. Sight Glass

4.

Separator/sump Tank

3.5 APPLICATION GUIDE

Sullair encourages its customers to participate in a fluid analysis program with the fluid suppliers. In some cases the analysis results suggest a fluid change interval which differs from the User Manual. Contact a Sullair representative for details.

3.6 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE, FLUID FILTER AND SEPARATOR

LUBRICANT

FLUID CHANGE

FLUID FILTER CHANGE

SEPARATOR CHANGE

Sullube (5 gallon cap.)

A,E

G,C

A,D

SRF 1/4000 (5 gallon cap.)

B, E

G, C

B, D

24kt (5 gallon cap.)

F, E

G, C

A, D

CP-4600-32-F (5 gallon cap.)

B, E

G, C

A, D

A - 8,000 hours or once per year.

B - 4,000 hours or more frequntly if conditions require.

 

C - When measured pressure loss exceeds 20 psig (1.3 bar).

D - When measured pressure loss exceeeds 10 psig (0.7 bar).

E - When required as the result of fluid analysis or known contamination.

 

F - Does not require replacement under normal service conditions.

 

G - Every 2,000 hours.

  F - Does not require replacement under normal service conditions.   G - Every 2,000

27

4500-7500 USER MANUAL

28

SECTION 3

4500-7500 USER MANUAL 28 SECTION 3 Figure 3-2: Identification - 4500P, 5500 and 7500 Air-Cooled 02250161-702R00

Figure 3-2: Identification - 4500P, 5500 and 7500 Air-Cooled

4500-7500 USER MANUAL 28 SECTION 3 Figure 3-2: Identification - 4500P, 5500 and 7500 Air-Cooled 02250161-702R00

02250161-702R00

SECTION 3

4500-7500 USER MANUAL

29

SECTION 3 4500-7500 USER MANUAL 29 Identification - 4500P, 5500 and 7500 Air-Cooled      

Identification - 4500P, 5500 and 7500 Air-Cooled

         

N

KEY

NO.

PART NO.

Q

T

Y

DESCRIPTION

O

T

E

1

ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.

2

A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.

 

3

ALL DIMENSIONS ARE +/-.50" [12.7MM]

 

4

RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.

 

5

IF DUCTWORK IS TO BE INSTALLED FOR COOLING AIR HIGH STATIC FAN MUST BE SELECTED. MAX ALLOWABLE ADDITIONAL STATIC PRESSURE 0.75 IN WATER WITH HIGH STATIC FAN.

6

DOORS ARE REMOVABLE USING LIFT-OFF HINGE PINS.

 

7

ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER DIMEN- SIONS IN PARENTHESES. AN ADDITIONAL .75 IN/WG STATIC PRESSURE CAN BE ADDED WHEN USING HIGH STATIC FAN

 

A1: ALTERNATE INCOMING POWER SUPPLY LOCATION 2.50 DIA. [63.5]

A2: SPACE REQUIRED TO OPEN DOORS TYP. SEE NOTE #6

 

A3: SPACE REQUIRED TO OPEN STARTER PANEL

 

A4: CONTROLLER

 

A5: E-STOP

 

A6: OIL LEVEL SIGHTGLASS LOCATION

 

A7: AIR INLET

 

A8: EXHAUST AIR OUT

 

A9: CONTAINMENT PAN DRAIN

 

A10: INCOMING CUSTOMER POWER SUPPLY 3.0 DIA. (76.2)

 

A11: MOISTURE DRAIN CONNECTION 1/4"-18 NPT

 

A12: AIR OUT CONNECTION 2"-11 1/2 NPT

 
 

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

 
 

MACHINE WEIGHTS

 
 

MAIN MOTOR

 

COOLING AIR

 

HP

WEIGHT

CFM

4500P

60

odp pe

2,815 lbs (1,276 kg)

8,100

4500P

60

tefc pe

3,181 lbs (1,442 kg)

8,100

5500

75

odp pe

2,886 lbs) 1,308 kg)

8,100

5500

75

tefc pe

3,210 lbs (1,455 kg)

8,100

7500

100

odp pe

3,213 lbs (1,457 kg)

8,400

7500

100

tefc pe

3,432 lbs (1,556 kg)

8,400

4500

60

odp pe

2,949 lbs (1,337 kg)

8,100

4500

60

tefc pe

3,227 lbs (1,463 kg)

8,100

5500

75

odp pe

3,135 lbs) 1,421 kg)

8,100

5500

75

tefc pe

3,249 lbs (1,473 kg)

8,100

7500

100

odp pe

3,277 lbs (1,463 kg)

8,400

7500

100

tefc pe

3,421 lbs (1,551 kg)

8,400

SECTION 3 4500-7500 USER MANUAL Figure 3-3: Identification - 4500P, 5500 and 7500 Water-Cooled 02250170-715-R00
SECTION 3
4500-7500 USER MANUAL
Figure 3-3: Identification - 4500P, 5500 and 7500 Water-Cooled
02250170-715-R00
30

SECTION 3

4500-7500 USER MANUAL

31

SECTION 3 4500-7500 USER MANUAL 31 Identification - 4500P, 5500 and 7500 Water-Cooled      

Identification - 4500P, 5500 and 7500 Water-Cooled

       

N

KEY

NO.

PART NO.

Q

T

Y

DESCRIPTION

O

T

E

Notes:

1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.

2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.

3. ALL DIMENSIONS ARE +/- .50" [12.7]

 

4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.

 

5. DOORS ARE REMOVABLE USING LIFT-OFF HINGE PINS. 6. ALL DIMENSIONS SHOWN IN INCHES WITH MILLIMETER DIMENSIONS IN PARENTHESES.

A1: ALTERNATE INCOMING POWER SUPPLY LOCATION 2.50 DIA. [63.5]

A2: SPACE REQUIRED TO OPEN DOORS TYP. SEE NOTE #6

 

A3: SPACE REQUIRED TO OPEN STARTER PANEL

 

A4: CONTROLLER

 

A5: E-STOP

 

A6: OIL LEVEL SIGHTGLASS LOCATION

 

A7: AIR INLET

 

A8: EXHAUST AIR OUT 2,845 CFM

 

A9: CONTAINMENT PAN DRAIN

 

A10: INCOMING CUSTOMER POWER SUPPLY 3.0 DIA. (76.2)

 

A11: MOISTURE DRAIN CONNECTION 1/4"-18 NPT

 

A12: AIR OUT CONNECTION 2"-11 1/2 NPT

 

A13: COOLING WATER OUT 1 1/2"-11 1/2 NPT

 

A14: COOLING WATER IN 1 1/2"-11 1/2 NPT

 
 

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

 
 

MACHINE WEIGHTS

 
 

MAIN MOTOR HP

WEIGHT

4500P

60

ODP EE

2,755 LBS (1,249 kg)

4500P

60

TEFC EE

3,121 LBS (1,415 kg)

5500

75

ODP EE

2,826 LBS (1.281 kg)

5500

75

TEFC EE

3,150 LBS (1,428 kg)

7500

100

ODP EE

3,178 LBS (1,441 kg)

7500

100

TEFC EE

3,427 LBS (1,554 kg)

4500P

60

ODP PE

2,889 LBS (1,310 kg)

4500P

60

TEFC PE

3,167 LBS (1,436 kg)

5500

75

ODP PE

3,075 LBS (1,394 kg)

5500

75

TEFC PE

3,189 LBS (1,446 kg)

7500

100

ODP PE

3,250 LBS (1,470 kg)

7500

100

TEFC PE

3,386 LBS (1,535 kg)

4500-7500 USER MANUAL SECTION 3 Figure 3-4: Identification - 4500P, 5500, and 7500 Air-Cooled with
4500-7500 USER MANUAL
SECTION 3
Figure 3-4: Identification - 4500P, 5500, and 7500 Air-Cooled with Integral Dryer
02250172-305-R01
32

SECTION 3

4500-7500 USER MANUAL

33

SECTION 3 4500-7500 USER MANUAL 33 Identification - 4500P, 5500, and 7500 Air-Cooled with Integral Dryer

Identification - 4500P, 5500, and 7500 Air-Cooled with Integral Dryer

       

N

KEY

NO.

PART NO.

Q

T

Y

DESCRIPTION

O

T

E

AN ADDITIONAL .75 IN/WG STATIC PRESSURE CAN BE ADDED WHEN USING HIGH STATIC FAN

 

A1: ALTERNATE INCOMING POWER SUPPLY LOCATION 2.50 DIA. [63.5]

A2: SPACE REQUIRED TO OPEN DOORS TYP. SEE NOTE #6

 

A3: SPACE REQUIRED TO OPEN STARTER PANEL

 

A4: CONTROLLER

 

A5: E-STOP

 

A6: OIL LEVEL SIGHTGLASS LOCATION

 

A7: COMPRESSOR PACKAGE AIR INLET

 

A8: COMPRESSOR PACKAGE EXHAUST AIR OUT

 

A9: CONTAINMENT PAN DRAIN

 

A10: INCOMING CUSTOMER POWER SUPPLY 3.0 DIA. (76.2)

 

A11: MOISTURE DRAIN CONNECTION 1/4”-18 NPT

 

A12: AIR OUT CONNECTION 2”-11 1/2 NPT

 

A13: DRYER AIR INLET

 

A14: DRYER EXHAUST AIR OUTLET

 

NOTES:

1. ALLOW 4.00 FEET [1.25 METERS] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.

2. A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSSOR FRAME LEVEL IS REQUIRED.

3. ALL DIMENSIONS ARE +/- .50” [12.7MM]

 

4. RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.

 
 

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

 
         

N

KEY