USER MANUAL

ROTARY SCREW AIR COMPRESSOR

ES-8 SERIES MOBILE APPLICATION

PART NUMBER:
02250184-779 R00
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions
©
SULLAIR CORPORATION
and procedures in this manual The information in this manual is current
as of its publication date and applies to
or, misuse of this equipment will compressor serial number
VOID its warranty! :
200903010000
and all subsequent serial numbers.
 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 CUSTOMER CARE TRAINING DEPARTMENT

1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.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 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—INSTALLATION
11 2.1 LOCATION OF COMPRESSOR
11 2.2 VENTILATION AND COOLING
11 2.3 SERVICE AIR PIPING
12 2.4 COUPLING ALIGNMENT CHECK
12 2.5 FLUID LEVEL CHECK
12 2.6 MOTOR ROTATION DIRECTION CHECK
12 2.7 ELECTRICAL PREPARATION

SECTION 3—SPECIFICATIONS
13 3.1 TABLE OF SPECIFICATIONS
13 3.2 COMPRESSOR SPECIFICATIONS
13 3.3 MOTOR SPECIFICATIONS
13 3.4 FLUID FILTER
13 3.5 FLUID SEPARATOR ELEMENT
14 3.6 LUBRICATION GUIDE
14 3.7 LUBRICATION CHANGE RECOMMENDATIONS & MAINTENANCE
SCHEDULE
TABLE OF CONTENTS

SECTION 4—COMPRESSOR SYSTEMS

15 4.1 INTRODUCTION
15 4.2 DESCRIPTION OF COMPONENTS
15 4.3 ENCAPSULATED COMPRESSOR SYSTEM, FUNCTIONAL DESCRIP-
TION
16 4.4 COMPRESSOR COOLING SYSTEM, FUNCTIONAL DESCRIPTION
16 4.5 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
17 4.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION

SECTION 5—WS CONTROLLER

19 5.1 CONTROLLER LAYOUT
19 5.2 CONTROLLER KEYPAD
20 5.3 LCD DISPLAY
21 5.4 LED LIGHTS

SECTION 6—MAINTENANCE
23 6.1 INTRODUCTION
23 6.2 DAILY OPERATION
23 6.3 MOTOR BEARING LUBRICATION
23 6.4 FLUID FILTER MAINTENANCE
24 6.5 COOLER MAINTENANCE
24 6.6 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
28 6.7 MAINTENANCE RECORD

SECTION 7—TROUBLESHOOTING
29 7.1 INTRODUCTION

SECTION 8—PARTS LIST

31 8.1 PROCEDURE FOR ORDERING PARTS
32 8.2 RECOMMENDED SERVICE PARTS LIST
34 8.3 INLET CONTROL, SEAL/DRIVE GEAR AND PARTS
36 8.4 MOTOR, COUPLING, FAN AND PARTS
38 8.5 INLET FILTER, COMPRESSOR HOUSING/SUMP AND PARTS
40 8.6 COMPRESSOR COOLER SYSTEM AND PARTS
42 8.7 PNEUMATIC CONTROL SYSTEM AND PARTS
44 8.8 CONTROL STARTER—MFV
46 8.9 DECAL GROUP
50 8.10 WIRING DIAGRAM—FULL VOLTAGE (STANDARD)
 Section 1

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

1.2 PERSONAL PROTECTIVE

EQUIPMENT
OPERATOR IS REQUIRED TO READ A. Prior to installing or operating the compressor,
ENTIRE INSTRUCTION MANUAL. 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
1.1 GENERAL regula- tions relative to personal protective
Sullair Corporation and its subsidiaries design and equipment, such as eye and face protective
manufacture all of their products so they can be equipment, respiratory protective equipment,
operated safely. However, the responsibility for safe equipment intended to protect the extremities,
operation rests with those who use and maintain protective clothing, protective shields and
these products. The following safety precautions are barriers and elec- trical protective equipment, as
offered as a guide which, if conscientiously followed, well as noise exposure administrative and/or
will minimize the possibility of accidents throughout engineering con- trols and/or personal hearing
the useful life of this equipment. protective equip- ment.

The compressor should be operated only by those

who have been trained and delegated to do so, and
1.3 PRESSURE RELEASE
who have read and understood this Operator's A. Install an appropriate flow-limiting valve between
Manual. Failure to follow the instructions, procedures the service air outlet and the shut-off (throttle)
and safety precautions in this manual may result in valve, either at the compressor or at any other
accidents and injuries. NEVER start the compressor point along the air line, when an air hose
unless it is safe to do so. DO NOT attempt to exceed- ing 1/2" (13mm) inside diameter is to be
operate the compressor with a known unsafe con- nected to the shut-off (throttle) valve, to
condition. Tag the compressor and render it reduce pressure in case of hose failure, per
inoperative by disconnecting and locking out all OSHA Stan- dard 29 CFR 1926.302(b)(7) and/or
power at source or otherwise disabling its prime any applica- ble Federal, State and Local codes,
mover so others who may not know of the unsafe standards and regulations.
condition cannot attempt to operate it until the
condition is corrected. B. When the hose is to be used to supply a mani-
fold, install an additional appropriate flow-limiting
Install, use and operate the compressor only in full valve between the manifold and each air hose
compliance with all pertinent OSHA regulations and/ exceeding 1/2" (13mm) inside diameter that is to
or any applicable Federal, State, and Local codes, be connected to the manifold to reduce pressure
standards and regulations. DO NOT modify the in case of hose failure.
compressor and/or controls in any way except with
written factory approval. C. Provide an appropriate flow-limiting valve at the
beginning of each additional 75 feet (23m) of
While not specifically applicable to all types of hose in runs of air hose exceeding 1/2" (13mm)
compressors with all types of prime movers, most of

5
 SECTION 1

inside diameter to reduce pressure in case of accumulate on, under or around acoustical
hose failure. mate- rial, or on any external surfaces of the air
D. Flow-limiting valves are listed by pipe size and com- pressor. Wipe down using an aqueous
flow-rated. Select appropriate valves industrial cleaner or steam clean as required. If
accordingly, in accordance with their necessary, remove acoustical material, clean all
manufacturer's recom- mendations. surfaces and then replace acoustical material.
Any acous- tical material with a protective
E. DO NOT use air tools that are rated below the covering that has been torn or punctured should
maximum rating of the compressor. Select air be replaced immediately to prevent
tools, air hoses, pipes, valves, filters and other accumulation of liquids or fluid film within the
fittings accordingly. DO NOT exceed manufac- material. DO NOT use flam- mable solvents for
turer's rated safe operating pressures for these cleaning purposes.
items.
D. Disconnect and lock out all power at source prior
F. Secure all hose connections by wire, chain or to attempting any repairs or cleaning of the com-
other suitable retaining device to prevent tools or pressor or of the inside of the enclosure, if any.
hose ends from being accidentally disconnected
and expelled. E. Keep electrical wiring, including all terminals and
pressure connectors in good condition. Replace
G. Open fluid filler cap only when compressor is not any wiring that has cracked, cut, abraded or oth-
running and is not pressurized. Shut down the erwise degraded insulation, or terminals that are
compressor and bleed the receiver tank to zero worn, discolored or corroded. Keep all terminals
internal pressure before removing the cap. and pressure connectors clean and tight.
H. Vent all internal pressure prior to opening any F. Keep grounded and/or conductive objects such
line, fitting, hose, valve, drain plug, connection as tools away from exposed live electrical parts
or other component, such as filters and line such as terminals to avoid arcing which might
oilers, and before attempting to refill optional air serve as a source of ignition.
line anti-icer systems with antifreeze compound.
G. Remove any acoustical material or other
I. Keep personnel out of line with and away from material that may be damaged by heat or that
the discharge opening of hoses or tools or other may sup- port combustion and is in close
points of compressed air discharge. proximity, prior to attempting weld repairs.
J. DO NOT use air at pressures higher than 2.1 H. Keep suitable fully charged Class BC or ABC fire
bar for cleaning purposes, and then only with extinguisher or extinguishers nearby when ser-
effec- tive chip guarding and personal protective vicing and operating the compressor.
equip- ment per OSHA Standard 29 CFR
1910.242 (b) and/or any applicable Federal, I. Keep oily rags, trash, leaves, litter or other com-
State, and Local codes, standards and bustibles out of and away from the compressor.
regulations. J. DO NOT operate the compressor without proper
K. DO NOT engage in horseplay with air hoses as flow of cooling air or water or with inadequate
death or serious injury may result. flow of lubricant or with degraded lubricant.
K. DO NOT attempt to operate the compressor in
1.4 FIRE AND EXPLOSION any classification of hazardous environment
unless the compressor has been specially
A. Clean up spills of lubricant or other combustible designed and manufactured for that duty.
substances immediately, if such spills occur.
B. Shut off the compressor and allow it to cool. 1.5 MOVING PARTS
Then keep sparks, flames and other sources of
ignition away and DO NOT permit smoking in A. Keep hands, arms and other parts of the body
the vicinity when checking or adding lubricant or and clothing away from couplings, belts, pulleys,
when refilling air line anti-icer systems with anti- fans and other moving parts.
freeze compound. B. DO NOT attempt to operate the compressor with
C. DO NOT permit fluids, including air line anti-icer the fan, coupling or other guards removed.
system antifreeze compound or fluid film, to
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- Death or serious injury can result from inhaling compressed air with
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. B. DO NOT use air line anti-icer systems in air lines
supplying respirators or other breathing air utili-
1.6 HOT SURFACES, SHARP zation equipment and DO NOT discharge air
EDGES AND SHARP from these systems into unventilated or other
CORNERS confined areas.

A. Avoid bodily contact with hot fluid, hot coolant, C. Operate the compressor only in open or ade-
hot surfaces and sharp edges and corners. quately ventilated areas.

B. Keep all parts of the body away from all points of D. Locate the compressor or provide a remote inlet
air discharge. so that it is not likely to ingest exhaust fumes or
other toxic, noxious or corrosive fumes or sub-
C. Wear personal protective equipment including stances.
gloves and head covering when working in, on
or around the compressor. E. Coolants and lubricants used in this compressor
are typical of the industry. Care should be taken
D. Keep a first aid kit handy. Seek medical assis- to avoid accidental ingestion and/or skin contact.
tance promptly in case of injury. DO NOT ignore In the event of ingestion, seek medical treatment
small cuts and burns as they may lead to infec- promptly. Wash with soap and water in the event
tion of skin contact. Consult Material Safety Data
Sheet for information pertaining to fluid of fill.
1.7 TOXIC AND F. Wear goggles or a full face shield when adding
IRRITATING antifreeze compound to air line anti-icer
SUBSTANCES systems.
A. DO NOT use air from this compressor for respi- G. If air line anti-icer system antifreeze compound
ration (breathing) except in full compliance with enters the eyes or if fumes irritate the eyes, they
OSHA Standards 29 CFR 1910 and/or any should be washed with large quantities of clean
appli- cable Federal, State or Local codes or water for fifteen minutes. A physician, preferably
regula- tions. 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
 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. Call a physician immediately. All field equipment must be tested for elec-
trostatic fields prior to servicing or making
1.8 ELECTRICAL SHOCK contact with the machine using the follow-
ing or equivalent test equipment:
A. This compressor should be installed and main-
• 90-600 VAC: Volt detector such
tained in full compliance with all applicable Fed-
as Fluke Model 1AC-A
eral, State and Local codes, standards and
regulations, including those of the National Elec- • 600-7000 VAC: Voltage detector
trical Code, and also including those relative to such as Fluke Networks Model
equipment grounding conductors, and only by C9970
personnel that are trained, qualified and dele- It is the responsibility of each organization
gated to do so. to provide/arrange training for all their
associates expected to test for electrostatic
B. Keep all parts of the body and any hand-held fields.
tools or other conductive objects away from
exposed live parts of electrical system. Maintain
dry footing, stand on insulating surfaces and DO 1.9 LIFTING
NOT contact any other portion of the
compressor when making adjustments or repairs A. If the compressor is provided with a lifting bail,
to exposed live parts of the electrical system. then lift by the bail provided. If no bail is
Make all such adjustments or repairs with one provided, then lift by sling. Compressors to be
hand only, so as to minimize the possibility of air-lifted by helicopter must not be supported by
creating a current path through the heart. the lifting bail but by slings instead. In any event,
C. Attempt repairs in clean, dry and well lighted and lift and/or handle only in full compliance with
ventilated areas only. OSHA stan- dards 29 CFR 1910 subpart N
and/or any appli- cable Federal, State, and Local
D. DO NOT leave the compressor unattended with codes, standards and regulations.
open electrical enclosures. If necessary to do
so, then disconnect, lock out and tag all power at B. Inspect points of attachment for cracked welds
source so others will not inadvertently restore and for cracked, bent, corroded or otherwise
power. degraded members and for loose bolts or nuts
prior to lifting.
E. Disconnect, lock out, and tag all power at source
prior to attempting repairs or adjustments to C. Make sure entire lifting, rigging and supporting
rotating machinery and prior to handling any structure has been inspected, is in good condi-
ungrounded conductors. 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.
I. 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
J. Set compressor down only on a level surface prior to attempting to forklift or transport them.
capable of safely supporting at least its weight NEVER attempt to forklift a compressor that is
and its loading unit. not secured to its pallet, as uneven floors or sud-
den stops may cause the compressor to tumble
K. When moving the compressor by forklift truck, off, possibly causing serious injury or property
utilize fork pockets if provided. Otherwise, utilize damage in the process.
pallet if provided. If neither fork pockets or pallet
are provided, then make sure compressor is
secure and well balanced on forks before 1.10 ENTRAPMENT
attempting to raise or transport it any significant
A. If the compressor enclosure, if any, is large
distance.
enough to hold a man and if it is necessary to
L. Make sure forklift truck forks are fully engaged enter it to perform service adjustments, inform
and tipped back prior to lifting or transporting the other personnel before doing so, or else secure
compressor. and tag the access door in the open position to
avoid the possibility of others closing and possi-
M. Forklift no higher than necessary to clear obsta- bly latching the door with personnel inside.
cles at floor level and transport and corner at
minimum practical speeds. B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.
NOTES

10
 ES-8 MOBILE APPLICATION MANUAL R00

Section
2
INSTALLATION
2.1 LOCATION OF Figure 2-1. A shut-off valve should be installed to
COMPRESSOR isolate the compressor from the service line. Also
The ES-8 Series compressor package may be notice that the service line should be equipped with
placed on any level surface able to support its water legs and condensate drains throughout the
weight. The unit is mounted on vibration mounts and system.
can be bolted to a fixed mounting surface to avoid
the possibility of externally applied forces or vibration
which would disturb the piping or wiring.
WARNING
“The Plastic Pipe Institute recommends
2.2 VENTILATION against the use of thermoplastic pipe to
AND COOLING transport compressed air or other com-
Select a location to permit sufficient unobstructed air pressed gases in exposed above ground
flow in and out of the compressor to keep the locations, e.g. in exposed plant piping.” (I)
operating temperature stable. The minimum
distance that the machine should be from Sullube 32 should not be used with PVC
surrounding walls and ceiling is what is needed piping systems. It may affect the bond at
for service and three (3) feet (914mm) or more cemented joints.Certain other plastic mate-
from the compressor fluid cooler. rials may also be affected.

(I) Plastic Pipe Institute, Recommendation

2.3 SERVICE AIR PIPING B, Adopted January 19, 1972.
Service air piping should be installed as shown in

Figure 2-1: Service Air Piping

2.4 COUPLING ALIGNMENT OSHA, National Electrical Code, and/or any other
CHECK applicable State, Federal and local electrical codes
With the compressor unit directly flange-mounted to concerning isolation switches, fused disconnects,
its drive, the coupling supplied with the compressor etc. Sullair provides a wiring diagram for use by the
is always properly aligned for opertion. However, we installer.
recommend that you re-check the coupling gap
before start-up or when handling the unit. a 1.5 to
3mm axial clearance should be maintained for the
coupling gap. See Section 6.4.

2.5 FLUID LEVEL CHECK

The Sullair air compressor is equipped with the
proper amount of fluid. However, it is necessary to
check the fluid level at installation. The level is
checked by looking at the fluid level sight tube
located on the end bell. If the sump is properly filled,
the fluid level should cover 1/4 to 1/2 of the level
range during operation. With the compressor shut
down, the level should be 3/4 of the sight tube. DO
NOT overfill.

2.6 MOTOR ROTATION

DIRECTION
CHECK
After the electrical wiring has been done, it is
necessary to check the direction of the motor
rotation.
Pull out the EMERGENCY STOP button and press
once, quickly and in succession, the (START) I and
(STOP) O pads. This action will bump start the
motor for a very short time. When looking at the
motor from the control panel side, view the coupling
by looking through the air inlet duct on the lower side
of the adapter fan housing. The coupling should be
turning clockwise. If the reversed rotation is noted,
disconnect the power to the starter and exchange
any two of the three power input leads, then re-
check rotation. A “Direction of Rotation” decal is
located on the motor and cooler shroud to show
proper motor/compressor rotation.

2.7 ELECTRICAL PREPARATION

Interior electrical wiring is performed at the factory.
Required customer wiring is minimal, but should be
done by a qualified electrician in compliance with
 NOTE
Customer must provide electrical supply power disconnect within sight of machine.

A few electrical checks should be made to help

assure that the first start-up will be trouble-
free.

Lethal shock hazard inside. Disconnect all

WARNING
power at source before opening or servicing.

1. Check incoming voltage. Be sure that

com- pressor is wired for the correct
incoming volt- age.
2. Check starter for correct size, proper
over- load relay, and heaters.
3. Check all electrical connections for
tight- ness.
4. “DRY RUN” the electrical controls by
discon- necting the three (3)motor
leads from the starter. Pull out the
EMERGENCY STOP button on the
control panel.
5. Reconnect the motor leads and jog the
motor for a direction of rotation check
as explained in Section 2.6.

Wiring diagram for standard compressors

NOTE
is supplied on the inside cover of the
Control Center. Optional compressor wir-
ing diagrams will vary.
ES-8 MOBILE APPLICATION MANUAL R00 SECTION 3

SPECIFICATIONS
3.1 TABLE OF SPECIFICATIONS
DIMENSIONS
Length Width Height Weight dBA (I)
60 HZ
w/Encls./
in mm in mm in mm lbs kg w/o Encls.
Model HP ACFM PSIG
30XH 30 95 185 52 32 32 1065 78/85
(I) Ratings for dBA at one meter.

3.2 COMPRESSOR SPECIFICATIONS

COMPRESSOR:
Type: SIngle Stage Fluid Injected Screw Compressor
Minimum Full Load Operating Pressure: 60 psig (4.2 bar)
Maximum Full Load Operating Pressure: Nameplate Pressure
Bearing Type: Anti-friction
Cooling: Pressurized Fluid
see Section 3.7: Lubrication Change Recommendations &
Lubricant:
Maintenance Schedule
Sump Capacity: 3 gallons (11.4 liters)

3.3 MOTOR SPECIFICATIONS

MOTOR: 60 Hz
Type: TEFC, C-flange
Synchronous Speed: 30 HP = 3600 RPM
Voltage:
Standard All Sizes: 460
Type:
Insulation Class: B- (Min.)
Maximum Ambient Temp.: 50ºC (122ºF)

3.4 FLUID FILTER

Fluid Filter
Type: Spin on, Sullair Proprietary
Micron: 23 Microns Abs.
Internal Bypass Valve Set at 25 psig (1.7 bar):

3.5 FLUID SEPARATOR ELEMENT

Fluid Separator Element
Type: Push In Cartridge, Sullair Proprietary
Efficiency at Maximum Capacity: 5PPM Maximum
3.6 LUBRICATION GUIDE For light-duty high-humidity service where
condensed moisture and emulsification
For best value and longest uninterrupted service, the (mayonnaise) may occur, the fluid change interval
ES-8 compressor is factory filled and tested with a must be reduced to 300 hours maximum. A non-
long life lubricant. detergent fluid with rust, oxidation and foam
inhibitors and good water separation characteristics
should be used.
WARNING
DO NOT MIX DIFFERENT TYPES OF FLUIDS.
Contamination of non-detergent mineral fluids with
“The Plastic Pipe Institute recommends traces of ATF or detergent motor fluids may lead to
against the use of thermoplastic pipe to operational problems such as foaming, filter
transport compressed air or other com- plugging, orifice or line plugging.
pressed gases in exposed above ground
locations, e.g. in exposed plant piping.” (I)
NOTE
Sullube 32 should not be used with PVC
piping systems. It may affect the bond at Flush system when switching lubricant brands.
cemented joints. Certain other plastic mate-
rials may also be affected.

(I) Plastic Pipe Institute, Recommendation When ambient conditions exceed those noted or if
B, Adopted January 19, 1972. conditions warrant use of “extended” life lubricants
contact Sullair for recommendation.
Maintenance of all other components is still Sullair encourages the user to participate in a fluid
recommended as indicated in the Operator’s analysis program. This could result in a fluid change
Manual. interval that is different from those stated in this
manual.

3.7 LUBRICATION CHANGE RECOMMENDATIONS &

MAINTENANCE SCHEDULE
FLUID & FILTER
AMBIENT SEPARATOR CHANGES AIR FILTER CHANGE
LUBRICANT CHANGE
TEMPERATURE PERIOD (HRS.) PERIOD (HRS.)
PERIOD (HRS.)
-10°F to +90°F
Sullube 32 8000 8000 4000 (II)
(-23°C to +32°C)
(I) 8,000 Hours or once a year
(II) 4,000 Hours or more frequently if conditions so require.
ES-8 MOBILE APPLICATION MANUAL R00 SECTION 4

COMPRESSOR SYSTEMS
4.1 INTRODUCTION
Your new Sullair flood-lubricated rotary screw air
compressor will provide you with improved reliability
and greatly reduced maintenance.
WARNING
Compared with other types of compressors, the DO NOT remove caps, plugs and/or other com-
Sullair rotary screw is unique in mechanical ponents when compressor is running or pres-
reliability, with “no wear” and “no inspection”
surized.
required of the working parts within the compressor
unit.
Stop compressor and relieve all internal pres-
Read Section 6: Maintenance to keep your sure before doing so.
compressor in top operating condition. Should any
questions arise which cannot be answered in the
following text, call your nearest Sullair office or the Fluid is injected into the compressor unit in large
Sullair Corporation Service Department. quantities and mixes directly with the air as the
rotors turn, compressing the air. The fluid flow has
4.2 DESCRIPTION OF three main functions:
COMPONENTS 1. As coolant, it controls the rise of air
tempera- ture normally associated with the
Refer to Figure 4-1. The components and heat of compression.
assemblies of the ES-8 Series air compressor are
clearly shown. The complete compressor consists of 2. It seals the leakage paths between the
an encapsulated compressor system, inlet system, rotors and the stator and also between the
cooling system, control system and WS control rotors themselves.
system. 3. It acts as a lubricating film between the
The compact design of the ES-8 Series air rotors allowing one rotor to directly drive the
compressor provides easy access to all serviceable other, which is an idler.
components. The air/fluid mixture discharges directly into the fluid
management system.
4.3 ENCAPSULATED The fluid cooler bypass valve helps assure proper
COMPRESSOR SYSTEM, cooling by directing the fluid to the fluid cooler when
FUNCTIONAL DESCRIPTION discharge temperature reaches the thermostat
temperature setting.
Refer to Figure 4-2. The encapsulated compressor
includes compressor unit, fluid management system, During start-up in cool ambient conditions, the cooler
and drive motor. The Sullair compressor unit is a pressure drop may cause the filter bypass valve to
single-stage positive displacement lubricated type open up, assuring adequate fluid supply to the
compressor. This unit is equipped with tapered roller compressor.
bearings on the discharge and cylindrical roller All fluid entering the compressor unit passes through
bearings on the inlet end for high load carrying the replaceable fluid filter element. This replaceable
capacity. This unit provides continuous pulse-free air filter element contains a built-in bypass valve. Under
compression to meet your needs. With a Sullair conditions of restricted flow through the element, the
compressor there will be no maintenance or internal bypass valve helps ensure adequate compressor
inspection of the compressor. fluid flow, as well as helps prevent element failure.
 Figure 4-1: Description of Components
FLUID MANAGEMENT SYSTEM DRIVE MOTOR
The Fluid Management System consists of a multi-- The Drive Motor consists of a squirrel cage induction
chambered primary/secondary separator, the final motor which is connected to the integrated drive
air/fluid separator element, cooler bypass and fluid gearing by a drive coupling.
filter.
As compressed air/fluid enters the sump, the first 4.4 COMPRESSOR COOLING
fluid separation takes place due to a reduction of SYSTEM, FUNCTIONAL
flow speed coupled with a change of direction of the DESCRIPTION
flow within the sump housing. The compressed air
reaches the separator and the finest fluid drops and The Compressor Cooling System consists of a fluid
mist are separated. cooler, fan and cooler shroud. The fan is mounted
on the compressor shaft. Air is drawn through the
The minimum pressure/discharge check valve is motor adaptor by the fan and exits through the
mounted on the compressor drive housing. Its coolers on top of the compressor. The air provides
functions are as follows: cooling for compressor fluid and cooling of air on
units with air aftercoolers.
1. Maintains a minimum sump pressure of 60
psig (4.2 bar) under full load operation to
help assure adequate fluid pressure. 4.5 AIR INLET SYSTEM,
FUNCTIONAL DESCRIPTION
2. Acts as a check valve to isolate the
compres- sor from the system at shutdown The compressor inlet system consists of a dry-type
or unload. air filter and an inlet control valve. Reacting on a
pressure signal, the valve closes the intake for
unloaded operation. The valve also acts as a check
valve upon shutdown.
ES-8 MOBILE APPLICATION MANUAL R00 SECTION 4

Figure 4-2: Encapsulated Compressor System

4.6 CONTROL SYSTEM, and the solenoid valve are closed, the inlet valve is
FUNCTIONAL DESCRIPTION fully open and the compressor pumps at full rated
The purpose of the compressor control system is to capacity. The rising compressor air pressure is
regulate the amount of air being compressed to isolated from the service line in this phase by the
match the amount of compressed air being used. minimum pressure valve set at approximately 60
The capacity control system consists of a solenoid psig (4.2 bar).
valve, regulator valve and an inlet valve. The FULL LOAD MODE—60 TO 100 PSIG (4.2
functional description of the control system is
TO 6.9 BAR)
described below in 4 distinct phases of operation.
The following description text applies to all Series When the compressed air pressure rises above 60
ES-8 compressors. For explanitory purposes, this psig (4.2 bar), the minimum pressure valve opens
description will apply to a compressor with an allowing compressed air to flow into the service line.
operating range of 100 to 110 psig (6.9 to 7.6 bar). A From this point on, the line air pressure is continually
compressor with any other pressure range would monitored by the Supervisor. The pressure regulator
operate in the same manner except stated and the solenoid valve remain closed during this
pressures. phase. The inlet valve is in the fully open position as
long as the compressor is running at 100 psig (6.9
START MODE—0 TO 60 PSIG (0 TO 4.2 bar) or below.
BAR)
MODULATING MODE—100 TO 110 PSIG
When the compressor “I” pad is depressed, the
(6.9 TO 7.6 BAR)
sump pressure will quickly rise from 0 to 60 psig (0 -
4.2 bar). During this period, both the pressure If less than the rated capacity of compressed air is
regulator being used, the service line pressure will rise above
100 psig (6.9 bar). The pressure regulator valve When the line pressure drops to the low setting(cut-
gradually opens, directing air pressure to the inlet in pressure; usually 100 psig [6.9 bar] on low
control valve, reducing air entering the compressor pressure [“L”] compressors and 125 psig [8.6 bar] on
until it matches the amount of air being used. The high pressure [“HH”] compressors, 175 psig [12.1
control system functions continually in this manner bar] on [“XH”] compressors), Supervisor energizes
between the limits of 100 to 110 psig (6.9 to 7.6 bar) the solenoid valve and allows the blowdown valve to
in response to varying demands from the service close. The re-energized solenoid valve again
line. The pressure regulator has an orifice which prevents line pressure from reaching the inlet control
vents a small amount of air to the atmosphere when valve. Should the pressure begin to rise, the
the pressure regulator controls the inlet control pressure regulator will resume its normal function as
valve. previously described.
The orifice also bleeds any accumulated moisture
from the pressure regulator.
AUTOMATIC OPERATION
For applications with varied periods of time when
UNLOAD MODE—IN EXCESS OF 110 there are no air requirements, Supervisor’s
PSIG (7.6 BAR) AUTOMATIC mode allows the compressor to
When a relatively small amount or no air is being shutdown (time delayed) when no compressed air
used, the service line pressure continues to rise. requirement is present and restart as compressed
When it exceeds 110 psig (7.6 bar), the Supervisor air is needed.
Control System de--energizes the solenoid valve
allowing sump air pressure to be supplied directly to
close the inlet valve. Simultaneously, the solenoid
valve sends a pneumatic signal to the blowdown
valve. The blowdown valve opens the sump to the
atmosphere, reducing the sump pressure to
approximately 20 to 30 psig (1.4 to 2.1 bar). The
check valve in the air service line prevents line
pressure from returning to the sump.
ES-8 MOBILE APPLICATION MANUAL R00 SECTION 5

Section 5

WS CONTROLLER
5.1 CONTROLLER LAYOUT

2
10

7 9

6 4

Figure 5-1: 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

5.2 CONTROLLER KEYPAD • To start the compressor operation, press the green
Start pad " ".
See WS Controller manual P/N 02250165-411 for
complete operation capabailities. The WS Controller • To stop compressor operation, press the red Stop
keypad has two main pads for compressor control. pad " ".

• The Run mode indicator " " lights up whenever

the control is in an operating mode.
5.3 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.

Figure 5-5:

Refer to Figure 5-6. 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
Figure 5-2: reading.
Refer to Figure 5-2 and Figure 5-3. The lower line is
occasionally interrupted to describe the compressor
package's operating state.

Figure 5-6:

Refer to Figure 5-7. When you continue beyond the

status information, the display will show a list of
Figure 5-3: control settings. The upper line will indicate "Show
Setting" and the name of the setting. The lower line
Refer to Figure 5-4. If a machine fault occurs, the shows the present value.
red fault " " indicator will light up, and the display will
indicate that a fault has occurred.

Figure 5-7:
Figure 5-4: Refer to Figure 5-8. To change the setting, press the
Enter pad " ". The display indicates that you are in a
Refer to Figure 5-5. The lower line periodically will
change mode with reverse characters. Use the Up "
display the cause of the fault. Refer to service
" or Down " " arrow keys to change the setting, and
instructions to correct the cause. Press the Stop pad
press Enter again to save the new setting.
" " to reset the controller.
SECTION 5 ES-8 MOBILE APPLICATION MANUAL R00

5.4 LED LIGHTS

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

The green Power indicator " " simply indicates

that power is applied to the controller. It will blink
Figure 5-8: very slowly if the WS Controller is set up to
automatically restart after power failure.
Refer to Figure 5-8. 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 The green Run mode indicator " " indicates
display also returns to normal view. If either of these compressor operation is enabled. It lights steadily if
occur, the setting will not be altered. the motor is running. If the motor stops while in
Automatic mode, this LED will blink to indicate that
If there are any warnings or recommended service the motor may restart.
instructions, these will be periodically displayed on
the normal view.
The list of displays may be navigated from either The yellow Maintenance indicator " " comes on
whenever there is recommended maintenance or a
direction by using the Up " " or Down " " warning. The text display will periodically indicate the
arrow keys. For example, to change language from recommended actions or the cause of the warning.
normal view, press the Up arrow pad once, press the
Enter key " ", select your language, and press
The red Fault indicator " " indicates that a
Enter again. The number of displays varies with
compressor fault has occurred and needs to be
compressor model, but will follow this pattern.
repaired before further operation. The text display
The large Emergency Stop button located near the will indicate the cause of the fault.
controller overrides all electronic functions to turn off
the control devices. The controller senses this, and The PC support program for the WS controller
will display E-stop. To reset, twist and pull out the provides additional information about compressor
Emergency Stop button, then press the Stop pad to operation and advanced setup adjustments to
reset the WS Controller. 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.

21
NOTES
 ES-8 MOBILE APPLICATION MANUAL R00

Section 6

MAINTENANCE
6.1 INTRODUCTION Troubleshooting under Excessive Fluid Consumption
for a probable cause and remedy.

WARNING After a routine start has been made, a general check

of the overall compressor should bemade to assure
that the compressor is running properly.
Before doing compressor maintenance,
dis- connect compressor from power 6.3 MOTOR BEARING
source and lock out power source. Isolate LUBRICATION
com- pressor from line pressure by closing
rec- ommended discharge shut-off valve
and releasing all internal pressure from WARNING
com- pressor.
As you proceed in reading this section, it will be easy Before doing compressor maintenance,
to see that the maintenance program for the air dis- connect compressor from power
compressor is quite minimal. The Supervisor source and lock out power source. Isolate
monitors the status of the separator element. When com- pressor from line pressure by closing
maintenance to this device is required, the rec- ommended discharge shut-off valve
Supervisor will display the appropriate maintenance and releasing all internal pressure from
message and flash the location LED on the graphics com- pressor.
map as a visual reminder. See instructions for each
item in Section 6.6: Parts Replacement And See motor manufacturer’s lubrication instructions.
Adjustment Procedures .
6.4 FLUID FILTER
MAINTENANCE
WARNING
WARNING
DO NOT remove caps, plugs, and/or other components when compressor is running or pressurized. Stop compressor and relieve
Fluid filter has internal bypass. DO NOT
SUBSTITUTE.

Replace the fluid filter element under any of the

following conditions:
6.2 DAILY OPERATION
1. As recommended in the Lubrication Guide in
Prior to starting the compressor, it is necessary to the Specification Section, and below.
check the fluid level in the sump. Should the level be 2. Every year.
low, simply add the necessary amount. If the
addition of fluid becomes too frequent, a minor 3. Every fluid change.
problem has developed which is causing this
excessive loss. See

23
ES-8 MOBILE APPLICATION MANUAL R00 SECTION 6

6.5 COOLER MAINTENANCE

If cooler becomes restricted, use standard spray
degreaser/cleaner and brush to clean cooler. Use air
pressure to blow cooler clean. Care must be taken
as not to damage cooler fins.

WARNING
Before doing compressor maintenance,
dis- connect compressor from power
source and lock out power source. Isolate
com- pressor from line pressure by closing
rec- ommended discharge shut-off valve
and releasing all internal pressure from
com- pressor.

6.6 PARTS REPLACEMENT

AND ADJUSTMENT
PROCEDURES

WARNING Figure 6-1: Fluid Filter (P/N 250026--982)

Before doing compressor maintenance, * Replacement Element Kit P/N 02250050--602

dis- connect compressor from power
source and lock out power source. Isolate
FLUID FILTER REPLACEMENT
com- pressor from line pressure by closing Refer to Figure 6-1.
rec- ommended discharge shut-off valve
and releasing all internal pressure from 1. To prevent spillage and loss of reusable fluid,
com- pressor. place a contaminate-free fluid receptacle beneath
fluid drain valve and fluid filter.
RELIEF VALVE 2. Drain fluid by removing fluid drain valve cap at tee
DO NOT tamper with the preset factory pressure located beneath compressor (for complete fluid
setting of the valve. DO NOT plug the valve for any change, drain fluid from cooler).
reason; should it leak, have it replaced. 3. Using a strap wrench, remove the old element
and gasket.
4. Clean gasket seating surface.
5. Apply a light film of fluid to the new gasket.
6. Hand tighten new element until gasket is seated.
7. Continue tightening element an additional 1/2 to
3/4 turn.
8. Replace fluid. DO NOT OVERFILL.
9. Restart compressor and check for leaks.
AIR FILTER MAINTENANCE 4. After the element has been installed, inspect
Refer to Figure 6-2. Air filter (P/N 02250125-365) and tighten (if necessary) all air inlet
maintenance should be performed every 6 months connec- tions prior to resuming operation.
or more frequent if conditions so require. SEPARATOR ELEMENT REPLACEMENT
Refer to Figure 6-3. The separator should be
WARNING changed once a year, or as needed. Follow the
procedure explained below for element replacement.

Before doing compressor maintenance,

dis- connect compressor from power
source and lock out power source. Isolate
com- pressor from line pressure by closing
rec- ommended discharge shut--off valve
and releasing all internal pressure from
com- pressor.

Figure 6-3: Separator Element

* Repair Kit P/N 02250050--604

WARNING
Before doing compressor maintenance,
dis- connect compressor from power
source and lock out power source. Isolate
com- pressor from line pressure by closing
rec- ommended discharge shut-off valve
Figure 6-2: Air Filter 02250125-365 and releasing all internal pressure from
com- pressor.
* Replacement Element Kit P/N 02250125-370
ELEMENT INSPECTION
1. Place a bright light inside the element to 1. Insert a 100mm maximum length, 6mm
inspect for damage or leak holes. Concen- diameter pin into the radially drilled hole in
trated light will shine through the element the separator cap. Loosen, unscrew
and locate any holes. counter- clockwise and remove the cap.

2. Inspect all gaskets and gasket contact sur- 2. Pull out the old element by gripping the end
faces of the housing. Should faulty gaskets of the element with channel lock pliers or a
be evident, correct the condition immedi- similar tool.
ately. 3. Install new o-rings on separator cap and
3. If the clean element is to be stored for later sep- arator element filter and oil lightly to
use, it must be stored in a clean container. make installation easier.
4. Insert and push the new element in place.
5. Reinstall the cap. Hand tighten using a
100mm maximum length, 6mm diameter pin
CONTROL SYSTEM ADJUSTMENT
in the radially drilled hole. All components in the Control System are designed
and manufactured to close tolerances to help
DRIVE COUPLING INSTALLATION eliminate any need for adjustments.
Refer to Figure 6-4. For coupling installation the
DANGER
tools required will be one set of Allen wrenches. All
ES-8 compressors are flange-mounted to the motor DO NOT touch the electrical contacts, terminal or
making them self-aligning, eliminating the need for leads with any part of the body or any uninsulated
alignment procedures. Proper hub separation is s metallic object. Severe electrical shock may occur.
hown in Figure 6-4.
PRESSURE VALVE ADJUSTMENT
If pressure valve adjustment is required the
adjustment procedure below should be followed:
1. Start compressor.
2. Lower line pressure (P2) until machine goes
on load.
3. Loosen hex nut on the regulator valve to
adjust machine modulation. Adjust screw in
or out until on load/off load modulation of
compressor takes place.
4. Close service valve downstream from
receiver tank. The pressure will increase
depending on the regulator valve adjustment
screw setting. Adjust screw until line pres-
sure (P2) rises to the Supervisor II prepro-
grammed off load setting. Tighten hex nut.
5. Open service valve and observe correct on
load/ off load modulation.
Figure 6-4: Hub Separation
INLET CONTROL VALVE Before doing compressor maintenance, disconnect
Refer to Figure 6-5. The inlet control valve normal compressor from power source and lock out power
maintenance requires only the replacement of the o- source. Isolate compressor from line pressure by
rings. Use repair kit no. 02250050-614 and follow closing recommended discharge shut-off valve and
the procedure below for proper disassembly and releasing all internal pressure from compressor.
assembly procedures.
WARNING
Assure that line pressure gauge on com- pressor indicates “ZERO” pressure before any work is done. Failure to

1. Remove the two (2) rear access panels

which cover the inlet valve assembly.
2. Identify and tag the hoses connected to the
blowdown valve and disconnect.
3. Remove the 3 capscrews from the inlet
valve cover.
4. Remove cover (with blowdown valve
attached) and o-rings.
5. Remove piston, piston spring, check spring
and valve stem.
6. Inspect and clean all parts.
7. Assemble valve stem, check spring, piston
spring and piston into inlet valve housing.
8. Lubricate new o-rings and install the inner
and outer o-rings onto cover.
9. Position cover in inlet valve housing and
Figure 6-5: Inlet Control Valve install capscrews. Tighten capscrews to 6
ft.- lbs. (8.1Nm).
* Repair Kit P/N 02250050--614 10. Reconnect the hoses to the appropriate fit-
tings on the valve.
11. Assemble two (2) rear access panels on the
compressor.
12. Start compressor and check for leaks.
NOTES
6.7 MAINTENANCE RECORD
Model No.: Serial No.

Date Hourmeter Maintenance Performed Work Performed By Authorized By

28
 ES-8 MOBILE APPLICATION MANUAL R00

Section 7

TROUBLESHOOTING
7.1 INTRODUCTION unnecessary damage to the compressor. Always
remember to:
The information contained in the Troubleshooting
chart is based upon both the actual applied a. Check for loose wiring.
situations and extensive testing at the factory. It b. Check for damaged piping.
contains symptoms and usual causes for the
described problems. However DO NOT assume that c. Check for parts damaged by heat or an elec-
these are the only problems that may occur. All trical short circuit, usually apparent by
available data concerning the trouble should be discol- oration or a burnt odor.
systematically analyzed before undertaking any Should your problem persist after making the
repair or component replacement procedures. recommended check, consult your nearest Sullair
A detailed visual inspection is worth performing for representative or the Sullair Corporation factory.
almost any problems which may prevent

Table 7-1: Controller Troubleshooting Guide

MESSAGE PROBABLE CAUSE REMEDY
T1 HI Message Discharge Temperature Exceeded
225°F (107°C) for Pre-Alarm
Discharge Temperature Exceeded
235°F (113°C) for Shutdown
Ambient temperature exceeded Improve local ventilation (i.e., remote intake
105°F (41°C) of process and/or cooling air.
Fluid Level in Sump is Too Low Check/correct fluid level.
Thermal Valve Malfunctioned Check/replace thermal valve.
Cooler Fins are Dirty Clean cooler fins.
Water Flow is Low (water--cooled Check cooling water supply (i.e., closed
packages only) valves).
Water Temperature is High (water- Increase water flow, lower water
cooled packages only) temperature.
Cooler is Plugged (water--cooled Clean tubes and/or shell -- if tube plugging
packages only) persists, provide cleaner water.
Temperature RTD Malfunction Check connections from RTD. If adequate,
replace RTD.
ES-8 MOBILE APPLICATION MANUAL R00 SECTION 7

Table 7-1: Controller Troubleshooting Guide

MESSAGE PROBABLE CAUSE REMEDY
P1 HI Message Discharge Pressure Exceeded
Shutdown Level Because:
P1 MAX--3psi (0.2 Bar) Exceeded
for Pre--Alarm
P1 MAX Exceeded for Shutdown
Unloading Device (i.e., Blowdown Check operation of unloading device.
Valve, Inlet Valve) Failed to
Operate
Pressure Regulator Maladjusted Check operation of pressure regulator.
Solenoid Valve Failed to Operate Check operation of solenoid valve.
Control Air Signal Leaks Check tubework feeding control signal for
leaks.
Control Air Signal Filter Clogged Service filter assembly.
SEP MNTN Message Plugged Separator Replace separator elements.
dP1 > 10 psi Check P1 & P2 pressure transducers.
COMPRESSOR DOES NOT Air Demand Exceeds Supply Check air service lines for open valves or
BUILD FULL DISCHARGE leaks.
PRESSURE Inlet Air Filter Clogged Check for maintenance message on
Supervisor display. Inspect and/or change
element.
Inlet Valve Not Fully Open Check actuation and butterfly disc position.
Pressure Sensor and/or Check connections from transducer. If
Connections at Fault adequate, replace transducer.
LINE PRESSURE RISES Pressure Sensor P2 at Fault Check connections from transducer. If
ABOVE UNLOAD SETTING adequate, replace transducer.
Unloading Device (i.e., Blowdown Check operation of unloading device.
Valve, Inlet Valve) Failed to
Operate
LINE PRESSURE RISES Solenoid Valve Failed to Operate Check operation of solenoid valve.
ABOVE UNLOAD SETTING Control Air Signal Leaks Check tubework feeding control signal for
leaks.
Control Air Signal Filter Clogged Service filter assembly.
EXCESSIVE FLUID Clogged Return Line Strainer or Clean strainer -- screen and o--ring
CONSUMPTION Orifice replacement kit available. Clean orifice.
Damaged or Improperly Installed Inspect separator elements and gaskets.
O-rings on Separator Elements Replace if damaged.
Fluid System Leaks Check tube/pipework for leaks.
Fluid Level Too High Drain excess fluid.
Excessive Fluid Foaming Drain and change fluid.

30
Section PARTS LIST PARTS MANUAL R00
9
8.1 PROCEDUR
E FOR
ORDERING
PARTS
Parts should be ordered
from the nearest Sullair
Representative or the
Representative from
whom the compressor
was purchased. If for any
reason parts cannot be
obtained in this manner,
contact the factory
directly at the address,
phone numbers or fax
numbers below.
When ordering parts
always indicate the Serial
Number of the
compressor. This can be
obtained from the Bill of
Lading for the
compressor unit or from
the Serial Number Plate
located on the
compressor unit.
The genuine Sullair
service parts listed meet
or exceed the demands
of this compressor. Use
of replacement parts
other than those
approved by Sullair
Corporation may lead to
hazardous conditions
over which Sullair
Corporation has
no control. Such
conditions include,
but are not limited
to, bodily injury
and compressor
failure.

SULLAIR CORPORATION
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A
www.sullair.com
Telephone: 1-800-SULLAIR (U.S.A. only)
Fax: 219-874-1273

CUSTOMER CARE for PARTS and SERVICE

1-888-SULLAIR (785-5247)
219-874-1835
RECOMMENDED SERVICE PARTS LIST

8.2 RECOMMENDED SERVICE PARTS LIST

KEY NO. ORDER PART NO. QTY DESCRIPTION NOTE

KITS
1 02250050-602 1 repair kit for fluid filter 250026--982
2 02250050-604 1 repair kit for air/fluid separator
3 02250125-370 1 repair kit for air filter 02250125-365
4 02250061-961 1 repair kit for shaft seal
5 001932-005 1 tool kit, shaft seal
6 02250078-204 1 replacement element for thermal valve
7 02250157-500 1 replacement kit for coil 02250157-502
8 02250049-634 1 blowdown valve
9 250019-453 1 repair kit for pressure regulator valve 250017-280
10 02250050-614 1 repair kit for inlet control valve
11 02250050-612 1 repair kit for minimum pressure/check valve

FLUID
12 250022-669 1 fluid, Sullube (5 gal./19 liter)
.

CAUTION
Mixing of other lubricants within the com- pressor unit will void all warranties.

PLEASE NOTE: WHEN ORDERING PARTS,

ALWAYS INDICATE SERIAL NUMBER OF COMPRESSOR

3
NOTES
INLET CONTROL, SEAL/DRIVE GEAR AND PARTS

8.3 INLET CONTROL, SEAL/DRIVE GEAR AND PARTS

3
 PARTS MANUAL R00

8.3 INLET CONTROL, SEAL/DRIVE GEAR AND PARTS

N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 02250152-847 1 housing, drive 24 829308--020 7 capscrew, M8 x 20MM
2 865006--012 1 screw, flat hd M6 x 12MM 25 02250119-254 1 cover, inlet control
3 02250048--229 1 washer 26 826502-235 1 o--ring, viton 3" x 3/32"
4 02250047--162 1 seat, minimum pressure valve (I) 27 826502--226 1 o--ring, viton 2" x 1/8"
5 02250047--163 1 stem, minimum pressure valve 28 02250048--909 1 piston, inlet valve
6 02250047--296 1 spring, minimum pressure valve (I) 29 250042--087 1 spring, inlet piston
7 02250048--908 1 piston, minimum pressure valve 30 250042--088 1 spring, inlet check
8 826502--124 1 o--ring, viton 1 1/4" x 3/32" (I) 31 250035--584 1 stem, inlet valve
9 02250047--161 1 spring, minimum pressure valve 32 02250078-204 1 element, thermal valve
10 250035--587 1 cap, minimum pressure valve 33 823204--000 1 nipple, pipe 1/4" x close
11 02250046--908 1 elbow, 45 37FL 1.312" 34 02250048--317 1 sleeve, wear (II)
12 02250107-919 1 hose, medium pressure 1" x 18" 35 829312--030 8 screw, socket M12 x 30MM
13 826502--152 1 o--ring viton 3 1/4" x 3/32" (II) 36 02250047--047 2 isolator, vibration (optional)
14 499080--206 1 bearing (I) Formaintenance on minimum pressure valve, order kit no.
15 1 gear consult factory 02250050-- 612 (Note: Items not sold separately).
(II) For maintenance on ES--8 shaft seal, order tool kit part
16 02250050--540 1 shaft, input numbers 02250061--961 and 001932--005.
17 865210--070 1 key, 10 x 8 x 70
PLEASE NOTE: WHEN ORDERING PARTS,
18 02250055--887 1 housing, cover drive INDICATE SERIAL NUMBER OF COMPRESSOR
19 499080--210 1 bearing
20 826502--152 1 o--ring, viton 3 1/4" x 3/32" (II)
21 02250133-494 1 seal (II)
22 026397 1 shim, set 3.5 x 3.0
23 250035--254 1 cover, shaft seal
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
MOTOR, COUPLING, FAN AND PARTS

8.4 MOTOR, COUPLING, FAN AND PARTS

 PARTS MANUAL R00

8.4 MOTOR, COUPLING, FAN AND PARTS

N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
1 02250121-285 1 support, motor (30 HP) 24 02250047--083 1 insert, 6MM
2 829312--030 4 capscrew, M12 x 30MM 25 02250077-588 1 element
3 02250045--833 1 housing, adaptor motor (30 HP) 26 02250077-587 1 coupling, 38mm
4 829108-125 4 capscrew, hex GR8 1/2"--13 x 1 1/4"
5 02250055--600 1 guard, fan (I) Pre--Heating required before assembly.
6 02250077-586 1 coupling, 1 5/8" (I) PLEASE NOTE: WHEN ORDERING PARTS,
7 02250046--603 1 Sventuri, fan inlet (25,30 HP) INDICATE SERIAL NUMBER OF COMPRESSOR

8 02250050--539 1 fan, backward inclined wheel (I)

9 02250075-477 1 housing, fan
10 865210--040 1 key, 10 x 8 x 40
11 consult factory 1 motor
12 829312--040 6 screw, socket M12 x 40MM
13 865712--370 2 washer, 12MM
14 825912--175 2 nut, M12 x 1.75
15 865406-125 1 washer, 8MM
16 828008--016 1 capscrew, 8MM x 16MM
17 865712--370 1 washer, 12MM
18 825912--175 1 nut, hex M12 x 1.75
19 02250047--047 1 isolator, vibration 75MM x 50MM (optional)
20 846500--125 1 elbow, 45 liq--tite 1 1/4" (not shown)
21 847006--040 2 washer, conduit red. 1 1/2"--1" (not shown)
22 02250049--159 1 spacer, shaft (30 HP)
23 02250121-070 1 angle, support cooler
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

3
INLET FILTER, COMPRESSOR HOUSING/SUMP AND PARTS

8.5 INLET FILTER, COMPRESSOR HOUSING/SUMP AND PARTS

02250170-953
 PARTS MANUAL R00

8.5 INLET FILTER, COMPRESSOR HOUSING/SUMP AND PARTS

Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 02250054-857 1 PLUG,1/2-14 NPT TO M20 THREAD 23 826502-235 1 O-RING, VITON 3 1/8 X 1/8”
2 02250054-858 1 BAIL,LIFTING E8E 24 829308-060 3 SCRW, SOC ISO 4762 M8 X 60MM
3 02250055-933 1 UNIT, COMPRESSOR ASSY 25 829316-060 4 SCRW, SOC ISO 4762 M16 X 60MM
4 02250057-182 1 CAP SEPARATOR ELEMENT ES-8 26 829316-100 16 SCRW, SOC ISO 4762 M16 X 100MM
5 02250071-022 1 ADPT, STRT THRD 1-1/16-12M X 1-1/16 27 839608-060 2 SCREW, DRIVE RD HD #8 X 3/8
37DEG M 28 842215-004 1 HOSE, NYLON 1/4”
6 02250103-227 1 HOSE,HUMP RED 3 X 2.5” X4.25LG 29 860104-012 2 CONN, 37 FL/MPT PLTD 1/4 X 1/8
7 02250106-789 1 SEPARATOR, ELEMENT E8E 30 865408-170 3 WASHER, METRIC-ISO7089- 8
8 02250125-365 1 FLTR,AIR 6”(PLASTIC) W/MTG & 31 866215-100 1 ELBOW, PIPE 90 DEG PLT 2 1/2”
9 02250155-175 1 P,RTD 100 OHM PLAT 3.5”X 6FT 32 866312-020 1 NIPPLE, PIPE PLTD 3/4 X 2
10 02250169-360 1 HSG, BELL P8 MACH 33 866340-035 1 NIPPLE, PIPE PLTD 2 1/2 X 3 1/2
11 47118 1 VALVE, BALL 3/4” SERVICE 34 866404-000 1 NIPPLE, PIPE-XS PLT 1/4 X CL
12 250006-938 1 VALVE,PRESSURE RELIEF 200 PSIG 35 866815-010 1 TEE, PIPE 150# PLT 1/4
13 250018-428 1 CONN, 1/4T X 1/4 NPT STR 36 866815-030 1 TEE, PIPE 150# PLT 3/4
14 250018-430 1 ELBOW, 90 1/4T PLS X 1/4 NPT M 37 866900-030 1 PLUG, PIPE 3/4” 3000# STL PLT
15 250018-550 2 CLAMP, HOSE 2-13/16 TO 3-3/4” 38 867100-005 1 BUSHING, RED PLTD 1/4 X 1/8
16 250025-524 1 ELEMENT, FLUID FILTER (REF 250025- 39 868512-075 1 NIPPLE, PIPE-HX PLTD 3/4 X 3/4
523 TAB)
40 873640-000 1 NIPPLE, HALF-XS 2 1/2 X CL
17 250025-914 1 ADAPTER, OIL FLTR .970-20 UNEF
PLEASE NOTE: WHEN ORDERING PARTS,
18 250026-859 1 NPL,SN-ID INDICATE SERIAL NUMBER OF COMPRESSOR
19 250028-635 1 FITTING, COMPRESS ADJ
20 250039-359 1 PLUG, E6E OIL FILL HX HD1 1/16
21 811506-075 1 ADAPTER, FEMALE PIPE 3/4 X 3/4
22 825920-250 1 NUT, HEX METRIC M20 X 2.5
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

3
COMPRESSOR COOLER SYSTEM AND PARTS

8.6 COMPRESSOR COOLER SYSTEM AND PARTS

 PARTS MANUAL R00

8.6 COMPRESSOR COOLER SYSTEM AND PARTS

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
1 02250047-083 1 INSR, MM THRD BLIND
2 02250071-022 4 ADPT, STRT THRD 1-1/16-12M X 1-1/16
37DEG M
3 02250075-426 1 MBR, R.H. SHROUD CLR SUPPORT
4 02250075-427 1 MBR, L.H. SHROUD CLR SUPPORT
5 02250121-070 1 ANL,SUPT-COOLERS ES8 GE SPCL
6 02250121-071 1 CVR,ACS-COOLERS ES8-30 GE SPLC
7 02250149-237 2 CLR,OIL ES8-30HP W/RLF FINS
8 02250170-956 1 SUPT,CLR ASSY ES8 SHOVEL PKG
9 250040-092 1 AFTERCOOLER, 8E
10 825906-100 10 NUT, HEX METRIC M6 X 1.0
11 825908-125 3 NUT, HEX METRIC M8 X 1.25
12 829306-012 7 SCRW, SOC ISO 4762 M6 X 12MM
13 829306-020 20 SCRW, SOC ISO 4762 M6 X 20MM
14 829308-016 3 SCRW, SOC ISO 4762 M8 X 16MM
15 829308-030 3 SCRW, SOC ISO 4762 M8 X 30MM
16 838806-160 36 WASHER, SPR LOCK-METRIC PLTD M6
17 838808-200 9 WASHER, SPR LOCK-METRIC PLTD M8
18 860216-075 1 ELBOW, 37FL 90M 1 X 3/4
19 866312-020 1 NIPPLE, PIPE PLTD 3/4 X 2
20 866815-030 1 TEE, PIPE 150# PLT 3/4
21 868903-005 1 BUSHING, RED HEX PLTD 3/4 X 1/8
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

4
PNEUMATIC CONTROL SYSTEM AND PARTS

8.7 PNEUMATIC CONTROL SYSTEM AND PARTS

 PARTS MANUAL R00

8.7 PNEUMATIC CONTROL SYSTEM AND PARTS

Q
KEY
PART NO. T DESCRIPTION
NO.
Y
1 02250049-634 1 VLV,BLWDN 1/4 NPT HI PRS
2 02250071-362 2 LOCKNUT, N4 CONDUIT SEALING
3 02250118-589 1 ORF, .125 .25 FNPT X .25 MNPT
4 02250155-714 2 VLV,SOL 3WNO 1/4 250# 24VDC
5 02250170-956 1 SUPT,CLR ASSY ES8 SHOVEL PKG
6 241771 1 STRAINER, V-TYPE 300PSIX1/4
7 250017-280 1 VALVE, PRESSURE REGULATOR
8 250018-430 2 ELBOW, 1/4” TUBE X 1/4” NPT
9 408893 1 VALVE, SHUTTLE 1/4” (DBL CHK)
10 841500-004 2 BULKHEAD, PIPE 1/4” NPT
11 847815-050 2 NIPPLE, CHASE COND 1/2
12 860104-025 4 CONN, 37 FL/MPT PLTD 1/4 X 1/4
13 860204-025 9 ELBOW, 37FL 90M 1/4 X 1/4
14 860404-025 4 NIPPLE, PIPE-HEX 1/4 X 1/4
15 866815-010 2 TEE, PIPE 150# PLT 1/4
16 869825-025 1 TEE, MALE PIPE BRASS 1/4
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

4
CONTROL STARTER—MFV

8.8 CONTROL STARTER—MFV

 PARTS MANUAL R00

8.8 CONTROL STARTER—MFV

Q Q
KEY KEY
PART NO. C-H P/N T DESCRIPTION PART NO. C-H P/N T DESCRIPTION
NO. NO.
Y Y
1 02250169-781 - 1 SPEC, ENCL P8/10 19” X 16 02250167-849 XTCEXFBG11 1 BLK, AUX CONT 1NO 1NC
24.5” X 7 FRONT
2 02250167-818 XTCE065D00TD 1 CNTOR, 65A 3P 24VDC 17 02250182-565 - 1 MDL, LINE REACTOR
1NO XT 480V 3.4A
3 02250154-052 - 1 CTL, I/O MOD WS 24VDC PLEASE NOTE: WHEN ORDERING PARTS,
4 02250101-721 25-10467 2 BAR, GROUND 5 POST INDICATE SERIAL NUMBER OF COMPRESSOR

5 02250154-051 - 1 CTL, DISPLAY WS

6 02250154-359 - 1 DECAL,
MICROPROCESSOR
OVERLAY Torque Values (in/lbs)
SULLAIR P/N DESCRIPTION LUG TERMINALS
7 02250161-759 - 4 SPACER, 6.35DIA X 10.4 02250167-818 CNTOR, 65A 3P 24VAC 1NP XT 29.2 10.6
LONG ALUM
8 849215-025 80-3132 8 LUG, GROUND
9 838405-034 - 2 WASHER, LOCK
EXTERNAL TOOTH 5/16”
10 02250085-504 E22LLB2 1 SW, PB OPER RED40MM
PUSH-TWIST
11 250027-125 E22BF1 1 BLOCK, CONTACT 1 N.C.
12 02250081-473 E22VA2 1 NPL, YELLOW RING
45MM E-STOP
13 02250159-547 - 1 RCPT, S4 PROGRAM
PORT NEMA 6P
14 02250159-549 - 1 CAP, S4 PROGRAM PORT
NEMA 6P
15 02250145-195 1423553 1 BLK, POWER
DISTRIBUTION 175A
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR

4
8.9 DECAL GROUP
8.9 DECAL GROUP (CONTINUED)

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
1 49685 1 sign, warning -- compressor fluid fill cap
2 49850 1 sign, danger electrocution
3 407408 1 sign, warning -- hot surfaces
4 41065 1 decal, warning auto start
5 250027--935 1 decal, danger breath air
6 250003--144 1 sign, warning “food grade" lube
7 250021-564 1 decal, rotation direction
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
8.9 DECAL GROUP (CONTINUED)
8.9 DECAL GROUP

N
Q
KEY O
PART NO. T DESCRIPTION
NO. T
Y
E
8 02250075-046 2 decal, earth ground
02250075-045 1 decal, protective earth ground (not shown)
02250075-540 1 decal, PE designation (not shown)
9 42218 1 decal, danger hi voltage
10 49852 1 sign, warning ground fault
11 02250059-288 1 decal, ISO 9001
12 02250055-510 1 decal, warning lift
PLEASE NOTE: WHEN ORDERING PARTS,
INDICATE SERIAL NUMBER OF COMPRESSOR
WIRING DIAGRAM—FULL VOLTAGE (STANDARD)

8.10 WIRING DIAGRAM—FULL VOLTAGE (STANDARD)

5
NOTES

51
 WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A.
Zuo Pao Tai Road, No. 1 3700 East Michigan Boulevard Zone Des Granges BP 82
Chiwan, Shekou Michigan City, Indiana, 46360 42602 Montbrison,
Shenzen, Guangdong U.S.A. www.sullair.com France
PRV. PRC POST CODE Telephone: 1-800-SULLAIR (U.S.A. Telephone: 33-477968470
518068 only) Fax: 219-874-1273 Fax: 33-477968499
Telephone: 755-6851686 www.sullaireurope.com
Fax: 755-6853473 CUSTOMER CARE
www.sullair-asia.com for PARTS and Service
1-888-SULLAIR (7855247)
219-874-1835

Champion Compressors, LTD.

Princes Highway
Hallam, Victoria
3803 Australia
Telephone: 61-3-9703-8000
Fax: 61-3-9703-8053
www.championcompressors.com.au

Printed in the U.S.A.

Specifications subject to
change without prior notice.
E09EP