User Manual: Industrial Air Compressor SN55, SN55S, SN55V, SN75, SN75S, SN75V

USER MANUAL
Industrial Air Compressor

SN55, SN55S, SN55V,
SN75, SN75S, SN75V
75 & 100 hp (55 & 75 kW)
PART NUMBER:
02250247-571 R04
SAFETY WARNING WARRANTY NOTICE The information in this manual is current as of its
publication date and applies to compressor models
indicated on this cover with serial number:
Users are required to read the Failure to follow the instructions
entire User Manual before han- and procedures in this manual,
201903080000
and all subsequent serial numbers until next revision of
dling or using the product. Keep or misuse of this equipment, will this manual or release of a replacement manual..
the User Manual in a safe place void its warranty.
for future reference. Publication date: 03/27/2020
Copyright © 2020 Sullair, LLC. All rights reserved.
Subject to EAR, ECCN EAR99 and related export control restrictions.

Service Training Courses
Sullair training courses provide hands-on and classroom instruction for the proper operation, maintenance, and
servicing of Sullair products. Individual courses on Stationary compressors, variable speed drives, compressor
electrical systems, and dryers are offered at regular intervals throughout the year at Sullair’s training facility located
in 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 courses are recommended for distributor
service personnel. There is also a basic Stationary compressor course available for end-users.
For details on course offerings, outlines, schedules, and cost information contact:
Sullair Training Department

1-888-SULLAIR or
219-879-5451 (ext. 5623)
training@sullair.com
www.SullairTraining.com
- Or Write -
Sullair
1 Sullair Way
Michigan City, IN 46360
Attn: Training Department

SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual Table of Contents
Table of Contents
Section 1: Safety.......................................................................................................6
1.1 General............................................................................................................................................ 6
1.2 Personal protective equipment ........................................................................................................ 6
1.3 Pressure release ............................................................................................................................. 6
1.4 Fire and explosion ........................................................................................................................... 7
1.5 Moving parts .................................................................................................................................... 7
1.6 Hot surfaces, sharp edges and sharp corners................................................................................. 8
1.7 Toxic and irritating substances ........................................................................................................ 8
1.8 Electrical shock................................................................................................................................ 8
1.9 Lifting ............................................................................................................................................... 9
1.10 Entrapment ...................................................................................................................................... 9
1.11 Implementation of lockout/tagout................................................................................................... 10
1.12 Safety warnings ............................................................................................................................. 11
1.13 Safety decals ................................................................................................................................. 12
Section 2: Description............................................................................................14
2.1 Introduction.................................................................................................................................... 14
2.2 Description of components ............................................................................................................ 14
2.3 Sullair compressor unit, functional description .............................................................................. 14
2.4 Compressor cooling and lubrication system, functional description .............................................. 17
2.5 Compressor discharge system, functional description .................................................................. 17
2.6 Control system, functional description........................................................................................... 17
2.7 Air inlet system, functional description .......................................................................................... 23
2.8 Variable speed drive (VSD) components ...................................................................................... 24
2.9 VSD control system, functional description ................................................................................... 24
Section 3: Specifications .......................................................................................26

3.1 Table of specifications—SN55, SN55S, SN75, SN75S................................................................. 26
3.2 Table of specifications—SN55V, SN75V....................................................................................... 27
3.3 Compressor specifications ............................................................................................................ 28
3.4 Motor specifications....................................................................................................................... 28
3.5 Lubrication guide ........................................................................................................................... 28
3.6 Application guide ........................................................................................................................... 29
3.7 Lubrication change recommendations and maintenance, fluid ..................................................... 30
3.8 Identification, air-cooled................................................................................................................. 31
3.9 Identification, water-cooled............................................................................................................ 33
3.10 Piping & instrumentation, air-cooled—SN55, SN75 ...................................................................... 35
3.11 Piping & instrumentation, water-cooled—SN55, SN75 ................................................................. 37
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Table of Contents SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual
3.12 Piping & instrumentation, air-cooled—SN55S, SN75S ................................................................. 39

3.13 Piping & instrumentation, water-cooled—SN55S, SN75S ............................................................ 41
3.14 Piping & instrumentation, air-cooled—SN55V, SN75V ................................................................. 43
3.15 Piping & instrumentation, water-cooled—SN55V, SN75V ............................................................ 45
3.16 Wiring diagram, wye-delta............................................................................................................. 47
3.17 Wiring diagram, VSD air-cooled parallel wye ................................................................................ 51
Section 4: Installation ............................................................................................ 54

4.1 Mounting of compressor................................................................................................................ 54
4.2 Ventilation & cooling...................................................................................................................... 54
4.2.1 Air-cooled compressors ...................................................................................................... 54
4.2.2 Water-cooled compressors................................................................................................. 54
4.2.3 Water system venting ......................................................................................................... 55
4.2.4 Draining the water system .................................................................................................. 55
4.2.5 Water quality recommendations ......................................................................................... 56
4.2.5.1 Scale ......................................................................................................................... 56
4.2.5.2 Corrosion................................................................................................................... 56
4.2.5.3 Biological and organic fouling (slime)........................................................................ 56
4.2.6 Seawater-cooled units ........................................................................................................ 56
4.3 Outdoor installation (sheltered) ..................................................................................................... 57
4.4 Service air piping........................................................................................................................... 57
4.4.1 Pipe sizing .......................................................................................................................... 58
4.4.2 Use of auxiliary receiver tank.............................................................................................. 58
4.5 Coupling alignment check ............................................................................................................. 59
4.6 Fluid level check............................................................................................................................ 59
4.7 Electrical preparation..................................................................................................................... 59
4.8 Motor rotation direction check ....................................................................................................... 59
Section 5: Controller .............................................................................................. 62

5.1 Controller layout ............................................................................................................................ 62
5.2 Home page.................................................................................................................................... 64
5.3 Main Menu page............................................................................................................................ 65
5.4 User Preferences page .................................................................................................................. 66
5.5 Menu hierarchy.............................................................................................................................. 67
5.6 AirLinx™ remote monitoring (optional).......................................................................................... 68
5.6.1 Troubleshooting AirLinx communications ........................................................................... 68
Section 6: Maintenance ......................................................................................... 70

6.1 General.......................................................................................................................................... 70
6.2 Daily operation .............................................................................................................................. 70
6.3 Maintenance after initial 50 hours of operation ............................................................................. 70
6.4 Maintenance every 2000 hours ..................................................................................................... 70
6.5 Fluid maintenance ......................................................................................................................... 70
6.6 Filter maintenance......................................................................................................................... 71
6.6.1 Fluid filter element replacement.......................................................................................... 71
6.6.2 Air filter element replacement ............................................................................................. 71
02250247-571 R04
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SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual Table of Contents
6.7 Separator maintenance ................................................................................................................. 72

6.7.1 Separator element replacement.......................................................................................... 72
6.8 Oil return / sight glass maintenance .............................................................................................. 73
6.9 Pressure regulator adjustment ...................................................................................................... 73
6.10 Water condensate drain maintenance........................................................................................... 74
6.11 Control line strainer ....................................................................................................................... 74
6.12 Shaft coupling maintenance .......................................................................................................... 74
6.13 Troubleshooting............................................................................................................................. 74
6.13.1 Introduction ......................................................................................................................... 74
6.13.2 Troubleshooting guide ........................................................................................................ 74
02250247-571 R04
Table of Contents SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual
Notes:
02250247-571 R04
SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual 1: Safety
Section 1
Safety
most compressors and the concepts behind these state-
NOTE ments are generally applicable to all compressors.
1.2 Personal protective equipment

A. Prior to installing or operating the compressor, own-
ers, employers and users should become familiar
with, and comply with, all applicable OSHA regula-
Operator is required to read tions and/or any applicable Federal, State and Local
entire instruction manual. codes, standards, and regulations relative to per-
sonal protective equipment, such as eye and face
protective equipment, respiratory protective equip-
1.1 General ment, equipment intended to protect the extremities,
protective clothing, protective shields and barriers
Sullair and its subsidiaries design and manufacture all of
and electrical protective equipment, as well as noise
their products so they can be operated safely. However,
exposure administrative and/or engineering controls
the responsibility for safe operation rests with those who
and/or personal hearing protective equipment.
use and maintain these products. The following safety
precautions are offered as a guide which, if conscien-
tiously followed, will minimize the possibility of accidents
throughout the useful life of this equipment.
1.3 Pressure release
A. Install an appropriate flow-limiting valve between the
The compressor should be operated only by those who service air outlet and the shut-off (throttle) valve,
have been trained and delegated to do so, and who have either at the compressor or at any other point along
read and understood this Operator’s Manual. Failure to the air line, when an air hose exceeding ½″ (13 mm)
follow the instructions, procedures and safety inside diameter is to be connected to the shut-off
precautions in this manual may result in accidents and (throttle) valve, to reduce pressure in case of hose
injuries. NEVER start the compressor unless it is safe to failure, per OSHA Standard 29 CFR 1926.302(b)(7)
do so. DO NOT attempt to operate the compressor with a and/or any applicable Federal, State and Local
known unsafe condition. Tag the compressor and render codes, standards and regulations.
it inoperative by disconnecting and locking out all power
at source or otherwise disabling its prime mover so B. When the hose is to be used to supply a manifold,
others who may not know of the unsafe condition cannot install an additional appropriate flow-limiting valve
attempt to operate it until the condition is corrected. between the manifold and each air hose exceeding
½″ (13 mm) inside diameter that is to be connected
Install, use and operate the compressor only in full to the manifold to reduce pressure in case of hose
compliance with all pertinent OSHA regulations and/or failure.
any applicable Federal, State, and Local codes,
standards and regulations. DO NOT modify the C. Provide an appropriate flow-limiting valve at the
compressor and/or controls in any way except with beginning of each additional 75 feet (23 m) of hose in
written factory approval. runs of air hose exceeding ½″ (13 mm) inside diame-
ter to reduce pressure in case of hose failure.
While not specifically applicable to all types of compres-
sors with all types of prime movers, most of the precau- D. Flow-limiting valves are listed by pipe size and flow-
tionary statements contained herein are applicable to rated. Select appropriate valves accordingly, in
02250247-571 R04
1: Safety SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual
accordance with their manufacturer's recommenda- material. Any acoustical material with a protective
tions. covering that has been torn or punctured should be
replaced immediately to prevent accumulation of liq-
E. DO NOT use air tools that are rated below the maxi-
uids or fluid film within the material. DO NOT use
mum rating of the compressor. Select air tools, air
flammable solvents for cleaning purposes.
hoses, pipes, valves, filters and other fittings accord-
ingly. DO NOT exceed manufacturer’s rated safe D. Disconnect and lock out all power at source prior to
operating pressures for these items. attempting any repairs or cleaning of the compressor
or of the inside of the enclosure, if any.
F. Secure all hose connections by wire, chain or other
suitable retaining device to prevent tools or hose E. Keep electrical wiring, including all terminals and
ends from being accidentally disconnected and pressure connectors in good condition. Replace any
expelled. wiring that has cracked, cut, abraded or otherwise
degraded insulation, or terminals that are worn, dis-
G. Open fluid filler cap only when compressor is not run-
colored or corroded. Keep all terminals and pressure
ning and is not pressurized. Shut down the compres-
connectors clean and tight.
sor and bleed the receiver tank to zero internal
pressure before removing the cap. F. Keep grounded and/or conductive objects such as
tools away from exposed live electrical parts such as
H. Vent all internal pressure prior to opening any line, fit-
terminals to avoid arcing which might serve as a
ting, hose, valve, drain plug, connection or other
source of ignition.
component, such as filters and line oilers, and before
attempting to refill optional air line anti-icer systems G. Remove any acoustical material or other material
with antifreeze compound. that may be damaged by heat or that may support
combustion and is in close proximity, prior to attempt-
I. Keep personnel out of line with and away from the
ing weld repairs.
discharge opening of hoses or tools or other points of
compressed air discharge. H. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when servicing
J. DO NOT use air at pressures higher than 2.1 bar for
and operating the compressor.
cleaning purposes, and then only with effective chip
guarding and personal protective equipment per I. Keep oily rags, trash, leaves, litter or other combusti-
OSHA Standard 29 CFR 1910.242(b) and/or any bles out of and away from the compressor.
applicable Federal, State, and Local codes, stan-
J. DO NOT operate the compressor without proper flow
dards and regulations.
of cooling air or water or with inadequate flow of lubri-
K. DO NOT engage in horseplay with air hoses as cant or with degraded lubricant.
death or serious injury may result.
K. DO NOT attempt to operate the compressor in any
classification of hazardous environment unless the
compressor has been specially designed and manu-
1.4 Fire and explosion factured for that duty.
A. Clean up spills of lubricant or other combustible sub-
stances immediately, if such spills occur.
B. Shut off the compressor and allow it to cool. Then
1.5 Moving parts
keep sparks, flames and other sources of ignition A. Keep hands, arms and other parts of the body and
away and DO NOT permit smoking in the vicinity clothing away from couplings, belts, pulleys, fans and
when checking or adding lubricant or when refilling other moving parts.
air line anti-icer systems with antifreeze compound.
B. DO NOT attempt to operate the compressor with the
C. DO NOT permit fluids, including air line anti-icer sys- fan, coupling or other guards removed.
tem antifreeze compound or fluid film, to accumulate
C. Wear snug-fitting clothing and confine long hair when
on, under or around acoustical material, or on any
working around this compressor, especially when
external surfaces of the air compressor. Wipe down
exposed to hot or moving parts.
using an aqueous industrial cleaner or steam clean
as required. If necessary, remove acoustical mate- D. Keep access doors, if any, closed except when mak-
rial, clean all surfaces and then replace acoustical ing repairs or adjustments.
02250247-571 R04
E. Make sure all personnel are out of and/or clear of the B. DO NOT use air line anti-icer systems in air lines
compressor prior to attempting to start or operate it. supplying respirators or other breathing air utilization
equipment and DO NOT discharge air from these
F. Disconnect and lock out all power at source and ver-
systems into unventilated or other confined areas.
ify at the compressor that all circuits are de-ener-
gized to minimize the possibility of accidental start- C. Operate the compressor only in open or adequately
up, or operation, prior to attempting repairs or adjust- ventilated areas.
ments. This is especially important when compres-
D. Locate the compressor or provide a remote inlet so
sors are remotely controlled.
that it is not likely to ingest exhaust fumes or other
G. Keep hands, feet, floors, controls and walking sur- toxic, noxious or corrosive fumes or substances.
faces clean and free of fluid, water or other liquids to
E. Coolants and lubricants used in this compressor are
minimize the possibility of slips and falls.
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
1.6 Hot surfaces, sharp edges and with soap and water in the event of skin contact.
sharp corners Consult Material Safety Data Sheet for information
A. Avoid bodily contact with hot fluid, hot coolant, hot pertaining to fluid of fill.
surfaces and sharp edges and corners. F. Wear goggles or a full face shield when adding anti-
B. Keep all parts of the body away from all points of air freeze compound to air line anti-icer systems.
discharge. G. If air line anti-icer system antifreeze compound
C. Wear personal protective equipment including gloves enters the eyes or if fumes irritate the eyes, they
and head covering when working in, on or around the should be washed with large quantities of clean
compressor. water for fifteen minutes. A physician, preferably an
eye specialist, should be contacted immediately.
D. Keep a first aid kit handy. Seek medical assistance
promptly in case of injury. DO NOT ignore small cuts H. DO NOT store air line anti-icer system antifreeze
and burns as they may lead to infection compound in confined areas.
I. The antifreeze compound used in air line antifreeze
systems contains methanol and is toxic, harmful or
1.7 Toxic and irritating substances fatal if swallowed. Avoid contact with the skin or eyes
A. DO NOT use air from this compressor for respiration and avoid breathing the fumes. If swallowed, induce
(breathing) except in full compliance with OSHA vomiting by administering a tablespoon of salt, in each
Standards 29 CFR 1910 and/or any applicable Fed- glass of clean, warm water until vomit is clear, then
eral, State or Local codes or regulations. 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.
DANGER
1.8 Electrical shock

A. This compressor should be installed and maintained
in full compliance with all applicable Federal, State
and Local codes, standards and regulations, includ-
ing those of the National Electrical Code, and also
including those relative to equipment grounding con-
Death or serious injury can result from inhaling ductors, and only by personnel that are trained, qual-
compressed air without using proper safety ified and delegated to do so.
equipment. See OSHA standards and/or any B. Keep all parts of the body and any hand-held tools or
applicable Federal, State, and Local codes, stan- other conductive objects away from exposed live
dards and regulations on safety equipment. parts of electrical system. Maintain dry footing, stand
on insulating surfaces and DO NOT contact any
other portion of the compressor when making adjust-
02250247-571 R04
ments or repairs to exposed live parts of the electrical D. Make sure lifting hook has a functional safety latch or
system. Make all such adjustments or repairs with equivalent, and is fully engaged and latched on the
one hand only, so as to minimize the possibility of bail or slings.
creating a current path through the heart.
E. Use guide ropes or equivalent to prevent twisting or
C. Attempt repairs in clean, dry and well lighted and swinging of the compressor once it has been lifted
ventilated areas only. clear of the ground.
D. DO NOT leave the compressor unattended with open F. DO NOT attempt to lift in high winds.
electrical enclosures. If necessary to do so, then discon-
G. Keep all personnel out from under and away from the
nect, lock out and tag all power at source so others will
compressor whenever it is suspended.
not inadvertently restore power.
H. Lift compressor no higher than necessary.
E. Disconnect, lock out, and tag all power at source
prior to attempting repairs or adjustments to rotating I. Keep lift operator in constant attendance whenever
machinery and prior to handling any ungrounded compressor is suspended.
conductors.
J. Set compressor down only on a level surface capa-
ble of safely supporting at least its weight and its
DANGER loading unit.
K. When moving the compressor by forklift truck, utilize
All field equipment must be tested for electro- fork pockets if provided. Otherwise, utilize pallet if
static fields prior to servicing or making contact provided. If neither fork pockets or pallet are pro-
with the machine using the following or equiva- vided, then make sure compressor is secure and well
lent test equipment: balanced on forks before attempting to raise or trans-
• 90 – 600 VAC: Volt detector such as Fluke port it any significant distance.
Model 1AC-A L. Make sure forklift truck forks are fully engaged and
• 600 – 7000 VAC: Voltage detector such as tipped back prior to lifting or transporting the com-
Fluke Networks Model C9970 pressor.
It is the responsibility of each organization to M. Forklift no higher than necessary to clear obstacles
provide/arrange training for all their associates at floor level and transport and corner at minimum
expected to test for electrostatic fields. practical speeds.
N. Make sure pallet-mounted compressors are firmly
bolted or otherwise secured to the pallet prior to
1.9 Lifting attempting to forklift or transport them. NEVER
attempt to forklift a compressor that is not secured to
A. If the compressor is provided with a lifting bail, then
its pallet, as uneven floors or sudden stops may
lift by the bail provided. If no bail is provided, then lift
cause the compressor to tumble off, possibly causing
by sling. Compressors to be air-lifted by helicopter
serious injury or property damage in the process.
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 standards 29 CFR 1910 sub-
part N and/or any applicable Federal, State, and
1.10 Entrapment
Local codes, standards and regulations. A. If the compressor enclosure, if any, is large enough
to hold a man and if it is necessary to enter it to per-
B. Inspect points of attachment for cracked welds and
form service adjustments, inform other personnel
for cracked, bent, corroded or otherwise degraded
before doing so, or else secure and tag the access
members and for loose bolts or nuts prior to lifting.
door in the open position to avoid the possibility of
C. Make sure entire lifting, rigging and supporting struc- others closing and possibly latching the door with
ture has been inspected, is in good condition and has personnel inside.
a rated capacity of at least the weight of the com-
B. Make sure all personnel are out of compressor
pressor. If you are unsure of the weight, then weigh
before closing and latching enclosure doors.
compressor before lifting.
02250247-571 R04
1.11 Implementation of lockout/tagout person shall be provided with their own padlock
and have possession of the only key. If more
The energy control procedure defines actions necessary than one person is working on a machine each
to lockout a power source of any machine to be repaired, person shall affix personal lock and tag using a
serviced or set-up, where unexpected motion, or an multi-lock device.
electrical or other energy source, would cause personal
injury or equipment damage. The power source on any 7. Tagout devices shall be used only when power
machine shall be locked out by each employee doing the sources are not capable of being locked out by
work except when motion is necessary during setup, use of padlocks and lockout hasp devices. The
adjustment or trouble-shooting. name of the person affixing tag to power source
must be on tag along with date tag was placed
A. The established procedures for the application of on power source.
energy control shall cover the following elements and 8. Release stored energy and bring the equipment
actions and shall be initiated only by Authorized Per- to a “zero mechanical state”.
sons and done in the following sequence:
9. Verify Isolation: Before work is started, test
1. Review the equipment or machine to be locked equipment to ensure power is disconnected.
and tagged out.
B. General Security
2. Alert operator and supervisor of which machine
is to be worked on, and that power and utilities 1. The lock shall be removed by the “Authorized”
will be turned off. person who put the lock on the energy-isolating
3. Check to make certain no one is operating the device. No one other than the person/persons
machine before turning off the power. placing padlocks and lockout hasps on power
shall remove padlock and lockout hasps and
4. Turn off the equipment using normal shutdown restore power. However, when the authorized
procedure. person who applied the lock is unavailable to
5. Disconnect the energy sources: remove it his/her Supervisor may remove pad-
a. Air and hydraulic lines should be bled, lock/padlocks and lockout hasps and restore
drained and cleaned out. There should be power only if it is first:
no pressure in these lines or in the reser- a. verified that no person will be exposed to
voir tanks. Lockout or tag lines or valves. danger.
b. Any mechanism under tension or pressure, b. verified that the “Authorized” person who
such as springs, should be released and applied the device is not in the facility.
locked out or tagged. c. noted that all reasonable efforts to contact
c. Block any load or machine part prior to the “Authorized” person have been made
working under it. to inform him or her that the lockout or
d. Electrical circuits should be checked with tagout device has been removed.
calibrated electrical testing equipment and d. ensured that the “Authorized” person is
stored energy and electrical capacitors notified of lock removal before returning to
should be safely discharged. work.
6. Lockout and/or Tagout each energy source using 2. Tagout System—Tags are warning devices
the proper energy isolating devices and tags. affixed at points of power disconnect and are not
Place lockout hasp and padlock or tag at the to be removed by anyone other that the person
point of power disconnect where lockout is placing tag on power lockout. Tags shall never be
required by each person performing work. Each by-passed, ignored, or otherwise defeated.
02250247-571 R04
1.12 Safety warnings

The following special instructions apply to VSD packages WARNING
provided with electronic adjustable speed motor drives.
These cautions that apply to VSD operation. Before opening the variable speed drive covers:
• Disconnect all power to the variable speed
WARNING drive.
• Wait a minimum of 5 (five) minutes after all
Ground the unit following the instructions in this the lights on the keypad are off.Wait a min-
manual. Ungrounded units may cause electric imum of 15 minutes after all the lights on
shock and/or fire. The variable speed drive has a the keypad are off. This allows time for the
large capacitive leakage current during opera- DC bus capacitors to discharge.
tion, which can cause enclosure parts to be • A hazard voltage may still remain in the DC
above ground potential. Proper grounding, as bus capacitors even if the power has been
described in this manual, is required. Failure to turned off. Confirm that the capacitors
observe this precaution could result in death or have fully discharged by measuring their
severe injury. voltage using a multimeter set to measure
DC voltage. Failure to follow the above
precautions may cause death or severe
injury.
WARNING
Before applying power to the variable speed
drive, make sure that the front and cable covers CAUTION
are closed and fastened to prevent exposure to
potential electrical fault conditions. Failure to Do not perform any megger or voltage withstand
observe this precaution could result in death or tests on any part of the variable speed drive or
severe injury. its components. Improper testing may result in
damage. Prior to any tests or measurements of
the motor or the motor cable, disconnect the
motor cable at the variable speed drive output
WARNING terminals (U, V, W) to avoid damaging the vari-
able speed drive during motor or cable testing.
Refer all drive service to trained technicians.
This equipment should be installed, adjusted,
and serviced by qualified electrical maintenance
personnel familiar with the construction and CAUTION
operation of this type of equipment and the haz-
ards involved and in accordance with published Do not touch any components on the circuit
service manuals. Failure to observe this precau- boards. Static voltage discharge may damage
tion could result in death or severe injury. the components.
WARNING
Line terminals (L1, L2, L3), motor terminals (U,
V, W) and the DC link/brake resistor terminals (-/
+) are live when the drive is connected to power,
even if the motor is not running. Contact with
this voltage is extremely dangerous and may
cause death or severe injury.
02250247-571 R04
CAUTION NOTE
Customer must provide electrical supply power
Install the variable speed drive in a well venti- disconnect within sight of machine.
lated room that is not subject to temperature
extremes, high humidity, or condensation, and
avoid locations that are directly exposed to sun-
light, or have high concentrations of dust, corro- 1.13 Safety decals
sive gas, explosive gas, inflammable gas,
grinding fluid mist, etc. Improper installation may
result in a fire hazard. WARNING
Auto start hazard
CAUTION This machine is equipped with an
auto start sequence that will start
Make sure that no power correction capacitors the unit when power is restored
are connected to the variable speed drive output after a power failure or as part of
or the motor terminals to prevent variable speed automatic operation, which can
drive malfunction and potential damage. result in serious injury or death.
Do not attempt to make any adjustments or per-
form any maintenance on this machine without
disconnecting both main line and control circuit
CAUTION electrical power and follow all of your company’s
prescribed safety practices for electrical equip-
Make sure that the variable speed drive output ment.
terminals (U, V, W) are not connected to the util-
ity line power as severe damage to the VSD may
occur.
NOTE
Interior electrical wiring is performed at the fac-
tory. Required customer wiring is minimal, but
should be done by a qualified electrician in com-
pliance with OSHA, National Electrical Code,
and/or any other applicable State, Federal, and
local electrical codes concerning isolation
switches, fused disconnects, etc. Sullair pro-
vides a wiring diagram for use by the installer.
02250247-571 R04
Notes:
02250247-571 R04
SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual 2: Description
Section 2
Description
2.1 Introduction cated- type compressor. This unit provides continuous
compression to meet your needs.
Your new Sullair flood-lubricated rotary screw air com-
pressor will provide you with a unique experience in
improved reliability and simplified maintenance. Com- NOTE
pared to other types of compressors, the Sullair rotary
screw is unique in mechanical reliability, with “No Wear” With a Sullair compressor, there is no mainte-
and “No Inspection” required of the working parts within nance or inspection of the internal parts of the
the compressor unit. Read Section 6: Maintenance on compressor unit permitted in accordance with
page 70 to see how surprisingly easy it is to keep your air the terms of the warranty.
compressor in top operating condition.
Sullair compressors are factory-filled with Sullube® lubri-
cant. For more information on fluid fill, consult Section
2.2 Description of components 3.7: Lubrication change recommendations and mainte-
Refer to Figure 2-1 and Figure 2-2. The components and nance, fluid on page 25.
assemblies of the air compressor are clearly shown. The
complete package includes compressor, electric motor,
starter, compressor inlet system, compressor discharge
system, compressor lubrication and cooling system, WARRANTY NOTICE
capacity control system, controller, aftercooler, a combi-
nation separator and trap, all mounted on a heavy gauge Mixing of other lubricants within the compressor
steel frame. unit will void all warranties.
On air-cooled models, a fan draws air into the enclosure
over the fan and main motors through the combined Fluid is injected into the compressor unit hoses and
aftercooler and fluid cooler thereby removing the com- mixes directly with the air as the rotors turn, compressing
pression heat from the compressed air and the cooling the air. The fluid flow has three basic functions:
fluid, and forces it out the top of the machine.
• As coolant, it controls the rise of air temperature nor-
On water-cooled models, a shell and tube heat mally associated with the heat of compression.
exchanger is mounted on the compressor frame. Fluid is • Seals the clearance paths between the rotors and
piped into the heat exchanger where compression heat is the stator and also between the rotors themselves.
removed from the fluid. Another similar heat exchanger
cools the compressed air. • Acts as a lubricating film between the rotors allow-
ing one rotor to directly drive the other, which is an
Both air-cooled and water-cooled versions have easily idler.
accessible items such as the fluid filter air/oil separator
and control valves. The inlet air filter is also easily acces- After the air/fluid mixture is discharged from the compres-
sible for servicing. sor unit, the fluid is separated from the air. At this time,
the air flows through an aftercooler and separator then to
your service line while the fluid is being cooled in prepa-
2.3 Sullair compressor unit, ration for reinjection.
functional description
Sullair air compressors feature the Sullair compressor
unit, a single-stage, positive displacement, flood lubri-
02250247-571 R04
2: Description SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual
1. Compressor unit 8. Moisture separator

2. Motor 9. Fluid filter
3. Cooler fan motor 10. Fluid fill
4. Electrical enclosure 11. Fluid fill sight glass
5. E-stop button 12. Separator/sump tank
6. Controller 13. Air inlet filter
7. Cooler
Figure 2-1: Overall component layout, air-cooled model
02250247-571 R04

2. Motor 9. Fluid filter
3. Oil cooler 10. Fluid fill
4. Electrical enclosure 11. Fluid fill sight glass
5. E-stop button 12. Separator/sump tank
6. Controller 13. Air inlet filter
7. Aftercooler 14. Canopy vent fan
Figure 2-2: Overall component layout, water-cooled model
02250247-571 R04
2.4 Compressor cooling and lubrication The fractional percentage of fluid remaining in the com-
system, functional description pressed air collects on the surface of the separator ele-
ment as the compressed air flows through the separator.
Refer to Figure 2-3 or Figure 2-4. The cooling and lubri- A return line (or scavenge tube) leads from the dry side of
cation system (air-cooled version) consists of a fan, fan the separator/sump tank to a medium pressure region of
motor, radiator-type aftercooler/fluid cooler, full flow fluid the compressor unit. Fluid collecting on the bottom of the
filter, thermal valve, and interconnecting hoses. For separator is returned to the compressor by a pressure
water-cooled models, two shell and tube heat exchang- differential between the separator/sump and the com-
ers are substituted for the radiator-type cooler listed pressor. A visual sight glass is located on the return line
above. The pressure in the separator/sump tank causes to observe this fluid flow. There is also an orifice in this
fluid flow by forcing the fluid from the high pressure area return line (protected by a strainer) to assure proper flow.
of the separator/sump tank to an area of lower pressure A message on the controller indicates if abnormal pres-
in the compressor unit. sure drop through the separator develops.Refer to Sec-
Fluid flows from the bottom of the separator/sump tank to tion 3.7: Lubrication change recommendations and
the thermal valve. The thermal valve is fully open when the maintenance, fluid on page 25.
fluid temperature is below 195°F (91°C) [210°F (99°C) for A minimum pressure/check valve, located downstream
pressures rated above 150 psig]. The fluid passes through from the separator, assures a minimum separator/sump
the thermal valve, the main filter and directly to the com- pressure of 50 psig (3.4 bar) during loaded conditions.
pressor unit where it lubricates, cools and seals the rotors This pressure is necessary for proper air/fluid separation
and the compression chamber. and proper fluid circulation.
As the discharge temperature rises above195°F (91 °C), A terminal check valve is incorporated into the minimum
due to the heat of compression, the thermal valve begins pressure/check valve to prevent compressed air in the
to adjust and a portion of the fluid then flows through the service line from bleeding back into the separator/sump
cooler. From the cooler the fluid flows to the fluid filter on shutdown and during operation of the compressor in
and then on to the compressor unit. an unloaded condition.
A portion of the fluid flowing to the compressor is routed A pressure relief valve (located on the wet side of the
to the anti-friction bearings which support the rotors separator) is set to open if the separator/sump tank pres-
inside the compressor unit. sure exceeds the separator/sump tank rating. The con-
The fluid filter has a replacement element and an integral pres- troller will shut down the compressor if the discharge
sure bypass valve. Refer to Section 3.7: Lubrication change temperature reaches 235°F (113°C).
recommendations and maintenance, fluid on page 25
Water-cooled models have a water pressure switch to WARNING
prevent operation with inadequate water pressure.
Do not remove caps, plugs, and/or other com-
ponents when compressor is running or pressur-
2.5 Compressor discharge system, ized. Stop compressor and relieve all internal
functional description pressure before doing so.
Refer to Figure 2-3 or Figure 2-4. The compressor unit
discharges the compressed air/fluid mixture into the com-
bination separator/sump tank. Fluid is added to the separator/sump tank via a capped
fluid filler opening, placed low on the tank to prevent
The separator/sump has three basic functions: overfilling of the separator/sump tank. A sight glass
• It acts as a primary fluid separator. enables the operator to visually monitor the separator/
sump tank fluid level.
• Serves as the compressor fluid sump.
• Houses the final fluid separator.
The compressed air/fluid mixture enters the separator/
2.6 Control system, functional description
sump tank and flows through an internal baffle system. Refer to Figure 2-5. The purpose of the compressor control
The direction of movement is changed and its velocity system is to regulate the amount of air being compressed to
significantly reduced, thus causing large droplets of fluid match the amount of compressed air being used. The capac-
to form and fall to the bottom of the separator/sump tank. ity control system consists of a solenoid valve, regulator valve
02250247-571 R04

2. Separator/sump tank 5. Cooler
3. Fluid filter
Figure 2-3: Air-cooled, cooling / lubrication and discharge system
02250247-571 R04

2. Separator/sump tank 5. Oil cooler
3. Fluid filter 6. Aftercooler
Figure 2-4: Water-cooled, cooling / lubrication and discharge system
02250247-571 R04
and an inlet valve. The functional description of the control bypass ports gradually. Excess air is then being returned
system is described below in four distinct phases of opera- back internally to the suction end of the compressor unit.
tion. For explanatory purposes, this description will apply to a Now the compressor is fully compressing only that amount
compressor with an operating range of 100 to 110 psig (6.9 to of air, which is being used. As air demand keeps dropping
7.6 bar). A compressor with any other pressure range would further, the spiral valve keeps opening more and more until
operate in the same manner except stated pressures. all the bypass ports are fully open. At this point, the spiral
valve has moved into the unload (minimum) position.
Start mode—0 to 50 psig (0 to 3.5 bar) The spiral valve provides a modulation range from 100 to
When the controller Start button is depressed, the separator/ 50%. During this period, the pressure rises approximately
sump tank pressure will quickly rise from 0 to 50 psig (0 to from 100 to 105 psig (6.9 to 7.2 bar).
3.4 bar). The compressor initially starts unloaded with the
solenoid valve open and the inlet valve closed. It then Unload mode—in excess of 110 psig (7.6 bar)
switches to full load when full rpm has been achieved. During
When a relatively small amount or no air is being used,
this period, both the pressure regulator and the solenoid valve
the service line pressure continues to rise. When it
are closed, the inlet valve is fully open and the compressor
exceeds 110 psig (7.6 bar), or 105 psig (7.2 bar) for spiral
pumps at full rated capacity. The rising compressor air pres-
valve machine, the controller control system de-ener-
sure is isolated from the service line in this phase by the mini-
gizes the solenoid valve allowing separator/sump tank air
mum pressure valve set at approximately 50 psig (3.4 bar).
pressure to be supplied directly to close the inlet valve.
Simultaneously, the solenoid valve sends a pneumatic
Full load mode—50 to 100 psig (3.4 to 6.9 bar) signal to the blowdown valve. The blowdown valve opens
When the compressed air pressure rises above 50 psig to the atmosphere, located in the compressor separator/
(3.4 bar), the minimum pressure valve opens allowing com- sump tank, reducing the separator/sump tank pressure to
pressed air to flow into the service line. From this point on, the approximately 17 psig (1.2 bar). The check valve in the
line air pressure is continually monitored by the controller. The air service line prevents line pressure from returning to
pressure regulator and the solenoid valve remain closed during the separator/sump tank.
this phase. The inlet valve is in the fully open position as long as
the compressor is running at 100 psig (6.9 bar) or below. When the line pressure drops to the low setting (cut-in pres-
sure; usually 100 psig (6.9 bar) on low pressure (7 bar)
Modulating mode—100 to 110 psig (6.9 to 7.6 bar) compressors and 125 psig (8.6 bar) on high pressure
[SN55, SN75] (9 bar) compressors, 150 psig (10.3 bar) on (10 bar) com-
If less than the rated capacity of compressed air is being pressors, 175 psig (12.0 bar) on (12 bar) compressors), the
used, the service line pressure will rise above 100 psig controller energizes the solenoid valve and allows the blow-
(6.9 bar). The pressure regulator valve gradually opens, down valve to close. The re- energized solenoid valve again
directing air pressure to the inlet control valve, reducing air prevents line pressure from reaching the inlet control valve.
entering the compressor until it matches the amount of air Should the pressure begin to rise, the pressure regulator will
being used. The control system functions continually in this resume its normal function as previously described.
manner between the limits of 100 to 110 psig (6.9 to 7.6 bar)
in response to varying demands from the service line. The Load / no load control
integrated inlet valve has an orifice which vents a small If desired by the customer, the compressor can be set to oper-
amount of air to the compressor inlet when the pressure ate load/no load without modulating control. This control mode
regulator controls the inlet control valve. The orifice also is often selected when a large amount of compressed air stor-
bleeds any accumulated moisture from the control lines. age (air tank) is available. From the Control Parameters
page on the STS Controller, change from Modulation to
Modulating mode with spiral valve—100 to 110 psig Load/Unload. On a machine rated for 100 psig (7 bar) the
(6.9 to 7.6 bar) [SN55S, SN75S] compressor will run in the full load mode up to 100 psig (7 bar).
As air demand drops below the rated capacity of the com- If less than the rated capacity is required, pressure will rise
pressor, the line pressure will rise above 100 psig (6.9 bar). above 100 psig and the controller will de- energize the solenoid
As a result, the differential pressure regulator for the spiral valve, causing the compressor to run in the unload mode.
valve gradually opens, applying air pressure to the spiral When the system pressure falls to 90 psig (6.3 bar), the con-
valve actuator. Air pressure at the actuator expands the dia- troller energizes the solenoid valve, causing the compressor to
phragm. The rack, in turn, engages with the pinion mounted return to the full load mode. The compressor will thus operate
on the spiral valve shaft assembly. This results in a rotary to keep the system pressure in the range of 90 – 100 psig (6.3
motion. As the spiral valve rotates, it starts opening the – 6.9 bar).
02250247-571 R04
Automatic operation compressor to shutdown (time delayed) when no compressed air

For applications with varied periods of time when there are no air requirement is present and restart as compressed air is needed.
requirements, the controller’s AUTOMATIC mode allows the
02250247-571 R04
1. Air inlet 5. Air outlet

2. Minimum pressure/check valve 6. Pressure regulator
3. Blowdown valve 7. Sequencing solenoid valve
4. Separator/sump tank 8. Unload solenoid valve
Figure 2-5: Standard pneumatic control system
02250247-571 R04
2.7 Air inlet system, functional

description WARNING
Refer to Figure 2-6. The compressor inlet system con-
sists of a dry-type air filter, a restriction gauge and an air “The Plastic Pipe Institute recommends against
inlet valve. the use of thermoplastic pipe to transport com-
The restriction gauge (located on the air filter) indicates pressed air or other compressed gases in
the condition of the air filter by showing red when filter exposed above ground locations, e.g. in exposed
maintenance is required. plant piping.”1
The poppet-type modulating air inlet valve directly con- Sullube® should not be used with PVC piping sys-
trols the amount of air intake to the compressor in tems. It may affect the bond at cemented joints.
response to the operation of the pressure regulator. Certain other plastic materials may also be
Refer to Full load mode—50 to 100 psig (3.4 to 6.9 bar) affected.
on page 20. The inlet valve also acts as a check valve, 1
Plastic Pipe Institute, Recommendation B. Adopted
thus preventing reverse rotation when the compressor is January 19, 1972.
shut down.
1. Air inlet filter 4. Separator/sump tank

2. Air inlet 5. Restriction indicator
3. Compressor unit
Figure 2-6: Air inlet system
02250247-571 R04
2.8 Variable speed drive (VSD) and the air-end provides a full flow to the separator/sump
components tank. A minimum pressure valve set at approximately
50 psig (3.4 bar) isolates the rising compressor air pres-
The VSD, located in the machine’s electrical enclosure, sure from the service line.
works in concert with the controller to allow the compres-
sor to match its output to the current demand of the sys-
Full load mode—50 to 100 psig (3.4 to 6.9 bar)
tem. The drive’s heat sink extends through the back of
When the compressed air pressure rises above 50 psig
the enclosure, and its cooled by air flowing through the
(3.4 bar) the minimum pressure valve opens allowing
compressor enclosure.
compressed air to flow into to the service line. From this
point on the controller monitors the line pressure which
2.9 VSD control system, functional controls the VSD. The pressure regulator and solenoid
valves remain closed with the inlet valve fully open, run-
description ning at 100 psig (6.9 bar) or lower.
Refer to Figure 2-5. The controls consist of:
• a VSD VSD part load control
• a solenoid valve The service line pressure increases to a value above
100 psig (6.9 bar) if the demand is less than the com-
• a regulating valve
pressor's rated capacity. In this condition, the VSD slows
• an inlet valve the motor's rpm which reduces the output to match the
Depending on the model, a compressor can be operated demand. The drive continuously adjusts the motor's rpm
at a setpoint pressure from 60 to 175 psig (4.1 to to maintain a 100 psig (6.9 bar) line pressure.The con-
12.1 bar). The controller automatically sets the frequency troller maintains the correct frequency when the VSD is
range based on the selected pressure. (The compres- operating in this mode.
sor's operating range is on its nameplate.)
Unload mode—in excess of 106 psig (7.3 bar)
The following paragraphs apply to a compressor with a When there is no demand or it is at a minimal level, the
100 psig (6.9 bar) operating pressure and a 6 psi service line pressure continues to rise. When it exceeds
(0.4 bar) load delta setting. 106 psig (7.3 bar), or reaches a preset unload pressure
value, the controller de-energizes the solenoid valve
NOTE allowing separator/sump tank air pressure to be supplied
directly which closes the inlet valve. The solenoid valve
The load delta default setting is 10 psi (0.7 bar). simultaneously sends a pneumatic signal to the blow
Sullair recommends a setting of 6 psi (0.4 bar) down valve which opens to the atmosphere, and reduces
for the most efficient operation. 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
Compressors with different pressure operating ranges
down after the programmed unload time setting expires.
perform in the same manner.
When the line pressure drops to the low pressure setting
of 100 psig (6.9 bar) the controller starts the motor and
Start mode—0 to 50 psig (0 to 3.5 bar) energizes the solenoid valve which closes the blowdown
Pressing the controller start button signals the VSD to valve. The re-energized solenoid valve prevents line
accelerate the motor to full speed, causing the separator/ pressure from reaching the inlet control valve, thereby
sump tank pressure to rise from 0 to 50 psig (0 to allowing it to fully open, and the compressor supplies
3.4 bar). At this time both the pressure regulator and compressed air to the system.
solenoid valves are closed; the inlet valve is fully open
02250247-571 R04
Notes:
02250247-571 R04
SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual 3: Specifications
Section 3
Specifications
3.1 Table of specifications—SN55, SN55S, SN75, SN75S
Dimensions
Length Width Height Weight
Power TEFC
Model hp kW in mm in mm in mm lbs kg
SN55 series
5507 75 55 87.6 2225 43.4 1103 68.5 1740 3313 1505
5509 75 55 87.6 2225 43.4 1103 68.5 1740 3313 1505
5510 75 55 87.6 2225 43.4 1103 68.5 1740 3313 1505
5512 75 55 87.6 2225 43.4 1103 68.5 1740 3313 1505
SN55S series
5507S 75 55 87.6 2225 43.4 1103 68.5 1740 3455 1570
5509S 75 55 87.6 2225 43.4 1103 68.5 1740 3455 1570
5510S 75 55 87.6 2225 43.4 1103 68.5 1740 3455 1570
5512S 75 55 87.6 2225 43.4 1103 68.5 1740 3455 1570
SN75 series
7507 100 75 87.6 2225 43.4 1103 68.5 1740 3567 1621
7509 100 75 87.6 2225 43.4 1103 68.5 1740 3567 1621
7510 100 75 87.6 2225 43.4 1103 68.5 1740 3567 1621
7512 100 75 87.6 2225 43.4 1103 68.5 1740 3567 1621
SN75S series
7507S 100 75 87.6 2225 43.4 1103 68.5 1740 3709 1685
7509S 100 75 87.6 2225 43.4 1103 68.5 1740 3709 1685
7510S 100 75 87.6 2225 43.4 1103 68.5 1740 3709 1685
7512S 100 75 87.6 2225 43.4 1103 68.5 1740 3709 1685
Rated pressure designations appearing after model number are as follows:
07—100 psig (6.9 bar) 09—125 psig (8.6 bar) 10—150 psig (10.3 bar) 12—175 psig (12 bar).
Maximum pressure is rated pressure plus 10 psig (0.7 bar).
02250247-571 R04
3: Specifications SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual
3.2 Table of specifications—SN55V, SN75V

Dimensions
Length Width Height Weight
Drive amp
Motor voltage /Hz rating in mm in mm in mm lbs kg
VSD series—SN55V (models 5507V through 5512V)
460/60 72 87.6 2225 43.4 1103 68.5 1740 3411 1550
TEFC
575/60 62 87.6 2225 43.4 1103 68.5 1740 3411 1550
VSD series—SN75V (models 7507V through 7512V)
460/60 88 87.6 2225 43.4 1103 68.5 1740 3745 1702
TEFC
575/60 77 87.6 2225 43.4 1103 68.5 1740 3745 1702
Rated pressure designations appearing after model number are as follows:
07—100 psig (6.9 bar) 09—125 psig (8.6 bar) 10—150 psig (10.3 bar) 12—175 psig (12 bar).
Maximum pressure is rated pressure plus 10 psig (0.7 bar).
02250247-571 R04
3.3 Compressor specifications

Compressor Standard models
Type Rotary screw
Standard operating pressure 100 psig (7 bar) 125 psig (9 bar)
Bearing type Anti-friction
Maximum ambient temperature1 104°F (40°C)
Minimum ambient temperature 40°F (4.4°C)
Cooling Pressurized fluid
Compressor fluid Sullair Sullube®, PristineFG™ is optional
Separator/sump capacity 5.5 gallons (20.8 liters)
Sullair Touchscreen Controller 7” touchscreen
1
Special compressors are available for operation in higher ambient temperature.
3.4 Motor specifications

Motor Standard models
Size 75, 100 hp / 55, 75 kW
Type C-flanged, totally enclosed fan cooled, premium efficiency, three phase, 230/460V 60 Hz
Starter Wye-delta or VSD
Speed—60, 75, 100 hp (45, 55, 75 kW) 1780 rpm (60 Hz)
Multi-frequency and voltage motors are used. The compressors must be used only with the specified electrical frequency and voltage.
3.5 Lubrication guide If fluid change is required, follow Section 3.7: Lubrication
change recommendations and maintenance, fluid on
Refer to Figure 3-1 for location of fluid fill port. For best
page 30.
value and longest uninterrupted service, Sullair compres-
sors are factory filled and tested with Sullube® lubricant.
WARNING
WARRANTY NOTICE
“The Plastic Pipe Institute recommends against
Mixing of other lubricants within the compressor the use of thermoplastic pipe to transport com-
unit will void all warranties. pressed air or other compressed gases in
exposed above ground locations, e.g. in exposed
plant piping.”1
Sullube® should not be used with PVC piping sys-
tems. It may affect the bond at cemented joints.
Certain other plastic materials may also be
affected.
1Plastic
Pipe Institute, Recommendation B. Adopted
January 19, 1972.
WARNING
Maintenance of all other components is still rec-
ommended as indicated in the Operator’s Man-
ual.
02250247-571 R04
Do not mix different types of fluids. Contamination of

compressor fluid with mineral oil or other fluids may lead
to operational problems such as foaming, filter plugging,
orifice or line plugging.
NOTE
Flush system when switching lubricant brands.
When ambient conditions exceed those noted or if condi-

tions warrant use of extended life lubricants contact Sul-
lair for recommendation.
3.6 Application guide

Sullair encourages the user to participate in a fluid analy-
sis program with the fluid suppliers. This could result in a
fluid change interval differing from that stated in the man-
ual. Contact your Sullair dealer for details.
1. Separator/sump tank
2. Fluid fill port
3. Sight glass
4. Fluid drain
Figure 3-1: Fluid fill location
02250247-571 R04
3.7 Lubrication change recommendations and maintenance, fluid

Lubricant Fluid change Fluid filter change Separator change
®
Sullube (7.2 gal / 27.3 L) E G, C I, D
PristineFG™ (7.2 gal / 27.3 L) H, E G, C B, D
B—4,000 hours or more frequently if conditions so require.
C—When measured pressure loss exceeds 20 psig (1.3 bar).
D—When measured pressure loss exceeds 10 psig (0.7 bar).
E—When required by fluid analysis or known contamination.
F—Does not require replacement during normal service conditions.
G—Every 2,000 hours.
H—6,000 hours or once a year.
I—8,000 hours or once a year.
02250247-571 R04
3.8 Identification, air-cooled
02250242-484 R02
02250247-571 R04
3.8 Identification, air-cooled
SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual

Drawing notes
1 ALLOW 1.25 METERS [4.00 FEET] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSOR
2 FRAME LEVEL IS REQUIRED. THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AND THE FOUNDATION.
NO PIPING LOADS ARE PERMITTED AT EXTERNAL CONNECTIONS.
3 ALL DIMENSIONS ARE ± 12.7MM [.50”].
4 RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.
5 ALL DIMENSIONS SHOWN IN MILLIMETERS WITH INCHES DIMENSIONS IN PARENTHESES.
02250247-571 R04
3: Specifications
32
3.9 Identification, water-cooled
02250242-503 R02
02250247-571 R04
3.9 Identification, water-cooled

Drawing notes
1 ALLOW 1.25 METERS [4.00 FEET] MINIMUM CLEARANCE AROUND MACHINE FOR ACCESS AND FREE CIRCULATION OF AIR.
A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE WEIGHT OF PACKAGE, AND RIGID ENOUGH TO MAINTAIN THE COMPRESSOR
2 FRAME LEVEL IS REQUIRED. THE COMPRESSOR FRAME MUST BE LEVELLED AND SECURED BETWEEN THE FRAME AND THE FOUNDATION.
NO PIPING LOADS ARE PERMITTED AT EXTERNAL CONNECTIONS.
3 ALL DIMENSIONS ARE ± 12.7MM [.50”].
4 RECOMMENDED INCOMING CUSTOMER POWER SUPPLY IS SHOWN ON DRAWING.
5 ALL DIMENSIONS SHOWN IN MILLIMETERS WITH INCHES DIMENSIONS IN PARENTHESES.
02250247-571 R04
3: Specifications
34
3.10 Piping & instrumentation, air-cooled—SN55, SN75
02250218-394 R02
02250247-571 R04
3.10 Piping & instrumentation, air-cooled—SN55, SN75

Key Description Qty Key Description Qty
1 FILTER,AIR 1 Drawing notes
2 INDICATOR, RESTRICTION 1 CONTROL/MOISTURE DRAIN LINES ARE 1/4" TUBING EXCEPT AS
1 NOTED.
3 VALVE,INLET 1
OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND
4 COMPRESSOR UNIT 1 MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS
2
5 MOTOR 1 STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE
REQUIREMENTS.
6 FILTER, OIL 1
3 PARTS VARY BY MODEL.
7 COOLER, AIR/OIL 1
8 VALVE, THERMAL 1
Component Description
9 ORIFICE 2
P1 WET SUMP PRESSURE
10 GLASS, SIGHT/ORF SAE 1 P2 LINE PRESSURE
11 FILTER,ASSY 1 SOL1 LOAD/UNLOAD SOLENOID VALVE
12 PLUG,SIGHT GLASS 1 SOL4 MEC/SEQUENCING/FULL LOAD SOLENOID VALVE
13 PROBE, THERMISTER 1 SOL5 COMBO DRAIN/JZL DRAIN SOLENOID VALVE
02250247-571 R04
14 VALVE, RELIEF 1 T1 WET DISCHARGE TEMPERATURE

15 TRANSDUCER, PRESSURE 2
16 VALVE, SHUTTLE 1 Tubing color Purpose
17 VALVE,MINIMUM PRESSURE CHK 1 BLUE TANK PRESSURE
18 VALVE, BLOWDOWN 1 YELLOW REGULATOR PRESSURE
19 SEPARATOR,WTR 1 RED UNLOAD PRESS
20 ELEMENT,SEP 1 CLEAR WATER DRAIN
21 VALVE, COMBO 1
22 STRAINER, VTYPE 1
23 VALVE,SOLENOID 2
24 VALVE, PRESSURE REG 1
25 TANK, SEPARATOR 1
26 FILTER,PNEUMATIC 1
3: Specifications
27 VALVE,CHECK 1
28 VALVE BALL/STNR COMBO 1
29 DRAIN 1
30 VENTILATOR 1
31 GAUGE,DIFF PRESS 1
36
3.11 Piping & instrumentation, water-cooled—SN55, SN75
02250218-395 R03
02250247-571 R04
3.11 Piping & instrumentation, water-cooled—SN55, SN75

1 FILTER, AIR 1 33 DRAIN,ZERO LOSS 1
2 INDICATOR, RESTRICTION 1 Drawing notes
3 VALVE,INLET 1 CONTROL/MOISTURE DRAIN LINES ARE 1/4" TUBING EXCEPT AS
1
4 COMPRESSOR UNIT 1 NOTED.
5 MOTOR 1 OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND

MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS
2
6 FILTER, OIL 1 STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE
REQUIREMENTS.
7 COOLER,OIL/WATER 1
3 PARTS VARY BY MODEL.
8 VALVE, THERMAL 1
9 ORIFICE 2
10 GLASS,SIGHT/ORF 1
11 FILTER, ASSY 1
P2 LINE PRESSURE
12 PLUG,SIGHTGLASS 1
SOL1 LOAD/UNLOAD SOLENOID VALVE
13 PROBE, THERMISTER 1
SOL4 MEC/SEQUENCING/FULL LOAD SOLENOID VALVE
02250247-571 R04
14 VALVE, RELIEF 1
SOL5 COMBO DRAIN/JZL DRAIN SOLENOID VALVE
T1 WET DISCHARGE TEMPERATURE
16 VALVE, SHUTTLE 1
17 VALVE, MIN PRESSURE 1
Tubing color Purpose
18 VALVE, BLOWDOWN 1
BLUE TANK PRESSURE
19 SEPARATOR,WTR 1
YELLOW REGULATOR PRESSURE
20 ELEMENT,SEP 1
RED UNLOAD PRESS
21 VALVE,COMBO 1
CLEAR MOISTURE DRAIN
22 STRAINER, V-TYPE 1
23 VALVE,SOLENOID 3WNO 2
24 VALVE, PRESSURE REG 1
27 VALVE,CHECK 2
3: Specifications
28 HEAT EXCHANGER 1
29 SWITCH, PRESS 1
30 VALVE, WATER REG 1
31 VALVE,SOLENOID 2WNC 1
32 VALVE,BALL/STNR COMBO 1
38
3.12 Piping & instrumentation, air-cooled—SN55S, SN75S
02250243-744 R00
02250247-571 R04
3.12 Piping & instrumentation, air-cooled—SN55S, SN75S

1 FILTER,AIR 1 OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND
2 INDICATOR,RESTRICTION 1 2 STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE
3 VALVE,INLET 1 REQUIREMENTS.
4 COMPRESSOR 1
5 MOTOR 1
6 FILTER,OIL 1 P1 WET SUMP PRESSURE
7 COOLER,AIR 1 P2 PACKAGE OUT
8 COOLER,OIL 1 P3 SPIRAL VALVE CONTROL PRESSURE

9 VALVE,THERMAL 1 SOL1 LOAD/UNLOAD SOLENOID VALVE
10 ORIFICE 5 SOL4 MEC/SEQUENCING/FULL LOAD SOLENOID
11 SIGHTGLASS 1 SOL5 COMBO DRAIN/JZL DRAIN SOLENOID
12 STRAINER 2 T1 DISCHARGE TEMPERATURE
13 PLUG,SIGHTGLASS 1
02250247-571 R04
14 PROBE,THERMISTER 1
BLUE TANK PRESSURE
15 VALVE,RELIEF 1
RED UNLOAD PRESS
17 VALVE, MIN PRESSURE 1
18 SEPARATOR,WATER 1
19 ELEMENT,AIR/OIL SEP 1
20 VALVE,DRAIN 1
21 VALVE,SOLENOID 3WNO 2
22 VALVE,BLOWDOWN 1
23 REGULATOR 1
24 TANK,SEPARATOR 1
26 VALVE,CHECK 2
27 VALVE,BALL/STNR COMBO 1
3: Specifications
28 DRAIN,ZERO LOSS 1
29 VALVE,SPRIAL 1
Drawing notes
CONTROL/MOISTURE DRAIN LINES ARE 1/4" TUBING EXCEPT AS
1 NOTED.
40
3.13 Piping & instrumentation, water-cooled—SN55S, SN75S
02250243-745 R00
02250247-571 R04
3.13 Piping & instrumentation, water-cooled—SN55S, SN75S

1 FILTER, AIR 1 Drawing notes
2 INDICATOR, RESTRICTION 1 1 CONTROL/MOISTURE DRAIN LINES ARE 1/4" TUBING EXCEPT AS
NOTED.
3 VALVE, INLET 1
4 COMPRESSOR 1 MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS
2
5 MOTOR 1 STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE
REQUIREMENTS.
6 FILTER, OIL 1
7 COOLER,OIL/WATER 1 Component Description
8 COOLER, AIR/WATER 1
9 ORIFICE 5
P2 LINE PRESSURE
10 SIGHTGLASS 1
P3 SPIRAL VALVE CONTROL PRESSURE
11 STRAINER 2
12 PLUG, SIGHT GLASS 1
SOL4 MEC/SEQUENCING/FULL LOAD SOLENOID VALVE
SOL5 COMBO DRAIN/ZL DRAIN SOLENOID VALVE
02250247-571 R04
14 VALVE, RELIEF 1
SOL6 WATER SOLENOID VALVE
16 VALVE, MINIMUM PRESSURE 1
17 VALVE, BLOWDOWN 1 Tubing color Purpose
18 SEPERATOR, WATER 1 BLUE TANK PRESSURE
19 ELEMENT, SEPARATOR 1 YELLOW REGULATOR PRESSURE
20 VALVE, DRAIN 1 RED UNLOAD PRESS
21 VALVE, SOLINOID 3WNO 2 CLEAR MOISTURE DRAIN
22 VALVE, PRESSURE REGULATOR 1
24 FILTER, PNEUMATIC 1
25 VALVE, CHECK 2
26 VALVE, THERMAL 1
27 SWITCH, PRESS 1
3: Specifications
28 VALVE, WATER REGULATOR 1
29 VALVE, SOLINOID 2WNC 1
30 VALVE, BALL/STRAINER COMBO 1
31 DRAIN, ZERO LOSS 1
32 SPIRAL VALVE 1
42
3.14 Piping & instrumentation, air-cooled—SN55V, SN75V
02250243-740 R00
02250247-571 R04
3.14 Piping & instrumentation, air-cooled—SN55V, SN75V

1 FILTER, AIR 1 OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND
2 INDICATOR, RESTRICTION 1 2 STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE
3 VALVE, INLET 1 REQUIREMENTS.
4 COMPRESSOR 1
5 MOTOR 1
6 FILTER, OIL 1 P1 WET SUMP PRESSURE
7 COOLER, AIR 1 P2 LINE PRESSURE
8 COOLER, OIL 1 SOL1 LOAD/UNLOAD SOLENOID VALVE

9 ORIFICE 3 SOL5 COMBO DRAIN/ZL DRAIN SOLENOID VALVE
10 SIGHTGLASS 1 T1 WET DISCHARGE TEMPERATURE
11 STRAINER 2
BLUE TANK PRESSURE
02250247-571 R04
14 VALVE, RELIEF 1
RED UNLOAD PRESS
16 VALVE, MINIMUM PRESSURE 1
17 VALVE, BLOWDOWN 1
18 SEPARATOR, WATER 1
19 ELEMENT, SEPARATOR 1
20 VALVE, DRAIN 1
21 VALVE, SOLINOID 3WNO 1
24 VALVE, CHECK 2
27 VALVE, THERMAL 1
3: Specifications
Drawing notes
CONTROL/MOISTURE DRAIN LINES ARE 1/4" TUBING EXCEPT AS
1 NOTED.
44
3.15 Piping & instrumentation, water-cooled—SN55V, SN75V
02250243-741 R00
02250247-571 R04
3.15 Piping & instrumentation, water-cooled—SN55V, SN75V

1 FILTER, AIR 1 CONTROL/MOISTURE DRAIN LINES ARE 1/4" TUBING EXCEPT AS
1 NOTED.
2 INDICATOR, RESTRICTION 1
3 VALVE, INLET 1 MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS
2
4 COMPRESSOR 1 STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE
REQUIREMENTS.
5 MOTOR 1
6 FILTER, OIL 1 Component Description
7 COOLER, OIL/WATER 1
8 COOLER, AIR/WATER 1
P2 LINE PRESSURE
9 ORIFICE 3
10 SIGHTGLASS 1
SOL5 COMBO DRAIN/ZL DRAIN SOLENOID VALVE
11 STRAINER 2
SOL6 WATER SOLENOID VALVE
02250247-571 R04
14 VALVE, RELIEF 1 Tubing color Purpose

15 TRANSDUCER, PRESSURE 2 BLUE TANK PRESSURE
16 VALVE, MINIMUM PRESSURE 1 YELLOW REGULATOR PRESSURE
17 VALVE, BLOWDOWN 1 RED UNLOAD PRESS
18 SEPARATOR, WATER 1 CLEAR MOISTURE DRAIN
19 ELEMENT, SEPARATOR 1
20 VALVE, DRAIN 1
21 VALVE, SOLENOID 3WNO 1
24 VALVE, CHECK 2
25 VALVE, THERMAL 1
26 SWITCH, PRESS 1
27 VALVE, WATER REG 1
3: Specifications
28 VALVE, SOLENOID 2WNC 1
Drawing notes
46
3.16 Wiring diagram, wye-delta
02250242-364 R04 (sh1)

02250247-571 R04
3.16 Wiring diagram, wye-delta
02250242-364 R04 (sh2)

02250247-571 R04
49
3: Specifications
Drawing notes
1 CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.
2 REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.
BELDEN TYPE 9842 4 CONDUCTOR 2 TWISTED PAIR WITH SHIELD OR EQUIVALENT TO MATCHING TERMINALS ON NEXT COMPRESSOR FOR
3 SEQUENCING.
SEE TRANSFORMER CONNECTION TABLE FOR PROPER VOLTAGE CONNECTION. TRANSFORMER FUSING ON CLIPS LOCATED ON
4 TRANSFORMER X1/XF INTERNALLY JUMPERED. SEE TRANSFORMER FUSE CHART FOR SIZING.
5 REFER TO SEQUENCING PROTOCOL MANUAL.
6 SEPARATE DC CONTROL WIRING FROM AC CONTROL WIRING.
7 FAN IS OPTIONAL ON WATER COOLED MACHINES.
8 REMOVE JUMPER WHEN INLET AIR FILTER SWITCH (PSW1) OPTION INSTALLED.
9 REMOVE JUMPER WHEN PHASE MONITOR RELAY (PHMRLY) OPTION INSTALLED.

10 SEE WIRING CHART FOR POWER AND MOTOR WIRE SIZE.
11 STANDARD MACHINE DISPLAY 24VDC WIRED TO PS; TB1 USED WITH AIRLINX OPTION.
12 2M FAN MOTOR CAN BE WIRED WITH OPTION 1 OR OPTION 2.
02250247-571 R04

Notes:
02250247-571 R04
3.17 Wiring diagram, VSD air-cooled parallel wye
02250243-116 R05 (sh1)

02250247-571 R04
02250243-116 R05 (sh2)

02250247-571 R04
53
3: Specifications
Drawing notes
1 CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT PER LOCAL CODES.
2 REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.
BELDEN TYPE 9842 4 CONDUCTOR 2 TWISTED PAIR WITH SHIELD OR EQUIVALENT TO MATCHING TERMINALS ON NEXT COMPRESSOR FOR
3 SEQUENCING.
SEE TRANSFORMER CONNECTION TABLE FOR PROPER VOLTAGE CONNECTION. TRANSFORMER FUSING ON CLIPS LOCATED ON
4 TRANSFORMER X1/XF INTERNALLY JUMPERED. SEE TRANSFORMER FUSE CHART FOR SIZING.
5 REFER TO SEQUENCING PROTOCOL MANUAL.
6 SEPARATE DC CONTROL WIRING FROM AC CONTROL WIRING.
7 FAN IS OPTIONAL ON WATER COOLED MACHINES.
8 REMOVE JUMPER WHEN INLET AIR FILTER SWITCH (PSW1) OPTION INSTALLED.
9 REMOVE JUMPER WHEN PHASE MONITOR RELAY (PHMRLY) OPTION INSTALLED.
10 SEE WIRING CHART FOR POWER AND MOTOR WIRE SIZE.
11 STANDARD MACHINE DISPLAY 24VDC WIRED TO PS; TB1 USED WITH AIRLINX OPTION.
12 2M FAN MOTOR CAN BE WIRED WITH OPTION 1 OR OPTION 2.
02250247-571 R04

NOTE
The VSD air-cooled parallel wye A1000 is 460V
only. It cannot be wired for 230/575V.
SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual 4: Installation
Section 4
Installation
4.1 Mounting of compressor require a minimum of 4 feet (1.25 meters) around the
perimeter of the compressor.
A suitable foundation or fabricated support must be
established to support the compressor. It should be rigid The location should be free from standing water and
enough to keep the compressor frame level and maintain allow access to clean air that is free from exhaust and
alignment of the compressor and motor. Tie-down bolts paint fumes, dust, metal filings or caustic chemicals.
of sufficient size must be used to provide uniform contact
Cooling air should be removed from the area in order to
between the foundation and the compressor frame.
prevent the re-introduction of heated exhaust air back
Materials such as rubber or cork can be used to provide
into the compressor’s cooling system.
uniform contact between the foundation and compressor
frame. Reduced headroom above the compressor will require
that cooling air be either ducted or in some way deflected
Piping loads must be eliminated through the use of flex
away from the compressor. Inadequate ventilation will
connectors or other systems which prevent piping loads
result in higher ambient operating temperatures.
from being transmitted to the compressor.
If discharge/inlet ductwork is added to the compressor
Special consideration should be made to meet national
package, then remove the louvers from the compressor
and local electrical codes for the required space around
package.
and in front of the electrical panel. Lighting should be pro-
vided for future service requirements.
NOTE
Accessibility for fork lift trucks, overhead cranes and
maintenance vehicles should be given careful consider- Systems that employ both a conventional recip-
ation in order to provide any maintenance that may be rocating compressor and a screw-type axial
required. Adequate space around the unit should be pro- compressor must be isolated from each other by
vided for access to all components of the compressor. use of a common receiver tank. Individual air-
Softer surfaces in walls or ceilings will absorb sound and lines from each compressor should be piped to
minimize ambient noise levels. Harder, reflective sur- the common receiver tank.
faces will increase ambient noise levels.
Water-cooled compressors must have provisions for
cooling water supply and drainage available. NOTE
Shipping straps are painted red in order to help
NOTE identify them for removal. Be sure to remove
them prior to operation of the drive assembly.
Ambient temperatures above 104°F (40°C)
require that the high ambient option is specified
for the compressor. 4.2.2 Water-cooled compressors
Adequate cooling water flow must be supplied to water-
cooled compressors. Water delivery must be verified to
4.2 Ventilation & cooling assure constant delivery of the volumes outlined in
Table 4-1: Water flow requirements. The cleaning of pip-
ing and water coolers is the customer’s responsibility.
4.2.1 Air-cooled compressors
Inspect all piping for deposits and clean as necessary.
An area with adequate space must be provided for the
Refer to Section 4.2.5: Water quality recommendations
compressor and its components. Air-cooled compressors
on page 56. The figures shown are for full-load operation
02250247-571 R04
4: Installation SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual
utilizing an aftercooler. Cooler water will reduce water- to assure a normal operating temperature. With air-
flow requirements and warmer water will increase water- cooled compressors it is possible to use this heat for
flow requirements. space heating, providing additional pressure drop across
Table 4-1: Water flow requirements the fan does not exceed 0.2 in H2O. Consult a Sullair
office for assistance in utilizing this heat. If ductwork is
Water temperature and added, the high static fan option is required.
required water flow1
Do not install a water-cooled or an air-cooled/after-
70°F (21°C) 80°F (27°C)
cooled compressor where it will be exposed to tempera-
Motor size gal/min L/min gal/min L/min tures less than 32°F (0°C). Consult factory for machine
75 hp (55 KW) 10.5 39.7 13.0 49.2 operation in ambient temperature less than 32°F (0°C).
100 hp (75 kW) 14.0 53.0 18.8 71.2 If machine is equipped with water regulating valve, use
1 Water pressure should be maintained between 25 and 75 psig (1.7 the water regulating valve to adjust compressor tempera-
and 5.2 bar), but not to exceed 145 psig (10 bar). ture to maintain a minimum of195°F (91°C) [210°F (99°C)
for 24KT® or pressures are rated above150 psig].
Water piping to and from the compressor unit must be a
Temperature and pressure gauges should be installed in
minimum of 1 inch diameter. Isolation valves with side
the water piping for use in troubleshooting of the water
drains should be installed on both input and return lines.
system. Water pressure should ideally be between 25
Input water should have a 2 mm strainer installed in-line.
and 75 psig (1.7 and 5.2 bar) but must not be above
A normally closed solenoid valve should be connected to
145 psi (10 bar).
the water outlet of the compressor. The compressor con-
trol circuit switches this circuit. Consult the Sullair Service
Department for assistance in these setups. 4.2.3 Water system venting
Vent the system upon installation or after draining the
Water quality is critical to proper cooling of the compres- system on start-up:
sor. Excessive build-up of lime, scale or other deposits
can restrict the flow of water to the compressor. These 1. Open the water valve(s) allowing water to flow to
deposits act as a thermal insulator and reduce the effi- the system.
ciency of the water cooler. 2. Open the vent cocks (located on top of the after-
cooler and the lubricant cooler) and allow all air
The cleaning of piping and water coolers is the cus-
to escape from the system. When water is
tomer’s responsibility. Inspect all piping for deposits and
observed at the vent cocks, close them.
clean as necessary. Refer to Section 4.2.5: Water quality
recommendations on page 56. The system is now vented.
Table 4-2: Ventilation requirements indicates the mini-
mum ventilation requirements necessary to keep the
4.2.4 Draining the water system
compressor running at its normal operating temperature. If the system needs to drained completely, follow the
The fan air requirement is the amount of air, which must steps outlined below:
flow through the compressor for proper ventilation. The 1. At the rear of the unit. Disconnect both the inlets
heat rejection requirement is the amount of heat that is and discharge water lines.
radiated by the compressor. This heat must be removed
Table 4-2: Ventilation requirements

Ventilating air— Cooling water—
Fan air heat rejection heat rejection
Cooling type Motor size cfm m3/h BTU/h kcal/h BTU/h kcal/h
75 hp (55 kW) 6,000 10,194 213,000 53,675 — —
Air-cooled with aftercooler
100 hp (75 kW) 8,200 13,932 286,000 72,071 — —
75 hp (55 kW) 2,845 4,834 13,300 3,352 213,000 53,675
Water-cooled
100 hp (75 kW) 2,845 4,834 15,800 3,982 286,000 72,071
02250247-571 R04
2. Remove the drain plugs located at the bottom of creation of corrosive scale. A thin coating of lime scale is
the aftercooler and lubricant cooler. often beneficial in helping to prevent corrosion from form-
3. Allow the system to drain completely. ing.
4.2.5 Water quality recommendations 4.2.5.3 Biological and organic fouling (slime)
Water quality considerations are crucial to the effective The heightened temperatures of compressor cooling
operation of a water-cooled compressor and yet are the operations help to reduce the likelihood that organic foul-
most often ignored. Premature failure of components can ing will become a major concern. In the event of an infes-
often be traced to a reduction in heat-transfer rate that tation, commercial chemical shock treatments are
has resulted from a reduced flow rate due to scale build- available to control any outbreaks.
up in water-cooling lines or the coolers themselves.
4.2.6 Seawater-cooled units
To ensure maximum life expectancy and best perfor-
mance of the compressor cooling system, refer to NOTE
Table 4-3: Water tests.
If seawater is to be used for cooling, optional
4.2.5.1 Scale copper-nickel coolers must be selected.
Scale is formed from calcium carbonate, which precipi-
tates out of water. Calcium content tends to be higher in
Water cleanliness is critical for operation of the compres-
water taken from wells than water taken from the surface
sor. A strainer must be installed in the inlet piping of the
of lakes. A higher pH value will also assist in the forma-
water system. It is also recommended that a solenoid
tion of lime scale. In all cases calcium will form scale
valve (normally closed) be installed into the water outlet
when water that has dissolved calcium is heated. It then
side of the compressor system. Consult the Sullair Ser-
forms lime-scale on surfaces such as the inside of pipes
vice Department for assistance in setting up these rec-
and the tubing that comprises water coolers. Scale for-
ommended precautionary functions. In addition, be
mation on the inside of pipes and inside of heat exchang-
aware that cleaning of coolers as a result of fouling is a
ers acts as a thermal insulator. This causes coolers to be
customer responsibility.
less effective, and piping to have reduced water flow,
making them less effective. Over time lime scale build-up Isolation valves with side drains should be installed on
can reduce water flow by 80% or greater. This renders both the inlet and outlet lines.
the cooling system ineffective and will damage the sys-
The recommended flow rate cannot be exceeded. An ori-
tem. Scale can be controlled with water treatment.
fice plate must be installed in the pipe-work at least 3.3 ft
(1 m) before the cooler. The orifice size must be calcu-
4.2.5.2 Corrosion
lated to ensure that the maximum seawater flow rate can-
As contrasted to lime scale build-up, corrosion eventually
not be exceeded. Without these precautions, the
causes a reduction in the wall thickness of pipes. High
seawater flow rate through the cooler may be several
levels of dissolved oxygen and low pH levels assist in the
Table 4-3: Water tests

Substances Test interval Acceptable concentration
Corrosivity hardness, pH, total dissolved solids, Monthly. If stable for 3 to 4 months,
Langerlier index 0 to 1
temperature at inlet, alkalinity analyze quarterly.
Iron Monthly < 2 ppm
Sulphate Monthly < 50 ppm
Chloride Monthly < 50 ppm
Nitrate Monthly < 2 ppm
Silica Monthly < 100 ppm
Desolated oxygen Daily. If stable, analyze weekly. 0 ppm (as low as possible)
Oil & grease Monthly < 5 ppm
Ammonia Monthly < 1 ppm
02250247-571 R04
times the recommended maximum, which will lead to weather conditions can be extreme such that direct rain
rapid system failure. or snow may fall on the unit, it should be in a fully
enclosed room or building.
Orifice diameter for maximum seawater
flow (or 40 US gal/min [152 L/min]) If installed under a shelter, air-cooled machines must be
Seawater
pressure in mm positioned in a way that prevents air recirculation (i.e.,
hot exhaust being allowed back to the system air inlet).
25 psi (1.7 bar) 0.675 17
In installations that include more than one compressor,
35 psi (2.4 bar) 0.62 16
hot air exhaust should not be directed toward the fresh
45 psi (3.1 bar) 0.58 15 air intake of the second unit or an air dryer.
55 psi (3.8 bar) 0.55 14
A standard machine installed outside must not be started
65 psi (4.5 bar) 0.53 13.5 or run if the ambient temperature in and around the com-
75 psi (5.2 bar) 0.51 13 pressor drops or may drop below 40°F (4.4°C).
For installation in a below freezing climate, a low ambient
No oil cooler manufacturer can guarantee that its prod- option with heat tracing and a separator/sump tank
ucts will have an indefinite life and for this reason, we heater must be installed.
suggest that the cooling system be designed to minimize
any damage caused by oil cooler leaking. This can be
achieved as follows: 4.4 Service air piping
• The oil pressure should be maintained at a pres- Review carefully the total air system before installing a
sure higher than the seawater pressure. In the new compressor. Items to consider for the total air sys-
event of a leak occurring, the oil will be prevented tem include liquid carryover, pipe sizing, and the use of
from becoming contaminated. an auxiliary receiver tank. The installation of a drip leg or
• When the hydraulic system is not in use, the cool- multiple drip legs, installation of a line filter(s) and the
ers should be isolated from incoming seawater installation of isolation valve or valves. These consider-
under pressure. ations are important to ensure a safe and effective sys-
tem. See Figure 4-1.
• The seawater outlet pipe from the cooler should
have an open run to waste piping.
NOTE
4.3 Outdoor installation (sheltered) Discharged air contains a very small amount of
compressor lubricating oil, and care should be
Many times a compressor must be installed outside due to
taken to ensure that this oil would not interfere
available space or other job site conditions. When this is nec-
with downstream equipment. Downstream fil-
essary, there are certain items that should be incorporated
ters and an air dryer can remove any carryover.
into the system to help ensure trouble-free operation. The
unit must be purchased with a TEFC motor and NEMA 4
controls, which are watertight.
NOTE
Variable speed drive compressors are NEMA 12
rated and must not be installed outside or
exposed to the elements.
The compressor should be on a concrete pad, which is

designed to drain water away from it. If the concrete pad
is sloped, then the compressor must be mounted so that
it is level. The base or skid must be fully supported where
it contacts the concrete pad.
A weatherhood option should be selected to prevent
direct rain and snow from falling on the unit. If local
02250247-571 R04
4.4.1 Pipe sizing

WARNING Pipe should be sized at least as large as the discharge
connection of the compressor. Piping and fittings should
The use of plastic bowls on line filters and other all be suitably rated for the discharge pressure.
plastic airline components without metal guards
can be hazardous. Synthetic coolants or the 4.4.2 Use of auxiliary receiver tank
additives used in mineral oils can alter their An auxiliary receiver tank should be used in cases where
structural integrity and create hazardous condi- large demand swings are expected. Isolation Valve(s) If
tions. Metal bowls should be used on any pres- isolation of the compressor from the service lines is
surized system for safety concerns. required, isolation valves should be installed close to the
discharge of the compressor. They should be installed
“The Plastic Pipe Institute recommends against with drip legs that drain sloping downward from the base
the use of thermoplastic pipe to transport com- in order to drain properly. Install a vent to the piping
pressed air or other compressed gases in downstream of the compressor outlet connection.
exposed above ground locations, e.g. in
exposed plant piping.”1 When two compressors are operated in parallel, provide
an isolation valve and a drain trap for each compressor
Sullube® should not be used with PVC piping before the common receiver.
systems. It may affect the bond at cemented
joints. Certain other plastic materials may also A built-in aftercooler reduces the discharge air tempera-
be affected. ture below the dew point. For most ambient conditions,
1Plastic
considerable water vapor is condensed. To remove the
Pipe Institute, Recommendation B. Adopted condensation, each compressor with built-in aftercooler
January 19, 1972.
is supplied with a combination condensate separator/
1. Sullair compressor 4. Sullair filter 7. Standard gate valve

2. Sullair dryer 5. Water leg drain valve A1. Customer connections
3. Shut-off gate valve 6. By-pass gate valve A2. Customer connections
Figure 4-1: Service air piping—typical installation
02250247-571 R04
trap. A drain line should be installed on the condensate voltage drops may impair the performance of the com-
drain. pressor. Cable sizes may vary considerably so the mains
terminals will accept up to 50 mm2 (1 awg) (37/4 Sk &
NOTE 50/60 H) and up to 90 mm2 (3/0 awg) (55/75 k & 75/
100 H) cable.
For low-volume systems that do not require an Feeder cable connections to incoming terminals L1-L2-
auxiliary separator/sump, compressor response L3 should be tight and clean.
time may need to be adjusted. Consult the Sul-
lair Service Department for assistance. The applied voltage must be compatible with the motor
and compressor data plate ratings.
A starter hole is provided for incoming power connection.
4.5 Coupling alignment check If it is necessary to make a hole in the control box in a dif-
ferent location, care should be taken to not allow metal
No coupling alignment is required.
shavings to enter the starter and other electrical compo-
nents within the box. If another hole is used, the original
hole must be blocked off.
4.6 Fluid level check
The air compressor is shipped with the proper amount of
fluid installed. However, it is necessary to check the fluid DANGER
level at the time of installation and during continued oper-
ation of the compressor. The fluid level is to be checked Lethal shock hazard inside. Disconnect all
when the compressor is in the SHUT DOWN mode (fluid power at source before opening or servicing.
level may not be visible when operating), and by looking
at the sight glass on the separator/sump tank. To be able
to see the fluid level it may be necessary to start the 1. Check incoming voltage. Be sure that the incom-
machine and build the separator/sump tank pressure up ing voltage is the same voltage that the compres-
to 10/20 psi and then shut down. Wait a few minutes to sor was wired for.
check oil level. If no fluid level is seen in the sight glass 2. Check motor starter and overload heater sizes.
add fluid to the center of the glass. Do not overfill in any 3. Check all electrical connections for tightness.
case. When a complete fluid change is performed, fill the
separator/sump tank to the maximum allowable fluid 4. Check the electrical controls by disconnecting
level, which is center of the sight glass. the three (3) motor leads from the starter. Ener-
gize the control circuits by pushing the Start but-
ton and check all protective devices to be sure
4.7 Electrical preparation that they will de-energize the starter coil when
tripped.
Interior electrical wiring is performed at the factory.
Required customer wiring should be done by a qualified 5. Reconnect the three (3) motor leads and jog the
electrician in compliance with OSHA, National Electric motor for a direction of rotation check, as
Code and/or any applicable local electrical code concern- explained in Section 4.8: Motor rotation direction
ing isolation switches, fused disconnects, etc. Sullair pro- check on page 59.
vides a wiring diagram for use by the installer. An
electrical check should be made to help assure that the
first start-up will be trouble-free. The compressor and 4.8 Motor rotation direction check
drive should be properly grounded/earthed in accordance Motor rotation check must be made at compressor start-
with Local and National Code requirements. up. The compressor can be damaged if it runs in the
wrong direction for more than a few seconds. Motor rota-
Installation of this compressor must be in accordance tion can be viewed through the opening in the drive
with recognized electrical codes and any local Health and adapter housing. After the electrical wiring has been
Safety Codes. done, it is necessary to check the direction of the motor
Feeder cables should be sized by the customer/electrical rotation. Pull out the EMERGENCY STOP button and
contractor to ensure that the circuit is balanced and not press once, quickly and in succession, the Start and Stop
overloaded by other electrical equipment. The length of buttons. This action will bump start the motor for a very
wiring from a suitable electrical feed point is critical as short time. When looking at the motor from the end oppo-
02250247-571 R04
site the compressor unit, the shaft should be turning bump start the motor for a very short time. If motor rota-
clockwise. If the reversed rotation is noted, disconnect tion is correct there will be immediate pressure shown. If
the power to the starter and exchange any two of the no pressure is present, reverse rotation is occurring. Dis-
three power input leads, then re-check rotation. A "Direc- connect the power to the starter and exchange any two of
tion of Rotation" decal is located on the motor drive hous- the three power input leads. Recheck rotation as outlined
ing to show proper motor/compressor rotation. An above.
alternative to this procedure is to set the STS monitor to
Fan motor rotation should also be checked. It should
display the P1 separator/sump tank pressure. Pull out the
rotate counter-clockwise when viewing the fan motor
EMERGENCY STOP button and press once, quickly and
from the backside of the motor.
in succession, the Start and Stop buttons. This action will
A. Fan motor rotation direction

B. Main motor rotation direction
Figure 4-2: Motor rotation direction
02250247-571 R04
Notes:
02250247-571 R04
SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual 5: Controller
Section 5
Controller
5.1 Controller layout
Figure 5-1: Controller layout and button functions
Key Description Function

Push to start the compressor. Can also be used to reset
1 Start button maintenance and warning messages while the compressor
is running.
Push to stop the compressor. Can also be used to clear
2 Stop button
fault messages when the compressor is stopped.
02250247-571 R04
5: Controller SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual
There are four status indicators that identify the current

operational status of the machine:
• Power-On Indicator (Blue) – Lights when power is
applied to the controller. It will blink slowly to indicate
that Automatic Restart After Power Failure is enabled.
• Automatic or Manual Run Mode Indicator (Green) –
Lights whenever the compressor is set to start and run
automatically. The light is constant whenever the
motor is running. The light will blink slowly if the com-
pressor motor is stopped while in Automatic Mode as
3 Indicator LEDs a warning that the machine may restart at any time.
The light may blink rapidly if a machine start is immi-
nent.
• Maintenance or Warning Indicator (Amber) - Lights
when recommended maintenance or service warning
is issued. In most cases, the machine will continue to
operate normally.
• Fault Indicator (Red) - Lights when a compressor fault
has occurred. The light remains steady and the com-
pressor remains inoperative until the fault condition is
corrected.
Read the QR code with the camera on your smartphone or
4 QR Code
tablet to access user manuals on your device.
Displays operating parameters and compressor information.
5 Touch screen display Provides interface between the user and the compressor
controller.
6 Menu button Returns to the main menu screen.
Use this port to upload information to the STS controller
7 USB Port
using a flash drive.
Used to stop the compressor immediately. The E-stop but-
8 Emergency Stop (E-stop) button ton is logged as a fault and should only be used when
essential.
02250247-571 R04
5.2 Home page
1. Main menu button (red square)
Figure 5-2: Home page—Analog/Digital Panel screen (default)
For a complete overview of the controller, see the Sullair • The gauge area below shows discharge tem-
Touch Screen (STS) Controller User Manual (P/N perature, discharge pressure, and sump pres-
02250241-178 R00) for more information. sure as analog gauges.
The Analog/Digital Panel screen is the default screen You can change the units of measure for pressure and
for the home page. This screen is divided into two main temperature on the User Preferences page (see Section
sections: 5.4 on page 66).
• The status area at the top shows the load and You can access the User Preferences page by pressing
run times, starts and cycles, and message the main menu button in the lower left corner of the
related to the current status (state and mode). screen, then selecting System Information, and then
selecting User Preferences. (See Section 5.5: Menu
hierarchy on page 67 for the complete menu structure.)
02250247-571 R04
5.3 Main Menu page
Figure 5-3: Main menu page
From the main menu, you can navigate to other pages You can reach the main menu by pressing the main
that allow you to: menu (home) button on the home page, or by pressing
the back arrow from other menus until you return to the
• View and change configuration settings
main menu.
• View reports, charts, and graphs
• The back arrow always takes you back one
• View fault and warning history
page.
• View maintenance information
• If you’re on the main menu page, the back
• Login in as an administrator arrow will return you to the home page.
• And perform other administrative functions • The main menu (home) button always takes
To view the complete menu hierarchy, see Section 5.5 you back to the home page.
on page 67.
02250247-571 R04
5.4 User Preferences page
Figure 5-4: User preferences page
The following user interface options are available under • Note: The display language changes
User Preferences: immediately upon selection.
• Pressure Units. The user can choose between • Home Screen. The user can choose between
PSI, BAR, and k/Pa as the unit of measure for Analog/Digital Panel, Mimic Panel, or Multi
pressure. Gauge for the home page screen. See the Sul-
lair Touch Screen (STS) Controller User
• Temperature Units. The user can choose
Manual (P/N 02250241-178 R00) for more
between Fahrenheit (F) and Celsius (C) as the
information.
unit of measure for temperature.
You can access the User Preferences page by selecting
• Language. The user can choose between
System Information from the main menu and then
English, Spanish, French, Portuguese, Russian
selecting User Preferences.
and Chinese for the display language.
02250247-571 R04
5.5 Menu hierarchy
Figure 5-5: Sullair touch screen controller menu hierarchy
02250247-571 R04
5.6 AirLinx™ remote monitoring .

Table 5-1: PWR LED definitions (LED #1, red/green)
(optional)
Sullair AirLinx allows remote monitoring of your compres- Power status LED state
sor. AirLinx provides access to all monitored compressor LMU off Off
readings—power, pressure, flow and more—24 hours a U-boot Red solid
day, seven days a week, on any device that can load a
Kernel start Green solid
browser.
LMU on Red solid
To sign up for an AirLinx account, please visit sullair.com
or e-mail CRC@sullair.com for a digital sign-up form. If Table 5-2: GPS LED definitions (LED #4, red/green)
you need connection assistance, please call 888-320-
8332 or send an e-mail to Support@opc247.com. GPS status LED state
U-boot Red solid
5.6.1 Troubleshooting AirLinx Kernel start Green solid
communications
GPS off Off
AirLinx consists of an antenna installed on the outside of
the compressor's enclosure and an M70 modem installed GPS on Green slow blinking
inside the compressor's control cabinet. The LED lights GPS time sync Green fast blinking
on the modem indicate the current status of the compres- GPS fix Green solid
sor. The definitions of these lights are shown in Table 5-1,
Table 5-2 and Table 5-3. Table 5-3: COMM LED definitions (LED #5, red/green)
Comm status LED state
Modem off Off
Comm on—searching Slow blinking
Network available Fast blinking
Registered (no inbound Alternates between solid and
acknowledgement) fast blink every one second
02250247-571 R04
Notes:
02250247-571 R04
SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual 6: Maintenance
Section 6
Maintenance
6.1 General “Excessive compressor fluid consumption” for a probable
cause and remedy.
WARNING After a routine start has been made, observe the control-
ler display and be sure it monitors the correct readings
for their particular phase of operation. After the compres-
Before any repairs are attempted, refer to Sec-
sor has warmed up, it is recommended that a general
tion 1: Safety before proceeding.
check on the overall compressor be made to assure that
the compressor is running properly.
As you proceed in reading this section, it will be easy to
see that the Maintenance Program for the air compressor
is quite simple. The use of the service indicators provided 6.3 Maintenance after initial 50 hours
for the fluid filter, air filter and fluid separator will alert you of operation
when service maintenance is required. When the WS After the initial 50 hours of operation, a few maintenance
Controller™ display indicates service, maintenance for requirements are needed to clean the system of any for-
that specific item is required. See instructions for each eign materials. Perform the following maintenance opera-
item in Section 6.6: Filter maintenance on page 71. tions to prevent unnecessary problems:
• Clean the return line strainer. Refer to Discharge,
WARNING separator/sump and piping system of the Parts
Manual for location.
• Clean the return line orifice.
6.4 Maintenance every 2000 hours

After 2000 hours of normal operation, or at a minimum
High-pressure hazard! every six months, it will be necessary to perform the fol-
lowing:
• Do not remove caps, plugs, and/or other
components when compressor is running or • Clean the return line strainer. Refer to Discharge,
pressurized. Stop compressor and relieve all separator/sump and piping system of the Parts
internal pressure before doing so. Manual for location.
• Failure to comply could result in death or • Replace the fluid filter element.
serious injury. • Pull oil sample for analysis.
• Check air filter. Change if necessary.
6.2 Daily operation

Prior to starting the compressor, it is necessary to check 6.5 Fluid maintenance
the fluid level in the separator/sump tank. Should the Drain the separator/sump tank and change the compres-
level be low, simply add the necessary amount. If the sor fluid using instructions shown in Section 3.7: Lubrica-
addition of fluid becomes too frequent, a simple problem tion change recommendations and maintenance, fluid on
has developed which is causing this excessive loss. See page 30
Section 6.13.2: Troubleshooting guide on page 74 under
02250247-571 R04
6: Maintenance SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual
6.6 Filter maintenance 5. Install the element into the filter canister.
6. Screw the canister to the filter head. Tighten to
30 to 35 ft•lb (40.5 to 47.3 N·m).
7. Restart compressor and check for leaks.
1. Housing 3. Cover
1
2. Element 4. Vacuator valve
1Replacement
air filter element kit P/N: 02250215-315
1. Fluid filter assembly
Air filter assembly P/N: 02250214-305
2. Element1
3. Body Figure 6-2: Air filter assembly
1Fluid
filter replacement kit: P/N: 02250168-084
Fluid filter assembly P/N: 02250197-189
Figure 6-1: Fluid filter assembly Refer to Figure 6-2. Air filter maintenance should be per-
formed when the maintenance gauge shows red with the
compressor running full load, or once a year, whichever
comes first. If the filter needs to be replaced, order a
Refer to Figure 6-1. Replace your fluid filter element replacement element. Below you will find procedures on
under any of the following conditions, whichever occurs how to replace the air filter element.
first:
• As indicated by the STS Controller. 6.6.2 Air filter element replacement
• Every fluid change. 1. Clean the air filter’s exterior housing.
2. Release the hold-down clips and remove the end
6.6.1 Fluid filter element replacement cover.
Refer to Figure 6-1.
3. Remove the air filter element by pulling it out of
1. Using a wrench, remove the filter canister. the housing.
2. Remove and dispose of filter element. Observe 4. Clean the housing interior with a damp cloth. Do
all laws and regulations for filter disposal. not blow dirt out with compressed air.
3. Clean gasket seating surface. 5. Replace the element.
4. Apply a light film of fluid to the element seal. 6. Reassemble in the reverse order.
02250247-571 R04
6.7 Separator maintenance Refer to Figure 6-3. The separator element must be
changed when indicated by the STS Controller, or once a
Replace the separator element when indicated by the
year, whichever occurs first. Follow the procedure
STS Controller or after one (1) year, whichever comes
explained below for separator element replacement.
first. The separator element must be replaced. Do not
attempt to clean the separator element.
WARNING
6.7.1 Separator element replacement
High-pressure hazard.
Relieve all pressure from the separator/sump
tank and all compressor lines.
1. Disconnect all piping connected to the separator

cover plate.
2. Loosen and remove thetwelve (12) hex head
capscrews(⅝ in × 2½ in) and lock washers from
the cover plate.
• Always discard the lock washers.
3. Lift the cover plate from the separator/sump tank.
4. Remove the separator element.
5. Scrape any old gasket material from the under-
side of the cover plate and the separator/sump
tank flange
• Do not let any scraps fall into the separator/
sump tank.
6. Inspect the separator/sump tank for rust, dirt, etc.
7. Insert a new separator element into the separa-
tor/sump tank taking care not to dent the element
against the tank opening.
• Do not remove the staples from the separator
element.
• Do not use any type of gasket eliminator.
8. Replace the cover plate, lock washers and cap-
screws. Torque to140 ft·lbs. (190 N·m).
• Always use new lock washers.
9. Verify continuity between the separator element
1. Capscrew
and the separator/sump tank.
2. Lock washer
10. Reconnect all piping.
3. Cover plate • The fluid return line tube should extend to ⅛″
4. Separator element1 above the bottom of the separator element to
5. Separator/sump tank flange ensure proper return line flow.
6. Separator/sump tank 11. Clean the return line strainer before restarting
the compressor.
7. Fluid drain
1
Separator element replacement kit P/N: 02250218-061
Separator element P/N: 02250214-961
Figure 6-3: Separator element assembly
02250247-571 R04
6.8 Oil return / sight glass ter assembly No. 02250117-782, and use the following
maintenance instructions as a guide.
1. Disconnect the tube at bottom of sight glass.
2. Unscrew the sight glass assembly where the
elbow fitting joins the strainer/filter.
1
3. Remove used filter assembly, and replace with
new assembly.
2 4. Inspect and clean the orifice inside the sight
glass blocks. The orifice must be removed with
3 an allen wrench.
5. Coat/lubricate the O-rings with silicone grease.
4
6. Reattach the connectors to the sight glass/orifice
blocks.
5 6.9 Pressure regulator adjustment
1. To separator/sump tank
2. Male tube connector
3. 90° pipe elbow
4. Filter assembly1
5. Sight glass / orifice block 2
6. Brass plug orifice 1
7. Female tube connector
8. To unit
1
Oil return filter replacement kit P/N: 02250117-782 1. Locking nut
Figure 6-4: Oil return / sight glass 2. Adjustment screw
Figure 6-5: Regulator adjustment
Refer to Figure 6-4. The oil return/sight glass subassem-

bly is attached to the side of the separator tank. Oil
Refer to Figure 6-5. Start the compressor and adjust the
return/sight glass maintenance should be performed on a
service valve to maintain service air pressure approxi-
routine basis parallel to that of the fluid filter, or as indi-
mately at 1 psi over rated pressure. Turn the inlet valve
cated in the troubleshooting section of this manual. The
regulator adjusting screw until air just begins to escape
maintenance on an oil return/sight glass is mainly con-
from the control air orifice, located at the bottom of the
cerned with the condition of the filter assembly. Order fil-
regulator. Lock the adjusting screw in place with the lock-
nut. The regulator is now properly set.
02250247-571 R04
6.10 Water condensate drain coupling alignment unnecessary. The coupling is a jaw
maintenance type in shear. If the elastomeric element requires
replacement due to wear or breakage, order replacement
If your compressor is fitted with the standard solenoid element no. 02250152-670, and follow the following
condensate drain valve, it is necessary to periodically steps.
clean the strainer. Remove the hex cap from the strainer
and remove the strainer screen. Clean the screen and 1. Remove the protective grill from the adapter
reinstall. If the screen is damaged, the strainer assembly housing.
must be replaced (P/N 241772). 2. Loosen the retaining screw located on the outer
sleeve. Slide the sleeve to one side, exposing
the coupling element.
6.11 Control line strainer 3. Unwrap the coupling element from the coupling
The regulator and solenoid valve(s), which control the jaws.
compressor, are protected by a strainer. Every 12 months
4. Install the new element by wrapping it around the
it is necessary to clean the strainer. Remove the hex cap
jaws, engaging the cogs on the element into the
from the strainer and remove the strainer screen. Clean
jaws.
the screen and reinstall. If the screen is damaged, the
strainer assembly must be replaced (P/N 241772). 5. Reinstall the outer sleeve and the protective grill.
Secure the outer sleeve by tightening the two
screws to 45 in·lbs (5 N·m).
6.12 Shaft coupling maintenance
The compressor unit and motor are rigidly connected via
a mounting adapter housing. This arrangement makes
6.13 Troubleshooting
6.13.1 Introduction A detailed visual inspection is worth performing for
The information contained in the Troubleshooting Guide almost all problems and may avoid unnecessary addi-
has been compiled from field report data and factory tional damage to the compressor. Always remember to:
experience. It contains symptoms and usual causes for • Check for loose wiring.
the described problems. However, DO NOT assume that
• Check for damaged piping.
these are the only problems that may occur. All available
data concerning a problem should be systematically ana- • Check for parts damaged by heat or an electrical
lyzed before undertaking any repairs or component short circuit, usually apparent by discoloration or a
replacement procedures. burnt odor.
Should your problem persist after making the recom-
mended check, consult your nearest Sullair representa-
tive.
6.13.2 Troubleshooting guide
Symptom Probable cause Remedy

Main disconnect switch open Close switch.
Line fuse blown Replace fuse.
Compressor will not Reset. Should trouble persist, check whether
start Motor starter overload tripped
motor starter contacts are functioning properly.
Check voltage. Should voltage check low, con-
Low incoming line voltage
sult power company.
02250247-571 R04

Check power supply for 24V DC output.
Loss of control voltage
Replace power supply if necessary.
Low incoming voltage Consult power company.
Reset. If trouble persists, check that line pres-
sure does not exceed maximum operating pres-
Excessive operating pressure
sure of the compressor (specified on
nameplate).
Separator requires mainte-
nance indicated by STS Con- Replace separator.
troller™
Machine programmed for
Reprogram using STS Controller.
wrong pressure setting
Regulator valve should cause inlet valve to
Defective regulator valve close when the pressure switch contacts open.
Repair if defective.
Blowdown valve should exhaust separator/
Compressor shuts sump tank pressure to 18 psig (1.2 bar) when
Defective blowdown valve
down with air demand maximum operating pressure is reached.
present Repair if defective.
Cooling water temperature too Reduce water temperature to 85°F (29.4°C) or
high less. Water-cooled only.
Check water lines and valves (water-cooled
Cooling water flow insufficient
only).
Clean tubes. If plugging persists, install water
Cooler plugged
conditioner (water-cooled only).
Cooling air flow restricted Clean cooler and check for proper ventilation.
Ambient temperature is too
Provide sufficient ventilation.
high
Low fluid level Add fluid.
Clogged filter Change the fluid filter element.
Thermal valve not functioning
Replace element.
properly
Water flow regulating valve not
Change (water-cooled only).
functioning properly
Air demand is too great Check service lines for leaks or open valves.
Check the filter indicator and inspect and/or
Dirty air filter
change element if required.
Inlet valve bleed orifice Ensure control line bleed orifice located inside
Compressor will not plugged inlet valve is not plugged.
build full discharge Pressure regulator out of Adjust regulator according to control adjust-
pressure adjustment ment instructions in the Maintenance section.
Defective pressure regulator Replace regulator.
Check that the valve closes when energized.
Defective unload solenoid
Replace the coil or the complete valve if defec-
valve
tive.
02250247-571 R04

Leak in control system caus-
Check for leaks.
ing loss of pressure signals
Remove the intake hose and check for inlet
Inlet valve stuck open
valve operation.
Defective unload solenoid Check that the valve is open when de-ener-
Line pressure rises
valve gized. Replace if necessary.
above unload pressure
set-point Clean strainer (screen and O-ring replacement
Plugged control line strainer
kit available).
Check that separator/sump tank pressure is
exhausted to the atmosphere when the sole-
Defective blowdown valve
noid valve opens. Repair or replace if neces-
sary (kit available).
Clean strainer (screen and O-ring replacement
Clogged return line or orifice kit available).
Clean orifice.
Separator element damaged or
Change separator.
Excessive compres- not functioning properly
sor fluid consumption Leak in the lubrication system Check all pipes, connections and components.
Excess fluid foaming Drain and change.
Drain and change. Check that the compressor
Fluid level too high temperature has not dropped below 170°F
(76.7°C).
Pressure relief valve Defective pressure relief valve Replace.
opens repeatedly Plugged separator Check separator differential.
Plugged strainer in moisture Clean and service strainer located in the line off
drain line the bottom of the water separator.
Remove the water vapor from compressed air
prior to distribution through the air system.
Check operation of aftercooler and moisture
separator. Install a compressed air dryer sized
Water vapor condensation for the flow and dryness level required. (Note:
from cooling and compression Filters may also be required to remove particu-
occurs naturally lates, liquid oil aerosols or for oil vapor removal.
Liquid water in com- Change cartridges as recommended by the fil-
pressed air lines ter manufacturer). Check all drain traps rou-
tinely to insure their proper operation. Maintain
them regularly.
Ensure valve opens and closes as signaled by
Defective drain solenoid valve
the STS Controller™.
Check STS Controller control drain interval and
drain time, and adjust accordingly. High humid-
Inadequate drain timer settings
ity conditions require longer drain times or more
frequent openings.
02250247-571 R04
Notes:
02250247-571 R04
Sullair, LLC
1 Sullair Way
Michigan City, IN 46360 USA
www.sullair.com
1-800-SULLAIR (USA only)
1-219-879-5451 (non-USA)
Information and specifications are subject to change without prior notice.


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USER MANUAL

Industrial Air Compressor

Subject to EAR, ECCN EAR99 and related export control restrictions.

Sullair Training Department

Subject to EAR, ECCN EAR99 and related export control restrictions.

Section 3: Specifications .......................................................................................26

3.12 Piping & instrumentation, air-cooled—SN55S, SN75S ................................................................. 39

Section 4: Installation ............................................................................................ 54

Section 5: Controller .............................................................................................. 62

Section 6: Maintenance ......................................................................................... 70

6.7 Separator maintenance ................................................................................................................. 72

1.2 Personal protective equipment

1.8 Electrical shock

1.12 Safety warnings

1. Compressor unit 8. Moisture separator

Figure 2-1: Overall component layout, air-cooled model

1. Compressor unit 8. Moisture separator

Figure 2-2: Overall component layout, water-cooled model

1. Compressor unit 4. Moisture separator

Figure 2-3: Air-cooled, cooling / lubrication and discharge system

1. Compressor unit 4. Moisture separator

Figure 2-4: Water-cooled, cooling / lubrication and discharge system

Automatic operation compressor to shutdown (time delayed) when no compressed air

1. Air inlet 5. Air outlet

Figure 2-5: Standard pneumatic control system

2.7 Air inlet system, functional

1. Air inlet filter 4. Separator/sump tank

Figure 2-6: Air inlet system

3.2 Table of specifications—SN55V, SN75V

3.3 Compressor specifications

3.4 Motor specifications

Do not mix different types of fluids. Contamination of

When ambient conditions exceed those noted or if condi-

3.6 Application guide

Figure 3-1: Fluid fill location

3.7 Lubrication change recommendations and maintenance, fluid

SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual

SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual

SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual

14 VALVE, RELIEF 1 T1 WET DISCHARGE TEMPERATURE

SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual

5 MOTOR 1 OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND

SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual

7 COOLER,AIR 1 P2 PACKAGE OUT

8 COOLER,OIL 1 P3 SPIRAL VALVE CONTROL PRESSURE

9 VALVE,THERMAL 1 SOL1 LOAD/UNLOAD SOLENOID VALVE

10 ORIFICE 5 SOL4 MEC/SEQUENCING/FULL LOAD SOLENOID

11 SIGHTGLASS 1 SOL5 COMBO DRAIN/JZL DRAIN SOLENOID

12 STRAINER 2 T1 DISCHARGE TEMPERATURE

SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual

SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual

7 COOLER, AIR 1 P2 LINE PRESSURE

8 COOLER, OIL 1 SOL1 LOAD/UNLOAD SOLENOID VALVE

9 ORIFICE 3 SOL5 COMBO DRAIN/ZL DRAIN SOLENOID VALVE

10 SIGHTGLASS 1 T1 WET DISCHARGE TEMPERATURE

SN55, SN55S, SN55V, SN75, SN75S, SN75V User Manual

14 VALVE, RELIEF 1 Tubing color Purpose

02250242-364 R04 (sh1)