AS45-75
`
Thank you very much for purchasing and
using stationary screw compressors
manufactured by Sullair Asia
We hope that our stationary screw compressors of all the sizes will play the
expected role in your work.
Please read through this manual carefully before you and your employees operate
and maintain the stationary screw compressors.
Sullair Asia reserves the right to make continuous research and improvement on
its products, and has no obligations of modifying and improving the products
delivered by it before.
Compressor Model:
Compressor Serial Number:
I
II
Foreword
This manual provides the instructions on the construction, functions, use and
maintenance of all the systems of AS45-75 stationary screw compressors.
Before installing and operating this compressor, users should read through this
manual carefully, and should not start the operation and maintenance of the unit
until they have a full understanding of the construction and functions.
It is necessary to use the special fluid supplied by Sullair for the compressor. It is
prohibited to use the fluids of different brands.
We remind the users that due to continuous improvement of the product
construction, the information provided in this manual may not completely reflect
the actual details of the product.
If there is any point not mentioned in this manual and the user has some unclear
points during the operation and use, you can contact the local dealer of Sullair or
the After-sales Marketing Dept. of Sullair.
―Editor
January 2016
III
Environment-friendly Use Instructions
There are no hazardous substances used in this product during the
manufacturing process which could directly affect human body and the environment.
We ensure you that there is no chance of hazardous leakage, discharge and safety
issues during the daily regular use of this product.
In order to protect our environment, Sullair strongly recommends and encourages
customers to carefully handle lubricant, storage battery and other parts which may
indirectly affect creatures and environment when the product is on maintenance or not
needed or the product life ends. Controllers and other electronic parts contained in this
product can’t be abandoned or buried carelessly and should be returned to the
qualified manufacturer to recycle and dispose. Customers should obey related laws
and regulations on recycling and disposal of electrical and electronic parts in this
product.
IV
Table of Contents
Chapter I Safety ..................................................................................................................................................... 7
1.1 Overview ................................................................................................................................................. 7
1.2 Safety Equipment .................................................................................................................................... 7
1.3 Fire and Explosion Protection ................................................................................................................. 7
1.4 Moving Parts ........................................................................................................................................... 7
1.5 Hot Surfaces, Sharp Edges and Corners .................................................................................................. 8
1.6 Toxic and Irritative Substances ............................................................................................................... 8
1.7 Electric Shock Protection ........................................................................................................................ 8
1.8 Hoisting and Transportation .................................................................................................................... 8
1.9 Miscellaneous .......................................................................................................................................... 9
Chapter II Compressor Structure........................................................................................................................... 4
2.1 Overview ................................................................................................................................................. 4
2.2 Air inlet system......................................................................................................................................11
2.2.1 Working procedure of air inlet system ...................................................................................................11
2.2.2 Air filter .................................................................................................................................................11
2.2.3 Air inlet valve ........................................................................................................................................11
2.3 Air discharge system .............................................................................................................................12
2.3.1 Working procedure of air discharge system .................................................................................. 12
2.3.2 Minimum pressure valve ............................................................................................................... 12
2.3.3 Automatic blowdown valve .......................................................................................................... 12
2.3.4 Relief valve ................................................................................................................................... 12
2.4 Fluid loop system...................................................................................................................................12
2.4.1 Working procedure of fluid loop system ....................................................................................... 12
2.4.2 Fluid filter ..................................................................................................................................... 12
2.4.3 Oil return pipe ............................................................................................................................... 13
2.5 Cooling system ......................................................................................................................................13
2.6 Fluid/air separator ..................................................................................................................................13
2.6.1 Function of fluid/air separator ....................................................................................................... 13
2.6.2 Filter element replacement ............................................................................................................ 13
2.6.3 Oil filling port and sight glass ....................................................................................................... 13
2.7 Air capacity adjustment system .............................................................................................................13
2.7.1 Line frequency model ................................................................................................................... 13
2.7.2 VSD model.................................................................................................................................... 14
2.8 Microprocessor controller......................................................................................................................14
Chapter III Installation of Compressor ................................................................................................................15
3.1 Machine Installation ..............................................................................................................................15
3.2 Ventilation and temperature reducing ....................................................................................................15
3.3 Check fluid level....................................................................................................................................15
3.4 Rotation Direction of Motor ..................................................................................................................15
3.4.1 Line frequency model ................................................................................................................... 15
3.4.2 VSD model.................................................................................................................................... 15
Chapter IV Compressor Operation ....................................................................................................................18
4.1 Safety Operation Procedure ...................................................................................................................18
4.2 Preparation before Initial Starting .........................................................................................................18
4.3 Normal Operation ..................................................................................................................................18
4.4 Stop ........................................................................................................................................................18
Chapter V Maintenance and Service ...................................................................................................................19
V
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
Overview ...............................................................................................................................................19
Daily Maintenance .................................................................................................................................19
Service After 50 Operation Hours .........................................................................................................19
Service After Every 1000 Operation Hours...........................................................................................19
Changing Fluid ......................................................................................................................................19
Maintenance Of Fluid Filter .................................................................................................................. 20
Maintenance Of Air Filter ...................................................................................................................... 20
Maintenance of Fluid/Air Separator ......................................................................................................22
Maintenance Of Minimum Pressure Valve ...........................................................................................23
Maintenance of Solenoid Valve.............................................................................................................23
Maintenance of Pressure Regulator .......................................................................................................23
Installation and Maintenance of Coupling .............................................................................................24
Maintenance Of The Motor For Sullair Compressor ............................................................................. 25
Chapter VI Wiring Diagram .................................................................................................................................28
6.1 Wiring diagram of the unit.....................................................................................................................28
6.2 Wiring diagram of the VSD unit............................................................................................................29
Chapter VII Troubleshooting ...............................................................................................................................30
7.1 Overview ...............................................................................................................................................30
7.2 Possible compressor fault and actions are listed in the following table.................................................30
Chapter VIII Spare Parts List ................................................................................................................................32
Chapter IX Parts List ............................................................................................................................................33
9.1 Motor - Compressor System(AS4500-7500—Line Frequency Model) .................................................33
9.2 Motor - Compressor System(AS4500-7500—VSD Model)..................................................................39
9.3 Air Inlet System(AS4500-7500—Line Frequency/VSD Model) ..........................................................43
9.4 Fluid Loop System(AS4500-7500— Line Frequency/VSD Model) .....................................................45
9.5 Cooling Fan System(AS4500-7500—Line Frequency/VSD Model) .................................................... 47
9.6 Fluid/air Separation System(AS4500-7500— Line Frequency/VSD Model) .......................................49
9.7 Air Discharge System(AS4500-7500—Line Frequency/VSD Model) ................................................. 53
9.8 Control System(AS4500-7500—Line Frequency Model) ..................................................................... 55
9.9 Control System(AS4500-7500—VSD Model) ...................................................................................... 57
9.10 Air-cooled Acoustical Enclosure System(AS4500-7500—Line Frequency Model) .............................59
9.11 Air-cooled Acoustical Enclosure System(AS4500-7500—VSD Model) ..............................................61
9.12 Decal System(AS4500-7500—Line Frequency Model) ........................................................................63
9.13 Decal System(AS4500-7500—VSD Model) .........................................................................................65
VI
AS45-75 Series Screw Compressor Operation Manual
Chapter I Safety
Chapter I Safety
1.1
Overview
Sullair designs and manufactures its products so that they can be operated safely. However, the
responsibility for safe operation rests with those who use and maintain these products. The following safety
precautions are offered as a guide, which, if conscientiously followed, will minimize the possibility of
accidents throughout the useful life of this equipment.
Only those who have been trained and delegated to do so, and who have read and understood this manual
should operate the air compressor. Failure to follow the instructions, procedures and safety precautions in
this manual can result in accidents and even injuries or death. Read this manual prior to start-up. Never
start the air compressor unless it is safe to do so. Do not attempt to operate the compressor with a known
unsafe condition. Tag the compressor and render it inoperative by disconnecting all source of power so that
others who may not know of the unsafe condition will not attempt to operate it until the condition is
corrected.
Installation and operation of the machine shall follow national and local laws and regulations.
Do not modify the devices and control unless approved by the manufacturer in writing.
1.2
Safety Equipment
Before installation and operation, all installers and operators shall be familiar with and follow the safety
regulations, national and local laws and standards. Safety equipment shall be provided, such gears to
protect eyes, faces and respiration, protection clothes, boards and electrician protection devices, noise
monitoring & control system, sound insulation equipment, etc.
1.3
Fire and Explosion Protection
1.3.1.
1.3.2.
Clean up spills of fluid or inflammable substances immediately;
Avoid spark, flame or inflammable substance. Never smoke near the machine when observing or
filling fluid. Service shall be carried out when the machine is stopped and compressor completely
cools down;
1.3.3. Do not permit fluid to splash on acoustical material or accumulate on compressor, lower surfaces
and inside of fence. Wipe down using an aqueous industrial cleaner or steam – clean as required. If
necessary, replace acoustical material and clean all surfaces. Any acoustical material with a
protective covering that has been damaged should be replaced immediately to prevent
accumulation of fluid within the material. Do not use inflammable detergent;
1.3.4. Disconnect all power supplies prior to attempting any repairs or cleaning inside the machine;
1.3.5. Keep the electrical system (including terminals and contactors) in good condition. If the cable is
damaged, scratched, deteriorating in insulation performance, lead aging, fading in color or
corroded, replace immediate. Keep the wire lead and contactor clean;
1.3.6. Keep grounded and/or conductive objects (such as tools) away from exposed live electrical parts
(such as terminals) to avoid arcing, which might serve as a source of ignition;;
1.3.7. In case welding is necessary when repairs, clear acoustical materials and other inflammables or
heat sensitive articles out of site;
1.3.8. Sufficient fire extinguishers shall be provided when servicing or operating the compressor;
1.3.9. Clean inflammable materials such as oil cloth or scrap of paper near the compressor;
1.3.10. If the cooling system or fluid system is not working property (poor circulation of cooling air or
fluid), do not start the machine;
1.3.11. Do not operate the compressor in a dangerous circumstance unless it is designed to do so.
1.4
Moving Parts
1.4.1.
Keep hands, arms and other parts of the body and also clothing away from couplings, fans and
other moving parts;
Do not attempt to operate the compressor with the fan, coupling or other guards removed;
1.4.2.
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AS45-75 Series Screw Compressor Operation Manual
1.4.3.
1.4.4.
1.4.5.
1.4.6.
1.4.7.
Chapter I Safety
Wear snug-fitting clothing and confine long hair when working around this compressor, especially
when exposed to hot or moving parts;
Keep access doors closed except when making maintenance;
Make sure all personnel are out of the compressor prior to attempting to start or operate it;
Disconnect all power supplies and make sure all circuits are powered off when servicing or
adjusting the machine. This is especially important in remote control mode;
Keep hands, feet, floors, and controls and walking surfaces clean and free of fluid, water, or other
liquids.
1.5
Hot Surfaces, Sharp Edges and Corners
1.5.1.
1.5.2.
1.5.3.
1.5.4.
Do not contact hot oil, coolant, surface or sharp edge/corner;
Keep your body away from the air discharge outlet;
Wear safety equipment such as gloves or helmet, etc. when operating within or around the machine;
Keep a first-aid kit handy. Seek medical assistance promptly in case of injury. Do not ignore small
cuts and burns as they may lead to infection.
1.6
Toxic and Irritative Substances
1.6.1.
1.6.2.
1.6.3.
1.6.4.
Do not use discharged air for breathing purpose unless it meets the requirement of relevant laws;
Operate the compressor only in open or well-ventilated areas;
No toxic or caustic gas shall be present around the compressor;
The fluid is unique in the industry. Avoid skin contact or swallow. In case of swallow, see a doctor
immediately. In case of skin contact, wash with soap and water.
1.7
Electric Shock Protection
1.7.1.
Installation and maintenance of the compressor shall follow national and local laws, standards and
regulations (including national electric codes and other regulations on safety grounding), and shall
be down by qualified personnel;
Keep all parts of the body and any hand-held tools or other conductive objects away from exposed
live parts of electrical system. Maintain dry footing, stand on insulating surface and do not contact
any other portion of the compressor when making adjustment or repairs to expose live parts of the
electrical system. Operate with only one hand such that the current will not flow through your
heart even if the electric shock occurs;
Maintain the compressor at a clean, dry and well lighting place;
Do not leave the machine until the electric box is wired up. Set up notification labels to avoid
unintentional operation if leaving the machine is inevitable;
Before servicing or adjusting moving parts or handling ungrounded conductors, disconnect the
power and set up notification on the power supply. For VSD models, service may only be carried
out with the machine being power off for 5 minutes;
Once installation is completed, please dry and test all electrical circuits before starting the
compressor.
1.7.2.
1.7.3.
1.7.4.
1.7.5.
1.7.6.
1.8
Hoisting and Transportation
1.8.1.
A forklift is recommended for transportation. If forklift is used, forklift hole or dedicated tray shall
be used. Remove the baffle for forklift on the chassis and secure the compressor motor and
fluid/air separator as required to avoid damage to shock absorber during transportation;
Make sure the forklift is secure and slanting backward before moving. Inspect and make sure the
supporting bolts on the fluid/air separator plate are secured against bottom surface;
The unit on the forklift should not be lifted up higher than necessary for crossing over the barriers.
The forklift should run at the lowest speed when it turns around;
If a plate support is used, secure the compressor with bolts or other means to prevent the
1.8.2.
1.8.3.
1.8.4.
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AS45-75 Series Screw Compressor Operation Manual
1.8.5.
1.8.6.
1.8.7.
1.8.8.
1.8.9.
1.8.10.
1.8.11.
1.8.12.
1.8.13.
1.8.14.
Chapter I Safety
compressor from dropping in case of bumping road or sudden brake;
Do not use the bolt eyes on compressor for hoisting. Hoist the entire compressor body. Use chain
when hoisting with a helicopter. Be aware that governmental and local regulations and laws shall
always be complied with;
Make sure entire hoisting, rigging and supporting structure has been inspected, is in good condition
and has a rated capacity of at least the weight of the compressor. If you are unsure of the weight,
then weigh compressor before hoisting;
Make sure entire hoisting, rigging and supporting structure has been inspected, is in good condition
and has a rated capacity of at least the weight of the compressor. If you are unsure of the weight,
then weigh compressor before hoisting;
The hook should be equipped with a safety buckle, which securely locks lugs or hoist chain during
hoisting;
Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been
lifted clear of the ground;
Do not hoist in case of strong wind;
No person is allowed under the compressor or crane once the compressor has been lifted;
Lift the compressor no higher than necessary;
The operator may not leave the site once the compressor has been lifted;
Set compressor down only on a level surface capable of safely supporting it.
1.9
Miscellaneous
1.9.1.
If it is necessary to enter the enclosure to perform service adjustments, inform other personnel
before doing so and setup notification. Block the door to avoid the possibility of others closing the
door;
Make sure all personnel are out of compressor before closing the door.
1.9.2.
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AS45-75 Series Screw Compressor Operation Manual
Chapter II Compressor Structure
Chapter II Compressor Structure
2.1 Overview
Presented to you is a stationary screw compressor for power purpose. It has single stage compressing unit, oil
injecting, air cooled and driving motor. The machine comprises the air end, motor, fluid/air separator, fluid
cooler, after cooler, cooling fan assembly, chassis assembly, etc. enclosed in a soundproof cover. An electric
control cabinet is equipped on one side of the acoustical enclosure. The machine is compact, elegant and easy
to operate.
Main specifications of the machine are listed in the table below.
Main specifications of AS4500 compressor:
Model
Capacity at Full Load Pressure m3/min (CFM)
AS4507
AS4508
AS4510
AS4512
50Hz
8.5 (300.2)
7.8 (275.5)
6.9 (243.7)
5.65 (199.5)
60Hz
8.5 (300.2)
7.93 (280)
6.6 (233)
N/A
Full Load Pressure - bar (psi)
Max Working Pressure - bar (psi)
Relief Valve Opening Pressure - bar (psi)
Power Supply
Motor kW (HP)
Motor Nominal rpm
Starter Type
Ambient Temperature - T( ℃)
Fluid Fill Capacity - Liter (U.S. Gal.)
Discharge Connection
Moisture Drain Connection
Machine Weight – kg
L×W ×H - mm
7 (100)
7.6 (110)
9 (130)
4
8 (115)
10 (145)
8.6 (125)
10.7 (155)
10 (145)
12.1 (175)
380V 50Hz，230V/380V/460V 60Hz
45（60）
1480(50Hz)/1780(60Hz)
Y-△
0＜T≤45
35（9.2）
Rc2
G1/2
1380
2000x1200x1690
12 (175)
12.7 (185)
14.1 (200)
AS45-75 Series Screw Compressor Operation Manual
Chapter II Compressor Structure
Main specifications of AS5500 compressor:
Model
Capacity at Full Load Pressure m3/min (CFM)
AS5507
AS5508
AS5510
AS5512
50Hz
10.5 (370.8)
9.5 (335.5)
8.6 (303.7)
7.6 (268)
60Hz
10.6 (374)
9.85 (348)
8.18 (289)
7.73 (273)
Full Load Pressure - bar (psi)
Max Working Pressure - bar (psi)
Relief Valve Opening Pressure - bar (psi)
Power Supply
Motor kW (HP)
Motor Nominal rpm
Starter Type
Ambient Temperature - T( ℃)
Fluid Fill Capacity - Liter (U.S. Gal.)
Discharge Connection
Moisture Drain Connection
Machine Weight - kg
L×W ×H - mm
7 (100)
7.6 (110)
9 (130)
8 (115)
10 (145)
8.6 (125)
10.7 (155)
10 (145)
12.1 (175)
380V 50Hz，230V/380V/460V 60Hz
55（75）
1480(50Hz)/1780(60Hz)
Y-△
0＜T≤45
35（9.2）
Rc2
G1/2
1410
2000x1200x1690
12 (175)
12.7 (185)
14.1 (200)
Main specifications of AS7500 compressor:
Model
Capacity at Full Load Pressure m3/min (CFM)
AS7507
AS7508
AS7510
AS7512
50Hz
13.5 (476.7)
12.5 (441.4)
11.1 (392)
10.3 (363.7)
60Hz
13.45 (475)
12.55 (443)
10.9 (385)
10.4 (367.3)
Full Load Pressure - bar (psi)
Max Working Pressure - bar (psi)
Relief Valve Opening Pressure - bar (psi)
Power Supply
Motor kW (HP)
Motor Nominal rpm
Starter Type
Ambient Temperature - T( ℃)
Fluid Fill Capacity - Liter (U.S. Gal.)
Discharge Connection
Moisture Drain Connection
Machine Weight - kg
L×W ×H - mm
7 (100)
7.6 (110)
9 (130)
8 (115)
10 (145)
12 (175)
8.6 (125)
10.7 (155)
12.7 (185)
10 (145)
12.1 (175)
14.1 (200)
380V 50Hz，230V/380V/460V 60Hz
75（100）
2960(50Hz)
2960(50Hz)
2960(50Hz)
1480(50Hz)
3550(60Hz)
1780(60Hz)
1780(60Hz)
1780(60Hz)
Y-△
0＜T≤45
35（9.2）
Rc2
G1/2
1520
2000x1200x1690
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AS45-75 Series Screw Compressor Operation Manual
Chapter II Compressor Structure
Main specifications of AS4500VSD compressor:
Model
AS4507V
AS4508V
AS4510V
AS4512V
8.5 (300.2)
7.93 (280)
6.9 (243.7)
5.65 (199.5)
1.95-8.5
(68.8-300.2)
7 (100)
7.6 (110)
9 (130)
1.92-7.93
1.90-6.9
(67.8-280)
(67.1-243.7)
8 (115)
10 (145)
8.6 (125)
10.7 (155)
10 (145)
12.1 (175)
380-480V 50/60Hz
45（60）
600-2616 (As per model)
VSD
0＜T≤45
35（9.2）
Rc2
G1/2
1480
2250x1200x1690
3
Capacity at Full Load Pressure - m /min
(CFM)
Capacity Regulation Range - m3/min
(CFM )
Full Load Pressure - bar (psi)
Max Working Pressure - bar (psi)
Relief Valve Opening Pressure - bar (psi)
Power Supply
Motor kW (HP)
Motor Nominal rpm
Starter Type
Ambient Temperature - T( ℃)
Fluid Fill Capacity - Liter (U.S. Gal.)
Discharge Connection
Moisture Drain Connection
Machine Weight – kg
L×W ×H - mm
1.78-5.65
(62.7-199.5)
12 (175)
12.7 (185)
14.1 (200)
Main specifications of AS5500VSD compressor:
Model
AS5507V
AS5508V
AS5510V
AS5512V
10.6 (374)
9.85 (348)
8.6 (304)
7.73 (273)
2.52-10.6
(89.1-374)
7 (100)
7.6 (110)
9 (130)
2.54-9.85
2.13-8.6
(89.8-348)
(75.2-304)
8 (115)
10 (145)
8.6 (125)
10.7 (155)
10 (145)
12.1 (175)
380-480V 50/60Hz
55（75）
600-2520 (As per model)
VSD
0＜T≤45
35（9.2）
Rc2
G1/2
1510
2250x1200x1690
2.09-7.73
(73.7-273)
12 (175)
12.7 (185)
14.1 (200)
3
Capacity at Full Load Pressure - m /min
(CFM)
Capacity Regulation Range - m3/min
(CFM )
Full Load Pressure - bar (psi)
Max Working Pressure - bar (psi)
Relief Valve Opening Pressure - bar (psi)
Power Supply
Motor kW (HP)
Motor Nominal rpm
Starter Type
Ambient Temperature - T( ℃)
Fluid Fill Capacity - Liter (U.S. Gal.)
Discharge Connection
Moisture Drain Connection
Machine Weight – kg
L×W ×H - mm
6
AS45-75 Series Screw Compressor Operation Manual
Chapter II Compressor Structure
Main specifications of AS7500VSD compressor:
Model
AS7507V
AS7508V
AS7510V
AS7512V
13.5 (477)
12.55 (443)
11.1 (392)
10.35 (365.5)
3.29-12.55
2.79-11.1
(116.2-443)
(98.6-392)
8 (115)
10 (145)
8.6 (125)
10.7 (155)
10 (145)
12.1 (175)
380-480V 50/60Hz
75（100）
600-2511 (As per model)
VSD
0＜T≤45
35（9.2）
Rc2
G1/2
1620
2250x1200x1690
2.84-10.35
(100.3-365.5)
12 (175)
12.7 (185)
14.1 (200)
3
Capacity at Full Load Pressure - m /min
(CFM)
Capacity Regulation Range - m3/min
(CFM )
Full Load Pressure - bar (psi)
Max Working Pressure - bar (psi)
Relief Valve Opening Pressure - bar (psi)
Power Supply
Motor kW (HP)
Motor Nominal rpm
Starter Type
Ambient Temperature - T( ℃)
Fluid Fill Capacity - Liter (U.S. Gal.)
Discharge Connection
Moisture Drain Connection
Machine Weight – kg
L×W ×H - mm
3.23-13.5
(113.9-477)
7 (100)
7.6 (110)
9 (130)
See Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 for the layout and system flowchart of AS45-75.
A pair of delicately machined rotors engages each other inside compressor's body. The male rotor has four
teeth, while the female rotor has six teeth. Motor drives the male rotor through an elastomer coupling and the
male rotor drives the female one at high speed. As the space between teeth is getting smaller, air from air filter
is compressed and pressure increased. When the teeth chamber reaches discharge port of compressor,
compressed air is pushed into fluid/air separator through discharge port for separation. Separated air then
flows through minimum pressure valve, after cooler and drain valve until it is utilized by user. Separated fluid
is settled to the bottom of fluid/air separator. Once cooled, it is recycled to air end working chamber under
pressure difference.
7
AS45-75 Series Screw Compressor Operation Manual
Chapter II Compressor Structure
Figure 1 General layout of AS45-75 unit
8
AS45-75 Series Screw Compressor Operation Manual
Chapter II Compressor Structure
Figure 2 General layout of AS45-75VSD unit
9
AS45-75 Series Screw Compressor Operation Manual
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
DESCRIPTION
Chapter II Compressor Structure
NO.
FLTR,AIR INLET
VACUUM INDICATOR
MANF,AIR INLET CONTROL
COMPRESSOR
SNSR,TEMP
GA,PRES
TANK
ELEM,AIR/OIL SEP PRIMARY
VALVE,MINIMUM PRESSURE
AFTER COOLER
SEPARATOR,TRAP
VALVE,RELIEVE
STRAINER
14
15
16
17
18
19
20
21
22
23
24
25
DESCRIPTION
GLASS,SIGHT
ORIFICE
STRAINER,V-TYPE
VALVE,BALL
PLUG,TANK
GLASS,SIGHT
THERMAL VALVE
FLUID FILTER
PRESS INDICATOR
SNSR,PRESSURE
ELEM,AIR/OIL SEP SECONDARY
ORIFICE
Figure 3 System flowchart of AS45-75 unit
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AS45-75 Series Screw Compressor Operation Manual
NO.
1
2
3
4
5
6
7
8
9
10
11
12
DESCRIPTION
FLTR,AIR INLET
VACUUM INDICATOR
MANF,AIR INLET CONTROL
COMPRESSOR
PROBE,TEMP
XDCR,PRESSURE
TANK
ELEM,AIR/OIL SEP PRIMARY
VALVE,MINIMUM PRESSURE
AFTER COOLER
SEPARATOR,TRAP
VALVE,RELIEVE
Chapter II Compressor Structure
NO.
13
14
15
16
17
18
19
20
21
22
23
24
DESCRIPTION
STRAINER
GLASS,SIGHT
ORIFICE
STRAINER,V-TYPE
VALVE,BALL
PLUG,TANK
GLASS,SIGHT
THERMAL VALVE
FLUID FILTER
PRESS INDICATOR
ELEM,AIR/OIL SEP SECONDARY
ORIFICE
Figure 4 System flowchart of AS45-75VSD unit
2.2 Air inlet system
2.2.1
Working procedure of air inlet system
Air inlet system is composed of air filter, air intake elbow, air inlet valve and compressor air end, etc..
When the machine is running, air is sucked from air filter and flows to compressing chamber through air inlet
valve. It is compressed by male/female rotors revolving at high speed and its pressure is increased. When the
teeth chamber reaches discharge port of compressor, compressed air is discharged through discharge port.
2.2.2
Air filter
Air filter is used to filter intake air and provide clean air to compressor. Impurities in air will cause wear on
rotor surface and pollution in fluid. Not following the air filter service requirement or not using original filter
element will cause early failure of fluid and fluid/air separator element and warranty void.
2.2.3
Air inlet valve
Air inlet valve of this series of compressor is integrated into the air end. Inlet valve is used to control intake
air volume using loading/unloading mechanism.
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AS45-75 Series Screw Compressor Operation Manual
Chapter II Compressor Structure
2.3 Air discharge system
2.3.1
Working procedure of air discharge system
Air discharge system is composed of compressor, fluid/air separator, minimum pressure valve, relief valve,
blowdown valve, after cooler, moisture separator and connection pipeline.
Compressed oil/air mixture from compressor enters fluid/air separator through the discharge port of
compressor. Fluid in compressed air is separated and clean compressed air is obtained.
Compressed air after oil/air separation flows through minimum pressure valve, after cooler and moisture
separator in sequence. After cooler is used to cool hot air. Moisture separator is not equipped with this series.
User may select the moisture separator when purchasing the machine or treat the discharged air otherwise.
Service connector of the machine is Rc2 with inner thread. User shall prepare a check valve on external air
pipeline. Do not expose after cooler to stress when piping.
Air tank is recommended to reduce the loading/unloading action of the compressor and extend the life of
components.
2.3.2
Minimum pressure valve
The minimum pressure valve is located on the top cap of fluid/air separator. It is used to maintain pressure in
fluid/air separator above 0.34MPa to ensure fluid flow in oil pipeline. It also reduces oil consumption.
Therefore only when pressure in fluid/air separator is above 0.34MPa and higher than pipeline pressure, the
minimum pressure valve will be opened. In parallel working mode, minimum pressure valve works as a check
valve to prevent compressed air from back flowing to separator and air end during compressor blowdown.
2.3.3
Automatic blowdown valve
An automatic blowdown valve is equipped in the control line. When the compressor is unloading or being
stopped, blowdown valve opens automatically to allow compressed air in fluid/air separator into inlet pipe,
thus release pressure.
2.3.4
Relief valve
A relief valve is equipped on fluid/air separator. When pressure in separator exceeds threshold, relief valve
will open to discharge pressure and make sure the machine is safe.
The machine also features a high pressure stop switch. When pressure in separator exceeds threshold, the
machine will stop automatically.
2.4 Fluid loop system
2.4.1 Working procedure of fluid loop system
Fluid loop system is composed of compressor, fluid/air separator, thermal valve, fluid cooler, fluid filter and
connection pipeline.
Fluid in fluid/air separator flows into fluid cooler through thermal valve. Cooled oil enters air end working
chamber through fluid filter. Then it is compressed along with intake air and enters fluid/air separator for a
complete cycle. Fluid serves for three roles:
(1) Coolant - Fluid injected into the machine absorbs large amount of heat generated during compressing as
a coolant.
(2) Lubricant - Fluid forms an oil layer between the rotors, avoiding direct contact between male and
female rotors. Therefore the wear between rotor surfaces is minimized. In addition, fluid flows to
lubrication positions through internal lubrication to lubricate bearings and gears.
(3) Sealant - Fluid with appropriate viscosity can fill up the gaps between rotor-rotor and between rotorcasing. It reduces leakage loss and enhances the cubage efficiency of compressor.
2.4.2 Fluid filter
Fluid filter clears the impurity in fluid and ensure that clean oil is transported to air end working chamber and
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AS45-75 Series Screw Compressor Operation Manual
Chapter II Compressor Structure
lubrication positions. Impurity in fluid will cause wear on rotor/gear engaging surfaces and bearing, and
reduces the life of compressor.
Fluid filter element should be replaced regularly to ensure good oil circulation.
2.4.3 Oil return pipe
An oil return pipe is located on the cap of fluid/air separator. Small amount of oil on the bottom of filter
element is recycled to compressor through the pipe.
2.5 Cooling system
The machine equips an axial flow cooling fan. Cooling air enters the machine through louver on both sides by
axial flow fan, exchanging heat with cooler before leaving the machine.
2.6 Fluid/air separator
2.6.1 Function of fluid/air separator
Fluid/air separator is composed of a tan and a filter element. It has the following functions:
(1) Primary filter.
Oil/air mixture from air end enters the fluid/air separator and crashes on the wall of separator to lower its
speed. Large oil drops are formed due to lower speed. Most of the oil drops set to the bottom of separator
under gravity.
(2) An oil reservoir of the compressor to store fluid.
(3) Filter element.
After collision separation, oil/air mixture flows through filter element for fine separation. Minor fluid
residue in compressed air is separated and accumulated on the bottom of filter element. Then the oil is
returned back to compressor's intake port and working chamber through the oil return pipe.
(4) Pressure regulation.
Certain amount of air inside the fluid/air separator effectively stabilizes pipeline pressure.
2.6.2 Filter element replacement
Impurities exist in the fluid loop system. Fluid separator element will be clogged up after a period. Resistance
of filter element to compressed air will increase and machine operation will be compromised. Operator should
replace filter element according to the signal on monitor on time.
Note: Fluid separator element may only be replaced instead of being repaired.
2.6.3 Oil filling port and sight glass
Oil filling port and sight glass are equipped on the outer side of fluid/air separator.
Since discharged air contains oil more or less, the oil level of separator will drop and need to be added. The
normal oil level shall be observable from the sight glass when the compressor is running at full load.
2.7 Air capacity adjustment system
2.7.1 Line frequency model
Air capacity adjustment system automatically adjusts the open/close of inlet valve based on air demand to
minimize fluctuation in service pressure.
The control system loads/unloads the compressor based on air demand. The control system comprises
solenoid valve, air inlet valve, blowdown valve and control line.
When air demand equals to or is higher than machine rating, the machine will run at full load. In such a case,
the starting/unloading solenoid valve is energized, cutting off the control line. Inlet valve of the air end is fully
opened under vacuum.
When air demand is lower than rating, line pressure of the machine builds up slowly. Once the pressure
exceeds rated pressure, pressure regulator will be activated, sending control air to inlet valve to reduce air
intake and keep the balance between supply and demand. If air demand is less than 50% of the rated capacity,
system pressure will continue to rise, Once the discharge pressure reaches unloading setting of the machine,
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AS45-75 Series Screw Compressor Operation Manual
Chapter II Compressor Structure
the compressor will change into unloading mode. The starting/unloading solenoid valve is de-energized,
opening the control line. In such a case, the inlet valve is closed through the control line. Meanwhile, the
blowdown valve is opened to release the pressure in fluid/air separator tank (to intake port) until pressure in
separator is stabilized to 15-25PSI. Now the machine runs at a lower pressure with no load. The machine will
keep running for a preset time period at unloading mode before stop. Once the pressure in user air line drops
to the lower limit set in the microprocessor controller, the compressor will enter loading mode from unloading
mode again, i.e. the starting/unloading solenoid valve is energized, cutting off the control line. Air inlet valve
of the air end is fully opened under vacuum.
2.7.2 VSD model
Air capacity adjustment system of VSD model varies the speed of electric motor via frequency variation to
match the fluctuation of air demand, and keep the balance between supply and demand. Minimum motor
frequency of WS45-75 series VSD machines is 20Hz and the maximum frequency varies from model to
model. Reference frequency of electric motor is 75Hz. Each VSD model has its own maximum output
frequency for VSD and maximum speed for motor. When air demand equals to rated capacity, the machine
runs in full load mode and the frequency of motor VSD is at rated value. If air demand is lower than rated
capacity, motor frequency will be reduced to lower the speed or air end, thus reducing air intake. If there is no
demand, motor frequency will be reduced to minimum, meanwhile inlet valve will be closed to stop air intake.
In such a case the machine runs on a lower back pressure in no-load mode.
2.8 Microprocessor controller
The machine is equipped with microprocessor controller. For detail information on controller, see 88290022798 EC2000 Controller Operation Manual.
The line frequency model may have the option, and VSD model is equipped with deluxe microprocessor
controller. For detail information on controller, see 88290010-484 Deluxe Microprocessor Controller I –
Operation Manual.
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AS45-75 Series Screw Compressor Operation Manual
Chapter III Installation of Compressor
Chapter III Installation of Compressor
3.1 Machine Installation
The machine should be mounted on supporting ground or foundation with sufficient strength. To ensure that
the transmission and internal piping work properly, the machine should be level and firmly contacting the
ground. A rubber plate is suggested under the machine with thickness of 10~20mm.
Air in/out interface is ready on the enclosure. See Dimension and Installation Diagram for detailed size.
Arrange ductworks when designing the equipment room.
See Figure 5、Figure 6 for the dimension and installation of the machine.
3.2 Ventilation and temperature reducing
To ensure compressor's normal operation, equipment room must be well ventilated with room temperature
no more than 45℃. No object shall be placed within 1m range of the compressor for the convenience of
ventilation and service. Room design should also satisfy ambient temperature requirement for starting in
winter, which is 32°F (0℃).
Note: it is improper to install the compressor in a place around which there is emitted explosive, toxic or
corrosive gas (substance), for the details please consult the After Sales Department of Sullair.
3.3 Check fluid level
Sufficient fluid has been added at Sullair factory. There is a sight glass in the fluid reservoir. Fluid level
should be normal when the compressor is running at full load. Otherwise, stop the machine and add fluid. It
is proper for the fluid level to be seen at 1/2 – 3/4 of the sight glass when fluid is filled to full-load running.
3.4 Rotation Direction of Motor
3.4.1 Line frequency model
User should check if motor rotation direction matches the mark of coupling guard as follows once the
machine is powered on.
Pull out emergency stop button from Microprocessor Controller and press "I" button (start) followed by "O"
button (stop) immediately. Let motor revolve for a moment. If motor rotates in the same direction of marked
arrow, it means wiring is correct. If not, cut off power and exchange any two power cables. Then test again.
Machine with phase sequence protector may not be started if the phase sequence is wrong. Please observe
the message shown on the controller.
3.4.2 VSD model
User should check rotation direction of main motor and fan motor separately once the wiring the completed.
Check main motor rotation direction:
Pull out emergency stop button from monitor's control panel and press "I" button (start) followed by "O"
button (stop) immediately. Let motor revolve for a moment. Looking from the rear end of the motor, if the
spindle rotates clockwise, then it is correct. If not, cut off power and exchange the phase on the output side
of VSD and test again. There is a sign on the barrel between motor and compressor to indicate rotation
direction.
Check fan motor rotation direction:
Check the rotation direction of fan motor together with the main motor. Both motor and fan have direction
indicator. If the direction is wrong, adjust fan motor contactor.
Never put the motor in reverse rotation direction!
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AS45-75 Series Screw Compressor Operation Manual
Chapter III Installation of Compressor
Figure 5 Dimension and installation diagram of AS45-75
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AS45-75 Series Screw Compressor Operation Manual
Chapter III Installation of Compressor
Figure 6 Dimension and installation diagram of AS45-75VSD
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AS45-75 Series Screw Compressor Operation Manual
Chapter IV Compressor Operation
Chapter IV Compressor Operation
4.1 Safety Operation Procedure
To avoid injury and machine damage, customer shall make detailed safety operation procedure. Please refer
to the following:
(1) Operator must be well trained before operation, and has read and understood this manual;
(2) The installation and operation of machine shall comply with national and local laws and regulations;
(3) Never modify machine structure and control mode, unless approved by manufacturer in written.
(4) If abnormal condition is encountered, stop the machine immediately and shut down all power supply.
(5) No inflammable, explosive, toxic and erosive gas shall be stored in the vicinity.
(6) Blowdown the compressor and shut down all power supply before maintenance or adjustment operation.
4.2 Preparation before Initial Starting
(1) Check if electric connection is safe and reliable;
(2) Set operation parameters according to the manual of accompanied computer controller;
(3) Check fluid level. It is required, at stop, for the fluid level to be visible from the sight glass or over the
sight glass;
(4) If ventilation tunnel is installed, make sure it is clean and clear;
(5) Open air discharge check valve;
(6) Power on the machine. Start the machine then stop immediately to check if motor rotates in the same
direction of marked arrow. Reset the machine if direction is wrong;
(7) The fluid level shall be visible from the sight glass at full-load running and the fluid, if insufficient
therein, shall be filled, with the motor stopped first, enough to have the fluid level visible at 1/2 to 3/4
of the sight glass at full-load running.
(8) Restart the compressor and close check valve gradually. Check if unloading pressure coincides with
settings. Reset the machine if not.
(9) Check if all systems work properly. Check for oil, air and water leakage and abnormal sound;
(10) If ambient temperature is too low, user must increase room temperature above 0℃ to start the machine
and keep its operation;
(11) Stop the machine.
4.3 Normal Operation
Once a new machine has been tested according to the first starting test procedures, it may be used for normal
operation. Check fluid level before starting. Press "I" button to start the compressor.
4.4 Stop
Press “O” button to stop the machine.
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AS45-75 Series Screw Compressor Operation Manual
Chapter V Maintenance and Service
Chapter V Maintenance and Service
5.1 Overview
Besides daily maintenance and inspections every 1000 hours, maintenance works are grouped according to
time interval (operation hours). The microprocessor controller has a programmable service timer. Once the
setting in the service timer has been reached, LCD status column of the controller will give corresponding
minor fault alarm message in rotation, reminding user of service. Reset the service timer after service
operation. See 88290021-984 EC2000 Compressor Controller Operation Manual or 88290010-484 Deluxe
Microprocessor Controller I – Operation Manual for detail. Normal operation of the machine relies on good
maintenance and service.
Warning
Do not carry out maintenance or service work when the power supply has not been cut off.
Do not disassemble any part when the compressor is running or pressurized. Shut down the machine,
bleed internal pressure to zero and cut off external pressure before disassembling.
Sullair genuine parts must be used when servicing Sullair compressor in accordance with the
requirements in Operation Manual. Otherwise, warranty may void.
5.2 Daily Maintenance
Check fluid level before starting the machine. Add fluid if level is too low. Once the machine is started,
check if displayed parameters are correct to make sure the machine is normal. Check operation condition of
various systems after the machine is warmed up, and check for leakage and abnormal sound.
5.3 Service After 50 Operation Hours
Check and proceed with the following after 50 operation hours:
(1) Clean oil return pipe filter;
(2) Replace fluid filter element;
5.4 Service After Every 1000 Operation Hours
(1) Clean oil return pipe filter;
(2) Replace fluid filter element, upon the necessity;
(3) Replace the air filter element, upon the necessity;
5.5 Changing Fluid
(1) In order to minimize service operation and reduce cost, AS45-75 series compressor has been tested
and filled with SRF or Sullube 2G fluid before delivery;
(2) Use non-Sullair fluid in compressor will void all Sullair warranties;
(3) Do not mix different type fluid. Mix dirty mineral oil may cause poor performance of the air end. It
could also cause bubble, filter element clogging and nozzle or pipe clogging;
(4) Note: Clean oil way system before changing oil. If ambient temperature exceeds range or use fluid
above its life, please contact Sullair dealer.
(5) Maintenance interval and guidance
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AS45-75 Series Screw Compressor Operation Manual
Fluid
SRF 1/4000
Sullube 2G
Fluid change interval
6 months or 4000 hours
or assay
One year or 8000 hours
or assay
Chapter V Maintenance and Service
Fluid filter
change interval
Fluid/air separator
element change interval
Air filter
1000 hours
6 months or 4000 hours
2000 hours
1000 hours
6 months or 4000 hours
2000 hours
(whichever comes first) In case the compressor is running in a dusty environment, service the filter more
frequently.
5.6 Maintenance Of Fluid Filter
Replace fluid filter element and gasket every 1000 hours or if indicated so by the pressure drop indicator of
fluid filter.
Top cover
Washer*
Filter element*
Figure 7 Fluid Filter
Spare Part No.: 250025-526
See Figure 7 for the maintenance of fluid filter.
(1) Remove the filter element and washer using a belt wrench;
(2) Clean the sealing surface;
(3) Coat the new washer with clean compressor oil.
(4) Screw up the new element with hand. Make sure the new gasket is in place. Avoid deformation,
damage or press to the gasket;
(5) Tighten another 1/2-3/4 circle with hand;
(6) Start the machine and check for leak.
5.7 Maintenance Of Air Filter
See Figure 8 and Figure 9, in case the service indicator of air filter is in red zone when the machine is
running at full load, or the machine has been operated for 2000 hours, replace air filter element as described
below:
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AS45-75 Series Screw Compressor Operation Manual
Chapter V Maintenance and Service
Figure 8 Air Filter Repair Indicator
Replacing filter element:
1. Stop the machine and bleed pressure;
2. Clean the shell of filter;
3. Screw out the airfoil nut to remove the shell and pour out the dust therein;
4. Screw out the nut to remove the sealing washer and the filter element;
5. Clean the inside of the shell after removing the filter element. Do not use compressed air;
6. Use the steps reversed to those of removal to set on the filter element. Securely fix the sealing washer
and the gasket on the shell;
7. Reassemble the filter;
8. Reset the service indicator.
Wing nut
Locknut
Canopy
Wing nut
Washer
Filter element*
Support
Figure 9 Air Filter
No. of the spare part of the internal air filter element
88290002-338
No. of the spare part of the external air filter element
88290002-337
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AS45-75 Series Screw Compressor Operation Manual
Chapter V Maintenance and Service
Check filter element
1. Place a shining light source in the filter element and, when the light sends out of the filtering screen,
view it from outside to check if it gets damaged;
2. Check all gaskets and mounting surface of the gasket. Replace damaged gasket immediately;
3. Spare filter element should be stored in a clean container;
4. With the element installed, check and tighten all connection parts before starting the machine.
5. When to clean the dirt on the filter element, never knock it on a hard object, or both sealing surface and
filter element would be made damaged;
6. Do not oil the filter element.
5.8 Maintenance of Fluid/Air Separator
The maintenance of fluid/air separator is the replacement of the elements. See Figure 10.
Replace fluid/air separator element every 4000 hours or in case pressure drop is greater than 10psi (0.7bar).
Caution: This element can be replaced only and can not be cleaned.
Steps to replace the fluid-air separating element:
(1) Stop the machine and discharge pressure;
(2) Disconnect the pipeline linked to top cap and remove the top cap;
(3) Take out the element and replace with new one.
Caution: Do not touch the sealing pad on filter element flange. Do not remove the metal holding screw
from sealing pad. Metal holding screw also serves as grounding function to prevent fire in separator caused
by static;
(4) Clean the inside surface of top cap and put in the new filter. Fasten bolts and pressing cap;
(5) Connect pipelines linked to top cap.
Caution: The oil return pipe shall be inserted to the bottom of the filter element in order not to affect the
back oil.
Figure 10 Fluid/Air Separation System
No. of the spare part of the Primary Fluid/Air separator element
No. of the spare part of the Secondary Fluid/Air separator element
22
250042-862
02250061-137
AS45-75 Series Screw Compressor Operation Manual
Chapter V Maintenance and Service
5.9 Maintenance Of Minimum Pressure Valve
See Figure 11 for the structure of minimum pressure valve. Normally only O-ring needs to be replaced.
Maintenance procedure is described below:
1. Separate the pipeline connected with the minimum pressure valve to remove the valve from the top of
the oil-gas separating tank;
2. Screw out the top cover to take out the primary spring;
3. Turn the valve upside-down and slightly knock the check valve assembly with a screwdriver till both
piston and said assembly fall off;
4. Clean the valve body and the undamaged parts;
5. Coat the new check valve with a layer of oil and put it into the body lightly, then mount a new check
spring in;
6. Coat the new “O”-ring with a layer of lubricating grease, put on the piston and the new piston spring,
remount the top cover and connect the pipeline.
Spring
Check valve assembly
Top cover
Gasket
Springlock washer
Hexhead set screw
Spring
*O-ring
Piston
Valve body
Figure 11 Minimum Pressure Valve
Spare part No.: 88290018-146
5.10
Maintenance of Solenoid Valve
Solenoid needs little service. However it should be cleaned regularly. Generally if working voltage is right
and the solenoid is acting slowly or is leaking, it should be cleaned.
5.11
Maintenance of Pressure Regulator
See Figure 12.Procedures:
1. Unscrew the locknut, and turn the adjusting screw counterclockwise until the spring is relaxed.
Now the spring screw is not under pressure;
2. Screw off spring chamber, take out the spring seat, spring and diaphragm assembly, remove the
gasket;
3. Unscrew the nut on the valve disc, remove the valve disc, diaphragm and bolts, remove retain ring
and discard;
4. Replace with parts and reinstall, replace with new retain ring、new gasket;
5. Replace with new spring if damaged, put in the spring seat, assemble other parts and install in the
spring chamber;
6. Tighten adjusting screw until it is under force from spring;
7. Readjust pressure regulator according to control system procedures.
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AS45-75 Series Screw Compressor Operation Manual
Chapter V Maintenance and Service
Valve body
Bolt*
Retainer ring*
Membrane *
Valve plate*
Locking washer*
Valve plate nut*
Gasket*
Spring
chamber
Plate nut
Locking nut
Spring se
Adjusting screw
Figure 12 Pressure Regulator
No. of the spare part of the Pressure Regulator
5.12
250019-453
Installation and Maintenance of Coupling
See Figure 13 for the structure of coupling. Connect the shafts of both compressor and motor rigidly to the
installation disks of their own. An elastomer is used for connecting the disks and required to be cared solely
under the general condition, as being noted below:
Warning
Cut off all the power supply prior to repair and adjustment.
Motor spindle plate
Elastomer
Fixing cap
Compressor mounting plate
Figure 13 Coupling
1.
Take out the shield on the connection barrel;
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AS45-75 Series Screw Compressor Operation Manual
Chapter V Maintenance and Service
2.
Remove the tightening screw on the fixing cover;
3.
Uncover the fixing cover axially to let the elastomer exposed;
4.
Take out the elastomer along with the radial direction and check if its surface is worn out, deformed or
torn away and, if any, replace it and contact Sullair for more help;
5.
Follow the steps reversed to those abovementioned to put back the elastomer and the fixing cover and
screw in the tightening screw, with the interval between the end-faces of the two shaft sleeves
guaranteed at 2-3mm. There is no need to remove the installation disks throughout the process of
maintenance, easily practicable and guaranteed for reliable work.
5.13
1.
Maintenance Of The Motor For Sullair Compressor
Operating conditions of Motor for Sullair Compressor (For exported units, they change with different
countries):
Ambient temperature
≤46℃
Altitude
≤1000m
See the name plate of motor and the following requirements for other conditions.
2.
Operation of the Motor for Sullair Compressor
(1) Motor should be grounded correctly. Generally, the ground wire of the motor for Sullair compressors is
connected in the electric cabinet. Users only need to connect the earth ground wire securely to this
point.
(2) Clear markings are provided on the lead wires of the motor for Sullair compressors
(3) For connection of the motor for Sullair compressors, a connection diagram is provided on the
nameplate.
(4) If the voltage and frequency of power source for the motor for a Sullair compressor are as indicated on
the nameplate, the motor can operate continuously at the rated power × utility coefficient. If the
frequency of the power source deviates from the rating value indicated on the nameplate by 1% of this
value or undervoltage/overvoltage exceeds 10%, it cannot be guaranteed that the motor will deliver
such output power.
(5) Sullair compressor specific motor works well when imbalance among three phases does not exceed 1%.
(6) Generally, a current detection device is mounted in the electric cabinet of a Sullair compressor and it is
used as motor overload protection. (Not applicable to VSD models.)
(7) There should be no intermittent or unusual noises or vibrations when the motor runs at no load or at
loads.
3. Maintenance and repair of Motor for Sullair Compressor
(1) Operating environment should be kept dry, the motor surface should be clean and its air inlet should
not be obstructed by dust or fibers.
(2) When the Overload protection device (line frequency model) or VSD (VSD model) is failure, check
the fault cause. The motor must not be put into operation until the fault is eliminated.
(3) Make sure bearings are well lubricated during operation. Generally, grease should be added or
replaced every 2000H (enclosed bearing does not need grease replacement during its life). If grease is
too hot or is deteriorated during operation, it should be replaced. Add grease after cleaning bearing and
cap slot. Different motor uses different type of grease. See motor nameplate or call Sullair After-sales
Marketing Department.
(4) When the service life of the bearing ends, shock and noises generated during motor operation will be
increased significantly, and in this case, the bearing should be replaced.
(5) After motor faults occur, we recommend that the user contact Sullair or its agents.
4. Periodic check
The motor shall be checked per year or six months upon the conditions of use, the irregular conditions for
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AS45-75 Series Screw Compressor Operation Manual
Chapter V Maintenance and Service
the check per six-month to be surely done are:
Exposed to one of the followings:
(1) Corrosive or conductive dust.
(2) Velveteen or a very dirty condition of use. The accumulated dust may affect the normal ventilation.
(3) Chemical smoking, steam, salt mist or oil mist.
(4) The atmosphere moisture or vary dry, radiation heated, pest intruded or mold caused to grow up.
Or working with one of the following conditions:
(1) The deviation to the rated voltage and (or) frequency is often over the limit set in the clause “Operation
of the motor special for Sullair compressor.
(2) In a room of poor ventilation or the ambient temperature is over 45℃.
(3) The motor is caused to frequently start due to the frequent fluctuation of the air volume being used.
List for check-up:
(1) Discharge, clean and fill bearing again with fluid (grease). Check the bearing if it is found abnormal.
Refer to the nameplate on the motor for the brand of the fluid (grease).
(2) Take some measure to settle the oil leak at the bearing seal.
(3) Check if there is condensation, deposited water, iron rust or corrosion on the end-cover or the top
mantle, which can be removed if necessary.
(4) Check if there is deposited dust or other foreign matters.
(5) Check if the non-insulated electric connections are contacted tightly, overheated, arc-over or corroded
and use the measures for remedy, if necessary.
(6) Check all the nuts and bolts and make sure of them secured.
(7) Check if there is overheat or corona with the main led-out wiring.
5. Check and sort-out of windings
The adoptable ways are listed below for reference upon the kind and quantity of the dust deposited on the
winding. (The rotor needs to be drawn out of the stator, in case of much dust deposited on the winding or
for all-respect check and clean of it).
(1) Drying wipe
When a surface which needs to be cleaned is accessible and what needs to get rid of is dust only, a
satisfactory effect can be made just by way of drying wipe with a clean lint-free cloth. “Cotton waste” shall
not be used, as the floss may be adhered on the insulation to get much more dust gathered and is adverse
particularly to the insulation on the high voltage motor, as corona discharge tendency would be caused.
(2) Way of cleaning by brush-off and suck-out
It is a satisfactory way that to get rid of dust by the way of brush-off with a short and hard brush (not a
metal brush) first and then to suck it out completely with vacuum, as there is no possibility for the dust to
be scattered and deposited on any other equipments.
(3) Blow-off
The way to blow off the dust with sprayed dry air is applicable only for the gap almost unable to access and
when the motor is kept dried and the direction for the air to blow off shall not make the dust blown into the
deep inside of the motor, causing it difficultly removed and the air duct possibly blocked.
Especially, the pressure of the air used therein shall not be over 0.2MPa, this is for preventing the insulation
from getting injury and that to blow off the dust with the insulation loosened and making sure of the air to
be dried and without containing the condensed water from the air pipeline.
(4) Way of cleaning with solvent
This way is more effective to get rid of the bitumen, grease, wax and oil on electric equipments and works
like that to wipe the surface with a cloth soaked in a solvent and then with a dry cloth (no “cotton waste”
shall be used to let no floss deposited on the insulation).
Sullair suggests to use a volatile solvent of inorganic or petroleum category to clean the insulation. At the
fire danger place, methyl chloroform of suppression can be adopted to clean. Because this solvent is
26
AS45-75 Series Screw Compressor Operation Manual
Chapter V Maintenance and Service
combustible in the general condition, and gently toxic, therefore partial ventilation is required when the
smell of the solvent steam becomes thicker.
6. See 3-phase Asynchronous Motor Maintenance Manual for other inspection and service of motor.
27
AS45-75 Series Screw Compressor Operation Manual
Chapter VI Wiring Diagram
Chapter VI Wiring Diagram
QF
LINE VOLTAGE
USER FURNISH POWER INLET PROTECTION
FAN
MOTOR
MONITOR
P2 p
s
T1
6.1 Wiring diagram of the unit
28
-XT1
101
PE
1
HT3
101
-XT2
HT1
FROM- XT1 101
102
FROM- XT1
HT4
120
HT1
HT1
HT2
HT2
HT3
HT3
HT4
HT4
HT2
BACK UP
PE
1 AC110V L
2 AC110V N
3 GND
J7
102
102
104
101
CAN 2L
CAN 2H
GND
3/RS-485
2/RS-485
105
SEQUENCE CONTROL
COMMUNICATION
102
1/RS-485
J1
FULL LOAD MODULATE
10
COMMON FAULT K6 9
K5
8
UNLOAD/LOAD
K4
7
K3
Y
6
K2
RUN
5
K1
COM
4
3
REM
2
GND
1
201
A+
BA+
BA+
B-
202
1
2
3
4
5
6
7
8
9
108
102
J2
2
1
RED
HT2
-SB1
151
1
1
S101 1
101
E-STOP
120
E-STOP
4
EH1
EH2
HT3 HT4
RED
BLK
P2
+ -
-KA9
-KM1
REMOTE START/STOP
VENT FAN CONTACTOR
-YV2 LOAD/UNLOAD SOL VALVE
-KA3 LOAD RELAY
-KA2 ALARM RELAY
E-STOP
-KM1
HT2
EH1
HT4
EH2
HT3
-
-KM1
-FU4
BLK
P1
+
RED
FAN OVERLOAD
CONVERTER FAULT
TO CUSTOMER 120VAC SOURCE
CUSEOMER SHORT CONECT HT2&HT4
HT1
S
-BP1
DISCH PRESS
REMOTE START/STOP
HYDRAULIC PRESSURE
WHT(GRN)
-CT1
R02
2
S
WHT(GRN)
-BT1
-BP2
LINE PRESS
CONNECT THE HEATER IN ACCORD WITH CUSTOMER SOURCE
-KM1
HT1
P
-SP2
R01 202A
1
RTD1
GND DISCH TEMPER
-BT2
MOTOR ANTI-CONDENSATION HEATER DIAGRAM
-KA9
WHT
TO CUSTOMER 220VAC SOURCE
10
PE
104
11
110
109
108
107
106
105
382
381
380
208
J5
203
RED
209
361
204
RED
210
362
363
364
205
RED
211
MODBUS
206
RTD2
212
VOUT1 3
VOUT2 2
GND 1
207
LINE TEMPER
211
3
~
T1
-M2
FAN MOTOR
T3
T2
3
4
RELAY
OUTPUT
PTC2
PTC1
FAN MOTOR
MONITOR
N 1
L 2
AC24V
-CT1
V
W
3
~
155℃
T3 T2 T1
U
PE
L1 L2 L3 PE
-M1
OPTIONS.
-FU1
-FU2
G120
-XB
100
110V
24V
-TC1 130 -FU3
-VSD
V3
U3
4 ONLY BE USED TO WC MACHINE.
5 SIGNAL LINES WITH SHIELDED
TO-CT1
102 TO-XT1
101
132
131
PRIOR TO STARTER AS REQUIRED BY LOCAL WIRING CODES.
2 REMOVE JUMPER TO ADD OPTIONS.
3 CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT
1
NOTES:
PE
3
COMPRESSOR MOTOR
132
131
203
211
-L1
EQUIPMENT AMBIT
-QF
2L1
WHT
213
2L2
219
218
217
216
215
214
213
212
211
210
209
208
207
206
205
204
203
202
201
214
2L3
2L2
1L1
1L2
1L3
PE
PE
2L3
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
217
+10V INTERNAL POWER SOURCE
J3
218
-SCN
219
3L1
3L2
3L3
U21
V21
W21
380
AI0:ANALOG INPUT 0～10V
AI0－
AI1:ANALOG INPUT 0～10V
AI1－
381
382
380
382
L1 L2 L3
DI COM1
+12V
RTD2 +
P3 SIG
RTD2 P4 SIG
GND
GND
RTD1 Ia DC4-20mA
-AP
RTD1 +
Ib DC4-20mA
P2 SIG
GND
P1 SIG
Ic DC4-20mA
+12V
EXTEND
GND
RTD3 +
LOCAL/MASTER D10
RTD3 REM LOAD/UNLOAD D9
GND
REM STA/STOP D8
RTD4 WATER PRESS D7
RTD4 +
POWER SURV. D6
D11 HI.VOLT.FAULT
OIL FILTER D5
GND
INL FILTER D4
MAIN MTR N.O
FAN MTR. D3
D13
MAIN MTR.NC D2
E.STOP D1
215
152
DI COM2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
216
START/LOW SPEED/STOP COMMAND 151
U22
V22
W22
381
0 TO 20mA MAXIMUM 500 OHM
J4
PE
DIGITAL INPUT
153
MAXIMUM SPEED COMAND
PID ENABLEMENT COMMAND
PTC/KTY
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
110
PE
PE
101
101
101
101
120
120
102
102
102
102
102
102
104
104
105
105
108
108
110
110
382
0 TO 20mA MAXIMUM 500 OHM
TO CUSTOMER SOURCE
150
PTC/KTY
PTC1
PTC2
2L1
θ
201
201
202
202
203
203
204
204
205
205
206
206
207
207
208
208
209
209
210
210
211
211
211
211
212
212
213
213
214
214
215
215
216
216
217
217
218
218
219
219
380
380
381
381
382
382
PE
PE
DO0
INVERTER FAULT 1
202
202A
CUSTOMER FURNISH
PROTCTION DEVICE
202A
211
+10
0V
AI0+
AI0AI1+
AI1DI0
DI1
DI2
DI3
DI4
DI5
U24V
U0V
-KM1
PE
DO2
INVERTER FAULT 2
EXTERNAL POWER
DO1
1
2
3
4
10
11
5
6
7
8
16
17
9
28
69
34
14
15
12
13
26
27
20
19
18
22
21
25
24
23
31
32
AO0+
AO0AO1+
AO1COM
NO
NC
COM
NO
COM
NO
NC
+24V
0V
29
-KA3
-KA1
AS45-75 Series Screw Compressor Operation Manual
Chapter VI Wiring Diagram
6.2 Wiring diagram of the VSD unit
AS45-75 Series Screw Compressor Operation Manual
Chapter VII Troubleshooting
Chapter VII Troubleshooting
7.1 Overview
Compressor’s fault may be caused by multiple reasons. Therefore, a systematic analysis on all causes of the
fault should be carried out before service or parts replacement. Do not disassemble the machine without
purpose. To avoid damage, visual check is necessary. Keep the following in mind:
a. If cable leads are loose or disconnected;
b. If pipeline is damaged;
c. If there is part damaged by over heat or short circuit. Phenomena are color changing or scorch odor.
7.2 Possible compressor fault and actions are listed in the following table
Symptom
Possibly generated causes
Actions
Low fluid level in fluid/air separator
Check fluid level, add fluid if necessary
Check thermal valve and replace thermal
components
Clean the cooler fins
Thermal valve failure
High discharge
air temperature
Cooler fin dirty
Fluid filter clogged up and bypass
valve failed
Ambient temperature high
Min pressure valve failure
Improve ventilation
1. Enlarge exhaust duct
2. Install exhaust fan in the duct
Check RTD connector. If the connector is good,
replace RTD
Check and repair fan motor
(1) Reduce air demand;
(2) Check for leakage on pipeline.
Replace filter element
Check motion of inlet valve, pressure reducing
valve and the setting of pressure regulator
Check transducer's contacts. Replace transducer
if contacts are normal
Check/repair min pressure valve
Oil/Air separator element clogged up
Check and replace Oil/Air separator element
Pressure transducer fault
Unloading devices (such as blow-off
valve, inlet regulation valve) failure
Solenoid valve failure
Check the operation of unloading components
Control pipeline filter clogged up
Repair filter assembly
Control air pipe leak
Check if control pipeline is leaking
High resistance in exhaust duct
Thermal
resistor
transducer RTD failure
Fan motor damaged
temperature
Air demand higher than air supply
Air supply
pressure lower
than rated
discharge
pressure
Line pressure
higher than
unloading
pressure setting
value
Replace the fluid filter
Air filter clogged up
Air inlet valve unable to open
completely
Pressure transducer fault
30
Check the operation of unloading components
Check the operation of solenoid valve
AS45-75 Series Screw Compressor Operation Manual
Symptom
Chapter VII Troubleshooting
Possibly generated causes
Actions
Oil return line filter or orifice blocked Clean filter
Check separator components and washer. Replace
Separator element or washer damaged
if necessary
Oil consumption
System is leaking
Check if pipeline system
too high
Fluid level too high
Discharge excess fluid
Vibration and
noise increased
Too much oil froth
Change fluid
Isolator damaged
Replace isolator
Fan or box fault
Check fan
31
AS45-75 Series Screw Compressor Operation Manual
Chapter VIII Spare Parts List
Chapter VIII Spare Parts List
Item
Service kit no.
Fluid filter element
Quantity
250025-526
Air filter 88290002-207 spare part of external filter 88290002-337
element
Air filter 88290002-207 spare part of internal filter 88290002-338
element
Primary Fluid/Air separator element
250042-862
Secondary Fluid/Air separator element
02250061-137
Air inlet valve 88291006-019 mini service kit
88292009-684
Air inlet valve 88291006-019 complete service kit
88292009-685
Pneumatic control integrated block repair package in the 88291006-021
air inlet valve control component assembly
88291006-018
Solenoid valve repair package in the air inlet valve 88291006-026
control component assembly 88291006-018
Pneumatic control integrated block repair package in the 88291010-178
air inlet valve control component assembly(Capacity
adjustment) 88291010-175
Solenoid valve repair package in the air inlet valve 88291010-180
control component assembly(Capacity adjustment)
88291010-175
Pressure regulator 250017-280 maintenance kit
250019-453
Minimum pressure valve 242405 maintenance kit
88290018-146
1
1
Thermal valve maintenance kit (Non-XH Model)
Thermal valve maintenance kit (XH Model)
Oil-return pipe filter repair package
Shaft seal maintenance kit
Coupling 88290003-312 elastomer
Coupling 88290003-311/88290007-806 elastomer
SRF Fluid (5gallon)
SRF Fluid (55gallon)
Sullube Fluid (5gallon)
Sullube Fluid (55gallon)
1
1
1
1
1
1
1
1
1
1
049542
88291004-703
02250117-782
02250050-364
88290003-322
88290003-326
250019-662
250019-663
87250022-669
87250022-670
1
1
1
1
1
1
1
1
1
1
1
Note: Please notify compressor model, series number and B.O.M number in ordering
spare parts to facilitate our service.
32
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
Chapter IX Parts List
9.1 Motor - Compressor System(AS4500-7500—Line Frequency Model)
33
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.1 Motor - Compressor System(AS4500-7500—Line Frequency Model) Parts List
S/N
P/N
Name
Qty.
1
02250155-285
Isolator
2
2
829108-150
Bolt
6
3
837808-125
Washer
6
Compressor Unit
1
4
Note
See Air End List
5
88290002-205
Connection Cylinder
1
6
88290002-206
Net Hood
2
88290003-311
Coupling
1
For AS45/55
88290003-312
Coupling
1
88290007-806
Coupling
1
Motor
1
For Motor Frame 365 Of AS75
For Motor Frame 404 And 405 Of
AS75
See Motor List
7
8
9
88290020-282
Isolator
2
10
88291005-892
Frame
1
11
88291005-932
Supporting Plate
1
For Motor Frame 364 And 365
88811112-050
Bolt
2
For Motor Frame 364 And 365
88811112-060
Bolt
2
For Motor Frame 404 And 405
13
88812110-020
Full Thread Bolt
8
14
88812112-025
Full Thread Bolt
2
15
88812116-045
Full Thread Bolt
4
16
88813108-016
Flange Bolt
10
17
88831110-020
Flat Washer
8
18
88831112-025
Flat Washer
2
19
88831116-030
Flat Washer
4
20
88832110-026
Spring Washer
8
21
88832112-031
Spring Washer
4
22
88832116-041
Spring Washer
4
23
88833112-033
Large Flat Washer
2
24
88290020-389
Motor Hole Sleeve
2
25
88290021-292
Air End Support
1
26
88290020-494
Primary Cable Jacket
2
27
88290020-284
Air End Mounting Plate
1
12
34
Support When Maintenance
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.1 Motor - Compressor System(AS4500-7500—Line Frequency Model) (Continued)
35
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.1 Motor - Compressor System(AS4500-7500—Line Frequency Model) Parts List
(Continued)
Motor List
S/N
P/N
Description
Frame Size
1
88290003-912
45kW 380-415V 50Hz IP23
364TSC
2
88290006-603
45kW 380-415V 50Hz IP55
365TSC
3
88290007-737
45kW 230/460V 60Hz IP23
364TSC
4
88290006-601
45kW 230/460V 60Hz IP55
365TSC
5
88290006-758
55kW 380-415V 50Hz IP23
365TSC
6
88290008-258
55kW 380-415V 50Hz IP55
405TSC
7
88290007-746
55kW 380-420V 60Hz IP23
365TSC
8
88290007-738
55kW 230/460V 60Hz IP23
365TSC
9
88290021-149
55kW 230/460V 60Hz IP55
405TSC
10
88290004-856
75kW 380-415V 50Hz IP23
365TSC
11
88290002-819
75kW 380-415V 50Hz IP23
404TSC
12
88290008-874
75kW 380-415V 50Hz IP55
405TSC
13
88290019-957
75kW 380-415V 50Hz IP55
405TSC
14
88290008-056
75kW 380-420V 60Hz IP23
365TSC
15
88290007-747
75kW 380-420V 60Hz IP23
404TSC
16
88290008-055
75kW 230/460V 60Hz IP23
365TSC
17
88290007-739
75kW 230/460V 60Hz IP23
404TSC
18
88290017-189
75kW 230/460V 60Hz IP55
405TSC
36
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.1 Motor - Compressor System(AS4500-7500—Line Frequency Model) (Continued)
37
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.1 Motor - Compressor System(AS4500-7500—Line Frequency Model) Parts List
(Continued)
Air End List
S/N
P/N
Note
1
88250126-028
AS4507 50Hz
2
88250125-942
AS4508 50Hz
3
88250124-217
AS4510 50Hz、AS5510 60Hz
4
88250125-944
AS4512 50Hz
5
88290012-458
AS4507 60Hz
6
88290009-321
AS4508 60Hz
7
88250142-562
AS4510 60Hz、AS7510 50Hz
8
88250120-600
AS5507 50Hz
9
88250120-601
AS5508 50Hz
10
88250120-603
AS5510 50Hz、AS7512 60Hz
11
88250120-602
AS5512 50Hz
12
88290009-339
AS5507 60Hz
13
88250146-440
AS5508 60Hz
14
88290009-774
AS5512 60Hz
15
88250118-612
AS7507 50Hz
16
88250118-613
AS7508 50Hz
17
88250155-031
AS7512 50Hz
18
88250145-512
AS7507 60Hz
19
88290009-322
AS7508 60Hz
20
88250198-176
AS7510 60Hz
38
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.2 Motor - Compressor System(AS4500-7500—VSD Model)
39
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.2 Motor - Compressor System(AS4500-7500—VSD Model) Parts List
S/N
P/N
Name
Qty.
Note
1
88833112-033
Large Flat Washer
2
2
88832112-031
Spring Washer
4
3
88832116-041
Spring Washer
4
4
88832110-026
Spring Washer
8
5
88291008-551
Frame
1
6
88290020-389
Motor Hole Sleeve
2
7
837808-125
Washer
6
8
88290020-284
Air End Mounting Plate
1
9
88290020-283
Isolator
2
10
88290020-282
Isolator
2
11
88290002-205
Connection Cylinder
1
12
88813108-016
Flange Bolt
10
13
829108-150
Bolt
6
14
88831112-025
Flat Washer
2
15
88831116-030
Flat Washer
4
16
88831110-020
Flat Washer
8
17
88812112-025
Full Thread Bolt
2
18
88812116-045
Full Thread Bolt
4
19
88812110-020
Full Thread Bolt
8
20
88290002-206
Net Hood
2
21
88290021-292
Air End Support
1
Support When Maintenance
Compressor Unit
1
See Air End List
Supporting Plate
1
For Motor Frame 364 And 365
Motor
1
See Motor List
88290007-806
Coupling
1
For Motor Frame 404 And 405
88290003-311
Coupling
1
For Motor Frame 364 And 365
88811112-050
Bolt
2
For Motor Frame 364 And 365
88811112-060
Bolt
2
For Motor Frame 404 And 405
22
23
88291005-932
24
25
26
40
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.2 Motor - Compressor System(AS4500-7500—VSD Model) (Continued)
41
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.2 Motor - Compressor System(AS4500-7500—VSD Model) Parts List (Continued)
Motor List
S/N
P/N
Description
Frame Size
1
88290020-085
VSD 75KW 380V 75Hz IP55
405TSC
2
88290020-086
VSD 75KW 380V 75Hz IP23
405TSC
3
88290020-089
VSD 55KW 380V 75Hz IP55
365TSC
4
88290020-810
VSD 45KW 380V 75Hz IP23
364TSC
5
88290020-819
VSD 55KW 380V 75Hz IP23
405TSC
6
88290020-820
VSD 45KW 380V 75Hz IP55
365TSC
7
88290022-037
VSD 55KW 380V 75Hz IP55
365TSC
8
88290022-038
VSD 45KW 380V 75Hz IP55
365TSC
9
88290022-041
VSD 75KW 380V 75Hz IP23
405TSC
10
88291007-133
VSD 45KW 380V 60Hz IP23
364TSC
11
88291007-134
VSD 45KW 380V 60Hz IP55
365TSC
12
88291005-755
VSD 75KW 220V 75Hz IP23
404TSC
13
88291007-379
VSD 55KW 220V 75Hz IP23
404TSC
14
88291008-955
VSD 55KW 440V 75Hz IP55
365TSC
Air End List
S/N
P/N
Note
1
88250124-217
AS7510V/AS7512V
2
88250125-944
AS5507V/AS5508V
3
88250186-337
AS4507V/AS4508V/AS4510V/AS4512V
4
88250186-338
AS5510V/AS5512V
5
88250186-339
AS7507V/AS7508V
42
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.3 Air Inlet System(AS4500-7500—Line Frequency/VSD Model)
43
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.3 Air Inlet System(AS4500-7500—Line Frequency/VSD Model) Parts List
S/N
P/N
Name
Qty.
1
02250061-835
Elbow
1
2
408153
Clamp
2
3
829108-150
Bolt
4
4
837808-125
Washer
4
5
88290002-207
Air Filter
1
6
88290002-208
Clamp
1
7
88290004-147
1
9
88291007-195
Washer
Air Inlet Valve Control
Component Assembly
Air Inlet Valve Control
Component Assembly
Support
10
88811110-070
Bolt
1
11
88812110-025
Full Thread Bolt
4
12
88821110-084
Nut
3
13
88831110-020
Flat Washer
5
14
88832110-026
Spring Washer
5
88291010-175
8
88291006-018
44
Note
1
For Line Frequency Model
1
For VSD Model
1
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.4 Fluid Loop System(AS4500-7500— Line Frequency/VSD Model)
45
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.4 Fluid Loop System(AS4500-7500— Line Frequency/VSD Model) Parts List
S/N
P/N
Name
Qty.
Note
1
88290005-222
Adjustable Rectangle Joint
5
2
88290001-578
1
3
88290023-074
4
250025-526
Joint
Differential Pressure Switch
Fluid filter Holder Integration
Fluid filter Element
5
88290005-223
Straight Joint
1
88291008-554
Fluid Supply Pipe
1
For VSD Model
88291009-572
Fluid Supply Pipe
1
For Line Frequency Model
7
88291008-555
Fluid Inlet Pipe
1
8
88291006-078
External Joint
2
9
88842035-037
O-Ring
10
10
88842026-025
O-Ring
6
11
88832110-026
Spring Washer
4
12
88818210-040
Socket Head Cap Screw
4
13
02250101-372
Seal Ring
1
14
88291008-556
Fluid Outlet Pipe
1
15
02250112-477
Valve seat
1
16
88813106-016
Flange Bolt
2
17
826502-144
O-Ring
1
18
88851035-058
Clip
1
88291004-703
Thermal Valve Element
1
For 12bar Model
049542
Thermal Valve Element
1
For non-12bar Model
250019-661
SRF 1/4000 Fluid (GA)
Sullube 2G Cooling &
Lubricating Oil (GA)
9.2
6
19
20
87250009-396
46
1
1
9.2
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.5 Cooling Fan System(AS4500-7500—Line Frequency/VSD Model)
47
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.5 Cooling Fan System(AS4500-7500—Line Frequency/VSD Model) Parts List
S/N
P/N
Name
Qty.
Note
02250075-404
Protection Net
1
AS75 50Hz Model
241079
Protection Net
1
241908
Fan
1
02250119-485
Fan
1
Not AS75 50Hz Model
AS45/55 50Hz Model, AS75
60Hz Model
AS75 50Hz Model
049971
Fan
1
AS45/55 60Hz Model
88290004-417
Motor
1
AS45/55 50Hz Model
88290004-944
Motor
1
AS75 50Hz Model
88290007-748
Motor
1
AS45/55 60Hz 230V/460V Model
88290007-749
Motor
1
AS45/55 60Hz 380V Model
88290007-733
Motor
1
AS75 60Hz 230V/460V Model
88290007-741
Motor
1
AS75 60Hz 380V Model
88290002-587
Motor Fixing Support
1
AS45/55 50Hz Model
88290002-209
Motor Fixing Support
1
AS75 50Hz Model
88290006-718
Motor Fixing Support
1
AS45/55 60Hz Model
88290007-268
Motor Fixing Support
1
88290006-321
Air Guide Cylinder
1
88290006-322
Air Guide Cylinder
1
AS75 60Hz Model
AS45/55 50Hz Model, AS75
60Hz Model
AS75 50Hz Model
88290006-719
Air Guide Cylinder
1
AS45/55 60Hz Model
88291006-030
Air Guide Hood
1
88291006-088
Fluid Air Cooler
1
For AS45/55
88291006-995
Fluid Air Cooler
1
For AS75
8
88811110-040
Bolt
4
9
88813108-016
Flange Bolt
4
10
88813108-020
Flange Bolt
27
11
88813108-025
Flange Bolt
3
12
88821110-084
Nut
4
13
88822108-076
Flange Nut
20
14
88831108-016
Flat Washer
30
15
88832108-021
Spring Washer
30
16
88832110-026
Spring Washer
4
17
88833110-027
Large Flat Washer
4
1
2
3
4
5
6
7
48
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.6 Fluid/air Separation System(AS4500-7500— Line Frequency/VSD Model)
49
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.6 Fluid/air Separation System(AS4500-7500— Line Frequency/VSD Model) Parts List
S/N
P/N
Name
Qty.
Note
1
88842035-023
O-Ring
1
2
88290002-688
Half Flange
1
3
88290002-435
Female Thread Ball Valve
1
4
88290002-836
Oil Plug
1
5
88842026-051
O-Ring
1
6
88290001-219
Sight Glass
1
7
88842035-047
O-Ring
1
8
88290001-031
1
9
250042-862
10
88871008-044
Oiler Plug
Primary Fluid/Air separator
element
Internal Joint
88291008-550
Fluid/Air Separator Tank
1
GB
88291010-492
Fluid/Air Separator Tank
1
ASME
12
020169
Joint
2
13
810504-025
Elbow
1
14
841215-004
Stainless Steel Pipe (FT)
15
02250101-490
Joint
2
16
02250117-782
Filtering Joint
2
17
02250126-129
Sight Glass
2
18
88831112-025
Flat Washer
4
19
88832112-031
Spring Washer
8
20
88811112-030
Bolt
4
21
837808-125
Washer
4
22
828408-150
Bi-Hexagonal Head Bolt
4
23
88811112-060
Bolt
4
24
88842035-069
O-Ring
1
25
88842035-075
O-Ring
1
26
88290005-474
Connection Base
1
For AS5507、AS7507、AS7508
27
88834233-027
Combined Gasket
1
For AS5507、AS7507、AS7508
88291006-621
Discharge Pipe
1
For Line Frequency Model
88291008-945
Discharge Pipe
1
For VSD Model
29
88290002-637
Pipe Board
1
30
88832108-021
Spring Washer
4
31
88813108-025
Flange Bolt
4
32
02250125-776
Orifice
1
For Not Of AS4512、AS5512
33
02250125-775
Orifice
1
For Not Of AS4512、AS5512
34
02250125-774
Orifice
2
For AS4512、AS5512
88290005-468
Relief Valve
1
For AS4508、AS5508
88290005-469
Relief Valve
1
For AS4510、AS5510、AS7510
88290001-780
Relief Valve
1
For AS4512、AS5512、AS7512
88290005-467
Relief Valve
1
For AS4507
11
28
35
50
1
1
9.7
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.6 Fluid/air Separation System(AS4500-7500— Line Frequency/VSD Model)
(Continued)
51
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.6 Fluid/air Separation System(AS4500-7500— Line Frequency/VSD Model) Parts List
(Continued)
S/N
35
P/N
Name
Qty.
Note
88290005-471
Relief Valve
1
For AS5507、AS7507
88290005-472
1
For AS7508
36
02250061-137
37
860704-025
Relief Valve
Secondary Fluid/Air
separator element
Elbow
38
869825-025
Tee Joint
1
39
810104-025
Joint
1
52
1
1
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.7 Air Discharge System(AS4500-7500—Line Frequency/VSD Model)
53
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.7 Air Discharge System(AS4500-7500—Line Frequency/VSD Model) Parts List
S/N
P/N
Name
Qty.
1
88291009-260
External Joint
2
2
88291006-087
Moisture Separator
1
3
242405
Minimum pressure valve
1
4
88290005-230
Adjustable Rectangle Joint
1
5
88290001-541
Joint
1
6
88290005-231
Joint
1
7
88291006-622
Air Inlet Pipe
1
8
88842035-065
O-Ring
1
9
88842026-042
O-Ring
2
10
88842035-045
O-Ring
4
11
88291007-773
Adjustable Rectangle Joint
1
54
Note
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.8 Control System(AS4500-7500—Line Frequency Model)
55
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.8 Control System(AS4500-7500—Line Frequency Model) Parts List
S/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
P/N
02250054-861
02250099-626
02250099-630
241771
250003-869
250018-427
250018-429
250023-496
807600-005
807602-010
868504-025
88290002-119
88290002-284
88290002-732
88290002-748
88290002-751
88290002-754
88290014-514
88290021-801
88290021-986
88290022-463
88291006-109
88291006-110
88291006-111
88291006-163
88291006-164
88291006-165
88291008-467
88291008-468
88291008-469
88812110-020
88821104-032
88831110-020
88832110-026
88290002-774
88290002-775
88290002-836
823202-000
88813108-016
88291010-070
88818004-012
88832104-011
Name
Qty.
Nylon Conduit (FT)
Elbow
Nylon Conduit (FT)
Filtering Screen
Indicator
Straight Joint
Elbow
Joint
Reducing Joint
Reducing Joint
Joint
Oil-Filling Pressure Gauge
Adapter
Plastic-Coated Hose (MT)
Plastic-Coated Metal Hose Connector
Adapter
Adapter
Pressure Transducer
Joint
Temperature Sensor
Cable Jacket
Electric Control Panel Assembly
Electric Control Panel Assembly
Electric Control Panel Assembly
Electric Control Panel Assembly
Electric Control Panel Assembly
Electric Control Panel Assembly
Electric Control Panel Assembly
Electric Control Panel Assembly
Electric Control Panel Assembly
Full Thread Bolt
Nut
Flat Washer
Spring Washer
Cable(MT)
Cable(MT)
Plug
Joint
Flange Bolt
Control Panel
Screw
Spring Washer
4
2
6
1
1
1
1
1
1
1
1
1
1
0.6
2
2
2
1
1
1
2
1
1
1
1
1
1
1
1
1
4
8
4
4
1.5
1.5
1
1
3
1
4
8
56
Note
For AS45/AS55
For AS75
AS45 380-420V
AS55 380-420V
AS75 380-420V
AS45 220-240V
AS55 220-240V
AS75 220-240V
AS45 440-480V
AS55 440-480V
AS75 440-480V
For AS45/AS55
For AS75
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.9 Control System(AS4500-7500—VSD Model)
57
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.9 Control System(AS4500-7500—VSD Model) Parts List
S/N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
P/N
02250054-861
88290022-463
88290003-806
250023-496
88290002-284
250018-427
250039-909
250003-869
88290021-801
88291008-571
88291009-652
88291009-663
88291009-665
88291009-664
88291009-666
250018-430
88831110-020
88832110-026
88812110-020
868504-025
241771
02250099-626
02250099-630
807602-010
88813108-016
88813108-012
88292036-888
88832104-011
88821104-032
02250048-822
88290004-495
88290001-535
88290001-536
88291009-248
807602-005
823202-000
250028-635
88290002-774
88290002-775
88290002-751
88290002-754
250018-429
Name
Nylon Conduit (FT)
Cable Jacket
Pressure Transducer
Joint
Adapter
Straight Joint
Temperature Sensor
Indicator
Joint
Electric Control Panel Assembly
Assembly
Electric
Control Panel Assembly
Assembly
Electric Control Panel Assembly
Electric Control Panel Assembly
Electric Control Panel Assembly
Electric Control Panel Assembly
Elbow
Flat Washer
Spring Washer
Full Thread Bolt
Joint
Filtering Screen
Elbow
Nylon Conduit (FT)
Reducing Joint
Flange Bolt
Flange Bolt
Deluxe Microprocessor Controller
Spring Washer
Nut
Gasket
Emergency Stop Alarm Ring
Emergency Stop Button
Contact
Cable Jacket Assembly
Reducing Joint
Joint
Joint
Cable(MT)
Cable(MT)
Adapter
Adapter
Elbow
58
Qty.
5.2
1
2
2
1
2
2
1
2
1
1
1
1
1
1
1
5
5
5
1
1
2
2.3
1
6
2
1
8
8
1
1
1
1
1
1
1
1
1.5
1.5
2
2
1
Note
AS75 380-420V
AS75 440-480V
AS55 380-420V
AS55 440-480V
AS45 380-420V
AS45 440-480V
SCN
For AS45/AS55
For AS75
For AS45/AS55
For AS75
AS45-75 Series Screw Compressor Operation Manual
9.10
Chapter IX Parts List
Air-cooled Acoustical Enclosure System(AS4500-7500—Line Frequency Model)
59
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.10 Air-cooled Acoustical Enclosure System(AS4500-7500—Line Frequency Model)
Parts List
S/N
P/N
Name
Qty.
Note
1
02250048-520
Plastic Cap
18
2
02250151-635
Door Gasket
4
3
250022-436
Sealing Strip (FT)
4
88291006-073
Pillar D
2
88291006-077
Angle Plate A
2
For AS45/AS55
88291010-323
Angle Plate C
2
For AS75
6
88291010-321
Angle Plate B
2
7
88291008-636
Beam C
2
8
88291009-416
Beam B
1
9
88291009-417
Door A
2
10
88291009-418
Door B
1
11
88291009-419
Door C
2
12
88291009-420
Beam A
1
13
88291009-421
Pillar B
1
14
88291009-423
Beam E
1
15
88291010-069
Pillar C
2
16
88291010-071
Beam D
1
17
88291010-072
Top Plate B
1
18
88291010-074
Door D
1
19
88291010-292
Top Plate A
1
20
88813108-012
Flange Bolt
8
21
88813108-016
Flange Bolt
94
23
88291012-890
Pillar A
1
5
60
47.5
AS45-75 Series Screw Compressor Operation Manual
9.11
Chapter IX Parts List
Air-cooled Acoustical Enclosure System(AS4500-7500—VSD Model)
61
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.11 Air-cooled Acoustical Enclosure System(AS4500-7500—VSD Model) Parts List
S/N
P/N
Name
Qty.
Note
1
02250151-635
Door Gasket
4
2
88291006-073
Pillar D
2
3
88291008-636
Beam C
1
4
88291008-599
Pillar B
1
5
88291008-754
Pillar C
1
6
88813108-012
Flange Bolt
6
7
88813108-016
Flange Bolt
82
8
88291009-257
Top Plate A
1
9
02250048-520
Plastic Cap
23
10
250022-436
Sealing Strip (FT)
11
88291008-600
Top Plate B
1
12
88291008-757
Beam D
1
13
88291012-890
Pillar A
1
14
88291009-423
Beam E
1
15
88291009-417
Door A
1
16
88291009-416
Beam B
1
17
88291010-358
Door D
1
18
88291009-418
Door B
1
19
88291009-419
Door C
2
20
88291009-420
Beam A
1
88291009-422
Angle Plate A
2
For AS45/AS55
88291010-322
Angle Plate C
2
For AS75
88291010-357
Angle Plate B
2
21
22
62
47.5
AS45-75 Series Screw Compressor Operation Manual
9.12
Chapter IX Parts List
Decal System(AS4500-7500—Line Frequency Model)
63
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.12 Decal System(AS4500-7500—Line Frequency Model) Parts List (For Domestic
Models)
S/N
P/N
Name
Qty.
Note
1
88291010-096
SULLAIR LOGO Decal
1
2
049855
Warning Decal
1
3
241814
Hoisting Position Decal
2
4
049850
Electric Shock Warning Decal
1
5
250017-903
Auto Start/Stop Warning Decal
1
6
042218
High Pressure Risk Decal
1
7
250021-564
Rotation Direction Decal
2
8
049852
Grounding Decal
1
9
250021-337
Initial Start Label
1
10
049685
Oil Filling Port Warning Decal
1
11
250027-935
Breathing Warning Decal
1
12
250003-144
Food Warning Decal
1
13
88290011-431
Website Decal
1
250023-361
Sullube Oil Reminder Decal
1
SULLUBE
250022-839
SRF Oil Reminder Decal
1
SRF
88291010-360
AS4500 Decal
1
AS45
88291010-361
AS5500 Decal
1
AS55
88291010-362
AS7500 Decal
1
AS75
16
88290016-067
Voltage Warning Combo Decal
1
17
88290013-683
Nameplate
1
18
88290013-723
Rivet
4
14
15
64
AS45-75 Series Screw Compressor Operation Manual
9.13
Chapter IX Parts List
Decal System(AS4500-7500—VSD Model)
65
AS45-75 Series Screw Compressor Operation Manual
Chapter IX Parts List
9.13 Decal System(AS4500-7500—VSD Model) Parts List
S/N
P/N
Name
Qty.
Note
1
88291010-096
SULLAIR LOGO Decal
1
2
049855
Warning Decal
1
3
241814
Hoisting Position Decal
2
4
049850
Electric Shock Warning Decal
1
5
250017-903
Auto Start/Stop Warning Decal
1
6
042218
High Pressure Risk Decal
1
7
250021-564
Rotation Direction Decal
2
8
049852
Grounding Decal
1
9
250021-337
Initial Start Label
1
10
049685
Oil Filling Port Warning Decal
1
11
250027-935
Breathing Warning Decal
1
12
250003-144
Food Warning Decal
1
13
88290011-431
Website Decal
1
250023-361
Sullube Oil Reminder Decal
1
SULLUBE
250022-839
SRF Oil Reminder Decal
1
SRF
88291010-360
AS4500 Decal
1
AS45
88291010-361
AS5500 Decal
1
AS55
88291010-362
AS7500 Decal
1
AS75
16
88290016-067
Voltage Warning Combo Decal
1
17
88290013-683
Nameplate
1
18
88290013-723
Rivet
4
19
88290020-725
VSD Decal
1
14
15
66
Global Sales & Service
Headquarter in US:
Headquarter in Asia:
SULLAIR CORPORATION
A Hitachi Group Company
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 001-219-879-5451 or 1-800-Sullair (U.S.A. only )
Fax: 001-219-874-1273
SULLAIR ASIA website: http://www.sullair-asia.com Hotline: 800-830-3977
Sullair Singapore: 74 Joo Koon Circle, Jurong Singapore 629093
Telephone: 65-68611211 Fax: 65-68612967
Sullair Taipei: No. 1, 3rd Floor, 248 Zhongshan Road, Linkou Village, Taipei
County
Tel: 02-26013500 Fax: 02-26013032
Suzhou Factory: 266 Changyang Street, Industrial Park, Suzhou, 215000
Tel: 0512-87162388
Fax: 0512-87162389, 87162387
Beijing Branch: Room 1506, Block B, Xingfu Building, 3 Eastern Third Ring
Road, Beijing City 100027
Tel: 010-64629770, 64629768 Fax: 010-64629773
Chengdu Branch: Block H, 28/F., Guancheng Plaza, 308 Shuncheng Street,
Chengdu City 610017
Tel: 028-86527506, 86527507 Fax: 028-86527505
Shenyang Branch: Room 1601, Gaodeng International Building, 355 Zhongshan
Road, Shenhe District, Shenyang City 110014
Tel: 024-22818450, 22818550
Fax: 024-22818590
Xi’an Branch: Room 701A, Jinxin International Building, 99 Heping Road,
Xi’an City 710001
Tel: 029-87206201, 87206202 Fax: 029-87206204
Wuhan Branch: Room 2909, Block B, Office Building, Zhongshang Plaza, 7
Zhongnan Road, Wuchang District, Wuhan City 430071
Tel: 027-87322745
Fax: 027-87322546
Xinjiang Branch: Unit J, 9th Floor, National Development Bank Tower, 339
Zhongshan Road, Urumqi 830002
Tel: 0991-2308451, 2308452
Fax: 0991-2308450
88291007-019
06