USER MANUAL

Oil Free Air Compressor

DR13
100 – 200 hp (75 – 150 kW)

PART NUMBER:
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The information in this manual is current as of its
SAFETY WARNING WARRANTY NOTICE publication date and applies to compressor models
indicated on this cover with serial number:
Users are required to read the Failure to follow the instructions 201609010000
entire User Manual before han- and procedures in this manual, and all subsequent serial numbers.
dling or using the product. or misuse of this equipment, will
void its warranty. Publication date: 09/14/2016
Copyright © 2016 Sullair, LLC. All rights reserved.

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

 Air Care Seminar Training
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and
servicing of Sullair products. Individual seminars on Stationary compressors and compressor electrical systems are
offered at regular intervals throughout the year at Sullair’s training facility located at Michigan City, Indiana.

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

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

Sullair Training Department

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

- Or Write -
Sullair, LLC
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.

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

DR13 100 – 200 hp (75 – 150 kW) User Manual Table of Contents

Table of Contents
Section 1: Safety.......................................................................................................1
1.1 General....................................................................................................... 1
1.2 Personal protective equipment ................................................................... 1
1.3 Pressure release ........................................................................................ 1
1.4 Fire and explosion ...................................................................................... 2
1.5 Moving parts ............................................................................................... 2
1.6 Hot surfaces, sharp edges and sharp corners............................................ 3
1.7 Toxic and irritating substances ................................................................... 3
1.8 Electrical shock........................................................................................... 4
1.9 Lifting .......................................................................................................... 4
1.10 Entrapment ................................................................................................. 5
1.11 Implementation of lockout/tagout................................................................ 5
1.12 Safety warnings .......................................................................................... 6

Section 2: Description..............................................................................................9
2.1 Introduction................................................................................................. 9
2.2 Description of components ......................................................................... 9
2.3 Compressor unit, functional description ..................................................... 9
2.4 Air inlet system, functional description ....................................................... 9
2.5 Load/unload capacity control system, functional description.................... 10
2.6 Cooling and silencing system, functional description ............................... 13
2.7 Lubrication system, functional description................................................ 15
2.8 Buffer air system, functional description................................................... 17

Section 3: Specifications .......................................................................................19

3.1 Tables of specifications ............................................................................ 19
3.2 Lubrication guide ...................................................................................... 20
3.3 Identification ............................................................................................. 22
3.4 Wiring diagram ......................................................................................... 24
3.5 Piping & instrumentation, compressor system ......................................... 26

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Table of Contents DR13 100 – 200 hp (75 – 150 kW) User Manual

Section 4: Installation ............................................................................................ 29

4.1 Mounting of compressor ........................................................................... 29
4.2 Ventilation and cooling.............................................................................. 29
4.3 Service air condensate piping................................................................... 29
4.4 Shaft coupling alignment check ................................................................ 29
4.5 Fluid level check ....................................................................................... 30
4.6 Electrical preparation ................................................................................ 30
4.7 Motor rotation check ................................................................................. 31

Section 5: Operation .............................................................................................. 33

5.1 General ..................................................................................................... 33
5.2 Purpose of controls ...................................................................................33
5.3 Supervisor™ operating parameters—setup.............................................. 34
5.4 Initial startup procedure ............................................................................34
5.5 System status messages .......................................................................... 34
5.6 Subsequent start-up procedure ................................................................ 35
5.7 Shutdown procedure................................................................................. 35

Section 6: Supervisor™ Controller ...................................................................... 37

6.1 Introduction ............................................................................................... 37
6.2 Supervisor keyboard layout ...................................................................... 37
6.3 Main display .............................................................................................. 38
6.4 Function menu ..........................................................................................38
6.5 Status—current pressures, temperatures, inputs and outputs.................. 39
6.6 Control parameters—pressure, temperature and timer settings............... 39
6.7 Maintenance—preventive maintenance information & timers................... 40
6.8 Fault log—log of previous faults................................................................ 40
6.9 Sensor log.................................................................................................40
6.10 Sequencing—sequencing & communication parameters ......................... 40
6.11 System display—display of modes of machines in a sequencing system... 41
6.12 Calibration—correction factors for pressures............................................ 41
6.13 Test ........................................................................................................... 42
6.14 Factory setup—model settings ................................................................. 42

Section 7: Maintenance ......................................................................................... 45

7.1 General ..................................................................................................... 45
7.2 Daily operation ..........................................................................................45
7.3 Initial maintenance after 50 hours of operation.........................................45
7.4 Maintenance every 8,000 hours or one year of operation ........................ 45

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DR13 100 – 200 hp (75 – 150 kW) User Manual Table of Contents

7.5 Maintenance every 16,000 hours or two years of operation..................... 45

7.6 Diagnostic service (optional) .................................................................... 46
7.7 Parts replacement and adjustment procedures........................................ 46
7.7.1 Air filter inspection and maintenance...................................................................46
7.7.2 Oil filter maintenance ...........................................................................................47
7.7.3 Shaft coupling maintenance ................................................................................48

Section 8: Troubleshooting ...................................................................................51

8.1 Introduction............................................................................................... 51
8.2 Troubleshooting guide .............................................................................. 51

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Table of Contents DR13 100 – 200 hp (75 – 150 kW) User Manual

Notes:

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DR13 100 – 200 hp (75 – 150 kW) User Manual 1: Safety

Section 1
Safety
most compressors and the concepts behind these state-
NOTE ments are generally applicable to all compressors.

1.2 Personal protective equipment

A. Prior to installing or operating the compressor, own-
ers, employers and users should become familiar
with, and comply with, all applicable OSHA regula-
Operator is required to read tions and/or any applicable Federal, State and Local
entire instruction manual. codes, standards, and regulations relative to per-
sonal protective equipment, such as eye and face
protective equipment, respiratory protective equip-
1.1 General ment, equipment intended to protect the extremities,
protective clothing, protective shields and barriers
Sullair and its subsidiaries design and manufacture all of
and electrical protective equipment, as well as noise
their products so they can be operated safely. However,
exposure administrative and/or engineering controls
the responsibility for safe operation rests with those who
and/or personal hearing protective equipment.
use and maintain these products. The following safety
precautions are offered as a guide which, if conscien-
tiously followed, will minimize the possibility of accidents
throughout the useful life of this equipment.
1.3 Pressure release
A. Install an appropriate flow-limiting valve between the
The compressor should be operated only by those who service air outlet and the shut-off (throttle) valve,
have been trained and delegated to do so, and who have either at the compressor or at any other point along
read and understood this Operator’s Manual. Failure to the air line, when an air hose exceeding ½″ (13 mm)
follow the instructions, procedures and safety inside diameter is to be connected to the shut-off
precautions in this manual may result in accidents and (throttle) valve, to reduce pressure in case of hose
injuries. NEVER start the compressor unless it is safe to failure, per OSHA Standard 29 CFR 1926.302(b)(7)
do so. DO NOT attempt to operate the compressor with a and/or any applicable Federal, State and Local
known unsafe condition. Tag the compressor and render codes, standards and regulations.
it inoperative by disconnecting and locking out all power
at source or otherwise disabling its prime mover so B. When the hose is to be used to supply a manifold,
others who may not know of the unsafe condition cannot install an additional appropriate flow-limiting valve
attempt to operate it until the condition is corrected. between the manifold and each air hose exceeding
½″ (13 mm) inside diameter that is to be connected
Install, use and operate the compressor only in full to the manifold to reduce pressure in case of hose
compliance with all pertinent OSHA regulations and/or failure.
any applicable Federal, State, and Local codes,
standards and regulations. DO NOT modify the C. Provide an appropriate flow-limiting valve at the
compressor and/or controls in any way except with beginning of each additional 75 feet (23 m) of hose in
written factory approval. runs of air hose exceeding ½″ (13 mm) inside diame-
ter to reduce pressure in case of hose failure.
While not specifically applicable to all types of compres-
sors with all types of prime movers, most of the precau- D. Flow-limiting valves are listed by pipe size and flow-
tionary statements contained herein are applicable to rated. Select appropriate valves accordingly, in

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accordance with their manufacturer's recommenda- material. Any acoustical material with a protective
tions. covering that has been torn or punctured should be
replaced immediately to prevent accumulation of liq-
E. DO NOT use air tools that are rated below the maxi-
uids or fluid film within the material. DO NOT use
mum rating of the compressor. Select air tools, air
flammable solvents for cleaning purposes.
hoses, pipes, valves, filters and other fittings accord-
ingly. DO NOT exceed manufacturer’s rated safe D. Disconnect and lock out all power at source prior to
operating pressures for these items. attempting any repairs or cleaning of the compressor
or of the inside of the enclosure, if any.
F. Secure all hose connections by wire, chain or other
suitable retaining device to prevent tools or hose E. Keep electrical wiring, including all terminals and
ends from being accidentally disconnected and pressure connectors in good condition. Replace any
expelled. wiring that has cracked, cut, abraded or otherwise
degraded insulation, or terminals that are worn, dis-
G. Open fluid filler cap only when compressor is not run-
colored or corroded. Keep all terminals and pressure
ning and is not pressurized. Shut down the compres-
connectors clean and tight.
sor and bleed the receiver tank to zero internal
pressure before removing the cap. F. Keep grounded and/or conductive objects such as
tools away from exposed live electrical parts such as
H. Vent all internal pressure prior to opening any line, fit-
terminals to avoid arcing which might serve as a
ting, hose, valve, drain plug, connection or other
source of ignition.
component, such as filters and line oilers, and before
attempting to refill optional air line anti-icer systems G. Remove any acoustical material or other material
with antifreeze compound. that may be damaged by heat or that may support
combustion and is in close proximity, prior to attempt-
I. Keep personnel out of line with and away from the
ing weld repairs.
discharge opening of hoses or tools or other points of
compressed air discharge. H. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when servicing
J. DO NOT use air at pressures higher than 2.1 bar for
and operating the compressor.
cleaning purposes, and then only with effective chip
guarding and personal protective equipment per I. Keep oily rags, trash, leaves, litter or other combusti-
OSHA Standard 29 CFR 1910.242(b) and/or any bles out of and away from the compressor.
applicable Federal, State, and Local codes, stan-
J. DO NOT operate the compressor without proper flow
dards and regulations.
of cooling air or water or with inadequate flow of lubri-
K. DO NOT engage in horseplay with air hoses as cant or with degraded lubricant.
death or serious injury may result.
K. DO NOT attempt to operate the compressor in any
classification of hazardous environment unless the
compressor has been specially designed and manu-
1.4 Fire and explosion factured for that duty.
A. Clean up spills of lubricant or other combustible sub-
stances immediately, if such spills occur.
B. Shut off the compressor and allow it to cool. Then
1.5 Moving parts
keep sparks, flames and other sources of ignition A. Keep hands, arms and other parts of the body and
away and DO NOT permit smoking in the vicinity clothing away from couplings, belts, pulleys, fans and
when checking or adding lubricant or when refilling other moving parts.
air line anti-icer systems with antifreeze compound.
B. DO NOT attempt to operate the compressor with the
C. DO NOT permit fluids, including air line anti-icer sys- fan, coupling or other guards removed.
tem antifreeze compound or fluid film, to accumulate
C. Wear snug-fitting clothing and confine long hair when
on, under or around acoustical material, or on any
working around this compressor, especially when
external surfaces of the air compressor. Wipe down
exposed to hot or moving parts.
using an aqueous industrial cleaner or steam clean
as required. If necessary, remove acoustical mate- D. Keep access doors, if any, closed except when mak-
rial, clean all surfaces and then replace acoustical ing repairs or adjustments.

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DR13 100 – 200 hp (75 – 150 kW) User Manual 1: Safety

E. Make sure all personnel are out of and/or clear of the

compressor prior to attempting to start or operate it. DANGER
F. Disconnect and lock out all power at source and ver-
ify at the compressor that all circuits are de-energized
to minimize the possibility of accidental start-up, or
operation, prior to attempting repairs or adjustments.
This is especially important when compressors are
remotely controlled.
G. Keep hands, feet, floors, controls and walking sur-
faces clean and free of fluid, water or other liquids to Death or serious injury can result from inhaling
minimize the possibility of slips and falls. compressed air without using proper safety
equipment. See OSHA standards and/or any
applicable Federal, State, and Local codes, stan-
1.6 Hot surfaces, sharp edges and dards and regulations on safety equipment.
sharp corners
A. Avoid bodily contact with hot fluid, hot coolant, hot B. DO NOT use air line anti-icer systems in air lines
surfaces and sharp edges and corners. supplying respirators or other breathing air utilization
B. Keep all parts of the body away from all points of air equipment and DO NOT discharge air from these
discharge. systems into unventilated or other confined areas.

C. Wear personal protective equipment including gloves C. Operate the compressor only in open or adequately
and head covering when working in, on or around the ventilated areas.
compressor. D. Locate the compressor or provide a remote inlet so
D. Keep a first aid kit handy. Seek medical assistance that it is not likely to ingest exhaust fumes or other
promptly in case of injury. DO NOT ignore small cuts toxic, noxious or corrosive fumes or substances.
and burns as they may lead to infection E. Coolants and lubricants used in this compressor are
typical of the industry. Care should be taken to avoid
accidental ingestion and/or skin contact. In the event
1.7 Toxic and irritating substances of ingestion, seek medical treatment promptly. Wash
A. DO NOT use air from this compressor for respiration with soap and water in the event of skin contact.
(breathing) except in full compliance with OSHA Consult Material Safety Data Sheet for information
Standards 29 CFR 1910 and/or any applicable Fed- pertaining to fluid of fill.
eral, State or Local codes or regulations. F. Wear goggles or a full face shield when adding anti-
freeze compound to air line anti-icer systems.
G. If air line anti-icer system antifreeze compound
enters the eyes or if fumes irritate the eyes, they
should be washed with large quantities of clean
water for fifteen minutes. A physician, preferably an
eye specialist, should be contacted immediately.
H. DO NOT store air line anti-icer system antifreeze
compound in confined areas.
I. The antifreeze compound used in air line antifreeze
systems contains methanol and is toxic, harmful or
fatal if swallowed. Avoid contact with the skin or eyes
and avoid breathing the fumes. If swallowed, induce
vomiting by administering a tablespoon of salt, in
each glass of clean, warm water until vomit is clear,
then administer two teaspoons of baking soda in a
glass of clean water. Have patient lay down and

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1: Safety DR13 100 – 200 hp (75 – 150 kW) User Manual

cover eyes to exclude light. Call a physician immedi-

ately. DANGER
All field equipment must be tested for electro-
1.8 Electrical shock static fields prior to servicing or making contact
A. This compressor should be installed and maintained with the machine using the following or equiva-
in full compliance with all applicable Federal, State lent test equipment:
and Local codes, standards and regulations, includ-
ing those of the National Electrical Code, and also • 90 – 600 VAC: Volt detector such as
including those relative to equipment grounding con- Fluke Model 1AC-A
ductors, and only by personnel that are trained, qual- • 600 – 7000 VAC: Voltage detector such
ified and delegated to do so. as Fluke Networks Model C9970
B. Keep all parts of the body and any hand-held tools or It is the responsibility of each organization to
other conductive objects away from exposed live provide/arrange training for all their associates
parts of electrical system. Maintain dry footing, stand expected to test for electrostatic fields.
on insulating surfaces and DO NOT contact any
other portion of the compressor when making adjust-
ments or repairs to exposed live parts of the electrical 1.9 Lifting
system. Make all such adjustments or repairs with
A. If the compressor is provided with a lifting bail, then
one hand only, so as to minimize the possibility of
lift by the bail provided. If no bail is provided, then lift
creating a current path through the heart.
by sling. Compressors to be air-lifted by helicopter
C. Attempt repairs in clean, dry and well lighted and must not be supported by the lifting bail but by slings
ventilated areas only. instead. In any event, lift and/or handle only in full
compliance with OSHA standards 29 CFR 1910 sub-
D. DO NOT leave the compressor unattended with open
part N and/or any applicable Federal, State, and
electrical enclosures. If necessary to do so, then discon-
Local codes, standards and regulations.
nect, lock out and tag all power at source so others will
not inadvertently restore power. B. Inspect points of attachment for cracked welds and
for cracked, bent, corroded or otherwise degraded
E. Disconnect, lock out, and tag all power at source
members and for loose bolts or nuts prior to lifting.
prior to attempting repairs or adjustments to rotating
machinery and prior to handling any ungrounded C. Make sure entire lifting, rigging and supporting struc-
conductors. ture has been inspected, is in good condition and has
a rated capacity of at least the weight of the com-
pressor. If you are unsure of the weight, then weigh
compressor before lifting.
D. Make sure lifting hook has a functional safety latch or
equivalent, and is fully engaged and latched on the
bail or slings.
E. Use guide ropes or equivalent to prevent twisting or
swinging of the compressor once it has been lifted
clear of the ground.
F. DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away from the
compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
I. Keep lift operator in constant attendance whenever
compressor is suspended.

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DR13 100 – 200 hp (75 – 150 kW) User Manual 1: Safety

J. Set compressor down only on a level surface capa- 1. Review the equipment or machine to be
ble of safely supporting at least its weight and its locked and tagged out.
loading unit. 2. Alert operator and supervisor of which
K. When moving the compressor by forklift truck, utilize machine is to be worked on, and that power
fork pockets if provided. Otherwise, utilize pallet if and utilities will be turned off.
provided. If neither fork pockets or pallet are pro- 3. Check to make certain no one is operating
vided, then make sure compressor is secure and well the machine before turning off the power.
balanced on forks before attempting to raise or trans- 4. Turn off the equipment using normal shut-
port it any significant distance. down procedure.
L. Make sure forklift truck forks are fully engaged and 5. Disconnect the energy sources:
tipped back prior to lifting or transporting the com- a. Air and hydraulic lines should be bled,
pressor. drained and cleaned out. There should
M. Forklift no higher than necessary to clear obstacles be no pressure in these lines or in the
at floor level and transport and corner at minimum reservoir tanks. Lockout or tag lines or
practical speeds. valves.
b. Any mechanism under tension or pres-
N. Make sure pallet-mounted compressors are firmly
sure, such as springs, should be
bolted or otherwise secured to the pallet prior to
released and locked out or tagged.
attempting to forklift or transport them. NEVER
attempt to forklift a compressor that is not secured to c. Block any load or machine part prior to
its pallet, as uneven floors or sudden stops may working under it.
cause the compressor to tumble off, possibly causing d. Electrical circuits should be checked with
serious injury or property damage in the process. calibrated electrical testing equipment
and stored energy and electrical capaci-
tors should be safely discharged.
1.10 Entrapment 6. Lockout and/or Tagout each energy source
A. If the compressor enclosure, if any, is large enough using the proper energy isolating devices
to hold a man and if it is necessary to enter it to per- and tags. Place lockout hasp and padlock or
form service adjustments, inform other personnel tag at the point of power disconnect where
before doing so, or else secure and tag the access lockout is required by each person perform-
door in the open position to avoid the possibility of ing work. Each person shall be provided with
others closing and possibly latching the door with their own padlock and have possession of
personnel inside. the only key. If more than one person is
working on a machine each person shall affix
B. Make sure all personnel are out of compressor personal lock and tag using a multi-lock
before closing and latching enclosure doors. device.
7. Tagout devices shall be used only when
1.11 Implementation of lockout/tagout power sources are not capable of being
locked out by use of padlocks and lockout
The energy control procedure defines actions necessary hasp devices. The name of the person affix-
to lockout a power source of any machine to be repaired, ing tag to power source must be on tag along
serviced or set-up, where unexpected motion, or an with date tag was placed on power source.
electrical or other energy source, would cause personal
8. Release stored energy and bring the equip-
injury or equipment damage. The power source on any
ment to a “zero mechanical state”.
machine shall be locked out by each employee doing the
work except when motion is necessary during setup, 9. Verify Isolation: Before work is started, test
adjustment or trouble-shooting. equipment to ensure power is disconnected.

A. The established procedures for the application of B. General Security

energy control shall cover the following elements and 1. The lock shall be removed by the “Autho-
actions and shall be initiated only by Authorized Per- rized” person who put the lock on the
sons and done in the following sequence: energy-isolating device. No one other than
the person/persons placing padlocks and

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lockout hasps on power shall remove pad-

lock and lockout hasps and restore power. WARNING
However, when the authorized person who
applied the lock is unavailable to remove it
Ground the unit following the instructions in this
his/her Supervisor may remove padlock/pad-
manual. Ungrounded units may cause electric
locks and lockout hasps and restore power
shock and/or fire. The variable speed drive has a
only if it is first:
large capacitive leakage current during opera-
a. verified that no person will be exposed to tion, which can cause enclosure parts to be
danger. above ground potential. Proper grounding, as
b. verified that the “Authorized” person who described in this manual, is required. Failure to
applied the device is not in the facility. observe this precaution could result in death or
c. noted that all reasonable efforts to con- severe injury.
tact the “Authorized” person have been
made to inform him or her that the lock-
out or tagout device has been removed.
WARNING
d. ensured that the “Authorized” person is
notified of lock removal before returning
Before applying power to the variable speed
to work.
drive, make sure that the front and cable covers
2. Tagout System—Tags are warning devices are closed and fastened to prevent exposure to
affixed at points of power disconnect and are potential electrical fault conditions. Failure to
not to be removed by anyone other that the observe this precaution could result in death or
person placing tag on power lockout. Tags severe injury.
shall never be by-passed, ignored, or other-
wise defeated.

WARNING
1.12 Safety warnings
The following special instructions apply to VSD packages Refer all drive service to trained technicians.
provided with electronic adjustable speed motor drives. This equipment should be installed, adjusted,
These cautions that apply to VSD operation. and serviced by qualified electrical maintenance
personnel familiar with the construction and
operation of this type of equipment and the haz-
ards involved and in accordance with published
service manuals. Failure to observe this precau-
tion could result in death or severe injury.

WARNING
Line terminals (L1, L2, L3), motor terminals (U,
V, W) and the DC link/brake resistor terminals (-/
+) are live when the drive is connected to power,
even if the motor is not running. Contact with
this voltage is extremely dangerous and may
cause death or severe injury.

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DR13 100 – 200 hp (75 – 150 kW) User Manual 1: Safety

WARNING CAUTION
Before opening the variable speed drive covers: Install the variable speed drive in a well venti-
lated room that is not subject to temperature
• Disconnect all power to the variable
extremes, high humidity, or condensation, and
speed drive.
avoid locations that are directly exposed to sun-
• Wait a minimum of 5 (five) minutes light, or have high concentrations of dust, corro-
after all the lights on the keypad are sive gas, explosive gas, inflammable gas,
off. This allows time for the DC bus grinding fluid mist, etc. Improper installation may
capacitors to discharge. result in a fire hazard.
• A hazard voltage may still remain in
the DC bus capacitors even if the
power has been turned off. Confirm
that the capacitors have fully dis- CAUTION
charged by measuring their voltage
using a multimeter set to measure DC Make sure that no power correction capacitors
voltage. Failure to follow the above are connected to the variable speed drive output
precautions may cause death or or the motor terminals to prevent variable speed
severe injury. drive malfunction and potential damage.

CAUTION CAUTION
Do not perform any megger or voltage withstand Make sure that the variable speed drive output
tests on any part of the variable speed drive or terminals (U, V, W) are not connected to the util-
its components. Improper testing may result in ity line power as severe damage to the VSD may
damage. Prior to any tests or measurements of occur.
the motor or the motor cable, disconnect the
motor cable at the variable speed drive output
terminals (U, V, W) to avoid damaging the vari- NOTE
able speed drive during motor or cable testing.
Interior electrical wiring is performed at the fac-
tory. Required customer wiring is minimal, but
should be done by a qualified electrician in com-
CAUTION pliance with OSHA, National Electrical Code,
and/or any other applicable State, Federal, and
Do not touch any components on the circuit local electrical codes concerning isolation
boards. Static voltage discharge may damage switches, fused disconnects, etc. Sullair pro-
the components. vides a wiring diagram for use by the installer.

NOTE
Customer must provide electrical supply power
disconnect within sight of machine.

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DR13 100 – 200 hp (75 – 150 kW) User Manual 2: Description

Section 2
Description
2.1 Introduction of which are protected with anti-corrosion coating, deliver
Your DR13 series rotary screw air compressor will pro- near pulse-free compressed air to meet your demands.
vide you with improved reliability and reduced mainte- The rotor shafts are mounted on anti-friction bearings
nance. and are sealed by floating carbon ring/stainless steel
cage assemblies. Both stages are driven by a common
Read Section 7: Maintenance to keep your compressor bull gear and speed optimized individual pinions, and are
in top operating condition. Should any questions arise precisely mounted to the rigid gear box. Timing gears
which cannot be answered in the following text call the synchronize each male/female rotor pair for contact-free
Sullair Service Department. operation. Variations of compressor speed, and ulti-
mately flow capacity, are determined by the ratio of pin-
ions- to-bull gear set chosen.
NOTE A gear-type pump, coupled to the main drive shaft, sup-
Your DR13 series compressor package utilizes a plies the required lubricating oil to the gears, anti-friction
bearings and cooling to compressor jacket (air-cooled).
simple to operate yet sophisticated computer-
For the water-cooled version, water is used to cool the
ized controller identified throughout this docu-
compressor jackets. A baseframe mounted, all-metal
ment as the Supervisor™. All pertinent use of
this device is covered herein. tank serves as the sump for the lubrication system.

Carefully familiarize yourself with it before The compressor/gear box assembly is driven by an elec-
attempting to operate the machinery. tric motor via a torsionally soft, flexible shaft coupling.
The NEMA C-flange electric motor is mounted to the gear
box through a rigid, cast adaptor which maintains the
gear box and motor shafts in optimum alignment and
2.2 Description of components allows the driveline assembly to be supported by soft,
Refer to Figure 2-1 on page 10. The standard package vibration isolating rubberized mounts.
includes a two-stage compressor and gear box assem-
bly, an electric motor and driveline system, a Supervi-
sor™ control assembly, an inlet air system, low pressure 2.4 Air inlet system, functional
(LP) and high pressure (HP) silencing/discharge air sys- description
tems, air or water cooling system, a load/unload control Refer to Figure 2-2. The compressor inlet system con-
system, an oil lubrication and cooling system, and a sists of a heavy duty three-stage, dry type air filter with
sound attenuating enclosure, all mounted on a fabricated inertial dust separation and· dust collection bowl,
steel frame. mounted inside the canopy and connected to the com-
Air-cooled heat exchangers are used on all models. A pressor inlet via a flange-to-duct adaptor.
motor driven fan is used to ventilate the interior of the A decrease in compressor inlet pressure, caused by the
sound attenuating enclosure. The Supervisor assembly collected airborne dirt, is sensed by the Supervisor and a
is easily accessible for servicing behind a hinged and filter maintenance announcement is displayed.
locked separate enclosure panel door.

2.3 Compressor unit, functional

description
DR13 Series compressors feature a two-stage, oil free,
rotary screw design. The rotor profiles and stators, some

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2: Description DR13 100 – 200 hp (75 – 150 kW) User Manual

1. Cooling fan motor 7. Low pressure compressor unit

2. Air filter 8. Oil sump tank
3. Compressor unit motor 9. Sump breather filter
4. Air inlet valve 10. High pressure compressor unit
5. Thermal valve 11. Control cylinder
6. By-pass relief valve 12. High pressure silencer/dampner

Figure 2-1: Description of components

2.5 Load/unload capacity control Default states

system, functional description Default states for the inlet valve and blowdown subsys-
Refer to Figure 2-3. The purpose of the capacity control tems are “mostly closed” and fully open respectively. In
system is to regulate the compressed air supply to the these states, the inlet control and blowdown control sole-
demand. It consists of the inlet throttling valve and blow- noids are both de-energized.
down subsystems integrated with the Supervisor™ con- For the inlet valve subsystem, a “closed” or deenergized
troller. inlet control solenoid, results in no pressurized oil being
Primary modes of operation are described below (for applied to the hydraulic actuator, and therefore the inlet
illustration purposes, 100 psig service operation will be butterfly valve is “mostly closed”, allowing a minimum
used). amount of inlet air to enter the compressor. During the
remainder of this description, the term “closed” will be

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DR13 100 – 200 hp (75 – 150 kW) User Manual 2: Description

discharge process air to the blowdown silencer and

atmosphere.
This combined inlet/blowdown configuration ensures the
air compressor defaults to a safe unloaded condition in
the unlikely event of: control signal loss, a component
failure, or loss of external power. A closed inlet and open
blowdown state are also the conditions for these subsys-
tems during the Unload mode.

Start mode: 0 to 8 psig (0 to 0.55 barg)

When the or pads on the Supervisor control panel
are depressed, the unit starts and ramps up to 100%
motor speed. During this mode, the Supervisor maintains
its default “closed” (deenergized) signal to the inlet con-
trol solenoid valve, keeping the inlet butterfly valve
1. Supervisor™ controller “closed”. The same Supervisor signal maintains its
default “closed” (deenergized) signal to the blowdown
2. Air filter subsystem solenoid valve, resulting in the pneumatic
3. Flange to duct adaptor blowdown valve staying open.
Typically, the motor/compressor should reach 100% full
Figure 2-2: Air inlet system
speed within 4 – 8 seconds. After a Supervisor pre-pro-
grammed delay period (typically @ 10 seconds), the
compressor should be up to 100% speed with the inlet
understood to mean, “mostly closed” in describing the and blowdown subsystems in the state described above.
inlet butterfly valve condition. Once this delay period expires, the Supervisor will auto-
matically switch to Full Load mode, described below.
NOTE Full load mode: @50 to 100 psig (3.4 to 6.9 barg)
Some minimum volumeof air must be allowed to After the delay period (typically @ 10 seconds) expires,
enter the compressor when running in order to the Supervisor switches into Full Load mode. The Super-
avoid excessive inlet depression. visor sends a control signal to the inlet control solenoid,
opening (energizing) the solenoid valve. The valve
directs pressurized oil to the actuator, which extends its
For the blowdown subsystem, a “closed” or deenergized control rod opening the butterfly valve to ingest air. The
blowdown solenoid valve, means no pilot air pressure is same Supervisor signal is sent to the blowdown solenoid
being routed to the pneumatic blowdown valve, and valve, opening (energizing) the solenoid and allowing LP
therefore the blowdown valve is open. The pneumatic pilot air to be routed to the pneumatic blowdown valve
blowdown valve uses a mechanical spring to keep the diaphragm. The pneumatic force overcomes the spring
valve open if LP pilot air is not routed to the valve’s dia- force and closes the blowdown. With the inlet open, blow-
phragm chamber. Once the Supervisor™ signals the down closed and the motor at 100% speed, the compres-
blowdown solenoid to open, LP pilot air is routed to the sor will quickly ramp up to its set-point pressure of
blowdown valve. Pilot air pressure of > 10 psig exceeds 100 psig.
the mechanical spring force, closing off the flow of HP

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1. Inlet control solenoid (4-way valve) 9. Aftercooler

2. Oil sump 10. Supervisor™ module
3. Double-acting hydro cylinder 11. 3-way solenoid valve
4. Butterfly valve 12. Relief valve
5. Low pressure stage 13. Blowdown valve
6. Intercooler 14. Blowdown silencer
7. High pressure stage A. Pressurized filtered oil supply
8. Check valve B. Compressor air discharge

Figure 2-3: Load/unload capacity control system

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DR13 100 – 200 hp (75 – 150 kW) User Manual 2: Description

. check valve closes. When P2 exceeds set point pressure

(100 psig) the Supervisor™ will signal the inlet control
NOTE solenoid to close (de-energizing), routing oil pressure to
the actuator retract position and closing the inlet butterfly
The programmable set-point pressure is also
valve. The same signal will close (de-energize) the blow-
known as the unload pressure. Therefore, when
down solenoid, removing LP pilot air pressure from the
P2 exceeds 100 psig, the machine will automati-
pneumatic blowdown valve, opening the valve so that
cally go into Unload mode. The minimum Full
process air will be evacuated to the silencer.
Load mode pressure, is set to a default value of
50 psig by programming the “unload pressure If the Supervisor is operating in continuous mode, the
differential” parameter. This sets the minimum compressor runs in the unloaded state until the line pres-
pressure = set point pressure - “unload pressure sure falls below the minimum full load pressure. When
differential”. In our example, this would be: this occurs, the Supervisor will automatically switch back
into Full Load mode.
• 50 psig (minimum full load pressure) =
100 psig (set-point pressure) - If the Supervisor is operating in automatic mode, the
50 psig (unload pressure differential) compressor runs unloaded for a pre-programmed period
of time. If during this period, the line pressure does not
This 50 psig pressure is also the absolute mini-
fall below the minimum full load pressure (50 psig), the
mum pressure the compressor can be run at for
compressor will automatically shutdown. After shutdown,
extended periods. The Supervisor™ has hard
the Supervisor continues to monitor line pressure (P2). If
programming that will shut down the compressor
the line pressure then falls below the minimum full load
if it is run below 50 psig for > 10 minutes. For fur-
pressure (50 psig), the Supervisor immediately initiates
ther programming assistance, please consult
Start mode, followed by Full Load mode as described
Section 6: Supervisor™ Controller in this man-
earlier.
ual.
If the service pressure (P2) exceeds the set
point pressure (10 psig) or falls below the mini- 2.6 Cooling and silencing system,
mum full load pressure (50 psig), the compres- functional description
sor will switch into Unload mode. Refer to Figure 2-4. As air is discharged by each com-
pressor stage, it is sequentially routed to:
• a silencer/dampener to reduce noise and pres-
NOTE sure pulsations caused by the compressor.
Typical installations set the minimum full load • heat exchangers to cool the compression pro-
pressure well above the 50 psig hard limit. For a cess.
100 psig unload pressure, differentials of 10 – • combination separator/drains to remove liquids
20 psid are more typical resulting in minimum full condensed in the heat exchangers.
load pressures of 80 – 90 psig.
The low pressure (LP) stage silencer is a reactive pipe-
work sized to dampen lower frequency air pulses, while
Unload mode: ≥ 100 psig (≥ 6.9 barg) the high pressure (HP) stage silencer is a reactive vessel
If the demand for compressed air falls below supply, sys- sized to dampen higher frequency pulses.
tem line pressure (P2) should increase as the discharge

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2: Description DR13 100 – 200 hp (75 – 150 kW) User Manual

1. High pressure stage compressor 8. Fluid cooler

2. High pressure silencer 9. Pressure relief valve
3. Check valve 10. Low pressure silencer
4. Low pressure condensate trap 11. Low pressure stage compressor
5. Moisture separator
6. Aftercooler A. Air in
7. Intercooler B. Air out

Figure 2-4: Low pressure (LP) and high pressure (HP) silencing/discharge air and cooling systems

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DR13 100 – 200 hp (75 – 150 kW) User Manual 2: Description

2.7 Lubrication system, functional requires lubricant to maintain its high speed bearings and
description gears in running order.
Refer to Figure 2-5 and Figure 2-6. The DR13 series A gear-type pump draws lube oil from the baseframe
compressor delivers oil free compressed air, but it mounted sump and delivers it at a rate of 18 gpm (68 L/

1. Fluid cooler 8. Fluid level sight glass

2. Gear box bearings and drive gears lube points 9. Fluid pump
3. High pressure stage bearings & timing gears lube points 10. Sump breather filter
4. Thermal valve 11. Fluid distribution manifold
5. By-pass relief valve 12. Fluid filter
6. Fluid sump 13. Low pressure stage bearings & timing gears lube points
7. Fluid drain valve

Figure 2-5: Lubrication system

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2: Description DR13 100 – 200 hp (75 – 150 kW) User Manual

1. Motor
2. Gearbox
3. First stage
4. Air inlet
5. Air filter
6. Solenoid valve
7. Control cylinder
8. Silencer
9. Oil filter
10. Oil distribution manifold
11. Relief valve
12. Oil pump
13. Constant bypass pressure
relief valve
14. Thermal valve
15. Oil sump tank
16. Oil level glass
17. Second stage unit
18. Silencer
19. Check valve
20. Relief valve
21. Silencer
22. Blowdown valve
23. Condensate trap
24. Intercooler
25. Aftercooler
26. Oil cooler
27. Moisture separator
28. Service air

A. Oil
B. Air

Figure 2-6: Flow diagram—air-cooled

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DR13 100 – 200 hp (75 – 150 kW) User Manual 2: Description

min), and a pressure equal to approximately 78 psig All tubed points return the oil to the sump by gravity.
(5.4 barg). An external bypass valve maintains the set Vents on the compressor timing gear covers and the gear
flow, while protecting the pump against undesirable over- box are also piped into the sump, to avoid releasing oil
pressures. A thermal mixing valve, set to open at 85°F vapor. The sump is vented to atmosphere via a breather,
(29°C) ensures fast oil warm-up by bypassing oil around which includes an oil vapor trap.
the heat exchanger.
The lube oil is sequentially pumped through a heat
exchanger, the first and second stage compressor cool-
2.8 Buffer air system, functional
ing jackets, a high efficiency, replaceable element filter, description
and a multi-port manifold, where the105°F (41°C) filtered A small supply of cooled, compressed air is taken at the
outflow is distributed to bearing and gear lubrication aftercooler moisture separator, and used to feed the buf-
points on the compressor and the gear box. The manifold fer air system. This compressed air goes through a con-
contains a regulatory valve, which maintains an accept- trol air filter, and then through a pressure regulator, where
able oil pressure to the gears and bearings as the oil filter the pressure is reduced from the compressor operating
resistance increases. Filtered oil is also used to actuate pressure to 10 psig (0.7 barg) unloaded (read from
the hydro actuator linked to the inlet control valve. locally-mounted pressure gauge). This clean, com-
pressed air supply is fed to both first and second com-
The Supervisor™ senses and displays the filter outlet pression stages. This air provides a positive pressure
pressure and temperature. As a safety measure, unless buffer to the seals between the compression air and oil
oil pressure builds up to 30 psig (2.1 barg) within 10 sec- sides of the stages, assuring oil free air. The buffer air is
onds after startup, the Supervisor shuts down the unit. In then drained from the stages, manifolded together, and
addition, if the pressure drop across the filter ports piped to the exterior of the package.
exceeds 20 psig (1.4 barg), the Supervisor displays a
maintenance requirement message.

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2: Description DR13 100 – 200 hp (75 – 150 kW) User Manual

Notes:

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DR13 100 – 200 hp (75 – 150 kW) User Manual 3: Specifications

Section 3
Specifications
3.1 Tables of specifications
Table 3-1: DR13 series (all models)
Length Width Height
Model in cm in cm in cm
DR13 (all 50 Hz & 60 Hz models) 144 366 72 183 88 224

Table 3-2: DR13 series (60 Hz)

Motor Max. operating pressure Capacity Dry weight
Model hp kW psig bar cfm m3/min lbs kg
100L 100 75 100 6.9 430 12.2 10000 4540
100H 100 75 125 8.6 428 12.1 10000 4540
125L 125 93 100 6.9 518 14.7 10400 4720
125H 125 93 125 8.6 517 14.6 10400 4720
125HH 125 93 150 10.3 427 12.1 10400 4720
150L 150 112 100 6.9 641 18.2 10700 4850
150H 150 112 125 8.6 640 18.1 10700 4850
150HH 150 112 150 10.3 517 14.6 10700 4850
200L 200 149 100 6.9 785 22.2 10700 4850
200H 200 149 125 8.6 785 22.2 10700 4850
200HH 200 149 150 10.3 639 18.1 10700 4850

Table 3-3: DR13 series (50 Hz)

Motor Max. operating pressure Capacity Dry weight
3
Model hp kW psig bar cfm m /min lbs kg
75L 100 75 100 6.9 420 11.9 10000 4540
75H 100 75 125 8.6 417 11.8 10000 4540
75HH 100 75 125 8.6 335 9.5 10000 4540
90L 125 90 100 6.9 523 14.8 10400 4720
90H 125 90 125 8.6 523 14.8 10400 4720
90HH 125 90 150 10.3 417 11.8 10400 4720
110L 150 110 100 6.9 646 18.3 10700 4850
110H 150 110 125 8.6 646 18.3 10700 4850
110HH 150 110 150 10.3 523 14.8 10700 4850
132HH 200 132 150 10.3 643 18.3 10700 4850

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Table 3-4: DR13 compressor specifications

Type Positive displacement, oil free, twin rotary screws
Configuration Two–stages, driven by single increaser gear box
Bearing Type Anti-friction
Lubricant Pressurize system for bearings, gears and cooling jackets (air–cooled only)
Sump capacity 10 gallons (38 liters)
Ambient temperature maximum 115°F (46°C)
Control Electro-hydro-pneumatic
maximum See Table 3-2 and Table 3-3.
Discharge pressure
minimum 50 psig (3.5 bar)

Table 3-5: DR13 motor specifications

Type TEFC M/C enclosure, NEMA frame, premium efficient
Size 100 through 200 hp, 2–pole speed
60 Hz 230V, 380V, 460V, 575V
Voltage
50 Hz 380V 415V, 400V
Service (ambient) 122°F (50°C)
Starter Solid state reduced voltage with disconnect switch

3.2 Lubrication guide Lubricant should be checked/changed every 8,000 hours

or once a year, whichever comes first. The fluid should
Sullair DR13 Series compressors are factory filled with
Sullair AWF® lubricant. be changed more frequently under severe operating con-
ditions, such as high ambient temperatures coupled with
high humidity or when high particulate level, corrosive
NOTE gases or strong oxidizing gases are present in the air.
Please refer to the electric motor manual for driver
Mixing of other lubricants within the compressor
requirements.
unit will void all warranties.
Maintenance of all other components is still recom-
mended as indicated in Section 7: Maintenance of this
manual.

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DR13 100 – 200 hp (75 – 150 kW) User Manual 3: Specifications

Notes:

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 3: Specifications DR13 100 – 200 hp (75 – 150 kW) User Manual
3.3 Identification

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 3.3 Identification

DR13 100 – 200 hp (75 – 150 kW) User Manual

Drawing notes
ALLOW A MINIMUM OF 48 INCHES CLEARANCE AROUND THE PERIMETER OF THE MACHINE TO FACILITATE FREE AIR CIRCULATION AND
1 ACCESS.
2 THE MACHINE MUST BE ON A SOLID AND LEVEL FOOTING PRIOR TO OPERATION.
3 NO PIPING LOADS ARE ALLOWABLE AT EXTERNAL CONNECTIONS.
4 PACKAGE DRY WEIGHTS: 100 HP - 10,000 lbs.; 125 HP - 10,400 lbs.; 150 HP - 10,700 lbs.; 200 HP - 10,700 lbs.
Subject to EAR, ECCN EAR99 and related export control restrictions.
02250225-533 R00

3: Specifications
23
 3: Specifications DR13 100 – 200 hp (75 – 150 kW) User Manual
3.4 Wiring diagram

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 3.4 Wiring diagram

DR13 100 – 200 hp (75 – 150 kW) User Manual

Component Description Component Description
1M COMPRESSOR MOTOR HTR2 HEAT TRACE
1M PS POWER SUPPLY FOR 1M STARTER HTR3 STAGE 1
1MOL COMPRESSOR OVERLOAD HTR4 STAGE 2
1CR COMPRESSOR STARTER CONTROL RELAY HTR5 CONTROL BOX HEATER
2CR COMMON FAULT RELAY HTR6 CONTROL BOX HEATER
2M COOLER FAN STARTER TH THERMOSTAT FOR HEAT TRACE
2MOL COOLER FAN MOTOR OVERLOAD PMR OPTIONAL PHASE MONITOR RELAY
1FU TRANSFORMER PRIMARY FUSES HORN OPTIONAL AUDIBLE ALARM
2FU TRANSFORMER SECONDARY FUSE Drawing notes
Subject to EAR, ECCN EAR99 and related export control restrictions.

3FU COOLER FAN BRANCH FUSES CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER
1
P1 STAGE 1 DISCHARGE PRESSURE SENSOR DISCONNECT PER LOCAL CODES.
P2 PACKAGE DISCHARGE PRESSURE SENSOR REMOVE JUMPER FOR AUXILIARY E-STOP STRING
2 DEVICES.
P3 OIL FILTER DISCHARGE PRESSURE SENSOR
BELDEN TYPE 9842 4 COND. 2 TWISTED PAIR W/SHIELD
P4 OIL FILTER UPSTREAM PRESSURE SENSOR OR EQUIVALENT. TO MATCHING TERMINALS ON NEXT
3
T1 UNIT DISCHARGE TEMPERATURE PROBE COMPRESSOR. REFER TO SUPERVISOR SEQUENCING
02250225-533 R00

PROTOCOL MANUAL.
T2 DRY DISCHARGE TEMPERATURE PROBE
T3 INJECTION OIL TEMPERATURE PROBE Transformer connections
T4 INTERSTAGE TEMPERATURE PROBE Primary Secondary
T5 SERVICE AIR TEMPERATURE
Volts Taps Volts Taps
PSW1 INLET AIR FILTER SWITCH 558.9 MM WC - 22 IN WC
200 H1–H2 110 X1–X4
SOL1 CONTROL SOLENOID VALVE
220 H1–H2 110 X1–X3
SOL2 BLOWDOWN CONTROL SOLENOID VALVE
230 H1–H2 115 X1–X3
SOL4 STAGE 1 ZERO LOSS DRAIN
240 H1–H2 120 X1–X3
SOL5 STAGE 2 ZERO LOSS DRAIN
380 H1–H3 110 X1–X3
SOLENOID 7 INTERSTAGE SEPARATOR DRAIN SOLENOID VALVE
400 H1–H3 115 X1–X3
1XFMR CONTROL VOLTAGE TRANSFORMER
416 H1–H3 120 X1–X3
K1 INTERNAL RUN RELAY CONTACT
440 H1–H4 110 X1–X3
K2 INTERNAL Y-DELTA RELAY CONTACT
460 H1–H4 120 X1–X3
K3 INTERNAL LOAD CONTROL RELAY CONTACT
480 H1–H4 115 X1–X3
K4 INTERNAL SEQUENCE RELAY CONTACT

3: Specifications
500 H1–H5 110 X1–X4
K5 INTERNAL ELECTRIC DRAIN RELAY CONTACT
525 H1–H5 115 X1–X4
K6 INTERNAL COMMON FAULT RELAY CONTACT
550 H1–H5 110 X1–X3
K7 INTERNAL COMMON WARNING RELAY CONTACT
575 H1–H5 115 X1–X3
K8 INTERNAL SPECIAL FUNCTION CONTACT
600 H1–H5 120 X1–X3
HTR1 SUMP HEATER
25
 3: Specifications DR13 100 – 200 hp (75 – 150 kW) User Manual
3.5 Piping & instrumentation, compressor system

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 3.5 Piping & instrumentation, compressor system

DR13 100 – 200 hp (75 – 150 kW) User Manual

Key Part number Qty Description Key Part number Qty Description
1 048456 1 FILTER, AIR 34 02250106-020 1 TANK, SUMP ASSY, OIL SUMP
2 040336 1 VALVE, BUTTERFLY 6" 35 02250100-731 1 RELIEF VALVE
3 02250049-631 1 CYLINDER, HYDRO 2" STROKE 36 049905 3 VALVE, CHECK 1/4"
4 02250119-178 1 VALVE, BLOW DOWN 2-WAY NO 37 241771 2 STRAINER, V-TYPE 300PSI X 1/4"
5 - 1 UNIT, FIRST STAGE LP 38 02250125-674 2 VALVE, SOLENOID 1/4" 2WNC 200#
6 02250116-968 1 MANIFOLD, SILENCER LP HOT 39 02250105-263 1 SEPARATOR, WATER DROP LEG
7 02250131-275 1 INTERCOOLER, AIR COOLED 40 02250115-992 1 ORIFICE, SET SCREW Ø.203
8 02250131-274 1 AFTERCOOLER, AIR COOLED 41 02250049-820 1 FILTER, OIL
Subject to EAR, ECCN EAR99 and related export control restrictions.

9 - 1 UNIT SECOND STAGE HP 42 02250127-388 2 VALVE, BYPASS RELIEF

10 02250117-406 1 SILENCER, AIR 2 1/2" FLANGED 43 250042-628 1 PLUG, OIL FILL
11 02250112-032 1 FILTER, AIR CONTROL LINE 44 02250119-563 1 HEATER, INTERSTAGE CONDENSATE TRAP
12 02250106-113 1 SEPARATOR, WATER COMB 2" 45 02250119-564 1 HEATER, DISCHARGE CONDENSATE TRAP
13 02250195-905 1 VALVE, CHECK 3" 46 045244 1 VALVE, CHECK INLINE 1/4"-NPT
14 250042-767 1 VALVE, RELIEF SECOND STAGE 47 02250189-632 1 PROBE, RTD 100 OHM W/HEATER
02250225-533 R00

15 02250105-982 1 STRAINER, SUCTION 1"FNPT 48 250026-357 1 VALVE, NEEDLE 1" NPT

16 02250118-040 1 SILENCER, BLOWDOWN 1 1/4" 49 02250209-760 2 DRAIN,ZERO LOSS 115VAC A1 ALARM
17 - 1 MANIFOLD, OIL 50 047115 2 VALVE,BALL 1/4"
18 02250107-457 1 VALVE, THERMAL MIXING 51 047117 1 VALVE, BALL 1/2 NPT
19 02250125-817 1 VALVE, SOLENOID 1/4" 3-WAY NC 1/8"ORF
20 02250100-362 1 PRESSURE, REGULATOR
Package interface piping
21 02250100-643 1 PRESSURE GAUGE Connection Description
22 250042-766 1 VALVE, RELIEF FIRST STAGE A STAGE 1 LUBE OIL INLET
23 02250111-061 1 PUMP, OIL INTERNAL B STAGE 1 LUBE OIL INLET
24 02250051-748 1 MANIFOLD, BUFFER DRAIN/SILENCER C STAGE 1 OIL DRAIN
25 02250131-276 1 OIL COOLER D STAGE 1 COOLING OIL INLET
26 02250189-631 4 PROBE,RTD 1000 OHM PLATINUM 20FT E STAGE 1 COOLING OIL OUTLET
27 02250119-562 1 HEATER, SUMP TANK F STAGE 2 LUBE OIL INLET
28 02250155-174 4 TRANSDUCER, PRESS. 0-250# G STAGE 2 LUBE OIL INLET

3: Specifications
29 044205 2 VALVE, 3-WAY BALL H STAGE 2 LUBE OIL DRAIN
30 02250097-611 1 GLASS, OIL LEVEL SIGHT 1-7/8 SAE J STAGE 2 COOLING OIL OUTLET
31 02250127-192 1 FILTER, SUMP BREATHER K STAGE 2 COOLING OIL INLET
32 250025-516 1 VALVE, SOLENOID 4-WAY L BUFFER SUPPLY
33 02250078-249 1 SWITCH, VACUUM 22" WC MODULAR BUFFER SEAL DRAIN
27
28
3.5 Piping & instrumentation, compressor system

3: Specifications
Settings, warnings, and shutdowns
Item #/
Symbol Setting Warning Shutdown
P1 - 49 psig [3.4 bar] 52 psig [3.6 bar]
10 MINUTES @ 50
P2 - N/A psig [3.4 bar]
30 psig [2.1 bar] > 2
P3 - - SEC
P3-P4 - 20 psid [1.4 bar] N/A
445°F [229°C] > 10
442°F [228°C] > 10
T1 - SEC OR
SEC 460°F[237°C]
Subject to EAR, ECCN EAR99 and related export control restrictions.

T2 - 442°F [228°C] 445°F [229°C]

T3 - 155°F [68°C] 160°F [71°C]
T4 - 155°F [68°C] 160°F [71°C]
T5 - 155°F [68°C] 160°F [71°C]
14 165 psig [11.3 bar] - -
10 psig [0.68
20 - -
02250225-533 R00

bar]UNLOADED
22 65 psig [4.4 bar] - -
22"H{2}O[559mmH{
33 N/A
2}O]
35 25 psig [1.7 bar] - -

DR13 100 – 200 hp (75 – 150 kW) User Manual

DR13 100 – 200 hp (75 – 150 kW) User Manual 4: Installation

Section 4
Installation
4.1 Mounting of compressor
The compressor package should be placed on a surface
or foundation that is capable of supporting its weight,
WARNING
while remaining level and free of deflections, which may
affect the driveline mounts or the inboard pipework. Note that the cooling air intake to the package
and the hot air discharge are both on top of the
It is recommended that the package frame be leveled package. There should be no restriction to the
and secured to the foundation with adequate anchorage, free flow of cooling air and discharge air, and
and that a good grade grouting be used to insure full con- care should be taken to ensure that cooling air
tact between the load bearing surfaces. Use 3/4" and discharge air remain separate.
(19 mm) foundation bolts.
The DR compressor/motor driveline is self-aligned by the If ductwork is installed, the total restriction on intake must
use of a rigid distance piece and supported by flexible not exceed 0.1 inches H20 (25 pascals). The total restric-
vibration isolation mounts. Poor leveling or excessive tion on the outlet must not exceed 0.1 inches H20 (25 pas-
deflections may adversely affect the operation and lon- cals).
gevity of these devices.
No piping loads or moments should be transmitted to the
air and water connections provided with the package. 4.3 Service air condensate piping
It is recommended that service air piping be installed as
shown in Figure 4-1 on page 30. A shut-off valve should
4.2 Ventilation and cooling be included to isolate the package from the supply line as
Select a location that allows an unrestricted flow of free required. The use of water legs and drain traps is also
ventilation air through the package, (approximately recommended throughout.
16,500 cfm [467 m3/min]). The maximum allowable ambi- No piping loads or moments should be transmitted to the
ent temperature is 115°F (46°C). Heat rejection to the air connections provided with the package.
surrounding environment will be up to 120% of the motor
horsepower (this is because of the latent heat of conden- Condensate drains shall be connected to a non-pressur-
sation of the moisture removed from the intake air and ized gravity feed drain. If the compressor drains are man-
the heat from the motor inefficiency). The 200 hp model ifolded together, care should be taken to insure that this
will discharge up to 615.000 BTU/hr to the surrounding drain is not pressurized when the machine condensate
environment (smaller models correspondingly less). drains (both automatic or manual) are in operation.

Maintain a 4 ft. (1.2 m) minimum separation between the All condensate should be disposed of in accordance with
package and any surrounding walls. Note that the electri- local governing laws.
cal enclosure has a 32.5 in (826 mm) access door hinged
on its right side.
4.4 Shaft coupling alignment check
The compressor unit and motor are rigidly connected via
a cast adaptor piece which maintains the shaft coupling
in proper alignment. It is recommended that prior to initial
startup all coupling fasteners be checked for proper
torque.
Refer to Section 7.7.3: Shaft coupling maintenance .

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{
1. Gate valves 4. Water leg
2. Sullair dryer 5. Air outlets (never take air
3. Trap from bottom of pipe)

Figure 4-1: Service air piping (typical)

4.5 Fluid level check 4.6 Electrical preparation

The package oil sump is supplied with the proper charge Interior electrical wiring is assembled at the factory.
of lube oil - a level reaching 75% of the sight glass should Required customer wiring is minimal (i.e., isolation
be visible when the compressor unit is shut down. Check switches, fusible disconnects, etc.), but should be done
this level after initial installation and periodically thereaf- by a qualified electrician, in compliance with OSHA,
ter. NEC, and any other applicable codes. All electrical
equipment should be sized for main motor, fan motor and
service factors. A wiring diagram is provided with the
package documentation.

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DR13 100 – 200 hp (75 – 150 kW) User Manual 4: Installation

4.7 Motor rotation check

After the electrical installation has been done, it is neces-
DANGER sary to check the direction of motor rotation.

Lethal shock hazard inside. Pull out the Emergency Stop button and press once,
quickly and in succession, the and pads. This
Disconnect all power at source before opening action will “bump start” the motor for a very short time.
or servicing. When looking at the motor from the rear end (opposite
shaft end), the driveline should be rotating counterclock-
1. Make sure incoming field voltage matches wise. If the reversed rotation is noted, disconnect the
required package voltage. power to the starter and exchange any two of the three
power input leads, then re-check rotation. A “Direction of
2. Check starter overload and heater sizes—
Rotation” nameplate is located on the top of the compres-
see Electrical section in Parts Manual.
sor/motor adaptor piece.
3. Check all electrical connections for tightness.
4. Check motor rotation, as explained in Sec-
tion 4.7.

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Notes:

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DR13 100 – 200 hp (75 – 150 kW) User Manual 5: Operation

Section 5
Operation
5.1 General
While Sullair has built into the DR13 series compressor
package a comprehensive array of controls and indica-
WARNING
tors to help assure proper operation, the user should rec-
ognize and interpret readings which call for service or The minimum continuous operating pressure is
indicate the onset of a malfunction. Before starting the 70 psig (4.8 barg). The compressor should not
unit, the user should become familiar with the controls be operated below this pressure except for short
and indicators—their purpose, location, and use. periods. The Supervisor™ will shut the machine
down if it is operated continuously below 70 psig
(4.8 barg) for ten minutes.

5.2 Purpose of controls

Control or indicator Purpose
Pushing in this switch, found adjacent to the Supervisor™, cuts all AC out-
puts from the latter and de-energizes the starter. A fault message (E STOP)
Emergency stop button
is displayed by the Supervisor until the button is pulled out and the pad is
pressed.
Momentarily pushing this button, found on the thermal overload element
housing in the starter box, re-closes the latter's contacts after a current over-
Motor overload reset
load takes place. Please be aware that the elements must be allowed to cool
sufficiently before resetting.
Isolates compressor from field pipework when shut down. Located between
Discharge check valve
the HP silencer/dampener and the aftercooler.
Found on the discharge pipework of both LP and HP stages, they vent the
Pressure relief valve compressed air to atmosphere in case of an over pressure condition—65
and 165 psig (4.5 and 11.4 barg), respectively.
The hydraulically operated butterfly valve throttles the air flow entering the
Inlet valve cylinder and control
unit inlet flange LP stage. A 4-way electric solenoid valve loads and unloads
valve assembly
the hydraulic actuator, in response to Supervisor commands.
Blowdown solenoid and pneu- The 3-way solenoid valve and pneumatic blowdown valve vents compressed
matic blowdown valve assembly air (HP discharge) to atmosphere through a muffler.
Furnished as manual backups to automatic drain valves used in the conden-
Drain valves
sate separator drain lines. Also used as lubricant sump drain valve.
Oil pressure bypass valve To maintain desired oil flow and to protect oil pump from over pressure situations.
This thermal valve automatically opens/closes to bypass cold oil around the
Thermal valve (air-cooled)
heat exchanger to ensure fast oil warmup and optimize operating temperature.
Indicates level of lubricant in the sump. Located on the sump side, it should
Sump sight glass
show 75% full (compressor stopped) for proper oil level.

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5.3 Supervisor™ operating necessary adjustment of the valve flapper

parameters—setup may be done as follows:
If the operating parameters need to be changed, refer to 1. Connect a 30 in (80 cm) Hg manometer
Section 6.1 through Section 6.4 for general Supervisor to the NPT connection provided at the
Controller instructions and Section 6.14 for the available inlet flange of the LP stage.
parameters. 2. Unload the package by a suitable
method.
• For example, reprogram the Supervi-
5.4 Initial startup procedure sor to unload at system line pressure, if
The following procedure should be followed for the initial such is available. If no system air pres-
start-up of the package: sure is yet available, locate and disen-
gage the pressure transducer
1. Read the preceding pages of this material
connection (P2), plug the open hole,
thoroughly.
and feed a separate air pressure sig-
2. Be sure that all preparations and checks nal, which exceeds the unload level set
described in Section 4: Installation have in the Supervisor.
been made.
3. Loosen the set screw locking the actua-
3. Close manual condensate drain valves and tor arm to the air control valve flapper
replace any cooler drain plugs, which may shaft and while firmly grasping the shaft
have been removed for shipment to prevent with a suitable tool, rotate slowly back-
freezing. and-forth until 23 in (58 cm) shows on
4. Open service valve to the air net system. the manometer (when operating the unit
5. Check that the Emergency Stop switch is at sea level—approximately 14.5 psia
armed (pulled out), reset faults (if any) by [1 bara]). For higher elevations, derate
pressing the pad. Energize the starter by the desired vacuum in direct proportion
pressing the pad. Compressor will start to the local barometric pressure.
unloaded, then load. 4. Refasten the flapper shaft to the actuator
6. Check for possible leaks in the pipework. arm with the set screw.
7. Slowly close and open the shut-off valve to 5. Cycle load and unload the package a
check that the Full Load and Unload set few times to insure that the flapper set-
pressures programmed in the Supervisor are ting has been properly achieved—this
adequate for the application. may be done by feeding and removing
the unloading pressure signal from the
8. Observe the operating temperatures T4
P2 sensor connection.
(interstage) and T5 (final package air outlet).
These should be no higher than 135°F 6. Replace the P2 sensor connection back
(57°C) or 20°F (11°C) above the ambient in the condensate separator vessel.
temperature. Observe the operating temper- 12. Open service valve to air net system. Com-
ature T3 and pressure P3 (lube oil filter dis- pressor will run loaded or unloaded as the
charge). When T3 reaches approximately system demands.
100°F (38°C), P3 should be approximately 13. Check operating conditions and reinspect for
40 psig (2.8 barg). This is controlled by the leaks the following day.
constant bypass pressure relief valve setting.
9. Close service valve to air net system.
10. Check the buffer supply pressure. The buffer 5.5 System status messages
supply regulator should be set at approxi- The top row of the display is for the system status mes-
mately 10 psi (0.7 bar) unloaded, maximum sages. These messages tell what mode the compressor
15 psi (11 bar) in the load condition. is in, if maintenance is required, or if the compressor is
11. Check the setting of the inlet control valve shutdown due to an operating parameter violation. True
flapper for unloaded operation—a vacuum first-out indication of a fault shutdown is assured by dis-
level of 23 in (58 cm) Hg should be measur- playing only the first condition of shutdown on the mes-
able at the inlet flange of the LP stage. If

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DR13 100 – 200 hp (75 – 150 kW) User Manual 5: Operation

sage display. Subsequent fault conditions may appear as • T5 HI—T5 was greater than 160°F (71°C). T5
LED indications on the graphic map. pre-alarm occurs at 155°F (68°C).
The following messages indicate that everything is nor- • E-STOP—The emergency stop button was
mal: pushed in.
• MOTOR OL—The motor overload contact has
• MANUAL—Compressor is off, in manual
opened.
mode.
• COOL FLT—Cooling fan motor overload con-
• STANDBY—Compressor is off, in automatic
tact was opened, or water pressure switch has
mode.
tripped on low water pressure (< 10 psig /
• OFF LOAD—Compressor is on, the load sole- 0.7 barg).
noid valves are de-energized.
• P2-LOW—The machine ran continuously for
• ON LOAD—Compressor is on, the load sole- ten minutes at a final pressure below 50 psig
noid valves are energized. (3.4 barg).
The following messages indicate that the compressor • P3 LO—P3 < 30 psig (2.1 barg) while the com-
may need maintenance: The messages are cleared by pressor is running.
pressing . • T1 FAIL through T5 FAIL—T1 through T5 <
• AIR MNTN—Air filter maintenance indication; 6°F (-14°C) while the compressor was running.
inspect and/or change air filter elements. Since this is an impossibly low value, the
Supervisor assumes that the temperature
• OIL MNTN—Oil filter maintenance indication;
probe has failed.
inspect and/or change oil filter element.
• P1 FAIL through P4 FAIL—P1 through P4 >
The following messages indicate that the compressor 198 psig (13.7 barg) while the compressor is
has exceeded an operational limit. Pressing will clear stopped. Since this is an impossibly high value,
these messages, but only if the condition causing these the Supervisor assumes that the pressure
messages is no longer present. The compressor will not transducer has failed.
run if any of these messages are still present.
• P1 HI—P1 was greater than 52 psig (3.6 barg).
P1 pre-alarm occurs at 49 psig (3.4 barg). 5.6 Subsequent start-up procedure
• T1 HI—T1 was greater than 445°F (229°C). T1 On subsequent start-ups, check that the steady-state
pre-alarm occurs at 443°F (228°C). indications supplied by the Supervisor and local gauges
are satisfactory. Also check for proper lubricant level in
• T2 HI—T2 was greater than 445°F (229°C). T2
the sump.
pre-alarm occurs at 443°F (228°C).
• T3 HI—T3 was greater than 160°F (71°C). T3
pre-alarm occurs at 155°F (68°C). 5.7 Shutdown procedure
• T4 HI—T4 was greater than 160°F (71°C). T4 To shut the package down, simply press the pad.
pre-alarm occurs at 155°F (68°C).

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Notes:

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DR13 100 – 200 hp (75 – 150 kW) User Manual 6: Supervisor™ Controller

Section 6
Supervisor™ Controller
6.1 Introduction 6.2 Supervisor keyboard layout
Refer to Figure 6-1. The display module has eleven keys
grouped in two rows.
NOTE
The top row has the following seven keys:
For more information about the Supervisor Con- —Help key, used to display possible causes of and
troller, refer to the Supervisor™ Controller User correction for an alarm or fault.
Manual (P/N 02250146-049) and the Remote
Variable Speed Drive User Manual (P/N —Returns to main display.
02250152-374). —Used to edit text or numbers (move cursor left).
—Used to edit text or numbers (move cursor right).
—Used to change numbers or text, or scroll.

Figure 6-1: Supervisor Controller panel

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—Used to change numbers or text, or scroll. If an alarm is active, pressing the ‘?’ key will
give troubleshooting information on that alarm.
—Used to select an item from a menu, or start and
end an edit on a parameter. • Line 3—P2—Line pressure
• Line 4—T1—Discharge Temperature
The bottom row has four keys:
—Stop, stops machine. Clears faults and warnings if
machine is stopped. 6.4 Function menu
—Run, starts machine. Clears warnings if machine is While in the main display, if any of the arrow keys are
running. pressed, the function menu is displayed. This menu is
used to view status or edit parameters.
—Toggles auto mode.
The function menu has the following entries:
—Toggles Local/Remote mode. This can be used to
disable sequencing. • Status—Current pressures, temperatures,
inputs and outputs.
• Control Parameters—Pressure and tempera-
6.3 Main display ture and timer settings.
• Line 1—Machine state: • Maintenance—Preventive maintenance infor-
• E Stop—E-Stop button pressed, or auxil- mation and timers.
iary E-Stop present. • Fault Log—Log of previous faults.
• Stopped—Machine not running. • Sensor Log—Log of sensor readings leading
• Unloaded—Machine running unloaded. up to a fault.
• Loaded—Machine running, loaded and • Sequencing—Sequencing parameters.
modulating. • System Display—Display of modes of
• Full Load—Machine forced to full load. machines in a sequencing system.
(Used only in sequencing modes). • Calibration—Correction factors for pressures.
• Remote Stop—Compressor is off but • Test—Used by Sullair personnel for trouble-
armed to start. The machine will start when shooting serial communications.
the remote start contact is closed. • Factory Setup—Model settings.
To select a function, use the up and down arrow keys to
scroll to the desired function as indicated on last line of
CAUTION display, then press the Enter key.

The machine may start at any time. After entering a function, the information can be viewed
by using the up and down arrow keys. If the function
shows status then values cannot be changed. If the func-
• Sequence Stop—Compressor is off but tion displays parameters, then the values can be
armed to start. The machine will start when changed.
the sequencing conditions meet the criteria
To change a value, scroll to the line to be changed using
to start.
the up arrow and down arrow keys, and push the enter
button. The value can be changed by using the up arrow
or down arrow keys. When editing is finished, pushing
CAUTION the enter key will fix the value. If during a change the
ESC key is pushed, editing is terminated and the original
The machine may start at any time. value is reset.
The left and right arrow keys can be used to move to
• Trim—Machine running, loaded and modu- other digits or letters in a value. For example to change a
lating in a sequenced system. value from 100 to 500, the left arrow key can be used to
• Line 2—Fault or Warning, blank means no fault position the cursor to the 1 digit in the 100, and the up
or warning is present. If there are multiple arrow key used to increment the digit to 5.
alarms, they will be shown for 2 seconds each.

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DR13 100 – 200 hp (75 – 150 kW) User Manual 6: Supervisor™ Controller

Text fields can also be edited in the same manner. Push • Load delta—The pressure differential below
the enter key to start the edit, use the left and right arrow the unload pressure where the machine is
keys to move to the letter to be changed, then use the up loaded. For example if the unload pressure is
and down arrow to change the letter. Push the enter key set to 110 psi (7.6 bar) and the load differential
to complete the edit. The following are detailed descrip- is set to 10 psid (0.7 bar), the machine will load
tions of the various displays. when the line pressure goes below 100 psi (6.9
bar).
• Unload Time—If the machine is running in
6.5 Status—current pressures, AUTO mode, this parameter specifies the
temperatures, inputs and outputs amount of time that the machine will run
All inputs and outputs are displayed showing both the unloaded before shutting off. If the time is set
designator and the description (eg. T1- Discharge) along less than 15 minutes (for example 5), there
with the selected temperature (C or F) or pressure (psi, may be times when the machine will run
bar, kPa) units. Digital inputs and outputs are shown unloaded for more than 15 minutes. This is
either as a ‘0’ (zero) or ‘1’ (one). Zero is off and one is on. because there is another timer that keeps the
This is a view only display. machine from being started more than four
times an hour.
The order of display is:
• Drain Interval—If the machine has an electric
• Temperatures—T1 through T4 depending on solenoid drain, this parameter and the following
model. parameter (Drain Time) are used to turn on the
• Pressures—P1 through P4 depending on drain. The interval is the time between activa-
model. tions of the drain and the Drain Time is the
• Delta pressures—dp1 through dp3 depending length of the time energized. This does not
on model. apply to the Sullair SCD zero loss drain, which
is not controlled or monitored by the Supervi-
• Load Hours—Hours machine has run loaded.
sor.
• Run Hours—Hours machine has run loaded or
• Drain Time—Length of time that drain is ener-
unloaded.
gized.
• Load Cycles—Number of load/unload cycles.
• Restart time—Time to wait after power up
• Starts—Number of times machine has started. before starting machine. This parameter is
• E-Stop String—E-Stop push button. used to keep several machines from starting at
• Aux E-Stop—Auxiliary E-Stop, wired by cus- the same time after power up, or to delay start
tomer. until other equipment is started. If disabled
parameter is zero, the machine will not auto-
• Digital Inputs—D1 through D10, depending on
matically start after power up. If this parameter
model.
is a number larger than zero, the machine
• Relay Outputs—K1 through K8, depending on restarts after a delay defined by this time. For
model. example, if the Restart Time is set to 10 sec-
onds, then the machine will be enabled to start
after 10 seconds.
6.6 Control parameters—pressure,
temperature and timer settings
Parameters that control the operation of the machine are WARNING
viewed and set using this display. These parameters may
vary by machine model. Enabling this function also enables automatic
The control parameters are: restart after power recovery. Be sure to depress
the Emergency Stop button to defeat this func-
• Unload—The pressure where the machine is tion when automatic start is to be prevented.
unloaded. For example if this parameter is set
to 110 psi (7.6 bar) the machine will unload
when the line pressure is above 110 psi (7.6 • Wye Delta—Also used to control the closed
bar). inlet start valve. Disable by setting to zero (0),
standard for full voltage start. Requires approx-

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imately 4-6 seconds for wye-delta or solid state 6.8 Fault log—log of previous faults
starting. The fault log shows the last 16 faults that occurred. The
• Modulate—Default state is Yes for normal top line of the display shows the run hours where the fault
machine control. For oil free applications, occurred, and the second line shows the fault. The faults
select No for Load/No Load operation. can be scrolled through using the up and down arrow
keys. They are ordered by most recent first. (ie. when the
function is entered the most recent fault is displayed.
NOTE Pressing the down arrow displays the previous fault etc).
Unload pressure must be lowered to rated pres-
sure when using Load/No Load mode.
6.9 Sensor log
Log of sensor readings leading up to a fault.
• Language—English, German, Spanish, Italian
The sensor log shows the sensor readings leading up to
and French may be selected for display lan-
a fault. The top line shows the last fault. The following
guage.
lines show T1, T2, P1 & P2. Each line represents read-
• Temp Units—Temperature units may be set to ings that are 5 seconds apart for one minute, then one
degrees F or degrees C. minute apart for 10 minutes. There is a second set of
• Press Units—Pressure units may be set to psi, readings for T3, T4, P3 & P4.
bar, or kPa.

6.10 Sequencing—sequencing &

6.7 Maintenance—preventive communication parameters
maintenance information & timers The following parameters can be viewed and edited. For
The following lines are on the Maintenance display. Infor- more details on sequencing see the Supervisor Sequenc-
mation—The top two lines may be changed to advise ing and Protocol Manual.
what to do when there is a maintenance warning. For
• Sequence By—Sequencing mode can be set
example a distributor can put in his name and telephone
to:
number.
• Disabled—Control does not do any
• Ser. No—Serial number of machine. sequencing.
• Warn at—When the following drop below this • Remote—Enables Remote Start/Stop,
number, a warning is issued. Remote Load/Unload and Local/Master
• Oil Filter—Hours before oil filter change. inputs
• PN—Oil filter part number. • Hours—Uses the Seq Hrs parameter to
• Separator—Hours before separator change. determine order of sequencing
• Prim.—Primary separator part number. • Number—Uses the Com Number to
determine order of sequencing
• Sec.—Secondary separator part number.
• Seq Hrs—This is an hour counter used when
• Air Filter—Hours before air filter change.
the Sequence By parameter is set to Hours.
• Prim.—Primary air filter part number. Each hour that the machine is running incre-
• Sec.—Secondary air filter part number. ments this counter. When the Sequence By
• Oil—Hours before oil change. parameter is set to Hours, the machine with
the least amount of Seq Hrs is started first, and
• PN—Oil part number.
the machine with the most Seq Hrs is shut off
• Oil Analysis—Hours before oil analysis. first.
These hours and part numbers can be changed using the • Com Number—Communications number.
enter and arrow keys. When two or more machines are connected
together using the network (RS-485 channel),
each machine must have a unique number or
address. These must be assigned in numerical
order. For example in a three machine system

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DR13 100 – 200 hp (75 – 150 kW) User Manual 6: Supervisor™ Controller

the machine communications numbers should network (RS-485) and the Sequence By parameters on
be 1, 2 & 3. each machine are set to Hours or Number.
• Machines—This is the total number of The columns are described below:
machines connected to the network (RS-485
channel). For example in a three machine sys- • Communication Number Status—
tem, this parameter should be set to 3. Up to • E—Emergency stop
sixteen machines may be networked if all have • M—Manual stop
Supervisor Controllers and limited to eight if
• R—Remote stop
some have Supervisor II’s.
• B—Standby
• Low Press—This is the lowest pressure
allowed before immediately starting a machine. • S—Starting
• Recovery Time—This parameter keeps multi- • U—Unloaded
ple machines from loading, unloading and start- • L—Loaded
ing at the same time. For example if a low • T—Trim machine
pressure condition causes a machine to start,
• F—Full load
the next machine will not start unless the
Recovery Time has elapsed, and the pressure • Sequencing Hours
has not recovered (i.e., has risen over ‘Low • Capacity—Not used at this time.
Press’). • Local System Pressure—Pressure read by
• Rotate—This parameter is used only in very machines pressure transducer.
special cases.
The top line is a legend that describes each column. The
right hand number on the top line is the system pressure.
NOTE The system pressure is the highest pressure reading of
all the machines. Note that the local pressure readings
Leave this parameter disabled unless instructed can be used to determine what machines may need to be
by Sullair Service Personnel. calibrated. The system pressure transducers on all
machines should read within 1 (one) psi of one another.
The calibration function can be used to set the readings
The only time this parameter should be used is to be the same.
in a situation where, once a machine is started,
it never stops (ie. the unload timer never
expires). This can happen when the load 6.12 Calibration—correction factors
matches the output of the machine, all the time. for pressures
In this case the machine will never unload and The first line of this display is the password. If the pass-
shut off. The rotate forces the machine to stop word is 0 then the following parameters are not protected
after it’s Seq Hrs are greater that the other and can be changed. If the password is non-zero, then
machines. For example in a two machine sys- enter the displayed number plus 4 to enable changing the
tem, with Rotate set at 100 hrs. The machine parameters. For example if the number displayed is 10
that is running will shut off when the Seq Hrs then changing the password to 14 will enable editing.
are 100 more that the machine that is stopped.
The four pressures P1, P2, P3 & P4 as well as the differ-
• Minute, Hour, Day, Month, Year—For control-
ential pressure dP1 can be calibrated. The number on
lers manufactured after April 2009 or if the
the right hand side of the line is added to the transducer
communications module is present in the sys-
reading to give the calibrated reading. The calibrated
tem, the time and date can be set using these
reading is shown in the middle of the line.
parameters.
There are also three other parameters in the calibration
function:
6.11 System display—display of modes
• Protect—When set to yes, protects the control
of machines in a sequencing system parameters from change.
Note that this display is only applicable when there are
• Fault on Warn—Force fault on warning.
two or more machines connected to the communications

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• Force Unload—When set to yes, forces the • Min Load Psi—Minimum acceptable load P1
machine to unload. pressure setting. Separator Maintenance warn-
ing is disabled for loaded P1 pressures below
this value (i.e., during start-up).
6.13 Test • Lube Cycle—Pre-lube/ Post-lube function
Used by Sullair personnel for troubleshooting of serial timer—0 seconds (disabled) to 30 seconds.
communications. • K8 Option—K8 output relay function selec-
tor—Disabled, Oil pump prelube and postlube
control, Master Control for special external
6.14 Factory setup—model settings sequence control.
The factory setup display is used by Sullair personnel to
• Stop Timer—Time to run machine before stop-
initially set up the machine. The following values reflect
ping.
the machine configuration.
• Protect—Protect control parameters.
• Model—Model number of machine.
• Load Hours—Hours machine was running and
• Cooling—Air or Water. loaded.
• Press Trans—Pressure transducer range 200, • Run Hours—Hours machine was running
250, 500. loaded and unloaded.
• P1 Max—Maximum discharge pressure. • Load Cycles—Number of load/unload cycles.
• KT Fluid—No (KT fluid not available on oil free • Starts—Number of machine starts.
applications).
• Capacity—Maximum capacity of machine.
• Water Switch—Water pressure switch, Yes or
• Com Module—Yes/No Enables or disables the
No.
communication module if installed.
• Oil Switch—Oil pressure differential switch,
Yes or No.

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DR13 100 – 200 hp (75 – 150 kW) User Manual 6: Supervisor™ Controller

MAIN SCREEN
Machine Status
Trouble State
P2-Line xxxPsi
T1-Discharge xxxF

Status Control Sequencing Calibration Factory

T1 -Discharge Parameters Setup
Sequence By xxxxx Password
T2 -Dry Side* P1
Sequence Hrs xxxxx Password
T3- Oil* Unload Psi P2
Com Number xx Set Defaults
T4 Interstage* Load Psi dP
Machines xx Model
P1-Sump Setpoint* P3
Low Press xxx Cooling
P2-Line Unload Time P4
Recover Time sec Press Trans
P3-Oil Filter* Drain Interval Cap
Rotate (hours) P1 Max
P4-Oil* Drain Time KW
Minute xx KT Fluid
dP2-Oil Filt* Restart Time Protect N/Y
Hour xx Water Switch
dP3-Oil* Wye-Delta Time Fault on Warn Y/N
Day xx Oil Switch
Load Hours Modulate Y/N Force Unload Y/N
Month xx Aux Overl0ad
Run Hours Language
Year xxxx Min Load Psi
Load Cycles Temp Units F/C
Stop Timer
Starts Press Units Psi/bar/kPa
Lube Cycle
E-Stop String Cost/KWH*
K8 Option
Aux E-Stop Saving VS*
D1-Motor Ovld Reset Load Est* Fault Log System Load Hours
Run Hours
D2-Aux Ovld
D3-Air Filter* Last 16 faults Display Load Cycles
recorded Starts Capactiy
D4-Water Press*
Com Module N/Y
D5-Remote Start Machine status
D6-Remote Unload of Sequenced
D7-Master Control machines
D8-Brownout
D9-Not Defined Maintenance Sensor Log Test
D10-Not Defined
K1-Run T1 T2 P1 P2 Serial
Info to be loaded by
K2-Wye-Delta T3 T4 P3 P4 communications
Distributor for all con-
K3-Load diagnostic
sumables
K4-Full Load screen
K5-Drain
K6-Common Fault
K7-Common Warn
K8-Option

* These parameters do not apply to some models.

Figure 6-2: Supervisor Controller menu tree

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6: Supervisor™ Controller DR13 100 – 200 hp (75 – 150 kW) User Manual

Notes:

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DR13 100 – 200 hp (75 – 150 kW) User Manual 7: Maintenance

Section 7
Maintenance
7.1 General 7.4 Maintenance every 8,000 hours
As you proceed to study this section, it will be easy to see or one year of operation
that maintenance for the air compressor is quite minimal. The following items should be checked every 8,000
The Supervisor™ monitors the status of the air and oil fil- hours of operation or one year, whichever comes first,
ters. When maintenance to either device is required, the although service conditions such as relative cleanliness
Supervisor will display the appropriate maintenance mes- of process air or quality of cooling medium may require
sage and flash the location LED on the graphics map as shorter inspection intervals.
a visual remainder.
• Replace oil charge and filter element.
• Replace control line filter element.
WARNING • Replace sump breather filter element.
• Replace air filter element.
Do not remove caps, plugs, and/or other compo- • Check/clean condensate drain valves screen.
nents when compressor is running or pressur-
• Check condition of shaft coupling element and
ized. Stop compressor and relieve all internal
tightness of fasteners.
pressure before doing so.
• Measure and record vibration signatures on
compressor, gear box and motor—optional.

7.2 Daily operation

Following a routine start, observe the various Supervisor NOTE
displays and local gauges to check that normal readings
are been made—previous records are very helpful in Please refer to the motor manufacturer's docu-
determining the normalcy of the measurements. These mentation for recommended maintenance. Keep
observations should be made during all expected modes in mind that the specified type and quantity of
of operation (i.e. full load, no-load, different line pres- lubricating grease for motor anti-friction bearings
sures, cooling water temperatures, etc.). is crucial.

7.3 Initial maintenance after 50 7.5 Maintenance every 16,000 hours

hours of operation or two years of operation
Upon completion of the first 50 hours of operation, a few In addition to those items covered by the 8000 hour or
maintenance requirements are needed to rid the system one year maintenance interval, the following items must
of any foreign materials which may have accumulated also be checked every 16,000 hours of operation or two
during assembly: years, depending upon conditions of service:
• Change the lubricant filter element. • Operate/test all safety devices.
• Clean the control line filter element. • Check/clean heat exchangers.
• Check/replace the sump breather element. • Check/clean blowdown valve.
• Check/clean check valves.
• Check condition of isolation mounts under com-
pressor unit and motor.

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• Check/clean strainer included in oil pump suc- 7.7.1 Air filter inspection and maintenance
tion line, inside oil sump.

7.6 Diagnostic service (optional)

Sullair and its representatives offer a diagnostic service
to check the condition of your compressor unit. The ser-
vice, which is recommended at 8,000 hour intervals, per-
forms the following:
• Tri-axial vibration measurements at the gear-
box and the compressor stages.
• Package performance data collection and anal-
ysis.
• Examination of shaft coupling assembly.
• Operational check of protective equipment.
• Final discussion with maintenance engineer.
This service, when supplemented by properly recorded
package operational performance and vibrations trends,
is most helpful in identifying the presence (or absence) of
equipment damage which can be repaired or replaced
before a catastrophic breakdown occurs.

7.7 Parts replacement and

adjustment procedures
Please, familiarize yourself with the safety guidelines 1. Housing 4. Element
offered in Section 1: Safety of this manual before
attempting any maintenance on the package. 2. Dust collector 5. Sealing washer
3. Retaining clip 6. Wingnut

Figure 7-1: Air filter

7.7.1.1 Element inspection

1. Place a bright light inside the elements to
inspect for damage or leak holes.
2. Inspect gaskets and matching sealing sur-
faces on the housing. It should be smooth or
replace in case of damage.
3. The secondary element must be replaced if
dirt obstruction is evident.
4. Do not strike elements against a hard sur-
face to dislodge dirt—this may damage the
sealing surfaces and/or rupture the element.

7.7.1.2 Air filter maintenance

Refer to Figure 7-1 on page 46. Air filter maintenance
should be performed at 8,000 hours, one year or when
the corresponding maintenance message is displayed by

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DR13 100 – 200 hp (75 – 150 kW) User Manual 7: Maintenance

the Supervisor™. This corresponds to a pressure loss

condition across the filter of 22 in (56 cm) of water. Your
filter assembly includes a primary element and a second-
ary element.
1. Clean exterior of filter housing.
2. Loosen the three retaining clamps and
remove cover with rubber dust collector
attached.
3. Remove wing nut, washer and primary ele-
ment.
4. Clean interior of housing with a damp cloth.
5. Remove wing nut, washer and secondary
element.
6. Replace secondary element with new ele-
ment.
7. Replace primary element with new element.
8. Replace clover and tighten the three retain-
ing clamps.

7.7.2 Oil filter maintenance

Refer to Figure 7-2. Oil filter maintenance (using repair kit 1. Filter head
P/N 02250049-820) should be performed at 8,000 hours,
2. Gasket
one year or when the corresponding maintenance mes-
sage is displayed by the Supervisor—this corresponds to 3. Element1
a pressure loss condition across the unit of 20 psig Available repair options:
(1.4 barg). Your oil filter includes a proprietary replace- 1Replacement
element P/N: 02250049-821
able element (P/N 02250049-821) available solely from
Sullair and its agents—do not substitute. Figure 7-2: Oil filter (P/N 02250049-820)
1. Using a strap wrench, remove the old ele-
ment and gasket.
2. Clean the gasket seating surfaces. 4. Continue tightening element by hand, an
additional ½ to ¾ turn.
3. Apply a light film of fresh oil to the new gas-
ket and hand-tighten new element until gas- 5. Restart package and check for leaks.
ket contacts the seat.

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7: Maintenance DR13 100 – 200 hp (75 – 150 kW) User Manual

7.7.3 Shaft coupling maintenance 3. Unwrap the coupling element from the cou-
The compressor unit and motor are rigidly connected pling jaws.
through the mounting adapter housing. This arrangement 4. Verify shaft hub gap = .062″
makes coupling alignment unnecessary. The coupling is 5. Install the new element by wrapping it
a jaw type in shear. If the elastomeris (rubber) element around the jaws, engaging the cogs on the
requires replacement due to wear or damage, order a element into the jaws.
replacement element and perform the following steps:
6. Reinstall the outer sleeve and secure by
1. Remove the protective grill from the adapter tightening the two screws to 45 in-lbs.
housing (5 Nm).
2. Loosen the retaining screw located on the 7. Reinstall the protective grill.
side outer sleeve. Slide the sleeve to one
side, exposing the coupling element.

1. Standard hub with set screw 3. Split element

2. Cover with fasteners

Figure 7-3: Drive coupling

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DR13 100 – 200 hp (75 – 150 kW) User Manual 7: Maintenance

A. Parallel misalignment B. Angular misalignment C. Normal gap

Figure 7-4: Coupling alignment (see Table 7-1)

Table 7-1: Alignment, installation, and operating limits (see Figure 7-4)
Maximum Installation limits Operating limits
distance
between Maximum Normal Maximum Normal
shaft parallel gap parallel gap
ends offset Maximum angular ±10% offset Maximum angular ±10% Allowable
[BE] [P] [X - Y] [GAP] [P] [X - Y] [GAP] speed
Size in. mm in. mm degrees in mm in mm in. mm degrees in mm in mm rpm
30R 1.40 .040 .25 .020 .062 .08 1.00 .081 .062 4500
40R 1.84 .060 .25 .026 .188 .12 1.00 .103 .188 3600
“BE” dimension tolerance is 10% of “normal gap” listed.
Parallel misalignment is distance “P” between hub and centerlines.
Angular misalignment is dimension “X” minus “Y”.
Standard hub shaft engagement to be greater than 80% of shaft diameter.
Taper bushing to have 100% engagement with shaft (no overhang allowed).

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Notes:

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DR13 100 – 200 hp (75 – 150 kW) User Manual 8: Troubleshooting

Section 8
Troubleshooting
8.1 Introduction • Check for damaged piping.
The following information has been compiled from opera- • Check for parts damaged by heat or an electri-
tional experience with your package. It identifies symptoms cal short circuit, usually apparent by discolor-
and describes probable causes for problems. However, do ation or a burnt odor.
not assume that these are the only problems that may occur. Should your problem persist after making the recom-
The collection of operational data concerning possible mended check, consult your nearest Sullair representa-
trouble should be analyzed to prevent complete com- tive or Sullair.
pressor breakdown. An example of this would be the Note on transducers: Whenever a sensor is suspected
vibrations signature increase of a damaged bearing or of fault, the recommended cause of action is to measure
the efficiency decrease of a dirty heat exchanger. the signal (pressure, temperature, etc.) with an alternate
A detailed visual inspection should be performed for all calibrated instrument and compare readings. If readings
problems. Always remember to: conflict, the electrical and/or tubing connections should be
inspected, and if no faults are evident, then replace the
• Check for loose wiring. sensor and re-evaluate against the calibrated instrument.

8.2 Troubleshooting guide

Symptom Probable cause Remedy
Compressor will not start
Main disconnect switch open Close switch.
Power LED off Line fuse blown Replace fuse.
Control transformer fuse blown Replace fuse.
Reset after heater elements cool down. Should
Motor starter overloads tripped trouble persist, check whether motor starter
MOTOROL contacts are functioning properly.
Check voltage. Should voltage check low, con-
Low incoming line voltage
sult power company.
T-1 FAIL
T-2 FAIL
Check connections from transducer. If ade-
T-3 FAIL Temperature transducer failure
quate, replace transducer.
T-4 FAIL
T-5 FAIL
P-1 FAIL
P-2 FAIL Check connections from transducer. If ade-
Pressure transducer failure
P-3 FAIL quate, replace transducer.
P-4 FAIL
E-STOP Emergency switch open (depressed) Close switch (pull).
Reset after heater elements cool down. Should
Cooling fan motor starter overloads
COOL FLT trouble persist, check whether motor starter
tripped
contacts are functioning property.
†
Also check that the compressor-motor driveline rotates freely. In case of rotating resistance or rubbing, contact Sullair Service Department.

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Symptom Probable cause Remedy

Compressor shuts down with air demand
Reset after heater elements cool down. Should
Motor starter overloads tripped trouble persist, check whether motor starter
MOTOROL contacts are functioning properly.†
Check voltage. Should voltage check low, con-
Low incoming line voltage
sult power company.
The machine ran at a final dis-
Adjust valve downstream of package to hold
P2 LO charge pressure below 50 psig
minimum 70 psig (4.8 barg) line pressure.
(3.4 barg) for five minutes
Oil pressure falls below 30 psig
(2.1 barg) while package is running
because:
Oil pump malfunctioned Consult Sullair Service Department.
Oil filter clogged Replace filter element.
P3 LO
Check state of globe valve feeding oil cooler. In
Oil temperature too low cold ambient environments below 40°F (4°C)
sump heating may be required.
Sump oil level too low Replenish oil level.
Sump strainer clogged Clean, repair or replace if necessary.
Check connection from transducer. If adequate,
P1 LO P1 transducer at fault
replace transducer.
LP inlet air temperature above
Maintain inlet air temperature below 115°F (46°C).
115°F (46°C)
Insufficient coolant flow to jackets. Insufficient
High interstage pressure (loaded)
air flow to intercooler. Defective HP stage.
High interstage pressure
Clogged blowdown silencer. Clean/replace.
(unloaded)
T1 HI Reset after heater elements cool tripped down.
Cooling fan motor starter overloads Should trouble persist, check whether motor
starter contacts are functioning properly.
Check connections from transducer If ade-
Temperature transducer failure
quate, replace transducer.
Blowdown valve failed to open or
Repair or replace if necessary.
operated sluggishly
Intercooler core fouled Clean tinning.
Discharge check valve leaking dur- Refer to compressor’s User Manual for check
ing unloaded operation valve maintenance.
Inlet throttling valve not fully open See inlet valve adjustment.
during loaded operation Low oil pressure defective control solenoid valve.
T2 HI See Section 7.7.1 on page 46 for air filter main-
Inlet air filter clogged
tenance.
Line pressure is too high Reset Supervisor™ unload pressure.
Check connection from transducer. If adequate,
Temperature transducer failure
replace transducer.
Blowdown valve failed to open or
Repair or replace if necessary.
operated sluggishly
†
Also check that the compressor-motor driveline rotates freely. In case of rotating resistance or rubbing, contact Sullair Service Department.

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DR13 100 – 200 hp (75 – 150 kW) User Manual 8: Troubleshooting

Symptom Probable cause Remedy

Defective HP stage Consult Sullair Service Department.
P1 HI Check connection from transducer. If adequate
Pressure transducer failure
replace transducer.
Blowdown valve failed to open Repair or replace if necessary.
Limit switch controlling blowdown
P2 HI Replace switch.
valve failed to operate
Control air filter clogged Repair or replace if necessary.
Reset after heater elements cool down. Should
Cooling fan motor starter overloads
COOL FLT trouble persist, check whether motor starter
tripped
contacts are functioning properly.
Air demand exceeds supply Check air service lines for open valves or leaks.
Check for maintenance message on Supervisor™
Inlet air filter clogged
display. Change element.
Check actuation and butterfly disc position.
Inlet air valve not fully open
Compressor does Low oil pressure defective control solenoid valve.
not build full dis- Check connections from transducer. If ade-
charge pressure Transducer P2 malfunction
quate, replace transducer.
Blowdown valve leaking or sluggish Repair or replace if necessary.
Limit switch controlling blowdown Check limit switch and cam adjuster on butterfly
valve failed to operate valve.
Defective LP stage Consult Sullair Service Department.
Blowdown valve failed to activate Repair or replace if necessary.
Inlet throttling valve not fully open See inlet valve adjustment.
Limit switch controlling blowdown Check limit switch and cam adjuster on butterfly
Line pressure rises
valve failed to operate valve.
above unload setting
Check connections from transducer. If ade-
Transducer P2 malfunction
quate, replace transducer.
Control air filter clogged Repair or replace if necessary.
†Also check that the compressor-motor driveline rotates freely. In case of rotating resistance or rubbing, contact Sullair Service Department.

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Notes:

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Subject to EAR, ECCN EAR99 and related export control restrictions.
 Sullair, LLC
3700 East Michigan Boulevard
Michigan City, IN 46360 USA
www.sullair.com
1-800-SULLAIR (USA only)
1-219-879-5451 (non-USA)

Information and specifications are subject to change without prior notice.

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