€&>. SULLAIR. INDUSTRIAL ROTARY SCREW AIR COMPRESSOR TS-20 200-250HP AIR COOLED & WATER COOLED OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 270010-960R00 @Sulair Argentina S.A,TABLE OF CONTENTS OPERATOR !S REQUIRED TO READ ENTIRE INSTRUCTION MANUAL, Section 1 Page SAFETY 1 4.1 GENERAL 1 1.2 PERSONAL PROTECTIVE EQUIPMENT 1 1.3 PRESSURE RELEASE 2 1.4 FIRE AND EXPLOSION 2 1.8 MOVING PARTS 2 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS 3 4.7 TOXIC AND IRRITATING SUBSTANCES 3 1.8 ELECTRICAL SHOCK 3 4.9 LIFTING 4 1.40 ENTRAPMENT Section 2 DESCRIPTION 5 2.4 INTRODUCTION 5 2.2 DESCRIPTION OF COMPONENTS. 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION 6 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION 8 2.5 COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTION 8 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION 18 2.7 AIR INLET SYSTEM, FUNCTIONAL DESORIPTION Section 3 SPECIFICATIONS = 7 a: suai ts.20 spEciFICATIONS 47 3.2. LUBRICATION GUIDE - STANDARD COMPRESSORS 18 Figure 3-1 identfication - TS20-200HP «Air Cooled 49 Figure 3-2 Identification - TS20-250HP - Alr Cooled 20 Figure 3-3 Identification - TS20-200HP - Water Cooled a Figure 8-4 Identification - TS20-250HP - Water Cooled 22 Figure 25 Piping and instrumentation - T820-200/250HP - Air Cooled 26 Figure 3-6 Piping and Instrumentation - TS20.200'250HP - Water CooledTABLE OF CONTENTS Section 4 INSTALLATION 314.1 MOUNTING OF COMPRESSOR 3142 VENTILATION AND COOLING 31 43SERVICEAIR PIPING 3144 COUPLING ALIGNMENT CHECK 3 4SFLUDLEVEL CHECK 22 AB FLUIO PIPING (REMOTE AIR-COOLED OPTION ONLY) 30. _-AT ELECTRIOAL PREPARATION 38.48 MOTOR ROTATION DIRECTION CHECK Section 5 SUPERVISOR 34 FIGURE 5-1 SUPERVISOR CONTROLLER CONTROL PANEL 38 FIGURE 52 SUPERVISOR DLX CONTROL PANEL COMPRESSOR OPERATION 37 6.4 INTRODUCTION a7 68.2 PURPOSE OF CONTROLS 38 6 INTIAL START-UP PROCEDURE 38 64 SUBSEQUENT START-UP PROCEDURE 3968 SHUTDOWN PROCEDURE Section 7 MAINTENANCE a 7.1 GENERAL 4 T2DAILY OPERATION 4) TSMAINTENANGE AFTER INTIAL 50 HOURS OF OPERATION 41 TANAINTENANCE AFTER 1000 HOURS #1 TSELUID CHANGE HT SEPARATOR MAINTENANCE 4477 PARTS RECLACEMENT AND ADJUSTMENT PROCEDURES “ FLUID FILTER MAINTENANCE 2 AIR FILTER MAINTENANCE “ SEPARATOR ELEMENTS REPLACEMENT “ OIL RETURNISIGHT GLASS MAINTENANCE “ DIFFERENTIAL PRESSURE REGULATOR ADUSTMENT “ eRESSURE REDUCING REGULATOR 4s DRIVE COUPLING INSTALLATION ANO ALIGNMENT. 250HP 47 7.8 TROUBLESHOOTINGSection 7 MAINTENANCE (Continued) ar Section 8 ILLUSTRATION AND PARTS LIST st 5 Ba2r8 60 62 66 68 70 2 14 76 78 82 82 84 86 88 92 TABLE OF CONTENTS 7.9 TROUBLESHOOTING GUIDE 8.1 PROCEDURE FOR ORDERING PARTS 8.2 RECOMMENDED SPARE PARTS LIST. 200/250H? 8.3 MOTOR, COMPRESSOR, FRAME AND PARTS: 84 AIR INLET SYSTEM 8.5 FLUID COOLING SYSTEM - AIR COOLED - 200HP 8.6 FLUID COOLING SYSTEM - AIR COOLED - 250HP 8.7 FLUID COOLING SYSTEM - WATER COOLED - 200HP 8.8 FLUID COOLING SYSTEM - WATER COOLED - 250HP 8.9 AIR PIPING SYSTEM - AIR COOLED - 200/250HP 8.10 AIR PIPING SYSTEM - WATER COOLED - 200/250HP 8.11 FLUID PIPING SYSTEM - AIR COOLED - 200/250HP 8,12 FLUID PIPING SYSTEM - WATER COOLED - 200HP 8.13 FLUID PIPING SYSTEM - WATER COOLED - 250H 8.14 SUMP AND PARTS 8,18 SULLICON CONTROL, 8,16 COMPRESSOR SPIRIAL VALVE ACTUATOR 8.17A MOISTURE DRAIN - AIR COOLED - 200/250HP 8.178 MOISTURE DRAIN . WATER COOLED - 200/250 8.18 ENCLOSURE SYSTEM - AIR COOLED - 200HP- 8,19 ENCLOSURE SYSTEM - AIR COOLED - 250HP. 8,20 ENCLOSURE SYSTEM - WATER COOLED - 200HP 6.21 ENCLOSURE SYSTEM - WATER COOLED - 250HP 8.22 WIRING DIAGRAM - AIR & WATER COOLED - 200/250?NOTES4.4 GENERAL Sullait Corporation and its subsidiaries design and manufacture all of their products so they can be operated safely. However, the responsibility for safe operation rests with those who use and main- tain these products. The following safety precau- tions are offered as a guide which, if conscientious- ly followed, will minimize the possibilty of accidents, throughout the useful life of this equipment. ‘The compressor should be operated only by those ‘who have been trained and delegated to do so, and who have fead and understood this Operator's ‘Manual. Failure to follow the instructions, proce- dures and safety precautions in this manual can result in accidents and injuries. Read this manuat prior to startup. NEVER start the compressor unless itis safe to do so. DO NOT attempt to operate the compressor with a known unsafe condition. Tag the compressor and render it inoperative by disconnecting and lock- ing out all power at source or otherwise disabling its prime mover, so others who may not know of the unsafe condition, cannot attempt to operate it until the condition is corrected. Install, use and operate the compressor only in full compliance with all pertinent regulations and all applicable Federal, State, and Local codes, stan- dards and regulations. DO NOT modify the compressor andlor controls in any way except with written factory approval. While net specifically applicable to all types of com pressors with all types of prime movers, most of the precautionary statements contained herein are applicable to most compressors and the concepts behind these statements are generally applicable to all compressors, 1.2 PERSONAL PROTECTIVE EQUIPMENT Prior to installing or operating the compressor, own- ‘ers, employers and users should become familiar with, and comply with, all applicable regulations and any applicable Federal, State and Local codes, standards, and regulations relative to personal pro- tective equipment, such as eye and face protective equipment, respiratory protective equipment, equip- ment intended to protect the extremities, protective clothing, protective shields and barriers and electri- cal protective equipment, as well as noise exposure administrative and/or engineering controls andior personal hearing protective equipment. 1.3 PRESSURE RELEASE AA. Install an appropriate flow-imiting valve between Section 1 SAFETY the service air outlet and the shut-off (throttle) valve, either at the compressor or at any other point along the air line, when an air hose exceeding 1/2" (13mm) inside diameter is to be connected to the ‘shut-off (throttle) vaive, to reduce pressure in case of hose failure, per all applicable Federal, State anc Local codes, standards and regulations, B. When the hose is to be used to supply a mani- fold, install an additional appropriate flow-limiting valve between the manifold and each air hose ‘exceeding 1/2" (13mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure C. Provide an appropriate flow-limiting valve at the beginning of each additional 75 feet (23m) of hose in runs of air hose exceeding 1/2" (18mm) inside diameter to reduce pressure in case of hose failure. D. Flowslimiting valves are listed by pipe size and rated CFM, Select appropriate valves accordingly in accordance with their manufacturer's recommen- dations, E. DO NOT use air tools that are rated below the maximum rating of the compressor. Select aif tools, air hoses, pipes, valves, filters, and other fittings accordingly. DO NOT exceed manufacturer's rated safe operating pressures fer these items. F. Secure all hose connections by wire, chain or ‘other sultable retaining devices to prevent tools or hose ends from being accidentaly disconnected and expelled G. Open fluid filer cap only when compressor is not running and is not pressurized. Shut down the com- pressor and bleed the sump (receiver) to zero inter- nal pressure before removing the cap. H. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as fiters and line oilers, and before attempting to refill optional air line ant-icer systems with antifreeze compound, 1. Keep personne! out of fine with and away from the discharge opening of hoses or tools or other points of compressed air discharge. J. Use air at pressures less than 30 psig (2.1 bar) for cleaning purposes, and then only with effective chip guarding and personal protective equipment. K. DO NOT engage in horseplay with air hoses as death or serious injury may result L. DO NOT tamper with sump and unt (if provid- ed) relief valves. Check the relief valve as recom- mended in the Maintenance Section of this manualSection 1 SAFETY 14 or at a minimum of at least weekly to make sure it is not blocked, clogged, obstructed or otherwise disabied. DO NOT change the factory setting of the relief valve M. If the compressor is insialled in an enclosed area, it is necessary to vent the relief valve to the outside of the structure or to an area of non-expo- sure. FIRE AND EXPLOSION A WARNING When installing a Base Load Transfer (BLT) System, remove jumpers between 16-17 & 18-18 (Dual Contra! Compressors) so the other com- pressor does not backleed defeating the shut- down circuitry, A. Clean up spills of lubricant or other combustible substances immediately, if such spills occur. B. Shut off the compressor and allow it to cool ‘Then keep sparks. flames and other sources of igni- tion away and DO NOT permit smoking in the vicin- ity when checking or adding lubricant or when refill ing air line anti-icer systems with antifreeze com- pound, ©. DO NOT permit fluids, including air line anti-icer system antiffeeze compound or fluid film to accu- mulate on, under, or around acoustical material, or on any external surfaces of the air compressor or fn internal surfaces of the enclosure. Wipe down using an aqueous industrial cleaner or steam-clean, ‘as required. If necessary, remove acoustical mate- Tial, clean all surfaces and then replace acoustical material. Any acoustical material with a protective covering that has been torn or punctured should be replaced immediately to prevent accumulation of liquids oF fluid fim within the material. DO NOT use flammable solvents for cleaning purposes. D, Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the com- pressor or of the inside of the enclosure, if any E. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace any wiring that has cracked, cut abraded or other- wise degraded insulation, or terminals that are worn, discolored or corroded, Keep all terminals and pressure connectors clean and tight. F. Keep grounded and/or conductive objects such a tools away from exposed live electrical parts ‘such as terminals to avoid arcing which might serve a8 a source of ignition. & Remove any acoustical material or other materi- 18 16 al that may be damaged by heat or that may sup- por combustion and is in close proximity, prior to attempting weld repairs. H. Keep suitable fully charged fire extinguisher or extinguishers nearby when servicing and operating the compressor |. Keep oily rags, trash, leaves, litter or other com bustibles out of and away from the compressor. 4. DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or with degraded lubricant K, DO NOT attempt to operate the compressor in any classification of hazardous environment unless, the compressor has been specially designed and manufactured for that duty. MOVING PARTS ‘A. Keep hands, arms and other parts of the body ‘and also ciothing away from couplings, fans and other moving parts B. DO NOT attempt to operate the compressor with the fan, coupling or other guards removed. C. Wear snug-fiting clothing and confine iong hair when working around this compressor, especially when exposed to hot or moving parts D. Keep access doors, if any, closed except when making repairs or adjustments. E, Make sure all personnel are out of andlor clear of the compressor prior to attempting to start or oper- ate it F, Disconnect and lock out all power at source end verify at the compressor that all circuits are de- energized to minimize the possibilty 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 surfaces clean and free of fluid, water, or other lige Lids to minimize the possibilty of slips and fais. HOT SURFACES, SHARP EDGES AND SHARP CORNERS A. Avoid bodily contact with hot fluid, hot cootant, hot surfaces and sharp edges and comers. B. Keep all parts of the body away from all points of air discharge. C. Wear personal protective equipment including gloves and head covering when working in, on oF around the compressor. D. Keep a first aid kit handy Seek medical assis- tance prompily in case of injury. DO NOT ignore47 18 small cuts and burns as they may lead to infection TOXIC AND IRRITATING SUBSTANCES ‘A. DO NOT use air from this compressor for respi- ration (breathing) except in full compliance with any Federal, State or Local Codes or regulations. Death or serious Injury can result from inhaling ‘compressed air without using proper safety ‘equipment. B, DO NOT use airline anti-icer systems in airlines supplying respirators or other breathing air utilize- tion equipment and DO NOT discharge air from these systems in unventilated or other confined areas ©. Operate the compressor only in open or ade- quately ventilated areas. D, Locate the compressor or provide a remote inlet 80 that it is not fikely to ingest exhaust fumes or other toxic, noxious or corrosive fumes or sub- stances. E, Coolants and lubricants used in this compressor are typical of the industry. Care should be taken to avoid accidental ingestion and/or skin contact. In the event of ingestion, seek medical treatment promptly. Wash with soap and water in the event of skin contact. Consult the compressor operator's manual lubrication section for information pertaining to compressor fluid fill F. Wear goggles or a full face shield when adding antifreeze compound to air line anti-icer systems. G If air line antiicer system antifreeze compound enters the eyes or if fumes irritate the eyes, they should be washed with large quantities of clean water for 15 minutes. A physician, preferably an eye specialist, should be contacted immediately. 1H. DO NOT store air line anti-icer system antifreeze ‘compound in confined areas, |. The antifreeze compound used in ait line antifreeze systems contains methanol and is toxic, harmful, or fatal f swallowed. Avoid contact with the skin or eyes and avoid breathing the fumes. If swal- lowed, induce vomiting by administering a table- spoon of salt, in each glass of clean, warm water until vomit is clear, then administer two teaspoons of baking soda in a glass of clean water. Have patient lay down and cover eyes to exclude light. Call a physician immediately. ELECTRICAL SHOCK A. This compressor should be installed and main- Section 1 SAFETY tained in full compliance with all applicable Federal State and Local codes, standards and regulations, including those of the National Electrical Code, and also including those relative to equioment ground- ing conductors, and only by personnel that are trained, qualified and delegated to do so. B. Keep all parts of the body and any hand-neld tools or other conductive objects away from exposed live parts of electrical system. Maintain dry footing, stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system. Make all such adjustments or repairs with one hand only, 80 as to minimize the possibilty of creating a current path through the heart C. Attempt repairs in clean, dry and well lighted ang ventilated areas only D. DO NOT leave the compressor unattended with open electrical enclosures. If necessary to do so, then disconnect, jock out and tag all power at source so others will not inadvertently restore power E, Disconnect, lock out, and tag all power at source prior to attempting repairs or adjustments to rotating machinery and prior to handling any ungrounded conductors, F. Dry {est all shutdown circuits prior to starting the compressor after installation, 1.9 LIFTING A. If the compressor is provided with a lifting bali, then It by the bail provided. If no bail is provided, then lif by sling. Compressors to be airlifted by hel- icopter must net be supported by the lifting bail but by slings instead. In any event, lift and/or handle only in full compliance with Federal, State and Local codes, B. Inspect points of attachment for cracked welds and for cracked, bent, corroded or otherwise degraded members and for loose bolts or nuts prior to lifing, C. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition and has a rated capacity of at least the weight of the compressor. If you are unsure of the weight, then weigh compressor before 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Section 1 SAFETY ‘or swinging of the compressor once it has been lift ed 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. |. Keep lift operator in constant attendance whenev- er compressor is suspended J. Set compressor down only on a fevel surface capable of safely supporting at least its weight and its toading unit, K. When moving compressors by forklift truck, uti- lize fork pockets if provided. Otherwise, utilize pal- let if provided. If neither fork pockets or pallet are provided, then make sure compressor is secure and well balanced on forks before attempting to raise or transport it any significant distance. L. Make sure forklift truck forks are fully engaged and tipped back prior to lifting or transporting the compressor. M, Forklift no higher than necessary to clear obsta: cles at floor level and transport and comer at mini- mum practical speeds, N. Make sure pallet-mounted compressors are firm- ly bolted or otherwise secured to the pallet prior to attempting to forklif or transport them. NEVER attempt to forklift a compressor that is not secured to its pallet, as uneven floors or sudden stops may cause the compressor to tumble off, possibly caus- ing serious injury or property damage in the process, ©. DO NOT use the lifting eye bolt on the compres- sor motor, if supplied, to lift the entire compressor package. 4.40 ENTRAPMENT ‘A. If the compressor enclosure is large enough to hold a person and ifit is necessary to enter it to per- form service adjustments, inform other personnel before doing so, or else secure and tag the access doar in the open position to avoid the possibility of others closing and possibly latching the door with personnel inside. B. Make sure all personnel are out of compressor before closing and latching enclosure doors,2.1 INTRODUCTION Refer to Figures 2-1A and 2-18. Your new Sullair lubricated rotary screw air compressor provides you with a unique experience in improved reliability and greatly reduced maintenance. Compared to other types of compressors, the Sullair rotary screw is unique in its mechanical reli- ability and lack of ‘wear". The compressor requires absolutely no inspection of its intemal parts, By reading through Section 6, you will notice the easy process of caring and maintaining this Sullair manufactured product. Should any questions arise which cannot be answered in this text, call your nearest Sullair representative or the Sullair Corporation Service Department, 2.2 DESCRIPTION OF COMPONENTS: Refer to Figures 2-1A and 2-18. The components and assemblies of the air compressors are clearly shown. The complete package includes compres Section 2 DESCRIPTION sor, electric motor, compressor inlet system, compressor discharge system, compressor cooling and lubrication system, capacity con- trol system and Supervisor Controller™, micro- processor system and starter all mounted on a structural steel frame On air-cooled models, a fan draws air over the fan motor and forces it through the combined after- cooler and fluid cooler, thereby removing the heat ‘of compression from the cooling fluid (On water-cooled models, fluid is piped into a water- cooled heat exchanger where the heat of compres- sion is removed from the fluid, A fan is used to sup- ply sufficient ventilating air to compressors equipped with an optional enclosure Both air-cooled and water-cooled versions have easily accessible items such as the fluid fiters and control valves. The inlet ar fiters are also mounted Figure 2-14 Sullair Series TS-20 Rotary Screw Compressor (Air Cooled Typical) Post Enfriedor). — friador de aceite Panel de Control: Gabinete Arrancodor Torque —~ Seporador ns Vy A _-7 Fillo de are —_Valvula Retencion de aceite /— nid Compresora: cargo de Filtro de Aceite AceiteSection 2 DESCRIPTION Figure 2-18 Sullair Series TS-20 Rotary Screw Compressor (Water Cooled Typical) Eniriedor de dire — fenfricdo por ogual_/ Presion Minima Vola —_ Yalvule | setencion | de Aceite ee “= corga de Aceite filtro de Aceite for easy access and servicing 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION Sullair tandem air compressors feature the Sullair compressor unit, @ two-stage, positive displace- ment fluid lubricated-type compressor. This. unit provides continuous air compression to meet your needs Fluid is injected into the compressor unit where it mixes directly with the air as the internal rotors turn, ‘compressing the air The fluid flow has three basic functions: 1. As coolant, it controls the rise of air temperature normally associated with the heat of compression 2, Seals the leakage paths between the rotors and the stator and also between the rotors themselves, 3. Acts as a lubricating film between the rotors allowing one rotor to directly drive the other, which is an idler. After the airfluid mixture is discharged from the compressor unit, the fluid is separated from the air. At this time, the air flows to the serv- ice line and the fluid is cooled in preparation for re- injection With 2 Sulla compressor, there is mo mainte- nance or inspection of the intemal parts ofthe compressor unit permitted in accordance with the torms ofthe warranty 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figures 2-2, 2-3A, 2-9B, 2-4A, 2-4B, 2-5A, 2-68. The cooling and lubrication system consists of a fluid cooler, full flow fluid filter, fluid stop valve, thermal valve, ‘The pressure in the receiverisump causes fluid flow by forcing the fluid from the high pressure area of the sump to an area of lower pressure in the com pressor unit Fluid flows from the receiver/sump to the thermalice pressure stig Sern ‘lve DIFFEREN Tu PaEssune Hise ive gure) oneee omar aay ete (Cn ‘aug paces ‘CHECK Valve Section 2 DESCRIPTION Figure 2-2 Compressor Piping and Instrument Diagram - Air Cooled & Water Cooled - 200/250HP_ we eonTAOL UNE Passe Pa EESWDOWN SALVE WC) ‘\ actuator Of "SOLENOID VALVE #2} (= sual) ay pee ‘Oran me ro eet Galt ‘wie FLUID GOOLE waite ny |wareR COOLED MODELS mourners uosrune sePsnOn A wo A & FLUO 3 WER IC conto: iin sumeSection 2 DESCRIPTION valve. The thermal valve Is fully open to the com pressor unit when the discharge temperature is below 170°F (77°C} for all compressors, water-cooled 2KT models and all models operat- ing at 160 psig (10.3 ber) and higher, which is fully open up to 198°F (91°C). The fluid passes through the thermal valve, the fluid stop valve, the main fluid fiter and directly to the compressor unit. As the discharge temperature rises above 170°F (77°C) for all compressors (196°F [91°C] for water- Cooled 24KT models and high pressure > 150 psig [10.3 bar), due to the heat of compression, the thermai valve begins to close and a portion of the fluid then flows through the cooler. From the cooler, the fluid flows to the main fiter, the fuid stop valve, and on to the compressor unit. The fluid fier has @ replacement element and an integral pressure bypass valve, The fluid stop valve prevents fluid from filing the compressor unit when the compressor is shut down. When the compressor is operating, the fluid stop valve is held open by air pressure from the ‘compressor Unit allowing a free flow of fluid from the receiverisump back to the compressor unit. On shutdown, the compressor unit pressure is reduced, causing the fluid stop valve to close and isolate the compressor unit from the cooling system. Water-cooled models have @ water pressure switch to prevent operation with inadequate water pres- sure. 2.6 COMPRESSOR DISCHARGE SYSTEM, FUNC- TIONAL DESCRIPTION Refer to Figures 2-2, 2-48 and 2-4B, The com- pressor unit discharges the compressed airifuid mixture through a discharge check valve into the combination receiver/sump. The discharge check vaive prevents airffuid in the receiver from return ing to the compression chamber after the compres- sor has been shut down. The receiver has three functions: 4. Itacts as a primary fluid separator. 2. It serves as the compressor fluid sump. 3. Ithhouses the final fuid/air separator elements. The compressed aitifluid mixture enters the receiv- er and is directed against an internal baffle. The direction of movement is changed and its velocity significantly reduced, thus causing the large droplets of fluid to fall to the bottom of the receiv- erisump. The fractional percentage of fiuid remain= ing in the compressed air collects on the surface of the nested separator elements (primary and sec- ondary) as the compressed air flows through them. Two return lines (or scavenge tubes) lead from the bottom of each separator element to the low pres- sure inlet region of the compressor unit. Fluid col- lecting on the bottom of each separator is returned to the compressor by a pressure difference between the receiver and the compressor inlet Sight glasses are located in the retum lines to observe this fluid flow. dP1 on the Supervisor Controller™ microprocessor control monitors the condition of the separator elements by reading the fferential pressure on the digital display. At a dif- ferential of 10 psig (0.7 bar), or greater, the oper- ator will be told to service the separator elements At this time, separator element replacement is nec- essary, ‘The receiver is an ASME pressure vessel. A combi- nation minimum pressure/check valve, located downstream from the separator, assures a mini- mum receiver pressure of 60 psig (3.4 bar) during ful load operation. This pressure i necessary for proper airffuid separation and proper fluid circula- tion while supplying air to the system. This valve also acts as a check valve preventing compressed air in the service line from bleeding back into the receiver on shutdown and during operation of the ‘compressor In an unloaded condition ‘A pressure relief valve (located on the wet side of the separator) is set to open if the sump pressure exceeds the rated pressure of the tank All Sullair compressor models are equipped with high pressure shutdown protection to shut down the compressor at 30 psi above rated pressure. This prevents the pressure relief valve from opening under normal conditions, thereby preventing fluid loss through the pressure relief valve. A tempera- ture switch will snut down the compressor ifthe dis- charge temperature reaches 235°F (113°C) PN DO NOT remove caps, plugs, andlor other com- ponents when compressor i running or pres- surized, ‘Stop compressor and relieve all intemal pressure before doing so. Fluid is added to the sump via @ capped fluid filler opening, placed low on the recaiver tank to prevent over-filing of the sump. Two sight glasses enables the operator to visually monitor the sump fluid level 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIP- TION Refer to Figures 2-5A and 2-58. The purpose ofthe compressor control system is to regulate the ‘amount of air being compressed to match the a- ‘mount of compressed air being used. ‘The capacity control system consists of @ spiral valve and an inlet butterfly valve. The functional description of the control system is described below in 4 distinct phases of compressor operation. The following applies to TS-20 Series compressors ranging from 200 through 260np. For explanatory purposes, this description applies to any compressor with an operating range of 100 to 110 psig (6.9 to 7.6 bar). A compressor with any other pressure range would operate in the ‘same manner except for the stated pressures. START MODE - 0 TO 50 PSIG (0 TO 3.4 BAR) when the compressor Ml (on) pad is depressed the sump pressure wil quickly rise from 0 to 60 psig (Oto 3.4 bar), During this period, both of the pres- sure regulators and the solenoid vaive are closed and the Sullicon Controt and spiral valve are inop- erative. The spring on the control holds the buttery valve fully open while the spiral valve is fully closed (maximum) position and the compressor pumps at full rated capacity. The rising compressor air pres- sure is isolated from the service lin in this phase by the minimum pressure valve set at approximate- ly 80 psig (3.4 bar. An optional closed inlet system is provided which uses air pressure to close the butterfly and opens the spiral valve to reduce motor torque for starting FULL LOAD MODE - 50 TO 100 PSIG (3.4 TO 6.9 BAR) When the compressed air pressure in the sump rises above 50 psig (3.4 bat), the minimum pres- sure valve opens, allowing compressed air to flow into the service line. From this point on, the ine air pressure is continually monitored by the Supervisor The pressure regulators and the solenoid valve remain closed during this phase, Keeping the Sullicon Control and spiral valve inactive. Both the spiral valve as well as the inlet buttery valve remain in the ful load position as long as the com pressor is running at 100 psig (6.9 bar) or below MODULATION - 100 TO 110 PSIG (6.9 TO 7.6 BAR) As air demand drops below the rated capacity of the compressor, the line pressure will rise above 100 psig (8 bar) As a result the diferential pressure regulator fr the spiral valve gradually opens, apply- ing air pressure to the spiral valve actuator. Air pes- sure at the actuator expands the diaphragm, The Section 2 DESCRIPTION rack, in turn, engages with the pinion mounted on the spiral valve shaft assembly. This results in rotary motion, As the spiral valve rotates, it starts opening the bypass ports gradually. Excess air is then being returned back internally to suction end of ‘compressor unit, Now the compressor is fully com- pressing only that amount of air which is being used. As air demand keeps dropping further, the spiral valve keeps opening more and more until all the bypass ports are fully open. At this point, the spiral valve has moved into the minimum position. ‘The spiral valve provides @ modulation range from 400 to approximately 0%. During this period, the pressure rises approximately from 100 to 108 psig (6.9 to 7.4 bar). As the air pressure exceeds 108 psig (7.4 bar), the differential pressure regulator controlling the Sullicon Control opens. This allows the air pressure to expand the diaphragm chamber of the Sullicon Control, which starts partially closing the iniet butterfly valve. The inlet butterfly valve pro- vides modulation range from 50 to 40%. During this period, the pressure rises approximately from 108 io 110 psig (7.4 to 7.6 bar). During this range, the spiral valve remains in the full open position. UNLOAD MODE - IN EXCESS OF 110 PSIG (7.6 BAR) ‘When a relatively small amount or no air is being used, the service line pressure continues to rise. When it exceeds 110 psig (7.6 bar), Supervisor de energizes the solenoid valve allowing line pressure to be supplied directly to the Sullicon diaphragm keeping the inlet butterfly closed; the spiral valve is in the fully open (minimum) position Simultaneously, the solenoid valve sends @ pneu- matic signal to the blowdown valve. The blowdown valve opens the sump to the atmosphere. This reduces the sump pressure to approximately 30 psig (2.1 bar) which results in low horsepower con- sumption. The check valve in the air service line prevents line pressure from returning to sump while the compressor is running in the unloaded mode Both the spiral valve and the butterfly vaive remain in the unload position. \When the line pressure drops back to 100 psig (6.9 bar) due to an increase in the air demand, Supervisor energizes the solenoid valve allowing the air pressure behind the Sullicon Control to be vented through the solenoid valve exhaust port ‘The blowdown valve closes, and the inlet butterfly valve opens. Also the air pressure at the spiral valve actuator diaphragm is reduced through 2 vent hole at the spiral valve differential pressure regulator, and a spring in the actuator causes the spiral valve 9Section 2 DESCRIPTION Figure 2-34 Compressor Cooling and Lubrication System - Air cooled 200 HP / 250 HP ENFRIADOR AIRE-ACEITE — VALVULA, TERMOSTATICA VALVULA | RETENCION DE ACEITESection 2 DESCRIPTION Figure 2-38 Compressor Cooling and Lubrication System - Water cooled VALU A \, TERMOSTATICA Pie VALVULA ReTENCION —! DE ACEITE, so YALL \ TERMESTATICA ENERIAOOR de ACETE Yentrieds por agual (CH wn RETENCION & DE ACETE FESSection 2 DESCRIPTION Figure 2-4A Compressor Discharge System - Air cooled 200 HP / 250 HP > _NALNULA DE PRESION MINMA L. SepaRADOR DE CONDENSADO a VALVULA DE ii] LS DESCARGA SEPARADORSection 2 DESCRIPTION Figure 2-4B Compressor Discharge System - Water cooled VALVULA DE —, PRESION MINIMA \ oe TANQUE SEPARADOR A POST-ENFRIADOR eC (enfriado por agua) a VALVULA DE DESCARGA 200 HP / “ | 250 HP aSection 2 DESCRIPTION Figure 2-54 Control System: START - FULL LOAD (Typical) PRESSURE SOLENOID VALVE BLOWDOWN — REGULATOR 9 START (0-80 PSI/ 0-3.5 BAR) SILENCER. AB INLET VALVE OPEN SPIRAL \, SOLENOID VALVE \ SHUTTLE SouTROL rescue VALVE INLET VALVE (ppessune. CONTROLAGD PRESSURE atowoown — SESSSURS, seep ve VAWE | FULL LOAD (50-100 PSI/ 3.5-6.9 BAR) SILENCER. AIR INLET VALVE OPEN CONTROL LINE | sotsnot ave \ suuticon sayin CONTROL [Mauve CONTROL ROD pressune fESULATOR 14Section 2 DESCRIPTION Figure 2-58 Contro| System: MODULATION - UNLOAD (Typical) PRESSSURE SOLENDIO VALVE MODULATION “ae a (100-710 PSI/6.8- 7.6 BAR) N\ SILENCER . AIR INLET SS PRESSURE vaUve MOB) ay SwiicH y CONTROL Cine FILTERS SHUTTLE VALVE ~~ \\ SOLENOID VALVE \. \. SHUTTLE sutticon / VALVE INLET VALVE See PRESSURE CONTROL ROD REGULATOR PRESSURE SOLENOID VALVE BLownown REGULATOR UNLOAD Cd SILENCER PRESSURE, AIR INLET ese LINE FILTERS: Sa 2) / COMPRESSOR | SOLENOID VALVE / \ f ‘SHUTTLE / eouTaOL jp wave wncer vatve ery PRESSURE ere REGULATOR 15Section 2 DESCRIPTION Figure 2-6 Compressor Air inlet System FILTRO DE AIRE —, VALVULA DE —~ ADMISION UNIDAD COMPRESORA 16 to retum to the full load (maximum) position AUTOMATIC OPERATION For applications with varied periods of time when there are no air requirements, Supervisor's Auto mode allows the compressor to shut down (time delayed) when no compressed air requirement is present and restart as compressed air is needed. LOAD NO LOAD OPERATION If applications call for loadino ioad operation, mod- ulation can be disabled in the Supervisor Controller™ in the “Control Parameters” menu. If modulation is disabled, the unload pressure must be reset to the rated load pressure of the machine. For example, an L modet rated for 100 psig full load operation and 710 psig unioad must have the unload pressure reset to 100 psig. This ensures that the motor will not run in an overload condition, 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIP- TION Refer to Figure 2-6. The compressor inlet system consists of one or two dry-type air fters, @ vacuum switch and an air inlet valve. The vacuum switch, located in the compressor Supervisor controt system, indicates the condition of the air filter. When the message “AIR FILTER MAINT RQD" is displayed, maintenance is required. The buttertly-type air inlet valve directly controls the amount of air intake to the compressor in response to the operation of the Sullican Control (Section 26)3.4 SULLAIR TS-20 SPECIFICATIONS: COMPRESSOR: Type Standard Operating Pressure ( Bearing Type Ambient Temperature (Max.) (I) Cooling Lubricant ‘Sump Capacity Controt {50 Hz Compressors) Section 3 SPECIFICATIONS STANDARD MODELS Positive displacement, fuid - lubricated, twin rotary screws See Specifications ‘Ant Friction 405° F (41° C), consult factory for higher ambient temperatures Pressurized Fluid Sullube Sullube 32 30 gallons (114 liters) Electro - Pneumatic, STANDARD MODELS 100 - 250 HP TEFC, Three Phase, 50 Cycles C., 105° F (41° C) Maximum Ambient Temperature Full Voltage, We - Delta, various voltages 1500 RPM (W) Special compressors are available for operation at higher pressures (ll) Special compressors are available for operation in higher ambient temperatures, MOTOR: (60 Hz Compressors) STANDARD MODELS Size 4100 - 250 HP Type: TEFC, Three Phase, 60 Cycles AC., 105° F (41° C) Maximum Ambient Temperature Starter Full Voltage, Wye - Delta, various voltages Speed 41800 RPM 3.2 LUBRICATION GUIDE-STANDARD COMPRES- Sulir TS-20 compressors av filed with Sullube Mixing of other fluids within the compressor will volld alt warranties. Sullube 32 fluid should be changed every 8000 hours or once a year, whichever Occurs first. The fiuid should be changed more frequently under se. vere operating conditions, such as high ambient temperatures coupled with high humidity, high par- ticulate fevel, corrosive or strong oxidizing gases are present in the air. Maintenance of all other components is still recom- mended as indicated in the Operator's Manual, APPLICATION GUIDE Sullair encourages the user to participate in a fluid analysis program with the fluid suppliers. This could result in a fluid change interval differing from that stated in the manual. For more information on a fluid analysis program, contact your local Sullair representative or the Sull- air Factory Service Department. “Tho Plastic Pipe institute recommends. ust of thermoplasile pipe fo transport compressed air or other comprested gasee in exposed above ‘ground loeations, &.g. n exposed pian piping.” lh Sulluve 22 should not be used with PVC piping aya fem. It may affeet the bond at cemented joints. Cer~ tain other plastic materials may also be affected ) Plastic Pipe Institute, Recommendation 8, Adopted January 19, 1572. "7Section 3 SPECIFICATIONS Figure 3-1 Identification - TS20-200HP - Air Cooled.Section 3 SPECIFICATIONS Figure 3-2 Identifcation - TS20-250HP - Air CooledSection 3 SPECIFICATIONS Figure 3-3 Identification - TS20-200HP - Water CooledSection 3 SPECIFICATIONS Figure 3-4 identification - TS20-250HP - Water Cooled. 24Section 3 SPECIFICATIONS Figure 3-5 Piping and Instrumentation - TS20-200/250HP - Air Cooled 22Section 3 SPECIFICATIONS Figure 3-5 Piping and instrumentation - TS20-200/250HP - Air Cooled, key part number deseipton number quent 4 filter, air inlet 02250140-798 - 2 viet tery oss : 3 control, sullicon 011682-003 as 4 viv, shuttle 1/4" 408893, - 5 viv, check 1/4" 049905, : wt press ce, 18 pt wos i viv, sol Sw 1/4" 115vac 02250125-657 . & filter, control 1/4" npt 022501 12-032 ict ear ors 10 orifice, 032” 02250125-774 - 1 viysst Sw 1 HEV UNIY onsosess 12a Boncown 12" ne 20 azsor000%2 13 sheneer ae 12" +1008 : 4 termi 100 om platinum cxasoouases 15 pressure transducer 2soosesi0 16 onfice, 062 02250125-775 - 7 glass, sight 1/4° 02250126-129 - 18 staner vp 14" 300ps1 (21 bar oxsoiir7e2 19 viv, min. press, check 250033-821 - 2 —_merometo vxsoviran9 21 vahola do coguriad moot 22 element, secondary separator 250034-134 - 2 element primary separator poosein 24 viv, spiral = - 25 soleolde 18" 118 UNIV oxsormseee 26 viv, relief 1-1/4" 175% (12.25 bar) 410103 - 2 tank tid sep 30" cxsoweas 28 cls, ti evel 1 12" lgt o4oara ; 29 viv, globe 3/4" 040520, - Soils gue unui ee : 3t viv, relief 65# 1 1/4" x 1 1/2" 02250083-571 : 32 wu themal 112" 1781784) usta : 23 ter ud oxasoiatess 7 Suit i : (Continued on page 25) 23Section 3 SPECIFICATIONS Figure 3-5 Piping and Instrumentation - TS20-200/250HP - Air Cooled 24Section 3 SPECIFICATIONS Figure 3-5 Piping and instrumentation - TS20-200/250HP - Air Cooled key part number description number quantity 35 cooler, fuid combo 200HP 02250151-822 - cooler, fluid combo 250HP 02250152-542 - 36 valvula drenaje oan . 37 separator, combo trap 250007-787 - 38 ly, oll stop 2” 016742 - 39 valvula reguladora de presion 048556 - 40 switch, vac. 22" we. nd 02250078-249 - 44 : - 42 unit, compressor - : 43 : - 44 heater tap 245872 - 45 : : 46 heater sump 2000W 120V 02250043-014 - 47 valvule reguladora 048556 : 48 ly, ball 1/2" opt oa7117 - 49 valvuia solenoide 02250125-674 - 50 filtro tipo ¥ 1/2" 406480 : 51 orf, cap. 031 x 1/4" 02250132-934 : 25Section 3 SPECIFICATIONS Figure 3-6 Piping and Instrumentation - TS20-200/250HP - Water Cooled.Section 3 SPECIFICATIONS Figure 3-6 Piping and Instrumentation - TS20-200/250HP - Water Cooled key part number description number quantity 1 fier irnet oxasooree 2 viet tery 40338 ; 3 cont son ortesz03 4 viv, shuttle 1/4" 408893 - 5 vv check oaeeos i 6 viv, Giff. press. reg. 1/4" npt 406929 . rd viv, sol 3w 1/4° 115vac 02250125-687 a 8 filter, control 1/4” npt 022501 12-032 ° vy reo 408275 : 10 orifice, .032" 02260125-774 iW sol sw "4157 UNIV oeasoize-sss 12 Blondonn 12" ne 20 casotcoe 13 silencer, aire 1/2" 041005 - 4 termi, 100 ohm datum cxzsconases 15 pressure transducer 250039-910 as 16 orifice, .062 02250125-775 - 17 alse. siht 18 oasotz6-129 18 ———_sraney, ype 18" 3009521 bax) omsorr7e2 19 viv, min. press. check (250033-821 7 20 manometro 02250117-009 - 2 alla de seguridad 24607 ‘ 22 element, secondary separator 250034-134 7 23 eamontpimary separator soosaiz2 2 Whspial i i 2% Ww solerade 1 18V UNIV onsorsses 2 whet Te 1758 (12.25 be) ‘0103 : 2 tank uid sep 30" dia onagorceo7s 28 glass level 112" slg o4oa7e ‘ 28 Wc lobes o4os20 f 30 ——_tanque scurutaer 221 i 3 vl, relief 65# 1 1/4" x 1 1/2" 02260083-571 - 32 Ww them 112" 1754 (794°C) ovser2 i 3 iter, ud oneorziese 34 aftercooler 042541 - (Continued on page 29) 2Section 3 SPECIFICATIONS Figure 3-6 Piping and Instrumentation - TS20-200/250HP - Water Cooled,Section 3 SPECIFICATIONS Figure 3-6 Piping and Instrumentation - TS20-200/250HP - Water Cooled key part number description number quantity 36 cooler, oli 200HP 043031 : cooler, oll 2560HP 043864 : 36 valvula drenaje ostatt : a separator, combo trap .250007-787 : 38 vv, oll stop 2" 16742 - 39 valvula reguladora de presion 046556 - 40 switch, vac. 22" we. n4 02250078-249 - 4a a ze 42 unit, compressor 7 : 43 a - - 44 heater trap 248572 - 45 a - : 46 heater sump 2000W 120V 02250043-014 : 47 valvula reguladora 046556 - 48 ly, ball 1/2" npt oarti7 - 49 valvula solenoide 02250125-874 : 50 filtro tipo ¥ 4/2" 406480 - 51 of, cap. 034 x 1/4" 02250132-934 : 52 valvula reguladora de agua o4g474 - 53 presostato 0-30 psi 250007-163 - 29NOTES4.1. MOUNTING OF COMPRESSOR ‘foundation or mounting capable of supporting the weight of the compressor, and tigid enough to main- Section 4 INSTALLATION protection where it will be exposed to temperature: less than 32°F(0°C), tain the compressor frame level and the compressor 4.3 SERVICE AIR PIPING in alignment Is required. The compressor frame must be leveled and secured with foundation bolts, and full uniform contact must be maintained be- tween the frame and foundation. The compressor unit and driver must be aligned atter installation as specified in the Operator's Manual. No piping loads shall be transmitted to the compressor at the exter- nal connections. 4.2 VENTILATION AND COOLING For air-cooled compressors. select a location to ppetmit sufficient unobstructed airflow in and out of the compressor cooling package to keep the oper- ating temperature stable. The minimum distance that the compressor should be from surrounding walls is three (3) feet (91 4or). To prevent excessive ambient temperature rise, itis imperative to provide adequate ventilation For water-cooled compressors, it is necessary to check the cooling water supply. The water system must be capable of supplying the following flows: WATER FLOW (TYPICAL) WATER TEMP. (epuiuemy F (°C) 100K 125HP 150HP 200HP 250KP Tek SOKW 1TaKW TSOKW TE7KW Jor!) AGNES 175/68 21.075 40/161 4/185 Service air piping should be installed as shown in Figure 4—1. A shut—off valve should be installed to isolate the compressor from the service line if re- quired. Also notice that the service line should be ‘equipped with water legs and condensate drains, throughout the system, PST “The Paste Pipe Insitute recommends against the Uuse-of thermoplastic pipe to ranepont compressed Sivor other somprostod gasee In expoeed above {round locations: e.g, m exposed plart piping." U) {ullube 22 should not be used with PVC piping ays- tems, itmay affect the bond at cemented jaints. Cer- tain other plastic materials may aleo be affected. () Plastic Pipe Institute, Recommendation 8, ‘Adopted January 19, 1972, 4.4 COUPLING ALIGNMENT CHECK In preparation for the factory test, the coupling sup- plied with your compressor is properly aligned for operation. However, due to shipping and handling, itis necessary to recheck the coupling alignment Refer to Coupling Alignment procedure explained in the Maintenance Section of this manual 80 (27) 18.75/77 238/89 ZeGI0 44/166 54/209 4.8 FLUID LEVEL CHECK (Water prossure should be between 2 and 75 psig (17 and 5.2 ba. ‘Table 1 below indicates the ventilation requirements necessary to keep the compressor running at a nor- mal operating temperature. The fan air requirement is the volume of air which must blow through the compressor for proper ventilation. The specified heat rejection requirement is the amount of heat that is radiated by the compressor. This heat must be re- moved to assure a normal operating temperature, With air—cooled compressors it is Possible to use this heat for space heating, proviging excessive pressure drop is not created across the fan. Consult a Sullair office for assistance in utlizing this heat DO NOT install a water—cooled or an air—cooled/ aftercooled compressor without adequate freeze ‘TABLE 1 VENTILATION REQUIREMENTS (TYPICAL) Your air compressor is also supplied with the proper amount of fluid. However, it is necessary to check the fluid level at installation. The level is checked by looking at the sight glass located on the sump. ifthe sump is properly flied, the coolant level should fil the sight glass Conta Tee aso eee ee Ta eae eg DT | OES beans OT VEAFINRgW a) vaconmee vason4 ves00 weocosse eanoese | Zara? 2aYoe? 2a7aeT 2s7DK7 2a7ae7 Se er a youn Fw AP eee ee es | sap a ae Bae Eee Ti Appice fo cornpressors with canepy only (vent Fan 34Section 4 INSTALLATION Figure 4-1 Service Air Piping (Typical Installation) SHUT-OFF VALVE = (GATE VALVE — RECOMMENDED) _ AROUTLETS (NEVER TAKE AIR FROM BOTTOM OF ~~} PIPE) WATER LEG 4.6 FLUID PIPING (REMOTE AIR-COOLED OPTION ONLY) To allow de-pressurization of the cooling package and connecting piping between the compressor and the cooling package upon shutdown of the com- pressor, 2 1/2°(13 mm) de-pressurization line must be installed between the top of the fluid cooler and the sump tank connection which is located on the fluid supply and return line connection bracket. This line must be maintained at a higher level than the supply and return piping for the fluid cooler. The supply and return piping for the fluid cooler must be adequately sized to prevent excessive pressure drop, The total pressure drop in the supply and return piping and associated fittings and valves, not including the cooler, shall not exceed 10 psig (0.7 bar) at the worst case operating condition 32 (usually fowest ambient). If the pressure drop is in excess of 10 psig (0.7 bar), a pump should be Installed. Consult the Sullair Service Department for recommendations. Itis recommended that shutoff vaives be installed in the supply and return piping to facilitate compressor ‘component's maintenance. Because of the variabilty in installations, the fuid necessary to fill the supply and return piping for the fluid cooler is not part of the standard scope of sup- ply for the compressor. The fluid necessary to fill this piping may be ordered trom the nearest Sullair representative or the representative from whom the ‘compressor was purchased. To assist in determin- ing the amount of fuid necessary to fill the piping, the following chart may be usedGALLONS/LITERS OF ELUID PIPESIZE PER 4 INCHES/304.8MM OF PIPE 16351.62 1 2555/97 368/1.39 (6542/2.48 1.471915.57 4,7 ELECTRICAL PREPARATION Interior electrical wiring is performed at the factory, Required customer wining is minimal, but should be by a qualified electrician in compliance with OSHA, National Electrical Code, and any other applicable state or local electrical code concerning isolation switches, fuse disconnects, etc. Sullair provides a wiring diagram for use by the installer A few electrical checks should be made to help assure that the first start-up will be trouble free, Ltnal shock hazard inside, Disconnect all power at source, before opening ‘or servicing starter or control panel 4, Check incoming voltage. Be sure that the incom- ing voltage is the same voltage that the com- pressor was wired for. 2. Check starter and overload heater sizes (see Electrical Parts in Parts Manual). 3. Check all electrical connections for tightness, 4, "DRY RUN’ the electrical controls by disconnect- ing the three (3) motor leads from the starter. Pull out the EMERGENCY STOP button on the Section 4 INSTALLATION contro! panei, press STOP W), then press stant lll Since some solid state starters have builtin power monitoring, a dry run will only indicate compre Sor overload when machine has this type of starr, 5, Reconnect the three (3) motor leads and jog the motor for @ direction of rotation check, as explained in Section 4.8 6. Verify all directions of rotations on all auxiliary motors. 4,8 MOTOR ROTATION DIRECTION CHECK After the electrical wiring has been done, it is nec- ‘essary to check the direction of the motor rotation, ‘With the control system in MANUAL mode, press the MIF anc ]@ pads in succession to bump start the compressor. When looking at the motor from the end opposite the compressor unit, the shaft should be tuming clockwise on all gear driven models, and counterclockwise on direct drive models. if the motor shaft is not turing in the proper direction, disconnect the power to the starter and exchange any two of the three power input leads, then re- check rotation, A “Direction of Rotation” decal is located on the coupling guard between the motor and compressor to show proper motoricompressor rotation. 33Section 5 SUPERVISOR Figure 5-1 Supervisor Controller Control Panel DISPLAY SUPERVISOR CONTROLLER. SULLA, KEYPADS E-STOP For information concerning all aspects of the Supervisor Controller, consult the Supervisor Controller manual no. 02250133-517.Section 5 SUPERVISOR Figure §-2 Supervisor DLX Controi Pane! : : SYSTEM GRAPHIC DISPLAY. a MESSAGE DISPLAY LOLI fe Le | on, (es | a VO) 22s0083-203 KEYPADS—NOTES6.1 INTRODUCTION While Sullair has built into the LS25S Series pack- age a comprehensive array of controls and indica- tors to assure its proper operation, the user should recognize and interpret readings which call for service or indicate the onset of a matfunction. Before starting the unit, the user should become familiar with the controls and indicators-their pur- Section 6 COMPRESSOR OPERATION pose, location, and use. 6.2 PURPOSE OF CONTROLS All Supervisor Controller related functions and indi- cators are presented in the Supervisor Controller Manual, so please refer to that manual for further information. Additional indicators and functions included in the package are as follows: CONTROL OR INDICATOR EMERGENCY STOP SWITCH THERMAL O/L RESET SPIRAL VALVE PURPOSE Pushing in this Switch, found adjacent to the Supervisor, cuts all AC outputs from the Supervisor and de-energizes the starter. A fault message (E STOP) is displayed by the ‘Supervisor until the button is pulled out and the "O" pad is depressed ‘Momentarily pushing this button, found on the starter's ther- mal overload element housing, re-cioses the starter's con- tacts after a current overload takes place. Please be aware that the elements must be allowed to cool sufficiently before resetting Internally bypasses and controls the air flow capacity of the compressor, in order to match air supply te the demand PRESSURE REGULATOR (LOAD CHAMBER) PRESSURE REGULATOR (UNLOAD CHAMBER) Maintains a maximum pilot pressure of 70 psig (4.8 bar). ‘Opens a pressure line between the sump and the inlet unload chamber, allowing the inlet valve to reguiate air delivery according to air demand. Works in conjunction with solenoid valve #3. SOLENOID VALVE #4 Electrically actuated, 3-way valve which controls the flow of pneumatic logic signals. Used throughout package to: Open the blowdown valve. -Pressurize the unload porticlose the inlet valve during shut- down operation. +Open the (optional) spiral valve. SOLENOID VALVE #2 ‘Opens when the Wye-delta timer closes; closes when the ‘Wye-delta timer Is open. Opens a pressure line between the sump and inlet load chamber allowing the inlet vaive to deliv- er air. This prevents any air system loss and de-pressurizes the controls when the compressor 1s shut off. SOLENOID VALVE #3 ‘Opens pressure line between sump and inlet unload chamber for modulation Serves to control machine during sequencing with muttiple machines, Designates whether machine is at full load or mod- ulating, 37Section 6 COMPRESSOR OPERATION CONTROL OR INDICATOR (CONT.) PURPOSE (CONT) PNEUMATIC INLET VALVE Blocks the reverse flow of airfiuid through the compressor unit during shutdown, and opens to allow air intake to the compressor during normal load. MINIMUM PRESSURE VALVE Maintains 50 psig (2.6 bar) in the receiver tank when the compressor is running loaded. Also incorporates a check valve, which prevents compressed air backflow from the sys- tem when unloaded or shutdown PRESSURE RELIEF VALVE Vents the sump vessel to aimosphere before the com- pressed air pressure exceeds rated tank pressure. Its oper- ation indicates fault with the Supervisor operation unload pressure set too high or failure of solenoid valve #1. BLOWDOWN VALVE ASSEMBLY Vents the sump vessel to atmosphere during unloading and shutdown, ‘THERMAL MIXING VALVE Bypasses fluid flow around the cooler until the fluid reaches a temperature of 170°F, 77°C (195°F for water cooled KT and > 150 psi 10.3 bar), Useful for fast warm-up during start Maintains a minimum temperature during periods of ow load or low ambient temperatures. FLUID STOP VALVE Blocks the flow of cooler fluid to the sump during shutdown, (remote-cooler package only) thus preventing the overfill of fluid in the sump. ‘SUMP SIGHT GLASSES. Indicates level of lubricant in the sump. Located on the sump side, fluid level should be maintained at a level between the high and low sight glass. SEPARATOR RETURN LINE SIGHT Indicate fluid flow in the separator return lines. Large flow GLASSES should be visible during full load operation; litle to no flow during unloaded operation. Sluggish flow during full load operation indicates the need to clean the strainers fitted to the return lines. WATER PRESSURE SWITCH De-energizes the starter, via the Supervisor ifthe water pres- sure falls below 10 psig (0.7 bar). This switch is not adjustable, Used on water-cooled packages only DRAIN VALVES Lubricant sump drain valve. 6.3 INITIAL START-UP PROCEDURE descrited in the Installation Section have been The following procedure should be used to make made. the initial start-up of the compressor. 4. Open the shutoff valve to the service line "Read the preceding pages of this manual thor. Check for possible leaks in piping. eet 6. Slowly close the shut-off valve to assure proper 2. Jog motor to check for correct rotation of fan nameplate pressure unload setting is correct. {refer to Section 4.8). ‘The compressor will unload at nameplate pres- 3. Be sure that all preparations and checks sure. If adjustments are necessary, see Control 38System Adjustments. 7. Observe the operating temperature. If the oper- ating temperature exceeds 200°F (93°C) [215°F (102°C) for water-cooled 24KT and > 150 psi), the cooling system and installation environment should be checked 8, Open shut-off valve to the service line ©. Reinspect the compressor for temperature and leaks the following day. Section 6 COMPRESSOR OPERATION 6.4 SUBSEQUENT START-UP PROCEDURE On subsequent start-ups, check that the proper level is visible in the fluid sight glass and simply press the START Il or AUTO MODE button When the compressor is running, observe the instrument panel and maintenance indicators. 6.5 SHUTDOWN PROCEDURE To shut the compressor down, simply press the stop @ button 3940 NOTES7.4 GENERAL As you proceed in reading this section, it will be easy to see that the Maintenance Program for the air compressor is quite minimal yet important. The use of the service indicators provided for the fluid fil- ter, air fiter and fuid separator, wil alert you when service maintenance is required. When the mainte- nance message is disployed by the Supervisor Controller™, maintenance for that specific item is required. See instructions for each item in Section 7.7, Parts Replacement and Adjustment proce- dures. 7.2 DAILY OPERATION Prior to starting the compressor, itis necessary to check the fluid level in the sump. Should the level be low, simply add the necessary amount, If the addition of fluid becomes too frequent, a simple problem nas developed which is causing this excessive loss. See the Troubleshooting Section (7.8) under Excessive Fluid Consumption for a probable cause and remedy ‘Atter a routine start has been made, observe the Supervisor control panel and be sure it monitors the correct readings for that particular phase of opers- tion. After the compressor has warmed up, itis rec- ‘ommended that @ general check of the overall com pressor and Supervisor be made to assure that the compressor is cunning properly. A WARNING 0 NOT remove caps, plugs, andor other com= ponents when compressr is running or pres- surized. ‘Stop compressor and reliove all intornal pros sure before doing so. MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION After the initial 50 hours of operation, few mainte- nance requirements are needed to rid the systam of any foreign materials if any. Perform the following maintenance operations to prevent unnecessary problems. 73 1, Clean the return line strainers. 2. Clean the return line orifices 3. Change the fluid filter element. 4, Clean the control line fiers 7.4 MAINTENANCE AFTER 1000 HOURS ‘After 1000 hours of operation, it will be necessary to perform the following, 4. Clean the return line strainers. 2. Replace the fluid filter element Section 7 MAINTENANCE 7.5 FLUID CHANGE Standard models are filled with the long life lubri- cant Sullube. Sullube should be changed under the following con- itions, whichever occurs fist: 4. Every 8000 hours. 2. Once a year. 3. As indicated by fluid analysis, A fiuid sample at every 1000 hours is recommend- ed. For a free Sullube analysis, send fluid to: Dow Chemical Lubricant Technology Center Building B-1605 Freeport, TX 77641 To facilitate this, a sample bottle is included with the ‘compressor. 7.6 SEPARATOR MAINTENANCE Replace the separator elements when a message is displayed or after one (1) year, whichever comes: first, The separator elements must be replaced, DO NOT clean the separator e'ements. 7.7 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES FLUID FILTER MAINTENANCE Refer to Figure 7-1. The fluid fiter (P/N 02250121- 856) is located schematically after the thermal valve. When servicing the fluid fier, shut the com- pressor down, be sure all pressure has been released, then follow the instructions below. For Figure 7-1 Fluid Fitter (P/N 02250121-656) Ss seas *Repair Kit P/N 02250139-995 4Section 7 MAINTENANCE element replacement order kit number 02260139- 995 4. Drain the fluid from the canister by removing the bottom drain plug 2. Loosen the spin-on canister u the bottom canister hex. 3, Pull the canister away from the filter head. The filter element will be attached to the head 4, Separate the element from the head. 5, Remove the canister seals. 6. Thoroughly clean the filter head and canister in solvent 1g a wrench on Lubricate the new seals with the same type of fluid used in the compressor and position each seal in its appropriate place. 8. Slide the element into the canister. 9. Thread the canister and element back on the fil ter head AIR FILTER MAINTENANCE Refer to Figure 7-2. Air filter maintenance should be performed when the air fiter maintenance mes- sage is displayed. The air filter is equipped with primary element and a secondary element. AS pre- viously stated, the Supervisor will alert you as to when the primary element maintenance is neces- Figure 7-2 Air Filter Replacement (P/N 02250140-798) = — : i DUST WA COLLECTOR Replacement Element PIN 02250135-150 sary. When removing the primary element, always ccheck the secondary element for visible dif, grease ‘or damage, The secondary element must be changed after every sixth primary element change. DO NOT clean the secondary element. ELEMENT REMOVAL 4, Clean the exterior of the air filter housing 2, Remove the cover assembly by loosening the wingnut securing it 3. Pull the element assembly out of the housing 4. On the inside of the element, you will notice a wingnut which fastens the element to the hous- ing, Remove the wingnut and pull the primary element out 8. Loosen and remove the hex nut securing the sec- ‘ondary element Remove the secondary ele- ment 6. Inspect the secondary element and replace it necessary, 7. Clean the interior ofthe housing by using a damp lath. DO NOT blow dirt out wth compressor air 8, Install the new secondary element and replace the sealing washer and hex nut 8. With the secondary element in place, replace the primary element HOUSING ELEMENT eT) 42Figure 7-3 Separator Element Replacement -—onrsorew |S LOCK WASHER SECONDARY ELEMENT —~ PRIMARY ELEMENT ‘SUMP TANK Primary Replacement Element P/N 250034-122 ‘Secondary Replacement Element PiN 250034-134 DO NOT strike the element against any hard sur- face to dislodge dust. This will damage the sealing surfaces and possibly rupture the element DO NOT ‘biow" dirt out of the interior of the fier housing. This may introduce dust downstream of ihe filter. Instead, use a clean damp cloth DO NOT oil the element ELEMENT INSPECTION 1. Place a bright light inside the element to inspect for damage or leak holes. Concentrated light will Section 7 MAINTENANCE shine through the element, revealing any holes. 2. Inspect ali gaskets and gasket contact surfaces of the housing. Should faulty gaskets be evident, correct the condition immediately 3. Ifthe clean element is to be stored for later use, it must be stored in a clean, closed container. 4, After the element has been installed, inspect ané tighten, if necessary, all air inlet connections prior to resuming operation. PRIMARY ELEMENT REPLACEMENT 1. Place the element in position over secondary ele- ment. Replace the sealing washer and wingnut Tighten the wingnut so as to fully seat the ele- ment gasket 2, Install the coverlelement assembly and replace the wingnut SEPARATOR ELEMENTS REPLACEMENT Refer to Figure 7-3. The separator elements must be changed when “Separator Maintenance Required’ message is displayed, or once a year whichever occurs first. Follow the procedure explained below for separator element replace- ment, PROCEDURE FOR ELEMENT REPLACEMENT 1. Relieve all pressure from the separator and all ‘compressor lines prior to disconnecting any pipes, tubing, ete 2. Disconnect all piping connected to the separator cover to allow removal (return lines, service lines, etc.) 3, Loosen and remove the twelve (12) 3/4” x 3" hex, head capscrews from the cover plate. 4, Lift the cover plate from the separator using a 3/4" jackscrew under the lifting arm post. The lid ‘can be pivoted to the side supported by the lift ing arm, 6. Remove the primary and secondary separator elements, 6, Scrape the old gasket material from the cover and flange on the sump being careful not to let the scraps fallin the sump. 7. Inspect the separator tank for rust, dir, etc. 8. Reinsert the separator elements with gaskets attached into the sump taking care not to dent them against the tank opening. DO NOT remove grounding staples. Check between separator element flange and tank for continuity afer torquing bolts. DO NOT use anti-seize com- 43Section 7 MAINTENANCE Figure 7-4 Oil Return/Sight Glass SRE Book 44 pound on gaskets. 9. Clean the underside of the separator tank cover and remove any rust, 10. Replace the cover plate, washers and 3/4-10, capscrews. Lubricate and torque to 200 ft-lbs, (271 Nm), 11, Reconnect all piping making sure return tine tubes extend to the bottom or 1/4" (6mm) above the bottom of the separator element. This will assure proper fluid return flow to the compres- sor 412, Check the retum line strainers before restarting the compressor (order replacement kit no 02250117-782). OIL RETURN/SIGHT GLASS MAINTENANCE Refer to Figure 7-4. The oil return/sight glass sub- assembly is attached to the separator tank lid. Oil retumisight glass maintenance should be per- formed on a routine basis paralie! to that of the fluid filter, or as indicated in the Troubleshooting Sections (both Supervisor and Maintenance) of this manual. The maintenance on an oil retum/sight glass is mainly concerned with the condition of the filter assembly. Order filter assembly no. 02250117- 782, and use the following instructions as a guide. NOTE Always performing maintenance on both oil returnisignt glasses atthe same time 1. Disconnect the tubes at the tops of the sight glass assemblies, 2. Unscrew male connector (for left-side giass), of the straight thread tube connector (For right-side glass) from sight glass/orifice blocks. 3, Remove used filter assembly, and replace with new assembly 4, Coatilubricate the o-rings will silicone grease. 5, Reattach the connectors to the sight glass/oriice blocks. DIFFERENTIAL ADJUSTMENT Refer to Figure 7-5. The differential pressure regu- lators are adjusted by loosening the jam nut on the fend of the cone shaped cover of the pressure reg- lator, When the jam nut is loose, turn the adjusting screw clockwise to increase or counterclockwise to decrease the setting. ‘Above 100 psig (6.9 bar), the inlet regulator should allow pressure to flow into the unload chamber of the inlet valve. Cycle the Control System several times and recheck all pressure settings. PRESSURE REGULATORFigure 7-5 Pressure Regulator Adjustments Section 7 MAINTENANCE TYPICAL PRESSURE REGULATOR ADJUSTING SCREW ‘Above 100 psig (6.9 bar), the optional spiral valve regulator should allow pressure to flow into the ‘chamber of the spiral valve actuator. The spiral valve should start to rotate at this time. PRESSURE REDUCING REGULATOR When running with compressor loaded, adjust the Figure 7-6 Drive Coupling (200/250) ae cuba [ xeasie Teroita de Acoale “Replacement Element P/N 02250055.425 pressure reducing regulator to maintain 70 psig (4.8 bar) signal to open the inlet valve. DRIVE COUPLING INSTALLATION AND ALIGN- MENT (200/250HP) Refer to Figures 7-6, 7-7 and 7-8. For coupling installation and alignment, the tools required are a straight edge, 2 measuring scale, one set of feeler gauges, a set of standard Allen wrenches and one Set of standard socket wrenches A. WARNING Disconnect all power at source, before attempt- ing maintenance or adjustments TABLE 7-4 INSTALLATION DATA (250HP, Max Operaling Misalignment Tightening | Coupling Paraliet | Anguiar Torque Gap Offset ‘relist | inchesicm | inchesicm | inchestom (1) 200 ~~*(2969+ 080) 010 o10 ‘009| a7inm | 7.5+.08] 03 93 =.000, TW Angular misalignment in Tiches equals maximum A minus ‘minimum 8 as shown in Figure 7-7. DO NOT exceed val- tues in Table above. 45Section 7 MAINTENANCE Figure 7-7 Drive Coupling Alignment ALIGNMENT ‘ua 4 rli 4 = rt pconees owh4 ‘OFFSET ALGHMENT 48 For installation and alignment of the drive coupling, follow the steps expiained below. STEP 1 MOUNT HUBS - HVount the motor hub and the compressor hub onto respective shaft. Position the hubs to establish the correct gap specified in Table 7-1 Installation Data. Secure each hub with 2 setscrew, STEP 2 OFFSET ALIGNMENT - Clean any oil grease, dirt or paint from coupling faces and the other surfaces of the drive flanges. Rotate shafts so that a straight edge will rest squarely (or within the 0.010 inch maximum limit shown in Table 7-1 Installation Data) on both flanges and at a point 90° away. The vertical offset alignment is adjusted by the addition or removal of motor mounting shims. Loosen the motor mounting bolts and slide the motor sideways to correct the horizontal offset. STEP 3 COUPLING GAP AND ANGULAR ALIGN- MENT - Position the hubs to establish the proper gap and angular alignment as indicated in Table 7- 1 installation Data, To determine the angular mis- alignment in inches, measure the maximum space between the hub flanges and the minimum space 180" away, and then subtract. To adjust the hori- zontal angular misalignment, loosen the motor mounting bolts and adjust the motor position until the angular alignment is within tolerance. DO NOT upset the offset alignment oF hub gap when adjusting motor pesition. When within the limits specified in Table 7-1 Installation Data, tighten the motor mounting bolts and recheck the offset and angular alignment. If the vertical angular alignment is not within .010 inch to erance, shim the front or rear of the motor sepa- rately to correct, Recheck the vertical offset STEP 4 INSTALL THE FLEXIBLE ELEMENT - Position the motor and compressor keyways 180° apart. Insert the fiexibie element between the two hubs. The element should be compressed prior to insertion. The element can be compressed by tight- ening a suitably sized radiator hose clamp around the outer edge of the element as shown in Figure 7- 8. Slide the ferry head capscrews with lockwashers through the holes in the hubs and element Tighten the capscrews to 200 ft-Ibs. (271 Nm). NOTE Capscrews are 314-10 x 4" LG ASTM A364 Grado BD yellow zinc di-chromate. DO NOT substitute with any other bolts After tightening the capscrews, tighten the shaft setscrews and remove the hose clamp from the flexible element. At this time, the coupling is ready for operation Figure 7-8 Paraliel/ Angular Offset Alignment (PARALLEL OS ALIGN OSES nae r{| Cy FLANGE —| SPACING. ZZ, MTERNATE METHOD.7.8 TROUBLESHOOTING ‘The information contained in the Troubleshooting chart is based upon both the actual applied situa- tions and extensive testing at the factory. It contains symptoms and usual causes for the described prob- lems, However DO NOT assume that these are the only problems that may occur. All available data concerning the trouble should be systematically analyzed before undertaking any repair or compo- nent replacement For additional information on troubleshooting, consult the Supervisor Controller manual 7.9 TROUBLESHOOTING GUIDE ‘SYMPTOM, ‘COMPRESSOR WiLL NOT START Line Fuse Blown Conte! Teanetormer Fuse Blown Motor Starter Overloads Thpped Low Incoming Line Voksge PROBABLE CAUSE Main Disconnect Switch Open Section 7 MAINTENANCE ‘A detalled visual inspection is worth performing for almost any problems which may prevent unneces- sary damage to the compressor. Always remember to: ‘a. Check for loose wiring . Check for damaged piping . Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a bumt odor. Should your problem persist after making the rec- ‘ommended check, consult your nearest Sulla rep resentative or the Sullair Corporation REMEDY Grose switch, Repiace fuse. Replace fuse. Reset, Should trouble persist, check whether motor starter contacts ave functioning propery Check voltage, Should vottage check low, consult power company! Replace Supervisor dsplay module no display or erratic display COMPRESSOR SHUTS DOWN WITH AIR DEMAND PRESENT Loss of Control Vokage Low Incoming Vatiage Excessive Operating Prossure Check incoming power. Check contrl fuses and wiring. Consul power company. The Sullair Supervisor wil provide Indication of most maintenance prob- lems ifcontrol poner has not been fost. Shutdown wall occur upon @ faully cnaition ora bad sender candtion Check maximum P2 pressure setting. HIGH PRESS P1 display; Max P1 pressure may be set oo low. Consult factory fer recalibration Defective solenoid vahe; solenoid valve should cause inlet fo unload when unloed pressure Is exceeded, Repair if detective Detective blowsown vahe; blowdown valve should exhaust sump prossure to 25 psig (1.7 bar) for integrated coolers; 50 pg (3.4 bar) for remote coolers when maximum operating pressure is reached, Repair if efecive Open oF shorted Pt, P2, P3 oF PA sender mes: sage, replace sender ingioates 47Section 7 MAINTENANCE 7.8 TROUBLESHOOTING GUIDE (CONTINUED) ‘SYMPTOM PROBABLE CAUSE REMEDY, COMPRESSOR SHUTS DOWN HIGH TEMP TT or TS Message Daplayed Cooling water tempersture foo high nerease WITH AIR DEMAND PRESENT water fiow (water-cooleé ony), (CONTINUED) Low Fuld Pressure (LOW PRESSURE F3 aisolay) Low Weter Pressure (FAN OLILOW WATER display) ‘Cooling water Now insufficient; check water lines, valves (water-cooled only) and availabe water pressure aterential ‘Cooler plugged: clean tubes. Ifplugging persists instal water conitioner ar water fiter water cooled eniy) Cooling air fow restricted: clean cooler end check for proper ventilation Ambient tempera ciant veatiaton ‘5 oo high provise suf Cooling air ductwork, if instated, may restrict aie flow. High sale fan must be epecinies wth cus- tomer-supplied ductwork, and ductwork must be sized to minimize fow restriction Low fis evel, add Nui Clogged ‘iter change the fuid fiter element as indicated by Supensor corto! “Thermal valve not functioning properly: replace lament ‘Optional Water ow regulating valve not function- Ing propery, change (water-cooled only) Open of shorted T1 of T2 sendar: check for & short or open crcuit te probe and correct wring, Excessive pressura drop in supply and return lines of emote air-cooled cooling package. Consult paragraph 46 ofthis manual. Check fd fev. Cheek fr clogged fi fitor Check the cooling fan motor or water flow sys- tem. COMPRESSOR WILLNOTAUILD Air Demand is Teo Great UP FULL DISCHARGE PRESSURE Dirty Air Filter Pressure Regulator Out of Adjustment Defective Pressure Regulator ‘Check service Ines for leaks or open valves (Check for fiter maintenance message on supery> Sor panel and change or ciean element f requires ‘Adjust regulator according to contol adjustment inetructions in the Maintenance Section Check diaphragm and replace necessary (kit avaiable) 48 LINE PRESSURE RISES ABOVE Leak in Contol System Causing Loss of UNLOAD P2 PRESSURE SETTING Pressure Signals, ‘ON THE SUPERVISOR Defective Blowedown Valve ‘Cheek fo leaks, ‘Chock that sump pressure is exhousted tothe simosphere whan in the OFF LOAD mode Repair or replace #f necessary ikt avaiable)7,9 TROUBLESHOOTING GUIDE (CONTINUED) ‘SYMPTOM LINE PRESSURE RISES ABOVE UNLOAD P2 PRESSURE SETTING ON THE SUPERVISOR (CONT) EXCESSIVE FLUID CONSUMP. TION PROBABLE CAUSE Plugges Control Line Filer (Clogged Reluin Line Saher of Orfice ‘Separator Element Damaged or Not Functioning Properly Leak inthe Lubrication System Excess Fluid Foaming Fd Level Too High Section 7 MAINTENANCE REMEDY, Clash or repar W hecessary Clean strainer (screen with ovng replacement it availabe) cca once Check Separator Ditferential (plugged) 41 Change Separator Check a pines, connections and components Drain ard change Dain exonss fid PRESSURE RELIEF VALVE ‘OPENS REPEATEDLY Detective Pressure Relief Valve Replace pressure relief valve. LIQUID WATER IN COMPRESSED AIR SERVICE LINE Water Vapor Condensation From Cooling ‘and Compression Occurs Naturally Remove the water vapor fom compressed air prior to dstrbuton through te air system. Check aperation of aftercooler and mo'siure separator Insiall a compressed air dryer sized fo" the flow ang dryness level requied. (Note: Fitrs may also be requited to remove particulates, lqud ol ‘aerosols or for all vapor removal. Change car- ‘ridges as recommended by th fiter manulactur fer) Check al drain traps routinely to insure the proper operation. Maintain them regulary 4950 NOTESat 8.2 PROCEDURE FOR ORDERING PARTS Section 8 ILLUSTRATIONS AND PARTS LIST Parts should be ordered from the nearest Sullair Representative or the Representative from whom the com- pressor was purchased, If for any reason parts cannot be obtained in this manner, contact the factory directly at the address or phone numbers listed at final page. When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the Bill cof Lading for the compressor or from the Serial Number Plate located on the compressor. For compressor unit parts only, order parts by the unit serial number piace located on the compressor unit, For ordering parts other than those pertaining to the compressor un ‘mounted on control panel RECOMMENDED SPARE PARTS LIST- 200/250HP_ DESCRIPTION element for air fiter 02250140-798 element for separator with gaskets 250034-122 (primary) ‘element for separator with gaskets 250034-134 (secondary) repair kit for water separator 250007-787 repair kt for thermal valve (170°F) 014512 repair kit for requtator valve 406929 repair kit for blowdown vaive 02250100-042 repair kit for control line filter 02250112-032 repair kit for fluid return strainer replacement kit for fluid iter 02250121-656 repair kit for solenoid valve 02250125-657 replacement coil for solenoid valve 02250125-657 repair kt for solenoid valve 02250125-656 replacement coll for solenoid valve 02250125-656 repair kt for regulator valve 408275 repair kit for minimum pressure valve 250033-621 repair kt for fuid stop valve 016742 repair kt for shaft seal element for drive coupling 200hp element for drive coupling 250h repair kit for Sullicon Control 011682-003 diaphragm repair kit for spiral vaive air cylinder 250016-183 compressor Sullube fluis (5 gallons) KIT NUMBER 02250135-150 250034-122 250034-134 Consult Factory 001168 041742 02250100-042 02250112-031 02250117-782 02250139-95 02250125-829 (valve) 02250125-864 (coil) 02250125-828 (valve) 02250125-858 (coil) 250028-693 250018-262 oote84 067329-001 02250056-425, 02250117-320 448791N 608311.001 250022-669 ary Use serial number located on nameplate PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 5tSection 8 ILLUSTRATIONS AND PARTS LIST 8.3 MOTOR, COMPRESSOR, FRAME AND PARTS 52Section 8 ILLUSTRATIONS AND PARTS LIST 8.3 MOTOR, COMPRESSOR, FRAME AND PARTS. key part number description number quantity 1 chasis TS20 270003-522 1 2 motor (I) - 1 3 cubo lado motor (1) : 1 4 elemento de acople (1) : 1 8 cubo lado unidad (1) : 1 6 proteccion cubos acople 225907RA 2 7 unidad compresora : 1 8 barra montaje 20/16 uc 270003-475 1 (l) This part may vary by machine. Consult factory with machine serial number (ll) The shaft seal is not considered part of the compressor unit in regard to the two year warranty. The normal Sullair parts warranty applies, For shaft seal repairs order repair kit. no, 067320-001 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 53Section 8 ILLUSTRATIONS AND PARTS LIST 8.4 AIR INLET SYSTEMSection 8 ILLUSTRATIONS AND PARTS LIST 8.4 AIR INLET SYSTEM key part number description number quantity 1 fitro de aire/elemento 16° (t) 02250140-798 1 2 tapa filtro de aire 046307 1 3 Zuncho fjacion fitro de aire TS20 270010-127 2 4 codo de goma 90° 8" x 7" 248796 1 5 soporte filtro de aire optimalair TS20 270010-030 4 6 acaptador de admision viv. mariposa 8" 013127RA 1 7 junta 8 4/2" x 10 1/2" x 1132" 040422 2 8 valvula mariposa 8" 040338 1 (I) For maintenance on air filter no, 02250140-798, order replacement element no. 02250136-150. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 56Section 8 ILLUSTRATIONS AND PARTS LIST 8.5 FLUID COOLING SYSTEM - AIR COOLED - 200HPSection 8 ILLUSTRATIONS AND PARTS LIST 8.5 FLUID COOLING SYSTEM - AIR COOLED - 200HP key part number description number quantity 1 fiuid cooler combo 200hp 02250151-822 1 2 pane! adaptador venturi 270010-295 1 3 panel venturi 245579 1 4 gtila ventilador 248744 1 5 soporte paquete entriamiento 200hp 250027-038, 2 6 angulo 2" x 2" x 47 4/2" 250022-720 1 7 soporte motor ventilador onse41 1 8 soporte arrancador/entriador 250022-857 2 9 buje de ventilador ( - 1 10 ventiacor (I) - 1 4 motor de ventilador (1) : 1 (I) This part may vary by machine. Consult factory with machine serial number PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR: 87Section 8 ILLUSTRATIONS AND PARTS LIST 8.6 FLUID COOLING SYSTEM - AIR COOLED - 250HP 58Section 8 ILLUSTRATIONS AND PARTS LIST 8.6 FLUID COOLING SYSTEM - AIR COOLED - 250HP ventiiador (I) e motor de ventilador (I) = key part number description number quantity 1 fluid cooler combo 250np 02250152-512 1 2 panel adaptador venturi 02250056-198 4 3 panel venturi 270010-636 1 4 gilla ventitador 248744 1 5 soporte paquete enfriamiento 250hp 270008-638 2 6 angulo 2" x 2" x 47 1/2" 250022-720 1 7 soporte motor ventiiador 270009-837 1 8 soporte arrancadorlenfriador 250022-657 2 8 buje de ventilador (I) 7 1 1 1 (1) This part may vary by machine, Consuit factory with machine serial number PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 59Section 8 ILLUSTRATIONS AND PARTS LIST 8.7 FLUID COOLING SYSTEM - WATER COOLED - 200HP. oy part number description number quantity 1 soporte arrancadorfenfriador 250022-857 2 2 enfriador de aire casco y tubo 8" x 36" 042541 1 3 u-bolt 1/2" x 8 pipe 868308-800 2 4 enfriador de aceite casco y tubo 8 x 48" 043031 1 5 codo 90° 1 1/2" tx 1 412" nptm 810524-150 4 6 buje red. hex. 2" x 1 1/2" #150 802108-060 3 es nipie 1 1/4" npt x 4" sch40 822120-040 3 8 union doble 1 1/4" asiento br 802515-050 2 9 hiple 1 1/4" npt x 3" soho 822120-030 1 10 codo 20° 1 1/4" npt 801515-050 3 " tube, clifin 7 4/2" od 270010-764 1 12 niple 1 1/4" npt x 2 1/2" sch40 2120-025 1 B soporte salida de agua 250027-022 1 4 buje red. hex. 1 1/2" x 1 1/4" #160 802106-050 1 18 niple 1 1/4" npt x corto sch40 822120-000 2 6 vv, termorreguiadora de agua 1 1/4” oasara 4 7 buje red, hex. 2" x 1 1/4" #150 802108-050 1 18 tube, clricir 1 1/2" od 270010-350 1 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR 61key number Section ILLUSTRATIONS AND PARTS LIST 8.8 FLUID COOLING SYSTEM - WATER COOLED - 250HP. description soporte arrancador/entriador eniriador de aire casco y tubo 8" x 36" u-bott 1/2" x 8" pipe eniriador de aceite casco y tubo 8 x 48° buje red. hex. 2” x 1 1/2" #150 odo 90° 1 1/2"tx 11/2" npt tube, clricir 1 1/2" o.¢. tube, clrfin 4 1/2" 0.d. 43" x 14" union tubo 1 1/2" tx 1 4/2"t tube clin 1 1/2" 0.4. 25.5" x 29.5" codo 90° 4 1/4" npt niple 1 4/4" npt x 4 1/2" schao union doble 1 1/4" asiento br niple 1 1/4" apt x corto sch40 vlv. termorreguladora de agua 1 1/4” buje red, hex. 11/2" x 1 1/4" #150 niple 1 1/4" npt x 3° schao buje red. hex. 2" x1 1/4" #150 nipie 1 1/4" npt x 4” sch4o niple 1 4/4" npt x 2 1/2" sch40 soporte salida de agua 250np nipiet 1/2" npt x 14" sch40 codo 90" 1 1/2" tx 1.1/2" npth part number 250022-657 042541 868308-800 043034 1802108-080 810524-150 270010-765 02250114-753 811324-150 02250046-123, 801515-050 22120-0485 802515-050 822120-000 049474 802106-050 822120-030 8021 08-060 222120-040 82220-0265 270010-766 922124-140 10424-1860 quantity PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR 63Section 8 ILLUSTRATION AND PARTS LIST 8.9 AIR PIPING SYSTEM - AIR COOLED - 200/250HP BD) Desde Tanque Separador @eacsvonre 64key number Section 8 ILLUSTRATIONS AND PARTS LIST 8.9 AIR PIPING SYSTEM - AIR COOLED - 200/250HP description tee red. 3/4 x12 x 12 niple 1/2" npt x 5 valvula blowdown 2 vias 1/2" npt (I) niple 3/4” npt corto sch40 tee 3° x 3/4" x 3" #150 nipple, pipe 3° x 3" valvula presion minima 3° (ll) nipple, pipe 3° x 18" cod red. 90° 3" x 2 1/2" npt s.2000 nipple, pipe 2 112" x 4" flexible viv. press min /aftreir union doble 3" asiento bronce nipple, pipe 3° x § 4/2" codo 90° 3° nipple, pipe 2 1/2" x corto nipple, pipe 3" x 10 1/2" nipple, pipe 3° x 4 1/2" u-bolt 1/2" x 3° pipe separador de condensado con trampa 3” nipple, pipe 3° x 15" nipple, pipe 3° x 6" soporte separador de humedad 3° part number 802203-022 822108-050 02250400-042 822212-000 0222-022 822148-030 250033-821 822148-180 801612-100 622140-040 02250058-939 802515-120 822148-055 801515-120 822140-000 822148-105 822148-045 868308-300 250007-787 822148-150 622148-050 260023-077 quantity (1) For maintenance on blowdown valve no. 02250100-042, order repair kit no. 02250100-042. (i) For maintenance on min, press. valve no, 250033-821, order repair kit no. 260018-262. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR 65Section 8 ILLUSTRATION AND PARTS LIST 8.10 AIR PIPING SYSTEM - WATER COOLED - 200/250HP ) Desde Tonave Separador B) Solida de AiraSection 8 ILLUSTRATIONS AND PARTS LIST 8.10 AIR PIPING SYSTEM - WATER COOLED - 200/250HP key part number description number quantity 1 valwuta blowdown 2 vias 1/2" npt (I) 02250100-042 1 2 niple 1/2" npt x 5° 822108-050 1 3 tee red. 3/4 x 1/2 x 1/2 802203-022 1 4 niple 34” npt corto sch40 822212-000 1 5 tee 3" x 3/4" x 3° #150 802212-022 1 6 nipple, pipe 3" x 9° 822148-090 3 7 Union doble 3" asiento bronce 802515-120 1 8 nipple, pine 3 x 3 1/2" 822148-035, 1 9 nipple, pipe 3" x 3° 822148-030 3 10 valvula presion minima 3° (I) 250033-821 1 "1 brida roscada 3" #150 rf 819315-048 4 2 flexible viv. press min. Jaftrcir 02250058-939 1 3 codo 90° 3" 801515-120 4 14 flexible aficir/ trampa condensado 02250088.057 1 15 nipple, pipe 3" x 6 1/2" €22148-065, 1 16 ubolt 1/2" x 3" pipe 868308-300 2 7 separador de condensado con trampa 3° 280007-787 1 18 nipple, pipe 3" x 5° 822148050 1 19 soporte separador de humedad 3° 250023-07 2 (l) For maintenance on blowdown valve no. 02260100-042, order repair kit no. 02250100-042 (ll) For maintenance on min. press. valve no. 250033-821, order repair kit no, 250018-262. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSORSection 8 ILLUSTRATION AND PARTS LIST 8.11 FLUID PIPING SYSTEM - AIR COOLED - 200/250HP t \ ‘ \ \s (beste Torque Separaor Ba Unidas Compresora8.11 FLUID PIPING SYSTEM - AIR COOLED - 200/250HP key number description 1 niple 1 1/2" npt x 8" sch 40 2 ccodo 90° 1 1/2" npt #150 $.2000 3 valvula termostatica (I) 4 niple 1 1/2" npt x3 4/2" sch 40 5 tee 1 172" #150 6 conn, tube-m 1 1/2" x 1 1/2" 7 buje red. nex. 2" «1 1/2" #180 8 fube 1 1/2" 90° teelolr 8 niple pipe xs 2° x close 10 codo red. 90° 2" x 1 1/2" §.2000 " tube 1 1/2" 90° tviclr 12 tube 11/2" 90° tviftr 13 adpt, fig 2" sae 4 bolt - 1,5, 4 filtro de aceite sae 2° fig (I) 18 adpt, fig 2" sae 4 bolt - 2 16 valvula retencion de aceite 2° npt (Il) part number 822124-090 801515-060 014512 822124-035 802415-060 10224-1560 87608-0860 02250114-114 822232-000 1801608-060 02250114-118 250033-663, 02250133-365 02250121-686 02280133-366 016742 {l) For maintenance on (170°F) thermal vaive no. 014512, order repair kit no. 001168 (il) For maintenance on fluid filter no. 02250121-656, order repair kit no. 02260139-995. (ill) For maintenance on oil stop valve no, 016742, order repair kit no. 001684 Section 8 ILLUSTRATIONS AND PARTS LIST quantity PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR. 69Section 8 ILLUSTRATION AND PARTS LIST 8.12 FLUID PIPING SYSTEM - WATER COOLED - 200HP ®oesde Tanaue Separador 3) A Unidad compresora 70Section 8 ILLUSTRATIONS AND PARTS LIST 8.12 FLUID PIPING SYSTEM - WATER COOLED - 200HP key part number description number quantity 1 niple pipe xs 2" x close 822252-000 2 2 vaivula retencion de aceite 2” npt (I) 016742 1 3 dot, fig 2" sae 4 bolt - 2 02260133-366 1 4 filtro de aceite sae 2" fg (I) 02250121-655 1 5 adpt, fig 2" sae 4 bolt - 1,5 02250133-365 1 6 conn, tube-m 1 1/2" x 4.1/2" 810224-150 4 7 tube 1 1/2" 90° tvifite 250033-663 1 8 tee 1 1/2" #150 802415-060 1 9 niple 1 1/2" npt x 3.4/2" sch 40 82124-0385 1 10 valvuia termostatica (II) 014512 1 " niple 1 1/2" npt x 7" seh 40 822124-070 1 2 codo 80° 1 1/2" npt #150 $.2000 801515-060 1 B niple 1 1/2" npt x 8" sch 40 822124-090 1 4 tube, oltee 20033-9867 1 15 tube, 11/2" 43" x 14" 02250114-753 1 16 code 90° 1 1/2" x 1 1/2" npt 810524-150 2 7 buje red. 3x1 1/2" 807612-060 1 8 tee red, 2° x 1/2" x 1 1/2" #150 802208-026 1 19 nile 2" x 7" sch40 822132-070 1 20 buje ted. 3° x2" 807612-080 1 (I) For maintenance on oil stop valve no. 076742, order repair kit no. 001684. (ll) For maintenance on fluid filter no, 02250121-656, order repair kit no. 02250139-996. {Ill) For maintenance on (170°F) thermal valve no, 014512, order repair kit no. 001168. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR