TS20 de 200 A 250HP Ingles 270010-960R00

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
©Sullair Argentina S.A.
TABLE OF CONTENTS
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL
Section 1 Page
SAFETY 1 1.1 GENERAL
1 1.2 PERSONAL PROTECTIVE EQUIPMENT
1 1.3 PRESSURE RELEASE
2 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
3 1.9 LIFTING
4 1.10 ENTRAPMENT
Section 2
DESCRIPTION 5 2.1 INTRODUCTION
5 2.2 DESCRIPTION OF COMPONENTS
6 2.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
6 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM,
8 2.5 COMPRESSOR DISCHARGE SYSTEM,
8 2.6 CONTROL SYSTEM, FUNCTIONAL
DESCRIPTION
16 2.7 AIR INLET SYSTEM, FUNCTIONAL
DESCRIPTION
Section 3
SPECIFICATIONS 17 3.1 SULLAIR TS-20 SPECIFICATIONS
17 3.2 LUBRICATION GUIDE - STANDARD COMPRESSORS
18 Figure 3-1 Identification - TS20-200HP - Air Cooled
19 Figure 3-2 Identification - TS20-250HP - Air Cooled
20 Figure 3-3 Identification - TS20-200HP - Water Cooled
21 Figure 3-4 Identification - TS20-250HP - Water Cooled
22 Figure 3-5 Piping and Instrumentation - TS20-200/250HP - Air Cooled
26 Figure 3-6 Piping and Instrumentation - TS20-200/250HP - Water Cooled
TABLE OF CONTENTS
Section 4
INSTALLATION 31 4.1 MOUNTING OF COMPRESSOR
31 4.2 VENTILATION AND COOLING
31 4.3 SERVICE AIR PIPING
31 4.4 COUPLING ALIGNMENT CHECK
31 4.5 FLUID LEVEL CHECK
32 4.6 FLUID PIPING (REMOTE AIR-COOLED OPTION ONLY)
33 4.7 ELECTRICAL PREPARATION
33 4.8 MOTOR ROTATION DIRECTION CHECK
Section 5
SUPERVISOR 34 FIGURE 5-1 SUPERVISOR CONTROLLER CONTROL PANEL
35 FIGURE 5-2 SUPERVISOR DLX CONTROL PANEL
Section 6
COMPRESSOR
OPERATION 37 6.1 INTRODUCTION
37 6.2 PURPOSE OF CONTROLS
38 6.3 INITIAL START-UP PROCEDURE
39 6.4 SUBSEQUENT START-UP PROCEDURE
39 6.5 SHUTDOWN PROCEDURE
Section 7
MAINTENANCE 41 7.1 GENERAL
41 7.2 DAILY OPERATION
41 7.3 MAINTENANCE AFTER INITIAL 50 HOURS
OF OPERATION
41 7.4 MAINTENANCE AFTER 1000 HOURS
41 7.5 FLUID CHANGE
41 7.6 SEPARATOR MAINTENANCE
41 7.7 PARTS REPLACEMENT AND ADJUSTMENT
PROCEDURES
41 FLUID FILTER MAINTENANCE
42 AIR FILTER MAINTENANCE
43 SEPARATOR ELEMENTS REPLACEMENT
44 OIL RETURN/SIGHT GLASS MAINTENANCE
44 DIFFERENTIAL PRESSURE REGULATOR
ADJUSTMENT
45 PRESSURE REDUCING REGULATOR
45 DRIVE COUPLING INSTALLATION AND ALIGNMENT- 250HP
47 7.8 TROUBLESHOOTING
TABLE OF CONTENTS
Section 7
MAINTENANCE
(Continued) 47 7.9 TROUBLESHOOTING GUIDE
Section 8
ILLUSTRATION AND
PARTS LIST 51 8.1 PROCEDURE FOR ORDERING PARTS
51 8.2 RECOMMENDED SPARE PARTS LIST- 200/250HP
52 8.3 MOTOR, COMPRESSOR, FRAME AND PARTS
54 8.4 AIR INLET SYSTEM
56 8.5 FLUID COOLING SYSTEM - AIR COOLED - 200HP
58 8.6 FLUID COOLING SYSTEM - AIR COOLED - 250HP
60 8.7 FLUID COOLING SYSTEM - WATER COOLED - 200HP
62 8.8 FLUID COOLING SYSTEM - WATER COOLED - 250HP
64 8.9 AIR PIPING SYSTEM - AIR COOLED - 200/250HP
66 8.10 AIR PIPING SYSTEM - WATER COOLED - 200/250HP
68 8.11 FLUID PIPING SYSTEM - AIR COOLED - 200/250HP
70 8.12 FLUID PIPING SYSTEM - WATER COOLED - 200HP
72 8.13 FLUID PIPING SYSTEM - WATER COOLED - 250HP
74 8.14 SUMP AND PARTS
76 8.15 SULLICON CONTROL
78 8.16 COMPRESSOR SPIRIAL VALVE ACTUATOR
82 8.17A MOISTURE DRAIN - AIR COOLED - 200/250HP
82 8.17B MOISTURE DRAIN - WATER COOLED - 200/250HP
84 8.18 ENCLOSURE SYSTEM - AIR COOLED - 200HP
86 8.19 ENCLOSURE SYSTEM - AIR COOLED - 250HP
88 8.20 ENCLOSURE SYSTEM - WATER COOLED - 200HP
90 8.21 ENCLOSURE SYSTEM - WATER COOLED - 250HP
92 8.22 WIRING DIAGRAM - AIR & WATER COOLED - 200/250HP
NOTES
Section 1
SAFETY
1.1 GENERAL the service air outlet and the shut-off (throttle)
Sullair Corporation and its subsidiaries design and valve, either at the compressor or at any other point
manufacture all of their products so they can be along the air line, when an air hose exceeding 1/2”
operated safely. However, the responsibility for (13mm) inside diameter is to be connected to the
safe operation rests with those who use and main- shut-off (throttle) valve, to reduce pressure in case
tain these products. The following safety precau- of hose failure, per all applicable Federal, State and
tions are offered as a guide which, if conscientious- Local codes, standards and regulations.
ly followed, will minimize the possibility of accidents B. When the hose is to be used to supply a mani-
throughout the useful life of this equipment. fold, install an additional appropriate flow-limiting
The compressor should be operated only by those valve between the manifold and each air hose
who have been trained and delegated to do so, and exceeding 1/2” (13mm) inside diameter that is to be
who have read and understood this Operator’s connected to the manifold to reduce pressure in
Manual. Failure to follow the instructions, proce- case of hose failure.
dures and safety precautions in this manual can C. Provide an appropriate flow-limiting valve at the
result in accidents and injuries. Read this manual beginning of each additional 75 feet (23m) of hose
prior to startup. in runs of air hose exceeding 1/2” (13mm) inside
NEVER start the compressor unless it is safe to do diameter to reduce pressure in case of hose failure.
so. DO NOT attempt to operate the compressor D. Flow-limiting valves are listed by pipe size and
with a known unsafe condition. Tag the compressor rated CFM. Select appropriate valves accordingly,
and render it inoperative by disconnecting and lock- in accordance with their manufacturer’s recommen-
ing out all power at source or otherwise disabling its dations.
prime mover, so others who may not know of the
unsafe condition, cannot attempt to operate it until E. DO NOT use air tools that are rated below the
the condition is corrected. maximum rating of the compressor. Select air tools,
air hoses, pipes, valves, filters, and other fittings
Install, use and operate the compressor only in full accordingly. DO NOT exceed manufacturer’s rated
compliance with all pertinent regulations and all safe operating pressures for these items.
applicable Federal, State, and Local codes, stan-
dards and regulations. F. Secure all hose connections by wire, chain or
other suitable retaining devices to prevent tools or
DO NOT modify the compressor and/or controls in hose ends from being accidentally disconnected
any way except with written factory approval. and expelled.
While not specifically applicable to all types of com- G. Open fluid filler cap only when compressor is not
pressors with all types of prime movers, most of the running and is not pressurized. Shut down the com-
precautionary statements contained herein are pressor and bleed the sump (receiver) to zero inter-
applicable to most compressors and the concepts nal pressure before removing the cap.
behind these statements are generally applicable to
all compressors. H. Vent all internal pressure prior to opening any
line, fitting, hose, valve, drain plug, connection or
1.2 PERSONAL PROTECTIVE EQUIPMENT other component, such as filters and line oilers, and
Prior to installing or operating the compressor, own- before attempting to refill optional air line anti-icer
ers, employers and users should become familiar systems with antifreeze compound.
with, and comply with, all applicable regulations and
any applicable Federal, State and Local codes, I. Keep personnel out of line with and away from the
standards, and regulations relative to personal pro- discharge opening of hoses or tools or other points
tective equipment, such as eye and face protective of compressed air discharge.
equipment, respiratory protective equipment, equip- J. Use air at pressures less than 30 psig (2.1 bar)
ment intended to protect the extremities, protective for cleaning purposes, and then only with effective
clothing, protective shields and barriers and electri- chip guarding and personal protective equipment.
cal protective equipment, as well as noise exposure K. DO NOT engage in horseplay with air hoses as
administrative and/or engineering controls and/or death or serious injury may result.
personal hearing protective equipment.
L. DO NOT tamper with sump and unit (if provid-
1.3 PRESSURE RELEASE ed) relief valves. Check the relief valve as recom-
A. Install an appropriate flow-limiting valve between mended in the Maintenance Section of this manual
1
Section 1
SAFETY
or at a minimum of at least weekly to make sure it al that may be damaged by heat or that may sup-
is not blocked, clogged, obstructed or otherwise port combustion and is in close proximity, prior to
disabled. DO NOT change the factory setting of the attempting weld repairs.
relief valve. H. Keep suitable fully charged fire extinguisher or
M. If the compressor is installed in an enclosed extinguishers nearby when servicing and operating
area, it is necessary to vent the relief valve to the the compressor.
outside of the structure or to an area of non-expo- I. Keep oily rags, trash, leaves, litter or other com-
sure. bustibles out of and away from the compressor.
1.4 FIRE AND EXPLOSION J. DO NOT operate the compressor without proper
flow of cooling air or water or with inadequate flow
of lubricant or with degraded lubricant.
When installing a Base Load Transfer (BLT)
System, remove jumpers between 16-17 & 18-19
K. DO NOT attempt to operate the compressor in
(Dual Control Compressors) so the other com- any classification of hazardous environment unless
pressor does not backfeed defeating the shut- the compressor has been specially designed and
down circuitry. manufactured for that duty.
A. Clean up spills of lubricant or other combustible 1.5 MOVING PARTS
substances immediately, if such spills occur. A. Keep hands, arms and other parts of the body
B. Shut off the compressor and allow it to cool. and also clothing away from couplings, fans and
Then keep sparks, flames and other sources of igni- other moving parts.
tion away and DO NOT permit smoking in the vicin- B. DO NOT attempt to operate the compressor with
ity when checking or adding lubricant or when refill- the fan, coupling or other guards removed.
ing air line anti-icer systems with antifreeze com- C. Wear snug-fitting clothing and confine long hair
pound. when working around this compressor, especially
C. DO NOT permit fluids, including air line anti-icer when exposed to hot or moving parts.
system antifreeze compound or fluid film to accu- D. Keep access doors, if any, closed except when
mulate on, under, or around acoustical material, or making repairs or adjustments.
on any external surfaces of the air compressor or
on internal surfaces of the enclosure. Wipe down E. Make sure all personnel are out of and/or clear of
using an aqueous industrial cleaner or steam-clean the compressor prior to attempting to start or oper-
as required. If necessary, remove acoustical mate- ate it.
rial, clean all surfaces and then replace acoustical F. Disconnect and lock out all power at source and
material. Any acoustical material with a protective verify at the compressor that all circuits are de-
covering that has been torn or punctured should be energized to minimize the possibility of accidental
replaced immediately to prevent accumulation of start-up or operation, prior to attempting repairs or
liquids or fluid film within the material. DO NOT use adjustments. This is especially important when
flammable solvents for cleaning purposes. compressors are remotely controlled.
D. Disconnect and lock out all power at source prior G. Keep hands, feet, floors, controls and walking
to attempting any repairs or cleaning of the com- surfaces clean and free of fluid, water, or other liq-
pressor or of the inside of the enclosure, if any. uids to minimize the possibility of slips and falls.
E. Keep electrical wiring, including all terminals and 1.6 HOT SURFACES, SHARP EDGES AND SHARP
pressure connectors in good condition. Replace CORNERS
any wiring that has cracked, cut abraded or other- A. Avoid bodily contact with hot fluid, hot coolant,
wise degraded insulation, or terminals that are hot surfaces and sharp edges and corners.
worn, discolored or corroded. Keep all terminals
and pressure connectors clean and tight. B. Keep all parts of the body away from all points of
air discharge.
F. Keep grounded and/or conductive objects such
as tools away from exposed live electrical parts C. Wear personal protective equipment including
such as terminals to avoid arcing which might serve gloves and head covering when working in, on or
as a source of ignition. around the compressor.
G. Remove any acoustical material or other materi- D. Keep a first aid kit handy. Seek medical assis-
tance promptly in case of injury. DO NOT ignore
2
Section 1
SAFETY
small cuts and burns as they may lead to infection. tained in full compliance with all applicable Federal,
1.7 TOXIC AND IRRITATING SUBSTANCES State and Local codes, standards and regulations,
A. DO NOT use air from this compressor for respi- including those of the National Electrical Code, and
ration (breathing) except in full compliance with any also including those relative to equipment ground-
Federal, State or Local Codes or regulations. 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-held
Death or serious injury can result from inhaling tools or other conductive objects away from
compressed air without using proper safety exposed live parts of electrical system. Maintain dry
equipment. footing, stand on insulating surfaces and DO NOT
contact any other portion of the compressor when
B. DO NOT use air line anti-icer systems in air lines making adjustments or repairs to exposed live parts
supplying respirators or other breathing air utiliza- of the electrical system. Make all such adjustments
tion equipment and DO NOT discharge air from or repairs with one hand only, so as to minimize the
these systems in unventilated or other confined possibility of creating a current path through the
areas. heart.
C. Operate the compressor only in open or ade- C. Attempt repairs in clean, dry and well lighted and
quately ventilated areas. ventilated areas only.
D. Locate the compressor or provide a remote inlet D. DO NOT leave the compressor unattended with
so that it is not likely to ingest exhaust fumes or open electrical enclosures. If necessary to do so,
other toxic, noxious or corrosive fumes or sub- then disconnect, lock out and tag all power at
stances. source so others will not inadvertently restore
E. Coolants and lubricants used in this compressor power.
are typical of the industry. Care should be taken to E. Disconnect, lock out, and tag all power at source
avoid accidental ingestion and/or skin contact. In prior to attempting repairs or adjustments to rotating
the event of ingestion, seek medical treatment machinery and prior to handling any ungrounded
promptly. Wash with soap and water in the event of conductors.
skin contact. Consult the compressor operator’s
manual lubrication section for information pertaining F. Dry test all shutdown circuits prior to starting the
to compressor fluid fill. compressor after installation.
F. Wear goggles or a full face shield when adding 1.9 LIFTING

antifreeze compound to air line anti-icer systems. A. If the compressor is provided with a lifting bail,
then lift by the bail provided. If no bail is provided,
G. If air line anti-icer system antifreeze compound then lift by sling. Compressors to be air lifted by hel-
enters the eyes or if fumes irritate the eyes, they icopter must not be supported by the lifting bail but
should be washed with large quantities of clean by slings instead. In any event, lift and/or handle
water for 15 minutes. A physician, preferably an eye only in full compliance with Federal, State and Local
specialist, should be contacted immediately. codes.
H. DO NOT store air line anti-icer system antifreeze B. Inspect points of attachment for cracked welds
compound in confined areas. and for cracked, bent, corroded or otherwise
I. The antifreeze compound used in air line degraded members and for loose bolts or nuts prior
antifreeze systems contains methanol and is toxic, to lifting.
harmful, or fatal if swallowed. Avoid contact with the C. Make sure entire lifting, rigging and supporting
skin or eyes and avoid breathing the fumes. If swal- structure has been inspected, is in good condition
lowed, induce vomiting by administering a table- and has a rated capacity of at least the weight of
spoon of salt, in each glass of clean, warm water the compressor. If you are unsure of the weight,
until vomit is clear, then administer two teaspoons then weigh compressor before lifting.
of baking soda in a glass of clean water. Have
patient lay down and cover eyes to exclude light. D. Make sure lifting hook has a functional safety
Call a physician immediately. latch or equivalent, and is fully engaged and latched
on the bail or slings.
1.8 ELECTRICAL SHOCK E. Use guide ropes or equivalent to prevent twisting
A. This compressor should be installed and main-
3
Section 1
SAFETY
or swinging of the compressor once it has been lift- mum practical speeds.
ed clear of the ground. N. Make sure pallet-mounted compressors are firm-
F. DO NOT attempt to lift in high winds. ly bolted or otherwise secured to the pallet prior to
G. Keep all personnel out from under and away attempting to forklift or transport them. NEVER
from the compressor whenever it is suspended. attempt to forklift a compressor that is not secured
to its pallet, as uneven floors or sudden stops may
H. Lift compressor no higher than necessary. cause the compressor to tumble off, possibly caus-
I. Keep lift operator in constant attendance whenev- ing serious injury or property damage in the
er compressor is suspended. process.
J. Set compressor down only on a level surface O. DO NOT use the lifting eye bolt on the compres-
capable of safely supporting at least its weight and sor motor, if supplied, to lift the entire compressor
its loading unit. package.
K. When moving compressors by forklift truck, uti- 1.10 ENTRAPMENT
lize fork pockets if provided. Otherwise, utilize pal- A. If the compressor enclosure is large enough to
let if provided. If neither fork pockets or pallet are hold a person and if it is necessary to enter it to per-
provided, then make sure compressor is secure form service adjustments, inform other personnel
and well balanced on forks before attempting to before doing so, or else secure and tag the access
raise or transport it any significant distance. door in the open position to avoid the possibility of
L. Make sure forklift truck forks are fully engaged others closing and possibly latching the door with
and tipped back prior to lifting or transporting the personnel inside.
compressor. B. Make sure all personnel are out of compressor
M. Forklift no higher than necessary to clear obsta- before closing and latching enclosure doors.
cles at floor level and transport and corner at mini-
4
Section 2
DESCRIPTION
2.1 INTRODUCTION sor, electric motor, compressor inlet system,
Refer to Figures 2-1A and 2-1B. Your new Sullair compressor discharge system, compressor
lubricated rotary screw air compressor provides you cooling and lubrication system, capacity con-
with a unique experience in improved reliability and trol system and Supervisor ControllerTM, micro-
greatly reduced maintenance. processor system and starter all mounted on a
Compared to other types of compressors, the structural steel frame
Sullair rotary screw is unique in its mechanical reli- On air-cooled models, a fan draws air over the fan
ability and lack of “wear”. The compressor requires motor and forces it through the combined after-
absolutely no inspection of its internal parts. cooler and fluid cooler, thereby removing the heat
By reading through Section 6, you will notice the of compression from the cooling fluid.
easy process of caring and maintaining this Sullair On water-cooled models, fluid is piped into a water-
manufactured product. Should any questions arise cooled heat exchanger where the heat of compres-
which cannot be answered in this text, call your sion is removed from the fluid. A fan is used to sup-
nearest Sullair representative or the Sullair ply sufficient ventilating air to compressors
Corporation Service Department. equipped with an optional enclosure.
2.2 DESCRIPTION OF COMPONENTS Both air-cooled and water-cooled versions have
Refer to Figures 2-1A and 2-1B. The components easily accessible items such as the fluid filters and
and assemblies of the air compressors are clearly control valves. The inlet air filters are also mounted
shown. The complete package includes compres-
Figure 2-1A Sullair Series TS-20 Rotary Screw Compressor (Air Cooled Typical)
Post Enfriador /
Enfriador de Aceite
Panel de Control Valvula

Presion Mnima
Filtro de Aire
Valvula
Retencion
de Aceite
Unidad
Gabinete Compresora
Arrancador
Tanque
Separador Carga de Filtro de Aceite
Aceite
5
Section 2
DESCRIPTION
Figure 2-1B Sullair Series TS-20 Rotary Screw Compressor (Water Cooled Typical)
Enfriador de Aire
(enfriado por agua)
Valvula
Panel de Control Presion Minima
Filtro de Aire
Valvula
Retencion
de Aceite
Gabinete Unidad
Arrancador Compresora
Tanque
Separador Filtro de Aceite
Carga de Aceite
for easy access and servicing. from the air. At this time, the air flows to the serv-
2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL ice line and the fluid is cooled in preparation for re-
DESCRIPTION injection.
Sullair tandem air compressors feature the Sullair
compressor unit, a two-stage, positive displace-
ment fluid lubricated-type compressor. This unit With a Sullair compressor, there is no mainte-
provides continuous air compression to meet your nance or inspection of the internal parts of the
needs. compressor unit permitted in accordance with
the terms of the warranty.
Fluid is injected into the compressor unit where it 2.4 COMPRESSOR COOLING AND LUBRICATION
mixes directly with the air as the internal rotors turn, SYSTEM, FUNCTIONAL DESCRIPTION
compressing the air. The fluid flow has three basic Refer to Figures 2-2, 2-3A, 2-3B, 2-4A, 2-4B, 2-5A,
functions: 2-5B. The cooling and lubrication system consists
1. As coolant, it controls the rise of air temperature of a fluid cooler, full flow fluid filter, fluid stop
normally associated with the heat of compression. valve, thermal valve.
2. Seals the leakage paths between the rotors and The pressure in the receiver/sump causes fluid flow
the stator and also between the rotors themselves. by forcing the fluid from the high pressure area of
3. Acts as a lubricating film between the rotors the sump to an area of lower pressure in the com-
allowing one rotor to directly drive the other, which pressor unit.
is an idler. After the air/fluid mixture is discharged Fluid flows from the receiver/sump to the thermal
from the compressor unit, the fluid is separated
6
Section 2
DESCRIPTION
Figure 2-2 Compressor Piping and Instrument Diagram - Air Cooled & Water Cooled - 200/250HP
SOLENOID VALVE #1
(N.O.)
SOLENOID VALVE #2
(SPIRAL VALVE)
7
Section 2
DESCRIPTION
valve. The thermal valve is fully open to the com- ondary) as the compressed air flows through them.
pressor unit when the discharge temperature is Two return lines (or scavenge tubes) lead from the
below 170°F (77°C) for all compressors, bottom of each separator element to the low pres-
water-cooled 24KT models and all models operat- sure inlet region of the compressor unit. Fluid col-
ing at 150 psig (10.3 bar) and higher, which is fully lecting on the bottom of each separator is returned
open up to 195°F (91°C). The fluid passes through to the compressor by a pressure difference
the thermal valve, the fluid stop valve, the main fluid between the receiver and the compressor inlet.
filter and directly to the compressor unit. Sight glasses are located in the return lines to
As the discharge temperature rises above 170°F observe this fluid flow. dP1 on the Supervisor
(77°C) for all compressors (195°F [91°C] for water- ControllerTM microprocessor control monitors the
cooled 24KT models and high pressure > 150 psig condition of the separator elements by reading the
[10.3 bar]), due to the heat of compression, the differential pressure on the digital display. At a dif-
thermal valve begins to close and a portion of the ferential of 10 psig (0.7 bar), or greater, the oper-
fluid then flows through the cooler. From the cooler, ator will be told to service the separator elements.
the fluid flows to the main filter, the fluid stop valve, At this time, separator element replacement is nec-
and on to the compressor unit. The fluid filter has a essary.
replacement element and an integral pressure The receiver is an ASME pressure vessel. A combi-
bypass valve. nation minimum pressure/check valve, located
The fluid stop valve prevents fluid from filling the downstream from the separator, assures a mini-
compressor unit when the compressor is shut mum receiver pressure of 50 psig (3.4 bar) during
down. When the compressor is operating, the fluid full load operation. This pressure is necessary for
stop valve is held open by air pressure from the proper air/fluid separation and proper fluid circula-
compressor unit allowing a free flow of fluid from the tion while supplying air to the system. This valve
receiver/sump back to the compressor unit. On also acts as a check valve preventing compressed
shutdown, the compressor unit pressure is reduced, air in the service line from bleeding back into the
causing the fluid stop valve to close and isolate the receiver on shutdown and during operation of the
compressor unit from the cooling system. compressor in an unloaded condition.
Water-cooled models have a water pressure switch A pressure relief valve (located on the wet side of
to prevent operation with inadequate water pres- the separator) is set to open if the sump pressure
sure. exceeds the rated pressure of the tank.
2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC- All Sullair compressor models are equipped with
TIONAL DESCRIPTION high pressure shutdown protection to shut down the
Refer to Figures 2-2, 2-4A and 2-4B. The com- compressor at 30 psi above rated pressure. This
pressor unit discharges the compressed air/fluid prevents the pressure relief valve from opening
mixture through a discharge check valve into the under normal conditions, thereby preventing fluid
combination receiver/sump. The discharge check loss through the pressure relief valve. A tempera-
valve prevents air/fluid in the receiver from return- ture switch will shut down the compressor if the dis-
ing to the compression chamber after the compres- charge temperature reaches 235°F (113°C).
sor has been shut down. The receiver has three
functions:
1. It acts as a primary fluid separator. DO NOT remove caps, plugs, and/or other com-
ponents when compressor is running or pres-
2. It serves as the compressor fluid sump. surized.
3. It houses the final fluid/air separator elements. Stop compressor and relieve all internal pressure
The compressed air/fluid mixture enters the receiv- before doing so.
er and is directed against an internal baffle. The Fluid is added to the sump via a capped fluid filler
direction of movement is changed and its velocity opening, placed low on the receiver tank to prevent
significantly reduced, thus causing the large over-filling of the sump. Two sight glasses enables
droplets of fluid to fall to the bottom of the receiv- the operator to visually monitor the sump fluid level.
er/sump. The fractional percentage of fluid remain- 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIP-
ing in the compressed air collects on the surface of TION
the nested separator elements (primary and sec- Refer to Figures 2-5A and 2-5B. The purpose of
8
Section 2
DESCRIPTION
the compressor control system is to regulate the rack, in turn, engages with the pinion mounted on
amount of air being compressed to match the a- the spiral valve shaft assembly. This results in a
mount of compressed air being used. rotary motion. As the spiral valve rotates, it starts
The capacity control system consists of a spiral opening the bypass ports gradually. Excess air is
valve and an inlet butterfly valve. The functional then being returned back internally to suction end of
description of the control system is described below compressor unit. Now the compressor is fully com-
in 4 distinct phases of compressor operation. The pressing only that amount of air which is being
following applies to TS-20 Series compressors used. As air demand keeps dropping further, the
ranging from 200 through 250hp. spiral valve keeps opening more and more until all
For explanatory purposes, this description applies the bypass ports are fully open. At this point, the
to any compressor with an operating range of 100 spiral valve has moved into the minimum position.
to 110 psig (6.9 to 7.6 bar). A compressor with The spiral valve provides a modulation range from
any other pressure range would operate in the 100 to approximately 50%. During this period, the
same manner except for the stated pressures. pressure rises approximately from 100 to 108 psig
START MODE - 0 TO 50 PSIG (0 TO 3.4 BAR) (6.9 to 7.4 bar). As the air pressure exceeds 108
psig (7.4 bar), the differential pressure regulator
When the compressor (ON) pad is depressed, controlling the Sullicon Control opens. This allows
the sump pressure will quickly rise from 0 to 50 psig the air pressure to expand the diaphragm chamber
(0 to 3.4 bar). During this period, both of the pres- of the Sullicon Control, which starts partially closing
sure regulators and the solenoid valve are closed the inlet butterfly valve. The inlet butterfly valve pro-
and the Sullicon Control and spiral valve are inop- vides modulation range from 50 to 40%. During this
erative. The spring on the control holds the butterfly period, the pressure rises approximately from 108
valve fully open while the spiral valve is fully closed to 110 psig (7.4 to 7.6 bar). During this range, the
(maximum) position and the compressor pumps at spiral valve remains in the full open position.
full rated capacity. The rising compressor air pres- UNLOAD MODE - IN EXCESS OF 110 PSIG (7.6
sure is isolated from the service line in this phase BAR)
by the minimum pressure valve set at approximate- When a relatively small amount or no air is being
ly 50 psig (3.4 bar). used, the service line pressure continues to rise.
An optional closed inlet system is provided which When it exceeds 110 psig (7.6 bar), Supervisor de-
uses air pressure to close the butterfly and opens energizes the solenoid valve allowing line pressure
the spiral valve to reduce motor torque for starting. to be supplied directly to the Sullicon diaphragm
FULL LOAD MODE - 50 TO 100 PSIG (3.4 TO 6.9 keeping the inlet butterfly closed; the spiral valve is
BAR) in the fully open (minimum) position.
When the compressed air pressure in the sump Simultaneously, the solenoid valve sends a pneu-
rises above 50 psig (3.4 bar), the minimum pres- matic signal to the blowdown valve. The blowdown
sure valve opens, allowing compressed air to flow valve opens the sump to the atmosphere. This
into the service line. From this point on, the line air reduces the sump pressure to approximately 30
pressure is continually monitored by the Supervisor. psig (2.1 bar) which results in low horsepower con-
The pressure regulators and the solenoid valve sumption. The check valve in the air service line
remain closed during this phase, keeping the prevents line pressure from returning to sump while
Sullicon Control and spiral valve inactive. Both the the compressor is running in the unloaded mode.
spiral valve as well as the inlet butterfly valve Both the spiral valve and the butterfly valve remain
remain in the full load position as long as the com- in the unload position.
pressor is running at 100 psig (6.9 bar) or below. When the line pressure drops back to 100 psig (6.9
MODULATION - 100 TO 110 PSIG (6.9 TO 7.6 bar) due to an increase in the air demand,
BAR) Supervisor energizes the solenoid valve allowing
As air demand drops below the rated capacity of the the air pressure behind the Sullicon Control to be
compressor, the line pressure will rise above 100 vented through the solenoid valve exhaust port.
psig (6.9 bar). As a result, the differential pressure The blowdown valve closes, and the inlet butterfly
regulator for the spiral valve gradually opens, apply- valve opens. Also the air pressure at the spiral valve
ing air pressure to the spiral valve actuator. Air pres- actuator diaphragm is reduced through a vent hole
sure at the actuator expands the diaphragm. The at the spiral valve differential pressure regulator,
and a spring in the actuator causes the spiral valve
9
Section 2
DESCRIPTION
Figure 2-3A Compressor Cooling and Lubrication System - Air cooled
200 HP /
250 HP
ENFRIADOR AIRE-ACEITE
VALVULA
TERMOSTATICA
FILTRO DE ACEITE
VALVULA
RETENCION
DE ACEITE
10
Section 2
DESCRIPTION
Figure 2-3B Compressor Cooling and Lubrication System - Water cooled
VALVULA
TERMOSTATICA
ENFRIADOR de ACEITE
(enfriado por agua)
200 HP
FILTRO DE ACEITE
VALVULA
RETENCION
DE ACEITE VALVULA
TERMOSTATICA
250 HP
ENFRIADOR de ACEITE
(enfriado por agua)
FILTRO DE ACEITE
VALVULA
RETENCION
DE ACEITE
11
Section 2
DESCRIPTION
Figure 2-4A Compressor Discharge System - Air cooled
200 HP /
250 HP ENFRIADOR AIRE-ACEITE
VALVULA DE
PRESION MINIMA
SEPARADOR DE
CONDENSADO
TANQUE VALVULA DE
SEPARADOR DESCARGA
12
Section 2
DESCRIPTION
Figure 2-4B Compressor Discharge System - Water cooled
VALVULA DE
PRESION MINIMA
TANQUE
SEPARADOR
POST-ENFRIADOR
(enfriado por agua)
VALVULA DE
DESCARGA
200 HP /
250 HP SEPARADOR DE
CONDENSADO
13
Section 2
DESCRIPTION
Figure 2-5A Control System: START - FULL LOAD (Typical)
SOLENOID VALVE
(0--50 PSI/ 0--3.5 BAR)
SOLENOID VALVE
SOLENOID VALVE
(50--100 PSI/ 3.5--6.9 BAR)
SOLENOID VALVE
14
Section 2
DESCRIPTION
Figure 2-5B Control System: MODULATION - UNLOAD (Typical)
SOLENOID VALVE
(100--110 PSI/ 6.9-- 7.6 BAR)
SOLENOID VALVE
SOLENOID VALVE
SOLENOID VALVE
15
Section 2
DESCRIPTION
Figure 2-6 Compressor Air Inlet System
FILTRO DE AIRE
UNIDAD
COMPRESORA
VALVULA DE
ADMISION
to return to the full load (maximum) position. unload pressure reset to 100 psig. This ensures
AUTOMATIC OPERATION that the motor will not run in an overload condition.
For applications with varied periods of time when 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIP-
there are no air requirements, Supervisor’s Auto TION
mode allows the compressor to shut down (time Refer to Figure 2-6. The compressor inlet system
delayed) when no compressed air requirement is consists of one or two dry-type air filters, a vacuum
present and restart as compressed air is needed. switch and an air inlet valve.
LOAD/ NO LOAD OPERATION The vacuum switch, located in the compressor
If applications call for load/no load operation, mod- Supervisor control system, indicates the condition
ulation can be disabled in the Supervisor of the air filter. When the message “AIR FILTER
ControllerTM in the “Control Parameters” menu. If MAINT RQD” is displayed,maintenance is required.
modulation is disabled, the unload pressure must The butterfly-type air inlet valve directly controls the
be reset to the rated load pressure of the machine. amount of air intake to the compressor in response
For example, an L model rated for 100 psig full load to the operation of the Sullicon Control (Section
operation and 110 psig unload must have the 2.6).
16
Section 3
SPECIFICATIONS
3.1 SULLAIR TS-20 SPECIFICATIONS
COMPRESSOR: STANDARD MODELS

Type: Positive displacement, fluid - lubricated, twin rotary screws
Standard Operating Pressure (I): See Specifications
Bearing Type Anti Friction
Ambient Temperature (Max.) (II): 105° F (41° C), consult factory for higher ambient temperatures
Cooling: Pressurized Fluid Sullube
Lubricant: Sullube 32
Sump Capacity: 30 gallons (114 liters)
Control: Electro - Pneumatic
MOTOR: (50 Hz Compressors) STANDARD MODELS

Size: 100 - 250 HP
Type: TEFC, Three Phase, 50 Cycles
A.C., 105° F (41° C) Maximum Ambient Temperature
Starter: Full Voltage, Wye - Delta, various voltages
Speed: 1500 RPM
(I) Special compressors are available for operation at higher pressures

(II) Special compressors are available for operation in higher ambient temperatures.
MOTOR: (60 Hz Compressors)

STANDARD MODELS
Size: 100 - 250 HP
Type: TEFC, Three Phase, 60 Cycles
A.C., 105° F (41° C) Maximum Ambient Temperature
Starter: Full Voltage, Wye - Delta, various voltages
Speed: 1800 RPM
3.2 LUBRICATION GUIDE---STANDARD COMPRES-

SORS result in a fluid change interval differing from that
Sullair TS---20 compressors are filled with Sullube stated in the manual.
32.
For more information on a fluid analysis program,
contact your local Sullair representative or the Sull-
! WARNING air Factory Service Department.
Mixing of other fluids within the compressor will
voild all warranties.
Sullube 32 fluid should be changed every 8000 ! WARNING

hours or once a year, whichever occurs first. The
fluid should be changed more frequently under se-
vere operating conditions, such as high ambient “The Plastic Pipe Institute recommends against the
use of thermoplastic pipe to transport compressed
temperatures coupled with high humidity, high par- air or other compressed gases in exposed above
ticulate level, corrosive or strong oxidizing gases are ground locations, e.g. in exposed plant piping.” (I)
present in the air.
Maintenance of all other components is still recom- Sullube 32 should not be used with PVC piping sys-
mended as indicated in the Operator’s Manual. tems. It may affect the bond at cemented joints. Cer-
tain other plastic materials may also be affected.
APPLICATION GUIDE
Sullair encourages the user to participate in a fluid (I) Plastic Pipe Institute, Recommendation B,
analysis program with the fluid suppliers. This could Adopted January 19, 1972.
17
Espacio Necesario
para Remocion de
18
Elementos Separadores
Enfriador Conbinado Panel de Control Limite de Cabina

Aire - Aceite Supervisor II DLX
270010-961R00
FLUJO DE AIRE
Section 3
Salida de
Gabinete Aire 3" NPT
Tablero Arrancador 1985
270000-305
1731 1680,1
SPECIFICATIONS
1448,1
Entrada
de Aire
850,9
101,6
Figure 3-1 Identification - TS20-200HP - Air Cooled
606,3 1828,8 606,6 27,7 1765,3 27,7

3040 1820,7
112,3 Calado Acceso 980,2
4 Agujeros para Autoelevador Drenaje de Condensado
Montaje O 7/8" 4 Agujeros cuadrados Cupla 1/2" NPT
76 x 190 mm
Entrada Filtro de 327,7

Aire Servicio Pesado 828,1
O ext. 7"
1827,3
1219,2
3040
601,2
1219,2
342,9
Valvula
Retencion 1731
de Aceite
1820,7 Filtro de Aceite
Valvula de
Presion Minima
Carga de Aceite
Drenaje Tanque
Separador
3/4" NPT
335,8
118,4
Separador de
Condensado
3040
Espacio Necesario
para Remocion de
Enfriador Conbinado Panel de Control Limite de Cabina
270010-965R00
Aire - Aceite Supervisor II DLX
FLUJO DE AIRE
Gabinete Salida de
Tablero Arrancador Aire 3" NPT
270000-305 1985
1731 1680,1
1403,7
Entrada
de Aire
850,9
101,6
Figure 3-2 Identification - TS20-250HP - Air Cooled
Drenaje de Condensado
606,3 1828,8 980,2 Cupla 1/2" NPT
3041,6 27,7 1765,3 27,7
112,3 4 Agujeros para Calado Acceso 1820,7
Montaje O 7/8" Autoelevador
4 Agujeros cuadrados
76 x 190 mm 174,1
Entrada Filtro de 1827,3

Aire Servicio Pesado 1371,6
O ext. 7" 828,1
3042,8
1219,2
601,2
342,9
1730,9
Valvula
Retencion
de Aceite
Valvula de
Presion Minima
Carga de Aceite
Drenaje Tanque
Separador
3/4" NPT
335,8
118,4
15
Separador de
Condensado
3041,6
19
Section 3
SPECIFICATIONS
Espacio Necesario
para Remocion de
20
Panel de Control Limite de Cabina Entrada Filtro de

Supervisor II DLX Aire Servicio Pesado
O ext. 7"
270010-963R00
Section 3
Gabinete
Tablero Arrancador
270000-305 Salida de
Aire 3" NPT 1985
1731 1680
1414,8
Entrada
SPECIFICATIONS
de Aire
850,9 850,9
292,1 292,1
101,6
60,5
Enfriador de Aceite 27,7 1765,3 27,7
606,3 1828,8 606,6
1820,7
3041,6 980,2 Drenaje de Condensado
4 Agujeros para Montaje Cupla 1/2" NPT
Calado Acceso
Figure 3-3 Identification - TS20-200HP - Water Cooled
O 7/8" Autoelevador
4 Agujeros Cuadrados
76 x 190 mm
827,8 1827,3
3048,4 913
600,4 1524
719,8
B 1732
Valvula Retencion
de Aceite
152,4
A Valvula de
Presion Minima
Carga de Aceite
Drenaje de Tanque
Separador
840,5 3/4" NPT
335,8
117,4
112,3 Separador de
Condensado Enfriador de Aire
3041,6
A Entrada de Agua 1 1/2" NPT

B Salida de Agua 1 1/2" NPT
Gabinete Entrada Filtro de Espacio Necesario
Panel de Control Limite de Cabina Aire Servicio Pesado
Tablero Arrancador Supervisor II DLX para Remocion de
270000-305 O ext. 7" Elementos Separadores
270010-767R00
Salida de Aire
3" N.P.T.
1981
1727 1677
1415
Entrada
de Aire
851
292 Drenaje de Condensado

1/2" N.P.T.
102
28 840
60 4 Agujeros para Montaje Calado Acceso
O 7/8" Autoelevador 1765
1822 4 Agujeros cuadrados 1821
606 76 x 190 mm
3042
Figure 3-4 Identification - TS20-250HP - Water Cooled
Enfriador de Aceite
A Entrada de Agua 1 1/2" NPT 1827

B Salida de Agua 1 1/2" NPT 828
3045 914
459 1524
A 600
152 1727
Valvula Retencion
B de Aceite
Filtro de
Aceite
1821
Valvula de
Presion Minima
Carga de Aceite
Drenaje de Tanque
Separador
840 3/4" N.P.T.
336
117
Separador de
112 Condensado Enfriador de Aire
15
3042
21
Section 3
SPECIFICATIONS
Section 3
SPECIFICATIONS
Figure 3-5 Piping and Instrumentation - TS20-200/250HP - Air Cooled
8
1/4" TUBE
4
1/4" TUBE 1/4" TUBE P2
15
7
3 2
C 8
11
1 1/4" TUBE
SOL 4 1 2
7 3
3 2
6 9
1 37
1/4" TUBE
12
D 35
19
13
1" PIPE 3" PIPE SALIDA DE AIRE
E
3" NPT
4
1/4" TUBE
H
F
10 17 18
1/4" TUBE
1/4" TUBE
G J
3" PIPE
16 17 18
1/4" TUBE DRENAJE
51
26
3 24
31 14 14 15
1 T4 T1 P1 27 22
42
2 14
23
AIR
T2
INLET
28
40
L
PRESET @ 22" WC
29
32
38 33
15 LINEA DE AGUA
P3
LINEA DE CONTROL
LINEA DE ACEITE
T3 P4
15 35 LINEA DE AIRE/ACEITE
14
LINEA DE AIRE
LINEA CONTROL DE TEMPERATURA
FROST FREE TRAP L SUMP HEATER OPT
H L 46
44
C, D & E CLOSED INLET SYSTEM 5 F & G FOR OPERATING J ELEC DRAIN VALVE OPT
C AC VSD FAN DRIVE
PRESS ABOVE 150 PSI
TEMP PROBE
21 47 F
30 20 J
39 AC
SOL 3
2 3 25 36 SOL 5
20
4 14
1
D 48 49
T6
E MOISTURE DRAIN
G 1/4" NPT
SET AT 135°F
50 (57.2° C)
USED FOR OPERATING PRESSURE GREATER THAN 125 PSI
270007-400R01
22
Section 3
SPECIFICATIONS
key part
number description number quantity
1 filter, air inlet 02250140-798 -

2 vlv, inlet butterfly 040338 -
3 control, sullicon 011682-003 -
4 vlv, shuttle 1/4” 408893 -
5 vlv, check 1/4" 049905 -
6 vlv, diff. press. reg. 1/4" npt 406929 -
7 vlv, sol 3w 1/4” 115vac 02250125-657 -
8 filter, control 1/4” npt 02250112-032 -
9 vlv, press. reg. 408275 -
10 orifice, .032” 02250125-774 -
11 vlv, sol. 3w 1/4" 115v UNIV. 02250125-656 -
12 vlv, blowdown 1/2" nc 2w 02250100-042 -
13 silencer, aire 1/2" 041006 -
14 termistor 100 ohm rtd platinum 02250044-985 -
15 pressure transducer 250039-910 -
16 orifice, .062 02250125-775 -
17 glass, sight 1/4” 02250126-129 -
18 strainer, v-type 1/4" 300psi (2.1 bar) 02250117-782 -
19 vlv, min. press. check 250033-821 -
20 manometro 02250117-009 -
21 valvula de seguridad 249807 -
22 element, secondary separator 250034-134 -
23 element, primary separator 250034-122 -
24 vlv, spiral - -
25 vlv. solenoide 1/4" 115v UNIV 02250125-684 -
26 vlv, relief 1-1/4” 175# (12.25 bar) 410103 -
27 tank, fluid sep 30" dia. 02250108-073 -
28 glass, fluid level 1 1/2" sight 040279 -
29 vlv, globe 3/4" 040520 -
30 tanque acumulador 242221 -
31 vlv, relief 65# 1 1/4" x 1 1/2" 02250083-571 -
32 vlv, thermal 1 1/2" 175°f (79.4 °C) 014512 -
33 filter, fluid 02250121-656 -
34 ------------- - -
(Continued on page 25)
23
Section 3
SPECIFICATIONS
8
1/4" TUBE
4
15
7
3 2
C 8
11
1 1/4" TUBE
SOL 4 1 2
7 3
3 2
6 9
1 37
1/4" TUBE
12
D 35
19
13
E
3" NPT
4
1/4" TUBE
H
F
10 17 18
1/4" TUBE
1/4" TUBE
G J
3" PIPE
16 17 18
1/4" TUBE DRENAJE
51
26
3 24
31 14 14 15
1 T4 T1 P1 27 22
42
2 14
23
AIR
T2
INLET
28
40
L
PRESET @ 22" WC
29
32
38 33
15 LINEA DE AGUA
P3
LINEA DE CONTROL
LINEA DE ACEITE
T3 P4
15 35 LINEA DE AIRE/ACEITE
14
LINEA DE AIRE
H L 46
44
C AC VSD FAN DRIVE
PRESS ABOVE 150 PSI
TEMP PROBE
21 47 F
30 20 J
39 AC
SOL 3
2 3 25 36 SOL 5
20
4 14
1
D 48 49
T6
E MOISTURE DRAIN
G 1/4" NPT
SET AT 135°F
50 (57.2° C)
270007-400R01
24
Section 3
SPECIFICATIONS
key part
35 cooler, fluid combo 200HP 02250151-822 -

cooler, fluid combo 250HP 02250152-512 -
36 valvula drenaje 041111 -
37 separator, combo trap 250007-787 -
38 vlv, oil stop 2” 016742 -
39 valvula reguladora de presion 046556 -
40 switch, vac. 22” w.c. n4 02250078-249 -
41 ------------- - -
42 unit, compressor - -
43 ------------- - -
44 heater trap 245572 -
45 ------------- - -
46 heater sump 2000W 120V 02250043-014 -
47 valvula reguladora 046556 -
48 vlv, ball 1/2" npt 047117 -
49 valvula solenoide 02250125-674 -
50 filtro tipo Y 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
8
1/4" TUBE
4
15
7
3 2
C
11 8
1 2
1/4" TUBE
1
SOL 4 7 3
3 2
6 9 SOL 2
1 37
SOL 1
1/4" TUBE
12
D 34
19
13
E
3" NPT
4
1/4" TUBE
H
F
10 17 18
1/4" TUBE
1/4" TUBE
G J
3" PIPE
16 17 18 53 DRENAJE
1/4" TUBE
51 Baja presión de agua

26
3 24
31 14 14 15
T4 T1 P1 27 22
1
42
2 14
23
AIR
T2
INLET
28
40
L
PRESET @ 22" WC
29
32
38 33 ENTRADA DE AGUA
15
P3
T3 P4
14 15 35 52
SALIDA DE AGUA
LINEA DE AGUA
LINEA DE CONTROL
LINEA DE ACEITE
LINEA DE AIRE/ACEITE
LINEA DE AIRE
H L 46
44
C AC VSD FAN DRIVE
PRESS ABOVE 150 PSI
TEMP PROBE
21 47 F
30 20 J
39 AC
SOL 3
2 3 25 36 SOL 5
20
4 14
1
D 48 49
T6
E MOISTURE DRAIN
G 1/4" NPT
SET AT 135°F
50 (57.2° C)
270007-401R01
26
Section 3
SPECIFICATIONS
key part
1 filter, air inlet 02250140-798 -

2 vlv, inlet butterfly 040338 -
3 control, sullicon 011682-003 -
4 vlv, shuttle 1/4” 408893 -
5 vlv, check 1/4" 049905 -
6 vlv, diff. press. reg. 1/4" npt 406929 -
7 vlv, sol 3w 1/4” 115vac 02250125-657 -
8 filter, control 1/4” npt 02250112-032 -
9 vlv, press. reg. 408275 -
10 orifice, .032” 02250125-774 -
11 vlv, sol. 3w 1/4" 115v UNIV. 02250125-656 -
12 vlv, blowdown 1/2" nc 2w 02250100-042 -
13 silencer, aire 1/2" 041006 -
14 termistor, 100 ohm rtd platinum 02250044-985 -
15 pressure transducer 250039-910 -
16 orifice, .062 02250125-775 -
17 glass, sight 1/4” 02250126-129 -
18 strainer, v-type 1/4" 300psi (2.1 bar) 02250117-782 -
19 vlv, min. press. check 250033-821 -
20 manometro 02250117-009 -
21 valvula de seguridad 249807 -
22 element, secondary separator 250034-134 -
23 element, primary separator 250034-122 -
24 vlv, spiral - -
25 vlv. solenoide 1/4" 115V UNIV 02250125-684 -
26 vlv, relief 1-1/4” 175# (12.25 bar) 410103 -
27 tank, fluid sep 30" dia. 02250108-073 -
28 glass, fluid level 1 1/2" sight 040279 -
29 vlv, globe 3/4" 040520 -
30 tanque acumulador 242221 -
31 vlv, relief 65# 1 1/4" x 1 1/2" 02250083-571 -
32 vlv, thermal 1 1/2" 175°f (79.4 °C) 014512 -
33 filter, fluid 02250121-656 -
34 aftercooler 042541 -
(Continued on page 29)
27
Section 3
SPECIFICATIONS
8
1/4" TUBE
4
15
7
3 2
C
11 8
1 2
1/4" TUBE
1
SOL 4 7 3
3 2
6 9 SOL 2
1 37
SOL 1
1/4" TUBE
12
D 34
19
13
E
3" NPT
4
1/4" TUBE
H
F
10 17 18
1/4" TUBE
1/4" TUBE
G J
3" PIPE
16 17 18 53 DRENAJE
1/4" TUBE
51 Baja presión de agua

26
3 24
31 14 14 15
T4 T1 P1 27 22
1
42
2 14
23
AIR
T2
INLET
28
40
L
PRESET @ 22" WC
29
32
38 33 ENTRADA DE AGUA
15
P3
T3 P4
14 15 35 52
SALIDA DE AGUA
LINEA DE AGUA
LINEA DE CONTROL
LINEA DE ACEITE
LINEA DE AIRE/ACEITE
LINEA DE AIRE
H L 46
44
C AC VSD FAN DRIVE
PRESS ABOVE 150 PSI
TEMP PROBE
21 47 F
30 20 J
39 AC
SOL 3
2 3 25 36 SOL 5
20
4 14
1
D 48 49
T6
E MOISTURE DRAIN
G 1/4" NPT
SET AT 135°F
50 (57.2° C)
270007-401R01
28
Section 3
SPECIFICATIONS
key part
35 cooler, oil 200HP 043031 -

cooler, oil 250HP 043864 -
36 valvula drenaje 041111 -
37 separator, combo trap 250007-787 -
38 vlv, oil stop 2” 016742 -
39 valvula reguladora de presion 046556 -
40 switch, vac. 22” w.c. n4 02250078-249 -
41 ------------- - -
42 unit, compressor - -
43 ------------- - -
44 heater trap 245572 -
45 ------------- - -
46 heater sump 2000W 120V 02250043-014 -
47 valvula reguladora 046556 -
48 vlv, ball 1/2" npt 047117 -
49 valvula solenoide 02250125-674 -
50 filtro tipo Y 1/2" 406480 -
51 orf, cap. .031 x 1/4" 02250132-934 -
52 valvula reguladora de agua 049474 -
53 presostato 0-30 psi 250007-163 -
29
NOTES
30
Section 4
INSTALLATION
4.1 MOUNTING OF COMPRESSOR protection where it will be exposed to temperature

A foundation or mounting capable of supporting the less than 32_F(0_C).
weight of the compressor, and rigid enough to main-
tain the compressor frame level and the compressor 4.3 SERVICE AIR PIPING
in alignment is required. The compressor frame Service air piping should be installed as shown in
must be leveled and secured with foundation bolts, Figure 4 --- 1. A shut --- off valve should be installed to
and full uniform contact must be maintained be- isolate the compressor from the service line if re-
tween the frame and foundation. The compressor quired. Also notice that the service line should be
unit and driver must be aligned after installation as equipped with water legs and condensate drains
specified in the Operator’s Manual. No piping loads throughout the system.
shall be transmitted to the compressor at the exter-
nal connections.
! WARNING
4.2 VENTILATION AND COOLING
For air---cooled compressors, select a location to “The Plastic Pipe Institute recommends against the
use of thermoplastic pipe to transport compressed
permit sufficient unobstructed air flow in and out of air or other compressed gases in exposed above
the compressor cooling package to keep the oper- ground locations, e.g. in exposed plant piping.” (I)
ating temperature stable. The minimum distance
that the compressor should be from surrounding Sullube 32 should not be used with PVC piping sys-
tems. It may affect the bond at cemented joints. Cer-
walls is three (3) feet (91.4cm). To prevent excessive tain other plastic materials may also be affected.
ambient temperature rise, it is imperative to provide
adequate ventilation. (I) Plastic Pipe Institute, Recommendation B,
Adopted January 19, 1972.
For water---cooled compressors, it is necessary to
check the cooling water supply. The water system
must be capable of supplying the following flows: 4.4 COUPLING ALIGNMENT CHECK
In preparation for the factory test, the coupling sup-
WATER FLOW (TYPICAL) plied with your compressor is properly aligned for
WATER TEMP. (GPM/LPM) operation. However, due to shipping and handling,
_F (_C) 100HP 125HP 150HP 200HP 250HP it is necessary to recheck the coupling alignment.
75KW 93KW 112KW 150KW 187KW Refer to Coupling Alignment procedure explained in
the Maintenance Section of this manual.
70 (21) 14.0/15.3 17.5/66 21.0/79.5 40/151 49/185
80 (27) 18.75/71 23.5/89 28.0/106 4.5 FLUID LEVEL CHECK
44/166 54/204
Your air compressor is also supplied with the proper
(Water pressure should be between
25 and 75 psig (1.7 and 5.2 bar). 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. If the
Table 1 below indicates the ventilation requirements sump is properly filled, the coolant level should fill
necessary to keep the compressor running at a nor- the sight glass.
mal operating temperature. The fan air requirement
is the volume of air which must blow through the 4.6 ELECTRICAL PREPARATION
compressor for proper ventilation. The specified Interior electrical wiring is performed at the factory.
heat rejection requirement is the amount of heat that Any other wiring should be performed by a qualified
is radiated by the compressor. This heat must be re- electrician and in full compliance with OSHA, Na-
moved to assure a normal operating temperature. tional Electrical code and/or any applicable Federal,
With air---cooled compressors it is possible to use State and Local codes, standards and regulations
this heat for space heating, providing excessive concerning isolation switches, fuse disconnects
pressure drop is not created across the fan. Consult etc. Customer wiring is very minimal. Sullair pro-
a Sullair office for assistance in utilizing this heat. vides a wiring diagram for use by the installer.
DO NOT install a water---cooled or an air---cooled/ A few electrical checks should be made for a
aftercooled compressor without adequate freeze trouble---free start---up.
TABLE 1 VENTILATION REQUIREMENTS (TYPICAL)
Cooling Type Air---cooled Water---cooled

Motor HP/KW: 100/75 125/93 150/112 200/150 250/187 100/75 125/93 150/112 200/150 250/187
Vent Fan Flow (I) 13,000/368 14,500/411 14,500/411 19,000/538 19,000/538 2,370/67 2,370/67 2,370/67 2,370/67 2,370/67
CFM/ M3/MIN:
Heat Rejection BTU/Hour 285,100 353,940 412,500 545,040 699,875 22,410 28,110 33,610 50,390 55,990
KCAL/HR: 71848 89196 103954 137355 176375 5648 7084 8470 12700 14110
(I) Applies to compressors with canopy only (vent fan).
31
21
Section 4
INSTALLATION
Figure 4-1 Service Air Piping (Typical Installation)
4.6 FLUID PIPING (REMOTE AIR-COOLED OPTION (usually lowest ambient). If the pressure drop is in
ONLY) excess of 10 psig (0.7 bar), a pump should be
To allow de-pressurization of the cooling package installed. Consult the Sullair Service Department for
and connecting piping between the compressor and recommendations.
the cooling package upon shutdown of the com- It is recommended that shutoff valves be installed in
pressor, a 1/2”(13 mm) de-pressurization line must the supply and return piping to facilitate compressor
be installed between the top of the fluid cooler and component’s maintenance.
the sump tank connection which is located on the
fluid supply and return line connection bracket. This Because of the variability in installations, the fluid
line must be maintained at a higher level than the necessary to fill the supply and return piping for the
supply and return piping for the fluid cooler. fluid cooler is not part of the standard scope of sup-
ply for the compressor. The fluid necessary to fill
The supply and return piping for the fluid cooler this piping may be ordered from the nearest Sullair
must be adequately sized to prevent excessive representative or the representative from whom the
pressure drop. The total pressure drop in the supply compressor was purchased. To assist in determin-
and return piping and associated fittings and ing the amount of fluid necessary to fill the piping,
valves, not including the cooler, shall not exceed 10 the following chart may be used.
psig (0.7 bar) at the worst case operating condition
32
Section 4
INSTALLATION
GALLONS/LITERS OF FLUID
PIPE SIZE PER 12 INCHES/304.8MM OF PIPE control panel, press STOP , then press
2 .1635/.62 START .
2 1/2 .2555/.97
3 .368/1.39
4 .6542/2.48
6 1.4719/5.57 Since some solid state starters have built-in power
monitoring, a dry run will only indicate compres-
4.7 ELECTRICAL PREPARATION sor overload when machine has this type of
Interior electrical wiring is performed at the factory. starter.
Required customer wiring is minimal, but should be
by a qualified electrician in compliance with OSHA, 5. Reconnect the three (3) motor leads and jog the
National Electrical Code, and any other applicable motor for a direction of rotation check, as
state or local electrical code concerning isolation explained in Section 4.8.
switches, fuse disconnects, etc. Sullair provides a 6. Verify all directions of rotations on all auxiliary
wiring diagram for use by the installer. motors.
A few electrical checks should be made to help 4.8 MOTOR ROTATION DIRECTION CHECK
assure that the first start-up will be trouble free. 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
Lethal shock hazard inside.
the and pads in succession to bump start
Disconnect all power at source, before opening
or servicing starter or control panel.
the compressor. When looking at the motor from the
end opposite the compressor unit, the shaft should
1. Check incoming voltage. Be sure that the incom- be turning clockwise on all gear driven models, and
ing voltage is the same voltage that the com- counterclockwise on direct drive models. If the
pressor was wired for. motor shaft is not turning in the proper direction,
2. Check starter and overload heater sizes (see disconnect the power to the starter and exchange
Electrical Parts in Parts Manual). any two of the three power input leads, then re-
3. Check all electrical connections for tightness. check rotation. A “Direction of Rotation” decal is
located on the coupling guard between the motor
4. “DRY RUN” the electrical controls by disconnect-
and compressor to show proper motor/compressor
ing the three (3) motor leads from the starter.
rotation.
Pull out the EMERGENCY STOP button on the
33
Section 5
SUPERVISOR
Figure 5-1 Supervisor Controller Control Panel
For information concerning all aspects of the Supervisor Controller,

consult the Supervisor Controller manual no. 02250133-517.
34
Section 5
SUPERVISOR
Figure 5-2 Supervisor DLX Control Panel
35
NOTES
36
Section 6
COMPRESSOR OPERATION
6.1 INTRODUCTION pose, location, and use.
While Sullair has built into the LS25S Series pack- 6.2 PURPOSE OF CONTROLS
age a comprehensive array of controls and indica- All Supervisor Controller related functions and indi-
tors to assure its proper operation, the user should cators are presented in the Supervisor Controller
recognize and interpret readings which call for Manual, so please refer to that manual for further
service or indicate the onset of a malfunction. information. Additional indicators and functions
Before starting the unit, the user should become included in the package are as follows:
familiar with the controls and indicators-their pur-
CONTROL OR INDICATOR PURPOSE

EMERGENCY STOP SWITCH 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.
THERMAL O/L RESET Momentarily pushing this button, found on the starter’s ther-
mal overload element housing, re-closes 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.
SPIRAL VALVE Internally bypasses and controls the air flow capacity of the
compressor, in order to match air supply to the demand.
Maintains a maximum pilot pressure of 70 psig (4.8 bar).
PRESSURE REGULATOR
(LOAD CHAMBER)
PRESSURE REGULATOR Opens a pressure line between the sump and the inlet unload
(UNLOAD CHAMBER) chamber, allowing the inlet valve to regulate air delivery
according to air demand. Works in conjunction with solenoid
valve #3.
SOLENOID VALVE #1 Electrically actuated, 3-way valve which controls the flow of
pneumatic logic signals. Used throughout package to:
•Open the blowdown valve.
•Pressurize the unload port/close 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 valve to deliv-
er air. This prevents any air system loss and de-pressurizes
the controls when the compressor is shut off.
SOLENOID VALVE #3 Opens pressure line between sump and inlet unload chamber
for modulation.
Serves to control machine during sequencing with multiple
machines. Designates whether machine is at full load or mod-
ulating.
37
Section 6
CONTROL OR INDICATOR (CONT.) PURPOSE (CONT.)
PNEUMATIC INLET VALVE Blocks the reverse flow of air/fluid through the compressor
unit during shutdown, and opens to allow air intake to the
compressor during normal load.
Maintains 50 psig (3.5 bar) in the receiver tank when the
MINIMUM PRESSURE VALVE
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 atmosphere 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 low 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; little 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, if the 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 described 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 shut-off valve to the service line.
1. Read the preceding pages of this manual thor- 5. Check for possible leaks in piping.
oughly.
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
Section 6
System Adjustments. 6.4 SUBSEQUENT START-UP PROCEDURE
7. Observe the operating temperature. If the oper- On subsequent start-ups, check that the proper
ating temperature exceeds 200°F (93°C) [215°F level is visible in the fluid sight glass and simply
(102°C) for water-cooled 24KT and > 150 psi], press the START or AUTO MODE button.
the cooling system and installation environment When the compressor is running, observe the
should be checked. instrument panel and maintenance indicators.
8. Open shut-off valve to the service line. 6.5 SHUTDOWN PROCEDURE
9. Reinspect the compressor for temperature and To shut the compressor down, simply press the
leaks the following day.
STOP button.
39
NOTES
40
Section 7
MAINTENANCE
7.1 GENERAL 7.5 FLUID CHANGE
As you proceed in reading this section, it will be Standard models are filled with the long life lubri-
easy to see that the Maintenance Program for the cant Sullube.
air compressor is quite minimal yet important. The Sullube should be changed under the following con-
use of the service indicators provided for the fluid fil- ditions, whichever occurs first:
ter, air filter and fluid separator, will alert you when
service maintenance is required. When the mainte- 1. Every 8000 hours.
nance message is displayed by the Supervisor 2. Once a year.
ControllerTM, maintenance for that specific item is 3. As indicated by fluid analysis.
required. See instructions for each item in Section A fluid sample at every 1000 hours is recommend-
7.7, Parts Replacement and Adjustment proceed. For a free Sullube analysis, send fluid to:
dures. Dow Chemical
7.2 DAILY OPERATION Lubricant Technology Center
Prior to starting the compressor, it is necessary to Building B-1605
check the fluid level in the sump. Should the level Freeport, TX 77541
be low, simply add the necessary amount. If the To facilitate this, a sample bottle is included with the
addition of fluid becomes too frequent, a simple compressor.
problem has developed which is causing this
7.6 SEPARATOR MAINTENANCE
excessive loss. See the Troubleshooting Section
Replace the separator elements when a message is
(7.8) under Excessive Fluid Consumption for a
displayed or after one (1) year, whichever comes
probable cause and remedy.
first. The separator elements must be replaced. DO
After a routine start has been made, observe the NOT clean the separator elements.
Supervisor control panel and be sure it monitors the
7.7 PARTS REPLACEMENT AND ADJUSTMENT
correct readings for that particular phase of opera-
PROCEDURES
tion. After the compressor has warmed up, it is rec-
ommended that a general check of the overall com- FLUID FILTER MAINTENANCE
pressor and Supervisor be made to assure that the Refer to Figure 7-1. The fluid filter (P/N 02250121-
compressor is running properly. 656) is located schematically after the thermal
valve. When servicing the fluid filter, shut the com-
pressor down, be sure all pressure has been
DO NOT remove caps, plugs, and/or other com-
released, then follow the instructions below. For
ponents when compressor is running or pres-
surized. Figure 7-1 Fluid Filter (P/N 02250121-656)
Stop compressor and relieve all internal pres-
sure before doing so.
7.3 MAINTENANCE AFTER INITIAL 50 HOURS OF
OPERATION
After the initial 50 hours of operation, a few mainte-
nance requirements are needed to rid the system of
any foreign materials if any. Perform the following
maintenance operations to prevent unnecessary
problems.
1. Clean the return line strainers.
2. Clean the return line orifices.
3. Change the fluid filter element.
4. Clean the control line filters.
7.4 MAINTENANCE AFTER 1000 HOURS
After 1000 hours of operation, it will be necessary to
perform the following:
1. Clean the return line strainers.
2. Replace the fluid filter element.
*Repair Kit P/N 02250139-995
41
Section 7
MAINTENANCE
element replacement order kit number 02250139- sary. When removing the primary element, always
995. check the secondary element for visible dirt, grease
1. Drain the fluid from the canister by removing the or damage. The secondary element must be
bottom drain plug changed after every sixth primary element change.
DO NOT clean the secondary element.
2. Loosen the spin-on canister using a wrench on
the bottom canister hex. ELEMENT REMOVAL
3. Pull the canister away from the filter head. The 1. Clean the exterior of the air filter housing.
filter element will be attached to the head. 2. Remove the cover assembly by loosening the
4. Separate the element from the head. wingnut securing it.
5. Remove the canister seals. 3. Pull the element assembly out of the housing.
6. Thoroughly clean the filter head and canister in 4. On the inside of the element, you will notice a
solvent. wingnut which fastens the element to the hous-
ing. Remove the wingnut and pull the primary
7. Lubricate the new seals with the same type of element out.
fluid used in the compressor and position each
seal in its appropriate place. 5. Loosen and remove the hex nut securing the sec-
ondary element. Remove the secondary ele-
8. Slide the element into the canister. ment.
9. Thread the canister and element back on the fil- 6. Inspect the secondary element and replace if
ter head. necessary.
AIR FILTER MAINTENANCE 7. Clean the interior of the housing by using a damp
Refer to Figure 7-2. Air filter maintenance should cloth. DO NOT blow dirt out with compressor air.
be performed when the air filter maintenance mes-
sage is displayed. The air filter is equipped with a 8. Install the new secondary element and replace
primary element and a secondary element. As pre- the sealing washer and hex nut.
viously stated, the Supervisor will alert you as to 9. With the secondary element in place, replace the
when the primary element maintenance is neces- primary element.
Figure 7-2 Air Filter Replacement (P/N 02250140-798)
HOUSING
ELEMENT
DUST
COLLECTOR
WINGNUT
Replacement Element P/N 02250135-150
42
Section 7
MAINTENANCE
Figure 7-3 Separator Element Replacement
shine through the element, revealing any holes.
2. Inspect all gaskets and gasket contact surfaces
of the housing. Should faulty gaskets be evident,
correct the condition immediately.
3. If the 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 and
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 cover/element 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, etc.
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
Primary Replacement Element P/N 250034-122 3/4” jackscrew under the lifting arm post. The lid
Secondary Replacement Element P/N 250034-134 can be pivoted to the side supported by the lift-
ing arm.
5. Remove the primary and secondary separator
elements.
6. Scrape the old gasket material from the cover
DO NOT strike the element against any hard sur- and flange on the sump being careful not to let
face to dislodge dust. This will damage the sealing the scraps fall in the sump.
surfaces and possibly rupture the element.
7. Inspect the separator tank for rust, dirt, etc.
DO NOT “blow” dirt out of the interior of the filter
8. Reinsert the separator elements with gaskets
housing. This may introduce dust downstream of
attached into the sump taking care not to dent
the filter. Instead, use a clean damp cloth.
them against the tank opening. DO NOT remove
DO NOT oil the element. grounding staples. Check between separator
ELEMENT INSPECTION element flange and tank for continuity after
1. Place a bright light inside the element to inspect torquing bolts. DO NOT use anti-seize com-
for damage or leak holes. Concentrated light will
43
Section 7
MAINTENANCE
Figure 7-4 Oil Return/Sight Glass
pound on gaskets.
9. Clean the underside of the separator tank cover
Always performing maintenance on both oil
and remove any rust.
return/sight glasses at the same time.
10. Replace the cover plate, washers and 3/4-10 1. Disconnect the tubes at the tops of the sight
capscrews. Lubricate and torque to 200 ft.-lbs. glass assemblies.
(271 Nm).
2. Unscrew male connector (for left-side glass), or
11. Reconnect all piping making sure return line the straight thread tube connector (for right-side
tubes extend to the bottom or 1/4” (6mm) above glass) from sight glass/orifice blocks.
the bottom of the separator element. This will
assure proper fluid return flow to the compres- 3. Remove used filter assembly, and replace with
sor. new assembly.
12. Check the return line strainers before restarting 4. Coat/lubricate the o-rings will silicone grease.
the compressor (order replacement kit no. 5. Reattach the connectors to the sight glass/orifice
02250117-782). blocks.
OIL RETURN/SIGHT GLASS MAINTENANCE DIFFERENTIAL PRESSURE REGULATOR
Refer to Figure 7-4. The oil return/sight glass sub- ADJUSTMENT
assembly is attached to the separator tank lid. Oil Refer to Figure 7-5. The differential pressure regu-
return/sight glass maintenance should be per- lators are adjusted by loosening the jam nut on the
formed on a routine basis parallel to that of the fluid end of the cone shaped cover of the pressure reg-
filter, or as indicated in the Troubleshooting ulator. When the jam nut is loose, turn the adjusting
Sections (both Supervisor and Maintenance) of this screw clockwise to increase or counterclockwise to
manual. The maintenance on an oil return/sight decrease the setting.
glass is mainly concerned with the condition of the Above 100 psig (6.9 bar), the inlet regulator should
filter assembly. Order filter assembly no. 02250117- allow pressure to flow into the unload chamber of
782, and use the following instructions as a guide. the inlet valve. Cycle the Control System several
times and recheck all pressure settings.
44
Section 7
MAINTENANCE
Figure 7-5 Pressure Regulator Adjustments
Above 100 psig (6.9 bar), the optional spiral valve pressure reducing regulator to maintain 70 psig (4.8
regulator should allow pressure to flow into the bar) signal to open the inlet valve.
chamber of the spiral valve actuator. The spiral DRIVE COUPLING INSTALLATION AND ALIGN-
valve should start to rotate at this time. MENT (200/250HP)
PRESSURE REDUCING REGULATOR Refer to Figures 7-6, 7-7 and 7-8. For coupling
When running with compressor loaded, adjust the installation and alignment, the tools required are a
straight edge, a measuring scale, one set of feeler
Figure 7-6 Drive Coupling (200/250HP) gauges, a set of standard Allen wrenches and one
set of standard socket wrenches.
Tornillo Cubo
Acople
Elemento Disconnect all power at source, before attempt-

de Acople* ing maintenance or adjustments.
TABLE 7-1
INSTALLATION DATA (250HP)
Cubo Max. Operating Misalignment
Acople
Tightening Coupling Parallel Angular
Torque Gap Offset
ft.-lbs./Nm inches/cm inches/cm inches/cm (I)
200 2.969 + .030 .010 .010
- .000
Elemento 271Nm 7.5 + .08 .03 .03
de Acople* - .000
Tornillo
(I) Angular misalignment in inches equals maximum A minus
minimum B as shown in Figure 7-7. DO NOT exceed val-
*Replacement Element P/N 02250056-425 ues in Table above.
45
Section 7
MAINTENANCE
Figure 7-7 Drive Coupling Alignment rately to correct. Recheck the vertical offset.
STEP 4 INSTALL THE FLEXIBLE ELEMENT -
Position the motor and compressor keyways 180°
apart. Insert the flexible 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.-lbs. (271 Nm).
For installation and alignment of the drive coupling,
follow the steps explained below.
Capscrews are 3/4-10 x 4” LG ASTM A354 Grade
STEP 1 MOUNT HUBS - Mount the motor hub and BD yellow zinc di-chromate. DO NOT substitute
the compressor hub onto respective shaft. Position with any other bolts.
the hubs to establish the correct gap specified in After tightening the capscrews, tighten the shaft
Table 7-1 Installation Data. Secure each hub with a setscrews and remove the hose clamp from the
setscrew. flexible element. At this time, the coupling is ready
STEP 2 OFFSET ALIGNMENT - Clean any oil, for operation.
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° Figure 7-8 Parallel/ Angular Offset Alignment
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 or hub gap

when adjusting motor position.
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 tol-
erance, shim the front or rear of the motor sepa-
46
Section 7
MAINTENANCE
7.8 TROUBLESHOOTING A detailed visual inspection is worth performing for
The information contained in the Troubleshooting almost any problems which may prevent unneces-
chart is based upon both the actual applied situa- sary damage to the compressor. Always remember
tions and extensive testing at the factory. It contains to:
symptoms and usual causes for the described prob- a. Check for loose wiring.
lems. However DO NOT assume that these are the b. Check for damaged piping.
only problems that may occur. All available data c. Check for parts damaged by heat or an electrical
concerning the trouble should be systematically short circuit, usually apparent by discoloration or a
analyzed before undertaking any repair or compo- burnt odor.
nent replacement.
Should your problem persist after making the rec-
ommended check, consult your nearest Sullair rep-
For additional information on troubleshooting, resentative or the Sullair Corporation.
consult the Supervisor Controller manual.
7.9 TROUBLESHOOTING GUIDE

SYMPTOM PROBABLE CAUSE REMEDY
COMPRESSOR WILL NOT START Main Disconnect Switch Open Close switch.
Line Fuse Blown Replace fuse.
Control Transformer Fuse Blown Replace fuse.
Motor Starter Overloads Tripped Reset. Should trouble persist, check whether
motor starter contacts are functioning properly.
Low Incoming Line Voltage Check voltage. Should voltage check low, consult
power company.
Replace Supervisor display module if no display

or erratic display.
COMPRESSOR SHUTS DOWN Loss of Control Voltage Check incoming power.

WITH AIR DEMAND PRESENT
Low Incoming Voltage Check control fuses and wiring.
Consult power company. The Sullair Supervisor
will provide indication of most maintenance prob-
lems if control power has not been lost. Shutdowns
will occur upon a faulty condition or a bad sender
condition.
Excessive Operating Pressure Check maximum P2 pressure setting.
HIGH PRESS P1 display; Max P1 pressure may

be set too low. Consult factory for recalibration.
Defective solenoid valve; solenoid valve should

cause inlet to unload when unload pressure is
exceeded. Repair if defective.
Defective blowdown valve; blowdown valve

should exhaust sump pressure to 25 psig (1.7 bar)
for integrated coolers; 50 psig (3.4 bar) for remote
coolers when maximum operating pressure is
reached. Repair if defective.
Open or shorted P1, P2, P3 or P4 sender mes-

sage; replace sender indicated.
47
Section 7
MAINTENANCE
7.9 TROUBLESHOOTING GUIDE (CONTINUED)
COMPRESSOR SHUTS DOWN HIGH TEMP T1 or T3 Message Displayed Cooling water temperature too high; increase
WITH AIR DEMAND PRESENT water flow (water-cooled only).
(CONTINUED)
Cooling water flow insufficient; check water lines,
valves (water-cooled only) and available water
pressure differential.
Cooler plugged; clean tubes. If plugging persists,

install water conditioner or water filter(water-
cooled only).
Cooling air flow restricted; clean cooler and check

for proper ventilation.
Ambient temperature is too high; provide suffi-

cient ventilation.
Cooling air ductwork, if installed, may restrict air

flow. High static fan must be specified with cus-
tomer-supplied ductwork, and ductwork must be
sized to minimize flow restriction.
Low fluid level; add fluid.
Clogged filter; change the fluid filter element as

indicated by Supervisor control.
Thermal valve not functioning properly; replace

element.
Optional Water flow regulating valve not function-

ing properly; change (water-cooled only).
Open or shorted T1 or T2 sender; check for a

short or open circuit to probe and correct wiring.
Excessive pressure drop in supply and return

lines of remote air-cooled cooling package.
Consult paragraph 4.6 of this manual.
Low Fluid Pressure Check fluid level.

(LOW PRESSURE P3 display)
Check for clogged fluid filter.
Low Water Pressure Check the cooling fan motor or water flow sys-
(FAN OL/LOW WATER display) tem.
COMPRESSOR WILL NOT BUILD Air Demand is Too Great Check service lines for leaks or open valves.
UP FULL DISCHARGE PRESSURE
Dirty Air Filter Check for filter maintenance message on supervi-
sor panel and change or clean element if
required.
Pressure Regulator Out of Adjustment Adjust regulator according to control adjustment

instructions in the Maintenance Section.
Defective Pressure Regulator Check diaphragm and replace if necessary (kit

available).
LINE PRESSURE RISES ABOVE Leak in Control System Causing Loss of Check for leaks.
UNLOAD P2 PRESSURE SETTING Pressure Signals
ON THE SUPERVISOR
Defective Blowdown Valve Check that sump pressure is exhausted to the
atmosphere when in the OFF LOAD mode.
Repair or replace if necessary (kit available).
48
Section 7
MAINTENANCE
7.9 TROUBLESHOOTING GUIDE (CONTINUED)
LINE PRESSURE RISES ABOVE Plugged Control Line Filter Clean or repair if necessary.
UNLOAD P2 PRESSURE SETTING
ON THE SUPERVISOR (CONT.)
EXCESSIVE FLUID CONSUMP- Clogged Return Line Strainer or Orifice Clean strainer (screen with o-ring replacement kit
TION available)
Clean orifice.
Separator Element Damaged or Not Check Separator Differential (plugged) dP1.

Functioning Properly
Change Separator
Leak in the Lubrication System Check all pipes, connections and components.
Excess Fluid Foaming Drain and change.
Fluid Level Too High Drain excess fluid.
PRESSURE RELIEF VALVE Defective Pressure Relief Valve Replace pressure relief valve.
OPENS REPEATEDLY
LIQUID WATER IN COMPRESSED Water Vapor Condensation From Cooling Remove the water vapor from compressed air
AIR SERVICE LINE and Compression Occurs Naturally prior to distribution through the air system. Check
operation of aftercooler and moisture separator.
Install a compressed air dryer sized for the flow
and dryness level required. (Note: Filters may also
be required to remove particulates, liquid oil
aerosols or for oil vapor removal. Change car-
tridges as recommended by the filter manufactur-
er.) Check all drain traps routinely to insure their
proper operation. Maintain them regularly.
49
NOTES
50
Section 8
ILLUSTRATIONS AND PARTS LIST
8.1 PROCEDURE FOR ORDERING PARTS
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
of 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 place located on the compressor unit.
For ordering parts other than those pertaining to the compressor unit, use serial number located on nameplate
mounted on control panel.
8.2 RECOMMENDED SPARE PARTS LIST- 200/250HP

DESCRIPTION KIT NUMBER QTY
element for air filter 02250140-798 02250135-150 6

element for separator with gaskets 250034-122 (primary) 250034-122 1
element for separator with gaskets 250034-134 (secondary) 250034-134 1
repair kit for water separator 250007-787 Consult Factory 1
repair kit for thermal valve (170°F) 014512 001168 1
repair kit for regulator valve 406929 041742 1
repair kit for blowdown valve 02250100-042 02250100-042 1
repair kit for control line filter 02250112-032 02250112-031 2
repair kit for fluid return strainer 02250117-782 2
replacement kit for fluid filter 02250121-656 02250139-995 8
repair kit for solenoid valve 02250125-657 02250125-829 (valve) 2
replacement coil for solenoid valve 02250125-657 02250125-861 (coil) 2
repair kit for solenoid valve 02250125-656 02250125-828 (valve) 1
replacement coil for solenoid valve 02250125-656 02250125-858 (coil) 1
repair kit for regulator valve 408275 250028-693 1
repair kit for minimum pressure valve 250033-821 250018-262 1
repair kit for fluid stop valve 016742 001684 1
repair kit for shaft seal 067329-001 1
element for drive coupling 200hp 02250056-425 1
element for drive coupling 250hp 02250117-320 1
repair kit for Sullicon Control 011682-003 11579/N 1
diaphragm repair kit for spiral valve air cylinder 250016-183 608311-001 1
compressor Sullube fluid (5 gallons) 250022-669 6
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
51
Section 8
8.3 MOTOR, COMPRESSOR, FRAME AND PARTS
7
6
2
8
4
52
Section 8
8.3 MOTOR, COMPRESSOR, FRAME AND PARTS
key part
1 chasis TS20 270003-522 1

2 motor (I) - 1
3 cubo lado motor (I) - 1
4 elemento de acople (I) - 1
5 cubo lado unidad (I) - 1
6 proteccion cubos acople 225907RA �2
7 unidad compresora - 1
8 barra montaje 20/16 uc 270003-475 1
(I) This part may vary by machine. Consult factory with machine serial number
(II) 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. 067329-001
53
Section 8
8.4 AIR INLET SYSTEM
1
4 1
1
1
54
Section 8
8.4 AIR INLET SYSTEM
key part
1 filtro de aire/elemento 16" (I) 02250140-798 1

2 tapa filtro de aire 046307 1
3 zuncho fijacion filtro de aire TS20 270010-127 2
4 codo de goma 90° 8" x 7" 245796 1
5 soporte filtro de aire optimalair TS20 270010-030 1
6 adaptador de admision vlv. mariposa 8" 013127RA �1
7 junta 8 1/2" x 10 1/2" x 1/32" 040422 2
8 valvula mariposa 8" 040338 1
(I) For maintenance on air filter no. 02250140-798, order replacement element no. 02250135-150.
55
Section 8
8.5 FLUID COOLING SYSTEM - AIR COOLED - 200HP
10
5
6
11
56
Section 8
key part
1 fluid cooler combo 200hp 02250151-822 1

2 panel adaptador venturi 270010-295 1
3 panel venturi 245579 1
4 grilla ventilador 248744 1
5 soporte paquete enfriamiento 200hp 250027-038 2
6 angulo 2" x 2" x 47 1/2" 250022-720 1
7 soporte motor ventilador 015641 1
8 soporte arrancador/enfriador 250022-657 2
9 buje de ventilador (I) - 1
10 ventilador (I) - 1
11 motor de ventilador (I) - 1
57
Section 8
10
5 6
11
58
Section 8
key part
1 fluid cooler combo 250hp 02250152-512 1

2 panel adaptador venturi 02250056-198 1
3 panel venturi 270010-636 1
4 grilla ventilador 248744 1
5 soporte paquete enfriamiento 250hp 270009-638 2
6 angulo 2" x 2" x 47 1/2" 250022-720 1
7 soporte motor ventilador 270009-637 1
9 buje de ventilador (I) - 1
10 ventilador (I) - 1
11 motor de ventilador (I) - 1
59
Section 8
8.7 FLUID COOLING SYSTEM - WATER COOLED - 200HP
6
3 5
7
8
9
6 10
5 11
17 12
10
15
15
8
6
7
10
18
5
16
7 14 13
60
Section 8
key part

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" t x 1 1/2" nptm 810524-150 4
6 buje red. hex. 2" x 1 1/2" #150 802108-060 3
7 niple 1 1/4" npt x 4" sch40 822120-040 3
8 union doble 1 1/4" asiento br 802515-050 2
9 niple 1 1/4" npt x 3" sch40 822120-030 1
10 codo 90º 1 1/4" npt 801515-050 3
11 tube, clr/in 1 1/2" o.d. 270010-764 1
12 niple 1 1/4" npt x 2 1/2" sch40 822120-025 1
13 soporte salida de agua 250027-022 1
14 buje red. hex. 1 1/2" x 1 1/4" #150 802106-050 1
15 niple 1 1/4" npt x corto sch40 822120-000 2
16 vlv. termorreguladora de agua 1 1/4" 049474 1
17 buje red. hex. 2" x 1 1/4" #150 802108-050 1
18 tube, clr/clr 1 1/2" o.d. 270010-350 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR
61
Section 8
1
5
3
22
3
23
18
19
11
5 20
4
8
7
14 11
12
13 13
9 17 14
11
15
10 14
16
5
6
21
6
62
Section 8
key part

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 buje red. hex. 2" x 1 1/2" #150 802108-060 3
6 codo 90° 1 1/2" t x 1 1/2" npt 810524-150 3
7 tube, clr/clr 1 1/2" o.d. 270010-765 1
8 tube, clr/in 1 1/2" o.d. 43" x 14" 02250114-753 1
9 union tubo 1 1/2" t x 1 1/2" t 811324-150 1
10 tube clr/in 1 1/2" o.d. 25.5" x 29.5" 02250046-123 1
11 codo 90º 1 1/4" npt 801515-050 3
12 niple 1 1/4" npt x 4 1/2" sch40 822120-045 1
13 union doble 1 1/4" asiento br 802515-050 2
14 niple 1 1/4" npt x corto sch40 822120-000 3
15 vlv. termorreguladora de agua 1 1/4" 049474 1
16 buje red. hex. 1 1/2" x 1 1/4" #150 802106-050 1
17 niple 1 1/4" npt x 3" sch40 822120-030 1
18 buje red. hex. 2" x 1 1/4" #150 802108-050 1
19 niple 1 1/4" npt x 4" sch40 822120-040 1
20 niple 1 1/4" npt x 2 1/2" sch40 822120-025 1
21 soporte salida de agua 250hp 270010-766 1
22 niple1 1/2" npt x 14" sch40 822124-140 1
23 codo 90° 1 1/2" t x 1 1/2" npth 810424-150 1
63
Section 8
ILLUSTRATION AND PARTS LIST
8.9 AIR PIPING SYSTEM - AIR COOLED - 200/250HP
1
2
3
4
5
6
7
14
13
12
11 14
8 18
AFTERCOOLER
9
21
10 20
18
15
14
9 16
11 B
12
17
A Desde Tanque Separador 14
B Salida de Aire
22
19
22
64
Section 8
8.9 AIR PIPING SYSTEM - AIR COOLED - 200/250HP
key part
1 tee red. 3/4 x 1/2 x 1/2 802203-022 1

2 niple 1/2" npt x 5" 822108-050 1
3 valvula blowdown 2 vias 1/2" npt (I) 02250100-042 1
4 niple 3/4" npt corto sch40 822212-000 1
5 tee 3" x 3/4" x 3" #150 802212-022 1
6 nipple, pipe 3" x 3" 822148-030 2
7 valvula presion minima 3" (II) 250033-821 1
8 nipple, pipe 3" x 18" 822148-180 1
9 codo red. 90° 3" x 2 1/2" npt s.2000 801612-100 2
10 nipple, pipe 2 1/2" x 4" 822140-040 1
11 flexible vlv. press min./aftrclr 02250058-939 2
12 union doble 3" asiento bronce 802515-120 2
13 nipple, pipe 3" x 5 1/2" 822148-055 1
14 codo 90° 3" 801515-120 4
15 nipple, pipe 2 1/2" x corto 822140-000 1
16 nipple, pipe 3" x 10 1/2" 822148-105 1
17 nipple, pipe 3" x 4 1/2" 822148-045 1
18 u-bolt 1/2" x 3" pipe 868308-300 2
19 separador de condensado con trampa 3" 250007-787 1
20 nipple, pipe 3" x 15" 822148-150 1
21 nipple, pipe 3" x 5" 822148-050 1
22 soporte separador de humedad 3" 250023-077 2
(I) For maintenance on blowdown valve no. 02250100-042, order repair kit no. 02250100-042.
(II) For maintenance on min. press. valve no. 250033-821, order repair kit no. 250018-262.
65
Section 8
8.10 AIR PIPING SYSTEM - WATER COOLED - 200/250HP
3
2
4 1
5
6
7
8
A
10
6
9
11
16
11
18
12 AFTERCOOLER
(WC) 6 13
16
13
13
B
14
11
A Desde Tanque Separador
B Salida de Aire
11
15
19
13
17
19
66
Section 8
8.10 AIR PIPING SYSTEM - WATER COOLED - 200/250HP
key part
1 valvula 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 3/4" 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, pipe 3" x 3 1/2" 822148-035 1
9 nipple, pipe 3" x 3" 822148-030 3
10 valvula presion minima 3" (II) 250033-821 1
11 brida roscada 3" #150 rf 819315-048 4
12 flexible vlv. press min./aftrclr 02250058-939 1
13 codo 90° 3" 801515-120 4
14 flexible aftclr / trampa condensado 02250088-057 1
15 nipple, pipe 3" x 6 1/2" 822148-065 1
16 u-bolt 1/2" x 3" pipe 868308-300 2
17 separador de condensado con trampa 3" 250007-787 1
18 nipple, pipe 3" x 5" 822148-050 1
19 soporte separador de humedad 3" 250023-077 2
(I) For maintenance on blowdown valve no. 02250100-042, order repair kit no. 02250100-042.
(II) For maintenance on min. press. valve no. 250033-821, order repair kit no. 250018-262.
67
Section 8
8.11 FLUID PIPING SYSTEM - AIR COOLED - 200/250HP
8
6
7
DESDE
6 COOLER
6
2
5 1 A
4 COOLER
3
6 1
9
10
A 6
11
12
6
13
14
A Desde Tanque Separador
B 15
B A Unidad Compresora
9
16
9
68
Section 8
8.11 FLUID PIPING SYSTEM - AIR COOLED - 200/250HP
key part
1 niple 1 1/2" npt x 9" sch 40 822124-090 2

2 codo 90º 1 1/2" npt #150 S.2000 801515-060 1
3 valvula termostatica (I) 014512 1
4 niple 1 1/2" npt x 3 1/2" sch 40 822124-035 1
5 tee 1 1/2" #150 802415-060 1
6 conn, tube-m 1 1/2" x 1 1/2" 810224-150 6
7 buje red. hex. 2" x 1 1/2" #150 807608-060 1
8 tube 1 1/2" 90º tee/clr 02250114-114 1
9 niple pipe xs 2" x close 822232-000 3
10 codo red. 90° 2" x 1 1/2" S.2000 801608-060 1
11 tube 1 1/2" 90º tv/clr 02250114-118 1
12 tube 1 1/2" 90º tv/fltr 250033-663 1
13 adpt, flg 2" sae 4 bolt - 1,5 02250133-365 1
14 filtro de aceite sae 2" flg (II) 02250121-656 1
15 adpt, flg 2" sae 4 bolt - 2 02250133-366 1
16 valvula retencion de aceite 2" npt (III) 016742 1
(I) For maintenance on (170ºF) thermal valve no. 014512, order repair kit no. 001168.
(II) For maintenance on fluid filter no. 02250121-656, order repair kit no. 02250139-995.
(III) For maintenance on oil stop valve no. 016742, order repair kit no. 001684.
69
Section 8
8.12 FLUID PIPING SYSTEM - WATER COOLED - 200HP
7
6
5
4
3
1
2 12
1
11
9 10
6
8
13
6
B A
6
14
15
16

B A Unidad Compresora
16
18
ENFRIADOR DE ACEITE 19
(WC)
20
70
Section 8
key part

2 valvula retencion de aceite 2" npt (I) 016742 1
3 adpt, flg 2" sae 4 bolt - 2 02250133-366 1
5 adpt, flg 2" sae 4 bolt - 1,5 02250133-365 1
6 conn, tube-m 1 1/2" x 1 1/2" 810224-150 4
7 tube 1 1/2" 90º tv/fltr 250033-663 1
8 tee 1 1/2" #150 802415-060 1
9 niple 1 1/2" npt x 3 1/2" sch 40 822124-035 1
10 valvula termostatica (III) 014512 1
11 niple 1 1/2" npt x 7" sch 40 822124-070 1
12 codo 90º 1 1/2" npt #150 S.2000 801515-060 1
13 niple 1 1/2" npt x 9" sch 40 822124-090 1
14 tube, clr/tee 250033-967 1
15 tube, 1 1/2" 43" x 14" 02250114-753 1
16 codo 90° 1 1/2" t x 1 1/2" npt 810524-150 2
17 buje red. 3" x 1 1/2" 807612-060 1
18 tee red. 2" x 1/2" x 1 1/2" #150 802208-026 1
19 niple 2" x 7" sch40 822132-070 1
20 buje red. 3" x 2" 807612-080 1
(I) For maintenance on oil stop valve no. 016742, order repair kit no. 001684.
(III) For maintenance on (170ºF) thermal valve no. 014512, order repair kit no. 001168.
71
Section 8
7
6
5
4
3
1
2
1 12
11
6
13
8
A
9
14 10
B
15
16
17
16
ENFRIADOR DE ACEITE
B A Unidad Compresora (WC)
19
20
72
Section 8
key part

2 valvula retencion de aceite 2" npt (I) 016742 1
3 adpt, flg 2" sae 4 bolt - 2 02250133-366 1
5 adpt, flg 2" sae 4 bolt - 1,5 02250133-365 1
6 conn, tube-m 1 1/2" x 1 1/2" 810224-150 4
7 tube 1 1/2" 90º tv/fltr 250033-663 1
8 tee 1 1/2" #150 802415-060 1
9 niple 1 1/2" npt x 3 1/2" sch 40 822124-035 1
10 valvula termostatica (III) 014512 1
11 niple 1 1/2" npt x 7" sch 40 822124-070 1
12 codo 90º 1 1/2" npt #150 S.2000 801515-060 1
13 niple 1 1/2" npt x 9" sch 40 822124-090 1
14 tube, clr/tee 250033-967 1
15 tube, 1 1/2" clr/tv 02250114-641 1
16 codo 90° 1 1/2" t x 1 1/2" npt 810524-150 2
17 buje red. 3" x 1 1/2" 807612-060 1
18 tee red. 2" x 1/2" x 1 1/2" #150 802208-026 1
19 niple 2" x 7" sch40 822132-070 1
20 buje red. 3" x 2" 807612-080 1
(I) For maintenance on oil stop valve no. 016742, order repair kit no. 001684.
(III) For maintenance on (170ºF) thermal valve no. 014512, order repair kit no. 001168.
73
Section 8
8.14 SUMP AND PARTS
DESDE
UNIDAD
COMPRESORA 4
5
6
7
8
9
10 11 12
74
Section 8
8.14 SUMP AND PARTS
key part
1 tanque separador TS20 lf 02250108-073 1

2 elemento separador secundario (I) 250034-134 1
3 elemento separador primario (II) 250034-122 1
4 gasket, asa flange (# 150) 4" 240621-010 1
5 flexible descarga uc / tanque TS20 lf 02250114-067 1
6 gasket, asa flange (# 150) 3" 240621-008 1
7 niple con brida 3" descarga uc TS20 02250114-084 1
8 soporte cañeria descarga 20/16 250033-187 1
9 adapter, straight thread with nut 02250098-809 1
10 valvula ddr 20 brz vit. 018435-003 1
11 plat adapt ddr 20 check vlv. 02250098-808 1
12 bulon u 1/2" x 3" 829008-300 1
(I) For maintenance on secondary separator element, order replacement kit no. 250034-134
(II) For maintenance on primary separator element, order replacement kit no. 250034-122
75
Section 8
8.15 SULLICON CONTROL
02250134-158R00
76
Section 8
8.15 SULLICON CONTROL
key part
1 lever, control Sullicon 011084 1

2 plunger 020094 1
3 stop, control 020864 1
4 washer, back-up (I) 021172 1
5 body, control 021635 1
6 cover, control 021654 1
7 bolt, adj sullicon spring yellow zinc 02250112-184 1
8 pin, yoke 1/4” 040065 1
9 rod-end, yoke 040138 1
10 screw, flathead countersunk (I) 041264 1
11 cup seal (I) 042538 1
12 spring, control light 250006-526 1
13 diaphragm, external (I) 250020-028 1
14 nut, hex pltd 5/16-18 825205-273 3
15 nut, hex pltd 3/8-16 825206-337 7
16 nut, hex locking 5/16-18 825505-166 1
17 pin, cotter ep-sc 1/16 x 3/4 827101-075 1
18 capscrew, ferry head hd 3/8-16 x 2 828406-200 1
19 capscr, hex gr5 5/16-18 x 2 1/4 829105-225 2
20 capscr, hex gr5 5/16-18 x 2 1/2 829105-250 1
21 capscr, hex gr5 3/8-16 x 2 1/4 829106-225 1
22 capscr, hex gr5 3/8-16 x 2 1/2 829106-250 3
23 screw, shoulder 3/8 x 2 830506-200 1
24 screw, mach-hex 5/16-24 x 2 831105-200 1
25 washer, spr lock reg pltd 5/16 837805-078 3
26 washer, spr lock reg pltd 3/8 837806-094 5
27 nut, hex jam rh pltd 5/16-24 868205-195 1
(I) This part is included in Sullicon repair kit no. 11579/N. For maintenance, order repair kit no. 11579/N
77
Section 78
Section
8.2 COMPRESSOR
8.16 U NIT TUBINGSPIRIAL VALVE
AND SPIRAL ACTUATOR
VALVE --- ALL MODELS
56
56
62
59
53
64
55
54
61
63
Y X
65
66
48
78
Section 7
ILLUSTRATIONS AND PARTS LIST8
Section
7.26 UNIT TUBING AND SPIRAL VALVE --- ALL MODELS
8.16 COMPRESSOR SPIRIAL VALVE ACTUATOR
key part
1 elbow, tube---M 3/8” x 1/8” 810506---012 1

2 tube, .38” 221083 1
3 elbow, tube---M 3/8” x 1/4” 810506---025 8
4 orifice, 1/8”M x 1/4”F x .188” 220959 2
5 tube, .38” 221081 1
6 tube, .38” 221082 1
7 connector, tube---M 3/8” x 1/4” 810206---025 4
8 tube, .038” 221080 1
9 elbow, tube---M 3/4” x 3/4” 810512---075 2
10 tube, .75” 250033---990 1
11 tee, tube union 3/8” 811406---038 1
12 tee, tube union 1/2” 811408---050 1
13 tube, .50” 250033---995 1
14 elbow, tube---M 1/2” x 1/2” 810508---050 4
15 tube, .50” 250033---994 1
16 tube, .50” 250033---993 1
17 tube, .38” 221079 1
18 manifold, .75”in x .25”out 220945 1
19 orifice, .062” x .25”M x .25”F 028831 2
21 tube, .38” 250033---991 1
22 tube, .38” 250033---992 1
23 tube, .75” 250033---989 1
25 manifold, 1.00”in x .50”out 250000---574 1
27 nipple, pipe 1” x 2” 822116---020 2
28 elbow, tube---M 3/8” x 1/2” 810506---050 2
29 manifold, 2.00”in x .50”out 250023---950 1
30 tube, .38” 250033---998 1
31 support, manifold 250023---965 1
32 capscrew, hex GR8 3/8”---16 x 3/4” 828206---075 4
33 bushing, reducing hex 1 1/4” x 1” 802105---040 1
34 tee, reducing 1” x 3/4” x 3/4” 802204---033 1
35 bushing, reducing 3/4” x 1/2” 807603---020 1
36 tube, .38” 250033---999 1
37 tube, .50” 250033---988 1
(Continued on Page 81)
79
Section 8
Section 7
8.16 COMPRESSOR SPIRIAL VALVE ACTUATOR
7.26 UNIT TUBING AND SPIRAL VALVE --- ALL MODELS
56
56
62
59
53
64
55
54
61
63
Y X
65
66
. .
48
80
58
Section 7
ILLUSTRATIONS AND PARTS LIST8
Section
7.26 COMPRESSOR
8.16 UNIT TUBING AND SPIRAL
SPIRIAL VALVE
VALVE --- ALL MODELS (Continued)
ACTUATOR
key part
38 elbow, tube---M 5/8” x 3/8” 810510---038 1

39 tube, .625” 02250055---802 1
41 orifice, 1/2”M x 1/2”F x .140” 234125---140 1
42 clamp, tube 3/4” 02250046---540 1
43 washer, springlock #10 837502---047 2
44 screw, machine round hd #10---24 x 1” 831602---100 1
45 capscrew, ferry hd 1/2”---13 x 3/4” 828408---075 1
46 support, tube 02250050---181 1
47 nut, hex #10---24 825202---130 1
48 plug, pipe 1/4” 807800---010 5
49 plug, pipe 1/2” 807800---020 4
50 spring, comp 250016---394 1
53 shaft 250027---276 1
54 nut, hex jam 824906---227 1
55 rack and gear 250016---197 1
56 cylinder, air (I) 250016---183 1
57 capscrew, socket 828906---400 1
58 capscrew, hex head 828204---050 4
59 orifice 028831 1
61 capscrew, ferry head 828405---125 3
62 spacer, (not shown) 250029---245 1
63 mount, air cylinder 250016---188 1
64 decal, warning act 250029---836 1
65 spacer 250034---302 2
66 capscr, 1/2---13 X 2 1/4 828408---225 2
(I) For maintenance on air cylinder no. 250016---183, order repair kit no. 608311---001 and actuator dia-
phragm repair tool kit no. 02250052---625.
81
Section 8
8.17A MOISTURE DRAIN - AIR COOLED - 200/250HP A
8.17B MOISTURE DRAIN - WATER COOLED - 200/250HP
2
A Desde Separador de Condensado
B A cupla drenaje condensado en Chasis
3
A
2
2
3
4
3
5 B
A Desde Aftercooler 9
B Desde Separador de Condensado
C A cupla drenaje condensado en Chasis 10
7
6
8
6
7
C
82
Section 8
8.17A MOISTURE DRAIN - AIR COOLED - 200/250HP
key part
1 buje reduccion 3/4" x 1/2" npt 804103-060 1

2 conector recto 3/8" t x 1/2" nptm 813606-500 1
3 tubo de poliamida 3/8" 250024-746 -
8.17B MOISTURE DRAIN - WATER COOLED - 200/250HP
1 niple 3/8" x 2" npt 822106-020 1

2 codo reduccion H/H 1/2" x 3/8" 801602-015 1
3 niple 1/2" x corto 822108-000 2
4 union doble 1/2" 802515-020 1
5 trampa de agua 1/2" npt 042034RA 1
6 conector recto bronce 3/8" t x 1/2" nptm 813606-500 4
7 tubo de poliamida 3/8" 250024-746 -
8 tee 1/2" npt 804415-020 1
9 buje reduccion 3/4" x 1/2" npt 804103-060 1
10 niple 1/2" x 1 1/2" npt 822108-015 1
83
Section 8
8.18 ENCLOSURE SYSTEM - AIR COOLED - 200HP
14
13
13
15
16
4
13 13
8
19
9
11
10
11 17
1
18
2 1
4
3
5
7
20
2
6
6
12
10
11
20 2
8
7
3
84
Section 8
key part
1 panel lateral portagrilla 016887 2

2 panel lateral de acceso 018922 3
3 perfil zocalo 019603 2
4 grilla cabina 249651 2
5 panel esquinero calado salida aire 270010-296 1
6 perfil inferior 20/16 250028-543 2
7 perfil inferior lateral 250022-772 2
8 panel esquinero 250028-542 2
9 panel de cierre 231568 1
10 parante de cabina 231516 2
11 puerta acceso grande 017231 3
12 puerta tablero 250024-012 1
13 angulo 1 1/4" x 2 1/4" x 47 3/4" 232876 4
14 grilla enfriador 249749 1
15 panel de techo 250028-548 1
16 panel techo ciego 250028-574 1
17 panel de cierre lado motor 230485 1
18 panel esquinero lado unidad 250028-541 1
19 puerta ventilacion de motor 270002-530 1
20 manija de puerta 000306 16
85
Section 8
14
16 16
15
4 17
16 16
7
8
9
13
12
13 19
1
18
2 1
4
3
5
20
6
2
10
11 10
12
13
20 2
7 3
86
Section 8
key part

9 panel de cierre 231568 1
10 perfil inferior 20/16 250028-543 2
14 grilla enfriador ts20-250 270009-655 1
15 techo ts20-250 conjunto 270009-640 1
16 angulo 1 1/4" x 2 1/4" x 47 3/4" 232876 4
87
Section 8
8.20 ENCLOSURE SYSTEM - WATER COOLED - 200HP
3
4
5 6
7
6 8
11
9
13 12
14
13
15 9
7
8
22 10
22
16 9 18
15
13
19
19
17 14
20
22
21
18
88
Section 8
key part
1 grilla proteccion ventilador 270001-376 1

2 panel techo TS20 calado ventilador 270004-557 1
3 ventilador 20" 270002-751 1
4 soporte grilla motor auxiliar 270002-152 1
5 motor 0,75 hp 270002-750 1
17 perfil zocalo calado conexion cuplas 270010-297 1
19 perfil inferior 20/16 250028-543 2
89
Section 8
3
4
5 6
7
6 8
11
9
13 12
14
13
15 9
7
8
22 10
22
16 9 18
15
13
19
19
14
17
20
22
21
18
90
Section 8
key part
1 grilla proteccion ventilador 270001-376 1

2 panel techo TS20 calado ventilador 270004-557 1
3 ventilador 20" 270002-751 1
4 soporte grilla motor auxiliar 270002-152 1
5 motor 0,75 hp 270002-750 1
17 perfil zocalo calado conexion cuplas 270010-769 1
19 perfil inferior 20/16 250028-543 2
91
92
LINE VOLTAGE
3PH 50/60 HZ
143 102
S L3 L2 L1
141 102
1M
Section 8
1
142 144
OIL FILTER OIL FILTER 2M
LOW PRESS HI PRESS SUPERVISOR II 8
7 MICROCONTROLLER
208 1 MOL 1 MOL 1M
P3 1 FU
P4 - - 121 122 202 206 116 117
- + S - + S
J3 J2 OPTIONAL 1M
RED RED WTH 301 CONTACTOS SECOS
1 P3 SIG RTN 18 PARA INDICACION DE
A TERMINAL DE OTRO FALLA POR TERMICO
105 141
WTH WTH 302
2 P4 SIG RS485 - 17 SUPERVISOR 6
BLK BLK 303
3 + 16
GND
RED RTD2 + W T1 2M
4 15 5 6 7
RTD2 - R DRY- SIDE DISCH T6
STAGE 2 5 14 RTD2
WTH TEMP
INLET TEMP GND R 1M
6 RTD3+ 13 R
RTD4 RED UNIT DISCH RFF
7 RTD1 - 12 R RTD1 S
RTD3- TEMP T4 1 4
WTH W S
8 RTD1 + 11 2M 101 120
RED
RTD4+ WTH
RTD3 P2 SIG 210
9 RTD4- 10
RED 209 WTH S RELE DE FALTA DE FASE
RETURN OIL TEMP 10 RTD GND P1 SIG 9 RED T2 1M
208 BORNES 5, 6 Y 7 DEL
11 RTD5- +12V 8 BLK SLIMLINE SP-430
207 RED
12 GND 7 T3
RTD5+ BLK 2M
GND 206
13 RTD6- 6 T5
9 205 20 PSID 10 - + S - + S
LWP 14 RTD6+ OIL FILTER D5 5
315 204 24"wc P1 P2 1M
15 D6 INLET FILTER D4 4
REMOTO CONTROL MODE 2M
10 PSI D3 203
16 D7 3 C
317 202 UNIT LINE 107 143
OPEN : NORMAL, CLOSED : MASTER CONTROL LOCAL/MASTER CONTROL 17 D8 D2 2 DISCH PRESS
318 201 A S
OPEN : NORMAL, CLOSED : FORCED UNLOAD REMOTE LOAD / UNLOAD 18 D9 D1 1 206
E-STOP MOTOR
319
OPEN : STOP, CLOSED : RUN REMOTE START / STOP 19 D10 105 141
COMPRESOR
320 20 J1 S
GND
FULL LOAD MODULATE
(REFER TO SUPERVISOR II SEQUENCING AND PROTOCOL SOL VALVE (OPT`L) 141 142
MANUAL 02250057-696 ) 115
15 ELECTRIC DRAIN
FULL LOAD MODULATE K6 114 115
14 SOL VALVE (OPT`L)
113
13 113
ELECTRIC DRAIN K5 112 AUDIBLE ALARM
6 CONTROL BOX HEATER 12 111 102 105
111 (OPT`L) 3M
11 LOAD CTL
COMMON FAULT K4 110
10 VALVE BY-PASS VLV. REGULADORA 109 T3
109 CLOUSED INLET SYSTEM
9
UNLOAD/LOAD K3 108 SOL VALVE (OPT´L) 107
HEAT TRACE 8 2M B B
107 143 T2
7 S 105
* DELTA K2 106 (OPT`L)
6 HCR
S
105 141 102 T1
50 WATT TRAP HEATER 5 1M 104
FILTRO ELECTRICO 02250081-029
RUN K1 104 120 1M S
4 142 144 TR
2M
E-STOP 3 MOL
3 3M
8 3M MOTOR 203 206
HCR SUMP HEATER 120V N 2
101 2 102 VENTILADOR 118 119
2 FU
AC L 1 TR
OPTIONAL
HT3 CONTACTOS SECOS
PARA INDICACION DE
6 EQUIPO EN MARCHA
8.22 WIRING DIAGRAM - AIR & WATER COOLED - 200/250HP
4 X2
HT1 HT2
TO CUSTOMER
120 VAC POWER
HEATER OPTIONS 3 FU
X1 H1
NOTAS: ESTE DIAGRAMA DE CABLEADO REEMPLAZA A LOS PLANOS: 270006-206 ; 270006-241 y 270004-657 110VAC SECONDARY
50/60 HZ
1 PROVISTO POR EL CLIENTE SEGUN LEYES LOCALES

SPIRAL CONTROL CON FULL LOAD MODULATE
SPIRAL CONTROL
(OPTIONAL)
317
318
319
320
TB3 1 CR
315
301
302
303
303
1 MOL 3 MOL LWP
2 QUITAR PUENTES PARA AGREGAR OPCIONALES SOL VLV SOL VLV
105 220 SPIRAL VLV 203 203A 206
105 102 102 202 202A 202B 202C 202D 206
REMOVER PUENTES Y CONECTAR TERMOSTATOS (OPTIONAL) 1 CR 10 PSI

3 REEMPLAZAR EN A 115 102 TERMOSTATO TERMOSTATO TERMOSTATO TERMOSTATO
MOTOR PPAL.
6 6 3 11
TB2
201
202
203
204
205
206
206
207
207
208
208
209
210
202A
4 QUITAR EN EQUIPOS LS 10-20 / 30 / 40
6 OPCIONAL
3 MOL
203 206
TB1
120
102
102
102
104
105
105
106
107
107
108
109
110
111
112
114
116
117
121
101
101
113
115
HT1
HT2
7 SOLO EN EQUIPOS CON SUPERVISOR II DLX

122
118
119
HT3
6 8
12
8 RELE DE FALTA DE FASE OPCIONAL
9 SOLO EN EQUIPOS ENFRIADOR POR AGUA
10 ELIMINAR EN EQUIPOS CON SUPERVISOR II DLX
11 REEMPLAZAR EN C SOLO EN EQUIPOS CON SUPERVISOR II STD ENFRIADOR POR AGUA
12 REEMPLAZAR EN C SOLO EN EQUIPOS CON SUPERVISOR II STD ENFRIADOR POR AIRE Y

EN EQUIPOS CON SUPERVISOR II DLX ENFRIADOR POR AIRE O AGUA
SERVICIO DE VENTA Y POST-VENTA
Goncalves Dias 1145

C 1276 ACQ Buenos Aires
Argentina
Tel: (54-11) 5941-4444
[email protected]
www.sullairargentina.com
Sullair Argentina S.A.

División Repuestos
Goncalves Dias 1145
Argentina
Tel: (54-11) 5941-4444
Fax: (54-11) 5941-4541
Sullair Argentina S.A.

División Postventa
Goncalves Dias 1145
Argentina
Tel: (54-11) 5941-4444
Fax: (54-11)5941-4544
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INDUSTRIAL ROTARY SCREW

F. Wear goggles or a full face shield when adding 1.9 LIFTING

Panel de Control Valvula

(0--50 PSI/ 0--3.5 BAR)

(50--100 PSI/ 3.5--6.9 BAR)

(100--110 PSI/ 6.9-- 7.6 BAR)

COMPRESSOR: STANDARD MODELS

MOTOR: (50 Hz Compressors) STANDARD MODELS

(I) Special compressors are available for operation at higher pressures

MOTOR: (60 Hz Compressors)

A.C., 105° F (41° C) Maximum Ambient Temperature

Starter: Full Voltage, Wye - Delta, various voltages

Speed: 1800 RPM

3.2 LUBRICATION GUIDE---STANDARD COMPRES-

Sullube 32 fluid should be changed every 8000 ! WARNING

Enfriador Conbinado Panel de Control Limite de Cabina

606,3 1828,8 606,6 27,7 1765,3 27,7

Entrada Filtro de 327,7

1820,7 Filtro de Aceite

Enfriador Conbinado Panel de Control Limite de Cabina

Entrada Filtro de 1827,3

Panel de Control Limite de Cabina Entrada Filtro de

A Entrada de Agua 1 1/2" NPT

292 Drenaje de Condensado

A Entrada de Agua 1 1/2" NPT 1827

LINEA CONTROL DE TEMPERATURA

FROST FREE TRAP L SUMP HEATER OPT

1 filter, air inlet 02250140-798 -

(Continued on page 25)

LINEA CONTROL DE TEMPERATURA

FROST FREE TRAP L SUMP HEATER OPT

35 cooler, fluid combo 200HP 02250151-822 -

51 Baja presión de agua

LINEA CONTROL DE TEMPERATURA

FROST FREE TRAP L SUMP HEATER OPT

1 filter, air inlet 02250140-798 -

(Continued on page 29)

51 Baja presión de agua

LINEA CONTROL DE TEMPERATURA

FROST FREE TRAP L SUMP HEATER OPT

35 cooler, oil 200HP 043031 -

4.1 MOUNTING OF COMPRESSOR protection where it will be exposed to temperature

Cooling Type Air---cooled Water---cooled

For information concerning all aspects of the Supervisor Controller,

CONTROL OR INDICATOR PURPOSE

Figure 7-2 Air Filter Replacement (P/N 02250140-798)

Elemento Disconnect all power at source, before attempt-

DO NOT upset the offset alignment or hub gap

7.9 TROUBLESHOOTING GUIDE

Line Fuse Blown Replace fuse.

Control Transformer Fuse Blown Replace fuse.

Replace Supervisor display module if no display

COMPRESSOR SHUTS DOWN Loss of Control Voltage Check incoming power.

Excessive Operating Pressure Check maximum P2 pressure setting.

HIGH PRESS P1 display; Max P1 pressure may

Defective solenoid valve; solenoid valve should

Defective blowdown valve; blowdown valve

Open or shorted P1, P2, P3 or P4 sender mes-

Cooler plugged; clean tubes. If plugging persists,