TS-32 02250131-544

INDUSTRIAL ROTARY SCREW AIR COMPRESSOR200-350HP/ 149-261KW AIR-COOLED & WATER-COOLED STANDARD AND 24KT OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250131-544 ©Sullair Corporation TS-32 AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are 3-day courses that provide hands-on instruction in the proper operation, maintenance and service of Sullair equipment. Individual seminars on Industrial compressors and compressor electrical systems are presented at regular intervals throughout the year at a dedicated training facility at Sullair’s corporate headquarters in Michigan City, Indiana. Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of the most common problems, and actual equipment operation. The seminars are recommended for maintenance and service personnel. For detailed course outlines, schedule and cost information contact: Sullair Corporate Training Department 1-800-SULLAIR or 219-879-5451 (ext. 5630) - Or Write Sullair Corporation 3700 E. Michigan Blvd. Michigan City, IN 46360 Attn: Service Training Department TABLE OF CONTENTS OPERATOR IS REQUIRED TO READ ENTIRE INSTRUCTION MANUAL Section 1 Page 1 1 1 2 2 2 3 3 3 4 1.1 GENERAL 1.2 PERSONAL PROTECTIVE EQUIPMENT 1.3 PRESSURE RELEASE 1.4 FIRE AND EXPLOSION 1.5 MOVING PARTS 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS 1.7 TOXIC AND IRRITATING SUBSTANCES 1.8 ELECTRICAL SHOCK 1.9 LIFTING 1.10 ENTRAPMENT SAFETY Section 2 DESCRIPTION 5 5 5 6 8 11 16 2.1 INTRODUCTION 2.2 DESCRIPTION OF COMPONENTS 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION Section 3 SPECIFICATIONS 17 17 17 17 17 18 19 3.1 SULLAIR SERIES TS-32 SPECIFICATIONS 3.2 LUBRICATION GUIDE- STANDARD COMPRESSORS 3.3 LUBRICATION GUIDE- 24KT COMPRESSORS 3.4 APPLICATION GUIDE 3.5 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE Figure 3-2A Identification- TS-32 Air-cooled 200-250HP/ 149-261KW Figure 3-2B Identification- TS-32 Water-cooled 200-250HP/ 149-261KW TEMPERATURE.PRESSURE.SEQUENCING & COMMUNICATION PARAMETERS 5.3 5.4 4.6 MOUNTING OF COMPRESSOR VENTILATION AND COOLING SERVICE AIR PIPING COUPLING ALIGNMENT CHECK FLUID LEVEL CHECK FLUID PIPING (REMOTE AIR-COOLED OPTION ONLY) 4.1 INTRODUCTION .CORRECTION FACTORS FOR PRESSURES 5.DISPLAY OF MODES OF MACHINES IN A SEQUENCING SYSTEM 5.4 SUPERVISOR KEYBOARD LAYOUT MAIN DISPLAY FUNCTION MENU STATUS.TABLE OF CONTENTS Section 3 Page 20 21 22 Figure 3-2C Identification.3 4.9 CALIBRATION.TS-32 Water-cooled 300-350HP/ 224-261KW Figure 3-3 Piping and Instrumentation SPECIFICATIONS (CONTINUED) Section 4 INSTALLATION 27 27 27 27 27 28 29 29 4.1 4.5 CONTROL PARAMETERS.Model settings. 5. INPUTS AND OUTPUTS 5.CURRENT PRESSURES.13 TROUBLESHOOTING GUIDESUPERVISOR CONTROLLER Table 5-1 Alarms Section 6 COMPRESSOR OPERATION 39 6.2 4. AND TIMER SETTINGS 5. TEMPERATURES.7 ELECTRICAL PREPARATION 4.1 5.10 FACTORY SETUP.2 5.6 MAINTENANCE.8 SYSTEM DISPLAY.11 TEST 5.12 TROUBLESHOOTING INTRODUCTION 5.TS-32 Air-cooled 300-350HP/ 224-261KW Figure 3-2D Identification.7 SEQUENCING.8 MOTOR ROTATION DIRECTION CHECK Section 5 SUPERVISOR 31 31 31 32 32 33 33 34 34 34 35 35 35 38 5.PREVENTIVE MAINTENANCE INFORMATION AND TIMERS 5.5 4. 7 FLUID COOLING SYSTEM.3 RECOMMENDED SPARE PARTS LIST300 and 350HP/ 224 and 261KW 8.6 AIR INLET SYSTEM 8.6 SEPARATOR MAINTENANCE 7.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION 7. FRAME AND PARTS.4 MOTOR. FRAME AND PARTS.5 FLUID CHANGE 7.TABLE OF CONTENTS Section 6 Page COMPRESSOR OPERATION (CONTINUED) 39 40 41 41 6.3 6.1 GENERAL 7.2 DAILY OPERATION 7.AIR-COOLED 300-350HP/ 224-261KW .9 TROUBLESHOOTING GUIDE Section 8 ILLUSTRATION AND PARTS LIST 53 53 55 56 58 60 64 8.8 FLUID COOLING SYSTEM.AIR-COOLED 200-250HP/ 149-186KW 68 8.8 TROUBLESHOOTING 7. COMPRESSOR.GEAR DRIVE 8.2 6.4 6.5 PURPOSE OF CONTROLS INITIAL START-UP PROCEDURE SUBSEQUENT START-UP PROCEDURE SHUTDOWN PROCEDURE Section 7 MAINTENANCE 43 43 43 43 43 43 43 43 44 45 46 46 46 49 49 7.5 MOTOR.4 MAINTENANCE AFTER 1000 HOURS 7. COMPRESSOR.2 RECOMMENDED SPARE PARTS LIST200 and 250HP/ 149 and 186KW 8.1 PROCEDURE FOR ORDERING PARTS 8.DIRECT DRIVE 8.7 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES MAIN FILTER MAINTENANCE AIR FILTER MAINTENANCE SEPARATOR ELEMENTS REPLACEMENT OIL RETURN/SIGHT GLASS MAINTENANCE DIFFERENTIAL PRESSURE REGULATOR ADJUSTMENT DRIVE COUPLING INSTALLATION AND ALIGNMENT (200-350HP/ 149-261KW) 7. 13 FLUID PIPING SYSTEM.28 DECALS 8.20 MOISTURE DRAIN SEPARATOR 8.12 AIR PIPING SYSTEM.32 WIRING DIAGRAM.AIR-COOLED 300-350HP/ 224-261KW 8.200-250HP/ 149-261KW 8.WATER-COOLED/WYE-DELTA 8.300-350HP/ 224-261KW 8.WATER-COOLED 200-350HP/ 149-261KW 8.AIR-COOLED 200-350HP/ 149-261KW 78 8.26 ENCLOSURE.37 WIRING DIAGRAM.31 DECAL LOCATIONS.WATER-COOLED 200-350HP/ 149-261KW 80 8.AIR-COOLED & WATER-COOLED 300-350HP/ 224-261KW 86 8.SOLID STATE 8.AIR-COOLED/SOLID STATE 8.15 FLUID PIPING SYSTEM.22 CONTROL BOX.17 SUMP AND PARTS.33 WIRING DIAGRAM.REMOTE COOLER 300-350HP/ 224-261KW 90 92 94 96 98 100 106 108 110 112 116 120 124 130 132 134 136 137 138 139 140 141 142 8.AIR-COOLED/REMOTE COOLER ILLUSTRATION AND PARTS LIST (CONTINUED) .REMOTE COOLER 300-350HP/ 224-261KW 82 8.9 WATER COOLER PIPING.AIR-COOLED 200-250HP/ 149-186KW 8.WATER-COOLED/FULL VOLTAGE 8.36 WIRING DIAGRAM.10 AIR PIPING SYSTEM.AIR-COOLED & WATER-COOLED 200-250HP/ 149-186KW 84 8.FULL VOLTAGE 8.WATER-C00LED/SOLID STATE 8.AIR-COOLED/FULL VOLTAGE 8.11 AIR PIPING SYSTEM.23 CONTROL BOX.25 ENCLOSURE.24 CONTROL BOX.30 DECAL LOCATIONS.21 PNEUMATIC CONTROLS 8.38 WIRING DIAGRAM.35 WIRING DIAGRAM.29 DECAL LOCATIONS 8.ENCLOSURE 8.WYE-DELTA 8.27 ENCLOSURE.200-250HP/ 149-186KW 8.14 FLUID PIPING SYSTEM.CONTROL BOX 8.34 WIRING DIAGRAM.TABLE OF CONTENTS Section 8 Page 72 74 8.18 SULLICON CONTROL 8.AIR-COOLED/WYE-DELTA 8.16 SUMP AND PARTS.19 COMPRESSOR ACTUATOR 8. State and Local codes. and then only with effective chip guarding and personal protective equipment. Tag the compressor and render it inoperative by disconnecting and locking out all power at source or otherwise disabling its prime mover. hose. per all applicable Federal. DO NOT tamper with sump and unit (if provided) relief valves. owners. However. The following safety precautions are offered as a guide which. Install. if conscientiously followed. and who have read and understood this Operator’s Manual. drain plug. Open fluid filler cap only when compressor is not running and is not pressurized. Check the relief valve as recommended in the Maintenance Section of this manual 1 . respiratory protective equipment. 1. fitting. protective clothing. so others who may not know of the unsafe condition. DO NOT exceed manufacturer’s rated safe operating pressures for these items. chain or other suitable retaining devices to prevent tools or hose ends from being accidentally disconnected and expelled. K. standards.1 GENERAL Sullair Corporation and its subsidiaries design and manufacture all of their products so they can be operated safely. When the hose is to be used to supply a manifold. Install an appropriate flow-limiting valve between the service air outlet and the shut-off (throttle) valve. such as eye and face protective equipment. DO NOT modify the compressor and/or controls in any way except with written factory approval. most of the precautionary statements contained herein are applicable to most compressors and the concepts behind these statements are generally applicable to all compressors. Provide an appropriate flow-limiting valve at the beginning of each additional 75 feet (23m) of hose in runs of air hose exceeding 1/2” (13mm) inside diameter to reduce pressure in case of hose failure.1 bar) for cleaning purposes. Flow-limiting valves are listed by pipe size and rated CFM. G. State and Local codes. DO NOT use air tools that are rated below the maximum rating of the compressor. use and operate the compressor only in full compliance with all pertinent regulations and all applicable Federal. Shut down the compressor and bleed the sump (receiver) to zero internal pressure before removing the cap. as well as noise exposure administrative and/or engineering controls and/or personal hearing protective equipment. and regulations relative to personal protective equipment. the responsibility for safe operation rests with those who use and maintain these products. and comply with. will minimize the possibility of accidents throughout the useful life of this equipment. J. B. Use air at pressures less than 30 psig (2. Keep personnel out of line with and away from the discharge opening of hoses or tools or other points of compressed air discharge.Section 1 SAFETY 1. Select appropriate valves accordingly. State. procedures and safety precautions in this manual can result in accidents and injuries.2 PERSONAL PROTECTIVE EQUIPMENT Prior to installing or operating the compressor. 1. DO NOT engage in horseplay with air hoses as death or serious injury may result. equipment intended to protect the extremities.3 PRESSURE RELEASE A. filters. cannot attempt to operate it until the condition is corrected. to reduce pressure in case of hose failure. Failure to follow the instructions. protective shields and barriers and electrical protective equipment. connection or other component. D. C. valves. air hoses. Select air tools. such as filters and line oilers. H. Read this manual prior to startup. DO NOT attempt to operate the compressor with a known unsafe condition. in accordance with their manufacturer’s recommendations. and before attempting to refill optional air line anti-icer systems with antifreeze compound. Secure all hose connections by wire. all applicable regulations and any applicable Federal. employers and users should become familiar with. E. and other fittings accordingly. I. standards and regulations. standards and regulations. when an air hose exceeding 1/2” (13mm) inside diameter is to be connected to the shut-off (throttle) valve. F. either at the compressor or at any other point along the air line. valve. L. While not specifically applicable to all types of compressors with all types of prime movers. pipes. Vent all internal pressure prior to opening any line. and Local codes. NEVER start the compressor unless it is safe to do so. The compressor should be operated only by those who have been trained and delegated to do so. install an additional appropriate flow-limiting valve between the manifold and each air hose exceeding 1/2” (13mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure. If necessary. flames and other sources of ignition away and DO NOT permit smoking in the vicinity when checking or adding lubricant or when refilling air line anti-icer systems with antifreeze compound. including air line anti-icer system antifreeze compound or fluid film to accumulate on. or terminals that are worn. C. Keep a first aid kit handy. DO NOT attempt to operate the compressor with the fan. M. J. Wear snug-fitting clothing and confine long hair when working around this compressor. 1. Keep hands. cut abraded or otherwise degraded insulation. feet. Avoid bodily contact with hot fluid. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or operate it. remove acoustical material. G. DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or with degraded lubricant. This is especially important when compressors are remotely controlled. 1. on or around the compressor. Any acoustical material with a protective covering that has been torn or punctured should be replaced immediately to prevent accumulation of liquids or fluid film within the material. Keep access doors. Disconnect and lock out all power at source and verify at the compressor that all circuits are deenergized to minimize the possibility of accidental start-up or operation. 1. prior to attempting repairs or adjustments. Wipe down using an aqueous industrial cleaner or steam-clean as required.4 FIRE AND EXPLOSION al that may be damaged by heat or that may support combustion and is in close proximity. floors. trash. discolored or corroded. Keep oily rags. clogged. H. hot surfaces and sharp edges and corners. hot coolant. Clean up spills of lubricant or other combustible substances immediately.Section 1 SAFETY or at a minimum of at least weekly to make sure it is not blocked. DO NOT change the factory setting of the relief valve. if any. B. Keep all parts of the body away from all points of air discharge. Keep electrical wiring.6 HOT SURFACES. Keep suitable fully charged fire extinguisher or extinguishers nearby when servicing and operating the compressor. water. Remove any acoustical material or other materi2 . clean all surfaces and then replace acoustical material. prior to attempting weld repairs. Wear personal protective equipment including gloves and head covering when working in. closed except when making repairs or adjustments. coupling or other guards removed. F. I. C. litter or other combustibles out of and away from the compressor. it is necessary to vent the relief valve to the outside of the structure or to an area of non-exposure. Seek medical assistance promptly in case of injury. D.5 MOVING PARTS A. DO NOT permit fluids. Then keep sparks. under. if any. especially when exposed to hot or moving parts. including all terminals and pressure connectors in good condition. A. D. Keep grounded and/or conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition. SHARP EDGES AND SHARP CORNERS A. E. D. or other liquids to minimize the possibility of slips and falls. remove jumpers between 16-17 & 18-19 (Dual Control Compressors) so the other compressor does not backfeed defeating the shutdown circuitry. Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the compressor or of the inside of the enclosure. or on any external surfaces of the air compressor or on internal surfaces of the enclosure. Shut off the compressor and allow it to cool. controls and walking surfaces clean and free of fluid. or around acoustical material. if such spills occur. Replace any wiring that has cracked. DO NOT attempt to operate the compressor in any classification of hazardous environment unless the compressor has been specially designed and manufactured for that duty. fans and other moving parts. B. DO NOT ignore When installing a Base Load Transfer (BLT) System. K. F. B. obstructed or otherwise disabled. G. DO NOT use flammable solvents for cleaning purposes. arms and other parts of the body and also clothing away from couplings. leaves. If the compressor is installed in an enclosed area. Keep hands. C. Keep all terminals and pressure connectors clean and tight. E. 1. F. lock out and tag all power at source so others will not inadvertently restore power. then lift by sling. so as to minimize the possibility of creating a current path through the heart. D. Make sure entire lifting. or fatal if swallowed. DO NOT use air line anti-icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems in unventilated or other confined areas. Compressors to be air lifted by helicopter must not be supported by the lifting bail but by slings instead. Disconnect. DO NOT leave the compressor unattended with open electrical enclosures. then weigh compressor before lifting. B. Dry test all shutdown circuits prior to starting the compressor after installation. Locate the compressor or provide a remote inlet so that it is not likely to ingest exhaust fumes or other toxic.8 ELECTRICAL SHOCK A. State or Local Codes or regulations. Wear goggles or a full face shield when adding antifreeze compound to air line anti-icer systems. and only by personnel that are trained. corroded or otherwise degraded members and for loose bolts or nuts prior to lifting. Care should be taken to avoid accidental ingestion and/or skin contact. B. dry and well lighted and ventilated areas only. If the compressor is provided with a lifting bail. preferably an eye specialist. Call a physician immediately.9 LIFTING A. stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system. C. 1.Section 1 SAFETY small cuts and burns as they may lead to infection. Make sure lifting hook has a functional safety latch or equivalent. Use guide ropes or equivalent to prevent twisting 3 Death or serious injury can result from inhaling compressed air without using proper safety equipment. 1. If swallowed. Attempt repairs in clean. Make all such adjustments or repairs with one hand only. induce vomiting by administering a tablespoon of salt. F. then lift by the bail provided. In any event. and tag all power at source prior to attempting repairs or adjustments to rotating machinery and prior to handling any ungrounded conductors. If air line anti-icer system antifreeze compound enters the eyes or if fumes irritate the eyes. is in good condition and has a rated capacity of at least the weight of the compressor. lift and/or handle only in full compliance with Federal. Keep all parts of the body and any hand-held tools or other conductive objects away from exposed live parts of electrical system. bent. Avoid contact with the skin or eyes and avoid breathing the fumes. including those of the National Electrical Code. rigging and supporting structure has been inspected. lock out. State and Local codes. and is fully engaged and latched on the bail or slings. Wash with soap and water in the event of skin contact. B. Maintain dry footing. harmful. E. E. DO NOT store air line anti-icer system antifreeze compound in confined areas. In the event of ingestion. Operate the compressor only in open or adequately ventilated areas.7 TOXIC AND IRRITATING SUBSTANCES A. C. and also including those relative to equipment grounding conductors. warm water until vomit is clear. Inspect points of attachment for cracked welds and for cracked. in each glass of clean. D. tained in full compliance with all applicable Federal. A physician. DO NOT use air from this compressor for respiration (breathing) except in full compliance with any Federal. noxious or corrosive fumes or substances. Consult the compressor operator’s manual lubrication section for information pertaining to compressor fluid fill. seek medical treatment promptly. should be contacted immediately. G. If necessary to do so. standards and regulations. The antifreeze compound used in air line antifreeze systems contains methanol and is toxic. qualified and delegated to do so. D. I. they should be washed with large quantities of clean water for 15 minutes. H. . C. then administer two teaspoons of baking soda in a glass of clean water. Coolants and lubricants used in this compressor are typical of the industry. This compressor should be installed and mainE. then disconnect. If no bail is provided. State and Local codes. If you are unsure of the weight. Have patient lay down and cover eyes to exclude light. DO NOT attempt to lift in high winds. as uneven floors or sudden stops may cause the compressor to tumble off. L. G. 4 . or else secure and tag the access door in the open position to avoid the possibility of others closing and possibly latching the door with personnel inside. N. Keep lift operator in constant attendance whenever compressor is suspended. J. Make sure pallet-mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them. utilize fork pockets if provided. Set compressor down only on a level surface capable of safely supporting at least its weight and its loading unit. NEVER attempt to forklift a compressor that is not secured to its pallet. O. Otherwise. When moving compressors by forklift truck. then make sure compressor is secure and well balanced on forks before attempting to raise or transport it any significant distance. if supplied. I.10 ENTRAPMENT A. If neither fork pockets or pallet are provided. 1. Make sure forklift truck forks are fully engaged and tipped back prior to lifting or transporting the compressor. K.Section 1 SAFETY or swinging of the compressor once it has been lifted clear of the ground. Keep all personnel out from under and away from the compressor whenever it is suspended. B. utilize pallet if provided. Lift compressor no higher than necessary. Make sure all personnel are out of compressor before closing and latching enclosure doors. M. DO NOT use the lifting eye bolt on the compressor motor. Forklift no higher than necessary to clear obstacles at floor level and transport and corner at minimum practical speeds. possibly causing serious injury or property damage in the process. inform other personnel before doing so. If the compressor enclosure is large enough to hold a person and if it is necessary to enter it to perform service adjustments. H. to lift the entire compressor package. F. compressor discharge system. 2. The compressor requires absolutely no inspection of its internal parts. On water-cooled models. thereby removing the heat of compression from the cooling fluid. electric motor. Both air-cooled and water-cooled versions have easily accessible items such as the fluid filters and control valves. The inlet air filters are also mounted for easy access and servicing. fluid is piped into a watercooled heat exchanger where the heat of compression is removed from the fluid. The complete package includes compressor. a fan draws air over the fan motor and forces it through the combined aftercooler and fluid cooler. the Sullair rotary screw is unique in its mechanical reliability and lack of “wear”. A fan is used to supply sufficient ventilating air to compressors equipped with an optional enclosure.3 SULLAIR COMPRESSOR UNIT. Your new Sullair lubricated rotary screw air compressor provides you with a unique experience in improved reliability and greatly reduced maintenance. positive displacement fluid lubricated-type compressor. capacity control system and Supervisor ControllerTM. Compared to other types of compressors. 2.1 INTRODUCTION Refer to Figures 2-1A and 2-1B. FUNCTIONAL DESCRIPTION Sullair tandem air compressors feature the Sullair compressor unit.2 DESCRIPTION OF COMPONENTS Refer to Figures 2-1A and 2-1B. microprocessor system and starter all mounted on a structural steel frame On air-cooled models. compressor cooling and lubrication system. This unit Figure 2-1A Sullair Series TS-32 Rotary Screw Compressor (Air-cooled Version) 5 . call your nearest Sullair representative or the Sullair Corporation Service Department. The components and assemblies of the air compressors are clearly shown. a two-stage. Should any questions arise which cannot be answered in this text. you will notice the easy process of caring and maintaining this Sullair manufactured product. By reading through Section 6. compressor inlet system.Section 2 DESCRIPTION 2. The pressure in the receiver/sump causes fluid flow by forcing the fluid from the high pressure area of the sump to an area of lower pressure in the compressor unit. The thermal valve is fully open to the compressor unit when the discharge temperature is below 170°F (77°C) for all compressors. The fluid flow has three basic functions: 1. 2. 2-4A. which is fully open up to 195°F (91°C). which is an idler. the air flows to the service line and the fluid is cooled in preparation for reinjection. Fluid is injected into the compressor unit where it mixes directly with the air as the internal rotors turn. The cooling and lubrication system consists of a fluid cooler. As coolant. the main fluid filter and directly to the compressor unit. fluid stop valve. After the air/fluid mixture is discharged from the compressor unit. compressing the air. due to the heat of compression.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM. At this time. 2-3B. 2-5B. 3. the fluid is separated from the air. the fluid stop valve. the thermal valve begins to close and a portion of the fluid then flows through the cooler. full flow fluid filter. FUNCTIONAL DESCRIPTION Refer to Figures 2-2. it controls the rise of air temperature normally associated with the heat of compression. except water-cooled 24KT models. 2-4B.Section 2 DESCRIPTION Figure 2-1B Sullair Series TS-32 Rotary Screw Compressor (Water-cooled Version) provides continuous air compression to meet your needs. Acts as a lubricating film between the rotors allowing one rotor to directly drive the other. there is no maintenance or inspection of the internal parts of the compressor unit permitted in accordance with the terms of the warranty. 2-5C and 2-5D. thermal valve. As the discharge temperature rises above 170°F (77°C) for all compressors (195°F [91°C] for watercooled 24KT models). 6 . Seals the leakage paths between the rotors and the stator and also between the rotors themselves. The fluid passes through the thermal valve. 2. 2-5A. From the With a Sullair compressor. 2-3A. Fluid flows from the receiver/sump to the thermal valve. 225KW) 7 . 187.Section 2 DESCRIPTION Figure 2-2 Compressor Piping and Instrument Diagram (200. 250. 300HP/ 150. 2-4A and 2-4B. Water-cooled models have a water pressure switch to prevent operation with inadequate water pressure. On shutdown. Two return lines (or scavenge tubes) lead from the bottom of each separator element to the low pressure inlet region of the compressor unit. The receiver has three functions: 1. the fluid stop valve is held open by air pressure from the compressor unit allowing a free flow of fluid from the receiver/sump back to the compressor unit. When the compressor is operating. and on to the compressor unit. The compressor unit discharges the compressed air/fluid 8 mixture through a discharge check valve into the combination receiver/sump. Fluid col- . The compressed air/fluid mixture enters the receiver and is directed against an internal baffle. The fractional percentage of fluid remaining in the compressed air collects on the surface of the nested separator elements (primary and secondary) as the compressed air flows through them. FUNCTIONAL DESCRIPTION Refer to Figures 2-2. It serves as the compressor fluid sump. 3. thus causing the large droplets of fluid to fall to the bottom of the receiver/sump.Section 2 DESCRIPTION Figure 2-3A Compressor Cooling and Lubrication System (300-350HP/ 224-261KW Air-cooled) cooler. causing the fluid stop valve to close and isolate the compressor unit from the cooling system. The direction of movement is changed and its velocity significantly reduced. It houses the final fluid/air separator elements. The discharge check valve prevents air/fluid in the receiver from returning to the compression chamber after the compressor has been shut down. the fluid flows to the main filter. the compressor unit pressure is reduced. It acts as a primary fluid separator. The fluid filter has a replacement element and an integral pressure bypass valve. 2. the fluid stop valve. 2.5 COMPRESSOR DISCHARGE SYSTEM. The fluid stop valve prevents fluid from filling the compressor unit when the compressor is shut down. A temperature switch will shut down the compressor if the discharge temperature reaches 235°F (113°C). The receiver is an ASME pressure vessel. located downstream from the separator. All Sullair compressor models are equipped with high pressure shutdown protection to shut down the compressor at 20-35psi above rated pressure. A combination minimum pressure/check valve. plugs. or greater. DO NOT remove caps.4 bar) during full load operation. assures a minimum receiver pressure of 50 psig (3.7 bar). This pressure is necessary for proper air/fluid separation and proper fluid circulation while supplying air to the system. the operator will be told to service the separator elements. At a differential of 10 PSIG (0. A pressure relief valve (located on the wet side of the separator) is set to open if the sump pressure exceeds the rated pressure of the tank. Two sight glasses enables Figure 2-3B Compressor Cooling and Lubrication System (300-350HP/ 224-261KW Water-cooled) 9 . This valve also acts as a check valve preventing compressed air in the service line from bleeding back into the receiver on shutdown and during operation of the compressor in an unloaded condition. This prevents the pressure relief valve from opening under normal conditions. dP1 on the Supervisor ControllerTM microprocessor control monitors the condition of the separator elements by reading the differential pressure on the digital display. Sight glasses are located in the return lines to observe this fluid flow. Stop compressor and relieve all internal pressure before doing so. Fluid is added to the sump via a capped fluid filler opening.Section 2 DESCRIPTION lecting on the bottom of each separator is returned to the compressor by a pressure difference between the receiver and the compressor inlet. separator element replacement is necessary. and/or other components when compressor is running or pressurized. At this time. placed low on the receiver tank to prevent over-filling of the sump. thereby preventing fluid loss through the pressure relief valve. Section 2 DESCRIPTION Figure 2-4A Compressor Discharge System (200-350HP/ 149-261KW Air-cooled) Figure 2-4B Compressor Discharge System (200-350HP/ 149-261KW Water-cooled) 10 . This results in a rotary motion. the line pressure will rise above 100 psig (6. Supervisor energizes the solenoid valve allowing the air pressure behind the Sullicon Control to be vented through the solenoid valve exhaust port. FUNCTIONAL DESCRIPTION Refer to Figures 2-5A.6 bar). allowing compressed air to flow into the service line. A compressor with any other pressure range would operate in the same manner except for the stated pressures. The spring on the control holds the butterfly valve fully open while the spiral valve is fully closed (maximum) position and the compressor pumps at full rated capacity.4 to 7. Air pressure at the actuator expands the diaphragm.9 TO 7. 2. During this range.1 bar) which results in low horsepower consumption. This reduces the sump pressure to approximately 30 psig (2.4 TO 6. The inlet butterfly valve provides modulation range from 50 to 40%. The rising compressor air pressure is isolated from the service line in this phase by the minimum pressure valve set at approximately 50 psig (3. the spiral valve remains in the full open position. During this period. Both the spiral valve as well as the inlet butterfly valve remain in the full load position as long as the compressor is running at 100 psig (6. MODULATION . As the spiral valve rotates. The rack. When the line pressure drops back to 100 psig (6. Both the spiral valve and the butterfly valve remain in the unload position.9 bar) due to an increase in the air demand. The capacity control system consists of a spiral valve and an inlet butterfly valve.9 bar) or below.0 TO 50 PSIG (0 TO 3. The blowdown valve closes.6 BAR) As air demand drops below the rated capacity of the compressor. From this point on. applying air pressure to the spiral valve actuator. 2-5C and 2-5D. engages with the pinion mounted on the spiral valve shaft assembly. the line air pressure is continually monitored by the Supervisor. The following applies to TS-32 Series compressors ranging from 200 through 350HP.4 bar). the spiral valve keeps opening more and more until all the bypass ports are fully open.4 bar). UNLOAD MODE .6 bar). this description applies to any compressor with an operating range of 100 to 110 psig (6.6 BAR) When a relatively small amount or no air is being used. both of the pressure regulators and the solenoid valve are closed and the Sullicon Control and spiral valve are inoperative. During this period.9 bar).4 bar).4 BAR) When the compressor (ON) pad is depressed. it starts opening the bypass ports gradually. At this point. START MODE .6 CONTROL SYSTEM. the differential pressure regulator controlling the Sullicon Control opens. The functional description of the control system is described below in 4 distinct phases of compressor operation. For explanatory purposes. the minimum pressure valve opens. As air demand keeps dropping further.9 to 7.100 TO 110 PSIG (6.4 bar).4 bar). The spiral valve provides a modulation range from 100 to approximately 50%. Simultaneously. Excess air is then being returned back internally to suction end of compressor unit. the pressure rises approximately from 100 to 108 psig (6. and the inlet butterfly 11 .9 BAR) When the compressed air pressure in the sump rises above 50 psig (3. The pressure regulators and the solenoid valve remain closed during this phase. the pressure rises approximately from 108 to 110 psig (7. As a result. Supervisor deenergizes the solenoid valve allowing line pressure to be supplied directly to the Sullicon diaphragm keeping the inlet butterfly closed.IN EXCESS OF 110 PSIG (7.6 bar). keeping the Sullicon Control and spiral valve inactive.9 to 7. This allows the air pressure to expand the diaphragm chamber of the Sullicon Control. FULL LOAD MODE . the differential pressure regulator for the spiral valve gradually opens. Now the compressor is fully compressing only that amount of air which is being used. the spiral valve is in the fully open (minimum) position. 2-5B. The purpose of the compressor control system is to regulate the amount of air being compressed to match the amount of compressed air being used. the spiral valve has moved into the minimum position. which starts partially closing the inlet butterfly valve.Section 2 DESCRIPTION the operator to visually monitor the sump fluid level. When it exceeds 110 psig (7. the solenoid valve sends a pneumatic signal to the blowdown valve.50 TO 100 PSIG (3. During this period. in turn. The check valve in the air service line prevents line pressure from returning to sump while the compressor is running in the unloaded mode. the sump pressure will quickly rise from 0 to 50 psig (0 to 3. A standard closed inlet system is provided which uses air pressure to close the butterfly and opens the spiral valve to reduce motor torque for starting. As the air pressure exceeds 108 psig (7. the service line pressure continues to rise. The blowdown valve opens the sump to the atmosphere. START (200-350HP/ 149-261KW) 12 .Section 2 DESCRIPTION Figure 2-5A Control System. Section 2 DESCRIPTION Figure 2-5B Control System MODULATION (200-350HP/ 149-261KW) 13 . Section 2 DESCRIPTION Figure 2-5C Control System.UNLOAD (200-350HP/ 149-261KW) 14 . FULL LOAD (200-350HP/ 149-261KW) 15 .Section 2 DESCRIPTION Figure 2-5D Control System. The vacuum switch. When the message “AIR FILTER MAINT RQD” is displayed. LOAD/ NO LOAD OPERATION If applications call for load/no load operation. modulation can be disabled in the Supervisor ControllerTM in the “Control Parameters” menu. located in the compressor Supervisor control system. 16 . AUTOMATIC OPERATION For applications with varied periods of time when there are no air requirements. FUNCTIONAL DESCRIPTION Refer to Figure 2-6. a vacuum switch and an air inlet valve. indicates the condition of the air filter. 2. an L model rated for 100 psig full load operation and 110 psig unload must have the unload pressure reset to 100 psig. This ensures that the motor will not run in an overload condition.6). For example. The butterfly-type air inlet valve directly controls the amount of air intake to the compressor in response to the operation of the Sullicon Control (Section 2. If modulation is disabled. Also the air pressure at the spiral valve actuator diaphragm is reduced through a vent hole at the spiral valve differential pressure regulator. Supervisor’s Auto mode allows the compressor to shut down (time delayed) when no compressed air requirement is present and restart as compressed air is needed. The compressor inlet system consists of one or two dry-type air filters.maintenance is required.7 AIR INLET SYSTEM. and a spring in the actuator causes the spiral valve to return to the full load (maximum) position.Section 2 DESCRIPTION Figure 2-6 Compressor Air Inlet System valve opens. the unload pressure must be reset to the rated load pressure of the machine. corrosive gases or strong oxidizing gases are present in the air. such as high ambient temperatures coupled with high humidity.3 bar). C Sullube fluid should be changed every 8000 hours or once a year.24KT COMPRESSORS See Figure 3-1. 3. Sullair TS-32 Series standard compressors are filled with Sullube fluid as factory fill. after the first year.Every 1000 hours. C . 3. B SEPARATOR CHANGE A.When measured pressure loss exceeds 20 psig (1. Sullair recommends that 24KT sample be taken at the first filter change and sent to the factory for analysis. Contact your Sullair dealer for details.When required by fluid analysis or known contamination. Maintenance of all other components is still recommended as indicated in the Maintenance section of this manual. consult Sullair Factory Sales Department. F. This is a free service. or when high particulate level. D FLUID FILTER CHANGE F./18 cm for enclosure. use only Sullair 24KT fluid. The fluid should be changed more frequently under severe operating conditions.2 LUBRICATION GUIDE-STANDARD COMPRESSORS Refer to Figure 3-1. D .7 bar).4 APPLICATION GUIDE Sullair encourages the user to participate in a fluid analysis program with the fluid suppliers. Mixing of other lubricants within the compressor unit will void all warranties.5 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE LUBRICANT Sullube 24KT FLUID CHANGE A. For noise level information.Does not require replacement during normal service conditions.When measured pressure loss exceeds 10 psig (0. A . please contact the Sullair Factory Service Department.000 Hours or once a year B . 17 . 3./70 cm (200-350HP/149-261KW) for servicing the separator. E . This could result in a fluid change interval differing from that stated in the manual. A 24KT sample should be sent in annually.1 SULLAIR SERIES TS-32 SPECIFICATIONS 60 HZ MODEL (AC & WC) LENGTH (IN) 154 50Hz MODEL (AC & WC) LENGTH (CM) 392 WIDTH (IN) 78 WIDTH (CM) 198 HEIGHT (I) (IN) 86 HEIGHT (I) (CM) 218 WEIGHT (LB) (II) WEIGHT (KG) (II) (I) Add 7 in.3 LUBRICATION GUIDE. B F. D E. In the event a change of fluid or make-up fluid is required. Figure 3-1 Fluid Fill Location Mixing of other lubricants within the compressor unit will void all warranties. 3.8. C A. The user will receive an analysis report with recommendations. (II) For data on package weights. A sample kit with instructions and self addressed container is to supplied by your Sullair representative at start-up. Add 27. whichever comes first. Sullair 24KT compressors are filled with a lubricant which rarely ever needs to be changed.5 in.Section 3 SPECIFICATIONS 3. Section 3 SPECIFICATIONS Figure 3-2A Identification.TS-32 Air-cooled 200-250HP/ 149-186KW 02250126-371R00 18 . Section 3 SPECIFICATIONS Figure 3-2B Identification.TS-32 Water-cooled 200-250HP/ 149-186KW 02250134-047R01 19 . TS-32 Air-cooled 300-350HP/ 224-261KW 02250126-376R01 20 .Section 3 SPECIFICATIONS Figure 3-2C Identification. Section 3 SPECIFICATIONS Figure 3-2D Identification.TS-32 Water-cooled 300-350HP/ 224-261KW 02250126-378R01 21 . Section 3 SPECIFICATIONS Figure 3-3 Piping and Instrumentation DERIVED FROM: 02250133-234R3 22 . Section 3 SPECIFICATIONS Figure 3-3 Piping and Instrumentation key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 part number 250006-718 02250126 -220 011682-003 408893 406929 02250125-657 02250112 -032 408275 02250125-774 02250101-191 409783 047226 02250125 -679 02250078-933 02250125-776 02250126 -129 02250117-782 250033-821 041111 250034-129 250034-123 02250117-009 02250044-985 02250092 -138 02250048-966 (Continued on page 25) description filter, assy air inlet (heavy duty) vlv , inlet butterfly 10" control, sullicon ls25s vlv, shuttle 1 /4" vlv, spiral vlv, diff. press. reg. 1/4" npt vlv, sol 3w no 1/4" 115v ac filter, control 1 /4" npt vlv, press. reg. orifice, .032" orifice, .03" vlv, blowdown 1/2" nc 2-way heater, sump vlv , solenoid 1 /4" 2 -way pressure transducer n4 orifice, .094 glass, sight 1 /4" strainer, in line sae vlv, min. press. check 3" npt vlv, moisture bleed element, secondary separator element, primary separator gauge, pressure probe, 100 ohm rtd 20' vlv, relief 1/2" 150psi vlv, relief 1 -1/2" 210# quantity 1 1 1 2 1 1 1 2 1 1 1 1 1 2 4 1 2 2 1 1 1 1 1 4 1 1 23 Section 3 SPECIFICATIONS Figure 3-3 Piping and Instrumentation 02250133-234R3 24 Section 3 SPECIFICATIONS Figure 3-3 Piping and Instrumentation (continued) key number 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 part number 02250132-854 02250097-611 02250125-221 250029-330 242221 02250127-962 02250128-717 042034 02250122-217 02250133-021 02250111-105 02250122-004 047117 02250078-249 02250087-631 02250125-657 02250110-557 046556 02250117-009 description tank, fluid sep. glass, fluid level sight vlv, ball 3/4" vlv, relief 60# 2" x 2 -1/2" tank, accumulator 415 cu. in. vlv, thermal assy w/sae ports filter, fluid trap, condensate 3/4" cooler, fluid w/1-7/s"-12 sae oil ports aftercooler, air to air separator, combo trap vlv, oil stop w/sae ports vlv,ball 1/2" npt switch, v ac. 22" w. c. n4 heater, moisture separator unit, compressor vlv, sol 3w no 1/4" sequencing vlv, check 1/4" regulator,press 2-150# ga,air press 0-200psi quantity 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 25 NOTES 26 . and rigid enough to maintain the compressor frame level and the compressor in alignment is required.4 COUPLING ALIGNMENT CHECK In preparation for the factory test. Water flow rates will vary with operating conditions. consult your local Sullair representative. Refer to Coupling Alignment procedure explained in the Maintenance section of this manual. 4. The level is checked by looking at the sight glass located on the sump.000 31. To prevent excessive ambient temperature rise.2 bar). it is necessary to recheck the coupling alignment.000 AIR FLOW CFM 18. After the compressor package has been mounted to a foundation. Table 4-1 Ventilation Requirements WATER COOLED OR REMOTE COOLED COMPRESSOR PACKAGE MODEL TS-32-200 TS-32-250 TS-32-300 TS-32-350 MOTOR HP/KW 200/150 250/187 300/225 350/260 HEAT REJECTION BTU/HR 47. The compressor frame must be leveled and secured with foundation bolts. 4. It is recommended that the frame be grouted to the foundation.170 74. This heat must be removed to assure a normal operating temperature. The water system must be capable of supplying the following flows: MODEL-HP/KW TS-32 TS-32 TS-32 TS-32 200HP/150KW 250HP/187KW 300HP/225KW 350HP/260KW WATER FLOW (GPM) 45 54 65 76 Table 4-1 Ventilation Requirements below indicates the ventilation requirements necessary to keep the compressor running at a normal operating temperature.360 64. it is necessary to check the cooling water supply.000 (I) Applicable to air-cooled models only. The minimum distance that the compressor should be from surrounding walls is three (3) feet (914mm).620 57. the coolant level should fill 1/2 of the upper sight glass when the Water flow requirements are based on 80°F to 85°F (27°C to 29°C) water inlet temperature. No piping loads shall be transmitted to the compressor or the cooling package at the external connections. Also notice that the service line should be equipped with water legs and condensate drains throughout the system. If the sump is properly filled. it is imperative to provide adequate ventilation. the coupling supplied with your compressor is properly aligned for operation. For rates based on criteria other than that listed.3 SERVICE AIR PIPING Service air piping should be installed as shown in Figure 4-1. select a location to permit sufficient unobstructed air to flow in and out of the compressor cooling package to keep the operating temperature stable. The fan air requirement is the volume of air which must flow through the compressor and/or cooling package for proper ventilation. DO NOT install a water-cooled or an aircooled/aftercooled compressor without adequate freeze protection where it will be exposed to temperature less than 32°F(0°C). 4. For water-cooled compressors.100 929. The specified heat rejection requirement is the amount of heat that is radiated by the compressor. A shut-off valve should be installed to isolate a compressor from the service line if required. it is necessary to check the fluid level at installation. With air-cooled compressors it is possible to use this heat for space heating.2 VENTILATION AND COOLING For air-cooled compressors. 4. (II) Applicable to compressors with enclosure.Section 4 INSTALLATION 4.320 VENT FAN FLOW (II) CFM 4150 4150 4150 4150 AIR-COOLED (I) COOLING PACKAGE HEAT REJECTION BTU/HR 560. Recommended water pressure range is 40 to 75 psig (2. The compressor unit and driver must be aligned after installation as specified in the Operator’s Manual.5 FLUID LEVEL CHECK Your air compressor is also supplied with the proper amount of fluid. providing excessive pressure drop is not created across the fan.8 to 5. However.000 28. and full uniform contact must be maintained between the frame and foundation.1 MOUNTING OF COMPRESSOR A foundation or mounting capable of supporting the weight of the compressor.000 18. Consult a Sullair office for assistance in utilizing this heat.800 802. 27 .200 674. fluid must be added. the fluid necessary to fill the supply and return piping for the fluid cooler is not part of the standard scope of supply for the compressor. When the oil level falls below the center of the lower sight glass. a pump should be installed. If the pressure drop is in excess of 10 psig (0.Section 4 INSTALLATION Figure 4-1 Service Air Piping (Typical Installation) compressor is shutdown. a 1/2”(13 mm) de-pressurization line must be installed between the top of the fluid cooler and the sump tank connection which is located on the fluid supply and return line connection bracket. The fluid necessary to fill this piping may be ordered from the nearest Sullair representative or the representative from whom the .7 bar). Consult the Sullair Service Department for recommendations. Because of the variability in installations. This line must be maintained at a higher level than the supply and return piping for the fluid cooler.7 bar)at the worst case operating condition (usually lowest ambient). The total pressure drop in the supply and return piping and associated fittings and valves shall not exceed 10 psig (0. 4.6 FLUID PIPING (REMOTE AIR-COOLED OPTION ONLY) To allow de-pressurization of the cooling package and connecting piping between the compressor and the cooling package upon shutdown of the compressor. It is recommended that shutoff valves be installed in the supply and return piping to facilitate compressor component’s maintenance. The supply and return piping for the fluid cooler must be adequately sized to prevent excessive 28 pressure drop. before opening or servicing starter or control panel. fuse disconnects.8MM OF PIPE . If the motor shaft is not turning in the proper direction. press the and pads in succession to bump start the compressor. 5.39 . the following chart may be used. “DRY RUN” the electrical controls by disconnecting the three (3) motor leads from the starter. 4.57 3. National Electrical Code. but should be by a qualified electrician in compliance with OSHA. it is necessary to check the direction of the motor rotation. 2. Lethal shock hazard inside. the shaft should be turning clockwise on all gear driven models. 29 . When looking at the motor from the end opposite the compressor unit.7 ELECTRICAL PREPARATION Interior electrical wiring is performed at the factory. With the control system in MANUAL mode.48 1. Disconnect all power at source. A “Direction of Rotation” decal is located on the coupling guard between the motor and compressor to show proper motor/compressor rotation. and counterclockwise on direct drive models. PIPE SIZE 2 2 1/2 3 4 6 GALLONS/LITERS OF FLUID PER 12 INCHES/304.6542/2.1635/. then recheck rotation. A few electrical checks should be made to help assure that the first start-up will be trouble free. 1. 4. a dry run will only indicate compressor overload when machine has this type of starter.8 MOTOR ROTATION DIRECTION CHECK After the electrical wiring has been done. and any other applicable state or local electrical code concerning isolation switches. disconnect the power to the starter and exchange any two of the three power input leads. as explained in Section 4. Pull out the EMERGENCY STOP button on the control panel and press . To assist in determining the amount of fluid necessary to fill the piping. Required customer wiring is minimal.2555/.97 .4719/5. Since some solid state starters have built-in power monitoring.Section 4 INSTALLATION compressor was purchased.368/1. Check all electrical connections for tightness. Check starter and overload heater sizes (see Electrical Parts in Parts Manual).8. 4. Be sure that the incoming voltage is the same voltage that the compressor was wired for.62 . Check incoming voltage. etc. Sullair provides a wiring diagram for use by the installer. Reconnect the three (3) motor leads and jog the motor for a direction of rotation check. Section 5 SUPERVISOR Figure 5-1 Supervisor Control Panel 30 . Full Load . Stopped .Correction factors for pressures. Unloaded . The Display module has eleven keys grouped in two rows. Calibration .Model settings. or start and end an edit on a parameter The bottom row has four keys : . or auxiliary estop present. Sensor Log .Used to change numbers or text. . pushing the enter key will fix the 31 . This can be used to disable sequencing. If the function displays parameters.Machine state : E-Stop . loaded and modulating. Seq Stop . Maintenance .Stop button pressed.Section 5 SUPERVISOR 5. inputs and outputs.Stop.Used to edit text or numbers (move cursor right). Clears warnings if machine is running. Factory Setup .Used to select an item from a menu. . blank means no fault or warning is present. stops machine. use the up and down arrow keys to scroll to the desired function as indicated on last line of display.3 FUNCTION MENU While in the main display. Sequencing .Machine running. . The function menu has the following entries : Status . .Compressor is off but armed to start.Used to change numbers or text. Line 2 . NOTE: the machine may start at any time. if any of the arrow keys are pressed.T1 . The value can be changed by using the up arrow or down arrow keys. To change a value.Current pressures.Preventive maintenance information and timers. . The machine will start when the remote start contact is closed.Fault or Warning. -Toggles Local/Remote mode.Machine running unloaded.Line pressure Line 4 .Display of modes of machines in a sequencing system.Sequencing parameters. NOTE : the machine may start at any time. 5. . When editing is finished. The top row has the following seven keys : .P2 . Loaded . If an alarm is active. scroll to the line to be changed using the up arrow and down arrow keys. Control Parameters .Machine forced to full load.Log of sensor readings leading up to a fault. -Used to edit text or numbers (move cursor left). and push the enter button. used to display possible causes of and correction for an alarm or fault. starts machine. After entering a function.2 MAIN DISPLAY Line 1 .Compressor is off but armed to start. System Display . .E. then press the enter key. pressing the ‘?’ key will give troubleshooting information on that alarm. or scroll. the function menu is displayed. Test . Clears fault and warning if machine is stopped. This menu is used to view status or edit parameters. Remote Stop .Used by Sullair personnel for troubleshooting To select a function.Help key. then the values can be changed. temperatures.Toggles auto mode. The machine will start when the sequencing conditions meet the criteria to start. the information can be viewed by using the up and down arrow keys.Returns to main display.Machine not running.Pressure and temperature and timer settings.Discharge Temperature 5.1 SUPERVISOR KEYBOARD LAYOUT Refer to Figure 5-1. If there are multiple alarms.Log of previous faults. or scroll. If the function shows status then values cannot be changed. and conditions have been eliminated. Fault Log .Run. they will be shown for 2 seconds each. Line 3 . Be sure to depress the Emergency Stop button to defeat this function when automatic start is to be prevented. kpa) units.5 CONTROL PARAMETERS .6bar) and the load differential is set to 10 psid (0. T1Discharge) along with the selected temperature (C or F) or pressure (psi. This parameter is used to keep several machines from starting at the same time after power up. and the up arrow key used to increment the digit to 5.6 bar) the machine will unload when the line pressure is above 110 psi (7.Number of load/unload cycles Starts .If the machine is running in AUTO mode. which is not controlled or monitored by the Supervisor. Unload pressure . For example if the unload pressure is set to 110 psi (7.K1 through K8. Aux E-Stop . TEMPERA TURES. Unload Time . the machine will not automatically start after power up. Push the enter key to complete the edit. Drain Time . wired by customer. the machine will load when the line pressure goes below 100 psi (6. Disable by setting to zero (0)-full voltage start (standard for full voltage start). If the time is set less than 15 minutes (for example 5).P1 through P4 depending on model Delta pressures . this parameter and the following parameter (Drain Time) are used to turn on the drain. then use the up and down arrow to change the letter. Drain Interval . then the machine will be enabled to start after 10 seconds.Number of time machine has started E-Stop String .Auxiliary E-Stop. the left arrow key can be used to position the cursor to the 1 digit in the 100.dp1 through dp3 depending on model Load Hours .6 bar). Restart time - Time to wait after power up before starting machine. The interval is the time between activations of the drain and the Drain Time is the length of the time energized. Text fields can also be edited in the same manner.7 bar). Load delta . this parameter specifies the amount of time that the machine will run unloaded before shutting off. Wye to delta transition timer . there may be times when the machine will run unloaded for more than 5 minutes. Digital inputs and outputs are shown either as a ‘0’ (zero) or ‘1’ (one). INPUTS AND OUTPUTS All inputs and outputs are displayed showing both the designator and the description (eg.E-Stop push button.The pressure differential below the unload pressure where the machine is loaded. The following are detailed descriptions of the various displays.CURRENT PRESSURES. use the left and right arrow keys to move to the letter to be changed. depending on model 5. These parameters may vary by machine model. depending on model Relay Outputs . If disabled parameter is zero. the machine restarts after a delay defined by this time. For example to change a value from 100 to 500. 5. This is a view only display. The left and right arrow keys can be used to move to other digits or letters in a value. Push the enter key to start the edit.4 STATUS . TEMPERATURE AND TIMER SETTINGS Parameters that control the operation of the machine are viewed and set using this display. Digital Inputs . or to delay start until other equipment is started. The order of display is : Temperatures .PRESSURE.If set to “No” the spiral valve and inlet valve modulation control are disabled.Also used to control the closed inlet start valve.Hours machine has run loaded or unloaded Load Cycles . editing is terminated and the original value is reset.The pressure where the machine is unloaded.Length of time that drain is energized.9 bar).Hours machine has run loaded Run Hours .D1 through D10. If during a change the ESC key is pushed.T1 through T5 depending on model Pressures . For example. If this parameter is a number larger than zero.If the machine has an optional electric solenoid drain. bar. and the . Requires approximately 4-6 seconds for wyedelta or solid state starting. This is because there is another timer that keeps the machine from being started more than four times an hour.Section 5 SUPERVISOR value. This does not apply to the Sullair SCD zero loss drain. Zero is off and one is on. For example if this parameter is set to 110 psi (7. if the Restart Time is set to 10 seconds. Modulate . The Control Parameters are : 32 Enabling this function also enables automatic restart after power recovery. Hours before oil analysis These hours and part numbers can be changed using the enter and arrow keys. For example if a low pressure condition causes a machine to start. P3 & P4. There is a second set of readings for T3.Pressure units may be set to psi.Hours before oil change PN .This is the total number of machines connected to the network (RS-485 channel).Uses the Seq Hrs parameter to determine order of sequencing Number .Primary separator part number Air Filter hours . For example a distributor can put in his name and telephone number. Low Press .Uses the Com Number to determine order of sequencing Seq Hrs . The top line shows the last fault.Log of sensor readings leading up to a fault. when the function is entered the most recent fault is displayed. Press Units . Oil Filter hours . German.Log of previous faults.The top two lines may be changed to advise what to do when there is a maintenance warning. Language select .Section 5 SUPERVISOR machine runs load/ no load.Communications number. (ie. Temp Units . Information . unload pressure must be reset to the rated load pressure of the machine. Machines . Italian and French may be selected for display language. Remote Load/Unload and Local/Master inputs Hours . This ensures that the motor will not overload. The following lines show T1.PREVENTIVE MAINTENANCE INFORMATION AND TIMERS The following lines are on the Maintenance display. a warning is issued. When two or more machines are connected together using the network (RS-485 channel).SEQUENCING & COMMUNICATION PARAMETERS Sequencing requires an optional communications module. the next machine will not start unless the Recovery Time has elapsed. Each hour that the machine is running increments this counter. The fault log shows the last 16 faults that occurred. These must be assigned in numerical order. 5.Oil part number Oil Anal. Sensor Log . Com Number . P1 & P2. 5. the machine with the least amount of Seq Hrs is started first. T4.Sequencing mode can be set to: Disabled . Remote .Control does not do any sequencing. . They are ordered by most recent first.This is an hour counter used when the ‘Sequence By’ parameter is set to ‘Hours’. When then ‘Sequence By’ parameter is set to ‘Hours’. For example in a three machine system the machine communications numbers should be 1. Each line represents readings that are 5 seconds apart for one minute.Hours before oil filter change PN . . Pressing the down arrow displays the next fault etc). this parameter should be set to 3. For more details on sequencing see the Supervisor Sequencing and Protocol Manual.6 MAINTENANCE . Sequence By .This is the lowest pressure allowed before immediately starting a machine.This parameter keeps multiple machines from loading. and the second line shows the fault.Temperature units may be set to degrees F or degrees C.English.7 SEQUENCING . The faults can be scrolled through using the up and down arrow keys. T2.2 & 3. No . Fault Log .Hours before separator change Prim.Oil Filter part number Separator hours . 33 . unloading and starting at the same time. . For example in a three machine system. each machine must have a unique number or address. The sensor log shows the sensor readings leading up to a fault. or kPa.When any one of the following drop below this number. bar. The top line of the display shows the run hours where the fault occurred. then one minute apart for 10 minutes. The following parameters can be viewed and edited.Secondary air filter part number Oil hours .Enables Remote Start/Stop.Hours before air filter change Prim. the unload pressure must be set at 100 psig. If modulate is set to “No”. Ser. .Primary air filter part number Sec. and the machine with the most Seq Hrs is shut off first. for an L model rated for 100 psig full load operation. Recovery Time . For example. Spanish.Serial number of machine Warn at . CORRECTION FACTORS FOR PRESSURES The first line of this display is the password. The right hand number on the top line is the system pressure. Rotate . it never stops (ie. 5.Pressure read by machines’ pressure transducer The top line is a legend that describes each column. machines may need to be calibrated. Any subsequent use of this setting will clear all user-entered or model-specific inputs and the parameters as well as any accumulated hours. has risen over ‘Low Press’). The four pressures P1.9 CALIBRATION .Not used at this time Local System Pressure . For example if the number displayed is 10 then changing the password to 14 will enable editing. as well as any accumulated hours. .Force fault on warning. protects the control parameters from change. The system pressure is the highest pressure reading of all the machines.e. The factory setup display is used by Sullair personnel to initially set up the machine. The following values may be set.Unloaded L . Hour. the time and date can be set using these parameters. 5. Set Defaults - Leave this parameter disabled unless instructed by Sullair Service Personnel.DISPLAY OF MODES OF MACHINES IN A SEQUENCING SYSTEM Note that this display is only applicable when there are two or more machines connected to the communications network (RS-485) and the Sequence By parameters on each machine are set to ‘Hours’ or ‘Number’. Minute.Manual stop R .10 FACTORY SETUP. The only time this parameter should be used is in a situation where. The calibration function can be used to set the readings to be the same. The machine that is running will shut off when the Seq Hrs. In this case the machine will never unload and shut off. Note that the local pressure readings can be used to determine what 34 Do not change this parameter unless requested by Sullair Service Department. The columns are described below Communication Number Status E . The number on the right hand side of the line is added to the transducer reading to give the calibrated reading.Emergency Stop M . Fault on Warn . The system pressure transducers on all machines should read within 1 psi of one another. If the password is non-zero. then enter the displayed number plus 4 to enable changing the parameters. all the time.Loaded T . Day.Section 5 SUPERVISOR and the pressure has not recovered (i.8 SYSTEM DISPLAY .Starting U . 5. with Rotate set at 100 hrs. are 100 more that the machine that is stopped. P2. once a machine is started. The calibrated reading is shown in the middle of the line. This can happen when the load matches the output of the machine.Model settings. This parameter is used to clear all user-entered or model-specific inputs and parameters. are greater that the other machines.When set to yes. For example in a two machine system. There are also two other parameters in the calibration function : Protect . Force Unload . Year. This can be used to set all factory.Standby S . or replacement in the field) then this should be set to ‘Yes’. Month. The rotate forces the machine to stop after it’s Seq Hrs. P3 & P4 as well as the differential pressure dP1 can be calibrated. control and sequencing parameters to factory defaults.Trim machine F .Full load Sequencing Hours Capacity .If the Communications Module is present in the system. If the password is 0 then the following parameters are not protected and can be changed. After setting to ‘Yes’ the parameters will be set to factory defaults and the parameter will return to ‘No’.This parameter is used only in very special cases. the unload timer never expires).When set to yes. forces the machine to unload.Remote stop B . If this is the first time the Supervisor has been powered up (as in initial installation at the factory. It contains symptoms and usual causes for the described problems. A detailed visual inspection is worth performing for almost all problems and may avoid unnecessary additional damage to the compressor. Check for loose wiring. Oil Pump or Other Motor Pressure Across Inlet Filter High REMEDY Replace filter.Air or Water Press Trans .Hours machine was running loaded and unloaded Load Cycles . 5.Section 5 SUPERVISOR Model .Maximum discharge pressure Water Switch .Water pressure switch.11 TEST. Yes or No Stop Timer . Separator Change Due. 250.13 TROUBLESHOOTING GUIDE-SUPERVISOR CONTROLLER MESSAGE MODEL ENABLE PROBABLE CAUSE Air Filter Maint ALL ALL Aux Motor Overload ALL ALWAYS ALWAYS ALWAYS Auxiliary Motor Tripped on Cooling Fan. b. However. Reset auxiliary overload after heater element cools. Oil Change Due. Auxiliary E-Stop String Open Check auxiliary E-Stop devices.Used by Sullair personnel for troubleshoot ing. Check for damaged piping.Number of machine starts Capacity . Select Maintenance from menu to see service due and part numbers. Cooling .Maximum capacity of machine 5. Oil Analysis Due Main Motor Overload ALL ALWAYS ALL ALWAYS Main Motor Overload Reset overload after heater element cools down. All available data concerning the trouble should be systematically analyzed before undertaking any repairs or component replacement procedures. Protect .Number of load/unload cycles Starts .Hours machine was running and loaded Run Hours . Should your problem persist after making the recommended check. 5. Check wiring. Check inlet filter pressure switch. Check for parts damaged by heat or an electrical short circuit. Yes or No Oil Switch .Model number of machine. Air Filter Change.Protect control parameters Load Hours . Cooling Water Pressure Below 10 psi (0.7bar) Maintenance Due Check for closed valves or broken pipes.Oil pressure differential switch. Always remember to: a. Oil Filter Change.Time to run machine before stopping. if low consult power company. ALL ALWAYS ALL ALWAYS E-Stop E-Stop Push Button E-Stop E-Stop String Low Water Pressure ALL ALL ALL ALL ALL ALWAYS ALWAYS ALWAYS ALWAYS Watercooled E-Stop Button Active Release button. c. Check motor starter contact for proper operation. Check line voltage. DO NOT assume that these are the only problems that may occur. Check wiring. 500 P1 Max . usually apparent by discoloration or a burnt odor. 35 .Pressure transducer range 200.12 TROUBLESHOOTING INTRODUCTION The information contained in the Troubleshooting chart has been compiled from factory experience. consult your nearest Sullair Distributor or the Sullair Corporation factory Service Department. P2 Sensor Fail. replace oil filter.4 bar) while running Oil filter clogged. check sensor wiring. Check line voltage. ALL ALWAYS ALL ALWAYS I/O Mod Com Error. FLOODED ALWAYS FLOODED ALWAYS P1 Sensor Fail. dP2 Oil Filter High ALL ALWAYS FLOODED ALWAYS Low ambient temperature. check sensor. sump heater may be required in ambients below 40°F (4°C). replenish oil to proper level. Factory Setup Error ALL ALWAYS The Factory Setup Information Needs to be Reviewed for Correct Values Sump Pressure High If problem persists replace Supervisor.Section 5 SUPERVISOR 5. P3 Oil Pressure Low. dP3 Oil Pressure Low ALL ALWAYS ALWAYS FLOODED ALWAYS Sump oil level low. Low ambient temperature. wiring and tubing. T5 Sensor Fail dP1 Separator Maint. Com Mod Com Error. T3 Sensor Fail. ALL ALWAYS Replace module referred to in error message. consult Sullair service department. Oil filter clogged. if low consult power company. replace. 36 . Motor Mod Com Error ALL ALWAYS Module Network Error. check valves. T4 Sensor Fail. ALL P3 Oil Pressure Low. P1-P2 ALL ALWAYS FLOODED ALWAYS Pressure Across Separator High Plugged separator elements. replace filter. P4 Sensor Fail. Oil pump may be required for remote coolers. P3 Sensor Fail. I/O Module and Other Optional Modules is Not Working Correctly Check wiring. Sensor or Wiring Failure Check sensor wiring. spiral or blowdown valve failed.. T1 Sensor Fail. The Network that Connects the Display Module. P1 Sump Pressure High FLOODED ALWAYS Sullicon. Oil Pressure Low Oil pump failure. T2 Sensor Fail. Pressure Across Oil Filter Above 20 psi (1. Oil Filter Maint. Pressure sensor failure. sump heater may be required in ambeints below 40°F (4°C). if problem persists replace display module. Check sensor. Sensor failure.13 TROUBLESHOOTING GUIDE-SUPERVISOR CONTROLLER (CONTINUED) MESSAGE MODEL ENABLE PROBABLE CAUSE Main Motor Overload (continued) ALL ALWAYS REMEDY Make sure unload pressure set below limit of compressor Check motor starter contacts for proper operation. ) REMEDY Solenoid valves. clean fins and fan. Fault Machine may have failed to start. improve local ventilation. Cooler fins dirty. check operation. Ambient above 105°F (41°C).Section 5 SUPERVISOR 5. increase flow or lower water temperature. use cleaner water. T3 Oil Temp HIgh. check for valve closed.13 TROUBLESHOOTING GUIDE-SUPERVISOR CONTROLLER (CONTINUED) MESSAGE MODEL ENABLE PROBABLE CAUSE P1 Sump Pressure High (continued) ALL ALWAYS Sump Pressure High (cont. check operation and wiring. T3 Oil Temp High. check adjustment and operation. Check minimum pressure check valve. Low water flow. High water temperature. FLOODED ALWAYS FLOODED ALL ALL ALL ALWAYS Aircooled Watercooled Watercooled ALL Watercooled ALL ALWAYS 37 . Sensor failure. if plugging persists. T5 Discharge High. Pressure regulator. wiring and tubing. clean tubes and shell. pump off or broken pipe. T4 Intercool High. replenish to proper level. T1 Discharge High. Fluid level low. Check pressure sensor. Thermal valve. check sensor and wiring. Cooler plugged. T2 Discharge High. T2 Dry Side High. ALL ALWAYS ALL ALWAYS P1 Sump Pressure Low FLOODED ALWAYS Sump Pressure Low FLOODED T1 Interstage HIgh. T4 Interstage High ALL ALWAYS ALWAYS High Temp. if machine is running If Enabled . alarms are checked : Constantly . OIL ANALYSIS Check OIL CHANGE Check OIL FILTER MAINT.machine is loaded and above min load pressure 38 .5) dP1Max = P1Max .if parameter is non-zero At Start .will not allow start if alarm present Over Min Psi .if machine running or stopped When Running .P1 dP1Max = P1Max . SEPARATOR CHANGE Check dP_1 dP_2 dP_3 dP1Max dP1Max P_1 P_1 P_1 P_2 P_3 P_4 T_1 T_1 T_1 T_1 T_1 T_1 T_2 T_2 T_2 T_3 T_3 T_4 T_4 Type On On On On Fault Fault Fault Fault Limit 0 0 0 0 Delay 0 0 0 0 Start Run Delay Check (*) 0 0 0 0 Constantly Constantly Constantly Constantly Comment Factory Setup Check Sum Fail Communication failure I/O Module Communication failure Com Module Communication failure Motor On Fault On Fault On Warn On Fault On Fault On Fault Maint Warn Maint Warn Maint Warn Maint Warn Maint Warn High Warn High Warn Low Fault High Fault High Warn High Inhibit Low Fault High Fault High Fault High Fault High Fault Low Fault High Warn High Fault High Warn High Fault High Fault Low Fault High Warn High Fault Low Warn High Warn Low Fault High Fault 0 0 0 0 0 0 0 0 0 0 0 10 20 1 0 3 5 5 500 500 500 500 -40 225 235 245 255 500 -40 225 235 -40 500 -40 500 1 1 5 5 0 0 0 0 0 0 0 5 5 5 5 5 0 5 0 0 0 0 0 5 5 0 0 0 0 5 5 0 0 0 0 1 1 5 5 0 0 0 0 0 0 0 55 2 55 0 0 0 0 0 0 0 0 0 30 30 0 0 0 0 30 30 0 0 0 0 Constantly Constantly When Running When Running Constantly Constantly If Enabled If Enabled If Enabled If Enabled If Enabled Over Min Psi When Running When Running When Running When Running At Start When Running Constantly Constantly Constantly Constantly Constantly Constantly Constantly Constantly Constantly Constantly Constantly Constantly Constantly Constantly Constantly Constantly Constantly Motor overload Aux motor overload Air filter maintenance Low water pressure E-Stop Push Button Auxiliary E-Stop Air Filter change due Oil Analysis due Oil change due Oil filter change due Separator change due Separator maint P1-P2 Oil filter maint P4-P3 Low Oil psi P3-(P1/2.Section 5 SUPERVISOR Table 5-1 Alarms Sensor System Check I/O Module Check Com Module Check Motor Module Check Module D_1 D_2 D_3 D_4 E_1 E_2 AIR FILTER MAINT.P1 High sump psi at start Immediate Fault Sensor failure fault Sensor failure fault Sensor failure fault Sensor failure fault Sensor failure fault Delayed for temp spikes Delayed for temp spikes Immediate Warning Immediate Fault Sensor failure fault Sensor failure fault Delayed for temp spikes Delayed for temp spikes Sensor failure warning Sensor failure warning Sensor failure fault Sensor failure fault (*) In the ‘Check’ column above. in order to match air supply to the demand. Blocks the reverse flow of air/fluid through the compressor unit during shutdown. THERMAL O/L RESET SULLICON ACTUATOR SPIRAL VALVE PRESSURE REGULATOR (SULLICON) PRESSURE REGULATOR (WITH SPIRAL VALVE) SOLENOID VALVE #1 SOLENOID VALVE #2 DISCHARGE CHECK VALVE 39 . Opens a pressure line between the service line and the spiral valve actuator allowing the spiral valve to regulate air delivery according to air demand. so please refer to that section for your information. ·Load the Sullicon device/close the inlet butterfly valve during shutdown operation.2. Opens when the compressor starts. 3-way valve which controls the flow of pneumatic logic signals. Opens a pressure line between the sump and Sullicon Control allowing the Sullicon Control to regulate air delivery according to the air demand. Additional indicators and functions included in the package are as follows: CONTROL OR INDICATOR EMERGENCY STOP SWITCH PURPOSE Pushing in this switch. cuts all AC outputs from the Supervisor and de-energizes the starter. Actuates the inlet butterfly valve which throttles the air flow to the compressor inlet. Internally bypasses and controls the air flow capacity of the compressor. Please be aware that the elements must be allowed to cool sufficiently before resetting. re-closes the starter’s contacts after a current overload takes place. found adjacent to the Supervisor. Momentarily pushing this button. closes when the compressor is shut off.Section 6 COMPRESSOR OPERATION 6. A fault message (E STOP) is displayed by the Supervisor until the button is pulled out and the “O” pad is depressed.1 INTRODUCTION While Sullair has built into the TS-32 Series package a comprehensive array of controls and indicators to assure its proper operation. ·Open the spiral valve. Before starting the unit. 6. the user should recognize and interpret readings which call for service or indicate the onset of a malfunction. the user should become familiar with the controls and indicators-their purpose. location. in order to match air supply to the demand. This prevents any air system loss and depressurizes the controls when the compressor is shut off. Used throughout package to: ·Open the blowdown valve.2 PURPOSE OF CONTROLS All Supervisor Controller related functions and indicators are presented in Section 5. and use. found on the starter’s thermal overload element housing. Electrically actuated. 8). 40 4. Lubricant sump drain valve.) MINIMUM PRESSURE VALVE PURPOSE (CONT. If adjustments are necessary. 77°C (195°F for water cooled KT and ≥ 150 psi/ 10.7 bar). Open the shut-off valve to the service line. . Vents the sump vessel to atmosphere during unloading and shutdown. Vents the sump vessel to atmosphere before the compressed air pressure exceeds rated tank pressure. Large flow should be visible during full load operation.) Maintains 50 psig (3. if the water pressure falls below 10 psig (0. 1. De-energizes the starter. Located on the sump side. Slowly close the shut-off valve to assure proper nameplate pressure unload setting is correct.3 INITIAL START-UP PROCEDURE The following procedure should be used to make the initial start-up of the compressor. see Control System Adjustments. fluid level should be maintained at a level between the high and low sight glass. Used on water-cooled packages only. The compressor will unload at nameplate pressure. thus preventing the discharge of fluid through the compressor inlet pipework. Sluggish flow during full load operation indicates the need to clean the strainers fitted to the return lines. Useful for fast warm-up during start.3 bar). Check for possible leaks in piping. little to no flow during unloaded operation. Indicate fluid flow in the separator return lines. If the operating temperature exceeds 200°F (93°C) [215°F (102°C) for water-cooled 24KT and > 150 psi]. Its operation indicates fault with the Supervisor operation unload pressure set too high or failure of solenoid valve #1. Observe the operating temperature. PRESSURE RELIEF VALVE BLOWDOWN VALVE ASSEMBLY THERMAL MIXING VALVE FLUID STOP VALVE SUMP SIGHT GLASSES SEPARATOR RETURN LINE SIGHT GLASSES WATER PRESSURE SWITCH DRAIN VALVES 6. 6. 7. Be sure that all preparations and checks described in the Installation Section have been made. Maintains a minimum temperature during periods of low load or low ambient temperatures. Also incorporates a check valve. Blocks the flow of fluid to the compressor during shutdown. 2. Read the preceding pages of this manual thoroughly. Jog motor to check for correct rotation of fan (refer to Section 4.Section 6 COMPRESSOR OPERATION CONTROL OR INDICATOR (CONT. Bypasses fluid flow around the cooler until the fluid reaches a temperature of 170°F. 5.5 bar) in the receiver tank when the compressor is running loaded. Indicates level of lubricant in the sump. 3. This switch is not adjustable. via the Supervisor. which prevents compressed air backflow from the system when unloaded or shutdown. check that the proper level is visible in the fluid sight glass and simply press the START or AUTO MODE button. Reinspect the compressor for temperature and leaks the following day. 6. 41 . 8.Section 6 COMPRESSOR OPERATION the cooling system and installation environment should be checked. When the compressor is running.5 SHUTDOWN PROCEDURE To shut the compressor down.4 SUBSEQUENT START-UP PROCEDURE On subsequent start-ups. observe the instrument panel and maintenance indicators. simply press the STOP button. 9. 6. Open shut-off valve to the service line. NOTES 42 . it is necessary to check the fluid level in the sump.7 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES MAIN FILTER MAINTENANCE Refer to Figure 7-1. A fluid sample analysis at every 4000 hours is recommended. it will be necessary to perform the following: 1. Drain the fluid from the canister by removing the bottom drain plug Figure 7-1 Main Filter (P/N 02250128-717) DO NOT remove caps. When the maintenance message is displayed by the Supervisor ControllerTM. The main filter (P/N 02250128717) is located schematically between the compressor and the fluid stop valve. Clean the control line filters. 2. Change the fluid filter element. If the addition of fluid becomes too frequent. Clean the return line strainers. Perform the following maintenance operations to prevent unnecessary problems. For element replacement order kit number 02250121-657. plugs. 3. 1. shut the compressor down. The separator elements must be replaced. 3. DO NOT clean the separator elements. whichever comes first. See the Troubleshooting Section (7. The use of the service indicators provided for the fluid filter. Every 8000 hours. Stop compressor and relieve all internal pressure before doing so. 2.Section 7 MAINTENANCE 7. 1.7. Sullube should be changed under the following conditions. then follow the instructions below. 7. After the compressor has warmed up. and/or other components when compressor is running or pressurized. will alert you when service maintenance is required. Parts Replacement and Adjustment procedures. *Repair Kit P/N 02250121-657 43 .5 FLUID CHANGE Standard models are filled with the long life lubricant Sullube. 2. As indicated by fluid analysis. it is recommended that a general check of the overall compressor and Supervisor be made to assure that the compressor is running properly. whichever occurs first: 1. See instructions for each item in Section 7. simply add the necessary amount. To facilitate this.1 GENERAL As you proceed in reading this section. Clean the return line strainers. 4.2 DAILY OPERATION Prior to starting the compressor. Clean the return line orifices. air filter and fluid separator. After a routine start has been made. be sure all pressure has been released. Once a year. Replace the fluid filter element. it will be easy to see that the Maintenance Program for the air compressor is quite minimal yet important. 7. 7. a sample bottle is included with the compressor. Return fluid to Sullair Corporation in Michigan City for free analysis. 7.6 SEPARATOR MAINTENANCE Replace the separator elements when a message is displayed or after one (1) year. a simple problem has developed which is causing this excessive loss.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION After the initial 50 hours of operation.4 MAINTENANCE AFTER 1000 HOURS After 1000 hours of operation.8) under Excessive Fluid Consumption for a probable cause and remedy. Should the level be low. 7. observe the Supervisor control panel and be sure it monitors the correct readings for that particular phase of operation. 7. a few maintenance requirements are needed to rid the system of any foreign materials if any. Lubricate the Sullicon Control linkage. maintenance for that specific item is required. 3. When servicing the main filter. As previously stated. Pull the element assembly out of the housing. 5. AIR FILTER MAINTENANCE Refer to Figure 7-2. Inspect the secondary element and replace if necessary. grease or damage. Remove the canister seals. 6. When removing the primary element. Loosen and remove the hex nut securing the secondary element. 9. Clean the interior of the housing by using a damp cloth. 3. DO NOT strike the element against any hard surface to dislodge dust. ELEMENT REMOVAL 1. 6. you will notice a wingnut which fastens the element to the housing. Lubricate the new seals with the same type of fluid used in the compressor and position each seal in its appropriate place. always check the secondary element for visible dirt. The secondary element must be changed after every sixth primary element change. Thoroughly clean the filter head and canister in solvent. On the inside of the element. This will damage the sealing surfaces and possibly rupture the element. Thread the canister and element back on the filter head.Section 7 MAINTENANCE 2. replace the primary element. 8. 4. DO NOT blow dirt out with compressor air. Remove the secondary element. With the secondary element in place. 4. Pull the canister away from the filter head. Remove the wingnut and pull the primary element out. Figure 7-2 Air Filter Replacement (P/N 250006-718) DO NOT clean the secondary element. Separate the element from the head. Install the new secondary element and replace the sealing washer and hex nut. *Primary Replacement Element P/N 250007-838 **Secondary Replacement Element P/N 250007-839 44 . Slide the element into the canister. 7. 3. The air filter is equipped with a primary element and a secondary element. Loosen the spin-on canister using a wrench on the bottom canister hex. 8. The filter element will be attached to the head. Remove the cover assembly by loosening the wingnut securing it. Clean the exterior of the air filter housing. 9. Air filter maintenance should be performed when the air filter maintenance message is displayed. 5. 7. the Supervisor will alert you as to when the primary element maintenance is necessary. 2. DO NOT use anti-seize compound on gaskets.Section 7 MAINTENANCE Figure 7-3 Separator Element Replacement tighten. revealing any holes. Tighten the wingnut so as to fully seat the element gasket. 2. The separator elements must be changed when “Separator Maintenance Required” message is displayed. 2. Inspect all gaskets and gasket contact surfaces of the housing. 4. Reconnect all piping making sure return line 45 DO NOT “blow” dirt out of the interior of the filter housing. tubing. etc.-lbs. Relieve all pressure from the separator and all compressor lines prior to disconnecting any pipes. Scrape the old gasket material from the cover and flange on the sump being careful not to let the scraps fall in the sump. 4. After the element has been installed. 9. 3. If the clean element is to be stored for later use. ELEMENT INSPECTION 1. *Primary Replacement Element P/N 250034-122 **Secondary Replacement Element P/N 250034-134 6. 10. This may introduce dust downstream of the filter. Lift the cover plate from the separator using a 3/4” jackscrew under the lifting arm post. washers and 3/4-10 capscrews. 2. DO NOT oil the element. Loosen and remove the twelve (12) 3/4” x 3” hex head capscrews from the cover plate. etc. use a clean damp cloth. PROCEDURE FOR 200-350HP/149-261KW ELEMENT REPLACEMENT 1. Concentrated light will shine through the element. etc. it must be stored in a clean. SEPARATOR ELEMENTS REPLACEMENT Refer to Figure 7-3. Reinsert the separator elements with gaskets attached into the sump taking care not to dent them against the tank opening. 8. Instead. or once a year whichever occurs first. Place a bright light inside the element to inspect for damage or leak holes. Should faulty gaskets be evident. PRIMARY ELEMENT REPLACEMENT 1.). Check between separator element flange and tank for continuity after torquing bolts. Lubricate and Torque to 200 ft. correct the condition immediately. if necessary. Place the element in position over secondary element. Inspect the separator tank for rust. The lid can be pivoted to the side supported by the lifting arm. Disconnect all piping connected to the separator cover to allow removal (return lines. 3. Remove the primary and secondary separator elements. all air inlet connections prior to resuming operation. Replace the cover plate. Replace the sealing washer and wingnut. dirt. DO NOT remove grounding staples. 5. closed container. Follow the procedure explained below for separator element replacement. Clean the underside of the separator tank cover and remove any rust. 11. 7. Install the cover/element assembly and replace the wingnut. (271 Nm). inspect and . service lines. the Sullicon regulator should allow pressure to flow into the control chamber of the Sullicon Control. DRIVE COUPLING INSTALLATION AND ALIGNMENT (200-350HP/ 149-261KW) Refer to Figures 7-7. For coupling Always performing maintenance on both oil return/sight glasses at the same time. The Sullicon Control level should start to move at this time. 4. OIL RETURN/SIGHT GLASS MAINTENANCE Refer to Figure 7-4. The spiral valve should start to rotate at this time. or the straight thread tube connector (for right-side glass) from sight glass/orifice blocks. 7-8 and 7-9. turn the adjusting screw clockwise to increase or counterclockwise to decrease the setting. 5. 2. Order filter assembly no. At approximately 108 psig (7. or as indicated in the Troubleshooting Sections (both Supervisor and Maintenance) of this manual. The differential pressure regulators are adjusted by loosening the jam nut on the end of the cone shaped cover of the pressure regulator. The oil return/sight glass subassembly is attached to the separator tank lid. When the jam nut is loose.9 bar). 46 . Unscrew male connector (for left-side glass). Remove used filter assembly. Cycle the Control System several times and recheck all pressure settings.Oil return/sight glass maintenance should be performed on a routine basis parallel to that of the fluid filter. the spiral valve regulator should allow pressure to flow into the chamber of the spiral valve actuator. This will assure proper fluid return flow to the compressor.5 bar). and replace with new assembly. and use the following instructions as a guide. Coat/lubricate the O-rings will silicone grease.Section 7 MAINTENANCE Figure 7-4 Oil Return/Sight Glass *Replacement Filter Assembly P/N 02250117-782 tubes extend to the bottom or 1/4” (6mm) above the bottom of the separator element. 12. 1. Above 100 psig (6. Check the return line strainers before restarting the compressor (order replacement kit no. 3. 02250117-782). 02250117782. The maintenance on an oil return/sight glass is mainly concerned with the condition of the filter assembly. Reattach the connectors to the sight glass/orifice blocks. Disconnect the tubes at the tops of the sight glass assemblies. DIFFERENTIAL PRESSURE REGULATOR ADJUSTMENT Refer to Figure 7-5 and 7-6. a set of standard Allen wrenches and one set of standard socket wrenches. grease. follow the steps explained below.Clean any oil. Position the hubs to establish the correct gap specified in Table 1..969 + .030 . dirt or paint from coupling faces and the other surfaces of the drive flanges.-lbs.03 .-Nm 200 Coupling Gap inches/cm Parallel Offset inches/cm Angular inches/cm (I) 2.010 . one set of feeler gauges. STEP 1 MOUNT HUBS . Rotate shafts so TABLE 1 INSTALLATION DATA (200-350HP/149-261KW) Max. before attempting maintenance or adjustments. STEP 2 OFFSET ALIGNMENT .000 (I) Angular misalignment in inches equals maximum A minus minimum B as shown in Figure 7-8.08 .Section 7 MAINTENANCE Figure 7-5 Pressure Regulator Adjustments installation and alignment.. the tools required are a straight edge. Operating Misalignment Tightening Torque ft.5 + . Secure each hub with a setscrew.03 .Mount the motor hub and the compressor hub onto respective shaft. DO NOT exceed values in Table above. Figure 7-6 Sullicon Control (P/N 011682-003) Disconnect all power at source. 47 . a measuring scale.010 .000 271Nm 7. For installation and alignment of the drive coupling. Section 7 MAINTENANCE Figure 7-7 Drive Coupling (200-300HP/ 150-225KW) When within the limits specified in Table 1, tighten the motor mounting bolts and recheck the offset and angular alignment. If the vertical angular alignment is not within .010 inch tolerance, shim the front or rear of the motor separately 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 tightening a suitably sized radiator hose clamp around the outer edge of the element as shown in Figure 78. Slide the ferry head capscrews with lockwashers Figure 7-9 Parallel/ Angular Offset Alignment *Replacement Element P/N 046999 that a straight edge will rest squarely (or within the 0.010 inch maximum limit shown in Table 1) on both flanges and at a point 90° away. The vertical offset alignment is adjusted by the addition or removal of motor mounting shims. Loosen the motor mounting bolts and slide the motor sideways to correct the horizontal offset. STEP 3 COUPLING GAP AND ANGULAR ALIGNMENT - Position the hubs to establish the proper gap and angular alignment as indicated in Table 1. To determine the angular misalignment in inches, measure the maximum space between the hub flanges and the minimum space 180° away, and then subtract. To adjust the horizontal 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. Figure 7-8 Drive Coupling Alignment through the holes in the hubs and element. Tighten the capscrews to 200 ft.-lbs. (271 Nm). Capscrews are 3/4-10 x 4” LG ASTM A354 Grade BD yellow zinc di-chromate. DO NOT substitute with any other bolts. After tightening the capscrews, tighten the shaft setscrews and remove the hose clamp from the flexible element. At this time, the coupling is ready for operation. 48 Section 7 MAINTENANCE 7.8 TROUBLESHOOTING The information contained in the Troubleshooting chart is based upon both the actual applied situations and extensive testing at the factory. It contains symptoms and usual causes for the described problems. However DO NOT assume that these are the only problems that may occur. All available data concerning the trouble should be systematically analyzed before undertaking any repair or component replacement. A detailed visual inspection is worth performing for 7.9 TROUBLESHOOTING GUIDE (I) SYMPTOM PROBABLE CAUSE COMPRESSOR WILL NOT START Main Disconnect Switch Open Line Fuse Blown Control Transformer Fuse Blown Motor Starter Overloads Tripped Close switch. Replace fuse. Replace fuse. Reset. Should trouble persist, check whether motor starter contacts are functioning properly. Check voltage. Should voltage check low, consult power company. almost any problems which may prevent unnecessary damage to the compressor. Always remember to: a. Check for loose wiring. b. Check for damaged piping. c. Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor. Should your problem persist after making the recommended check, consult your nearest Sullair representative or the Sullair Corporation. REMEDY Low Incoming Line Voltage Replace Supervisor display module if no display or erratic display. COMPRESSOR SHUTS DOWN WITH AIR DEMAND PRESENT Loss of Control Voltage Low Incoming Voltage Check incoming power. Check control fuses and wiring. Consult power company. The Sullair Supervisor will provide indication of most maintenance problems if control power has not been lost. Shutdowns will occur upon a faulty condition or a bad sender condition. 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 Sullicon Control lever to move to unload stop when the unload pressure setting P2A is exceeded. Repair if defective. Defective blowdown valve; blowdown valve should exhaust sump pressure to 30 psig (2.1 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 message; replace sender indicated. Operating lever of inlet butterfly valve is loose on valve shaft. Reposition the valve plate and tighten lever set screw. Excessive Operating Pressure (I) Consult Section 5.13 for additional Supervisor aids to troubleshooting. 49 Section 7 MAINTENANCE 7.9 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM PROBABLE CAUSE COMPRESSOR SHUTS DOWN WITH AIR DEMAND PRESENT (CONTINUED) HIGH TEMP T1 or T3 Message Displayed REMEDY Cooling water temperature too high; increase water flow (water-cooled only). 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(watercooled only). Cooling air flow restricted; clean cooler and check for proper ventilation. Ambient temperature is too high; provide sufficient ventilation. Cooling air ductwork, if installed, may restrict air flow. High static fan must be specified with customer-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 (air-cooled only). Optional Water flow regulating valve not functioning 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 (LOW PRESSURE P3 display) Check fluid level. Check for clogged fluid filter. Low Water Pressure (FAN OL/LOW WATER display) COMPRESSOR WILL NOT BUILD UP FULL DISCHARGE PRESSURE Air Demand is Too Great Dirty Air Filter Check the cooling fan motor or water flow system. Check service lines for leaks or open valves. Check for filter maintenance message on supervisor panel and change or clean element if required. Adjust regulator according to control adjustment instructions in the Maintenance Section. Check diaphragm and replace if necessary (kit available). Pressure Regulator Out of Adjustment Defective Pressure Regulator Broken Sullicon Spring LINE PRESSURE RISES ABOVE UNLOAD P2 PRESSURE SETTING ON THE SUPERVISOR Leak in Control System Causing Loss of Pressure Signals Replace. Check for leaks. 50 Drain excess fluid. Replace. connections and components. Repair or replace if necessary (kit available). Replace pressure relief valve.) Defective Solenoid Valve REMEDY Check that Sullicon Control lever is moved to unload stop when Supervisor is in NO LOAD mode. Install a compressed air dryer sized for the flow and dryness level required. Change Separator Leak in the Lubrication System Excess Fluid Foaming Fluid Level Too High PRESSURE RELIEF VALVE OPENS REPEATEDLY LIQUID WATER IN COMPRESSED AIR SERVICE LINE Defective Pressure Relief Valve Check all pipes. Clean or repair if necessary. liquid oil aerosols or for oil vapor removal. Maintain them regularly.9 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM PROBABLE CAUSE LINE PRESSURE RISES ABOVE UNLOAD P2 PRESSURE SETTING ON THE SUPERVISOR (CONT. Change cartridges as recommended by the filter manufacturer.Section 7 MAINTENANCE 7. Check operation of aftercooler and moisture separator. Clean strainer (screen with o-ring replacement kit available) Clean orifice. Drain and change. Repair or replace if necessary (kit available). Water Vapor Condensation From Cooling and Compression Occurs Naturally Remove the water vapor from compressed air prior to distribution through the air system. 51 . Check that sump pressure is exhausted to the atmosphere when in the OFF LOAD mode. (Note: Filters may also be required to remove particulates.) Check all drain traps routinely to insure their proper operation. Defective Blowdown Valve Ruptured Sullicon Control Diaphragm Plugged Control Line Filter EXCESSIVE FLUID CONSUMPTION Clogged Return Line Strainer or Orifice Separator Element Damaged or Not Functioning Properly Check Separator Differential (plugged) dP1. NOTES 52 . and ≥ 150 psig compressors.A.S. Only) or 1-219-879-5451 Fax: (219) 874-1273 Fax: (219) 874-1835 (Parts) Fax: (219) 874-1205 (Service) 8.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was purchased. No.Section 8 ILLUSTRATIONS AND PARTS LIST 8. For compressor unit parts only. Sullair Road. Shekou Shenzhen.200 and 250HP/ 149 and 186KW DESCRIPTION repair kit for fluid stop valve 02250113-668 repair kit for thermal valve (175°) 02250127-119 repair kit for thermal valve (195°) 02250127-962 (I) element for separator with gaskets (primary) element for separator with gaskets (secondary) repair kit for regulator valve 406929 repair kit for blowdown valve 044912 repair kit for Sullicon Control 011682-003 repair kit for control line filter 02250112-032 replacement kit for fluid return strainer element for 18” diameter air filter 250006-718 (primary) element for 18” diameter air filter 250006-718 (secondary) repair kit for water separator 02250111-105 KIT NUMBER 02250116-697 02250105-553 02250112-709 250034-122 250034-134 041742 046782 250020-353 02250112-031 02250117-782 250007-838 250007-839 QUANTITY 1 1 1 1 1 1 1 1 1 1 1 1 Consult Factory 1 (Continued on page 54) (I) For 24KT water-cooled. Indiana 46360 U. For ordering parts other than those pertaining to the compressor unit. 1 Chiwan. Guangdong PRV. INDICATE SERIAL NUMBER OF COMPRESSOR 53 . S.A. Telephone: 1-800-SULLAIR (U. When ordering parts always indicate the Serial Number of the compressor. LTD. PRC POST CODE 518068 Telephone: 755-6851686 Fax: 755-6853473 SULLAIR EUROPE. France Telephone: 33-477968470 Fax: 33-477968499 SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City. If for any reason parts cannot be obtained in this manner.2 RECOMMENDED SPARE PARTS LIST . use serial number located on nameplate mounted on control panel.S. SULLAIR ASIA. order parts by the unit serial number place located on the compressor unit.A. This can be obtained from the Bill of Lading for the compressor or from the Serial Number Plate located on the compressor. PLEASE NOTE: WHEN ORDERING PARTS. Zone Des Granges BP 82 42602 Montbrison Cedex. contact the factory directly at the address or phone numbers listed below. Section 8 ILLUSTRATIONS AND PARTS LIST 8. INDICATE SERIAL NUMBER OF COMPRESSOR 54 .2 RECOMMENDED SPARE PARTS LIST .200 and 250HP/ 149 and 186KW (CONTINUED) DESCRIPTION KIT NUMBER QUANTITY replacement kit for fluid filter 02250121-658 repair kit for solenoid valve 02250125-657 replacement coil for solenoid valve 02250125-657 repair kit for solenoid valve 02250125-679 replacement coil for solenoid valve 02250125-679 repair kit for regulator valve 408275 repair kit for minimum pressure valve 250033-821 repair kit for shaft seal element for drive coupling diaphragm repair kit for spiral valve air cylinder 250016-183 repair kit for SCD zero loss drain 02250130-866 o-ring for 2 1/2 -12 SAE tube fittings o-ring for 1 7/8 -12 SAE tube fittings compressor Sullube fluid (5 gallons) compressor 24KT fluid (5 gallons) compressor CP-4600-32-F fluid (5 gallons) 02250121-657 02250125-829 (valve) 02250125-861 (coil) 02250125-824 02250125-861 (coil) 250028-693 250018-262 067329-001 046999 608311-001 02250131-044 250042-649 250042-648 250022-669 02250051-153 250029-008 1 1 1 1 1 1 1 1 1 1 1 - PLEASE NOTE: WHEN ORDERING PARTS. and ≥ 150 psig compressors.300 and 350HP/ 224 and 261KW DESCRIPTION QUANTITY repair kit for fluid stop valve 02250122-004 repair kit for thermal valve (170°) 02250120-955 repair kit for thermal valve (195°) 02250127-962 (I) element for separator with gaskets 250034-123 (primary) element for separator with gaskets 250034-129 (secondary) repair kit for regulator valve 406929 repair kit for blowdown valve 409783 repair kit for Sullicon Control 011682-003 repair kit for control line filter 02250112-032 repair kit for fluid return strainer element for 18” diameter air filter 250006-718 (primary) element for 18” diameter air filter 250006-718 (secondary) replacement kit for fluid filter 02250128-717 repair kit for solenoid valve 02250125-657 replacement coil for solenoid valve 02250125-657 repair kit for solenoid valve 02250125-679 replacement coil for solenoid valve 02250125-679 repair kit for regulator valve 408275 repair kit for minimum pressure valve 250033-821 repair kit for shaft seal element for drive coupling diaphragm repair kit for spiral valve air cylinder 250016-183 repair kit for SCD zero loss drain 02250130-866 o-ring for 2 1/2 -12 SAE tube fittings (I) For 24KT water-cooled.Section 8 ILLUSTRATIONS AND PARTS LIST 8. INDICATE SERIAL NUMBER OF COMPRESSOR 001684 02250120-957 02250127-963 250034-124 250034-130 041742 001667 250020-353 02250112-031 02250117-782 250007-838 250007-839 02250121-657 02250125-829 (valve) 02250125-861 (coil) 02250125-824 02250125-861 (coil) 250028-693 250018-262 067329-001 046999 608311-001 02250131-044 250042-649 KIT NUMBER 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 55 . PLEASE NOTE: WHEN ORDERING PARTS.3 RECOMMENDED SPARE PARTS LIST . 4 MOTOR.GEAR DRIVE 02250132-848R01 56 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. COMPRESSOR. FRAME AND PARTS. coupling r. hex ser washer 5/16-18 x 1 washer. contact your nearest Sullair representative or the Sullair Corporation. frame.GEAR DRIVE key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 part number 02250113-548 02250113-565 02250113-566 02250122-221 046999 250004-635 250005-091 250007-215 250007-218 250024-587 824206-337 824214-776 825212-665 825305-283 829106-125 829112-400 829114-350 829705-075 829705-100 837506-094 837812-188 837814-219 838205-071 838206-071 049855 description guard. For shaft seal repairs order repair kit no. COMPRESSOR. main ts32-300/350 element.hex unfin 7/8-9 nut. Consult factory with machine serial number. hex gr5 7/8-9 x 3 1/2 screw. 046999. hex gr5 3/8-16 x 1 1/4 capscr. guard. (III) Motor may vary.25” nut. main (III) sign.001. hex ser washer 5/16-18 x 3/4 screw. coupling saga 34a 2-3/8 x 5/8 hub. INDICATE SERIAL NUMBER OF COMPRESSOR 57 . coupling cntr ts32-200/300 gd/dd adj. ts32-200/300h gd adj. The shaft seal is not considered part of the compressor unit in regard to the two year warranty. coupling saga 34a 3-1/4 x 3/4 motor support. coupling l. warning-sever-fan quantity 1 1 1 1 1 1 1 2 2 3 4 3 4 3 4 4 6 6 1 4 4 6 5 8 1 1 1 (I) For maintenance on drive coupling element. spr lock reg pltd 3/4 washer.h.hex unfin 3/8-16 nut. FRAME AND PARTS. (II) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sullair distributors or the factory at less cost than the owner could repair the unit.hex f pltd 5/16-18 capscr.25 x 23.mtr supt 5 x .hex pltd 3/4-10 nut. 067329.ddr321170a (II) motor. ts32-200/300 gd adj. pl-b reg pltd 3/8 compressor & part. PLEASE NOTE: WHEN ORDERING PARTS. For information regarding the unit exchange program. The normal Sullair parts warranty applies. order drive coupling replacement no. toshiba 447tss bar. guard. spr lock reg pltd 7/8 washer. spr lock 3/8 washer.assy compr mtg 32/25 nut.h.dr couplg-saga 34 (I) hub.4 MOTOR. hex gr5 3/4-10 x 4 capscr.Section 8 ILLUSTRATIONS AND PARTS LIST 8. pl-b reg pltd 5/16 washer. DIRECT DRIVE 02250131-577R01 58 .5 MOTOR.Section 8 ILLUSTRATIONS AND PARTS LIST 8. COMPRESSOR. FRAME AND PARTS. hex gr5 3/4-10 x 4 capscr. pl-b reg pltd 3/8 compressor & part. Consult factory with machine serial number. For information regarding the unit exchange program.cplg lh ts32 200-300h dd guard. FRAME AND PARTS.hex pltd 7/8-9 nut. COMPRESSOR.hex pltd 3/8-16 nut. spr lock reg pltd 7/8 washer. coupling saga 34a 2-3/8 x 5/8 hub. PLEASE NOTE: WHEN ORDERING PARTS. 046999. hex gr5 7/8-9 x 3 1/2 washer.5 MOTOR.ddr321170a10me57vcb (II) motor. toshiba 447tss nut. frame.assy compr mtg 32/25 element. (II) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sullair distributors or the factory at less cost than the owner could repair the unit. 067329-001.hex pltd 3/4-10 nut. hex gr5 3/8-16 x 1 1/4 capscr. contact your nearest Sullair representative or the Sullair Corporation.hex f pltd 5/16-18 capscr. pl-b reg pltd 5/16 washer. hex gr5 5/16-18 x 1 capscr. order drive coupling replacement no. For shaft seal repairs order repair kit no. main ts32-300/350 nut. (III) Motor may vary. coupling cntr ts32-200/300 gd/dd adj.dr couplg-saga 34 (I) hub.assy compr mtg 32/25 nut. coupling saga 34a 3-1/4 x 3/4 motor support.DIRECT DRIVE key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 part number 02250113-546 02250113-547 02250113-548 02250122-221 02250135-358 046999 250004-635 250005-091 250007-215 250024-587 825206-337 825212-665 825214-776 825305-283 829105-100 829106-125 829112-400 829114-350 837806-094 837812-188 837814-219 838205-071 838206-071 049855 description gd. coupling rh ts32-200-300h dd guard. warning-sever-fan quantity 1 1 1 1 4 1 1 1 2 3 4 7 3 2 6 4 4 6 8 4 6 4 4 1 1 1 (I) For maintenance on drive coupling element. spr lock reg pltd 3/4 washer.Section 8 ILLUSTRATIONS AND PARTS LIST 8. The shaft seal is not considered part of the compressor unit in regard to the two year warranty. main (III) sign. spr lock reg pltd 3/8 washer. INDICATE SERIAL NUMBER OF COMPRESSOR 59 . The normal Sullair parts warranty applies. 6 AIR INLET SYSTEM 02250133-129R01 60 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. hex gr5 5/16-18 x 1 3/4 capscr. tube-m 1/4 x 1/4 nut. hex gr5 3/8-16 x 1 quantity 1 2 1 1 1 1 1 2 2 1 1 2 1 1 1 1 1 1 1 1 1 4 1 2 2 2 (Continued on page 63) (I) For details of the Sullicon Control. Sullicon less brkt (I) washer. and secondary replacement element no. PLEASE NOTE: WHEN ORDERING PARTS. consult Section 8.hex unfin 3/8-16 nut. inl vlv(3/4”shft)adj hose. hump 10” id elbow.18. hose 8” regulator.press-1/4npt 2-150# (II) support.hex pltd 5/16-18 nut. 250007-839. (III) For maintenance on air filter no. (II) This part is used only on machines with pressures higher than 125 psig/ 8. air inlet 90 rubber clamp.063”alum x 14”lg rod.5id x 13. Sullicon Control. hose t-bolt 10” rod end. sprlock hi clr 5/16” gage. (III) cap.air inlet 10” bracket. Lower pressures will not have tube elbow threaded directly into assembly. ctl mtg 32/25 lever.25od clamp. 10”od x . .link compressor rod end.18” dia air fltr filter.06 x 10. 250007-838. compressor inlet 10” to 8” w/1”npt p tube.Section 8 ILLUSTRATIONS AND PARTS LIST 8. spherical rh 5/16 gasket. tube 90 deg m 1/4 x 1/4 connector.hex f pltd 5/16-18 capscr. spheical lh 5/16 elbow. air press 2 1/2” 0-200 psi (II) adapter.6 AIR INLET SYSTEM key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 part number 011682-003 02250112-561 02250117-009 02250130-375 029846 029910 040136 041079 041902 042004 043406 043598 046556 250003-374 250006-718 250007-712 250014-397 250019-036 250019-721 810504-025 813604-250 824206-337 825205-273 825305-283 828605-175 829106-100 description control.6 bar. INDICATE SERIAL NUMBER OF COMPRESSOR 61 . order primary replacement element no. 250006-718. air 18” dia. Section 8 ILLUSTRATIONS AND PARTS LIST 8.6 AIR INLET SYSTEM 02250133-129R01 62 . pipe-brs seat 1/4 gal 300# valve. spr lock reg pltd 3/8 washer. (IV) Butterfly valve may vary. spr lock reg pltd 7/8 washer. Lower pressures will not have tube elbow threaded directly into assembly. hex gr5 3/8-16 x 1 1/4 capscr. hex gr5 7/8-9 x 4 washer. spr lock reg pltd 5/16 washer.pipe-hx pltd 1/4 x 1/4 (II) union. pipe 90 deg plt 1/4” (II) nut. spr lock 3/8 washer. hex jam lh pltd 5/16-24 capscrew. hex jam rh pltd 5/16-24 nipple. ferry head hd pltd 5/16-18 x 1 1/4 nut. butterfly 10” (IV) quantity 4 8 4 1 2 8 4 1 1 1 1 3 1 1 (II) This part is used only on machines with pressures higher than 125 psig/ 8. PLEASE NOTE: WHEN ORDERING PARTS.Section 8 ILLUSTRATIONS AND PARTS LIST 8. INDICATE SERIAL NUMBER OF COMPRESSOR 63 .6 bar. pl-b reg pltd 3/8 elbow.6 AIR INLET SYSTEM (CONTINUED) key number 27 28 29 30 31 32 33 34 35 36 37 38 39 40 part number 829106-125 829114-400 837506-094 837805-078 837806-094 837814-219 838206-071 866215-010 866605-195 867305-125 868205-195 868504-025 873530-010 - description capscr. Consult factory with machine serial number. Section 8 ILLUSTRATIONS AND PARTS LIST 8.AIR-COOLED 200-250HP/ 149-186KW 02250134--080R00 64 .7 FLUID COOLING SYSTEM. 7 FLUID COOLING SYSTEM. fan 42” ts20-150/250hpacac bar. pl-b reg pltd 1/2 eyebolt.oil(ac)200/250hp 200psi guard.hex pltd 1/2-13 nut. spr lock reg pltd 1/2 washer. pl-b reg pltd 3/8 washer. hex ser washer 3/8-16 x 3/4 screw.retainer 5/16-18 . venturi panel 200/250hpac part adapter.cooler ts32a-200/250 intac spcl lug. door support.rubber nut.hex f pltd 3/8-16 nut.back-up horizontal clr pk adapter. hex ser washer 3/8-16 x 1 1/4 washer.cooler ts32a-200/250 intac support. spr lock reg pltd 3/8 washer. clean out cover panel. venturi panel 200/250hpac part hinge.AIR-COOLED 200-250HP/ 149-186KW key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 part number 02250121-098 02250121-123 02250122-381 02250122-428 02250122-858 02250123-366 02250123-797 02250123-920 02250124-924 02250125-402 02250126-432 02250126-433 02250132-040 040125 825208-448 825305-283 825306-347 825505-166 825508-262 829108-175 829705-075 829705-100 829706-075 829706-100 829706-125 837806-094 837808-125 838205-071 838206-071 838208-112 839105-112 861405-092 (Continued on page 67) PLEASE NOTE: WHEN ORDERING PARTS. fan motor ts20-250hpacac (256t m heat exchanger.5/16-18 x 1 1/8” pltd nut. pl-b reg pltd 5/16 washer. venturi 42”fan ts20-250hpac support.hex f pltd 5/16-18 nut.092 quantity 1 4 1 1 1 1 2 2 2 4 3 1 4 16 14 44 12 8 4 14 50 10 4 16 22 22 14 8 22 4 8 6 65 . INDICATE SERIAL NUMBER OF COMPRESSOR description cooler. hex ser washer 3/8-16 x 1 screw.90deg bend grommet.Section 8 ILLUSTRATIONS AND PARTS LIST 8.lifting clr pk . hex ser washer 5/16-18 x 3/4 screw. hex ser washer 5/16-18 x 1 screw.hex locking 5/16-18 nut. hex gr5 1/2-13 x 1 3/4 screw. air after 200/250hp 200psi plate.hex locking 1/2-13 capscr. 7 FLUID COOLING SYSTEM.AIR-COOLED 200-250HP/ 149-186KW 02250134--080R00 66 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. hex ser washer 1/2-13 x various (I) fan (I) motor (I) quantity 1 4 1 1 (I) This item may vary with machine. PLEASE NOTE: WHEN ORDERING PARTS.7 FLUID COOLING SYSTEM.AIR-COOLED 200-250HP/ 149-186KW (CONTINUED) key number 33 34 35 36 part number - description bushing (I) screw. INDICATE SERIAL NUMBER OF COMPRESSOR 67 . Consult factory with machine serial number.Section 8 ILLUSTRATIONS AND PARTS LIST 8. AIR-COOLED 300-350HP/ 224-261KW 02250128-959R01 68 .Section 8 ILLUSTRATIONS AND PARTS LIST 8.8 FLUID COOLING SYSTEM. retainer 5/16-18 . INDICATE SERIAL NUMBER OF COMPRESSOR 69 .lifting clr pk . cooler ts32a-300/350 intac strside hinge. hex gr5 1/2-13 x 1 3/4 screw. hex ser washer 3/8-16 x 3/4 screw.hex f pltd 5/16-18 nut. pl-b reg pltd 3/8 washer. hex ser washer 5/16-18 x 1 screw.AIR-COOLED 300-350HP/ 224-261KW key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 part number 02250121-117 02250121-118 02250121-119 02250121-120 02250121-123 02250121-343 02250122-218 02250122-219 02250123-797 02250123-834 02250123-835 02250125-402 02250132-040 040125 241347 825208-448 825305-283 825505-166 829106-125 829108-175 829705-075 829705-100 829706-075 829706-100 837806-094 837808-125 838205-071 838206-071 838208-112 839105-112 861405-092 (Continued on page 71) description panel. pl-b reg pltd 1/2 eyebolt.hex pltd 1/2-13 nut. pl-b reg pltd 5/16 washer. spr lock reg pltd 1/2 washer.90deg bend grommet. air aft 300/350 hp bar. adapter 400hp clr pk w/clean saddle. hex gr5 3/8-16 x 1 1/4 capscr. adapter 400hp clr pk panel. spr lock reg pltd 3/8 washer. mtr 300/400hp clr pk plate.Section 8 ILLUSTRATIONS AND PARTS LIST 8.rubber guard.8 FLUID COOLING SYSTEM.092 quantity 2 2 1 1 4 1 1 1 2 2 2 4 4 14 2 15 20 8 14 12 32 12 6 16 9 12 8 9 8 8 10 PLEASE NOTE: WHEN ORDERING PARTS. door lug. clean out cover panel.5/16-18 x 1 1/8” pltd nut.back-up horizontal clr pk support. fan (1600q) nut. hex ser washer 5/16-18 x 3/4 screw. motor supt 300/400hp clr pk support. hex ser washer 3/8-16 x 1 washer.hex locking 5/16-18 capscr. oil 300/350 hp cooler. cooler ts32a-300/350 intac mtrside support. venturi 48” ts32-300-450 cooler. AIR-COOLED 300-350HP/ 224-261KW 02250128-959R01 70 .8 FLUID COOLING SYSTEM.Section 8 ILLUSTRATIONS AND PARTS LIST 8. PLEASE NOTE: WHEN ORDERING PARTS.8 FLUID COOLING SYSTEM. Consult factory with machine serial number.Section 8 ILLUSTRATIONS AND PARTS LIST 8. INDICATE SERIAL NUMBER OF COMPRESSOR 71 . hex gr5 1/2-13 x various len (I) bushing (I) motor (I) quantity 1 4 1 1 (I) This item may vary with machine.AIR-COOLED 300-350HP/ 224-261KW (CONTINUED) key number 32 33 34 35 part number - description bushing (I) capscr. 9 WATER COOLER PIPING.Section 8 ILLUSTRATIONS AND PARTS LIST 8.200-350HP/ 149-261KW 02250127-756R01 & 02250128-479R01 72 . aftclr/oilclr 1-1/2” o. tube.Section 8 ILLUSTRATIONS AND PARTS LIST 8.pipe 1 1/2 x 6 1/2 nipple.red hx 3 x 1 1/2 connector. water in decal. 2” npt oil in/out elbow. INDICATE SERIAL NUMBER OF COMPRESSOR 73 . support.wc aftclr/ac discharge pipe tube.200-350HP/ 149-261KW key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 part number 02250124-430 02250124-618 02250124-619 02250128-850 02250134-267 02250134-347 250008-245 801608-060 802112-060 810224-150 810524-150 822124-065 822132-130 825208-448 829108-150 837808-125 838208-112 866215-060 866324-030 866324-050 867108-060 868308-800 866432-000 049873 250019-107 250019-108 description support. water out quantity 2 1 1 1 1 1 1 1 2 5 1 1 1 16 16 20 18 4 1 2 3 2 1 1 1 1 1 1 (I) This item may vary with machine.ts32-200/250wc serpp wtrout to •tube.d. fluid (I) aftercooler (I) nipple. spr lock reg pltd 1/2 washer. pl-b reg pltd 1/2 elbow. aftercooler tube.ts32-300/350wc serpp wtrout to bracket.pipe-xs plt 2 x cl (300-350 only) decal. PLEASE NOTE: WHEN ORDERING PARTS.9 WATER COOLER PIPING. hex gr5 1/2-13 x 1 1/2 washer.pipe pltd 1 1/2 x 3 nipple. tube-m 1 1/2 x 1 1/2 elbow. tube 90 deg m 1 1/2 x 1 1/2 nipple. Consult factory with machine serial number. pipe 90 deg plt 1 1/2” nipple. water in/aftclr 1-1/2” o.hex pltd 1/2-13 capscr.pipe pltd 1 1/2 x 5 bushing.1/2” x 8” pipe pltd cooler.pipe 2 x 13 (250 only) nut.d. water inlet-outlet decal.red pltd 2 x 1 1/2 u-bolt. red 2 x 1 1/2 150# bushing. 10 AIR PIPING SYSTEM.AIR-COOLED 200-350HP/ 149-261KW 02250132-275R01&02250128-960R02 74 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. 068” valve. consult factory with machine serial number. expansion ts32a-200/250ac mpv/intac •joint. expansion ts32a-300/350 mpv/intac valve.pipe pltd 1 1/2 x 5 washer. PLEASE NOTE: WHEN ORDERING PARTS.pipe 1/2 x 1 1/2 nipple.pipe 3 x 5 1/2 (300-350hp/224-261kw) nipple. 250018-262. 046782. (II) For maintenance on pneumatic valve no.AIR-COOLED 200-350HP/ 149-261KW key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 part number 02250111-105 02250121-831 02250127-208 02250123-836 044912 240621-008 249616-015 250033-821 801515-020 801604-020 819315-048 822108-015 822108-030 822148-035 822148-030 822148-070 822148-055 822148-140 825210-559 829106-075 829110-300 866324-050 837806-094 837808-125 837810-156 838206-071 838208-112 860116-100 description separator. seperator mount joint. press. pipe 90 deg 1/2” 150# elbow. order repair kit no.pipe 3 x 14 nut.Section 8 ILLUSTRATIONS AND PARTS LIST 8. water dh ws800 3”npt (I) bracket. 250033-821.pipe 1/2 x 3 nipple.pipe 3 x 3 (300-350hp/224-261kw) nipple. 1” x .pipe 3 x 3 1/2 (200-250hp/149-186kw) •nipple. pl-b reg pltd 3/8 washer. spr lock reg pltd 5/8 washer.10 AIR PIPING SYSTEM. pl-b reg pltd 1/2 connector.hex pltd 5/8-11 capscr. hex gr5 5/8-11 x 3 nipple. asa flange 150# 3” hose. red 1 x 1/2 150# flange. (III) For maintenance on minimum pressure check valve no. 02250111-105.37 fl/mpt pltd 1 x 1 quantity 1 1 1 1 1 3 1 1 1 1 3 1 1 2 2 1 1 1 12 4 4 2 4 2 12 4 2 2 (Continued on page 77) (I) For maintenance on water separator no. INDICATE SERIAL NUMBER OF COMPRESSOR 75 .pipe 3 x 7 (200-250hp/149-186kw) •nipple. min press check 3” (spl) (III) elbow. hex gr5 3/8-16 x 3/4 capscr. 2-way pneumatic n.med. spr lock reg pltd 1/2 washer. 044912. order repair kit no. spr lock reg pltd 3/8 washer. thrd 3” 150# rf nipple.c. (II) gasket. 10 AIR PIPING SYSTEM.Section 8 ILLUSTRATIONS AND PARTS LIST 8.AIR-COOLED 200-350HP/ 149-261KW 02250132-275R01&02250128-960R02 76 . 1/2” x 3” pipe pltd valve. blwdwn 1”nc 2way #c6654 (IV) nipple. order repair kit no.Section 8 ILLUSTRATIONS AND PARTS LIST 8.pipe-brs seat 1 150# quantity 1 1 1 1 2 1 1 1 (IV) For maintenance on blowdown valve no. 001667. 409783. PLEASE NOTE: WHEN ORDERING PARTS.10 AIR PIPING SYSTEM. 37fl 90m 1 x 1 elbow.AIR-COOLED 200-350HP/ 149-261KW (CONTINUED) key number 26 27 28 29 30 31 32 33 part number 866408-000 868308-300 409783 822116-025 822216-000 860216-100 866215-040 871615-040 description nipple. pipe 90 deg plt 1” union.pipe 1 x 2 1/2 nipple.pipe-xs plt 1/2 x cl u-bolt.pipe-xs 1 x cl elbow. INDICATE SERIAL NUMBER OF COMPRESSOR 77 . 11 AIR PIPING SYSTEM.Section 8 ILLUSTRATIONS AND PARTS LIST 8.WATER-COOLED 200-350HP/ 149-261KW 02250128-576R01&02250128-577R01 78 . WATER-COOLED 200-350HP/ 149-261KW key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18A 18B 19 20 21 22 23 24 25 26 description separator. spr lock reg pltd 5/8 connector. order repair kit no.pipe 1 x 2 1/2 nipple. 250033-821. order repair kit no. asa flange 150# 3” gasket. pipe 90 deg plt 1/2” nipple. min press check 3” (spl) (III) elbow. hex gr5 5/8-11 x 3 washer.pipe pltd 1/2 x 5 nipple. (II) gasket. red 1 x 1/2 150# flange.pipe-xs 1 x cl elbow.068 valve.pipe-xs plt 1/2 x cl nipple. consult factory with machine serial number. INDICATE SERIAL NUMBER OF COMPRESSOR 79 . 2-way pneumatic n. 4” 125# flg full face hose. expansion mpv to aftclr 3” dia. (IV) For maintenance on blowdown valve no. 409783.11 AIR PIPING SYSTEM.Section 8 ILLUSTRATIONS AND PARTS LIST 8.pipe-brs seat 1 150# valve. thrd 3” 150# rf flange. 046782.pipe 3 x 20 (300-350hp/224-261kw) nipple. (III) For maintenance on minimum pressure check valve no. order repair kit no.med press 1 x . 250018-262. water dh ws800 3”npt (I) joint.pipe pltd 3 x 16 (200-250hp/149-186kw) •nipple.pipe pltd 3 x 16 (200-250hp/149-186kw) •nipple. 37fl 90m 1 x 1 part number 02250111-105 02250124-433 044912 240621-008 242437-010 249616-015 250033-821 801604-020 819315-048 819548-090 822148-080 822148-035 825210-559 829110-300 837810-156 860116-100 866215-020 866308-050 866348-160 822148-065 866348-160 822148-200 866408-000 866448-000 866215-040 871615-040 409783 822116-025 822216-000 860216-100 quantity 1 1 1 1 2 1 1 1 2 1 1 1 20 20 20 2 1 1 2 1 2 1 2 1 1 1 1 1 2 1 (I) For maintenance on water separator no.hex pltd 5/8-11 capscr. pipe 90 deg plt 1” union. 001667. (II) For maintenance on pneumatic valve no. blwdwn 1”nc 2way #c6654 (IV) nipple. 02250111-105.c.pipe 3 x 6 1/2 (300-350hp/224-261kw) nipple.pipe 3 x 3 1/2 (300-350hp/224-261kw) nut.37 fl/mpt pltd 1 x 1 elbow. PLEASE NOTE: WHEN ORDERING PARTS.pipe-xs plt 3 x cl elbow.pipe 3 x 8 (200-250hp/149-186kw) •nipple. 044912. valve. thrd red 3 x 9” nipple. 12 AIR PIPING SYSTEM.REMOTE COOLER 300-350HP/ 224-261KW 02250129-126R01 80 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. thrd 3” 150# rf nipple. (II) For maintenance on blowdown valve no.med press 1.pipe-brs seat 1 150# union.REMOTE COOLER 300-350HP/ 224-261KW key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 part number 02250124-430 02250128-850 040284 249616-015 250033-821 409783 819315-048 822148-030 822148-075 822148-200 822148-960 822416-000 825208-448 829108-150 837808-125 838206-071 838208-112 860116-100 860216-100 866215-040 866215-120 866416-025 871615-040 871615-120 description support. 250018-262. aftercooler support. 250033-821. pipe 90 deg plt 1” elbow.12 AIR PIPING SYSTEM. spr lock reg pltd 1/2 washer.wc aftclr/ac discharge pipe clamp.pipe-brs seat 3 150# quantity 2 1 2 1 1 1 1 1 2 1 1 2 10 10 10 4 2 1 1 1 1 1 1 2 (I) For maintenance on minimum pressure check valve no.Section 8 ILLUSTRATIONS AND PARTS LIST 8.pipe 3 x 20 nipple.pipe-xs plt 1 x 2 1/2 union. INDICATE SERIAL NUMBER OF COMPRESSOR 81 . 001667. order repair kit no. pipe 90 deg plt 3” nipple. blwdwn 1”nc 2way #c6654 (II) flange.37 fl/mpt pltd 1 x 1 elbow.pipe 3 x 3 nipple. 409783.hex pltd 1/2-13 capscr. pl-b reg pltd 1/2 connector. pl-b reg pltd 3/8 washer.pipe 3 x 96 nipple. exhaust 3 1/2” hose.00 x . hex gr5 1/2-13 x 1 1/2 washer.pipe 3 x 7 1/2 nipple. 37fl 90m 1 x 1 elbow.068” valve.half-xs 1 x cl nut. PLEASE NOTE: WHEN ORDERING PARTS. order repair kit no. min press check 3” (spl) (I) valve. 13 FLUID PIPING SYSTEM.AIR-COOLED & WATER-COOLED 200-250HP/ 149-186KW 02250130-765R01&02250132-477R01 82 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. 02250113-668. 02250105-553. order replacement kit no.AIR-COOLED & WATER-COOLED 200-250HP/ 149-186KW key number 1 2 3 4 5 part number 02250055-014 02250101-372 02250113-668 02250121-658 02250127-119 02250127-962 02250127-347 02250127-349 02250127-351 02250126-478 02250127-353 049542 811224-150 811624-188 811624-188 811824-188 811824-188 826502-144 837806-094 867306-150 870032-024 02250126-426 02250126-476 02250134-340 811324-150 description adapter.thermal valve to oil cooler tube.u-cup viton thermal vlv (I) valve. (III) For maintenance on coreless filter no.1 7/8-12 sae coreless (III) housing. ferry head hd pltd 3/8-16 x 1 1/2 reducer. thermal valve 175deg f. 02250127-962 (24KT and water-cooled compressors rated > 150 psig). viton 2 1/2 x 3/32” (I) washer. sae 1 7/8-12 x 1 7/8-12 seal.13 FLUID PIPING SYSTEM. order repair kit no. oil return oilfltr/union 1-1/2 (air-cooled) •tube. oil stop (II) filter. tube str thd 1 1/2 x 1 7/8 (air-cooled) •connector. 02250112-709. oil return union/unit 1-1/2” element. INDICATE SERIAL NUMBER OF COMPRESSOR 83 . order replacement element no. (II) For maintenance on oil stop valve no. thermal (195º) (24KT & water-cooled compressors rated > 150 psig) (IV) quantity 2 1 1 1 1 1 1 1 1 1 1 1 1 3 4 3 2 1 4 4 1 1 1 1 1 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 tube. tube str thrd 1 1/2 x 1 7/8 (air-cooled) •elbow.oc/thrmvlv ts32-200/250 1-1/2”w union. spr lock reg pltd 3/8 capscrew.therm vlv 1 7/8”-12 conn w/ ext (I) •valve. 02250121-657.tube hex 1 1/2” (I) For maintenance on thermal valve rated at 175º.1-1/2” clr/thrmvlv ts32a-200/250 tube. 02250121-658. tube union 1 1/2 elbow. tube str thrd 1 1/2 x 1 7/8 (water-cooled) connector. oil return 1-1/2” (water-cooled) tube.Section 8 ILLUSTRATIONS AND PARTS LIST 8. oil return 1-1/2” tube.1-1/2” thrmvlv/clr ts32a-200/250 tube. PLEASE NOTE: WHEN ORDERING PARTS.str thrd viton 2 1/2 x 1 1/2 tube. (IV) For maintenance on thermal valve no. (I) elbow. consult factory for replacement parts list. tube str thd 1 1/2 x 1 7/8 (water-cooled) o-ring. AIR-COOLED & WATER-COOLED 300-350HP/ 224-261KW 02250128-961R1&02250128-481R1 84 .Section 8 ILLUSTRATIONS AND PARTS LIST 8.14 FLUID PIPING SYSTEM. INDICATE SERIAL NUMBER OF COMPRESSOR 85 .d. tube str thd 2 x 2 1/2 o-ring. (IV) For maintenance on coreless filter no.elbow/unit 2” o.thrmvlv/oilclr 2” o.d. (II) For maintenance on thermal valve no. 02250127-962 (24KT and water-cooled compressors rated > 150 psig). (III) For maintenance on coreless filter no. 02250120-955.d. 02250112-709. tube.intac/thrmvlv 2” o. order repair kit no. 02250121-658. (I) For maintenance on thermal valve no. thermal 2. 02250121-657. tube union 2 elbow. 001684. order repair kit no.thrmvlv/intac 2” o. ferry head hd pltd 1/2-13 x 3 tube. 02250120-957.oilfltr/elbow 2” o. elbow. 02250121-657.Section 8 ILLUSTRATIONS AND PARTS LIST 8. PLEASE NOTE: WHEN ORDERING PARTS.d. tube. sae 2-1/2-12 x 2-1/2-12 valve. order replacement element no.d. viton 2 3/4 x 1/8” washer.5” sae 170deg (I) •valve. order replacement kit no. oil stop 2. (V) For maintenance on oil stop valve no.AIR-COOLED & WATER-COOLED 300-350HP/ 224-261KW key number 1 2 part number 02250110-661 02250120-955 02250127-962 02250121-658 02250128-717 02250122-004 02250124-659 02250124-660 02250124-662 02250124-663 811232-200 811632-250 811832-250 826502-232 837808-125 867308-300 02250124-633 02250124-634 description adapter. spr lock reg pltd 1/2 capscrew.oilclr/thrmvlv 2” o. tube str thrd 2 x 2 1/2 connector. tube. thermal (195º) (24KT & water-cooled compressors rated > 150 psig) (II) quantity 2 1 1 1 1 1 1 1 1 1 1 5 1 1 4 4 1 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 filter. tube. 02250122-004.14 FLUID PIPING SYSTEM.d. order replacement element no. 2-1/2 sae coreless 80cn-1 (water-cooled) (IV) valve. 02250128-717.1 7/8-12 sae coreless (air-cooled) (III) •filter.5” sae (V) tube. 15 FLUID PIPING SYSTEM.Section 8 ILLUSTRATIONS AND PARTS LIST 8.REMOTE COOLER 300-350HP/ 224-261KW 02250129-289R01 86 . tube-m 2 x 2 elbow. 2-1/2” sae check valve insert filter.o.pipe-xs 2 x cl nut. thermal 2. tube union 2 union.tube hex 2” elbow. oil stop 2. 2” npt oil in/out tee.hex pltd 1/2-13 (I) For maintenance on thermal valve no. check 1/2” switch. 2-1/2 sae coreless 80cn-1 (IV) tube. (IV) For maintenance on coreless filter no.d. 02250120-957. 115f bracket. sae 2-1/2-12 x 2-1/2-12 valve. order repair kit no. 02250121-657. 02250120-955.2”dia ts32-300rc union to oil tube. 02250127-962 (24KT and water-cooled compressors rated > 150 psig). tube str thrd 2 x 2 1/2 nipple. order replacement kit no. 02250112-709. temp n. order repair kit no. thermal (195º) (24KT & water-cooled compressors rated > 150 psig) (II) quantity 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 valve. (III) For maintenance on oil stop valve no. 02250128-717.2”dia ts32-300rc thrmvlv to un tube.oilfltr/elbow 2” o. tube 90 deg m 1/2 x 1/2 elbow.d. tube. PLEASE NOTE: WHEN ORDERING PARTS.2”dia ts32-300rc union to thrm valve.5” sae 170deg (I) •valve.REMOTE COOLER 300-350HP/ 224-261KW key number 1 2 part number 02250110-661 02250120-955 02250127-962 02250122-004 02250124-659 02250124-660 02250125-617 02250128-717 02250129-215 02250129-219 02250129-221 02250129-223 042694 043239 250008-245 802208-082 810208-050 810232-200 810508-050 811232-200 811332-200 811632-250 822232-000 825208-448 (Continued on page 89) description adapter. tube-m 1/2 x 1/2 connector.15 FLUID PIPING SYSTEM. INDICATE SERIAL NUMBER OF COMPRESSOR 87 . order replacement element no.5” sae (III) tube.reducing 2 x 2 x 1/2 connector. (II) For maintenance on thermal valve no.Section 8 ILLUSTRATIONS AND PARTS LIST 8. 001684.elbow/unit 2” o. 02250122-004.2”dia ts32-300rc oil in to uni tube. Section 8 ILLUSTRATIONS AND PARTS LIST 8.15 FLUID PIPING SYSTEM.REMOTE COOLER 300-350HP/224-261KW 02250129-289R01 88 . pipe-hx pltd 1/4 x 1/4 quantity 1 2 6 2 1 4 1 PLEASE NOTE: WHEN ORDERING PARTS.red pltd 1/2 x 1/4 capscrew. spr lock reg pltd 1/2 washer. pl-b reg pltd 1/2 bushing. INDICATE SERIAL NUMBER OF COMPRESSOR 89 .REMOTE COOLER 300-350HP/224-261KW (CONTINUED) key number 24 25 26 27 28 29 30 part number 826502-232 829108-150 837808-125 838208-112 867102-010 867308-300 868504-025 description o-ring.Section 8 ILLUSTRATIONS AND PARTS LIST 8. hex gr5 1/2-13 x 1 1/2 washer. ferry head hd pltd 1/2-13 x 3 nipple. viton 2 3/4 x 1/8” capscr.15 FLUID PIPING SYSTEM. 16 SUMP AND PARTS.200-250HP/ 149-186KW 02250131-903R3 90 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. ball 3/4”sae x 3/4”npt joint.Section 8 ILLUSTRATIONS AND PARTS LIST 8.o-ring boss sae 1 1/4 gasket. spr lock reg pltd 5/8 washer. oil sump 24” vert std (II) valve.ts32-200/350 disch. PLEASE NOTE: WHEN ORDERING PARTS. 6” 125# flg full face element. (II) This item may vary with machine.hex pltd 5/8-11 capscr. expansion unit/sump ts32a-200/250hp tube. hex gr5 3/4-10 x 2 1/2 washer. sump drain 3/4” boom.sight glass 1-7/8” sae valve. hex gr5 5/8-11 x 3 1/4 capscr. INDICATE SERIAL NUMBER OF COMPRESSOR 91 .16 SUMP AND PARTS. tube str thd 3/4 x 1 1/16 nut. hex gr5 1/2-13 x 2 capscr.200-250HP/ 149-186KW key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 part number 020169 02250097-611 02250125-221 02250126-431 02250126-483 02250127-249 02250129-876 02250131-223 02250136-549 040029 240621-010 242437-012 250034-121 811812-106 825208-448 825210-559 829108-200 829108-250 829110-325 829112-250 837808-125 837810-156 837812-188 838208-112 866900-010 866900-030 868512-075 - description connector.flex hose plug.pipe-hx pltd 3/4 x 3/4 tank. and (secondary) replacment element no. relief 1-1/2” 1950cfm viton s (II) quantity 2 2 1 1 1 1 1 1 1 1 1 1 1 2 4 8 4 2 8 9 6 8 8 10 1 1 1 1 1 (I) For maintenance on separator elements.flex 1/4t x 1/4p plug. 02250131-225. pl-b reg pltd 1/2 plug. spr lock reg pltd 1/2 washer. secondary separator (I) support. Consult factory with machine serial number.oil rtn/sight gls line element. order (primary) replacement element no.lid lifting sub assembly. hex gr5 1/2-13 x 2 1/2 capscr. asa flange 150# 4” gasket. spr lock reg pltd 3/4 washer. pipe 1/4” 3000# stl plt plug.hex pltd 1/2-13 nut. pipe 3/4” 3000# stl plt nipple. 250034-122. primary 25-200 (I) connector. 300-350HP/ 224-261KW 02250128-162R01 92 .Section 8 ILLUSTRATIONS AND PARTS LIST 8.17 SUMP AND PARTS. 17 SUMP AND PARTS.o-ring boss sae 1 1/4 gasket. relief 1-1/2” 1950cfm viton s (II) quantity 2 2 1 1 1 1 1 1 2 1 1 1 1 2 8 4 2 8 13 2 2 (I) For maintenance on separator elements. ball 3/4”sae x 3/4”npt tube. bevel 3/4 washer.3/4” sump drain sub assembly. 250034-130.pipe-hx pltd 3/4 x 3/4 tank. pipe 1/4” 3000# stl plt plug. sep/sec (II) connector. spr lock reg pltd 5/8 washer. and (secondary) replacment element no.300-350HP/ 224-261KW key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 part number 020169 02250097-611 02250120-730 02250125-221 02250125-918 02250126-164 02250127-249 02250128-598 040029 240621-010 242437-012 250034-123 250034-129 811812-106 825210-559 825212-665 829108-275 829110-325 829112-250 837012-150 837808-125 837810-156 837812-188 838208-112 838212-112 866900-010 866900-030 868512-075 12 2 6 1 1 1 1 1 description connector. 6” 125# flg full face element. spr lock reg pltd 3/4 washer.oil return/sightglass line plug. pl-b reg pltd 1/2 washer. pipe 3/4” 3000# stl plt nipple. PLEASE NOTE: WHEN ORDERING PARTS. Consult factory with machine serial number. expansion ts32-200/350 4” vert tnk valve. sep/pri (I) element. oil separator 30”dia (II) valve. asa flange 150# 4” gasket. hex gr5 3/4-10 x 2 1/2 washer. hex gr5 5/8-11 x 3 1/4 capscr.oil return/sightglass line boom.flex 1/4t x 1/4p plug. order (primary) replacement element no. hex gr5 1/2-13 x 2 3/4 capscr. pl-b reg pltd 3/4 plug.Section 8 ILLUSTRATIONS AND PARTS LIST 8.lid lifting support. spr lock reg pltd 1/2 washer.sight glass 1-7/8” sae joint.hex pltd 3/4-10 capscr. (II) This item may vary with machine. 250034-124.hex pltd 5/8-11 nut. INDICATE SERIAL NUMBER OF COMPRESSOR 93 . tube str thd 3/4 x 1 1/16 nut. Section 8 ILLUSTRATIONS AND PARTS LIST 8.18 SULLICON CONTROL 02250134-158R0 94 . external (I) nut. control Sullicon plunger stop. order repair kit no.hex locking 5/16-18 pin.yoke 1/4” rod-end. hex gr5 3/8-16 x 2 1/4 capscr.adj sullicon spring yellow zinc pin. hex gr5 5/16-18 x 2 1/2 capscr. 250020-353. mach-hex 5/16-24 x 2 washer.hex pltd 3/8-16 nut. ferry head hd 3/8-16 x 2 capscr. control light diaphragm. PLEASE NOTE: WHEN ORDERING PARTS. flathead countersunk (I) cup seal (I) spring.control cover. spr lock reg pltd 3/8 nut. yoke screw.cotter ep-sc 1/16 x 3/4 capscrew. control washer. control bolt. INDICATE SERIAL NUMBER OF COMPRESSOR 95 . For maintenance. back-up (I) body.hex pltd 5/16-18 nut.Section 8 ILLUSTRATIONS AND PARTS LIST 8. shoulder 3/8 x 2 screw. hex gr5 3/8-16 x 2 1/2 screw. 250020353. spr lock reg pltd 5/16 washer. hex gr5 5/16-18 x 2 1/4 capscr. hex jam rh pltd 5/16-24 quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 3 7 1 1 1 2 1 1 3 1 1 3 5 1 (I) This part is included in Sullicon repair kit no.18 SULLICON CONTROL key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 part number 011084 020094 020864 021172 021635 021654 02250112-184 040065 040138 041264 042538 250006-526 250020-028 825205-273 825206-337 825505-166 827101-075 828406-200 829105-225 829105-250 829106-225 829106-250 830506-200 831105-200 837805-078 837806-094 868205-195 description lever. 19 COMPRESSOR ACTUATOR 96 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. hex jam 1/4”-20 decal. hex jam 3/8”-16 shaft. air cylinder cylinder.Section 8 ILLUSTRATIONS AND PARTS LIST 8.direct •shaft. weight counterbalance capscrew. pinion indicator.geared valve. rack gear. INDICATE SERIAL NUMBER OF COMPRESSOR 97 . valve . set 1/2”-13 x 1. ball seal. ferry head 1/2”-18 x 1 1/4” spring.062 x . seal 2 1/4” rack. 250016-183. hex unfinished 1/2”-13 screw. warning actuator decal. hex head gr8 1/4”-20 x 1/2” cover. lip screw. gear nut. order diaphragm repair kit no. roll unfinished 1/4”x 1” capscrew. air (I) orifice.25f nut. air cylinder capscrew.25m x . machine rod #8-32 x 1/2” mount. machine hex 1/4”-20 x 1 3/4” nut. actuator valve positioning quantity 1 1 1 2 1 1 1 1 1 6 1 1 1 1 4 1 6 6 1 3 1 1 1 1 1 1 1 1 1 1 1 (I) For maintenance on air cylinder no. 608311-001.19 COMPRESSOR ACTUATOR key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 part number 250030-981 250030-982 250016-193 828906-100 499068-005 499002-207 250016-200 250024-465 250016-182 828408-150 250016-199 250016-196 250030-983 827404-100 828204-050 250016-195 838201-045 831601-050 250016-188 828405-125 250016-394 250016-197 824906-227 250016-194 250016-183 028831 824208-448 830104-175 824904-164 250029-836 250029-784 description shaft. actuator pin. .62 br adapter. socket 3/8”-16 x 1” ring. ferry head 1/2”-13 x 1 1/2” guide. adapter washer. retaining bearing. air cylinder capscrew. regular #8 screw. PLEASE NOTE: WHEN ORDERING PARTS. valve . Section 8 ILLUSTRATIONS AND PARTS LIST 8.20 MOISTURE DRAIN SEPARATOR 98 Section 8 ILLUSTRATIONS AND PARTS LIST 8.20 MOISTURE DRAIN SEPARATOR key number 1 2 3 4 5 6 7 8 9 part number 02250130-866 047117 250024-695 250024-713 250024-714 841500-008 868508-050 868512-050 250022-810 description drain,electric condensate - scd300 valve,ball 1/2”npt connector,tube-strt 1/2”mnpt x 1/2”tube connector, tube-el 3/8”npt x 1/2”tube connector, tube-el 1/2”npt x 1/2”tube bulkhead, pipe 1/2” npt nipple,pipe-hx pltd 1/2 x 1/2 nipple,pipe-hx pltd 3/4 x 1/2 decal, water drain quantity 2 2 1 2 1 1 2 2 1 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 99 Section 8 ILLUSTRATIONS AND PARTS LIST 8.21 PNEUMATIC CONTROLS 02250128-163R2 100 solenoid 2wnc 1/4 150# n4 (III) support.str box ls20s ac channel.conduit 1/2 x 1.supt bracket. nipple. pressure 0-25psi 1-5vdc n4 valve. 02250125-679.125-. bracket transducer mounting valve.25m nptf support. INDICATE SERIAL NUMBER OF COMPRESSOR 101 . 02250125-861. drain-self close 1/8npt band. ctl tubing supt angle.187 x 1/2” locknut. .031” x . 02250112-032.press-1/4npt 2-150# reservoir. air press 2 1/2” 0-200 psi valve.125” nipple. pressure relief 1/2”npt-150 psig orifice. 02250125-829. 90 1/4t pls x 1/4 npt m quantity 4 5 6 1 4 1 1 1 2 2 1 2 2 2 1 2 1 1 1 1 2 1 1 1 3 2 (I) For maintenance on control filter no.25m x . order repair kit no. order repair kit no.in. PLEASE NOTE: WHEN ORDERING PARTS.support bracket. cord n4 . 02250125-824. check 1/4”nptf viton seat filter. cord n4 .conduit 1/2 x 1. 02250125-657. mounting 7” dia regulator. (II) For maintenance on 3-way solenoid valve no.250-. n4 conduit sealing grip. (III) For maintenance on 2-way solenoid valve no. air 415 cu. and replacement coil no.375 x 1/2” switch.control air 1/4”npt (I) gage.5” elbow.support bracket. 02250112-031. order repair kit no. solenoid 3wno 1/4 235# n4 (II) valve. 02250125-861. tubing manifold valve. and replacement coil no. vacuum 22”wc n4 6ft cable 5a transducer.Section 8 ILLUSTRATIONS AND PARTS LIST 8.21 PNEUMATIC CONTROLS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 part number 02250071-279 02250071-362 02250071-381 02250078-249 02250078-933 02250092-138 02250101-191 02250110-132 02250110-557 02250112-032 02250117-009 02250125-657 02250125-679 02250127-380 02250127-559 02250133-550 02250133-551 02250133-552 02250133-564 041111 044285 046556 242221 250007-168 250007-169 250018-430 (Continued on page 103) description grip. Section 8 ILLUSTRATIONS AND PARTS LIST 8.21 PNEUMATIC CONTROLS 02250128-163R2 102 . tube bhd 1/4” connector.Section 8 ILLUSTRATIONS AND PARTS LIST 8. conduit 1/2” elbow.hex pltd 1/2-13 nut. hex ser washer 5/16-18 x 3/4 screw. shuttle 1/4” npt (dbl chk) connector. pressure reg 100psi (V) valve. tube-m 1/4 x 1/8 connector. tube 90 deg m 1/4 x 1/4 tee. straight lq-tite 1/2 elbow. 406929. pl-b reg pltd 3/8 bulkhead. tube-m 1/4 x 1/4 elbow. tube-m 1/4 x 1/8 nut. 041742. pipe 1/8” npt connector. spr lock reg pltd 3/8 washer.hex pltd 3/8-16 nut. entrance 1/2 bushing. spr lock reg pltd 1/2 washer. (V) For maintenance on pressure regulator valve no. hex gr5 1/2-13 x 1 1/2 screw. PLEASE NOTE: WHEN ORDERING PARTS.conduit plastic 1/2 part number 250018-495 406929 408275 408893 810104-025 810204-012 810204-025 810504-025 810904-025 811104-025 813604-125 825206-337 825208-448 825305-283 829106-150 829106-175 829108-150 829705-075 829705-100 837806-094 837808-125 838206-071 841500-002 846400-050 846600-050 847200-050 847715-050 848815-050 quantity 1 1 1 2 2 4 7 4 2 11 1 5 5 12 4 1 4 6 6 5 4 10 4 1 1 6 1 3 (Continued on page 105) (IV) For maintenance on differential pressure regulator valve no. 250028-693. INDICATE SERIAL NUMBER OF COMPRESSOR 103 . hex ser washer 5/16-18 x 1 washer. hex gr5 3/8-16 x 1 1/2 capscr. tube-male run 1/4 x 1/4 union.21 PNEUMATIC CONTROLS (CONTINUED) key number 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 description grip. hex gr5 3/8-16 x 1 3/4 capscr.cord so 12/4 st 1/2” valve. order repair kit no. 90deg lq-tite 1/2 locknut. order repair kit no. 408275. diff press reg 1/4”npt (IV) valve.hex f pltd 5/16-18 capscr. tube-f 1/4 x 1/4 connector. 21 PNEUMATIC CONTROLS 02250128-163R2 104 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. INDICATE SERIAL NUMBER OF COMPRESSOR 105 .pipe-hx pltd 1/4 x 1/4 nipple.red pltd 3/8 x 1/8 nipple. pipe 90m/f 3/8 x 1/2 tee. pipe-90m 1/4 x 1/4 elbow.assy ts32a (VI) part number 860504-025 860604-025 860704-025 860706-050 866815-010 866900-010 867101-005 868504-025 868506-025 869825-025 - quantity 3 1 2 1 4 2 1 4 1 4 1 (VI) This item may vary with machine. Consult factory with machine serial number.male pipe brass 1/4 starter. PLEASE NOTE: WHEN ORDERING PARTS.Section 8 ILLUSTRATIONS AND PARTS LIST 8.21 PNEUMATIC CONTROLS (CONTINUED) key number 55 56 57 58 59 60 61 62 63 64 65 description elbow. pipe 1/4” 3000# stl plt bushing. pipe 90f 1/4 x 1/4 elbow. pipe 150# plt 1/4 plug.pipe-hx pltd 3/8 x 1/4 tee. pipe 90m/f 1/4 x 1/4 elbow. SOLID STATE 02250122-005R3 106 .22 CONTROL BOX.Section 8 ILLUSTRATIONS AND PARTS LIST 8. SOLID STATE key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 part number 02550108-859 02550109-465 02250089-302 02550090-872 02250119-331 02250119-330 02250048-822 250026-648 250019-751 02250083-189 0250120-644 d45496 46467 02550110-334 02550101-721 02250122-042 02250120-789 02250120-792 02250122-043 02250122-044 02250120-645 02250122-046 02250130-344 02550086-259 02550085-504 250027-125 02550086-265 description enclosure door bezel beze. gasket I/0 module display module display gasket primary fuse 305 amp secondary fuse 5 amp univ. 250 va trans power supply 24v relay relay base ground bus ground bar 240A IT starter 304A IT starter 360A IT starter 420A IT starter 500A IT starter 650A IT starter 850A IT starter display label E-stop decal E-stop operator contact block plate quantity 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PLEASE NOTE: WHEN ORDERING PARTS.Section 8 ILLUSTRATIONS AND PARTS LIST 8.22 CONTROL BOX. INDICATE SERIAL NUMBER OF COMPRESSOR 107 . FULL VOLTAGE 02250122-511R2 108 .Section 8 ILLUSTRATIONS AND PARTS LIST 8.23 CONTROL BOX. Section 8 ILLUSTRATIONS AND PARTS LIST 8.23 CONTROL BOX. 500 va trans primary fuse 4 amp secondary fuse 6 a ground bus ground bar display module display label starter9 size 5 starter9 size 5dp starter9 size 6 display module gasket E-stop operator contact block I-NC E-stop decal plate quantity 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 PLEASE NOTE: WHEN ORDERING PARTS. INDICATE SERIAL NUMBER OF COMPRESSOR 109 . 350 va trans univ.FULL VOLTAGE key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 part number 02550108-859 02550109-465 02250129-958 02550090-872 02550119-331 02250135-283 250026-648 250019-751 02250083-189 02250083-192 250026-649 250019-762 02550110-334 02550101-721 02550119-330 02550130-344 250038-284 02250113-513 250038-285 02250048-822 02250085-504 250027-125 02250086-259 02250086-265 description enclosure door bezel bezel gasket I/O module transformer 24v primary fuse 3.5 amp secondary fuse 5 amp univ. 24 CONTROL BOX.WYE-DELTA 02250122-516R4 110 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. Section 8 ILLUSTRATIONS AND PARTS LIST 8. 350 va trans primary fuse 3.24 CONTROL BOX. INDICATE SERIAL NUMBER OF COMPRESSOR 111 .5 amp secondary fuse 5 amp door enclosure bezel bezel gasket I/O module display module transformer 24v size 5 contactor size 4 contactor size 5dp contactor size 5dp starter starter size 5 starter size n rev contactors size n display label E-stop operator contact block plate E-stop decal quantity PLEASE NOTE: WHEN ORDERING PARTS.5 amp secondary fuse 3 amp ground bar univ. 250 va trans primary fuse 2.WYE-DELTA key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 part number 02550110-334 02250083-188 250026-646 250019-758 02550101-721 02250083-190 250026-648 250019-761 02550109-465 02550108-859 02250089-302 02550090-872 02550119-331 02550119-330 02250135-283 02250083-824 02550083-823 02550113-514 02550113-513 250038-284 250038-283 250041-589 02550130-344 02550085-504 250027-125 02550086-265 02550086-259 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 description ground bus univ. Section 8 ILLUSTRATIONS AND PARTS LIST 8.AIR-COOLED 200-250HP/ 149-186KW 02250128-119R01 112 .25 ENCLOSURE. baffle sep access door ts32a panel. starter side ts32a support. separator access panel.25 ENCLOSURE.header end ts32a panel.Section 8 ILLUSTRATIONS AND PARTS LIST 8.baffle unit end ts32a hinge. hex ser washer 5/16-18 x 3/4 screw. access assy 30” x 57” grommet. roof seal ts32a-200/250ac panel. roof end ts32a-200/250ac panel.header 60” str ts32 encl angle.header side ts32a panel.rubber handle. center ts32a hinge. hex gr8 1/4-20 x 3/4 capscr. hex ser washer 5/16-18 x 1/2 screw. sill ts32a support. corner spcl ts32a panel.AIR-COOLED 200-250HP/ 149-186KW key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 description panel.hex f pltd 5/16-18 nut. roof mid ts32a-200/250ac panel. roof sump end ts32a cover. roof side ts32a-200/250ac panel. separator access door panel.hex locking 5/16-18 capscr.hex pltd 1/4-20 nut. 180deg. corner ts32a support. INDICATE SERIAL NUMBER OF COMPRESSOR 113 . hex gr5 5/16-18 x 3/4 screw.sill short ts32a panel. canopy nut. self-drill 1/4 x 1/2 part number 02250124-938 02250124-939 02250124-940 02250124-942 02250125-070 02250126-923 02250126-924 02250126-925 02250129-475 02250129-478 02250129-761 02250129-762 02250129-838 02250129-863 02250130-219 02250130-221 02250130-222 02250130-223 02250130-224 02250130-226 02250130-227 040125 042262 825104-226 825305-283 825505-166 827904-075 829105-075 829705-050 829705-075 834504-050 quantity 1 2 4 1 4 1 1 2 5 2 1 1 1 33 5 1 3 1 1 1 11 4 1 2 13 2 2 6 94 60 44 (Contiued on page 115) PLEASE NOTE: WHEN ORDERING PARTS. screw-on lift-off rh support. canopy ts32a support. 25 ENCLOSURE.AIR-COOLED 200-250HP/ 149-186KW 02250128-119R1 114 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. pl-b reg pltd 5/16 eyebolt.AIR-COOLED 200-250HP/ 149-186KW (CONTINUED) key number 32 33 34 35 description washer.092 part number 837804-062 838205-071 839105-112 861405-092 quantity 2 2 2 16 PLEASE NOTE: WHEN ORDERING PARTS.Section 8 ILLUSTRATIONS AND PARTS LIST 8.5/16-18 x 1 1/8” pltd nut. spr lock reg pltd 1/4 washer.25 ENCLOSURE. INDICATE SERIAL NUMBER OF COMPRESSOR 115 .retainer 5/16-18 . 26 ENCLOSURE.Section 8 ILLUSTRATIONS AND PARTS LIST 8.AIR-COOLED 300-350HP/ 224-261KW 02250128-122R01 116 . hex locking 5/16-18 capscr. corner spcl ts32a cover. separator access door panel. screw-on lift-off rh support. canopy ts32a support. roof starter side ts32a-300/350 panel. roof seal ts32a-300/350ac panel.AIR-COOLED 300-350HP/ 224-261KW key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 description panel. roof motor side ts32a-300/350ac panel. access assy 30” x 57” roof.baffle unit end ts32a hinge. hex gr5 1/4-20 x 3/4 capscr. corner ts32a support. canopy nut. roof seal ts32a-300/350ac angle. hex gr5 5/16-18 x 3/4 screw.sill short ts32a panel. hex ser washer 5/16-18 x 1/2 part number 02250124-938 02250124-939 02250124-940 02250124-942 02250127-099 02250127-100 02250127-101 02250127-102 02250127-103 02250127-104 02250129-475 02250129-478 02250129-761 02250129-762 02250129-838 02250129-863 02250130-219 02250130-221 02250130-222 02250130-223 02250130-226 02250130-227 02250133-148 040125 042262 825104-226 825305-283 825505-166 829104-075 829105-075 829705-050 quantity 1 2 4 1 1 1 1 1 2 2 5 2 1 1 1 33 5 1 3 1 1 11 1 4 1 2 13 2 2 6 94 (Continued on page 119) PLEASE NOTE: WHEN ORDERING PARTS. 180deg.header end ts32a panel. roof center ts32a-300/350ac panel.Section 8 ILLUSTRATIONS AND PARTS LIST 8. separator access panel.header 60” str ts32 encl panel.26 ENCLOSURE. sill ts32a support. INDICATE SERIAL NUMBER OF COMPRESSOR 117 .baffle sep access door ts32a panel. starter side ts32a support.hex f pltd 5/16-18 nut.rubber handle.hex pltd 1/4-20 nut. center ts32a hinge.header side ts32a panel. roof end ts32a-300/350ac angle.ts32-350 intclr rmtinl grommet. AIR-COOLED 300-350HP/ 224-261KW 02250128-122R01 118 .Section 8 ILLUSTRATIONS AND PARTS LIST 8.26 ENCLOSURE. 092 quantity 60 44 2 2 2 16 PLEASE NOTE: WHEN ORDERING PARTS.26 ENCLOSURE.Section 8 ILLUSTRATIONS AND PARTS LIST 8.5/16-18 x 1 1/8” pltd nut. spr lock reg pltd 1/4 washer.retainer 5/16-18 . hex ser washer 5/16-18 x 3/4 screw.AIR-COOLED 300-350HP/ 224-261KW (CONTINUED) key number 32 33 34 35 36 37 part number 829705-075 834504-050 837804-062 838205-071 839105-112 861405-092 description screw. INDICATE SERIAL NUMBER OF COMPRESSOR 119 . self-drill 1/4 x 1/2 washer. pl-b reg pltd 5/16 eyebolt. Section 8 ILLUSTRATIONS AND PARTS LIST 8.WATER-COOLED 200-350HP/ 149-261KW 02250128-124R01 120 .27 ENCLOSURE. sill spcl ts32a-200/350 wc & rc support. fan support nut.75hp 230/460v tefc spacer. screw-on lift-off rh support. roof sump end ts32a panel. canopy ts32a support. roof mtr end ts32a-200/350 wc & cover. sill ts32a support. corner spcl ts32a panel. corner ts32a support. INDICATE SERIAL NUMBER OF COMPRESSOR description support. separator access panel.hex pltd 1/4-20 quantity 1 1 1 4 2 1 1 4 2 1 1 1 33 1 1 4 1 3 1 1 1 1 9 2 2 4 1 1 1 1 3 2 121 .baffle sep access door ts32a panel. 180deg. blower 20”-30 deg 185q8f panel.baffle mtr end ts32a-200/350wc grommet. access assy 30” x 57” panel.WATER-COOLED 200-350HP/ 149-261KW key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 part number 014613 02250107-474 02250124-938 02250124-939 02250124-940 02250124-942 02250126-834 02250129-475 02250129-478 02250129-761 02250129-762 02250129-838 02250129-863 02250129-995 02250130-216 02250130-219 02250130-221 02250130-222 02250130-223 02250130-224 02250130-225 02250130-226 02250130-227 02250130-228 02250131-583 040125 041765 042262 043357 050288 227267 825104-226 (Continued on page 123) PLEASE NOTE: WHEN ORDERING PARTS.header 60” str ts32 encl panel. .27 ENCLOSURE. canopy clamp. roof center ts32a-200/350 wc & panel. access assy 30” x 54” panel. center ts32a hinge. separator access door panel. fan 24” handle. fan motor fan.Section 8 ILLUSTRATIONS AND PARTS LIST 8. canopy spcl ts32a panel.baffle unit end ts32a hinge.rubber guard. starter side ts32a support.header side ts32a panel.header end ts32a panel. speed tube 1/4” motor.sill short ts32a panel. 27 ENCLOSURE.WATER-COOLED 200-350HP/ 149-261KW 02250128-124R01 122 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. pl-b reg pltd 3/8 eyebolt.hex f pltd 5/16-18 nut. hex ser washer 5/16-18 x 1/2 screw.hex pltd 1/2-13 nut. hex gr5 5/16-18 x 3/4 screw.5/16-18 x 1 1/8” pltd quantity 7 4 14 2 4 3 4 2 6 94 44 42 2 3 4 2 7 2 PLEASE NOTE: WHEN ORDERING PARTS. hex ser washer 5/16-18 x 3/4 screw. hex gr5 3/8-16 x 4 capscr.WATER-COOLED 200-350HP/ 149-261KW (CONTINUED) key number 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 part number 825106-337 825108-448 825305-283 825505-166 828606-125 828606-400 828608-100 829104-075 829105-075 829705-050 829705-075 834504-050 837804-062 837806-094 837808-125 838205-071 838206-071 839105-112 description nut. spr lock reg pltd 3/8 washer.hex pltd 3/8-16 nut. hex gr5 1/4-20 x 3/4 capscr. spr lock reg pltd 1/4 washer. pl-b reg pltd 5/16 washer. INDICATE SERIAL NUMBER OF COMPRESSOR 123 . self-drill 1/4 x 1/2 washer. spr lock reg pltd 1/2 washer.Section 8 ILLUSTRATIONS AND PARTS LIST 8.hex locking 5/16-18 capscr. hex gr5 1/2-13 x 1 capscr.27 ENCLOSURE. hex gr5 3/8-16 x 1 1/4 capscr. Section 8 ILLUSTRATIONS AND PARTS LIST 8.28 DECALS 124 . warning sever . warning “food grade” lube decal.Section 8 ILLUSTRATIONS AND PARTS LIST 8. warning “compressor fluid fill cap” sign. Sullair logo quantity 1 1 2 1 1 1 1 1 2 (Continued on page 127) PLEASE NOTE: WHEN ORDERING PARTS. INDICATE SERIAL NUMBER OF COMPRESSOR 125 . air breathing (danger) decal. warning actuator sign. warning sever-fan port sign.28 DECALS key number 1 2 3 4 5 6 7 8 9 part number 049965 407408 049855 049850 250003-144 250029-836 049685 250027-935 02250059-048 description sign. danger electrocution sign. warning hot surfaces sign.fan sign. 28 DECALS 126 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. warning ground fault decal. fluid Sullube decal. warning actuator decal. fluid 24KT decal. warning auto start decal. V 380/3/50 international decal. water inlet-outlet decal. INDICATE SERIAL NUMBER OF COMPRESSOR 127 . water drain decal. PE designation decal. protective earth ground decal. V 460/3/60 international decal. water in decal. earth ground decal. fluid CP-4600-32-F decal. autostart decal.Section 8 ILLUSTRATIONS AND PARTS LIST 8. water out decal.28 DECALS (CONTINUED) key number 10 11 12 12 13 14 15 16 17A 17B 17C 18 19A 19B 19C 19D 20 21 22 23 part number 049852 250017-903 041065 250029-836 042218 049873 250019-107 250019-108 02250069-389 02250069-395 02250118-342 250022-810 02250069-399 02250069-400 02250069-412 02250069-397 02250075-045 02250075-540 02250075-046 02250110-891 description sign. danger high voltage decal. V 230/3/60 international decal. V 575/3/60 international decal. warning mixing fluids quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (Continued on page 129) PLEASE NOTE: WHEN ORDERING PARTS. 28 DECALS 128 .Section 8 ILLUSTRATIONS AND PARTS LIST 8. PLEASE NOTE: WHEN ORDERING PARTS. consult factory with machine serial number. ISO 9001 (I) decal. To determine the proper part number of this decal. electrical component ID sign. TS-32 decal. fork lifting quantity 1 1 1 1 1 1 1 1 4 (I) ISO decal may vary per machine. fluid sample decal. rotation decal. compressor fluid 24KT decal.Section 8 ILLUSTRATIONS AND PARTS LIST 8. INDICATE SERIAL NUMBER OF COMPRESSOR 129 . power energized decal. rotation decal.28 DECALS (CONTINUED) key number 24 25 26 27 28 29 30 31 32 part number 02250061-379 02250061-022 250021-564 250021-286 250022-675 250038-457 249544-049 241814 description decal. Section 8 ILLUSTRATIONS AND PARTS LIST 8.29 DECAL LOCATIONS 130 . ISO 9001 (I) decal. To determine the proper part number of this decal. warning sever-fan port decal. water drain decal. Sullair logo decal. consult factory with machine serial number. danger electrocution decal. (II) Fluid decal will vary per machine fill. TS-32 decal. compressor fluid 24KT sign. warning sever . consult factory with machine serial number.fan decal.Section 8 ILLUSTRATIONS AND PARTS LIST 8. warning sever . autostart sign. PLEASE NOTE: WHEN ORDERING PARTS. fluid (II) sign. warning “compressor fluid fill cap” decal. warning mixing fluids sign. INDICATE SERIAL NUMBER OF COMPRESSOR 131 . warning auto start sign.29 DECAL LOCATIONS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 part number 250027-935 250003-144 250022-810 02250061-022 049850 250017-903 049855 241814 02250059-048 02250061-379 041065 049855 02250110-891 049685 049965 250021-564 1 1 description sign.fan decal. warning “food grade” lube decal. To determine the compressor’s proper fill decal. air breathing (danger) sign. fork lifting decal. rotation quantity 1 1 1 1 1 1 2 4 2 1 1 1 2 1 1 (I) ISO decal may vary per machine. 30 DECAL LOCATIONS.Section 8 ILLUSTRATIONS AND PARTS LIST 8.ENCLOSURE 132 . warning hot surfaces sign. warning “compressor fluid fill cap” sign. TS-32 decal.Section 8 ILLUSTRATIONS AND PARTS LIST 8. danger electrocution decal.ENCLOSURE key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 part number 250027-935 250003-144 250022-810 407408 049850 250017-903 049855 241814 02250059-048 02250061-379 041065 049873 049685 049965 250021-564 description sign. warning auto start sign.fan decal. PLEASE NOTE: WHEN ORDERING PARTS. To determine the proper part number of this decal. air breathing (danger) sign. warning sever-fan port decal. warning “food grade” lube decal. rotation quantity 1 1 1 1 1 1 2 4 2 1 1 1 1 1 1 1 (I) ISO decal may vary per machine. Sullair logo decal. ISO 9001 (I) decal. consult factory with machine serial number. water inlet-outlet sign. water drain sign. INDICATE SERIAL NUMBER OF COMPRESSOR 133 . warning sever .30 DECAL LOCATIONS. autostart decal. fork lifting decal. CONTROL BOX 134 .Section 8 ILLUSTRATIONS AND PARTS LIST 8.31 DECAL LOCATIONS. V 380/3/50 international •decal. INDICATE SERIAL NUMBER OF COMPRESSOR 135 .CONTROL BOX key number 1 2 3 part number 02250075-045 042218 02250069-399 02250069-400 02250069-412 02250069-397 02250075-540 049852 description decal.Section 8 ILLUSTRATIONS AND PARTS LIST 8. danger high voltage decal. warning ground fault PLEASE NOTE: WHEN ORDERING PARTS.31 DECAL LOCATIONS. V 460/3/60 international •decal. V 575/3/60 international •decal. V 230/3/60 international quantity 2 1 1 1 1 1 1 1 4 5 decal. protective earth ground decal. PE designation sign. 32 WIRING DIAGRAM.Section 8 ILLUSTRATIONS AND PARTS LIST 8.AIR-COOLED/FULL VOLTAGE 02250130-732R0 136 . 33 WIRING DIAGRAM.Section 8 ILLUSTRATIONS AND PARTS LIST 8.WATER-COOLED/FULL VOLTAGE 02250130-726R0 137 . Section 8 ILLUSTRATIONS AND PARTS LIST 8.34 WIRING DIAGRAM.AIR-COOLED/WYE-DELTA 02250130-730R0 138 . WATER-COOLED/WYE-DELTA 02250130-728R0 139 .Section 8 ILLUSTRATIONS AND PARTS LIST 8.35 WIRING DIAGRAM. Section 8 ILLUSTRATIONS AND PARTS LIST 8.36 WIRING DIAGRAM- AIR-COOLED/SOLID STATE 02250130-731R1 140 Section 8 ILLUSTRATIONS AND PARTS LIST 8.37 WIRING DIAGRAM- WATER-COOLED/SOLID STATE 02250130-727R1 141 Section 8 ILLUSTRATIONS AND PARTS LIST 8.38 WIRING DIAGRAM- AIR-COOLED/REMOTE COOLER 02250130-723R0 142 NOTES 143 . S. Indiana 46360 U.A.WORLDWIDE SALES AND SERVICE SULLAIR ASIA.A. Only) or 1-219-879-5451 Fax: (219) 874-1273 Fax: (219) 874-1835 (Parts) Fax: (219) 874-1205 (Service) Printed in the U.A. Specifications Subject To Change Without Prior Notice E02 .A. Sullair Road. PRC POST CODE 518068 Telephone: 755-6851686 Fax: 755-6853473 SULLAIR EUROPE.S. 1 Chiwan. LTD. Telephone: 1-800-SULLAIR (U. France Telephone: 33-477968470 Fax: 33-477968499 SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City. Zone Des Granges BP 82 42602 Montbrison Cedex. No.S. S. Shekou Shenzhen. Guangdong PRV.