Ts32-200 Manual

INDUSTRIAL ROTARY SCREW
AIR COMPRESSOR
TS---32
200 through 600HP
150 through 450KW
OPERATOR’S
MANUAL AND
PARTS LIST
Part Number 02250061---747
eSullair Corporation, 1994
Effective 8/94
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. 1816)
--- Or Write ---
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
TABLE OF CONTENTS
Section 1 PAGE
SAFETY 1 1.1 GENERAL
1 1.2 PERSONAL PROTECTIVE EQUIPMENT

1 1.3 PRESSURE RELEASE
1 1.4 FIRE AND EXPLOSION
2 1.5 MOVING PARTS
2 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
2 1.7 TOXIC AND IRRITATING SUBSTANCES
3 1.8 ELECTRICAL SHOCK
3 1.9 LIFTING
4 1.10 ENTRAPMENT
Section 2
INSTALLATION 5 2.1 MOUNTING OF COMPRESSOR
5 2.2 VENTILATION AND COOLING
6 2.3 SERVICE AIR PIPING
5 2.4 COUPLING ALIGNMENT CHECK
5 2.5 FLUID LEVEL CHECK
6 2.6 FLUID PIPING (AIR---COOLED ONLY)
7 2.7 ELECTRICAL PREPARATION
7 2.8 MOTOR ROTATION DIRECTION CHECK
Section 3
SPECIFICATIONS 8 TABLE OF SPECIFICATIONS
9 LUBRICATION GUIDE
Section 4
SUPERVISOR 10 4.1 INTRODUCTION
10 4.2 INSTRUMENTATION, FUNCTIONAL DESCRIPTION

11 4.3 AUTOMATIC OPERATION
11 4.4 SUPERVISOR I OUTPUT RELAYS
11 4.5 SUPERVISOR I SPECIAL FUNCTION INPUTS
12 4.6 SUPERVISOR I AUXILIARY DIGITAL INPUTS
12 4.7 OPTIONAL FACTORY CONFIGURATIONS
13 4.8 SUPERVISOR I MICROCONTROLLER PROGRAMMING
14 4.9 CONTROL SYSTEM ADJUSTMENT
14 4.10 MESSAGE DISPLAY DEFINITIONS
15 4.11 TROUBLE INDICATION SETPOINTS
TABLE OF CONTENTS
(CONTINUED)
Section 5 PAGE
DESCRIPTION 17 5.1 INTRODUCTION
17 5.2 DESCRIPTION OF COMPONENTS

18 5.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION
18 5.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM,
FUNCTIONAL DESCRIPTION
18 5.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL
DESCRIPTION (200, 250 and 300HP/150, 187 AND 225KW)
20 5.6 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL
DESCRIPTION (400, 500 AND 600HP/300, 375 AND 450KW)
24 5.7 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
30 5.8 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
Section 6
COMPRESSOR OPERATION
31 6.1 GENERAL
31 6.2 PURPOSE OF CONTROLS
33 6.3 INITIAL START---UP PROCEDURE
34 6.4 SUBSEQUENT START---UP PROCEDURE
34 6.5 SHUTDOWN PROCEDURE
Section 7
MAINTENANCE 35 7.1 GENERAL
35 7.2 DAILY OPERATION

35 7.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
35 7.4 MAINTENANCE AFTER 1000 HOURS
35 7.5 FLUID CHANGE
35 7.6 SEPARATOR MAINTENANCE
35 7.7 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
36 AIR FILTER MAINTENANCE
38 SEPARATOR ELEMENTS REPLACEMENT
38 CONTROL SYSTEM ADJUSTMENT
39 DRIVE COUPLING INSTALLATION AND ALIGNMENT
(200, 250 and 300HP/150, 187 and 225KW)
40 DRIVE COUPLING INSTALLATION AND ALIGNMENT
(400, 500 and 600HP/300, 375 and 450KW)
43 CONTROL LINE FILTER MAINTENANCE
43 MOTOR CONNECTION INSTRUCTIONS
44 7.8 TROUBLESHOOTING
TABLE OF CONTENTS
(CONTINUED)
Section 8
ILLUSTRATIONS
AND PARTS LIST 49 8.1 PROCEDURE FOR ORDERING PARTS
49 8.2 RECOMMENDED SPARE PARTS LIST
(200, 250 and 300HP/150, 187 and 225KW)
50 8.3 RECOMMENDED SPARE PARTS LIST
(400, 500 and 600HP/300, 375 and 450KW)
52 8.4 MOTOR, COMPRESSOR, FRAME AND PARTS ---
200HP THROUGH 300HP/150KW THROUGH 225KW
400HP/300KW
58 8.7 AIR INLET SYSTEM --- 200HP THROUGH 300HP/
150KW THROUGH 225KW
60 8.8 AIR INLET SYSTEM --- 400HP THROUGH 600HP/
300KW THROUGH 450KW
62 8.9 FLUID COOLING SYSTEM --- 200HP THROUGH 300HP/
150KW THROUGH 225KW (WATER---COOLED)
66 8.10 FLUID COOLING SYSTEM --- 400HP/300KW (WATER---COOLED)
70 8.11 FLUID COOLING SYSTEM --- 500HP THROUGH 600HP/
74 8.12 REMOTE COOLER FLUID COOLING SYSTEM ---
(AIR---COOLED)
(AIR---COOLED)
(AIR---COOLED)
86 8.15 REMOTE COOLER FLUID COOLING PIPING ---
(AIR---COOLED)
88 8.16 REMOTE COOLER FLUID COOLING PIPING ---
400 THROUGH 600HP/300 THROUGH 450KW (AIR---COOLED)
90 8.17 COMPRESSOR DISCHARGE SYSTEM
(WATER---COOLED)
96 8.18 REMOTE COOLER COMPRESSOR DISCHARGE
SYSTEM 200HP THROUGH 300HP/150KW THROUGH 225KW
(WATER---COOLED)
SYSTEM 400HP/300KW (AIR---COOLED)
SYSTEM 500HP THROUGH 600HP/375KW THROUGH 450KW
(AIR---COOLED)
118 8.21 SULLICON CONTROL --- 200HP THROUGH 600HP/
150KW THROUGH 450KW
120 8.22 COMPRESSOR ACTUATOR --- 200HP THROUGH 600HP/
150KW THROUGH 450KW
122 8.23 ELECTRO---PNEUMATIC CONTROL SYSTEM ---
TABLE OF CONTENTS
(CONTINUED)
Section 8
ILLUSTRATIONS
AND PARTS LIST
(Continued)
126 8.24 ENCLOSURE 200HP THROUGH 300HP/
150KW THROUGH 225KW
130 8.25 ENCLOSURE --- 400HP THROUGH 600HP
300KW THROUGH 450KW
134 8.26 RTD PROBES --- 200HP THROUGH 300HP/
150KW THROUGH 225KW
136 8.27 RTD PROBES --- 400HP THROUGH 600HP/
300KW THROUGH 450KW
138 8.28 AFTERCOOLER --- 400HP/300KW (WATER---COOLED)
142 8.29 AFTERCOOLER --- 500HP THROUGH 600HP/
146 8.30 DECAL GROUP
154 8.31 WIRING DIAGRAM --- STANDARD FULL---VOLTAGE
155 8.32 WIRING DIAGRAM --- WYE---DELTA
Section 1
SAFETY
1.1 GENERAL 1926.302(b)(7) and/or any applicable Federal,

Sullair Corporation and its subsidiaries designs State and Local codes, standards and regulations.
and manufactures all of its products so they can be
operated safely. However, the responsibility for B. When the hose is to be used to supply a mani-
safe operation rests with those who use and main- fold, install an additional appropriate flow---limiting
tain these products. The following safety precau- valve between the manifold and each air hose ex-
tions are offered as a guide which, if conscien- ceeding !@2” (13mm) inside diameter that is to be
tiously followed, will minimize the possibility of acci- connected to the manifold to reduce pressure in
dents throughout the useful life of this equipment. case of hose failure.
The compressor should be operated only by those C. Provide an appropriate flow---limiting valve at the
who have been trained and delegated to do so, and beginning of each additional 75 feet (23m) of hose
who have read and understood this Operator’s in runs of air hose exceeding !@2” (13mm) inside di-
Manual. Failure to follow the instructions, proce- ameter to reduce pressure in case of hose failure.
dures and safety precautions in this manual may D. Flow---limiting valves are listed by pipe size and
result in accidents and injuries. rated CFM. Select appropriate valves accordingly,
NEVER start the compressor unless it is safe to do in accordance with their manufacturer’s recom-
so. DO NOT attempt to operate the compressor mendations.
with a known unsafe condition. Tag the compres- E. DO NOT use air tools that are rated below the
sor and render it inoperative by disconnecting and maximum rating of the compressor. Select air tools,
locking out all power at source or otherwise dis- air hoses, pipes, valves, filters and other fittings ac-
abling its prime mover so others who may not know cordingly. DO NOT exceed manufacturer’s rated
of the unsafe condition cannot attempt to operate it safe operating pressures for these items.
until the condition is corrected.
F. Secure all hose connections by wire, chain or
Install, use and operate the compressor only in full other suitable retaining device to prevent tools or
compliance with all pertinent OSHA regulations hose ends from being accidentally disconnected
and/or any applicable Federal, State, and Local and expelled.
codes, standards and regulations.
G. Open fluid filter cap only when compressor is
DO NOT modify the compressor and/or controls in not running and is not pressurized. Shut down
any way except with written factory approval. the compressor and bleed the sump (receiver) to
zero internal pressure before removing the cap.
While not specifically applicable to all types of com-
pressors with all types of prime movers, most of the H. Vent all internal pressure prior to opening any
precautionary statements contained herein are ap- line, fitting, hose, valve, drain plug, connection or
plicable to most compressors and the concepts other component, such as filters and line oilers,
behind these statements are generally applicable and before attempting to refill optional air line anti---
to all compressors. icer systems with antifreeze compound.
1.2 PERSONAL PROTECTIVE EQUIPMENT I. Keep personnel out of line with and away from the
Prior to installing or operating the compressor, discharge opening of hoses or tools or other points
owners, employers and users should become fa- of compressed air discharge.
miliar with, and comply with, all applicable OSHA
regulations and/or any applicable Federal, State J. Use air at pressures less than 30 psig (2.1 bar) for
and Local codes, standards, and regulations rela- cleaning purposes, and then only with effective
tive to personal protective equipment, such as eye chip guarding and personal protective equipment
and face protective equipment, respiratory protec- per OSHA Standard 29 CFR 1910.242 (b) and/or
tive equipment, equipment intended to protect the any applicable Federal, State, and Local codes,
extremities, protective clothing, protective shields standards and regulations.
and barriers and electrical protective equipment, K. DO NOT engage in horseplay with air hoses as
as well as noise exposure administrative and/or en- death or serious injury may result.
gineering controls and/or personal hearing protec-
tive equipment. 1.4 FIRE AND EXPLOSION
A. Clean up spills of lubricant or other combustible
1.3 PRESSURE RELEASE substances immediately, if such spills occur.
A. Install an appropriate flow---limiting valve be-
tween the service air outlet and the shut---off (throt- B. Shut off the compressor and allow it to cool.
tle) valve, either at the compressor or at any other Then keep sparks, flames and other sources of ig-
point along the air line, when an air hose exceeding nition away and DO NOT permit smoking in the vi-
!@2” (13mm) inside diameter is to be connected to cinity when checking or adding lubricant or when
the shut---off (throttle) valve, to reduce pressure in refilling air line anti---icer systems with antifreeze
case of hose failure, per OSHA Standard 29 CFR compound.
1
Section 1
SAFETY
C. DO NOT permit fluids, including air line anti--- E. Make sure all personnel are out of and/or clear of
icer system antifreeze compound or fluid film to ac- the compressor prior to attempting to start or oper-
cumulate on, under, or around acoustical material, ate it.
or on any external surfaces of the air compressor or
on internal surfaces of the enclosure. Wipe down F. Disconnect and lock out all power at source and
using an aqueous industrial cleaner or steam clean verify at the compressor that all circuits are de---en-
as required. If necessary, remove acoustical mate- ergized to minimize the possibility of accidental
rial, clean all surfaces and then replace acoustical start---up, or operation, prior to attempting repairs
material. Any acoustical material with a protective or adjustments. This is especially important when
covering that has been torn or punctured should be compressors are remotely controlled.
replaced immediately to prevent accumulation of G. Keep hands, feet, floors, controls and walking
liquids or fluid film within the material. DO NOT use surfaces clean and free of fluid, water or other liq-
flammable solvents for cleaning purposes. uids to minimize the possibility of slips and falls.
D. Disconnect and lock out all power at source prior 1.6 HOT SURFACES, SHARP EDGES AND SHARP
to attempting any repairs or cleaning of the com- CORNERS
pressor or of the inside of the enclosure, if any. A. Avoid bodily contact with hot fluid, hot coolant,
hot surfaces and sharp edges and corners.
E. Keep electrical wiring, including all terminals and
pressure connectors in good condition. Replace B. Keep all parts of the body away from all points of
any wiring that has cracked, cut, abraded or other- air discharge.
wise degraded insulation, or terminals that are
worn, discolored or corroded. Keep all terminals C. Wear personal protective equipment including
and pressure connectors clean and tight. gloves and head covering when working in, on or
around the compressor.
F. Keep grounded and/or conductive objects such
as tools away from exposed live electrical parts D. Keep a first aid kit handy. Seek medical assis-
such as terminals to avoid arcing which might tance promptly in case of injury. DO NOT ignore
serve as a source of ignition. small cuts and burns as they may lead to infection.
1.7 TOXIC AND IRRITATING SUBSTANCES
G. Remove any acoustical material or other mate- A. DO NOT use air from this compressor for respi-
rial that may be damaged by heat or that may sup- ration (breathing) except in full compliance with
port combustion and is in close proximity, prior to OSHA Standards 29 CFR 1910 and/or any applica-
attempting weld repairs. ble Federal, State or Local codes or regulations.
H. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when servic- ! DANGER
ing and operating the compressor.
Death or serious injury can result from inhaling
I. Keep oily rags, trash, leaves, litter or other com- compressed air without using proper safety
bustibles out of and away from the compressor. equipment. See OSHA standards and/or any ap-
plicable Federal, State, and Local codes, stan-
dards and regulations on safety equipment.
J. DO NOT operate the compressor without proper
flow of cooling air or water or with inadequate flow
of lubricant or with degraded lubricant. B. DO NOT use air line anti---icer systems in air
lines supplying respirators or other breathing air
K. DO NOT attempt to operate the compressor in utilization equipment and DO NOT discharge air
any classification of hazardous environment unless from these systems in unventilated or other con-
the compressor has been specially designed and fined areas.
manufactured for that duty.
C. Operate the compressor only in open or ade-
1.5 MOVING PARTS quately ventilated areas.
A. Keep hands, arms and other parts of the body
and also clothing away from couplings, fans and D. Locate the compressor or provide a remote inlet
other moving parts. so that it is not likely to ingest exhaust fumes or
other toxic, noxious or corrosive fumes or sub-
B. DO NOT attempt to operate the compressor stances.
with the fan, coupling or other guards removed.
E. Coolants and lubricants used in this compressor
C. Wear snug fitting clothing and confine long hair are typical of the industry. Care should be taken to
when working around this compressor, especially avoid accidental ingestion and/or skin contact. In
when exposed to hot or moving parts. the event of ingestion, seek medical treatment
promptly. Wash with soap and water in the event of
D. Keep access doors, if any, closed except when skin contact. Consult Material Safety Data Sheet for
making repairs or adjustments. information pertaining to fluid of fill.
2
Section 1
SAFETY
F. Wear goggles or a full face shield when adding helicopter must not be supported by the lifting bail
antifreeze compound to air line anti---icer systems. but by slings instead. In any event, lift and/or han-
dle only in full compliance with OSHA standards 29
G. If air line anti---icer system antifreeze compound CFR 1910 subpart N and/or any applicable Feder-
enters the eyes or if fumes irritate the eyes, they al, State, and Local codes, standards and regula-
should be washed with large quantities of clean tions.
water for 15 minutes. A physician, preferably an
eye specialist, should be contacted immediately. B. Inspect points of attachment for cracked welds
and for cracked, bent, corroded or otherwise de-
H. DO NOT store air line anti---icer system anti- graded members and for loose bolts or nuts prior to
freeze compound in confined areas. lifting.
I. The antifreeze compound used in air line anti- C. Make sure entire lifting, rigging and supporting
freeze systems contains methanol and is toxic, structure has been inspected, is in good condition
harmful or fatal if swallowed. Avoid contact with the and has a rated capacity of at least the weight of
skin or eyes and avoid breathing the fumes. If swal- the compressor. If you are unsure of the weight,
lowed, induce vomiting by administering a table- then weigh compressor before lifting.
spoon of salt, in each glass of clean, warm water
until vomit is clear, then administer two teaspoons D. Make sure lifting hook has a functional safety
of baking soda in a glass of clean water. Have pa- latch or equivalent, and is fully engaged and
tient lay down and cover eyes to exclude light. Call latched on the bail or slings.
a physician immediately. E. Use guide ropes or equivalent to prevent twisting
1.8 ELECTRICAL SHOCK or swinging of the compressor once it has been
A. This compressor should be installed and main- lifted clear of the ground.
tained in full compliance with all applicable Federal, F. DO NOT attempt to lift in high winds.
State and Local codes, standards and regulations,
including those of the National Electrical Code, and G. Keep all personnel out from under and away
also including those relative to equipment ground- from the compressor whenever it is suspended.
ing conductors, and only by personnel that are
trained, qualified and delegated to do so. H. Lift compressor no higher than necessary.
B. Keep all parts of the body and any hand---held I. Keep lift operator in constant attendance when-
tools or other conductive objects away from ex- ever compressor is suspended.
posed live parts of electrical system. Maintain dry J. Set compressor down only on a level surface ca-
footing, stand on insulating surfaces and DO NOT pable of safely supporting at least its weight and its
contact any other portion of the compressor when loading unit.
making adjustments or repairs to exposed live
parts of the electrical system. Make all such adjust- K. When moving the compressor by forklift truck,
ments or repairs with one hand only, so as to mini- utilize fork pockets if provided. Otherwise, utilize
mize the possibility of creating a current path pallet if provided. If neither fork pockets or pallet are
through the heart. provided, then make sure compressor is secure
and well balanced on forks before attempting to
C. Attempt repairs in clean, dry and well lighted and raise or transport it any significant distance.
ventilated areas only.
L. Make sure forklift truck forks are fully engaged
D. DO NOT leave the compressor unattended with and tipped back prior to lifting or transporting the
open electrical enclosures. If necessary to do so, compressor.
then disconnect, lock out and tag all power at
source so others will not inadvertently restore M. Forklift no higher than necessary to clear obsta-
power. cles at floor level and transport and corner at mini-
mum practical speeds.
E. Disconnect, lock out, and tag all power at source
prior to attempting repairs or adjustments to rotat- N. Make sure pallet---mounted compressors are
ing machinery and prior to handling any un- firmly bolted or otherwise secured to the pallet prior
grounded conductors. to attempting to forklift or transport them. NEVER
attempt to forklift a compressor that is not secured
1.9 LIFTING to its pallet, as uneven floors or sudden stops may
A. If the compressor is provided with a lifting bail, cause the compressor to tumble off, possibly caus-
then lift by the bail provided. If no bail is provided, ing serious injury or property damage in the proc-
then lift by sling. Compressors to be air lifted by ess.
3
Section 1
SAFETY
1.10 ENTRAPMENT
A. If the compressor enclosure, if any, is large
enough to hold a man and if it is necessary to enter
it to perform service adjustments, inform other per-
sonnel before doing so, or else secure and tag the
access door in the open position to avoid the possi-
bility of others closing and possibly latching the
door with personnel inside.
B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.
4
Section 2
INSTALLATION
2.1 MOUNTING OF COMPRESSOR Water flow rates will vary with operating condi-
A foundation or mounting capable of supporting tions. For rates based on criteria other than that
listed, consult your local Sullair representative.
the weight of the compressor, and rigid enough to
maintain the compressor frame level and the com-
pressor in alignment is required. The compressor The table below indicates the ventilation require-
frame must be leveled and secured with foundation ments necessary to keep the compressor running
bolts, and full uniform contact must be maintained at a normal operating temperature. The fan air re-
between the frame and foundation. It is recom- quirement is the volume of air which must flow
mended that the frame be grouted to the founda- through the compressor and/or cooling package
tion. The compressor unit and driver must be for proper ventilation. The specified heat rejection
aligned after installation as specified in the Opera- requirement is the amount of heat that is radiated
tor’s Manual. No piping loads shall be transmitted by the compressor. This heat must be removed to
to the compressor or the cooling package at the ex- assure a normal operating temperature. With air---
ternal connections. cooled compressors it is possible to use this heat
for space heating, providing excessive pressure
2.2 VENTILATION AND COOLING drop is not created across the fan. Consult a Sullair
For air---cooled compressors, select a location to office for assistance in utilizing this heat.
permit sufficient unobstructed air to flow in and out DO NOT install a water---cooled or an air---cooled/
of the compressor cooling package to keep the op- aftercooled compressor without adequate freeze
erating temperature stable. The minimum distance protection where it will be exposed to temperature
that the compressor should be from surrounding less than 32_F(0_C).
walls is three (3) feet (914mm). To prevent exces-
sive ambient temperature rise, it is imperative to 2.3 SERVICE AIR PIPING
provide adequate ventilation. Service air piping should be installed as shown in
Figure 2 --- 1. A shut --- off valve should be installed to
For water---cooled compressors, it is necessary to isolate a compressor from the service line if re-
check the cooling water supply. The water system quired. Also notice that the service line should be
must be capable of supplying the following flows: equipped with water legs and condensate drains
throughout the system.
MODEL---HP/KW WATER FLOW (GPM)
2.4 COUPLING ALIGNMENT CHECK
TS---32 200HP/150KW 45 In preparation for the factory test, the coupling sup-
TS---32 250HP/187KW 54 plied with your compressor is properly aligned for
TS---32 300HP/225KW 65 operation. However, due to shipping and handling,
TS---32 400HP/300KW 87 it is necessary to recheck the coupling alignment.
TS---32 500HP/375KW 106 Refer to Coupling Alignment procedure explained
TS---32 600HP/450KW 129 in the Maintenance section of this manual.
2.5 FLUID LEVEL CHECK
Your air compressor is also supplied with the
NOTE proper amount of fluid. However, it is necessary to
check the fluid level at installation. The level is
Water flow requirements are based on 80_F to checked by looking at the sight glass located on
85_F (27_C to 29_C) water inlet temperature. the sump. If the sump is properly filled, the coolant
Recommended water pressure range is 40 to 75 level should fill 1/2 of the sight glass when the com-
PSIG (2.8 to 5.2 bar). pressor is shutdown.
VENTILATION REQUIREMENTS
REMOTE AIR---COOLED (I)

COMPRESSOR PACKAGE COOLING PACKAGE
HEAT REJECTION VENT FAN FLOW (II) HEAT REJECTION AIR FLOW
MODEL MOTOR HP/KW BTU/HR CFM BTU/HR CFM
TS---32---200 200/150 47,620 4150 560,200 21,500
TS---32---250 250/187 57,360 4150 674,800 21,500
TS---32---300 300/225 64,170 4150 802,100 32,500
TS---32---400 400/300 81,360 8300 1,084,800 32,500
TS---32---500 500/375 85,900 8300 --- ---
TS---32---600 600/450 104,440 8300 --- ---
(I) Applicable to air---cooled models only.
(II) Applicable to compressors with enclosure.
5
Section 2
INSTALLATION
Figure 2 ---1 Service Air Piping (Typical Installation)
2.6 FLUID PIPING (AIR---COOLED ONLY) valves shall not exceed 10 PSIG (0.7 bar). If the
To allow depressurization of the cooling package pressure drop is in excess of 10 PSIG (0.7 bar), a
and connecting piping between the compressor pump should be installed. Consult the Sullair Ser-
and the cooling package upon shutdown of the vice Department for recommendations.
compressor, a !@2”(13 mm) depressurization line
must be installed between the top of the fluid cooler It is recommended that shutoff valves be installed
and the sump tank connection which is located on in the supply and return piping to facilitate com-
the fluid supply and return line connection bracket. pressor component’s maintenance.
This line must be maintained at a higher level than
the supply and return piping for the fluid cooler. Because of the variability in installations, the fluid
necessary to fill the supply and return piping for the
fluid cooler is not part of the standard scope of sup-
The supply and return piping for the fluid cooler ply for the compressor. The fluid necessary to fill
must be adequately sized to prevent excessive this piping may be ordered from the nearest Sullair
pressure drop. The total pressure drop in the sup- representative or the representative from whom the
ply and return piping and associated fittings and compressor was purchased. To assist in determin-
6
Section 2
INSTALLATION
ing the amount of fluid necessary to fill the piping, 2. Check starter and overload heater sizes (see
the following chart may be used. Electrical Parts in Parts Manual).
3. Check all electrical connections for tightness.
GALLONS/LITERS OF FLUID 4. “DRY RUN” the electrical controls by discon-
PIPE SIZE PER 12 INCHES/304.8MM OF PIPE necting the three (3) motor leads from the
2 .1635/.62 starter. Pull out the EMERGENCY STOP button
2 1/2 .2555/.97 on the control panel. Depress the PROG pad
3 .368/1.39 twice to get to AUTOMATIC/MANUAL mode se-
4 .6542/2.48 lection and use the cursor pad to change to
6 1.4719/5.57 MANUAL mode.
5. Reconnect the three (3) motor leads and jog the
motor for a direction of rotation check, as ex-
2.7 ELECTRICAL PREPARATION plained in Section 2.8.
Interior electrical wiring is performed at the factory.
Required customer wiring is minimal, but should
be done by a qualified electrician in compliance
with OSHA, National Electrical Code, and any other 2.8 MOTOR ROTATION DIRECTION CHECK
applicable state or local electrical code concerning After the electrical wiring has been done, it is nec-
isolation switches, fuse disconnects, etc. Sullair essary to check the direction of the motor rotation.
provides a wiring diagram for use by the installer. With the control system in MANUAL mode, press
the ON/OFF pad twice in succession to bump start
A few electrical checks should be made to help as- the compressor. When looking at the motor from
sure that the first start---up will be trouble free. the end opposite the compressor unit, the shaft
should be turning clockwise on Models
TS---32---200, 250, 500 and 600HP/150, 187, 375
! DANGER
and 450KW, and counterclockwise on Models
Lethal shock hazard inside. TS---32---300, 400HP/225 and 300KW. If the motor
shaft is not turning in the proper direction, discon-
Disconnect all power at source, before opening nect the power to the starter and exchange any two
or servicing starter or control panel. of the three power input leads, then re---check rota-
tion. A “Direction of Rotation” decal is located on
1. Check incoming voltage. Be sure that the incom- the coupling guard between the motor and com-
ing voltage is the same voltage that the compressor to show proper motor/compressor rota-
pressor was wired for. tion.
7
Section 3
SPECIFICATIONS
SULLAIR SERIES TS---32 SPECIFICATIONS

(50 Hz)
HP/KW COOLING CAPACITY LENGTH WIDTH HEIGHT (I) WEIGHT (II)
(ACFM/M 3/MIN) (IN/MM) (IN/MM) (IN/MM) (LB/KG)
200/150 Air 1125/31.9 159/4039 87/2210 80.5/2045 10,000/4536
200/187 1350/38.2 159/4039 87/2210 80.5/2045 11,500/5216
300/225 1650/46.7 159/4039 87/2210 80.5/2045 13,000/5897
400/300 2200/62.3 198/5029 96/2438 82.5/2096 15,500/7031
500/345 2600/73.6 198/5029 96/2438 82.5/2096 17,300/7847
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
200/150 Water 1125/31.9 159/4039 87/2210 80.5/2045 10,500/4763
250/187 1350/38.2 159/4039 87/2210 80.5/2045 12,000/5443
300/225 1650/46.7 159/4039 87/2210 80.5/2045 13,500/6124
400/300 2200/62.3 198/5029 96/2438 82.5/2096 16,000/7257
500/375 2600/73.6 198/5029 96/2438 82.5/2096 17,800/8074
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
(60 Hz)
200/150 Air 1125/31.9 159/4039 87/2210 80.5/2045 10,000/4536
250/187 1350/38.2 159/4039 87/2210 80.5/2045 11,500/5216
300/225 1650/46.7 159/4039 87/2210 80.5/2045 13,000/5897
400/300 2200/62.3 198/5029 96/2438 82.5/2096 15,500/7031
500/375 2600/73.6 198/5029 96/2438 82.5/2096 17,300/7847
600/450 3100/87.8 198/5029 96/2438 82.5/2096 19,300/8754
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
200/150 Water 1125/31.9 159/4039 87/2210 80.5/2045 10,500/4763
250/187 1350/38.2 159/4039 87/2210 80.5/2045 12,000/5443
300/225 1650/46.7 159/4039 87/2210 80.5/2045 13,500/6124
400/300 2200/62.3 198/5029 96/2438 82.5/2096 16,000/7257
500/375 2600/73.6 198/5029 96/2438 82.5/2096 17,800/8074
600/450 3100/87.8 198/5029 96/2438 82.5/2096 19,800/8981
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
(I) Add 7 in./18 cm for enclosure. Add 27.5 in./70 cm (200, 250, 300HP/150, 187, 225KW), and 31.5 in./80 cm
(400, 500, 600HP/300, 375, 450KW) for servicing separator.
(II) Add 1500 lbs/ 681 Kg for enclosure (200--300HP/150--225KW). Add 2000 lbs/827 Kg for enclosure
(400--600HP/300--450KW).
COMPRESSOR: STANDARD MODELS

Type Rotary Screw
Standard Operating Pressure (III) 100 psig (6.9 bar)
Bearing Type Anti---Friction
Ambient Temperature (Max.) (IV) 104_F (40_C)
Cooling Pressurized Fluid
Lubricant Sullube 32 or Equivalent
Sump Capacity 60 Gallons (227 Liters) (200 --- 300HP/150 --- 225KW)
80 Gallons (302 Liters) (400 --- 600HP/300 --- 450KW)
Control Electro---Pneumatic
(III) Special compressors are available for operating at higher pressures.
(IV) Special compressors are available for operation in higher ambient temperatures.
MOTOR (60 Cycle Compressors)

STANDARD MODELS
Size 200---400HP/150 --- 300KW --- 460V
500---600HP/375 --- 450KW --- 2300V
Type Open Dripproof, Three Phase, 60 Cycles
105_F (41_C) Maximum Ambient Temperature,
Options Available: Other Voltages
TEFC also Available
Speed 1770 RPM
8
Section 3
SPECIFICATIONS
MOTOR (50 Cycle Compressors)
STANDARD MODELS
Size 200---400HP/150 --- 300KW --- 380V
500---600HP/375 --- 450KW --- 3300V
Type Open Dripproof, Three Phase, 50 Cycles
104_F (40_C) Maximum Ambient Temperature
Options Available: Other Voltages
T.E.F.C. also Available
Speed 1500 RPM
LUBRICATION GUIDE---STANDARD COMPRES- temperatures coupled with high humidity, or when

SORS high particulate level, corrosive gases or strong oxi-
Sullair TS---32 Series standard compressors are dizing gases are present in the air.
filled with Sullube 32 fluid as factory fill. MIXING OF
OTHER FLUIDS WITHIN THE COMPRESSOR Maintenance of all other components is still recom-
SHOULD BE AUTHORIZED BY THE FACTORY mended as indicated in the Maintenance section of
OTHERWISE THIS WILL VOID ALL WARRAN- this manual.
TIES. APPLICATION GUIDE
Sullair encourages the user to participate in a fluid
Sullube 32 fluid should be changed every 8000 analysis program with the fluid suppliers. This
hours or once a year, whichever comes first. The could result in a fluid change interval differing from
fluid should be changed more frequently under se- that stated in the manual. Contact your Sullair
vere operating conditions, such as high ambient dealer for details.
9
Section 4
SUPERVISOR
4.1 INTRODUCTION S The sump pressure transducer (P1) monitors

Your compressor is equipped with a Supervisor I the sump/unit discharge pressure.
microprocessor controller. This section explains
the functions and operation of the Supervisor con- S Injection oil pressure (P3) monitors oil pressure
trol as well as how to program its features for your at the point of injection into the compressor down-
particular application. stream of the oil filter.
S Filter oil pressure (P4) monitors oil pressure
4.2 INSTRUMENTATION, FUNCTIONAL DE- ahead of the oil filter and is used with P3 to calculate
SCRIPTION oil filter differential; ∆ P2=P4---P3.
Refer to Figure 4---1. The Supervisor I control panel
consists of displays for pressure, temperature, S The discharge temperature probe (T1) moni-
time (run hours), and a status message. Default tors the temperature of the air leaving the compres-
pressure is line pressure (P2) which is normally dis- sor unit. For both air---cooled and water---cooled
played with pad selections for sump pressure, fluid compressors the normal reading is approximately
pressure, separator differential and fluid filter differ- 180_F (82_C) based on 80_F (27_C) ambient tem-
ential. Default temperature is unit discharge temperature.
perature (T1) which is normally displayed with a S The injection temperature probe (T2) monitors
pad selection for injection fluid temperature. An the temperature of the fluid just before it is injected
LED map provides a graphic illustration of the into the unit.
points being monitored. Operator controls consist S The air filter maintenance switch monitors the
of EMERGENCY STOP, ON/OFF, monitor display condition of the air intake filter. When the Supervi-
pads and programming pads. All compressor con- sor displays the message “AIR FILTER MAINT
trol, pressure and temperature displays are pro- RQD”, filter service is required.
vided in the Supervisor I.
S The ON/OFF pad turns the compressor on and
S The line (terminal) pressure transducer (P2) is off.
connected to the dry side of the receiver down- S The hour display records cumulative hours of
stream from the check valve and continually moni- operation for the compressor and is useful for plan-
tors the plant air pressure. ning and logging service operations. A selectable
Figure 4 ---1 Supervisor Control Panel
10
Section 4
SUPERVISOR
display of “load” hours or “load” as a percent of S The amber light on the control panel indicates
“run” hours is available by pressing “HR LOAD” or when power to the compressor is supplied.
“HR%” respectively. S The green message display indicates the status
of the compressor.
S Separator differential pressure can be dis-
played by pressing the “∆P1” pad. When a differ- 4.3 AUTOMATIC OPERATION
ential of 10 PSID (0.7 bar) is reached, the message For applications with varied periods of time when
“SEPARATOR MAINT RQD” is displayed and the there are no air requirements, Supervisor’s Auto-
∆P1 LED will flash. matic mode allows the compressor to stop (time
delayed) when no compressed air requirement is
S Oil filter differential pressure can be displayed present and restart as compressed air is needed.
by pressing the “∆P2” pad. When a differential of AUTOMATIC also incorporates the 10 second un-
20 PSID (1.4 bar) is reached, the message “OIL FIL- loaded STOP MODE feature which allows the mo-
TER MAINT RQD” will be displayed and the ∆P2 tor to stop from an unloaded condition when the
LED will flash. ON/OFF pad is pressed or after the timed stop peri-
od. If immediate stop is required when operating in
S The “ON” LED indicates when the compressor is AUTOMATIC mode, press the EMERGENCY STOP
running. button on the control panel.
4.4 SUPERVISOR I OUTPUT RELAYS
PARAMETERS OPERATION
COMPRESSOR RUN Initiates starter controls and all auxiliary contacts that
operate simultaneously with the main starter. Supervi-
sor assumes compressor is running if contact is
closed and P1 discharge pressure is at a satisfactory
level.
LOAD/UNLOAD SOLENOID VALVE Controls regulator bypass solenoid valve to load or
unload the compressor as demand varies.
COMMON FAULT ALARM Initiates to provide a common signal for remote in-
dication of a fault shutdown.
WYE---DELTA TRANSITION Contact is used to control Wye---Delta starter transi-
tions logic. This contact is controlled by the Wye to
Delta timing function.
DRAIN SOLENOID VALVE Controlled by the drain time and drain interval timers,
this contact is used to control an optional condensate
drain solenoid valve.
4.5 SUPERVISOR I SPECIAL FUNCTION INPUTS
PARAMETER OPERATION
REMOTE STOP/START (J1/1---2) Closing this contact initiates the STOP mode. Open-
ing this contact permits a compressor start if permis-
sives are satisfied. Please note that AUTOMATIC/
MANUAL mode characteristics are maintained even
though remote STOP/START is used. The RUN LED
will flash if stopped with remote contact.
PARAMETERS SELECT (J1/15---16) With this contact open, compressor operates within
pressure range P2A. With this contact closed, com-
pressor operates within pressure range P2B. Suitable
for 2 compressor base/load sequencing.
RS 232 SERIAL PORT (J4) Full 2---way communication and control that provides
analog display transmission, signal status and com-
pressor status indication, as well as remote STOP/
START via computer. A great tool for preventive main-
tenance programs and customer DCS management
packages. Baud rates are factory settable from 150 to
4800. Consult factory for communication protocol.
11
Section 4
SUPERVISOR
4.6 SUPERVISOR I AUXILIARY DIGITAL INPUTS
PARAMETERS OPERATION
MOTOR/OVERLOAD (J1/7---8) Monitors normally closed compressor motor over-

load contact. Will initiate compressor shutdown, flash
the motor LED on the graphic map and display the
message “MOTOR OVERLOAD” if the contact opens.
COOLING SYSTEM MONITOR (J1/9---10) Monitors cooler fan overload (AC), water pressure
switch (WC), and/or canopy fan motor overload. Nor-
mally closed signal when opened will initiate com-
pressor shutdown and display the message “FAN OL/
LOW WATER”
DRY---SIDE DISCHARGE TEMPERATURE Separate electronic switch monitors discharge
(J1/11---12) (T3) temperature on the dry side of the separator and will
initiate a shutdown if greater than 235_F (113_C).
Message display is “HIGH TEMP T3”.
INTERSTAGE TEMPERATURE (J1/13---14) (T4) Only used on tandem compressors. Parameters are
same as T3. Message display is “HIGH TEMP T4.
4.7 OPTIONAL FACTORY CONFIGURATIONS selected. With this modification range “C” is pro-
vided. To select the “C” range, close terminals 1---2
A. MULTIPLE PRESSURE RANGES on additional input board. All ranges may be pro-
Supervisor I offers the convenience of program- grammed irrespective of the range selected for op-
ming 1, 2, or 3 UNLOAD/LOAD pressure ranges eration.
that can be enabled at the flip of a switch. The stan-
dard program offers “A” or “B” ranges that are se- B. AUXILLARY DRY CONTACTS
lectable based on the status of the J1/15---16 termi- With the addition of an extra 8---relay output board,
nals. With the terminals open, the “A” range is se- auxillary dry contracts can be provided to remotely
lected. With the terminals closed, the “B” range is indicate each annunciation point as listed below.
ON EXISTING RELAY BOARD K6 --- Max Press P1 Prealarm

(J10 Slot #7) Indicates at 98% of Max Press P1 shutdown.
Does not latch.
K7 --- Low Press P3 Prealarm

Indicates at 5 PSI above Min Press P3
shutdown. Does not latch.
K8 --- High Temp T1 Prealarm
Indicates at 225_F (107_C). Does not latch.
ON ADDITIONAL 8 RELAY OUTPUT BOARD K1 --- Max Press P1 shutdown, P1 or P2 sensor
(J11 Slot #8) failure.
K2 --- Min Press P3 shutdown, P3 or P4 sensor
failure.
K3 --- High Temp T1, T2, T3, T4 shutdown, T1 or
T2 sensor failure.
K4 --- Compressor Motor Overload.
K5 --- Fan Overload/Low Water Pressure.
K6 --- Oil Filter Maintenance Required.
K7 --- Separator Maintenance Required.
K8 --- Inlet Filter Maintenance Required.
12
Section 4
SUPERVISOR
4.8 SUPERVISOR I MICROCONTROLLER PRO- message display through the various program-
GRAMMING mable parameters. The cursor pad (Y) is used to
Several display and operational functions are user change parameter values. A built---in timed delay
programmable from the Supervisor keypad. Re- feature returns the message display to operation
peatedly pressing the “PROG” pad will scroll the mode after 5 seconds of inactivity.
PARAMETER (IN SEQUENTIAL ORDER) OPERATION
LANGUAGE Press the cursor pad for 2 seconds to change to next

language for the message display. Languages in or-
der are: French, German, Italian, Spanish and Eng-
lish.
AUTOMATIC/MANUAL The controller default state is AUTOMATIC operation.
If line pressure is adequate and/or the sump pressure
is greater than 5 to 10 psig (0.3 to 0.7 bar), pressing
the ON/OFF pad will put the control in STANDBY
mode until line pressure drops to the programmed
differential value and the sump pressure is low
enough to permit a START. AUTOMATIC mode pro-
vides a timed STOP with automatic restart operation.
Automatic restart after power failure is also included
in AUTOMATIC mode.
MANUAL mode ignores the line pressure permissive
of AUTOMATIC and starts the compressor with ON/
OFF as long as the minimum sump pressure and oth-
er fault conditions are satisfied. The compressor is
only stopped manually with no time stop and no auto-
matic restart after power failure.
PRESSURE UNITS Selects bar or psig; use cursor key to select. 1 bar =
14.5 psig.
TEMPERATURE UNITS _C OR _F; use cursor key to select.
MAXIMUM PRESSURE P2A Use the cursor key to set the OFF LOAD pressure set-
ting. Depressing the cursor pad for more than 2 se-
conds will initiate a fast scrolling mode to quickly
reach the desired setpoint for all programmable set-
points. A wraparound feature (on all functions) re-
turns the value to its lowest limit if scrolling exceeds
the high limit. Typically set for 110 psig (7.6 bar).
PRESSURE DIFFERENTIAL P2A Selects the ON LOAD setting by subtracting the differ-
ential from P2A. Normally set for 10 psig (0.7 bar).
MAXIMUM PRESSURE P2B Same as P2A, but provides a second OFF LOAD set-
ting for base/load operation.
PRESSURE DIFFERENTIAL P2B Same as P2A, but provides a second ON LOAD set-
ting for base/load operation.
UNLOAD TIME Adjusts timed stop function if compressor is running
unloaded for 0 to 60 minutes.
WYE TO DELTA TIME Adjusts transition timer for Wye---Delta starters from 0
to 30 seconds. ON LOAD function is delayed by the
value of Wye to Delta time. A separate relay contact is
provided with this function. It is recommended that a
transition time of 8 seconds not be exceeded.
DRAIN TIME AND DRAIN INTERVAL A timed contact is furnished to control a condensate
(OPTIONAL) removal solenoid valve. Both drain dura-
tion time (1 to 10 seconds) and time internal between
drains (1 to 10 minutes) may be set from these
modes.
13
Section 4
SUPERVISOR
4.9 CONTROL SYSTEM ADJUSTMENT ues will be entered when the display is returned to
Refer to Figure 4 --- 1. Before starting the compres- operating mode condition by continuing to press
sor, but with power applied, press the PROG pad PROG through the end of the PROGRAMMING
on the Supervisor panel three times to enter the menu or allowing the display to automatically re-
PROGRAMMING mode. Continue pressing the turn to operating mode status after 5 seconds of in-
PROG pad until “MAX PRESS P2A” is displayed. activity. While scrolling with the PROG pad, all exist-
Use the cursor (UP arrow) pad to set the desired ing user programmable values will be displayed.
UNLOAD pressure (110 psig [7.6 bar]). Note that
pressing the pad for over 2 seconds will initiate fast 4.10 MESSAGE DISPLAY DEFINITIONS
scrolling of the value being set. In addition to programming prompts, the 20---char-
acter electro---luminescent display provides in-
Once the correct value is selected, press the PROG formation regarding machine status and trouble
pad to proceed to the display “PRES DIF P2A”. This conditions. These messages can be displayed in
value is used to set the LOAD pressure where the any one of five languages; English, French, Span-
compressor will begin building pressure (10 PSID ish, German or Italian. The following table explains
[0.7 bar]). This will provide LOAD/UNLOAD opera- what each message means as it relates to the com-
tion at 100 to 110 psig [6.7 to 7.6 bar]). These val- pressor.
MESSAGE DISPLAY DEFINITIONS

MACHINE STATUS MESSAGES EXPLANATION
MANUAL SHUTDOWN The machine is ready to be started. Machine

control is powered up; permissives are made;
machine has been stopped via the ON/OFF
pad, the remote start/stop contact (if the
RUNNING LED is flashing), or a computer com---
mand through the RS232 port.
STANDBY The machine is in AUTOMATIC mode and a
start was initiated, but either the line pressure
P2 is higher than the LOAD setpoint or sump
pressure P1 is higher than 14.5 psig (1 bar).
Machine start will occur when these pressures
are satisfied.
ON LOAD The compressor is running and P2 is less than
the UNLOAD setpoint. The LOAD/UNLOAD
solenoid valve relay (output J10/50---51) is en---
ergized. The compressor is attempting to meet
the system air demand.
OFF LOAD The compressor is running and P2 has exceed---
ed UNLOAD setpoint, but has not dropped
below the LOAD setpoint (DIFF PRESS P2). The
UNLOAD solenoid valve relay is deenergized
and the compressor is unloading.
STOP MODE The machine is in AUTOMATIC mode and a
stop command has been initiated either via
the ON/OFF pad or the remote STOP/START
contact (J1/1---2). This mode runs the com---
pressor for 10 seconds with the LOAD/UNLOAD
valve relay deenergized before stopping.
14
Section 4
SUPERVISOR
4.11 TROUBLE INDICATION SETPOINTS
CONDITION/DISPLA Y CAUSE
P1 High Discharge Pressure Shutdown Default is 135 psig (9.3 bar), factory settable for
HIGH PRESSURE P1 high pressure machines.
50 --- 200 psig (3.5 --- 13.8 bar)
Machine will shut down and must be cleared
and reset by pressing ON/OFF once before
restart is possible.
P1 High Discharge Pressure Prealarm Indicates at 98% of Max Press P1.
HIGH PRESSURE P1
Failure to Run, P1 Pressure Loss Since no run contact is used to indicate run
PRESSURE LOSS status, the Supervisor examines P1 pressure
to see if a minimum of 14.5 psig (1 bar) is being
produced when the RUN output is energized.
Reading is overridden for 1 minute at startup.
Low Oil Pressure P3 Shutdown Min Press P3 is factory preset at 10 psig (.7 bar).
(Injection Oil Pressure) Factory adjustable 3 --- 145 psig (.2 --- 10 bar).
LOW PRESSURE P3 Requires clearing of shutdown by pressing
ON/OFF once to reset.
Low Oil Pressure P3 Prealarm Set for 5 psig (.3 bar) above Min Press P3. Not
LOW PRESSURE P3 latching.
High Temperature T1 Shutdown Pre---programmed shutdown at 235_F (113_C).
(Compressor Discharge Temperature) Requires ON/OFF reset to clear.
HIGH TEMPERATURE T1
High Temperature T1 Prealarm Pre---programmed indication at 225_F (107_C).
HIGH TEMPERATURE T1 Not latching.
High Temperature T2 Shutdown Pre---programmed shutdown at 235_F (113_C).
(Injection Oil Temperature)
HIGH TEMPERATURE T2
High Temperature T3 Shutdown Separate RTD controller board provides
(Dry---side Discharge Temperature) a digital input at J1/11---12. Preset at
HIGH TEMPERATURE T3 235_F (113_C).
High Temperature T4 Shutdown Second channel of RTD controller board
(Tandem Interstage Temperature) provides a digital input at J1/13---14. Preset
HIGH TEMPERATURE T4 at 235_F (113_C). (Note: J1/13---14 must be
jumpered if not a tandem compressor).
P1 --- P4 Shorted Sensor Shutdown Signal voltage > 4.82 volts (196 psig/13.5 bar).
SHORT CIRC Px SENDER
P1 --- P4 Open Sensor Shutdown Signal voltage < 0.15 volts.
OPEN CIRC Px SENDER
T1 --- T2 Shorted Sensor Shutdown Resistance < 81 ohms (---45 C).
SHORT CIRC Tx SENDER
T1 --- T2 Open Sensor Shutdown Resistance >176 ohms (200 C).
OPEN CIRC Tx SENDER
Inlet Filter Maintenance Required Vacuum Switch connected to J1/5---6 and
AIR FILTER MAINT RQD preset for 22” WC. Indicates when inlet
filter is too dirty for proper air flow. Not
latched and not a shutdown condition.
Separator Maintenance Required Calculated: P1 --- P2 --- 2 psig (.14 bar)
SEPARATOR MAINT RQD Preset to warn at 10 psig. Warnings will
occur in unloading/unloaded states and
should be ignored. Only valid at full load
condition. Not latched and not a shutdown
condition.
15
Section 4
SUPERVISOR
4.11 TROUBLE INDICATION SETPOINTS (Cont’d.)

CONDITION/DISPLA Y CAUSE
Oil Filter Maintenance Required Calculated: P4 --- P3. Preset at 20 psig (1.38 bar).
OIL FILTER MAIN RQD P4 is located on the high pressure side of the
oil filter. P3 is the injection oil pressure on the
low pressure side of the oil filter. Not latched,
not a shutdown condition.
Emergency Stop Indicates if Emergency Stop button is depress---
EMERGENCY SHUTDOWN ed or if optional sensors wired in series with
the E---Stop button and its master control relay
are open. Must be cleared and reset by press---
ing ON/OFF once.
Fan Overload/Low Water Pressure Shutdown of canopy or cooler fan motor
FAN OL/LOW WATER overload as well as water pressure switch for
water---cooled machines. Normally closed
contact wired to J1/9---10. (Water pressure
switch is normally open and closes with 10
psig minimum water pressure. Fault must be
cleared and reset by pressing ON/OFF pad
once.
16
Section 5
COMPRESSOR SYSTEMS
5.1 INTRODUCTION motor, compressor inlet system, compressor

Your new Sullair lubricated rotary screw air com- discharge system, compressor cooling and lu-
pressor provides you with a unique experience in brication system, capacity control system and
improved reliability and greatly reduced mainte- Supervisor Control System all mounted on a
nance. structural steel frame (optional starters mounted
on 200 through 300HP/150 through 225KW).
Compared to other types of compressors, the Sul-
lair rotary screw is unique in its mechanical reliabil- On air---cooled models, the cooling package is re-
ity and lack of “wear”. The compressor requires ab- mote---mounted and shipped as a separate unit.
solutely no inspection of its internal parts. The separate motor---driven fan cooling package
forces air through the coolers, thereby removing
By reading through Section 6, you will notice the the heat of compression from the cooling fluid.
easy process of caring and maintaining this Sullair On water---cooled models, fluid is piped into a
manufactured product. Should any questions arise water---cooled heat exchanger where the heat of
which cannot be answered in this text, call your compression is removed from the fluid. Two fans on
nearest Sullair representative or the Sullair Corpo- 400 through 600HP/300 through 450KW (one fan
ration Service Department. on 200 through 300HP/150 through 225KW) are
used to supply sufficient ventilating air to compres-
5.2 DESCRIPTION OF COMPONENTS sors equipped with an optional enclosure.
Refer to Figure 5 --- 1. The components and assem-
blies of the air compressors are clearly shown. The Both air---cooled and water---cooled versions have
complete package includes compressor, electric easily accessible items such as the fluid filters and
Figure 5 ---1 Sullair Series TS ---32 Rotary Screw Compressor (Air ---cooled Version)
17
Section 5
COMPRESSOR SYSTEMS
control valves. The inlet air filters are also mounted mal valve begins to close and a portion of the fluid
for easy access and servicing. then flows through the cooler. From the cooler, the
fluid flows to the main filter, (or filters) and on to the
5.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL compressor unit. Each fluid filter has a replacement
DESCRIPTION element and an integral pressure bypass valve.
Sullair tandem air compressors feature the Sullair
compressor unit, a two---stage, positive displace- The fluid stop valve prevents fluid from filling the
ment fluid lubricated---type compressor. This unit compressor unit when the compressor is shut
provides continuous air compression to meet your down. When the compressor is operating, the fluid
needs. stop valve is held open by air pressure from the
compressor unit allowing a free flow of fluid from
Fluid is injected into the compressor unit in large the receiver/sump back to the compressor unit. On
quantities where it mixes directly with the air as the shutdown, the compressor unit pressure is re-
internal rotors turn, compressing the air. The fluid duced, causing the fluid stop valve to close and iso-
flow has three basic functions: late the compressor unit from the cooling system.
1. As coolant, it controls the rise of air temperature
normally associated with the heat of compres- Water---cooled versions of the compressor have a
sion. water---flow regulating valve which operates to
2. Seals the leakage paths between the rotors and conserve water during periods of varying load on
the stator and also between the rotors them- the compressor. This same valve automatically
selves. shuts off the water supply when the compressor is
3. Acts as a lubricating film between the rotors al- shut down. In addition, water---cooled models have
lowing one rotor to directly drive the other, which a water pressure switch to prevent operation with
is an idler. inadequate water pressure.
After the air/fluid mixture is discharged from the
compressor unit, the fluid is separated from the air. 5.5 COMPRESSOR DISCHARGE SYSTEM, FUNC-
At this time, the air flows to the service line and the TIONAL DESCRIPTION (200, 250 and
fluid is cooled in preparation for re---injection. 300HP/150, 187 AND 225KW)
Refer to Figures 5 --- 2, 5 --- 4 and 5 --- 6. The compres-
sor unit discharges the compressed air/fluid mix-
NOTE ture through a discharge check valve into the com-
bination receiver/sump. The discharge check valve
With a Sullair compressor, there is no mainte- prevents air/fluid in the receiver from returning to
nance or inspection of the internal parts of the the compression chamber after the compressor
compressor unit permitted in accordance with has been shut down. The receiver has three func-
the terms of the warranty. tions:
1. It acts as a primary fluid separator.
5.4 COMPRESSOR COOLING AND LUBRICATION 2. It serves as the compressor fluid sump.
SYSTEM, FUNCTIONAL DESCRIPTION 3. It houses the final fluid/air separator elements.
Refer to Figures 5 --- 2, 5 --- 3, 5 --- 4 and 5 --- 5. The The compressed air/fluid mixture enters the re-
cooling and lubrication system consists of a fluid ceiver and is directed against the ends of the tank.
cooler, aftercooler, full flow fluid filter, fluid stop The direction of movement is changed and its ve-
valve, thermal valve and a water regulating locity significantly reduced, thus causing the large
valve (for water---cooled models only). For water--- droplets of fluid to fall to the bottom of the receiver/
cooled models, a fluid cooler and aftercooler are sump. The fractional percentage of fluid remaining
mounted on the compressor package. For air--- in the compressed air collects on the surface of the
cooled models, they are mounted on separate nested separator elements (primary and secon-
cooling packages. dary) as the compressed air flows through them.
The pressure in the receiver/sump causes fluid flow Two return lines (or scavenge tubes) lead from the
by forcing the fluid from the high pressure area of bottom of each separator element to the low pres-
the sump to an area of lower pressure in the com- sure inlet region of the compressor unit. Fluid col-
pressor unit. lecting on the bottom of each separator is returned
to the compressor by a pressure difference be-
Fluid flows from the bottom of the receiver/sump to tween the receiver and the compressor inlet. Sight
the thermal valve. The thermal valve is fully open to glasses are located in the return lines to observe
the compressor unit when the discharge tempera- this fluid flow. By pressing the ∆P1 pad on the Su-
ture is below 170_F (77_C). The fluid passes pervisor, the operator can monitor the condition of
through the thermal valve, the main fluid filter and the separator elements by reading the differential
directly to the compressor unit. pressure on the digital display. At a differential of 10
PSID (0.7 bar), or greater, the operator will be told
As the discharge temperature rises above 170_F to service the separator elements. At this time,
(77_C), due to the heat of compression, the ther- separator element replacement is necessary.
18
Section 5
COMPRESSOR SYSTEMS
Figure 5 ---2 Compressor Piping and Instrument Diagram (200, 250, 300HP/150, 187, 225KW)
19
Section 5
COMPRESSOR SYSTEMS
Figure 5 ---3 Compressor Cooling and Lubrication System (200, 250, 300HP/150, 187, 225KW Water ---cooled)
The receiver(s) is an ASME pressure vessel. A

combination minimum pressure/check valve, lo-
! WARNING
cated downstream from the separator, assures a DO NOT remove caps, plugs, and/or other com-
minimum receiver pressure of 50 PSIG (3.4 bar) ponents when compressor is running or pressur-
during full load operation. This pressure is neces- ized.
sary for proper air/fluid separation and proper fluid Stop compressor and relieve all internal pres-
circulation while supplying air to the system. This sure before doing so.
valve also acts as a check valve preventing com-
pressed air in the service line from bleeding back
into the receiver on shutdown and during operation Fluid is added to the sump via a capped fluid filler
on the compressor in an unloaded condition. opening, placed low on the receiver tank to prevent
overfilling of the sump. A sight glass enables the
operator to visually monitor the sump fluid level.
A pressure relief valve (located on the wet side of 5.6 COMPRESSOR DISCHARGE SYSTEM, FUNC-
the separator) is set to open if the sump pressure TIONAL DESCRIPTION (400, 500 AND
exceeds 150 PSIG (10.3 bar). 600HP/300, 375 AND 450KW)
Refer to Figures 5 --- 4 and 5 --- 7. The compressor
unit discharges the compressed air/fluid mixture
All Sullair compressor models are equipped with through a discharge check valve into the sump.
high pressure shutdown protection to shut down The air/fluid mixture enters the sump and is di-
the compressor at 135 PSIG (9.3 bar). This pre- rected against the tank. Its direction of movement
vents the pressure relief valve from opening under is changed and its velocity significantly reduced,
normal conditions, thereby preventing fluid loss thus causing the large droplets of fluid to fall to the
through the pressure relief valve. A temperature bottom of the tank. The compressed air with the re-
switch will shut down the compressor if the dis- maining fluid enters the receiver. As the com-
charge temperature reaches 235_F (113_C). pressed air passes through nested separators (pri-
20
Section 5
COMPRESSOR SYSTEMS
Figure 5 ---4 Compressor Piping and Instrument Diagram (400, 500, 600HP/300, 375, 450KW)
500---600HP/375---450KW air cooled models only
21
Section 5
COMPRESSOR SYSTEMS
Figure 5 ---5 Compressor Cooling and Lubrication System (400, 500, 600HP/300, 337, 450KW Water ---cooled)
mary and secondary), the remaining fluid is re- A minimum pressure valve is provided to assure
moved from the air. The fluid removed in the re- minimum sump pressure of 50 PSIG (3.5 bar). This
ceiver in turn flows to the bottom of each separator pressure is necessary for proper air/fluid separa-
which is in turn returned back to the compressor tion and to assure proper fluid circulation while
through two scavenger lines. Some fluid will drop supplying air to the system. Also, a check valve is
to the bottom of the receiver prior to the air entering provided to prevent compressed air in the service
the separator elements. This fluid is also returned line from bleeding back into the receiver during
shutdown, as well as in the unload operation.
to the compressor via another scavenger tube.
Sight glasses are provided in the scavenger lines to A pressure relief valve (located on the sump) is set
observe this fluid flow. There are also orifices on to open if the sump pressure exceeds 150 PSIG
these lines (protected by strainers to assure proper (10.3 bar).
flow). By pressing the ∆P1 pad on the Supervisor,
The compressor is also equipped with high pres-
the operator may monitor the condition of the sepa- sure shutdown protection to shut down the com-
rator elements by reading differential pressure on pressor at 135 PSIG (9.3 bar). This prevents the re-
the digital display. At a differential of 10 PSID (0.7 lief valve from opening and dumping fluid under
bar) or greater, the operator will be told to service normal conditions. Also, a high discharge tempera-
the separator element. At this time, separator ele- ture switch with three (3) sensing probes is pro-
ment replacement is necessary. All tanks, sump vided to shut down the compressor if the discharge
and receiver are ASME pressure vessels. temperature reaches 235_F (113_C).
22
Section 5
COMPRESSOR SYSTEMS
Figure 5 ---6 Compressor Discharge System (200, 250, 300HP/150, 187, 225KW)
Figure 5 ---7 Compressor Discharge System (400, 500, 600HP/300, 375, 450KW)
23
Section 5
COMPRESSOR SYSTEMS
MODULATION --- 100 to 110 PSIG (6.9 TO 7.6

! WARNING bar)
As air demand drops below the rated capacity of
DO NOT remove caps, plugs, and/or other com- the compressor, the line pressure will rise above
ponents when compressor is running or pressur- 100 PSIG (6.9 bar). As a result, the differential pres-
ized.
sure regulator for the spiral valve gradually opens,
Stop compressor and relieve all internal pres- applying air pressure to the spiral valve actuator. Air
sure before doing so. pressure at the actuator expands the diaphragm.
The rack, in turn, engages with the pinion mounted
on the spiral valve shaft assembly. This results in a
rotary motion. As the spiral valve rotates, it starts
Fluid is added to the sump via a capped fluid filler opening the bypass ports gradually. Excess air is
opening, placed low on the receiver tank to prevent then being returned back internally to suction end
overfilling of the sump. A sight glass enables the of compressor unit. Now the compressor is fully
operator to visually monitor the sump fluid level. compressing only that amount of air which is being
used. As air demand keeps dropping further, the
5.7 CONTROL SYSTEM, FUNCTIONAL DESCRIP- spiral valve keeps opening more and more until all
TION the bypass ports are fully open. At this point, the
Refer to Figures 5 --- 8 and 5 --- 9. The purpose of the spiral valve has moved into the unload (minimum)
compressor control system is to regulate the position.
amount of air being compressed to match the The spiral valve provides a modulation range from
amount of compressed air being used. 100 to 50%. During this period, the pressure rises
approximately from 100 to 108 PSIG (6.9 to 7.4
The capacity control system consists of a spiral bar). As the air pressure exceeds 108 PSIG (7.4
valve and an inlet butterfly valve. The functional de- bar), the differential pressure regulator controlling
scription of the control system is described below the Sullicon Control opens. This allows the air pres-
in 4 distinct phases of compressor operation. The sure to expand the diaphragm chamber of the Sul-
following applies to all TS---32 Series compressors licon Control, which starts partially closing the inlet
ranging from 200 through 600HP/150 through butterfly valve. The inlet butterfly valve provides
450KW models. For explanatory purposes, this de- modulation range from 50 to 40%. During this pe-
scription applies to any compressor with an operat- riod, the pressure rises approximately from 108 to
ing range of 100 to 110 PSIG (6.9 to 7.6 bar). A com- 110 PSIG (7.4 to 7.6 bar). During this range, the spi-
pressor with any other pressure range would oper- ral valve remains in the unload position.
ate in the same manner except for the stated pres-
sures. UNLOAD MODE --- IN EXCESS OF 110 PSIG (7.6
bar)
START MODE --- 0 TO 50 PSIG (0 TO 3.4 bar) When a relatively small amount or no air is being
When the compressor ON/OFF pad is depressed, used, the service line pressure continues to rise.
the sump pressure will quickly rise from 0 to 50 When it exceeds 110 PSIG (7.6 bar), Supervisor
PSIG (0 to 3.4 bar). During this period, both of the de---energizes the solenoid valve allowing line
pressure regulators and the solenoid valve are pressure to be supplied directly to the Sullicon dia-
closed and the Sullicon Control and spiral valve are phragm keeping the inlet butterfly closed; the spiral
inoperative. The spring on the control holds the valve is in the fully open (minimum) position. Simul-
butterfly valve fully open while the spiral valve is ful- tateously, the solenoid valve sends a pneumatic
ly closed (maximum) position and the compressor signal to the blowdown valve. The blowdown valve
pumps at full rated capacity. The rising compressor opens the sump to the atmosphere. This reduces
air pressure is isolated from the service line in this the sump pressure to approximately 30 (water---
phase by the minimum pressure valve set at ap- cooled) to 50 (air---cooled) PSIG (2.1 to 3.4 bar)
proximately 50 PSIG (3.4 bar). which results in low horsepower consumption. The
check valve in the air service line prevents line pres-
FULL LOAD MODE --- 50 TO 100 PSIG (3.4 TO 6.9 sure from returning to sump while the compressor
bar) is running in the unloaded mode. Both the spiral
When the compressed air pressure in the sump valve and the butterfly valve remain in the unload
rises above 50 PSIG (3.4 bar), the minimum pres- position.
sure valve opens, allowing compressed air to flow When the line pressure drops back to 100 PSIG
into the service line. From this point on, the line air (6.9 bar) due to an increase in the air demand, Su-
pressure is continually monitored by the Supervi- pervisor energizes the solenoid valve allowing the
sor. The pressure regulators and the solenoid valve air pressure behind the Sullicon Control to be
remain closed during this phase, keeping the Sulli- vented through the solenoid valve exhaust port.
con Control and spiral valve inactive. Both the spi- The blowdown valve closes, and the inlet butterfly
ral valve as well as the inlet butterfly valve remain in valve opens. Also the air pressure at the spiral valve
the full load position as long as the compressor is actuator diaphragm is reduced through a vent hole
running at 100 PSIG (6.9 bar) or below. at the spiral valve differential pressure regulator,
24
Section 5
COMPRESSOR SYSTEMS
Figure 5 ---8 Control System (200, 250, 300HP/150, 187, 225KW)
25
Section 5
COMPRESSOR SYSTEMS
Figure 5 ---8 Control System Diagram (200, 250, 300HP/150, 187, 225KW)
26
Section 5
COMPRESSOR SYSTEMS
27
Section 5
COMPRESSOR SYSTEMS
28
Section 5
COMPRESSOR SYSTEMS
Figure 5 ---10 Compressor Air Inlet System
/
150, 187, 225 KW
/
300, 375, 450 KW
29
Section 5
COMPRESSOR SYSTEMS
and a spring in the actuator causes the spiral valve 5.8 AIR INLET SYSTEM, FUNCTIONAL DESCRIP-
to return to the full load (maximum) position. TION
Refer to Figure 5 --- 10. The compressor inlet system
AUTOMATIC OPERATION consists of one or two dry ---type air filters, a vac-
For applications with varied periods of time when uum switch and an air inlet valve.
there are no air requirements, Supervisor’s Auto-
matic mode allows the compressor to shut down
(time delayed) when no compressed air require- The vacuum switch, located in the compressor Su-
ment is present and restart as compressed air is pervisor control system, indicates the condition of
needed. AUTOMATIC mode also incorporates the the air filter. When the message “AIR FILTER MAINT
60 second unloaded STOP mode feature which al- RQD” is displayed,maintenance is required.
lows the motor to stop from an unloaded condition
when the ON/OFF pad is pressed or after the timed The butterfly ---type air inlet valve directly controls
stop period. If immediate stop is required when op- the amount of air intake to the compressor in re-
erating in AUTOMATIC mode, press the EMER- sponse to the operation of the Sullicon Control
GENCY STOP button on the control panel. (Section 5.6).
30
Section 6
6.1 GENERAL call for service or indicate the beginning of a mal-

While Sullair has built into this compressor a com- function. Before starting your Sullair compressor,
prehensive array of controls and indicators to as- read this section thoroughly and familiarize your-
sure you that it is operating properly, you will want self with the controls and indicators --- their pur-
to recognize and interpret the reading which will pose, location and use.
6.2 PURPOSE OF CONTROLS
CONTROL OR INDICATOR PURPOSE
ON/OFF PAD Depress to turn compressor ON. Depress again to

turn compressor OFF. If a fault shutdown occurs, or
EMERGENCY STOP, the ON/OFF button must be
pressed once to acknowledge the fault and silence
the alarm. Once the fault has been cleared, ON/OFF
must be pressed once to return to MANUAL SHUT-
DOWN in preparation for start.
HOUR DISPLAY Displays accumulated hours of compressor opera-
tion; useful for planning and logging service sched-
ules. Alternate displays by use of their respective
touchpads are --- hours ON LOAD and percentage of
hours running when on LOAD.
PRESSURE DISPLAY Continuously monitors service line air pressure (P2).
Located on dry side of receiver downstream of mini-
mum pressure/check valve. Selectable alternate dis-
plays via touchpad include:
SUMP PRESSURE (P1) displays receiver/sump
pressure at various ON LOAD and/or OFF LOAD con-
ditions.
SEPARATOR DIFFERENTIAL (∆P1) displays the dif-
ferential pressure across the separator element/s. A
preset limit of 10 PSID (0.7 bar) will trigger the ∆P1
LED and a message will warn that a separator change
is required.
OIL FILTER DIFFERENTIAL (∆P2) displays the dif-
ferential pressure across the fluid filter. A preset limit
of 20 PSID (1.4 bar) will trigger the ∆P2 LED and a
message will warn that a filter change is required.
TEMPERATURE DISPLAY Continuously monitors the temperature of the air leav-
ing the compressor unit (T1). The normal readings
should be approximately 180_F to 205_F (82_C to
96_C). An alternate display of injection fluid tempera-
ture (T2) is available from the touchpad. Normal read-
ings should be approximately 130_F to 160_F (54_C
to 71_C).
AIR FILTER MAINTENANCE Indicates when the air filter change is required. The
LED shown on the air filter of the graphic map will flash
and a message of “AIR FILTER MAINT RQD” will be
displayed.
“POWER ENERGIZED” LIGHT Indicates when the control panel is receiving power.
“ON” LED Indicates when the compressor is running. If the ON
LED is flashing while the compressor is stopped, it is in-
dicating that the compressor was stopped by a remote
START/STOP contact and could be restarted without
notice.
31
Section 6
FLUID LEVEL SIGHT GLASS Monitors fluid level in the sump. Proper level should fill
1/2 of the sight glass when the compressor is shut
down. Check the level when the compressor is shut
down. DO NOT OVERFILL.
SEPARATOR RETURN LINE SIGHT GLASS Used to indicate fluid flow in the return line. When the
compressor is running at full load, fluid flow should be
visible in this sight glass. There may be little or no flow
when the compressor is running unloaded, but a slug-
gish flow at full load indicates a need to clean the return
line strainers.
FLUID STOP VALVE Cuts off flow of fluid to compressor unit at compressor
shutdown and allows flow of fluid to the unit on start---
up.
DISCHARGE CHECK VALVE Cuts off the reverse flow of air/fluid mixture through
compressor discharge system at compressor shut-
down.
THERMAL VALVE Regulates flow of fluid to and around the cooler. De-
signed to maintain a minimum operating temperature
of 170_F (77_C); used for fast warm---up on start---up.
MINIMUM PRESSURE/CHECK VALVE Maintains minimum of 50 PSIG (3.4 bar) in the com---
(200---300HP/ 150---225KW) pressor sump. Valve piston restricts receiver air dis---
charge from receiver/sump when pressure is below 40
PSIG (2.8 bar). Prevents line pressure backflow in sump
during unload conditions and after shutdown.
COMPRESSOR DISCHARGE The Supervisor will shut the compressor down when
TEMPERATURE PROBE (T1) the discharge temperature reaches 235_F (113_C).
The message displays “HIGH TEMP T1”.
SUMP PRESSURE TRANSDUCER (P1) The Supervisor will shut the compressor down if the
sump pressure becomes too high. This transducer is
factory set per the designed operating range of the
compressor; normally 135 PSIG (9.3 bar). P1 status in
conjunction with the status of the “compressor run”
output contact determines if compressor is running. If
the run contact is closed, the compressor is ON
LOAD, and P1 is below 14.5 PSIG (1 bar), the Supervi-
sor will initiate a shutdown and display a “Pressure
Loss” message.
INJECTION OIL PRESSURE The Supervisor will initiate a protective shutdown
TRANSDUCER (P3) and display a ”Low Pressure P3” message if the
fluid pressure goes below a factory set minimum
value; approximately 10 PSIG (0.7 bar).
FLUID FILTER TRANSDUCER (P4) Used in conjunction with P3 to calculate fluid filter dif-
ferential pressure and warn of need for filter replace-
ment.
WATER PRESSURE SWITCH Prevents compressor operation if water pressure is
(water---cooled compressors only) too low. Standard setting is 10 PSIG (0.7 bar). The
message “FAN OL/LO WATER” will be
displayed if pressure is too low.
32
Section 6
PRESSURE RELIEF VALVE Opens sump pressure to the atmosphere should

pressure inside the sump become too high (150 PSIG
[10.3 bar]). Operation of this valve indicates that the
high pressure switch is either faulty or out of adjust-
ment.
SULLICON CONTROL Regulates the amount of air allowed to enter the air in-
let valve. This regulation is determined by the amount
of air being used at the service line.
PRESSURE REGULATOR --- SULLICON Opens a pressure line between the sump and Sul-
licon Control allowing the Sullicon Control to regulate
air delivery according to the air demand.
PRESSURE REGULATOR--- SPIRAL VALVE 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.
SOLENOID VALVE #1 Bypasses the pressure regulator valve causing the
Sullicon Control to close the inlet valve when the
compressor reaches maximum operating pressure.
SOLENOID VALVE #2 (spiral valve control) Opens when the compressor starts; closes when the
compressor is shut off. This prevents any air system
loss when the compressor is shut off.
LINE PRESSURE TRANSDUCER (P2) Senses service line pressure. When line pressure
reaches maximum setting, the Supervisor signals the
solenoid valve to OFF LOAD the compressor. The
message “ON LOAD” or “OFF LOAD” will be dis-
played to indicate the status of the control. P2 is also
used to calculate separator differential pressure ∆P1.
BLOWDOWN VALVE Vents sump pressure to the atmosphere during un-
load conditions and shutdown.
WATER REGULATING VALVE Regulates the amount of cooling water used in the
(water---cooled only) cooler to keep the compressor running at a normal
operating temperature.
6.3 INITIAL START---UP PROCEDURE 4. Set the compressor in MANUAL mode and start
The following procedure should be used to make the compressor by pressing the ON/OFF pad.
the initial start---up of the compressor: 5. Check for possible leaks in piping.
1. Read the preceding pages of this manual thor- 6. Slowly close the shut---off valve and check that
oughly. the maximum pressure (P2) and pressure differ-
2. Be sure that all preparations and checks de- ential (P2) are correctly programmed.
scribed in the Installation Section have been 7. Observe the operating temperature. If the oper-
made. ating temperature exceeds 205_F (96_C), the
3. Crack open the shut off valve to the service line. cooling system or installation environment
should be checked.
8. Observe return line sight glasses and mainte-
! WARNING nance indicators.
Be sure that the depressurization line between
9. Open shut---off valve to service line.
the sump and the air---cooled cooler package is 10. Reinspect the compressor for temperature and
connected as explained in Section 4 (Par 4.6). leaks the following day.
33
Section 6
6.4 SUBSEQUENT START---UP PROCEDURE

On subsequent start---ups, check that the proper
level is visible in the fluid sight glass and simply
press the ON/OFF pad. When the compressor is
running, observe the control panel for mainte-
nance indications.
6.5 SHUTDOWN PROCEDURE
To shut the compressor down, simply press the
ON/OFF pad. On MANUAL operation, shutdown is
immediate; on AUTOMATIC operation, shutdown
is preceded by a 10 second UNLOAD mode.
34
Section 7
MAINTENANCE
7.1 GENERAL 7.5 FLUID CHANGE

As you proceed in reading this section, it will be Standard models are filled with the long life lubri-
easy to see that the Maintenance Program for the cant Sullube 32.
air compressor is quite minimal yet important. The
use of the service indicators provided for the fluid Sullube 32 should be changed under the following
filter, air filter and fluid separator, will alert you when conditions, whichever occurs first:
service maintenance is required. When the mainte- 1. Every 8000 hours.
nance message is displayed by the Supervisor 2. Once a year.
control, maintenance for that specific item is re- 3. As indicated by fluid analysis.
quired. See instructions for each item in Section A fluid sample analysis at every 4000 hours is rec-
7.7, Parts Replacement and Adjustment proce- ommended. Return fluid to Sullair Corporation in
dures. Michigan City for free analysis. To facilitate this, a
sample bottle is included with the compressor.
7.2 DAILY OPERATION
Prior to starting the compressor, it is necessary to 7.6 SEPARATOR MAINTENANCE
check the fluid level in the sump. Should the level Replace the separator elements when a message
be low, simply add the necessary amount. If the is displayed or after one (1) year, whichever comes
addition of fluid becomes too frequent, a simple first. The separator elements must be replaced. DO
problem has developed which is causing this ex- NOT clean the separator elements.
cessive loss. See the Troubleshooting Section (7.8)
under Excessive Fluid Consumption for a probable 7.7 PARTS REPLACEMENT AND ADJUSTMENT
cause and remedy. PROCEDURES
MAIN FILTER MAINTENANCE
After a routine start has been made, observe the Refer to Figure 7---1. The main filter (P/N
Supervisor control panel and be sure it monitors 250007---219) is located schematically between
the correct readings for that particular phase of op- the compressor and the fluid stop valve. When
eration. After the compressor has warmed up, it is servicing the main filter, shut the compressor
recommended that a general check of the overall
compressor and Supervisor be made to assure Figure 7 ---1 Main Filter (P/N 250007 ---219)
that the compressor is running properly.
! WARNING
DO NOT remove caps, plugs, and/or other com- *

ponents when compressor is running or pressur-
ized.
Stop compressor and relieve all internal pres-

sure before doing so. *
*
7.3 MAINTENANCE AFTER INITIAL 50
HOURS OF OPERATION *
After the initial 50 hours of operation, a few mainte-
nance requirements are needed to rid the system
of any foreign materials if any. Perform the following
maintenance operations to prevent unnecessary *
problems.
1. Clean the return line strainers.
2. Clean the return line orifices.
3. Change the fluid filter element.
4. Clean the control line filters.
7.4 MAINTENANCE AFTER 1000
HOURS
After 1000 hours of operation, it will be necessary to
perform the following:
1. Clean the return line strainers.
2. Lubricate the Sullicon Control linkage.
3. Replace the fluid filter element. * Repair Kit P/N 250008---956
35
Section 7
MAINTENANCE
down, be sure all pressure has been released, then AIR FILTER MAINTENANCE
follow the instructions below. For element replace- Refer to Figure 7 --- 2. Air filter maintenance should
ment order kit number 250008---956. be performed when the air filter maintenance mes-
1. Remove the four (4) capscrews which secure the sage is displayed. The air filter is equipped with a
filter head to the canister. primary element and a secondary element. As pre-
2. Pull the canister away from the filter head. The fil- viously stated, the Supervisor will alert you as to
ter elements will be attached to the head. when the primary element maintenance is neces-
3. Separate the upper element from the head. sary. When removing the primary element, always
These elements are joined together with an check the secondary element for visible dirt,
adapter piece. Remove, clean and use to rejoin grease or damage. The secondary element must
elements. be changed after every sixth primary element
4. Remove the canister seal. change. DO NOT clean the secondary element.
5. Thoroughly clean the filter head and canister in
solvent. ELEMENT REMOVAL
6. Lubricate the new seals with the same type of 1. Clean the exterior of the air filter housing.
fluid used in the compressor and position each 2. Remove the cover assembly by loosening the
seal in its appropriate place. wingnut securing it.
7. Carefully push the element back in position on 3. Pull the element assembly out of the housing.
the filter head. 4. On the inside of the element, you will notice a
8. Hold the canister in position under the housing wingnut which fastens the element to the hous-
and replace the capscrews, securing the canis- ing. Remove the wingnut and pull the primary
ter and filter head. element out.
Figure 7 ---2 Air Filter Replacement (P/N 250006 ---718)
* Replacement element P/N 250007---838 (primary)

** Replacement element P/N 250007---839 (secondary)
36
Section 7
MAINTENANCE
5. Loosen and remove the hex nut securing the ELEMENT INSPECTION
secondary element. Remove the secondary ele- 1. Place a bright light inside the element to inspect
ment. for damage or leak holes. Concentrated light will
6. Inspect the secondary element and replace if shine through the element, revealing any holes.
necessary. 2. Inspect all gaskets and gasket contact surfaces
7. Clean the interior of the housing by using a damp of the housing. Should faulty gaskets be evi-
cloth. DO NOT blow dirt out with compressor air. dent, correct the condition immediately.
8. Install the new secondary element and replace 3. If the clean element is to be stored for later use, it
the sealing washer and hex nut. must be stored in a clean, closed container.
9. With the secondary element in place, replace the 4. After the element has been installed, inspect and
primary element. tighten, if necessary, all air inlet connections
prior to resuming operation.
DO NOT strike the element against any hard sur-
face to dislodge dust. This will damage the sealing PRIMARY ELEMENT REPLACEMENT
surfaces and possibly rupture the element. 1. Place the element in position over secondary ele-
DO NOT “blow” dirt out of the interior of the filter ment. Replace the sealing washer and wingnut.
housing. This may introduce dust downstream of Tighten the wingnut so as to fully seat the ele-
the filter. Instead, use a clean damp cloth. ment gasket.
2. Install the cover/element assembly and replace
DO NOT oil the element. the wingnut.
Figure 7 ---3 Separator Element Replacement
200, 250, 300HP 400, 500, 600HP

150, 187, 225KW 300, 375, 450KW
* Primary replacement element P/N 250034---124 (200, 250, 300HP/150 --- 225K) and 250034---126 (400,
500, 600HP/300 --- 450KW)
** Secondary replacement element P/N 250034---130 (200, 250, 300HP/150 --- 225KW) and 250034---132
(400, 500, 600HP/300 --- 450KW)
37
Section 7
MAINTENANCE
SEPARATOR ELEMENTS REPLACEMENT Figure 7 ---4 Sullicon Control (P/N 011682 ---003)
Refer to Figure 7 --- 3. The separator elements must
be changed when “Separator Maintenance Re-
quired” message is displayed, or once a year
whichever occurs first. Follow the procedure ex-
plained below for separator element replacement.
PROCEDURE FOR 200---300HP/150---225K W

ELEMENT REPLACEMENT
1. Relieve all pressure from the separator and all
compressor lines prior to disconnecting any
pipes, tubing, etc.
2. Disconnect all piping connected to the separator
cover to allow removal (return lines, service
lines, etc.).
3. Loosen and remove the twelve (12) #@4” x 3” hex
head capscrews from the cover plate.
4. Lift the cover plate from the separator.
5. Remove the primary and secondary separator
elements.
6. Scrape the old gasket material from the cover
and flange on the sump being careful not to let
the scraps fall in the sump.
7. Inspect the separator tank for rust, dirt, etc.
8. Reinsert the separator elements with gaskets at-
tached into the sump taking care not to dent
them against the tank opening. DO NOT re-
move grounding staples. Check between sepa-
rator element flange and tank for continuity after
torquing bolts. DO NOT use anti---seize com-
pound on gaskets.
9. Clean the underside of the separator tank cover
and remove any rust.
10. Replace the cover plate, washers and
capscrews. Torque to 200 ft.---lbs. (271 Nm).
11. Reconnect all piping making sure return line
tubes extend to the bottom or !@4” (6mm) above * Repair Kit P/N 250020---353
the bottom of the separator element. This will as-
sure proper fluid return flow to the compressor.
12. Check the return line strainer before restarting ring, washers and nuts and resecure. Torque to
the compressor (order replacement kit P/N 30 ft.---lbs. (41 Nm). Check between separator
241772 if required). element flange and tank for continuity after
torquing bolts. DO NOT use anti---seize com-
PROCEDURE FOR 400---600HP/300---450K W pound on gaskets.
ELEMENT REPLACEMENT 9. Clean the underside of the separator tank cover
1. Relieve all pressure from the separator and all and remove any rust.
compressor lines prior to disconnecting any 10. Replace the cover plate, washers and
pipes, tubing, etc. capscrews. Torque to 200 ft.---lbs. (271 Nm).
2. Loosen and remove the twelve (12) #@4” x 3” hex 11. Reconnect all piping making sure return line
head capscrews from the cover plate. tubes extend to the bottom or !@4” (6mm) above
3. Lift the cover plate from the separator. the bottom of the separator element. This will as-
4. Loosen and remove the twelve (12) nuts and sure proper fluid return flow to the compressor.
washers from the retaining ring studs and re- 12. Check the return line strainer before restarting
move the retaining ring. the compressor (order replacement kit P/N
5. Remove the gasket, and primary and secondary 241772 if required).
separator elements.
6. Scrape the old gasket material from the retaining CONTROL SYSTEM ADJUSTMENT
ring and flange on the sump being careful not to Refer to Figure 7 --- 4. Before starting the compres-
let the scraps fall in the sump. sor, but with power applied, press the PROG pad
7. Inspect the separator tank for rust, dirt, etc. on the Supervisor panel three times to enter the
8. Reinsert the replacement separator elements PROGRAMMING mode. Continue pressing the
into the sump taking care not to dent them PROG pad until “MAX PRESS P2A” is displayed.
against the tank opening. Reinsert retaining Use the cursor (UP arrow) pad to set the desired
38
Section 7
MAINTENANCE
UNLOAD pressure (110 psig [7.6 bar]). Note that

pressing the pad for over 2 seconds will initiate fast Figure 7 ---5 Drive Coupling (200 ---300HP/150 ---225KW)
scrolling of the value being set.
Once the correct value is selected, press the PROG
pad to proceed to the display “PRES DIF P2A. This
value is used to set the LOAD pressure where the
compressor will begin building pressure (10 PSID
[0.7 bar]). This will provide LOAD/UNLOAD opera-
tion at 100 to 110 psig [6.7 to 7.6 bar]). These val-
ues will be entered when the display is returned to
operating mode condition by continuing to press
PROG through the end of the PROGRAMMING
menu or allowing the display to automatically re-
turn to operating mode status after 5 seconds of in-
activity. While scrolling with the PROG pad, all exist-
ing user programmable values will be displayed.
FOR DIFFERENTIAL PRESSURE REGULATOR
ADJUSTMENT:
The differential pressure regulators are adjusted by
loosening the jam nut on the end of the cone
shaped cover of the pressure regulator. When the
jam nut is loose, turn the adjusting screw clockwise
to increase or counterclockwise to decrease the
setting.
Above 100 psig (6.9 bar), the spiral valve regulator
should allow pressure to flow into the chamber of
the spiral valve actuator. The spiral valve should
start to rotate at this time. Element P/N 046999
other surfaces of the drive flanges. Rotate shafts so
At approximately 108 psig (7.5 bar), the Sullicon that a straight edge will rest squarely (or within the
regulator should allow pressure to flow into the 0.010 inch maximum limit shown in Table 1) on both
control chamber of the Sullicon Control. The Sul- flanges and at a point 90_ away. The vertical offset
licon Control level should start to move at this time. alignment is adjusted by the addition or removal of
Cycle the Control System several times and re- motor mounting shims. Loosen the motor mount-
check all pressure settings. ing bolts and slide the motor sideways to correct
DRIVE COUPLING INSTALLATION AND the horizontal offset.
ALIGNMENT (200, 250 and 300HP/150, 187 STEP 3 COUPLING GAP AND ANGULAR ALIGN-
and 225KW) MENT --- Position the hubs to establish the proper
Refer to Figures 7 --- 5, 7 --- 6 and 7 --- 7. For coupling gap and angular alignment as indicated in Table 1.
installation and alignment, the tools required are a To determine the angular misalignment in inches,
straight edge, a measuring scale, one set of feeler measure the maximum space between the hub
gauges, a set of standard Allen wrenches and one flanges and the minimum space 180_ away, and
set of standard socket wrenches. then subtract. To adjust the horizontal angular
misalignment, loosen the motor mounting bolts
and adjust the motor position until the angular
! WARNING alignment is within tolerance.
Disconnect all power at source, before attempting
maintenance or adjustments. ! WARNING
DO NOT upset the offset alignment or hub gap
when adjusting motor position.
For installation and alignment of the drive coupling,
follow the steps explained below. When within the limits specified in Table 1, tighten
the motor mounting bolts and recheck the offset
STEP 1 MOUNT HUBS --- Mount the motor hub and angular alignment. If the vertical angular align-
and the compressor hub onto respective shaft. Po- ment is not within .010 inch tolerance, shim the
sition the hubs to establish the correct gap speci- front or rear of the motor separately to correct. Re-
fied in Table 1. Secure each hub with a setscrew. check the vertical offset.
STEP 2 OFFSET ALIGNMENT --- Clean any oil, STEP 4 INSTALL THE FLEXIBLE ELEMENT --- Po-
grease, dirt or paint from coupling faces and the sition the motor and compressor keyways 180_
39
Section 7
MAINTENANCE
apart. Insert the flexible element between the two

hubs. The element should be compressed prior to Figure 7 ---7 Parallel / Angular Offset Alignment
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 7 --- 6. Slide the ferry head capscrews with
lockwashers through the holes in the hubs and ele-
ment. Tighten the capscrews to 200 ft.---lbs. (271
Nm).
NOTE
Capscrews are 3/4 --- 10 x 4” LG NAS 144 black ox-

ide coated. 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.
DRIVE COUPLING INSTALLATION AND ALIGN-
MENT (400, 500 AND 600HP/300, 375 AND
450KW
Refer to Figures 7 --- 6, 7 --- 7, 7 --- 8, 7 --- 9, 7 --- 10 and
7 --- 11. For coupling installation and alignment, the
tools required are a straight edge, a measuring
scale, one set of feeler gauges, a set of standard
Allen wrenches, one set of standard socket
wrenches, and a 17mm end wrench for shrink disc
locking screws.
Figure 7 ---6 Drive Coupling Alignment
TABLE 1
INSTALLATION DATA (200, 250 and 300HP/150, 187, 225KW)
Max. Operating Misalignment
Tightening Coupling Parallel Angular

Torque Gap Offset
ft.---lbs./Nm inches/cm inches/cm inches/cm (I)
200 2.969 + .030 .010 .010
---.000
271Nm 7.5 + .08 .03 .03
--- .000
(I) Angular misalignment in inches equals maximum A mi-
nus minimum B as shown in Figure 7 --- 6. DO NOT ex-
ceed values in Table above.
! WARNING
Disconnect all power at source, before attempt-
ing maintenance or adjustments.
Use the following procedure for proper mainte-

nance and alignment of the coupling:
40
Section 7
MAINTENANCE
Figure 7 ---8 Drive Coupling (P/N 02250043 ---132 for 400HP/300KW, P/N 250039 ---660 for 500 ---600HP/375 ---450KW)
* Repair Kit P/N 02250044---346
1. Disassemble the coupling. Note arrangement of 2. Inspect both shafts and hub bores, making sure
bolts, washers, and nuts as they must be re- they are free of burrs. File if necessary. Be sure
placed in the same order. the key fits the motor shaft properly. For installa-
tion of the drive coupling, follow the steps below:
Figure 7 ---9 Bolt Tightening
STEP 1 --- MOUNT HUBS
Motor Hub --- This hub has an interference fit. Heat
the hub using an oven, oil bath or an induction
heater up to 300_F (149_C). Mount the hub to the
motor shaft as quickly as possible. The hub face
must be flush to the motor shaft. Allow hub to cool
before proceeding.
Compressor Hub --- This hub has a slide fit to the
compressor. A special shrink disc hub is used to
transmit power. Slide compressor hub and shrink
disc assembly on to the compressor shaft. Shaft
should be recessed #@8” (9.5mm) from the face of
the hub. Gradually tighten all shrink disc locking
screws to 42 ft.---lbs. (57 Nm) (see Installation of
Shrink Disc and Figure 7 --- 9).
STEP 2 --- CHECK ALIGNMENT

Angular --- Take readings with an inside microme-
ter at 90_ intervals between flange faces. If a dial in-
dicator is used, compensate for sag and attach it
on one shaft and rotate the hub 360_ while taking
readings on the flange face as shown. DO NOT ex-
ceed installation ANGULAR limit specified in Table
2. When using a dial indicator, the best results are
achieved by rotating both driver and driven shafts
together.
41
Section 7
MAINTENANCE
STEP 3 --- INSTALLATION OF CENTER ASSEM-

Figure 7 ---10 Compressor Hub Cutaway BLY --- Check the drive bolts (see Figure 7 --- 8) of
center assembly for proper torque per Table 2, be-
fore installation. Place the center assembly into po-
sition between the two (2) hubs. Dip adapter bolts
(see Figure 7 --- 8) in SAE 30 oil and insert bolts with
lockwashers through hub flange holes and engage
tapped holes in each adaptor. Tighten adapter
bolts to recommended torque per Table 2. After
torquing all adapter bolts, recheck the alignment.
STEP 4 --- INSTALLATION OF SHRINK DISC
Refer to Figures 7 --- 9 and 7 --- 10. Shrink discs are
supplied ready for installation. Therefore, they
should not be disassembled prior to initial installa-
tion.
INSTALLATION SEQUENCE
1. Remove spacers placed between collars for pro-
tection during transportation.
2. Take any three locking screws forming the points
of an equilateral triangle (e.g. screw 1, 5 and 9 in
Figure 7 --- 9) and tighten them slightly until the
inner ring can still just be turned.
3. Slide shrink disc over the hub. The hub outside
surface can be greased.
! WARNING
Never tighten locking screws before shaft is inside
the hub.
! CAUTION
4. Degrease the hub bore and shaft seat.
5. Insert shaft or slide hub over the shaft.
Dial indicator face readings should not be used 6. Tighten all locking screws gradually and all the
on journal bearing equipment due to the liberal
end float inherent in such a design. way around (not in diametrically opposite se-
quence; see Figure 7 --- 10).
Several passes are required until all screws are
Parallel Offset --- Refer to Figure 7 --- 7. Lay a torqued to specified tightening torque of 42 ft.---lbs.
straight edge squarely across the top of the flanges (57 Nm). Check tightening torque (42 ft.---lbs. [57
of both shaft hubs as shown and also at a point 90_ Nm]) with a torque wrench. Both collars must re-
away. This value must not exceed the installation main in equal distance.
Parallel Offset indicated in Table 2. If a dial indicator
is used, compensate for sag and attache it on one REMOVAL
shaft and rotate the hub 360_ while taking readings Shrink disc removal procedure is similar to installa-
on the other hub male register outside diameter. tion.
DO NOT exceed the installation Parallel Offset lim- 1. Gradually release locking screws all the way
its as calculated in Table 2. around. Initially each screw should be released
TABLE 2 --- Refer to Figure 7---8
INSTALLATION DATA (400, 500 and 600HP/300, 375 and 450KW)
Max. Operating Misalignment
Tightening Coupling Angular

Bolt Torque Coupling Parallel
Description ft.---lbs./Nm Gap Offset (I)
(oiled) (inches/cm) (inches/cm) degrees inches/cm
Adaptor Bolt 28 in. 7.0 ± .015 in. .005 in. .5 .005 in.
38 cm 17.8 ± .04 cm .01 cm .01 cm
Drive Bolt 169 ft---lbs.

229 Nm
(I) Angular misalignment in inches equals maximum A minus minimum B as

shown in Figure 7 --- 6. DO NOT exceed values in Table above.
42
Section 7
MAINTENANCE
Figure 7 ---11 Parallel Offset Alignment about a quarter of a turn only. Thus tilting and
jamming of collars will be avoided. DO NOT re-
move locking screws.
2. Remove shaft or pull hub from the shaft. Any rust
formed on shaft in front of hub must first be re-
moved.
3. Pull shrink disc from hub.
CLEANING AND LUBRICATION
Removed shrink discs need not to be taken apart or
lubricated prior to reinstallation. Only a dirty shrink
disc should be cleaned and lubricated.
For the tapered surfaces, one of the following lubri-
cants should be used:
LUBRICANT (MoS2) TYPE
Molykote 321 R
(lube coat) Spray
Molykote Spray
(powder spray) Spray
Molykote G Rapid
Aemason MO 19 P Spray or Paste
DIO---setral 57 N
(lube coat) Spray or Paste
Locking screws are lubricated with a multipurpose
grease such as Molykote BR 2 or similar.
Damaged o---rings must be replaced.
CONTROL LINE FILTER MAINTENANCE
Refer to Figure 7 --- 12. Control line filter (P/N
408389) maintenance normally requires replace-
ment of the filter element, strainer gasket and o---
rings. Use repair kit number 001692 and follow the
procedure explained below for proper installation.
1. Loosen the body from the bowl and unscrew the
two assemblies.
2. At this time, unscrew the baffle, holding the filter
element in place. Remove the element, louver
and o---ring.
3. Discard the o---ring and element.
4. Replace the o---ring on the louver and reinsert
into the body.
5. Insert the filter element and baffle and tighten.
6. Loosen and remove the nut on the bottom of the
body.
7. Remove the automatic drain assembly and re-
place the internal gasket.
8. Replace the body o---ring at this time.
9. Reassemble the automatic drain assembly and
place it back in the body. Tighten the nut.
10. Reconnect the body and bowl assemblies.
Tighten 2!@2 turns.
MOTOR CONNECTION INSTRUCTIONS
1. Once a year while the equipment is discon-
nected from the power source and locked out
for maintenance, remove the cover to the motor
conduit box.
2. Inspect the rubber boots’ or connections’ insu-
lating materials covering the motor connections
for signs of thermal damage.
43
Section 7
MAINTENANCE
3. If boots or insulating material remain pliable and Figure 7 ---12 Control Line Filter (P/N 408389)
there is no sign of damage, connections are sat-
isfactory.
4. If boot or insulating material show distress as
mentioned above, then investigate to determine
the source of thermal damage and repair the
connection as necessary.
5. Replace the damaged boot(s) with new boot(s)
as required or retape connections per National,
State or Local codes.
6. Replace the conduit cover prior to reconnecting
the power source.
! WARNING
Electrical shock hazard. Disconnect all power at
the source before attempting maintenance.
7.8 TROUBLESHOOTING
The information contained in the Troubleshooting
chart is based upon both the actual applied situa-
tions and extensive testing at the factory. It contains
symptoms and usual causes for the described
problems. However DO NOT assume that these
are the only problems that may occur. All available
data concerning the trouble should be systemati-
cally analyzed before undertaking any repair or
component replacement procedures.
A detailed visual inspection is worth performing for
almost any problems which may prevent unneces-
sary damage to the compressor. Always remember
to:
a. Check for loose wiring.
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 rec-
ommended check, consult your nearest Sullair
representative or the Sullair Corporation.
* Repair Kit P/N 001692
44
Section 7
MAINTENANCE
TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE REMEDY
COMPRESSOR WILL NOT START Main Disconnect Switch Open Close switch.
Line Fuse Blown Replace fuse.
Control Transformer Fuse Blown Replace fuse.
Motor Starter Overloads Tripped Reset. Should trouble persist, check
whether motor starter contacts are
functioning properly.
Low Incoming Line Voltage Check voltage. Should voltage check low,
consult power company.
Supervisor Panel Fuse is Blown Replace fuse.
Replace Supervisor controller if no display
or erratic display.
COMPRESSOR SHUTS DOWN

WITH AIR DEMAND PRESENT Loss of Control Voltage Check incoming power.
Check control fuses and wiring.
Low Incoming Voltage 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.
Excessive Operating Pressure Check maximum P2 pressure setting.
HIGH PRESS P1 display; Max P1 pressure
may be set too low. Consult factory for
recalibration.
Defective solenoid valve; solenoid valve
should cause 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 to 50
psig (2.1 to 3.4 bar) 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.
HIGH TEMP T1 or T3 Message Cooling water temperature too high;
Displayed 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
(water---cooled only).
Cooling air flow restricted; clean cooler and
check for proper ventilation.
Ambient temperature is too high; provide
sufficient ventilation.
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).
Water flow regulating valve not functioning
properly; change (water---cooled only).
45
Section 7
MAINTENANCE
TROUBLESHOOTING (continued)
COMPRESSOR SHUTS DOWN

WITH AIR DEMAND PRESENT
(cont’d.) HIGH TEMP T1 or T3 Message Open or shorted T1 or T2 sender; check for
Displayed (cont’d.) 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.
Low Water Pressure
(FAN OL/LOW WATER display) Check the cooling fan motor or water
flow system.
COMPRESSOR WILL NOT BUILD

UP FULL DISCHARGE PRESSURE Air Demand is Too Great Check service lines for leaks or open
valves.
Dirty Air Filter Check for filter maintenance message on
Supervisor panel and change or clean
element if required.
Pressure Regulator Out
of Adjustment Adjust regulator according to control
adjustment instructions in the Maintenance
Section.
Defective Pressure Regulator Check diaphragm and replace if necessary
(kit available).
Broken Sullicon Spring Replace.
LINE PRESSURE RISES ABOVE

UNLOAD P2 PRESSURE
SETTING ON THE
SUPERVISOR Leak in Control System Causing
Loss of Pressure Signals Check for leaks.
Defective Solenoid Valve Check that Sullicon Control lever is moved
to unload stop when Supervisor is in NO
LOAD mode. Repair or replace if
necessary (kit available).
Defective Blowdown Valve Check that sump pressure is exhausted to
the atmosphere when in the OFF LOAD
mode. Repair or replace if necessary
(kit available).
Ruptured Sullicon Control
Diaphragm Replace.
Plugged Control Line Filter Clean or repair if necessary.
EXCESSIVE FLUID
CONSUMPTION Clogged Return Line Strainer
or Orifice Clean strainer (screen and o---ring replace---
ment kit available).
Clean orifice.
Separator Element Damaged or
Not Functioning Properly Change separator.
Leak in the Lubrication System Check all pipes, connections and compo---
nents.
Excess Fluid Foaming Drain and change.
Fluid Level Too High Drain excess fluid.
46
Section 7
MAINTENANCE
TROUBLESHOOTING (continued)
PRESSURE RELIEF VALVE

OPENS REPEATEDLY Defective Pressure Relief Valve Replace pressure relief valve.
Check Separator Differential
(plugged) ∆P1.
LIQUID WATER IN COMPRESSED Water vapor condensation from cooling Remove the water vapor from compressed air prior
AIR LINES and compression occurs naturally. to distribution through the air system. Check
operation of aftercooler and moisture separator.
Install a compressed air dryer sized for the flow and
dryness level required. (Note: Filters may also be
required to remove particulates, liquid oil aerosols
or for oil vapor removal. Change cartridges as
recommended by the filter manufacturer.) Check all
drain traps routinely to insure their proper
operation. Maintain them regularly.
47
NOTES
48
Section 8
ILLUSTRATIONS AND PARTS LIST
8.1 PROCEDURE FOR ORDERING PARTS

Parts should be ordered from the nearest Sullair Representative or the Representative from whom the com-
pressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly
at the address or phone numbers listed below.
When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the Bill
of Lading for the compressor or from the Serial Number Plate located on the compressor. For compressor unit
parts only, order parts by the unit serial number place located on the compressor unit.
For ordering parts other than those pertaining to the compressor unit, use serial number located on name-
plate mounted on control panel.
SULLAIR CORPORATION
Subsidiary of Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 1 -- 800 -- SULLAIR or
1-- 219-- 879-- 5451
FAX: (219) 874-- 1273
FAX: (219) 874-- 1835 (Parts)
FAX: (219) 874 -- 1805 (Service)
SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A.

ROOM 2304A Chemin de Genas BP 639
Shartex Plaza Ctr. 69800 Saint Priest, France
No. 88 Zun Yi Nan Rd. Telephone: 33-- 72232425
Shanghai, P.R.C. FAX: 33-- 78907168
Telephone: 21-- 2192066
FAX: 21-- 2196568
8.2 RECOMMENDED SPARE PARTS LIST -- 200, 250 and 300HP/150, 187 and 225KW
DESCRIPTION KIT NUMBER QUANTITY
repair kit for fluid stop valve 016742 001684 1
repair kit for thermal valve 041299 001084 1
element for separator with gaskets 250034---123 (primary) 250034---124 1
element for separator with gaskets 250034---129 (secondary) 250034---130 1
repair kit for regulator valve 406929 041742 1
repair kit for blowdown valve 409783 001667 1
repair kit for Sullicon Control 011682---003 250020---353 1
repair kit for control line filter 408389 001692 1
repair kit for fluid return strainer 241771 241772 1
element for 18” diameter air filter 250006---718 (primary) 250007---838 1
element for 18” diameter air filter 250006---718 (secondary) 250007---839 1
replacement kit for fluid filter 250007---219 250008---956 1
repair kit for 3” flexible coupling 040327 040523 1
repair kit for solenoid valve 250038---668 250038---673 (valve) 1
250031---738 (coil) 1
repair kit for solenoid valve 409067 250010---377 1
repair kit for regulator valve 408275 250028---693 1
repair kit for minimum pressure valve 250033---821 250018---262 1
repair kit for shaft seal 067329---001 1
element for drive coupling 046999 1
diaphragm repair kit for air cylinder 250016---183 608311---001 1
repair kit for 3” separator combination trap w/heater
250004---596 250033---036 1
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
49
Section 8
8.2 RECOMMENDED SPARE PARTS LIST -- 200, 250 and 300HP/150, 187 and 225KW (Continued)
DESCRIPTION KIT NUMBER QUANTITY
heater replacement for separator combination trap w/heater
250004---596 245572 1
repair kit for 4” separator combination trap w/ heater
250004---597 250033---036 1
250004---597 245572 1
repair kit for 4” separator combination trap 250000---511 250033---036 1
8.3 RECOMMENDED SPARE PARTS LIST -- 400, 500 and 600HP/300, 375 and 450KW
repair kit for fluid stop valve 016742 001684 1
repair kit for thermal valve 041299 001084 1
element for separator with gaskets 250034---125 (primary) 250034---126 1
element for separator with gaskets 250034---131 (secondary) 250034---132 1
repair kit for regulator valve 406929 041742 1
repair kit for blowdown valve 409783 001667 1
repair kit for regulator valve 408275 250028---693 1
repair kit for Sullicon Control 011682---003 250020---353 1
repair kit for control line filter 408389 001692 1
repair kit for fluid return strainer 241771 241772 1
element for 18” diameter air filter 250006---718 (primary) 250007---838 1
element for 18” diameter air filter 250006---718 (secondary) 250007---839 1
replacement kit for fluid filter 250007---219
(400 --- 600HP/300---450KW) 250008---956 2
repair kit for drive coupling 02250043---132 (400HP/300KW) 02250044---346 1
repair kit for drive coupling 250039---660
(500, 600HP/375, 450KW) 02250044---346 1
repair kit for solenoid valve 250038---668 250038---673 (valve) 1
250031---738 (coil) 1
repair kit for solenoid valve 409067 250010---377 1
repair kit for shaft seal 067329---001 1
repair kit for air cylinder 250016---183 608311---001 1
repair kit for separator combination trap w/heater
250004---597 250033---036 1
250004---597 245572 1
repair kit for sight glass 036559 250021---312 1
50
Section 8
NOTES
51
Section 8
8.4 MOTOR, COMPRESSOR, FRAME AND PARTS -- 200HP -- 300HP/150 -- 225KW
52
Section 8
8.4 MOTOR, COMPRESSOR, FRAME AND PARTS -- 200 -- 300HP/150 -- 225KW
key part
number description number quantity
1 motor, 200HP/150KW 050982 1

S motor, 250HP/187KW 050401 1
S motor, 300HP/225KW 250007---820 1
2 hub, coupling 2 3/4” x 5/8” 250004---635 1
3 element, drive coupling 046999 1
4 hub, coupling 3 1/4” x 3/4” 250005---091 1
5 capscrew, hex gr5 3/8”---16 x 3/4” 828606---075 2
6 guard, coupling --- left hand 250025---105 1
7 guard, coupling --- right hand 250025---104 1
8 nut, hex 3/8”---16 824206---337 5
9 capscrew, hex gr5 3/8”---16 x 1 1/4” 828606---125 3
10 washer, springlock 3/8” 837506---094 5
11 compressor unit (I) --- 1
12 capscrew, hex gr5 7/8”---9 x 3 1/2” 8286140---350 4
13 shim set, motor mounting 32E 022031 4
14 washer, plain 7/8” 837514---174 4
16 nut, hex 7/8”---9 824214---776 4
17 frame, base 250024---571 1
18 washer, plain 3/8” 837206---071 8
19 support, motor 250007---215 2
20 conduit, 2” 846315---200 12
21 elbow, 90_ 2” 846600---200 2
22 capscrew, hex gr5 5/8”---11 828610---300 4
24 washer, regular 5/8” 837210---112 4
25 nut, hex 5/8”---11 824210---559 1
26 jacking block, short (not shown) 230450 2
27 jacking block, long (not shown) 222054 4
28 jacking screws (not shown) 241102 6
(I) 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. For information regarding the unit exchange program, contact your nearest
Sullair representative or the Sullair Corporation.
The shaft seal is not considered part of the compressor unit in regard to the 2 year
warranty. The normal Sullair parts warranty applies. For shaft seal repairs, order shaft
seal repair kit No. 067329---001.
53
Section 8
8.5 MOTOR, COMPRESSOR, FRAME AND PARTS -- 400HP/300KW
54
Section 8
8.5 MOTOR, COMPRESSOR, FRAME AND PARTS -- 400HP/300KW
key part
1 motor, 400HP/300KW 250022---787 1

2 capscrew, hex gr5 5/8”---11 x 3” 828610---300 4
3 coupling, assembly 2 3/8” diameter (I) 02250043---132 1
4 support, motor 250009---569 2
5 disc, shrink 250009---242 1
7 washer, regular 3/8” 837206---071 3
8 capscrew, hex gr5 3/8”---16 x 1 1/4” 828606---125 3
9 nut, hex 3/8”---16 824206---337 3
10 capscrew, hex gr5 3/8”---16 x 3/4” 828606---075 3
12 compressor unit (II) --- 1
13 capscrew, hex gr5 3/8”---9 x 4” 828614---400 4
14 shim set, motor mounting 022031 4
15 washer, regular 7/8” 837214---174 4
16 washer, springlock regular 7/8” 837514---219 4
17 nut, hex 7/8”---9 824214---776 4
18 frame, base 250024---572 1
19 nut, hex 5/8”---11 824210---559 4
21 washer, regular 5/8” 837210---112 4
(I) For maintenance on coupling no. 02250043---132, order repair kit no. 02250044---346.
(II) There is an exchange program whereby a remanufactured compressor unit can be
55
Section 8
56
Section 8
key part
1 motor, 500HP/375KW 250007---822 1

S motor, 600HP/450KW 250007---823 1
2 support, motor 250008---221 1
3 coupling, assembly 3 3/8” diameter (I) 250039---660 1
4 support, motor 250008---137 1
5 disc, shrink 250009---242 1
7 washer, regular 3/8” 837206---071 3
8 capscrew, hex gr5 3/8”---16 x 1 1/4” 828606---125 3
9 nut, hex 3/8”---16 824206---337 3
10 capscrew, hex gr5 3/8”---16 x 3/4” 828606---075 3
12 compressor unit (II) --- 1
13 capscrew, hex gr5 3/8”---9 x 4” 828614---400 4
14 shim set, motor mounting 022031 4
15 washer, regular 7/8” 837214---174 4
17 nut, hex 7/8”---9 824214---776 4
18 frame, base 250024---572 1
19 nut, hex 5/8”---11 824210---559 4
21 washer, regular 5/8” 837210---112 4
22 capscrew, hex gr5 5/8”---11 x 3” 828610---300 4
(I) For maintenance on coupling no. 250039---660, order repair kit no. 02250044---346.
(II) There is an exchange program whereby a remanufactured compressor unit can be
57
Section 8
8.7 AIR INLET SYSTEM -- 200 -- 300HP/150 -- 225KW
58
Section 8
key part
1 filter, air 18” diameter (I) 250006---718 1

2 connector, tube---m 1/4” x 1/4” 813604---250 2
3 capscrew, hex gr5 3/8”x 1 1/4” 828606---125 4
4 support, 18” diameter air filter 250003---374 1
5 washer, plain 3/8” 837206---071 4
7 nut, hex 3/8” 824206---337 4
8 capscrew, hex gr5 7/8” x 3 1/2” 828614---350 8
10 adaptor, compressor inlet 10” to 8” 250003---378 1
11 gasket, 1/16” x 10 1/2” id x 13 1/4”od 041079 2
12 valve, butterfly --- 200HP/150KW 250040---245 1
S valve, butterfly --- 250HP/187KW 250040---246 1
13 lever, inlet valve 250019---036 1
14 clamp, hose 8” 043598 2
15 elbow, rubber 90_ 8” 043406 1
16 cap, air inlet 10” 250007---712 1
17 hose, nylon 1/4”” 842215---004 10
(I) For maintenance on air filter no. 250006---718, order replacement element no. 250007---838
(primary) and 250007---839 (secondary).
59
Section 8
60
Section 8
key part
1 gasket, 1/16” x 10 1/2” id x 13 1/4” od 041079 2

2 valve, butterfly --- 400HP/300KW 250040---249 1
4 lever, inlet valve 250019---036 1
6 capscrew, hex gr5 7/8”---9 x 3 1/2” 828614---350 8
7 adapter, compressor inlet 8” 250006---676 1
8 clamp, hose 8” 043598 8
9 elbow, rubber 90_ 8” 043406 1
10 duct, air inlet 8” x 12” 250006---651 1
11 hose, hump 8” x 8” 044733 1
12 cap, air inlet 10” 250007---712 2
13 filter, air 18” diameter (I) 250006---718 2
14 capscrew, hex gr5 3/8”---16 x 1” 828606---100 8
15 washer, regular 3/8” 837206---071 8
17 nut, hex 3/8”---16 824206---337 8
18 support, air filter 250006---658 1
19 capscrew, hex gr5 1/2”---13 x 1 1/2” 828608---150 4
20 washer, regular 1/2” 837208---112 4
22 nut, hex 1/2”---13 824208---448 4
23 elbow, rubber 45_ 8” 250005---776 1
24 duct, 8” x 8 1/2” 025068 1
25 valve, rubber 040705 2
26 hose, nylon 1/4” 842215---004 10 ft.
(I) For maintenance on air filter no. 250006---718, order replacement element no. 250007---838
(B) --- primary and 250007---839 (A) --- secondary.
61
Section 8
8.9 FLUID COOLING SYSTEM -- 200 -- 300HP/150 -- 225KW (WATER-- COOLED)
62
Section 8
key part
1 nipple, pipe 2” x 5” 822132---050 1

2 elbow, pipe 90_ x 2” 801515---080 1
3 nipple, pipe 2” x 28” 822132---280 1
4 connector, tube---m 2” x 2” 810232---200 5
5 tube, 2” 02250058---447 1
6 elbow, pipe 2” x 2 1/2” 801610---080 1
7 nipple, pipe 2 1/2” x 23” 822140---023 1
8 nipple, pipe 1 1/2”x close 822224---000 1
9 elbow, pipe 1 1/2” x 2” 801608---060 1
10 nipple, pipe 2” x 3 1/2” 822132---035 1
11 nipple, pipe 2” x 6” 822132---060 1
12 union, pipe 2” 802515---080 3
13 adaptor, port 2” 250007---220 2
14 fliter, fluid (I) 250007---219 1
15 elbow, tube 1/4”t x 1/4” npt 810504---025 1
16 nipple, pipe 2” x close 822232---000 4
17 valve, fluid stop (II) 016742 1
18 nipple, pipe 2” x 4” 822132---040 1
19 plug, pipe 1/2” 807800---020 1
20 tee, pipe 2” x 1/2” x 2” 802208---028 1
21 nipple, pipe 2” x 7” 822132---070 1
22 nipple, pipe 2” x 4 1/2” 822132---045 1
23 tee, 2” 802415---081 1
24 bushing, reducing hex 2” x 3” 802112---080 2
25 elbow, tube---m 2” x 2” 810532---200 2
26 tube, 2” 02250058---445 1
27 cooler, fluid 041664 1
28 tee, pipe 2 1/2”x 2” x 2” 802210---088 1
30 valve, thermal 2” (III) 041299 1
31 bushing, reducing hex 2” x 1 1/2” 802108---040 1
(continued on Page 65)
(I) For maintenance on fluid filter no. 250007---219, order replacement kit no. 250008---956.
(II) For maintenance on fluid stop valve no. 016742, order repair kit no. 001684.
(III) For maintenance on thermal valve no. 041299, order repair kit no. 001084.
63
Section 8
64
Section 8
8.9 FLUID COOLING SYSTEM -- 200 -- 300HP/150 -- 225KW (WATER-- COOLED) (continued)
key part
32 elbow, tube 1 1/2” x 1 1/2” 810524---150 1

33 tube, 1 1/2” 02250058---451 1
34 capscrew, hex gr5 1/2” x 1 1/2” 828608---150 6
35 washer, plain 1/2” 837208---112 6
37 nut, hex 1/2” 824208---448 1
38 elbow, pipe 2” x 1 1/4” 801608---050 1
39 nipple, pipe 1 1/4” x close 822220---000 2
40 tee, pipe 1 1/4” x 1/2” x 1 1/4” 802205---025 1
41 bushing, reducing hex 1/2” x 1 1/4” 802102---010 1
42 valve, water regulating 248743 1
43 connector, tube 1 1/4” x 1 1/4” 810220---125 2
44 tube, 1 1/4” 02250058---456 1
45 elbow, pipe 1 1/2” x 1 1/4” 801606---050 1
46 bracket, water in---out 1 1/2” 250007---710 1
47 tube, 1/4” 844115---004 15 ft.
65
Section 8
8.10 FLUID COOLING SYSTEM -- 400HP/300KW (WATER-- COOLED)
66
Section 8
key part
1 cooler, fluid 250007---802 1

4 nipple, pipe 2” x 4” 822232---000 1
5 manifold 02250055---260 1
6 adaptor, port 250007---221 2
7 union, pipe 2” 802515---080 1
8 plug, pipe 1/2” 807800---020 2
9 tee, reducing 2” x 1/2” x 2” 802208---028 3
10 tee, reducing 2 1/2” x 2” x 2” 802210---088 1
11 adaptor, port 2” 250007---220 4
12 filter, fluid (I) 250007---219 2
13 valve, fluid stop 2” (II) 016742 1
14 elbow, pipe 90_ 2” 801515---080 4
15 connector, tube 810224---150 4
16 tube 02250058---225 2
18 union, tube hex 1 1/2” x 1 1/2” 811332---200 1
19 nipple, pipe 2” x 9” 822132---090 2
20 elbow, pipe 1 1/2” 801515---060 2
21 tee, reducing 1 1/2” x 1/2” x 1 1/2” 802206---026 1
22 nipple, pipe 2 1/2” x 4” 822140---040 1
23 valve, water regulating 2” 249970 1
25 tubing, steel 2” 02250057---724 24 ft.
26 elbow, tube---m 2” x 2” 810532---200 1
27 bracket, in---out 2” 250008---245 1
28 capscrew, hex gr5 1/2”---13 x 1 1/2” 828608---150 2
29 washer, regular 1/2” 837208---112 2
30 tubing, steel 1 1/2” 02250057---728 1 ft.
32 nut, hex 1/2”---13 824208---448 2

67
Section 8
68
Section 8
8.10 FLUID COOLING SYSTEM -- 400HP/300KW (WATER-- COOLED) (continued)
key part

35 tee, reducing 2 1/2” x 2” x 2” 802210---088 2
36 nipple, pipe 2 1/2” x 3 1/2” 822140---035 1
37 elbow, reducing 2 1/2” x 2” 801610---080 2
38 tube 2” 02250057---726 1
40 tee, pipe 1 1/2” 802415---060 1
41 tube 1 1/2” 02250057---723 1
69
Section 8
70
Section 8
key part
1 cooler, fluid 250007---801 1

3 elbow, pipe 90_ 2” 801515---080 3
4 nipple pipe 2” x 6” 822132---060 1
5 manifold 02250055---260 1
6 tee, pipe 2 1/2” x 2” x 2” 802210---088 1
7 nipple, pipe 2 1/2” x 4” 822140---040 2
8 flange, threaded reducing 2 1/2” x 7 1/2” 819540---075 3
9 gasket, flange 240621---8 4
10 nut, hex 5/8”---11 824210---559 16
12 capscrew, hex gr5 5/8”---11 x 3” 828610---300 16
13 nipple, pipe 2 1/2” x 6” 822140---060 1
14 adaptor, port 1 1/2” 250007---221 1
16 connector, tube---m 1 1/2” x 1 1/2” 810224---150 1
17 tube, 1 1/2” 02250058---225 1
18 tee, 1 1/2” 802415---060 1
19 plug, pipe 1/2” 807800---020 3
20 tee, reducing 2” x 1/2” x 2” 802208---028 3
21 adaptor, port 2” 250007---220 4
22 filter, fluid (I) 250007---219 2
23 tee, pipe 2” 802415---080 1
25 nipple, pipe 2” x 4” 822132---040 2
26 elbow, pipe 1 1/2” 801515---060 2
28 tee, reducing 1 1/2” x 1/2” x 1 1/2” 802206---026 1
30 nipple, pipe 2 1/2” x 7” 822140---060 1
31 elbow, pipe 90_ 2 1/2” 801515---100 3
32 nipple, pipe 2 1/2” x 14” 822140---140 1

71
Section 8
72
Section 8
8.11 FLUID COOLING SYSTEM -- 500 -- 600HP/375 -- 450KW (WATER-- COOLED) (continued)
key part
33 nipple, pipe 2 1/2” x 9” 822140---090 1

34 union, pipe 2 1/2” 802515---100 1
35 nipple, pipe 2” x 3” 822232---030 1
36 nipple, pipe 2” x 3” 822132---030 1
37 flange, threaded reducing 2” x 7 1/2” 819532---075 1
40 nipple, pipe 2” x 16” 822132---160 1
41 valve, water regulating 2” 249970 1
42 elbow, reducing 2 1/2” x 2” 801610---080 2
43 tee, reducing 2 1/2” x 1/2” x 2 1/2” 802210---020 1
44 tube, fluid bypass 2” 250010---163 1
45 tube, thermal valve in 2” 250010---165 1
46 union, tube hex 2” 811332---200 1
47 tube, separator out 2” 250010---164 1
48 union, pipe 2” 802515---080 1
73
Section 8
8.12 REMOTE COOLER FLUID COOLING SYSTEM -- 200 -- 250HP/150 -- 187KW (AIR-- COOLED)
74
Section 8
key part
1 screw, hex serrated washer 1/16” x 1 1/4” 829705---125 6

2 washer, pl---b regular unfinished 1/2” 837205---071 18
3 nut, hex flanged plated 1/16”---18 825305---283 12
4 guard, fan 42” 241283 1
5 fan, 42” diameter 406966 1
6 panel, Venturi 250001---202 1
7 capscrew, hex gr5 3/8”---16 x 1” 828606---100 26
10 panel, left hand 250001---207 1
11 nut, hex unfinished 3/8”---16 824206---337 26
12 elbow, reducing 3” x 2” 150# 801612---080 1
13 nipple, pipe xs 2” x close 822232---000 3
14 panel, top and bottom 250001---209 2
15 nut, retainer 1/2”---18 860905---163 12
16 cooler, fluid 040961 1
17 screw, hex serrated washer 1/2” x 1” 829705---100 12
18 aftercooler 041807 1
19 panel, right hand 250001---203 1
20 tee, reducing 2” 802208---082 1
21 nameplate, serial aluminum 040052 1
22 rivet, pop 1/8” x 3/8” 843102---038 4
23 capscrew, hex gr5 1/2”---13 x 2” 828608---200 12
25 elbow, pipe 90_ 2” 150# 801515---080 2
26 nipple, pipe 2” x 10” 822132---100 1
27 union, pipe brass seat 2” 150# 802515---080 1
28 bushing, reducer hex 3” x 2” 802112---080 1
29 separator, 3” combination trap/heater (I) 250004---596 1
30 u---bolt, 1/2” x 8” pipe 829008---800 2
32 union, pipe brass seat 3” 150# 802515---120 1
33 motor, 7.5 HP/5.6KW 050795 1
34 support, motor 250001---197 1

(I) For maintenance on combination trap with heater separator no. 250004---596, order repair
kit no. 250033---036, and heater element replacement no. 245572.
75
Section 8
76
Section 8
(continued)
key part

37 sign, danger electrocution 049850 1
38 sign, warning compressor fluid fill cap 049685 1
39 plug, pipe 1/2” 807800---020 1
40 tube, 2” 841115---032 0.5 ft.
41 capscrew, hex gr5 5 1/2”---13 x 1 1/4” 828608---200 12
42 washer, bevel 1/2” 837008---125 10
43 decal, fork lifting 241814 2
44 nipple, pipe 2” x 16” 822132---160 1
45 frame, base 250001---191 1
46 decal, warning “food grade” lube 250003---144 1
47 decal, danger breath air 250007---935 1
48 decal, warning sever (fan) 049855 1
49 decal, warning sever fan port 049965 1
50 connector, tube 2” 810232---200 2
77
Section 8
78
Section 8
key part
1 core, aftercooler 049984 1

2 core, a/c fluid cooler 250004---201 1
3 shroud, fan 250000---467 1
4 sign, warning---sever (fan) 049855 1
5 panel, left hand 250000---468 1
6 bracket, ac 250000---475 2
7 fan, 48” 8 blade 35_ pitch 049986 1
8 guard, fan 48” 241247 1
10 screw, hex serrated washer 1/2” x 3/4” 829705---075 10
11 capscrew, hex gr5 3/8”---16 x 1” 828606---100 76
13 nut, retainer 1/2”---18 .092 861405---092 1
16 plug, pipe 2” 150# 802815---080 4
18 frame, ac base 250000---454 1
19 plug, pipe 1/2” 807800---020 1
20 panel, right hand 250000---472 1
21 nameplate, serial number aluminum 040052 1
22 rivet, pop 1/8” x 3/8” 843102---038 4
23 capscrew, hex gr5 1/2”---13 x 2” 828608---200 12
26 bushing, taper 042520 1
27 motor, 15HP/11.2KW tefc 050387 1
30 sign, warming---compressor fluid fill cap 049685 1
31 support, motor 250000---461 1
34 tee, reducing 2” x 1/2” x 2” 802208---028 1
35 capscrew, hex gr5 1/2”---13 x 2 1/2” 828608---250 2
36 capscrew, hex gr5 3/8”---16 x 4” 828606---400 2
37 band, 9” air filter 049104 2
79
Section 8
80
Section 8
(continued)
key part

41 gasket, 4” 125# flange full force 242437---010 1
42 flange, threaded 4” 125# 818312---064 1
43 capscrew, hex gr5 5/8”---11 x 3” 828610---300 8
44 nipple, pipe 4” x 8” 822164---080 1
45 nipple, pipe 4” x 14” 822164---140 1
46 elbow, pipe 90_ 4” 150# 801515---160 1
48 washer, bevel 1/2” 837008---125 10
51 angle, 2” x 1 1/4”x 58” 250001---565 2
52 decal, warning “food grade” lube 250003---144 1
53 decal, danger breath air 250007---935 1
54 decal, warning---sever---fan---port 049965 1
81
Section 8
82
Section 8
key part
1 panel, left hand 250000---468 1

2 bracket 250000---475 2
3 plug, pipe 3” 150# 802815---120 2
7 core, cooler 64” x 62” 250007---856 1
9 capscrew, hex gr5 3/8”---16 x 1” 828606---100 64
10 plug, pipe 1/2” 807800---020 1
11 panel, right side 250000---472 1
12 nameplate, serial number aluminum 040052 1
13 rivet, pop 1/8” x 3/8” 843102---038 4
14 capscrew, hex gr5 5 1/2”---13 x 2” 828608---200 12
16 pipe, 2” 150# 802815---080 1
17 core, aftercooler 049984 1
18 panel, Venturi 48” 250000---467 1
19 sign, warning---sever (fan) 049855 1
20 nut, retainer 1/2”---18 861405---092 6
21 fan, 48” blade 35_ pitch 049986 1
22 guard, fan 48” 241347 1
25 bushing, taper 042520 1
26 motor, 15HP/11.2KW tefc 050387 1
29 capscrew, hex gr5 3/8”---16 x 4” 828606---400 2
30 screw. hex serrated washer 1/2” x 3/4” 829705---075 10
31 band, 9” air filter 049104 2
83
Section 8
84
Section 8
(continued)
key part
35 gasket, 4” 125# flange full face 242437---010 1

36 flange, threaded 4” 125# 818312---064 1
37 capscrew, hex gr5 5/8”---11 x 3” 828610---300 8
38 nipple, pipe 4” x 8” 822164---080 1
39 nipple, pipe 4” x 16” 822164---140 1
40 elbow, pipe 90_ 4” 150# 801515---160 1
41 washer, bevel 1/2” 837008---125 10
44 frame 250000---454 1
46 support, motor 250000---461 1
47 sign, warning compressor fluid fill cap 049685 1
50 tee, reducing 3” x 1” x 3” 802212---042 1
52 bushing, reducing 1” x 1/2” 802104---020 1
85
Section 8
8.15 REMOTE COOLER FLUID COOLING PIPING -- 200 -- 300HP/150 -- 225KW (AIR-- COOLED)
86
Section 8
key part
1 nipple, 2” X 24” 822132---240 1

2 elbow, tube 1/2”t x 1/2”mnpt 810508---050 2
3 tube, 1/2” steel 841115---008 12 ft.
4 adaptor, port 2” 250007---220 2
5 filter, fluid (I) 250007---219 1
8 nipple, pipe 2” close 822224---000 8
9 valve, check 2” 040671 1
12 tubing, steel 2” 841115---032 30 ft.
13 elbow, pipe 2” 90_ 801515---080 3
14 nipple, pipe 2” x 16” 822132---160 1
15 tee, pipe 2” 802415---080 1
16 capscrew, hex gr5 1/2”---13 x 1 1/2” 828608---150 2
18 bracket, in---out 2” 250008---245 1
20 nut, hex 1/2”---13 824208---448 2
21 elbow, pipe 2” x 1 1/2” 90_ 801608---060 1
23 tee, reducing 2” x 2” x 1/2” 802208---082 1
24 switch, temp 043239 1
(I) For maintenance on fluid filter no. 250007---219, order repair kit no. 250008---956.
87
Section 8
88
Section 8
key part
1 manifold 02250055---260 1
2 adaptor, port 2” 250007---220 4
3 filter, fluid (I) 250007---219 2
4 adaptor, port 11/2” 250007---221 1
6 tube, 11/2” 02250058---185 2
7 nipple, pipe 2” x 24” 822132---240 1
8 elbow, pipe 1 1/2” 801515---060 3
9 nipple, 1 1/2” x close 822224---000 3
10 union, pipe 2” 802515---080 1
11 nipple, pipe 1 1/2” x 3” 822124---030 1
12 tee, pipe 1 1/2” 802415---060 1
16 valve, check 2” 040671 1
18 tube, 2” 02250058---184 1
19 elbow, pipe 90_ 2” 801515---080 1
20 elbow, tube---m 1/2” x 1/2” 810508---050 2
21 tubing, steel 1/2” 841115---008 17 ft.
22 tee, reducing 2” x 1/2” x 2” 802208---028 1
23 valve, thermal 2” (II) 041299 1
24 bracket, valve support 250016---378 1
26 tee, reducing 2” x 2” x 3/4” 802208---083 1
27 tee, pipe 2” 802415---080 1
28 valve, gate 2” 041562 1
29 bracket, in---out 2” 250008---245 1
30 nut, hex 1/2”---13 824208---448 2
32 washer, regular 1/2” 837208---112 2
33 capscrew, hex gr5 1/2”---13 x 1 1/2” 828608---150 2
34 valve, fluid stop 2” (III) 016742 1
35 switch, temp 043239 1
(II) For maintenance on thermal valve no. 041299, order repair kit no. 001084.
(III) For maintenance on fluid stop valve no. 016742, order repair kit no. 001684.
89
Section 8
8.17 COMPRESSOR DISCHARGE SYSTEM -- 200 -- 300HP/150 -- 225KW (WATER-- COOLED)
200---250HP
150---187KW
ONLY
90
Section 8
key part
1 aftercooler, water---cooled 042950 1

2 nut, hex 5/8” 829210---559 24
4 flange, threaded reducing 3” x 9” 819548---090 1
5 capscrew, hex gr5 5/8” x 3” 828610---300 24
6 nipple, pipe 3” x 3” 822148---030 1
7 elbow, pipe 90_ 3” 801515---120 2
8 coupling, flexible 3” (I) 040327 1
9 nipple, half pipe 4” x 15” 822864---150 1
10 nipple, half pipe 3” x 7 1/2” 822848---075 1
11 nipple, pipe 3” x 9” 822148---090 1
12 valve, minimum pressure check 3” npt (II) 250033---821 1
13 elbow, tube---m 1/4”x 1/4” 810504---025 1
14 tubing, steel 1/4” 841115---004 6 ft.
16 reinforcement, 3” 250035---136 8
17 silencer, air 3/4” 040758 1
19 nipple, half pipe 822864---140 1
20 valve, blowdown 1” ac 2---way (III) 409783 1
21 tubing, steel 3/8” 841115---006 10 ft.
23 elbow, pipe reducing 90_ 1 1/4”x 1” 801605---040 1
24 union, pipe 11/4” 802515---050 1
25 valve, relief 1 1/2” 150 psig (10.3 bar) 407003 1
26 capscrew, hex gr5 3/4” x 2 1/2” 828612---250 8
27 washer, regular 3/4” 837212---112 4
28 plug, o---ring boss 1 1/4” 040029 1
29 adapter, filler 020044 1
30 glass, fluid level sight 1 1/2” 040279 1
31 tee, pipe 1 1/2” x 1 1/2” x 1 1/2” 802415---060 1

(I) For maintenance on flexible coupling no. 040327, order repair kit no. 040523.
(II) For maintenance on minimum pressure/check valve no. 250033---821, order repair kit
no. 250018---262.
(III) For maintenance on blowdown valve no. 409783, order repair kit no. 001667.
91
Section 8
92
Section 8

(continued)
key part

34 nut, hex 3/4” 824212---665 4
35 nipple, pipe 3/4” x 31/2” 822112---035 1
36 elbow, pipe 90_ 3/4” 801515---030 3
37 nipple, pipe 3/4” x 7” 822112---070 1
38 valve, globe 3/4” 040520 1
39 tank, sump fluid separator 30” 250002---038 1
40 plug, pipe 1 1/2” 802815---060 2
41A element, separator (primary) (IV) 250034---123 1
41B S element, separator (secondary) (V) 250034---129 1
42 connector, 1/4”x 1/4” 020169 1
43 fitting, tube---m 1/2” x 1/4” 020501 1
45 elbow, pipe 90_ 4” 801515---160 3
47 elbow, tube---m 3/8” x 1/4” 810506---025 1
48 coupling, flexible (VI) 041085 1
49 nipple, pipe 4” x 61/2” 822164---065 1
50 capscrew, hex 3/4” x 3 1/2” 828612---035 4
53 gasket, flange 240621---12 1
54 separator, 3” combination trap (VII) 250004---596 1
55 capscrew, ferry head 5/8” x 6” 828410---600 6
56 tubing, steel 1 1/2” 841115---024 20 ft.
57 reinforcement, 15 1/2” 250035---138 2
58 support, cooler 250005---041 2
59 plug, pipe 3/8” 802815---010 1
60 elbow, pipe 90_ 1 1/2” 801515---060 2

(IV) For maintenance on primary separator element no. 250034---123, order replacement kit
no. 250034---124.
(V) For maintenance on secondary separator element no. 250034---129, order replacement kit
no. 250034---130.
(VI) For maintenance on flexible coupling no. 041085, order repair kit no. 041353.
(VII) For maintenance combination trap w/heater no. 250004---596, order repair kit no.
250033---036 and heater element replacement no. 245572.
93
Section 8
94
Section 8

(continued)
key part
61 nut, hex 1/2” 824208---385 4

64 capscrew, hex 1/2” x 1 3/4” 828608---175 6
65 washer, regular 1/2” 837208---112 6
66 capscrew, hex 1/2” x 1 1/4” 828608---125 4
68 brace, aftercooler 250009---509 1
69 capscrew, hex 1/2” x 1 1/2” 828608---150 6
70 separator, 4” combination trap (VIII) 250000---511 1
71 nipple, pipe 3” x 22”
(200 --- 250HP/150 --- 187KW) 822148---220 1
Snipple, pipe 4” x 21” (300HP/225KW) 822164---210 1
72 flange, threaded reducing 3” x 9”
(200 --- 250HP/150 --- 187KW) 819548---090 1
Sflange, threaded 4” 150# (300HP/225KW) 819315---064 1
73 u---bolt, 1/2” x 4” pipe 829008---400 1
74 flange, threaded 4” 125# 818312---064 1
76 u---bolt, 1/2” x 8” pipe 829008---800 1
77 capscrew, hex 3/8” x 1 1/4” 828606---125 2
79 nut, hex 1/4” 824204---226 2
80 valve, discharge check 067339---001 1
81 nipple, half pipe 3” x 11 1/2” 822848---115 1
82 gasket, flange 6” 150# 241621---12 1
83 gasket, flange 4” 125# 242437---010 3
84 tee, reducing 3/4” x 3/4” x 1” 802203---034 1
85 plug, pipe 3/4” 807800---030 1
(VIII) For maintenance on combination trap no. 250000---511, order repair kit no. 250033---036.
95
Section 8
8.18 REMOTE COOLER COMPRESSOR DISCHARGE SYSTEM -- 200 -- 300HP/150 -- 225KW

(AIR-- COOLED)
96
Section 8

(AIR-- COOLED)
key part
1 flange, 3” threaded 819315---048 1

2 nipple, pipe 3” x 94” 822148---940 1
3 clamp, exhaust 3 1/2” 040284 1
4 elbow, pipe 90_ 3” 801515---120 2
5 nipple, half 3” x 9” 822848---090 1
6 reinforcement 3” x 2 1/2” 250035---136 12
7 coupling, 3” (I) 040327 1
8 reinforcement, 15 1/2” 250035---138 3
9 capscrew, hex 1/4” x 5/8” 828604---088 4
10 nipple, half 3” x 7 1/2” 822848---075 1
12 nut, hex 1/4” 824204---226 4
13 valve, minimum pressure/check 3” (II) 250033---821 1
14 elbow, tube---m 3/8” x 1/4” 810506---025 1
15 tubing, steel 3/8” 841115---006 6
16 tubing, steel 1/2” 841115---008 1
17 plug, pipe 3/4” 807800---030 1
19 capscrew, ferry head 5/8” x 6” 828410---600 6
20 valve, discharge check 067339---001 1
22 capscrew, hex gr5 3/4” x 2 1/2” 828612---250 8
24 nipple, pipe 4” x 6 1/2” 822164---065 1
25 elbow, pipe 90_ 4” 801515---160 3
26 elbow, tube---m 1/4” x 1/4” 810504---025 2
27 silencer, air 3/4” 040758 1
30 valve, blowdown 1” nc 2---way (III) 409783 2
31 elbow, pipe reducing 90_ 1 1/4”x 1” 801605---040 1

(II) For maintenance on minimum pressure/check valve no. 250033---821, order repair kit
no. 250018---262.
(III) For maintenance on blowdown valve no. 409783, order repair kit no. 001667.
97
Section 8

(AIR-- COOLED)
98
Section 8

(AIR-- COOLED) (continued)
key part

33 union, pipe 1 1/4” 802515---050 1
34 tank, sump fluid separator 30” 250002---038 1
35 connector, 1/4”x 1/4” 021069 1
36 fitting, 1/2” x 1/4” 020501 1
37A element, separator (primary) (IV) 250034---123 1
37B element, separator (secondary) (V) 250034---129 1
38 valve, relief 1 1/2” 150 psig (10.3 bar) 407003 1
39 bushing, reducing 1 1/2” x 1/2” 802106---020 1
40 plug, o---ring boss 1 1/4” 040029 1
42 glass, fluid level sight 1 1/2” 040279 1
43 tee, pipe 1 1/2” x 1 1/2” x 1 1/2” 802415---060 1
45 capscrew, hex gr5 3/4” x 2 1/2” 828612---250 4
46 washer, regular 3/4” 837212---112 4
48 nut, hex 3/4” 824212---665 4
49 nipple, pipe 3/4” x 3 1/2” 822112---035 1
50 elbow, pipe 90_ 3/4” 801515---030 1
51 nipple, pipe 3/4” x 7” 822112---070 2
52 valve, globe 3/4” 040520 1
53 capscrew, hex 1/2” x 1 1/2” 828608---150 1
55 coupling, flexible 4” (VI) 041085 1
59 tubing, steel 1/4” 841115---004 6 ft.
60 capscrew, hex 1/2” x 1 3/4” 828608---175 2

(IV) For maintenance on primary separator element no. 250034---123, order replacement kit
no. 250034---124.
(V) For maintenance on secondary separator element no. 250034---129, order replacement kit
no. 250034---130.
(VI) For maintenance on flexible coupling no. 041085, order repair kit no. 041353.
99
Section 8

(AIR-- COOLED)
100
Section 8

key part
61 washer, regular 1/2” 837208---112 2

63 nut, hex 1/2” 824208---385 4
65 capscrew, hex 1/2” x 1 1/4” 828608---125 2
66 support, cooler 250005---041 2
67 gasket, flange 6” 150# 240621---12 1
68 nipple, pipe 1/4”x 1/2” 823104---015 1
69 elbow, pipe 90_ x 1/2” 801515---020 1
70 nipple, pipe 1/4” x close 823204---000 5
71 orifice, 1/32” 040381 1
72 orifice, .062” 027443 1
73 bushing, reducing 1/2” x 1/4” 807602---010 2
74 glass, sight 046559 2
75 strainer, v---type (VII) 241771 2
76 elbow, tube 1/4”t x 1/4”mpt 810504---025 1
77 elbow, tube 1/2”t x 1/4”mpt 810505---025 1
78 elbow, tube union 1/2” 811205---031 1
79 elbow, tube union 1/4” 811204---025 1
81 elbow, pipe 45_ 2” 150# 801415---080 1
82 valve, check 1/2” 042694 1
83 connector, tube 1/2” 810208---050 1
84 nipple, pipe sch 80 1/2” x close 822208---000 1
85 elbow, tube 1/2” npt x 1/2” tube 810508---050 1
86 reducer, bushing hex 3/4” x 1/2” 802103---020 1
87 connection, bracket 250008---245 1
88 tee, pipe 802203---034 1
(VII) For maintenance on v---type strainer no. 241771, order repair kit no. 241772.
101
Section 8
8.19 REMOTE COOLER COMPRESSOR DISCHARGE SYSTEM -- 400HP/300KW (AIR-- COOLED)
102
Section 8
key part
1 union, tube hex 1/4” 811304---025 3

2 tubing, steel 1/4” 841115---004 12 ft.
3 connector, 1/4”x 1/4” 020169 1
5 tee, pipe 1/4” 802415---010 3
7 nut, hex 3/4”---10 824212---665 32
9 gasket, flange 6” 042790 2
10 flange, slip---on 6” 819215---096 2
11 pipe, discharge 6” x 24 1/2” 250006---671 1
12 capscrew, hex gr5 3/4”---10 x 3 1/2” 828612---350 24
13 capscrew, hex gr5 7/8”---9 x 2 1/2” 828614---250 4
14 washer, regular 7/8” 837214---219 8
16 nut, hex 7/8”---9 824214---776 4
17 fitting, 1/2” x 11/4” 020501 1
18 nut, hex 1/2”---18 825305---283 2
20 capscrew, hex gr5 1/4”---20 x 1/2” 828204---050 2
22 capscrew, hex serrated washer 1/2” x 1” 829705---100 2
23 bracket 250000---025 1
25 elbow, reducing 3/4” x 1/4” 801603---010 1
27 filter, fluid (I) 250007---219 1
28 nipple, pipe 3/4” x 2” 822112---020 1
29 elbow, reducing 3/4” x 1/2” 801603---020 2
31 valve, ball 1/2” 047117 1
33 tubing, steel 1/2” 841115---008 3 ft.
34 washer, regular 7/8” 837214---219 8

103
Section 8
104
Section 8

(continued)
key part
36 nut, hex 7/8”---9 824214---776 4

37 capscrew, hex gr5 7/8”---9 x 2 1/2” 828614---250 4
38 screw, hex socket set 1/2”---18 x 1/2” 832205---050 1
39 lever, valve 250010---326 1
40 nut, hex locking 7/16”---20 825707---223 2
41 rod, end spherical 7/16”---20 250010---158 1
42 cylinder, air 1 1/2” 408825 1
43 screw, machine shoulder 3/8” x 2” 830506---200 1
44 elbow, pipe 90_ 1/4”---18 860504---025 1
45 hose, hydraulic 1/4” x 64” 040413 1
46 bracket, actuator 019634 1
47 nut, hex 3/8” 824206---337 1
48 nut, hex 5/8” 824210---559 8
50 gasket 242437---010 2
51 valve, butterfly 4” 049151 1
52 flange, threaded 4” 819315---064 1
53 capscrew, hex gr5 5/8”---11 x 5” 828610---500 8
54 elbow, tube---m 1/4” x 1/4” 810504---025 2
55 capscrew, hex gr5 3/4”---10 x 3 1/2” 828612---350 16
56 valve, check 4” 041076 1
57 valve, check assembly part of unit 1
58 tank, fluid sump 30” x 84” horizontal 250005---579 1
59 gasket, flange 240621---12 1
60 tank, fluid separator 24” x 70” vertical 250005---582 1
61 valve, globe 3/4” 040520 1
62 nipple, pipe 3/4” x 9” 822112---090 1
63 elbow, pipe 90_ 3/4” 801515---030 1
64 nipple, pipe 3/4” x 1 1/2” 822112---015 1
65 separator, air/fluid --- primary (II) 250034---125 1
66 separator, air/fluid --- secondary (III) 250034---131 1
67 washer, springlock regular plated 3/4” 838512---188 12

(II) For maintenance on primary air/fluid separator no. 250034---125, order repair kit
no. 250034---126.
(III) For maintenance on secondary air/fluid separator no. 250034---131, order repair kit
no. 250034---132.
105
Section 8
106
Section 8

(continued)
key part
68 capscrew, hex gr8 3/4”---10 x 3” 828212---300 12

70 union, pipe 1 1/2” 802515---060 1
71 tee, reducing 1” x 1” x 1 1/2” 802204---046 1
73 valve, check 1/2” 042694 1
74 tee,tube 1/4” x 1/4” x 1/4” 810804---025 1
75 nipple, pipe 1/2” x 12” long 822108---120 1
76 tubing, steel 1/4” 841115---004 16 ft.
77 tee, pipe 3/4” x 3/4” x 1” 802203---034 2
78 nipple, pipe 4” x 4” 822164---040 1
79 silencer, air 3/4” 040758 4
80 nipple, pipe 2” x 4” 822232---040 1
81 tee, pipe 2” 802415---080 1
82 valve, relief 250009---241 2
83 elbow, pipe 90_ 1/4” 801515---010 2
84 valve, check 1/4” 049905 1
85 glass, sight 24KT (IV) 046559 4
86 elbow, pipe 1/2” 801515---020 1
87 strainer, v---type (V) 241771 2
88 orifice, 0.94 022033 1
89 orifice, restrictor 1/32” 040381 1
90 plug, pipe 3/4” 807800---030 1
92 capscrew, hex gr5 3/4”---10 x 2 1/2” 828612---250 8
93 flange, slip---on 6” 242319---012 1
94 pipe, discharge 6” 45_ 250006---665 1
95 flange, slip---on 6” 819215---096 1
97 valve, relief 250010---221 1
98 plug, pipe 1 1/2” 802815---060 1
99 nut, hex 3/4”---10 824212---665 32
100 plug, o---ring 1 1/4” 040029 1

(IV) For maintenance on sight glass no. 036559, order repair kit no. 250021---312.
(V) For maintenance on v---type strainer no. 241771, order repair kit no. 241772.
107
Section 8
108
Section 8

(continued)
key part

102 glass, fluid level 1 1/2” 040279 1
103 tee, pipe 1 1/2” 802415---060 1
104 nipple, pipe 1 1/2” x 10” 822124---100 1
105 valve, blowdown 2---way (I) 409783 2
107 nipple, pipe 2” x 3” long 822132---030 1
108 elbow, pipe 2” 801515---080 1
109 nipple, pipe galvanized 1/4” x 1 1/2” 823104---015 2
112 flange, back ---up 32E 221338 1
113 gasket, cover 049155 1
115 washer, springlock 3/8” regular unfinished 837506---094 12
117 stud, threaded 3/8”---16 x 2” 839406---020 12
119 elbow, pipe 1/2” x 1/4” 801602---010 1
120 elbow, tube 1/2”t x 1/4”npt 810508---025 1
(I) For maintenance on blowdown valve no. 409783, order repair kit no. 001667.
109
Section 8

(AIR-- COOLED)
110
Section 8

(AIR-- COOLED)
key part
1 tubing, steel 1/4” 841115---004 28 ft.

2 union, tube hex 1/4” 811304---025 3
3 connector, 1/4” x 1/4” 020169 1
5 tee, pipe 1/4” 802415---010 3
6 plug, pipe 1/2” 807800---020 1
7 gasket, flange 240621---12 2
8 flange, slip---on 6” 819215---096 2
10 capscrew, hex gr5 3/4”---10 x 3” 828612---300 16
11 capscrew, hex gr5 3/4”---10 x 2” 828612---200 4
12 washer, regular 3/4” 837212---112 16
14 nut, hex 3/4”---10 824212---665 32
16 fitting, flex 1/2” x 1/4” 020501 1
17 nut, hex 1/2”---18 825305---283 2
18 capscrew, hex gr2 1/4”---20 x 1/2” 829104---050 2
19 bracket, strainer 250000---896 1
20 screw, hex serrated washer 1/2”---18 x 1” 829705---100 2
21 connector, tube 1/2” x 1/4” 810205---025 1
22 elbow, reducing 3/4” x 1/4” 801603---010 1
24 filter, fluid (I) 250007---219 1
25 nipple, pipe 3/4” x 3” 822112---030 1
26 elbow, reducing 3/4” x 1/2” 801603---020 2
28 valve, ball 1/2” 047117 1
29 connector, tube 1/2” x 1/2” 810208---050 2
30 tubing, steel 1/2” 841115---008 3 ft.
32 elbow, pipe 90_ 3/4” 801515---030 1
33 tank, fluid sump 30” x 84” horizontal 250005---579 1
34 capscrew, hex gr5 3/4”---10 x 2 1/4” 828612---225 4

111
Section 8

(AIR-- COOLED)
112
Section 8

(AIR-- COOLED)(continued)
key part
35 nut, hex 5/8”---11 824210---559 8

37 tank, fluid separator 24” x 70” vertical 250005---582 1
38 capscrew, ferry head 1/2”---18 x 1 1/2” 828405---150 1
39 nut, hex 1/2”---18 824205---273 1
40 screw, set, square head 1/2” x 3/4”---18 408383 1
41 lever, valve 250010---326 1
42 nut, hex locking 7/16”---20 825707---223 2
43 rod end, spherical 7/16”---20 250010---158 1
44 cylinder, air 1 1/2” 408825 1
46 elbow, tube 1/4” x 1/8” 860204---012 1
47 hose, hydraulic 1/4” x 64” 040413 1
48 bracket, actuator 019634 1
50 valve, butterfly 4” 049151 1
51 nut, hex 3/8”---16 824206---337 1
52 elbow, tube---m 1/2” x 1/4” 810505---025 1
53 capscrew, hex gr5 5/8”---11 x 5” 828610---500 8
54 flange, threaded 4” 819315---064 1
55 nipple, pipe 4” x 4” 822164---040 1
56 valve, check 4” 041076 1
57 nipple, pipe 3/4” x 1 1/2” 822112---015 1
58 plug, o---ring 1 1/4” 040029 1
60 glass, fluid level 1 1/2” 040279 1
61 tee, pipe 1 1/2” 802415---060 1
62 nipple, pipe 1 1/2” x 10” 822124---100 1
63 plug, pipe 1 1/2” 802815---060 2
64 gasket, 6” 240621---12 1
65 nipple, pipe 3/4” x 9” 822112---090 1
66 plug, pipe 3/4” 802815---030 1
68 union, pipe 1 1/2” 802515---060 1
69 cross, pipe 1 1/2” 801315---060 1
70 bushing, reducing 1” x 1 1/2” 802106---040 3
71 nipple, pipe 1” 822216---000 13
113
Section 8

(AIR-- COOLED)
114
Section 8

key part

73 tee, tube 1/4” x 1/4” x 1/4” 810804---025 2
74 elbow, tube 1/4” x 1/4” 810504---025 2
75 tee. 3/4” x 3/4” x 1” 802203---034 3
76 bushing, reducing 1/2” x 1/4” steel 807602---010 3
77 silencer, air 3/4” 040758 6
78 separator, air/fluid --- primary (II) 250034---125 1
79 separator, air/fluid --- secondary (III) 250034---131 1
81 capscrew, hex gr8 3/4” x 3” 838212---300 12
82 nipple, pipe 2” x 4” 822232---040 1
83 valve, relief 2” x 2 1/2”
(400, 500HP/300,375KW) 250009---241 2
S valve, relief 2” x 2 1/2” (600HP/450KW) 250029---330 2
84 tee, pipe 2” 802415---080 1
85 nipple, pipe 1/4”x 1 1/2” 823104---015 2
86 elbow, pipe 1/4” 801515---010 2
87 valve, check 1/4” 049905 1
88 glass, sight 24KT (IV) 046559 4
89 orifice, .094 022033 1
90 orifice, restrictor 1/32” 040381 1
91 strainer, v---type (V) 241771 2
92 connector, tube---m 1/4”x 1/4” 810204---025 2
94 capscrew, ferry head 3/4”---10 x 6” 828412---600 8
95 nipple, pipe 2 1/2” x 6” 822140---060 1
96 elbow, pipe 45_ 2 1/2” 801415---100 1
98 valve, relief 2” x 2 1/2” (500HP/375KW) 250010---221 1
S valve, relief 2” x 2 1/2” (600HP/450KW) 250026---785 1

(II) For maintenance on primary air/fluid separator no. 250034---125, order repair kit
no. 250034---126.
(III) For maintenance on secondary air/fluid separator no. 250034---131, order repair
kit 250034---132.
(IV) For maintenance on sight glass no. 036559, order repair kit no. 250021---312.
(V) For maintenance on v---type strainer no. 241771, order repair kit no. 241772.
115
Section 8

(AIR-- COOLED)
116
Section 8

key part
99 elbow, pipe 45_ 2” 801415---080 1

101 gasket, 6” 242437---012 1
102 valve, globe 3/4” 040520 1
103 capscrew, hex gr5 3/4”---10 x 2 1/2” 828612---250 8
104 flange, slip---on 6” 242319---012 1
105 pipe, discharge 45_ 6” 250006---665 1
106 flange, slip---on 6” 819215---064 1
108 valve, check 1/2” 042694 1
109 flange, back ---up 32E 221338 1
110 gasket, cover 049155 1
112 washer, springlock 3/8” regular unfinished 837506---094 12
114 stud, threaded 3/8”---16 x 2” 839406---020 12
115 elbow, pipe 1/2” x 1/4” 90_ 801602---010 1
116 elbow, tube 1/2”t x 1/4” npt 90_ 810508---025 1
117 valve, blowdown 2---way (I) 409783 3
(I) For maintenance on blowdown valve no. 409783, order repair kit no. 001667.
117
Section 8
8.21 SULLICON CONTROL -- 200 -- 600HP/150 -- 450KW
118
Section 8
8.21 SULLICON CONTROL -- 200 -- 600HP/150 -- 450KW
key part

2 nut, hex 3/8”---16 824206---337 10
4 bracket, cont. stop 020864 1
6 control, Sullicon (I) 011682---003 1
7 lever, control 011084 1
8 bracket, control 250014---397 1
9 pin, yoke 1/4” 040065 1
10 yoke, rod end 1/4”---28 040138 1
11 pin, cotter 1/16” x 3/4” 827101---075 1
12 nut, hex jam unfinished 1/2”---24 --- right hand 824605---195 2
15 rod end, spherical 1/2” --- left hand 042004 1
16 nut, hex jam 1/2” --- left hand 824705---195 2
17 rod, link 1/2”---24 x 9 1/2” 021287 1
19 rod end, spherical 1/2” --- right hand 040136 1
20 plunger 020094 1
21 seal, cup 042538 1
22 screw, machine hex head 1/2”---24 x 2” 831105---200 1
23 nut, hex locking plated 3/8”---16 825506---198 1
25 body, control 021635 1
26 diaphragm, external 041269 1
27 tubing, steel 1/4” 841115---004 16 ft.
28 washer, back ---up 021172 1
29 screw, ferry head 1/4”---28 x 3/4” 041264 1
30 spring, control light 250006---526 1
31 bolt, adjustable Sullicon spring 250009---134 1
32 cover, control 021654 1
33 capscrew, hex gr2 3/8”---16 x 2 1/2” 828106---250 3
34 connector, tube 1/4”x 1/4” 810204---025 1
(I) For maintenance on Sullicon Control no. 011682---003, order repair kit no. 250020---353.
119
Section 8
8.22 COMPRESSOR ACTUATOR -- 200 -- 600HP/150 -- 450KW
120
Section 8
8.22 COMPRESSOR ACTUATOR -- 200 -- 600HP/150 -- 450KW
key part
1 shaft, valve --- direct 250030---981 1

S shaft, valve --- geared 250030---982 1
2 valve, weight counterbalance 250016---193 1
3 capscrew, socket 3/8”---16 x 1” 828906---100 2
4 ring, retaining 499068---005 1
5 bearing, ball 499002---207 1
6 seal, lip 250016---200 1
7 screw, set 1/2”---13 x 1.62 br 250024---465 1
8 adapter, air cylinder 250016---182 1
10 guide, rack 250016---199 1
11 gear, pinion 250016---196 1
12 indicator, actuator 250030---983 1
13 pin, roll unfinished 1/4”x 1” 827404---100 1
14 capscrew, hex head gr8 1/4”---20 x 1/2” 828204---050 4
15 cover, adapter 250016---195 1
16 washer, regular #8 838201---045 6
17 screw, machine rod #8---32 x 1/2” 831601---050 6
18 mount, air cylinder 250016---188 1
20 spring, seal 2 1/4” 250016---394 1
21 rack, gear 250016---197 1
22 nut, hex jam 3/8”---16 824906---227 1
23 shaft, air cylinder 250016---194 1
24 cylinder, air (I) 250016---183 1
25 orifice, .062 x .25m x .25f 028831 1
27 screw, machine hex 1/4”---20 x 1 3/4” 830104---175 1
28 nut, hex jam 1/4”---20 824904---164 1
29 decal, warning actuator 250029---836 1
30 decal, actuator valve positioning 250029---784 1
(I) For maintenance on air cylinder no. 250016---183, order diaphragm repair kit no. 608311---001.
121
Section 8
8.23 ELECTRO-- PNEUMATIC CONTROL SYSTEM -- 200 -- 600HP/150 -- 450KW
122
Section 8
key part
1 frame, control box support 250042---499 1

2 box, control 250038---777 1
3 block, terminal and track 041093 1
4 panduit 047322 1
5 snaptrack 250024---522 1
6 control, temperature dual 250039---911 1
7 pin, socket for 120V plug---in relay 045497 1
8 relay, control 045496 1
9 fuse 241957 1
10 holder, fuse 041147 1
11 transducer, pressure 250039---910 4
12 nipple, chase --- conduit 1/2” 847815---050 2
13 locknut, conduit 1/2” 847200---050 1
14 switch, vacuum 22” wc 250014---656 1
15 switch, emergency stop 250028---588 1
16 block, contact 250027---125 1
17 light, power energized 250000---105 1
18 decal, power energized 249544---049 1
19 panel, control 250038---779 1
·gasket, panel (not shown) 02250048---821 1
20 grip, cord 250023---496 4
21 bulkhead, pipe 1/8” 841500---002 4
23 tee, pipe 1/4” 804415---010 4
24 elbow, pipe 90_ x 1/4” 801515---010 2
26 filter, control line air 1/4” (I) 408389 2
27 elbow, tube---m 1/4” x 1/4” 810504---025 5
28 tubing, steel 1/4” 841015---004 62 ft.
30 tubing, plastic 1/4” 250024---745 16 ft.
31 valve, solenoid 1/4” 3---way 115V (II) 250038---668 1
32 tee,tube 1/4” 810904---025 1
33 valve, shuttle 408893 2
(I) For maintenance on control line filter no. 408389, order repair kit no. 001692.
(II) For maintenance on solenoid valve no. 250038---668, order repair kit no. 250038---673
(valve) and no. 250031---738 (coil).
123
Section 8
124
Section 8
8.23 ELECTRO-- PNEUMATIC CONTROL SYSTEM -- 200 -- 600HP/150 -- 450KW (continued)
key part
34 valve, solenoid 1/4” 3---way 115V (II) 409067 1

35 valve, differential pressure regulator
(spiral valve) (III) 408275 1
36 valve, differential pressure regulator 1/4”(IV) 406929 1
37 bracket, fluid stop valve support 231584 1
38 capscrew, hex gr5 1/2”---13 x 1 1/2” 828608---150 1
39 angle, pressure switch 230452 1
41 nut, hex plated 1/2” 824815---005 2
42 washer, regular unfinished 1/2” 837208---112 1
45 switch, water pressure 043428 1
(II) For maintenance on solenoid valve no. 409067, order repair kit no. 250010---377.
(III) For maintenance on differential pressure regulator no. 408275, order repair kit
no. 250028---693.
(IV) For maintenance on differential pressure regulator no. 406929, order repair kit no. 041742.
125
Section 8
8.24 ENCLOSURE -- 200 -- 300HP/150 -- 225KW
126
Section 8
8.24 ENCLOSURE -- 200 -- 300HP/150 -- 225KW
key part
1 panel, roof 30” x 87” 250007---112 3

2 panel, fiberglass 29.50” x 41.00” x 2M 047823---157 7
4 panel, roof 30” x 87” 250007---113 7
5 clamp, speed tube 1/4” 043357 8
6 guard, fan 24” 041765 2
7 capscrew, hex gr5 1/2”---18 x 1” 828605---100 8
8 capscrew hex gr5 3/8”---16 x 3 1/2” 828606---350 6
9 fan, 20” 245748 1
12 spacer, fan support 227267 6
16 capscrew, hex gr5 3/8”---16 x 1 1/4” 828606---125 4
17 support, motor mount 014613 1
20 motor, .75HP/.5KW 050288 1
22 nut, hex flange plated 1/2”---18 825305---283 150
23 grille, enclosure end 249651 2
24 post, corner 6” 250007---117 2
25 support, end 8 5/8” 250007---124 1
26 panel, end header 250007---126 2
27 panel, bottom end 250007---122 1
28 panel fiberglass 32.50” x 49.00” x 2M 047823---158 2
29 panel, access 33” x 50” 250007---123 1
30 channel, end sill 250007---121 2
31 panel, side header 250007---115 2
32 support, side 8 5/8” 250007---118 6
34 panel, access 014661 8
35 nut, hex plated 1/4”---20 825204---226 40
36 capscrew, hex gr5 1/4”---20 x 1” 828604---100 40
37 handle, canopy 042262 28
38 channel, side sill 250007---131 2
127
Section 8
8.24 ENCLOSURE -- 200 -- 300HP/150 -- 225KW
128
Section 8
8.24 ENCLOSURE -- 200 -- 300HP/150 -- 225KW (continued)
key part

40 panel, access 33” x 39.50” 250042---830 1
46 support, end 8 5/8” 250007---124 1
47 post, corner 6” x 15” 250009---423 2
50 panel, access 33” x 50” 250007---123 2
54 panel, roof 38.75” x 87” 250007---114 1
129
Section 8
8.25 ENCLOSURE -- 400 -- 600HP/300 -- 450KW
130
Section 8
8.25 ENCLOSURE -- 400 -- 600HP/300 -- 450KW
key part
1 panel, roof 33” x 96” 250009---421 5

4 panel, roof 250009---422 1
5 clamp, speed tube 1/4” 043357 8
6 guard, fan 24” 041765 2
7 capscrew, hex gr5 1/2”---18 x 1” 828605---100 8
8 capscrew hex gr5 3/8”---16 x 3 1/2” 828606---350 6
9 fan, 20” 245748 1
12 spacer, fan support 227267 6
16 capscrew, hex gr5 3/8”---16 x 1 1/4” 828606---125 4
17 support, motor mount 014613 1
20 motor, .75HP/.5KW 050288 1
22 nut, hex flange plated 1/2”---18 825305---283 150
23 grille, enclosure end 249651 2
24 post, corner 6” 250007---117 2
25 support, end 11 5/8” 250009---916 1
26 panel, end header 250007---126 2
27 panel, bottom end 250007---122 1
28 panel fiberglass 29.50 x 49.00 x 2M 047823---168 2
29 panel, access 30” x 50” 250009---917 1
30 channel, end sill 250009---424 2
32 support, side 8 5/8” 250007---118 6
34 panel, access 014661 8
35 nut, hex plated 1/4”---20 825204---226 40
36 capscrew, hex gr5 1/4”---20 x 1” 828604---100 40
37 handle, canopy 042262 28
131
Section 8
8.25 ENCLOSURE -- 400 -- 600HP/300 -- 450KW
132
Section 8
8.25 ENCLOSURE -- 400 -- 600HP/300 -- 450KW (continued)
key part

40 panel, access 33” x 39.50” 250042---830 1
46 support, end 8 5/8” 250007---124 1
47 post, corner 6” x 15” 250009---423 2
50 panel, access 33” x 50” 250007---123 2
133
Section 8
8.26 RTD PROBES -- 200 -- 300HP/150 -- 225KW
134
Section 8
8.26 RTD PROBES -- 200 -- 300HP/150 -- 225KW
key part
1 bushing, reducer 3/4” x 1/8”npt 802103---005 4

2 fitting, compression 250028---633 4
3 probe, RTD 250039---909 4
135
Section 8
8.27 RTD PROBES -- 400 -- 600HP/300 -- 450KW
136
Section 8
8.27 RTD PROBES -- 400 -- 600HP/300 -- 450KW
key part
1 bushing, reducer 3/4” x 1/8”npt 802103---005 4

2 fitting, compression 250028---633 4
3 probe, RTD 250039---909 4
137
Section 8
8.28 AFTERCOOLER -- 400HP/300KW (WATER-- COOLED)
138
Section 8
8.28 AFTERCOOLER -- 400HP/300KW(WATER-- COOLED)
key part
1 support, cooler 250009---924 3

2 capscrew, hex gr5 1/2”---13 x 2” 828608---200 8
4 nut, hex 1/2”---13 824208---448 6
6 capscrew, hex gr5 1/2”---13 x 1 1/2” 828608---150 2
8 nut, hex 3/8”---16 824206---337 4
11 capscrew, hex gr5 3/8”---16 x 1 1/2” 828606---150 4
12 u---bolt, 1/2” x 4” pipe 829008---400 2
13 nipple, pipe 4” x 69 1/2” 822164---695 1
14 flange, threaded 4” 819315---064 2
15 capscrew, hex gr5 5/8”---11 x 3” 828610---300 24
16 gasket, 4” 125# flange full face 242437---010 3
18 nut, hex 5/8”---11 824210---559 24
19 tubing, steel 2” 02250057---297 1
20 elbow, tube---m 2” x 2” 810532---200 3
22 aftercooler 042950 1
23 u---bolt, 1/2” x 8” pipe 829008---800 1
24 nipple, pipe 4” x 17 1/2” 822164---175 1
25 flange, threaded 4” 818312---064 1
26 separator, 4” combination trap (I) 250000---511 1
27 connector, tube 5/8” x 1/2” 810210---075 2
28 tubing, steel 3/4” 841115---012 7 ft.
31 bracket, in---out 2” 250008---245 1
32 nut, hex 3/4”---10 824212---665 24
33 rod, stiffener 3/4” x 20” 250009---918 1
34 channel, 3” x 1 1/2” x 50” 250010---022 1
35 nipple, pipe 4” x 4” 822164---040 2
36 elbow, pipe 90_ 4” 801515---160 2
37 nipple, half 4” x 8” 822864---080 2
38 reinforcement, 3” 227152 4
(I) For maintenance on combination separator trap no. 250000---511, order repair kit no. 250033---036.
139
Section 8
8.28 AFTERCOOLER -- 400HP/300KW(WATER-- COOLED)
140
Section 8
8.28 AFTERCOOLER -- 400HP/300KW(WATER-- COOLED) (continued)
key part
39 capscrew, hex gr5 1/2”---18 x 1 1/2” 838605---150 4

40 reinforcement, 13” 227154 2
41 nut, hex 1/2”---18 824205---273 4
43 coupling, flexible 4” (I) 041085 1
44 nipple, pipe 3/4” x 3” 822112---030 1
45 elbow, pipe 3/4” 801515---030 2
47 elbow, pipe 2” 801515---080 2
48 nipple, pipe 2” x 2 1/2” long 822132---035 1
49 nipple, pipe 2” x 3 1/2” long 822132---025 1
51 tube 02250057---725 1
141
Section 8
8.29 AFTERCOOLER -- 500 -- 600HP/375 -- 450KW (WATER-- COOLED)
142
Section 8
key part
1 aftercooler 250007---805 1
2 gasket, 5” 242437---011 2
3 stud, 1/2” x 4 1/4” 842708---042 24
4 union, pipe 2 1/2” 802515---100 3
5 u---bolt, 1/2” x 8” pipe 829008---800 2
6 flange, slip---on flat face 5” 242319---011 2
7 pipe, outlet 8” x 5” 250009---736 1
8 u---bolt, 1/2” x 5” pipe 829008---500 1
9 capscrew, hex gr5 3/4”---10 x 3” 828612---300 8
11 nut, hex 3/4”---10 824212---665 8
12 separator, 5” 250007---799 1
14 tubing, steel 1/2” 841115---008 7 ft.
15 bracket, in---out 250016---803 1
16 capscrew, hex gr5 1/2”---13 x 1 1/2” 828608---150 2
18 nut, hex 1/2”---13 824208---448 6
19 elbow, pipe 2 1/2” 801515---100 1
20 elbow, pipe reducing 2 1/2” x 1 1/2” 801610---060 2
21 nipple, pipe 2 1/2” x 132 3/4” Consult Factory 1
22 nipple, pipe 2 1/2” x 43 3/4” 822140---437 1
24 support, cooler 250009---924 3
25 capscrew, hex gr5 1/2”---13 x 2” 828608---200 8
27 nut, hex 3/4”---10 824212---665 32
28 elbow, inlet 8” x 4” reducer 250009---737 1
29 nut, hex 3/8”---16 824206---337 4
31 capscrew, hex gr5 3/8”---16 x 1 1/2” 828606---150 4
32 reinforcement, 13” 250035---138 2
33 coupling, flexible 4”(I) 041085 4
34 reinforcement, 3” 250035---136 4
35 nipple, half 4” x 8” 822864---080 1
(I) For maintenance on Flexmaster coupling no. 041085, order repair kit no. 041353.
143
Section 8
144
Section 8
8.29 AFTERCOOLER -- 500 -- 600HP/375 -- 450KW (WATER-- COOLED) (continued)
key part
36 elbow, pipe 90_ 4” 801515---160 1

37 nipple, pipe 4” x 9” 822164---090 1
38 nipple, pipe 2 1/2” x 14 1/2” 822140---145 1
39 nipple, pipe 2 1/2” x 33” 822140---330 1
40 nipple, pipe 2 1/2” x 14” 822140---140 1
41 nipple, pipe 2 1/2” x 13” 822140---013 1
42 reducer, bell 2 1/2” x 1 1/2” 801020---012 1
43 elbow, pipe 1/2” 90˚ 801515---020 2
44 nipple, pipe 1/2” x 5” 822108---050 1
45 nipple, pipe 1/2” x 2” 822108---020 1
46 reducer, bushing 1/2” x 1” 802104---020 1
145
Section 8
8.30 DECAL GROUP
146
Section 8
8.30 DECAL GROUP
key part
1 sign, warning sever --- fan 049855 2

2 sign, warning sever---fan port 049965 1
4 decal, rotation 250021---286 1
5 decal, rotation 250021---564 1
6 decal, 460 volt 040631 1
Sdecal, 380 volt (I) 241926 1
Sdecal, 415 volt (I) 241927 1
Sdecal, 525 volt (I) 02250047---898 1
Sdecal, 575 volt (I) 041124 1
7 decal, compressor fluid Sullube---32 250023---361 1
8 decal, compressor fluid SRF 1/4”000 250022---839 1
9 sign, air breathing (danger) 250027---935 1
10 sign, power energized 249544---049 1
(I) Decal is for optional voltage (not shown).
147
Section 8
8.30 DECAL GROUP
148
Section 8
8.30 DECAL GROUP (continued)
key part
11 sign, warning ground fault 049852 1

12 decal, warning actuator 250029---836 1
13 decal, danger high voltage 042218 1
14 decal, water inlet---outlet 049873 1
15 decal, water in 250019---107 1
16 decal, water out 250019---108 1
17 decal, water drain 250022---810 1
18 decal, TS---32 02250061---379 1
19 decal, fluid stop valve P/N 016742 410239 1
149
Section 8
8.30 DECAL GROUP
150
Section 8
8.30 DECAL GROUP (continued)
key part
21 decal, ISO 9001 Consult Factory 1

22 decal, compressor fluid 24KT (not shown) 02250061---022 1
23 sign, warning “food grade” lube 250003---144 1
24 sign, warning “compressor fluid fill cap” 049685 1
25 decal, warning auto start 250017---903 1
151
Section 8
8.30 DECAL GROUP
152
Section 8
8.30 DECAL GROUP
key part
26 decal, logo SRF 1/4”000 250021---483 1

27 decal, autostart 041065 1
28 decal, Sullair logo 02250059---048 2
29 decal, fluid sample 250022---675 1
30 decal, grounding lug 045433 1
153
Section 8
8.31 WIRING DIAGRAM -- STANDARD FULL-- VOLTAGE
154
Section 8
8.32 WIRING DIAGRAM -- WYE-- DELTA
155
WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A.

ROOM 2304A Chemin de Genas BP 639
Shartex Plaza Ctr. 69800 Saint Priest, France
No. 88 Zun Yi Nan Rd. Telephone: 33---72232425
Shanghai, P.R.C. FAX: 33---78907168
Telephone: 21---2192066
FAX: 21---2196568
SULLAIR CORPORATION
Subsidiary of Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 1---800---SULLAIR (U.S.A. Only) or
1---219---879---5451
FAX: (219) 874---1273
FAX: (219) 874---1835 (Parts)
FAX: (219) 874---1805 (Service)
Printed in U.S.A.
Specifications Subject To
Change Without Prior Notice

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INDUSTRIAL ROTARY SCREW

1 1.2 PERSONAL PROTECTIVE EQUIPMENT

10 4.2 INSTRUMENTATION, FUNCTIONAL DESCRIPTION

17 5.2 DESCRIPTION OF COMPONENTS

35 7.2 DAILY OPERATION

1.1 GENERAL 1926.302(b)(7) and/or any applicable Federal,

REMOTE AIR---COOLED (I)

Figure 2 ---1 Service Air Piping (Typical Installation)

SULLAIR SERIES TS---32 SPECIFICATIONS

COMPRESSOR: STANDARD MODELS

MOTOR (60 Cycle Compressors)

MOTOR (50 Cycle Compressors)

LUBRICATION GUIDE---STANDARD COMPRES- temperatures coupled with high humidity, or when

4.1 INTRODUCTION S The sump pressure transducer (P1) monitors

4.4 SUPERVISOR I OUTPUT RELAYS

4.5 SUPERVISOR I SPECIAL FUNCTION INPUTS

4.6 SUPERVISOR I AUXILIARY DIGITAL INPUTS

MOTOR/OVERLOAD (J1/7---8) Monitors normally closed compressor motor over-

ON EXISTING RELAY BOARD K6 --- Max Press P1 Prealarm

K7 --- Low Press P3 Prealarm

PARAMETER (IN SEQUENTIAL ORDER) OPERATION

LANGUAGE Press the cursor pad for 2 seconds to change to next

MESSAGE DISPLAY DEFINITIONS

MANUAL SHUTDOWN The machine is ready to be started. Machine

4.11 TROUBLE INDICATION SETPOINTS (Cont’d.)

5.1 INTRODUCTION motor, compressor inlet system, compressor

The receiver(s) is an ASME pressure vessel. A

500---600HP/375---450KW air cooled models only

MODULATION --- 100 to 110 PSIG (6.9 TO 7.6

Figure 5 ---8 Control System (200, 250, 300HP/150, 187, 225KW)

Figure 5 ---9 Control System (400, 500, 600HP/300, 375, 450KW)

Figure 5 ---9 Control System (400, 500, 600HP/300, 375, 450KW)

Figure 5 ---10 Compressor Air Inlet System

6.1 GENERAL call for service or indicate the beginning of a mal-

6.2 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE

ON/OFF PAD Depress to turn compressor ON. Depress again to

6.2 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE

6.2 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE

PRESSURE RELIEF VALVE Opens sump pressure to the atmosphere should

6.4 SUBSEQUENT START---UP PROCEDURE

7.1 GENERAL 7.5 FLUID CHANGE

DO NOT remove caps, plugs, and/or other com- *

Stop compressor and relieve all internal pres-

* Replacement element P/N 250007---838 (primary)

Figure 7 ---3 Separator Element Replacement

200, 250, 300HP 400, 500, 600HP

PROCEDURE FOR 200---300HP/150---225K W

UNLOAD pressure (110 psig [7.6 bar]). Note that

apart. Insert the flexible element between the two

Capscrews are 3/4 --- 10 x 4” LG NAS 144 black ox-

After tightening the capscrews, tighten the shaft

Figure 7 ---6 Drive Coupling Alignment

Max. Operating Misalignment

Tightening Coupling Parallel Angular

Use the following procedure for proper mainte-

* Repair Kit P/N 02250044---346

STEP 2 --- CHECK ALIGNMENT