USER MANUAL

INDUSTRIAL ROTARY SCREW AIR COMPRESSOR

TS32
200-350HP/149-261KW
AIR-COOLED & WATER-COOLED
STANDARD AND 24KT

PART NUMBER:
02250184-893 R00
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions ©
SULLAIR CORPORATION
and procedures in this manual or, The information in this manual is current
as of its publication date, and applies to
misuse of this equipment will compressor serial number:
VOID its warranty!
200906010000
and all subsequent serial numbers.
 AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on Industrial compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.

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

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

SULLAIR CUSTOMER CARE TRAINING DEPARTMENT

1-888-SULLAIR or
219-879-5451 (ext. 5623)
www.sullair.com
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
 TABLE OF CONTENTS
SECTION 1—SAFETY
5 1.1 GENERAL
5 1.2 PERSONAL PROTECTIVE EQUIPMENT
5 1.3 PRESSURE RELEASE
6 1.4 FIRE AND EXPLOSION
6 1.5 MOVING PARTS
7 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
7 1.7 TOXIC AND IRRITATING SUBSTANCES
8 1.8 ELECTRICAL SHOCK
8 1.9 LIFTING
9 1.10 ENTRAPMENT

SECTION 2—DESCRIPTION
11 2.1 DESCRIPTION OF COMPONENTS
11 2.2 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION
14 2.3 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTION-
AL DESCRIPTION
14 2.4 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION
24 2.5 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
25 2.6 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION

SECTION 3—SPECIFICATIONS
27 3.1 TABLE OF SPECIFICATIONS—TS32
27 3.2 COMPRESSOR SPECIFICATIONS
28 3.3 MOTOR SPECIFICATIONS
28 3.4 LUBRICATION GUIDE— STANDARD COMPRESSORS
29 3.5 LUBRICATION GUIDE—24KT COMPRESSORS
29 3.6 LUBRICATION GUIDE— OPTIONAL FLUID

SECTION 4—INSTALLATION
55 4.1 COMPRESSOR MOUNTING— SUPPORT AND LOCATION
55 4.2 VENTILATION AND COOLING
TABLE OF CONTENTS

61 4.3 SERVICE AIR PIPING

61 4.4 COUPLING ALIGNMENT CHECK
61 4.5 FLUID LEVEL CHECK
61 4.6 MOTOR ROTATION DIRECTION CHECK
62 4.7 FLUID PIPING (REMOTE AIR-COOLED OPTION ONLY)
62 4.8 ELECTRICAL PREPARATION

SECTION 5—OPERATION
63 5.1 INTRODUCTION
63 5.2 PURPOSE OF CONTROLS— INTRODUCTION
65 5.3 INITIAL START-UP PROCEDURE
65 5.4 SUBSEQUENT START-UP PROCEDURE
65 5.5 SHUTDOWN PROCEDURE

SECTION 6—MAINTENANCE
67 6.1 GENERAL
67 6.2 DAILY OPERATION
67 6.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
67 6.4 MAINTENANCE EVERY 1000 HOURS
67 6.5 FLUID CHANGE
68 6.6 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
73 6.7 DRIVE COUPLING INSTALLATION AND ALIGNMENT
75 6.8 TROUBLESHOOTING— INTRODUCTION
 Section 1
SAFETY
NOTE
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL.
1.1 GENERAL
Sullair Corporation and its subsidiaries design and
manufacture all of their products so they can be
operated safely. However, the responsibility for safe
operation rests with those who use and maintain
these products. The following safety precautions are
offered as a guide which, if conscientiously followed,
will minimize the possibility of accidents throughout
the useful life of this equipment.
The compressor should be operated only by those
who have been trained and delegated to do so, and
who have read and understood this Operator's
Manual. Failure to follow the instructions, procedures
and safety precautions in this manual may result in
accidents and injuries. NEVER start the compressor
unless it is safe to do so. DO NOT attempt to operate
the compressor with a known unsafe condition. Tag
the compressor and render it inoperative by
disconnecting and locking out all power at source or
otherwise disabling its prime mover so others who
may not know of the unsafe condition cannot attempt
to operate it until the condition is corrected.
Install, use and operate the compressor only in full
compliance with all pertinent OSHA regulations and/
or any applicable Federal, State, and Local codes,
standards and regulations. DO NOT modify the
compressor and/or controls in any way except with
written factory approval.
While not specifically applicable to all types of
compressors with all types of prime movers, most of
the precautionary statements contained herein are
applicable to most compressors and the concepts
behind these statements are generally applicable to
all compressors.
1.2 PERSONAL PROTECTIVE
EQUIPMENT
A. Prior to installing or operating the compressor,
owners, employers and users should become
familiar with, and comply with, all applicable
OSHA regulations and/or any applicable Federal,
State and Local codes, standards, and regula-
tions relative to personal protective equipment,
such as eye and face protective equipment,
respiratory protective equipment, equipment
intended to protect the extremities, protective
clothing, protective shields and barriers and elec-
trical protective equipment, as well as noise
exposure administrative and/or engineering con-
trols and/or personal hearing protective equip-
ment.
1.3 PRESSURE RELEASE
A. Install an appropriate flow-limiting valve between
the service air outlet and the shut-off (throttle)
valve, either at the compressor or at any other
point along the air line, when an air hose exceed-
ing 1/2" (13mm) inside diameter is to be con-
nected to the shut-off (throttle) valve, to reduce
pressure in case of hose failure, per OSHA Stan-
dard 29 CFR 1926.302(b)(7) and/or any applica-
ble Federal, State and Local codes, standards
and regulations.
B. When the hose is to be used to supply a mani-
fold, install an additional appropriate flow-limiting
valve between the manifold and each air hose
exceeding 1/2" (13mm) inside diameter that is to
be connected to the manifold to reduce pressure
in case of hose failure.
C. Provide an appropriate flow-limiting valve at the
beginning of each additional 75 feet (23m) of
hose in runs of air hose exceeding 1/2" (13mm)
5

inside diameter to reduce pressure in case of
hose failure.
D. Flow-limiting valves are listed by pipe size and
flow-rated. Select appropriate valves accordingly,
in accordance with their manufacturer's recom-
mendations.
E. DO NOT use air tools that are rated below the
maximum rating of the compressor. Select air
tools, air hoses, pipes, valves, filters and other
fittings accordingly. DO NOT exceed manufac-
turer's rated safe operating pressures for these
items.
F. Secure all hose connections by wire, chain or
other suitable retaining device to prevent tools or
hose ends from being accidentally disconnected
and expelled.
G. Open fluid filler cap only when compressor is not
running and is not pressurized. Shut down the
compressor and bleed the receiver tank to zero
internal pressure before removing the cap.
H. Vent all internal pressure prior to opening any
line, fitting, hose, valve, drain plug, connection or
other component, such as filters and line oilers,
and before attempting to refill optional air line
anti-icer systems with antifreeze compound.
I. Keep personnel out of line with and away from
the discharge opening of hoses or tools or other
points of compressed air discharge.
J. DO NOT use air at pressures higher than 2.1 bar
for cleaning purposes, and then only with effec-
tive chip guarding and personal protective equip-
ment per OSHA Standard 29 CFR 1910.242 (b)
and/or any applicable Federal, State, and Local
codes, standards and regulations.
K. DO NOT engage in horseplay with air hoses as
death or serious injury may result.
1.4 FIRE AND EXPLOSION
A. Clean up spills of lubricant or other combustible
substances immediately, if such spills occur.
B. Shut off the compressor and allow it to cool.
Then keep sparks, flames and other sources of
ignition away and DO NOT permit smoking in the
vicinity when checking or adding lubricant or
when refilling air line anti-icer systems with anti-
freeze compound.
C. DO NOT permit fluids, including air line anti-icer
system antifreeze compound or fluid film, to
6
SECTION 1
accumulate on, under or around acoustical mate-
rial, or on any external surfaces of the air com-
pressor. Wipe down using an aqueous industrial
cleaner or steam clean as required. If necessary,
remove acoustical material, clean all surfaces
and then replace acoustical material. Any acous-
tical material with a protective covering that has
been torn or punctured should be replaced
immediately to prevent accumulation of liquids or
fluid film within the material. DO NOT use flam-
mable solvents for cleaning purposes.
D. Disconnect and lock out all power at source prior
to attempting any repairs or cleaning of the com-
pressor or of the inside of the enclosure, if any.
E. Keep electrical wiring, including all terminals and
pressure connectors in good condition. Replace
any wiring that has cracked, cut, abraded or oth-
erwise degraded insulation, or terminals that are
worn, discolored or corroded. Keep all terminals
and pressure connectors clean and tight.
F. Keep grounded and/or conductive objects such
as tools away from exposed live electrical parts
such as terminals to avoid arcing which might
serve as a source of ignition.
G. Remove any acoustical material or other material
that may be damaged by heat or that may sup-
port combustion and is in close proximity, prior to
attempting weld repairs.
H. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when ser-
vicing and operating the compressor.
I. Keep oily rags, trash, leaves, litter or other com-
bustibles out of and away from the compressor.
J. DO NOT operate the compressor without proper
flow of cooling air or water or with inadequate
flow of lubricant or with degraded lubricant.
K. DO NOT attempt to operate the compressor in
any classification of hazardous environment
unless the compressor has been specially
designed and manufactured for that duty.
1.5 MOVING PARTS
A. Keep hands, arms and other parts of the body
and clothing away from couplings, belts, pulleys,
fans and other moving parts.
B. DO NOT attempt to operate the compressor with
the fan, coupling or other guards removed.
SECTION 1
C. Wear snug-fitting clothing and confine long hair
when working around this compressor, especially
when exposed to hot or moving parts.
D. Keep access doors, if any, closed except when
making repairs or adjustments.
E. Make sure all personnel are out of and/or clear of
the compressor prior to attempting to start or
operate it.
F. Disconnect and lock out all power at source and
verify at the compressor that all circuits are de-
energized to minimize the possibility of acciden-
tal start-up, or operation, prior to attempting
repairs or adjustments. This is especially impor-
tant when compressors are remotely controlled.
G. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water or other
liquids to minimize the possibility of slips and
falls.
1.6 HOT SURFACES, SHARP
EDGES AND SHARP
CORNERS
A. Avoid bodily contact with hot fluid, hot coolant,
hot surfaces and sharp edges and corners.
B. Keep all parts of the body away from all points of
air discharge.
C. Wear personal protective equipment including
gloves and head covering when working in, on or
around the compressor.
D. Keep a first aid kit handy. Seek medical assis-
tance promptly in case of injury. DO NOT ignore
small cuts and burns as they may lead to infec-
tion
1.7 TOXIC AND IRRITATING
SUBSTANCES
A. DO NOT use air from this compressor for respi-
ration (breathing) except in full compliance with
OSHA Standards 29 CFR 1910 and/or any appli-
cable Federal, State or Local codes or regula-
tions.
DANGER
Death or serious injury can result from
inhaling compressed air without using
proper safety equipment. See OSHA stan-
dards and/or any applicable Federal, State,
and Local codes, standards and regulations
on safety equipment.
B. DO NOT use air line anti-icer systems in air lines
supplying respirators or other breathing air utili-
zation equipment and DO NOT discharge air
from these systems into unventilated or other
confined areas.
C. Operate the compressor only in open or ade-
quately ventilated areas.
D. Locate the compressor or provide a remote inlet
so that it is not likely to ingest exhaust fumes or
other toxic, noxious or corrosive fumes or sub-
stances.
E. Coolants and lubricants used in this compressor
are typical of the industry. Care should be taken
to avoid accidental ingestion and/or skin contact.
In the event of ingestion, seek medical treatment
promptly. Wash with soap and water in the event
of skin contact. Consult Material Safety Data
Sheet for information pertaining to fluid of fill.
F. Wear goggles or a full face shield when adding
antifreeze compound to air line anti-icer systems.
G. If air line anti-icer system antifreeze compound
enters the eyes or if fumes irritate the eyes, they
should be washed with large quantities of clean
water for fifteen minutes. A physician, preferably
an eye specialist, should be contacted immedi-
ately.
H. DO NOT store air line anti-icer system antifreeze
compound in confined areas.
I. The antifreeze compound used in air line anti-
freeze systems contains methanol and is toxic,
harmful or fatal if swallowed. Avoid contact with
the skin or eyes and avoid breathing the fumes. If
7

swallowed, induce vomiting by administering a
tablespoon of salt, in each glass of clean, warm
water until vomit is clear, then administer two
teaspoons of baking soda in a glass of clean
water. Have patient lay down and cover eyes to
exclude light. Call a physician immediately.
1.8 ELECTRICAL SHOCK
A. This compressor should be installed and main-
tained in full compliance with all applicable Fed-
eral, State and Local codes, standards and
regulations, including those of the National Elec-
trical Code, and also including those relative to
equipment grounding conductors, and only by
personnel that are trained, qualified and dele-
gated to do so.
B. Keep all parts of the body and any hand-held
tools or other conductive objects away from
exposed live parts of electrical system. Maintain
dry footing, stand on insulating surfaces and DO
NOT contact any other portion of the compressor
when making adjustments or repairs to exposed
live parts of the electrical system. Make all such
adjustments or repairs with one hand only, so as
to minimize the possibility of creating a current
path through the heart.
C. Attempt repairs in clean, dry and well lighted and
ventilated areas only.
D. DO NOT leave the compressor unattended with
open electrical enclosures. If necessary to do so,
then disconnect, lock out and tag all power at
source so others will not inadvertently restore
power.
E. Disconnect, lock out, and tag all power at source
prior to attempting repairs or adjustments to
rotating machinery and prior to handling any
ungrounded conductors.
8
SECTION 1
DANGER
All field equipment must be tested for elec-
trostatic fields prior to servicing or making
contact with the machine using the follow-
ing or equivalent test equipment:
• 90-600 VAC: Volt detector such as
Fluke Model 1AC-A
• 600-7000 VAC: Voltage detector
such as Fluke Networks Model
C9970
It is the responsibility of each organization
to provide/arrange training for all their
associates expected to test for electrostatic
fields.
1.9 LIFTING
A. If the compressor is provided with a lifting bail,
then lift by the bail provided. If no bail is provided,
then lift by sling. Compressors to be air-lifted by
helicopter must not be supported by the lifting
bail but by slings instead. In any event, lift and/or
handle only in full compliance with OSHA stan-
dards 29 CFR 1910 subpart N and/or any appli-
cable Federal, State, and Local codes, standards
and regulations.
B. Inspect points of attachment for cracked welds
and for cracked, bent, corroded or otherwise
degraded members and for loose bolts or nuts
prior to lifting.
C. Make sure entire lifting, rigging and supporting
structure has been inspected, is in good condi-
tion and has a rated capacity of at least the
weight of the compressor. If you are unsure of
the weight, then weigh compressor before lifting.
D. Make sure lifting hook has a functional safety
latch or equivalent, and is fully engaged and
latched on the bail or slings.
E. Use guide ropes or equivalent to prevent twisting
or swinging of the compressor once it has been
lifted clear of the ground.
F. DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away
from the compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
SECTION 1
I. Keep lift operator in constant attendance when-
ever compressor is suspended.
J. Set compressor down only on a level surface
capable of safely supporting at least its weight
and its loading unit.
K. When moving the compressor by forklift truck,
utilize fork pockets if provided. Otherwise, utilize
pallet if provided. If neither fork pockets or pallet
are provided, then make sure compressor is
secure and well balanced on forks before
attempting to raise or transport it any significant
distance.
L. Make sure forklift truck forks are fully engaged
and tipped back prior to lifting or transporting the
compressor.
M. Forklift no higher than necessary to clear obsta-
cles at floor level and transport and corner at
minimum practical speeds.
N. Make sure pallet-mounted compressors are
firmly bolted or otherwise secured to the pallet
prior to attempting to forklift or transport them.
NEVER attempt to forklift a compressor that is
not secured to its pallet, as uneven floors or sud-
den stops may cause the compressor to tumble
off, possibly causing serious injury or property
damage in the process.
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 personnel before doing so, or else secure
and tag the access door in the open position to
avoid the possibility of others closing and possi-
bly latching the door with personnel inside.
B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.
9
NOTES

10
 TS32 USER MANUAL

Section 2

DESCRIPTION
2.1 DESCRIPTION OF 2.2 SULLAIR COMPRESSOR
COMPONENTS UNIT, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-1 (air-cooled) or Figure 2-2
(watercooled). The components and assemblies of Sullair air compressors feature the Sullair
the air compressors are clearly shown. The complete compressor unit, a two-stage, positive displacement,
package includes compressor, electric motor, lubricated-type compressor. This unit provides
compressor inlet system, compressor discharge continuous pulse-free air compression to meet your
system, compressor cooling and lubrication system, needs. With a Sullair compressor, there is no
capacity control system, and Supervisor control maintenance or inspection of the internal parts of the
system, all mounted on a structural steel frame. compressor unit permitted in accordance with the
terms of the warranty.
On air-cooled models, a separate motor-driven fan
forces air through the cooler/aftercooler assembly, Fluid is injected into the compressor unit in large
thereby removing the heat of compression from the quantities and mixes directly with the air as the rotors
cooling fluid. turn, compressing the air. The fluid flow has three
primary functions. It cools, seals and lubricates the
On water-cooled models, fluid is piped into a
compressor.
fourpass exchanger where the heat of compression
is removed from the fluid. A fan is used to supply
sufficient ventilating air to the compressors equipped
with a canopy.
Both air-cooled and water-cooled versions have
easily accessible items such as the fluid filters and
control valves. The inlet air filters are also mounted
for easy access and servicing.

11
TS32 USER MANUAL SECTION 2

Figure 2-1: Sullair Series TS32 Rotary Screw Compressor (Air-cooled Typical)

12
SECTION 2 TS32 USER MANUAL

Figure 2-2: Sullair Series TS32 Rotary Screw Compressor (Water-cooled Typical)

13
TS32 USER MANUAL
After the air/fluid mixture is discharged from the
compressor unit, the fluid is separated from the air.
At this time, the air flows to the service line and the
fluid is cooled in preparation for re-injection.
The fluid also serves as lubricant for the anti-friction
bearings and the drive gear sets.
2.3 COMPRESSOR COOLING
AND LUBRICATION
SYSTEM, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-3 through Figure 2-11. The cooling
and lubrication system (air-cooled version) consists
of a fan, radiator-type cooler/aftercooler assembly,
full-flow main line filter, thermal valve and
interconnecting piping.
NOTE
Standard thermal valve temperature is
175ºF/79ºC (operating temperature of 180ºF/
82ºC). Thermal valve temperature is 190ºF/
88ºC (operating temperature of 195ºF/ 91ºC)
for HH, XH and 24KT machines.
For the water-cooled models, a shell and tube fluid
cooler, and aftercooler are substituted for the
radiator- type cooler on air-cooled compressors. The
pressure in the separator/sump tank causes fluid
flow by forcing the fluid from the high pressure area
of the sump to an area of lower pressure in the
compressor unit.
Fluid flows from the bottom of the separator/sump
tank to the thermal valve. The thermal valve is fully
open to the compressor unit when the fluid
temperature is below 185ºF (85ºC). The fluid passes
through the thermal valve, the main filter and directly
to the compressor unit where it lubricates, cools and
seals the rotors and the compression chamber.
As the discharge temperature rises above 185ºF
(85ºC), due to the heat of compression, the thermal
valve begins to close and a portion of the fluid then
flows through the cooler. From the cooler, the fluid
flows to the main filter and on to the compressor unit.
The filter has a replacement element and an integral
pressure bypass valve. When the element pressure
exceeds 20 psid (1.4 bar), the filter begins to bypass.
The Supervisor monitors the filter pressure drop and
displays a maintenance requirement message.
A fluid stop valve is also present in the lubrication
circuit. The fluid stop valve prevents fluid from filling
the compressor unit when the compressor is shut
14
SECTION 2
down. When the compressor is operating, the fluid
stop valve is held open by air pressure from the
compressor unit allowing a free flow of fluid from the
separator/sump tank back to the compressor unit. On
shutdown, the compressor unit pressure is reduced,
causing the fluid stop valve to close and isolate the
compressor unit from the cooling system.
Water-cooled models have a water pressure switch
to prevent operation with inadequate water pressure.
2.4 COMPRESSOR DISCHARGE
SYSTEM, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-3, Figure 2-5 and Figure 2-6. The
compressor unit discharges the compressed air/fluid
mixture into the combination separator/sump tank.
The separator/sump tank has three functions:
• It acts as a primary fluid separator.
• Serves as the compressor fluid sump.
• Houses the final fluid separator elements.
The compressed air/fluid mixture enters the
separator/sump tank and is directed through a
centrifugal baffle. Through centrifugal action and a
velocity reduction large droplets of fluid form and fall
to the bottom of the separator/sump tank. The
fractional percentage of fluid remaining in the
compressed air collects on the surface of the dual
separator elements as the compressed air flows
through them. Two return lines (or scavenge tubes)
lead from the bottom of each separator element to
the low pressure region of the compressor unit. Fluid
collecting on the bottom of each separator is returned
to the compressor by a pressure difference between
the separator/sump tank and the compressor inlet.
Sight glasses are located in the return lines to
observe this fluid flow. There are also orifices
(protected by strainers) within the sight glasses to
assure proper flow. When the total pressure drop
across the elements exceeds 10 psid (0.7 bar), the
Supervisor displays a maintenance requirement
message.
The separator/sump tank is a pressure vessel
designed and built to codes administered by
appropriate governing bodies. A combination
minimum pressure/check valve, located downstream
from the separator, assures a minimum separator/
sump tank pressure of 50 psig (3.5 bar) during all
conditions. This pressure is necessary for proper air/
fluid separation and proper fluid circulation while
supplying air to the system. This valve also acts as a
check valve preventing compressed air in the service
line from bleeding back into the separator/sump tank
on shutdown and during operation on the
compressor in an unloaded condition.
SECTION 2 TS32 USER MANUAL

Figure 2-3: Compressor Piping and Instrument Diagram (Typical)

15
TS32 USER MANUAL SECTION 2

Figure 2-4: Compressor Cooling and Lubrication System—Air-cooled

16
SECTION 2 TS32 USER MANUAL

Figure 2-5: Compressor Cooling and Lubrication System—Water-cooled

17
TS32 USER MANUAL SECTION 2

Figure 2-6: Compressor Discharge System—Air-cooled 200-350HP

18
SECTION 2 TS32 USER MANUAL

Figure 2-7: Compressor Discharge System—Water-cooled 200-350HP

19
TS32 USER MANUAL SECTION 2

Figure 2-8: Control System—START (Typical)

20
SECTION 2 TS32 USER MANUAL

Figure 2-9: Control System—MODULATION (Typical)

21
TS32 USER MANUAL SECTION 2

Figure 2-10: Control System—UNLOAD (Typical)

22
SECTION 2 TS32 USER MANUAL

Figure 2-11: Control System—FULL LOAD (Typical)

23
NOTES
A pressure relief valve (located on the wet side of the
separator) is set to open if the sump pressure
exceeds the rated pressure of the tank. For added
safety the Supervisor is programmed to shutdown
the package when:
a. A pressure level, above unload setting but
below relief valve setting, is reached.
b. A temperature level exceeding 235ºF
(113ºC) is reached.
See Supervisor functional description for further
details on shutdown pressure levels.
The high pressure shutdown protection will shut
down the compressor at 20 psig (1.4 bar) above
rated pressure. This prevents the pressure relief
valve from opening under routine conditions, thereby
preventing fluid loss through the pressure relief
valve. Temperature is monitored via the controller
and will shut down the compressor if the discharge
temperature reaches 235ºF (113ºC).
WARNING
DO NOT remove caps, plugs, and/or other
components when compressor is running
or pressurized.
Stop compressor and relieve all internal
pressure before doing so.
Fluid is added to the sump via a capped fluid filler
opening, placed low on the tank to prevent overfilling
of the sump. Two sight glasses enable the operator
to visually monitor the sump fluid level.
2.5 CONTROL SYSTEM,
FUNCTIONAL DESCRIPTION
Refer to Figure 2-8, Figure 2-9, Figure 2-10 and
Figure 2-11. The Section 2 DESCRIPTION 8
purpose of the compressor control system is to
regulate the amount of air being compressed to
match the amount of compressed air being used.
The capacity control system consists of a spiral valve
and an inlet butterfly valve. The functional description
of the control system is described below in 4 distinct
phases of compressor operation. The following
applies to TS32 Series compressors ranging from
400 through 600hp (298-447kw). For explanatory
purposes, this description applies to any compressor
with an operating range of 100 to 110 psig (6.9 to 7.6
24
bar). A compressor with any other pressure range
would operate in the same manner except for the
stated pressures.
NOTE
Always refer to the machine nameplate for
designed operating pressure.
START MODE—0 TO 50 PSIG (0 TO 3.4
BAR)
When the compressor (ON) pad is
depressed, the sump pressure will quickly rise from 0
to 50 psig (0 to 3.4 bar). During this period, both of
the pressure regulators and the solenoid valve are
closed and the Sullicon Control and spiral valve are
inoperative. The spring on the control holds the
butterfly valve fully open while the spiral valve is fully
closed (maximum) position and the compressor
pumps at full rated capacity. The rising compressor
air pressure is isolated from the service line in this
phase by the minimum pressure valve set at
approximately 50 psig (3.4 bar). An optional closed
inlet system is provided which uses air pressure to
close the butterfly and opens the spiral valve to
reduce motor torque for starting.
FULL LOAD MODE—50 TO 100 PSIG (3.4
TO 6.9 BAR)
50 TO 100 PSIG (3.4 TO 6.9 BAR) When the
compressed air pressure in the sump rises above 50
psig (3.4 bar), the minimum pressure valve opens,
allowing compressed air to flow into the service line.
From this point on, the line air pressure is continually
monitored by the Supervisor. The pressure
regulators and the solenoid valve remain closed
during this phase, keeping the Sullicon Control and
spiral valve inactive. Both the spiral valve as well as
the inlet butterfly valve remain in the full load position
as long as the compressor is running at 100 psig (6.9
bar) or below.
MODULATING MODE—100 TO 110 PSIG
(6.9 TO 7.6 BAR)
100 TO 110 PSIG (6.9 TO 7.6 BAR) As air demand
drops below the rated capacity of the compressor,
the line pressure will rise above 100 psig (6.9 bar).
As a result, the differential pressure regulator for the
spiral valve gradually opens, applying air pressure to
the spiral valve actuator. Air pressure at the actuator
SECTION 2
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 opening the bypass ports
gradually. Excess air is then being returned back
internally to suction end of compressor unit. Now the
compressor is fully compressing only that amount of
air which is being used. As air demand keeps
dropping further, the spiral valve keeps opening
more and more until all the bypass ports are fully
open. At this point, the spiral valve has moved into
the minimum position. The spiral valve provides a
modulation range from 100 to approximately 50%.
During this period, the pressure rises approximately
from 100 to 108 psig (6.9 to 7.4 bar). As the air
pressure exceeds 108 psig (7.4 bar), the differential
pressure regulator controlling the Sullicon Control
opens. This allows the air pressure to expand the
diaphragm chamber of the Sullicon Control, which
starts partially closing the inlet butterfly valve. The
inlet butterfly valve provides modulation range from
50 to 40%. During this period, the pressure rises
approximately from 108 to 110 psig (7.4 to 7.6 bar).
During this range, the spiral valve remains in the full
open position.
UNLOAD MODE— IN EXCESS OF 110
PSIG (7.6 BAR)
When a relatively small amount or no air is being
used, the service line pressure continues to rise.
When it exceeds 110 psig (7.6 bar), Supervisor
deenergizes the solenoid valve allowing line
pressure to be supplied directly to the Sullicon
diaphragm keeping the inlet butterfly closed; the
spiral valve is in the fully open (minimum) position.
Simultaneously, the solenoid valve sends a
pneumatic signal to the blowdown valve. The
blowdown valve opens the sump to the atmosphere.
This reduces the sump pressure to approximately 30
psig (2.1 bar) which results in low horsepower
consumption. The check valve in the air service line
prevents line pressure from returning to sump while
the compressor is running in the unloaded mode.
Both the spiral valve and the butterfly valve remain in
the unload position. When the line pressure drops
back to 100 psig (6.9 bar) due to an increase in the
air demand, Supervisor energizes the solenoid valve
allowing the air pressure behind the Sullicon Control
to be vented through the solenoid valve exhaust port.
The blowdown valve closes, and the inlet butterfly
valve opens. Also the air pressure at the spiral valve
actuator diaphragm is reduced through a vent hole at
the spiral valve differential pressure regulator, and a
TS32 USER MANUAL
spring in the actuator causes the spiral valve to
return to the full load (maximum) position.
AUTOMATIC OPERATION
For applications with varied periods of time when
there are no air requirements, Supervisor’s Auto
mode allows the compressor to shut down (time
delayed) when no compressed air requirement is
present and restart as compressed air is needed.
LOAD/ NO LOAD OPERATION
If applications call for load/no load operation,
modulation can be disabled in the Supervisor
ControllerTM in the “Control Parameters” menu. If
modulation is disabled, the unload pressure must be
reset to the rated load pressure of the machine. For
example, an L model rated for 100 psig full load
operation and 110 psig unload must have the unload
pressure reset to 100 psig. This ensures that the
motor will not run in an overload condition.
2.6 AIR INLET SYSTEM,
FUNCTIONAL DESCRIPTION
Refer to Figure 2-12. The compressor inlet system
consists of one or two dry-type air filters, a vacuum
switch and an air inlet valve.
The vacuum switch, located in the compressor
Supervisor control system, indicates the condition of
the air filter. When the message “AIR FILTER MAINT
RQD” is displayed,maintenance is required.
The butterfly-type air inlet valve directly controls the
amount of air intake to the compressor in response to
the operation of the Sullicon Control (Section 2.5).
CAUTION
“The Plastic Pipe Institute recommends against
the use of thermoplastic pipe to transport com-
pressed air or other compressed gases in
exposed above ground locations, e.g. in
exposed plant piping.” (I) PVC piping should
not be used with Sullube. It may affect the
bond at cemented joints. Certain other plastic
materials may also be affected.
(I) Plastic Pipe Institute, Recommendation B,
Adopted January 19, 1972.
25
TS32 USER MANUAL SECTION 2

Figure 2-12: Compressor Air Inlet System

26
 TS32 USER MANUAL

Section 3

SPECIFICATIONS
3.1 TABLE OF SPECIFICATIONS—TS32
DIMENSIONS (I)
Length Width Height
Weight
in cm in cm in cm
Model Hz
TS32 AC 50/60 154 392 78 198 86 218 (II)
TS32 WC 50/60 154 392 78 198 86 218 (II)
(I) Dimensions for enclosed model

(II) Consult factory.

NOTE
Noise levels vary with machine and enclo-
sure. For machine dBA output, consult
factory with machine serial number.

3.2 COMPRESSOR SPECIFICATIONS

COMPRESSOR: STANDARD MODELS:
Type: Positive displacement, fluid-lubricated, twin rotary screws
Configuration: Two-stage tandem, geared integral drive
Bearing Type: Anti-friction
Cooling: See Section 2.3
Lubricant: Pressurized fluid - see sections Section 3.4, Section 3.5 and Section 3.6
Sump Capacity: 24 gallons/91 liters for 200/250HP, 35 gallons/ 132.5 liters for 300/350HP
System Fluid Capacity: Varies by cooling type - see Section 4.7
Duty Pressure: 100-110 psig (6.9-7.6 bar), other pressures available
Control Type: Spiral valve, Electro - pneumatic
24KT lubricant, Cold Weather Package, EES Remote Heat Recovery,
Options: Enclosure, Phase Monitor Relay, Remote Air Cooler, Water Solenoid
Valve, Water Regulator Valve

27
TS32 USER MANUAL SECTION 3

3.3 MOTOR SPECIFICATIONS

MOTOR: (60 Hz Compressors) STANDARD MODELS:
Size: 200-350HP/150-261Kw- Consult factory for specific voltages
Open Dripproof enclosure, 3-phase, 50 or 60 hz, 104°F / 40°C Maximum
Type:
Ambient Temperature
Various voltages, TEFC enclosure, CE approved (50 hz), Premium
Options:
efficiency
Speed: 1780 RPM (60 hz), 1475 RPM (50 hz)
Starter: Full-Voltage, Wye-Delta or Solid State

3.4 LUBRICATION GUIDE—

STANDARD COMPRESSORS

WARNING
Before changing or recharging system fluid
always relieve all pressure from the sump tank
and all compressor lines.
NOTE
Sullair standard compressors are filled with
Sullube fluid as factory fill.
Mixing of other lubricants within the com-
pressor unit will void all warranties.
Refer to Figure 3-1. Sullube fluid should be changed
every 8000 hours or once a year, whichever comes
first. The fluid should be changed more frequently
under severe operating conditions, such as high
ambient temperatures coupled with high humidity, or
when high particulate level, corrosive gases or strong
oxidizing gases are present in the air.
CAUTION
“The Plastic Pipe Institute recommends against
the use of thermoplastic pipe to transport com-
pressed air or other compressed gases in
exposed above ground locations, e.g. in
exposed plant piping.” (I) PVC piping should
not be used with Sullube. It may affect the
bond at cemented joints. Certain other plastic
materials may also be affected.
(I) Plastic Pipe Institute, Recommendation B,
Adopted January 19, 1972.
Maintenance of all other components is still
recommended as indicated in the Operator's Manual.
Sullair encourages the user to participate in a fluid
analysis program with the fluid suppliers. This could
result in a fluid change interval differing from that
stated in the manual. Contact your Sullair dealer for
details.
A fluid sample at every 1000 hours is recommended.
For a free Sullube analysis, send fluid to:
Dow Chemical
Lubricant Technology Center
Building B-1605
Freeport, TX 77541
To facilitate this, a sample bottle is included with the
compressor.

28
SECTION 3
Figure 3-1: Fluid Fill Location
3.5 LUBRICATION GUIDE—24KT
COMPRESSORS
WARNING
Before changing or recharging system fluid
always relieve all pressure from the sump
tank and all compressor lines.
NOTE
DO NOT mix different types of fluids.
MIXING OF OTHER LUBRICANTS WITHIN
THE COMPRESSOR UNIT WILL VOID ALL
WARRANTIES.
Flush system when switching lubricant
brands.
Refer to Figure 3-1. Sullair 24KT compressors are
filled with a lubricant which rarely needs to be
changed. In the event a change of fluid is required,
use only Sullair 24KT fluid.
Sullair recommends that a 24KT sample be taken at
the first filter change and sent to the factory for
analysis. This is a free service. A sample kit with
instructions and self-addressed container is to be
supplied by your Sullair Representative at start-up.
The user will receive an analysis report with
recommendations.
TS32 USER MANUAL
3.6 LUBRICATION GUIDE—
OPTIONAL FLUID
WARNING
Before changing or recharging system fluid
always relieve all pressure from the sump
tank and all compressor lines.
NOTE
DO NOT mix different types of fluids.
MIXING OF OTHER LUBRICANTS WITHIN
THE COMPRESSOR UNIT WILL VOID ALL
WARRANTIES.
Flush system when switching lubricant
brands.
Refer to Figure 3-1. Sullair compressors may use
SRF 1/4000 fluid as an optional factory fill.
SRF 1/4000 fluid should be changed every 4000
hours or once a year, whichever comes first. The
fluid should be changed more frequently under
severe operating conditions, such as high ambient
temperatures coupled with high humidity, or when
high particulate level, corrosive gases or strong
oxidizing gases are present in the air.
For extended life synthetic lubricants contact the
nearest Sullair representative.
Maintenance of all other components is still
recommended as indicated in the Operator's Manual.
29
 Figure 3-2: Identification—Air-Cooled
30

TS32 USER MANUAL

SECTION 3
02250126-376 R02
 Figure 3-0: Identification—Air-Cooled

SECTION 3
INSTALLATION NOTE:

A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE

WEIGHT ( 12,670# ) OF THE MACHINE AND RIGID ENOUGH TO MAIN-
TAIN THE COMPRESSOR FRAME LEVEL AND THE COMPRESSOR IN
ALIGNMENT IS REQUIRED. THE COMPRESSOR FRAME MUST BE LEV-
ELED AND SECURED WITH FOUNDATION BOLTS, AND FULL UNIFORM
CONTACT MUST BE MAINTAINED BETWEEN THE FRAME AND FOUN-
DATION. IT IS RECOMMENFED THAT THE FRAME BE GROUTED TO
THE FOUNDATION. THE COMPRESSOR UNIT AND DRIVER MUST BE
ALIGNED AFTER THE FRAME INSTALLATION IS COMPLETED AS SPEC-
IFIED IN THE OPERATORS MANUAL. NO PIPING LOADS SHALL BE
TRANSMITTED TO THE MACHINE BY EXTERNAL CONNECTIONS.

NOTES:

1. ALLOW 4 FT. MIN. CLEARANCE ALL AROUND FOR ACCESS,AS

WELL AS FREE CIRCULATION OF AIR.

2. ALL DIMENSIONS ARE +/-.5 INCH.

TS32 USER MANUAL

31
 Figure 3-2: Identification—Water-Cooled
32

TS32 USER MANUAL

SECTION 3
02250126-378 R03
 Figure 3-2: Identification—Water-Cooled

SECTION 3
INSTALLATION NOTE:

A FOUNDATION OR MOUNTING CAPABLE OF SUPPORTING THE

WEIGHT ( 12,160# ) OF THE MACHINE AND RIGID ENOUGH TO MAIN-
TAIN THE COMPRESSOR FRAME LEVEL AND THE COMPRESSOR IN
ALIGNMENT IS REQUIRED. THE COMPRESSOR FRAME MUST BE LEV-
ELED AND SECURED WITH FOUNDATION BOLTS, AND FULL UNIFORM
CONTACT MUST BE MAINTAINED BETWEEN THE FRAME AND FOUN-
DATION. IT IS RECOMMENFED THAT THE FRAME BE GROUTED TO
THE FOUNDATION. THE COMPRESSOR UNIT AND DRIVER MUST BE
ALIGNED AFTER THE FRAME INSTALLATION IS COMPLETED AS SPEC-
IFIED IN THE OPERATORS MANUAL. NO PIPING LOADS SHALL BE
TRANSMITTED TO THE MACHINE BY EXTERNAL CONNECTIONS.

NOTES:

1. ALLOW 4 FT. MIN. CLEARANCE ALL AROUND FOR ACCESS,AS

WELL AS FREE CIRCULATION OF AIR.

2. ALL DIMENSIONS ARE +/-.5 INCH.

TS32 USER MANUAL

33
 Figure 3-3: Piping and Instrumentation Diagram—Air-Cooled
34

TS32 USER MANUAL

SECTION 3
02250179-499 R01
 Figure 3-3: Piping and Instrumentation Diagram—Air-Cooled

SECTION 3
Q Q
KEY PART NO. PART NO. KEY PART NO. PART NO.
T DESCRIPTION T DESCRIPTION
NO. 200/250HP 300/350HP NO. 200/250HP 300/350HP
Y Y
1 250006-718 250006-718 1 FLTR,INL OPTIMALAIR 29 02250125-221 02250125-221 1 VLV,BALL 3/4"SAE X 3/4"NPT
2 02250126-220 02250126-220 1 VLV,10" INL BTFLY TS32C 30 250029-330 250029-330 1 VLV,RLF 2" X 2 1/2"
3 011682-003 011682-003 1 CONTROL, SULLICON LESS BRKT 31 242221 242221 1 RESERVOIR, AIR 415 CU.IN.
4 408893 408893 2 VALVE, SHUTTLE 1/4" (DBL CHK) 32 02250127-119 02250120-955 1 SA,THRM VLV
5 - - 1 VLV, SPIRAL 33 02250121-658 02250121-638 1 FLTR,1 7/8-12 SAE CORELESS
6 02250148-608 02250148-608 1 VLV,PRESS REG 1/4" NPT 34 02250182-545 02250182-545 1 DRN,ZERO LOSS 115V 1/2"NPT
7 02250125-657 02250125-657 1 VLV,SOL 3WN0 1/4 235# N4 35 02250122-858 02250122-218 1 CLR,OIL
8 02250112-032 02250112-032 2 FLTR,CONTROL AIR 1/4"NPT 36 02250121-098 02250122-219 1 AFTERCOOLER
9 02250148-609 02250148-609 1 VLV,PRESS REG 1/4" NPT 70-250 37 02250166-744 02250166-744 1 SEP,WTR SCWS-1700N 2 1/2”
10 02250125-774 02250125-774 1 ORF,PLUG BRASS 1/8"NPT X1/32 38 02250113-668 02250122-004 1 VLV,OIL STP CI 1 7/8-12 PORTS
11 02250101-191 02250101-191 1 ORF,.031 BRASS 1/4MNPT 39 047117 047117 1 VALVE, BALL 1/2 NPT
12 044912 409783 1 VALVE, 2-WAY PNEUMATIC 40 02250078-249 02250078-249 1 SW,VAC 22"WC N4 6FT CABLE
13 02250132-934 02250132-934 1 ORF,CAP 031 X 1/4"NPT 41 02250182-548 02250182-548 1 VLV,BALL/STNR COMBO-1/2"NPT
14 02250125-679 02250125-679 2 VLV,SOL 2WNC 1/4 150# N4 42 - - 1 UNIT, COMPRESSOR
15 02250155-174 02250155-174 4 XDCR,PRESS 0-250# RATIOMETRIC 43 02250125-657 02250125-657 1 VLV,SOL 3WN0 1/4 235# N4
16 02250125-776 02250125-776 1 ORF,PLUG BRASS 1/8"NPT X 3/32 44 02250110-557 02250110-557 3 VLV,CHK 1/4"NPTF VITON SEAT
17 02250126-129 02250126-129 2 GL,SIGHT/ORF BLK-SAE 45 02250184-677 02250184-677 1 HTR,JZL DRAIN 115V 50W
18 02250117-782 02250117-782 2 FLTR,ASSEMBLY GENISIS FILTR 46 047226 047226 1 HEATER, DRUM-115V 1000W
19 250033-821 250033-821 1 VALVE, MIN PRESS CHECK 3" 47 046556 046556 2 REGULATOR,PRESS-1/4NPT
20 041111 041111 1 VALVE, DRAIN-SELF CLOSE 1/8NPT 48 042034 042034 1 TRAP, AUTOMATIC 3/4" 150#
21 250034-133 250034-129 1 ELEMENT, SEP/SEC 49 02250170-782 02250170-782 1 VLV,DR COMBO 115 VAC
22 250034-121 250034-123 1 ELEMENT, PRIMARY 25-200 Continued on page 37
23 02250117-009 02250117-009 2 GA,PRESS LIQ FILL PSI/BAR 2.5" PLEASE NOTE: WHEN ORDERING PARTS,

TS32 USER MANUAL

24 02250179-431 02250179-431 4 P,THERMISTOR 3000 OHM NTC INDICATE SERIAL NUMBER OF COMPRESSOR
25 02250092-138 02250092-138 1 VLV,PRESS RLF 1/2"NPT-150 PSIG
26 02250119-109 02250119-109 1 VLV,RLF 1-1/2" 150# 1950CFM
27 02250120-350 02250120-612 1 TNK,OIL SUMP
28 02250097-611 02250097-611 2 PLUG,SIGHT GLASS 1 7/8" SAE

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR
35
 Figure 3-4: Piping and Instrumentation Diagram—Air-Cooled (Continued)
36

TS32 USER MANUAL

SECTION 3
02250179-499 R01
 Figure 3-4: Piping and Instrumentation Diagram—Air-Cooled

SECTION 3
COMP DESCRIPTION NOTES:

P1 WET SUMP PRESSURE 1. PART NUMBERS ARE FOR REFERENCE ONLY. REFER TO BILL OF
MATERIAL AND OR FACE OF ORDER FOR ACTUAL PARTS.
P2 LINE PRESSURE
2. SECTION BETWEEN LETTERED POINTS ARE TO BE REPLACED
P3 INJECTION FLUID PRESSURE
WITH CORRESPONDING OPTION PICTURED BELOW, AS
P4 HIGH PRESSURE SIDE OF FLUID FILTER REQUIRED BY FACE OF ORDER.
PSW1 INLET FILTER VACUUM SWITCH 3. CONTROL LINES ARE 1/4" TUBING EXCEPT AS NOTED.
SOL1 LOAD/UNLOAD SOLENOID VALVE 4. OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND
SOL2 SPIRAL CONTROL SOLENOID VALVE (OPTIONAL) MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS
STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE
SOL3 START CONTROL SOLENOID VALVE (OPTIONAL) REQUIREMENTS.
MEC/SEQUENCING/FULL LOAD SOLENOID VALVE
SOL4 (OPTIONAL)
SOL5 COMBO DRAIN/JZL DRAIN SOLENOID VALVE
T1 WET DISCHARGE TEMPERATURE
T2 DRY DISCHARGE TEMPERATURE
T3 INJECTION FLUID TEMPERATURE
T4 INTERSTAGE AIR/FLUID TEMPERATURE
HTR1 SUMP HEATER
HTR3 TRAP HEATER

TS32 USER MANUAL

37
 Figure 3-5: Piping and Instrumentation Diagram—Remote Air-Cooled
38

TS32 USER MANUAL

SECTION 3
02250179-498 R01
 Figure 3-5: Piping and Instrumentation Diagram—Remote Air-Cooled

SECTION 3
Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
1 250006-718 1 FLTR,INL OPTIMALAIR 32 02250120-955 1 VLV,THRM 180 DEG 2.5IN SAE
2 02250126-220 1 VLV,10" INL BTFLY TS32C 33 02250121-638 1 FLTR,2.5-12 SAE CORELESS
3 011682-003 1 CONTROL, SULLICON LESS BRKT 34 02250132-934 1 ORF,CAP 031 X 1/4"NPT
4 408893 2 VALVE, SHUTTLE 1/4" (DBL CHK) 35 02250122-218 1 CLR,OIL 8 X 60 W/SAE PORTS
5 - 1 VLV, SPIRAL 36 02250122-219 1 CLR,AIR AFT 300-350 HP
6 02250148-608 1 VLV,PRESS REG 1/4" NPT 37 02250166-744 1 SEP,WTR SCWS-1700N 3??L/AD
7 02250125-657 1 VLV,SOL 3WN0 1/4 235# N4 38 02250122-004 1 VLV, OIL STOP 2-1/2" SAE
8 02250112-032 2 FLTR,CONTROL AIR 1/4"NPT 39 02250182-545 1 DRN,ZERO LOSS 115V 1/2"NPT
9 02250148-609 1 VLV,PRESS REG 1/4" NPT 70-250 40 02250078-249 1 SW,VAC 22"WC N4 6FT CABLE
10 02250125-774 1 ORF,PLUG BRASS 1/8"NPT X1/32 41 02250170-782 1 VLV,DR COMBO 115 VAC
11 02250101-191 1 ORF,.031 BRASS 1/4MNPT 42 - 1 UNIT, COMPRESSOR
12 409783 1 VALVE, BLWDWN 1"NC 2WAY 43 02250125-657 1 VLV,SOL 3WN0 1/4 235# N4
13 02250125-617 1 VALVE, BLWDWN 1"NC 2WAY 44 02250110-557 4 VLV,CHK 1/4"NPTF VITON SEAT
14 02250125-679 2 VLV,SOL 2WNC 1/4 150# N4 45 02250184-677 1 HTR,JZL DRAIN 115V 50W
15 02250155-174 4 XDCR,PRESS 0-250# RATIOMETRIC 46 047226 1 HEATER, DRUM-115V 1000W
16 02250125-776 1 ORF,PLUG BRASS 1/8"NPT X 3/32 47 047117 1 VALVE, BALL 1/2 NPT
17 02250126-129 2 GL,SIGHT/ORF BLK-SAE 48 046556 2 REGULATOR,PRESS-1/4NPT
18 02250117-782 2 FLTR,ASSEMBLY GENISIS FILTR 49 042034 1 TRAP, AUTOMATIC 3/4" 150#
19 250033-821 1 VALVE, MIN PRESS CHECK 3" 50 02250125-632 1 STNR,Y-LINE OIL 2"NPT 100MESH
20 041111 1 VALVE, DRAIN-SELF CLOSE 1/8NPT 51 043239 1 SW,TEMP N.O. 115F 1/2"NPT
21 250034-129 1 ELEMENT, SEP/SEC 52 043877 1 VALVE, CONTROL 3 WAY
22 250034-123 1 ELEMENT, PRIMARY 25-200 53 042694 2 VALVE, CHECK 1/2
23 02250117-009 3 GA,PRESS LIQ FILL PSI/BAR 2.5" 54 250018-782 1 PUMP, OIL SYS 80GPM
24 02250179-431 4 P,THERMISTOR 3000 OHM NTC 55 VARIOUS 1 MTR, 5HP
25 02250092-138 1 VLV,PRESS RLF 1/2"NPT-150 PSIG 56 02250182-548 1 VLV,BALL/STNR COMBO-1/2"NPT

TS32 USER MANUAL

26 02250119-109 1 VLV,RLF 1-1/2" 150# 1950CFM Continued on page 41
27 02250120-612 1 TNK,OIL SUMP
PLEASE NOTE: WHEN ORDERING PARTS,
28 02250097-611 2 PLUG,SIGHT GLASS 1 7/8" SAE INDICATE SERIAL NUMBER OF COMPRESSOR
29 02250125-221 1 VLV,BALL 3/4"SAE X 3/4"NPT
30 250029-330 1 VLV,RLF 2" X 2 1/2"
31 242221 1 RESERVOIR, AIR 415 CU.IN.

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR
39
 Figure 3-5: Piping and Instrumentation Diagram—Remote Air-Cooled (Continued)
40

TS32 USER MANUAL

SECTION 3
02250179-498 R01
 Figure 3-5: Piping and Instrumentation Diagram—Remote Air-Cooled

SECTION 3
COMP DESCRIPTION NOTES:

P1 WET SUMP PRESSURE 1. PART NUMBERS ARE FOR REFERENCE ONLY. REFER TO BILL OF
MATERIAL AND OR FACE OF ORDER FOR ACTUAL PARTS.
P2 LINE PRESSURE
2. SECTION BETWEEN LETTERED POINTS ARE TO BE REPLACED
P3 INJECTION FLUID PRESSURE
WITH CORRESPONDING OPTION PICTURED BELOW, AS
P4 HIGH PRESSURE SIDE OF FLUID FILTER REQUIRED BY FACE OF ORDER.
PSW1 INLET FILTER VACUUM SWITCH 3. OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND
SOL1 LOAD/UNLOAD SOLENOID VALVE MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS
STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE
SOL2 SPIRAL CONTROL SOLENOID VALVE (OPTIONAL) REQUIREMENTS.
SOL3 START CONTROL SOLENOID VALVE (OPTIONAL) 4. ITEM 39 OR 41 TO BE INSTALLED BY SULLAIR BUT ELECTRI-
MEC/SEQUENCING/FULL LOAD SOLENOID VALVE CALLY INSTALLED BY THE CUSTOMER IN THE FIELD.
SOL4
(OPTIONAL)
5. THE SUPPLY AND RETURN PIPING FOR THE FLUID COOLER
SOL5 COMBO DRAIN/JZL DRAIN SOLENOID VALVE MUST BE ADEQUATELY SIZED TO PREVENT EXCESSIVE PRES-
SURE DROP. THE TOTAL PRESSURE DROP IN THE SUPPLY AND
AUX. FLUID PUMP RELIEF SOLENOID VALVE RETURN PIPING AND ASSOC. FITTINGS AND VALVES SHALL NOT
SOL8
(OPTIONAL) EXCEED 10 PSIG (0.7 BAR). IF THE PRESSURE DROP IS EXCES-
T1 WET DISCHARGE TEMPERATURE SIVE, A PUMP MAY BE INSTALLED.

T2 DRY DISCHARGE TEMPERATURE 6. MINIMUM OPERATING TEMPERATURE OF 32°F FOR LOWER

TEMPS. OIL LINES NEED TO BE HEATED AND INSULATED.
T3 INJECTION FLUID TEMPERATURE
T4 INTERSTAGE AIR/FLUID TEMPERATURE
HTR1 SUMP HEATER
HTR3 TRAP HEATER

TS32 USER MANUAL

41
 Figure 3-6: Piping and Instrumentation Diagram—Water-Cooled
42

TS32 USER MANUAL

SECTION 3
02250179-496 R01
 Figure 3-6: Piping and Instrumentation Diagram—Water-Cooled

SECTION 3
N N
Q Q
KEY O KEY O
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. T NO. T
Y Y
E E
400 HP 500/600 HP PARTS LIST (BILL OF MATERIAL) 400 HP 500/600 HP PARTS LIST (BILL OF MATERIAL)
1 250006-718 250006-718 1 FLTR,INL OPTIMALAIR 32 02250127-343 02250127-343 1 SA,THRM VLV 190 DEG 5
2 02250126-220 02250126-220 1 VLV,10" INL BTFLY TS32C 32 02250127-342 02250127-342 1 SA,THRM VLV 175 DEG 5
3 011682-003 011682-003 1 CONTROL, SULLICON LESS BRKT 33 02250121-658 02250121-658 1 RESERVOIR, AIR 415 CU.IN.
4 408893 408893 2 VALVE, SHUTTLE 1/4" (DBL CHK) 34 02250125-653 02250125-653 1 VLV,SOL 2WNC 1-1/2 150# N4
5 - - 1 VLV, SPIRAL 35 02250126-002 02250126-002 1 CLR,OIL 8 X 60 W/SAE PORTS
6 02250148-608 02250148-608 1 VLV,PRESS REG 1/4" NPT 36 02250053-383 02250053-383 1 AFTERCOOLER >= 150# 5
7 02250125-657 02250125-657 1 VLV,SOL 3WN0 1/4 235# N4 36 042950 042950 1 AFTERCOOLER <= 150# 5
8 02250112-032 02250112-032 2 FLTR,CONTROL AIR 1/4"NPT 37 02250166-743 02250166-743 1 SEP,WTR SCWS-1700N 2 1/2”
9 02250148-609 02250148-609 1 VLV,PRESS REG 1/4" NPT 70-250 38 02250113-668 02250113-668 1 VLV,OIL STP CI 1 7/8-12 PORTS
10 02250125-774 02250125-774 1 ORF,PLUG BRASS 1/8"NPT X1/32 39 02250170-782 02250170-782 1 VLV,DR COMBO 115 VAC
11 02250101-191 02250101-191 1 ORF,.031 BRASS 1/4MNPT 40 02250078-249 02250078-249 1 SW,VAC 22"WC N4 6FT CABLE
12 409783 409783 1 VALVE, 2-WAY PNEUMATIC 41 02250182-545 02250182-545 1 DRN,ZERO LOSS 115V 1/2"NPT
13 02250132-934 02250132-934 1 ORF,CAP 031 X 1/4"NPT 42 - - 1 UNIT, COMPRESSOR
14 02250125-679 02250125-679 2 VLV,SOL 2WNC 1/4 150# N4 43 02250125-657 02250125-657 1 VLV,SOL 3WN0 1/4 235# N4
15 02250155-174 02250155-174 4 XDCR,PRESS 0-250# RATIOMETRIC 44 02250110-557 02250110-557 3 VLV,CHK 1/4"NPTF VITON SEAT
16 02250125-776 02250125-776 1 ORF,PLUG BRASS 1/8"NPT X 3/32 45 02250184-677 02250184-677 1 HTR,JZL DRAIN 115V 50W
17 02250126-129 02250126-129 2 GL,SIGHT/ORF BLK-SAE 46 047226 047226 1 HEATER, DRUM-115V 1000W
18 02250117-782 02250117-782 2 FLTR,ASSEMBLY GENISIS FILTR 47 02250182-548 02250182-548 1 VLV,BALL/STNR COMBO-1/2"NPT
19 250033-821 250033-821 1 VALVE, MIN PRESS CHECK 3" 48 046556 046556 2 REGULATOR,PRESS-1/4NPT
20 041111 041111 1 VALVE, DRAIN-SELF CLOSE 1/8NPT 49 042034 042034 1 TRAP, AUTOMATIC 3/4" 150#
21 250034-129 250034-129 1 ELEMENT, SEP/SEC 50 248743 248743 1 VALVE, WATER REG 1 1/4"
22 250034-123 250034-123 1 ELEMENT, PRIMARY 25-200 51 250017-992 250017-992 1 SWITCH, PRESS NO 10 PSI
23 02250117-009 02250117-009 2 GA,PRESS LIQ FILL PSI/BAR 2.5" 52 047117 047117 1 VALVE, BALL 1/2 NPT

TS32 USER MANUAL

24 02250179-431 02250179-431 4 P,THERMISTOR 3000 OHM NTC Continued on page 45
25 02250092-138 02250092-138 1 VLV,PRESS RLF 1/2"NPT-150 PSIG
26 02250119-109 02250119-109 1 VLV,RLF 1-1/2" 150# 1950CFM
27 02250120-612 02250120-612 1 TNK,OIL SUMP
28 02250097-611 02250097-611 2 PLUG,SIGHT GLASS 1 7/8" SAE
29 02250125-221 02250125-221 1 VLV,BALL 3/4"SAE X 3/4"NPT
30 250029-330 250029-330 1 VLV,RLF 2" X 2 1/2"
31 242221 242221 1 RESERVOIR, AIR 415 CU.IN.
43
 Figure 3-6: Piping and Instrumentation Diagram—Water-Cooled (Continued)
44

TS32 USER MANUAL

SECTION 3
02250179-496 R01
 Figure 3-6: Piping and Instrumentation Diagram—Water-Cooled

SECTION 3
COMP DESCRIPTION NOTES:
P1 WET SUMP PRESSURE
1. PART NUMBERS ARE FOR REFERENCE ONLY. REFER TO BILL OF
P2 LINE PRESSURE MATERIAL AND OR FACE OF ORDER FOR ACTUAL PARTS.
P3 INJECTION FLUID PRESSURE
2. SECTION BETWEEN LETTERED POINTS ARE TO BE REPLACED
P4 HIGH PRESSURE SIDE OF FLUID FILTER WITH CORRESPONDING OPTION PICTURED BELOW, AS
PSW1 INLET FILTER VACUUM SWITCH REQUIRED BY FACE OF ORDER.
PSW2 WATER PRESSURE SWITCH 3. CONTROL LINES ARE 1/4" TUBING EXCEPT AS NOTED.
SOL1 LOAD/UNLOAD SOLENOID VALVE
4. OPTIONAL HEAT TRACE IS APPLIED ONLY TO CONTROL AND
SOL2 SPIRAL CONTROL SOLENOID VALVE (OPTIONAL) MOISTURE DRAIN LINES AND USED ONLY WITH STAINLESS
SOL3 START CONTROL SOLENOID VALVE (OPTIONAL) STEEL TUBING. REFER TO FACE OF ORDER FOR HEAT TRACE
REQUIREMENTS.
SOL4 MEC/SEQUENCING/FULL LOAD SOLENOID VALVE
(OPTIONAL) 5. PART VARIES BY MODEL.
SOL5 COMBO DRAIN/JZL DRAIN SOLENOID VALVE
SOL6 WATER SHUTOFF SOLENOID VALVE (OPTIONAL)
T1 WET DISCHARGE TEMPERATURE
T2 DRY DISCHARGE TEMPERATURE
T3 INJECTION FLUID TEMPERATURE
T4 INTERSTAGE AIR/FLUID TEMPERATURE
HTR1 SUMP HEATER
HTR3 TRAP HEATER

TS32 USER MANUAL

45
 Figure 3-7: Wiring Diagram—Water-Cooled Wye Delta
46

TS32 USER MANUAL

SECTION 3
02250178-841 R01
 Figure 3-7: Wiring Diagram—Water-Cooled Wye Delta

SECTION 3
COMP DESCRIPTION COMP DESCRIPTION
1M COMPRESSOR MOTOR STARTER K2 INTERNAL Y-DELTA RELAY CONTACT
1MOL COMPRESSOR MOTOR STARTER OVERLOAD CONTACT K3 INTERNAL LOAD CONTROL RELAY CONTACT
2M COMPRESSOR MOTOR STARTER RUN CONTACTOR K4 INTERNAL SEQUENCE RELAY CONTACT
S COMPRESSOR START CONTACTOR K5 INTERNAL ELECTRIC DRAIN RELAY CONTACT
3M FAN MOTOR STARTER K6 INTERNAL COMMON FAULT RELAY CONTACT
3MOL FAN MOTOR STARTER OVERLOAD CONTACT K7 INTERNAL COMMON WARNING RELAY CONTACT
4MOL FAN MOTOR STARTER OVERLOAD CONTACT K8 INTERNAL SPECIAL FUNCTION CONTACT
6M OPTIONAL CONTACTOR FOR PF CAPACITOR PMR OPT'L POWER MONITOR RELAY
1FU TRANSFORMER PRIMARY FUSES HRN OPT'L AUDIBLE ALARM
2FU TRANSFORMER SECONDARY FUSE HTR1 SUMP HEATER
3FU COOLER FAN BRANCH FUSES HTR2 HEAT TRACE
WET SUMP PRESSURE SENSOR - SET PER FACE OF HTR3 TRAP HEATER
P1 ORDER HTR4 CONTROL PANEL HEATER
P2 PACKAGE DISCHARGE PRESSURE SENSOR TH THERMOSTAT FOR HEAT TRACE
P3 OIL FILTER DISCHARGE PRESSURE SENSOR
P4 OIL FILTER UPSTREAM PRESSURE SENSOR NOTES:
T1 UNIT DISCHAGE TEMPERATURE RTD 1. CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCON-
T2 DRY DISCHARGE TEMPERATURE RTD NECT PER LOCAL CODES.
T3 INJECTION OIL TEMPERATURE RTD 2. REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.
T4 INTERSTAGE TEMPERATURE RTD
3. OPTIONAL
DPSW1 OIL FILTER DIFFERENTIAL PRESSURE SWITCH (OPT'L)
PSW1 INLET AIR FILTER SWITCH: 22 IN WC (558.9 MM WC) 4. 2ND FAN MOTOR FOR 400HP AND LARGER.

PSW2 WATER PRESSURE SWITCH:10PSI (0.7 BAR) 5. BELDEN TYPE 9842 COND. 6 2 TWISTED PAIR W/SHIELD OR
SOL1 LOAD CONTROL SOLENOID VALVE EQUIVALENT. TO MATCHING TERMINALS ON NEXT COMPRES-
SOR. REFER TO SUPERVISOR SEQUENCING PROTOCOL MAN-
SOL2 SPIRAL CONTROL SOLENOID VALVE (OPTIONAL)

TS32 USER MANUAL

UAL.
SOL3 START CONTROL SOLENOID VALVE
SOL4 SEQUENCING/FULL LOAD SOLENOID VALVE (OPT)
SOL5 COMBO DRAIN/JZL DRAIN SOLENOID VALVE
SOL6 WATER SHUTOFF SOLENOID VALVE (OPTIONAL)
1XFMR CONTROL VOLTAGE TRANSFORMER
2XFMR SUPERVISOR 3 STEPDOWN TRANSFORMER 24VAC
K1 INTERNAL RUN RELAY CONTACT
47
 Figure 3-8: Wiring Diagram—Air-Cooled Full Voltage
48

TS32 USER MANUAL

SECTION 3
02250178-845 R01
 Figure 3-8: Wiring Diagram—Air-Cooled Full Voltage

SECTION 3
COMP DESCRIPTION COMP DESCRIPTION
1M COMPRESSOR MOTOR STARTER CONTACT HRN OPT'L AUDIBLE ALARM
1MOL COMPRESSOR MOTOR STARTER OVERLOAD CONTACT HTR1 SUMP HEATER
2M COMPRESSOR MOTOR STARTER RUN CONTACTOR HTR2 HEAT TRACE
2MOL FAN MOTOR STARTER OVERLOAD CONTACT HTR3 TRAP HEATER
1FU TRANSFORMER PRIMARY FUSES HTR4 CONTROL PANEL HEATER
2FU TRANSFORMER SECONDARY FUSE TH THERMOSTAT FOR HEAT TRACE
3FU COOLER FAN BRANCH FUSES
P1 WET SUMP PRESSURE SENSOR - SET PER FACE OF ORDER NOTES:
P2 PACKAGE DISCHARGE PRESSURE SENSOR 1. CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCON-
P3 OIL FILTER DISCHARGE PRESSURE SENSOR NECT PER LOCAL CODES.
P4 OIL FILTER UPSTREAM PRESSURE SENSOR 2. REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.
T1 UNIT DISCHAGE TEMPERATURE RTD
3. BELDEN TYPE 9842 COND. 6 2 TWISTED PAIR W/SHIELD OR
T2 DRY DISCHARGE TEMPERATURE RTD
EQUIVALENT. TO MATCHING TERMINALS ON NEXT COMPRES-
T3 INJECTION OIL TEMPERATURE RTD SOR. REFER TO SUPERVISOR SEQUENCING PROTOCOL MAN-
T4 INTERSTAGE TEMPERATURE RTD UAL.
DSW1 OIL FILTER DIFFERENTIAL PRESSURE SWITCH
PSW1 INLET AIR FILTER SWITCH: 22 IN WC (558.9 MM WC)
PSW2 WATER PRESSURE SWITCH:10PSI (0.7 BAR) (OPT'L)
SOL1 LOAD CONTROL SOLENOID VALVE
SOL2 SPIRAL CONTROL SOLENOID VALVE (OPTIONAL)
SOL3 START CONTROL SOLENOID VALVE
SOL4 SEQUENCING/FULL LOAD SOLENOID VALVE (OPT)
SOL5 COMBO DRAIN/JZL DRAIN SOLENOID VALVE
1XFMR CONTROL VOLTAGE TRANSFORMER
2XFMR SUPERVISOR 3 STEPDOWN TRANSFORMER 24VAC
K1 INTERNAL RUN RELAY CONTACT

TS32 USER MANUAL

K2 INTERNAL Y-DELTA RELAY CONTACT
K3 INTERNAL LOAD CONTROL RELAY CONTACT
K4 INTERNAL SEQUENCE RELAY CONTACT
K5 INTERNAL ELECTRIC DRAIN RELAY CONTACT
K6 INTERNAL COMMON FAULT RELAY CONTACT
K7 INTERNAL COMMON WARNING RELAY CONTACT
K8 INTERNAL SPECIAL FUNCTION CONTACT
PMR OPT'L POWER MONITOR RELAY
49
 Figure 3-9: Wiring Diagram—Air-Cooled SSRV
50

TS32 USER MANUAL

SECTION 3
02250178-844 R03
 Figure 3-9: Wiring Diagram—Air-Cooled SSRV

SECTION 3
COMP DESCRIPTION COMP DESCRIPTION
1M COMPRESSOR MOTOR STARTER K5 INTERNAL ELECTRIC DRAIN RELAY CONTACT
1MOL COMPRESSOR MOTOR STARTER OVERLOAD CONTACT K6 INTERNAL COMMON FAULT RELAY CONTACT
2M CANOPY FAN STARTER K7 INTERNAL COMMON WARNING RELAY CONTACT
2MOL FAN MOTOR STARTER OVERLOAD CONTACT K8 INTERNAL SPECIAL FUNCTION CONTACT
3MOL FAN MOTOR STARTER OVERLOAD CONTACT PMR OPT'L POWER MONITOR RELAY
6M OPTIONAL CONTACTOR FOR PF CAPACITOR HRN OPT'L AUDIBLE ALARM
1FU TRANSFORMER PRIMARY FUSES HTR1 SUMP HEATER
2FU TRANSFORMER SECONDARY FUSE HTR2 HEAT TRACE
3FU CANOPY FAN BRANCH FUSES HTR3 TRAP HEATER
WET SUMP PRESSURE SENSOR - SET PER FACE OF HTR4 CONTROL PANEL HEATER
P1 ORDER TH THERMOSTAT FOR HEAT TRACE
P2 PACKAGE DISCHARGE PRESSURE SENSOR 1CR COMPRESSOR START CONTROL RELAY
P3 OIL FILTER DISCHARGE PRESSURE SENSOR
COMP DESCRIPTION
P4 OIL FILTER UPSTREAM PRESSURE SENSOR
T1 UNIT DISCHAGE TEMPERATURE RTD NOTES:
T2 DRY DISCHARGE TEMPERATURE RTD
1. CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCON-
T3 INJECTION OIL TEMPERATURE RTD
NECT PER LOCAL CODES.
T4 INTERSTAGE TEMPERATURE RTD
2. REMOVE JUMPER FOR AUXILLIARY E-STOP STRING DEVICES.
DPSW1 OIL FILTER DIFFERENTIAL PRESSURE SWITCH
PSW1 INLET AIR FILTER SWITCH: 22 IN WC (558.9 MM WC) 3. OPTIONAL
PSW2 WATER PRESSURE SWITCH:10PSI (0.7 BAR) 4. 2ND FAN MOTOR FOR 400HP AND LARGER.
SOL1 LOAD CONTROL SOLENOID VALVE 5. BELDEN TYPE 9842 COND. 2 TWISTED PAIR W/SHIELD OR EQUIV-
SOL2 SPIRAL CONTROL SOLENOID VALVE ALENT. TO MATCHING TERMINALS ON NEXT COMPRESSOR.
SOL3 START CONTROL SOLENOID VALVE REFER TO SUPERVISOR SEQUENCING PROTOCOL MANUAL.
SOL4 SEQUENCING/FULL LOAD SOLENOID VALVE

TS32 USER MANUAL

SOL5 COMBO DRAIN/JZL DRAIN SOLENOID VALVE
SOL6 WATER SHUTOFF SOLENOID VALVE (OPTIONAL)
1XFMR CONTROL VOLTAGE TRANSFORMER
K1 INTERNAL RUN RELAY CONTACT
K2 INTERNAL Y-DELTA RELAY CONTACT
K3 INTERNAL LOAD CONTROL RELAY CONTACT
K4 INTERNAL SEQUENCE RELAY CONTACT
51
 Figure 3-10: Wiring Diagram—Remote Air-Cooled Wye Delta
52

TS32 USER MANUAL

SECTION 3
02250178-836 R01
 Figure 3-10: Wiring Diagram—Remote Air-Cooled Wye Delta

SECTION 3
COMP DESCRIPTION COMP DESCRIPTION
1M COMPRESSOR MOTOR STARTER 1XFMR CONTROL VOLTAGE TRANSFORMER
1MOL COMPRESSOR MOTOR STARTER OVERLOAD CONTACT 2XFMR SUPERVISOR 3 STEPDOWN TRANSFORMER 24VAC
2M COMPRESSOR MOTOR STARTER RUN CONTACTOR K1 INTERNAL RUN RELAY CONTACT
S COMPRESSOR START CONTACTOR K2 INTERNAL Y-DELTA RELAY CONTACT
3M FAN MOTOR STARTER K3 INTERNAL LOAD CONTROL RELAY CONTACT
3MOL FAN MOTOR STARTER OVERLOAD CONTACT K4 INTERNAL SEQUENCE RELAY CONTACT
4M CANOPY FAN STARTER (OPT'L) K5 INTERNAL ELECTRIC DRAIN RELAY CONTACT
4MOL CANOPY FAN MOTOR STARTER OVERLOAD CONTACT K6 INTERNAL COMMON FAULT RELAY CONTACT
5MOL SECOND CANOPY FAN MOTOR OVERLOAD K7 INTERNAL COMMON WARNING RELAY CONTACT
6M OPTIONAL CONTACTOR FOR PF CAPACITOR K8 INTERNAL SPECIAL FUNCTION CONTACT
1FU TRANSFORMER PRIMARY FUSES PMR OPT'L POWER MONITOR RELAY
2FU TRANSFORMER SECONDARY FUSE HRN OPT'L AUDIBLE ALARM
3FU COOLER FAN BRANCH FUSES HTR1 SUMP HEATER
4FU CANOPY FAN BRANCH FUSES HTR2 HEAT TRACE
WET SUMP PRESSURE SENSOR - SET PER FACE OF HTR3 TRAP HEATER
P1
ORDER HTR4 CONTROL PANEL HEATER
P2 PACKAGE DISCHARGE PRESSURE SENSOR TH THERMOSTAT FOR HEAT TRACE
P3 OIL FILTER DISCHARGE PRESSURE SENSOR TSW1 OIL TEMPERATURE SWITCH
P4 OIL FILTER UPSTREAM PRESSURE SENSOR
T1 UNIT DISCHAGE TEMPERATURE RTD NOTES:
T2 DRY DISCHARGE TEMPERATURE RTD 1. CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCON-
NECT PER LOCAL CODES.
T3 INJECTION OIL TEMPERATURE RTD
2. REMOVE JUMPER FOR AUXILIARY E-STOP STRING DEVICES.
T4 INTERSTAGE TEMPERATURE RTD

TS32 USER MANUAL

3. CUSTOMER WIRING REQUIRED BETWEEN COOLER MOTOR AND
DPSW1 OIL FILTER DIFFERENTIAL PRESSURE SWITCH (OPT'L)
MACHINE MOUNTED STARTER.
PSW1 INLET AIR FILTER SWITCH: 22 IN WC (558.9 MM WC)
4. OPTIONAL.
SOL1 LOAD CONTROL SOLENOID VALVE
5. 2ND FAN MOTOR FOR 400HP AND LARGER.
SOL2 SPIRAL CONTROL SOLENOID VALVE (OPTIONAL)
6. BELDEN TYPE 9842 4 COND. 2 TWISTED PAIR W/SHIELD OR
SOL3 START CONTROL SOLENOID VALVE EQUIVALENT. TO MATCHING TERMINALS ON NEXT COMPRESSOR.
SOL4 SEQUENCING/FULL LOAD SOLENOID VALVE (OPTIONAL) REFER TO SUPERVISOR SEQUENCING PROTOCOL MANUAL.
SOL5 COMBO DRAIN/JZL DRAIN SOLENOID VALVE
53
NOTES

54

Section 4
INSTALLATION
4.1 COMPRESSOR
MOUNTING— SUPPORT
AND LOCATION
A foundation or mounting capable of supporting the
weight of the compressor, and rigid enough to
maintain the compressor frame level and the
compressor in alignment is required. The
compressor frame must be leveled and secured with
foundation bolts, and full uniform contact must be
maintained between the frame and foundation. It is
recommended that the frame be grouted to the
foundation. The compressor unit and driver must be
aligned after installation as specified in the
Operator’s Manual. No piping loads shall be
transmitted to the compressor or the cooling package
at the external connections.
• Use flex connectors to prevent piping loads
from being transmitted to the compressor.
• National and local electrical codes specify-
ing the required clearances for the area
around the electrical panel must be com-
plied with.
• Ensure the lighting at the compressor’s
location is sufficient for safe operation and
maintenance.
• The compressor’s location should be one
that allows access for maintenance vehi-
cles and lifting equipment.
• The clearances around the compressor
should permit easy access to all compres-
sor components.
• Walls and ceilings with soft or porous sur-
faces absorb sound and reduce ambient
noise levels. Hard surfaces reflect noise
and have little effect on ambient noise lev-
els.
• Water-cooled compressors must be located
where a cooling water supply and drainage
are available.
TS32 USER MANUAL
NOTE
When the compressor will be exposed to
temperatures lower than 32°F(0°C) the
cold weather option for freeze protection
must be installed. Consult Sullair Cus-
tomer Care regarding operation on sub-
freezing temperatures.
NOTE
Compressors operated in environments
where ambient temperatures average
above 104°F(40°C) must be equipped with
the high-ambient option.
4.2 VENTILATION AND
COOLING
AIR-COOLED COMPRESSORS
• Air-cooled compressors require a three foot
(one meter) clearance around their perime-
ter.
• The location should be free from standing
water.
• Clean air should be supplied to the com-
pressor, free from exhaust and paint
fumes, dust, metal particles, or caustic
chemical vapors.
• Hot exhaust air should be vented out of the
area to prevent its recirculation back into
the compressor’s cooling system.
• Ducting or some other means must be
used to ensure that hot exhaust air is
vented away from the compressor if the
compressor’s housing has minimal over-
head clearance.
55
TS32 USER MANUAL
NOTE
The “waste heat” from air-cooled com-
pressors can be used for local space
heating. If it is used for this purpose, the
additional static pressure drop across the
fan should not exceed 0.2 in. H20. The
high static fan option is required if duct-
work is added. Contact Sullair Customer
Care for additional information.
NOTE
Housing the compressor in an inade-
quately ventilated enclosure will cause
higher compressor operating tempera-
tures.
NOTE
Systems using both reciprocating and
rotary screw compressors must isolate
the two types from each other through the
use of a common receiver tank. Air lines
from each individual compressor should
be connected directly to the common
receiver tank.
WATER-COOLED COMPRESSORS
• Water-cooled compressors require a cool-
ing water supply delivered at a constant
rate and volume. (See Table 4-1:Water
Flow Requirements. The table data applies
to full load operation using an aftercooler.)
• Compressor water input and return lines
must be sized as a minimum to match the
compressor water connection size, and
have isolation valves with side drains. The
input water line should have a 2mm
strainer installed in-line. A solenoid valve
56
SECTION 4
(normally closed), controlled by the com-
pressor control circuit, should be con-
nected to the compressor’s water outlet.
(Contact Sullair Customer Care for assis-
tance.)
Table 4-1: Water Flow Requirements
Water Water Flow
Temp °F/ Gallons Per Minute /Liters Per Minute (I)
°C
200HP/ 250HP/ 300HP/ 350HP/
150KW 187KW 225KW 260KW
70/21 36/136 43/163 52/196 61/231
80/27 45/170 54/204 65/246 76/288
(I) Water pressure should be maintained between 25 and 75
psig (1.7 and 5.2 bar), but not to exceed 145 psig (10 bar).
• Cooling water quality is a critical factor
effecting proper machine cooling. Exces-
sive deposit build-ups, such as lime or
scale, restrict the water flow and act as
thermal insulators. These deposits can
increase the compressor’s operating tem-
perature by reducing the cooling system’s
efficiency.
• Regularly inspect and clean all water piping
and coolers.
• Table 4-2:Ventilation Requirements speci-
fies the minimum ventilation required for
compressor operation at normal tempera-
tures. The fan air requirement applies to
the volume of air that must pass though the
compressor to ensure proper ventilation.
The heat rejection requirement applies the
amount of heat generated by the compres-
sor which must be removed to maintain a
normal operating temperature.
• If the compressor has a water regulating
valve, it can be used to adjust the compres-
sor temperature to maintain a minimum of
185°F (82.2°C); 195°F (87.8°C) for 24 KT
machines.
• Temperature and pressure gauges should
be installed for water system troubleshoot-
ing.
SECTION 4 TS32 USER MANUAL

Table 4-2: Ventilation Requirements

WATER COOLED OR REMOTE

COOLED COMPRESSOR AIR-COOLED (I) COOLING PACKAGE
PACKAGE

VENT
MOTOR HEAT REJECTION FAN HEAT REJECTION
MODEL AIR FLOW CFM
HP/KW BTU/HR FLOW (II) BTU/HR
CFM

TS32-200 200/150 47,620 4150 560,200 18,000

TS32-250 250/187 57,360 4150 674,800 18,000

TS32-300 300/225 64,170 4150 802,100 28,000

TS32-350 350/260 74,320 4150 929,000 31,000

(I) Applicable to air-cooled models only.

(II) Applicable to compressors with enclosure.

1. Disconnect both the inlets and discharge

NOTE
The required flow rate depends upon the
cooling water’s temperature before it
enters the cooling system. The higher the
initial temperature, the higher the
required flow rate: the lower the initial
temperature, the lower the required flow
rate.
WATER SYSTEM VENTING
Vent the system after installation, or after draining
the system at startup:
1. Open the water valve(s).
2. Open the vent cocks (located on top of the
aftercooler and lubricant cooler on the water
side) and let air escape from the system.
Close the vent cocks when water is visible at
their location - at this point the system has
been vented.
DRAINING THE WATER SYSTEM
To drain the system completely:
water lines located at the rear of the com-
pressor.
2. Remove the drain plugs that are located at
the bottom of the aftercooler and the lubri-
cant cooler end caps.
3. Allow the system to drain completely.
WATER QUALITY RECOMMENDATIONS
Water quality can significantly effect the efficiency of
the water cooling system. Dissolved minerals, gases,
and pH values are factors that contribute to the
formation of deposits and corrosion which can form
on the interior of cooling system pipes and heat
exchangers.
Scale can be a problem if the water supply has a
high concentration of calcium carbonate. It forms
lime scale deposits which act as thermal insulators
and restrict the water flow through the cooling
system. If scale is allowed to build up over time, it will
reduce the system’s ability to remove heat and the
compressor can be damaged. Scale buildup can be
controlled with proper water treatment.
A thin lime scale coating is desirable and can inhibit
corrosion.

57
TS32 USER MANUAL SECTION 4

Corrosion damages pipes and reduces their strength.

This type of damage is more likely if the water supply
has a high amount of dissolved oxygen and a low pH
level.
Biological/organic fouling (slime) is relatively
uncommon since the compressor’s cooling fluids are
hot enough to generally prevent this type of problem.
Chemical treatments are available to rid the system
of biological contaminants.
NOTE
NOTE
The maximum recommended flow rate
cannot be exceeded. An excessive flow
rate can cause rapid system failure.
An orifice plate must be installed in the piping at least
3.3 feet (1M) before the cooler. The orifice’s diameter
must be properly sized to ensure that the
recommended flow rate is not exceeded (See Table
4-4).

Seawater-cooled systems must be

installed with with the optional copper- Table 4-4: Orifice Plate Diameters for Seawater Flow
nickel coolers. Orifice diameter in inches (mm) to
Seawater Pressure give a maximum seawater flow
psi (bar) velocity of 3m/sec
NOTE 200/250HP 300/350HP
25 (1.7) 1.38 (35) 1.43 (36)
Routine water testing will extend the com- 35 (2.4) 1.28 (33) 1.33 (34)
pressor’s operational life and help main- 45 (3.1) 1.19 (30) 1.24 (32)
tain an acceptable performance level.
55 (3.8) 1.14 (29) 1.19 (30)
Refer to Table 4-3:Water Tests.
65 (4.5) 1.09 (28) 1.13 (29)
75 (5.2) 1.05 (27) 1.10 (28)
SEAWATER-COOLED SYSTEMS
A strainer must be installed in the system’s inlet The cooling system should be set up to limit damage
piping to ensure the supply water is clean. Sullair from oil cooler leaks:
also recommends installing a solenoid valve • Isolate the cooling water from the compres-
(normally open) on the system’s outlet side. Both sor when it is not in use.
inlet and outlet lines should have isolation valves with
• The cooler’s seawater outlet pipe should
side drains installed.
have an open path to the waste piping.

Table 4-3: Water Tests

Substances Test Interval Acceptable Concentration

Corrosivity Hardness, pH, Total Dis- Monthly - if stable for 3 to 4 months, Langelier Index 0 to 1
solved Solids, Temperature at inlet, analyze quarterly.
Alkalinity
Iron Monthly < 2 ppm
Sulphate Monthly < 50 ppm
Chloride Monthly < 50 ppm
Nitrate Monthly < 2 ppm
Silica Monthly < 100 ppm
Desolated Oxygen Daily - if stable, analyze weekly 0 ppm (as low as possible)
Oil & Grease Monthly < 5 ppm
Ammonia Monthly < 1 ppm

58
SECTION 4
OUTDOOR INSTALLATION (SHELTERED)
Compressor packages installed in locations where
they will be exposed to outside elements must be
equipped with a TEFC motor. Standard compressors
have water tight controls that are NEMA 4 rated and
are suitable for this type of installation.
The compressor should be mounted on a concrete
pad. If the pad is not level, the compressor must be
mounted in such a manner that its base or skid is
level in relation to the pad’s surface and fully
supported.
An optional weather hood should be installed to
protect the compressor from precipitation. If the
compressor will exposed to blowing rain or snow, it
should be housed in a covered, four-walled
enclosure.
TS32 USER MANUAL
• Sheltered air-cooled machines must have
their exhaust air vented outside of the
enclosure.
• Installations consisting of more than one
compressor should be done in such a man-
ner that each compressor’s exhaust is
directed away from the air intakes of other
compressors or air dryers.
• A standard compressor should not be
started if the ambient temperature is 35°F
(1.7°C) or lower, or may decrease below
that point.
• Compressor’s operated in sub-freezing
conditions must utilize the cold weather
package. Consult the factory for further
information.
59
TS32 USER MANUAL
PIPE SIZING
Pipes should be sized as a minimum to match the
dimensions of the compressor’s discharge
connection. All piping and fittings should be rated for
the discharge pressure.
AUXILIARY RECEIVER TANK
An Auxiliary receiver tank should be installed in
systems where large demand fluctuations will occur.
ISOLATION VALVES
Install isolation valves where isolation of the
compressor from the service lines is required. These
valves should have drip legs that drain at an angle
downward from the base. A vent to the piping should
be installed downstream of the compressor outlet
connection.
Figure 4-1: Typical Service Air Piping
60
SECTION 4
When two compressors are installed to operate in
parallel with a common receiver tank, an isolation
valve and drain trap for each compressor should be
installed before the common separator/sump.
Compressors have built-in aftercoolers and are
equipped with a condensate drain located next to the
air outlet connection. A drain line should be installed
to remove the condensate, which builds up during
compressor operation. See Figure 4-1.
NOTE
Compressors not equipped with an auxil-
iary receiver tank may need to have their
response times adjusted. Contact Sullair
Customer Care for assistance.
SECTION 4
Figure 4-2: Fluid Fill Location
4.3 SERVICE AIR PIPING
Service air piping should be installed as shown in
Figure 4-1. A shut-off valve should be installed to
isolate a compressor from the service line if required.
Also notice that the service line should be equipped
with water legs and condensate drains throughout
the system.
4.4 COUPLING ALIGNMENT
CHECK
In preparation for the factory test, the coupling
supplied with your compressor is properly aligned for
operation. After the compressor package has been
mounted to a foundation, it is necessary to recheck
the coupling alignment. Refer to Coupling Alignment
procedure explained in the Maintenance section of
this manual.
4.5 FLUID LEVEL CHECK
The air compressor is also supplied with the proper
amount of fluid. However, it is necessary to check the
fluid level at installation. The level is checked by
looking at the sight glass located near the sump. If
the sump is properly filled, the fluid level should be
visible in the upper sight glass.
When the oil level falls below the center of the lower
sight glass, fluid must be added.
TS32 USER MANUAL
CAUTION
DO NOT overfill.
NOTE
Motor rotation check must be made at com-
pressor start-up. Remove compressor
panel as needed to view motor rotation.
After the electrical wiring has been done, it
is necessary to check the direction of the
motor rotation.
4.6 MOTOR ROTATION
DIRECTION CHECK
After the electrical wiring has been done, it is
necessary to check the direction of the motor
rotation. With the control system in MANUAL mode,
press the and pads in succession to
bump start the compressor. When looking at the
motor from the end opposite the compressor unit, the
shaft should be turning clockwise on all gear driven
models, and counterclockwise on direct drive
models.
If the motor shaft is not turning in the proper
direction, lockout out all power sources to the
compressor and exchange any two of the three
power input leads, then recheck rotation. A “Direction
61
NOTES
of Rotation” decal is located on the coupling guard
between the motor and compressor to show proper
GALLONS/LITERS OF
motor/compressor rotation. FLUID PIPE SIZE PER 12
PIPE SIZE
Finally, verify all directions of rotations on all auxiliary INCHES/304.8MM OF
motors per their directional decals. PIPE

2 .1635/.62
4.7 FLUID PIPING (REMOTE AIR-
COOLED OPTION ONLY) 2 1/2 .2555/.97

To allow de-pressurization of the cooling package 3 .368/1.39

and connecting piping between the compressor and 4 .6542/2.48
the cooling package upon shutdown of the
compressor, a 1/2” (13 mm) de-pressurization line 6 1.4719/5.57
must be installed between the top of the fluid cooler
and the sump tank connection which is located on
the fluid supply and return line connection bracket. 4.8 ELECTRICAL PREPARATION
This line must be maintained at a higher level than
the supply and return piping for the fluid cooler. The Interior electrical wiring is performed at the factory.
supply and return piping for the fluid cooler must be Required customer wiring is minimal, but should be
adequately sized to prevent excessive pressure done by a qualified electrician in compliance with
drop. The total pressure drop in the supply and return applicable local electrical codes concerning isolation
piping and associated fittings and valves shall not switches, fuse disconnects, etc. Sullair provides a
exceed 10 psig (0.7 bar)at the worst case operating wiring diagram for use by the installer.
condition (usually lowest ambient). If the pressure A few electrical checks should be made to help
drop is in excess of 10 psig (0.7 bar), a pump should assure that the first start-up will be trouble free.
be installed. Consult the Sullair Service Department
for recommendations.
It is recommended that shutoff valves be installed in
the supply and return piping to facilitate compressor
DANGER
component’s maintenance.
Lethal shock hazard inside. Disconnect all
Because of the variability in installations, the fluid power at source before opening or servicing.
necessary to fill the supply and return piping for the
fluid cooler is not part of the standard scope of supply
1. Check incoming voltage. Be sure that the
for the compressor. The fluid necessary to fill this
incoming voltage is the same voltage that the
piping may be ordered from the nearest Sullair
compressor was wired for. Verify that control
representative or the representative from whom the
transformer primary is wired for correct line
compressor was purchased. To assist in determining
voltage.
the amount of fluid necessary to fill the piping, the
following chart may be used. 2. Check starter and overload heater sizes (see
Electrical Controls Section in Parts Manual).
3. Check all electrical connections for tight-
ness.

62
 TS32 USER MANUAL

Section 5

OPERATION
5.1 INTRODUCTION
While Sullair has built into the TS32 Series package
a comprehensive array of controls and indicators to
assure its proper operation, the user should
recognize and interpret readings which call for
service or indicate the onset of a malfunction. Before
starting the unit, the user should become familiar with
the controls and indicators-their purpose, location,
and use.
5.2 PURPOSE OF CONTROLS—
INTRODUCTION
Indicators and functions included in the package are
listed in the following guide. However, all Supervisor
Controller-related functions and indicators are
presented in the Supervisor Controller Manual, so
please refer to that document for additional
information.

CONTROL: PURPOSE:
EMERGENCY STOP SWITCH Pushing in this switch, found adjacent to the Supervisor,
cuts all AC outputs from the Supervisor and de-
energizes the starter. A fault message (E STOP) is
displayed by the Supervisor until the button is pulled out
and the “O” pad is depressed.
THERMAL O/L RESET Momentarily pushing this button, found on the starter’s
thermal overload element housing, re-closes the
starter’s contacts after a current overload takes place.
Please be aware that the elements must be allowed to
cool sufficiently before resetting.
SULLICON ACTUATOR Actuates the inlet butterfly valve which throttles the air
flow to the compressor inlet, in order to match air supply
to the demand.
SPIRAL VALVE Internally bypasses and controls the air flow capacity of
the compressor, in order to match air supply to the
demand.
PRESSURE REGULATOR (SULLICON) Opens a pressure line between the sump and inlet valve
piston allowing the inlet valve to regulate air delivery
according to the air demand.
PRESSURE REGULATOR (WITH Opens a pressure line between the service line and the
SPIRAL VALVE) spiral valve actuator allowing the spiral valve to regulate
air delivery according to air demand.
SOLENOID VALVE #1 Electrically actuated, 3-way valve which controls the
flow of pneumatic logic signals. Used throughout
package to:
• Open the blowdown valve.
• Load the Sullicon device/close the inlet butterfly valve
during shutdown operation. ·Open the spiral valve.
SOLENOID VALVE #2 Opens when the compressor starts; closes when the
compressor is shut off. This prevents any air system
loss and depressurizes the controls when the
compressor is shut off.

63
NOTES
DISCHARGE CHECK VALVE
MINIMUM PRESSURE VALVE
PRESSURE RELIEF VALVE
BLOWDOWN VALVE ASSEMBLY
THERMAL MIXING VALVE
SUMP SIGHT GLASSES
SEPARATOR RETURN LINE SIGHT GLASSES
WATER PRESSURE SWITCH
DRAIN VALVES
64
Blocks the reverse flow of air/fluid through the
compressor unit during shutdown.
Maintains 50 psig (3.5 bar) in the separator/sump tank
when the compressor is running loaded. Also
incorporates a check valve, which prevents compressed
air backflow from the system when unloaded or
shutdown.
Vents the sump vessel to atmosphere before the
compressed air pressure exceeds rated tank pressure.
Its operation indicates fault with the Supervisor
operation unload pressure set too high or failure of
solenoid valve #1.
Vents the sump vessel to atmosphere during unloading
and shutdown.
Bypasses fluid flow around the cooler until the fluid
reaches a temperature of 185°F, 85°C (195°F for water
cooled KT and ≥ 150 psi/ 10.3 bar). Useful for fast
warm-up during start. Maintains a minimum temperature
during periods of low load or low ambient temperatures.
Indicates level of lubricant in the sump. Located on the
sump side, fluid level should be maintained at center of
the sight glass with machine shut down.
Indicate fluid flow in the separator return lines. Flow
should be visible during full load operation; little to no
flow during unloaded operation. Sluggish flow during full
load operation indicates the need to clean the strainers
fitted to the return lines.
De-energizes the starter, via the Supervisor, if the water
pressure falls below 10 psig (0.7 bar). This switch is not
adjustable. Used on water-cooled packages only.
Lubricant sump drain valve.
SECTION 5
5.3 INITIAL START-UP
PROCEDURE
The following procedure should be used to make the
initial start-up of the compressor.
NOTE
Before initial start up check that fluid is at
proper level in the sight glass. Grease
motor per manufacturer’s recommenda-
tions.
1. Read the preceding pages of this manual
thoroughly.
2. Jog motor to check for correct rotation of
main motor and fan (refer to Section 4.6).
3. Be sure that all preparations and checks
described in the Installation Section have
been made.
4. Start the compressor (manual mode
or AUTO mode ) 5.5
5. Open the shut-off valve to the service line.
6. Check for possible leaks in piping.
TS32 USER MANUAL
7. Slowly close the shut-off valve to assure
proper nameplate pressure unload setting is
correct. The compressor will unload at
nameplate pressure. If adjustments are nec-
essary, see Control System Adjustments.
8. Observe the operating temperature. Refer to
Section 2.3 for proper operating temperature
range. If temperature exceeds this range, the
cooling system and installation environment
should be checked.
9. Open shut-off valve to the service line.
10. Reinspect the compressor for temperature
and leaks the following day.
5.4 SUBSEQUENT START-UP
PROCEDURE
On subsequent start-ups, check that the proper level
is visible in the fluid sight glass and simply press the
START button. When the compressor is
running, observe the instrument panel and
, maintenance indicators.
SHUTDOWN PROCEDURE
To shut the compressor down, simply press the
STOP button.
65
TS32 USER MANUAL SECTION 5

Figure 5-1: Supervisor Control Panel

NOTE
For information concerning all aspects of
the Supervisor Controller, consult the
Supervisor Controller manual 02250146-
049.

66
 TS32 USER MANUAL

Section 6

MAINTENANCE
6.1 GENERAL
As you proceed in reading this section, it will be easy
to see that the Maintenance Program for the air
compressor is quite minimal yet important. The use
of the service indicators provided for the fluid filter,
air filter and fluid separator, will alert you when
service maintenance is required. When the
maintenance message is displayed by the
Supervisor Controller™, maintenance for that
specific item is required. See instructions for each
item in Section 6.6, Parts Replacement and
Adjustment procedures.
6.3 MAINTENANCE AFTER
INITIAL 50 HOURS OF
OPERATION
After the initial 50 hours of operation, a few
maintenance 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

6.2 DAILY OPERATION 4. Clean the control line filters or strainers

Prior to starting the compressor, it is necessary to 6.4 MAINTENANCE EVERY 1000

check the fluid level in the sump. Should the level be
low, simply add the necessary amount. If the addition
of fluid becomes too frequent, a simple problem has
developed which is causing this excessive loss. See
the Section 6.8: Troubleshooting— Introduction
under Excessive Fluid Consumption for a probable
cause and remedy.
After a routine start has been made, observe the
Supervisor control panel and be sure it monitors the
correct readings for that particular phase of
operation. After the compressor has warmed up, it is
recommended that a general check of the overall
compressor and Supervisor be made to assure that
the compressor is running properly.
WARNING
DO NOT remove caps, plugs, and/or other
components when compressor is running or
pressurized. Stop compressor and relieve all
internal pressure before doing so.
HOURS
Every 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.
6.5 FLUID CHANGE
Standard models are filled with the long life lubricant
Sullube.
Sullube should be changed under the following
conditions, whichever occurs first:
1. Every 8000 hours.
2. Once a year.
3. As indicated by fluid analysis.

67
TS32 USER MANUAL SECTION 6

compressor and the fluid stop valve. When servicing

the main filter, shut the compressor down, be sure all
pressure has been released, then follow the
instructions below. For element replacement order kit
number 02250139-996.
1. Drain the fluid from the canister by removing
the bottom drain plug
2. Loosen the spin-on canister using a wrench
on the bottom canister hex.
3. Pull the canister away from the filter head.
The filter element will be attached to the
head.
4. Separate the element from the head.
5. Remove the canister seals.
6. Thoroughly clean the filter head and canister
in solvent.
Figure 6-1: Main FIlter (P/N 02250121-638) 7. Lubricate the new seals with the same type
of fluid used in the compressor and position
*Repair Kit P/N 02250139-996 each seal in its appropriate place.
8. Slide the element into the canister.
A fluid sample at every 1000 hours is recommended.
For a free Sullube analysis, send fluid to: 9. Thread the canister and element back on the
filter head.
Dow Chemical
Lubricant Technology Center AIR FILTER MAINTENANCE
Building B-1605
Refer to Figure 6-2. Air filter maintenance should be
Freeport, TX 77541
performed when the air filter maintenance message
To facilitate this, a sample bottle is included with the is displayed. The air filter is equipped with a primary
compressor. element and a secondary element. As previously
stated, the Supervisor will alert you as to when the
6.6 PARTS REPLACEMENT AND primary element maintenance is necessary. When
ADJUSTMENT removing the primary element, always check the
PROCEDURES secondary element for visible dirt, grease or damage.
The secondary element must be changed after every
MAIN FILTER MAINTENANCE sixth primary element change. DO NOT clean the
secondary element.
Refer to Figure 6-1. The main filter (P/N 02250121-
638) is located schematically between the

68
SECTION 6 TS32 USER MANUAL

Figure 6-2: Air Filter Replacement (P/N 250006-718)

*Primary Replacement Element Kit P/N 02250135-149

**Secondary Replacement Element Kit P/N 25007-839

6. Clean the interior of the housing by using a

ELEMENT REMOVAL
1. Clean the exterior of the air filter housing.
2. Remove the cover assembly by loosening
the wingnut securing it.
3. On the inside you will notice a wingnut which
fastens the element to the housing. Remove
the wingnut and pull the primary element out.
4. Loosen and remove the hex nut securing the
secondary element. Remove the secondary
element.
5. Inspect the secondary element and replace if
necessary.
damp cloth. DO NOT blow dirt out with com-
pressor air.
7. Install the new secondary element and
replace the sealing washer and hex nut.
8. With the secondary element in place, replace
the primary element.
DO NOT strike the element against any hard surface
to dislodge dust. This will damage the sealing
surfaces and possibly rupture the element.
DO NOT “blow” dirt out of the interior of the filter
housing. This may introduce dust downstream of the
filter. Instead, use a clean damp cloth.
DO NOT oil the element.

69
TS32 USER MANUAL
Figure 6-3: Separator Element Replacement
(I) Replacement Element P/N 02250034-085
(primary)
(II) Element Replacement Kit P/N 02250145-897
(secondary)
ELEMENT INSPECTION
1. Place a bright light inside the element to
inspect for damage or leak holes. Concen-
trated light will shine through the element,
revealing any holes.
2. Inspect all gaskets and gasket contact sur-
faces of the housing. Should faulty gaskets
be evident, correct the condition immedi-
ately.
70
SECTION 6
3. If the clean element is to be stored for later
use, it must be stored in a clean, closed con-
tainer.
4. After the element has been installed, inspect
and tighten, if necessary, all air inlet connec-
tions prior to resuming operation.
PRIMARY ELEMENT REPLACEMENT
1. Place the element in position over secondary
element. Replace the sealing washer and
wingnut. Tighten the wingnut so as to fully
seat the element gasket.
2. Install the cover/element assembly and
replace the wingnut.
SEPARATOR ELEMENTS REPLACEMENT
Refer to Figure 6-3. The separator elements must be
changed when “Separator Maintenance Required”
message is displayed, or once a year whichever
occurs first. Follow the procedure explained below
for separator element replacement.
PROCEDURE FOR ELEMENT REPLACEMENT
1. Relieve all pressure from the separator and
all compressor lines prior to disconnecting
any pipes, tubing, etc.
2. Disconnect all piping connected to the sepa-
rator cover to allow removal (return lines,
service lines, etc.).
3. Loosen and remove the twelve (12) 3/4” x 3”
hex head capscrews from the cover plate.
4. Lift the cover plate from the separator using
a 3/4” jackscrew under the lifting arm post.
The lid can be pivoted to the side supported
by the lifting arm.
5. Remove the primary and secondary separa-
tor 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 gas-
kets attached into the sump taking care not
to dent them against the tank opening. DO
NOT remove grounding staples. Check
between separator element flange and tank
for continuity after torquing bolts. DO NOT
use anti-seize compound on gaskets.
SECTION 6 TS32 USER MANUAL

Figure 6-4: Fluid Return / Sight Glass

(I) Replacement Filter Assembly P/N 02250117-782

9. Clean the underside of the separator tank
cover and remove any rust.
10. Replace the cover plate, washers and 3/4-10
capscrews. Lubricate and Torque to 200 ft.-
lbs. (271 Nm).
11. Reconnect all piping making sure return line
tubes extend to the bottom or 1/4” (6mm)
above the bottom of the separator element.
This will assure proper fluid return flow to the
compressor.
12. Check the return line strainers before restart-
ing the compressor (order replacement kit
no. 02250117-782).
OIL RETURN/SIGHT GLASS MAINTENANCE
Order filter assembly no. 02250117- 782, and use
the following instructions as a guide.
NOTE
Always performing maintenance on both oil
return/sight glasses at the same time.
1. Disconnect the tubes at the tops of the sight
glass assemblies.
2. Unscrew male connector (for left-side glass),
or the straight thread tube connector (for
right-side glass) from sight glass/orifice
blocks.

Refer to Figure 6-4. The oil return/sight glass 3. Remove used filter assembly, and replace
subassembly is attached to the separator tank lid.Oil with new assembly.
return/sight glass maintenance should be performed 4. Coat/lubricate the O-rings will silicone
on a routine basis parallel to that of the fluid filter, or grease.
as indicated in the Troubleshooting Sections (both
Supervisor and Maintenance) of this manual. The 5. Reattach the connectors to the sight glass/
maintenance on an oil return/sight glass is mainly orifice blocks.
concerned with the condition of the filter assembly.

71
TS32 USER MANUAL SECTION 6

DIFFERENTIAL PRESSURE REGULATOR

ADJUSTMENT
Refer to Figure 6-5 and Figure 6-6. 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. At approximately 108 psig (7.5 bar), the
Sullicon regulator should allow pressure to flow into
the control chamber of the Sullicon Control. The
Sullicon Control level should start to move at this
time. Cycle the Control System several times and Figure 6-5: Pressure Regulator Adjustments
recheck all pressure settings.
COMPRESSOR DRIVE COUPLING
The performance and life of couplings depend largely
upon how you install and maintain them.
The use of stainless steel shims under the motor feet
is recommended. Measuring misalignment and
positioning equipment within alignment tolerances is
simplified with an alignment computer. These
calculations can also be done graphically or
mathematically.

NOTE
Before installing couplings, make certain
that foundations of equipment to be con-
nected meet requirements of Section 4.1.
The drive coupling must be aligned after
installation and prior to initial start-up of the
compressor.
Figure 6-6: Sullicon Control (P/N 011682-003)

72
SECTION 6 TS32 USER MANUAL

SHAFT COUPLING MAINTENANCE STEP 2 OFFSET ALIGNMENT

The compressor unit and motor are rigidly connected Clean any oil, grease, dirt or paint from coupling
through the mounting adapter housing. This faces and the other surfaces of the drive flanges.
arrangement makes coupling alignment Rotate shafts so that a straight edge will rest
unnecessary. The coupling is a jaw type in shear. If squarely (or within the 0.010 inch maximum limit
the elastomeric (rubber) element requires shown in Table 6-1) on both flanges and at a point
replacement due to wear or damage, order a 90° away. The vertical offset alignment is adjusted by
replacement element and perform the following the addition or removal of motor mounting shims.
steps: Loosen the motor mounting bolts and slide the motor
sideways to correct the horizontal offset.
1. Remove the coupling guard.
2. Loosen the retaining screw located on the
outer sleeve. Slide the sleeve to one side,
exposing the coupling element. Table 6-1: INSTALLATION DATA
3. Unwrap the coupling element from the
coupling jaws. Max. Operating
Misalignment
4. Position the motor and compressor keyways
180 degrees apart Coupling Gap
Parallel
inches/mm Angular
5. Install the new element by wrapping it Offset
inches/
around the jaws, engaging the cogs on the inches/
mm (I)
element into the jaws. mm
6. Reinstall the outer sleeve and secure by .188
tightening the two screws to 45 in·lbs (5 Nm). .010 in. .010 in.
+/- .020 in.
7. Reinstall the coupling guard.
4.77
.25 mm .25 mm
+/- .50 mm
6.7 DRIVE COUPLING
INSTALLATION AND (I) Angular misalignment in inches equals
ALIGNMENT maximum A minus minimum B as shown in
Figure 6-7. DO NOT exceed values in Table
Refer to Figure 6-7 and Figure 6-8. above.

STEP 3 COUPLING GAP AND ANGULAR

WARNING
Disconnect all power at source, before
attempting maintenance or adjustments.
For installation and alignment of the drive coupling,
follow the steps explained below.
STEP 1 MOUNT HUBS
Mount the motor hub and the compressor hub onto
respective shaft. Position the hubs to establish the
correct gap specified in Table 6-1. Secure each hub
with a setscrew.
ALIGNMENT
Position the hubs to establish the proper gap and
angular alignment as indicated in Table 6-1. To
determine the angular misalignment in inches,
measure the maximum space between the hub
flanges and the minimum space 180° away, and then
subtract. To adjust the horizontal angular
misalignment, loosen the motor mounting bolts and
adjust the motor position until the angular alignment
is within tolerance.When within the limits specified in
WARNING
Disconnect all power at source, before
attempting maintenance or adjustments.

73
TS32 USER MANUAL SECTION 6

Table 6-1, tighten the motor mounting bolts and STEP 4 INSTALL THE FLEXIBLE ELEMENT
recheck the offset and angular alignment. If the
Refer to shaft coupling maintenance for installation of
vertical angular alignment is not within specifications,
drive coupling element.
shim the front or rear of the motor separately to
correct. Recheck the vertical offset.

Figure 6-7: Drive Coupling Alignment

Figure 6-8: Coupling Detail

1 02250152-730 hub,taper-lock 40/50/60r

2 02250152-741 bushing,taper-lock 3.25 40/50/60r
3 COVER cover,cplg element 40r
4 ELEMENT element,cplg 40r
5 HUB hub, coupling 2.375 bore 40r
6 SPACER spacer,taper-lock 40r

74
SECTION 6 TS32 USER MANUAL

6.8 TROUBLESHOOTING— A detailed visual inspection is worth performing for

INTRODUCTION almost all problems and may avoid unnecessary
additional damage to the compressor. Always
The information contained in the Troubleshooting remember to:
Guide has been compiled from field report data and
1. Check for loose wiring.
factory experience. It contains symptoms and usual
causes for the described problems. However, DO 2. Check for damaged piping.
NOT assume that these are the only problems that
3. Check for parts damaged by heat or an elec-
may occur. All available data concerning a problem
trical short circuit, usually apparent by discol-
should be systematically analyzed before
oration or a burnt odor.
undertaking any repairs or component replacement
procedures. Should your problem persist after making the
recommended check, consult your nearest Sullair
In addition to the Troubleshooting Guide, consult the
representative.
Supervisor Controller manual for additional
troubleshooting guidelines pertaining to the
Supervisor Controller.

Table 6-2: Troubleshooting Guide

SYMPTOM
Compressor will not start
PROBABLE CAUSE
Main disconnect switch open
Line fuse blown
Control Transformer Fuse Blown
Motor Starter Overloads Tripped
Low Incoming Line Voltage
REMEDY
Close switch.
Replace fuse.
Replace fuse.
Reset. Should trouble persist, check whether
motor starter contacts are functioning properly.
Check voltage. Should voltage check low,
consult power company.

Replace Supervisor display module if no

Compressor Shuts Down With
Air Demand Present
Loss of control voltage
Low incoming voltage
Excessive operating pressure
display or erratic display.
Check incoming power.
Check control fuses and wiring.
Consult power company. The Sullair
Supervisor will provide indication of most
maintenance problems if control power has not
been lost. Shutdowns will occur upon a faulty
condition or a bad sender condition.
Check maximum P2 pressure setting.
HIGH PRESS P1 display; Max P1 pressure
may be set too low. Consult factory for
recalibration.
Defective solenoid valve; solenoid valve
should cause inlet to unload when unload
pressure is exceeded. Repair if defective.
Defective blowdown valve; blowdown valve
should open when in the unload mode. 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.

75
TS32 USER MANUAL
Table 6-2: Troubleshooting Guide
SYMPTOM PROBABLE CAUSE
Compressor Shuts Down With HIGH TEMP T1 or T3 Message
Air Demand Present (continued) Displayed
Low Fluid Pressure
(LOW PRESSURE P3 display)
Low Water Pressure
(FAN OL/LOW WATER display)
Compressor Will Not Air Demand is Too Great
Build Full Discharge Pressure
Dirty Air Filter
Pressure Regulator Out of
Adjustment
Defective Pressure Regulator
Broken Sullicon spring
76
SECTION 6
REMEDY
Cooling water temperature too high; increase
water flow (water-cooled only).
Cooling water flow insufficient; check water
lines, valves (water-cooled only) and available
water pressure differential.
Cooler plugged; clean tubes. If plugging
persists, install water conditioner or water
filter(watercooled only).
Cooling air flow restricted; clean cooler and
check for proper ventilation.
Ambient temperature is too high; provide
sufficient ventilation.
Cooling air ductwork, if installed, may restrict
air flow. High static fan must be specified with
customer-supplied ductwork, and ductwork
must be sized to minimize flow restriction.
Low fluid level; add fluid.
Clogged filter; change the fluid filter element as
indicated by Supervisor control.
Thermal valve not functioning properly;
replace element (air-cooled only).
Optional Water flow regulating valve not
functioning properly; change (water-cooled
only).
Open or shorted T1 or T2 sender; check for a
short or open circuit to probe and correct
wiring.
Excessive pressure drop in supply and return
lines of remote air-cooled cooling package.
Consult Section 4.7 of this manual.
Check fluid level.
Check for clogged fluid filter.
Check the cooling fan motor or water flow
system.
Check service lines for leaks or open valves
up.
Check for filter maintenance message on
supervisor panel and change or clean element
if required.
Adjust regulator according to control
adjustment instructions in the Maintenance
section.
Check diaphragm and replace if necessary
(kit availble).
Replace
SECTION 6
Table 6-2: Troubleshooting Guide
SYMPTOM
Line Pressure Rises Above
Unload P2 Pressure Setting On
The Supervisor
Excessive Fluid Consumption
Pressure Relief Valve Opens
Repeatedly
Liquid Water In Compressed
Air Lines
PROBABLE CAUSE
Leak in control system causing
loss of pressure signals
Defective Solenoid Valve
Defective Blowdown Valve
Ruptured Sullicon control
diaphragm
Plugged Control Line Filter
Clogged return line strainer or
orifice
Separator element damaged or not Check separator differential (plugged) dP1.
functioning properly
Change separator.
Leak in the lubrication system
Excess fluid foaming
Fluid level too high
Defective pressure relief valve
Water Vapor Condensation from
Cooling and Compression Occurs
Naturally
TS32 USER MANUAL
REMEDY
Check for leaks.
Check that inlet valve closes when Supervisor
is in NO LOAD mode. Repair or replace if
necessary (kit available).
Check that sump pressure is exhausted to the
atmosphere when in the OFF LOAD mode.
Repair or replace if necessary (kit available).
Replace
Clean or repair if necessary.
Clean strainer (screen with o-ring replacement
kit available).
Clean orifice.
Check all pipes, connections and components
Drain and change.
Drain excess fluid.
Replace pressure relief valve.
Remove the water vapor from compressed air
prior to distribution through the air system.
Check operation of aftercooler and moisture
separator. Install a compressed air dryer sized
for the flow and dryness level required. (Note:
Filters may also be required to remove
particulates, liquid oil aerosols or for oil vapor
removal. Change cartridges as recommended
by the filter manufacturer.) Check all drain
traps routinely to insure their proper operation.
Maintain them regularly.
77
NOTES

78
NOTES

79
 WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A.
Zuo Pao Tai Road, No. 1 3700 East Michigan Boulevard Zone Des Granges BP 82
Chiwan, Shekou Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France
Shenzen, Guangdong PRV. www.sullair.com Telephone: 33-477968470
PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A. only) Fax: 33-477968499
Telephone: 755-6851686 Fax: 219-874-1273 www.sullaireurope.com
Fax: 755-6853473
www.sullair-asia.com CUSTOMER CARE
for PARTS and Service
1-888-SULLAIR (7855247)
219-874-1835

Champion Compressors, LTD.

324-332 Frankston Dandenong Road
Dandenong VIC
Australia 3175
Ph: +61397039000
Fx: +61397039053
www.championcompressors.com.au

Printed in the U.S.A.

Specifications subject to
change without prior notice.
E09EP