Sullair 12 Series User manual

Operator’s Manual
Series 12 & 16 40, 50, 60 and 75 HP Standard & 24 KT
Industrial Rotary Screw Air Compressor
Part Number 252646-002
©Sullair Corporation

AIR CARE
SEMINAR TRAINING
SullairAirCareSeminarsare3-daycoursesthatprovidehands-oninstructionin
the proper operation, maintenance and service of Sullair equipment.Individual
seminars on Industrial compressors and compressor electrical systems are
presentedatregular intervalsthroughoutthe yearatadedicatedtrainingfacility
at Sullair’s corporate headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service
parts, troubleshooting of the most common problems, and actual equipment
operation. The seminars are recommended for maintenance and service
personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1-800-348-2722 or 219-879-5451 (ext. 1867)
-OrWrite-
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department

TABLE OF CONTENTS
Section 1
SAFETY 11.1 GENERAL
11.2 PERSONAL PROTECTIVE EQUIPMENT
11.3 PRESSURE RELEASE
11.4 FIRE AND EXPLOSION
21.5 MOVING PARTS
21.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
21.7 TOXIC AND IRRITATING SUBSTANCES
31.8 ELECTRICAL SHOCK
31.9 LIFTING
31.10 ENTRAPMENT
Section 2
DESCRIPTION 42.1 INTRODUCTION
42.2 DESCRIPTION OF COMPONENTS
42.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
62.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
82.5 COMPRESSOR DISCHARGE SYSTEM,
FUNCTIONAL DESCRIPTION
92.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
11 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
11 2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION
Section 3
SPECIFICATIONS 13 TABLE OF SPECIFICATIONS
14 LUBRICATION GUIDE --- STANDARD
14 LUBRICATION GUIDE --- 24KT
Section 4
INSTALLATION 15 4.1 MOUNTING OF COMPRESSOR
15 4.2 VENTILATION AND COOLING
15 4.3 SERVICE AIR PIPING
15 4.4 COUPLING ALIGNMENT CHECK
15 4.5 FLUID LEVEL CHECK
15 4.6 ELECTRICAL PREPARATION
16 4.7 MOTOR ROTATION DIRECTION CHECK

TABLE OF CONTENTS
(CONTINUED)
Section 5
OPERATION 17 5.1 GENERAL
17 5.2 PURPOSE OF CONTROLS
18 5.3 INITIAL START-UP PROCEDURE
19 5.4 SUBSEQUENT START-UP PROCEDURE
19 5.5 SHUTDOWN PROCEDURE
Section 6
MAINTENANCE 21 6.1 GENERAL
21 6.2 DAILY OPERATION
21 6.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
21 6.4 MAINTENANCE EVERY 1000 HOURS
21 6.5 FILTER MAINTENANCE
21 6.6 SEPARATOR MAINTENANCE
21 6.7 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
29 6.8 TROUBLESHOOTING
Section 7
ILLUSTRATIONS AND
PARTS LIST 35 7.1 PROCEDURE FOR ORDERING PARTS
35 7.2 RECOMMENDED SPARE PARTS LIST
36 BILLS OF MATERIAL

Section 1
SAFETY
1
1.1 GENERAL
Sullairr Corporation and its subsidiaries design and
manufacture all of its products so they can be oper-
ated safely. However, the responsibility for safe op-
erationrests with those whouseand maintain these
products. The following safety precautions are of-
fered 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
whohavereadandunderstoodthisOperator’sMan-
ual. Failure to follow the instructions, procedures
and safety precautions in this manual can result in
accidents and injuries.
NEVER start the compressor unless it is safe to do
so.DONOTattempttooperatethecompressorwith
a known unsafe condition. Tag the compressor and
render it inoperative by disconnecting and locking
out all power at source or otherwise disabling its
primemover,sootherswhomaynotknowofthe un-
safe 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
allapplicableFederal, State, andLocalcodes,stan-
dards 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 com-
pressors with all types of prime movers, most of the
precautionary statements contained herein are ap-
plicable to most compressors and the concepts be-
hindthesestatementsaregenerally applicabletoall
compressors.
1.2 PERSONAL PROTECTIVE EQUIPMENT
Prior to installing or operatingthe compressor, own-
ers, employers, and users should become familiar
with, and comply with, all applicable OSHA regula-
tions and any applicable Federal, State and Local
codes, standards, and regulations relative to per-
sonal protective equipment, such as eye and face
protective equipment, respiratory protective equip-
ment, equipment intended to protect the extremi-
ties,protectiveclothing,protectiveshieldsandbarri-
ers and electrical protective equipment, as well as
noise exposure administrative and/or engineering
controls and/or personal hearing protective equip-
ment.
1.3 PRESSURE RELEASE
A. Install an appropriate flow limiting valve between
theserviceairoutletand theshut-off(throttle)valve,
either at the compressor or at any other point along
the air line, when an air hose exceeding !@2” inside
diameter is to be connected to the shut-off (throttle)
valve,toreducepressureincaseofhosefailure,per
OSHA Standard 29 CFR 1926.302(b)(7).
B. Whenthehoseistobeusedtosupplyamanifold,
install an additional appropriate flow limiting valve
between the manifold and each air hose exceeding
!@2” 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 of hose in runs
of air hose exceeding !@2” inside diameter to re-
duce pressure in case of hose failure.
D. Flow limiting valves are listed by pipe size and
rated CFM. Select appropriate valves accordingly,
inaccordance withtheir manufacturer’s recommen-
dations.
E. DO NOT use air tools that are rated below the
maximum rating of thecompressor.Select air tools,
air hoses, pipes,valves, filters, andother fittingsac-
cordingly. DO NOT exceed manufacturer’s rated
safe operating pressures for these items.
F. Secure all hose connections by wire, chain or
other suitable retaining devices to prevent tools or
hose ends from being accidentally disconnected
and expelled.
G.Openfluidfiltercaponlywhencompressor isnot
running and is not pressurized. Shut down the
compressor and bleed the sump (receiver) 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. Use air at pressures less than 30 PSIG (207kPa)
for cleaning purposes, and then only with effective
chip guarding and personal protective equipment
per OSHA Standard 29 CFR 1910.242 (b).
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, when such spills occur.
B.Shutoffthecompressorandallowittocool. 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 antifreeze compound.
C.DO NOT permit fluids, including air line anti-icer
system antifreeze compound or fluid film to accu-
mulate on, under, or around acoustical material, or
onany externalsurfacesoftheair compressor oron
internalsurfaces of the enclosure. Wipe downusing
an aqueous industrial cleaner or steam clean as re-

Section 1
SAFETY
2
quired. If necessary, remove acoustical material,
cleanallsurfaces andthenreplaceacousticalmate-
rial. Any acoustical material with a protective cover-
ing that has been torn or punctured should be re-
placed immediately to prevent accumulation of liq-
uids or fluid film within the material.DONOTuse
flammable solvents for cleaning purposes.
D. Disconnect and lock out all power at source prior
to attempting any repairs or cleaning of the com-
pressor or of the inside of the enclosure, if any.
E. Keep electrical wiring, including all terminals and
pressureconnectorsingoodcondition. Replaceany
wiring that has cracked, cut abraded or otherwise
degraded insulation, or terminals that are worn, dis-
colored or corroded. Keep all terminals and pres-
sure 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.Removeanyacousticalmaterialorothermaterial
that may be damaged by heat or that may support
combustion and is in close proximity, prior to at-
tempting weld repairs.
H. Keep suitable fully charged Class BC or ABC fire
extinguisherorextinguishersnearbywhenservicing
and operating the compressor.
I. Keep oily rags, trash, leaves, liter or other com-
bustibles out of and away from the compressor.
J. DO NOT operate the compressor without proper
flowofcoolingair orwaterorwithinadequateflowof
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 also clothing away from couplings, fans and
other moving parts.
B. DO NOT attempt to operatethe compressor with
the fan, coupling or other guards removed.
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 oper-
ate it.
F. Disconnect and lock out all power at source and
verifyatthecompressorthatallcircuitsarede-ener-
gized to minimize the possibility of accidental start-
uporoperation, priortoattemptingrepairsoradjust-
ments. This is especially important when compres-
sors are remotely controlled.
G. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water, or other liq-
uids 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 infection.
1.7 TOXIC AND IRRITATING SUBSTANCES
A.DONOTuseairfromthiscompressorforrespira-
tion(breathing)exceptin fullcompliancewithOSHA
Standards 29 CFR 1910 and any other Federal,
State or Local Codes or regulations.
DANGER
!
Death or serious injury can result from inhaling
compressed air without using proper safety
equipment.SeeOSHA standardsonsafetyequip-
ment.
B. DO NOT use air line anti-icer systems in air lines
supplying respirators or other breathing air utiliza-
tion equipment and DO NOT discharge air from
these systems in unventilated or other confined ar-
eas.
C. Operate the compressor only in open or ade-
quately ventilated areas.
D. Locate the compressor or provide a remote inlet
sothatitisnotlikelytoingestexhaustfumesorother
toxic, noxious or corrosive fumes or substances.
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.
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 15minutes. A physician,preferablyaneye
specialist, should be contacted immediately.

Section 1
SAFETY
3
H. DO NOT store air lineanti-icer system antifreeze
compound in confined areas.
I. The antifreeze compound used in air line anti-
freeze systems contains methanol and is toxic,
harmful, orfatal if swallowed. Avoidcontact withthe
skin or eyes and avoid breathing the fumes. If swal-
lowed, induce vomiting by administrating a table-
spoonofsalt, ineachglassof clean,warmwaterun-
til vomit is clear, then administer two teaspoons of
baking soda in a glass of clean water. Have patient
laydownandcovereyestoexcludelight.Callaphy-
sician immediately.
1.8 ELECTRICAL SHOCK
A. This compressor should be installed and main-
tained in full compliance with all applicableFederal,
State and Local codes, standards and regulations,
including those of the National Electrical Code, and
alsoincludingthoserelativetoequipmentgrounding
conductors, and only by personnel that are trained,
qualified and delegated to do so.
B. Keep all parts of the body and any hand-held
tools or other conductive objects away from ex-
posed 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 toexposed 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,
thendisconnect,lockoutandtagallpower atsource
so others will not inadvertently restore power.
E. Disconnect, lock out, andtag all power at source
priortoattemptingrepairs oradjustmentstorotating
machinery and prior to handling any ungrounded
conductors.
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 tobe air lifted by heli-
coptermustnotbesupportedbytheliftingbailbutby
slingsinstead. Inany event,lift and/orhandleonlyin
full compliance withOSHA standards 29 CFR 1910
subpart N.
B. Inspect points of attachment for cracked welds
and for cracked, bent, corroded or otherwise de-
graded 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 conditions
andhas aratedcapacity of atleast the weight ofthe
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, andis fully engaged and latched
on the bail or slings.
E. Use guide ropes or equivalent to prevent twisting
orswingingofthecompressoronceithasbeenlifted
clear of the ground.
F. DO NOT attempt to lift in high winds.
G.Keepallpersonneloutfromunderandawayfrom
the compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
I. Keep lift operator in constant attendance when-
ever compressor is suspended.
J. Set compressor down only on level surfaces ca-
pable of safely supporting at least its weight and its
loading unit.
K. When moving compressors by forklift truck, util-
ize fork pockets if provided. Otherwise, utilize pallet
if provided. If neither fork pockets or pallet are pro-
vided, then make sure compressor is secure and
well balanced on forks before attempting to raise or
transport it any significant distance.
L.Makesureforklift truckforksarefullengagedand
tipped back prior to lifting or transporting the com-
pressor.
M. Forklift no higher than necessary to clear obsta-
cles at floor level and transport and corner at mini-
mum 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
attempttoforkliftacompressorthatisnotsecuredto
its pallet, as uneven floors or sudden stops may
cause the compressor to tumble off, possibly caus-
ingseriousinjuryorpropertydamageintheprocess.
1.10 ENTRAPMENT
A. If the compressor enclosure, if any, is large
enoughtoholdamanandifitisnecessarytoenterit
to perform service adjustments, inform other per-
sonnel before doing so, or else secure and tag the
access door in the open position to avoid the possi-
bility ofothers closingandpossiblylatching thedoor
with personnel inside.
B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.

4
NOTES

Section 2
DESCRIPTION
5
2.1 INTRODUCTION
Your new Sullair flood-lubricated rotary screw air
compressor will provide you with a unique experi-
ence in improved reliability and greatly reduced
maintenance.
Compared to other types of compressors, the Sull-
air rotary screw is unique in mechanical reliability,
with “no wear” and “no inspection” required of the
working parts within the compressor unit.
Read Section 5 (Maintenance) to see how surpris-
inglyeasyitis to keepyouraircompressorintopop-
erating condition.
2.2 DESCRIPTION OF COMPONENTS
Refer to Figures 2-1 and 2-2. The components and
assembliesoftheaircompressorareclearlyshown.
The complete package includes compressor, elec-
tric motor, starter, compressor inlet system, com-
pressor discharge system, compressor lubrication
andcoolingsystem, capacitycontrolsystem,instru-
ment panel, aftercooler, a combination separator
andtrap, allmountedonaheavygaugesteelframe.
Onair-cooledmodels,afandrawsairoverthemotor
and forces it out through the combined aftercooler
and fluid cooler thereby removing the compression
heat from the compressed air and the cooling fluid.
On water-cooled models, a shell and tube heat ex-
changer ismounted onthe compressor frame. Fluid
ispipedintotheheatexchangerwherecompression
heat is removed from the fluid. Another similar heat
exchanger cools the compressed air.
Both air-cooled and water-cooled versions have
easily accessible items such as the fluid filters and
controlvalves. Theinletairfilterisalsoeasilyacces-
sible for servicing.
2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL
DESCRIPTION
Sullair air compressors feature the Sullair compres-
sorunit, asingle-stage,positivedisplacement,flood
lubricated-type compressor. Thisunit providescon-
tinuouspulse-freecompressiontomeetyourneeds.
With a Sullair compressor, there is no maintenance
or inspection of the internal parts of the compressor
unit permitted in accordance with the terms of the
warranty.
Sullair 24KT compressors are filled with a fluid
which rarely needs to be changed. In the event a
change of fluid is required, use only Sullair 24KT
fluid. MIXING OF OTHER LUBRICANTS WITHIN
THECOMPRESSORUNITWILLVOIDALLWAR-
RANTIES!
Figure 2-1 Sullair Rotary Screw Air Compressor

Section 2
DESCRIPTION
6
Figure 2-2 Sullair Rotary Screw Air Compressor
Sullairrecommendsthata24KTsamplebetakenat
the first filter change and sent to the factory for
analysis. This is a free service. The sample kit with
instruction and self-addressed container is to be
supplied by your Sullair dealer at start-up. The user
will receive an analysis report with recommenda-
tions.
Fluid is injected into the compressor unit in large
quantities and mixes directly with the air as the ro-
tors turn compressing the air. The fluid flow has
three basic functions:
1. As coolant, it controls the rise of air temperature
normally associated with the heat of compres-
sion.
2. Seals the leakage paths between the rotors and
the stator and also between the rotors them-
selves.
3. Acts as a lubricating film between the rotors al-
lowing one rotor to directly drive the other, which
is an idler.
After the air/fluid mixture is discharged from the
compressor unit, the fluid is separated from the air.
At this time, the air flows through an aftercooler and
separator then to your service line while the fluid is
being cooled in preparation for reinjection.
2.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
Refer to Figure 2-3. The cooling system (air-cooled
version) consists of a fan, fan motor, radiator-type
aftercooler/fluid cooler, full flow fluid filter thermal
valve, fluid stop valve and interconnecting piping
and tubing. For water-cooled models, two shell and
tube heat exchangers and a water-flow regulating
valve are substituted for the radiator-type cooler
listed above.
The pressure in the receiver/sump causes fluid flow
byforcingthefluidfromthehighpressureareaofthe
sump to an area of lower pressure in the compres-
sor unit.
Fluid flows from the bottom of the receiver/sump to
the thermal valve. The thermal valve is fully open

Section 2
DESCRIPTION
7
Figure 2-3 Compressor Fluid Cooling and Lubrication System
when the fluid temperature is below 170ºF (77ºC).
Thefluidpassesthroughthethermalvalve,themain
filter and directly to the compressor unit where it lu-
bricates, cools and seals the rotors and the com-
pression chamber.
As the discharge temperature rises above 170ºF
(77ºC), 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 then on to the compres-
sor unit.
A portion of the fluid flowing to the compressor is
routedtotheanti-frictionbearingswhichsupportthe
rotors inside the compressor unit. Prior to entering
the compressor unit, this fluid is taken through the
fluid filter, thus assuring properly filtered lubricant
for bearing supply.
The fluid filter has a replacement element and anin-
tegralpressurebypassvalve.A gaugeontheinstru-
ment panel shows red when the filter needs servic-
ing. This gauge has a pressure setting lower than
that of the bypass valve. Aftertheinitial50hourfilter
change,thegaugewillrarely showredundernormal
operating conditions.
The fluid stop valve prevents fluid from filling the
compressorunitwhenthecompressoris shutdown.
When the compressor is operating, the fluid stop
valveisheldopenbyair pressurefromthecompres-
sorunitallowingafreeflowoffluidfromthereceiver/
sump back to the compressor unit. On shutdown,
the compressor unit pressure is reduced, causing
thefluidstopvalvetocloseandisolatethecompres-
sor unit from the cooling system
Water-cooled versions of the compressor have a
water-flow regulating valve (not shown) whichoper-
ates to conserve water during periods of varying
load on the compressor. This same valve automati-
cally shuts off the water supply when the compres-
sor is shut down. In addition, water-cooled models
have a water pressure switch to prevent operation
with inadequate water pressure.

Section 2
DESCRIPTION
8
2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC-
TIONAL DESCRIPTION.
Refer to Figure 2-4. The compressor unit dis-
charges the compressed air/fluid moisture through
a discharge check valve into the combination re-
ceiver/sump. The discharge check valve prevents
air in the receiver from returning to the compression
chamber after the compressor has been shut down.
The receiver has three basic functions:
1. It acts as a primary fluid separator.
2. Serves as the compressor fluid sump.
3. Houses the final fluid separator.
The compressed air/fluid mixture enters the re-
ceiver and is directed towards the bottom of the
separator element. The direction of movement is
changed and its velocity significantly reduced, thus
causingthelargedropletsoffluidtofalltothebottom
of the receiver/sump. The fractional percentage of
fluid remaining inthe compressed air collects on the
surface of the separator element as the com-
pressed air flows through the separator. A return
line (or scavenge tube) leads from the bottom of the
separatorelementtotheinletregionofthecompres-
sorunit.Fluidcollectingonthebottomof thesepara-
tor is returned to the compressor by a pressure dif-
ferential between the receiver and the compressor
inlet. A visual sight glass islocated on the return line
to observe this fluid flow. There is also an orifice in
this return line (protected by a strainer) to assure
proper flow. A gauge, located on the instrument
Figure 2-4 Compressor Discharge System

Section 2
DESCRIPTION
9
panel, shows red if abnormal pressure drop through
the separator develops. At this time, separator ele-
ment replacement is necessary.
The receiver is ASME code rated at 175 PSIG
(1206kPa) working pressure. A minimum pressure/
check valve, located downstream from the separa-
tor, assures a minimum receiver pressure of 55
PSIG (379kPa) during all conditions. This pressure
is necessary for proper air/fluid separation and
proper fluid circulation.
A terminal check valve is incorporated into the mini-
mum pressure/check valve to prevent compressed
air inthe service line form bleeding back into the re-
ceiver on shutdown and during operation of the
compressor in an unloaded condition.
A pressure relief valve (located on the wet side of
theseparator)issettoopenifthesumppressureex-
ceeds 175 PSIG (1206kPa). A temperature switch
will shut down the compressor if the discharge tem-
perature reaches 240ºF (115ºC).
All compressor models are equipped with a high
pressure shutdown switch to shut down the com-
pressor at 135 PSIG (931kPa). This prevents the
pressure relief valve from opening under routine
conditions, thereby preventing fluidloss throughthe
pressure relief valve.
WARNING
!
DO NOT remove caps, plugs, or other compo-
nents when compressor is running or pressur-
ized.
Stop compressor and relieve all internal pressure
before doing so.
Fluid is added to the sump via a capped fluid filler
opening,placedlowonthetanktopreventoverfilling
of the sump. A sight glass enables the operator to
visually monitor the sump fluid level.
2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIP-
TION
Refer to Figure 2-5. The purpose of thecompressor
control system is to regulate the compressor air in-
take to match the amount of compressed air being
used. The Control System consists of a Sullicon
Control, a butterfly valve (located on the compres-
sor air inlet), a pressure switch, a pilot valve and
pressureregulator.Thefunctional descriptionofthe
control system is described below in four distinct
phases of compressor operation.The following de-
scriptive text applies to all 12 and 16 Series com-
pressors. For explanation purpose this description
will apply to a compressor with an operating pres-
sure range of 100 to 110 PSIG (689 to 758kPa). A
compressor with any other pressure range would
operate in the same manner except for the stated
pressures.
START MODE - 0 TO 55 PSIG (0 TO 379kPa)
When the compressor START button is depressed,
the pressure will quickly rise from 0 to 55 PSIG (0to
379kPa). During this period both the pressure regu-
lator and the pilot valve are closed and the Sullicon
Control is inoperative. The spring on the control
holdsthebutterflyvalvefully openandthecompres-
sorpumpsatfullratedcapacity.Therisingcompres-
sor air pressure is isolated from the service line in
this phase by the minimum pressure valve, set ap-
proximately at 55 PSI (379kPa).
NORMAL OPERATION MODE - 55 TO 100 PSIG
(379 TO 689kPa)
When the compressor air pressure rises above 55
PSIG (379kPa), the minimum pressure valve opens
and delivers compressed air to the service line.
Fromthispointon,thelineairpressureiscontinually
monitored by a line pressure gauge. The pressure
regulator and the pilot valve remain closed during
this phase, keeping the Sullicon Control inactive.
MODULATING MODE - 100TO 110 PSIG (689TO
758kPa)
If less than the rated capacity of compressed air is
being used, the service line pressure will rise above
100 PSIG (689kPa). The pressure regulator valve
gradually opens, applying air pressure to the dia-
phragm chamber of the Sullicon Control which par-
tiallyclosesthebutterflyvalveonthecompressorair
inlet; reducing the amount of air entering the com-
pressor until it matches the amount of air being
used. The control system functions continually in
this manner, between the limits of 100 to 110 PSIG
(689 to 758kPa), in response to varying demands
from the service line.
The pressure regulator has an orifice which vents a
small amount of air to the atmosphere when the
pressure regulator controls the butterfly valve. The
orifice also bleeds any accumulated moisture from
the Sullicon Control.
UNLOAD - IN EXCESS OF 110 PSIG (758kPa)
LINE PRESSURE
When no air is being used, the service line pres-
sures rises to the setting (cut-out pressure) of the
pressure switch. The pressure switch opens, inter-
ruptingtheelectricalpowertothesolenoid-typepilot
valve. At this time, the pilot valve allows dry sump
tank air pressure to be applied directly to thecontrol
diaphragm, keeping the butterfly valve closed. Si-
multaneously,thepilotvalvesendsapneumaticsig-
nal to the blowdown valve. The blowdown valve
opens the sump to the atmosphere, reducing the
sumppressuretoapproximately40to50PSIG(276
to 379kPa). The check valve in the air service line
prevents line pressure from returning to the sump.
Whenthelinepressuredropstothelowsetting(cut-
in pressure) of the pressure switch (usually 100
PSIG [689kPa] on low pressure compressors and
115PSIG[793kPa] onhighpressurecompressors),
the pressure switch closes, re-energizing the three-

Section 2
DESCRIPTION
10
Figure 2-5 Control System, Sequence of Operation

Section 2
DESCRIPTION
11
Figure 2-6 Compressor Air Inlet System
way pilot valve and allowing the blowdown valve to
close. The re-energized pilot valve again prevents
line pressure from reaching the Sullicon Control.
Should the pressure begin to rise, the pressure
regulator will resume its normal function as previ-
ously described.
For a compressor with varied periods of time, when
there are not air requirements, a “dual control” op-
tion is available. This option allows you to set the
compressor in an automatic position whereby the
compressor will shut down whenno compressed air
requirement is present and restart as compressed
air is needed.
2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIP-
TION
Refer to Figure 2-6. The compressor inlet system
consists of a dry-type air filter, a restriction gauge
and a control valve.
Therestrictiongauge,locatedonthecompressorin-
strument panel, indicates the condition of the air fil-
ter by showing red when filter maintenance is re-
quired.
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 (see Section
2.6, Control System).
See Section 5 for Air Filter Maintenance Proce-
dures. Dust collectors should be checked and
cleaned daily.
2.8 INSTRUMENT PANEL GROUP, FUNCTIONAL
DESCRIPTION
Refer to Figure 2-7 for specific location of parts de-
scribed. The instrument panel group consists of a
panel containing the line pressure,sump pres-
sure and discharge temperature gauges,the air
filter,theseparator element and the fluid filter,
restriction gauges,theair filter,theseparator
element and the fluid filter,restriction gauges,
along with START and STOP pushbuttons and an
hourmeter.
Refer toFigure 2-7forlocations ofthefollowingindi-
cators and controls:
STheline (terminal) pressure gauge isconnected
to the dry side of the receiver downstream from the
check valve and continually monitors the air pres-
sure.
SThe sump pressure gauge continually monitors
thesumppressure atthevariousloadand/orunload
conditions.
SThe discharge temperature gauge monitors the
temperature of the air leaving the compressor unit.
For both air-cooled and water-cooled compressors
the normal reading is approximately 180ºF (82ºC).
STheair filter restriction gauge monitors the con-
ditionoftheairintakefilterandshowsintheredzone
(20 to 30” water[51 to 76 cm]) when filter service is
Figure 2-7 Instrument Panel Group

Section 2
DESCRIPTION
12
required (see Figure 2-7) .
SThe START pushbutton turns the compressor on.
SThe STOP pushbutton turns the compressor off.
SThehourmeterrecords accumulativehoursofop-
erationforthecompressorandisusefulforplanning
and logging service operations.
SThe separator maintenance gauge monitors
condition of the separator element and shows in the
red zone when the element restriction isexcessive.
SThefluid filter maintenancegaugemonitorsthe
condition of the bearing lube filter element and
shows in the red zone when the element should be
changed.
SThe red light on the instrument panel indicates
when power to the compressor is supplied.
SThegreen lightindicates when the compressor is
running.
SThe optional dual control package is supplied
with an amber auto mode indicator light to indicate
that the unit is running in the automatic mode. A po-
sition selector switch provides selector between
hand operation and automatic control.

Section 3
SPECIFICATIONS
13
SULLAIR SERIES 12 AND 16 SPECIFICATIONS
DIMENSIONS
Model Series Length Width Height Weight (I)
in mm in mm in mm lb kg
12B-40 and 50HP (STD & KT) 72 1830 48 1220 60 1524 2060 935
12B-60HP (STD & KT) 72 1830 48 1220 60 1524 2350 1066
16-60 HP (STD & KT) 72 1830 48 1220 60 1524 2590 1175
16-75 HP (STD & KT) 72 1830 48 1220 60 1524 2680 1217
ENCLOSURE (Optional) 72 1830 48 1220 62 1588 500 227
EES PACKAGE (Optional) 89 2262 48 1220 103 2618 510 259
(I)Theweights shownfor theEnclosure andEES packages doesnot includethe weightof thecompres-
sor package.
COMPRESSOR: 24KT MODELS STANDARD MODELS
Type Rotary Screw Rotary Screw
Standard Operating Pressure (II) 100 PSI (689kPa) (L) 100 PSI (689kPa) (L)
115 PSI (792kPa) (R) 115 PSI (792kPa) (R)
Bearing Type Anti-Friction Anti-Friction
Ambient Temperature (Max.) (III) 105ºF (40ºC) 105ºF (40ºC)
Cooling Pressurized Fluid Pressurized Fluid
Compressor Fluid Sullair 24KT Coolant Fluid SRF/400
Sump Capacity 8.0 U.S. Gallons (30 Liters) 8.0 U.S. Gallons (30.25 Liters)
(40 and 50HP) (40 and 50HP)
9.0 U.S. Gallons (34 Liters) 9.0 U. S. Gallons (34 Liters)
(60 and 75HP) (60 and 70HP)
Control Electro-Pneumatic Electro-Pneumatic
MOTOR: (60 Cycle Compressors)
24KT MODELS STANDARD MODELS
Size 40,50,60 and 75 HP 40,50,60 and 75 HP
Type C-Flanged, Open Dripproof, 460V, A.C., C-Flanged, Open Dripproof, 460V, A.C.,
Three Phase, 60 Cycles Three Phase, 60 Cycles
40ºC Maximum Ambient Temperature 40ºC Maximum Ambient Temperature
Options Available: 200V, 230V and 575V Options Available: 200V, 230V and 575V
T.E.F.C. Also Available T.E.F.C. Also Available
Starter 460V Full Voltage Magnetic 460V Full Voltage Magnetic
Options Available: 200V, 230V and 575V Options Available 200V, 230V and 575V
Speed 1770 RPM 1770RPM
(II) Special compressors are available for operating at higher pressures.
(III) Special compressors are available for operation in higher ambient temperature.

Section 3
SPECIFICATIONS
14
SULLAIR SERIES 12 AND 16 SPECIFICATIONS (continued)
MOTOR: (50 Cycle Compressors)
Size 40-50-60 and 75 HP 40-50-60 and 75 HP
Type C-Flanged, Open Dripproof, 380V, C-Flanged, Open Dripproof, 380V,
A.C., Three Phase, 50 Cycles A.C., Three Phase, 50 Cycles
40ºC Maximum Ambient Temperature 40ºC Maximum Ambient Temperature
Starter 460V Full Voltage Magnetic 460V Full Voltage Magnetic
Speed 1500 RPM 1500 RPM
LUBRICATION GUIDE-STANDARD COMPRES-
SORS
Sullair standard compressors are filled with SRF
1/4000 fluid factory fill. MIXING OF OTHER FLU-
IDS WITHIN THE COMPRESSOR WILL VOID
ALL WARRANTIES.
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 se-
vere operating conditions, such as high ambient
temperatures coupled with high humidity, or when
high particle level, corrosive gases or strong oxidiz-
ing gases are present in the air.
For extended life synthetic lubricants contact the
nearest Sullair representative.
Maintenance of all other components is still recom-
mended as indicated in the Operator’s Manual.
LUBRICATION GUIDE-24KT COMPRESSORS
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. MIXING OF OTHER LUBRICANTS WITHIN
THECOMPRESSORUNITWILLVOIDALLWAR-
RANTIES!
Sullairrecommendsthata24KTsamplebetakenat
the first filter change and sent to the factory for
analysis. This is a free service. A sample kit with in-
structions and self-addressed container is to be
supplied by your Sullair Representative at start-up.
The user will receive analysis report with recom-
mendations.
APPLICATION GUIDE
Sullair encourages the user to participate in a oil
analysis program with the oil suppliers. This could
result in an oil change interval differing from that
stated in the manual. Contact your Sullair dealer for
details.