Sullair TS-20 Installation and maintenance instructions

INDUSTRIAL
100---250HP/75---187KW
MANUAL AND
Part Number 02250059---860
eSullair Corporation
AIR COMPRESSOR
TS---20 SERIES
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Manual Brought to You By: IndustrialAirPower.com

AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are 3---day courses that provide hands---on instruction
in the proper operation, maintenance and service of Sullair equipment.
Individual seminars on Industrial compressors and compressor electrical
systems are presented at regular intervals throughout the year at a dedicated
Instruction includes discussion of the function and installation of Sullair service
parts, troubleshooting of the most common problems, and actual equipment
operation. The seminars are recommended for maintenance and service
personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1---800---SULLAIR or 219---879---5451 (ext. 1816)
--- Or Write ---
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department

TABLE OF CONTENTS
Section 1 PAGE
SAFETY 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
41.10 ENTRAPMENT
Section 2
DESCRIPTION 52.1 INTRODUCTION
52.2 DESCRIPTION OF COMPONENTS
62.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
62.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
62.5 COMPRESSOR DISCHARGE SYSTEM,
FUNCTIONAL DESCRIPTION
92.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
12 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
12 2.8 INSTRUMENTATION, FUNCTIONAL DESCRIPTION
Section 3
SPECIFICATIONS 15 3.1 SULLAIR TS---20 SPECIFICATIONS
16 3.2 LUBRIFICATION GUIDE---STANDARD COMPRESSORS
Section 4
INSTALLATION 17 4.1 MOUNTING OF COMPRESSOR
17 4.2 VENTILATION AND COOLING
17 4.3 SERVICE AIR PIPING
17 4.4 COUPLING ALIGNMENT CHECK
17 4.5 FLUID LEVEL CHECK
17 4.6 ELECTRICAL PREPARATION
18 4.7 MOTOR ROTATION DIRECTION CHECK
Section 5
OPERATION 19 5.1 GENERAL
19 5.2 PURPOSE OF CONTROLS
20 5.3 INITIAL START---UP PROCEDURE
21 5.4 SUBSEQUENT START---UP PROCEDURE
21 5.5 SHUTDOWN PROCEDURE

TABLE OF CONTENTS
(CONTINUED)
Section 6 PAGE
MAINTENANCE 23 6.1 GENERAL
23 6.2 DAILY OPERATION
23 6.3 MAINTENANCE AFTER INITIAL 50 HOURS
OF OPERATION
23 6.4 MAINTENANCE AFTER 1000 HOURS
23 6.5 FILTER MAINTENANCE
23 6.6 SEPARATOR MAINTENANCE
23 6.7 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
28 6.8 TROUBLESHOOTING
Section 7
RECOMMENDED
SPARE PARTS LIST 31 7.1 PROCEDURE FOR ORDERING PARTS
31 7.2 RECOMMENDED SPARE PARTS LIST
32 7.3 MOTOR, COMPRESSOR AND FRAME --- 100, 125, 150 & 200HP/
75, 93, 112 & 150KW
36 7.4 MOTOR, COMPRESSOR AND FRAME --- 250HP/187KW
38 7.5 AIR INLET SYSTEM --- 100, 125 & 150HP/75, 93 & 112KW
40 7.6 AIR INLET SYSTEM --- 200 & 250HP/150 & 187KW
42 7.7 COMPRESSOR COOLING AND LUBRICATION SYSTEM ---
100HP/75KW (AIR---COOLED)
44 7.8 COMPRESSOR COOLING AND LUBRICATION SYSTEM ---
125 & 150HP/93 & 112KW (AIR---COOLED)
48 7.9 COMPRESSOR COOLING AND LUBRICATION SYSTEM ---
200HP/150KW (AIR---COOLED)
52 7.10 COMPRESSOR COOLING AND LUBRICATION SYSTEM ---
250HP/187KW (AIR---COOLED)
56 7.11 COMPRESSOR COOLING AND LUBRICATION SYSTEM ---
100HP/75KW (WATER---COOLED)
60 7.12 COMPRESSOR COOLING AND LUBRICATION SYSTEM ---
125 & 150HP/93 & 112KW (WATER---COOLED)
64 7.13 COMPRESSOR COOLING AND LUBRICATION SYSTEM ---
200HP/150KW (WATER---COOLED)
68 7.14 COOLER ASSEMBLY --- ALL MODELS
70 7.15 COMPRESSOR DISCHARGE SYSTEM --- 100, 125 & 150HP/
75, 93 & 112KW
76 7.16 COMPRESSOR DISCHARGE SYSTEM --- 200HP/150KW
82 7.17 COMPRESSOR DISCHARGE SYSTEM --- 250HP/187KW
88 7.18 INSTRUMENT PANEL --- ALL MODELS
90 7.19 PNEUMATIC CONTROLS --- ALL MODELS
94 7.20 ELECTRIC CONTROL BOX --- ALL MODELS
96 7.21 SULLICON CONTROL --- 100, 125 & 150HP/75, 93 & 112KW
98 7.22 SULLICON CONTROL --- 200 & 250HP/150 & 187KW
100 7.23 CANOPY --- ALL MODELS
102 7.24 COOLER/AFTERCOOLER WATER PLUMBING---
100, 125 & 150HP/75, 93 & 112KW
104 7.25 COOLER/AFTERCOOLER WATER PIPING --- 200HP/150KW

TABLE OF CONTENTS
(CONTINUED)
Section 7 PAGE
RECOMMENDED
SPARE PARTS LIST 106 7.26 UNIT TUBING AND SPIRAL VALVE--- ALL MODELS
110 7.27 DECAL GROUP
118 7.28 WIRING DIAGRAM---SINGLE CONTROL
119 7.29 WIRING DIAGRAM---DUAL CONTROL
120 7.30 WIRING DIAGRAM---WYE DELTA---SINGLE CONTROL
121 7.31 WIRING DIAGRAM---WYE DELTA---DUAL CONTROL

NOTES

Section 1
SAFETY
1
1.1 GENERAL
Sullair Corporation and its subsidiaries design and
manufacture all of their products so they can be op-
erated 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 fol-
lowed, 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
Manual. Failure to follow the instructions, proce-
dures 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 compres-
sor and render it inoperative by disconnecting and
locking out all power at source or otherwise disab-
ling 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 com-
pressors with all types of prime movers, most of the
precautionary statements contained herein are ap-
plicable to most compressors and the concepts
behind these statements are generally applicable
to all compressors.
1.2 PERSONAL PROTECTIVE EQUIPMENT
Prior to installing or operating the compressor,
owners, employers and users should become fa-
miliar with, and comply with, all applicable OSHA
regulations and/or any applicable Federal, State
and Local codes, standards, and regulations rela-
tive to personal protective equipment, such as eye
and face protective equipment, respiratory protec-
tive equipment, equipment intended to protect the
extremities, protective clothing, protective shields
and barriers and electrical protective equipment,
as well as noise exposure administrative and/or en-
gineering controls and/or personal hearing protec-
tive equipment.
1.3 PRESSURE RELEASE
A. Install an appropriate flow--- limiting valve be-
tween 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 ex-
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 applicable
Federal, State and Local codes, standards and
regulations.
B. When the hose is to be used to supply a man-
ifold, install an additional appropriate flow---limiting
valve between the manifold and each air hose ex-
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
ameter to reduce pressure in case of hose failure.
D. Flow--- limiting valves are listed by pipe size and
rated CFM. Select appropriate valves accordingly,
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 ac-
cordingly. DO NOT
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 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 components, 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 (2.1 bar) for
cleaning purposes, and then only with effective
chip guarding and personal protective equipment
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 antifreeze
compound.

Section 1
SAFETY
2
C. DO NOT permit fluids, including air line anti---
icer system antifreeze compound or fluid film to ac-
cumulate on, under or around acoustical material,
or on any external surfaces of the air compressor or
on internal surfaces of the enclosure. Wipe down
using an aqueous industrial cleaner or steam clean
as required. If necessary, remove acoustical mate-
rial, clean all surfaces and then replace acoustical
material. Any acoustical material with a protective
covering that has been torn or punctured should be
replaced immediately to prevent accumulation of
liquids or fluid film within the material. DO NOT use
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
pressure connectors in good condition. Replace
any wiring that has cracked, cut, abraded or other-
wise 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 materi-
al 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 servic-
ing 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 also clothing away from couplings, fans and
other moving parts.
B. DO NOT attempt to operate the 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
verify at the compressor that all circuits are de---en-
ergized to minimize the possibility of accidental
start---up, or operation, prior to attempting repairs
or adjustments. This is especially important when
compressors 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. DO NOT use air from this compressor for respi-
ration (breathing) except in full compliance with
OSHA Standards 29 CFR 1910 and/or any applica-
ble Federal, State or Local codes or regulations.
DANGER
!
Death or serious injury can result from inhaling
compressed air without using proper safety
equipment. See OSHA standards and/or any ap-
plicable Federal, State, and Local codes, stan-
dards and regulations on safety equipment.
B. DO NOT use air line anti--- icer systems in air
lines supplying respirators or other breathing air
utilization equipment and DO NOT discharge air
from these systems into unventilated or other con-
fined 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 oth-
er 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. 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.

Section 1
SAFETY
3
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 15 minutes. A physician, preferably an
eye specialist, should be contacted immediately.
H. DO NOT store air line anti---icer system anti-
freeze 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 swal-
lowed, induce vomiting by administering a table-
spoon 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 pa-
tient 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 Federal,
State and Local codes, standards and regulations,
including those of the National Electrical Code, and
also including those relative to equipment ground-
ing conductors, and only by personnel that are
trained, qualified and delegated to do so.
B. Keep all parts of the body and any hand---held
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 to exposed live
parts of the electrical system. Make all such adjust-
ments or repairs with one hand only, so as to mini-
mize 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 pow-
er.
E. Disconnect, lock out and tag all power at source
prior to attempting repairs or adjustments to rotat-
ing machinery and prior to handling any un-
grounded 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 to be air lifted by he-
licopter 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 standards 29
CFR 1910 subpart N and/or any applicable Feder-
al, State, and Local codes, standards and regula-
tions.
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 condition,
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.
I. Keep lift operator in constant attendance when-
ever compressor is suspended.
J. Set compressor down only on a level surface ca-
pable 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 ob-
stacles 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 sudden stops may
cause the compressor to tumble off, possibly caus-
ing serious injury or property damage in the pro-
cess.

Section 1
SAFETY
4
1.10 ENTRAPMENT
A. If the compressor enclosure, if any, is large
enough to hold a man and if it is necessary to enter
it to perform service adjustments, inform other per-
sonnel before doing so, or else secure and tag the
access door in the open position to avoid the possi-
bility of others closing and possibly latching the
door with personnel inside.
B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.

Section 2
DESCRIPTION
5
2.1 INTRODUCTION
Your new Sullair lubricated rotary screw air com-
pressor will provide you with a unique experience in
improved reliability and greatly reduced mainte-
nance.
Compared to other types of compressors, the Sull-
air rotary screw is unique in mechanical reliability,
working parts within the compressor unit.
Read Maintenance section to see how surprisingly
easy it is to keep your air compressor in top operat-
ing condition. Should any questions arise which
cannot be answered in the following text, call your
nearest Sullair representative or the Sullair Corpo-
ration Service Department.
2.2 DESCRIPTION OF COMPONENTS
RefertoFigure2---1.Thecomponentsandassem-
blies of the air compressors are clearly shown. The
complete package includes compressor, electric
motor, compressor inlet system, compressor
discharge system, compressor cooling and lu-
brication system, capacity control system and
instrument panel all mounted on a heavy gauge
steel frame.
On air--- cooled models, a separate motor---driven
fan blows air through the cooler/aftercooler assem-
bly, thereby removing the heat of compression from
the cooling fluid.
On water---cooled models, fluid is piped into a four-
pass exchanger where the heat of compression is
removed from the fluid. A fan is used to supply suffi-
cient ventilating air to compressors equipped with a
canopy.
Both air---cooled and water--- cooled versions have
easily accessible components such as the fluid fil-
Figure 2 ---1 Sullair TS ---20 Rotary Screw Air Compressor

Section 2
DESCRIPTION
6
ters and control valves. The inlet air filters are also
mounted for easy access and servicing.
2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL
DESCRIPTION
Sullair tandem air compressors feature the Sullair
compressor unit, a two---stage, positive displace-
ment fluid lubricated---type compressor. This unit
provides continuous (pulse--- free) air compression
to meet your needs.
Fluid is injected into the compressor unit in large
quantities where it mixes directly with the air as the
internal rotors 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. It seals the leakage paths between the rotors and
the stator and also between the rotors them-
selves.
3. It 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 to the service line and the
fluid is cooled in preparation for injection.
NOTE
With a Sullair compressor, there is no mainte-
nance or inspection of the internal parts of the
compressor unit permitted in accordance with the
terms of the warranty.
2.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
RefertoFigures2---2.Thecoolingandlubrication
system (air--- cooled version) consists of a fan, ra-
diator---type cooler/aftercooler assembly, full ---
flow fluid filter, thermal valve, fluid stop valve and
interconnection piping. For water---cooled mod-
els, a shell and tube fluid cooler, aftercooler and
water---flow regulating valve are substituted for
the radiator--- type cooler on air---cooled compres-
sors.
The pressure in the receiver/sump causes fluid flow
by forcing the fluid from the high pressure area of
the sump to an area of lower pressure in the com-
pressor unit.
Fluid flows from the bottom of the receiver/sump to
the thermal valve. The thermal valve is fully open
when the fluid temperature is below 170_F (77_C).
The fluid passes through the thermal valve, the main
fluid filter and directly to the compressor unit where
it lubricates, cools and seals the rotors and the com-
pression chamber.
As the discharge temperature rises above 170_F
(77_C), 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 fluid filter, and on to the compressor unit.
A portion of the fluid flowing to the compressor is
routed to the anti---friction bearings which support
the rotors inside the compressor unit.
The fluid filter has a replacement element and an in-
tegral pressure bypass valve. An associated service
gauge shows red when the filter needs servicing.
This gauge has a pressure setting lower than that of
the bypass valve. After the initial 50 hour filter
change, the gauge will rarely show red under nor-
mal operating conditions.
The fluid stop valve prevents fluid from filling the
compressor unit when the compressor is shut
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
receiver/sump back to the compressor unit. On
shutdown, the compressor unit pressure is re-
duced, causing the fluid stop valve to close and iso-
late the compressor unit from the cooling system.
Water---cooled versions of the compressor have a
water---flow regulating valve which operates to con-
serve water during periods of varying load on the
compressor. The same valve automatically shuts off
the water supply when the compressor is shut
down. In addition, water---cooled models have a wa-
ter pressure switch to prevent operation with inade-
quate water pressure.
2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC-
TIONAL DESCRIPTION
RefertoFigures2---3.Thecompressorunitdis-
charges the compressed air/fluid mixture through a
discharge check valve into the combination receiv-
er/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. It serves as the compressor fluid sump.
3. It houses the final fluid/air separator elements.
The compressed air/fluid mixture enters the receiver
and is directed against the far side of the tank,
where its direction of movement is changed and its
velocity significantly reduced. This causes large
droplets of fluid to collect, separate and fall to the
bottom of the receiver/sump. The fractional percent-
age of fluid remaining in the compressed air collects
on the surface of the dual separator elements (pri-
mary and secondary) 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 inlet region of the compressor unit.
Fluid collecting on the bottom of each separator is
returned to the compressor by a pressure difference
between the receiver and the compressor inlet.

Section 2
DESCRIPTION
7
Figure 2 ---2 Compressor Cooling and Lubrication and Discharge System (Air---cooled)

Section 2
DESCRIPTION
8
Figure 2 ---3 Compressor Cooling and Lubrication and Discharge System (Water---cooled)

Section 2
DESCRIPTION
9
Sight glasses are located in the return lines to ob-
serve this fluid flow. A gauge, located on the instru-
ment panel, will be in the red zone when excessive
pressure drop through the separator develops. At
this time, separator element(s) replacement is nec-
essary.
The receiver is an ASME pressure vessel. A com-
bination minimum pressure/check valve, located
downstream from the separator, assures a mini-
mum receiver pressure of 50 psig (3.5 bar) during
full load operation. This pressure is necessary for
proper air/fluid separation and proper fluid circula-
tion 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 re-
ceiver on shutdown and during operation on the
compressor in an unloaded condition.
A pressure relief valve (located on the wet side of the
separator) is set to open if the sump pressure ex-
ceeds 175 psig (12.1 bar).
All Sullair compressor models are equipped with a
high pressure shutdown switch to shut down the
compressor at 135 psig (9.3 bar). This prevents the
pressure relief valve from opening under normal
conditions, thereby preventing fluid loss through
the pressure relief valve. A temperature switch will
shut down the compressor if the discharge temper-
ature reaches 240_F (116_C).
WARNING
!
DO NOT remove caps, plugs, and/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, placed low on the receiver tank to prevent
overfilling of the sump. A sight glass enables the op-
erator to visually monitor the sump fluid level.
2.6 CONTROL SYSTEM, FUNCTIONAL DE-
SCRIPTION
Refer to Figure 2---4. The purpose of the compres-
sor control system is to regulate the amount of air
being compressed to match the amount of com-
pressed air being used.
The capacity control system consists of a Sulli-
con Control, abutterfly valve (located on the com-
pressor air inlet), a spiral valve, apressure switch,
two (2) solenoid valve pressure regulators, and
two (2) control line filters. The functional descrip-
tion of the control system is described below in four
distinct phases of compressor operation. The fol-
lowing applies to all TS---20 Series compressors.
This description applies to any compressor with an
operating range of 100 to 110 psi (6.9 to 7.6 bar). A
compressor with any other pressure range would
operate in the same manner except for the stated
pressures.
1. START MODE --- 0 TO 50 PSIG (0 TO 3.5 BAR)
When the compressor START button is depressed,
the sump pressure will quickly rise from 0 to 50 psig
(0 to 3.5 bar). During this period, the spiral valve
fully closes, while the inlet butterfly valve fully opens.
As a result, the compressor runs at full capacity.
2. FULL LOAD MODE --- 50 TO 100 PSI (3.5 TO 6.9
BAR)
When the sump pressure rises above 50 psi (3.5
bar), the minimum pressure valve opens, allowing
compressed air to flow into the service line. 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 psi (6.9 bar) or below.
3. MODULATION MODE --- 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 apply-
ing air pressure to the spiral valve actuator. Air pres-
sure at the actuator assembly expands the dia-
phragm. The rack, which engages with the pinion
mounted on the spiral valve shaft assembly, begins
to stroke. This results in a rotary motion. As the spi-
ral valve rotates, it starts opening the bypass ports
gradually. Excess air is then being returned back to
suction. Now the compressor is compressing only
that amount of air which is being used. As air de-
mand keeps on dropping further, the spiral valve
opens gradually until all the bypass ports are fully
open. At this point, the spiral valve has moved into
the unload position.
The spiral valve provides a modulation range from
50 to 100%. During this period, the pressure rises
approximately from 100 to 108 psi (6.9 to 7.5 bar).
As the air pressure exceeds 108 psi (7.5 bar), the dif-
ferential pressure regulator controlling the Sullicon
Control opens. This allows the air pressure to the di-
aphragm chamber of the Sullicon Control which
starts to close the inlet butterfly valve partially. The
inlet butterfly valve provides modulating range from
40 to 50%. During this period, the pressure rises
approximately from 108 to 110 psi (7.5 to 7.6 bar).
Within this range, the spiral valve remains in the un-
load position.
4. UNLOAD MODE --- IN EXCESS OF 110 PSI (7.6
BAR)
When a relatively small amount, or no air is being
used, the service line pressure keeps on rising.
When it exceeds 110 psig (7.6 bar), the air pressure
switch opens de---energizing the solenoid valve.
The line pressure through the solenoid valve holds
inlet butterfly valve closed, and at the same time it
opens the blowdown valve. Reduced sump pres-
sure during blowdown results in low unload power
consumption. While the compressor is running un-
loaded, the inlet butterfly valve remains in the un-

Section 2
DESCRIPTION
10
Figure 2 ---4A Control System TS ---20 (with Spiral Valve)
(0--50 PSI/ 0--3.5 BAR)
(50--100 PSI/ 3.5--6.9 BAR)
SOLENOID VALVE
SOLENOID VALVE
SOLENOID VALVE
SOLENOID VALVE

Section 2
DESCRIPTION
11
Figure 2 ---4B Control System TS ---20 (with Spiral Valve)
(100--110 PSI/ 6.9-- 7.6 BAR)
SOLENOID VALVE
SOLENOID VALVE
SOLENOID VALVE
SOLENOID VALVE

Section 2
DESCRIPTION
12
load position. As the line pressure fluctuates be-
tween 100 and 110 psi (6.9 to 7.6 bar), the spiral
valve will modulate.
When the line pressure falls to 100 psi (6.9 bar), due
to an increase in the air demand, the air pressure
switch closes. The solenoid valve is then energized
allowing the air pressure behind the Sullicon Con-
trol to be vented through the solenoid valve exhaust
port. The blowdown valve closes, and the inlet but-
terfly valve opens. Also at this time, the air pressure
at the diaphragm of the spiral valve actuator has
been released through a vent hole in the spiral valve
differential pressure regulator. This allows the spiral
valve to close as a result of the movement of the rack
and pinion. The compressor is now running again in
full load mode. The spiral valve as well as the inlet
butterfly valve are in full load position.
For a compressor with varied periods of time when
there are no air requirements, a “
tion is available. This option allows you to set the
compressor in an automatic position whereby the
compressor will shut down (time delayed) when no
compressed air requirement is present and restart
as compressed air is needed.
2.7 AIR INLET SYSTEM, FUNCTIONAL DE-
SCRIPTION
RefertoFigure2---5.Thecompressorinletsystem
consists of a dry---type air filter, a restriction
gauge and an air inlet valve.
The restriction gauge, located on the compressor
instrument panel, indicates the condition of the air
filter. When the pointer reaches the red zone, filter
maintenance is required.
The butterfly---type air inlet valve directly controls
the amount of air intake by the compressor in re-
sponsetotheoperationoftheSulliconControl(Sec-
tion2.6).
2.8 INSTRUMENTATION, FUNCTIONAL DE-
SCRIPTION
RefertoFigure2---6forspecificlocationofpartsde-
scribed. The panel group consists of a number of
gauges, buttons and status indicator lights. Refer to
Figure2---6asyoureadthissegment.Locatethefol-
lowing: line pressure, sump pressure and dis-
charge temperature gauges and the air filter,
separator and fluid filter restriction gauges,
along with start and stop buttons and an hourmet-
er.
RefertoFigure2---7forfunctionallocationsofthe
following indicators and controls:
SThe line (terminal) pressure gauge is con-
nected to the dry side of the receiver downstream
from the check valve. It continually monitors the air
pressure.
SThe sump pressure gauge continually monitors
the sump pressure at the various load and/or un-
load conditions.
Figure 2 ---5 Compressor Air Inlet System
100, 125, & 150 HP
(75, 93, & 112 kW)
200 & 250 HP
(150 & 187 kW)
SThe discharge temperature gauge monitors the
temperature of the air leaving the compressor unit.
SThe air filter restriction gauge monitors the
condition of the air intake filter. When pointer reach-
estheredzone,filterserviceisrequired(seeFigure
2---6).
SThe start pushbutton turns the compressor on and
resets the compressor.

Section 2
DESCRIPTION
13
Figure 2 ---6 Instrument Panel Group SThe stop pushbutton turns the compressor off.
SThe hourmeter records cumulative hours of op-
eration of the compressor. It is useful for planning
and logging service operations.
SThe separator maintenance gauge monitors the
condition of the separator elements. Pointer will
move into the red zone when the elements should
be replaced. This gauge is automatically reset after
the elements have been replaced.
SThe fluid filter maintenance gauge monitors the
condition of the fluid filter element. Pointer will move
into the red zone when the element should be re-
placed. This gauge is also automatically re---set af-
ter elements have been changed (for fluid filter loca-
tion see Figure 2---3).
SThe red light on the instrument panel indicates
when power to the compressor is supplied.
SThe green light indicates when the compressor is
running.

Section 2
DESCRIPTION
14
Figure 2 ---7 Piping and Instrument Diagram
SOLENOID VALVE #1
SOLENOID VALVE #2
(SPIRAL VALVE)
(N.O.)