Sullair TS20C User manual

Failure to follow the instructions
and procedures in this manual or,
misuse of this equipment will
VOID its warranty!
WARRANTY NOTICE
PART NUMBER:
KEEP FOR
FUTURE
REFERENCE
USER MANUAL
©SULLAIR CORPORATION
The information in this manual is current
as of its publication date, and applies to
compressor serial number:
and all subsequent serial numbers.
02250184-783 R00
200910010000
INDUSTRIAL AIR COMPRESSOR
TS20C/V200TSV

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 INTRODUCTION
11 2.2 COMPRESSOR COMPONENT DESCRIPTION
17 2.3 COMPRESSOR COOLING AND LUBRICATION SYSTEM—FUNCTION-
AL DESCRIPTION
17 2.4 COMPRESSOR DISCHARGE SYSTEM—FUNCTIONAL DESCRIPTION
18 2.5 CONTROL SYSTEM— FUNCTIONAL DESCRIPTION FOR TS20C
19 2.6 CONTROL SYSTEM— FUNCTIONAL DESCRIPTION V200TS
22 2.7 AIR INLET SYSTEM— FUNCTIONAL DESCRIPTION
SECTION 3—SPECIFICATIONS
73 3.1 TABLE OF SPECIFICATIONS—TS-20C
73 3.2 TABLE OF SPECIFICATIONS—V200TS
73 3.3 COMPRESSOR SPECIFICATIONS
74 3.4 MOTOR SPECIFICATIONS
74 3.5 MOTOR SPECIFICATIONS
74 3.6 LUBRICATION GUIDE
75 3.7 APPLICATION GUIDE
75 3.8 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE,
FLUID FILTER AND SEPARATOR

TABLE OF CONTENTS
SECTION 4—INSTALLATION
101 4.1 COMPRESSOR MOUNTING— SUPPORT AND LOCATION
101 4.2 VENTILATION AND COOLING
105 4.3 SERVICE AIR PIPING
105 4.4 COUPLING ALIGNMENT CHECK
105 4.5 FLUID LEVEL CHECK
106 4.6 ELECTRICAL PREPARATION
106 4.7 MOTOR ROTATION DIRECTION CHECK
SECTION 5—SUPERVISOR CONTROLLER
SECTION 6—MAINTENANCE
111 6.1 GENERAL
111 6.2 DAILY OPERATION
111 6.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
111 6.4 MAINTENANCE EVERY 2000 HOURS
111 6.5 FLUID MAINTENANCE
112 6.6 FLUID FILTER MAINTENANCE
113 6.7 AIR FILTER MAINTENANCE
114 6.8 SEPARATOR MAINTENANCE
116 6.9 FLUID RETURN/SIGHT GLASS MAINTENANCE
117 6.10 PRESSURE REGULATOR ADJUSTMENT
118 6.11 WATER CONDENSATE DRAIN MAINTENANCE
118 6.12 CONTROL LINE FILTER
118 6.13 SHAFT COUPLING MAINTENANCE
SECTION 7—TROUBLESHOOTING
119 7.1 TROUBLESHOOTING— INTRODUCTION

Section 1
5
SAFETY
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)
NOTE
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL.

SECTION 1
6
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
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
7
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.
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
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.

SECTION 1
8
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.
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.
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.

SECTION 1
9
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.

NOTES
10

Section 2
11
TS20C USER MANUAL
DESCRIPTION
2.1 INTRODUCTION
The design of the Sullair TS20C/V200TS compressor
unit is a two stage, positive displacement, flood
lubricated one. A complete package includes the:
• Compressor unit
• Electric motor
• MFV STR/Variable speed drive
• Compressor inlet and discharge systems
• Compressor lubrication and cooling system
• Capacity control system
• Supervisor™ Controller
• Aftercooler
• Moisture separator
• Moisture Trap
• Heavy gauge steel mounting frame
Although the compressor requires no inspection of
the unit’s internal components, external piping,
connectors, and the enclosure should be inspected
and maintained in accordance with the procedures
and recommendations in this manual.
2.2 COMPRESSOR
COMPONENT DESCRIPTION
The components and assemblies of the air
compressors are clearly shown. The complete
package includes compressor, electric motor,
variable speed drive, Supervisor Controller,
compressor inlet system, compressor discharge
system, compressor lubrication and cooling system,
capacity control system, instrument panel,
aftercooler and combination separator and trap, all
mounted on a heavy gauge steel frame.
On air-cooled models, a fan draws air over the motor
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
exchanger is mounted on the compressor frame.
Fluid is piped into the heat exchanger where
compression heat is removed from the fluid. Another
similar heat exchanger cools the compressed air.
After the fluid is cooled, it is injected into the
compressor, and mixes directly with the air as the
rotors turn which compresses the air. The fluid flow
has three basic functions:
1. As a coolant, it controls the air temperature
rise normally associated with the heat of
compression.
2. Seals the clearance paths between the
rotors and the stator, and also between the
two rotors.
3. Provides a lubricating film between the rotors
allowing 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, and then to the service line while the fluid
is cooled and filtered in preparation for reinjection.
Both air-cooled and water-cooled versions have
easily accessible items such as the fluid filters and
control valves. The inlet air filter is also easily
accessible for servicing.
CAUTION
Use only one type of a recommended com-
pressor lubricant. Adding a different one, or
mixing lubricants can cause damage and/or
malfunctions, and will void the compres-
sor’s warranty.
NOTE
The compressor requires no internal
inspections or maintenance actions. Open-
ing the compressor’s housing may void its
warranty. (This does not apply to the shaft
seal which is replaceable.)

TS20C USER MANUAL SECTION 2
12
Figure 2-1: Sullair Rotary Screw Air Compressor- Air-Cooled 100/150HP

SECTION 2 TS20C USER MANUAL
13
Figure 2-2: Sullair Rotary Screw Air Compressor- Air-Cooled 200HP

TS20C USER MANUAL SECTION 2
14
Figure 2-3: Sullair Rotary Screw Air Compressor- Air-Cooled 250HP

SECTION 2 TS20C USER MANUAL
15
Figure 2-4: Sullair Rotary Screw Air Compressor- Air-Cooled 200HP with Mounted VSD

TS20C USER MANUAL SECTION 2
16
Figure 2-5: Air-Cooled, Cooling/Lubrication and Discharge System
AA: FROM UNIT DISCHARGE CHECK VALVE
BB: TO FLUID COOLER
CC: FROM FLUID COOLER
DD: TO UNIT INJECTION
EE: TO AFTERCOOLER
FF: FROM AFTERCOOLER
GG: PACKAGE AIR OUTLET
HH: MOISTURE DRAIN OUTLET
1. FLUID FILTER
2. FLUID STOP VALVE
3. MINIMUM PRESSURE CHECK VALVE
4. AIR/FLUID SUMP/SEPARATOR TANK
5. MOISTURE SEPARATOR
6. MOISTURE DRAIN/TRAP
7. AIR
8. AIR/FLUID MIX
9. FLUID

SECTION 2 TS20C USER MANUAL
17
2.3 COMPRESSOR COOLING
AND LUBRICATION
SYSTEM—FUNCTIONAL
DESCRIPTION
Refer to Figure 2-5. For air-cooled models, the
cooling and lubrication system consists of a fan, fan
motor, aftercooler/fluid cooler, full flow fluid filter,
thermal valve, and interconnecting tubes. For water-
cooled models, a shell and tube fluid cooler,
aftercooler and water-flow regulating valve are
substituted for the radiator-type cooler on air-cooled
compressors.
The pressure in the sump tank starts the fluid flow by
forcing the fluid from the high pressure area of the
tank to an area of lower pressure in the compressor.
Fluid flows from the sump tank to the thermal valve
that is fully open when the fluid temperature is below
170°F (77°C). The fluid passes through the thermal
valve, the main filter, and directly to the compressor
where it lubricates, cools and seals the rotors, and
the compression 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. A
portion of the fluid flow to the compressor is routed to
the anti-friction bearings which support the
compressor rotors. Water-cooled versions of the
compressor that have an optional water-flow
regulating valve, it operates to conserve 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 water pressure switch to
prevent operation with inadequate water pressure.
The fluid filter has a replacement element and an
integral bypass valve. Refer to Section 6.6 on page
112.
2.4 COMPRESSOR DISCHARGE
SYSTEM—FUNCTIONAL
DESCRIPTION
Refer to Figure 2-5. The compressor discharges the
compressed air/fluid mixture into the combination
sump tank. The sump tank has three basic functions:
1. It acts as an air/fluid separator.
2. Serves as the compressor fluid sump.
3. Houses the air/fluid separator elements.
The compressed air/fluid mixture enters the sump
tank and flows through an internal baffle system that
changes the flow’s direction and velocity, which
causes most of the fluid to fall to the bottom of the
sump tank. A small amount of fluid remaining in the
compressed air collects on the surface of the
separator elements as the air flows through the
separators.
Two return lines (or scavenge tube) lead from the
bottom of the separators dry side to a medium
pressure region in the compressor. Scavenged fluid
is returned by a pressure differential between the
sump tank and compressor.
Visual sight glasses are located on the return line to
observe this flow. This return line also has an orifice
(protected by a strainer) to ensure an unobstructed
flow.
The Supervisor™ Controller will show an abnormal
pressure drop through the separator if the element
becomes dirty or plugged. (Refer to Section 6.8 on
page 114.) It will also shut down the compressor if
the discharge temperature reaches 235°F (113°C).
A minimum pressure/check valve located
downstream from the separator maintains the sump
tank pressure at approximately 50 psig (3.4 bar)
during load conditions. This pressure level is
necessary for proper air/fluid separation and
sufficient fluid circulation.
A terminal check valve is a sub-component of the
minimum pressure/check valve that prevents
compressed air in the service line from back-flowing
into the sump tank on shutdown or when the
compressor is operating in an unload condition. Also,
a pressure relief valve on the compressor’s wet side
opens if the sump tank pressure exceeds its rating.
Add fluid to the sump tank through the capped fluid
filter port. There is also a sight glass that enables the
user to check the sump tank fluid level. See Section
4.5: Fluid Level Check on page 105.
WARNING
Stop the compressor and relieve all internal
pressure before removing caps, plugs, and/
or other components when the compressor
is running or pressurized.

TS20C USER MANUAL SECTION 2
18
2.5 CONTROL SYSTEM—
FUNCTIONAL DESCRIPTION
FOR TS20C
Refer to Figure 2-9. The purpose of the compressor
control system is to regulate the amount of the air
being compressed to match the amount of
compressed air being used. The Capacity Control
System consists of a pneumatic inlet valve, solenoid
valve, pressure regulator valve and a pressure
transducer. The functional description of the Control
System is described below in four distinct phases of
operation. The following description text applies to all
series compressors with the Supervisor Controller.
For explanatory purposes, this description will apply
to a compressor with an operating range of 100 to
110 psig (6.9 to 7.6 bar). A compressor with any
other pressure range would operate in the same
manner except stated pressures.
START MODE—0-50 PSIG (0 TO 3.5 BAR)
When the compressor (START) button is
depressed, the sump pressure will quickly rise from 0
to 50 psig (0-3.4 bar). During this period both the
pressure regulator and the solenoid valve are closed,
the inlet valve is fully open 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).
FULL LOAD MODE—50 TO 100 PSIG (3.4 TO 6.9
BAR)
When the compressed air pressure rises over 50
psig (3.4 bar) the minimum pressure valve is opened
allowing compressed air to flow into the service line.
From this point on the line pressure is continually
monitored by the Supervisor™ Controller, which
controls the variable speed drive. The pressure
regulator and the solenoid valve remain closed
during this phase. The inlet valve is in the fully open
position as long as the compressor is running at 100
psig (6.9 bar) or below.
MODULATING MODE WITH SPIRAL VALVE—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 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 the suction end of the
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 unload (minimum)
position.
The spiral valve provides a modulation range from
100 to 50%. During this period, the pressure rises
approximately from 100 to 105 psig (6.9 to 7.2 bar).
As the air pressure exceeds 105 psig (7.2 bar), the
differential pressure regulator controlling the inlet
poppet valve starts opening and forcing the poppet
closed, thus throttling inlet air flow to the compressor.
The inlet poppet valve provides a modulation range
from 50 to 40%. During this period, the pressure
rises approximately from 106 to 110 psig (7.3 to 7.6
bar). During this range, the spiral valve remains in
the unload 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), the Supervisor™
control system de-energizes the solenoid valve
allowing line air pressure to be supplied directly to
close the inlet valve. Simultaneously, the solenoid
valve sends a pneumatic signal to the blow down
valve. The blow- down valve opens to the
atmosphere, reducing sump pressure to
approximately 25 to 30 psig (1.7 to 2.1 bar). The
check valve in the air service line prevents line
pressure from returning to the sump.
When the line pressure drops to the low setting cut-in
pressure; usually 100 psig (6.9 bar) on low pressure
[“L”] compressors; 125 psig (8.6 bar) on high
pressure [“H”] compressors; 150 psig (10.3 bar) on
[“HH”] compressors; and 175 psig (12.0 bar) [“XH”].
Supervisor energizes the solenoid valve and allows
NOTE
Always refer to the machine nameplate for
designed operating pressure.

NOTES
19
the blowdown valve to close. The re-energized
solenoid valve again prevents line pressure from
reaching the inlet control valve. Should the pressure
begin to rise, the pressure regulator will resume its
normal function as previously described.
.
2.6 CONTROL SYSTEM—
FUNCTIONAL DESCRIPTION
V200TS
The purpose of the compressor control system is to
regulate the amount of the air being compressed to
match the amount of compressed air being used.
The Capacity Control system consist of variable
speed drive, solenoid valve, regulating valve, and the
inlet valve. The functional description of the control
system is described below in six distinct phases of
operation. The following description text applies to V-
200 series variable speed drive compressors with
Supervisor Controller. Depending on the model, the
compressor can be operated at a setpoint pressure
from 60 to 175 psig (4.1 to 12.1 bar). Refer to the
nameplate for operating pressure range. The
NOTE
For information concerning all aspects of
the Supervisor Controller, consult the
Supervisor Controller Manual.
Figure 2-6: Supervisor™ Controller Panel

TS20C USER MANUAL SECTION 2
20
Supervisor Controller will automatically set the
frequency range based on the selected pressure. For
explanatory purposes, this description will apply to a
compressor with an operating pressure of 100 psig
(6.9 bar). A compressor with any other pressure
range would operate in the same manner except
stated pressures.
START MODE—0 – 50 PSIG (0 TO 3.5 BAR)
When the Supervisor™ Controller (START)
button is depressed, the VSD ramps the motor to full
speed and the sump pressure will quickly rise from 0
to 50 psig (0-3.4 bar). During this period, the solenoid
valve is closed, the inlet valve is fully open and the
air-end delivers full capacity to the sump tank. 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).
FULL LOAD MODE—50 TO 100 PSIG (3.4 TO 6.9
BAR)
When the compressed air pressure rises over 50
psig (3.4 bar) the minimum pressure valve is opened
allowing compressed air to flow into the service line.
From this point on the line pressure is continually
monitored by the Supervisor™ Controller, which
controls the variable speed drive. The solenoid valve
remains closed with the inlet valve fully open running
at 100 psig (6.9 bar) or below.
VARIABLE SPEED DRIVE PART LOAD CONTROL
If less than rated capacity of compressed air is being
used, the service line pressure will rise above 100
psig (6.9 bar). Consequently, the Variable Speed
Drive will begin to decelerate the motor, thereby
reducing the output capacity to match demand. The
drive will continuously adjust the motor speed
(accelerate or decelerate) to maintain a line pressure
of 100 psig (6.9 bar). In this mode the VSD will
operate within the appropriate frequency range
determined by the Supervisor™ Controller.
MODULATING MODE WITH SPIRAL VALVE:
As demand decreases, the variable speed drive
reduces motor speed to maintain the set point pres-
sure. When the speed approaches the minimum
setting, a solenoid valve opens feeding air pressure
to the spiral valve actuator. This in turn expands the
diaphragm and engages the pinion mounted on the
spiral valve shaft assembly, resulting in a rotary
motion and full opening of the spiral valve, effectively
reducing the rotor length by 50%. Excess air will be
returned back internally to the suction side of the
compressor unit. In this mode, the VSD will modulate
the motor speed within a specified range to maintain
the set point pressure as follows:
Increasing demand condition:
If demand increases, the VSD increases the motor
speed until the set point pressure is achieved. If set
point pressure is not achieved while at maximum
speed, the controller will close the spiral valve,
thereby eliminating internal air bypass.
Consequently, the VSD will regulate the motor speed
to achieve the set point pressure.
Decreasing demand condition:
While the spiral valve is open, if demand continues to
decrease the VSD will reduce the motor speed until
the set point pressure is achieved. This action will
continue until the minimum speed is reached. When
the system pressure reaches 106 psig (7.3 bar), or
alternatively set unload pressure, the compressor
unloads, or turns off.
UNLOAD MODE- IN EXCESS OF 106 PSIG (7.3 BAR)
When a relatively small amount or no air is being
used, the service line pressure continues to rise.
When it exceeds 106 psig (7.3 bar), or alternatively
set unload pressure, the Supervisor™ control system
de-energizes the solenoid valve allowing sump air
pressure to be supplied directly to close the inlet
valve. Simultaneously, the solenoid valve sends a
pneumatic signal to the blow down valve. The blow-
down valve opens to the atmosphere, reducing sump
pressure. The check valve in the air service line
prevents line pressure from returning to the sump.
The compressor will shut down after the unload time
setting expires if programmed (the default setting is
zero [0] seconds for an immediate shutdown upon
unload).
When the line pressure drops to the low setting
pressure of 100 psig (6.9 bar) The Supervisor™
Controller starts the motor and energizes the sole-
noid valve which closes the blow down valve. The re-
energized solenoid valve prevents line pressure from
reaching the inlet control valve, thereby allow- ing it
to fully open.
Automatic Operation
For applications with varied periods of time when
NOTE
This operation does not have inlet modula-
tion.)