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AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are courses that provide hands-on instruction in the proper operation, mainte- nance and service of Sullair equipment. Individual seminars on Industrial compressors and compressor electrical systems are presented at regular intervals throughout the year at a dedicated training facility at Sullair’s corporate headquarters in Michigan City, Indiana.
2.2 DESCRIPTION OF COMPONENTS 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION 2.4 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION Figure 2-2A V-200TS Piping and Instrumentation (Air-cooled) Figure 2-2B V-200TS Piping and Instrumentation (Water-cooled) Figure 2-3 Identification- V-200TS Air-cooled with Optional Enclosure (VSD inside electrical enclosure)
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TABLE OF CONTENTS Section 4 OPERATION 4.3 MOTOR ROTATION DIRECTION CHECK (CONTINUED) 4.4 FAN MOTOR ROTATION CHECK Section 5 SUPERVISOR CONTROLLER™ Figure 5-1 Supervisor Controller™ Panel Section 6 MAINTENANCE 6.1 SPIRIAL VALVE REGULATOR Section 7 ILLUSTRATIONS AND PARTS LIST 7.1 PROCEDURE FOR ORDERING PARTS 7.2 RECOMMENDED SPARE PARTS LIST 7.3 MOTOR, COMPRESSOR AND FRAME - VSD IN STARTER BOX...
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TABLE OF CONTENTS Section 7 ILLUSTRATIONS AND PARTS LIST (CONTINUED) 7.21 DECAL LOCATIONS- WATER-COOLED OPEN (VSD Outside Electrical Enclosure) 7.22 DECAL LOCATIONS- AIR-COOLED (ENCLOSED MODEL) 7.23 DECAL LOCATIONS- WATER-COOLED (ENCLOSED MODEL) 7.24 DECAL LOCATIONS- CONTROL BOX 7.25 WIRING DIAGRAM- NON-CE 7.26 WIRING DIAGRAM- CE...
(throttle) valve, either at the compressor or at any other point Sullair Corporation and its subsidiaries design and along the air line, when an air hose exceeding manufacture all of their products so they can be 13mm inside diameter is to be connected to the operated safely.
Section 1 SAFETY J. Use air at pressures less than 2.1 bar for clean- I. Keep oily rags, trash, leaves, litter or other com- ing purposes, and then only with effective chip bustibles out of and away from the compressor. guarding and personal protective equipment per J.
Section 1 SAFETY 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 Death or serious injury can result from inhaling compressed air without using proper safety exposed live parts of electrical system.
Section 1 SAFETY I. Keep lift operator in constant attendance when- N. Make sure pallet-mounted compressors are ever compressor is suspended. firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them. NEVER J. Set compressor down only on a level surface attempt to forklift a compressor that is not secured capable of safely supporting at least its weight and to its pallet, as uneven floors or sudden stops may...
VARIABLE SPEED DRIVE APPLICATIONS 2.1 INTRODUCTION 1. As coolant, it controls the rise of air temperature Your new Sullair lubricated rotary screw air com- normally associated with the heat of compres- pressor with variable speed drive will provide you sion.
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Section 2 VARIABLE SPEED DRIVE APPLICATIONS monitored by the Supervisor Controller, which con- Decreasing demand condition: trols the variable speed drive. The solenoid valve While the spiral valve is open, if demand continues remains closed with the inlet valve fully open run- to decrease the VSD will reduce the motor speed ning at 100 psig (6.9 bar) or below.
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Section 2 VARIABLE SPEED DRIVE APPLICATIONS Figure 2-2A V-200TS Piping and Instrumentation (Air-cooled) description part part part quantity number number number number 100HP/75KW 125-150HP/ 200HP/ 93-112KW 150KW filter, air inlet 409264 02250140-798 02250140-798 valve, inlet butterfly 40336 40336 40338 control, Sullicon...
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Section 2 VARIABLE SPEED DRIVE APPLICATIONS Figure 2-2B V-200TS Piping and Instrumentation (Water-cooled) description part part part quantity number number number number 100HP/75KW 125-150HP/ 200HP/ 93-112KW 150KW filter, air inlet 409264 02250140-798 02250140-798 valve, inlet butterfly 040336 040336 040338 control, Sullicon 25s...
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Section 2 VARIABLE SPEED DRIVE APPLICATIONS Figure 2-2B V-200TS Piping and Instrumentation (Water-cooled) (continued) description part part part quantity number number number number 100HP/75KW 125-150HP/ 200HP/ 93-112KW 150KW vlv, sol 2wnc no 1/4 200# n4 110/120 02250125-674 02250125-674 02250125-674 strainer, y 1/4”...
Motor direction and rotation direction have been weight of the compressor, and rigid enough to checked at Sullair prior to delivery. However if there maintain the compressor frame level and the com- is a need to check direction, proceed with the fol- pressor in alignment is required.
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Section 5 SUPERVISOR CONTROLLER™ Figure 5-1 Supervisor Controller™ Panel For information concerning all aspects of the Supervisor Controller, consult the Supervisor Controller manual.
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Section 6 MAINTENANCE 6.1 SPIRAL VALVE PRESSURE REGULATOR Figure 6-1 Pressure Regulator Adjustment See Figure 6-1. This downstream pressure regula- tor protects the spiral valve actuator diaphragm from over pressurization and ensures that ade- quate pressure is supplied for proper operation. To set the regulator, slowly decrease demand until the compressor runs at minimum speed.
ILLUSTRATIONS AND PARTS LIST 7.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative. If for any reason parts cannot be obtained in this manner, contact the factory directly at the addresses, fax or phone numbers below.
Section 7 ILLUSTRATIONS AND PARTS LIST 7.3 MOTOR, COMPRESSOR AND FRAME- VSD IN STARTER BOX 02250150-027R00...
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(I) This part may vary per machine order specification. Consult factory with machine serial number to deter- mine correct part number. (II) There is an exchange program whereby a remanufactured compressor unit canbe obtained from Sullair distributors or the factory at less cost than the owner could repair the unit. For information regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation.
Section 7 ILLUSTRATIONS AND PARTS LIST 7.4 MOTOR, COMPRESSOR AND FRAME- EXTERNAL VSD 02250149-916R00...
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(I) This part may vary per machine order specification. Consult factory with machine serial number to deter- mine correct part number. (II) There is an exchange program whereby a remanufactured compressor unit canbe obtained from Sullair distributors or the factory at less cost than the owner could repair the unit. For information regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation.
Section 7 ILLUSTRATIONS AND PARTS LIST 7.7 AIR INLET 200-250HP/150-187KW 02250150-052R01...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.7 AIR INLET 200-250HP/150-187KW part number description number quantity adapter, air inlet (8"o.d. x 4-3/16" lg) 13127 anl, hfd rh supt ts20/ls25-200 02250114-282 anl, hfd lh supt ts25/ls25-200 02250114-283 fltr, inl optimalair 16odx7inl (I) 02250140-798 gasket, 8 5/8 x 11 x 1/16 40422...
Section 7 ILLUSTRATIONS AND PARTS LIST 7.8 AIR PIPING- AIR-COOLED 02250149-919R01...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.8 AIR PIPING- AIR-COOLED part number description number quantity elbow, red 2 x 1 1/2 150# plt 869208-060 u-bolt, 3/8" x 3" pipe pltd 868306-300 u-bolt, 3/8" x 2" pipe pltd 868306-200 bushing, red pltd 2 x 1 1/2 867108-060 tee, pipe 150# plt 1 1/2 866815-060...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.8 AIR PIPING- AIR-COOLED 02250149-919R01...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.8 AIR PIPING- AIR-COOLED (CONTINUED) part number description number quantity sep, wtr d-h 2" npt 1/4"drn 02250144-632 sep, wtr d-h ws700 2.5"npt 02250106-113 joint, expansion ts-20 discharge to tank 02250058-939 thermal, val. asy, 12/16s 014512 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR...
Section 7 ILLUSTRATIONS AND PARTS LIST 7.9 AIR PIPING- WATER-COOLED (100HP/75KW ONLY) 02250149-251R00...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.9 AIR PIPING- WATER-COOLED (100HP/75KW ONLY) part number description number quantity joint, expansion 2" 02250087-928 vlv, sol 2w nc 1 1/2" 150#vac n4 (I) 02250125-653 sep, wtr d-h 2" npt 1/4"drn (II) 02250144-632 support, bracket aftrclr v200ts 02250146-306 support, brkt moist sep v200ts 02250146-311...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.9 AIR PIPING- WATER-COOLED (100HP/75KW ONLY) 02250149-251R00...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.9 AIR PIPING- WATER-COOLED (100HP/75KW ONLY) (CONTINUED) part number description number quantity nut, hex f pltd 3/8-16 825306-347 nut, hex f pltd 1/2-13 825308-458 screw, hex ser washer 3/8-16 x 3/4 829706-075 screw, hex ser washer 1/2-13 x 1 829708-100 bulkhead, pipe 1/2"...
Section 7 ILLUSTRATIONS AND PARTS LIST 7.10 AIR PIPING- WATER-COOLED (125-150HP/93-112KW ONLY) 02250149-249R00...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.10 AIR PIPING- WATER-COOLED (125-150HP/93-112KW ONLY) part number description number quantity joint, expansion 2" 02250087-928 joint, expts20-200 aftclr to sep 02250088-057 separator, water d-h ws700 2.5"npt (I) 02250106-113 valve, solenoid 2w nc 1 1/2" 150#vac n4 (II) 02250125-653 separator, water d-h 2"...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.10 AIR PIPING- WATER-COOLED (125-150HP/93-112KW ONLY) 02250149-249R00...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.10 AIR PIPING- WATER-COOLED (125-150HP/93-112KW ONLY) (CONTINUED) part number description number quantity elbow, tube 90 deg m 1 1/4 x 1 1/4 810520-125 flange, thrd 3" 150# rf 819315-048 nipple, pipe 1 1/4 x 3 1/2 822120-035 nipple, pipe 1 1/2 x 9 822124-090...
Section 7 ILLUSTRATIONS AND PARTS LIST 7.11 AIR PIPING- WATER-COOLED (200HP/93-150KW ONLY) 02250149-248R00...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.11 AIR PIPING- WATER-COOLED (200HP/93-150KW ONLY) part number description number quantity jnt, expts20-200 aftclr to sep 02250088-058 sep, wtr d-h ws700 2.5"npt (I) 02250106-113 vlv, sol 2w nc 1 1/2" 150#vac n4 II) 02250125-653 sep, wtr d-h 2"...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.11 AIR PIPING- WATER-COOLED (200HP/93-150KW ONLY) 02250149-248R00...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.11 AIR PIPING- WATER-COOLED (200HP/93-150KW ONLY)(CONTINUED) part number description number quantity nipple, pipe 1 1/4 x 3 1/2 822120-035 nipple, pipe 1 1/2 x 2 822124-020 nipple, pipe 2 x 4 822132-040 nipple, pipe 2 x 4 1/2 822132-045 nipple, pipe 2 x 5 822132-050...
Section 7 ILLUSTRATIONS AND PARTS LIST 7.12 PNEUMATIC CONTROLS...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.12 PNEUMATIC CONTROLS part number description number quantity elbow, 90 1/4t pls x 1/4 npt m 250018-430 valve, solenoid 3-way n.o. (I) 02250125-657 regulator, reducing 1/4npt (II) 02250046-568 gauge, pressure 02250117-009 tee, pipe galv 1/4” 804415-010 elbow, tube-M 1/4”...
Section 7 ILLUSTRATIONS AND PARTS LIST 7.13 STARTER ASSEMBLY WITH VSD IN STARTER BOX 02250148-476R01...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.13 STARTER ASSEMBLY WITH VSD IN STARTER BOX part number description number quantity gasket, panel supervisor ii 02250048-822 panel, cover supervisor ii 02250054-854 gasket, ctl pnl super ii 02250071-093 grip, cord n4 .125-.187 x 1/2” 02250071-379 grip, cord n4 .250-.375 x 1/2”...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.13 STARTER ASSEMBLY WITH VSD IN STARTER BOX 02250148-476R01...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.13 STARTER ASSEMBLY WITH VSD IN STARTER BOX (CONTINUED) part number description number quantity screw, tc-f pan #8-32 x 1/2 835601-050 washer, spr lock-metric pltd m4 838804-090 bushing, red pltd 1/2 x 1/8 867102-005 bushing, red pltd 3/4 x 1/8 867103-005 breaker, circ-h hi inrush...
Section 7 ILLUSTRATIONS AND PARTS LIST 7.14 STARTER ASSEMBLY WITH EXTERNAL VSD 02250148-479R01...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.14 STARTER ASSEMBLY WITH EXTERNAL VSD part number description number quantity gskt, panel supervisor ii 02250048-822 panel, cover supervisor ii 02250054-854 gskt, ctl pnl super ii 02250071-093 grip, cd n4 .125-.187 x 1/2" 02250071-379 grip, cd n4 .250-.375 x 1/2"...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.14 STARTER ASSEMBLY WITH EXTERNAL VSD 02250148-479R01...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.14 STARTER ASSEMBLY WITH EXTERNAL VSD (CONTINUED) part number description number quantity screw, tc-f pan #8-32 x 1/2 835601-050 washer, spr lock-metric pltd m4 838804-090 bushing, red pltd 1/2 x 1/8 867102-005 bushing, red pltd 3/4 x 1/8 867103-005 cb, c-h hi inrush (I) spec, encl ls-12/16 30w x 10d x 36lg (I)
Section 7 ILLUSTRATIONS AND PARTS LIST 7.16 ENCLOSURE- WATER-COOLED 02250148-555R00...
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20/25 enclosure 02250103-205 pnl, encl front side ls25-200 02250113-686 pnl,assy side 20/25 enclosure 02250116-349 channel,btm sill 02250126-144 channel,btm sill 02250126-145 panel, end enclosure v-200ts 02250146-030 panel,encl front left 02250146-031 panel,encl rear left 02250146-032 grille, enclosure end 02250146-432 panel,assy end v-200ts 02250146-439...
Section 7 ILLUSTRATIONS AND PARTS LIST 7.17 DECAL GROUP...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.17 DECAL GROUP part number description number quantity sign, warning sever - fan port 049965 decal, warning mixing fluids 02250110-891 sign, warning sever - fan 049855 sign, danger electrocution 049850 sign, air breathing (danger) 250027-935 sign, warning- comp oil fill cap 049685...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.17 DECAL GROUP...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.17 DECAL GROUP (CONTINUED) part number description number quantity decal, warning actuator 250029-836 sign, warning ground fault 049852 decal, rotation 250021-286 decal, rotation 250021-564 decal, 380-415/3/50 volt international (I) 02250069-403 decal, 460/3/60 volt international (I) 02250069-399 decal, 230/3/60 volt international (I) 02250069-397...
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.17 DECAL GROUP...
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PE designation 02250075-540 decal, auto start 041065 decal, fluid stop valve P/N 016742 410239 decal, Sullair 2.5 X 20 black (open model) 02250059-054 •decal, Sullair 4.5 X 36 black (canopy model) 02250057-603 decal, energy savings solutions 02250146-267 Continued on page 79 (II) Fluid fill may vary in accordance with machine requirements.
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.17 DECAL GROUP...
Section 7 ILLUSTRATIONS AND PARTS LIST 7.18 DECAL LOCATIONS- AIR-COOLED OPEN (VSD Inside Electrical Enclosure)
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250029-836 (I) Sullair compressors use Sullube as standard fill (Sullube fluid decal no. 02250069-389). However, this decal part number may vary in accordance with machine specifications. To confirm the proper decal number for your machine, consult the factory with serial number.
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.19 DECAL LOCATIONS- AIR-COOLED OPEN (VSD Outside Electrical Enclosure)
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250029-836 (I) Sullair compressors use Sullube as standard fill (Sullube fluid decal no. 02250069-389). However, this decal part number may vary in accordance with machine specifications. To confirm the proper decal number for your machine, consult the factory with serial number.
Section 7 ILLUSTRATIONS AND PARTS LIST 7.20 DECAL LOCATIONS- WATER-COOLED OPEN (VSD Inside Electrical Enclosure)
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049873 (I) Sullair compressors use Sullube as standard fill (Sullube fluid decal no. 02250069-389). However, this decal part number may vary in accordance with machine specifications. To confirm the proper decal number for your machine, consult the factory with serial number.
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Section 7 ILLUSTRATIONS AND PARTS LIST 7.21 DECAL LOCATIONS- WATER-COOLED OPEN (VSD Outside Electrical Enclosure)
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049873 (I) Sullair compressors use Sullube as standard fill (Sullube fluid decal no. 02250069-389). However, this decal part number may vary in accordance with machine specifications. To confirm the proper decal number for your machine, consult the factory with serial number.