Sullair 32 250L Series Operator's Manual
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Sullair 32 250L Series Operator's Manual

Sullair 32 250L Series Operator's Manual

24kt compressor
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Operators Manual and Parts List
Series 32 250L and 300H Rotary Screw Air Compressor
P/N 252433

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Summary of Contents for Sullair 32 250L Series

  • Page 1 Operators Manual and Parts List Series 32 250L and 300H Rotary Screw Air Compressor P/N 252433...
  • Page 2 KEEP YOUR MACHINE IN TOP OPERATING CONDITION GENUINE SERVICE PARTS CONTACT YOUR NEAREST SULLAIR DISTRIBUTOR OR CALL 1-800-348-2722...

  • Page 3: Table Of Contents

    1.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION 1.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION 1.8 INSTRUMENT PANEL GROUP FUNCTIONAL DESCRIPTION Section 2 SPECIFICATIONS 2.1 SULLAIR SERIES 32 SPECIFICATIONS Section 3 INSTALLATION 3.1 LOCATION OF COMPRESSOR 3.2 VENTILATION AND COOLINGS SERVICE AIR PIPING 3.4 COUPLING ALIGNMENT CHECK 3.5 COOLANT FLUID LEVEL CHECK...
  • Page 4 TABLE OF CONTENTS (continued) Section Title Page Section Number & Description Section 5 MAINTENANCE (CONTINUED) 5.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION 5.4 FILTER MAINTENANCE 5.5 SEPARATOR MAINTENANCE 5.6 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES BEARING FILTER ELEMENT REPLACEMENT SERVICING THE MAIN FILTER AIR FILTER MAINTENANCE PRIMARY SEPARATOR REPLACEMENT SECONDARY SEPARATOR REPLACEMENT...
  • Page 5 TABLE OF CONTENTS (continued) Section Title Page Section Number & Description Section 6 ILLUSTRATIONS AND PARTS LIST (CONT.) 6.11 SULLICON CONTROL 6.12 INSTRUMENT PANEL ASSEMBLY 6.13 CONTROL BOX ASSEMBLY 6.14 WATER-COOLED - AFTERCOOLED OPTION (BASCO HORIZONTAL MOUNTED) 6.15 AIR-COOLED - AFTERCOOLED OPTION 6.16 ELECTRICAL SCHEMATIC...
  • Page 6 NOTES...

  • Page 7: Introduction

    1.1 INTRODUCTION This coolant does not form abrasive precipitates or break down to shellac, varnish or sludge that would Your new Sullair® 24KT, a flood-lubricated rotary otherwise damage the compressor unit or cooling screw air compressor, will provide you with a system.

  • Page 8: Sulliscrew Compressor Unit, Functional Description

    This unit provides continuous pulse-free air com- ter-cooled models with the exceptions being a ra- pression to meet your needs. With a Sullair ma- diator-type cooler and a fan are used in place of the chine, no maintenance or internal inspection of the shell and tube heat exchanger and the water flow compressor unit is required.

  • Page 9: Compressor Discharge System, Functional Description

    Section 1 DESCRIPTION Figure 1-3 Compressor Discharge System Diagram 24KT coolant fluid flows from the bottom of the re- change, the indicator will rarely show red under ceiver/sump to the thermal valve. The thermal valve normal operating conditions. is fully open when the coolant temperature is below The flow control valve prevents coolant fluid from 170°F.

  • Page 10: Control System, Functional Description

    Section 1 DESCRIPTION shut down. WARNING The receiver has three main functions: DO NOT remove caps, plugs, or oth- er components when compressor is • Acts as the primary coolant separator running or pressurized. Stop compressor and relieve all internal pressure •...
  • Page 11 Section 1 DESCRIPTION Figure 1-4 Control System, Sequence of Operation...

  • Page 12: Air Inlet System, Functional Description

    Section 1 DESCRIPTION high pressure machines), the pressure switch Figure 1-5 Compressor Air Inlet System closes, re-energizing the three-way pilot valve and allowing the blowdown valve to close. The re-ener- gized pilot valve also prevents line pressure from reaching the Sullicon control. Should the pressure begin to rise, the pressure regulator will resume its normal function as previously described.
  • Page 13 Section 1 DESCRIPTION indicators (one for the separator element and one service is required. This restriction gauge must be for the bearing lube filter). Located on the electrical reset manually (See Figure 1-5). control box door are the stop and start push but- •...
  • Page 14 NOTES...

  • Page 15: Sullair Series 32 Specifications

    Section 2 SPECIFICATIONS 2.1 SULLAIR SERIES 32 SPECIFICATIONS DIMENSIONAL: Cooling Model Series Length Width Height Weight Water 32-250L 2920 2286 1980 8800 3990 32-300H 2920 2286 1980 8800 3990 32-250L 2920 2286 1980 8600 3900 32-300H 2920 2286 1980 8800...
  • Page 16 NOTES...

  • Page 17: Location Of Compressor

    Consult a Sullair office for assistance in uti- ments are significantly higher. lizing this heat.

  • Page 18: Service Air Piping

    Also applicable local electrical code concerning isola- notice that the service line should be equipped with tion switches, fused disconnects, etc. Sullair pro- water legs and condensate drains throughout the vided a wiring diagram for use by the installer.

  • Page 19: General

    OPERATION 4.1 GENERAL call for service or indicate the beginning of a mal- While Sullair has built into this compressor a com- function. Before starting your Sullair compressor, prehensive array of controls and indicators to as- read this section thoroughly and familiarize your-...

  • Page 20: Initial Start-Up Procedure

    Section 4 OPERATION 4.2 PURPOSE OF CONTROLS (CONTINUED) CONTROL OR INDICATOR PURPOSE MINIMUM PRESSURE/CHECK VALVE Maintains minimum of 40 PSI in the compressor sump. Valve piston restricts receiver air discharge from the receiver/sump when pressure falls to 40 PSI. COMPRESSOR DISCHARGE Opens the electrical circuit to shut down the machine TEMPERATURE SWITCH when the discharge temperature reaches 240_F...

  • Page 21: General

    Section 5 MAINTENANCE Figure 5-1 Bearing Filter DANGER DO NOT remove caps, plugs, or other components when compressor in run- ning or pressurized. Stop compressor and relieve all internal pressure before doing so. 5.1 GENERAL As you proceed in reading this Section, it will be easy to see that the Maintenance Program for your 24KT Air Compressor is quite minimal.

  • Page 22: Air Filter Maintenance

    Section 5 MAINTENANCE AIR FILTER ELEMENT REPLACEMENT Figure 5-2 Main Filter 1. Clean exterior of air filter housing. 2. Remove the air filter cover by loosening wing nuts securing the cover. 3. Remove the internal cover plate. 4. Remove element and clean the interior of the housing using a damp cloth.

  • Page 23: Primary Separator Replacement

    Section 5 MAINTENANCE heated air must be well-circulated and must not be 9. Reconnect all piping. Return line tube should ex- over 1800 F. Do not use a light bulb for drying. Also, tend to the bottom of the separator element or compressed air must not be used for drying, as the no more than 1/2”...
  • Page 24 Section 5 MAINTENANCE down, remove the pressure switch cover and dis- Figure 5-3 Penn Pressure Switch connect one of the three lead wires that are con- nected to the micro-switch. After disconnecting the lead, tape the exposed wire with electricians tape to make sure that it does not come in contact with any metallic surface.

  • Page 25: Minimum Pressure Valve Maintenance

    Section 5 MAINTENANCE 3. Remove the spring. Figure 5-5 Sullicon Control 4. Remove piston rod. 5. Remove quad ring. 6. Remove the cover plate and sleeve. 7. Discard the stop and cover plate ”0” ring. 8. Clean all parts thoroughly including the cover bore, housing bore and sleeve.

  • Page 26: Drive Coupling Installation And Alignment

    Section 5 MAINTENANCE 6. Replace element. Figure 5-8 Drive Coupling Shaft Alignment 7. Reassemble the housing. DRIVE COUPLING INSTALLATION AND ALIGN- MENT For coupling installation and alignment, the tools required will be a straight edge, a measuring scale, one set of feeler gauges, one set of standard Allen wrenches, and one set of standard socket wrenches.

  • Page 27: Drive Coupling Disassembly And Removal

    Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor. Should your problem persist after making the rec- ommended check, consult your nearest Sullair representative or Sullair Corporation Service De- partment. 5.8 TROUBLESHOOTING - GUIDE...
  • Page 28 Section 5 MAINTENANCE 5.8 TROUBLESHOOTING - GUIDE (CONTINUED) SYMPTOM CAUSE REMEDY MACHINE WILL NOT START (cont.) Motor starter overloads tripped Reset. Should trouble persist, check whether motor starter contacts are func- tioning properly. Low incoming line voltage Check voltage. Should voltage check low, consult your power company.
  • Page 29 Section 5 MAINTENANCE 5.8 TROUBLESHOOTING - GUIDE (CONTINUED) SYMPTOM CAUSE REMEDY MACHINE SHUTS DOWN WITH AIR DE- Cooler plugged Clogged fluid filter, clean the main filter MAND PRESENT (cont.) element and change the bearing filter element if maintenance indicator shows a red signal.
  • Page 30 Section 5 MAINTENANCE 5.8 TROUBLESHOOTING - GUIDE (CONTINUED) SYMPTOM CAUSE REMEDY PRESSURE RELIEF VALVE OPENS RE- High pressure shutdown switch is defec- Re-adjust below pressure relief valve set- PEATEDLY tive or out of adjustment: ting or replace. Defective Pressure Relief Valve Replace Pressure Relief Valve...

  • Page 31: Procedure For Ordering Parts

    ILLUSTRATIONS AND PARTS LIST 6.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the com- pressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the address or phone numbers listed below.

  • Page 32: Motor, Compressor, Frame And Parts

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.3 MOTOR, COMPRESSOR, FRAME AND PARTS...
  • Page 33 ** For part number on motor, see specific machine sales order. *** It is Sullair’s policy not to sell or replace repair parts on the compressor unit. There is an exchange pro- gram whereby a reconditioned compressor unit can be obtained from Sullair distributors or the factory at less cost than the owner could repair the unit.

  • Page 34: Compressor Air Inlet System

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.4 COMPRESSOR AIR INLET SYSTEM...
  • Page 35 Section 6 ILLUSTRATIONS AND PARTS LIST 6.4 COMPRESSOR AIR INLET SYSTEM part number description number quantity nut, wing 1/2”-13 housing, air filter 44418 plate, cover 240S6 element, air filter 40402 base, air filter 41075 nut, hex 7/S”-9 washer, lock 7/8” stud, air filter 7/8”-9 x 4 1/2”...

  • Page 36: Compressor Cooling And Lubrication System - Water-Cooled

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.5 COMPRESSOR COOLING AND LUBRICATION SYSTEM - WATER-COOLED...
  • Page 37 Section 6 ILLUSTRATIONS AND PARTS LIST 6.5 COMPRESSOR COOLING AND LUBRICATION SYSTEM - WATER-COOLED part number description number quantity elbow, 2” connector, tube 2”t x 2”p tube, 2” steel tee, reducing 2” x 3/4” x 2” nipple, 2” x 6” valve, thermal** 41299 nipple, 2”...

  • Page 38: Compressor Unit Tubing

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.6 COMPRESSOR UNIT TUBING...
  • Page 39 Section 6 ILLUSTRATIONS AND PARTS LIST 6.6 COMPRESSOR UNIT TUBING part number description number quantity plug, 1/2” manifold 222915 connector, tube 5/S”t x 1/2”p tube, outlet bearing 222924 tube, outlet bearing 222923 elbow, tube S/S”t x 3/S”p tube, bearing filter supply 223016 connector, tube 1 1/4”t x 1 1/4”p bushing, reducing 2”...
  • Page 40 Section 6 ILLUSTRATIONS AND PARTS LIST 6.6 COMPRESSOR UNIT TUBING...
  • Page 41 Section 6 ILLUSTRATIONS AND PARTS LIST 6.6 COMPRESSOR UNIT TUBING part number description number quantity elbow, tube 3/4”t x 3/4”p bushing, reducing 1 1/4” x 3/4” tee, 1 1/4” nipple, close 1 1/4” orifice, 1/32” 40381 connector, 1/4”t x 1/4”p filter, bearing*** 46967 capscrew, ferry hd.

  • Page 42: Updraft Assembly

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.7 UPDRAFT ASSEMBLY...
  • Page 43 Section 6 ILLUSTRATIONS AND PARTS LIST 6.7 UPDRAFT ASSEMBLY part number description number quantity back cover, inner 22506 capscrew, whiz-lock 5/16”-18 x 3/4” screw hex self tap 1/4”-14 x 3/4” washer, lock 1/4” washer, flat 1/4” side panel, inner 22505 nut, whiz-lock 5/16”-18 side panel, inner 22504...

  • Page 44: Compressor Cooling And Lubrication System - Air-Cooled

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.8 COMPRESSOR COOLING AND LUBRICATION SYSTEM - AIR-COOLED...
  • Page 45 Section 6 ILLUSTRATIONS AND PARTS LIST 6.8 COMPRESSOR COOLING AND LUBRICATION SYSTEM - AIR-COOLED part number description number quantity elbow, 2” connector, tube 2”t x 2”p tube, 2” 221364 tee, reducing 2” x 2” x 1 1/2” nipple, 2” x 6” valve, thermal..
  • Page 46 Section 6 ILLUSTRATIONS AND PARTS LIST 6.8 COMPRESSOR COOLING AND LUBRICATION SYSTEM - AIR-COOLED...
  • Page 47 Section 6 ILLUSTRATIONS AND PARTS LIST 6.8 COMPRESSOR COOLING AND LUBRICATION SYSTEM - AIR-COOLED (CONTINUED) part number description number quantity motor, tan 41903 capscrew, hex 3/8”-16 x 1 1/2” washer, lock 3/8” nut, hex 3/8”-16 plate, cover 21250 connector, conduit 1/2” conduit, 1/2”...

  • Page 48: Compressor Discharge System

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.9 COMPRESSOR DISCHARGE SYSTEM...
  • Page 49 Section 6 ILLUSTRATIONS AND PARTS LIST 6.9 COMPRESSOR DISCHARGE SYSTEM part number description number quantity thermistor probe 46867 capscrew, 1/2”-13 x 1 1/2” cover assembly 18165 O-ring, Viton 8 1/4” x 1/8” 826502-267 spring 41133 discharge valve assembly 18164 O-ring, Buna N 5 5/8” x 3/16” 826102-358 capscrew, whiz-lock 5/16”...
  • Page 50 Section 6 ILLUSTRATIONS AND PARTS LIST 6.9 COMPRESSOR DISCHARGE SYSTEM...
  • Page 51 Section 6 ILLUSTRATIONS AND PARTS LIST 6.9 COMPRESSOR DISCHARGE SYSTEM (CONTINUED) part number description number quantity decal, ”24KT” 46415 decal, ”Sulliscrew” 46416 gasket, separator 40423 primary separator element*** 40260 gauge, fluid level 46558 cover, sump 21451 capscrew, hex 3/4”-10 x 3” gr 8 gasket, separator 28822 secondary separator element (I)
  • Page 52 Section 6 ILLUSTRATIONS AND PARTS LIST 6.9 COMPRESSOR DISCHARGE SYSTEM...
  • Page 53 Section 6 ILLUSTRATIONS AND PARTS LIST 6.9 COMPRESSOR DISCHARGE SYSTEM (CONTINUED) part number description number quantity nipple, close 1 1/2” nut, whiz-lock 5/16” decal. ”WARNING” 49346 decal, ”WARNING” 49685 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR...

  • Page 54: Electro-Pneumatic Control System

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.10 ELECTRO-PNEUMATIC CONTROL SYSTEM...
  • Page 55 Section 6 ILLUSTRATIONS AND PARTS LIST 6.10 ELECTRO-PNEUMATIC CONTROL SYSTEM part number description number quantity bracket, mounting 25987 nut, whiz-lock 3/8”-18 screw, whiz-lock 3/8”-18 x 1” locknut, conduit 1/2” nipple, close 1/2” switch, pressure (Penn)** 40427 nipple, close 1/4” tee, tube 1/4”t x 1/4”p nipple, 1/4”...
  • Page 56 Section 6 ILLUSTRATIONS AND PARTS LIST 6.10 ELECTRO-PNEUMATIC CONTROL SYSTEM...
  • Page 57 Section 6 ILLUSTRATIONS AND PARTS LIST 6.10 ELECTRO-PNEUMATIC CONTROL SYSTEM (CONTINUED) part number description number quantity nipple, close 1” union, 1” tee, reducing 1” x 1/2” x 1” bushing, reducing 1/2” x 1/4” union, tube 1/4” decal, ”Danger” 49850 switch, pressure (Barksdale)** 241963 elbow PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR...

  • Page 58: Sullicon Control

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.11 SULLICON CONTROL...
  • Page 59 Section 6 ILLUSTRATIONS AND PARTS LIST 6.11 SULLICON CONTROL part number description number quantity Sullicon control (includes items 2 through 25)* 11682 •nut, self-locking 5/16”-18 •cotter pin 11084 •lever 40138 •yoke •yoke pin 40065 20094 •plunger •cup, teflon 42538 •shoulder screw, socket head 21635 •body •diaphragm, external...
  • Page 60 Section 6 ILLUSTRATIONS AND PARTS LIST 6.11 SULLICON CONTROL...
  • Page 61 Section 6 ILLUSTRATIONS AND PARTS LIST 6.11 SULLICON CONTROL (CONTINUED) part number description number quantity rod end, spherical (I.h.) 42004 rod, control –compressor 22374 plug, pipe 1/4” nipple, close 1/4” tee, pipe 1/4” connector, tube 1/4”t x 1/4”p elbow, reducing 1/4” x 1/8” valve, moisture bleed 41111 capscrew, hex 5/16”-24 x 1 1/2”...

  • Page 62: Instrument Panel Assembly

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.12 INSTRUMENT PANEL ASSEMBLY...
  • Page 63 Section 6 ILLUSTRATIONS AND PARTS LIST 6.12 INSTRUMENT PANEL ASSEMBLY part number description number quantity gauge, line pressure 46432 gauge, sump pressure 46432 gauge, temperature 40314 panel, instrument 29359 indicator, filter 40025 nameplate, serial number 46413 rivet, ”pop” 1/16” x 3/8” connector, 1/4”t x 1/8”p indicator, bearing filter 46551...

  • Page 64: Control Box Assembly

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.13 CONTROL BOX ASSEMBLY...
  • Page 65 Section 6 ILLUSTRATIONS AND PARTS LIST 6.13 CONTROL BOX ASSEMBLY air- water- number description cooled cooled quantity control DOX (consisting of items 2 through 12) 40689 40713 •duct & cover, plastic 41370 41370 •terminal & track (12 pt.) 41493 41493 •block, fuse 41147 41147...
  • Page 66 Section 6 ILLUSTRATIONS AND PARTS LIST 6.13 CONTROL BOX ASSEMBLY...
  • Page 67 Section 6 ILLUSTRATIONS AND PARTS LIST 6.13 CONTROL BOX ASSEMBLY (CONTINUED) air- water- number description cooled cooled quantity elbow, tube 1/4”t x 1/8”p decal, ”AIRANTEED” 46420 46420 decal, ”DANGER” 49850 49850 decal, ”WARNING” 49852 49852 * Standard hardware item, purchase locally. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR...

  • Page 68: Water-Cooled - Aftercooled Option (Basco Horizontal Mounted)

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.14 WATER-COOLED - AFTERCOOLED OPTION (BASCO HORIZONTAL MOUNTED)
  • Page 69 Section 6 ILLUSTRATIONS AND PARTS LIST 6.14 WATER-COOLED - AFTERCOOLED OPTION (BASCO HORIZONTAL MOUNTED part number description number quantity nipple, close 3” elbow, 3” nipple, half 3” x 7” coupling, flexible 3”** 40327 nipple, 3” x 6” flange, threaded 3” gasket, flange 3”...

  • Page 70: Air-Cooled - Aftercooled Option

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.15 AIR-COOLED - AFTERCOOLED OPTION...
  • Page 71 Section 6 ILLUSTRATIONS AND PARTS LIST 6.15 AIR-COOLED - AFTERCOOLED OPTION part number description number quantity aftercooler core 41907 nipple, close 2” elbow, 900 2” nipple, half 2” x 7 1/2” coupling, flexible pipe 2”** 40913 nipple, 2” x 51 1/2” nut, whiz-lock 5/16”-18 capscrew, whiz.lock 5/16”-18 x 3/4”...
  • Page 72 Section 6 ILLUSTRATIONS AND PARTS LIST 6.15 AIR-COOLED - AFTERCOOLED OPTION...
  • Page 73 Section 6 ILLUSTRATIONS AND PARTS LIST 6.15 AIR-COOLED - AFTERCOOLED OPTION (CONTINUED) part number description number quantity 41946 capscrew, 5/8”*11 x 3” gr 5 washer, lock 5/8” nut, hex 5/8”-11 * Standard hardware item, purchase locally. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR...

  • Page 74: Electrical Schematic

    Section 6 ILLUSTRATIONS AND PARTS LIST 6.16 ELECTRICAL SCHEMATIC...
  • Page 75 NOTES...
  • Page 76 WORLDWIDE SALES AND SERVICE SULLAIR CORPORATION A SUBSIDIARY OF SUNDSTRAND CORPORATION 3700 E. Michigan Blvd. Michigan City, Indiana 46360---9990 Telephone (219) 879---5451 Telex 4946922 Printed in U.S.A. Effective 10/89 Specifications Subject To Change Without Prior Notice Part No. 252433...

This manual is also suitable for:

300h series32-250l32-300h

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