USER MANUAL

INDUSTRIAL AIR COMPRESSOR

TSR32
VARIABLE SPEED DRIVE & FIXED SPEED DRIVE

PART NUMBER:
02250178-398 R00
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions ©
SULLAIR CORPORATION
and procedures in this manual or, The information in this manual is current
as of its publication date, and applies to
misuse of this equipment will compressor serial number:
VOID its warranty!
200809300000
and all subsequent serial numbers.
 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 throu ate 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
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

11 2.1 INTRODUCTION
11 2.2 COMPRESSOR COMPONENT DESCRIPTION
15 2.3 COMPRESSOR COOLING AND
AL DESCRIPTION
15 2.4 COMPRESSOR DISCHARGE SYST
15 2.5 VSD CONTROL SYSTEM
18 2.6 FIXED SPEED CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
FUNCTIONAL DESCRIPTION

25 3.2 COMPRESSOR SPECIFICATIONS

26 3.3 LUBRICATION GUIDE
26 3.4 APPLICATION GUIDE
26 3.5 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE,
FLUID FILTER AND SEPARATOR

SUPPORT AND LOCATION

TABLE OF CONTENTS

33 4.2 VENTILATION AND COOLING

33 4.3 SERVICE AIR PIPING
34 4.4 AUXILIARY RECEIVER TANK
34 4.5 COUPLING ALIGNMENT CHECK
34 4.6 FLUID LEVEL CHECK
35 4.7 ELECTRICAL PREPARATION
36 4.8 MOTOR ROTATION DIRECTION CHECK

37 5.1 ROUTINE OPERATION

SETUP

39 6.1 GENERAL
39 6.2 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION
39 6.3 MAINTENANCE EVERY 2000 HOURS
39 6.4 FLUID MAINTENANCE
39 6.5 FILTER MAINTENANCE
40 6.6 AIR FILTER MAINTENANCE
40 6.7 SEPARATOR MAINTENANCE
 Section 1

SAFETY
the precautionary statements contained herein are
NOTE 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,
OPERATOR IS REQUIRED TO READ
owners, employers and users should become
ENTIRE INSTRUCTION MANUAL.
familiar with, and comply with, all applicable
OSHA regulations and/or any applicable Federal,
State and Local codes, standards, and regula-
1.1 GENERAL tions relative to personal protective equipment,
Sullair Corporation and its subsidiaries design and such as eye and face protective equipment,
manufacture all of their products so they can be respiratory protective equipment, equipment
operated safely. However, the responsibility for safe intended to protect the extremities, protective
operation rests with those who use and maintain clothing, protective shields and barriers and elec-
these products. The following safety precautions are trical protective equipment, as well as noise
offered as a guide which, if conscientiously followed, exposure administrative and/or engineering con-
will minimize the possibility of accidents throughout trols and/or personal hearing protective equip-
the useful life of this equipment. ment.

The compressor should be operated only by those 1.3 PRESSURE RELEASE

who have been trained and delegated to do so, and
who have read and understood this Operator's A. Install an appropriate flow-limiting valve between
Manual. Failure to follow the instructions, procedures the service air outlet and the shut-off (throttle)
and safety precautions in this manual may result in valve, either at the compressor or at any other
accidents and injuries. NEVER start the compressor point along the air line, when an air hose exceed-
unless it is safe to do so. DO NOT attempt to operate ing 1/2" (13mm) inside diameter is to be con-
the compressor with a known unsafe condition. Tag nected to the shut-off (throttle) valve, to reduce
the compressor and render it inoperative by pressure in case of hose failure, per OSHA Stan-
disconnecting and locking out all power at source or dard 29 CFR 1926.302(b)(7) and/or any applica-
otherwise disabling its prime mover so others who ble Federal, State and Local codes, standards
may not know of the unsafe condition cannot attempt and regulations.
to operate it until the condition is corrected.
B. When the hose is to be used to supply a mani-
Install, use and operate the compressor only in full fold, install an additional appropriate flow-limiting
compliance with all pertinent OSHA regulations and/ valve between the manifold and each air hose
or any applicable Federal, State, and Local codes, exceeding 1/2" (13mm) inside diameter that is to
standards and regulations. DO NOT modify the be connected to the manifold to reduce pressure
compressor and/or controls in any way except with in case of hose failure.
written factory approval.
C. Provide an appropriate flow-limiting valve at the
While not specifically applicable to all types of beginning of each additional 75 feet (23m) of
compressors with all types of prime movers, most of hose in runs of air hose exceeding 1/2" (13mm)

5
 SECTION 1

inside diameter to reduce pressure in case of accumulate on, under or around acoustical mate-
hose failure. rial, or on any external surfaces of the air com-
pressor. Wipe down using an aqueous industrial
D. Flow-limiting valves are listed by pipe size and
cleaner or steam clean as required. If necessary,
flow-rated. Select appropriate valves accordingly,
remove acoustical material, clean all surfaces
in accordance with their manufacturer's recom-
and then replace acoustical material. Any acous-
mendations.
tical material with a protective covering that has
E. DO NOT use air tools that are rated below the been torn or punctured should be replaced
maximum rating of the compressor. Select air immediately to prevent accumulation of liquids or
tools, air hoses, pipes, valves, filters and other fluid film within the material. DO NOT use flam-
fittings accordingly. DO NOT exceed manufac- mable solvents for cleaning purposes.
turer's rated safe operating pressures for these
D. Disconnect and lock out all power at source prior
items.
to attempting any repairs or cleaning of the com-
F. Secure all hose connections by wire, chain or pressor or of the inside of the enclosure, if any.
other suitable retaining device to prevent tools or
E. Keep electrical wiring, including all terminals and
hose ends from being accidentally disconnected
pressure connectors in good condition. Replace
and expelled.
any wiring that has cracked, cut, abraded or oth-
G. Open fluid filler cap only when compressor is not erwise degraded insulation, or terminals that are
running and is not pressurized. Shut down the worn, discolored or corroded. Keep all terminals
compressor and bleed the receiver tank to zero and pressure connectors clean and tight.
internal pressure before removing the cap.
F. Keep grounded and/or conductive objects such
H. Vent all internal pressure prior to opening any as tools away from exposed live electrical parts
line, fitting, hose, valve, drain plug, connection or such as terminals to avoid arcing which might
other component, such as filters and line oilers, serve as a source of ignition.
and before attempting to refill optional air line
G. Remove any acoustical material or other material
anti-icer systems with antifreeze compound.
that may be damaged by heat or that may sup-
I. Keep personnel out of line with and away from port combustion and is in close proximity, prior to
the discharge opening of hoses or tools or other attempting weld repairs.
points of compressed air discharge.
H. Keep suitable fully charged Class BC or ABC fire
J. DO NOT use air at pressures higher than 2.1 bar extinguisher or extinguishers nearby when ser-
for cleaning purposes, and then only with effec- vicing and operating the compressor.
tive chip guarding and personal protective equip-
I. Keep oily rags, trash, leaves, litter or other com-
ment per OSHA Standard 29 CFR 1910.242 (b)
bustibles out of and away from the compressor.
and/or any applicable Federal, State, and Local
codes, standards and regulations. J. DO NOT operate the compressor without proper
flow of cooling air or water or with inadequate
K. DO NOT engage in horseplay with air hoses as
flow of lubricant or with degraded lubricant.
death or serious injury may result.
K. DO NOT attempt to operate the compressor in
1.4 FIRE AND EXPLOSION any classification of hazardous environment
unless the compressor has been specially
A. Clean up spills of lubricant or other combustible designed and manufactured for that duty.
substances immediately, if such spills occur.
B. Shut off the compressor and allow it to cool. 1.5 MOVING PARTS
Then keep sparks, flames and other sources of
A. Keep hands, arms and other parts of the body
ignition away and DO NOT permit smoking in the
and clothing away from couplings, belts, pulleys,
vicinity when checking or adding lubricant or
fans and other moving parts.
when refilling air line anti-icer systems with anti-
freeze compound. B. DO NOT attempt to operate the compressor with
the fan, coupling or other guards removed.
C. DO NOT permit fluids, including air line anti-icer
system antifreeze compound or fluid film, to

6
SECTION 1

C. Wear snug-fitting clothing and confine long hair

when working around this compressor, especially
when exposed to hot or moving parts. DANGER
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- Death or serious injury can result from
energized to minimize the possibility of acciden- inhaling compressed air without using
tal start-up, or operation, prior to attempting proper safety equipment. See OSHA stan-
repairs or adjustments. This is especially impor- dards and/or any applicable Federal, State,
tant when compressors are remotely controlled. and Local codes, standards and regulations
on safety equipment.
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 B. DO NOT use air line anti-icer systems in air lines
falls. supplying respirators or other breathing air utili-
zation equipment and DO NOT discharge air
from these systems into unventilated or other
1.6 HOT SURFACES, SHARP confined areas.
EDGES AND SHARP
CORNERS C. Operate the compressor only in open or ade-
quately ventilated areas.
A. Avoid bodily contact with hot fluid, hot coolant,
hot surfaces and sharp edges and corners. D. Locate the compressor or provide a remote inlet
so that it is not likely to ingest exhaust fumes or
B. Keep all parts of the body away from all points of other toxic, noxious or corrosive fumes or sub-
air discharge. stances.
C. Wear personal protective equipment including E. Coolants and lubricants used in this compressor
gloves and head covering when working in, on or are typical of the industry. Care should be taken
around the compressor. to avoid accidental ingestion and/or skin contact.
D. Keep a first aid kit handy. Seek medical assis- In the event of ingestion, seek medical treatment
tance promptly in case of injury. DO NOT ignore promptly. Wash with soap and water in the event
small cuts and burns as they may lead to infec- of skin contact. Consult Material Safety Data
tion Sheet for information pertaining to fluid of fill.
F. Wear goggles or a full face shield when adding
1.7 TOXIC AND IRRITATING antifreeze compound to air line anti-icer systems.
SUBSTANCES G. If air line anti-icer system antifreeze compound
A. DO NOT use air from this compressor for respi- enters the eyes or if fumes irritate the eyes, they
ration (breathing) except in full compliance with should be washed with large quantities of clean
OSHA Standards 29 CFR 1910 and/or any appli- water for fifteen minutes. A physician, preferably
cable Federal, State or Local codes or regula- an eye specialist, should be contacted immedi-
tions. 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

7
 SECTION 1

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
DANGER
exclude light. Call a physician immediately.
All field equipment must be tested for elec-
trostatic fields prior to servicing or making
1.8 ELECTRICAL SHOCK contact with the machine using the follow-
ing or equivalent test equipment:
A. This compressor should be installed and main-
tained in full compliance with all applicable Fed-
eral, State and Local codes, standards and Fluke Model 1AC-A
regulations, including those of the National Elec-
trical Code, and also including those relative to such as Fluke Networks Model
equipment grounding conductors, and only by C9970
personnel that are trained, qualified and dele- It is the responsibility of each organization
gated to do so. to provide/arrange training for all their
associates expected to test for electrostatic
B. Keep all parts of the body and any hand-held
fields.
tools or other conductive objects away from
exposed live parts of electrical system. Maintain
dry footing, stand on insulating surfaces and DO 1.9 LIFTING
NOT contact any other portion of the compressor
when making adjustments or repairs to exposed A. If the compressor is provided with a lifting bail,
live parts of the electrical system. Make all such then lift by the bail provided. If no bail is provided,
adjustments or repairs with one hand only, so as then lift by sling. Compressors to be air-lifted by
to minimize the possibility of creating a current helicopter must not be supported by the lifting
path through the heart. bail but by slings instead. In any event, lift and/or
C. Attempt repairs in clean, dry and well lighted and handle only in full compliance with OSHA stan-
ventilated areas only. dards 29 CFR 1910 subpart N and/or any appli-
cable Federal, State, and Local codes, standards
D. DO NOT leave the compressor unattended with and regulations.
open electrical enclosures. If necessary to do so,
then disconnect, lock out and tag all power at B. Inspect points of attachment for cracked welds
source so others will not inadvertently restore and for cracked, bent, corroded or otherwise
power. degraded members and for loose bolts or nuts
prior to lifting.
E. Disconnect, lock out, and tag all power at source
prior to attempting repairs or adjustments to C. Make sure entire lifting, rigging and supporting
rotating machinery and prior to handling any structure has been inspected, is in good condi-
ungrounded conductors. 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.

8
SECTION 1

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.
J. Set compressor down only on a level surface
NEVER attempt to forklift a compressor that is
capable of safely supporting at least its weight
not secured to its pallet, as uneven floors or sud-
and its loading unit.
den stops may cause the compressor to tumble
K. When moving the compressor by forklift truck, off, possibly causing serious injury or property
utilize fork pockets if provided. Otherwise, utilize damage in the process.
pallet if provided. If neither fork pockets or pallet
are provided, then make sure compressor is 1.10 ENTRAPMENT
secure and well balanced on forks before
attempting to raise or transport it any significant A. If the compressor enclosure, if any, is large
distance. enough to hold a man and if it is necessary to
enter it to perform service adjustments, inform
L. Make sure forklift truck forks are fully engaged
other personnel before doing so, or else secure
and tipped back prior to lifting or transporting the
and tag the access door in the open position to
compressor.
avoid the possibility of others closing and possi-
M. Forklift no higher than necessary to clear obsta- bly latching the door with personnel inside.
cles at floor level and transport and corner at
B. Make sure all personnel are out of compressor
minimum practical speeds.
before closing and latching enclosure doors.

9
NOTES

10
 TSR32 USER MANUAL R00

Section 2

DESCRIPTION
2.1 INTRODUCTION Although the compressor requires no inspection of

The design of the Sullair TSR-32 compressor unit is connectors, and the enclosure should be inspected
a two stage, positive displacement, flood lubricated and maintained in accordance with the procedures
one. A complete package includes the: and recommendations in this manual.

2.2 COMPRESSOR
COMPONENT DESCRIPTION
d discharge systems Refer to Figure 2-1 use a fan to draw outside air into
the enclosure, cooling the motors, the combined
radiator fluid cooler, and air aftercooler. This hot air is
then vented out thru enclosure exhaust duct work.
The TSR32 comes equipped with a fluid filter, air/oil
separator(s), control valves, and an inlet air filter.
Fluid 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
CAUTION rise normally associated with the heat of
compression.
Use only one type of a recommended com-
2. Seals the clearance paths between the
pressor lubricant. Adding a different one, or
rotors and the stator, and also between the
mixing lubricants can cause damage and/or
two rotors.
malfunctions, and will void the compres-
3. Provides a lubricating film between the rotors
allowing one rotor to directly drive the other,
which is an idler.

NOTE 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
The compressor requires no internal separator, and then to the service line while the fluid
inspections or maintenance actions. Open- is cooled and filtered in preparation for reinjection.
warranty. (This does not apply to the shaft
seal which is replaceable.)

11
TSR32 USER MANUAL R00 SECTION 2

Figure 2-1: Sullair TSR-32 Rotary Screw Air Compressor- Air-Cooled VSD

12
SECTION 2 TSR32 USER MANUAL R00

Figure 2-2: Sullair TSR-32 Rotary Screw Air Compressor- Air-Cooled Fixed Speed

13
TSR32 USER MANUAL R00 SECTION 2

Figure 2-3: Cooling/Lubrication and Discharge System

AA: FROM UNIT DISCHARGE FLANGE 1. FLUID FILTER

BB: TO FLUID COOLER 2. FLUID STOP VALVE
CC:FROM FLUID COOLER 3. MINIMUM PRESSURE/CHECK VALVE
DD:TO UNIT INJECTION BLOCK 4. THERMAL VALVE
EE: TO AFTERCOOLER 5. AIR/OIL SEPARATOR TANK
FF: FROM AFTERCOOLER 6. MOISTURE SEPARATOR
GG:AIR SUPPLY OUTLET 7. MOISTURE TRAP/DRAIN
HH:MOISTURE DRAIN OUTLET 8. OPTIONAL SCF FILTER

14
SECTION 2 TSR32 USER MANUAL R00

2.3 COMPRESSOR COOLING bottom of the separators dry side to a medium

AND LUBRICATION pressure region in the compressor. Scavanged fluid
is returned by a pressure differential between the
DESCRIPTION receiver and compressor.
Visual sight glasses are located on the return line to
Refer to Figure 2-3. The cooling and lubrication
observe this flow. This return line also has an orifice
system consists of a fan, fan motor, aftercooler/
(protected by a strainer) to ensure an unobstructed
fluid cooler, full flow fluid filter, thermal valve,
flow.
and interconnecting tubes.
The Supervisor Controlle
The pressure in the receiver tank starts the fluid flow
pressure drop through the separator if the element
by forcing the fluid from the high pressure area of the
becomes dirty or plugged. (Refer to Section 3.5:
tank to an area of lower pressure in the compressor.
Lubrication Change Recommendations and
Fluid flows from the receiver tank to the thermal
Maintenance, Fluid Filter and Separator on page 26.)
valve that is fully open when the fluid temperature is
It will also shut down the compressor if the discharge
below 175°F. The fluid passes through the thermal
temperature reaches 250°F (121°C).
valve, the main filter, and directly to the compressor
where it lubricates, cools and seals the rotors, and A minimum pressure/check valve located
the compression chamber. downstream from the separator maintains the
receiver pressure at approximately 50 psig (3.4 bar)
As the discharge temperature rises above 175°F,
during load conditions. This pressure level is
due to the heat of compression, the thermal valve
necessary for proper air/fluid separation and
begins to close and a portion of the fluid then flows
sufficient fluid circulation.
through the cooler. From the cooler the fluid flows to
the fluid filter and on to the compressor. A portion of A terminal check valve is a sub-component of the
the fluid flow to the compressor is routed to the anti- minimum pressure/check valve that prevents
friction bearings which support the compressor compressed air in the service line from back-flowing
rotors. into the receiver on shutdown or when the
compressor is operating in an unload condition. Also,
The fluid filter has a replacement element and an
integral bypass valve. Refer to Section 3.5:
opens if the receiver tank pressure exceeds its
Lubrication Change Recommendations and
rating.
Maintenance, Fluid Filter and Separator on page 26.

2.4 COMPRESSOR DISCHARGE

WARNING
DESCRIPTION
Stop the compressor and relieve all internal
Refer to Figure 2-3. The compressor discharges the pressure before removing caps, plugs, and/
compressed air/fluid mixture into the combination or other components when the compressor
receiver tank. The receiver has three basic functions: is running or pressurized.
1. It acts as an air/fluid separator.
2. Serves as the compressor fluid sump. Add fluid to the receiver tank through the capped
3. Houses the air/fluid separator elements. fluid filter port. There is also a sight glass that
enables the user to check the receiver tank fluid
The compressed air/fluid mixture enters the receiver level. See Section 4.6: Fluid Level Check on page
tank and flows through an internal baffle system that 34.

causes most of the fluid to fall to the bottom of the

receiver tank. A small amount of fluid remaining in FUNCTIONAL DESCRIPTION
the compressed air collects on the surface of the
separator elements as the air flows through the Refer to Figure 2-6. The purpose of the compressor
separators. control system is to regulate the amount of the air
being compressed to match the amount of
Two return lines (or scavenge tube) lead from the compressed air being used. The Capacity Control

15
TSR32 USER MANUAL R00 SECTION 2

System consist of variable speed drive and spiral spiral valve shaft assembly, resulting in a rotary
valve. The functional description of the control motion and full opening of the spiral valve, effec-
system is described below in five distinct phases of tively reducing the rotor length by 50%. Excess air
operation. The following description text applies to will be returned back internally to the suction side of
TSR-20 variable speed drive compressors with the compressor unit. In this mode, the VSD will
The compressor can be modulate the motor speed within a specified range to
operated at a setpoint pressure from 100 to 175 maintain the set point pressure as follows:
psig (4.1 to 12.1 bar) along with a horsepower
Increasing demand condition:
range from 200 to 300 HP. The Supervisor
If demand increases, the VSD increases the motor
range based on the selected pressure and speed until the set point pressure is achieved. If set
horsepower. For explanatory purposes, this point pressure is not achieved while at maximum
description will apply to a compressor with an speed, the controller will close the spiral valve,
operating pressure of 100 psig (6.9 bar). A thereby eliminating internal air bypass.
compressor with any other pressure range would Consequently, the VSD will regulate the motor speed
operate in the same manner except stated to achieve the set point pressure.
pressures.
Decreasing demand condition:
PSIG (0 TO 3.4 BAR)
While the spiral valve is open, if demand continues to
START) decrease the VSD will reduce the motor speed until
button is depressed, the VSD ramps the motor to full the set point pressure is achieved. This action will
speed and the sump pressure will quickly rise from 0 continue until the minimum speed is reached. When
to 50 psig (0-3.4 bar). During this period, the solenoid the system pressure reaches 106 psig (7.3 bar), or
valve is closed, the inlet valve is fully open and the alternatively set unload pressure, the compressor
air-end delivers full capacity to the sump tank. The unloads, or turns off.
rising compressor air pressure is isolated from the UNLOAD MODE- IN EXCESS OF 106 PSIG (7.3 BAR)
service line in this phase by the minimum pressure
valve set at approximately 50 psig (3.4 bar). When a relatively small amount or no air is being
used, the service line pressure continues to rise.
FULL LOAD MODE- 50 TO 100 PSIG (3.4 TO 6.9 BAR) When it exceeds 106 psig (7.3 bar), or alternatively
When the compressed air pressure rises over 50
psig (3.4 bar) the minimum pressure valve is control system de-energizes the solenoid valve
opened allowing compressed air to flow into the allowing sump air pressure to be supplied directly to
service line. From this point on the line pressure is close the inlet valve. Simultaneously, the solenoid
valve sends a pneumatic signal to the blow down
which controls the variable speed drive. The solenoid valve. The blow- down valve opens to the
valve remains closed with the inlet valve fully open atmosphere, reducing sump pressure. The check
running at 100 psig (6.9 bar) or below. valve in the air service line prevents line pressure
from returning to the sump. The compressor will shut
VARIABLE SPEED DRIVE PART LOAD CONTROL down after the unload time setting expires if
If less than rated capacity of compressed air is being programmed (the default setting is zero [0] seconds
used, the service line pressure will rise above 100 for an immediate shutdown upon unload).
psig (6.9 bar). Consequently, the Variable Speed When the line pressure drops to the low setting
Drive will begin to decelerate the motor, thereby pressure of 100 psig (6.9 bar) The Supervisor
reducing the output capacity to match demand. The
drive will continuously adjust the motor speed noid valve which closes the blow down valve. The
(accelerate or decelerate) to maintain a line pressure re-energized solenoid valve prevents line pressure
of 100 psig (6.9 bar). In this mode the VSD will from reaching the inlet control valve, thereby allow-
operate within the appropriate frequency range ing it to fully open.
determined by the Su
AUTOMATIC OPERATION
MODULATING MODE WITH SPIRAL VALVE:
For VSD applications, th
As demand decreases, the variable speed drive
reduces motor speed to maintain the set point pres- allows the compressor to shutdown when no com-
sure. When the speed approaches the minimum pressed air requirement is present and restarts when
setting, a solenoid valve opens feeding air pressure compressed air is needed. Restart will only take
to the spiral valve actuator. This in turn expands the place when sump pressure is below 5 psig.
diaphragm and engages the pinion mounted on the

16
SECTION 2 TSR32 USER MANUAL R00

17
TSR32 USER MANUAL R00 SECTION 2

2.6 FIXED SPEED CONTROL psig (6.9 bar). As a result, the differential pressure
SYSTEM, FUNCTIONAL regulator for the spiral valve gradually opens, apply-
DESCRIPTION ing air pressure to the spiral valve actuator. Air
pressure at the actuator expands the diaphragm. The
Refer to Figure 2-7. The purpose of the compressor rack, in turn, engages with the pinion mounted on the
control system is to regulate the amount of air being spiral valve shaft assembly. This results in a rotary
compressed to match the amount of compressed air motion. As the spiral valve rotates, it starts opening
being used. the bypass ports gradually. Excess air is then being
returned back internally to suction end of compressor
The capacity control system consists of a spiral valve
unit. Now the compressor is fully compressing only
and an inlet butterfly valve. The functional description
that amount of air which is being used. As air
of the control system is described below in 4 distinct
demand keeps dropping further, the spiral valve
phases of compressor operation. For explanatory
keeps opening more and more until all the bypass
purposes, this description applies to any compressor
ports are fully open. At this point, the spiral valve has
with an operating range of 100 to 110 psig (6.9 to 7.6
moved into the minimum position.
bar). A compressor with any other pressure range
would operate in the same manner except for the The spiral valve provides a modulation range from
stated pressures. 100 to approximately 50%. During this period, the
pressure rises approximately from 100 to 108 psig
START MODE - 0 TO 50 PSIG (0 TO 3.4 BAR)
(6.9 to 7.4 bar). As the air pressure exceeds 108 psig
When the compressor (ON) pad is depressed, the (7.4 bar), the differential pressure regulator
sump pressure will quickly rise from 0 to 50 psig (0 to controlling the Sullicon Control opens. This allows
3.4 bar). During this period, both of the pressure the air pressure to expand the diaphragm chamber of
regulators and the solenoid valve are closed and the the Sullicon Control, which starts partially closing the
Sullicon Control and spiral valve are inop- erative. inlet butterfly valve. The inlet butterfly valve pro-
The spring on the control holds the butterfly valve vides modulation range from 50 to 40%. During this
fully open while the spiral valve is fully closed period, the pressure rises approximately from 108 to
(maximum) position and the compressor pumps at 110 psig (7.4 to 7.6 bar). During this range, the spiral
full rated capacity. The rising compressor air pres- valve remains in the full open position.
sure is isolated from the service line in this phase by
UNLOAD MODE - IN EXCESS OF 110 PSIG (7.6
the minimum pressure valve set at approximately 50
BAR)
psig (3.4 bar).
When a relatively small amount or no air is being
A standard closed inlet system is provided which
used, the service line pressure continues to rise.
uses air pressure to close the butterfly and opens the
When it exceeds 110 psig (7.6 bar), Supervisor
spiral valve to reduce motor torque for starting.
es the solenoid valve
FULL LOAD MODE - 50 TO 100 PSIG (3.4 TO 6.9 allowing line pressure to be supplied directly to the
BAR) Sullicon diaphragm keeping the inlet butterfly closed;
the spiral valve is in the fully open (minimum)
When the compressed air pressure in the sump rises
position. Simultaneously, the solenoid valve sends a
above 50 psig (3.4 bar), the minimum pres- sure
pneumatic signal to the blowdown valve. The
valve opens, allowing compressed air to flow into the
blowdown valve opens the sump to the atmosphere.
service line. From this point on, the line air pressure
This reduces the sump pressure to approximately 30
is continually monitored by the Supervisor
psig (2.1 bar) which results in low horsepower
consumption. The check valve in the air service line
solenoid valve remain closed during this phase,
prevents line pressure from returning to sump while
keeping the Sullicon Control and spiral valve
the compressor is running in the unloaded mode.
inactive. Both the spiral valve as well as the inlet
Both the spiral valve and the butterfly valve remain in
butterfly valve remain in the full load position as long
the unload position.
as the compressor is running at 100 psig (6.9 bar) or
below. When the line pressure drops back to 100 psig (6.9
bar) due to an increase in the air demand, Supervisor
MODULATION - 100 TO 110 PSIG (6.9 TO 7.6 BAR)
solenoid valve allowing
As air demand drops below the rated capacity of the the air pressure behind the Sullicon Control to be
compressor, the line pressure will rise above 100 vented through the solenoid valve exhaust port. The

18
 NOTES
blowdown valve closes, and the inlet butterfly valve rol system, indicates the
opens. Also the air pressure at the spiral valve
actuator diaphragm is reduced through a vent hole at splayed, maintenance is
the spiral valve differential pressure regulator, and a required.
spring in the actuator causes the spiral valve to
The butterfly-type air inlet valve directly controls the
return to the full load (maximum) position.
amount of air intake to the compressor in response to
AUTOMATIC OPERATION the operation of the Sullicon Control.
For applications with varied periods of time when
there are no air requirements, Supervisor
llows the compressor to
shut down (time delayed) when no compressed air
requirement is present and restart as compressed air
is needed.
LOAD/ NO LOAD OPERATION
If applications call for load/no load operation, mod-
ulation can be disabled in the Supervisor

modulation is disabled, the unload pressure must be

reset to the rated load pressure of the machine. For
example, an L model rated for 100 psig full load
operation and 110 psig unload must have the unload
pressure reset to 100 psig. This ensures that the
motor will not run in an overload condition.
Figure 2-5: Air Inlet System

FUNCTIONAL DESCRIPTION 1. Air Inlet Filter

Refer to Figure 2-6. The compressor inlet system 2. Inlet Butterfly Valve
consists of two dry-type air filters, a vacuum switch 3. Compressor Unit
and an air inlet butterfly valve.
4. Sullicon Control
The vacuum switch located in the compressor

19
 Figure 2-6: TSR-32 Piping and Instrumentation (VSD)

20
TSR32 USER MANUAL R00

02250177-348 R01
SECTION 2
 Figure 2-6: TSR-32 Piping and Instrumentation (VSD)
Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
SECTION 2

1 250006-718 1 FILTER, AIR INLET

28 02250097-611 2 GLASS, FLUID LEVEL SIGHT
3 011682-003 1 CONTROL, SULLICON
30 250029-330 1 VALVE, RELIEF 60#
5 ------ 1 VALVE, SPIRAL-COMPRESSOR 31 02250175-507 1 UNIT, COMPRESSOR&PARTS 0.79GR
32 02250120-955 1 VALVE, THERMAL ASSEMBLY
33 02250121-638 1 FILTER, FLUID

35 02250175-451 1 COOLER, FLUID SAE HERESITE

36 02250176-032 1 AFTERCOOLER, AXA HERESITE

38 02250122-004 1 VALVE, OIL STOP W/SAE

PLEASE NOTE: WHEN ORDERING PARTS,
14 02250152-161 2 INDICATE SERIAL NUMBER OF COMPRESSOR

15 02250155-536 4 TRANSDUCER, PRESSURE N4

18 02250117-782 2 STRAINER, IN LINE SAE

19 250033-821 1 VALVE, MINIMUM PRESSURE CHECK
20 047226 1 HEATER, SUMP
21 250034-129 1 ELEMENT, SECONDARY SEPARATOR
22 250034-123 1 ELEMENT, PRIMARY SEPARATOR
23 02250117-009 2 GAUGE, PRESSURE

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

21
TSR32 USER MANUAL R00
 Figure 2-7: TSR-32 Piping and Instrumentation (Fixed Speed)

22
TSR32 USER MANUAL R00

02250177-349 R01
SECTION 2
 TSR-32 Piping and Instrumentation (Fixed Speed)
Q Q
KEY KEY
PART NO. T DESCRIPTION PART NO. T DESCRIPTION
NO. NO.
Y Y
SECTION 2

1 250006-718 1 FILTER, AIR INLET 28 02250097-611 2 GLASS, FLUID LEVEL SIGHT

3 011682-003 1 CONTROL, SULLICON 30 250029-330 1 VALVE, RELIEF 60#

31 242221 1 TANK, ACCUMULATOR CI
5 ------ 1 VALVE, SPIRAL-COMPRESSOR 32 02250120-955 1 VALVE, THERMAL ASSEMBLY
6 02250148-608 1 VALVE, PRESSURE REGULATOR 33 02250121-638 1 FILTER, FLUID

35 02250175-451 1 COOLER, FLUID SAE HERESITE

9 02250148-609 1 VALVE, PRESSURE REGULATOR 36 02250176-032 1 AFTERCOOLER, AXA HERESITE

38 02250122-004 1 VALVE, OIL STOP W/SAE

15 02250155-536 4 TRANSDUCER, PRESSURE N4 42 02250176-505 1 UNIT, COMPRESSOR&PARTS 0.91GR

18 02250117-782 2 STRAINER, IN LINE SAE

19 250033-821 1 VALVE, MINIMUM PRESSURE CHECK 46 047226 1 HEATER, SUMP
20 041111 1 VALVE, MOISTURE BLEED PLEASE NOTE: WHEN ORDERING PARTS,
21 250034-129 1 ELEMENT, SECONDARY SEPARATOR INDICATE SERIAL NUMBER OF COMPRESSOR

22 250034-123 1 ELEMENT, PRIMARY SEPARATOR

23 02250117-009 2 GAUGE, PRESSURE

PLEASE NOTE: WHEN ORDERING PARTS,

INDICATE SERIAL NUMBER OF COMPRESSOR

23
TSR32 USER MANUAL R00
NOTES

24
 TSR32 USER MANUAL R00

Section 3

SPECIFICATIONS
3.1 TABLE OF SPEC
TSR-20
MOTOR TEFC
HZ/VOLTAGE 460/60
DRIVE AMP
385A
RATING
WEIGHT (lbs) 19,900
LENGTH (in) 220
WIDTH (in) 84
HEIGHT (in) 104

3.2 COMPRESSOR SPECIFICATIONS

COMPRESSOR: TSR-32
Type: Rotary Screw
100 psig (7 bar) 125 psig (9 bar) / 150 psig (10.0 bar)
Standard Operating Pressure:
175 psig (12.0 bar)
Bearing Type: Anti-friction
Ambient Temperature (Max.): 104ºF (40ºC)

25
TSR32 USER MANUAL R00 SECTION 3

3.3 LUBRICATION GUIDE

Refer to Figure 3-1 for the fluid fill port location.

tested at the factory with (35 GAL) Sullube lubricant.

CAUTION
Contamination of compressor fluids with
mineral oil or other fluids can cause foam-
ing, filter plugging, or orifice line obstruc-
tion.

CAUTION
Do not mix different types of lubricants.
Mixing lubricants can cause malfunctions
or compressor damage: will void the com-

Figure 3-1: Fluid Fill Location

3.4 APPLICATION GUIDE
1. Fluid Fill Port 4. Air/Oil Separator Tank
Sullair encourages its customers to participate in a
fluid analysis program with the fluid suppliers. In 2. Fluid Level Sight Glass 5. Relief Valve
some cases the analysis results suggest a fluid 3. Fluid Drain Valve
change interval which differs from the User Manual.
Contact a Sullair representative for details.
NOTE
When performing a fluid change or topping
off the fill, the proper level should be at half
of the sight glass, with the machine off.

Mixing, changing or adding other lubricants

within the compressor unit may void the
air-end warranty.

3.5 LUBRICATION CHANGE RECOMMENDATIONS AND

MAINTENANCE, FLUID FILTER AND SEPARATOR
LUBRICANT FLUID CHANGE FLUID FILTER CHANGE SEPARATOR CHANGE
Sullube A,E G,C A,D
A - 8,000 hours or once per year.
C - When measured pressure loss exceeds 20 psig (1.3 bar).
D - When measured pressure loss exceeeds 10 psig (0.7 bar).
E - When required as the result of fluid analysis or known contamination.
G - Every 2,000 hours.

26
NOTES

27
TSR32 USER MANUAL R00 SECTION 3

02250175-423 R01

28
SECTION 3 TSR32 USER MANUAL R00

02250177-017 R01

29
 Figure 3-4: Wiring

30
TSR32 USER MANUAL R00

02250177-397 R00
SECTION 3
SECTION 3 TSR32 USER MANUAL R00

02250177-398 R00

31
NOTES

32
 TSR32 USER MANUAL R00

Section 4

INSTALLATION
SUPPORT AND LOCATION pressor, free from exhaust and paint
fumes, dust, metal particles, or caustic
The compressor must have a stable firm foundation, chemical vapors.
or mounting structure that is rigid enough to keep the
compressor frame level, and maintain the alignment
of the compressor and motor. Tie-down bolts of NOTE
sufficient size must be used to ensure that the
compressor frame is firmly anchored to its Systems using both reciprocating and
foundation. Rubber, cork, or other pliable materials rotary screw compressors must isolate
can be inserted between the foundation and the two types from each other through the
compressor frame to provide a uniform contact use of a common receiver tank. Air lines
surface. from each individual compressor should
be connected directly to the common
receiver tank.
from being transmitted to the compressor.

ing the required clearances for the area

around the electrical panel must be com-
NOTE
plied with.
Housing the compressor in an inade-
quately ventilated enclosure will cause
location is sufficient for safe operation and higher compressor operating tempera-
maintenance. tures.

that allows access for maintenance vehi-

cles and lifting equipment. Table 4-1: Ventilation Requirements

Air-Cooled with
should permit easy access to all compres- Cooling Type
Aftercooler
sor components.
Motor (HP) 200 250 300
faces absorb sound and reduce ambient
Fan Air (CFM) 28,500
noise levels. Hard surfaces reflect noise
and have little effect on ambient noise lev- Ventilation 9,915 11,825 14,022
els. (BTU/MIN)

4.2 VENTILATION AND

COOLING 4.3 SERVICE AIR PIPING
AIR-COOLED COMPRESSORS Before installing the compressor, review the service
ing: pipe sizes, auxiliary
clearance around their perimeter. receiver, drip legs, line filter(s), and isolation valves
(See Table 4-1).
water.

33
TSR32 USER MANUAL R00 SECTION 4

PIPE SIZING
Pipes should be sized as a minimum to match the
NOTE
connection. All piping and fittings should be rated for
the discharge pressure. Compressors not equipped with an auxiliary
receiver tank may need to have their
4.4 AUXILIARY RECEIVER TANK response times adjusted. Contact Sullair
Customer Care for assistance.
An Auxiliary receiver tank should be installed in
systems where large demand fluctuations will occur.
ISOLATION VALVES
4.5 COUPLING ALIGNMENT
CHECK
Install isolation valves where isolation of the
compressor from the service lines is required. These No coupling alignment check is required.
valves should have drip legs that drain at an angle
downward from the base. A vent to the piping should 4.6 FLUID LEVEL CHECK
be installed downstream of the compressor outlet
connection. The compressor is shipped fully charged with the
proper amount of fluid. However, it is necessary to
When two compressors are installed to operate in check the fluid level at the time of installation and
parallel with a common receiver tank, an isolation during compressor operation. Check the fluid level
valve and drain trap for each compressor should be when the compressor is in the SHUT DOWN MODE
installed before the common receiver. (fluid level may not be visible when operating), and
Compressors have built-in aftercoolers and are by looking at the sight glass on the receiver tank
equipped with a condensate drain located next to the (See Figure 3-1). The full level is at half the sight
air outlet connection. A drain line should be installed glass. Add fluid if fluid level is not visible in the sight
to remove the condensate, which builds up during glass when machine is shut down.
compressor operation.

34
SECTION 4 TSR32 USER MANUAL R00

4.7 ELECTRICAL PREPARATION Parallel feeder cable connections to incoming

terminal cam-locks L1-L2-L3 should be tight and
Interior electrical wiring is installed at the factory. clean. These are located on end of package. Behind
Required customer wiring should be done by a the access door located above the cam-loks is the
qualified electrician in compliance with OSHA, package circuit breaker disconnect, supplied for
National Electric Code and/or any applicable local additional safety.
electrical codes. Customer to supply power via cam-
The applied voltage must conform to the motor and
lock located on end of enclosures. An electrical
check should be made to ensure that the first start-up compressor data plate ratings.
will be successful. The compressor and drive should
be properly grounded/earthed in accordance with
applicable codes, regulations, and requirements. WARNING
Feeder cables should be sized by the customer/
electrical contractor to ensure that the circuit is Energized internal components are a poten-
balanced and not overloaded by other electrical tially FATAL SHOCK HAZARD. Disconnect
equipment. The length of wiring from a suitable all power before performing any work on the
electrical power source is critical because voltage
drops can adversely effect the performance of the
compressor. Refer to Table 4-2:Motor Wiring Basic 1. Check incoming voltage. The incoming
Data.
rating/specifications.
Table 4-2: Motor Wiring Basic Data 2. Check motor starting device and overload
heater sizes.
480 V 40 C
3. Check all electrical connections for
HP (I low) Current I Phase Wire GND tightness.
low OL MCM Conductor

MAX 300 HP 385 2x300 300MCM

35
TSR32 USER MANUAL R00 SECTION 4

4.8 MOTOR ROTATION the motor end opposite the compressor unit, the
DIRECTION CHECK shaft should turn clockwise. If reverse rotation
occurs, disconnect the power to the starter and
Motor rotation check must be done at compressor exchange any two of the three power input leads,
start-up after the wiring has been installed. The then re-check rotation. A "Direction of Rotation"
compressor can be damaged if it runs in the wrong nameplate is located on the motor/compressor
direction for more than a few seconds. Motor rotation adapter to show proper motor/compressor rotation.
can be viewed through the opening in the drive
Fan motor rotation should also be checked. It should
adapter housing. Pull out the EMERGENCY STOP
rotate counter-clockwise when viewing the fan motor
button and press once, quickly and in succession,
from the backside of the motor.
the (START) and (STOP) pads. This
action will bump start the motor. When looking from

36
 TSR32 USER MANUAL R00

Section 5

OPERATION
5.1 ROUTINE OPERATION
Before starting the compressor, check the fluid level
in the receiver tank. If the fluid level is not showing in
the sight glass, add the required amount of fluid up to WARNING
the mid-point to bring it to its proper level. Frequent
addition of fluid indicates the presence of a leak or a HIGH-PRESSURE HAZARD!
condition causing excessive fluid consumption. See
Section 6.8: Troubleshooting— Introduction on page DO NOT remove caps, plugs, and/or other
43 under EXCESSIVE COMPRESSOR FLUID components when compressor is running
CONSUMPTION for a probable cause and corrective or pressurized. Stop compressor and
action. relieve all internal pressure before doing so.

Failure to comply could result in death or

serious injury.

After a routine start, observe the controller display for

the proper indications for this phase of operation.
After the compressor has warmed up, check all
compressor operation indications to ensure that it is
running properly.

37
TSR32 USER MANUAL R00 SECTION 5

5.2 MACHINE MODEL The TSR32 VSD design can be setup in a variety of
SELECTION & SUPERVISOR horsepowers and pressures. This can be done
under the Factory Setup menu on the Supervisor

The following values reflect the machine

configuration.

Model: TSR32_200L (100 PSIG)

TSR32_200H (125 PSIG)
TSR32_200HH (150 PSIG)
TSR32_200XH (175 PSIG)
TSR32_250L (100 PSIG)
TSR32_250H (125 PSIG)
TSR32_250HH (150 PSIG)
TSR32_250XH (175 PSIG)
TSR32_300L (100 PSIG)
TSR32_300H (125 PSIG)
TSR32_300HH (150 PSIG)
TSR32_300XH (175 PSIG)
Cooling: Air
Press Trans: 250PSI
P1 Max: Maximum discharge pressure
KT Fluid: No
Water Switch: No
Oil Switch: No
Aux Overload: Yes
Min. Load PSI: Minimum acceptable load P1 pressure setting.

to 20 seconds
K8 Option: Disabled
Stop Timer: Time to run machine before stopping
Load Hours: Hours machine was running and loaded
Run Hours: Hours machine was running loaded and unloaded
Load Cycles: Number of load/unload cycles
Starts: Number of machine starts
Capacity: Maximum capacity of machine
Spiral Valve: Yes
VSD: Serial
Com Module: No
Mtr Module: No

38
 TSR32 USER MANUAL R00

Section 6

MAINTENANCE
6.1 GENERAL
This compressor requires a minimal amount of
inspections and maintenance. The Supervisor

situations requiring maintenance, or fault conditions.

6.2 MAINTENANCE AFTER

INITIAL 50 HOURS OF
OPERATION
After the initial 50 hours of operation, a few
maintenance actions are required to clean the
system of any foreign materials. Perform the
following maintenance operations:
1. Clean the return line strainer. Refer to
Maintenance Every 2000 Hours for location.
2. Clean the return line orifice.
Figure 6-1: Fluid Filter Assembly
6.3 MAINTENANCE EVERY 2000
HOURS
1. Filter Head 2. Element (I)
After 2000 hours of operation: 3. O-ring Seals (I) 4. Bowl
1. Clean the return line strainer. Refer to 5. Drain Plug w/O-ring (I)
Discharge, Receiver and Piping System.
(I) Element Replacement Kit P/N 02250139-996
2. Replace the fluid filter element.
FLUID FILTER ELEMENT REPLACEMENT
6.4 FLUID MAINTENANCE
Refer to Figure 6-1.
Drain the receiver tank and change the compressor
1. Use a wrench to remove the filter canister.
fluid using instructions shown in the Lubrication Guide.
2. Remove and dispose of filter element properly.
6.5 FILTER MAINTENANCE
Refer to Figure 6-1 Replace the fluid filter element NOTE
under any of the following conditions, or whichever
occurs first: Dispose of fluids in accordance with
applicable federal, state and local regula-
1. Every 2000 hours. tions.

indicates high differential pressure.

3. Clean gasket seating surface.
3. Every fluid change.
4. Apply a light film of fluid to the element seal.

39
TSR32 USER MANUAL R00 SECTION 6

5. Install the element into the filter canister. 6.7 SEPARATOR MAINTENANCE
6. Thread the canister and element back on the
filter head. Replace the separator elements when shown by the
7. Restart compressor and check for leaks. year, whichever comes first. The separator elements
must be replaced. DO NOT attempt to clean and
6.6 AIR FILTER MAINTENANCE reinstall the separator elements.
Refer to Figure 6-2. Air filter maintenance on air filter SEPARATOR ELEMENT REPLACEMENT
no. 250006-718 should be performed when the
lays Air Filter Maint, or Refer to Figure 6-3. The separator elements must be
once a year, whichever comes first. If the filter needs changed when indicated by the Supervisor
to be replaced, order replacement element no. , whichever occurs first.
02250135-149. Consult the following procedures to Use the following procedure below to change the
replace the air filter element. separator elements.

AIR FILTER ELEMENT REMOVAL

1. Clean exterior of air filter housing.
2. Release the three retaining clamps and
remove the end cap.
3. Remove element and clean interior of
housing using a damp cloth.
ELEMENT REPLACEMENT

Figure 6-2: Air Filter Assembly

1. Housing 3. Dust Collector

2. Element (I) 4. Sealing Washer Figure 6-3: Separator Element Assembly
(I) Element Replacement Kit P/N 02250135-149
1. Cover 3. Element-Primary (I)
2. Element-Secondary (II) 4. Receiver Tank

Element replacement is performed by reversing the (I) Primary Element Replacement Kit P/N -
removal instructions. Make sure that the element is 250034-124
fully seated into the housing. (II) Secondary Element Replacement Kit P/N -
250034-130

40
SECTION 6 TSR32 USER MANUAL R00

10. Re-connect all piping making sure return line

bottom of the separator element. This will

assure proper fluid return flow to the com-
CAUTION pressor.

Relieve all pressure from the receiver tank 11. Check the return line strainer before re-start-
and all compressor lines. ing the compressor. If needed, either clean
or replace the strainer.

1. Disconnect all piping connected to the sepa-

rator cover to allow removal (return lines,
service lines, etc.)
FLUID RETURN/SIGHT GLASS MAINTENANCE
2. Loosen and remove the twelve (12)3/4-10 x Refer to Figure 6-4. The fluid return/sight glass
subassembly is located on the side of the separator
plate. tank. Fluid return/sight glass maintenance should be
performed along with that of the fluid filter. Fluid
3. Lift cover plate from the separator tank. return/sight glass usually results from condition of the
4. Remove the primary and secondary separa- filter assembly. Order filter assembly no. 02250117-
tor elements. 782, and use the following instructions as a guide:

5. Scrape the old gasket material off the cover 1. Disconnect the tube at bottom of sight glass.
and flange on the separator tank, being care- 2. Unscrew the sight glass assembly where the
ful not to let the scraps fall in the tank. elbow fitting joins the strainer/filter.
6. Inspect the separator tank for rust, dirt, etc. 3. Remove used filter assembly, and replace
with the new assembly.
7. DO NOT remove the grounding staples from
4. Inspect and clean the orifice inside the sight
the gaskets. DO NOT use any type of gasket glass blocks. Remove the orifice with an
eliminator. Re-insert the separator elements allen wrench.
with the gaskets attached into the separator
tank taking care not to dent it against the 5. Coat/lubricate the O-rings with silicone
grease.
tank opening.
6. Re-attach the connectors to the sight glass/
8. Clean the underside of the separator tank lid orifice blocks.
and remove any rust. Paint surface with an
epoxy paint as required. If epoxy being PROTECTION PRESSURE REGULATOR
applied, assure clean surface for the epoxy ADJUSTMENT
to adhere to properly. If not properly cleaned,
Refer to Figure 6-5. Start the compressor and adjust
the epoxy will peel off.
the service valve to maintain service air pressure at
9. Replace the cover plate, washers, and cap- approximately 1 psi over its rated pressure. Turn the
screws. Torque to 200 ft-lbs(272 Nm). inlet valve protection regulator adjusting screw until
100psi is showing on the pressure gauge. Lock the
adjusting screw in place with the locknut. The

41
TSR32 USER MANUAL R00 SECTION 6

Figure 6-4: Fluid Return / Sight Glass

1. Tube Connectors
2. Filter Assembly (I) Figure 6-5: Pressure Regulator Adjustment
3. Sight Glass/Orifice Block
4. Secondary Element orifice .03 1. Adjustment Nut 2. Adjustment Screw
5. Primary Element orifice .09 (I) Rebuild Kit P/N 02250152-207
6. 90° Elbow
7. Pipe Tee
8. Tube Connector
A: From Primary Separator Element WATER CONDENSATE DRAIN MAINTENANCE
B: From Secondary Separator Element It is necessary to periodically clean the strainer.
C: To Unit Second Stage Remove the hex cap from the strainer and remove
(I) Replcement Filter Assembly P/N the strainer screen. Clean the screen and reinstall. If
02250117-782 the screen is damaged, the strainer assembly must
be replaced (406480) or order repair kit (250031-
271).

42
SECTION 6 TSR32 USER MANUAL R00

CONTROL LINE FILTER

The regulators and solenoid valves, which control the 5. Install the new element by wrapping it
around the jaws, engaging the cogs on the
compressor, are protected by a control line filter.
element into the jaws.
Remove the bowl and verify condition of element and
drain-float. Replace if needed, do not clean element, 6. Reinstall the outer sleeve and secure by
with element/seal kit (02250153-288) and/or float tightening the two screws to 45 in·lbs (5 Nm).
assembly/seal kit (02250153-280). 7. Reinstall the protective grill.
SHAFT COUPLING MAINTENANCE
The compressor unit and motor are rigidly connected INTRODUCTION
through the mounting adapter housing. This
arrangement makes coupling alignment The information in the Troubleshooting Guide
unnecessary. The coupling is a jaw type in shear. If describe symptoms and usual causes for the listed
the elastomeric (rubber) element requires discrepancies. However, DO NOT assume that these
replacement due to wear or damage, order a are the only malfunctions or fault conditions that may
replacement element and perform the following occur.
steps:
1. Remove the protective grill from the adapter
housing.
NOTE
2. Loosen the retaining screw located on the For additional troubleshooting guidelines,
outer sleeve. Slide the sleeve to one side,
exposing the coupling element. ual.
3. Unwrap the coupling element from the
coupling jaws.

Table 6-1: Troubleshooting Guide

SYMPTOM PROBABLE CAUSE REMEDY
Compressor will not start Main disconnect switch open Close switch.
Line fuse blown Replace fuse.
Control Transformer Fuse Blown Reset. Should trouble persist, check whether
motor starter contacts are functioning properly.
Motor Starter Overloads Tripped Check voltage. Should voltage check low,
consult power company.
Replace
module if no display or erratic
display.
Low incoming line voltage Check voltage. Should voltage check low,
consult power company.

module if no display or erratic display.

43
TSR32 USER MANUAL R00 SECTION 6

Table 6-1: Troubleshooting Guide

SYMPTOM PROBABLE CAUSE REMEDY
Compressor Shuts Down With Loss of control voltage Check incoming power
Air Demand Present Low incoming voltage Check control fuses and wiring. Consult power

will provide indication of most maintenance

problems if control power has not been lost.
Shutdowns will occur upon a faulty condition or
a bad sensor condition.
Excessive operating pressure Check maximum P2 pressure setting.

HIGH PRESS P1 display; Max P1 pressure

may be set too low. Consult factory for
recalibration.

Defective solenoid valve; solenoid valve

should cause Sullicon Control lever to move to
unload stop when the unload pressure setting
P2A is exceeded. Repair if defective.

Defective blowdown valve; blowdown valve

should exhaust sump pressure to 30 psig (2.1
bar) for integrated coolers; 50 psig (3.4 bar) for
remote coolers when maximum operating
pressure is reached. Repair if defective.

Open or shorted P1, P2, P3 or P4 sensor

message; replace sensor indicated.

Operating lever of inlet butterfly valve is loose

on valve shaft. Reposition the valve plate and
tighten lever set screw.
HIGH TEMP T1 or T3 Message Cooling air flow restricted; clean cooler and
Displayed check for proper ventilation.

Ambient temperature is too high; provide

sufficient ventilation.

Low fluid level; add fluid.

Clogged fluid filter; change the fluid filter

element as indicated by Supervisor

Thermal valve not functioning properly; replace

element.

Open or shorted T1 or T2 sensor; check for a

short or open circuit to probe and correct
wiring.
Low fluid pressure (LOW Check fluid level.
PRESSURE P3 DISPLAY)
Check for clogged fluid filter.
Cooling fan motor (FAN OL Check the cooling fan motor.
display)

44
SECTION 6 TSR32 USER MANUAL R00

Table 6-1: Troubleshooting Guide

SYMPTOM PROBABLE CAUSE REMEDY
Compressor Shuts Down With P1 is less than 10 psig (0.7 bar) First, check starter wiring. If discharge
Air Demand Present (continued) (P1 low display) pressure is above 10 psig (0.7 bar) was

connections from transducer. If adequate,

replace transducer.
Compressor will not build up full Air demand is too great Check service lines for leaks or open valves.
discharge pressure Dirty air filter Check for filter maintenance message on

clean element if required.

Pressure Regulator Out of Adjust regulator according to control
Adjustment adjustment instructions in the Maintenance
Section.
Defective Pressure Regulator Check diaphragm and replace if necessary (kit
available).
Broken Sullicon Spring Replace.
Line pressure rises above Leak in control system causing Check for leaks.
unload P2 pressure setting on loss of pressure signals
Defective solenoid valve Check that Sullicon control lever is moved to

NO LOAD mode. Repair or replace if

necessary (kit available).
Defective blowdown valve Check that sump pressure is exhausted to the
atmosphere when in the OFF LOAD mode.
Repair or replace if necessary (kit available).
Ruptured Sullicon control Replace.
diaphragm
Plugged control line filter. Clean or repair if necessary.
Excessive Fluid Consumption Clogged return line strainer or Clean strainer (screen with o-ring replacement
orifice kit available).

Clean orifice.
Separator element damaged or not Check separator differential (plugged) dP1.
functioning properly Change separator elements.
Leak in the lubrication system Check all pipes, connections and components
Excess fluid foaming Drain and change.
Fluid level too high Drain excess fluid.
Pressure Relief Valve Opens Defective pressure relief valve Replace pressure relief valve.
Repeatedly
Liquid Water in Compressed Air Water Vapor Condensation From Remove the water vapor from compressed air
Service Line Cooling and Compression Occurs prior to distribution through the air system.
Naturally Check operation of aftercooler and moisture
separator. Install a compressed air dryer sized
for the flow and dryness level required. (Note:
Filters may also be required to remove
particulates, liquid oil aerosols or for oil vapor
removal. Change cartridges as recommended
by the filter manufacturer.) Check all drain
traps routinely to insure their proper operation.
Maintain them regularly.

45
NOTES

46
NOTES

47
 WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A.
Zuo Pao Tai Road, No. 1 3700 East Michigan Boulevard Zone Des Granges BP 82
Chiwan, Shekou Michigan City, Indiana, 46360 U.S.A. 42602 Montbrison, France
Shenzen, Guangdong PRV. www.sullair.com Telephone: 33-477968470
PRC POST CODE 518068 Telephone: 1-800-SULLAIR (U.S.A. only) Fax: 33-477968499
Telephone: 755-6851686 Fax: 219-874-1273 www.sullaireurope.com
Fax: 755-6853473
www.sullair-asia.com CUSTOMER CARE
for PARTS and Service
1-888-SULLAIR (7855247)
219-874-1835

Champion Compressors, LTD.

Princes Highway
Hallam, Victoria 3803
Australia
Telephone: 61-3-9703-8000
Fax: 61-3-9703-8053
www.championcompressors.com.au

Printed in the U.S.A.

Specifications subject to
change without prior notice.
E08EP