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SECTION 1

 

7

C.

Wear  snug-fitting  clothing  and  confine  long  hair
when working around this compressor, especially
when exposed to hot or moving parts.

D.

Keep  access  doors,  if  any,  closed  except  when
making repairs or adjustments.

E.

Make sure all personnel are out of and/or clear of
the  compressor  prior  to  attempting  to  start  or
operate it.

F.

Disconnect and lock out all power at source and
verify at the  compressor  that all circuits  are  de-
energized to minimize the possibility of acciden-
tal  start-up,  or  operation,  prior  to  attempting
repairs or adjustments. This is especially impor-
tant when compressors are remotely controlled.

G.

Keep  hands,  feet,  floors,  controls  and  walking
surfaces  clean  and  free  of  fluid,  water  or  other
liquids  to  minimize  the  possibility  of  slips  and
falls.

1.6

HOT SURFACES, SHARP 

EDGES AND SHARP 

CORNERS

A.

Avoid  bodily  contact  with  hot  fluid,  hot  coolant,
hot surfaces and sharp edges and corners.

B.

Keep all parts of the body away from all points of
air discharge.

C.

Wear  personal  protective  equipment  including
gloves and head covering when working in, on or
around the compressor.

D.

Keep  a  first  aid  kit  handy.  Seek  medical  assis-
tance promptly in case of injury. 

DO NOT

 ignore

small cuts and burns as they may lead to infec-
tion

1.7

TOXIC AND IRRITATING 

SUBSTANCES

A. DO NOT

 use air from this compressor for respi-

ration  (breathing)  except  in  full  compliance  with
OSHA Standards 29 CFR 1910 and/or any appli-
cable  Federal,  State  or  Local  codes  or  regula-
tions. 

B. DO NOT

 use air line anti-icer systems in air lines

supplying  respirators  or  other  breathing  air  utili-
zation  equipment  and 

DO  NOT

  discharge  air

from  these  systems  into  unventilated  or  other
confined areas.

C.

Operate  the  compressor  only  in  open  or  ade-
quately ventilated areas.

D.

Locate the compressor or provide a remote inlet
so that it is not likely to ingest exhaust fumes or
other  toxic,  noxious  or  corrosive  fumes  or  sub-
stances.

E.

Coolants and lubricants used in this compressor
are typical of the industry. Care should be taken
to avoid accidental ingestion and/or skin contact.
In the event of ingestion, seek medical treatment
promptly. Wash with soap and water in the event
of  skin  contact.  Consult  Material  Safety  Data
Sheet for information pertaining to fluid of fill.

F.

Wear  goggles  or a full  face  shield  when adding
antifreeze compound to air line anti-icer systems.

G.

If  air  line  anti-icer  system  antifreeze  compound
enters the eyes or if fumes irritate the eyes, they
should be washed with large quantities of clean
water for fifteen minutes. A physician, preferably
an  eye  specialist,  should  be  contacted  immedi-
ately.

H. DO NOT

 store air line anti-icer system antifreeze

compound in confined areas.

I.

The  antifreeze  compound  used  in  air  line  anti-
freeze  systems  contains  methanol  and  is  toxic,
harmful or fatal if swallowed. Avoid contact with
the skin or eyes and avoid breathing the fumes. If

 DANGER

Death or serious injury can result from 
inhaling compressed air without using 
proper safety equipment. See OSHA stan-
dards and/or any applicable Federal, State, 
and Local codes, standards and regulations 
on safety equipment.

Summary of Contents for TSR20

Page 1: ...Y NOTICE PART NUMBER KEEP FOR FUTURE REFERENCE USER MANUAL SULLAIR CORPORATION The information in this manual is current as of its publication date and applies to compressor serial number and all subs...

Page 2: ...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 r...

Page 3: ...ING 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 S...

Page 4: ...4 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...

Page 5: ...rein are applicable to most compressors and the concepts behind these statements are generally applicable to all compressors 1 2 PERSONAL PROTECTIVE EQUIPMENT A Prior to installing or operating the co...

Page 6: ...including air line anti icer system antifreeze compound or fluid film to accumulate on under or around acoustical mate rial or on any external surfaces of the air com pressor Wipe down using an aqueo...

Page 7: ...codes or regula tions B DO NOT use air line anti icer systems in air lines supplying respirators or other breathing air utili zation equipment and DO NOT discharge air from these systems into unventi...

Page 8: ...otating machinery and prior to handling any ungrounded conductors 1 9 LIFTING A If the compressor is provided with a lifting bail then lift by the bail provided If no bail is provided then lift by sli...

Page 9: ...a cles at floor level and transport and corner at minimum practical speeds N Make sure pallet mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to forklift o...

Page 10: ...NOTES 10...

Page 11: ...directly with the air as the rotors turn which compresses the air The fluid flow has three basic functions 1 As a coolant it controls the air temperature rise normally associated with the heat of comp...

Page 12: ...TSR32 USER MANUAL R00 SECTION 2 12 Figure 2 1 Sullair TSR 32 Rotary Screw Air Compressor Air Cooled VSD...

Page 13: ...SECTION 2 TSR32 USER MANUAL R00 13 Figure 2 2 Sullair TSR 32 Rotary Screw Air Compressor Air Cooled Fixed Speed...

Page 14: ...TO FLUID COOLER CC FROM FLUID COOLER DD TO UNIT INJECTION BLOCK EE TO AFTERCOOLER FF FROM AFTERCOOLER GG AIR SUPPLY OUTLET HH MOISTURE DRAIN OUTLET 1 FLUID FILTER 2 FLUID STOP VALVE 3 MINIMUM PRESSUR...

Page 15: ...amount of fluid remaining in the compressed air collects on the surface of the separator elements as the air flows through the separators Two return lines or scavenge tube lead from the bottom of the...

Page 16: ...solenoid valve opens feeding air pressure to the spiral valve actuator This in turn expands the diaphragm and engages the pinion mounted on the spiral valve shaft assembly resulting in a rotary motio...

Page 17: ...SECTION 2 TSR32 USER MANUAL R00 17...

Page 18: ...tor for the spiral valve gradually opens apply ing air pressure to the spiral valve actuator Air pressure at the actuator expands the diaphragm The rack in turn engages with the pinion mounted on the...

Page 19: ...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 p...

Page 20: ...TSR32 USER MANUAL R00 SECTION 2 20 Figure 2 6 TSR 32 Piping and Instrumentation VSD 02250177 348 R01...

Page 21: ...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 28 02250097 611 2 GLASS FLUI...

Page 22: ...TSR32 USER MANUAL R00 SECTION 2 22 Figure 2 7 TSR 32 Piping and Instrumentation Fixed Speed 02250177 349 R01...

Page 23: ...4 129 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 28 02250097 611 2 GL...

Page 24: ...NOTES 24...

Page 25: ...0 MOTOR TEFC HZ VOLTAGE 460 60 DRIVE AMP RATING 385A WEIGHT lbs 19 900 LENGTH in 220 WIDTH in 84 HEIGHT in 104 COMPRESSOR TSR 32 Type Rotary Screw Standard Operating Pressure 100 psig 7 bar 125 psig 9...

Page 26: ...oam 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 1 Fluid Fill Port...

Page 27: ...NOTES 27...

Page 28: ...TSR32 USER MANUAL R00 SECTION 3 28 02250175 423 R01...

Page 29: ...SECTION 3 TSR32 USER MANUAL R00 29 02250177 017 R01...

Page 30: ...TSR32 USER MANUAL R00 SECTION 3 30 Figure 3 4 Wiring 02250177 397 R00...

Page 31: ...SECTION 3 TSR32 USER MANUAL R00 31 02250177 398 R00...

Page 32: ...NOTES 32...

Page 33: ...mponents faces absorb sound and reduce ambient noise levels Hard surfaces reflect noise and have little effect on ambient noise lev els 4 2 VENTILATION AND COOLING AIR COOLED COMPRESSORS clearance aro...

Page 34: ...iver Compressors have built in aftercoolers and are equipped with a condensate drain located next to the air outlet connection A drain line should be installed to remove the condensate which builds up...

Page 35: ...from a suitable electrical power source is critical because voltage drops can adversely effect the performance of the compressor Refer to Table 4 2 Motor Wiring Basic Data Parallel feeder cable connec...

Page 36: ...once quickly and in succession the START and STOP pads This action will bump start the motor When looking from the motor end opposite the compressor unit the shaft should turn clockwise If reverse ro...

Page 37: ...6 8 Troubleshooting Introduction on page 43 under EXCESSIVE COMPRESSOR FLUID CONSUMPTION for a probable cause and corrective action After a routine start observe the controller display for the proper...

Page 38: ...0XH 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 N...

Page 39: ...d Piping System 2 Replace the fluid filter element 6 4 FLUID MAINTENANCE Drain the receiver tank and change the compressor fluid using instructions shown in the Lubrication Guide 6 5 FILTER MAINTENANC...

Page 40: ...ELEMENT REPLACEMENT Element replacement is performed by reversing the removal instructions Make sure that the element is fully seated into the housing 6 7 SEPARATOR MAINTENANCE Replace the separator...

Page 41: ...ssor 11 Check the return line strainer before re start ing the compressor If needed either clean or replace the strainer FLUID RETURN SIGHT GLASS MAINTENANCE Refer to Figure 6 4 The fluid return sight...

Page 42: ...406480 or order repair kit 250031 271 Figure 6 4 Fluid Return Sight Glass 1 Tube Connectors 2 Filter Assembly I 3 Sight Glass Orifice Block 4 Secondary Element orifice 03 5 Primary Element orifice 09...

Page 43: ...ng element from the coupling jaws 5 Install the new element by wrapping it around the jaws engaging the cogs on the element into the jaws 6 Reinstall the outer sleeve and secure by tightening the two...

Page 44: ...ar 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 Opera...

Page 45: ...place if necessary kit available Ruptured Sullicon control diaphragm Replace Plugged control line filter Clean or repair if necessary Excessive Fluid Consumption Clogged return line strainer or orific...

Page 46: ...NOTES 46...

Page 47: ...NOTES 47...

Page 48: ...sors LTD Princes Highway Hallam Victoria 3803 Australia Telephone 61 3 9703 8000 Fax 61 3 9703 8053 www championcompressors com au SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City Indian...

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