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TS32 USER MANUAL

SECTION 4

58

Corrosion damages pipes and reduces their strength.
This type of damage is more likely if the water supply
has a high amount of dissolved oxygen and a low pH
level.

Biological/organic fouling (slime) is relatively
uncommon since the compressor’s cooling fluids are
hot enough to generally prevent this type of problem.
Chemical treatments are available to rid the system
of biological contaminants.

S

EAWATER

-C

OOLED

 S

YSTEMS

A strainer must be installed in the system’s inlet
piping to ensure the supply water is clean. Sullair
also recommends installing a solenoid valve
(normally open) on the system’s outlet side. Both
inlet and outlet lines should have isolation valves with
side drains installed.

An orifice plate must be installed in the piping at least
3.3 feet (1M) before the cooler. The orifice’s diameter
must be properly sized to ensure that the
recommended flow rate is not exceeded (See 

Table

4-4

).

The cooling system should be set up to limit damage
from oil cooler leaks:

• Isolate the cooling water from the compres-

sor when it is not in use.

• The cooler’s seawater outlet pipe should

have an open path to the waste piping.

 NOTE

Seawater-cooled systems must be 
installed with with the optional copper-
nickel coolers.

 NOTE

Routine water testing will extend the com-
pressor’s operational life and help main-
tain an acceptable performance level. 
Refer to 

Table 4-3:Water Tests

.

Table 4-3: Water Tests

Substances

Test Interval

Acceptable Concentration

Corrosivity Hardness, pH, Total Dis-
solved Solids, Temperature at inlet, 
Alkalinity

Monthly - if stable for 3 to 4 months, 
analyze quarterly.

Langelier Index 0 to 1

Iron

Monthly

< 2 ppm

Sulphate

Monthly

< 50 ppm

Chloride

Monthly

< 50 ppm

Nitrate

Monthly

< 2 ppm

Silica

Monthly

< 100 ppm

Desolated Oxygen

Daily - if stable, analyze weekly

0 ppm (as low as possible)

Oil & Grease

Monthly

< 5 ppm

Ammonia

Monthly

< 1 ppm

 NOTE

The maximum recommended flow rate 
cannot be exceeded. An excessive flow 
rate can cause rapid system failure.

Table 4-4: Orifice Plate Diameters for Seawater Flow

Seawater Pressure

psi (bar)

Orifice diameter in inches (mm) to 

give a maximum seawater flow 

velocity of 3m/sec

200/250HP

300/350HP

25 (1.7)

1.38 (35)

1.43 (36)

35 (2.4)

1.28 (33)

1.33 (34)

45 (3.1)

1.19 (30)

1.24 (32)

55 (3.8)

1.14 (29)

1.19 (30)

65 (4.5)

1.09 (28)

1.13 (29)

75 (5.2)

1.05 (27)

1.10 (28)

Содержание TS32 AC

Страница 1: ...BER KEEP FOR FUTURE REFERENCE USER MANUAL SULLAIR CORPORATION The information in this manual is current as of its publication date and applies to compressor serial number and all subsequent serial num...

Страница 2: ...cated 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 The...

Страница 3: ...L DESCRIPTION 14 2 3 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTION AL DESCRIPTION 14 2 4 COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTION 24 2 5 CONTROL SYSTEM FUNCTIONAL DESCRIPTION 25 2 6 AIR...

Страница 4: ...DUCTION 63 5 2 PURPOSE OF CONTROLS INTRODUCTION 65 5 3 INITIAL START UP PROCEDURE 65 5 4 SUBSEQUENT START UP PROCEDURE 65 5 5 SHUTDOWN PROCEDURE SECTION 6 MAINTENANCE 67 6 1 GENERAL 67 6 2 DAILY OPERA...

Страница 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...

Страница 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...

Страница 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...

Страница 8: ...andling any ungrounded conductors 1 9 LIFTING A If the compressor is provided with a lifting bail then lift by the bail provided If no bail is provided then lift by sling Compressors to be air lifted...

Страница 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...

Страница 10: ...NOTES 10...

Страница 11: ...e fluid A fan is used to supply sufficient ventilating air to the compressors equipped with a canopy Both air cooled and water cooled versions have easily accessible items such as the fluid filters an...

Страница 12: ...TS32 USER MANUAL SECTION 2 12 Figure 2 1 Sullair Series TS32 Rotary Screw Compressor Air cooled Typical...

Страница 13: ...SECTION 2 TS32 USER MANUAL 13 Figure 2 2 Sullair Series TS32 Rotary Screw Compressor Water cooled Typical...

Страница 14: ...sure is reduced causing the fluid stop valve to close and isolate the compressor unit from the cooling system Water cooled models have a water pressure switch to prevent operation with inadequate wate...

Страница 15: ...SECTION 2 TS32 USER MANUAL 15 Figure 2 3 Compressor Piping and Instrument Diagram Typical...

Страница 16: ...TS32 USER MANUAL SECTION 2 16 Figure 2 4 Compressor Cooling and Lubrication System Air cooled...

Страница 17: ...SECTION 2 TS32 USER MANUAL 17 Figure 2 5 Compressor Cooling and Lubrication System Water cooled...

Страница 18: ...TS32 USER MANUAL SECTION 2 18 Figure 2 6 Compressor Discharge System Air cooled 200 350HP...

Страница 19: ...SECTION 2 TS32 USER MANUAL 19 Figure 2 7 Compressor Discharge System Water cooled 200 350HP...

Страница 20: ...TS32 USER MANUAL SECTION 2 20 Figure 2 8 Control System START Typical...

Страница 21: ...SECTION 2 TS32 USER MANUAL 21 Figure 2 9 Control System MODULATION Typical...

Страница 22: ...TS32 USER MANUAL SECTION 2 22 Figure 2 10 Control System UNLOAD Typical...

Страница 23: ...SECTION 2 TS32 USER MANUAL 23 Figure 2 11 Control System FULL LOAD Typical...

Страница 24: ...r the stated pressures START MODE 0 TO 50 PSIG 0 TO 3 4 BAR When the compressor ON pad is depressed the sump pressure will quickly rise from 0 to 50 psig 0 to 3 4 bar During this period both of the pr...

Страница 25: ...e butterfly valve remain in the unload position When the line pressure drops back to 100 psig 6 9 bar due to an increase in the air demand Supervisor energizes the solenoid valve allowing the air pres...

Страница 26: ...TS32 USER MANUAL SECTION 2 26 Figure 2 12 Compressor Air Inlet System...

Страница 27: ...itive displacement fluid lubricated twin rotary screws Configuration Two stage tandem geared integral drive Bearing Type Anti friction Cooling See Section 2 3 Lubricant Pressurized fluid see sections...

Страница 28: ...X 77541 To facilitate this a sample bottle is included with the compressor MOTOR 60 Hz Compressors STANDARD MODELS Size 200 350HP 150 261Kw Consult factory for specific voltages Type Open Dripproof en...

Страница 29: ...changed more frequently under severe operating conditions such as high ambient temperatures coupled with high humidity or when high particulate level corrosive gases or strong oxidizing gases are pre...

Страница 30: ...TS32 USER MANUAL SECTION 3 30 Figure 3 2 Identification Air Cooled 02250126 376 R02...

Страница 31: ...ELED AND SECURED WITH FOUNDATION BOLTS AND FULL UNIFORM CONTACT MUST BE MAINTAINED BETWEEN THE FRAME AND FOUN DATION IT IS RECOMMENFED THAT THE FRAME BE GROUTED TO THE FOUNDATION THE COMPRESSOR UNIT A...

Страница 32: ...TS32 USER MANUAL SECTION 3 32 Figure 3 2 Identification Water Cooled 02250126 378 R03...

Страница 33: ...ELED AND SECURED WITH FOUNDATION BOLTS AND FULL UNIFORM CONTACT MUST BE MAINTAINED BETWEEN THE FRAME AND FOUN DATION IT IS RECOMMENFED THAT THE FRAME BE GROUTED TO THE FOUNDATION THE COMPRESSOR UNIT...

Страница 34: ...TS32 USER MANUAL SECTION 3 34 Figure 3 3 Piping and Instrumentation Diagram Air Cooled 02250179 499 R01...

Страница 35: ...5 24 02250179 431 02250179 431 4 P THERMISTOR 3000 OHM NTC 25 02250092 138 02250092 138 1 VLV PRESS RLF 1 2 NPT 150 PSIG 26 02250119 109 02250119 109 1 VLV RLF 1 1 2 150 1950CFM 27 02250120 350 022501...

Страница 36: ...TS32 USER MANUAL SECTION 3 36 Figure 3 4 Piping and Instrumentation Diagram Air Cooled Continued 02250179 499 R01...

Страница 37: ...ZLDRAINSOLENOIDVALVE T1 WET DISCHARGE TEMPERATURE T2 DRY DISCHARGE TEMPERATURE T3 INJECTION FLUID TEMPERATURE T4 INTERSTAGE AIR FLUID TEMPERATURE HTR1 SUMP HEATER HTR3 TRAP HEATER NOTES 1 PART NUMBERS...

Страница 38: ...TS32 USER MANUAL SECTION 3 38 Figure 3 5 Piping and Instrumentation Diagram Remote Air Cooled 02250179 498 R01...

Страница 39: ...RLF 1 1 2 150 1950CFM 27 02250120 612 1 TNK OIL SUMP 28 02250097 611 2 PLUG SIGHT GLASS 1 7 8 SAE 29 02250125 221 1 VLV BALL 3 4 SAE X 3 4 NPT 30 250029 330 1 VLV RLF 2 X 2 1 2 31 242221 1 RESERVOIR A...

Страница 40: ...TS32 USER MANUAL SECTION 3 40 Figure 3 5 Piping and Instrumentation Diagram Remote Air Cooled Continued 02250179 498 R01...

Страница 41: ...NUMBERS ARE FOR REFERENCE ONLY REFER TO BILL OF MATERIAL AND OR FACE OF ORDER FOR ACTUAL PARTS 2 SECTION BETWEEN LETTERED POINTS ARE TO BE REPLACED WITH CORRESPONDING OPTION PICTURED BELOW AS REQUIRE...

Страница 42: ...TS32 USER MANUAL SECTION 3 42 Figure 3 6 Piping and Instrumentation Diagram Water Cooled 02250179 496 R01...

Страница 43: ...50092 138 02250092 138 1 VLV PRESS RLF 1 2 NPT 150 PSIG 26 02250119 109 02250119 109 1 VLV RLF 1 1 2 150 1950CFM 27 02250120 612 02250120 612 1 TNK OIL SUMP 28 02250097 611 02250097 611 2 PLUG SIGHT G...

Страница 44: ...TS32 USER MANUAL SECTION 3 44 Figure 3 6 Piping and Instrumentation Diagram Water Cooled Continued 02250179 496 R01...

Страница 45: ...LVE SOL6 WATERSHUTOFFSOLENOIDVALVE OPTIONAL T1 WET DISCHARGE TEMPERATURE T2 DRY DISCHARGE TEMPERATURE T3 INJECTION FLUID TEMPERATURE T4 INTERSTAGE AIR FLUID TEMPERATURE HTR1 SUMP HEATER HTR3 TRAP HEAT...

Страница 46: ...TS32 USER MANUAL SECTION 3 46 Figure 3 7 Wiring Diagram Water Cooled Wye Delta 02250178 841 R01...

Страница 47: ...CONTROL SOLENOID VALVE SOL2 SPIRAL CONTROL SOLENOID VALVE OPTIONAL SOL3 START CONTROL SOLENOID VALVE SOL4 SEQUENCING FULL LOAD SOLENOID VALVE OPT SOL5 COMBO DRAIN JZL DRAIN SOLENOID VALVE SOL6 WATER S...

Страница 48: ...TS32 USER MANUAL SECTION 3 48 Figure 3 8 Wiring Diagram Air Cooled Full Voltage 02250178 845 R01...

Страница 49: ...D VALVE SOL2 SPIRAL CONTROL SOLENOID VALVE OPTIONAL SOL3 START CONTROL SOLENOID VALVE SOL4 SEQUENCING FULL LOAD SOLENOID VALVE OPT SOL5 COMBO DRAIN JZL DRAIN SOLENOID VALVE 1XFMR CONTROL VOLTAGE TRANS...

Страница 50: ...TS32 USER MANUAL SECTION 3 50 Figure 3 9 Wiring Diagram Air Cooled SSRV 02250178 844 R03...

Страница 51: ...ONTROL SOLENOID VALVE SOL3 START CONTROL SOLENOID VALVE SOL4 SEQUENCING FULL LOAD SOLENOID VALVE SOL5 COMBO DRAIN JZL DRAIN SOLENOID VALVE SOL6 WATER SHUTOFF SOLENOID VALVE OPTIONAL 1XFMR CONTROL VOLT...

Страница 52: ...TS32 USER MANUAL SECTION 3 52 Figure 3 10 Wiring Diagram Remote Air Cooled Wye Delta 02250178 836 R01...

Страница 53: ...D CONTROL SOLENOID VALVE SOL2 SPIRAL CONTROL SOLENOID VALVE OPTIONAL SOL3 START CONTROL SOLENOID VALVE SOL4 SEQUENCING FULL LOAD SOLENOID VALVE OPTIONAL SOL5 COMBO DRAIN JZL DRAIN SOLENOID VALVE 1XFMR...

Страница 54: ...NOTES 54...

Страница 55: ...arances around the compressor should permit easy access to all compres sor components Walls and ceilings with soft or porous sur faces absorb sound and reduce ambient noise levels Hard surfaces reflec...

Страница 56: ...oper ventilation The heat rejection requirement applies the amount of heat generated by the compres sor which must be removed to maintain a normal operating temperature If the compressor has a water r...

Страница 57: ...gers Scale can be a problem if the water supply has a high concentration of calcium carbonate It forms lime scale deposits which act as thermal insulators and restrict the water flow through the cooli...

Страница 58: ...or when it is not in use The cooler s seawater outlet pipe should have an open path to the waste piping NOTE Seawater cooled systems must be installed with with the optional copper nickel coolers NOTE...

Страница 59: ...ather hood should be installed to protect the compressor from precipitation If the compressor will exposed to blowing rain or snow it should be housed in a covered four walled enclosure Sheltered air...

Страница 60: ...e base A vent to the piping should be installed downstream of the compressor outlet connection When two compressors are installed to operate in parallel with a common receiver tank an isolation valve...

Страница 61: ...ed near the sump If the sump is properly filled the fluid level should be visible in the upper sight glass When the oil level falls below the center of the lower sight glass fluid must be added 4 6 MO...

Страница 62: ...ssor component s maintenance Because of the variability in installations the fluid necessary to fill the supply and return piping for the fluid cooler is not part of the standard scope of supply for t...

Страница 63: ...hermal overload element housing re closes the starter s contacts after a current overload takes place Please be aware that the elements must be allowed to cool sufficiently before resetting SULLICON A...

Страница 64: ...d the cooler until the fluid reaches a temperature of 185 F 85 C 195 F for water cooled KT and 150 psi 10 3 bar Useful for fast warm up during start Maintains a minimum temperature during periods of l...

Страница 65: ...plate pressure If adjustments are nec essary see Control System Adjustments 8 Observe the operating temperature Refer to Section 2 3 for proper operating temperature range If temperature exceeds this...

Страница 66: ...TS32 USER MANUAL SECTION 5 66 Figure 5 1 Supervisor Control Panel NOTE For information concerning all aspects of the Supervisor Controller consult the Supervisor Controller manual 02250146 049...

Страница 67: ...orrect readings for that particular phase of operation After the compressor has warmed up it is recommended that a general check of the overall compressor and Supervisor be made to assure that the com...

Страница 68: ...m the filter head The filter element will be attached to the head 4 Separate the element from the head 5 Remove the canister seals 6 Thoroughly clean the filter head and canister in solvent 7 Lubricat...

Страница 69: ...he housing by using a damp cloth DO NOT blow dirt out with com pressor air 7 Install the new secondary element and replace the sealing washer and hex nut 8 With the secondary element in place replace...

Страница 70: ...rocedure explained below for separator element replacement PROCEDURE FOR ELEMENT REPLACEMENT 1 Relieve all pressure from the separator and all compressor lines prior to disconnecting any pipes tubing...

Страница 71: ...on a routine basis parallel to that of the fluid filter or as indicated in the Troubleshooting Sections both Supervisor and Maintenance of this manual The maintenance on an oil return sight glass is m...

Страница 72: ...amber of the Sullicon Control The Sullicon Control level should start to move at this time Cycle the Control System several times and recheck all pressure settings COMPRESSOR DRIVE COUPLING The perfor...

Страница 73: ...STEP 2 OFFSET ALIGNMENT Clean any oil grease dirt or paint from coupling faces and the other surfaces of the drive flanges Rotate shafts so that a straight edge will rest squarely or within the 0 010...

Страница 74: ...to correct Recheck the vertical offset STEP 4 INSTALL THE FLEXIBLE ELEMENT Refer to shaft coupling maintenance for installation of drive coupling element Figure 6 7 Drive Coupling Alignment Figure 6 8...

Страница 75: ...ssor will not start Main disconnect switch open Close switch Line fuse blown Replace fuse Control Transformer Fuse Blown Replace fuse Motor Starter Overloads Tripped Reset Should trouble persist check...

Страница 76: ...ng properly replace element air cooled only Optional Water flow regulating valve not functioning properly change water cooled only Open or shorted T1 or T2 sender check for a short or open circuit to...

Страница 77: ...ly Check separator differential plugged dP1 Change separator Leak in the lubrication system Check all pipes connections and components Excess fluid foaming Drain and change Fluid level too high Drain...

Страница 78: ...NOTES 78...

Страница 79: ...NOTES 79...

Страница 80: ...ors LTD 324 332 Frankston Dandenong Road Dandenong VIC Australia 3175 Ph 61397039000 Fx 61397039053 www championcompressors com au SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City Indian...

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