Preliminary

Copy
2006

INDUSTRIAL
AIR COMPRESSOR
DR---13
100---200 HP

OPERATOR’S
MANUAL AND
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Part Number
02250116---296
ESullair Corporation
 AIR CARE
SEMINAR TRAINING

Sullair Air Care Seminars are 3---day courses that provide hands---on instruction
in the proper operation, maintenance and service of Sullair equipment.
Individual seminars on Industrial compressors and compressor electrical
systems are presented at regular intervals throughout the year at a dedicated
training facility at Sullair’s corporate headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service
parts, troubleshooting of the most common problems, and actual equipment
operation. The seminars are recommended for maintenance and service
personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1---800---SULLAIR or 219---879---5451 (ext. 5630)
--- Or Write ---
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
 TABLE OF CONTENTS

OPERATOR IS REQUIRED TO READ

ENTIRE INSTRUCTION MANUAL

Section 1 Page
SAFETY 1 1.1 GENERAL
1 1.2 PERSONAL PROTECTIVE EQUIPMENT
1 1.3 PRESSURE RELEASE
1 1.4 FIRE AND EXPLOSION
2 1.5 MOVING PARTS
2 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
2 1.7 TOXIC AND IRRITATING SUBSTANCES
3 1.8 ELECTRICAL SHOCK
3 1.9 LIFTING
4 1.10 ENTRAPMENT

Section 2
INSTALLATION 5 2.1 MOUNTING OF COMPRESSOR
5 2.2 VENTILATION AND COOLING
5 2.3 SERVICE AIR CONDENSATE PIPING
6 2.4 SHAFT COUPLING ALIGNMENT CHECK
6 2.5 FLUID LEVEL CHECK
6 2.6 ELECTRICAL PREPARATION
6 2.7 MOTOR ROTATION CHECK

Section 3
SPECIFICATIONS 7 3.1 SULLAIR DR--- 13 COMPRESSOR PACKAGE
7 3.2 LUBRICATION GUIDE

Section 4
COMPRESSOR
SYSTEMS 9 4.1 INTRODUCTION
9 4.2 DESCRIPTION OF COMPONENTS
9 4.3 COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
10 4.4 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
11 4.5 LOAD/UNLOAD CAPACITY CONTROL SYSTEM,
FUNCTIONAL DESCRIPTION
13 4.6 COOLING AND SILENCING SYSTEM, FUNCTIONAL
DESCRIPTION
13 4.7 LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION
14 4.8 BUFFER AIR SYSTEM, FUNCTIONAL DESCRIPTION
 TABLE OF CONTENTS
(CONTINUED)

Section 5 Page
SUPERVISOR II 16 5.1 INTRODUCTION
16 5.2 KEYPAD
16 5.3 STATUS DISPLAYS
17 5.4 LAMP INDICATORS
18 5.5 OPERATING PARMETER SET--- UP
19 5.6 OPERATING THE COMPRESSOR
20 5.7 SUPERVISOR II OUTPUT RELAYS
21 5.8 SUPERVISOR II CONTROL PARAMETERS---
DR--- 13

Section 6
COMPRESSOR
OPERATION 23 6.1 GENERAL
23 6.2 PURPOSE OF CONTROLS
24 6.3 SUPERVISOR II OPERATING PARAMETERS--- SET UP
24 6.4 INITIAL START--- UP PROCEDURE
25 6.5 SYSTEM STATUS MESSAGES
25 6.6 SUBSEQUENT START--- UP PROCEDURE
25 6.7 SHUTDOWN PROCEDURE

Section 7
MAINTENANCE 27 7.1 GENERAL
27 7.2 DAILY OPERATION
27 7.3INITIAL MAINTENANCE AFTER 50 HOURS
OF OPERATION
27 7.4 MAINTENANCE EVERY 8000 HOURS OF OPERATION
27 7.5 MAINTENANCE EVERY 16000 HOURS OF OPERATION
27 7.6 DIAGNOSTIC SERVICE (OPTIONAL)
27 7.7 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
27 7.7.1 AIR FILTER INSPECTION/MAINTENANCE
28 7.7.2 OIL FILTER MAINTENANCE
28 7.7.3 CONTROL LINE FILTER MAINTENANCE
29 7.7.4 INLET CONTROL SOLENOID VALVE MAINTENANCE
31 7.7.5 SOLENOID VALVE (02250119--- 220) MAINTENANCE
32 7.7.6 SOLENOID VALVE (02250044--- 392) MAINTENANCE
33 7.7.7 CONTROL PRESSURE REGULATOR (02250100--- 362)
MAINTENANCE
 TABLE OF CONTENTS
(CONTINUED)

Section 7 Page
MAINTENANCE 34 7.7.8 SUMP BREATHER FILTER MAINTENANCE

(CONTINUED) 34 7.7.9 OIL SUMP STRAINER MAINTENANCE

34 7.7.10 BLOWDOWN VALVE MAINTENANCE
34 7.7.11 DRIVE COUPLING MAINTENANCE

Section 8
TROUBLESHOOTING 37 8.1 INTRODUCTION

37 8.2 TROUBLESHOOTING
39 8.3 CALIBRATION

Section 9
PARTS LIST 41 9.1 PROCEDURE FOR ORDERING PARTS

41 9.2 RECOMMENDED SPARE PARTS LIST

42 9.3 COMPRESSOR, MOTOR AND FRAME
44 9.4 AIR INLET SYSTEM
46 9.5 COOLER ASSEMBLY
48 9.6 LP HOT & LP COLD
50 9.7 HP DISCHARGE
52 9.8 LUBE SYSTEM
54 9.9 ELECTRICAL BOX
56 9.10 CONTROL SYSTEM/ CONDENSATE DRAIN
58 9.11 CANOPY
60 9.12 DECALS
66 9.13 DECAL LOCATIONS
72 9.14 WIRING DIAGRAM
NOTES
 Section 1
SAFETY

1.1 GENERAL 1926.302(b)(7) and/or any applicable Federal,

Sullair Corporation and its subsidiaries designs State and Local codes, standards and regulations.
and manufactures all of its products so they can be
operated safely. However, the responsibility for B. When the hose is to be used to supply a mani-
safe operation rests with those who use and main- fold, install an additional appropriate flow ---limiting
tain these products. The following safety precau- valve between the manifold and each air hose ex-
tions are offered as a guide which, if conscien- ceeding 1/2” (13mm) inside diameter that is to be
tiously followed, will minimize the possibility of acci- connected to the manifold to reduce pressure in
dents throughout the useful life of this equipment. case of hose failure.

The compressor should be operated only by those C. Provide an appropriate flow ---limiting valve at the
who have been trained and delegated to do so, and beginning of each additional 75 feet (23m) of hose
who have read and understood this Operator’s in runs of air hose exceeding 1/2” (13mm) inside di-
Manual. Failure to follow the instructions, proce- ameter to reduce pressure in case of hose failure.
dures and safety precautions in this manual may D. Flow ---limiting valves are listed by pipe size and
result in accidents and injuries. rated CFM. Select appropriate valves accordingly,
NEVER start the compressor unless it is safe to do in accordance with their manufacturer’s recom-
so. DO NOT attempt to operate the compressor mendations.
with a known unsafe condition. Tag the compres- E. DO NOT use air tools that are rated below the
sor and render it inoperative by disconnecting and maximum rating of the compressor. Select air tools,
locking out all power at source or otherwise dis- air hoses, pipes, valves, filters and other fittings ac-
abling its prime mover so others who may not know cordingly. DO NOT exceed manufacturer’s rated
of the unsafe condition cannot attempt to operate it safe operating pressures for these items.
until the condition is corrected.
F. Secure all hose connections by wire, chain or
Install, use and operate the compressor only in full other suitable retaining device to prevent tools or
compliance with all pertinent OSHA regulations hose ends from being accidentally disconnected
and/or any applicable Federal, State, and Local and expelled.
codes, standards and regulations.
G. Open fluid filler cap only when compressor is
DO NOT modify the compressor and/or controls in not running and is not pressurized. Shut down
any way except with written factory approval. the compressor and bleed the sump to zero inter-
nal pressure before removing the cap.
While not specifically applicable to all types of com-
pressors with all types of prime movers, most of the H. Vent all internal pressure prior to opening any
precautionary statements contained herein are ap- line, fitting, hose, valve, drain plug, connection or
plicable to most compressors and the concepts other component, such as filters and line oilers,
behind these statements are generally applicable and before attempting to refill optional air line anti---
to all compressors. icer systems with antifreeze compound.
1.2 PERSONAL PROTECTIVE EQUIPMENT I. Keep personnel out of line with and away from the
Prior to installing or operating the compressor, discharge opening of hoses or tools or other points
owners, employers and users should become fa- of compressed air discharge.
miliar with, and comply with, all applicable OSHA
regulations and/or any applicable Federal, State J. Use air at pressures less than 30 psig (2.1 barg)
and Local codes, standards, and regulations rela- for cleaning purposes, and then only with effective
tive to personal protective equipment, such as eye chip guarding and personal protective equipment
and face protective equipment, respiratory protec- per OSHA Standard 29 CFR 1910.242 (b) and/or
tive equipment, equipment intended to protect the any applicable Federal, State, and Local codes,
extremities, protective clothing, protective shields standards and regulations.
and barriers and electrical protective equipment, K. DO NOT engage in horseplay with air hoses as
as well as noise exposure administrative and/or en- death or serious injury may result.
gineering controls and/or personal hearing protec-
tive equipment. 1.4 FIRE AND EXPLOSION
A. Clean up spills of lubricant or other combustible
1.3 PRESSURE RELEASE substances immediately, if such spills occur.
A. Install an appropriate flow ---limiting valve be-
tween the service air outlet and the shut---off (throt- B. Shut off the compressor and allow it to cool.
tle) valve, either at the compressor or at any other Then keep sparks, flames and other sources of ig-
point along the air line, when an air hose exceeding nition away and DO NOT permit smoking in the vi-
1/2” (13mm) inside diameter is to be connected to cinity when checking or adding lubricant or when
the shut ---off (throttle) valve, to reduce pressure in refilling air line anti---icer systems with antifreeze
case of hose failure, per OSHA Standard 29 CFR compound.

1
Section 1
SAFETY

C. DO NOT permit fluids, including air line anti--- E. Make sure all personnel are out of and/or clear of
icer system antifreeze compound or fluid film to ac- the compressor prior to attempting to start or oper-
cumulate on, under, or around acoustical material, ate it.
or on any external surfaces of the air compressor or
on internal surfaces of the enclosure. Wipe down F. Disconnect and lock out all power at source and
using an aqueous industrial cleaner or steam clean verify at the compressor that all circuits are de---en-
as required. If necessary, remove acoustical mate- ergized to minimize the possibility of accidental
rial, clean all surfaces and then replace acoustical start ---up, or operation, prior to attempting repairs
material. Any acoustical material with a protective or adjustments. This is especially important when
covering that has been torn or punctured should be compressors are remotely controlled.
replaced immediately to prevent accumulation of G. Keep hands, feet, floors, controls and walking
liquids or fluid film within the material. DO NOT use surfaces clean and free of fluid, water or other liq-
flammable solvents for cleaning purposes. uids to minimize the possibility of slips and falls.
D. Disconnect and lock out all power at source prior 1.6 HOT SURFACES, SHARP EDGES AND SHARP
to attempting any repairs or cleaning of the com- CORNERS
pressor or of the inside of the enclosure, if any. A. Avoid bodily contact with hot fluid, hot coolant,
hot surfaces and sharp edges and corners.
E. Keep electrical wiring, including all terminals and
pressure connectors in good condition. Replace B. Keep all parts of the body away from all points of
any wiring that has cracked, cut, abraded or other- air discharge.
wise degraded insulation, or terminals that are
worn, discolored or corroded. Keep all terminals C. Wear personal protective equipment including
and pressure connectors clean and tight. gloves and head covering when working in, on or
around the compressor.
F. Keep grounded and/or conductive objects such
as tools away from exposed live electrical parts D. Keep a first aid kit handy. Seek medical assis-
such as terminals to avoid arcing which might tance promptly in case of injury. DO NOT ignore
serve as a source of ignition. small cuts and burns as they may lead to infection.
1.7 TOXIC AND IRRITATING SUBSTANCES
G. Remove any acoustical material or other mate- A. DO NOT use air from this compressor for respi-
rial that may be damaged by heat or that may sup- ration (breathing) except in full compliance with
port combustion and is in close proximity, prior to OSHA Standards 29 CFR 1910 and/or any applica-
attempting weld repairs. ble Federal, State or Local codes or regulations.
H. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when servic- ! DANGER
ing and operating the compressor.
Death or serious injury can result from inhaling
I. Keep oily rags, trash, leaves, litter or other com- compressed air without using proper safety
bustibles out of and away from the compressor. equipment. See OSHA standards and/or any ap-
plicable Federal, State, and Local codes, stan-
dards and regulations on safety equipment.
J. DO NOT operate the compressor without proper
flow of cooling air or water or with inadequate flow
of lubricant or with degraded lubricant. B. DO NOT use air line anti---icer systems in air
lines supplying respirators or other breathing air
K. DO NOT attempt to operate the compressor in utilization equipment and DO NOT discharge air
any classification of hazardous environment unless from these systems in unventilated or other con-
the compressor has been specially designed and fined areas.
manufactured for that duty.
C. Operate the compressor only in open or ade-
1.5 MOVING PARTS quately ventilated areas.
A. Keep hands, arms and other parts of the body
and also clothing away from couplings, fans and D. Locate the compressor or provide a remote inlet
other moving parts. so that it is not likely to ingest exhaust fumes or
other toxic, noxious or corrosive fumes or sub-
B. DO NOT attempt to operate the compressor stances.
with the fan, coupling or other guards removed.
E. Coolants and lubricants used in this compressor
C. Wear snug fitting clothing and confine long hair are typical of the industry. Care should be taken to
when working around this compressor, especially avoid accidental ingestion and/or skin contact. In
when exposed to hot or moving parts. the event of ingestion, seek medical treatment
promptly. Wash with soap and water in the event of
D. Keep access doors, if any, closed except when skin contact. Consult Material Safety Data Sheet for
making repairs or adjustments. information pertaining to fluid of fill.

2
 Section 1
SAFETY

F. Wear goggles or a full face shield when adding helicopter must not be supported by the lifting bail
antifreeze compound to air line anti---icer systems. but by slings instead. In any event, lift and/or han-
dle only in full compliance with OSHA standards 29
G. If air line anti---icer system antifreeze compound CFR 1910 subpart N and/or any applicable Feder-
enters the eyes or if fumes irritate the eyes, they al, State, and Local codes, standards and regula-
should be washed with large quantities of clean tions.
water for 15 minutes. A physician, preferably an
eye specialist, should be contacted immediately. B. Inspect points of attachment for cracked welds
and for cracked, bent, corroded or otherwise de-
H. DO NOT store air line anti---icer system anti- graded members and for loose bolts or nuts prior to
freeze compound in confined areas. lifting.
I. The antifreeze compound used in air line anti- C. Make sure entire lifting, rigging and supporting
freeze systems contains methanol and is toxic, structure has been inspected, is in good condition
harmful or fatal if swallowed. Avoid contact with the and has a rated capacity of at least the weight of
skin or eyes and avoid breathing the fumes. If swal- the compressor. If you are unsure of the weight,
lowed, induce vomiting by administering a table- then weigh compressor before lifting.
spoon of salt, in each glass of clean, warm water
until vomit is clear, then administer two teaspoons D. Make sure lifting hook has a functional safety
of baking soda in a glass of clean water. Have pa- latch or equivalent, and is fully engaged and
tient lay down and cover eyes to exclude light. Call latched on the bail or slings.
a physician immediately. E. Use guide ropes or equivalent to prevent twisting
1.8 ELECTRICAL SHOCK or swinging of the compressor once it has been
A. This compressor should be installed and main- lifted clear of the ground.
tained in full compliance with all applicable Federal, F. DO NOT attempt to lift in high winds.
State and Local codes, standards and regulations,
including those of the National Electrical Code, and G. Keep all personnel out from under and away
also including those relative to equipment ground- from the compressor whenever it is suspended.
ing conductors, and only by personnel that are
trained, qualified and delegated to do so. H. Lift compressor no higher than necessary.

B. Keep all parts of the body and any hand---held I. Keep lift operator in constant attendance when-
tools or other conductive objects away from ex- ever compressor is suspended.
posed live parts of electrical system. Maintain dry J. Set compressor down only on a level surface ca-
footing, stand on insulating surfaces and DO NOT pable of safely supporting at least its weight and its
contact any other portion of the compressor when loading unit.
making adjustments or repairs to exposed live
parts of the electrical system. Make all such adjust- K. When moving the compressor by forklift truck,
ments or repairs with one hand only, so as to mini- utilize fork pockets if provided. Otherwise, utilize
mize the possibility of creating a current path pallet if provided. If neither fork pockets or pallet are
through the heart. provided, then make sure compressor is secure
and well balanced on forks before attempting to
C. Attempt repairs in clean, dry and well lighted and raise or transport it any significant distance.
ventilated areas only.
L. Make sure forklift truck forks are fully engaged
D. DO NOT leave the compressor unattended with and tipped back prior to lifting or transporting the
open electrical enclosures. If necessary to do so, compressor.
then disconnect, lock out and tag all power at
source so others will not inadvertently restore M. Forklift no higher than necessary to clear obsta-
power. cles at floor level and transport and corner at mini-
mum practical speeds.
E. Disconnect, lock out, and tag all power at source
prior to attempting repairs or adjustments to rotat- N. Make sure pallet---mounted compressors are
ing machinery and prior to handling any un- firmly bolted or otherwise secured to the pallet prior
grounded conductors. to attempting to forklift or transport them. NEVER
attempt to forklift a compressor that is not secured
1.9 LIFTING to its pallet, as uneven floors or sudden stops may
A. If the compressor is provided with a lifting bail, cause the compressor to tumble off, possibly caus-
then lift by the bail provided. If no bail is provided, ing serious injury or property damage in the proc-
then lift by sling. Compressors to be air lifted by ess.

3
Section 1
SAFETY

1.10 ENTRAPMENT
A. If the compressor enclosure, if any, is large
enough to hold a man and if it is necessary to enter
it to perform service adjustments, inform other per-
sonnel before doing so, or else secure and tag the
access door in the open position to avoid the possi-
bility of others closing and possibly latching the
door with personnel inside.
B. Make sure all personnel are out of compressor
before closing and latching enclosure doors.

4
 Section 2
INSTALLATION

2.1 MOUNTING OF COMPRESSOR because of the latent heat of condensation of the

The compressor package should be placed on a moisture removed from the intake air and the heat
surface or foundation that is capable of supporting from the motor inefficiency). The 200HP model will
its weight, while remaining level and free of deflec- discharge up to 615,000 BTU/hr to the surrounding
tions which may affect the driveline mounts or the environment (smaller models correspondingly
inboard pipework. less).
If the package is to be secured to a foundation, it is Maintain a 3ft. (914mm) minimum separation be-
recommended that the package frame be leveled tween the package and any surrounding walls.
and secured to the foundation with adequate an- Note that the electrical enclosure has a 32.5 in
chorage, and that a good grade grouting be used (826mm) access door hinged on its right side.
to insure full contact between the load bearing sur-
faces. Use 3/4” (19mm) foundation bolts.
! WARNING
The DR compressor/motor driveline is self---al-
igned by the use of a rigid distance piece and sup- Note that the cooling air intake to the package and
ported by flexible vibration isolation mounts. Poor the hot air discharge are both on top of the pack-
leveling or excessive deflections may adversely af- age. There should be no restriction to the free
flow of cooling air and discharge air, and care
fect the operation and longevity of these devices. should be taken to ensure that cooling air and dis-
No piping loads or moments should be transmitted charge air remain separate.
to the air and water connections provided with the
package. If ductwork is installed, the total restriction on in-
take and outlet combined must not exceed 0.12 in
2.2 VENTILATION AND COOLING H2O (30 Pascals).
Select a location that allows an unrestricted flow of
ambient ventilation air through the package 2.3 SERVICE AIR CONDENSATE PIPING
(approximately 18,000 CFM). The maximum allow- It is recommended that service air piping be in-
able ambient temperature is 115_F (46_C). Heat stalled as shown in Fig 2---1. A shut---off valve
rejection to the surrounding environment will be up should be included to isolate the package from the
to 20% greater than the motor horsepower (this is supply line as required. The use of water legs and
Figure 2 ---1 Service Air Piping (Typical)

5
Section 2
INSTALLATION

drain traps is also recommended throughout. done by a qualified electrician, in compliance with
No piping loads or moments should be transmitted OSHA, NEC, and any other applicable codes. A
to the air connections provided with the package. wiring diagram is provided with the package docu-
mentation.
Condensate drains shall be connected to a non---
pressurized gravity feed drain. If the compressor
drains are manifolded together, care should be tak- ! DANGER
en to insure that this drain is not pressurized when
the machine condensate drains (both automatic or Lethal shock hazard inside.
manual) are in operation. Disconnect all power at source before opening or
servicing.
All condensate should be disposed of in accor-
dance with local governing laws.
1. Make sure incoming field voltage matches re-
2.4 SHAFT COUPLING ALIGNMENT CHECK quired package voltage.
The compressor unit and motor are rigidly con- 2. Check starter overload and heater sizes --- see
nected via a cast adaptor piece which maintains Electrical section in Parts Manual.
the shaft coupling in proper alignment. It is recom- 3. Check all electrical connections for tightness.
mended that prior to initial startup shaft alignment 4. Check motor rotation, as explained in Section
be checked, and all coupling fasteners are 2.7.
checked for proper tensioning. Refer to the Cou- 2.7 MOTOR ROTATION CHECK
pling Service Procedures included in the Mainte- After the electrical installation has been done, it is
nance section of this manual. necessary to check the direction of motor rotation.
2.5 FLUID LEVEL CHECK Pull out the EMERGENCY STOP button and press
The package oil sump is supplied with the proper once, quickly and in succession, the “I” and “O”
charge of lube oil --- a level reaching 75% of the pads. This action will “Bump Start” the motor for a
sight glass should be visible when the compressor very short time. When looking at the motor from the
unit is shut down. Check this level after initial instal- rear end, the driveline should be rotating counter-
lation and periodically thereafter. clockwise (opposite shaft end). If the reversed ro-
tation is noted, disconnect the power to the starter
2.6 ELECTRICAL PREPARATION and exchange any two of the three power input
Interior electrical wiring is assembled at the factory. leads, then re---check rotation. A “Direction of Ro-
Required customer wiring is minimal (i.e., isolation tation” nameplate is located on the top of the com-
switches, fusible disconnects, etc.), but should be pressor/motor adaptor piece.

6
 Section 3
SPECIFICATIONS

3.1 SULLAIR DR-- 13 COMPRESSOR PACKAGE

DIMENSIONS
MAXIMUM
DR ---13--- SERIES 60 Hz OPERATING
TYPE HP LENGTH WIDTH HEIGHT WEIGHT PRESSURE
IN/CM IN/CM IN/CM LB/KG PSI
DR13 100H 100 144/366 72/183 80/203 9350/4250 125
DR13 125H 125 144/366 72/183 80/203 9900/4500 125
DR13 125HH 125 144/366 72/183 80/203 9900/4500 150
DR13 150H 150 144/366 72/183 80/203 10100/4690 125
DR13 150HH 150 144/366 72/183 80/203 10100/4690 150
DR13 200H 200 144/366 72/183 80/203 10350/4700 125
DR13 200HH 200 144/366 72/183 80/203 10350/4700 150

MAXIMUM
DR ---13--- SERIES 50 Hz OPERATING
TYPE HP LENGTH WIDTH HEIGHT WEIGHT PRESSURE
IN/CM IN/CM IN/CM KG BAR
DR13 75H 100 144/366 72/183 80/203 9750/4430 8.5
DR13 75HH 100 144/366 72/183 80/203 9750/4430 10.3
DR13 90H 125 144/366 72/183 80/203 9900/4500 8.5
DR13 90HH 125 144/366 72/183 80/203 9900/4500 10.3
DR13 110H 150 144/366 72/183 80/203 10100/4690 8.5
DR13 110HH 150 144/366 72/183 80/203 10100/4690 10.3
DR13 132H 200 144/366 72/183 80/203 10350/4700 8.5
DR13 132HH 200 144/366 72/183 80/203 10350/4700 10.3

COMPRESSOR:
Type: Positive Displacement, Oil---Free, Twin Rotary Screws
Configuration: Two---stages, Driven by Single Increaser Gear Box
Bearing Type: Anti---Friction
Lubrication: Pressurize System for Bearings, Gears and Cooling Jackets
Sump Capacity: 10 gallons (37.9 liters)
Duty Temperature: 115_F (46_C) Max.
Control: Electro---hydro---pneumatic
Discharge Pressure: Maximum (see Table 3.1); Minimum 70 psi (4.8 bar)

MOTOR:
Type: TEFC Enclosure, NEMA Frames 365TSC through 445TSC,
Premium Efficient
Size: 100 through 200 HP, 2---pole speed
Voltage: 230V, 460V, 575V, 380V @ 60 Hz; 400V, 380---415V @ 50 Hz
Service: 50_C Ambient
Starter: Solid State Reduced Voltage with Disconnect Switch

3.2 LUBRICATION GUIDE fluid should be changed more frequently under se-
Sullair DR---13 compressors are factory filled with vere operating conditions, such as high ambient
Sullair lubricant (no. 02250057---198). temperatures coupled with high humidity or when
high particulate level, corrosive gases or strong oxi-
! WARNING dizing gases are present in the air.
Mixing of other fluids within the compressor Maintenance of all other components is still recom-
should be authorized by the factory. Otherwise,
this may void all warranties. mended as indicated in the Maintenance section of
this manual.
Lubricant should be checked/changed every 8,000
hours or once a year, whichever comes first. The

7
 NOTES

8
 Section 4
COMPRESSOR SYSTEMS

4.1 INTRODUCTION lubrication and cooling system, and a sound at-

Your Sullair DR---13, rotary screw air compressor tenuating enclosure, all mounted on a fabricated
will provide you with improved reliability and re- steel frame.
duced maintenance.
Air---cooled heat exchangers are used on all mod-
Read Section 7 (Maintenance) to keep your com- els. A motor driven fan is used to ventilate the interi-
pressor in top operating condition. Should any or of the sound attenuating enclosure. The Super-
questions arise which cannot be answered in the visor II assembly is easily accessible for servicing
following text, call your nearest Sullair office or the behind a hinged and locked separate enclosure
Sullair Corporation Service Department. panel door.
IMPORTANT --- Your DR---13 compressor package 4.3 COMPRESSOR UNIT, FUNCTIONAL DESCRIP-
utilizes a simple to operate yet sophisticated com- TION
puterized controller identified throughout this doc- Sullair DR---13 compressors feature a two---stage,
ument as the Supervisor II. All pertinent use of this oil free, rotary screw design. The rotor profiles and
device is covered herein. Carefully familiarize your- stators, which are protected with anti---corrosion
self with it before attempting to operate the machin- coatings, deliver near pulse---free compressed air
ery. to meet your demands. The rotor shafts are
mounted on anti---friction bearings and are sealed
4.2 DESCRIPTION OF COMPONENTS by floating carbon ring/stainless steel cage assem-
Refer to Figure 4---1. The standard package in- blies. Both stages are driven by a common bull
cludes a two -- stage compressor and gear box gear and speed optimized individual pinions, and
assembly, an electric motor and driveline sys- are precisely mounted to the rigid gear box. Timing
tem, a Supervisor II control assembly, an inlet gears synchronize each male/female rotor pair for
air system, low pressure (LP) and high pressure contact---free operation. Variations of compressor
(HP) silencing/discharge air systems, air cool- speed, and ultimately flow capacity, are deter-
ing system, a load/unload control system, an oil mined by the ratio of pinions--- to---bull gear set

Figure 4 ---1 Description of Components (Typical)

CHECK VALVE COOLING FAN

MOTOR

HIGH PRESSURE
SILENCER

CONTROL
CYLINDER
HIGH PRESSURE
COMPRESSOR UNIT AIR
FILTER

COMPRESSOR
UNIT MOTOR
OIL SUMP AIR INLET
TANK VALVE
THERMAL
LOW PRESSURE VALVE
COMPRESSOR UNIT

9
Section 4
COMPRESSOR SYSTEMS

chosen. Figure 4 ---2 Compressor Inlet System

A gear---type pump, coupled to the main drive
shaft, supplies the required lubricating oil to the
gears, anti---friction bearings and cooling to com-
pressor jacket. A baseframe mounted, all---metal
tank serves as the sump for the lubrication system.
The compressor/gear box assembly is driven by an
electric motor via a torsionally soft, flexible shaft
coupling. The NEMA C---flange electric motor is
mounted to the gear box through a rigid, cast adap-
tor which maintains the gear box and motor shafts
in optimum alignment and allows the driveline as-
sembly to be supported by soft, vibration isolating
rubberized mounts. SUPERVISOR II
4.4 AIR INLET SYSTEM, FUNCTIONAL DESCRIP- MODULE
TION AIR FILTER
Refer to Figure 4---2. The compressor inlet system
consists of a heavy duty three---stage, dry type air
filter with inertial dust separation and dust collec- FLANGE TO
tion bowl, mounted inside the canopy and con- DUCT ADAPTOR
nected to the compressor inlet via a flange---to---
duct adaptor.
Figure 4 ---3 Load/Unload Capacity Control System

10
 Section 4
COMPRESSOR SYSTEMS

4 ---4 LP and HP Silencing/Discharge Air and Cooling Systems

A decrease in compressor inlet pressure, caused START MODE -- 0 TO 5 PSIG (0 TO 0.34 BAR)
by the collected airborne dirt, is sensed by the Su- When the “I” or “ ” pads are depressed, the unit
pervisor II and a filter maintenance announcement starts. The inlet valve cylinder control solenoid
is displayed. valve is deenergized. The blowdown valve remains
open, reducing air compression at the HP pipe-
work, and the inlet valve remains nearly closed (hy-
4.5 LOAD/UNLOAD CAPACITY CONTROL SYSTEM, dro actuator retracted), nearly shutting off inlet air
FUNCTIONAL DESCRIPTION to the unit.
Refer to Figure 4---3. The purpose of the capacity
control system is to regulate the compressed air FULL LOAD MODE -- 75 TO 100 PSIG (5.2-- 6.9
supply to the demand. It consists of an inlet BAR)
throttling valve and hydraulic actuator assembly, After a two second interval, the Supervisor II ener-
and a discharge blowdown valve and muffler as- gizes the inlet valve cylinder control solenoid valve
sembly, all controlled by the Supervisor II. The dif- which opens the inlet valve (hydro actuator ex-
ferent phases of operation are described below (for tended), and closes the blowdown valve via the lim-
illustration purposes, 100 psi service operation will it switch, allowing the package to intake and com-
be used): press at 100% capacity.

11
Section 4
COMPRESSOR SYSTEMS

Figure 4 ---5 Piping and Instrumentation Diagram (Air ---cooled)

12
 Section 4
COMPRESSOR SYSTEMS

UNLOAD MODE -- 100+ PSIG (6.9+ BAR) 4.6 COOLING AND SILENCING SYSTEM, FUNC-
If the demand of compressed air falls below that TIONAL DESCRIPTION
supplied by the package, the line pressure (P2) in- Refer to Figure 4---4 and 4---5. As air is discharged
creases. When the line pressure reaches the 100 by each compressor stage, it is sequentially routed
psig (6.9 bar) setting programmed in the Supervi- to:
sor II, the inlet valve cylinder control solenoid is S a silencer to reduce noise caused by the dis-
deenergized, which closes the inlet valve (hydro charged air.
actuator retracted), and opens the blowdown valve S heat exchangers to cool the high temperature air
via the limit switch, unloading the package to the delivered by the oil---free screw compressor
state described in the Start Mode. stages.
S combination separator/drains to eliminate liq-
If the Supervisor II is operating in continuous uids condensed in the preceeding heat ex-
mode, the compressor runs unloaded until the line changers.
(P2) pressure falls below the 90 psig (6.2 bar) set- The LP stage silencer is a reactive pipework sized
ting, at which point it proceeds to the Full Load to dampen lower frequency air pulses, while the HP
Mode. stage silencer is a reactive vessel sized to dampen
higher frequency pulses.
If the Supervisor II is operating in automatic mode, 4.7 LUBRICATION SYSTEM, FUNCTIONAL DE-
the compressor runs unloaded for a standard fac- SCRIPTION
tory pre---set length of time, and the line pressure Refer to Figure 4---5 and 4---6. The DR---13 Series
(P2) does not fall below the 90 psig (6.2 bar) set- Compressor delivers oil---free compressed air, but
ting, the compressor will stop at the end of this peri- it requires lubricant to maintain its high speed bear-
od. When the line pressure (P2) falls below the 90 ings and gears in running order.
psig (6.2 bar) setting, a Start Mode automatically
takes place, followed by package operation in the A gear---type pump draws lube oil from the base-
Full Load Mode. frame mounted sump and delivers it at a pressure
Figure 4 ---6 Lubrication System

13
Section 4
COMPRESSOR SYSTEMS

equal to approximately 45 psig (3.1 bar). An inte- All lubed points return the oil to the sump by gravity.
gral bypass valve maintains the set flow, while pro- Vents on the compressor timing gear covers and
tecting the pump against undesirable overpressur- the gear box are also piped into the sump, to avoid
es. A thermal mixing valve, set to open at 85˚F releasing oil vapor. The sump is vented to atmo-
(30˚C) ensures fast oil warm---up by bypassing oil sphere via a breather which includes an oil vapor
around the heat exchanger. trap.
The lube oil is sequentially pumped through a heat 4.8 BUFFER AIR SYSTEM, FUNCTIONAL DE-
exchanger, the first and second stage compressor SCRIPTION
cooling jackets, a high efficiency, replaceable ele-
ment filter, and a multiport manifold, where the fil- A small supply of cooled, compressed air is taken
tered outflow is distributed to bearing and gear lu- at the aftercooler moisture separator, and used to
brication points on the compressor and the gear feed the buffer air system. This compressed air
box. Filtered oil is also used to actuate the hydro goes through a control air filter, and then through a
actuator linked to the inlet control valve. pressure regulator, where the pressure is reduced
from the compressor operating pressure to 12 psig
The Supervisor II senses and displays the filter out- (0.08 bar) (read from locally---mounted pressure
let pressure and temperature. As a safety mea- gauge). This clean, compressed air supply is fed to
sure, unless oil pressure builds up to 25 psig (1.7 both first and second compression stages. This air
bar) within 10 seconds after startup, the Supervisor provides a positive pressure buffer to the seals be-
II shuts down the unit. In addition, if the pressure tween the compression air and oil sides of the
drop across the filter ports exceeds 10 psig (6.9 stages, assuring oil---free air. The buffer air is then
bar), the Supervisor II displays a maintenance re- drained from the stages, manifolded together, and
quirement message. piped to the exterior of the package.

14
 Section 5
SUPERVISOR II

Figure 5 ---1 Supervisor II Panel

15
Section 5
SUPERVISOR II

5.1 INTRODUCTION mode to increment a value.

Refer to Figure 5---1. The Supervisor II has a two
line display to show temperature, pressure and sta-
tus. It has a keypad for operating the compressor,
programming the control points and selecting dis-
plays. There is a graphic illustration with lamps that
light to show the item being displayed. The lamps S Down arrow, lamp test --- Used in status
flash if that component is in an alarm condition. displays to change displays and in param-
eter setup mode to increment a value.
When in the default display the key will light
5.2 KEYPAD all the lamps for three seconds.
The keypad is used to control the machine as well
as display status and change setpoints. Refer to
figure 5---1 for following key descriptions.
S Stop --- Used to put the machine into
manual stop. It is also used to clear alarm 5.3 STATUS DISPLAYS
conditions. By default the line pressure (P2) and discharge
temperature (T2) are shown on the bottom line of
the display, and machine status on the top line.
The following are the various machine status mes-
sages that indicate the state of the compressor:
S Continuous --- Starts machine if no alarm (Display graphics shown below.)
conditions are present. Also used to clear
alarm conditions while machine is running. S STOP --- Compressor is off.
S STANDBY --- Compressor is off but armed
to start. This state may be entered because
of a power up, or the unload timer had ex-
pired and stopped the machine. NOTE :
S Auto --- Starts machine and selects auto The machine may start at any time.
mode if no alarm conditions are present.
Also used to clear alarm conditions while S STARTING --- Machine is trying to start.
machine is running.
S OFF LOAD --- Machine is running and off
loaded.
S ON LOAD --- Machine is running and
S Display --- Used to display pressures, loaded.
temperatures and other status information S RMT STOP --- Compressor is off but
(See section on STATUS DISPLAYS). armed to start. The machine will start when
the remote start contact is closed. NOTE :
the machine may start at any time.
S SEQ STOP --- Compressor is off but armed
S Logo --- Used for various functions de- to start. The machine will start when the se-
scribed in later sections quencing conditions meet the critera to
start. NOTE : the machine may start at any
time.
This default display appears as follows:

S Program --- Used to enter the parameter STOP

change mode where control parameters 110 350
may be displayed and changed (See PA-
RAMETER SETUP). If there are alarms active they will alternately be
shown with the default display. The machine status
will be displayed for 2 seconds then the alarms for 2
seconds each. For example:

T1 HI
S Up arrow --- Used in status displays to 110 350
change displays and in parameter setup

16
 Section 5
SUPERVISOR II

To view other status press the DSP key. All temper- the limit a T5 HI shutdown will occur.
atures and pressures may be displayed as well as
other status information. To scroll through the dis- T5 100
plays press the up arrow or down arrow keys. Up MAX 160
arrow moves to the next display, down arrow the
previous display. To return to the default display
press the display key. S Total hours that the compressor has been
running.
S Interstage discharge pressure and line
pressure. HRS RUN
001234.0
P1 30
P2 110 S Total hours that the compressor has been
loaded.
S Oil filter differential pressure and the maxi- HRS LOAD
mum limit. If the limit is exceeded oil main- 000987.0
tenance warning will be displayed.
S Last fault log. This shows the fault on the
dP2 4 first line and the run hours when the fault
MAX 20 occcured.

S Pressure before (P4) and after (P3) oil filter. T1 HI

@1 234
P3 40
P4 44 S Next to last fault log. This shows the fault
on the first line and the run hours when the
fault occcured.
S Interstage discharge temperature. Shuts
off the compressor it T1 exceeds T1 MAX T1 HI
and system status will display T1 HI.
@2 204
T1 350
MAX 445 5.4 LAMP INDICATORS
Embedded into the front panel schematic of the
compressor are several lamps. Pressing the lamp
S Final discharge temperature and the maxi- test key will light all the lamps for 3 seconds. Each
mum limit. If the temperature exceeds the LED lamp has the following purpose.
limit a T2 HI shutdown will occur.
P1 --- (Interstage pressure) If lit steady, signifies
that P1 is being displayed, if flashing denotes the
T2 350 presence of an alarm.
MAX 445 P2 --- (Line pressure) If lit steady, signifies that P2 is
being displayed, if flashing denotes the presence
S Oil temperature and the maximum limit. of an alarm.
If the temperature exceeds the limit a T3 HI P3 --- Pressure after oil filter is being displayed.
shutdown will occur.
P4 --- Pressure before oil filter is being displayed.
T3 100 T1 --- (First stage discharge temperature) If lit
MAX 160 steady, signifies that T1 is being displayed, if flash-
ing denotes the presence of an alarm.
S Interstage temperature after the intercool- T2 --- (Second stage discharge temperature) If lit
er and the maximum limit. If the tempera- steady, signifies that T2 is being displayed, if flash-
ture exceeds the limit a T4 HI shutdown will ing denotes the presence of an alarm.
occur. T3 --- (Oil temperature) If lit steady, signifies that T3
is being displayed, if flashing denotes the presence
T4 100 of an alarm.
MAX 160 T4 --- (Interstage temperature) If lit steady, signifies
that T4 is being displayed, if flashing denotes the
S Package discharge temperature and the presence of an alarm.
maximum limit. If the temperature exceeds T5 --- (Package discharge temperature)

17
Section 5
SUPERVISOR II

MOTOR --- If flashing, indicates the motor overload S Wye to delta transition timer --- For the
contact has opened. full voltage starters and solid state starters
INLET FILTER --- If flashing, indicates that inlet filter supplied, this parameter is set to 0.
maintenance is needed.
OIL FILTER --- If flashing, indicates that oil filter WYE DELT
maintenance is needed (oil filter differential pres- 10 SEC
sure dP2 maximum has been reached).
POWER ON --- Lit if 120VAC power is applied to the S Restart time --- Time to wait after powerup
Supervisor II. before starting machine. This parameter is
used to keep several machines from start-
ON --- If lit steady, the compressor is running. If ing at the same time after power up, or to
flashing, indicates that the compressor is armed delay start until other equipment is started.
but stopped because of restart timer not expired, If disabled the machine will not automati-
remote stop or sequence stop. The compressor cally start after power up.
may start at any time.
AUTO --- If lit steady, the compressor is running and
in auto mode. If flashing, indicates that the com- RST TIME
10 SEC
pressor is armed but stopped because of restart
timer not expired, remote stop or sequence stop.
The compressor may start at any time. S Unload Stop Timer --- If the machine is
running in AUTO mode, this parameter
specifies the amount of time that the ma-
5.5 OPERATING PARAMETER SETUP chine will run unloaded before shutting off.
Pressing the program key enters parameter dis- If the time is set less than 15 minutes (for
play and edit mode. To move to the next parameter example 5), there may be times when the
press the program key. To increment a parameter machine will run unloaded for more than 5
press the up arrow key or logo key. The logo key minutes. This is because there is another
will increment by 10. To decrement the value press timer that keeps the machine from being
the down arrow key. started more than four times an hour.
The parameters are displayed in the following or-
der: UNLD TIM
15 MIN
S Unload pressure --- The pressure where
the machine is unloaded. For example if
this parameter is set to 110 psi (7.6 bar) the S Language select --- English, German,
machine will unload when the line pressure Spanish, Italian and French may be se-
reaches 110 psi (7.6 bar). lected for display language.

UNLOAD LANGUAGE
110 PSI ENGLISH

S Load differential --- The pressure differ- S Units --- English or metric units may be se-
ential below the unload pressure where the lected.
machine is loaded. For example if the un-
load pressure is set to 110 psi (7.6 bar) and
the load differential is set to 10 psid (0.7 UNITS
bar), the machine will load when the line ENGLISH
pressure goes below 100 psi (6.9 bar).
S Communications ID # --- This is the net-
work address of a machine. If there is more
LOAD that one machine connected to the net-
10 PSI
work, each machine must have a unique
number
S P1 Max --- Maximum oil sump pressure.
An alarm and shut down will occur when
the oil sump pressure rises above this COM ID #
pressure. 1

P1 MAX S Communications baud rate --- This

135 PSI should always be selected to 9600 baud
for all sequencing modes. It may be lower

18
 Section 5
SUPERVISOR II

for slave or monitoring modes. Manual for details.

BAUDRATE CAPACITY
9600 100

S Sequence method --- This parameter sets S Sequence Hours --- Used only for se-
the method used for sequencing. The quencing, see Sequencing & Protocol
choices are DISABLED, REMOTE, SLAVE, Manual for details.
HOURS, COM ID#. See the Sequencing &
Protocol Manual (P/N 02250057---696) for SEQ HRS
details about these modes. 1000

SEQUENCE 5.6 OPERATING THE COMPRESSOR

HOURS Before operating the compressor the operating pa-
rameters must be setup. See Section 6.3, Supervi-
S Drain interval --- The time between actua- sor II Operating Parameters--- Setup, on operating
tion of the drain valve. parameter setup.
MANUAL OPERATION MODE
DRN INTV In this mode the compressor will run indefinitely, as
10 MIN long as temperatures and pressure remain within
the valid operating ranges, and the motor overload
S Drain time --- The amount of time that the or emergency stop contacts are not tripped. Press-
drain valve is actuated. ing the “I”will turn on the compressor and put it in
manual mode. If the compressor is already run-
ning, but in automatic mode, pressing “I” will
DRN TIM switch operation to manual. Pressing “I” while al-
1 SEC ready running in manual mode will cause the Su-
pervisor to turn off the common fault relay, if en-
S Last Communication Number --- Used gaged, and clear any maintenance indicators.
only for sequencing, see Sequencing & To stop the compressor, press “O”. If the compres-
Protocol Manual for details. sor is already off when “O” is pressed, the common
fault relay will be turned off, if engaged, and it will try
LAST COM to clear the alarm and maintenance indicators. Re-
3 gardless of what the compressor is doing, pressing
“O” puts the Supervisor in manual stop mode.
S Lowest Allowable Pressure --- Used only AUTOMATIC OPERATION MODE
for sequencing, see Sequencing & Proto- In this mode the compressor will start if line pres-
col Manual for details. sure (P2) is less than the LOAD parameter. It will
stop if the compressor runs unloaded for the num-
LOWEST ber of minutes indicated by the UNLD TIM parame-
90 PSI ter . To put the compressor in automatic mode
press “ ”. If P2 is already less than LOAD the com-
pressor will start immediately, otherwise the sys-
S Recovery Time --- Used only for sequenc- tem status will indicate STANDBY and the LED
ing, see Sequencing & Protocol Manual for marked AUTO will flash.
details.
If the compressor is already running, but in continu-
ous mode, pressing “ ” will switch operation to
RECOVER automatic. Pressing “ ” while already running in
10 SEC automatic mode will cause the Supervisor to turn
off the common fault relay, if engaged, and clear
SRotate Time --- Used only for sequencing, any maintenance indicators.
see Sequencing & Protocol Manual for de- In automatic mode the compressor can be
tails. stopped manually by pressing “O”. Stopping the
compressor using “O” will put the Supervisor in
ROTATE manual stop mode.
50 Regardless of whether in “automatic” or “manual”
mode, control of the load solenoid will be based on
S Machine Capacity --- Used only for se- the parameters UNLD and LOAD. This operation is
quencing, see Sequencing & Protocol as follows:

19
Section 5
SUPERVISOR II

P2 > UNLD -- -- > load solenoid turned off S REMOTE --- Responds to status and pa-
P2 < LOAD -- -- > load solenoid turned on rameter change messages but will not re-
spond to start, stop, load or unload mes-
POWER FAILURE RESTART sages. The remote inputs and outputs are
If the restart timer (RST TIME parameter) is dis- enabled (start/stop, load/unload, master/
abled the compressor will not try to start after a local).
power up. If this time is set to a value the machine
will go into standby after power up. When the line S SLAVE --- Will respond to all messages,
pressure drops below the load setpoint, the restart but will not start or load unless comman-
timer will start timing. When the timer expires the ded to do so by a message. This mode is
machine will start. used to control the machine from a master
computer.
SEQUENCING MODES
The following is a brief description of sequencing S HOURS --- Sends status message about
modes, for details see the Supervisor II Sequenc- once a second, starts, loads and unloads
ing & Protocol Manual (P/N 02250057---696). machines based on sequencing hours.
S DISABLED --- Responds to status and S COM ID # --- Sends status message
parameter change messages via the about once a second, starts, loads and un-
RS485 network but will not respond to loads machines based on machine Com
start, stop, load or unload messages. ID#.

5.7 SUPERVISOR II OUTPUT RELAYS

RELAY OPERATION

RUN RELAY (K1) Contact closure energizes the compressor starter.

*---DELTA (K2) A timed contact used to provide wye---delta transition
time. Not used on DS---13 Series.
UNLOAD/LOAD (K3) Controls ON LOAD/OFF LOAD operaton of the load
control solenoid valve.
COMMON FAULT (K4) May be used to provide remote indication of any pre---
alarm, maintenance or fault shutdown condition.
ELECTRIC DRAIN VALVE (K5) Controls a solenoid valve to provide automatic con-
densate removal.
FULL LOAD/MODULATE (K6) Used with sequencing feature.

NOTE: All output relays will handle 8 amperes at 120/240 VAC.

Table 5 ---1
Parameter Value Range Notes
Load P2 75 --- 140 psi Load pressure setting
(5.2 --- 9.7 bar)
Unload P2 85 --- 150 psi Unload pressure setting
(5.9 --- 10.3 bar)
Max P2 160 psi System shutdown pressure setting
(11 bar)
Unload Time 10---60 Min. Time lapse to system shutdown on
AUTO mode
Electric Drain Interval 0---10 Min.
Duration 0---10 Sec.

20
 Section 5
SUPERVISOR II

5.8 SUPERVISOR II CONTROL PARAMETERS-- DS-- 13

SENSOR FUNCTION UNITS PREALARM SHUTDOWN FAILURE

MODE
P1 Interstage Air Pressure psig/bar 49/ 3.4 52/ 3.6 Hi
P2 Discharge Air Pressure psig/bar N/A 50/ 3.4 Lo
P3 Oil Filter Outlet Pressure psig/bar N/A 25/ 1.7 Lo
P4 Oil Filter Inlet Pressure psig/bar N/A N/A N/A
Dp1 Inet Filter Vacuum inches H2O 15 N/A Hi
Dp2 Oil Filter Differential (P4---P3) psig/bar 20/ 1.4 N/A Hi
T1 1st Stage Discharge Air Temp. ˚F/˚C 435/ 224 445/ 229 Hi
T2 2nd Stage Discharge Air Temp. ˚F/˚C 435/ 224 445/ 229 Hi
T3 Oil Filter Outlet Temp. ˚F/˚C 155/ 68 160/ 71 Hi
T4 2nd Stage Inlet Air Temp. ˚F/˚C 155/ 68 160/ 71 Hi
T5 Aftercooler Discharge Temp. ˚F/˚C 155/ 68 160/ 71 Hi

21
 NOTES

22
 Section 6
COMPRESSOR OPERATION

6.1 GENERAL ! WARNING

While Sullair has built into the DR---13 compressor
package a comprehensive array of controls and in-
dicators to help assure proper operation, the user
should recognize and interpret readings which call The minimum continuous operating pressure is
70 psig (4.8 bar). the compressor should not be
for service or indicate the onset of a malfunction. operated below this pressure except for short pe-
Before starting the unit, the user should become fa- riods. The Supervisor II will shut the machine
miliar with the controls and indicators --- their pur- down if it is operated continuously below 50 psig
pose, location, and use. (3.4 bar) for five minutes.

6.2 PURPOSE OF CONTROLS

CONTROL OR INDICATOR PURPOSE

EMERGENCY STOP SWITCH Pushing in this switch, found adjacent to the Supervisor
II, cuts all AC outputs from the latter and de---energizes
the starter. A fault message (E STOP) is displayed by
the Supervisor II until the button is pulled out and the
“O” pad is pressed.
MOTOR O/L RESET Momentarily pushing this button, found on the thermal
overload element housing in the starter box, re---closes
the latter’s contacts after a current overload takes place.
Please be aware that the elements must be allowed to
cool sufficiently before resetting.
LIMIT SWITCH Operates blowdown valve.
DISCHARGE CHECK VALVE Isolates compressor from field pipework when shut
down. Located between the HPsilencer and the after-
cooler.
PRESS RELIEF VALVES Found on the discharge pipework of both LP and HP
stages, they vent the compressed air to atmosphere in
case of an over pressure condition --- 65 and 165 psi
(4.5 and 11.4 bar), respectively.
INLET VALVE CYLINDER AND CONTROL VALVE
ASSEMBLY The hydraulically operated butterfly valve throttles the
air flow entering the unit inlet flange --- LP stage. A
4---way electric solenoid valve loads and unloads the hy-
draulic actuator, in response to Supervisor II com-
mands.
BLOWDOWN VALVES The 2---way valve vents compressed air (HP discharge)
to atmosphere through a muffler.
DRAIN GLOBE VALVES Furnished as manual backups to automatic drain valves
used in the condensate separator vessels. Also used as
lubricant sump drain valve.
OIL PRESSURE BYPASS VALVE To maintain desired oil flow and to protect oil pump from
over pressure situations.
THERMAL VALVE This thermal valve automatically opens/closes to by-
pass warm oil around the heat exchanger to ensure fast
oil warmup and optimize operating temperature.
SUMP SIGHT GLASS Indicates level of lubricant in the sump. Located on the
sump side, it should show 75% full (compressor
stopped) for proper oil level.

23
Section 6
COMPRESSOR OPERATION

6.3 SUPERVISOR II OPERATING PARAMETERS -- 5. Check that the Emergency Stop switch is armed
SET UP (pulled out), reset faults (if any) by pressing the
“O” pad. Energize the starter by pressing the “I”
Refer to Figure 5---1 in Section 5, Supervisor II. pad. Compressor will start unloaded, then load.
6. Check for possible leaks in the pipework.
S To change operating parameters you must go 7. Slowly close and open the shut---off valve to
into “PROGRAM” mode. PROGRAM mode can check that the Full Load and Unload set pressur-
only be accessed from the default display mode. To es programmed in the Supervisor II are ade-
enter PROGRAM mode press “PRG”. quate for the application.
8. Observe the operating temperatures T4 (inter-
stage) and T5 (final package air outlet). These
should be no higher than 135˚F (57˚C) or 20˚F
(11˚C) above the ambient temperature. Ob-
serve the operating temperature T3 and press
S When in PROGRAM mode you will be prompted P3 (tube oil filter discharge). When T3 reaches
with the name of the parameter, its current value approximately 100˚F (38˚C), P3 should be
and its units. To increase the value press “Y”. approximately 40 psig (2.8 bar). This is con-
trolled by the constant bypass pressure relief
valve setting.
9. Close service valve to air net system.
10. Check the buffer supply pressure. The buffer
supply regulator should be set at minimum 10
S If you desire a lower value, you must increase psi (0.69), maximum 14 psi (0.95 bar).
until you reach the maximum allowable value; at 11. Check the setting of the inlet control valve flapper
this point the next increase will set the value to the for unloaded operation --- a vacuum level of 24
minimum. in. (61 cm) Hg should be measurable at the inlet
flange of the LP stage.
S To confirm the new value, or to go to the next item
on the list, press “PRG”. If necessary adjustment of the valve flapper may
be done as follows:
S Connect a 30 in. Hg manometer to the NPT
connection provided at the inlet flange of the LP
stage.
S Unload the package by a suitable method. For
S While modifying a setpoint, you may want to re- example, reprogram the Supervisor II to unload
store the original value. To do so, press the Sullair at system line pressure, if such is available. If no
logo. system air pressure is yet available, locate and
disengage the pressure transducer connection
(P2), plug the open hole, and feed a separate air
pressure signal which exceeds the unload level
set in the Supervisor II.
S Loosen the set screw locking the actuator arm
S To return to the default display, cancelling any to the air control valve flapper shaft and while
changes to the current parameter, press firmly grasping the shaft with a suitable tool, ro-
“DSP”. tate slowly back ---and---forth until 24 in. (61 cm)
shows on the manometer (when operating the
unit at sea level --- approximately. 14.5 psia [1
bar]). For higher elevations, derate the desired
vacuum in direct proportion to the local baromet-
6.4 INITIAL START-- UP PROCEDURE ric pressure.
S Refasten the flapper shaft to the actuator arm
The following procedure should be followed for the with the set screw.
initial start---up of the package: S Cycle load and unload the package a few times
1. Read the preceding pages of this material thor- to insure that the flapper setting has been prop-
oughly. erly achieved --- this may be done by feeding and
2. Be sure that all preparations and checks de- removing the unloading pressure signal from the
scribed in Section 2, Installation, have been P2 sensor connection.
made. S Replace the P2 sensor connection back in the
3. Close manual condensate drain valves and re- condensate separator vessel.
place any cooler drain plugs which may have 12. Check adjustment of limit switch actuation--- see
been removed for shipment to prevent freezing. limit switch maintenance in Section 7, Mainte-
4. Open service valve to the air net system. nance.

24
 Section 6
COMPRESSOR OPERATION

13. Open service valve to air net system. Compres- T1 HI --- T1 was greater than 445_F (229_C).
sor will run loaded or unloaded as the system T1 prealarm occurs at 435_F (224_C).
demands.
14. Check operating conditions and reinspect for T2 HI --- T2 was greater than 445_F (229_C). T2
leaks the following day. prealarm occurs at 435_F (224_C).

6.5 SYSTEM STATUS MESSAGES E-- STOP --- The emergency stop pushbutton was
pushed in.
The top row of the display is for the System Status
Messages. These messages tell what mode the MOTOR OL --- The motor overload contact has
compressor is in, if maintenance is required, or if opened.
the compressor is “shutdown” due to an operating
parameter violation. True first---out indication of a COOL FLT --- Cooling fan motor overload contact
fault shutdown is assured by displaying only the was opened.
first condition of shutdown on the message display.
Subsequent fault conditions may appear as LED P1-- LOW --- P1 < 25 psig (1.7 bar) while running.
indications on the graphic map. This will also occur if the motor fails to run when the
RUN relay is energized. An alternate cause for this
The following messages indicate that everything is condition may be a defective P1 transducer.
normal:
P2-- LOW --- The machine ran continuously for five
MANUAL --- Compressor is off, in manual mode. minutes at a final pressure below 50 psig (3.4 bar).
STANDBY --- Compressor is off, in automatic
mode. T1 or T2 FAIL --- T1 ± 6_F while the compressor
was running. Since this is an impossibly low value,
the Supervisor assumes that the temperature
OFF LOAD --- Compressor is on, the load solenoid probe has failed.
valves are de---energized.
P1 FAIL --- P1 ² 198 psig (13.7 bar) while the com-
ON LOAD --- Compressor is on, the load solenoid
valves are energized. pressor is stopped. Since this is an impossibly high
value, the Supervisor assumes that the pressure
transducer has failed.
The following messages indicate that the compres-
sor may need maintenance: The messages are
cleared by pressing “O”. P2 FAIL --- P2 ² 198 psig (13.7 bar) while the com-
pressor is stopped. Since this is an impossibly high
value, the Supervisor assumes that the pressure
AIR MNTN--- Air filter maintenance indication; in- transducer has failed.
spect and/or change air filter elements.

OIL MNTN-- Oil filter maintenance indication; in- P3 FAIL --- P3 ± 25 psig (1.7 bar) while the com-
spect and/or change oil filter element. pressor is running.
6.6 SUBSEQUENT START-- UP PROCEDURE
The following messages indicate that the compres-
sor has exceeded an operational limit. Pressing On subsequent start ---ups, check that the steady---
“O” will clear these messages, but only if the condi- state indications supplied by the Supervisor II and
tion causing these messages is no longer present. local gauges are satisfactory. Also check for proper
The compressor will not run if any of these mes- lubricant level in the sump.
sages are still present.
6.7 SHUTDOWN PROCEDURE
P1 HI --- P1 was greater than 52 psig (3.6 bar). To shut the package down, simply press the “O”
P1 prealarm occurs at 49 psig (3.4 bar). pad.

25
 NOTES

26
 Section 7
MAINTENANCE

7.1 GENERAL must also be checked every 16000 hours of opera-

As you proceed to study this section, it will be easy to tion or two years, depending upon conditions of ser-
see that maintenance for the air compressor is quite vice:
minimal. The Supervisor II monitors the status of the 1. Operate/test all safety devices.
air and oil filters. When maintenance to either device 2. Check/clean heat exchangers.
is required, the Supervisor II will display the appropri- 3. Check/clean blowdown valve.
ate maintenance message and flash the location 4. Check/clean check valves.
LED on the graphics map as a visual remainder. 5. Check condition of isolation mounts under com-
pressor unit and motor.
! WARNING 6. Check/clean strainer included in oil pump suction
line, inside oil sump.
DO NOT remove caps, plugs, and/or other compo- 7.6 DIAGNOSTIC SERVICE (OPTIONAL)
nents when compressor is running or pressurized.
Sullair and its representatives offer a diagnostic ser-
Stop compressor and relieve all internal pressure vice to check the condition of your compressor unit.
before doing so. The service, which is recommended at 8000 hour in-
tervals, performs the following:
7.2 DAILY OPERATION
Following a routine start, observe the various Super- 1. Tri--axial vibration measurements at the gearbox
visor II displays and local gauges to check that nor- and the compressor stages.
mal readings are been made -- previous records are 2. Package performance data collection and analy-
very helpful in determining the normalcy of the mea- sis.
surements. These observations should be made 3. Examination of shaft coupling assembly.
during all expected modes of operation (i.e. full load, 4. Operational check of protective equipment.
no--load, different line pressures, cooling water tem- 5. Final discussion with maintenance engineer.
peratures, etc.). This service, when supplemented by properly re-
corded package operational performance and vibra-
7.3 INITIAL MAINTENANCE AFTER 50 HOURS OF tions trends, is most helpful in identifying the pres-
OPERATION ence (or absence) of equipment damage which can
Upon completion of the first 50 hours of operation, a be repaired or replaced before a catastrophic break-
few maintenance requirements are needed to rid the down occurs.
system of any foreign materials which may have ac-
cumulated during assembly: 7.7 PARTS REPLACEMENT AND ADJUSTMENT
PROCEDURES
1. Change the lubricant filter element. Please, familiarize yourself with the safety guidelines
2. Clean the control line filter element. offered in Section 1 of this manual before attempting
3. Check/replace the sump breather element. any maintenance on the package.
7.4 MAINTENANCE EVERY 8000 HOURS OR ONE 7.7.1 AIR FILTER INSPECTION/MAINTENANCE
YEAR OF OPERATION ELEMENT INSPECTION
The following items should be checked every 8000 1. Place a bright light inside the elements to inspect
hours of operation or one year, whichever comes for damage or leak holes.
first, although service conditions such as relative 2. Inspect gaskets and matching sealing surfaces on
cleanliness of process air or quality of cooling me- the housing. It should be smooth or replace in
dium may require shorter inspection intervals. case of damage.
1. Replace oil charge and filter element. 3. The secondary element must be replaced if dirt ob-
2. Replace control line filter element. struction is evident.
3. Replace sump breather filter element. 4. DO NOT strike elements against a hard surface to
4. Replace air filter element. dislodge dirt -- this may damage the sealing sur-
5. Check/clean condensate drain valves screen. faces and/or rupture the element.
6. Check condition of shaft coupling element and AIR FILTER MAINTENANCE
tightness of fasteners. Refer to Figure 7--1. Air filter maintenance should be
7. Measure and record vibration signatures on com- performed at 8000 hours, one year or when the cor-
pressor, gear box and motor -- optional. responding maintenance message is displayed by
the Supervisor II. This corresponds to a pressure
NOTE loss condition across the filter of 22 in. (56 cm) of wa-
ter. Your filter assembly includes a primary element
Please refer to the motor manufacturer’s docu-
mentation for recommended maintenance. Keep and a secondary element.
in mind that the specified type and quantity of lu- 1. Clean exterior of filter housing.
bricating grease for motor anti-- friction bearings is 2. Loosen retaining band and remove cover with rub-
crucial.
ber dust collector attached.
7.5 MAINTENANCE EVERY 16000 HOURS OR TWO 3. Remove wing nut, washer and primary element.
YEARS OF OPERATION 4. Clean interior of housing with a damp cloth.
In addition to those items covered by the 8000 hour 5. Remove wing nut, washer and secondary ele-
or one year maintenance interval, the following items ment.

27
Section 7
MAINTENANCE

Figure 7-1 Air Filter (P/N 048456)

RETAINING CLIP

*Replacement Element P/N 048462

** Replacement Element P/N 048463

6. Replace secondary element with new element.

7. Replace primary element with new element. Figure 7-2 Oil Filter (P/N 02250049-820)
8. Replace clover and tighten retaining band.
7.7.2 OIL FILTER MAINTENANCE
Refer to Figure 7--2. Oil filter maintenance (using re-
pair kit P/N 02250049--820) should be performed at
8,000 hours, one year or when the corresponding
maintenance message is displayed by the Supervi-
sor II -- this corresponds to a pressure loss condition
across the unit of 20 psig (1.4 barg). Your oil filter in-
cludes a proprietary replaceable element (P/N
02250049--821) available solely from Sullair and its
agents -- DO NOT substitute.
1. Using a strap wrench, remove the old element and
gasket.
2. Clean the gasket seating surfaces.
3. Apply a light film of fresh oil to the new gasket and
hand--tighten new element until gasket contacts
the seat.
4. Continue tightening element by hand, an addition-
al 1/2 to 3/4 turn.
5. Restart package and check for leaks.
7.7.3 CONTROL LINE FILTER MAINTENANCE
Refer to Figure 7--3. Control line filter (P/N
02250112-032) maintenance normally requires re-
placement of the filter element, float assembly and *Replacement Element P/N 02250049-821
seals. Use repair kit no. 02250112-031 (filter ele-

28
 Section 7
MAINTENANCE

Stop compressor and relieve all internal pressure

Figure 7-3 Control Air Filter (P/N 02250112-032) before doing so.

1. Detach the body from the bowl by twisting the body

about the bowl as far as it can go (approximately
1/8 turn), and pulling apart.
2. At this time, unscrew the baffle from the body. Re-
move the element.
3. Discard the element.
4. Replace the element with the new one found in the
repair kit, and reinstate into position on the body
stem. Replace baffle and tighten.
5. Loosen and remove the nut on the bottom of the
bowl.
6. Remove the float assembly and seals.
7. Replace the seals with those found in the repair kit.

NOTE
Coat seals with same fluid as used in compressor
fill before installation to promote proper sealing.
8. Replace those items in the float assembly with
those found in the repair kit.
9. Replace the float assembly into the bowl. Tighten
the nut.
10. Re--connect the body and bowl assemblies.
7.7.4 INLET CONTROL SOLENOID VALVE (P/N
250025--516) MAINTENANCE
Refer to Figure 7--4. Solenoid valve (P/N
250025--516) maintenance is quite minimal but a pe-
riodic cleaning is desirable. The time between clean-
ings will vary depending on operating conditions. In
general, if the voltage to the coils is correct, sluggish
valve operation or excessive leakage will indicate
that cleaning is required. If parts replacement is re-
quired, order repair kit no. 02250053--334 (valve)
and no. 250031--431 (coil) and follow the procedure
explained below.

! WARNING
Turn off all power, relieve package pressure, and
disconnect coil lead wires to the valve before mak-
ing repairs. It is not necessary to remove the valve
from pipework for repairs.

DISASSEMBLY AND REASSEMBLY

1. Remove the retaining clip from top of solenoid.
! CAUTION
When metal retaining clip disengages it will spring
upward.
*Repair Kit P/N 02250112-031
2. Remove nameplate, cover and spring washer.
3. Slip yoke containing coil, sleeves, insulating wash-
ment and seal), and repair kit no. 02250115--960 ers (omitted from molded coil) and grounding wire
(float assembly and seals). off solenoid base sub--assembly.
4. Coil is now accessible for replacement.
5. Reassemble in reverse order of assembly.
! WARNING
! CAUTION
DO NOT remove caps, plugs, and/or other compo- Solenoid must be fully reassembled because the
nents when compressor is running or pressurized. housing and internal parts complete the magnetic

29
Section 7
MAINTENANCE

Figure 7-4 Solenoid Valve (P/N 250025-516)

**
**
**

**

**
**
**
**

**

*
*
* *

*
*

* *
*
*
*

*Replacement Valve P/N 02250053-334

**Replacement Coil P/N 250031-431

circuit. Place an insulating washer at each end of

the non-- molded coil. ! CAUTION
When metal retaining clip disengages it will spring
upward.
VALVE DISASSEMBLY MAINTENANCE
2. Unscrew solenoid base sub--assembly and re-
move core spring guide and core spring.
! WARNING 3. Unscrew capscrews (4) and remove end cap and
Turn off all power, relieve line pressure, and dis- end cap gasket from body.
connect coil lead wires to the valve before making 4. Pull inner disc sub--assembly, disc spring, sleeve
repairs. and outer disc sub--assembly from valve body.
Remove sleeve spring, core and bonnet gasket.
1. Remove retaining clip and pull entire solenoid en- 5. If cleaning is all that is required, do not remove
closure off solenoid base sub--assembly. body (exhaust) seat, body seat gasket, end cap

30
 Section 7
MAINTENANCE

(cylinder) seat, end cap gasket or orifice gaskets. Figure 7-5 Solenoid Valve (P/N 02250119-220)
Remove these only if replacement seats and gas-
kets are available.
6. To remove body seat and seat gasket, insert an
appropriate tool or a heavy gauge wire with a bent
hook on the end through the center hole in the
seat. Pull to dislodge seat. if seat will not dislodge
easily, remove piping from exhaust port and push
seat out with a thin rod through the exhaust port.
To remove end cap seat and gaskets, push seat
from end cap, using a thin, blunt rod inserted
through hole between cylinder port “A” and cylin-
der port “B”. When the end cap is of the type using
metering devices, compressed air applied
through either pipe connection or small vent hole
in the end cap should force out the seat with the
gasket. If this fails, using the appropriate tool or
bent wire described above should dislodge the
seat with the seat gasket.
7. All parts are now accessible for cleaning or re-
placement.

VALVE REASSEMBLY
1. Lubricate end cap gasket, end cap (cylinder) seat
gasket, body seat gasket, bonnet gasket and ori-
fice gaskets (2) with Dow Corningâ III Compound
lubricant or an equivalent high--grade silicone
grease. Lubricate seating surface of end cap seat,
body seat, and disc sub--assemblies (including u--
cups) with lubricant supplied in kit.
2. Replace body seat gasket on body seat and install
seat with gasket side first into valve body.
3. Preassemble disc sub--assembly on disc spring
and install into sleeve. Install remaining disc sub--
assembly from the opposite end. The disc sub--
assemblies will snap onto the disc spring if
pushed evenly and twisted slightly.
4. Install the sleeve (with disc assemblies and disc
spring engaged) into the valve body and onto core
at the same time.
5. Install the end cap assembly consisting of end cap,
end cap gasket, end cap seat, seat gasket and ori-
fice gaskets (2). Install end cap screws (4) and
torque in a criss--cross manner to 110 ± 10 in.--lbs.
(12.4 ± 1.1Nm).
6. Move the core up and down to see that it is properly
engaged and there is no misalignment or binding
of parts.
7. Replace bonnet gasket, sleeve spring, core spring
and core spring guide. *Replacement Kit P/N 02250119-221
8. Replace solenoid base sub--assembly and torque **Replacement Coil P/N 02250120--659
to 175 ± 25 in.--lbs. (19.8 ± 2.8Nm).
9. Replace solenoid enclosure and retaining clip.
10. After maintenance is completed, operate valve a that cleaning is required. Disassemble valve and
few times to be sure of proper operation. clean all parts. If parts are worn or damaged, order
replacement kit no. 02250119-221, and replacement
7.7.5 SOLENOID VALVE (P/N 02250119-220) MAINTE- coil no. 02250120-659.
NANCE
Refer to Figure 7-5. Solenoid valve maintenance is
quite minimal, but a periodic cleaning is desirable.
! WARNING
The time between cleanings will vary depending on Turn off all power, relieve line pressure, and dis-
operating conditions. In general, if the voltage to the connect coil lead wires to the valve before making
coils is correct, sluggish valve operation will indicate repairs.

31
Section 7
MAINTENANCE

It is not necessary to remove the valve from the pipe Figure 7-6 Solenoid Valve (P/N 02250044-392)
line for repairs.

DISASSEMBLY
Prior to performing this, be sure all pressure is re-
moved from the system.
1. Remove the retaining cap. Push down on the coil
while prying the nameplate/retainer cover in the
direction of the arrow [ ] (See Figure 7-5).
Nameplate/retainer cover will slip forward, releas-
ing the coil assembly. Slip the coil assembly off of
the solenoid base subassembly.
2. Unscrew the solenoid base assembly. Remove
the solenoid base gasket, core/insert sub-assem-
bly, core spring and insert gasket.
3. All parts are now accessible for cleaning or re-
placement.
REASSEMBLY
1. Lubricate all gaskets with Dow Corningr 111 Com-
pound lubricant, or equivalent high-grade silicone
grease. If replacing parts, exchange worn or dam-
aged parts with new parts found in the replace-
ment kit, and/or replacement coil.
2. Snap insert gasket into the groove of the core/in-
sert sub-assembly. Be sure to use the proper size
gasket.
3. Install core/insert sub-assembly into body cavity
and push it gently down until the gasket of the in-
sert just seals in the cavity of the body.
4. Install core spring in top of core/insert into top of
core/insert sub-assembly. Close end of core
spring protrudes from top of core.
5. Install solenoid base gasket and solenoid base
sub-assembly. Torque solenoid base sub-assem-
bly to 260 ± 25 in.-lbs. (30 ± 3 Nm).
6. Re--install solenoid.
7.7.6 SOLENOID VALVE (P/N 02250044-392) MAINTE-
NANCE
Refer to Figure 7-6. Solenoid valve maintenance is
quite minimal, but a periodic cleaning is desireable.
The time between cleanings will vary depending on
operating conditions. In general, if the voltage to the
coils is correct, sluggish valve operation will indicate
that cleaing is required. Disassemble valve and
clean all parts. If parts are worn or damaged, order
replacement kit no. 02250044-391, and replacement
coil no. 250031-738.

! WARNING
*Replacement Kit P/N 02250044-391
Turn off all power, relieve line pressure, and dis- **Replacement Coil P/N 250031-738
connect coil lead wires to the valve before making
repairs. ***Refer to Figure 7-7 for re-assembly notes.

32
 Section 7
MAINTENANCE

DISASSEMBLY 6. Check manual operator for proper operation. Turn

Prior to performing this, be sure all pressure is re- stem clockwise and couterclockwise; stem should
moved from the system. turn freely without binding.
1. Remove the retaining cap. Push down on the coil Figure 7-8 Pressure Regulator (P/N 02250100-362)
while prying the nameplate/retainer cover in the
direction of the arrow [ ] (See Figure 7-6).
Nameplate/retainer cover will slip forward, releas-
ing the coil assembly. Slip the coil assembly and
spring washer off of the solenoid base subas-
sembly.
2. Unscrew solenoid base sub-assembly from
manual operator body.
3. Unscrew manual operator body from valve body.
Then remove body gasket and stem retainer.
4. All parts are now accessible for cleaning or re-
placement.
REASSEMBLY
1. Lubricate all gaskets with Dow Corningr 111
Compound lubricant, or equivalent high-grade sil-
icone grease. If replacing parts, exchange worn or
damaged parts with new parts found in the replac-
ment kit, and/or replacement coil.
2. Position core assembly with core spring into base
of manual operator body. Then install stem/
spacer sub-assembly into manual operator body
to engage with core assembly.
3. Reinstall stem retainer on body and stem/spacer
sub-assembly.
*Replacement Kit P/N 02250122-521
NOTE
See Figure 7-7.The spacer on the stem/spacer sub-
7.7.7 CONTROL PRESSURE REGULATOR (P/N
assembly must be outside of the stem retainer for 02250100-362) MAINTENANCE
external spring construction. Refer to Figure 7--8. Maintenance for this control
pressure regulator normally requires the replace-
ment of the internal diaphragm, o--ring, and dia-
4. Replace body gasket and install manual operator phragm gasket. Use replacement kit no.
assembly in valve body. Torque manual operator 02250122-521, and follow the procedure below for
body to 175 ± 25 in-lbs (19.8 ± 2.8 Nm). proper installation.
5. Replace solenoid base gasket and solenoid base
sub-assembly. Torque solenoid base sub-assem-
bly to 175 ± 25 in-lbs (19.8 ± 2.8 Nm). ! WARNING
DO NOT remove caps, plugs, and/or other compo-
nents when compressor is running or pressurized.
Figure 7-7 Solenoid Valve (P/N 02250044-392) Stop compressor and relieve all internal pressure
External Spring Type Solenoid- before doing so.
Spacer Location
NOTE
SPACER
When replacing parts, always visually inspect
those parts that are not included with the kit. If
these parts show wear, consult Sullair factory.

1. Loosen the locknut and turn the adjusting screw

counterclockwise until the inner spring tension is
relieved. The adjusting screw should turn freely
STEM when the spring tension is relieved.
RETAINER 2. Remove the spring chamber from the body to allow
access to internal parts.

33
Section 7
MAINTENANCE

3. At this time, remove the diaphragm assembly, dia- Figure 7-10 Blowdown Valve (P/N 02250119-178)
phragm gasket, adjusting spring and spring but-
ton from the spring chamber.
4. Discard the brass diaphragm gasket, and replace
it with the new gasket from the kit.
5. Discard the diaphragm assembly, and replace it
with the new diaphragm assembly from the kit.
6. Remove the body plug from the body to allow ac-
cess to the post assembly. Remove and discard
the o--ring on the plug.
7. Replace the o--ring with the new o--ring from the
kit.
8. Re--assemble the piston, post assembly, piston
spring, o--ring and body plug into the body portion
of the regulator. Use Figure 7-8 as a guide.
9. Re--assemble the spring button, adjusting spring,
diaphragm gasket and diaphragm assembly into
the spring chamber. Use Figure 7-8 as a guide.
10. Replace the body and spring chamber; tighten
the adjusting screw until tension is realized.
7.7.8 SUMP BREATHER FILTER MAINTENANCE
Refer to Figure 7--9. This filter (P/N 02250118--025)
prevents sump pressure build--up and traps oil aero-
sol emanating from the compressor stages and gear
box. It uses a fine, replaceable element P/N
02250118--258, which may be accessed as follows:
INSPECTION/REPLACEMENT OF ELEMENT * Repair Kit P/N 02250122-079
1. Unscrew filter from vent line.
2. Inspect or replace the element with the new filter. 7.7.9 OIL SUMP STRAINER MAINTENANCE
The suction line of the oil pump is fItted with a 100
Figure 7-9 Sump Breather Filter mesh, stainless steel strainer to protect its internals
(P/N 022500118-025) from foreign matter. To service the cleanable strain-
er, proceed as follows:
1. With package starter de--energized, remove
sump--to--oil pump hose and disconnect oil by-
pass hose.
2. Loosen/remove bolts/washers securing circular
cover plate to sump tank.
3. Remove cover plate and gasket away from sump
tank-- some 1/4” control tubing may have to be re-
moved to provide clearance.
4. Inspect, clean, and/or replace strainer.
5. Reassemble in reverse order.
7.7.10 BLOWDOWN VALVE MAINTENANCE
Refer to Figure 7-10. The blowdown valve (P/N
02250119-178) vents air to atmosphere in unload
mode. To maintenance the blowdown valve, follow
these directions:
1. Loosen/remove bolts/washers and nuts securing
cover to valve body.
2. Remove cover.
3. Remove diaphragm.
4. Replace diaphragm with new diaphragm.
5. Re-secure cover by re-positioning bolts, washers
and nuts. Tighten.
7.7.11 DRIVE COUPLING MAINTENANCE
Refer to Figures 7-11 and 7-12. The compressor unit
and motor are rigidly connected via a rigid adaptor
piece, thus the shafts are maintained in proper align-
ment at assembly. However, during the initial start--
*Replacement Element P/N 02250118-258 up, after transportation and installation, drive cou-

34
 Section 7
MAINTENANCE

Figure 7-11 Drive Coupling

pling alignment should be checked. For reference 4. Re--assemble in reverse order. Bolts must be re--
only, the allowable angular and parallel shaft mis- torqued to 30 ft.--lbs. (41 Nm) (dry). Please note
alignments are presented in Table 1 and Figure 7--12. that bolts have self--locking patches good for two
re--uses, but the application of a thread--locking
The only component requiring regular inspection or adhesive increases this number. DO NOT LU-
servicing is the coupling’s flexible element, which BRICATE BOLT THREADS!
may be accessed as follows: Please note that replacement of either shaft hub re-
quires the removal of the motor, an operation best
handled by Sullair personnel.
! DANGER
Disconnect all power at source before attempting Figure 7-12 Couping Alignment
maintenance or adjustments.

INSPECTION/REMOVAL OF FLEXIBLE ELE-

MENT
1. Loosen fasteners securing wireform guard to the
distance piece and remove to allow access to the
coupling assembly.
2. Loosen and remove all bolts securing each flexible
element half to the shaft hubs.
3. Inspect each element body for signs of tears or
separation away from the metal flanges -- if any
faults are found, elements must be replaced and
Sullair contacted for further assistance.

35
 Section 7
MAINTENANCE

Table 1- Installation Data

36
 Section 8
TROUBLESHOOTING

8.1 INTRODUCTION decrease of a dirty heat exchanger.

The following information has been compiled A detailed visual inspection should be per-
from operational experience with your package. formed for all problems. Always remember to:
It identifies symptoms and describes probable
causes for problems. However DO NOT assume 1. Check for loose wiring.
that these are the only problems that may occur. 2. Check for damaged piping.
3. Check for parts damaged by heat or an electri-
The collection of operational data concerning cal short circuit, usually apparent by discolor-
possible trouble should be analyzed to prevent ation or a burnt odor.
complete compressor breakdown. An example Should your problem persist after making the
of this would be the vibrations signature in- recommended check, consult your nearest Sull-
crease of a damaged bearing or the efficiency air representative or the Sullair Corporation.
8.2 TROUBLESHOOTING
SYMPTOM/MESSAGE PROBABLE CAUSE REMEDY

COMPRESSOR WILL NOT START; Main Disconnect Switch Open Close switch.
POWER LED OFF
Line Fuse Blown Replace fuse.
Control Transformer Fuse Blown Replace fuse.

MOTOR OL Motor Starter Overloads Tripped Reset after heater elements cool
down. Should trouble persist, check
whether motor starter contacts are
functioning properly.
Low Incoming Line Voltage Check voltage. Should voltage check
low, consult power company.

T--- 1, T--- 2, T--- 3 Temperature Transducer Failure Check connections from

T--- 4, T--- 5 FAIL transducer. If adequate, replace
transducer.

P--- 1, P--- 2, P--- 3 Pressure Transducer Failure Check connections from

P--- 4 FAIL transducer. If adequate, replace
transducer.

E--- STOP Emergency Switch Open Close switch (pull).

(Depressed)

COOL FLT Cooling Fan Motor Starter Overloads Reset after heater elements cool
Tripped down. Should trouble persist, check
whether motor starter contacts are
functioning properly.

COMPRESSOR SHUTS DOWN Motor Starter Overloads Tripped Reset after heater elements cool
WITH AIR DEMAND: down. Should trouble persist,
MOTOR OL check whether motor starter contacts
are functioning properly.(I)
Low Incoming Line Voltage Check voltage. Should voltage
check low, consult power company.

P2 LO The Machine Ran at a Final Discharge Adjust valve downstream of package to

Pressure Below 50 psig (3.4 bar) for hold minimum 70 psig (4.8 bar) line
five minutes pressure.

P3 LO Oil Pressure Falls Below 25 psig

(1.7 bar) While Package is Running
Because:
Oil Pump Malfunctioned Consult Sullair Service Dept.
Oil Filter Clogged Replace filter element.

(I) Also check that the compressor---motor driveline rotates freely. In case of rotating resistance or rubbing, contact
Sullair Service Department.

37
Section 8
TROUBLESHOOTING

8.2 TROUBLESHOOTING (CONTINUED)

SYMPTOM/MESSAGE PROBABLE CAUSE REMEDY

P3 LO (continued) Oil Pressure Falls Below 25 psig

(1.7 bar) While Package is Running
Because:
Oil Temperature Too Low Check state of globe valve feeding
oil cooler. In cold ambient envi---
ronments below 40_F (4_C) sump
heating may be required.
Sump Oil Level Too Low Replenish oil level.
Sump Strainer Clogged Refer to Section 7.7.5 for oil sump strainer
maintenance.

LO P1 P3 and/or dP Transducer at Fault Check connection from

transducer. If adequate, replace
transducer.

T1 HI LP Inlet Air Temperature Above Maintain inlet air temperature below

115_F (46_C) 115_F (46_C).
High Interstage Pressure (Loaded) Insufficient oil flow to jackets.
Air flow to intercooler.
Defective HP stage.

Cooling Fan Motor Starter Overloads Reset after heater elements cool
tripped down. Should trouble persist,
check whether motor starter
contacts are functioning
properly.

Temperature Transducer Failure Check connections from transducer

If adequate, replace transducer.
Blowdown Valve Failed to Open Refer to Component Manual for valve
or Operated Sluggishly maintenance.

T2 HI Intercooler Core Fouled Clean finning.

Discharge Check Valve Leaking Refer to compressor’s Operators Manual
During Unloaded Operation for check valve maintenance.

Inlet Throttling Valve Not Fully Open See inlet valve adjustment.
During Loaded Operation Low oil pressure defective control
solenoid valve.
Inlet Air Filter Clogged Refer to compressor’s Operators
Manual
for filter maintenance.
Line Pressure is Too High Reset Supervisor unload pressure.
Temperature Transducer Failure Check connection from trans---
ducer. If adequate, replace
transducer.
Blowdown Valve Failed to Open Refer to Component Manual for valve
or Operated Sluggishly maintenance.

P1 HI Defective HP Stage Consult Sullair Service Department.

Pressure Transducer Failure Check connection from trans---
ducer. If adequate replace
transducer.

P2 HI Blowdown Valve Failed to Open Refer to Component Manual for valve

maintenance.
Limit Switch Controlling Blowdown Check actuation and butterfly disc
Valve Failed to Operate See Section 7.7 for blowdown
valve maintenance.
Control Air Filter Clogged See Section 7.7 for control filter
maintenance.

38
 Section 8
TROUBLESHOOTING

8.2 TROUBLESHOOTING (CONTINUED)

SYMPTOM/MESSAGE PROBABLE CAUSE REMEDY

COOL FLT Cooling Fan Motor Starter Overloads Reset after heater elements cool down.
Tripped Should trouble persist, check whether
motor starter contacts are functioning
properly.
COMPRESSOR DOES NOT Air Demand Exceeds Supply Check air service lines for open
BUILD FULL DISCHARGE valves or leaks.
PRESSURE
Inlet Air Filter Clogged Check for maintenance message
on Supervisor II display. Change
element.
Inlet Air Valve Not Fully Open Check actuation and butterfly disc
position.
Low oil pressure defective control
solenoid valve.
Transducer P2 Malfunction Check connections from trans---
ducer. If adequate, replace trans---
ducer.
Blowdown Valve Leaking Refer to Component Manual for
or Sluggish valve maintenance.
Limit Switch Controlling BVD Failed Check limit switch and cam adjuster
to Operate on butterfly valve.

Defective LP Stage Consult Sullair Service Department.

LINE PRESSURE RISES ABOVE Blowdown Valve Failed to Refer to Component Manual for
UNLOAD SETTING Activate valve maintenance.
Inlet Throttling Valve Not Fully Open See inlet valve adjustment.
Limit Switch Controlling BVD Failed Check limit switch and cam adjuster
to Operate on butterfly valve.
Transducer P2 Malfunction Check connections from transducer.
If adequate, replace transducer.
Control Air Filter Clogged Refer to Component Manual for valve
maintenance. Check operation of limit
switch.

NOTE ON TRANSDUCERS: Whenever a sen- To enter calibration mode, you must press the
sor is suspected of fault, the recommended following keys in sequence: “LOGO”, DELTA,
cause of action is to measure the signal (pres- DSP, “ ”, PRG. Once in calibration mode, you
sure, temperature, etc.) with an alternate cali- will see a screen like the following: In the above
brated instrument and compare readings. If example, “0” refers to the amount of adjustment
readings conflict, the electrical and/or tubing (in psi or _F, “97” refers to the current value of
connections should be inspected, and if no P1).
faults are evident, then replace the sensor and
re---evaluate against the calibrated instrument.
CAL P1
8.3 CALIBRATION 0 97
The Supervisor II has software calibration of the
pressure and temperature probes. This calibra- To make adjustments, Press the “DELTA” key to
tion affects the offset but not the slope of the increase the value, press the “ ” key to de-
pressure and temperature calculations. Be- crease the value. The number on the left will in-
cause of this, the most accurate method is to crease or decrease always showing the total
heat or pressurize the transducer to its operating amount of adjustment. Maximum adjustments is
value. If this is too difficult, room temperature/ +/ ---7.
open atmosphere calibration is adequate. Cal-
ibration may only be done while machine is Other keys operate the same as in program
stopped and unarmed. mode. The “LOGO” key restores the original val-
ue of the current item. The “DSP” key exits, wip-
ing out changes to the current item, while saving
NOTE changes to any previous items. The “PRG” key
Calibration mode may be entered from the de-
saves the current item and advances to the next.
fault display mode when the machine is in Items following P1 calibration are (in order): P1,
“MANUAL” SHUTDOWN. P2, P3, P4, T1, T2, T3, T4 and T5 calibration.

39
 NOTES

40
 Section 9
ILLUSTRATIONS AND PARTS LIST
9.1 PROCEDURE FOR ORDERING PARTS
Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor
was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the ad-
dress, fax or phone numbers below.
When ordering parts always indicate the Serial Number of the compressor unit. This can be obtained from the Bill
of Lading for the compressor or from the Serial Number Plate located on the compres-
sor.
SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A.
Sullair Road, No. 1 Zone Des Granges BP 82
Chiwan, Shekou 42602 Montbrison Cedex, France
Shenzhen, Guangdong PRV. Telephone: 33--477968470
PRC POST CODE 518068 Fax: 33--477968499
Telephone: 755--6851686 SULLAIR CORPORATION
Fax: 755--6853473 Subsidiary of Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 1--800--SULLAIR (U.S.A. Only) or
1--219--879--5451
Fax: (219) 874--1273
Fax: (219) 874--1835 (Parts)
Fax: (219) 874--1205 (Service)

9.2 RECOMMENDED SPARE PARTS LIST

DESCRIPTION KIT NUMBER QUANTITY
ANNUAL MAINTENANCE SPARE PARTS:
element, primary replacement for air filter 048456 048462 1
element, secondary replacement for air filter 048456 048463 1
kit, repair for fluid filter 02250049--820 02250049--821 1
kit, control line filter element and seals for filter 02250112--032 02250112--031 1
element, oil sump breather 02250118--025 02250118--258 ‘1
lubricant, oil free compressor (5 gallons) 02250057--198 10 gal.
INSURANCE SPARE PARTS:
kit, control line filter element and seals for filter 02250112--032 02250112--031 1
kit, repair for V ---type strainer 241771 241772 1
replacement, buffer air silencer 250009--221 1
replacement, thermal valve 02250107--457 1
replacement, inlet control hydraulic cylinder 02250049--631 1
replacement, inlet differential vacuum switch 02250078--249 1
replacement, pressure transducer 02250078--933 2
replacement, heated RTD probe (T2) 02250119--594 1
replacement, heated RTD probe (T1, T3, T4, T5) 02250099--836 2
kit, repair for blowdown valve 02250119--178 02250122--079 1
replacement, blowdown silencer 405815--005 1
kit, repair for pressure regulator 02250100--362 02250122--521 1
kit, repair for inlet control solenoid valve 250025--516 02250053--334 1
replacment, coil for inlet control solenoid valve 250025--516 250031--431 1
kit, repair for condensate drain solenoid valve 02250044--392 02250044--391 2
replacement, coil for condensate drain
solenoid valve 02250044--392 250031--738 2
kit, repair for blowdown solenoid valve 02250119--220 02250119--221 1
replacement, coil for blowdown solenoid valve 02250119--220 02250120--659 1
replacement, oil sump strainer 02250105--982 1
replacement, drive coupling (various) consult factory 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR.

41
Section 9
ILLUSTRATIONS AND PARTS LIST
9.3 COMPRESSOR, MOTOR AND FRAME

42
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.3 COMPRESSOR, MOTOR AND FRAME

key part
number description number quantity

1 unit, compressor (I) 1

2 isolator, vibration 250042--757 4
3 guard, coupling 02250050--131 2
4 adaptor, motor/compressor 444/445 tsc 02250118--572 1
Sadaptor, motor/compressor 365/405 tsc 02250118--571 1
5 hub, coupling E--50 50mm 250042--754 1
6 element, coupling 406631 1
7 hub, coupling E--50 2.375 dia 407988 1
Shub, coupling 2.125 dia 407986 1
Shub, coupling 1.875 dia 250033--538 1
8 motor (I) 1
9 block, mounting 224511 (I)
10 frame 02250114--747 1
11 kit, replacement for drive coupling (I) 1

(I) Consult factory for information.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

43
Section 9
ILLUSTRATIONS AND PARTS LIST
9.4 AIR INLET SYSTEM

44
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.4 AIR INLET SYSTEM

key part
number description number quantity

1 filter, air 150/200 HP (I) 048456 1

Selement, filter primary 150/200 HP 048462 1
Selement, filter secondary 150/200 HP 048463 1
2 band, mounting 044248 1
3 adapter, inlet 6” 02250105--687 1
4 clamp, hose 7” 041992 1
5 elbow, rubber reducing 7” x 6” 049625 1
6 clamp, hose 6 1/2” 040305 1
7 gasket 040696 3
8 valve, butterfly 6” 040336 1
9 spacer, inlet 250026--509 1
10 support, inlet control valve 02250106--135 1
11 lever, inlet valve 02250106--137 1
12 rod, end spherical RH 5/16” 040136 1
13 cylinder, hydraulic 1 1/2” 02250049--631 1
14 rod, end spherical LH 5/16” 042004 1
15 spacer, tube 1/2” 02250106--136 1
16 hose, hydraulic 02250107--882 2
17 isolator, vibration 3/8”--16 02250106--601 2

(I) For maintenance on air filter no. 048456, order primary replacement element no. 048462, and secondary re-
placement element no. 048463.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

45
Section 9
ILLUSTRATIONS AND PARTS LIST
9.5 COOLER ASSEMBLY

46
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.5 COOLER ASSEMBLY

key part
number description number quantity

1 cooler, assembly 02250104--126 1

2 panel, LH fan box 02250105--470 1
3 plate, stiffener air box 02250107--842 2
4 panel, lower fan box 02250105--471 1
5 plate, venturi 40” 02250105--475 1
6 panel, RH fan box 02250105--472 1
7 panel, upper fan box 02250105--473 1
8 fan, 12 blade 40” 60hz 02250109--349 1
9 guard, fan 42” 02250107--833 1
10 motor, fan 7.5HP 460/60hz 02250108--627 1
11 support, motor 02250105--476 1
12 support, bracket HP hot ”I” 02250106--633 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

47
Section 9
ILLUSTRATIONS AND PARTS LIST
9.6 LP HOT & LP COLD

48
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.6 LP HOT & LP COLD

key part
number description number quantity

1 flange, 4” SAE 02250105--533 2

2 pipe, assembly LP hot flex 02250116--965 1
3 gasket, flange 240621--008 6
4 pipe, assembly LP hot 02250116--967 1
5 valve, relief 250042--766 1
6 u--bolt, 3” pipe 02250117--186 3
7 support, bracket “C” 02250107--479 3
8 isolator, vibration 3/8”--16 02250106--601 3
9 support, bracket LP hot 02250107--478 2
10 pipe, assembly hot 02250116--964 1
11 manifold, assy 3” x 8” 02250116--968 1
12 gasket, flange 4” 240621--010 2
13 pipe, assembly LP cold 02250105--262 1
14 pipe, assembly LP cold intermediate 02250107--547 1
15 pipe, assembly LP cold 02250105--263 1
16 pipe, assembly LP cold flex 02250106--468 1
17 support, bracket LP cold “L” 02250107--019 1
18 kit, insulation thermal pipe 02250115--573 1
19 heater, condensate trap interstage 02250114--688 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

49
Section 9
ILLUSTRATIONS AND PARTS LIST
9.7 HP DISCHARGE

50
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.7 HP DISCHARGE

key part
number description number quantity

1 flange, 3” SAE 02250105--534 2

2 pipe, assembly HP cold 2 1/2” 02250107--361 1
3 separator, water combo 2 1/2” 02250106--113 1
4 heater, condensate trap discharge 02250114--689 1
5 support, bracket turnbuckle 02250109--012 1
6 turnbuckle, 3/8” 02250108--460 1
7 pipe, assembly HP hot flex 02250119--267 1
8 isolator, vibration 3/8”--16 02250106--601 1
9 gasket, 3” 046120 4
10 pipe, assembly HP hot 02250119--269 1
11 silencer, blowdown 1 1/2” (I) 405815--005 1
12 valve, check 3” 02250108--623 1
13 silencer, air 02250117--406 1
14 pipe assembly, blowdown 02250118--646 1
15 valve, relief 1” 250042--767 1
16 support, bracket manifold 02250119--440 1
17 valve, blowdown 1 1/2” (II) 02250119--178 1
18 support, air filter 02250106--215 1
19 support, pipe assembly 02250117--561 1
20 kit, insulation thermal pipe 02250115--573 1

(I) For maintenance on blowdown silencer no. 405815--005, order replacment silencer no. 405815--005.
(II) For maintenance on blowdown valve no. 02250119--178, order repair kit no. 02250122--079.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

51
Section 9
ILLUSTRATIONS AND PARTS LIST
9.8 LUBE SYSTEM

52
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.8 LUBE SYSTEM

key part
number description number quantity

1 filter, oil (I) 02250049--820 1

2 orifice, set screw 3/4”--10 x .203 02250115--992 1
3 tee 02250110--549 1
4 hose, assembly flex 3/4” 02250108--308 2
5 hose, assembly flex 3/4” 02250107--874 2
6 valve, thermal 1” (II) 02250107--457 1
7 relief/bypass valve assembly 02250111--586 1
8 filter, sump breather (III) 02250118--025 1
9 hose, assembly flex 1” 02250107--873 1
10 hose, assembly flex 3/4” 02250107--875 1
11 plate, cover sump 02250106--159 1
12 gasket, cover plate 02250092--588 1
13 strainer, suction 1” 02250105--982 1
14 hose, assembly flex 1” 02250107--876 1
15 hose, assembly flex 3/4” 02250107--877 1
16 heater, sump 02250114--687 1
17 valve, ball 1/2” 047117 1
18 tank, oil sump 02250106--020 1
19 plug, glass oil level 1 7/8” 02250097--611 1
20 plug, fill 250042--628 1

(I) For maintenance on oil filter no. 02250049--820, order repair kit no. 02250049--821.
(II) For maintenance on thermal valve no. 02250107--457, order replacment valve no. 02250107--457.
(III) For maintenance on sump breather filter no. 02250118--025, order replacement element no. 02250118--258.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

53
Section 9
ILLUSTRATIONS AND PARTS LIST
9.9 ELECTRICAL BOX

54
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.9 ELECTRICAL BOX

key part
number description number quantity

1 tape, heat 407403 60 ft

2 box, junction heat trace 02250056--336 1
3 seal, heat trace end 02250056--337 2
4 sensor, temperature 02250118--769 1
5 receptacle, twistlock 02250116--384 1
6 socket, relay 250034--430 1
7 relay, phase monitor consult factory 1
8 supply, power
9 board, cam--lok consult factoy 1
10 starter, size 1 250021--836 1
Scontact, aux. 1 NC 250023--371 1
11 block, fuse 250023--290 1
12 transformer, universal 350 VA 02250083--190 1
Sfuse, primary 3.5 amp 250026--648 2
Sfuse, secondary 5 amp 250019--751 1
13 starter consult factory 1
14 disconnect 02250114--874 1
15 block, terminal 250041--102 26
Send, terminal block 250041--103 2
Sjumper, terminal 02250055--172 19
16 heater, enclosure 50W consult factory 1
17 breaker, circuit 120V 20A 02250116--385 1
18 transformer, 40VA 120--24 250016--280 1
19 bezel 02250089--302 1
Sgasket, bezel 02250090--872 1
20 light 250027--122 1
Slens, red 250027--113 1
21 plate, auxillary 02250086--265 1
Sgasket, auxillary plate 02250086--269 1
Sdecal, auxillary plate 02250116--128 1
22 switch, operator emergency stop 02250085--504 1
Sblock, contact 250027--125 2
23 Supervisor II, assy 02250112--897 1
Sgasket, Supervisor II 02250048--822 1
Sdecal, Supervisor II front 02250073--286 1
24 enclosure 02250108--859 1
25 door 02250109--465 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

55
Section 9
ILLUSTRATIONS AND PARTS LIST
9.10 CONTROL SYSTEM/ CONDENSATE DRAIN

56
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.10 CONTROL SYSTEM/ CONDENSATE DRAIN

key part
number description number quantity

1 valve, solenoid 2--way NC 1/4” (I) 02250044--392 2

2 strainer, V--type (II) 241771 2
3 valve, 3--way ball 044205 2
4 valve, check 1/4” 049905 2
5 support, bracket transducer 02250110--132 1
6 transducer, pressure (III) 02250078--933 4
7 switch, vacuum (IV) 02250078--249 1
8 valve, solenoid 4--way 1/4” (V) 250025--516 1
9 bracket, support pneumatic controls 02250110--131 1
10 filter, control 1/4” (VI) 02250112--032 1
11 gauge, 0--30 Bkm 1/4” 02250100--643 1
12 regulator, pressure (VII) 02250100--362 1
13 valve, relief 1/4” NPT 25# 02250100--731 1
14 valve, solenoid 1/4” 3--way (VIII) 02250119--220 1

(I) For maintenance on 2--way solenoid valve no. 02250044--392, order repair kit no. 02250044--391, and replace-
ment coil no. 250031--738.
(II) For maintenance on V--type strainer no. 241771, order repair kit no. 241772.
(III) For maintenance on pressure transducer no. 02250078--933, order replacement transducer no.
02250078--933.
(IV) For maintenance on vacuum switch no. 02250078--249, order replacement switch no. 02250078--249.
(V) For maintenance on 4--way solenoid valve no. 250025--516, order repair kit no. 02250053--334, and replace-
ment coil no. 250031--431.
(VI) For maintenance on control filter no. 02250112--032, order kit no. 02250112--031.
(VII) for maintenance on pressure regulator no. 02250100--362, order repair kit no. 0220122--521.
(VIII) For maintenance on 3--way solenoid valve no. 02250119--220, order repair kit no. 02250119--221, and re-
placement coil no. 02250120--659.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

57
Section 9
ILLUSTRATIONS AND PARTS LIST
9.11 CANOPY

58
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.11 CANOPY

key part
number description number quantity

assembly, enclosure (I) 02250114--748 1

(I) For replacement enclosure parts, consult factory with drawing part number shown on page 54.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

59
Section 9
ILLUSTRATIONS AND PARTS LIST
9.12 DECALS

60
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.12 DECALS

key part
number description number quantity

1 sign, warning sever fan 049855 2

2 sign, warning sever fan port 049965 2
3 sign, danger electrocution 049850 1
4 decal, warning auto start 250017--903 1
5 decal, voltage 460/3/60 international (I) 02250069--399 1
6 decal, rotation 250021--286 1
7 decal, fluid Mobil DTE 02250069--390 1
8 decal, earth ground 02250075--046 4
9 decal, protective earth ground 02250075--045 1
10 decal, PE designation 02250075--540 1
11 decal, warning auto start 041065 1
12 sign, danger air breathing 250027--935 1
13 sign, “food grade” lube 250003--144 1

(Continued on Page 63)

(I) Voltage decal varies with voltage of machine. To determine correct voltage decal, consult factory with serial
number of your machine.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

61
Section 9
ILLUSTRATIONS AND PARTS LIST
9.12 DECALS

62
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.12 DECALS

key part
number description number quantity

14 sign, warning ground fault 049852 1

15 decal, danger high voltage 042218 1
16 decal, electrical component ID 250038--457 1
17 decal, ISO 9001 02250057--624 1
18 decal, water drain 250022--810 1
19 decal, water in 250019--107 1
20 decal, water out 250019--108 1
21 decal, fork lifting 241814 4

(Continued on page 65)

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

63
Section 9
ILLUSTRATIONS AND PARTS LIST
9.12 DECALS

64
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.12 DECALS

key part
number description number quantity

22 sign, warning hot surfaces 407408 1

23 decal, electrocution hazard 02250077--472 1
24 decal, oil fill cap DS-13 02250115--652 1
25 decal, Supervisor II (I) 02250044--204 1

(I) For detailed view of decal no. 02250073-286, consult Section 5, Supervisor II, Figure 5-1.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

65
Section 9
ILLUSTRATIONS AND PARTS LIST
9.13 DECAL LOCATIONS

66
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.13 DECAL LOCATIONS

key part
number description number quantity

1 decal, oil fill cap DS-13 02250115--652 1

2 decal, fluid Mobil DTE 02250069--390 1
3 decal, fork lifting 241814 4
5 sign, warning sever fan port 049965 2
6 sign, warning sever fan 049855 2
7 decal, rotation 250021--286 1
8 sign, warning hot surfaces 407408 1

(Continued on page 69)

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

67
Section 9
ILLUSTRATIONS AND PARTS LIST
9.13 DECAL LOCATIONS

68
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.13 DECAL LOCATIONS

key part
number description number quantity

10 sign, warning sever fan 049855 2

11 sign, warning sever fan port 049965 2
12 decal, earth ground 02250075--046 4
13 decal, PE designation 02250075--540 1
14 decal, protective earth ground 02250075--045 1
15 sign, warning ground fault 049852 1
16 decal, danger high voltage 042218 1
17 decal, voltage 460/3/60 international (I) 02250069--399 1

(Continued on page 71)

(I) Voltage decal varies with voltage of machine. To determine correct voltage decal, consult factory with serial
number of your machine.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

69
Section 9
ILLUSTRATIONS AND PARTS LIST
9.13 DECAL LOCATIONS

70
 Section 9
ILLUSTRATIONS AND PARTS LIST

9.13 DECAL LOCATIONS

key part
number description number quantity

1 sign, danger electrocution 049850 1

2 decal, warning auto start 250017--903 1
3 decal, ISO 9001 02250057--624 1
4 decal, electrocution hazard 02250077-472 1
5 decal, warning auto start 041065 1
6 sign, “food grade” lube 250003--144 1
7 sign, danger air breathing 250027--935 1
8 decal, water drain 250022--810 1
9 decal, water in 250019--107 1
10 decal, water out 250019--108 1
11 decal, earth ground 02250075--046 4

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

71
Section 9
ILLUSTRATIONS AND PARTS LIST
9.14 WIRING DIAGRAM

72
NOTES
WORLDWIDE SALES AND SERVICE

SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A.

Sullair Road, No. 1 Zone Des Granges BP 82
Chiwan, Shekou 42602 Montbrison Cedex, France
Shenzhen, Guangdong PRV. Telephone: 33-- 477968470
PRC POST CODE 518068 Fax: 33 -- 477968499
Telephone: 755-- 6851686
Fax: 755 -- 6853473

SULLAIR CORPORATION
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 1 -- 800 -- SULLAIR (U.S.A. Only) or
1-- 219-- 879-- 5451
Fax: (219) 874 -- 1273
Fax: (219) 874-- 1835 (Parts)
Fax: (219) 874-- 1205 (Service)

Printed in U.S.A.
Specifications Subject To
Change Without Prior Notice
E00