TS32S Air Compressor Manual

DRAFT
STATIONARY SCREW COMPRESSOR

OPERATION & MAINTENANCE MANUAL
TS32S-400/450 & TS32S-500/600
SHENZHEN SULLAIR ASIA INDUSTRIAL CO.,LTD.
Part Number: 88290006-556

Date of Entry into Force: Mar. 2003
DRAFT
Thank you for choosing
stationary screw compressors
manufactured by
Sullair Asia Co., Ltd.
We hope various stationary screw compressors manufactured by Sullair Asia Co.,
Ltd. might bring expected functions into play during your work.
Before operating and maintaining the stationary screw compressor, please
familiarize yourself with this manual thoroughly.
At Sullair, we are committed to continuous product improvement. While all
attempt will be made to update the manual, Sullair reserves the right to make
changes to the product without prior notice.
Type of compressor: ____________________

Series number of compressor: ____________________
I
DRAFT
DRAFT
Preface
This manual describes in detail the structures, functions as well as
operation and maintenance method of each system of the TS32S-400/450 type
and TS32S-500/600 screw compressors.
Before installing and operating this machine, the customer shall read this
manual carefully. After fully understanding the structure and function of each
part of the machine set can they operate and maintain the unit.
Special fluid provided by Sullair Co. must be used. The mixing with other
fluid is strictly prohibited.
From time to time, the product is being redesigned to seek improvement.
After a certain period, there will be discrepancies between this manual and the
product itself. The customer should be aware of it.
For anything ambiguous that the customer meets during operation and
application and this manual does not cover, please contact the local agent or the
customer services of Sullair.
Editor
March 2003
I
II
DRAFT
III
CONTENTS
Preface
Chapter 1 Structure
1.1 General ……………………………………………………………………………………………1
1.2 Principal Machine …………………………………………………………………………………2
1.3 Air Inlet System ……………………………………………………………………………… 10
1.4 Discharge System …………………………………………………………………………………10
1.5 Air Fluid Separator ……………………………………………………………………………… 11
1.6 Fluid Piping System …………………………………………………………………………… 11
1.7 Water Piping System …………………………………………………………………………… 12
1.8 Air Volume Adjusting System ……………………………………………………………………12
Chapter 2 Installation
2.1 Foundation ……………………………………………………………………………………… 15
2.2 Vibration Absorption and Noise Reduction ………………………………………………………15
2.3 Air Intake and Outtake ………………………………………………………………………… 15
2.4 Ventilation …………………………………………………………………………………………15
2.5 Profile of Unit and Installation Drawing …………………………………………………………15
2.6 Air Supply Pipe ………………………………………………………………………………… 16
2.7 Motor Rotation Direction ……………………………………………………………………… 16
Chapter 3 Supervisor
3.1 Function of Supervisor …………………………………………………………………………21
3.2 Keypad …………………………………………………………………………………………21
3.3 Status Display …………………………………………………………………………………21
3.4 Indicator Lights …………………………………………………………………………………24
3.5 Parameters Setup ………………………………………………………………………………24
3.6 Operating Modes of Compressor …………………………………………………………………26
Chapter 4 Operations of Compressor

4.1 Regulations for Safety Operation ………………………………………………………………28
4.2 Initial Start-up Procedure ……………………………………………………………………28
4.3 Subsequent Start-up Procedure …………………………………………………………………28
IV
DRAFT
4.4 Shutdown ………………………………………………………………………………………28
Chapter 5 Maintenance
5.1 General ……………………………………………………………………………………… 29
5.2 Daily Maintenance …………………………………………………………………………… 29
5.3 Maintenance after Initial 50 Hours’ Operation …………………………………………………29
5.4 Maintenance after Every 1000 Hours’ Operation ………………………………………………29
5.5 Replacement of Fluid ……………………………………………………………………………29
5.6 Maintenance of Fluid Filter ………………………………………………………………………29
5.7 Maintenance of Air Fluid Separator …………………………………………………………… 30
5.8 Maintenance of Air Filter ……………………………………………………………………… 31
5.9 Maintenance of Pressure Regulator ………………………………………………………………31
5.10 Maintenance of Control Line Strainer ………………………………………………………… 32
5.11 Installation and Test of Coupling …………………………………………………………………32
5.12 Maintenance of Special Motors for Sullair Compressors …………………………… 34
Chapter 6 Schematic Circuit Diagram

6.1 Low-Voltage Unit Schematic Circuit Diagram …………………………………………………37
6.2 High-Voltage Unit Schematic Circuit Diagram …………………………………………………39
6.3 Schematic Circuit Diagram of Cooling Element of Air-Cooled Unit ……………………………41
Chapter 7 Trouble Shooting and Remedies

7.1 General ……………………………………………………………………………………………43
7.2 Possible Faults and Remedies ……………………………………………………………………43
7.3 Application of Transducers and Calibration of Supervisor Parameters …………………………45
Chapter 8 Commonly Used Spare Parts …………………………………………………45
V
TS32S-400~600 Series Screw Compressor Operation Manual Chapter 1 Structure
Chapter 1 Structure
1.1 General
This machine is a low-noise fluid-injection screw compressor for power purpose. It mainly
consists of a principal machine, a motor, air fluid separators, coolers and an electric control system.
Enclosed in an acoustical enclosure, all these parts are secured to a solid foundation, featuring
attractive appearance and easier serviceability.
Either air-cooled or water-cooled version is available to meet your specific requirements.
For main performance parameters of TS32S-400/450 units, see Table 1.
For main performance parameters of TS32S-500/600 units, see Table 2.
For the general arrangement diagram of TS32S-400/450 water-cooled units, see Figure 1.
For the general arrangement diagram of TS32S-500/600 water-cooled units, see Figure 2.
For the system chart of TS32S-400~600 water-cooled units, see Figure 3.
For the general arrangement diagram of TS32S-500/600 air-cooled units, see Figure 4.
For the system chart of TS32S-400~600 air-cooled units, see Figure 5.
Table 1 Main performance parameters of TS32S-400/450 units
Model 400L 400H 400HH 400XH 450L 450H 450HH 450XH

Nominal volume flow rate 61.7 57.1 49.8 47.2 65.9 65.9 57.1 49.8
m3/Minc (CFM) (2178) (2016) (1757) (1666) (2326) (2326) (2016) (1757)
Delivery rated pressure 7.0 8.0 10.0 12.0 7.0 8.0 10.0 12.0
bar (psi) (100) (116) (145) (175) (100) (116) (145) (175)
Popping pressure of pressure relief 9.0 10.0 12.0 14.0 9.0 10.0 12.0 14.0
valve (130) (145) (175) (200) (130) (145) (175) (200)
bar (psi)
Unit weight: kg (Lb) 8000(17640)
L×W×H mm 5010×2210×2130
Compressor principal machine
Type Fluid-injected twin-screw compressor
Configuration Two-stage gear drive
Bearing Wearproof
Fluid makes Sullube32 or 24KT
Fluid capacity (L) 210
Motor
Model Y3151-4/UYG4001-4 Y3152-4/UYG4002-4
Rated power kW(HP) 300(400) 338(450)
Rated speed rpm 1475/1487 1475/1487
Voltage/frequency 380V/6000V, 50Hz 380V/6000V, 50Hz
Coefficient of performance 1.15
Operating ambient temperature℃ ≤40
Startup mode Y-△ startup/direct startup
1
Table 2 Main performance parameters of TS32S-500/600 units
Model 500L 500H 500HH 500XH 600L 600H 600HH 600XH

Nominal volume flow rate 73 73 65 57.1 84.8 84.8 73 65.9
m3/Minc (CFM) (2577) (2577) (2295) (2016) (2993) (2993) (2577) (2326)
Delivery rated pressure 7.0 8.0 10.0 12.0 7.0 8.0 10.0 12.0
bar (psi) (100) (116) (145) (175) (100) (116) (145) (175)
Popping pressure of pressure 9.0 10.0 12.0 14.0 9 10 12 14
relief valve (130) (145) (175) (200) (130) (145) (175) (200)
bar (psi)
Unit weight: kg (Lb) 8700(19180) 96000(21160)
L×W×H mm 5010×2210×2130
Compressor principal machine
Type Fluid-injected twin-screw compressor
Configuration Two-stage gear drive
Bearing Wearproof
Fluid makes Sullube32 or 24KT
Fluid capacity (L) 210
Motor
Model UYG4003-4/Y4503-4 UYG4005-4/Y4505-4
Rated power kW(HP) 375(500) 450(600)
Rated speed rpm 1487/1500 1487/1500
Voltage/frequency 6000V/10000V, 50Hz 6000V/10000V, 50Hz
Coefficient of performance 1.15
Operating ambient temperature℃ ≤40
Startup mode Direct startup
1.2 Principal Machine

The principal machine is an important component in a compressor unit.
A pair of rotors engaged with each other are built in the principal machine, which, driven by a
motor, rotate rapidly. As the volume between teeth reduces continuously, the air taken in from the air
filter is continuously compressed, thus its pressure getting higher and higher. Meanwhile, fluid is
continuously injected into the working space of the principal machine for cooling, lubrication and
sealing purposes. When the intertooth volume gets through to the outlet of the principal machine, the
air fluid mixture is discharged from the outlet and enters the air fluid separator.
2
5 6 7 8
4
供气
1 进水
排水
排污
12 11 10
13 9
进水
排水
14 15 16 17
供气 air supply 进水 water inlet 排水 water outlet 排污 blowdown
Figure 1 general arrangement diagram of TS32S-400/450 water-cooled units
1. pedestal 2. acoustical enclosure 3. air fluid separator 4. pressure relief valve

5. air inlet control valve 6. air filter 7. moisture separator 8. discharge pipe 9.
motor 10. coupling 11. aftercooler 12. fluid cooler 13. principal machine 14.
fluid filter
15. electric control cabinet 16. fluid pipe 17. water pipe
3
供气
接断油阀
进水
排水
进水
供气、排污
排水
Figure 2 General arrangement diagram of TS32S-500/600 water-cooled units

5. air inlet control valve 6. air filter 7. discharge pipe 8. moisture separator 9. motor
10. coupling 11. aftercooler 12. fluid cooler 13. principal machine 14. fluid filter
15. fluid pipe 16. electric control box 17. water pipe
4
44 88290001-129 气缸
43 250038-666 SULLICON锁定电磁阀(2位3通常开）
8
42 -------- 压缩机
1/4”管
设定值随机型而异 41 250038-674 启动电磁阀(2位3通常开）
40 250014-656 真空开关
4 P2 23 39 02250058-087 喷油温度器探头
1/4”管 1/4”管
38 016742 停油阀
YV3 37 --------- 疏水阀
32 7 11
YV4 YV2 36 --------- 后冷器
3 1/4”管 8
1/4”管
43 1 1 35 --------- 油冷器
2 34 喷油压力传感器
250039-910
1”管 33 02250121-655 油过滤器
12 12 36 32 88290001-006 温控阀
9 13 CYL 13 CYL 19 31 250035-291 停水电磁阀(2位2通常闭)
6 IN IN 1”管
1/4”管
30 --------- 压缩机螺旋阀执行器
P P 37 29 --------- 分离罐排油堵头
28 --------- 分离罐油位计
4 27 --------- 油气分离器罐
1/4”管排水 26 --------- 分离罐安全阀
25 250039-909 分离罐温度探头
32 41 10 17 5/16”管
24 压缩机排气温度探头
250039-909
YV1 23 250039-910 管压传感器
30 5/16”管
1/4”管
1
1/4”管
22 02250109-320 二级分离元件
16 18 21 02250109-318 初级分离元件
3 20 250039-910 管压传感器
TS32S-400~600 Series Screw Compressor Operation Manual
19 88290004-421 最小压力阀
26
18 241771 回油管路过滤器
44 温度设置 17 046559 回油管路视液镜
压力设置为0.07MPa 16 027443 初级过滤器回油节流孔
42 15 P1 。
进气 1 24 T1 为113 C
2 14 15 250039-910 压力传感器
压缩机压缩机
第二级
T2 25 14 250017-992 低水压停机开关
第一级
27 22 13 040758 消声器
18 12 409783 放空阀
1 T4 20 28 21 11 250038-755 螺旋阀锁定电磁阀（2位3通常闭）
5 10 二次回油节流孔
40 29 040381
管 pipe 进气 air intake 真空度 vacuum degree 压力为 The pressure is

9 408275 螺旋阀压力调节器
压力为560 mmH2O 33 32 8 02250112-032 控制线路过滤器
38
真空度 B A 进水（接 7 250038-674 卸载电磁阀（2位3通常开）
34 P3
C 口G1-1/2） 6 406929 SULLICON压力调节阀
压力设置为0.07MPa T3 P4 35 H I
33 5 049905 单向阀
39 15 4 408893 往复阀
水路电磁阀(任选件) 出水（接 3 88290001-135 SULLICON
口G1-1/2） 2 041110 进气阀
YV6
Chapter 1
31 TS32S-500/600 1 88290004-371 空气滤清器

机型增加1个
H I 序号33元件序号代号名称
Structure
5
压力设置为 The pressure is set to 水路电磁阀(任选件) water piping solenoid valve (optional)
压缩机第一级 compressor primary stage 压缩机第二级 compressor secondary stage
机型增加 1 个序号 33 元件 models have an additional No. 33 element.
设置值随机型而异 the setting is model dependent. 温度设置为 The temperature is set to
排水 water outlet 进水 water inlet 接口 interface
序号 No. 代号 code 名称 designation 气缸 cylinder 锁定电磁阀 locking solenoid valve
2 位 3 通常开 3/2 way normally open 真空开关 vacuum switch
喷油温度器探头 probe of fluid-injected temperature sensor
停油阀 fluid stop valve 疏水阀 moisture separator 后冷器 aftercooler 油冷器 fluid cooler
喷油压力传感器 injection pressure sensor 油过滤器 fluid filter 温控阀 temperature control valve
停水电磁阀 water stop solenoid valve 2 位 3 通常开 3/2 way normally closed
压缩机螺旋阀执行器 compressor screw valve performer
分离罐排油堵头 casing cap for fluid discharge of separator tank
分离罐油位计 fluid level gauge of separator tank 油气分离器罐 air fluid separator tank
分离罐安全阀 pressure relief valve of separator tank 分离罐温度探头 temperature probe of separator
tank
压缩机排气温度探头 compressor air discharge temperature probe 管压传感器 pipe pressure sensor
二级分离元件 secondary separating element 初级分离元件 primary separating element
最小压力阀 minimum pressure valve 回油管路过滤器 fluid return piping filter
回油管路视液镜 fluid return piping sight glass
初级过滤器回油节流孔 fluid return orifice of primary filter 压力传感器 pressure sensor
低水压停机开关 low water pressure shutdown switch 消声器 muffler 放空阀 blowdown valve
螺旋阀锁定电磁阀 screw valve locking solenoid valve 2 位 3 通常关 3/2 way normally closed
二次回油节流孔 secondary fluid return orifice 螺旋阀压力调节器 screw valve pressure regulator
控制线路过滤器 control line strainer 卸载电磁阀 unload solenoid valve
2 位 3 通常开 3/2 way normally open 压力调节阀 pressure regulating valve 单向阀 check valve
往复阀 shuttle valve 进气阀 suction valve 空气滤清器 air filter
Figure 3 System chart of TS32S-400~600 water-cooled units
6
Figure 4 General arrangement diagram of TS32S-500/600 air-cooled units

5. discharge pipe 6. air inlet control valve 7. air filter 8. motor 9. coupling
10. principal machine 11. fluid pipe 12. fluid filter 13. electric control box
Note: the cooling system, not indicated in this figure, is installed independently.
7
8
47 043239 温度开关
46 046559 视液镜
45 042694 止回阀 1/2"
44 88290001-129 气缸
43 250038-666 SULLICON锁定电磁阀(2位3通常开）
8
42 -------- 压缩机
1/4”管
设定值随机型而异 41 250038-674 启动电磁阀(2位3通常开）
40 250014-656 真空开关
4 P2 23 39 02250058-087 喷油温度器探头
1/4”管 1/4”管
38 016742 停油阀
YV3 37 --------- 疏水阀
3 2 7 11
YV4 YV2 36 --------- 后冷器
3 1/4”管 8
1/4”管
1 1 35 --------- 油冷器
43 2 34 250039-910 喷油压力传感器
1”管 33 02250121-655 油过滤器
12 12 36 32 88290001-006 温控阀
9 13 CYL 13 CYL 19 31
6 IN IN 1”管
1/4”管
30 --------- 压缩机螺旋阀执行器
P P 37 29 --------- 分离罐排油堵头
28 --------- 分离罐油位计
4 27 --------- 油气分离器罐
1/4”管排水 26 --------- 分离罐安全阀
25 250039-909 分离罐温度探头
32 41 10 17 5/16”管
24 压缩机排气温度探头
250039-909
YV1 23 250039-910 管压传感器
30 5/16”管
1/4”管
1
1/4”管
22 02250109-320 二级分离元件
16 18 21 02250109-318 初级分离元件
3 20 250039-910 管压传感器
26 19 88290004-421 最小压力阀
18 241771 回油管路过滤器
44 温度设置 17 046559 回油管路视液镜
42 15 P1 。 16 027443 初级过滤器回油节流孔
进气 1 24 T1 为113 C
2 15 250039-910 压力传感器
压缩机压缩机
T2 25 14 040671 止回阀 2"
机型增加 1 个序号 33 元件 models have an additional No. 33 element.

第一级第二级 22
27 13 040758 消声器
18 21 放空阀
1 12 409783
28
管 pipe 进气 air intake 真空度 vacuum degree 压力为 The pressure is

T4 20
46 11 250038-755 螺旋阀锁定电磁阀（2位3通常闭）
5 10 二次回油节流孔
40 29 管线连接接口 040381
45 9 408275 螺旋阀压力调节器
33 32 14 客户安装管线
压力为560 mmH2O 38 8 02250112-032 控制线路过滤器
真空度 B A 7 250038-674 卸载电磁阀（2位3通常开）
34 P3 油管线
压缩机第一级 compressor primary stage 压缩机第二级 compressor secondary stage

C 6 406929 SULLICON压力调节阀
压力设置为0.07MPa T3 33 P4 油，气混合管线 5 049905 单向阀
39 15 4 408893 往复阀
气体管线
35 3 88290001-135 SULLICON
47 控制管线 2 041110 进气阀
压力设置为 The pressure is set to 水路电磁阀(任选件) water piping solenoid valve (optional)
TS32S-500/600 温度设置 1 88290004-371 空气滤清器
机型增加1个。
序号33元件为46 C 序号代号名称
设置值随机型而异 the setting is model dependent. 温度设置为 The temperature is set to

排水 water outlet 进水 water inlet 接口 interface
管线连接接口 piping connecting interface 客户安装管线 customer installed piping 油管线 fluid piping
油气混合管线 air fluid mixture piping 气体管线 air piping 控制管线 control line
序号 No. 代号 code 名称 designation 温度开关 temperature switch 视液镜 sight glass 止回阀 check
valve 气缸 cylinder 锁定电磁阀 locking solenoid valve
2 位 3 通常开 3/2 way normally open 压缩机 compressor 启动电磁阀 starting solenoid valve
真空开关 vacuum switch 喷油温度器探头 probe of fluid-injected temperature sensor
停油阀 fluid stop valve 疏水阀 moisture separator 后冷器 aftercooler 油冷器 fluid cooler
喷油压力传感器 injection pressure sensor 油过滤器 fluid filter 温控阀 temperature control valve
停水电磁阀 water stop solenoid valve 2 位 3 通常开 2/2 way normally closed
压缩机螺旋阀执行器 compressor screw valve performer
分离罐排油堵头 casing cap for fluid discharge of separator tank
分离罐油位计 fluid level gauge of separator tank 油气分离器罐 air fluid separator tank
分离罐安全阀 pressure relief valve of separator tank 分离罐温度探头 temperature probe of separator
tank
压缩机排气温度探头 compressor air discharge temperature probe 管压传感器 pipe pressure sensor
二级分离元件 secondary separating element 初级分离元件 primary separating element
最小压力阀 minimum pressure valve 回油管路过滤器 fluid return piping filter
回油管路视液镜 fluid return piping sight glass
初级过滤器回油节流孔 fluid return orifice of primary filter 压力传感器 pressure sensor
止回阀 check valve 消声器 muffler 放空阀 blowdown valve
螺旋阀锁定电磁阀 screw valve locking solenoid valve 2 位 3 通常关 3/2 way normally closed
二次回油节流孔 secondary fluid return orifice 螺旋阀压力调节器 screw valve pressure regulator
控制线路过滤器 control line strainer 卸载电磁阀 unload solenoid valve
2 位 3 通常开 3/2 way normally open 压力调节阀 pressure regulating valve 单向阀 check valve
往复阀 shuttle valve 进气阀 suction valve 空气滤清器 air filter
Figure 5 System chart of TS32S-400~600 air-cooled units
9
1.3 Air Inlet System
The air inlet system mainly consists of air filters and air inlet control valves. See the chart of the
air inlet system in the Parts Manual for reference.
The air filter functions to filter out impurities in the air, assuring only clean air entering into the
compressor.
The air inlet control valve is composed a butterfly valve and a cylinder regulator mechanism. The
butterfly valve functions to regulate air intake. When the unit runs in the full-load state, the butterfly
valve is completely open. When the customer needs less air, the cylinder regulator mechanism drives
the butterfly valve to reduce its opening, thus reducing air intake of the compressor. When the
customer stops using air, the butterfly valve is closed to stop taking air, and the compressor enters the
no-load operation state. When the customer resumes to use air, the regulator mechanism will reopen
the butterfly valve.
1.4 Discharge System

The discharge system mainly consists of a principal machine, an air fluid separator, a butterfly
valve, a check valve, pressure relief valves, blowdown valves, an aftercooler, a moisture separator and
connecting piping. See the chart of the discharge system in the Parts Manual for reference.
The compressed air after air fluid separation passes the butterfly valve, the check valve, the
aftercooler and the moisture separator, and is finally discharged for customer’s application. Here, the
butterfly valve functions like a minimum pressure valve. When the pressure in the air fluid separator
exceeds 0.35MPa (50PSI), the butterfly valve opens and the unit delivers air.
A standby flange is fixed at the outside of the moisture separator. Just connecting aφ114×6
(400/450 horsepower units) or 140×6 (500/600 horsepower units) seamless steel pipe with one end
machined into thread R4 or R5, the customer may divert the compressed air to the working site. The
customer shall fix a cutoff valve on the external line.
The moisture separator acts to separate the condensed water from the compressed air and
discharge it automatically.
There is a manual drain valve (1/2” ball valve) below the moisture separator. In case that the
automatic drain valve is blocked, the operator may use the manual drain valve to discharge the water.
But this is only an emergency measure. The operator shall clean the automatic drain valve in time to
recover the moisture separator’s automatic draining function.
When the compressor is not in use, the operator shall open the manual drain valve and let out the
water to avoid internal corrosion of the moisture separator.
The butterfly valve above the right side of the air fluid functions to ensure the pressure in the air fluid
separator not less than 0.35MPa and to make the fluid capable of flowing freely in the piping. The
check valve at the right side of the butterfly valve functions to prevent the air in the pipe network from
flowing backwards.
10
The automatic blowdown valve locates in front of the air filter at the left side. When the
compressor is unloaded or stops, the two blowdown valves open automatically to discharge air and
release pressure.
There are two pressure relief valves fixed to the air fluid separator. In order to ensure unit safety,
when the pressure in the separator exceeds the preset value, the pressure relief valves open
automatically, and discharge air to release pressure immediately.
This machine has also a high-pressure shutdown switch. When the pressure in the air fluid
separator reaches the preset value, the machine will stop automatically. So in normal operating state,
the pressure relief valves will not be opened.
1.5 Air Fluid Separator

The air fluid separator consists of two parts: tank and filter element. See the chart of air fluid
separator in the Parts Manual for reference.
The air fluid mixture coming from the outlet of the principal machine rotates at a high speed
along the outer barrel wall outside the filter element. Under the effect of centrifugal force, the fluid is
separated from the air and forms larger fluid drops. Because of their dead weight, most of the fluid
drops settle down at the bottom of the separator. In this way the air fluid separator brings into play its
functions as a primary separator and fluid tank.
Inside the tank there are two filter elements: the primary filter element and the secondary filter
element. The primarily separated air fluid mixture passes through the secondary filter element for
further fine separation, where the remaining small amount of fluid in the compressed air is separated
and accumulates at the bottom of the filter element. Then the fluid flows through the two fluid return
pipes and returns to the air inlet of the principal machine, and finally is sucked into the working space.
1.6 Fluid Piping System

The fluid piping system consists of a principal machine, an air fluid separator, a thermal valve, a
fluid filter, a fluid cooler and the connecting piping. See the chart of the fluid piping system in the
Parts Manual for reference.
The fluid in the air fluid separator enters the fluid cooler via the thermal valve. And the cooled
fluid enters the working space of the principal machine via the fluid filter, where it is compressed
together with the sucked air and discharged to the air fluid separator. Thus a cycle is formed.
The function of the fluid lies in three aspects:
(1) Cooling. The fluid injected into the machine body may absorb plenty of heat generated from
air compression, thus realizing the cooling function.
(2) Lubrication. The fluid creates a fluid film between the two rotors, avoiding direct contact of
the female and male rotors, hence to prevent wearing of the rotors’ mold surfaces.
11
(3) Sealing. The fluid with a certain viscosity may fill up the clearance between the two rotors
and the clearance between the rotor and the casing, thus reducing internal leakage loss and enhancing
the volume efficiency of the compressor.
There is a sight glass in the fluid return pipe for the operator to observe fluid return. When the
compressor is fully loaded, there should be a large flow. When the compressor is unloaded, there
should be a small flow, even zero flow. In case that the flow is cut off or very small when the
compressor is fully loaded, stop the machine, release the pressure and clean the fluid return filter.
1.7 Water Piping System (for water-cooled units)

The water piping system is mainly composed of a fluid cooler, an aftercooler and corresponding
piping. See the chart of the water piping system in the Parts Manual for reference.
Pay attention to the following points when configuring the external water piping system:
(1) The water inlet pipe is connected to the aftercooler. It is to say the air is cooled first, then the
fluid.
(2) To maintain a long-term good heat exchange effect for the cooler and to prolong the life of
the cooler, be sure to use clean cooling water.
(3) The temperature of the cooling water shall be less than or equal to 30℃. If it is higher than 32
℃, individual water inlet pipes shall be configured for air cooling and fluid cooling respectively. In
addition, series connection is not allowed.
(4) The water intake pressure shall be larger than or equal to 0.2MPa and smaller than 0.5MPa.
(5) When the water temperature is 27-29℃, the water consumption of the units is:
400/450 horsepower units: 20T/h;
500 horsepower unit: 24T/h;
600 horsepower unit: 29T/h.
(6) To avoid frost crack in winter, the water in the cooler shall be discharged when the machine is
not running. If the unit will not work for a long period of time, the water shall also be discharged.
1.8 Air Volume Adjusting System

The function of the air volume adjusting system is to automatically adjust the compressor’s air
intake according to the customer’s air consumption, so as to realize balance of supply and demand as
well as energy conservation.
When the customer’s air consumption equals to the delivery rated air volume flow, the unit will
run in a full load state. At this time, the butterfly valve for air intake control keeps at the maximum
opening, and the pointer of the screw valve will point to the maximum position (MAX). When the air
consumption is lower than the delivery rated air volume flow, the system will control the opening of
the butterfly valve automatically to reduce the air intake correspondingly. When the customer stops
using air, the butterfly valve closes automatically to stop air intake (in fact, small air intake is
maintained to keep the minimum pressure in the air fluid separator). At this time, the unit will run
12
under a fairly low backpressure. In no-load state, the pointer of the screw valve points to the minimum
position (MIN).
The function of the air volume adjusting system is described as follows in details in four different
states. See Figure 3 (water-cooled units) or Figure 5 (air-cooled units) system chart for reference.
(1) Starting phase (light-load starting process)
Press down the Start button to power on the solenoid valve of the cylinder air source. At this time,
the butterfly valve is at its initial position (5°-10°to horizon), letting a small mount of air entering
the compressor. And the motor, in Y connection, runs with light load.
After a preset period of time (generally 6 seconds), the motor shifts to △ connection. At the
same time, the solenoid valve controlling the cylinder air source is powered off; the compressed air
enters the cylinder to drive the butterfly valve open, and the unit enters the routine operation state.
(2) Routine operation
When the pressure in the air fluid separator exceeds 3.4bar(50PSI), the butterfly valves opens,
and the compressor begins air delivery. At this time, the butterfly valve keeps at its maximum opening,
and the pointer of the screw valve points to the MAX position. The unit runs in a full-load state. As
long as the pressure in the system does not exceed 7.0bar(100PSI), this state will go on.
(3) Air volume adjustment
If the customer’s air consumption is less than the delivery rated air volume flow of the unit, the
pressure in the system will increase. When the pressure exceeds 7.0bar(100PSI), the pressure regulator
that controls the screw valve will act and control the air entering the screw valve. As the rack driving
the valve core, a part of discharge air flows to the air inlet by pass, thus reducing the air delivery of the
unit. The smaller the air consumption, the wider the opening of the screw valve will become. If the
customer’s air consumption is 50% of the delivery rated air volume flow, the pressure in the system
will reach 7.4bar(100PSI). At this time the opening of the screw valve reaches its maximum point. It
can be seen from outside that the pointer of the screw valve pointing to MIN (minimum). So the screw
valve’s adjustable range of air volume is 100%-50% of the rated air volume flow, and the
corresponding system pressure is 7.0-7.4bar. The pointer of the screw valve also moves from MAX to
MIN.
If the customer’s air consumption is less than 50% of the delivery rated air volume flow of the
unit, the pressure in the system will exceed 7.4bar. At this time, the pressure regulator that controls the
air intake regulator (Sullicon) will act and control the air entering the air intake regulator. The air
intake regulator will act and drive the butterfly valve via the cylinder to reduce its opening and further
reduce the air intake volume. If the air consumption reaches 40% of the delivery rated air volume flow,
the pressure in the system will increase to 7.6bar. So the adjustable range of air volume of the air
intake regulator (Sullicon) is 50%-40% of the rated air volume flow, and the corresponding system
pressure is 7.4-7.6bar.
In this process, the pointer of the screw valve always points to MIN.
(4) Unload operation
13
If the customer’s air consumption is less than 40% of the delivery rated air volume flow of the
unit, the pressure in the system will exceed 7.6bar. At this time, the supervisor (Supervisor) cuts off
the power of the load solenoid valve, and controls the air entering the intake regulator (Scullion) and
the blowdown valve. With the effect of the cylinder the intake regulator closes the butterfly valve and
stops air intake. At the same time, the blowdown valve opens to let out the compressed air in the
separator, thus reducing the pressure to 2.1-3.4bar. At this time, the minimum pressure valve closes to
separate the customer piping from the unit. The unit will run in a no-load state under a fairly low
backpressure, so as to reduce energy consumption.
If the air consumption increases, the pressure in the piping will decrease. When the pressure is
lower than 7.0bar(100PSI), the supervisor will turn on the power of the load solenoid valve; the air
intake regulator and the screw valve will return to their initial places; the pointer of the screw valve
will point to MAX; and the unit will enter the full load operating state again.
14
TS32S-400~600 Series Screw Compressor Operation Manual Chapter 2 Installation
Chapter 2 Installation
2.1 Foundation
The foundation for installation of the compressor should be solid and flat. To avoid unit noise
leaking out from gaps, the unit must be installed horizontally and close to the ground.
2.2 Vibration Absorption and Noise Reduction

To reduce vibration resulted from unit operation and to avoid noise leaking out from gaps, it is
recommended that the customer place a cycle rubber plate under the pedestal. It should be 5-6mm
thick and 80mm wide.
2.3 Air Intake and Outtake

To make it easier for the customer to connect an external air pipe, the machine’s air inlet and
outlet are both configured in the top cover of the acoustical enclosure.
To enhance the compressor’s air intake performance and to improve the working environment of
the compressor room, the customer should connect the air inlet and outlet to outdoor with pipes. The
top cover has hole sites for external pipes.
To reduce ventilation resistance, the section of the intake pipe shall be ≥0.41M2, equivalent to a
φ725mm barrel. A wire netting is placed at the air inlet to prevent taking in harmful objects like birds,
rats and insects.
The section of the outtake pipe shall be ≥0.3M2, equivalent to a φ600mm barrel. To reduce
ventilation resistance, the shorter the intake and outtake pipes the better (less than 5m).
2.4 Ventilation and Cooling

To assure normal operation of the compressor, the machine room must has good ventilation. The
indoor temperature shall be no higher than 40℃; the compressor shall be at least 1m away from the
wall; and the top cover shall be at least 1.5m away from the ceiling.
2.5 Profile of Unit and Installation Drawing

For the installation drawing of TS32S-400/450 water-cooled units, see Figure 6.
For the installation drawing of TS32S-500/600 water-cooled units, see Figure 7.
For the installation drawing of TS32S-500/600 air-cooled units, see Figure 8.
For the installation drawing of the cooling element of TS32S-500/600 air-cooled units, see Figure
9.
The customer may design and construct the piping system, including fluid piping and air piping
between the TS32S-500/600 air-cooled units and the cooler. Sullair’s agents and service departments
offer consultation services.
１５
2.6 Air Supply Pipe

A standby flange is installed at the outside of the moisture separator of the TS32S-400/450
water-cooled units. Its external thread is Rc4. Just screwing a φ114×6 steel pipe with an R4 end into
the flange, the customer may divert the compressed air out of the machine. The user shall also fix a
cutoff valve on the external line.
A standby flange is installed at the outside of the moisture separator of the TS32S-500/600
water-cooled units. Its external thread is Rp5. Just screwing a φ140×6 steel pipe with an R5 end
into the flange, the customer may divert the compressed air out of the machine. The user shall also fix
a cutoff valve on the external line.
2.7 Motor Rotation Direction

When the unit is powered on, it is necessary to check if the rotation direction of the motor is
identical to the mark on the protective enclosure of the coupling.
Follow the procedure below to check.
Pull out the Emergency Stop button on the supervisor panel, then press the ‘I’ (Start) button, then
immediately the ‘O’ (Stop) button, to run the motor for a while. If the rotation direction of the motor is
identical to the arrow direction marked on the protective enclosure of the coupling, it denotes that
wiring is correct. If not, cut off the power and exchange any two of the three power input leads. Then
try again.
No reversed rotation is allowed!
１６
排污接口
进水
外接进出水管 60X4
外接螺纹Rp4
外接螺纹2-G2
外接供气管
排水
可更换油气分离芯
打开此盖，
风
排风管外接
排
电控柜
380V机组电源进线
（顶盖进线）
机组电源进线
（地沟进线）
风
进
吸风管
外接
进水
排水
供气
外接供气管 external air supply pipe 外接螺纹 external thread 外接出水管 external water outlet pipe 进水 water inlet 出水 water
outlet 排污接口 Blowdown interface 供气 air supply 排风 air discharge 电控柜 electrical control cabinet 机组电源进线 unit power
supply coil-in 地沟进线 coil-in from trench 顶盖进线 coil-in from top cover 打开此盖，可更换油气分离芯 Remove this cover to
replace air fluid separator element. 排风管外接 air discharge pipe external connection 吸风管外接 air inlet pipe external connection
Figure 6 Installation drawing of TS32S-400/450 water-cooled units
１７
外接螺纹Rp5
排污接口
外接供气管
外接进出水管 76X3
外接螺纹2-G2-1/2
打开此盖，
排风
排风管外接
电控柜
（地沟进线）
电源进线
风
进
吸风管
外接
供气
进水
排水
外接供气管 external air supply pipe 外接螺纹 external thread 外接出水管 external water outlet pipe 进水 water inlet 出水 water
outlet 排污接口 Blowdown interface 供气 air supply 进风 air inlet 电控柜 electrical control cabinet 机组电源进线 unit power
supply coil-in 地沟进线 coil-in from trench 顶盖进线 coil-in from top cover 打开此盖，可更换油气分离芯 Remove this cover to
replace air fluid separator element. 排风管外接 air discharge pipe external connection 吸风管外接 air inlet pipe external connection
Figure 7 Installation drawing of TS32S-500/600 water-cooled units
１８
吸风管外接
进风
（地沟进线）
电源进线
监控器
外接进出油管 73X3.5
排风管外接
排风
外接螺纹Rp5
外接供气管
打开此盖，
排风 air discharge 外接供气管 external air supply pipe 外接螺纹 external thread 外接进出油管 external fluid inlet and outlet pipes
进风 air outlet 监控器 supervisor 机组电源进线 unit power supply coil-in 地沟进线 coil-in from trench 打开此盖，可更换油气
分离芯 Remove this cover to replace air fluid separator element. 吸风管外接 air inlet pipe external connection
Figure 8 Installation drawing of TS32S-500/600 air-cooled units
１９
B向
interfaces
２０
代号 code
B 向
0 形环 O-ring
1 2 3 4 5 6 7 8 (4) (5) (6)
Figure 9
冷却器排风冷却器排风
9
10
11
B 12
13
14
15
20
16
(8)
(4)
(5)
(6)
blowdown joint 疏水阀 moisture separator

19 18 17
A-A视图
法兰 flange 油冷却器 fluid cooler 后冷却器 aftercooler

20 88290005-174 转接法兰 2
19 88290002-270 管夹 2
18 88290001-041 排污管 1米 PVC塑料软管
17 88290001-040 排污接头 2 H62
16 88290002-435 球阀 1/2" 1
15 88871015-008 内接头 1/2" 1 KTH330-08 GB3289.26-82
14 02250111-238 疏水阀 DN100 2
13 88832016-041 弹簧垫圈 16 32 65Mn GB93-87
12 88821016-148 螺母 M16 32 8 GB6170-86
11 88811016-060 螺栓M16x60 32 8.8 GB5782-86
10 88842035-132 O形圈 132X3.55 4 氟橡胶 GB3452.1-82
9 88290004-901 外接法兰 2 Q235-A
8 88842035-109 O形圈 109X3.55 4 氟橡胶 GB3452.1-82
7 88290005-175 法兰 3" 2 Q235-A
6 88821020-180 螺母 M20 48 8 GB6170-86
3/4”NPTF 放油接口8处 5 88832020-050 弹簧垫圈 20 48 65Mn GB93-87
3/4”NPTF 排空气接口8处外接进油管
Chapter 2
B view 冷却器排风 cooler air discharge 排空气接口 8 处 8 air discharge interfaces 放油接口 8 处
4 88811020-080 螺栓 M20X80 48 8.8 GB5782-86
钢管? 73X3.5 3 88842035-085 O形圈 85X3.55 2 氟橡胶 GB3452.1-82
外接进气管 2 88290005-173 法兰 2-1/2" 2 Q235-A
钢管? 89X4 1 02250132-376 油冷却器/后冷却器 1 MCI
序号代号名称数量材料备注
Installation drawing of the cooling element of TS32S-500/600 air-cooled units

Installation
8 fluid outlet
名称 designation 数量 quantity 材料 material 备注 remarks 转接法兰 adapter flange 管夹 clamp 排污接头

球阀 ball valve 内接头 inner joint 弹簧垫圈 spring washer 螺母 nut 螺栓 bolt
PVC 塑料软管 PVC hose 氟橡胶 fluorine rubber
A-A 视图 A-A view 外接进气管 external air inlet pipe 钢管 steel pipe 外接进油管 external fluid inlet pipe 序号 No.
TS32S-400~600 Series Screw Compressor Operation Manual Chapter 3 Supervisor
Chapter 3 Supervisor
3.1 Function of Supervisor

This machine has a perfect SupervisorⅡsupervisor and other control elements. To assure normal
operation of the unit, the operator must be familiar with the significations of various marks on the
supervisor panel and can perform correct judgment on the displayed parameters and signals.
The temperature, pressure, running time and status of the unit can be displayed on the LCD of the
supervisor. The operator may use the keypad on the supervisor panel to control the compressor, set the
control parameters and display expected parameters. The indicator lights in the system drawing denote
the positions of each display parameters (See Figure 10). Flashing indicator lights denote alarm.
3.2 Keypad
Stop --- to stop the machine manually and clear alarm signals.
Manual --- to start the unit when there is no alarm signal, and to select the manual operating
mode. If the unit is running, it may clear alarm signals.
Automatic --- to start the unit when there is no alarm signal and to select the automatic
operating mode.
Display --- to display pressure, temperature and other status parameters.
Sullair’s trademark --- to be introduced in a later section.
Program --- to enter the programming mode. It may be used to modify some control
parameters. See Parameters Settings for detail.
Up arrow --- to change display item in the status display mode, or to increase values in the
parameter setting mode.
Down arrow --- to change display item in the status display mode, or to decrease values in the
parameter setting mode.
3.3 Status Display

The display displays two lines of data by default, the upper indicating the current status of the
unit, and the lower indicating pipeline pressure P2 and air discharge temperature T1.
The following are system modes that may be displayed. Unit: temperature: ℃, pressure: bar.
(You may also choose oF, PSI in the English system. If you do so, the display values will change
correspondingly. See Units Settings in the Parameters Settings section.)
※ STOP--- the machine is stopped.
※ STANDBY--- The machine is stopped temporarily. The unit may enter this state in case of
power off or when the unload timer is acting. Note: in this state the machine may start at any moment.
※ STARTING --- The machine is starting.
※ OFF LOAD --- The machine is running but does not deliver compressed air.
※ ON LOAD --- The machine is running and delivering compressed air.
２１
※ FULL LOAD --- The machine is running with 100% load. This state is only displayed in
online control if it is equipped with a full load valve.
※ RMT STOP --- Remote stop, the unit is stopped and stands by. The machine will start when
the remote start contact is closed. Note: in this state the machine may start at any moment.
Figure 10 Supervisor panel
※ SEQ STOP --- The unit is stopped. When the sequential control conditions are met, the
machine will restart. Note: in this state the machine may start at any moment.
This default display is as follows:
２２
STOP
7.6 82
If there are fault signals, they will appear alternatively, each screen taking 2 seconds. The fault
display is as follows:
T1 H1
7.6 82
To view other status parameters, press the DISPLY key. At this time, temperature, pressure, operating
time and other parameters can be displayed. The customer may use the up arrow and down arrow keys to
select the parameter to be displayed. To display the last screen, press the up arrow; to display the next
screen, press the down arrow. To return to the default display presses the DISPLAY key.
※ Separator differential pressure(△p1) and the maximum limit (MAX):
△P1 0.3
MAX 0.7
If △P1 is larger than MAX, the supervisor will give out an alarm signal.
※ Air fluid separator pressure P1 and pipeline pressure P2:
P1 7.8
P2 7.4
※ Compressor air discharge temperature and the maximum limit MAX:

T1 99
MAX 118
If the discharge temperature exceeds MAX, the supervisor will give out a Stop signal and display
T1HI.
※ Total hours that the compressor has been running (hours):
HRS RUN
001234.0
※ Total hours that the compressor has been loaded (hours):

HRS LOAD
00987.0
※ The last fault signal --- to record the fault alarm and the total running hours till the moment
the last fault occurred:
T1 HI
@1 234
※ The last but one fault signal --- to record the fault alarm and the total running hours till the
moment the last but one fault occurred:
２３
T1 HI
@2 204
3.4 Indicator Lights
There are 11 indicator lights on the supervisor panel. Press the “ ” key to see the running
states of the indicator lights. All lights will light for 3 seconds. If not, the corresponding light is failed.
The function of each indication light is as below:
P1- Pressure in the separator. If the lighting is steady, P1 and its value will be displayed; if it
flashes, it denotes that the controller has given out an alarm.
P2- Pipeline pressure. If the lighting is steady, P2 and its value will be displayed; if it flashes, it
indicates that the controller has given out an alarm.
T1 – Principal machine discharge temperature. If the lighting is steady, T1 and its value will be
displayed; if it flashes, it indicates that the controller has given out an alarm.
T2 – Dry side discharge temperature. If the lighting is steady, T2 will be displayed; if it flashes, it
indicates that the controller has given out an alarm.
△P1- Separator differential pressure. If the lighting is steady, △P1 and its value will be
displayed; if it flashes, it represents that the filter element must be replaced.
△p2 – Fluid filter differential pressure. If the lighting is steady, △P2 and its value will be
displayed; if it flashes, it indicates that the fluid filter element must be replaced.
MOTOR— Motor overload indicator light. If it flashes, it indicates that the motor overload
contact has been disconnected.
POWER – Power supply indicator light. It lights if 120V AC power is applied to the supervisor.
ON – Operation indicator light. If the lighting is steady, the unit is running. If it flashes, it
denotes that the compressor is temporarily suspended and may start at any moment. Remote stop or
sequential stop can make the unit enter the suspended state.
AUTO—Auto operation indicator light. If the lighting is steady, the unit is running automatically.
If it flashes, it denotes that the compressor is temporarily suspended and may start at any moment.
INLET FILTER – Air filter indicator light. If it flashes, it denotes that the air filter needs to be
maintained.
FLUID FILTER -- if flashing denotes the maintenance of fluid filter is needed.
3.5 Parameters Setup

Operating parameters must be set in advance before the compressor is started.
Press the ‘PROG’ button, the supervisor will enter the ‘program’ mode in which some parameter
settings may be modified. For reset, press the up arrow key or the Sullair mark key to increase the
parameter value; or press the down arrow key to decrease the value. The parameter’s increment step is
10 when the Sullair mark key is pressed.
The parameters are displayed in the following sequence:
２４
※ Unload pressure – if the value is set to 7.6bar, the unit will unload when the line pressure is
above the 7.6bar:
UNLD
6.9 bar
※ Load differential pressure - difference between load pressure and unload pressure. If the
unload pressure is set to 7.6bar and the load differential pressure is set to 0.7bar, the machine will load
when the pipeline pressure is below 6.9bar.
LOAD
0.7 bar
※ P1 MAX - the maximum separator pressure. If the pressure in the separator exceeds this value,
the supervisor will instruct the machine to shut down and an alarm signal will be displayed.
P1 MAX
9.3 bar
※ Y-△conversion time (second) – it is set to 0 if a full voltage starter is used.
WYE DELT
10SEC
※ Restart time – time necessary for the unit to start after the power is switched on. It may be
used to avoid all the machines starting at the same time can be avoided, or to make the unit start after
other equipment has been started. Without this parameter, the machine will not start automatically
when the power is switched on again.
RST TIME
10SEC
※ Unload time (minute) - In AUTO operating mode, the machine will stop automatically when
the no-load run time exceeds the set value. Note: if the parameter is set to a value lower than 15
minutes (say 5 minutes), since the unit has a timer used to limit the start times within an hour to 4, the
no-load run time before the machine stops may exceed the set value (5minutes).
UNLD TIM
15Min
※ Language – display language, English, Spanish, French, German and Italian are available.
LANGUAGE
ENGLISH
※ Unit -- Metric and English systems are available.

UNITS
ENGLISH
２５
※ Unit number – to determine the serial number of serial communication or that of sequential
control.
COM ID#
1
※ Communication baud rate – to set the baud rate of data transmission in serial communication.
Four rates, 1200, 2400, 4800 and 9600 are available.
BAUDRATE
9600
3.6 Operating Modes of Compressor
The compressor may operate in any of the following modes:

(1) Manual operating mode
Press the “I” key to start the compressor. The compressor will be set to the manual operating
mode.
If the compressor is running in the auto operating mode, press the “I” key, the compressor will
shift to the manual mode from the auto mode. If the compressor is already running in the manual mode,
press the “I” key, the alarm signal will be cleared, and the indicator light will go out.
To shut down the compressor, press the “O” key.
If the compressor is already stopped, press the “O” key, the alarm signal will be cleared, and the
indicator light will go out.
No matter what mode the compressor is in, press the “O” key, the supervisor will be set to the
manual mode.
(2) Automatic operating mode
Press the “ ” button to start the compressor. It will be set to the automatic operating mode.
If the compressor is in the manual operating mode, press the “ ” button, the compressor will
shift to the automatic mode.
If the compressor is in the automatic operating mode, press the “ ” button, the alarm signal
will be cleared and the indicator light will go out.
Press the “O ” button in the automatic mode to stop the compressor. The supervisor will be set to
the manual stop state.
(3) Sequential control mode
The following is a brief description of the sequential control. For details see the Supervisor II
Sequential Control and Communication Protocol Manual (P/N: 02250057-696).
※ Suspend – It responds to inquiry commands, may return unit status and parameter information,
but does not respond to Start, Stop, Load and Unload commands of the host (computer).
２６
※ Remote Control - It responds to inquiry commands, may return unit status and parameter
information, but does not respond to Start, Stop, Load and Unload commands of the host (computer).
This state allows remote input and output (start/stop, load/unload, master/local).
※ Slave -It responds to all commands. But it should be noticed that in this mode if no command
from the host is received, the slave will not start or load. The slave is under the supervision of the host
(computer).
※ Sequential Time – Basically the status information is sent once every one second. The unit is
controlled (start, load or unload) according to the sequential time.
COM ID#- Basically the status information is sent once every one second. The unit is controlled
(start, load or unload) according to the unit serial number (COM ID#).
２７
TS32S-400~600 Series Screw Compressor Operation Manual Chapter 4 Operation of Compressor
Chapter 4 Operations of Compressor

4.1 Regulations for Safety Operation
To avoid physical injuries as well as damage of machine, the customer shall make detailed safety
regulations. The following safety regulations are offered as reference.
(1) Only those who have been trained and delegated to do so, and who have read and understood
this manual should operate the compressor.
(2) Install, use and operate the compressor only in full compliance withal pertinent regulations
and applicable national and local laws and regulations.
(3) DO NOT modify the compressor and/or controls in any way except with factory’s written
approval.
(4) Immediately stop the machine and disconnect all power if anything is abnormal during the
operation.
(5) Avoid inflammable, explosive, toxic and irritating gases in the surrounding.
(6) Shut off, release pressure, and disconnect all power before modify and maintain the machine.
4.2 Initial start-up procedure

(1) Set up parameters according to Section 3.5 “Parameters Setup”;
(2) Make sure the electrical wiring is safe and secure;
(3) Fill fluid into the separator until the fluid level is around the middle of the sight glass;
(4) Connect to water piping (for water-cooled units);
(5) Open the discharge break valve;
(6) Switch on the power supply and jog motor to check if the rotation direction of motor is
identical to the arrow direction marked on the coupling enclosure. Make rewiring if necessary;
(7) Restart the compressor and slowly close the shutdown valve to check if the unload pressure
conforms to the setting. If it not, reset it;
(8) Check for possible leaks in piping and any abnormal noise;
(9) Open the discharge break valve;
(10) Stop the machine.
4.3 Subsequent Start-up

After initial start up test on your newly bought machine, proceed with the subsequent start up
procedure as following: before starting it, check the proper level first, and simply press the “I” button
(manual mode), or the “ ” button (auto mode) to start the machine.
4.4 Shutdown
To shutdown the compressor, simply press the “O” button.
２８
TS32S-400~600 Series Screw Compressor Operation Manual Chapter 5 Maintenance
Chapter 5 Maintenance
5.1 General
The maintenance program for air compressor is quite minimal. The Supervisor monitors such
parts as the air filter, the fluid filter and air fluid separator and once fault is found it sends signal for
maintenance by indicator lights on the panel.
5.2 Daily Maintenance
Prior to starting the compressor, it is necessary to check the fluid level. Should the level be low,
add the necessary amount of fluid. After starting, check the correctness of each reading. After the
compressor has been warmed up, check for leakage or abnormal noise.
5.3 Maintenance after Initial 50 Hours’ Operation

After the initial 50 hours’ operation, minimum maintenance must be made to eliminate
contaminant:
(1) Clean the return line filter;
(2) Clean the return line orifice.
(3) Change the fluid filter element.
(4) Clean the control line strainers.
5.4 Maintenance after Every 1000 Hours Operation

(1) Clean the return line filters;
(2) Change the fluid filter element.
5.5 Replacement of Fluid

The fluid added to the compressor is SULLUBE 32 fluid. Fluid should be changed under any of
the following conditions:
(1) After every 8000 hours’ operation;
(2) Once a year;
(3) Analysis shows that it is necessary.
For 24 KT units, fluid needs to be changed only as indicated by fluid analysis or when the fluid is
polluted.
5.6 Maintenance of Fluid Filter

For structure of the fluid filter, refer to Figure 11.
The operator shall maintain the filter or replace the filter element in time if necessary when the
supervisor sends filter maintenance signals (the △P2 flight on the panel flashes). The maintenance
should be performed as follows:
(1) Use a strap wrench to remove the filter element and the O-ring;
２９
(2) Clean the seal surface;

(3) Apply a film of clean compressor fluid on the O-ring of the new element;
(4) Replace and tighten the new element;
(5) Restart machine and check for leaks.
Note: no other product other than Sullair filter elements may be used.
顶盖螺栓
滤芯压板
二级滤芯
一级滤芯
Figure 11 Fluid filter assembly Figure 12 Air fluid separator

Spare part number of filter element: Spare part number of primary filter element:
02250139-996 02250109-319
Spare part number of secondary filter element:
02250109-321
顶盖 top cover O型圈 O-ring 滤芯 filter element 螺栓 bolt 滤芯压板 filter element pressboard
二级滤芯 secondary filter element 一级滤芯 primary filter element
5.7 Maintenance of Fluid Air Separator
Maintenance of the separator mainly refers to replacement of separator element. Refer to figure
16.
The separator elements should be changed when the △P1 light flashes. Note: only replacement
but no cleaning is allowed for separator elements.
The replacement should be performed as follows:
(1) Stop the machine and release pressure.
(2) Loose the bolts that fasten the top cover, take away the top cover, and then remove the fluid
return pipe and the filter element pressboard.
(3) Remove the two filter elements, and replace them with new ones. Note: Do not peel off the
sealing gasket on the filter element flange; do not remove the metal screw on the gasket. The metal
screw is grounded to avoid fire in the separator caused by static.
(4) Clean the underside of the pressboard and put in a new filter element. Fasten the filter element
pressboard, connect fluid return pipe and fix the cover cap.
３０
Note: to avoid affecting fluid return, the two return pipes should extend to the bottom of the filter
element.
5.8 Maintenance of Air Filter

After a period of operation, the surface of air filter (refer to Figure 13) will be covered with dust,
which might block the air flow. When the preset pressure differential of the air filter is reached, the
supervisor displays “alarm” signal. This indicates that it is necessary to remove the filter elements,
clear dust, or make replacement. The maintenance should be made as follows:
(1) Remove the bolt and the top cover, take out the filter element;
(2) To clear dust: keep the air outlet about 10mm away from the surface of the filter element, and
blow compressed air out from inside, from top to bottom in circle.
(3) Besides of clearing dust, the air filter shall also be check for damage. To do this, place a light
inside the filter element and see from the outside if there is light leaked out.
(4) The useful life of the filter element is about 1000 hours. It may be shortened correspondingly
in a dusty environment.
5.9 Maintenance of Pressure Regulator

For detailed structure of the pressure regulator, refer to Figure 14. Maintenance of the regulator
requires only replacement of retaining ring, diaphragm and gasket.
Perform the maintenance as follows:
(1) Loosen the locknut and turn the adjusting screw counterclockwise until the spring is loosened;
(2) Take out the spring holder, the spring and the diaphragm assembly.
(3) Take out the gasket and the retaining ring.
(4) Loosen the locknut on the valve disc; take out the disc, the diaphragm and the bolts.
(5) Replace with new retaining ring, diaphragm and gasket.
(6) Reassemble the pressure regulator valve.
Figure 13 Air filter Figure 14 Pressure regulator

Spare part number of filter element: 88290004-372 P/N: 406929 - for inlet valve control
３１
P/N: 408275 - for screw valve control

Maintenance P/N: 041742 - for 406929
Maintenance P/N: 250028-693 - for 408275
螺栓 bolt 端盖 top cover 壳体 shell 滤芯filter element 阀体valve body 挡圈 retaining ring
密封垫 gasket 锁紧螺母locknut 调节螺钉 adjusting screw 隔膜 diaphragm 阀盘 valve disc
防松垫片 check washer 螺母 nut 隔膜组件 diaphragm assembly 调节弹簧adjusting spring
弹簧座 spring holder
5.10 Maintenance of Control Line Strainer
For structure of the strainer, refer to Figure 15. Maintenance of the control line strainer normally
requires replacement of the float assembly and the gasket. The procedure is as follows:
(1) Unscrew off the bottom box;
(2) Replace the filter element;
(3) Loosen the nut under the bottom box, and take out the float assembly and the gasket;
(4) Replace the O-ring. Note: apply some compressor fluid on the gasket to improve sealing
effect;
(5) Replace the float assembly;
(6) Re-assemble the filter.
5.11 Installation and Test of Coupling

For structure of the coupling, refer to Figure 16.
(1) Installation of the coupling
Put the metal lamination and the spacing shaft between the two subpanels and place them in
position according to the marks, then install precision screws, bushing and locknut according to the
marks. If a part has no mark on it, it indicates that there is no angle, direction or position requirement
for the installation of this part.
３２
精密螺栓自锁螺母间隔轴金属叠片安装盘
Figure 15 Control Liner Strainer Figure 16 Metal lamination type flexible coupling
P/N: 02250112-032
*Maintenance P/N: 02250112-031
** Maintenance P/N: 02250115-960
阀体 valve body 过滤元件 filter element 折流板 baffle plate 帽盖bonnet 浮子 float
浮子组件 float assembly 密封圈 gasket 底盒 bottom box 螺母 nut 精密螺栓 precision screw
自锁螺母 self-locking nut 间隔轴 spacing shaft 金属叠片 metal lamination 安装盘 subpanel
It should be noticed that the nuts should be tightened with a torque wrench in the diagonal
sequence in at least 3 times according to the torque regulated in Table 3, first one end, then the other.
When tightening the nut, keep the screw still and do not let it move.
Use a little neutral grease when installing self-locking nuts. The self-locking nuts can be used
repeatedly. If the locking part of a self-locking nut can be screwed into the bolt, or there are cracks on
the closing-in part of a nut, the nut should be discard as useless.
(2) Test of coupling
For the method for coupling test, see Figure 17.
For installation requirement of coupling, see Table 3.
Table Installation requirement of coupling
Distance Radial deflection Angular Tightening torque

between shafts (mm) (mm) deflection (mm) (N·m)
130+0.40 0.05～0.10 0.08～0.12 80
３３
角度偏移angular deflection 径向偏移 radial deflection

Figure 17 Measuring angular deflection and radial deflection with a micrometer gauge
5.12 Maintenance of Special Motors for Sullair Compressors

5.12.1 Low-Voltage Motor
5.12.1.1 Working conditions (export machines depend on country of destination):
Ambient Temperature ≤40℃
Humidity <90% (no condensation)
Altitude ≤1000 m
Frequency see nameplate on the motor
Voltage see nameplate on the motor
Working system S1
Insulation class F
5.12.1.2 Operation
(1) The motor should be grounded properly. The grounded wire of the motor is generally routed
into the switch cabinet and connected to the cabinet body. The only thing you need to do is to connect
the customer grounded wire to this point securely.
(2) There are evident labels on the lead wire of Sullair motor:
Phase sequence A B C
Head T1 T2 T3
End T4 T5 T6
(3) The connection method of the motor is indicated clearly on the nameplate.
(4) When the voltage and frequency of the special motor for Sullair compressor remain within the
rated value shown on the nameplate, the motor runs continuously under the power which equals to the
rated power times the service factor. When the frequency deviation of the power supply exceeds 1% of
the value on the nameplate, or the voltage deviation exceeds 5%, the motor is not guaranteed to output
such power continuously.
３４
(5) When the three phases of the power supply are out of balance by less than 1%, the motor may
still run properly.
(6) Thermal relays are built in the cabinet for overload protection.
(7) There should be no intermittent or abnormal noise or vibration when the motor is running idly
or with load.
5.12.1.3 Maintenance and repair of low-voltage motor
(1) Keep the working conditions dry and the motor surface clean. The air inlet should not be
blocked with dust or fiber.
(2) When the thermo relay is actuated, check the cause of any fault. Put back into operation only
after the fault has been corrected.
(3) Maintain properly the bearings lubrication during the motor operation. Refill or change the
grease every 2000 hours operation (enclosed bearings need no replacement during its lifetime).
Immediately change the grease when the bearings are overheated or the grease has deteriorated. The
brand of grease is different from motor to motor. For details, please consult Sullair service department
755-26851686-270, 271, 272.
(4) When a bearing is reaching the end of its lifetime the motor’s noise and vibration are
increased considerably, which manifest that the bearing should be replaced.
(5) You are recommended to contact Sullair or local dealer in case of motor malfunction.
5.12.2 High-Voltage Motor
4.16.2.1 Working conditions
Ambient Temperature ≤40℃
Humidity <90% (no condensation)
Altitude ≤1000 m
Frequency see nameplate on the motor
Voltage see nameplate on the motor
Working system S1
Insulation class F
5.12.2.2 Start-up and operation
(1) Initial start-up
The initial start-up refers to operating the motor for the first time after it is newly installed,
overhauled, or out of service for over 1 month. It is recommended to proceed with initial start-up with
the compressor head unengaged, or unload start-up.
(2) The following items should be checked before the initial start-up.
a. All temporary supports and cover plates have been cleared;
b. Fluid level is normal;
c. Resistance to ground is not less than 3(Un+1) MΩ, Un in kV;
d. Check for consistency of power supply phases, voltage, and frequency with those on
nameplate;
３５
e. Check for obstruction of ventilation opening and ducts;

f. Check for noise in the motor;
g. Check correctness of wiring;
h. Check other factors that may affect the normal operation of the motor.
(3) Jog the motor to check for correct rotation direction of the motor and make rewiring, if
necessary. Start the motor again after cooled down to ambient temperature; check for any abnormal
operation, if any, in the subsequent 2 hours. In case of abnormity, switch off the power supply
immediately, stop the motor, and find the cause.
(4) Load start-up
Connect the coupling between the compressor head and the motor, according to section 5.11,
rotate the motor manually or with tools for several turns to check for sticking or any other abnormal
phenomenon and noise. When every thing is OK, start the machine, and check the current of the motor
and temperatures at each point frequently in the subsequent 4 hours. Make operation records of the
motor and the machine. Stop the machine as soon as any problem is spotted.
(5) Number of start-up
The motor is permitted to start consecutively twice in cold state, and only once in hot state, with
interval time not less than 4 hours, to prevent damage to the insulation due to overheat.
5.12.2.3 Maintenance of motor out of service
For the motor to be put out of service for over one month, regularly heat the motor or warm up
the motor with hot air (80℃ dry air), in order to keep the motor in dry state. Heating is implemented
by means of space heater attached on the motor. Otherwise when there is no such a heater, place
several lit lamps with rated power 100 w or 150 w inside the motor.
5.12.2.4 Maintenance and repair of motor
(1) Keep the environment and the motor clean and dry and ensure the ventilation opening and
duct free of obstruction due to accumulation of dust or the alike.
(2) Prepare a practical maintenance plan and check bearings of the motor regularly for lubrication.
Detailed instructions on greasing see the nameplate attached to the motor.
(3) In case of malfunction, please contact Sullair or its authorized dealer, never attempt to tamper
the motor.
３６
6.1
3～ 380V 50HZ
说明:
油过滤器压力传感器 L3 L2 L1
高压侧低压侧 1 由虚线连接的元件为任选件
BELDEN 9842
BP4 BP4 SUPERVISOR II 仅在链未一处接机壳带外屏蔽层的 2 增加任选件时必须拆除短接线
4芯 2-双绞线 3 有关遥控模式部分的接线请参考02250057-696/697 FU
P4 P3 DELUXE 或类似电缆线
J2 《SUPERVISOR II SEQUENCING & PROTOCOL MANUAL》 5
S + - S + -
J3 GND 4 有关SUPERVISOR II RS485联网的部分请参考88290002-027
RTN 18
WHT(GRN) 301 4 接下台压缩机上的相应端子《联机控制接线图》
1 P3 SIG RS-485 - 17 -
WHT(GRN) 302 + 5 用户必须自配电源进线开关设备
2 P4 SIG + 16 QF
BLK 303 215 干侧排气温度 6 仅安装于水冷机型
3 GND RTD2 + 15 WHT 5
BLK 304 214 RTD2 BT2 管线压力排气压力 7 仅安装于TS32系列LL机型
208 RED RED RED
4 RTD2 - 14 RED BP2 BP1
305 213 GND
喷油温度
5 GND 13 RED
306 212 排气温度 P2 P1 XT0
WHT 6 RTD3 + RTD1 - 12 RED
BT3 RTD3 307 211 RTD1 BT1 S + - S + -
RED 7 RTD3 - RTD1 + 11 WHT
WHT 308 210 WHT(GRN) 1L1 1L1
GND 8 RTD4 + P2 SIG 10 G1
RED 309 209 WHT(GRN) 1L2 1L2
9 RTD4 - P1 SIG 9 G1
级间温度 RED 310 208 RED RED 1L3
WHT 10 RTD GND +12V 8
BT4 RTD4 311 207 BLK BLK
RED 11 RTD5 - GND 7
312 206
1L3
1L2
1L1
12 RTD5 + GND 6
1L2
1L1
1L2
1L1
1L2
1L1
1L3
1L3
1L3
GND 313 205
6 13 RTD6 - D5 5 P
116
105
141
314 204 SP1 空滤器堵塞

水压开关 SP2 P 14 RTD6 + D4 4
315 203 FR2 2 FR3 KM1
15 D6 D3 3 FU1 FU4
316 202 220 221
102
16 D7 D2 2
117
141
虚框内部分仅用于遥控模式 KA 1 风机过载
317 201 7
LOCAL/MASTER CONTROL 17 D8 D1 1
318
3 REMOTE LOAD/UNLOAD 18 D9 2
W11
V11
U11
319
REMOTE START/STOP 19 D10 FR1 主电机过载 222 FR4 7 油泵电机过载
320 206
20 GND
202
SB1
V21
V31
W21
W31
U21
U31
急停按钮
FR1
KA1 强制加载继电器
222
107
142
141
90
105
J1
K6 115 YV4 强制加载电磁阀 KM4 KM5 KM2
W12
V12
U12
FULL LOAD 15
Low-Voltage Unit Schematic Circuit Diagram
MODULATE 14 114
102
143
102
91
102
K5 113 1 YV5 7
13 电动疏水电磁阀
V13
U13
W13
ELECTRIC DRAIN T2
12 112 T3 T1
K4 111 1 KA2
11 报警继电器 3
COMMON FAULT 110 M1
10
V22
V22
V32
W22
W22
W32
~
U22
U22
U32
K3 109 109 KA3

9 加载发讯继电器 T6 T4
UNLOAD/LOAD T5
203
221
222
8 108 123
K2 107 YV2 加载/卸载电磁阀 FR3
7 FR2 FR4
*-DELTA 106
W13
V13
U13
6 YV1 启动电磁阀
105
220
206
206
K1
5
星-三角机械联锁
RUN 104 120

4 KM2 143
V33
V23
V33
W33
W23
W33
U33
U23
U33
KM3 Y接触器
103急停按钮
Chapter 6 Schematic Diagram
AC GND 3 7
KM3 141 KM1
120V N 2 102 2 主接触器
105
141
143
AC L 1 KM1 KM3 142 KM2 T2 T2 T2

101
Chapter 6
△接触器 T1 T3 T1 T3 T1 T3 KM3
KM4 3 M3 3 M2 3 M4
风机接触器 ~ ~ ~ 7
102
141
142
KA1
122 YV3 螺旋阀控制电磁阀
FU2 排气扇电机#2 排气扇电机#1 油泵电机
TC1 1 YV6 停水电磁阀(选件)
1L1 U3 FU3 压缩机主电机
C10 100 101 121
1 ST1 1
380V
KA4
110V 辅助继电器(仅风冷机组)
1L2 V3 KA4
C10
7 KM5
XB 油泵接触器
102
KM1 KA2 KA3 KA4
2
90
91
92
93
94
95
3
6
XT1
101
101
120
102
102
102
102
102
104
105
105
106
107
107
108
109
110
111
112
113
114
115
115
116
117
121
122
123
202
203
204
205
206
206
206
207
208
208
209
210
211
212
213
214
215
216
217
218
220
221
222
301
302
303
306
307
308
309
310
315
317
318
319
320
320
３７
2
Schematic Circuit Diagram
pump motor 排风扇电机 air discharge motor 说明 Remarks 由虚线连接的元件为任选件 Elements

压缩机主电机 master compressor motor 星-三角机械联锁 Y-∆ mechanical interlock 油泵电机fluid
TS32S-400~600 Series Screw Compressor Operation Manual Chapter 6 Schematic Circuit Diagram
connected by dashed lines are optional. 增加任选件件时必须拆除短接线。The corresponding jumper

must be removed before adding any optional element. 有关遥控模式部分的接线请参考
02250057-696/697 。 For wiring of the remote control, please refer to 02250057-696/697. 有关
SUPERVISOR II RS485联网的部分请参考88290002-027 《联机控制接线图》。For the networking of
SUPERVISOR II RS485, please refer to 88290002-027.Online Control Wiring Diagram. 用户必须自配电
源进线开关设备。The switch devices for incoming wires of power supply must be supplied by the user. 仅
安装于水冷机型。For water-cooled models only. 仅安装于TS32系列LL机型。For TS32 series LL models
only. 空滤器堵塞 air filter blocked 风机过载 fan overloaded 油泵电机过载 fluid motor overloaded
急停按钮 emergency stop button 强制加载继电器 enforced loading relay 强制加载电磁阀 enforced
loading solenoid valve 电动疏水电磁阀 trapping solenoid valve 报警继电器 alarm relay 加载发讯继
电器 loading signaling relay 加载 /卸载电磁阀 load/unload solenoid valve 启动电磁阀 start-up
solenoid valve Y接触器 Y-contactor ∆接触器 ∆-contactor 风机接触器 fan contactor 螺旋阀控制电
磁阀 screw valve control solenoid valve 停水电磁阀（选件）water stop solenoid valve (optional) 辅助
继电器（仅风冷机组）auxiliary relay (for air-cooled units only) 油泵接触器 fluid pump contactor 管线
压力 pipeline pressure 排气压力 air discharge pressure 排气温度 air discharge temperature 干侧排气
温度 dry-side air discharge temperature 接下台压缩机上的相应端子 connecting to the corresponding
terminals of the next compressor 带外屏蔽层的4芯2-双绞线或类似电缆 4-core 2-twisted pair with an
outer shielding layer or other cable alike 仅在链末一处接机壳 connected to the enclosure only at one end
of the chain 主电机过载 master motor overloaded 油过滤器压力传感器 fluid filter pressure
transducer 高压侧 high-voltage side 低压侧 low-voltage side 喷油温度 injection temperature 级间温
度 inter-state temperature 水压开关 water switch 虚框内部分仅用于遥控模式 The part in the dashed
frame is for remote control mode only.
３８
3～380V50HZ 3～6KV/10KV
6.2
50HZ
油过滤器压力传感器
L13
L12
L11
L3
L2
L1
高压侧低压侧
BP4 BP3 SUPERVISOR II
DELUXE 高压控制柜
P4 P3 5
S + - S + - J2 由用户自备
J3 RTN 18 218
WHT(GRN) 301 去XT1
1 P3 SIG 17 217 QF1
WHT(GRN) 302 RS-485 -
2 P4 SIG + 16 216 建议
BLK 303 215 干侧排气温度
3 GND RTD2 + 15 WHT
去XT1 BLK 304 214 RTD2 BT2 管线压力排气压力
208 RED RED 4 RTD2 - 14 RED
305 213 RED BP2 BP1
5 GND 13 GND
喷油温度 306 212 RED 排气温度 P2 P1
WHT 6 RTD3 + RTD1 - 12 RED
BT3 RTD3 307 211 RTD1 BT1 S + - S + -
RED 7 RTD3 - RTD1 + 11 WHT
WHT 308 210 WHT(GRN)
8 RTD4 + P2 SIG 10
RED 309 209 WHT(GRN)
9 RTD4 - P1 SIG 9 101
级间温度 GND RED 310 208 RED XT0 去XT2
10 RTD GND +12V 8 RED 高压电机
BT4 RTD4 311 207 BLK BLK 故障信号
RED 11 RTD5 - GND 7
1L1
1L2
1L3
312 124 S1
206 去XT2
GND 12 RTD5 + GND 6 P
313 205 SP1 空滤器堵塞 400
高压电柜二次回路部分
13 RTD6 - D5 5 来自XT2
314 204 高压电机
6 水压开关 SP2 14 RTD6 + D4 4 FR1 FR3 FR2
P 315 起动信号
203 2 KA 2 S3
15 D6 D3 3 401
316 202 FU4 FU1 来自XT2
虚框内部分仅用于遥控模式 16 D7 D2 2 220 221 222
317 201 风机过载 402
LOCAL/MASTER CONTROL 17 D8 D1 1 7 7 来自XT2
高压电机
318 KA4
3 REMOTE LOAD/UNLOAD 18 D9 SB1 高压柜保护停机信号
319 403 S4
REMOTE START/STOP 19 D10 来自XT2
320 急停按钮
20 GND
说明: KA1 强制加载继电器
J1 90 来自XT2
V21
V11
U21
U11
W21
W11
K6 115
1 由虚线连接的元件为任选件 FULL LOAD 15
YV4 强制加载电磁阀机组启/停
114 KM2 KM1 (S2) 状态信号
2 增加任选件时必须拆除短接线 MODULATE K5 14 1
113 YV5
13 电动疏水电磁阀 7 91 来自XT2
3 有关遥控模式部分的接线请参 ELECTRIC DRAIN
V22
V12
U22
U12
W22
W12
12 112
K4 111 KA2 AC220V电源
11 报警继电器
High-Voltage Unit Schematic Circuit Diagram
考02250057-696/697《SUPER-
COMMON FAULT 110 U22
K3 10
VISOR II SEQUENCING & PRO- 109 V22
405
KA3 加载发讯继电器
404
9
TOCOL MANUAL》 UNLOAD/LOAD 108 W22
K2 8 123 YV2 加载/卸载电磁阀
107
去XT2
去XT2
4 有关SUPERVISOR II RS485联 7
*-DELTA YV1
220
203
221
6 106 启动电磁阀
K1 105 油温开关 ST1
网部分请参考88290002-027 5 θ 121 1 FR3 FR1 FR2
120 1 KA5 辅助继电器
RUN 104
《联机控制接线图》 4
V23
V13
V23
U23
U13
U23
W23
222
W13
220
W23
206
103 急停按钮
7
AC GND 3
5 有关高压电柜的要求请咨寿力 2 KA5 KM1 风机接触器
120V N 2 102
6 仅安装于水冷机组 101
AC L 1 KT0 主机起动发讯时间继电器(0.1S)
7 仅用于TS32系列LL机型 KA1 T2
122 YV3 螺旋阀控制电磁阀 T2 T2 T2 T1 T3
T1 T3 T1 T3 T1 T3
1 3 ~ 3 ~ 3 ~ 3~
FU2 FU3 YV6 停水电磁阀(选件)
M4 M2 M3
TC1 100 101 7 M1
Chapter 6
1L1 U1 7 YV7 油泵电磁阀

来自XT0
110V 7 KM2 油泵接触器 380V 50HZ 380V 50HZ 380V 50HZ
380V 6KV/10KV
S1 124 KA4 高压电机故障信号继电器
1L2 V1 50Hz
来自XT0 102 102 XB
风冷
KT0
冷却器 408
406
407
1
KT0
KT1
KA
KT1 主机停机发讯时间继电器(0.1S)
KA2
KA3
KA5
KT0
KT1
去电脑板
来自FU3
来自TC1
去电脑板
来自电脑板
去电脑板
来自电脑板
去电脑板
去KA4
去电脑板
去电脑板
去电脑板
去电脑板
去电脑板
去电脑板
去电脑板
去电脑板
去电脑板
去电脑板
来自电脑板
来自电脑板
去电脑板
去电脑板
去电脑板
去电脑板
来自电脑板
KM1(S2)
去电脑板
去电脑板
去电脑板
3
6
301
303
306
308
309
310
101
101
120
102
102
102
103
104
105
105
106
107
108
109 来自电脑板
110 去电脑板
111 来自电脑板
112 去电脑板
113 来自电脑板
114 去电脑板
115
115 来自电脑板
116
117
121
122
123
124
202 来自电脑板
203
204
205
206
206
206
207
208
208
209
210
211
212
213
214
215
216
217
218
315
317
318
319
320
320
90
91
92
93
94
95
220
221
222
302
307
400
401
402
403
404
405
XT1 XT2
3
6
66位 16位
301
303
306
308
309
310
101
101
120
102
102
102
103
104
105
105
106
107
108
109
110
111
112
113
114
115
115
116
117
121
122
123
202
205
206
206
206
208
208
211
214
215
216
217
218
220
221
222
315
317
318
319
320
320
90
91
92
93
94
95
302
307
400
401
402
403
404
405
2 机组机组风冷
2 报警
去SP2
加载冷却器
去FR1
来自SP2
仅在链未一
来自SP1
去电脑板
去联控S1
去SB1
去YV1
去YV2
去KM4
来自SB1
去KM4
去YV1
去KA2
去KA1
去YV4
去YV2
去KA4
来自FR1 203
来自SP1 204
来自FR1
来自SB1
去高压电柜
去高压电柜
去高压电柜
去高压电柜
去高压电柜
去高压电柜
来自联控S1 124
３９
+- GND 处接机壳 1
来自BT2(RED)
来自BT3(WHT)
来自BT3(RED)
来自BT2(WHT)
来自高压电柜
来自高压电柜
来自BT1(WHT)
4
S1
接下台压缩机的相应端子用户侧接线
来自BP3、BP4(RED) S1来自高压柜
来自BP1(WHT(GRN)) 209
来自BP2(WHT(GRN)) 210
来自BP1、BP2(RED)
来自BP3(WHT(GRN))
来自BP4(WHT(GRN))
来自BP3、BP4(BLK)
来自BT3(RED、GND)
来自BP1、BP2(BLK) 207
BELDEN 9842带外屏蔽层的4
BT1、BT2(RED、GND) 213
来自来自BT1(RED) 212
芯2-双绞线或类似电缆线
signal 高压电机启动信号 high-voltage motor start signal 高压电机停机信号 high-voltage motor stop
高压电柜二次回路部分 high-voltage cabinet secondary loop 高压控制柜由用户自备 The high-voltage
control cabinet is provided by the user. 建议 recommended 高压电机故障信号 high-voltage motor fault
signal 电源 power supply 去 to 来自 from 主机停机发讯时间继电器 principal machine stop

signaling time relay 来自高压电柜 from high-voltage cabinet 去高压电柜 to high-voltage cabinet 管线
压力 pipeline pressure 排气压力 air discharge pressure 空滤器堵塞 air filter blocked 风机过载 fan
overloaded 高压柜保护 high-voltage cabinet protection 油泵电机过载 fluid motor overloaded 急停按
钮 emergency stop button 强制加载继电器 enforced loading relay 强制加载电磁阀 enforced loading
solenoid valve 电动疏水电磁阀 trapping solenoid valve 报警继电器 alarm relay 加载发讯继电器
loading signaling relay 加载/卸载电磁阀 load/unload solenoid valve 启动电磁阀 start-up solenoid
valve 辅助继电器 auxiliary relay 风机接触器 fan contactor主机启动发讯时间继电器 principal
machine start signaling time relay 螺旋阀控制电磁阀 screw valve control solenoid valve 停水电磁阀
（选件）water stop solenoid valve (optional) 油泵接触器 fluid pump contactor 高压电机故障信号继
电器 high-voltage motor fault signal relay 来自电脑板 from computer board 去电脑板 to computer
board 干侧排气温度 dry-side air discharge temperature 排气温度 air discharge temperature 油温开关
fluid temperature switch 急停按钮 emergency stop button 风冷冷却器 air-cooled cooler 机组加载
unit loading 机组报警 unit alarm 用户侧接线user-side wiring 油过滤器压力传感器 fluid filter
pressure transducer 高压侧 high-voltage side 低压侧 low-voltage side 喷油温度 injection temperature
级间温度 inter-state temperature 水压开关 water switch 虚框内部分仅用于遥控模式 The part in the
dashed frame is for remote control mode only. 说明 Remarks 由虚线连接的元件为任选件 Elements
connected by dashed lines are optional. 增加任选件件时必须拆除短接线。The corresponding jumper
must be removed before adding any optional element. 有关遥控模式部分的接线请参考
02250057-696/697 。 For wiring of the remote control, please refer to 02250057-696/697. 有关
SUPERVISOR II RS485联网的部分请参考88290002-027 《联机控制接线图》。For the networking of
SUPERVISOR II RS485, please refer to 88290002-027.Online Control Wiring Diagram. 有关高压电柜的
要求请咨询寿力。 For requirement for high-voltage cabinet, please consult Sullair. 仅安装于水冷机型。
For water-cooled models only. 仅安装于TS32系列LL机型。For TS32 series LL models only.
４０
FU19-20 TC1 6.3
1.6A 150VA
50HZ 2
1L1 V1
FU21 0.5A KA
24VAC
380VAC
3～380V±5% 50HZ
1L3 U1
120VAC
FU22 2A HL1
1
PE
L1
L2
L3
FR1
KM1
QS1 SA1 4 5
与门联锁的 FR2
6
0
A
隔离开关 KM2
就地 6 7
FR3
配电板
K
A
5
3 6 KM3
远端 6 8
远端起动 FR4
1L1
1L2
1L3
KM4
9 10
FR5
KM5
11 12
FR6
KM6
13 14
1L1
1L2
1L3
1L1
1L2
1L3
1L1
1L2
1L3
1L1
1L2
1L3
1L1
1L2
1L3
1L1
1L2
1L3
15
15A
15A
15A
15A
15A
15A
FU1-3
FU4-6
FU7-9
FU10-12
FU13-15
FU16-18
24VAC NC NO 24VAC NC NO NC NO NC NO
空气温度油温度
temperature transducer 冷却器上电 cooler powered on

传感器 VDC 传感器 VDC
C C C C
V11
V21
V31
V41
V51
V61
U11
U21
U31
U41
U51
U61
W11
W21
W31
W41
W51
W61
BP1 TC1- COM BP2 TC2- COM
S350 S350 S350 S350
TC1+ SEN A1 TC2+ SEN A2 A3 A4
KM1
KM2
KM3
KM4
KM5
KM6
后冷冷却器油冷冷却器
冷却器上电
K
A
203 206
M
1
M
2
M
3
M
4
M
5
M
6
V12
V22
V32
V42
V52
V62
U12
U22
U32
U42
U52
U62
W12
W22
W32
W42
W52
W62
Schematic Circuit Diagram of Cooling Element of Air-Cooled Unit
Chapter 6
FR1
FR2
FR3
FR4
FR5
FR6
说明:冷却器与主机之间的电气连接由用户完成
3
6
XT
203
206
TC1-
TC1+
TC2-
TC2+
1T2
2T2
3T2
4T2
5T2
6T2
1T1
2T1
3T1
4T1
5T1
6T1
1T3
2T3
3T3
4T3
5T3
6T3
T2 T2 T2 T2 T2 T2
.
.
.
.
.
.
.
.
3
6
T1 T3 T1 T3 T1 T3 T1 T3 T1 T3 T1 T3
221
101
220
3 ~ 3 ~ 3 ~ 3 ~ 3 ~ 3 ~
M1 M2 M3 M4 M5 M6 XT1
压缩机内装控制柜接线端子
1#后冷风机 2#后冷风机 1#油冷风机 2#油冷风机 3#油冷风机 4#油冷风机
４１
3HP 3HP 3HP 3HP 3HP 3HP
油冷冷却器 oil-cooling cooler 远端起动 remote start 就地 local 远端 remote 空气温度传感器 air
压缩机内装控制柜接线端子 connecting
terminals of control cabinet in compressor 油冷风机 fluid-cooling fan 与门联锁的60A隔离开关 60A

isolating switch interlocked with the door 配电板 distribution panel board
４２
TS32S-400~600 Series Screw Compressor Operation Manual Chapter 7 Trouble Shooting and Remedies
Chapter 7 Trouble Shooting and Remedies
7.1 General
The machine may experience troubles due to various reasons.
It is important to systematically collect operation data, with which the operator may find out the
variation of unit performances as well as potential faults. For example, unit vibration getting severer
might be caused by over wear of bearing, while degraded unit efficiency might due to incrustation of heat
exchanger.
Detailed analysis on various possible causes of fault shall be made to find the exact ones before
repair or replace any component Never tamper this machine without definite intention, so as to avoid
meaningless damage.
The following items shall be checked first:
(1) Check for loosened or broken wiring;
(2) Check for damaged piping;
(3) Check for parts damaged by overheat or short circuit, usually apparent by discoloration or a burnt
odor.
7.2 Possible Faults and Remedies.
Symptom Possible causes Remedies

Too low level of fluid in the air fluid Check fluid level and add if necessary.
separator
Malfunction of thermal control valve Check and change the thermal control
Over high element.
discharge Too dirty cooler fins (air-cooled Clean the cooler fins.
temperature units)
(T1 HI) Fluid filter blocked, malfunction of Change fluid filter.
bypass valve
Too high ambient temperature Improve ventilation.
Too high resistance of outdoor 1. Enlarge the ventilation pipe;

ventilation pipe 2. Install a ventilation fan in the pipe.
Deficient cooling water flowing Increase cooling water flow.
Too hot cooling water Increase flow of cooling water, lower

water temperature.
Cooler blocked (water-cooled units) Clean the pipeline, use clean cooling
water.
Failure of resistance thermometer Check RTD connector. If good, replace
transducer RTD the thermometer transducer.
４３
Symptom Possible causes Remedies

Malfunction of unload parts (e.g. Check the action of unload parts.
Too high air blowdown valve, air inlet valve,
discharge optional screw valve)
pressure Malfunction of pressure regulator Check pressure regulator.
(tank Malfunction of solenoid valve Check solenoid valve.
pressure) Control line air leak Check for leakage in control line.
(P1 HI)
Control line strainer blocked Maintain the filter assembly.
Filter element of air fluid separator Replace the filter element of air fluid
blocked separator.
Malfunction of minimum pressure Check/repair the butterfly valve at the
valve --- butterfly valve air outlet of air fluid separator.
Air consumption exceeds supply a. Reduce consumption;
b. Check for leakage on the air
Air delivery transmission line.
pressure Air filter blocked Change the filter element.
lower than Air inlet valve can’t fully open Check the valve action and the setting
rated of the pressure regulator.
discharge Loosened connection of pressure Check the connector of the pressure
pressure transducer transducer, or replace the transducer
when necessary.
Malfunction of minimum pressure Check/repair the butterfly valve at the
valve --- butterfly valve air outlet of air fluid separator.
Optional screw valve open Check the screw valve pressure
regulator.
Filter element of air fluid separator Replace the filter element of air fluid
blocked separator.
Malfunction of pressure transducer Check the connector, or change the
Line P2 transducer when necessary.
pressure Malfunction of unload parts (e.g. Check the action of unload parts.
higher than blowdown valve, air inlet valve,
the set value optional screw valve)
of unload Malfunction of solenoid valve Check solenoid valve.
pressure Control line leakage Check for leakage in control line.
Control line strainer blocked Maintain the filter assembly.
Return line strainer or orifice Clean the strainer and orifice, or replace
blocked it with a spare part.
Excessive Damaged separator element or Check or replace when necessary
fluid gasket
consumption Leakage in the fluid system Check for leakage in the fluid piping.
Fluid level too high Drain out the excessive fluid.
Excessive bubbles Drain out and replace the fluid
４４
7.3 Application of Transducers and Calibration of Supervisor Parameters

Application of transducers:
Whenever a transducer is suspected of fault, it is recommended to measure (pressure, temperature,
etc.) with another standard instrument and compare readings. If readings are not correct, the wiring or
tubing connections should be inspected, and if no faults are found, then replace the transducer and
calibrate with the standard instrument.
Calibration of parameters:
The Supervisor has calibration software for the pressure transducer and the temperature transducer.
This calibration affects the offset but not the slope of conversion curve. Because of this, the most accurate
method is to heat or increase the pressure to its operating value. If this is too difficult, calibration in room
temperature/ atmosphere pressure can also be made. Calibration may only be done while the machine is
stopped and the external control is disabled.
To enter calibration mode, you must press the “ ”, “ ” “DISPLY”, “ ” and
“PROG” keys in sequence while in the default status mode. Once in calibration mode, you will see a
screen like the following:
CAL P1
0 6.7
In the above example, “0” refers to the amount of adjustment (in psi or ℉), 6.7 bar refers to current
value of P1. To adjust, press the “ ”(up arrow) key to increase the value or the “ ” (down
arrow/indicator light test) key to decrease the value. The number on the left will increase or decrease with
the total amount of adjustment always displayed. The maximum range of adjustment is ±7.
Press the “DISPLY” key to exit after canceling the change to the current item while saving changes
to any previous items. Press the “PROG” key to save the current item and go to the next item. All
pressures and temperatures may be calibrated individually.
４５
TS32S-400~600 Series Screw Compressor Operation Manual Chapter 8 Commonly Used Spare Parts
Chapter 8 Commonly Used Spare Parts
No. Designation Part Number Quantity
1 Fluid cut-off valve 001684 1

2 Core of temperature control valve 013697 1
400/450 models: 1
3 Fluid filter element 02250139-996
400/450 models: 2
4 Primary air fluid separator element 02250109-319 1
5 Secondary air fluid separator element 02250109-321 1
6 Air filter element 88290004-372 2

Pressure regulator 406929 (for air inlet
7 041742 1
valve)
Pressure regulator 408275 (for screw
8 250028-693 1
valve)
Maintenance kit for solenoid valve
250038-672 1
9 250038-666
Magnet coil 250038-730 1
Maintenance kit for solenoid valve
10 250038-767 1
250038-755
Magnet coil 250038-730 1
Maintenance kit for blowdown valve
11 001667 1
409783
Spare parts for control line strainer
02250112-032:
12
Sealing ring 02250112-031 1
Maintenance kit 02250115-960 1
13 24KT fluid (5 gallon) 02250051-153 1
14 24KT fluid (55 gallon) 02250051-150 1
15 SULLUBE fluid (5 gallon) 250022-669 1
16 SULLUBE fluid (55 gallon) 250022-670 1
Note: to let the company serve you better, please indicate your compressor’s model,
serial number and B.O.M.
４６
Global Sales and Services
American headquarter:
SULLAIR CORPORATION
Subsidiary of Hamilton-Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 001-219-879-5451 or
1-800-Sullair (U.S.A. only )
Fax: 001-219-874-1273
Fax: 001-219-874-1835 (Parts)
Fax: 001-219-874-1805 (Service)
European headquarter:
SULLAIR EUROPE, S.A.
Zone Des Granges BP 82
42602 Montbrison Cedex, France
Telephone: 0033-4-77968470
Fax: 0033-4-77968499
Asian headquarter:
SULLAIR ASIA LIMITED
Zuo Pao Tai Road, Chiwan, Shekou, Shenzhen, China
Telephone: 0755-26851686
Fax: 0755-26853473, 26853475
Services hotline: 800-830-3977
Web: http://www.sullair-asia.cc
Shanghai branch: Room 1209, Ganglu Piazza, No. 18, Middle Xizang Road,
Shanghai Zip code: 200001
Telephone: 021-53852036, 62192066-800 Fax: 021-53852035
Beijing branch: Room 1506, Block B, Happiness Building, No. 3, North Ring 3
Road, Beijing Zip code: 100027
Telephone: 010-64629770, 64629768 Fax: 010-64629773
Chengdu branch: D-2, 27th floor, New Era Piazza, No. 42, Wenwu Road, Xinhua
Avenue, Chengdu Zip code: 610017
Telephone: 028-86617869, 86764845, 86765246 Fax: 028-86765142
Shenyang branch: Room 1407, Gaodeng International Building, No. 355,
Zhongshan Road, Shenhe District, Shenyang Zip code: 110014
Telephone: 024-22818550, 22818650, 22818450 Fax: 024-22818590
４
８

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TS32S Air Compressor Manual

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DRAFT

STATIONARY SCREW COMPRESSOR

TS32S-400/450 & TS32S-500/600

SHENZHEN SULLAIR ASIA INDUSTRIAL CO.,LTD.

Part Number: 88290006-556

We hope various stationary screw compressors manufactured by Sullair Asia Co.,

Before operating and maintaining the stationary screw compressor, please

familiarize yourself with this manual thoroughly.

At Sullair, we are committed to continuous product improvement. While all

changes to the product without prior notice.

Type of compressor: ____________________

operation and maintenance method of each system of the TS32S-400/450 type

and TS32S-500/600 screw compressors.

fluid is strictly prohibited.

From time to time, the product is being redesigned to seek improvement.

product itself. The customer should be aware of it.

customer services of Sullair.

Chapter 4 Operations of Compressor

4.4 Shutdown ………………………………………………………………………………………28

Chapter 6 Schematic Circuit Diagram

Chapter 7 Trouble Shooting and Remedies

Chapter 8 Commonly Used Spare Parts …………………………………………………45

Table 1 Main performance parameters of TS32S-400/450 units

Model 400L 400H 400HH 400XH 450L 450H 450HH 450XH

Model 500L 500H 500HH 500XH 600L 600H 600HH 600XH

1.2 Principal Machine

供气 air supply 进水 water inlet 排水 water outlet 排污 blowdown

Figure 1 general arrangement diagram of TS32S-400/450 water-cooled units

1. pedestal 2. acoustical enclosure 3. air fluid separator 4. pressure relief valve

Figure 2 General arrangement diagram of TS32S-500/600 water-cooled units

1. pedestal 2. acoustical enclosure 3. air fluid separator 4. pressure relief valve

管 pipe 进气 air intake 真空度 vacuum degree 压力为 The pressure is

31 TS32S-500/600 1 88290004-371 空气滤清器

Figure 4 General arrangement diagram of TS32S-500/600 air-cooled units

1. pedestal 2. acoustical enclosure 3. air fluid separator 4. pressure relief valve

机型增加 1 个序号 33 元件 models have an additional No. 33 element.

管 pipe 进气 air intake 真空度 vacuum degree 压力为 The pressure is

压缩机第一级 compressor primary stage 压缩机第二级 compressor secondary stage

设置值随机型而异 the setting is model dependent. 温度设置为 The temperature is set to

1.4 Discharge System

1.5 Air Fluid Separator

1.6 Fluid Piping System

1.7 Water Piping System (for water-cooled units)

1.8 Air Volume Adjusting System

2.2 Vibration Absorption and Noise Reduction

2.3 Air Intake and Outtake

2.4 Ventilation and Cooling

2.5 Profile of Unit and Installation Drawing

2.6 Air Supply Pipe

2.7 Motor Rotation Direction

No reversed rotation is allowed!

Figure 6 Installation drawing of TS32S-400/450 water-cooled units

Figure 7 Installation drawing of TS32S-500/600 water-cooled units

blowdown joint 疏水阀 moisture separator

法兰 flange 油冷却器 fluid cooler 后冷却器 aftercooler

Installation drawing of the cooling element of TS32S-500/600 air-cooled units

名称 designation 数量 quantity 材料 material 备注 remarks 转接法兰 adapter flange 管夹 clamp 排污接头

3.1 Function of Supervisor

3.3 Status Display

Figure 10 Supervisor panel

※ Compressor air discharge temperature and the maximum limit MAX:

※ Total hours that the compressor has been loaded (hours):

3.4 Indicator Lights

3.5 Parameters Setup

精密螺栓自锁螺母间隔轴金属叠片安装盘

signal 电源 power supply 去 to 来自 from 主机停机发讯时间继电器 principal machine stop