SULLAIR

CORPORATION
A Subsidiary of Sundstrand Corporation
 SULLAIR
CORPORATION
 CORPORATE
HEADQUARTERS
MRD ASSEMBLY LINE
ROTOR MACHINING
 NEW MACHINE
WARRANTY
â 1 Year on Complete Package
â 5 Years on Standard Air End
â 10 Years on 24 KT Air End
â 5 Years on Toshiba & Lincoln
Motors
â 5 Years on Coolers and Tanks
â 90 Days on Replacement Parts
including labor
AIR END WARRANTY
â 5 Years on Standard Air End
â 10 Years on 24 KT Air End
â 2 Years on Standard Replacement
â 2.5 Years on 24 KT Replacement
THE FOURTH UTILITY
1. Electricity
2. Water
3. Gas
4. Compressed Air
 COMPRESSOR
TYPES
Rotary Vane

Rotary Screw

Reciprocating

Centrifugal
COST OF OPERATION
100 HP Compressor
Operating for 8700 hours @ 8 cents per KWH
costs approximately $60,000 per year.

(HP X .746 motor efficiency X cents per KWH

X hours of operation)
 OVERSIZING
Causes of Over-Sizing
 Recip mentality
 Hand me downs
 Anticipation of future expansion
 Auction “Deals”
 C Y R Theory
 Nightshift / Weekend operation
H.P. VS. CAPACITY
500 C.F.M. requires 100 HP
At 50% load, the machine still consumes
83% of the motors HP
A compressor unloading at 60 P.S.I.
consumes 62% of motor HP
A machine with spiral valve consumes 63%
of the motors HP at 50% load (a 20%
savings over inlet modulation)
DISADVANTAGES OF
OVERSIZING
High Energy Consumption
Increased Maintenance Costs
High Lubricant Carry-Over
IDENTIFICATION TAG
20/16 - 100L or H WCAC
20/16 Air End Series 204 and 163
MM rotors
100 Motor Horsepower
L 100 - 110 P.S.I
H 115 - 125 P.S.I
MODEL NUMBERS
ES 6 - 8 - 11
- 5 through 50 HP
LS 10 - 12 - 16 - 20 - 25 - 32
- 25 through 450 HP
TS 20/16 & 32/25
- 100 through 600 HP
DS 13
- 100 through 200 HP
COMPRESSOR UNIT
Thrust Bearings

Radial Bearings
 COMPRESSOR
OUTPUT FACTORS
Length of the Rotors

Diameter of the Rotors

Speed of the Rotors

SPIRAL VALVE
LUBRICANT INJECTION

Bearing
Injection
Lines

Main Injection
 COOLS
Female Rotor Male Rotor

Stator
 SEALS

Female Rotor
Male Rotor

Stator
 LUBRICATES
Female Rotor Male Rotor

Stator
DIRECTION OF
ROTATION
DIRECTION OF
ROTATION
 PHASE MONITOR

SINGLE PHASING / PHASE REVERSAL / VOLTAGE

IMBALANCE
PURPOSES OF THE
SHAFT SEAL

Keep Lubricant In
Keep Dirt Out
MECHANICAL SEAL

Spring
Holder
Spring
Drive Ring
Mating Retainer
Ring
O- Ring Flexible
Primary Diaphragm
Sealing
Ring
“LIP” TYPE SHAFT SEAL

Shaft Seal

Wear
Sleeve
 COUPLING
ALIGNMENT
LUBRICANTS
Functions
Properties
Types
FUNCTIONS OF
LUBRICANTS
Control Temperature
Form a Seal
Control Friction
Control Wear
Control Corrosion
Remove Contaminants
 PROPERTIES OF
A LUBRICANT
91% - 94% BASE STOCK
6% - 9% ADDITIVES

ADDITIVES FOR:
Antioxidant Metal deactivators
Anticorrosion VI Improver
Anti-wear Antifoam
 TYPES OF
LUBRICANTS
Hydrocarbons
Polyalphaolefins (PAO)
Diesters
Polypropylene Glycol
Silicones
 HYDROCARBONS
A.T.F., MOTOR OIL, TORQUE FLUID
APPLICATIONS:
 Hydrocarbons in Rotary Screw Air Compressors

CHARACTERISTICS:
 Inexpensive
 High Lubricity Properties
 Varnish Formation in RSAC’S
 Low Flash Point
 Short Life (1000 hours)
 Increased Carryover
POLYALPHAOLEFINS
(PAO’S)
SYNTHETIC HYDROCARBONS
APPLICATIONS:
Improved chemical resistance, less reactive

Basestock for food grade applications

 POLYALPHAOLEFINS
(PAO’S)
SYNTHETIC HYDROCARBONS
CHARACTERISTICS:
 Good Elastomer compatibility
 Moderate flash point (450° F)
 Good viscosity index, even without VI improvers
 Forms some varnish in rotary screw compressors
 DIESTERS
SYNTHETIC LUBRICANT
APPLICATIONS:
Developed for reciprocating air
compressors

Least expensive synthetic basestock

 DIESTERS
SYNTHETIC LUBRICANT: con’t
CHARACTERISTICS:
 Low carryover rate in Rotary Screw Air
Compressor (RSAC) applications
 Aggressive toward most Elastomers (E.G.
Buna)
 May form chemical deposits and sludge
 Very low VI without additives
 Lower lubricity than Hydrocarbons, PAO’s, or
PPG’s
 SILICONES
APPLICATIONS:
Very specialized, extreme long life
Arctic Applications

CHARACTERISTICS:
Best VI of any lubricant
Excellent thermal stability
Requires in-line filtration for painting and coating
POLYPROPYLENE
GLYCOL BLENDS
SYNTHETIC LUBRICANTS
APPLICATIONS:
Rotary Screw Air Compressors
POLYPROPYLENE GLYCOL
BLENDS
SYNTHETIC LUBRICANTS con’t
CHARACTERISTICS:
 No sludge varnish formation in compressor
 Very low carryover (low volatility)
 Highest thermal conductivity for efficient RSAC
cooling
 Highest flash point (505 F)
 Good elastomer and painting compatibility
 Higher lubricity than Diester, PAO’s or
Hydrocarbons
SULLUBE 32
BIODEGRADABLE

Condensate accepted by Publicly Owned

Treatment Works (POTW)
No need for expensive condensate
separator systems
Can the competition offer this?
LUBRICANT SELECTION
BASIC REQUIREMENTS
Viscosity

OPERATING VARIABLES

Speed Tolerances
Load Temperatures
Pressures

CONDITION OF EQUIPMENT - CAPATIBILITY

Seals Other Lubricants

Metals Paint
LIMITS TO FLUID
LIFE
High Operating Temperature
High Ambient Temperature
Chemical Ingestion
Improper Filter Maintenance
 FACTORY
LUBRICANTS
 LUBRICANT COST
COMPARISON
Hydrocarbon Sullube 32
Fluid Capacity: 30 gal. 30 gal.
Cost per gallon: $8.00 $45.30
Cost per Change: $240.00 $1359.00
Changes per Year: 8 1
Total Lubricant Cost: $1920.00 $1359.00

Annual Savings

with SULLUBE $561.00

DISCHARGE SYSTEM
Terminal
Check Valve

MPV
Separator Return Line

Sullicon
Capacity
Control

Discharge
Check Valve

Air End
STD. INLET FILTER

Cover

Element
H.D. INLET FILTER
Rubber Baffle Dust Cap

Wing Nut

Element
Body
Clamp
H.D. INLET FILTER

Housing

Secondary
Element

Cover Primary
Element
CONTROL PANEL WITH
ANNUNCIATOR
SUPERVISOR II

Inlet Filter
SULLICON & INLET
VALVE
Inlet Valve

Sullicon Control
INLET VALVES
Poppet

Butterfly
POPPET INLET FOR
ES MODEL
ES8 ES6
ITEMS REPLACED BY
A POPPET INLET
Butterfly Discharge Check
Valve

Sullicon Oil Stop Valve

ROTOR CAVITY
Rotor
Cavity
DISCHARGE CHECK
VALVE
BI-METALLIC TEMP.
SWITCH

Shut down at 240F / 115.5 C

 THERMISTOR
PROBE & BOARD

Shut down at 235F / 112.7 C

MICRO-PROCESSOR RTD

Shut down at 235F / 112.7 C

FLEXMASTER
COUPLING
FLEXIBLE DISCHARGE
FIRST STAGE
SEPARATION
SEPARATOR ELEMENTS
Primary

Secondary
NESTED SEPARATORS
Secondary Element

Primary Element
CONTROL PANEL WITH
ANNUNCIATOR
SUPERVISOR II

Separator
Differential
THE VALUE OF A GENUINE
SEPARATOR
 SEPARATOR COST
COMPARISON
LS 16-75L 300 DAYS:
Genuine Sullair Will Fit

Element Cost $364.50 $273.37

Carryover Rate 1 PPM 6 PPM
Oz. in 24 Hrs. .6 4
Oz. in 300 Days 180 1200
Gal. in 300 Days 1.5 9
Fluid cost @ $45.30 $67.95 $407.70

ANNUAL SAVINGS $248.44

 CAUSES OF HIGH
LUBRICANT CONSUMPTION
Leakage
Return Line Position
Plugged Orifice or Strainer
Defective Separator Element
Foaming Lubricant
Compressor Overfilled
Machine Running Unloaded
Machine Running Low Pressure
Ruptured Water Cooled Oil Cooler
FLUID RETURN LINES
Secondary

Primary

Cut at 45º and touching the bottom of the element

ES-6 SEPARATOR & OIL
RETURN LINE
Separator

Return Line
RETURN LINES

Strainer

Sight Glass

Orifice
MINIMUM PRESSURE
TERMINAL CHECK
Minimum
Line Pressure Pressure

High Temp
Protection

Terminal Check
AFTERCOOLER
Air

Water
MOISTURE SEPARATOR
Outlet Inlet

Drain Float
 AUTOMATIC
MOISTURE DRAIN
DISCHARGE SYSTEM
Terminal
Check Valve

MPV
Separator Return Line

Sullicon
Capacity
Control

Discharge
Check Valve

Air End
 AIR
FILTER

MOTOR

DRYER

10.78 Gal/24
Removed 10.78hours
removed
REFRIGERATED
DRYERS
DESICCANT DRYERS
IN-LINE FILTERS
Micron particles are Did you know?????
extremely small. A it takes 8 million 1.0 micron particles
micron is one millionth of to cover
a meter. The following this 1/8” dot..
illustrations provide a
comparison of relative
sizes.
….This dot is .01 micron

…...This dot is .1 micron

………….This arc is just “part” of a

1.0- micron particle
 COOLING LUBRICATION
SYSTEM
Cooler
C
Thermal
Valve B
Fluid Filter
A

Fluid
Stop
Valve
Sump
 COOLING LUBRICATION
SYSTEM
Cooler
C
Thermal
Valve B
Fluid Filter
A

Fluid
Stop
Valve
Sump
 COOLING LUBRICATION
SYSTEM
Cooler
C
Thermal
Valve B
Fluid Filter
A

Fluid
Stop
Valve
Sump
SUMP TANK
RELIEF VALVE

Seals
THERMAL VALVES
 COOLERS

Fluid Filter

After Cooler
SAFETY SWITCHES

LWP OLD STYLE

AIR-COOLED HEAT
EXCHANGER
FLUID FILTER
WASHABLE MAIN
STRAINER
Bypass

Clean Every 1000 Hours

FLUID FILTER BY-PASS
IN OUT IN OUT

Less than 20 PSI More than 20 PSI

Differential Differential
FLUID FILTER BYPASS

Metal Bypass - New Plastic Bypass - Old

Style Style
CONTROL PANELWITH
ANNUNCIATOR
 SUPERVISOR II

Fluid Filter
Differential
FILTER COMPARISON
FILTER COMPARISON
FILTER COMPARISON
FILTER COMPARISON
FILTER COMPARISON
MAGNIFIED MEDIA

Sullair Fiberglass Sullair Cellulose Auto. Cellulose

Micron particles are Did you know?????
extremely small. A it takes 8 million 1.0 micron particles
micron is one millionth of to cover
a meter. The following this 1/8” dot..
illustrations provide a
comparison of relative
sizes.
….This dot is .01 micron

…...This dot is .1 micron

………….This arc is just “part” of a

1.0- micron particle
Lubricant Filter Efficiency
99.3 99.9 99.1
100
87.7 89.1
90
80
70 56.5
60 54.6

50 Fiberglass
40 Cellulose
30 18.7 Automotive
20
10 2.0
0
5 Micron 10 Micron 20 Micron
COMPRESSOR UNIT
FLUID FILTER
Bypass
In Out
FLUID STOP VALVE
 HIGH TEMPERATURE
PROBLEMS
Cooler
C 150º F
Thermal
Valve B
Fluid Filter
A

180º F
Fluid
Stop
Valve
Sump

150º F
 HIGH TEMPERATURE
PROBLEMS
Cooler
180º F
C
Thermal
Valve B
Fluid Filter
A

210º F
Fluid
Stop
Valve
Sump

190º F
 HIGH TEMPERATURE
PROBLEMS
Cooler
C 195º F
Thermal
Valve B
Fluid Filter
A

210º F
Fluid
Stop
Valve
Sump

195º F
 HIGH TEMPERATURE
PROBLEMS
Cooler
C 140º F
Thermal
Valve B
Fluid Filter
A

210º F
Fluid
Stop
Valve
Sump

140º F
IDENTIFICATION TAG
REGULATOR

Direction of
Flow
SULLICON CONTROL &
REGULATOR
POPPET INLET
VALVE

Regulator
Port
POPPET INLET FOR
ES MODEL
ES8 ES6
PRESSURE SWITCH

CUT OUT SET POINT

CUT IN SET POINT
 SUPERVISOR II

Load / Unload
PILOT VALVE

3
2 1

Supply Air
Vent Signal Air
SULLICON / POPPET
BLOWDOWN
VALVES
 LOAD MODE
LOAD MODE

Inlet Valve
Inlet Valve Blowdown
Blown Valve
Valve
Pilot Valve
Pilot
Pressure
Pressure
Switch Valve
Check
Switch 2 Check
Valve
1 Valve

3
Sullicon Control
Sullicon
Regulator
Control
Regulator
Sump
Line Pressure
Line Pressure

0-0
100
- 100
PSIPSI
 MODULATION MODE

Inlet
Valve Blowdown Valve
Pilot
Pressure Valve
Switch Check
2
1 Valve

3
Sullicon Control

Regulator
Sump
Line Pressure

101 - 109 PSI

 UNLOAD MODE

Inlet Valve Blowdown Valve

Pilot
Pressure Valve Check
Switch 2 Valve
1

3
Sullicon Control

Regulator
Sump
Line Pressure

110 - 100 PSI

 LOAD MODE
LOAD MODE

Inlet Valve
Inlet Valve Blowdown Valve
Blowndown Valve
Pilot Valve
Pressure
Pilot
Pressure
Switch Valve Check
Switch 2 Check
Valve
1 Valve

3
Sullicon Control
Sullicon Control
Regulator
Regulator
Sump
Line Pressure
Line Pressure

100
0 - PSI
100 PSI
FACTORY TRAINING
CENTER
TRAINING FACILITY
MICHIGAN CITY, IN
SPIRAL VALVE
SPIRAL VALVE
CONTROL

MIN MAX
LOAD MODE
Spiral Valve Actuator Regulator Blocking Solenoid

Min Max
Blowdown
Valve
Regulator
Filter

Pressure Switch

Shuttle Filter
Valves

Sullicon
Control

Pilot Valve Sump

To System Tank

0 -100 PSI
 MODULATION WITH SPIRAL VALVE
Spiral Valve Actuator Regulator Blocking Solenoid

Min Max
Blowdown
Valve
Regulator
Filter
Inlet Valve

Pressure Switch
Shuttle
Valves

Filter MPV
Sullicon Terminal Check
Control

Sump
Pilot Valve To System Tank

100 - 105 PSI

FULL MODULATION MODE
Spiral Valve Actuator Regulator Blocking Solenoid

Min Max
Blowdown
Valve
Regulator
Filter
Inlet Valve

Pressure Switch

Shuttle
Valves
Filter MPV
Sullicon Terminal Check
Control

Pilot Valve Sump

To System
Tank
105 - 109 PSI
UNLOAD MODE
Regulator Blocking Solenoid
Spiral Valve Actuator

Min Max
Blowdown
Valve
Regulator
Filter
Inlet Valve

Pressure Switch

Shuttle
Valves
Filter MPV
Sullicon Terminal Check
Control

Sump
Pilot Valve To Plant
Tank
110 - 105 PSI
UNLOAD MODE
Regulator Blocking Solenoid
Spiral Valve Actuator

Min Max
Blowdown
Valve
Regulator
Filter

Inlet Valve
Pressure Switch

Minimum Pressure
Shuttle Terminal Check
Valves

Filter
Sullicon
Valve

Sump
Pilot Valve To System Tank

105 - 100 PSI

LOAD MODE
Spiral Valve Actuator Regulator Blocking Solenoid

Min Max
Blowdown
Valve
Regulator
Filter
Inlet Valve

Pressure Switch

Shuttle Filter
Valves

Sullicon
Control

Pilot Valve Sump

To System Tank
100 PSI
 ES - 6
5 - 7.5 - 10 H.P.
 Air End

Separator

Sight Glass

Thermal Valve Assy.

Fluid Filter
SOUND ENCLOSURE
 ES - 8
15 - 20 - 25 - 30 H.P.
SUPERVISOR I & IE
SUPERVISOR II