Two-Stage Rotary Screw Air Compressors

� Unparalleled Energy Efficiency and Durability

� Energy Savings up to 13% on Full Load

� Energy Savings up to 30% on Part Load

Constant Speed and Variable Speed Drives (VSD)75-450 kW � 100-600 Horsepower

2

Sullair Leadership

Since 1965, Sullair has beenrecognized around the world as aninnovator and a leader in rotary screwcompression technology. For morethan 40 years, Sullair has designedand manufactured its own rotors andair end assemblies at the corporateheadquarters in Michigan City,Indiana.

The award-winning rotary screwdesign sets the industry standardsand delivers the quality and reliabilityone expects from a leader.

Sullair Technology

Utilizing the most moderntechnologies, equipment andadvanced manufacturing techniques,Sullair designs, manufactures,assembles, and tests the mostadvanced compressed air productsin the industry. Sullair products areknown around the world for theiruniversally applicable design,outstanding craftsmanship andsuperior quality.

Sullair’s Statistical Process Control

Our Statistical Process Control (SPC)system monitors rotor qualitystandards to assure consistentcompressor performance.

Sullair’s Commitment to Innovation

Underlying Sullair’s leadership is adedication to excellence and acommitment to innovation. We areconstantly exploring new ideas andseeking new ways to meet industry’sneed for increasingly energy-efficientcompressed air solutions.

Sullair Capabilities

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Sullair offers air system solutions—a total compressed air system—tohelp compressed air users reduceenergy costs and improve productivity

by analyzing, managing andcontrolling total compressed airsystems. Sullair’s air system solutionsinclude: plant air system audits,

energy efficient products, compressedair system controls, monitoring andmanagement systems, air distributionproducts, and after-purchase support.

Sullair Air System Solutions

TS-20

Air Compressor Life Cycle Costs

According to Best Practices forCompressed Air Systems,Compressed Air Challenge, SecondEdition, 2007, energy costs now

represent 82 percent of the totaloperating expenses. Energy savingsfrom Sullair’s Two-Stage Compressorscan significantly reduce life cyclecosts.

Sullair’s Two-Stage Compressorssignificantly reduce operating andenergy costs over the entirecompressor life cycle. Contributing tothe energy savings are:

• Sullair’s proven air end with the lowrestriction inlet valve

• High efficiency fan

• Low pressure drop air-fluid separationsystem to prevent energy loss

Sullair designs deliver cost savings forthe life of the product. Improved airfiltration translates into:

• Extended separator life

• Improved fluid filter life

• Less lubricant contamination

To reduce fluid disposal costs, weoffer our biodegradable Sullube™

8000-hour fluid, or 24KT™, a long-lifefluid that never needs changing.

Sullair ReducesYour Life Cycle Costs

Equipment

Maintenance

Electricity

The Sullair System here includes:a Sullair compressor, “wet” receiver,Sullair pre-filter, your choice of a Sullairdesiccant or refrigerated air dryer,Sullair after-filter, “dry” receiver, andSullair flow controller. Monitoring andcontrolling the entire system is Sullair’sethernet-based eConnect™.

4

Two-stage compressors* have apower advantage of 11 percent to13 percent over equivalent sizedsingle-stage compressors for twokey reasons:

Compression is Divided BetweentheTwo Stages

In a single-stage compressoroperating at 100 psig at sea level,the compression ratio is 7.9 to 1 (inabsolute terms). A two-stagecompressor operating at the samepressure will have a compressionratio of 2.8 to 1 in each stage (2.8is the square root of 7.9) achievingthe compressor’s power savings.

Internal Leakage Losses areReduced

Reduced pressure differenceacross each stage facilitatesreduction in leakage losses.

Sullair’s Superior End-to-EndDesign

Sullair’s TS two-stage tandemcompressors use two sets of rotorsarranged in a unique end-to-enddesign that achieve higherefficiencies than other two-stagerotor arrangements. This design isbased on Sullair’s proventechnology used in its single-stageunits, which has set the standardsfor efficiency and reliability insingle-stage compressors for morethan 4 decades.

The industry standard since itsintroduction in 1984, the TS Seriestandem compressors offerunmatched full load efficiency;often providing a two-year paybackin energy savings compared withsingle-stage compressors. With thetandem’s variable capacity control,featuring spiral valve technology,

further operating efficiencies canbe achieved during part loadoperation.

Rotary Screw Reliability

These TS models use a two-stagerotary screw air end, featuringSullair’s rugged bearing design:tapered roller bearings on thedischarge end and cylindrical rollerbearings on the inlet for high loadcarrying capacity.

Extended Bearing Life

By dividing the compression ratioacross two stages, the two-stagetandem will significantly exceed thelife of the average single-stagecompressor.

Advantage of Two-Stage Compression at Full Load

Intake14.5 psia

Compression Ratio2.8 to 1

CompressionRatio2.8 to 1

Interstage41 psia

Discharge114.5 psia

Compression Ratio7.9 to 1

Discharge114.5 psia

Intake14.5 psia

*Compressed Air and Gas Handbook, Sixth Edition.

Two-Stage

Single-Stage

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Annual Cost of Electricity - $ per kW-hr

Sav

ing

s-

$p

er10

00cf

m

30000

25000

20000

15000

10000

5000

0

0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15

8000 Hrs

6000 Hrs

4000 Hrs

2000 Hrs

Power Savings Per 1000 cfm

Two-stage tandem vs single-stagerotary screw at full load. At a powercost of $.08/kW/hr, the black dottedline shows that a tandem two-stage

compressor will save $14,373 per1,000 cfm over a single-stagecompressor operating for 8,000 hoursat 100 psig. At a power cost of$.12/kW/hr, the green dotted line showsa saving of $21,560 per 1,000 cfm over

a single-stage compressor operatingfor 8,000 hours at 100 psig. Thesavings will be significantly greater forhigher capacity compressors.

Power Savings per 1000 cfm onTS-32

Energy SavingsTwo-Stage Over Single-Stage, Full Load

Decades of Proven Reliability areTestimony to the Quality of theSullair Air End

Although the principle of rotary screwcompression remains the same, Sullairis continually improving materials,engineering and design of its air endsand compressor packages.

No Loss of Capacity or Efficiency

Sullair air ends have only two movingparts: the asymmetrical profile rotors.Contact occurs only on a lubricatedpitchline, so wear is virtually eliminated.As a result, Sullair compressors do notlose capacity or efficiency.

Longer Air End Life

Controlled pressure lubrication andBearing Fluid Reservoirs (BFR) assurea reliable supply of fluid to rotatingelements.

Lower Operating Costs

Discharge port matches ratios ofvolume and operating pressure formaximum efficiency. Axial air inletavoids preheating inlet air for furthersavings.

The Reliable Sullair Air End

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The Sullair TS-20,

Variable Capacity Control SystemFeaturing Spiral Valve Technology

• Lowers part load operating costs

• Reduces cycling duty on package

• Maintains consistent plant pressure

• Simple control

• Reduces bearing load

Two-Stage Compressor Air End• Delivers more air

• Reduces power consumption

• Extends air end bearing life

Time Proven End-to-End Design

• Reduces pressure drop throughstages

• Easier serviceability

Fiberglass Fluid Filter

• Aircraft-quality media provides betterfiltration

• Up to 20% more efficient thanconventional paper elements

• Lengthens life of the compressor

Multi-stage Air Fluid Separation

• Dual nested Optimizer™ separatorelements, reduce fluid carry-over toa maximum of 1 ppm

• Reduced carryover lowers make-upfluid costs

• Pleated Optimizer™ elements lowerinitial pressure drop for greaterefficiency and extends element life

• Easy to change with built-in lidlifting device on models TS-32and TS-32S

Optimalair™ Heavy-Duty AirIntake Filter

• Includes remote air intakeconnection

• Provides finest inlet filtration in theindustry (.4 microns using FineFiber Technology)

• Keeps fluid clean and extends lifeof other internal components

• Reduces pressure drop throughoutthe operating life, resulting inenergy savings

Sullair Supervisor™ Controller

• Computer-compatible micro-processor controller has simplegraphic illustration of monitoredfunctions and an easy-to-readkeypad

• Constant readout of pressure andtemperature

• On-demand readout of all operatingand maintenance conditions

• Monitors key functions and safetyshutdowns

• Power failure auto re-start

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Bearing Fluid Reservoirs

• Ensure that fluid is available atstartup

• Extend air end life

TS-32 andTS-32S

Interstage Cooling Process

• Absorbs heat of compression

• Dramatically reduces power costs

Motor Coupled to Air End ThroughNon-lubricated, Flexible Coupling

• Allows use of standard NEMAframe motor

• Simplifies installation and start-up

Select a Long-Life Fluid...

Sullube™ is Standard Factory Fill• 5-year air end warranty• Biodegradable• 1 year or 8000 hour service life• Reduces fluid disposal costs

24KT™ is Optional• Exclusive 10-year air end warranty• Eliminates annual fluid changes• Eliminates fluid disposal costs

Free fluid sampling and analysisprogram with either fluid.

Best Warranties in the Industry

Sullair’s Emerald 5-YearWarrantyThis unmatched warrantyincludes: the air end, motor,air/fluid receiver andcooler(s).

Sullair’s 24KT™ 10-YearWarrantyThis unprecedentedwarranty includes:10 years on the air end,5 years on the motor,air/fluid receiver andcooler(s).

• Dual control, provides automaticstart-stop operation

• Lead-lag and sequencing withmultiple compressors

• Service and preventivemaintenance schedule

• Hours are recorded for “Run”,“Loaded” and “Consumable Parts”

• Fault history with sensor readings

• “Help” key provides built-in

troubleshooting

Easy Maintenance

• Access to all critical components evenwith a sound enclosure installed

NEMA 4

• Wye Delta starter for softer start• Standard on TS-20, 250 HP and TS-32.• Optional on TS-20,100–200 HP

Enhanced Serviceability forAir-Cooled Oil Cooler andAftercoolers

• Easy to remove panels provideaccess for cleaning coolers

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It’s a fact: the electric power cost torun an air compressor continuously forone year is often 2 to 3 times greaterthan the purchase price of thecompressor itself.

That’s why Sullair developed the two-stage tandem compressor. Bycombining two-stage compressionand a spiral valve, the TS performswith unmatched full load and partload efficiency and often providesa two-year payback in energy savingscompared to a single-stagecompressor.

Energy Savings Built In

Sullair two-stage tandem compressorshave been proven to be 13 percentmore efficient than single-stage screwcompressors at full load operation. At60 percent load, the Sullair two-stagetandems provide up to 30 percentsavings over single-stagecompressors.

How ItWorks

The compression volume varies to suitthe air demand by progressivelyopening or closing internal bypassports on the air end.

Capacity is matched to systemdemand, reducing cycling time andextending component life.

Part load capacity and efficiency canproduce energy savings up to 17percent.

Variable Capacity Control SavesYouPower

The compressor displacement ismatched to the output need. The VCCtechnology assures precisionoperation for virtually any part loadpoint. It provides significant powersavings at part load conditions,compared to compressors usingsuction throttling, or load/no loadcontrol.

Increases Capacity ControlEfficiency

By activating automatically when theunit is operating under partial load,and allowing the compression of onlythe required quantity of air, the spiralvalve increases the efficiency of thecompression process. The ultimateresult is greater compressionefficiency and reduced powerconsumption.

The Sullair Two-StageTandem CompressorPart Load Savings

EffectiveCompressionVolume

CompressedAir Out

Air Inlet

Closed Bypass Ports Partially Open Bypass Ports Open Bypass Ports

EffectiveCompressionVolume

CompressedAir Out

Air Inlet

EffectiveCompressionVolume

CompressedAir Out

Air Inlet

Rotors withdrawn to show bypassports in stator.

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Sullair VSD Compressors with Smart Technology

Sullair Smart Technology GivesYou

• Simplicity • Reliability

• Flexibility • System protection

Variable Speed Drive AvoidsPotential Peak Demand Charges

The Sullair Two-Stage Seriescompressors provide the highestpower factor over the entire frequencyrange, often avoiding utility companypenalties.

Reliability

• Designed from the frame up as acomplete package — not built witha variety of off-the-shelf components

• Serial communication between theSupervisor™ Controller and VSDeliminates the need for hard wiredrelays

Soft Start is Standard

• Eliminate the need for Wye Deltaand other soft starter

• Avoid high electrical current atstart-up

Compressors with Sullair SmartTechnology Provide:

• Excellent energy savings

• Relief from potential peakdemand charges

• Alleviation from electrical harmonics

• Stable system pressure

• Consistent product quality

• Reduced storage requirements

• Flexibility for future growth

• Lowest five-year life cycle cost

• Potential utility company rebate

Variable Speed Drive is the superioralternative to other compressorcontrol systems.

Stable system pressure improves theconsistency of your process reducingproduct rejects. Maximizing energysavings means increased profits.

Energy Efficient

This compressor series is moreenergy efficient than similarcompressors, thanks to:

• Sullair’s proven air end with lowrestriction inlet valve

• Optimized fluid system that reducesfluid temperatures

• Premium efficient motors

• Low pressure drop air-fluidseparation system

• High efficiency fan

Considering that energy costsrepresent 82 percent of the total costof owning compressors, thesesavings significantly reduce total lifecycle costs.

Total Compressor Flexibility

Sullair’s Variable Speed Driveprovides the flexibility to vary bothcapacity and pressure. This flexibilitymakes it possible to “grow” your airsystem without adding anothercompressor.

It’s the compressor for today,tomorrow, and the future.

ConventionalSystem Pressure

SullairSmart TechnologySystem Pressure

0

20

40

60

80

100

120

1000 10 20 30 40 50 60 70 80 90

%P

ow

er

% Capacity

PART LOAD PERFORMANCE ASSESSMENT

Load/Unload

Inlet Modulation withBlowdown

Variable Speed withVariable Displacement

Variable Speed Drive is the superior alternative to other compressor control systems. The chart aboverepresents the nominal control systems for generic comparative purposes. A detailed and accuratecomparison of specific compressor models is available from your Sullair representative or authorized distributor.

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Lowest Fluid CarryoverWhile others claim a low carryover of 5 ppm or more,Sullair’s singe-stage compressors offer a carryover rateless than 1 ppm— the lowest in the industry. Sullair’sMSS, Multi-Stage Separation, uses a sump design, whichallows use of oversized dual nested separators.

Sullair Optimizer™ Air/FluidSeparatorA high-efficiency separator thatwill pay for itself (during the life ofthe separator) in reducedcompressor fluid carryover andelectrical power consumption.

Air Quality Is One of the Best in the Industry

Ounces of fluid carryover per 24 hours

0 200 400 600 800 1000 1200 1400 1600

18

16

14

12

10

8

6

4

6PPM

5PPM

4 PPM

3 PPM

2 PPM

1 PPM

CFM

Flu

idC

arry

ove

ro

z./2

4H

ou

rs

SullairOptimizer™

Two Levels of AirQualitySullair recognizesthat the requirementsfor air quality vary

according to eachcompressed air application. For thisreason, Sullair provides compressedair systems that achieve two distinctlevels of air quality and a guaranteefor each.

The Sullair SystemThe Sullair System matches a Sullaircompressor, a Sullair dryer and Sullairfilters. Sullair assures that its Systemwill meet specific performance levelsthroughout its operational life. We offera one-year test/review period, backedby a purchase refund guarantee, toverify the performance of the SullairSystem.

Select the SystemSelect the air quality level to meet yourplant air or process requirements. Youcan be assured that the quality of airfrom the Sullair System you specify willremain consistent for the life of theequipment. Sullair guarantees it... andthat’s as good as gold.

The Sullair Oil-Free Air QualityGuaranteeThe System consists of a Sullaircompressor, Sullair dryer, and SullairSCF and SCH or PF/PH filters. Thecompressed air from this systemcontains particulates no larger than.01 micron, including coalesced liquidwater and lubricants. Maximumremaining oil aerosol content is 0.01parts per million by weight (ppm/w) @70°F, including oil vapor. The air fromthis Sullair System meets the moststringent ISO standard (ISO 8573.1,

Class 1 for oil vapor and Class 2 forParticulate) for air quality.

The Sullair Critical Air QualityGuaranteeThe compressed air from this SullairSystem exceeds the ISO standard (ISO8573.1, Class 1 for oil vapor and Class2 for Particulate). The System includesa Sullair compressor, Sullair dryer, andSullair SCF, SCH, and SCC; or PF, PH,and PC filters. The odor-freecompressed air from this systemcontains particulates no larger than0.01 micron, including water and oilaerosol content of 0.01 parts permillion by weight (ppm/w) @ 70°F. Theremaining oil vapor content is less than0.003 ppm/w.

These Systems are not intended to remove carbonmonoxide, methyl isocyanate or other noxious,corrosive or toxic gases, vapors or fumes.The system does not provide breathing air.

Sullair Air Quality Guarantee

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Technical Specifications: 60 Hz Horsepower RatedTwo-Stage Compressors, 100 to 600 HP

24KT™ Models are available for 100 and 125 psig offerings.Data subject to change without notice.

Constant Speed Drive Performance Enclosed Dimensions andWeights

Full Load CapacityMotor acfm @ acfm @ acfm @ acfm @ Length Width Height Weight

Model HP 100 psig 125 psig 150 psig 175 psig inches inches inches lbsTS-20-100 100 575 500 —— —— 120 72 68 7350TS-20-125 125 680 615 575 500 120 72 68 7600TS-20-150 150 826 763 680 616 120 72 68 7900TS-20-200 200 1051 960 826 776 120 72 68 8100TS-20-250 250 1200 1132 1035 960 120 72 68 8450

TS-32-200 200 1105 —— —— —— 154 78 86 12480TS-32-250 250 1335 1240 1100 —— 154 78 86 12720TS-32-300 300 1640 1440 1330 1240 154 78 86 13270TS-32-350 350 1875 1733 1575 1440 154 78 86 13620

TS-32S-400 400 2220 1943 1681 —— 175 84 92 15900TS-32S-450 450 2350 2135 1943 —— 175 84 92 15900TS-32S-500 500 2530 2350 2220 —— 175 84 92 16400TS-32S-600 600 3000 2700 2530 —— 175 84 92 16400

Variable Speed Drive Performance Enclosed Dimensions andWeights

Full Load CapacityMotor acfm @ acfm @ acfm @ acfm @ Length Width Height Weight

Model HP 100 psig 125 psig 150 psig 175 psig inches inches inches lbsV-200TS-100 100 550 495 —— —— 120 72 68 7675V-200TS-125 125 606 555 515 —— 120 72 68 7975V-200TS-150 150 800 720 653 610 120 72 68 8375V-200TS-200 200 1000 918 815 750 120 72 68 8550

V-320TS-200 200 1105 945 —— —— 154 78 86 12480V-320TS-250 250 1300 1180 1050 —— 154 78 86 12720V-320TS-300 300 1550 1400 1250 —— 154 78 86 13270V-320TS-350 350 1800 1645 1480 —— 154 78 86 13620V-320TS-400 400 2075 1870 1695 —— 175 84 92 15900V-320TS-450 450 2310 2100 1900 —— 175 84 92 15900

Sullair Corporation3700 East Michigan Boulevard, Michigan City, IN 46360Telephone: 1-800-SULLAIR or 1-219-879-5451www.sullair.com

Sullair Corporation, a Business Unit of Hamilton Sundstrand,a United Technologies Company.© Copyright 2009 Sullair Corporation. All rights reserved.The color green is a registered trademark of Sullair Corporation.Specifications subject to change without notice.TS01E 0907R7.5

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SULLAIR CORPORATIONMichigan City, Indiana USA