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Sullair LS-120 series Operators Manual And Parts Lists

Industrial air compressor. 40, 50, 60, 75 & 100hp/ 37, 45, 56 & 75kw air-cooled & water-cooled std & 24kt
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INDUSTRIAL AIR
COMPRESSOR
LS-1 1 20 & &
LS-1 1 60
40, 50, 60, 75 & 100HP/
37, 45, 56 & 75KW
AIR-COOLED & WATER-COOLED
STD & 24KT
OPERATOR'S
MANUAL AND
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Part Number 02250143-898
©Sullair Corporation

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Summary of Contents for Sullair LS-120 series

  • Page 1 COMPRESSOR LS-1 1 20 & & LS-1 1 60 40, 50, 60, 75 & 100HP/ 37, 45, 56 & 75KW AIR-COOLED & WATER-COOLED STD & 24KT OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250143-898 ©Sullair Corporation...
  • Page 2 AIR CARE SEMINAR TRAINING Sullair Air Care Seminars are 3-day courses that provide hands-on instruction in the proper operation, maintenance and service of Sullair equipment. Individual seminars on Industrial compressors and com- pressor electrical systems are presented at regular intervals throughout the year at a dedicated training facility at Sullair’s corporate headquarters in Michigan City, Indiana.

  • Page 3: Table Of Contents

    1.8 ELECTRICAL SHOCK 1.9 LIFTING 1.10 ENTRAPMENT Section 2 DESCRIPTION 2.1 INTRODUCTION 2.2 DESCRIPTION OF COMPONENTS 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNCTIONAL DESCRIPTION 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION- STANDARD ELECTRO-MECHANICAL 2.7 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION-...
  • Page 4 TABLE OF CONTENTS Section 4 PAGE INSTALLATION 4.1 MOUNTING OF COMPRESSOR 4.2 VENTILATION AND COOLING 4.3 SERVICE AIR PIPING 4.4 COUPLING ALIGNMENT CHECK 4.5 FLUID LEVEL CHECK 4.6 ELECTRICAL PREPARATION- STANDARD ELECTRO- MECHANICAL 4.7 ELECTRICAL PREPARATION- SUPERVISOR CONTROLLER 4.8 MOTOR ROTATION DIRECTION CHECK- STANDARD ELECTRO-MECHANICAL 4.9 MOTOR ROTATION DIRECTION CHECK- SUPERVISOR CONTROLLER...
  • Page 5 TABLE OF CONTENTS Section 7 PAGE MAINTENANCE (CONTINUED) PRESSURE REGULATOR ADJUSTMENT DRIVE COUPLING INSTALLATION AND MAINTENANCE Section 8 TROUBLESHOOTING ELECTRO-MECHANICAL 8.1 TROUBLESHOOTING - STANDARD ELECTRO-MECHANICAL 8.2 TROUBLESHOOTING GUIDE - STANDARD ELECTRO- MECHANICAL Section 9 ILLUSTRATIONS AND PARTS LIST 9.1 PROCEDURE FOR ORDERING PARTS 9.2 RECOMMENDED SPARE PARTS LIST 9.3 MOTOR, FRAME, COMPRESSOR AND PARTS LS-120 (40-60HP/ 37-45KW)
  • Page 6 TABLE OF CONTENTS Section 9 ILLUSTRATIONS AND PARTS LIST (CONTINUED) 9.24 CANOPY- WATER-COOLED (40-75HP/ 37-56KW) 10.25 CANOPY- WATER-COOLED LS-160 (100HP/ 75KW) 9.26 DECAL GROUP 9.27 WIRING DIAGRAM - ELECTRO-MECHANICAL FULL VOLTAGE 9.28 WIRING DIAGRAM - SUPERVISOR CONTROLLER WYE-DELTA...

  • Page 7: General

    SAFETY 1.1 GENERAL the service air outlet and the shut-off (throttle) Sullair Corporation and its subsidiaries design and valve, either at the compressor or at any other point manufacture all of their products so they can be along the air line, when an air hose exceeding operated safely.

  • Page 8: Fire And Explosion

    Section 1 SAFETY death or serious injury may result. environment unless the compressor has been spe- cially designed and manufactured for that duty. 1.4 FIRE AND EXPLOSION A. Clean up spills of lubricant or other combustible 1.5 MOVING PARTS substances immediately, if such spills occur. A.

  • Page 9: Electrical Shock

    Section 1 SAFETY supplying respirators or other breathing air utiliza- or repairs with one hand only, so as to minimize the tion equipment and DO NOT discharge air from possibility of creating a current path through the these systems into unventilated or other confined heart.

  • Page 10: Entrapment

    Section 1 SAFETY pallet if provided. If neither fork pockets or pallet are cause the compressor to tumble off, possibly caus- provided, then make sure compressor is secure ing serious injury or property damage in the and well balanced on forks before attempting to process.

  • Page 11: Introduction

    With a Sullair compressor, there is no mainte- On air-cooled models, a fan draws air over the nance or inspection of the internal parts of the Figure 2-1 Sullair Rotary Screw Air Compressor - Air-cooled (Typical component layout)

  • Page 12: Compressor Cooling And Lubrication System, Functional Description

    Section 2 DESCRIPTION Figure 2-2 Sullair Rotary Screw Air Compressor- Water-cooled (Typical component layout) compressor unit permitted in accordance with the stator and also between the rotors themselves. terms of the warranty. 3. Acts as a lubricating film between the rotors...

  • Page 13: Compressor Discharge System, Functional Description

    Section 2 DESCRIPTION [190ºF (88ºC) for 24KT, and rated pressures 150 visual sight glass is located on the return line to psig and above]. The fluid passes through the ther- observe this fluid flow. There is also an orifice in mal valve, the main filter and directly to the com- each return line (protected by a strainer) to assure pressor unit where it lubricates, cools and seals the...
  • Page 14 Section 2 DESCRIPTION Figure 2-3 Compressor Fluid Cooling/ Lubrication and Discharge System- Air-cooled...
  • Page 15 Section 2 DESCRIPTION Figure 2-4 Compressor Fluid Cooling/ Lubrication and Discharge System- Water-cooled...
  • Page 16 Section 2 DESCRIPTION Figure 2-5 Control System...

  • Page 17: Control System, Functional Description- Supervisor Controller

    Section 2 DESCRIPTION guidelines apply to all Series 12 & 16 Series com- time, the solenoid valve allows dry sump tank air pressors. For explanatory purposes this description pressure or service air pressure through a shuttle will apply to a compressor with an operating pres- valve to be applied directly to the inlet valve piston sure range of 125 to 135 psig (8.6 to 9.3 bar).

  • Page 18: Air Inlet System, Functional Description

    Section 2 DESCRIPTION rpm has been achieved. During this period, both on high pressure [“H”] compressors, 150 psig [10.3 the pressure regulator and the solenoid valve are bar] on [“HH”] compressors, 175 psig [12.0 bar] closed, the inlet valve is fully open and the com- [“XH”] .
  • Page 19 Section 2 DESCRIPTION pressor must be running fully loaded for an Figure 2-6 Air Inlet System accurate indication. · The START " " pad turns the compressor • The STOP " " pad turns the compressor off. • The hourmeter records accumulative hours of operation for the compressor and is use- ful for planning and logging service opera- tions.
  • Page 20 Section 2 DESCRIPTION • The red light on the instrument panel indi- pressor is in AUTO mode. cates when power to the compressor is sup- • The HAND/AUTO switch (dual control plied. package) is supplied with an amber auto • The green light indicates when the com- mode indicator light to indicate that the unit pressor is running.

  • Page 21: Table Of Specifications

    2720/3210 L, H 59.4 2740/3410 For latest sound test data, consult Sullair Factory. Includes standard and 24KT. Rated pressure designations appearing after model number are as follows: “L”- 100 psig /6.9 bar “H”- 125 psig/8.6 bar “HH”- 150 psig/10.3 bar “XH”- 175 psig/12 bar...

  • Page 22: Lubrication Guide

    3560 RPM (60 Hz) or 2945 (50 Hz) 100 (“H”)HP: 1780 RPM (60 Hz) or 2945 (50 Hz) For latest sound test data, consult Sullair Factory. (V) Multi-frequency and voltage motors are used. The compressors must be used only with the specified electrical frequency and voltage.

  • Page 23: Application Guide

    3.3 APPLICATION GUIDE fice or line plugging. Sullair encourages the user to participate in a fluid analysis program with the fluid suppliers. This could result in a fluid change interval differing from that stated in the manual.
  • Page 24 Section 3 SPECIFICATIONS Figure 3-2 Identification- LS-120 & LS-160 Electro-mechanical Dual Control & Supervisor Controller (Water-cooled) 02250101-748R01...
  • Page 25 Section 3 SPECIFICATIONS Figure 3-3 Identification- LS-120 Electro-mechanical Dual Control & Supervisor Controller (Air-cooled) 02250142-969R00...
  • Page 26 Section 3 SPECIFICATIONS Figure 3-4 Identification- LS-120 & LS-160 Electro-mechanical Dual Control & Supervisor Controller with Enclosure (Water- cooled) 02250101-750R01...
  • Page 27 Section 3 SPECIFICATIONS Figure 3-5 Identification- LS-160 Electro-mechanical Dual Control & Supervisor Controller with Enclosure (Air-cooled) 02250142-736R02...
  • Page 28 NOTES...

  • Page 29: Mounting Of Compressor

    (up to the fill plug). heating, providing no additional pressure drop is ELECTRICAL PREPARATION- STANDARD created across the fan. Consult a Sullair office for ELECTRO-MECHANICAL assistance in utilizing this heat. Interior electrical wiring is performed at the factory.
  • Page 30 Lethal shock hazard inside. Disconnect all power at source before opening or servicing. concerning isolation switches, fused disconnects, etc. Sullair provides a wiring diagram for use by the 1. Check incoming voltage. Be sure that compres- installer. sor is wired for the correct incoming voltage.

  • Page 31: Electrical Preparation- Supervisor Controller

    " (STOP) push button immediately. ble local electrical code concerning isolation switch- This indicates improper motor rotation. Disconnect es, fused disconnects, etc. Sullair provides a wiring the power to the starter and exchange any two of diagram for use by the installer.
  • Page 32 Section 5 OPERATION- ELECTRO-MECHANICAL Figure 5-1 Instrument Panel- Electro-mechanical Controller...

  • Page 33: General Introduction- Standard Electro- Mechanical

    TRO-MECHANICAL malfunction. Before starting your Sullair compres- While Sullair has built into this compressor a com- sor, read this section thoroughly and familiarize prehensive array of controls and indicators to...
  • Page 34 Section 5 OPERATION- ELECTRO-MECHANICAL 5.2 PURPOSE OF CONTROLS- STANDARD ELECTRO-MECHANICAL (CONTINUED) CONTROL OR INDICATOR PURPOSE Indicates when the starter is receiving power. POWER ON ( ) LED Indicates when compressor is in operation: ON LED Indicates that machine is running. -SOLID (CONTINUOUS) LIGHT Indicates that machine is in ‘standby’...

  • Page 35: Initial Start-Up Procedure

    Section 5 OPERATION- ELECTRO-MECHANICAL 5.2 PURPOSE OF CONTROLS- STANDARD ELECTRO-MECHANICAL (CONTINUED) CONTROL OR INDICATOR PURPOSE PRESSURE SWITCH Senses service line pressure. When line pressure reaches maximum setting the pressure switch signals the pilot valves to unload the compressor. BLOWDOWN VALVE Vents sump pressure to the atmosphere during unload condi- tions and shutdown.
  • Page 36 Section 6 OPERATION- SUPERVISOR CONTROLLER™ Figure 6-1 Instrument Panel- Supervisor Controller For information concerning all aspects of the Supervisor Controller, consult the Supervisor Controller manual no. 02250133-517.

  • Page 37: General

    Section 7 MAINTENANCE 7.1 GENERAL Figure 7-1 Fluid Filter (P/N 02250054-605) As you proceed in reading this section, it will be easy to see that the Maintenance Program for the air compressor is quite minimal. The use of the service indicators provided for the fluid filter, air fil- ter and fluid separator, will alert you when service maintenance is required.
  • Page 38 5. At this time replace the element. ture, it is important that ONLY replacement ele- 6. Reassemble in the reverse order of the disas- ments identified with the Sullair name, logo and sembly. appropriate part number be used and that substi-...
  • Page 39 Section 7 MAINTENANCE Figure 7-3 Air Filter Replacement LS-160 (100HP/ 75KW) (P/N 02250059-096) *Primary Replacement Element P/N 02250046-012 **Secondary Replacement Element P/N 02250046-013 secure primary element in place. Figure 7-4 Separator Element Replacement 11. Replace the cover 12. Secure the cover by tightening the wingnut. ELEMENT INSPECTION 1.
  • Page 40 Section 7 MAINTENANCE Figure 7-5 Pressure Switch 12. Clean the return line strainers before restarting (P/N 040694) 50-75 HP/ 30-55 KW the compressor. CONTROL SYSTEM ADJUSTMENT Refer to Figure 7-5. Prior to adjusting the Control System, it is necessary to determine the desired operating pressure range and also the maximum pressure at which your compressor is to operate.
  • Page 41 Section 7 MAINTENANCE keeps on rising or if the modulation does not regulator until air just begins to escape from the begin, adjust the After adjustment, line pressure control air orifice. The regulator is now properly set. should be approximately 126 psig (8.7 bar) and DRIVE COUPLING INSTALLATION AND MAIN- 1.00 in.
  • Page 42 Section 7 MAINTENANCE After tightening the bolts, tighten the set screws and Figure 7-7 Drive Coupling remove the hose clamp form the flexible element. Check the coupling gap as listed in Table 1- Installation Data, and shown in Figure 7-6. At this time, the coupling is ready for operation.
  • Page 43 Section 7 MAINTENANCE Figure 7-8 Piping and Instrumentation Diagram- Standard...
  • Page 44 Section 7 MAINTENANCE Figure 7-9 Piping and Instrumentation Diagram- Supervisor Controller...

  • Page 45: Troubleshooting Guide - Standard Electro

    Should your problem persist after making the rec- tematically analyzed before undertaking any repairs ommended check, consult your nearest Sullair rep- or component replacement procedures. resentative. A detailed visual inspection is worth performing for almost all problems and may avoid unnecessary 8.2 TROUBLESHOOTING GUIDE-STANDARD ELECTRO-MECHANICAL...
  • Page 46 Section 8 TROUBLESHOOTING- ELECTRO-MECHANICAL 8.2 TROUBLESHOOTING GUIDE-STANDARD ELECTRO-MECHANICAL (CONTINUED) SYMPTOM PROBABLE CAUSE REMEDY COMPRESSOR SHUTS DOWN Discharge Temperature Switch Open Cooling water flow insufficient; check water WITH AIR DEMAND PRESENT (Continued) lines and valves (water-cooled only). (CONTINUED) Cooler plugged; clean tubes. If plugging per- sists, install water conditioner (water-cooled only).
  • Page 47 Section 8 TROUBLESHOOTING- ELECTRO-MECHANICAL 8.2 TROUBLESHOOTING GUIDE-STANDARD ELECTRO-MECHANICAL (CONTINUED) SYMPTOM PROBABLE CAUSE REMEDY LINE PRESSURE RISES ABOVE Defective Blowdown Valve Check that sump pressure is exhausted to the CUT-OUT PRESSURE SETTING atmosphere when the pressure switch con- ON PRESSURE SWITCH tacts open.
  • Page 48 NOTES...

  • Page 49: Procedure For Ordering Parts

    ILLUSTRATIONS AND PARTS LIST 9.1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the com- pressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly at the addresses, fax or phone numbers below.
  • Page 50 Section 9 ILLUSTRATIONS AND PARTS LIST 9.2 RECOMMENDED SPARE PARTS LIST DESCRIPTION KIT NUMBER kit, repair for thermal valve 049542 (I) 02250105-553 kit, repair for thermal valve 250028-762 (II) 02250112-709 kit, repair for pressure regulator 02250084-027 (120 Series) 250019-453 kit, repair for pressure regulator 250017-280 (160 Series) 250019-453 kit, repair for blowdown valve 02250100-042 02250100-042...
  • Page 51 Section 9 ILLUSTRATIONS AND PARTS LIST NOTES...
  • Page 52 Section 9 ILLUSTRATIONS AND PARTS LIST 9.3 MOTOR, FRAME, COMPRESSOR AND PARTS LS-120 (40-60HP/ 37-45KW)
  • Page 53 Section 9 ILLUSTRATIONS AND PARTS LIST 9.3 MOTOR, FRAME, COMPRESSOR AND PARTS LS-120 (40-60HP/ 37-45KW) part number description number quantity washer, reg pltd 5/8" 838210-112 •washer, reg pltd 1/2" (I) 838208-112 washer, springlock 5/8" 837810-156 •washer, springlock 1/2" (I) 837808-125 capscrew, hex GR5 5/8-11x 1 1/4"...
  • Page 54 Section 9 ILLUSTRATIONS AND PARTS LIST 9.3 MOTOR, FRAME, COMPRESSOR AND PARTS LS-120 (40-60HP/ 37-45KW)
  • Page 55 (I) Used on compressors with vibration mounts. (II) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sullair distributors or the factory at less cost than the owner could repair the unit. For information regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation.

  • Page 56: Motor, Frame, Compressor And Parts

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.4 MOTOR, FRAME, COMPRESSOR AND PARTS LS-160 (60-100HP/ 45-75KW)

  • Page 57: Motor, Frame, Compressor And Parts

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.4 MOTOR, FRAME, COMPRESSOR AND PARTS LS-160 (60-100HP/ 45-75KW) part number description number quantity washer, reg 5/8" 838210-112 •washer, reg 1/2" (I) 838208-112 washer, springlock 5/8" 837810-156 •washer, springlock 1/2" (I) 837808-125 capscrew, hex GR5 5/8"-11 x 1 1/4" 829110-125 Scapscrew, hex GR5 1/2"-13 x 1 1/4"...
  • Page 58 Section 9 ILLUSTRATIONS AND PARTS LIST 9.4 MOTOR, FRAME, COMPRESSOR AND PARTS LS-160 (60-100HP/ 45-75KW)
  • Page 59 (I) Used on compressors with vibration mounts. (II) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sullair distributors or the factory at less cost than the owner could repair the unit. For information regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation.
  • Page 60 Section 9 ILLUSTRATIONS AND PARTS LIST 9.5 AIR INLET SYSTEM LS-120...
  • Page 61 Section 9 ILLUSTRATIONS AND PARTS LIST 9.5 AIR INLET SYSTEM LS-120 part number description number quantity filter, air 9" (I) 02250127-683 elbow, tube-M 1/4" x 1/8" 250018-429 band, 9" air filter 049104 clamp, hose 040642 elbow, rubber 90º 4" 040550 gasket, 5 1/4"...

  • Page 62: Air Inlet System Ls-160 Air-Cooled

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.6 AIR INLET SYSTEM LS-160 AIR-COOLED...
  • Page 63 Section 9 ILLUSTRATIONS AND PARTS LIST 9.6 AIR INLET SYSTEM LS-160 AIR-COOLED part number description number quantity support, air filter 02250098-457 screw, hex ser washer 3/8" x 1" 829706-100 screw, hex ser washer 5/16" x 3/4" 829705-075 nut, hex flgd 5/16"-18 825305-283 filter, air inlet (60&...

  • Page 64: Air Inlet System Ls-160 Water-Cooled

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.7 AIR INLET SYSTEM LS-160 WATER-COOLED...
  • Page 65 Section 9 ILLUSTRATIONS AND PARTS LIST 9.7 AIR INLET SYSTEM LS-160 WATER-COOLED part number description number quantity support, air filter 02250106-704 screw, hex ser washer 3/8" x 1" 829706-100 capscrew, hex GR5 3/8"-16 x 2 1/2" 829106-250 washer, reg 3/8" 838206-071 filter, air inlet (60&...

  • Page 66: Cooling And Lubrication System (Air-Cooled)

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 COOLING AND LUBRICATION SYSTEM (AIR-COOLED)
  • Page 67 Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 COOLING AND LUBRICATION SYSTEM (AIR-COOLED) part number description number quantity cooler, fluid/after (40, 50HP/ 37KW) 02250096-705 •cooler, fluid/after (60-75HP/ 45-56KW) 02250096-706 •cooler, fluid/after (100HP/ 75KW) 02250053-915 elbow, tube 1" x 1 5/16" 811616-131 •elbow, tube (100HP/ 75KW) 811620-162 tube, thermal valve to cooler (40, 50HP/ 37KW)

  • Page 68: Cooling And Lubrication System

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 COOLING AND LUBRICATION SYSTEM (AIR-COOLED)
  • Page 69 Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 COOLING AND LUBRICATION SYSTEM (AIR-COOLED) (CONTINUED) part number description number quantity screw, hex ser washer 5/16" x 1/2" 829705-050 washer, springlock #10 837802-047 nut, hex plated #8 x 32 825201-130 decal, warning mixing fluids 02250110-891 decal, warning compressor fluid fill cap 049685...
  • Page 70 Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 COOLING AND LUBRICATION SYSTEM LS-120 (WATER-COOLED)
  • Page 71 Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 COOLING AND LUBRICATION SYSTEM LS-120 (WATER-COOLED) part number description number quantity o-ring, viton 2-1/2" x 3/32" 826502-144 element, thermal valve 175-deg 049542 •element, thermal valve 190-deg 250028-762 seal, u-cup viton 02250101-372 housing, thermal valve (I) 02250092-929 capscrew, ferry hd pltd 3/8"-16 x 1-1/2"...
  • Page 72 Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 COOLING AND LUBRICATION SYSTEM LS-120 (WATER-COOLED)
  • Page 73 Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 COOLING AND LUBRICATION SYSTEM LS-120 (WATER-COOLED) (CONTINUED) part number description number quantity clamp, exhaust 5" (40, 50HP/ 37KW) 043364 •clamp, exhaust 5" (60-75HP/ 45-56KW) 043364 washer, pl-b reg plated 1/2" (40, 50HP/ 37KW) 838208-112 •washer, pl-b reg plated 1/2"...
  • Page 74 Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 COOLING AND LUBRICATION SYSTEM LS-120 (WATER-COOLED)
  • Page 75 Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 COOLING AND LUBRICATION SYSTEM LS-120 (WATER-COOLED) (CONTINUED) part number description number quantity transducer, pressure 0-250psi n4 02250078-933 decal, warning mixing fluids 02250110-891 sign, warning compressor fluid fill cap 049685 decal, fluid Sullube (IV) 02250069-389 decal, "water out"...
  • Page 76 Section 9 ILLUSTRATIONS AND PARTS LIST 9.10 COOLING AND LUBRICATION SYSTEM LS-160 (WATER-COOLED)
  • Page 77 Section 9 ILLUSTRATIONS AND PARTS LIST 9.10 COOLING AND LUBRICATION SYSTEM LS-160 (WATER-COOLED) part number description number quantity o-ring, viton 2-1/2" x 3/32" 826502-144 element, thermal valve 175-deg 049542 •element, thermal valve 190-deg 250028-762 seal, u-cup viton 02250101-372 housing, thermal valve (I) 02250092-929 capscrew, ferry hd pltd 3/8"-16 x 1-1/2"...
  • Page 78 Section 9 ILLUSTRATIONS AND PARTS LIST 9.10 COOLING AND LUBRICATION SYSTEM LS-160 (WATER-COOLED)
  • Page 79 Section 9 ILLUSTRATIONS AND PARTS LIST 9.10 COOLING AND LUBRICATION SYSTEM LS-160 (WATER-COOLED) (CONTINUED) part number description number quantity clamp, exhaust 5" 043364 washer, pl-b reg plated 1/2" 838208-112 washer, springlock reg plated 1/2" 837808-125 tubing, nylon 1/4" black 02250054-861 heat exchanger, air/water 5"...

  • Page 80: Cooler Assembly (Air-Cooled)

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.11 COOLER ASSEMBLY (AIR-COOLED)
  • Page 81 Section 9 ILLUSTRATIONS AND PARTS LIST 9.11 COOLER ASSEMBLY (AIR-COOLED) part number description number quantity cooler, fluid/aftercooler (60-75HP/ 45-56KW) 02250096-706 cooler, fluid/aftercooler (100HP/ 75KW) 02250053-915 cooler, fluid/aftercooler (40, 50HP/ 37KW) 02250142-507 adapter, venturi (60-75HP/ 45-56KW) 250017-270 •adapter, venturi (100HP/ 75KW) 02250142-635 adapter, venturi (40, 50HP/ 37KW) 250017-271...
  • Page 82 Section 9 ILLUSTRATIONS AND PARTS LIST 9.11 COOLER ASSEMBLY (AIR-COOLED)
  • Page 83 Section 9 ILLUSTRATIONS AND PARTS LIST 9.11 COOLER ASSEMBLY (AIR-COOLED) (CONTINUED) part number description number quantity angle, cooler assembly support (60-75HP/ 45-56KW) 02250142-588 •angle, cooler assembly support (40, 50HP/ 37KW) 250018-121 nut, retainer 5/16"-18 861405-092 nut, hex locking 3/8"-16 825506-198 washer, springlock 3/8"...

  • Page 84: Compressor Discharge System (Air-Cooled)

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 COMPRESSOR DISCHARGE SYSTEM (AIR-COOLED)
  • Page 85 Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 COMPRESSOR DISCHARGE SYSTEM (AIR-COOLED) part number description number quantity cooler, fluid aftercooler (LS-120) 02250142-507 •cooler, fluid aftercooler (LS-160 60-75HP/45-56KW) 02250096-706 •cooler, fluid aftercooler (100HP/ 75KW) 02250053-915 nipple, pipe 1 1/2" x close 866424-000 coupling, reducing 2"...
  • Page 86 Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 COMPRESSOR DISCHARGE SYSTEM (AIR-COOLED)
  • Page 87 Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 COMPRESSOR DISCHARGE SYSTEM (AIR-COOLED) (CONTINUED) part number description number quantity filter, assy genesis (III) 02250117-782 separator, air/fluid secondary (IV) 02250100-754 separator, air/fluid primary (I) 02250100-753 tank, separator 14" (40, 50HP/ 37KW) 02250109-524 •tank, separator 14" (60-100HP/75KW) 02250110-502 decal, maintenance kit LS120/160 02250144-505...
  • Page 88 Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 COMPRESSOR DISCHARGE SYSTEM (AIR-COOLED)
  • Page 89 Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 COMPRESSOR DISCHARGE SYSTEM (AIR-COOLED) (CONTINUED) part number description number quantity adapter, discharge 02250097-526 capscrew, ferry hd 3/8"-16 x 2 1/4" 828406-225 elbow, tube-M 1/4" x 1/4" SS 250211-005 connector, tube-SAE 1/4" x 7/16" 870906-025 flange, split 2"...

  • Page 90: Discharge System (Water-Cooled

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 COMPRESSOR DISCHARGE SYSTEM (WATER-COOLED)
  • Page 91 Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 COMPRESSOR DISCHARGE SYSTEM (WATER-COOLED) part number description number quantity elbow, tube-M 1 1/2" x 1 1/2" (LS-120) 810524-150 •elbow, tube-M 2” x 2” (LS-160) 810532-200 heat exchange (40, 50HP/ 37KW) 250017-527 •heat exchange (60-75HP/ 45-56KW) 040680 •heat exchange (100HP/ 75KW) 043008...
  • Page 92 Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 COMPRESSOR DISCHARGE SYSTEM (WATER-COOLED)
  • Page 93 Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 COMPRESSOR DISCHARGE SYSTEM (WATER-COOLED) (CONTINUED) part number description number quantity separator, moisture (40, 50HP/ 37KW) (III) 02250144-635 •separator, moisture (60-75HP/ 45-75KW) (IV) 02250144-633 •separator, moisture (100HP/ 75KW) (V) 02250144-632 filter, assembly genesis (VI) 02250117-782 orifice 02250125-774...
  • Page 94 Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 COMPRESSOR DISCHARGE SYSTEM (WATER-COOLED)
  • Page 95 Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 COMPRESSOR DISCHARGE SYSTEM (WATER-COOLED) (CONTINUED) part number description number quantity plug, sight glass 1 7/8" 02250097-611 switch, temp 240º 3/4" SAE 02250100-095 coupling, conduit 1/2" 250007-179 locknut, conduit 1/2" 847200-050 elbow, conduit 1/2" 846600-050 capscrew, hex GR5 1/2"-13 x 1 1/2"...

  • Page 96: Control System Ls-120 Supervisor Controller

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.14 CONTROL SYSTEM- LS-120 SUPERVISOR CONTROLLER...
  • Page 97 Section 9 ILLUSTRATIONS AND PARTS LIST 9.14 CONTROL SYSTEM- LS-120 SUPERVISOR CONTROLLER part number description number quantity oirifice, .25 x 1/4”m x 1/4”f 02250143-403 elbow, 37º fl 90º m 1/2” x 1/4” 860208-025 hose, med pressure .5” x 32” 249608-008 connector, tube-F 1/4"...

  • Page 98: Control System Ls-120 Electro-Mechanical

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.15 CONTROL SYSTEM- LS-120 ELECTRO-MECHANICAL...
  • Page 99 Section 9 ILLUSTRATIONS AND PARTS LIST 9.15 CONTROL SYSTEM- LS-120 ELECTRO-MECHANICAL part number description number quantity oirifice, .25 x 1/4”m x 1/4”f 02250143-403 elbow, 37º fl 90º m 1/2” x 1/4” 860208-025 hose, med pressure .5” x 32” 249608-008 tee, male 1/4"T x 1/4"P 250028-582 strainer, v-type (I) 241771...

  • Page 100: Control System Ls-160 Supervisor Controller

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.16 CONTROL SYSTEM- LS-160 SUPERVISOR CONTROLLER...
  • Page 101 Section 9 ILLUSTRATIONS AND PARTS LIST 9.16 CONTROL SYSTEM- LS-160 SUPERVISOR CONTROLLER part number description number quantity tubing, nylon .25" 02250054-861 31 ft connector, 1/4"T x 1/8"P 250018-427 plug, pipe 1/8" 807800-005 elbow, 37º fl 1/4” x 1/2” 860208-025 oirifice, .25 x 1/4”m x 1/4”f 02250143-403 hose, med pressure .5”...

  • Page 102: Control System Ls-160 Electro-Mechanical

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.17 CONTROL SYSTEM- LS-160 ELECTRO-MECHANICAL...
  • Page 103 Section 9 ILLUSTRATIONS AND PARTS LIST 9.17 CONTROL SYSTEM- LS-160 ELECTRO-MECHANICAL part number description number quantity tubing, nylon .25" 02250054-861 31 ft. connector, 1/4"T x 1/8"P 250018-427 plug, pipe 1/8" 807800-005 elbow, 37º fl 1/4” x 1/2” 860208-025 oirifice, .25 x 1/4”m x 1/4”f 02250143-403 hose, med pressure .5”...

  • Page 104: Instrument Panel- Electro-Mechanical

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.18 INSTRUMENT PANEL- ELECTRO-MECHANICAL...
  • Page 105 Section 9 ILLUSTRATIONS AND PARTS LIST 9.18 INSTRUMENT PANEL- ELECTRO-MECHANICAL part number description number quantity elbow, 90º 1/4"T x 1/8"P 250041-286 tee, adaptor 1/4"T x 1/8"M x 1/8"F 869704-012 connector, tube-F 1/4" x 1/8" 250021-379 connector, tube-F 1/4"T x 1/8"P 250139-050 decal, warning auto start (I) 041065...

  • Page 106: Instrument Panel- Supervisor Controller

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.19 INSTRUMENT PANEL- SUPERVISOR CONTROLLER 02250138-633R00...
  • Page 107 041065 decal, LS-120 02250144-155 •decal, LS-160 (not shown) 02250144-157 sign, danger electrocution 049850 decal, Sullair 2 1/2" x 20" 02250059-054 decal, electrocution hazard intnl/glbl 02250077-472 decal, ISO 9001 02250057-624 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR...

  • Page 108: Electrical Box- Electro-Mechanical

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.20 ELECTRICAL BOX- ELECTRO-MECHANICAL...
  • Page 109 Section 9 ILLUSTRATIONS AND PARTS LIST 9.20 ELECTRICAL BOX- ELECTRO-MECHANICAL part number description number quantity support, starter LH 250017-978 support, starter RH 250017-977 locknut, conduit 1" 847200-100 nipple, chase 1" conduit 847815-100 nut, hex plated 3/8"-16 825306-337 starter, assy consult factory transformer, 250VA univ W/FH 02250083-188 plug, hole 1"...

  • Page 110: Electrical Box- Supervisor Controller

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.21 ELECTRICAL BOX- SUPERVISOR CONTROLLER...
  • Page 111 Section 9 ILLUSTRATIONS AND PARTS LIST 9.21 ELECTRICAL BOX- SUPERVISOR CONTROLLER part number description number quantity support, starter LH 250017-978 support, starter RH 250017-977 locknut, conduit 1" 847200-100 nipple, chase 1" conduit 847815-100 grip, cord 02250071-380 starter, assy consult factory transformer, 250VA univ W/FH 02250083-188 nut, hex plated 3/8"-16...
  • Page 112 Section 9 ILLUSTRATIONS AND PARTS LIST 9.22 CANOPY- AIR-COOLED LS-120 & LS-160 (40-75HP/ 37-56KW)
  • Page 113 Section 9 ILLUSTRATIONS AND PARTS LIST 9.22 CANOPY- AIR-COOLED LS-120 & LS-160 (40-75HP/ 37-56KW) part number description number quantity frame, roof (40, 50HP/37KW) 250018-268 •frame, roof (60-100HP/45-75KW) 02250142-593 angle, seal (40, 50HP/37KW) 250018-291 •angle, seal (60-100HP/45-75KW) 02250142-712 angle, seal (40, 50HP/37KW) 250018-291 •angle, seal (60-100HP/45-75KW) 02250142-714...
  • Page 114 Section 9 ILLUSTRATIONS AND PARTS LIST 9.23 CANOPY- AIR-COOLED LS-160 (75-100HP/ 56-75KW) WITH TEFC MOTOR...
  • Page 115 Section 9 ILLUSTRATIONS AND PARTS LIST 9.23 CANOPY- AIR-COOLED LS-160 (75-100HP/ 56-75KW) WITH TEFC MOTOR part number description number quantity angle, seal 02250142-714 angle, seal 02250142-712 frame, roof 02250142-985 roof, panel assy 02250142-695 grille, enclosure end 250018-667 panel, corner LH 02250142-669 panel, end 250018-646...

  • Page 116: Canopy- Water-Cooled (40-75Hp/ 37-56Kw)

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.24 CANOPY- WATER-COOLED (40-75HP/ 37-56KW)
  • Page 117 Section 9 ILLUSTRATIONS AND PARTS LIST 9.24 CANOPY- WATER-COOLED (40-75HP/ 37-56KW) part number description number quantity motor, .25HP (230, 460V) 250000-031 grip, cord 1/2" 250021-321 wire, neoprene #16-4 850604-016 nut, hex flanged 5/16" 825305-283 screw, hex serrated washer 5/16" x 3/4" 829705-075 guard, exhaust fan 410179...

  • Page 118: Canopy- Water-Cooled Ls-160 (100Hp/75Kw)

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.25 CANOPY- WATER-COOLED LS-160 (100HP/75KW)
  • Page 119 Section 9 ILLUSTRATIONS AND PARTS LIST 9.25 CANOPY- WATER-COOLED LS-160 (100HP/75KW) part number description number quantity guard, fan 20" upper 241137 roof, panel assy 250026-022 panel, access roof 250017-308 roof, panel assy 02250123-534 fan, 18" 410358 guard, fan 20" lower 410179 motor consult factory...

  • Page 120: Decal Group

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.26 DECAL GROUP...
  • Page 121 V 230/3/60 international 02250069-397 decal, V 380-415/3/50 international 02250069-403 decal, V 200/3/60 international 02250069-406 decal, V 575/3/60 international 02250069-400 decal, Sullair 2 1/2" x 20" 02250059-054 •decal, Sullair 4" x 32" 02250059-060 decal, rotation 250021-564 decal, water drain 250022-810...
  • Page 122 Section 9 ILLUSTRATIONS AND PARTS LIST 9.26 DECAL GROUP...
  • Page 123 Section 9 ILLUSTRATIONS AND PARTS LIST 9.26 DECAL GROUP (CONTINUED) part number description number quantity decal, warning auto start 250017-903 sign, warning "food grade" lube 250003-144 sign, warning compressor fluid fill cap 049685 sign, danger air breathing 250027-935 decal, danger high voltage 042218 decal, warning auto start 041065...
  • Page 124 Section 9 ILLUSTRATIONS AND PARTS LIST 9.26 DECAL GROUP...
  • Page 125 Section 9 ILLUSTRATIONS AND PARTS LIST 9.26 DECAL GROUP (CONTINUED) part number description number quantity decal, fluid sample 250022-675 decal, electrocution hazard intnl/glbl 02250077-472 decal, maintenance kit LS120/160 02250144-505 decal, ISO 9001 02250057-624 decal, 24KT 2.5" x 4" 02250061-016 decal, LS-120 02250144-155 decal, LS-160 02250144-157...

  • Page 126: Wiring Diagram- Electro-Mechanical Full Voltage

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.27 WIRING DIAGRAM- ELECTRO-MECHANICAL FULL VOLTAGE 02250129-076R04...

  • Page 127: Wiring Diagram- Supervisor Controller Wye-Delta

    Section 9 ILLUSTRATIONS AND PARTS LIST 9.28 WIRING DIAGRAM- SUPERVISOR CONTROLLER WYE-DELTA 02250134-817R04...
  • Page 130 WORLDWIDE SALES AND SERVICE SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A. Sullair Road, No. 1 Zone Des Granges BP 82 Chiwan, Shekou 42602 Montbrison Cedex, France Shenzhen, Guangdong PRV. Telephone: 33-477968470 PRC POST CODE 518068 Fax: 33-477968499 Telephone: 755-6851686 www.sullaireurope.com Fax: 755-6853473 www.sullair-asia.com...

This manual is also suitable for:

Ls-160 seriesLs-120Ls-160V-120V-160

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