Page 1
INDUSTRIAL AIR COMPRESSOR LS- -20S 125- -150HP/90- -110KW STANDARD AND 24KT OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250115-257 eSullair 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 compressor electrical systems are presented at regular intervals throughout the year at a dedicated training facility at Sullair’s corporate headquarters in Michigan City, Indiana.
Page 5
TABLE OF CONTENTS (CONTINUED) Section 8 ILLUSTRATIONS AND PARTS LIST (cont.) 8.3 MOTOR, COMPRESSOR AND FRAME 8.4 AIR INLET SYSTEM 8.5 COOLING AND LUBRICATION SYSTEM (AIR- -COOLED) 8.6 COOLING AND LUBRICATION SYSTEM (WATER-COOLED) 8.7 COOLER ASSEMBLY (AIR-COOLED) 8.8 COMPRESSOR DISCHARGE SYSTEM 8.9 AFTERCOOLER PIPING (AIR-COOLED- BEFORE JUNE 2000) 8.10 AFTERCOOLER PIPING (AIR-COOLED-...
SAFETY 1.1 GENERAL of hose failure, per all applicable Federal, State and Sullair Corporation and its subsidiaries design and Local codes, standards and regulations. manufacture all of their products so they can be op- erated safely. However, the responsibility for safe B.
Section 1 SAFETY 1.4 FIRE AND EXPLOSION K. DO NOT attempt to operate the compressor in any classification of hazardous environment unless the compressor has been specially designed and WARNING manufactured for that duty. 1.5 MOVING PARTS When installing a Base Load Transfer (BLT) Sys- A.
Section 1 SAFETY C. Operate the compressor only in open or ade- E. Disconnect, lock out, and tag all power at source quately ventilated areas. prior to attempting repairs or adjustments to rotating machinery and prior to handling any ungrounded D.
Section 1 SAFETY O. DO NOT use the lifting eye bolt on the compres- before doing so, or else secure and tag the access sor motor, if supplied, to lift the entire compressor door in the open position to avoid the possibility of package.
The inlet air filters are also mounted blies of the air compressors are clearly shown. The for easy access and servicing. Figure 2-1 Sullair Series LS-20S 150HP/ 110KW Rotary Screw Compressor (Air-cooled version) FLUID COOLER/ MINIMUM PRESSURE/ AFTERCOOLER...
With a Sullair compressor, there is no main- rotors and the compression chamber. tenance or inspection of the internal parts of the...
Page 13
Section 2 DESCRIPTION Figure 2-2 Compresor Piping and Instrumentation Diagram SEQUENCING LOAD CONTROL SOLENOID CHECK VALVE SOLENOID VALVE ORIFICE VALVE CONTROL FILTER INLET VALVE PRESSURE REGULATOR COMPRESSOR PRESSURE REGULATOR PRESSURE AIR FILTER FOR HIGH PRESSURE GAUGE SPIRAL MACHINES VALVE PRESSURE REGULATOR CLOSED INLET OPTION...
Page 14
Section 2 DESCRIPTION Figure 2-3 Compressor Cooling and Lubrication System Diagram FLUID FLUID COOLER FILTER WATER-COOLED FLUID MACHINES STOP VALVE THERMAL VALVE FLUID FILTER FLUID STOP VALVE FLUID THERMAL COOLER VALVE AIR-COOLED MACHINES ments exceeds 10 psid (0.7 bar), the Supervisor II valve, located downstream from the separator, as- module displays a maintenance requirement mes- sures a minimum receiver pressure of 50 psig (3.5...
Page 15
Section 2 DESCRIPTION Figure 2-4A Compressor Discharge System Diagram- Air-cooled Model MINIMUM PRESSURE/ AIR-COOLED CHECK VALVE MACHINES BEFORE JUNE 2000 BLOWDOWN VALVE SUMP TANK MOISTURE SEPARATOR FLUID LEVEL SIGHT GLASS FLUID FILL PLUG AFTERCOOLER MINIMUM PRESSURE/ CHECK VALVE BLOWDOWN VALVE MOISTURE SEPARATOR SUMP...
Page 16
The functional description of the control system is described below All Sullair compressor models are equipped with a in four distinct phases of operation. For explanation high pressure shutdown protection to shut down the purposes, this description will apply to a compressor compressor at 20 psig (1.4 bar).
Page 17
Section 2 DESCRIPTION Figure 2-5A Control System Diagram- Start and Full Load START BLOWDOWN VALVE SULLICON CONTROL INLET CONTROL CONTROL CYLINDER LINE FILTER PRESSURE SPIRAL GAUGE VALVE CHECK CHECK VALVE VALVE UNLOAD SOLENOID CLOSED INLET SOLENOID (OPTIONAL) SULLICON PRESSURE LIMITING REGULATOR SEQUENCING (HH &...
Page 18
Section 2 DESCRIPTION Figure 2-5B Control System Diagram- Modulation and Unload BLOWDOWN MODULATION VALVE SULLICON CONTROL INLET CONTROL CONTROL CYLINDER LINE FILTER PRESSURE SPIRAL GAUGE VALVE CHECK CHECK VALVE VALVE UNLOAD SOLENOID CLOSED INLET SOLENOID (OPTIONAL) SULLICON PRESSURE LIMITING REGULATOR SEQUENCING (HH &...
Page 19
Section 2 DESCRIPTION NORMAL OPERATING MODE - - 50 TO 100 PSIG Figure 2-6 Air Inlet System (3.5 TO 6.9 BAR) When the compressed air pressure rises above 50 AIR FILTER psig (3.5 bar), the minimum pressure valve opens and delivers compressed air to the service line. From this point on, the line air pressure is continually monitored by the Supervisor II.
Page 20
Section 2 DESCRIPTION sor II energizes the solenoid valve allowing the air consists of a two- -stage, heavy- -duty, dry- -type pressure behind the Sullicon Control and the spiral filter with inertial dust separation and collection, a valve actuator to be vented through the solenoid butterfly- -type air inlet valve, and an adaptor valve exhaust port.
SORS once a year, whichever comes first. The fluid should be changed more frequently under severe operating Sullair standard compressors are filled with Sullube conditions, such as high ambient temperatures cou- fluid as factory fill. pled with high humidity, or when high particulate...
Page 22
Section 3 SPECIFICATIONS Sullair recommends that a 24KT sample be taken at WARNING the first filter change and sent to the factory for analysis. This is a free service. A sample kit with in- “The Plastic Pipe Institute recommends against the...
Page 23
Section 3 SPECIFICATIONS Figure 3-1A Identification- Air-cooled Model (Prior to June 1, 2000)
Page 24
Section 3 SPECIFICATIONS Figure 3-1B Identification- Air-cooled Model (After June 1, 2000)
Consult a faces. Sullair representative for assistance in utilizing this heat. DANGER DO NOT install a water--cooled or an air--cooled/af- Do not twist frame.
Parts Manual). plicable local electrical codes concerning isolation 3. Check all electrical connections for tightness. switches, fuse disconnects, etc. Sullair provides a 4. “DRY RUN” the electrical controls by disconnect- wiring diagram for use by the installer.
Section 5 COMPRESSOR OPERATION 5.1 INTRODUCTION tion, and use. While Sullair has built into the LS--20S Series pack- age a comprehensive array of controls and indica- 5.2 PURPOSE OF CONTROLS tors to assure its proper operation, the user should All Supervisor II Module (Supervisor) related func-...
Section 6 COMPRESSOR OPERATION CONTROL OR INDICATOR PURPOSE BLOWDOWN VALVE ASSEMBLY Vents the sump vessel to atmosphere during unload- ing and shutdown. THERMAL MIXING VALVE Bypasses fluid flow around the cooler until the former reaches a temperature of 180_F (82_C). Useful for fast warm--up during start.
Page 32
AUTOMATIC MODE DISPLAY STOP BUTTON RUN LIGHT COMPRESSOR SYSTEM GRAPHIC COMPRESSOR RUN LIGHT POWER ON LIGHT CONTINUOUS START KEY PAD COMPRESSOR STOP/RESET KEY PAD DISPLAY PROGRAMMING AUTOMATIC MODE KEY SULLAIR LOGO KEY PAD MODE KEY PAD LCD SELECTION/PARAMETER VALUE CHANGE KEYPAD...
Section 6 SUPERVISOR II 6.1 BASIC INTRODUCTION mode to increment a value. Refer to Figure 6--1. The Supervisor II has a two line display to show temperature, pressure and status. It has a keypad for operating the compressor, pro- gramming the control points and selecting displays. There is a graphic illustration with lamps that light to S Down arrow, lamp test -- Used in status show the item being displayed.
Section 6 SUPERVISOR II If there are alarms active they will alternately be T2 210 shown with the default display. The machine status MAX 235 will be displayed for two seconds then the alarms for two seconds each. For example: S Total hours that the compressor has been running.
Section 6 SUPERVISOR II sump pressure rises above this pressure. presence of an alarm. MOTOR -- If flashing, indicates the motor overload P1 MAX contact has opened. 135 PSI INLET FILTER -- If flashing, indicates that inlet filter S Wye to delta transition timer --- For full maintenance is needed.
Section 6 SUPERVISOR II S Communications Baud Rate --- This S Machine Capacity -- Used only for se- should always be selected to 9600 baud quencing, see Sequencing & Protocol for all sequencing modes. It may be lower Manual for details. for slave or monitoring modes.
Section 6 SUPERVISOR II P2 < LOAD - -- -> load solenoid turned on spond to start, stop, load or unload mes- sages. The remote inputs and outputs are POWER FAILURE RESTART enabled (start/stop, load/unload, master/lo- If the restart timer (RST TIME parameter) is dis- cal).
Section 6 SUPERVISOR II 6.10 DAILY OPERATION tures, etc.). Following a routine start, observe the various Su- During the initial start--up or servicing of the pack- pervisor displays to check that normal readings are age, fluid may have to be added to the sump vessel being made -- previous records are very helpful in to restore an adequate level.
409264 should be performed when the Supervi- Your fluid filter includes a proprietary replaceable ele- sor displays AIR MNTN and the LED display flashes, ment available solely from Sullair and its agents -- DO or when corresponding maintenance message is dis- NOT substitute.
Section 7 MAINTENANCE Figure 7-1 Air Filter (P/N 409264) BODY SECONDARY ELEMENT** WINGNUT WASHER RETAINING PLATE RETAINING CLAMP WASHER WASHER PRIMARY ELEMENT* WINGNUT WINGNUT COVER *Replacement Element (Primary) P/N 409853 **Replacement Element (Secondary) P/N 409854 3. Apply a light film of fresh oil to the new gasket and hand tighten new element until gasket contacts Figure 7-2 Compressor Fluid Filter the seat.
Section 7 MAINTENANCE 2. Loosen/remove cap screw fastening the valve arm Figure 7-3 Separator Element Replacement link to the Sullicon control lever and let link hang aside. CAPSCREW 3. Loosen/remove the two (2) capscrew/nut assem- blies securing Sullicon to its mounting bracket and LOCK WASHER pull Sullicon away.
Page 42
-- if any faults are found, elements must be replaced and Please note that replacement of either shaft hub re- Sullair contacted for further assistance. quires the removal of the motor, an operation best 4. Reassemble in reverse order. Capscrews must be handled by Sullair personnel.
Sullair repre- decrease of a dirty heat exchanger. sentative or the Sullair Corporation factory toll free at A detailed visual inspection is worth performing for 1--800--SULLAIR.
Page 44
Section 7 MAINTENANCE 7.7 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM PROBABLE CAUSE REMEDY HI T1, HI T2 MESSAGE (cont.) Discharge Temperature Exceeded 235_F (113_C) Because: Fluid Level in Sump is Too Low Check/correct fluid level. Thermal Valve Malfunctioned Check/replace thermal valve. Cooler Fins are Dirty Clean cooler fins.
Section 7 MAINTENANCE 7.7 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM PROBABLE CAUSE REMEDY P1 HI MESSAGE (continued) Pressure Regulator Maladjusted Check operation of pressure regulator. Solenoid Valve Failed Check operation of solenoid valve. to Operate Control Air Signal Leaks Check tubework feeding control signal for leaks.
Section 7 MAINTENANCE crease or decrease always showing the total amount of adjustment. Maximum adjustment is + 7. The DSP key exits, wiping out changes to the current item, while saving changes to any previous items. The PRG key saves the current item and advances to the next.
8.1 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 address or phone numbers below.
Section 8 PARTS LIST 8.3 MOTOR, COMPRESSOR AND FRAME...
Page 49
(I) 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 infor- mation regarding the unit exchange program, contact your nearest Sullair representative or the S ullair Cor por at ion.
Section 8 PARTS LIST 8.4 AIR INLET SYSTEM WATER-COOLED MACHINES ONLY WATER-COOLED MACHINES ONLY...
Page 51
Section 8 PARTS LIST 8.4 AIR INLET SYSTEM part number description number quantity filter, air (I) 409264 nut, hex flanged 5/16”--18 825305--283 screw, hex ser washer 5/16” x 3/4” 829705--075 support, air filter (air-cooled only) 02250047--269 support, air filter (water-cooled only) 02250056--087 band, mounting 14”...
Section 8 PARTS LIST 8.5 COOLING AND LUBRICATION SYSTEM (AIR- -COOLED) 15 16...
Page 53
Section 8 PARTS LIST 8. 5 CO O L I NG AND L UBRI CAT I O N SYST EM (AI R - - CO O L ED) part number description number quantity cooler, fluid 02250114--969 connector, tube 1 1/4” x 1 5/8” 811820--163 tube, by--pass to cooler 1 1/4”...
Section 8 PARTS LIST 8.6 COOLING AND LUBRICATION SYSTEM (WATER- -COOLED) 18 19...
Page 55
Section 8 PARTS LIST 8.6 COOLING AND LUBRICATION SYSTEM (WATER- -COOLED) part number description number quantity elbow, tube 1 1/4” x 1 5/8” 811620--162 cooler, fluid WC 02250114--977 bushing, reducing hex 1/2” x 1/4” 807602--010 tubing, steel 1/4” 841015--004 6 ft elbow, tube--M 1/4”...
Section 8 PARTS LIST 8.8 COMPRESSOR DISCHARGE SYSTEM A- TO CONTROL LINE FILTER B- FROM LOAD CONTROL SOLENOID C- TO PRESSURE TRANSDUCER P1...
Page 59
Section 8 PARTS LIST 8.8 COMPRESSOR DISCHARGE SYSTEM part number description number quantity elbow, tube 1/4” x 1/4” 810504--025 tee, pipe 1/4” 868815--010 elbow, pipe--M to F 1/4” x 1/4” 860704--025 orifice 02250101--191 orifice 022033 glass, sight 1/4” 046559 nipple, pipe hex 1/4” x 1/4” 868504--025 strainer, v--type 1/4”...
Page 60
Section 8 PARTS LIST 8.8 COMPRESSOR DISCHARGE SYSTEM A- TO CONTROL LINE FILTER B- FROM LOAD CONTROL SOLENOID C- TO PRESSURE TRANSDUCER P1...
Page 61
Section 8 PARTS LIST 8.8 COMPRESSOR DISCHARGE SYSTEM (CONTINUED) part number description number quantity nut, hex 5/8”--11 825210--559 plug, o--ring boss 1 1/4” 040029 plug, sight glass 1 7/8” 02250097--611 bulkhead, pipe 1/2” 841500--008 connector, tube 1/2” x 1/2” 250024--695 t ube, t her m oplas t ic 1/ 2”...
Section 8 PARTS LIST 8.9 AFTERCOOLER PIPING (AIR-COOLED- BEFORE JUNE 2000)
Page 63
Section 8 PARTS LIST 8.9 AFTERCOOLER PIPING (AIR-COOLED- BEFORE JUNE 2000) part number description number quantity bushing, reducing hex 1/2” x 1/4” 802102--010 tee, reducing 2” x 2” x 1/2” 802208--082 U--bolt, 3/8” x 2 1/2” 868306--250 support, moisture separator 02250115--692 nipple, pipe 2”...
Page 64
Section 8 PARTS LIST 8.10 AFTERCOOLER PIPING (AIR-COOLED- AFTER JUNE 2000)
Page 65
Section 8 PARTS LIST 8.10 AFTERCOOLER PIPING (AIR-COOLED- AFTER JUNE 2000) part number description number quantity bushing, reducing hex 1/2” x 1/4” 802102--010 tee, reducing 2” x 2” x 1/2” 802208--082 U--bolt, 3/8” x 2 1/2” 868306--250 support, moisture separator 02250119--770 nipple, pipe 2”...
Page 69
Section 8 PARTS LIST 8.12 UNIT TUBING part number description number quantity connector, tube--M 3/8” x 1/4” 810206--025 capscrew, ferry hd 1/2”--13 x 1” 867308--100 capscrew, hex GR8 5/16”--18 x 3/4” 828205--075 support, manifold 02250044--911 manifold, oil 1 5/8” SAE 02250115--094 orifice, .062”...
Section 8 PARTS LIST 8.14 PNEUMATIC CONTROLS WITHOUT SPIRIAL VALVE A--TO BLOWDOWN VALVE B--TO SULLICON CONTROL C--TO TOP OF SEPARATOR TANK D--TO AFTERCOOLER (WATER) E--TO SIDE OF SEPARATOR TANK F--TO FLUID FILTER G--TO SERVICE AIR OUTLET H--TO AIR INLET ADAPTER 10 13 9 15...
Page 73
Section 8 PARTS LIST 8.14 PNEUMATIC CONTROLS WITHOUT SPIRIAL VALVE part number description number quantity plug, hole 1/2” 409918--002 RTD, 100 OHM 250039--909 locknut, conduit seal 1/2” 02250071--362 locknut, conduit 1/2” 847200--050 connector, tube--M 1/4” x 1/8” 810204--012 conduit 250007--170 elbow, 1/4”T x 1/4”P 250018--430 valve, solenoid 3--way 1/4”...
Section 8 PARTS LIST 8.15 PNEUMATIC CONTROLS WITH SPIRIAL VALVE A--TO BLOWDOWN VALVE B--TO SULLICON CONTROL C--TO TOP OF SEPARATOR TANK D--TO INLET CONTROL CYLINDER E--TO SIDE OF SEPARATOR TANK F--TO FLUID FILTER G--TO SERVICE AIR OUTLET H--TO AIR INLET ADAPTER 9 10 6 12 7 TO UNIT...
Page 75
Section 8 PARTS LIST 8.15 PNEUMATIC CONTROLS WITH SPIRIAL VALVE part number description number quantity rtd, 100 ohm 250039--909 locknut, conduit seal 1/2” 02250071--362 conduit 250007--170 valve, solenoid 3--way 1/4” (I) 250038--675 elbow, 1/4”T x 1/4”P 250018--430 nipple, pipe 1/4” 868504--025 connector, tube--M 1/4”...
Page 77
Section 8 PARTS LIST 8.16 ELECTRICAL BOX part number description number quantity grip, cord 12/4 250018--495 wire, neoprene #12--4 850604--012 grip, cord 1/0 250014--561 wir e, t y pe G -- G C 2/ 0 250014 -- 311 7 f t s t ar t er, c om pr es s or c ons ult f ac t or y transformer, 350VA universal voltage...
Page 85
Section 8 PARTS LIST 8.20 DECAL GROUP part number description number quantity sign, warning sever -- fan 049855 sign, warning sever--fan port 049965 decal, rotation 250021--286 decal, rotation 250021--564 decal, voltage 460V/ 60Hz international 02250069--399 Sdecal, 380--415V/ 50Hz (not shown) 02250069-403 Sdecal, 525V/ 50Hz (not shown) 02250069-415...
Page 87
Section 8 PARTS LIST 8.20 DECAL GROUP (CONTINUED) part number description number quantity sign, warning ground fault 049852 decal, warning actuator 250029--836 decal, danger high voltage 042218 decal, water inlet--outlet 049873 decal, water in 250019--107 decal, water out 250019--108 decal, water drain 250022--810 decal, actuator valve positioning 250029--784...
Page 89
Section 8 PARTS LIST 8.20 DECAL GROUP (CONTINUED) part number description number quantity decal, ISO 9001 02250057--624 decal, fluid sample 250022--675 sign, warning “food grade” lube 250003--144 sign, warning “compressor fluid fill cap” 049685 decal, warning auto start 250017--903 (Continued on page 85) PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR...
Page 91
8.20 DECAL GROUP (CONTINUED) part number description number quantity decal, electrical component ID 02250109--734 decal, LS--20S (open) 02250061--058 Sdecal, LS--20S (canopy) 02250061--161 decal, Sullair logo (open) 02250059-058 Sdecal, Sullair logo (canopy) 02250057--603 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR...
Page 93
LS--20S (open) 02250061--058 decal, warning auto start 250017--903 sign, warning sever -- fan 049855 decal, ISO 9001 02250057--624 decal, Sullair logo (open) 02250059-058 decal, fork lifting 241814 decal, warning mixing fluids 02250110--891 decal, fluid Sullube 02250069--389 Sdecal, fluid 24 KT...
Page 94
Section 8 PARTS LIST 8.21 DECAL LOCATIONS WATER-COOLED MODEL...
Page 95
-- fan 049855 sign, danger electrocution 049850 decal, ISO 9001 02250057--624 decal, fork lifting 241814 decal, fluid 24 KT (I) 02250069--395 decal, Sullair logo (canopy) 02250057--603 decal, LS--20S (canopy) 02250061--161 decal, autostart 041065 decal, water out 250019--108 decal, water in 250019--107 (I) Decal no.
Page 96
Section 8 PARTS LIST 8.21 DECAL LOCATIONS...
Page 97
Section 8 PARTS LIST 8.21 DECAL LOCATIONS part number description number quantity decal, earth ground international 02250075--046 decal, PE designation international 0225075--540 decal, danger high voltage 042218 decal, voltage 460V/ 60Hz international 02250069--399 Sdecal, 380--415/50Hz (not shown) 02250069-403 Sdecal, 525V/ 50Hz (not shown) 02250069-415 Sdecal, 575V/ 60Hz (not shown) 02250069-400...