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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.
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.
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.
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.
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.
DESCRIPTION 2.1 INTRODUCTION After the air/fluid mixture is discharged from the Your new Sullair lubricated rotary screw air com- compressor unit, the fluid is separated from the air. pressor will provide you with a unique experience in At this time, the air flows to the service line and the improved reliability and greatly reduced mainte- fluid is cooled in preparation for reinjection.
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Section 2 DESCRIPTION Figure 2-2 Compressor Cooling, Lubrication and Discharge System • Serves as the compressor fluid sump. on the digital display. At a differential of 10 psid (0.7 bar) or greater, the operator will be told to service • Houses the final fluid separator elements. the separator element.
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Section 2 DESCRIPTION discharge pressure exceeds approximately 160 psig (11 bar), the minimum pressure valve may DO NOT remove caps, plugs, and/or other compo- start to open and allow air to flow to the system nents when compressor is running or pressur- service line.
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Section 2 DESCRIPTION reduced. The unload pressure regulator is set to to flow through the check valve and into the poppet maintain the unload pressure at the designated valve keeping the inlet poppet valve closed. This value, 150 psig (10.3 bar). At this time, the com- also opens the blowdown valve to allow com- pressor is in the unload mode.
Section 2 DESCRIPTION 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIP- Figure 2-5 Air Inlet System TION Refer to Figure 2-5. The Compressor Inlet System consists of a dry-type air filter, a vacuum switch, and an air inlet valve. At 20” water column the inlet vacuum switch will allow the Supervisor II to indicate that “AIR FILTER MAINT RQD”...
Section 2 DESCRIPTION Figure 2-6 Supervisor II Panel plays to change displays and in parameter setup mode to increment a value. When in the default display the key will light all the The machine may start at any time. lamps for three seconds. •...
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Section 2 DESCRIPTION sequencing conditions meet the criteria to P3 LOW shutdown will occur. Oil differential start. (dP3) is defined as P3-P1/2 dP3 40 MIN 1 The machine may start at any time. This default display appears as follows: • Unit discharge temperature and the maxi- mum limit.
Section 2 DESCRIPTION 2.11 LAMP INDICATORS is being displayed. For monitoring only. Embedded into the front panel schematic of the T4 - (Interstage temperature) If lit steady, signifies compressor are several lamps. Pressing the lamp that T4 is being displayed, if flashing denotes the test key will light all the lamps for 3 seconds.
2339 (II) (II) (I) For information concerning enclosed compressors, please contact the Sullair Factory Sales Department. (II) For information concerning compressor weight, please contact the Sullair Factory Sales Department. For noise level information, please contact the Sullair Factory Service Department.
Maintenance of all other components is still recom- 3.3 APPLICATION GUIDE mended as indicated in the Operator’s Manual. 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 Mixing of other lubricants within the compressor stated in the manual.
It is recom- heating, providing excessive pressure drop is not mended that the frame be grouted to the founda- created across the fan. Consult a Sullair office for tion. The compressor unit and driver must be assistance in utilizing this heat.
” pads. This action will bump cerning isolation switches, fuse disconnects, etc. start the motor for a very short time. When looking Sullair provides a wiring diagram for use by the at the motor rear end, the driveline should be rotat- installer.
OPERATION 5.1 GENERAL will call for service or indicate the beginning of a While Sullair has built into this compressor a com- malfunction. Before starting your Sullair compres- prehensive array of controls and indicators to sor, read this section thoroughly and familiarize...
Section 5 OPERATION 5.2 PURPOSE OF CONTROLS (CONTINUED) CONTROL OR INDICATION PURPOSE BLOWDOWN SOLENOID VALVE Opens when a demand for an unload/shutdown condition exists. When valve is opened, it will supply air to the blow- down valve. BLOWDOWN VALVE Vents sump pressure to the atmosphere during unload/shut- down conditions.
Section 5 OPERATION • Units - English or metric units may be LOWEST selected. 90 PSI UNITS • Recovery Time - Used only for sequencing, ENGLISH see Sequencing & Protocol Manual for • Communications ID # - This is the network details.
Section 5 OPERATION common fault relay will be turned off, if engaged, POWER FAILURE RESTART and it will try to clear the alarm and maintenance If the restart timer (RST TIME parameter) is dis- indicators. Regardless of what the compressor is abled the compressor will not try to start after a power up.
Section 5 OPERATION 5.6 INITIAL START-UP PROCEDURE ating temperature exceeds 235ºF (113ºC), the The following procedure should be used to make cooling system or installation environment the initial start-up of the compressor: should be checked. 1. Read the preceding pages of this manual thor- 8.
To minimize the possibility of filter element rup- during compressor assembly. Perform the following ture, it is important that ONLY replacement ele- ments identified with the Sullair name, logo and maintenance operations to prevent unnecessary appropriate part numbers be used, and that sub- problems.
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Section 6 MAINTENANCE Figure 6-1 Main Filter (P/N 02250111-592) *Repair Kit P/N 250031-850 6. Lubricate the new seals with the same type of 8. Replace the canister by threading back onto the fluid used in the compressor and position each filter head.
PRIMARY ELEMENT REPLACEMENT 1. Place the element in position on the cover and To assist with the removal of the tank lid, Sullair has provided a 1”-8 nut to the top lid so it can be replace the locking to secure the cover and ele- removed by a 1”-8 eye bolt (which is available...
Section 6 MAINTENANCE 2. Remove the 3/4”-10 jam nut and sealing hex nut opposite sides of the cover. Lube torque cap- from the 3/4”-10 separator hold down rod. screws to 200 ft.-lbs. (271Nm). 3. Remove the round separator cover plate from the 8.
Section 6 MAINTENANCE Figure 6-5 Pressure Regulator Adjustments Table 6-1 Installation Data Figure 6-6 Drive Coupling Alignment Max. Operating Misalignment Parallel Coupling Angular Offset inches/mm +.03 in./ .762mm Degrees inches/ mm (I) .008/ .02 1.38/ 35.0mm .025 .005/ 127mm (I) Angular misalignment in inches equals maximum A minus mini- mum B as shown in Figure 6-6.
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Section 6 MAINTENANCE hub to engage the element. After engaging the ele- Figure 6-8 Parallel/ Angular Alignment ment, set the motor hub for the proper gap as spec- ified in Table 6-1 Installation Data, and secure the motor hub with a setscrew. When the hub gap is properly set, you will be able to move the element in a slight back and forth motion (unless the cou- pling is extremely out of alignment.
Should your problem persist after making the rec- nent replacement procedures. ommended check, consult your nearest Sullair rep- resentative or the Sullair Corporation factory. A detailed visual inspection is worth performing for almost any problems which may prevent unneces- 7.2 TROUBLESHOOTING GUIDE...
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Section 7 TROUBLESHOOTING 7.2 TROUBLESHOOTING GUIDE(CONTINUED) SYMPTOM PROBABLE CAUSE REMEDY Cooler plugged; clean tubes. If plugging per- COMPRESSOR SHUTS DOWN High Discharge Temperature (Cont.) sists, install water conditioner. (water-cooled). (CONTINUED) Low fluid level; add fluid. Clogged filter; change the fluid filter element if maintenance indicator shows red, and/or dP2 on controller indicates high dP.
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Section 7 TROUBLESHOOTING 7.2 TROUBLESHOOTING GUIDE (CONTINUED) SYMPTOM PROBABLE CAUSE REMEDY Check all pipes, connections and compo- EXCESSIVE COMPRESSOR- Leak in the Lubrication System nents. LUBRICANT CONSUMPTION (CONTINUED) Drain fluid and change. Excessive Fluid Foaming Drain excess fluid. Fluid Level Too High Readjust below pressure relief valve setting.
ILLUSTRATIONS AND PARTS LIST 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 addresses, phone or fax numbers below.When ordering parts always indicate the Serial Number of the...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.2 SPARE PARTS LIST- LS20TS (CONTINUED) DESCRIPTION KIT NUMBER Repair kit for solenoid valve 02250125-657 (I) 02250125-829 Replacement coil for solenoid valve 02250125-657 02250125-861 Repair kit for discharge check valve assembly 02250127-507 606208-001 Repair kit for shaft seal...
Section 8 ILLUSTRATIONS AND PARTS LIST 8.3 MOTOR, FRAME, COMPRESSOR AND PARTS- 300-450HP/ 224-336KW 02250142-662R00...
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(I) Due to customized motor variances consult factory for part number. (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.
Section 8 ILLUSTRATIONS AND PARTS LIST 8.4 AIR INLET SYSTEM 02250135-237R01...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.4 AIR INLET SYSTEM part number description number quantity sub assembly, 8” inlet valve (I) 02250045-626 orifice, .040 1/4fnpt x 1/4mnpt 02250091-395 tube, 7” x 6.5” w/3/8” conn 02250120-368 orifice, cap .031” x 1/4” npt 02250132-934 hose, hump 7”...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.4 AIR INLET SYSTEM 02250135-237R01...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.4 AIR INLET SYSTEM (CONTINUED) part number description number quantity plug, pipe 1/4” 3000# stl plt 866900-010 plug, pipe 1/2” 3000# stl plt 866900-020 elbow, pipe 90 deg 300# plt 1/4” 867030-010 bushing, red pltd 1/2 x 3/8 867102-015 tee, pipe pltd 1/2 868430-020...
Section 8 ILLUSTRATIONS AND PARTS LIST 8.5 AIR INLET SYSTEM WITH OIL INJECTION INLET VALVE 02250142-581R00...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.5 AIR INLET SYSTEM WITH OIL INJECTION INLET VALVE part number description number quantity orifice, .031” x .25m x .25m nptf 02250101-191 valve, check 1/4”nptf viton seat 02250110-557 filter, asembly genisis filter 02250117-782 orifice,.062 .25 fnpt x .25 mnpt 02250118-585 tube, 7”...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.5 AIR INLET SYSTEM WITH OIL INJECTION INLET VALVE 02250142-581R00...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.5 AIR INLET SYSTEM WITH OIL INJECTION INLET VALVE (CONTINUED) part number description number quantity screw, hex ser washer 3/8-16 x 1 829706-100 washer, spr lock reg pltd 5/8 837810-156 washer, spr lock reg pltd 3/4 837812-188 plug, pipe 1/4”...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.8 FLUID PIPING SYSTEM- 300-450HP/ 224-336KW WATER-COOLED 02250134-198R01...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.8 FLUID PIPING SYSTEM- 300-450HP/ 224-336KW WATER-COOLED (CONTINUED) part number description number quantity connector, tube-m 1/4 x 1/4 ss 876804-025 elbow, tube 90 deg m 1/4 x 1/8 ss 877004-012 elbow, tube 90 deg m 1/4 x 1/4 ss 877004-025 elbow, tube 90 deg m 1/4 x 3/8 ss 877004-038...
Section 8 ILLUSTRATIONS AND PARTS LIST 8.10 CONTROL/START SYSTEM 02250139-578R00...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.10 CONTROL/START SYSTEM part number description number quantity filter, coalescing 425 psi @ 265deg (I) 02250058-442 locknut, n4 conduit sealing 02250071-362 grip, cord n4 .125-.187 x 1/2” 02250071-379 grip, cord n4 .250-.375 x 1/2” 02250071-381 switch, vacuum 22”wc n4 6ft cable 5a 02250078-249...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.10 CONTROL/START SYSTEM 02250139-578R00...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.10 CONTROL/START SYSTEM (CONTINUED) part number description number quantity nut, hex f pltd 3/8-16 825306-347 capscr, hex gr5 3/8-16 x 1 829106-100 capscr, hex gr5 1/2-13 x 1 1/2 829108-150 screw, hex ser washer 1/4-20 x 3/4 829704-075 screw, hex ser washer 3/8-16 x 3/4 829706-075...
Section 8 ILLUSTRATIONS AND PARTS LIST 8.11 CONTROL PANEL 02250137-724R02...
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Supervisor II 02250048-822 panel, instrument Supervisor II 02250054-853 panel, cover Supervisor II 02250054-854 nameplate, Sullair serial number 02250059-318 decal, LS Super 2 front (I) (II) 02250116-245 harness, wire sii dlx std pwr 02250105-438 harness, wire s2 dlx ctl...
Section 8 ILLUSTRATIONS AND PARTS LIST 8.12 ENCLOSURE AND ENCLOSURE DECALS...
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“food grade” lube 250003-144 sign, air breathing (danger) 250027-935 decal, LS-16T black 4” ht. 02250071-282 decal, ISO 9001 02250057-624 decal, Sullair logo 4 x 32” black 02250059-060 decal, water drain 250022-810 decal, water in 250019-107 decal, water inlet-outlet 049873...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.13 DECAL GROUP...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.13 DECAL GROUP part number description number quantity sign, air breathing (danger) 250027-935 sign, warning “food grade” lube 250003-144 sign, warning ground fault 049852 decal, warning auto start 250017-903 sign, danger electrocution 049850 sign, warning hot surfaces 407408 sign, warning sever - fan 049855...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.13 DECAL GROUP...
Section 8 ILLUSTRATIONS AND PARTS LIST 8.13 DECAL GROUP (CONTINUED) part number description number quantity sign, warning “compressor fluid fill cap” 049685 decal, danger high voltage 042218 decal, warning mixing fluids 02250110-891 decal, rotation 250021-286 decal, rotation 250021-564 decal, fluid Sullube 02250069-389 decal, water inlet-outlet 049873...
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Section 8 ILLUSTRATIONS AND PARTS LIST 8.13 DECAL GROUP...
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ID 250038-457 decal, protective earth ground 02250075-045 decal, earth ground 02250075-046 decal, PE designation 02250075-540 decal, LS-20T black 4” ht. 02250071-287 decal, Sullair logo 4 x 32” black 02250059-060 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR...
Section 8 ILLUSTRATIONS AND PARTS LIST 8.14 DECAL LOCATIONS- OPEN WATER-COOLED...
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250017-903 decal, LS20T black 4” ht. 02250071-287 decal, ISO 9001 02250057-624 decal, Sullair logo 4 x 32” black 02250059-060 sign, warning sever - fan 049855 PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR...
Section 8 ILLUSTRATIONS AND PARTS LIST 8.15 DECAL LOCATIONS- CONTROL BOX...
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02250075-046 (I) Due to custom voltage requests, voltage decal may vary. For positive identification of machine volt- age decal, consult Sullair Factory with serial number of compressor. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE THE SERIAL NUMBER OF COMPRESSOR...