Sullair EES LS25S Series Operator'S Manual And Parts List Download Page 1

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SULLAIR

HEAT RECOVERY SYSTEM

EES

Series LS25S, LS32

& TS32

200-450HP/ 149-336KW

OPERATOR’S

MANUAL AND

PARTS LIST

KEEP FOR

FUTURE

REFERENCE

Part Number 02250135-752
©Sullair Corporation

Summary of Contents for EES LS25S Series

Page 1: ...SULLAIR HEAT RECOVERY SYSTEM EES Series LS25S LS32 TS32 200 450HP 149 336KW OPERATOR S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250135 752 Sullair Corporation ...

Page 2: ...rporate headquarters in Michigan City Indiana Instruction includes discussion of the function and installation of Sullair service parts troubleshooting of the most common problems and actual equipment operation The seminars are recommended for main tenance and service personnel For detailed course outlines schedule and cost information contact Sullair Corporate Training Department 1 888 SULLAIR or...

Page 3: ... 2 3 DESCRIPTION OF COMPONENTS Section 3 SPECIFICATIONS 9 3 1 SPECIFICATIONS Section 4 INSTALLATION 11 4 1 LOCATION AND ASSEMBLY OF COMPRESSOR 11 4 2 THERMOSTAT PLACEMENT 11 4 3 ELECTRICAL PREPARATION 11 4 4 DUCTWORK 12 Table 1 Duct Size Conversion 14 Table 2 Ductwork Static Pressure Loss Worksheet 15 Table 3 Loss Coefficient Calculations Section 5 OPERATION 17 5 1 INLET DAMPER LINKAGE ADJUSTMENT ...

Page 4: ...ACK ASSEMBLY WITH DRAIN OPTION 350HP 261KW 38 6 8 HORIZONTAL COOLER ASSEMBLY 450HP 336KW INTEGRAL 40 6 9 HORIZONTAL REMOTE COOLER PACK ASSEMBY WITH DRAIN OPTION 400 450HP 298 336KW 42 6 10 HORIZONTAL REMOTE COOLER PACK ASSEMBLY 450HP 336KW 44 6 11EES ENCLOSURE DOGHOUSE ASSEMBLY INTEGRAL 46 6 12 EES ENCLOSURE 200 250HP 149 186KW INTEGRAL 50 6 13 EES ENCLOSURE 300 350HP 224 261KW INTEGRAL 54 6 14 DE...

Page 5: ... engi neering controls and or personal hearing protective equipment 1 3 PRESSURE RELEASE A Install an appropriate flow limiting valve between the service air outlet and the shut off throttle valve either at the compressor or at any other point along the air line when an air hose exceeding 13mm inside diameter is to be connected to the shut off throttle valve to reduce pressure in case of hose fail...

Page 6: ...m the compressor J DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or with degraded lubricant K DO NOT attempt to operate the compressor in any classification of hazardous environment unless the compressor has been spe cially designed and manufactured for that duty 1 5 MOVING PARTS A Keep hands arms and other parts of the body and also...

Page 7: ...body and any hand held tools or other conductive objects away from exposed live parts of electrical system Maintain dry footing stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system Make all such adjustments or repairs with one hand only so as to minimize the possibility of creating a cu...

Page 8: ...re pallet mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them NEVER attempt to forklift a compressor that is not secured to its pallet as uneven floors or sudden stops may cause the compressor to tumble off possibly caus ing serious injury or property damage in the process 1 10 ENTRAPMENT A If the compressor enclosure if any is...

Page 9: ...d make up air or heating air for plants warehouses etc Heat may also be rejected from the system when it is not required Any make up air introduced into a heating or ven tilation system by this system must be of breath ing air quality as defined by applicable codes laws or regulations Because the heat recovery system is built into the compressor package it requires a minimal amount of installation...

Page 10: ... separate ducts for each machine Care should be taken in the design of such a sys tem because unlike duct elbows and straight duct divided flow duct fittings tees crosses laterals and wyes have different performance characteris tics depending on whether they are diverging flow or converging flow Generally speaking ductwork on the inlet side of the compressor may be treated as a supply system and d...

Page 11: ... When the outdoor temperature exceeds the set value on the temperature controller an electrical signal is sent to the exhaust plenum damper motor actuators and the heated cooling air will be reject ed outdoors At the same time the temperature controller sends an electrical signal to the mixed air damper motor actuator which positions the dampers so that all cooling air will enter the compressor ca...

Page 12: ...Section 2 DESCRIPTION 8 Figure 2 2 High Room Temperature Figure 2 3 Low Room Temperature Figure 2 4 No Power ...

Page 13: ...24VAC Output 50 60HZ Enclosure Nema 1 Mixed Air Range 10º to 90ºF 12º to 32ºC Outdoor Air Changeover Range 20º to 90ºF 6º to 32ºC ROOM THERMOSTAT Electrical 120VAC Range 40º to 90ºF 4º to 32ºC Solenoid Valve Electrical 120VAC 60HZ Enclosure Nema 1 AIR VOLUME at listed Water Gauge Duct Restriction 18 000 CFM 200HP 149KW 30 000 CFM 250 350HP 186 261KW 35 000 CFM 400 450HP 298 336KW Allowable ductwor...

Page 14: ...Section 3 SPECIFICATIONS 10 Figure 3 1 Identification TS32A 300 350 EES Typical 02250133 419R00 ...

Page 15: ...ould be used If the interior of the duct is insulated this will affect the air handling performance of the duct and should be accounted for in the ductwork static pres sure calculations For EES units located in an unheated space where the recovered air is ducted to a heated space that portion of the duct exposed to low ambient temperatures should be insulated to prevent excessive heat loss For EES...

Page 16: ...ation C III x Velocity ft min 2 Static Pressure Loss 4005 inches of water 6 Repeat Steps 2 through 5 for each fitting The calculations for each fitting and section of straight duct should be tabulated on the work sheet provided Table 2 7 Total the static pressure loss for each duct branch I Because fitting static pressure losses are zero length losses calculation of amount of straight duct should ...

Page 17: ... Figure 4 1 Static Pressure Loss TYPE ILLUSTRATION LOSS CONDITIONS COEFFICIENT A1 A2 C1 C2 0 1 0 81 81 0 2 0 64 16 0 3 0 49 5 Abrupt 0 4 0 36 2 25 Expansion 0 5 0 25 1 00 0 6 0 16 0 45 0 7 0 08 0 18 0 8 0 04 0 06 0 9 0 01 0 01 ...

Page 18: ...Section 4 INSTALLATION 14 Table 2 Ductwork Static Pressure Loss Worksheet ...

Page 20: ...NOTES 16 ...

Page 21: ...rt compressor observing the movement of the outdoor air damper and the bypass damper Within 60 sec onds of start up the outdoor air damper should be opened fully and the bypass damper should close fully Rotation of either damper should not exceed 90º and the damper actuator motor should not be stalled by the linkage If the bypass damper does not fully open or the damper actuator motor stalls proce...

Page 22: ...UTDOOR AIR DAMPER MINIMUM POSITION ADJUSTMENT This adjustment is made using the minimum posi tion knob Follow the instructions below for adjust ment 1 Place the outdoor air changeover dial and mixed air control dial at their highest settings 2 Immerse the outdoor temperature Probe B in the coldest medium available bucket of ice dry ice etc 3 The outdoor air damper should be closed when the minimum...

Page 23: ...om pressor cooling 5 4 TROUBLESHOOTING The information contained in Section 5 5 Troubleshooting Guide has been compiled from data gathered from field service reports and factory experience It contains symptoms and usual caus es for the service problems described However DO NOT assume that these are the only problems that may occur All available data concerning the trouble should be systematically ...

Page 24: ...l Compressor Defective Mixed Air Temperature Control Improperly Set Mixed Air Temperature Control Dial Improperly Adjusted Damper Linkage Improperly Set Mixed Air Temperature Control Defective Mixed Air Temperature Control Insufficient Motor Actuator Travel Improperly Designed Ductwork Improperly Adjusted Damper Linkage Defective Control Relay Improperly Wired Relay or Temperature Controller Impro...

Page 25: ... Closing Fully Broken Return Spring in Motor Actuator Insufficient Damper Pivot Pin Lubrication Improperly Adjusted Damper LInkage Reset Replace Rewire Replace Replace Relubricate Correct Readjust damper linkage or cable Replace spring Relubricate Readjust REJECTED AIR DAMPER WILL NOT OPEN WHEN ROOM THERMOSTAT SETTING IS EXCEEDED REJECTED AIR DAMPER WILL NOT CLOSE WHEN COMPRES SOR IS OFF COMPRESSO...

Page 26: ...NOTES 22 ...

Page 27: ...SPARE PARTS LIST DESCRIPTION KIT NUMBER QUANTITY repair kit for condensate drain no 02250130 866 02250131 044 1 repair kit for water separator no 02250111 105 I 1 repair kit for water separator no 02250111 106 I 1 I For a breakdown of maintenance parts for this item please consult factory with serial number of your Heat Recovery System PLEASE NOTE WHEN ORDERING PARTS INDICATE SERIAL NUMBER OF COMP...

Page 28: ...Section 6 ILLUSTRATIONS AND PARTS LIST 24 6 3 ASSEMBLY EES 200 250HP 149 186KW 02250126 958R03 ...

Page 29: ...tor link EES 02250122 546 1 15 enclosure EES ts20 lower 02250124 259 1 16 panel EES btm bypass 02250124 254 1 17 panel assembly acs EES lower 02250124 362 2 18 panel assembly EES side rh 02250124 363 1 19 panel assembly EES side lh 02250124 364 1 20 panel assembly access heat recovery 02250124 365 3 21 support EES enclosure 02250124 380 1 22 crank arm lvr27a 602 250000 991 1 23 actuator motor 2500...

Page 30: ...Section 6 ILLUSTRATIONS AND PARTS LIST 26 6 3 ASSEMBLY EES 200 250HP 149 186KW 02250126 958R03 ...

Page 31: ... cor pull 90deg 1 2 846915 050 2 39 nipple conduit 1 2 x 3 250007 171 1 40 bushing conduit plastic 1 2 848815 050 1 41 nipple chase cond 1 2 847815 050 1 42 nipple pipe hx pltd 1 2 x 1 2 868508 050 1 43 valve ball 1 2 npt 047117 1 44 nipple pipe hx pltd 3 4 x 1 2 868512 050 1 47 trap inverted bucket type 042034 1 48 bracket damper control 224694 2 49 bracket actuator motor link 224696 2 50 sensor ...

Page 32: ...Section 6 ILLUSTRATIONS AND PARTS LIST 28 6 4 HORIZONTAL REMOTE COOLER PACK ASSEMBLY 250HP 186KW 02250124 301R05 ...

Page 33: ...r water dh ws800 3 npt I 02250111 105 1 7 panel assembly cooler side 200 250hp 02250126 746 5 8 nipple pipe 3 x 3 822148 030 1 9 assy horiz clr integral 200 250 hp 02250125 550 1 10 nipple pipe 3 x 4 822148 040 1 11 adapter female pipe 1 1 2 x 1 1 2 811512 150 2 12 gasket asa flange 150 3 240621 008 1 13 panel assembly cooler side 200 250hp 02250126 983 3 I For a breakdown of maintenance parts for...

Page 34: ...Section 6 ILLUSTRATIONS AND PARTS LIST 30 6 5 HORIZONTAL REMOTE COOLER ASSEMBLY 350HP 261KW 02250123 146R03 ...

Page 35: ...r cord 312 cable x 1 2 hu 241585 1 16 coupling conduit rigid 250007 179 1 17 nipple conduit 1 2 x 2 250007 170 1 18 support EES enclosure 02250122 541 1 19 rod actuator link EES 02250122 546 1 20 actuator motor 250017 186 1 21 crank arm lvr27a 602 250000 991 1 22 locknut n4 conduit sealing 02250071 362 4 23 bracket actuator damper blade 224696 1 24 panel assembly side EES 02250124 332 1 25 control...

Page 36: ...Section 6 ILLUSTRATIONS AND PARTS LIST 32 6 5 HORIZONTAL REMOTE COOLER ASSEMBLY 350HP 261KW 02250123 146R03 ...

Page 37: ...61KW CONTINUED key part number description number quantity 34 nipple chase cond 1 2 847815 050 1 35 bushing conduit plastic 1 2 848815 050 1 36 elbow cor pull 90deg 1 2 846915 050 2 37 nipple conduit 1 2 x 4 250007 172 2 PLEASE NOTE WHEN ORDERING PARTS INDICATE SERIAL NUMBER OF COMPRESSOR ...

Page 38: ...Section 6 ILLUSTRATIONS AND PARTS LIST 34 6 6 HORIZONTAL COOLER PACK ASSEMBLY 350HP 261KW REMOTE 02250123 120R06 ...

Page 39: ... 6 panel assembly side 300 400 hp rem clr 02250124 335 4 7 drawing assy horiz clr integral 300 350 02250125 436 1 8 gasket asa flange 150 3 240621 008 1 9 adapter female pipe 2 x 2 811516 200 2 10 flange slp on 3 150 819215 048 1 11 flange thrd 3 150 rf 819315 048 1 12 nipple pipe 3 x 3 822148 030 1 13 nipple pipe 3 x 4 822148 040 1 14 u bolt 1 2 x 3 pipe pltd 868308 300 1 I For a breakdown of mai...

Page 40: ...Section 6 ILLUSTRATIONS AND PARTS LIST 36 6 7 HORIZONTAL REMOTE COOLER PACK ASSEMBLY WITH DRAIN OPTION 350HP 261KW 02250130 993R01 ...

Page 41: ...1 008 1 10 adapter female pipe 2 x 2 811516 200 2 11 flange slp on 3 150 819215 048 1 12 flange thrd 3 150 rf 819315 048 1 13 nipple pipe 3 x 3 822148 030 1 14 nipple pipe 3 x 4 822148 040 1 15 u bolt 1 2 x 3 pipe pltd 868308 300 1 16 nipple pipe hx pltd 1 2 x 1 2 868508 050 1 17 nipple pipe hx pltd 3 4 x 1 2 868512 050 1 18 cooler pack subassembly 300 350hp III 1 I For a breakdown of maintenance ...

Page 42: ...Section 6 ILLUSTRATIONS AND PARTS LIST 38 6 8 HORIZONTAL COOLER ASSEMBLY 450HP 336KW INTEGRAL 02250125 435R05 ...

Page 43: ...23 4 7 panel venturi 48 TS32 300 450 02250121 343 1 8 cooler air after 400 450 hp 02250122 215 1 9 cooler oil 400 450 hp side x side 02250122 217 1 10 bar back up horizontal clr pk 02250123 797 2 11 hinge door 02250125 402 4 12 lug lifting clr pk 90deg bend 02250132 040 4 13 grommet rubber 040125 16 14 guard fan 1600q 241347 2 15 fan 48 dia 25hp 1200rpm 250000 847 1 16 bushing split taper 2 1 8 bo...

Page 44: ...Section 6 ILLUSTRATIONS AND PARTS LIST 40 6 9 HORIZONTAL REMOTE COOLER PACK ASSEMBLY WITH DRAIN OPTION 400 450HP 298 336KW 02250131 037R01 ...

Page 45: ... pltd 3 4 x 1 2 868512 050 2 9 flange thrd 4 150 rf 819315 064 2 10 nipple pipe 4 x 3 822164 030 1 11 nipple pipe 4 x 4 822164 040 1 12 adapter female pipe 2 x 2 811516 200 2 13 valve ball 1 2 npt 047117 1 14 drain electric condensate scd400 III 02250130 866 1 15 gasket asa flange 150 4 240621 010 1 I For a breakdown of maintenance parts for this item please consult factory with serial number of y...

Page 46: ...Section 6 ILLUSTRATIONS AND PARTS LIST 42 6 10 HORIZONTAL REMOTE COOLER PACK ASSEMBLY 450HP 336KW 02250123 443R05 ...

Page 47: ...00 hp 02210121 124 1 7 panel assembly side 300 400 hp rem clr 02250124 335 4 8 flange thrd 4 150 rf 819315 064 2 9 nipple pipe 4 x 3 822164 030 1 10 nipple pipe 4 x 4 822164 040 1 11 adapter female pipe 2 x 2 811516 200 2 12 gasket asa flange 150 4 240621 010 1 I For a breakdown of maintenance parts for this item please consult factory with serial number of your Heat Recovery System II Cooler pack...

Page 48: ...Section 6 ILLUSTRATIONS AND PARTS LIST 44 6 11 EES ENCLOSURE DOGHOUSE ASSEMBLY INTEGRAL 02250133 207R00 ...

Page 49: ...17 2 4 angle positioner supt 250004 793 2 5 arm crank cas 500 408955 2 6 swivel damper control 1 4 28 409031 5 7 rod link 5 16 dia x 11 lg 250000 993 2 8 bracket damper control 250001 019 3 9 panel damper support 48 x 48 250001 011 2 10 panel assembly access 54x54 02250124 330 3 11 panel assembly access EES upper 02250124 331 3 12 elbow cor pull 90deg 1 2 846915 050 2 PLEASE NOTE WHEN ORDERING PAR...

Page 50: ...Section 6 ILLUSTRATIONS AND PARTS LIST 46 6 12 EES ENCLOSURE 200 250HP 149 186KW INTEGRAL 02250133 208R01 ...

Page 51: ...el roof sump end TS32A 02250130 224 1 15 cover separator access 02250130 226 1 16 panel access assy 30 x 57 02250130 227 9 17 panel enclosure EES end TS32 02250133 011 1 18 panel roof end TS32A 200 250 int EES 02250133 335 1 19 panel roof mid EES TS32A 200 250ac 02250133 336 1 20 grommet rubber 040125 4 21 handle canopy 042262 1 22 damper panel 48 x 48 nominal oppos 250000 992 1 23 nut hex pltd 1 ...

Page 52: ...Section 6 ILLUSTRATIONS AND PARTS LIST 48 6 12 EES ENCLOSURE 200 250HP 149 186KW INTEGRAL 02250133 208R01 ...

Page 53: ...description number quantity 33 washer spr lock reg pltd 1 4 837804 062 2 34 washer spr lock reg pltd 5 16 837805 078 8 35 washer pl b reg pltd 5 16 838205 071 10 36 eyebolt 5 16 18 x 1 1 8 pltd 839105 112 2 37 nut retainer 5 16 18 092 861405 092 16 PLEASE NOTE WHEN ORDERING PARTS INDICATE SERIAL NUMBER OF COMPRESSOR ...

Page 54: ...Section 6 ILLUSTRATIONS AND PARTS LIST 50 6 13 EES ENCLOSURE 300 350HP 224 261KW INTEGRAL 02250133 209R01 ...

Page 55: ...2A 02250130 221 1 14 support corner TS32A 02250130 222 3 15 support corner spcl TS32A 02250130 223 1 16 panel roof sump end TS32A 02250130 224 1 17 cover separator access 02250130 226 1 18 panel access assy 30 x 57 02250130 227 9 19 panel enclosure EES end TS32 02250133 011 1 20 panel roof center TS32A intac EES 02250133 070 1 21 panel roof end TS32A int EES 02250133 071 1 22 grommet rubber 040125...

Page 56: ...Section 6 ILLUSTRATIONS AND PARTS LIST 52 6 13 EES ENCLOSURE 300 350HP 224 261KW INTEGRAL 02250133 209R01 ...

Page 57: ...sher 5 16 18 x 3 4 829705 075 60 34 screw self drill 1 4 x 1 2 834504 050 67 35 washer spr lock reg pltd 1 4 837804 062 2 36 washer spr lock reg pltd 5 16 837805 078 8 37 washer pl b reg pltd 5 16 838205 071 6 38 eyebolt 5 16 18 x 1 1 8 pltd 839105 112 2 39 nut retainer 5 16 18 092 861405 092 16 PLEASE NOTE WHEN ORDERING PARTS INDICATE SERIAL NUMBER OF COMPRESSOR ...

Page 58: ...Section 6 ILLUSTRATIONS AND PARTS LIST 54 6 14 DECAL GROUP ...

Page 59: ...decal water drain 250022 810 1 2 sign air breathing danger 250027 935 1 3 sign warning food grade lube 250003 144 1 4 sign warning sever fan door closed 02250131 539 4 5 decal Sullair 4 5 X 36 02250057 603 2 6 decal fork lifting 241814 2 PLEASE NOTE WHEN ORDERING PARTS INDICATE SERIAL NUMBER OF COMPRESSOR ...

Page 60: ...Section 6 ILLUSTRATIONS AND PARTS LIST 56 6 15 DECAL LOCATIONS ...

Page 61: ...1 decal water drain 250022 810 1 2 sign air breathing danger 250027 935 1 3 sign warning food grade lube 250003 144 1 4 sign warning sever fan door closed 02250131 539 4 5 decal Sullair 4 5 X 36 02250057 603 2 6 decal fork lifting 241814 2 PLEASE NOTE WHEN ORDERING PARTS INDICATE SERIAL NUMBER OF COMPRESSOR ...

Page 62: ...Section 6 ILLUSTRATIONS AND PARTS LIST 58 6 16 WIRING DIAGRAM EES SUPERVISOR CONTROL 02250133 680R02 ...

Page 63: ...Section 6 ILLUSTRATIONS AND PARTS LIST 59 6 17 WIRING DIAGRAM EES REMOTE 02250134 081R00 ...

Page 64: ...Section 6 ILLUSTRATIONS AND PARTS LIST 60 6 18 WIRING DIAGRAM INTEGRAL HEAT RECOVERY WITH SUPERVISOR 02250064 078R04 ...

Page 65: ...NOTES 61 ...

Page 66: ...ULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City Indiana 46360 U S A www sullair com Telephone 1 800 SULLAIR U S A Only or 1 219 879 5451 Fax 219 874 1273 PARTS DEPARTMENT Fax 219 874 1835 www sullair com parts shtm SERVICE DEPARTMENT Fax 219 874 1205 www sullaircompressors com SULLAIR ASIA LTD Sullair Road No 1 Chiwan Shekou Shenzhen Guangdong PRV PRC POST CODE 518068 Telephone 755 6...

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