Sullair LS-120 series Operators Manual And Parts Lists Download Page 83

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Section 9

ILLUSTRATIONS AND PARTS LIST

9.11 COOLER ASSEMBLY (AIR-COOLED) (CONTINUED)

key

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" (60-75HP/ 45-56KW)

837806-094

•washer, springlock 3/8" (40, 50HP/ 37KW)

837806-094

nut, hex plated 3/8"-16

825206-337

screw, hex flanged plated 5/16"-18 x 3/4"

(60-100HP/ 45-75KW)

829705-075

•screw, hex flanged plated 5/16"-18 x 3/4"

(40, 50HP/ 37KW)

829705-075

support, fan motor (60-75HP/ 45-56KW)

250017-502

•support, fan motor (40, 50HP/ 37KW)

250017-499

screw, hex flanged plated 3/8"-16 x 3/4"

(60-75HP/ 45-56KW)

829706-075

•screw, hex flanged plated 3/8"-16 x 3/4"

(40, 50HP/ 37KW)

829706-075

nut, hex flanged plated 3/8"-16 (60-75HP/ 45-56KW)

825306-347

•nut, hex flanged plated 3/8"-16 (40, 50HP/ 37KW)

825306-347

sign, warning sever fan

049855

sign, warning sever fan port

049965

decal, rotation

250021-564

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

Summary of Contents for LS-120 series

Page 1: ...TRIAL AIR COMPRESSOR LS 1 120 LS 1 160 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: ...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: ... 6 2 4 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTIONAL DESCRIPTION 7 2 5 COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTION 10 2 6 CONTROL SYSTEM FUNCTIONAL DESCRIPTION STANDARD ELECTRO MECHANICAL 11 2 7 CONTROL SYSTEM FUNCTIONAL DESCRIPTION SUPERVISOR CONTROLLER 12 2 8 AIR INLET SYSTEM FUNCTIONAL DESCRIPTION 12 2 9 INSTRUMENT PANEL GROUP FUNCTIONAL DESCRIPTION STANDARD ELECTRO MECHANICAL CON...

Page 4: ...ION STANDARD ELECTRO MECHANICAL 27 5 2 PURPOSE OF CONTROLS STANDARD ELECTRO MECHANICAL 29 5 3 INITIAL START UP PROCEDURE 29 5 4 SUBSEQUENT START UP PROCEDURE 29 5 5 SHUTDOWN PROCEDURE Section 6 SUPERVISOR CONTROLLER 30 Figure 6 1 Instrument Panel Supervisor Controller Section 7 MAINTENANCE 31 7 1 GENERAL 31 7 2 DAILY OPERATION 31 7 3 MAINTENANCE AFTER INITAL 50 HOURS OF OPERATION 31 7 4 MAINTENANC...

Page 5: ...AIR INLET SYSTEM LS 160 WATER COOLED 60 9 8 COOLING AND LUBRICATION SYSTEM AIR COOLED 64 9 9 COOLING AND LUBRICATION SYSTEM LS 120 WATER COOLED 70 9 10 COOLING AND LUBRICATION SYSTEM LS 160 WATER COOLED 74 9 11 COOLER ASSEMBLY AIR COOLED 78 9 12 COMPRESSOR DISCHARGE SYSTEM AIR COOLED 84 9 13 DISCHARGE SYSTEM WATER COOLED 90 9 14 CONTROL SYSTEM LS 120 SUPERVISOR CONTROLLER 92 9 15 CONTROL SYSTEM LS...

Page 6: ...UED 110 9 24 CANOPY WATER COOLED 40 75HP 37 56KW 112 10 25 CANOPY WATER COOLED LS 160 100HP 75KW 114 9 26 DECAL GROUP 120 9 27 WIRING DIAGRAM ELECTRO MECHANICAL FULL VOLTAGE 121 9 28 WIRING DIAGRAM SUPERVISOR CONTROLLER WYE DELTA TABLE OF CONTENTS ...

Page 7: ... 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 8: ...perate 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 clothing away from couplin...

Page 9: ...s 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 current path through the heart C Attempt repairs in clean dry and well lighted and ven...

Page 10: ...se 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 large enough to hold a man and if it is necessary to ente...

Page 11: ...rap all mounted on a heavy gauge steel frame On air cooled models a fan draws air over the motor and forces it out through the combined after cooler and fluid cooler thereby removing the com pression heat from the compressed air and the cooling fluid On water cooled models a shell and tube heat exchanger is mounted on the compressor frame Fluid is piped into the heat exchanger where com pression h...

Page 12: ...otors themselves 3 Acts as a lubricating film between the rotors allowing one rotor to directly drive the other which is an idler After the air fluid mixture is discharged from the compressor unit the fluid is separated from the air At this time the air flows through an aftercooler and separator then to your service line while the fluid is being cooled in preparation for reinjection 2 4 COMPRESSOR...

Page 13: ...or by a pressure differ ential between the receiver and the compressor A visual sight glass is located on the return line to observe this fluid flow There is also an orifice in each return line protected by a strainer to assure proper flow A secondary separator element with a separate return line strainer sight glass and orifice further reduce the fluid carry over to less than 1 ppm parts per mill...

Page 14: ...Section 2 DESCRIPTION 8 Figure 2 3 Compressor Fluid Cooling Lubrication and Discharge System Air cooled ...

Page 15: ...Section 2 DESCRIPTION 9 Figure 2 4 Compressor Fluid Cooling Lubrication and Discharge System Water cooled ...

Page 16: ...Section 2 DESCRIPTION 10 Figure 2 5 Control System ...

Page 17: ... switch opens interrupting the electrical power to the solenoid valve At this time the solenoid valve allows dry sump tank air pressure or service air pressure through a shuttle valve to be applied directly to the inlet valve piston and keep it closed Simultaneously the solenoid valve sends a pneumatic signal to the blowdown valve The blowdown valve opens the sump to the compressor intake reducing...

Page 18: ...e check valve in the air serv ice line prevents line pressure from returning to the sump When the line pressure drops to the low setting cut in pressure usually 100 psig 6 9 bar on low pressure L compressors and 125 psig 8 6 bar on high pressure H compressors 150 psig 10 3 bar on HH compressors 175 psig 12 0 bar XH Supervisor Controller energizes the sole noid valve and allows the blowdown valve t...

Page 19: ...triction gauge monitors the condition of the air intake filter and shows in the red zone 20 to 30 water 51 to 76 cm when filter service is required The com pressor must be running fully loaded for an accurate indication The START pad turns the compressor on The STOP pad turns the compressor off The hourmeter records accumulative hours of operation for the compressor and is use ful for planning and...

Page 20: ...es when the com pressor is running The amber light indicates when the com pressor is in AUTO mode The HAND AUTO switch dual control package is supplied with an amber auto mode indicator light to indicate that the unit is running in the automatic mode A position selector switch provides selector between hand operation and automatic control ...

Page 21: ...I 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 Maximum pressure is rated pressure and 10 psig 0 7 bar II Except for 16 100 60Hz models Height listed is for models without enclosure Height for enclosed models is 1588 mm 62 5 in Add an additional length of 102 mm 4 in n...

Page 22: ...ice where con densed moisture and emulsification mayonnaise may occur the fluid change interval must be reduced to 300 hours maximum A non detergent fluid with rust oxidation and foam inhibitors and good water separation characteristics should be used DO NOT MIX DIFFERENT TYPES OF FLUIDS Contamination of non detergent mineral fluids with traces of detergent motor fluids may lead to opera MOTOR V S...

Page 23: ...LUID CHANGE FLUID FILTER CHANGE SEPARATOR CHANGE Sullube A E G C A D SRF 1 4000 B E G C B D 24KT F E G C A D CP 4600 32 F B E G C B D tional problems such as foaming filter plugging ori fice or line plugging Flush system when switching lubricant brands When ambient conditions exceed those noted or if conditions warrant use of extended life lubricants contact Sullair for recommendation 3 3 APPLICAT...

Page 24: ...Section 3 SPECIFICATIONS 18 Figure 3 2 Identification LS 120 LS 160 Electro mechanical Dual Control Supervisor Controller Water cooled 02250101 748R01 ...

Page 25: ...Section 3 SPECIFICATIONS 19 Figure 3 3 Identification LS 120 Electro mechanical Dual Control Supervisor Controller Air cooled 02250142 969R00 ...

Page 26: ...Section 3 SPECIFICATIONS 20 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 21 Figure 3 5 Identification LS 160 Electro mechanical Dual Control Supervisor Controller with Enclosure Air cooled 02250142 736R02 ...

Page 28: ...NOTES 22 ...

Page 29: ...tall a water cooled or an air cooled aftercooled compressor where it will be exposed to temperatures less than 32 F 0 C 4 3 SERVICE AIR PIPING Service air piping should be installed as shown in Figure 4 1 A shut off valve should be installed to isolate the compressor from the service line if required Also notice that the service line should be equipped with water legs and condensate drains through...

Page 30: ... all electrical connections for tightness 4 DRY RUN the electrical controls by disconnect ing the three 3 motor leads from the starter Energize the control circuits by pressing the TABLE 2 VENTILATION REQUIREMENTS Cooling Type Air Cooled w Aftercooler Water Cooled Motor HP KW 40 NA 50 37 60 45 75 55 100 75 40 NA 50 37 60 45 75 55 100 75 Fan Air CFM 6 000 6 000 8 500 8 500 8 500 1 440 1 440 2 845 2...

Page 31: ... STOP push buttons on the control panel Verify proper rotation by observ ing the motor shaft from the end opposite the com pressor unit the shaft should be turning clockwise If the motor shaft is not turning clockwise discon nect the power to the starter and exchange any two of the three power input leads then re check rota tion A Direction of Rotation decal is located on the motor to show proper ...

Page 32: ...Section 5 OPERATION ELECTRO MECHANICAL 26 Figure 5 1 Instrument Panel Electro mechanical Controller ...

Page 33: ...mat ic stop start AUTO operation Shuts off compressor auto matically after the compressor runs unloaded for a specified time ranging from 3 60 minutes T1 Restarts compressor when the pressure switch closes to the load setting Dual con trol is enabled by pressing the AUTO pad Records cumulative hours of compressor operation useful for planning and logging service schedules Continually monitors serv...

Page 34: ...82 C use for fast warm up on start up Maintains minimum of 55 psig 3 8 bar in the compressor sump Valve piston restricts receiver air discharge from receiv er sump when pressure falls to 55 psig 3 8 bar Also pre vents backflow into the sump during unload conditions and after shutdown Designed to shut the compressor down when the discharge TEMPERATURE SWITCH temperature reaches 235 F 113 C It preve...

Page 35: ...the operating temperature If the oper ating temperature exceeds 205 F 96 C the cooling system or installation environment should be checked 8 Observe return line sight glass and maintenance indicators 9 Open shut off valve to service line 10 Reinspect the compressor for temperature and leaks the following day 5 4 SUBSEQUENT START UP PROCEDURE On subsequent start ups check that fluid level is visib...

Page 36: ... OPERATION SUPERVISOR CONTROLLER 30 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: ...URS OF OPERATION After the initial 50 hours of operation a few mainte nance requirements are needed to clean the sys tem of any foreign materials Perform the following maintenance operations to prevent unnecessary problems 1 Clean the return line strainer Refer to Section 9 13 for strainer location 2 Clean the return line orifice 7 4 MAINTENANCE AFTER FIRST 1000 HOURS After 1000 hours of operation...

Page 38: ...embly 3 Remove air filter element by loosening the wingnut securing the element 4 Remove element and clean interior of housing using a damp cloth DO NOT blow dirt out with compressed air 5 At this time replace the element 6 Reassemble in the reverse order of the disas sembly AIR FILTER ELEMENT REPLACEMENT 160 SERIES 100HP 75KW 1 Clean exterior of air filter housing 2 Unscrew the wing nut securing ...

Page 39: ...lement has been installed inspect and tighten all air inlet connections prior to resuming operation SEPARATOR ELEMENT REPLACEMENT Refer to Figure 7 4 The separator elements must be changed when the maintenance gauge shows red with the compressor running full load or once a year whichever occurs first Follow the procedure explained below for separator element replace ment Section 7 MAINTENANCE 33 F...

Page 40: ...o a compressor with any other operating range excepting the stated pres sures Remove the cover of the pressure switch With the shut off valve closed or slightly cracked open start the compressor Observe the line pressure gauge and pressure switch contacts When the line pressure reaches 135 psig 9 3 bar the pressure switch contacts should open If the pressure switch contacts do not open or they ope...

Page 41: ...tch cover At this time start the compressor and cycle the Control System sev eral times and re check all pressure settings and adjustments DO NOT touch the pressure switch electrical con with any part of the body or any un insulated metallic object Severe electrical shock may occur PRESSURE REGULATOR ADJUSTMENT Start the compressor and adjust the service valve to maintain service air pressure at r...

Page 42: ...gure 7 6 At this time the coupling is ready for operation DRIVE COUPLING DISASSEMBLY AND REMOVAL Refer to Figure 7 7 Disassembly and removal of the drive coupling is done in the following manner 1 Place a suitably sized radiator hose clamp over the flexible element as show in Figure 7 7 and tighten sufficiently to compress the rubber 2 Remove the ferry head bolts from the hubs and element 3 Rotate...

Page 43: ...Section 7 MAINTENANCE 37 Figure 7 8 Piping and Instrumentation Diagram Standard ...

Page 44: ...Section 7 MAINTENANCE 38 Figure 7 9 Piping and Instrumentation Diagram Supervisor Controller ...

Page 45: ... Incoming Line Voltage Loss of Control Voltage Low Incoming Voltage Excessive Operating Pressure Discharge Temperature Switch Open COMPRESSOR WILL NOT START COMPRESSOR SHUTS DOWN WITH AIR DEMAND PRESENT Section 8 TROUBLESHOOTING ELECTRO MECHANICAL 39 8 1 TROUBLESHOOTING STANDARD ELECTRO MECHANICAL The information contained in the Standard Electro Mechanical Troubleshooting chart has been com piled...

Page 46: ... check for proper ventilation Ambient temperature is too high provide suf ficient ventilation Low fluid level add fluid Clogged filter change the fluid filter element and change the bearing filter element if main tenance indicator shows red Thermal valve not functioning properly replace element Water flow regulating valve not functioning properly change water cooled only Defective discharge temper...

Page 47: ...n tacts open Repair or replace if necessary kit available Clean strainer screen and o ring replace ment kit available Clean orifice Change separator Check all pipes connections and compo nents Drain and change Drain and change Replace Check separator differential Remove the water vapor from compressed air prior to distribution through the air system Check operation of aftercooler and moisture sepa...

Page 48: ...NOTES 42 ...

Page 49: ...ary replacement for separator 02250100 754 02250100 756 1 kit repair for minimum pressure valve 02250109 817 250018 456 1 kit cap for minimum pressure check valve 02250109 817 02250044 355 1 kit o ring for minimum pressure check valve 02250109 817 02250048 365 1 kit piston for minimum pressure check valve 02250109 817 02250051 336 1 kit repair for minimum pressure check valve 02250097 598 02250110...

Page 50: ... 635 40 50HP 37KW 02250144 735 1 kit repair for moisture separator 02250144 633 60 75HP 45 56KW 02250144 732 1 kit repair for moisture separator 02250144 632 100HP 75KW 02250144 732 1 manual Sequencing Protocol III 02250139 197 1 fluid SRF 1 4000 5 gal 19l 250019 662 IV lubricant Sullube Std 5 gal 19l 250022 669 IV lubricant 24 KT 5 gal 19l 02250051 053 IV lubricant Sullube Std 5 gal 19l 250022 66...

Page 51: ...Section 9 ILLUSTRATIONS AND PARTS LIST 45 NOTES ...

Page 52: ...Section 9 ILLUSTRATIONS AND PARTS LIST 46 9 3 MOTOR FRAME COMPRESSOR AND PARTS LS 120 40 60HP 37 45KW ...

Page 53: ...HP 45KW consult factory 1 9 adapter compressor motor 250014 882 1 10 capscrew hex GR5 3 8 16 x 2 1 4 829106 225 10 11 capscrew hex GR5 5 8 11 x 1 1 2 829110 150 4 12 guard coupling 250018 412 1 13 screw hex ser washer 5 16 x 3 4 829705 075 3 14 hub coupling 1 7 8 x 1 2 40 50HP 37KW 250018 005 1 hub coupling 60HP 45KW 250018 008 1 15 element coupling 40 50HP 37KW 250004 641 1 element coupling 60HP ...

Page 54: ...Section 9 ILLUSTRATIONS AND PARTS LIST 48 9 3 MOTOR FRAME COMPRESSOR AND PARTS LS 120 40 60HP 37 45KW ...

Page 55: ...ry 1 30 adapter SAE 3 dxx12 250016 605 1 31 decal sign warning sever fan 046855 1 32 decal fork lifting 241814 4 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 you...

Page 56: ...Section 9 ILLUSTRATIONS AND PARTS LIST 50 9 4 MOTOR FRAME COMPRESSOR AND PARTS LS 160 60 100HP 45 75KW ...

Page 57: ...HP 56KW consult factory 1 motor 100HP 75KW consult factory 1 9 adapter motor comp 75 100HP 56 75KW 250014 883 1 10 capscrew hex GR5 3 8 16 x 2 1 4 829106 225 12 11 capscrew hex GR5 5 8 11 x 1 1 2 829110 150 4 12 guard coupling 250018 412 1 13 screw hex ser washer 5 16 x 3 4 829705 075 3 14 hub coupling 1 7 8 x 1 2 75 100HP 56 75KW 250018 006 1 15 element coupling 75 100HP 56 75KW 250018 551 1 16 h...

Page 58: ...Section 9 ILLUSTRATIONS AND PARTS LIST 52 9 4 MOTOR FRAME COMPRESSOR AND PARTS LS 160 60 100HP 45 75KW ...

Page 59: ...XX 16 250016 611 1 32 decal fork lifting 241814 4 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 The...

Page 60: ...Section 9 ILLUSTRATIONS AND PARTS LIST 54 9 5 AIR INLET SYSTEM LS 120 ...

Page 61: ...ew hex GR5 5 8 11 x 1 1 4 829110 125 4 15 valve 3 poppet inlet III 02250143 374 1 16 capscrew hex GR5 5 8 11 x 1 1 2 829110 150 4 17 washer springlock 5 8 837810 156 4 18 elbow 37ºfl 90ºm 1 2 X 1 4 860208 025 1 19 connector tube M 1 4 T x 1 4 P 250018 428 1 20 washer springlock 3 8 837806 094 2 21 nut hex 3 8 16 866506 337 2 22 o ring viton 3 1 2 x 1 8 826502 238 1 23 orifice 25 x 1 4 m x 1 4 f 02...

Page 62: ...Section 9 ILLUSTRATIONS AND PARTS LIST 56 9 6 AIR INLET SYSTEM LS 160 AIR COOLED ...

Page 63: ...1 4 860208 025 1 13 elbow rubber 90º 5 02250061 835 1 14 valve air inlet 4 III 02250143 377 1 15 capscrew hex GR5 1 2 13 x 1 1 2 829108 150 4 16 washer springlock 1 2 837808 125 4 17 connector tube M 1 4 T x 1 4 P 250018 428 1 18 gasket 5 1 4 OD IV 040708 1 19 orifice 25 x 1 4 m x 1 4 f 02250143 403 1 I For maintenance on air filter no 02250091 634 order replacement element no 250018 652 II For ma...

Page 64: ...Section 9 ILLUSTRATIONS AND PARTS LIST 58 9 7 AIR INLET SYSTEM LS 160 WATER COOLED ...

Page 65: ...º 5 02250061 835 1 14 valve air inlet 4 III 02250143 377 1 15 capscrew hex GR5 1 2 13 x 1 1 2 829108 150 4 16 washer springlock 1 2 837808 125 4 17 connector tube M 1 4 T x 1 4 P 250018 428 1 18 gasket 5 1 4 OD IV 040708 1 19 washer springlock 3 8 837806 094 2 20 nut hex 3 8 825206 337 2 21 orifice 25 x 1 4 m x 1 4 f 02250143 403 1 I For maintenance on air filter no 02250091 634 order replacement ...

Page 66: ...Section 9 ILLUSTRATIONS AND PARTS LIST 60 9 8 COOLING AND LUBRICATION SYSTEM AIR COOLED ...

Page 67: ...apter SAE 1 5 8 x 1 5 8 02250055 015 1 12 filter fluid 1 5 8 III 02250054 605 1 13 connector tube M 1 4 x 1 8 E M 250139 024 2 connector tube M 1 4 x 1 8 Supervisor Controller 250139 024 4 14 tubing stainless steel 1 4 E M 841215 004 14 5 ft tubing stainless steel 1 4 Supervisor Controller 841215 004 0 9 ft 15 hose swivel end 1 x 35 02250098 622 1 16 elbow SAE 1 90º 50 75HP 37 56KW 02250087 070 1 ...

Page 68: ...Section 9 ILLUSTRATIONS AND PARTS LIST 62 9 8 COOLING AND LUBRICATION SYSTEM AIR COOLED ...

Page 69: ... 130 2 25 decal warning mixing fluids 02250110 891 1 26 decal warning compressor fluid fill cap 049685 1 27 decal Sullube III 02250069 389 1 28 reducer 1 7 8 x 1 5 8 100HP 75KW 870024 020 2 III Sullube is the standard fill for LS 120 and LS 160 air compressors If your compressor has an optional fill consult Section 9 26 Decal Group key numbers 20A 20D for matching fluid decal part number PLEASE NO...

Page 70: ...Section 9 ILLUSTRATIONS AND PARTS LIST 64 9 9 COOLING AND LUBRICATION SYSTEM LS 120 WATER COOLED ...

Page 71: ...3 806 2 14 filter fluid 1 5 8 sae strt thread II 02250054 605 1 15 connector tube m 1 4 x 1 8 s s E M DC 250139 024 2 connector tube m 1 4 x 1 8 s s Supervisor Controller 250139 024 4 16 hose mp orfs f swvl end 1 x 35 02250098 622 1 17 hose mp orfs f swvl end 1 x 60 02250105 496 1 18 elbow tube m 1 4 x 3 8 250018 530 1 19 capscrew hex gr5 3 8 16 x 1 1 4 plated 829106 125 8 20 washer pl b reg plate...

Page 72: ...Section 9 ILLUSTRATIONS AND PARTS LIST 66 9 9 COOLING AND LUBRICATION SYSTEM LS 120 WATER COOLED ...

Page 73: ...4 150 plated 869204 030 2 36 nipple pipe xs 3 4 x close plated III 866412 000 3 37 union pipe brass seat 3 4 300 plated III 868030 030 1 38 valve water regulating 3 4 160 230F III 047398 1 39 elbow pipe 90 deg 3 4 150 plated 866215 030 2 40 nipple pipe 3 4 x 2 plated 866312 020 1 41 bracket water connection 3 4 npt 250017 234 1 42 capscrew hex gr5 1 2 13 x 1 1 4 829108 125 1 43 washer springlock r...

Page 74: ...Section 9 ILLUSTRATIONS AND PARTS LIST 68 9 9 COOLING AND LUBRICATION SYSTEM LS 120 WATER COOLED ...

Page 75: ...250110 891 1 54 sign warning compressor fluid fill cap 049685 1 55 decal fluid Sullube IV 02250069 389 1 56 decal water out 250019 108 1 57 decal water in 250019 107 1 IV Sullube is the standard fill for LS 120 and LS 160 air compressors If your compressor has an optional fill consult Section 9 26 Decal Group key numbers 20A 20D for matching fluid decal part number PLEASE NOTE WHEN ORDERING PARTS ...

Page 76: ...Section 9 ILLUSTRATIONS AND PARTS LIST 70 9 10 COOLING AND LUBRICATION SYSTEM LS 160 WATER COOLED ...

Page 77: ...nnector tube m 1 4 x 1 8 s s Supervisor Controller 250139 024 4 16 hose mp orfs f swvl end 1 x 35 02250098 622 1 17 hose mp orfs f swvl end 1 x 60 02250105 496 1 18 elbow tube m 1 4 x 3 8 250018 530 1 19 capscrew hex gr5 3 8 16 x 1 1 4 plated 829106 125 8 20 washer pl b reg plated 3 8 837806 094 16 21 washer springlock reg plated 3 8 837806 094 8 22 nut hex plated 3 8 16 825206 337 8 23 clr oil wa...

Page 78: ...Section 9 ILLUSTRATIONS AND PARTS LIST 72 9 10 COOLING AND LUBRICATION SYSTEM LS 160 WATER COOLED ...

Page 79: ... 150 plated 869204 030 2 36 nipple pipe xs 3 4 x close plated 866412 000 3 37 union pipe brass seat 3 4 300 plated 868030 030 1 38 valve water regulating 3 4 160 230F 047398 1 39 elbow pipe 90 deg 3 4 150 plated 866215 030 2 40 nipple pipe 3 4 x 2 plated 866312 020 1 41 bracket water connection 3 4 npt 250017 234 1 42 capscrew hex gr5 1 2 13 x 1 1 4 829108 125 1 43 washer springlock reg plated 1 2...

Page 80: ...Section 9 ILLUSTRATIONS AND PARTS LIST 74 9 11 COOLER ASSEMBLY AIR COOLED ...

Page 81: ...crew hex GR5 5 16 18 x 1 40 50HP 37KW 829105 100 4 11 washer pl b reg plated 5 16 40 50HP 37KW 838205 071 4 12 nut hex locking plated 3 8 16 60 75HP 45 56KW 825506 198 4 nut hex locking 5 16 18 40 50HP 37KW 825505 166 4 13 motor electric fan 3HP 60 100HP 45 75KW consult factory 1 motor electric fan 2HP 40 50HP 37KW consult factory 1 14 capscrew hex GR5 3 8 16 x 1 829106 100 10 capscrew hex GR5 3 8...

Page 82: ...Section 9 ILLUSTRATIONS AND PARTS LIST 76 9 11 COOLER ASSEMBLY AIR COOLED ...

Page 83: ...7 2 24 screw hex flanged plated 5 16 18 x 3 4 60 100HP 45 75KW 829705 075 39 screw hex flanged plated 5 16 18 x 3 4 40 50HP 37KW 829705 075 23 25 support fan motor 60 75HP 45 56KW 250017 502 1 support fan motor 40 50HP 37KW 250017 499 1 26 screw hex flanged plated 3 8 16 x 3 4 60 75HP 45 56KW 829706 075 2 screw hex flanged plated 3 8 16 x 3 4 40 50HP 37KW 829706 075 6 27 nut hex flanged plated 3 8...

Page 84: ...Section 9 ILLUSTRATIONS AND PARTS LIST 78 9 12 COMPRESSOR DISCHARGE SYSTEM AIR COOLED ...

Page 85: ... 10 washer springlock 5 8 837510 156 8 11 elbow tube M 1 4 x 1 4 250018 430 4 12 adapter SAE 1 7 8 x 1 7 8 LS 120 02250055 014 1 adapter SAE 2 1 2 x 2 LS 160 02250110 661 1 13 connector flex 1 4 x 1 4 020169 2 14 tubing 1 4 stainless steel 841215 004 14 5 15 connector tube male bulkhead 1 4 02250101 490 1 16 bracket mounting support 02250101 192 1 17 connector tube M str thd 1 4 x 7 16 811804 044 ...

Page 86: ...Section 9 ILLUSTRATIONS AND PARTS LIST 80 9 12 COMPRESSOR DISCHARGE SYSTEM AIR COOLED ...

Page 87: ...dapter SAE x NPT 1 2 x 1 4 811504 025 1 38 bushing reducing 1 4 x 1 8 stl plated 867100 005 1 39 fitting compression adjustable 250028 635 1 40 probe RTD discharge temp 250039 909 1 41 plug straight thrd 3 4 16 SAE viton 250042 623 1 42 washer reg 1 2 838208 112 4 43 washer springlock 1 2 837808 125 4 44 capscrew hex GR5 1 2 13 x 1 1 2 829108 150 4 45 o ring viton 2 1 2 x 1 8 826502 230 1 Continue...

Page 88: ...Section 9 ILLUSTRATIONS AND PARTS LIST 82 9 12 COMPRESSOR DISCHARGE SYSTEM AIR COOLED ...

Page 89: ...18 x 1 829705 100 4 56 nut hex flange 5 16 18 825305 283 4 57 support water separator 02250142 589 2 58 nipple pipe 1 1 2 x 3 1 2 866324 035 1 59 U bolt 1 4 x 1 1 2 pipe 868304 150 1 60 separator moisture 40 50HP VII 02250144 635 1 separator moisture 60 75HP 45 75KW VIII 02250144 633 1 separator moisture 100HP 75KW IX 02250144 632 1 61 decal water drain 250022 810 1 62 tee reducing 1 1 2 x 1 1 2 x...

Page 90: ...Section 9 ILLUSTRATIONS AND PARTS LIST 84 9 13 COMPRESSOR DISCHARGE SYSTEM WATER COOLED ...

Page 91: ...0109 817 1 7 adapter SAE 1 7 8 x 1 7 8 LS 120 02250055 014 1 adapter SAE 2 1 2 x 2 LS 160 02250110 661 1 8 elbow tube M 1 4 x 1 4 250018 430 3 9 elbow tube M 1 4 x 1 8 250018 429 1 10 tube cooler to moisture separator 50 75HP 37 56KW 02250105 700 1 tube clr to moisture sep 100HP 75KW 02250046 585 1 11 decal maintenance kit LS120 160 02250144 505 1 12 connector flex 1 4 x 1 4 020169 2 13 tubing 1 4...

Page 92: ...Section 9 ILLUSTRATIONS AND PARTS LIST 86 9 13 COMPRESSOR DISCHARGE SYSTEM WATER COOLED ...

Page 93: ...rator air fluid primary IX 02250100 753 1 32 tank separator 14 50 75HP 37 56KW 02250109 524 1 tank separator 14 100HP 75KW 02250110 502 1 33 plug o ring 1 1 4 040029 1 Continued on page 89 III For maintenance on moisture separator no 02250144 635 order auto drain repair kit no 02250144 735 IV For maintenance on moisture separator no 02250144 633 order auto drain repair kit no 02250144 732 V For ma...

Page 94: ...Section 9 ILLUSTRATIONS AND PARTS LIST 88 9 13 COMPRESSOR DISCHARGE SYSTEM WATER COOLED ...

Page 95: ...drn 50 75HP 37 56KW 02250098 148 1 support air connect condensate drain 100HP 75KW 02250110 185 1 50 washer springlock 5 8 837510 156 8 51 plug straight thread 3 4 16 SAE viton 250042 623 1 52 capscrew hex GR8 5 8 11 x 2 828210 200 8 53 connector tube M 1 4 x 1 8 250018 429 1 54 tube sep air connect 1 1 2 50 75HP 37 56KW 02250098 227 1 tube separator air connection 2 100HP 75KW 02250045 594 1 55 a...

Page 96: ...Section 9 ILLUSTRATIONS AND PARTS LIST 90 9 14 CONTROL SYSTEM LS 120 SUPERVISOR CONTROLLER ...

Page 97: ...steel 1 4 841215 004 4 15 valve solenoid II 02250125 657 2 16 nipple chase conduit 1 2 847815 050 1 17 nipple pipe hex 1 4 x 1 4 868504 025 2 18 valve pressure regulator III 02250084 027 1 19 orifice 02250101 414 1 20 tee male pipe 1 4 869825 025 2 21 valve shuttle 1 4 408893 2 22 support bracket press switch 02250084 823 1 23 tee male run 1 4 T x 1 4 P 250038 059 1 24 transducer pressure 02250078...

Page 98: ...Section 9 ILLUSTRATIONS AND PARTS LIST 92 9 15 CONTROL SYSTEM LS 120 ELECTRO MECHANICAL ...

Page 99: ... 1 2 847815 050 1 17 tee male run 1 4 T x 1 4 P 250038 059 1 18 nipple pipe hex 1 4 x 1 4 868504 025 3 19 valve shuttle 1 4 408893 2 20 switch pressure 140PSI 040694 1 switch pressure 140PSI 407778 1 21 screw machine rd head 10 32 x 1 2 831602 050 2 22 orifice not shown 02250101 414 1 23 tee male pipe 1 4 869825 025 2 24 valve pressure regulator IV 02250084 027 1 25 bulkhead pipe 1 4 841500 004 1 ...

Page 100: ...Section 9 ILLUSTRATIONS AND PARTS LIST 94 9 16 CONTROL SYSTEM LS 160 SUPERVISOR CONTROLLER ...

Page 101: ...15 tubing stainless steel 1 4 841215 004 4 16 valve solenoid II 02250125 657 2 17 nipple chase conduit 1 2 847815 050 1 18 valve pressure regulator III 250017 280 1 19 tee male pipe 1 4 869825 025 2 20 valve shuttle 1 4 408893 2 21 orifice 02250091 395 1 22 support bracket press switch 02250084 823 1 23 tee male run 1 4 T x 1 4 P 250038 059 1 24 transducer pressure 02250078 933 2 25 strainer v typ...

Page 102: ...Section 9 ILLUSTRATIONS AND PARTS LIST 96 9 17 CONTROL SYSTEM LS 160 ELECTRO MECHANICAL ...

Page 103: ...7 nipple chase conduit 1 2 847815 050 1 18 tee male run 1 4 T x 1 4 P 250038 059 1 19 valve shuttle 1 4 408893 2 20 switch pressure 140PSI 040694 1 switch pressure 140PSI 407778 1 21 screw machine rd head 10 32 x 1 2 831602 050 2 22 valve pressure regulator IV 250017 280 1 23 tee male pipe 1 4 869825 025 2 24 orifice 02250091 395 1 25 bulkhead pipe 1 4 841500 004 1 26 support bracket press switch ...

Page 104: ...Section 9 ILLUSTRATIONS AND PARTS LIST 98 9 18 INSTRUMENT PANEL ELECTRO MECHANICAL ...

Page 105: ...304 236 1 13 panel instrument 02250125 351 1 14 decal instrument panel 02250051 301 1 15 gauge temperature 100º 250º 02250100 096 1 16 gauge pressure 0 230 250005 185 2 17 gauge differential pressure 0 30PSI 250003 799 1 18 gauge differential pressure 0 15PSI 250003 798 1 19 gauge vacuum 0 30 water 250003 797 1 20 plate serial number 02250059 318 1 21 rivet pop 1 8 x 1 2 843102 050 4 22 screw 8744...

Page 106: ...Section 9 ILLUSTRATIONS AND PARTS LIST 100 9 19 INSTRUMENT PANEL SUPERVISOR CONTROLLER 02250138 633R00 ...

Page 107: ... contact 1nc 250027 125 1 10 switch per red push pull e22 250028 588 1 11 nut hex f pltd 5 16 18 825305 283 4 12 nut hex metric m4 x 7 825904 070 8 13 screw tc f pan 8 32 x 1 2 835601 050 8 14 washer lock ext tooth 8 838401 023 8 15 washer spr lock metric pltd m4 838804 090 8 16 rivet pop 1 8 x 3 8 843102 038 4 17 decal warning auto start 250017 903 1 18 decal warning auto start 041065 1 19 decal ...

Page 108: ...Section 9 ILLUSTRATIONS AND PARTS LIST 102 9 20 ELECTRICAL BOX ELECTRO MECHANICAL ...

Page 109: ...0 2 15 fuse KTK 2 0A 250019 756 1 16 block terminal KT3 250041 102 1 17 contactor AC 3P 18A 120V coil 250025 703 1 18 starter consult factory 1 19 grip cord consult factory 2 20 relay 045496 1 21 socket 045497 1 22 decal warning ground fault 049852 1 23 decal danger high voltage 042218 1 24 decal V 460 3 60 international I 02250069 399 1 25 decal protective earth ground 02250075 045 1 26 decal PE ...

Page 110: ...Section 9 ILLUSTRATIONS AND PARTS LIST 104 9 21 ELECTRICAL BOX SUPERVISOR CONTROLLER ...

Page 111: ...tor consult factory 1 15 fuse KTK 2 0A 250019 756 16 block terminal KT3 250041 102 1 17 contactor AC 3P 18A 120V coil 250025 703 1 18 starter consult factory 1 19 grip cord consult factory 2 20 decal warning ground fault 049852 1 21 decal danger high voltage 042218 1 22 decal V 460 3 60 international I 02250069 399 1 23 decal protective earth ground 02250075 045 1 24 decal PE designation 02250075 ...

Page 112: ...Section 9 ILLUSTRATIONS AND PARTS LIST 106 9 22 CANOPY AIR COOLED LS 120 LS 160 40 75HP 37 56KW ...

Page 113: ...d 250018 609 2 10 screw hex serrated washer 5 16 18 829705 075 40 11 nut hex flanged 5 16 825305 283 20 12 panel access side special 250021 260 1 13 panel front side 02250099 223 1 14 panel acess side 250017 310 4 15 latch adjustable trigger lock 049764 6 16 decal LS 120 with stripe and logo 02250144 126 1 decal LS 160 with stripe and logo not shown 02250144 128 1 17 capscrew hex 1 4 20 829104 100...

Page 114: ...Section 9 ILLUSTRATIONS AND PARTS LIST 108 9 23 CANOPY AIR COOLED LS 160 75 100HP 56 75KW WITH TEFC MOTOR ...

Page 115: ...front side 02250099 462 1 13 door assy 250026 023 5 14 latch adjustable trigger 049764 6 15 panel corner extended RH 02250142 993 1 16 panel sill 02250111 440 1 17 panel corner extended LH 02250111 442 1 18 clamp wire 043194 16 19 panel back side 250017 312 1 20 decal black 12 x 43 5 02250144 131 1 21 decal black 12 x 14 02250144 130 1 22 decal ISO 9001 02250057 624 1 23 sign danger air breathing ...

Page 116: ...Section 9 ILLUSTRATIONS AND PARTS LIST 110 9 24 CANOPY WATER COOLED 40 75HP 37 56KW ...

Page 117: ...241137 1 15 panel corner left hand 02250142 669 2 16 panel enclosure end 250018 647 2 17 panel corner right hand 250018 609 2 18 panel access side special 250034 296 1 19 panel front side 02250099 223 1 20 panel access side 250017 310 4 21 latch adjustable trigger lock 049764 6 22 panel fiberglass door 250020 015 12 23 panel access side 250034 297 1 24 panel back side 250017 312 1 25 decal black 1...

Page 118: ...Section 9 ILLUSTRATIONS AND PARTS LIST 112 9 25 CANOPY WATER COOLED LS 160 100HP 75KW ...

Page 119: ...83 28 14 door assy 250034 320 1 15 panel enclosure front side 02250099 462 1 16 latch adjust trigger 049764 6 17 door assy 250026 023 4 18 panel corner extended RH 02250142 993 1 19 panel sill 02250111 440 1 20 panel corner extended LH 02250111 442 1 21 decal black 12 x 43 5 02250144 131 1 22 decal black 12 x 14 02250144 130 1 23 decal ISO 9001 02250057 624 1 24 sign danger air breathing 250027 93...

Page 120: ...Section 9 ILLUSTRATIONS AND PARTS LIST 114 9 26 DECAL GROUP ...

Page 121: ...nal 02250069 399 1 7B decal V 230 3 60 international 02250069 397 1 7C decal V 380 415 3 50 international 02250069 403 1 7D decal V 200 3 60 international 02250069 406 1 7E decal V 575 3 60 international 02250069 400 1 8 decal Sullair 2 1 2 x 20 02250059 054 1 decal Sullair 4 x 32 02250059 060 1 9 decal rotation 250021 564 1 10 decal water drain 250022 810 1 11 sign warning sever fan 049855 2 12 s...

Page 122: ...Section 9 ILLUSTRATIONS AND PARTS LIST 116 9 26 DECAL GROUP ...

Page 123: ...anger air breathing 250027 935 1 18 decal danger high voltage 042218 1 19 decal warning auto start 041065 1 20A decal fluid Sullube 02250069 389 1 20B decal fluid 24KT 02250069 395 1 20C decal fluid CP 4600 32 F 02250118 342 1 20D decal fluid SAS 02250108 243 1 21 decal warning mixing fluids 02250110 891 1 22 decal water in 250019 107 1 23 decal water out 250019 108 1 Continued on page 119 PLEASE ...

Page 124: ...Section 9 ILLUSTRATIONS AND PARTS LIST 118 9 26 DECAL GROUP ...

Page 125: ...02250057 624 1 28 decal 24KT 2 5 x 4 02250061 016 1 29 decal LS 120 02250144 155 1 30 decal LS 160 02250144 157 1 31 decal LS 120 w stripe and logo 02250144 126 1 decal LS 160 w stripe and logo not shown 02250144 128 1 32 decal instrument pnl universal not shown 02250051 301 1 33 decal instument pnl universal not shown 02250051 303 1 34 decal instrument pnl universal dual cntrl not shown 02250059 ...

Page 126: ...Section 9 ILLUSTRATIONS AND PARTS LIST 120 9 27 WIRING DIAGRAM ELECTRO MECHANICAL FULL VOLTAGE 02250129 076R04 ...

Page 127: ...Section 9 ILLUSTRATIONS AND PARTS LIST 121 9 28 WIRING DIAGRAM SUPERVISOR CONTROLLER WYE DELTA 02250134 817R04 ...

Page 128: ......

Page 129: ......

Page 130: ...SULLAIR 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 ...

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