Sullair LS-20S Operator'S Manual And Parts List Download Page 18

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Section 2

DESCRIPTION

LINE PRESSURE AIR
DRY SIDE AIR
MODULATING AIR

MODULATION

CHECK

VALVE

CONTROL

LINE FILTER

SULLICON

CONTROL

BLOWDOWN

VALVE

CHECK

VALVE

SPIRAL

VALVE

INLET

CONTROL

CYLINDER

PRESSURE

GAUGE

LINE PRESSURE AIR
DRY SIDE AIR
MODULATING AIR

UNLOAD

CHECK

VALVE

CONTROL

LINE FILTER

SULLICON

CONTROL

BLOWDOWN

VALVE

CHECK

VALVE

SPIRAL

VALVE

INLET

CONTROL

CYLINDER

PRESSURE

GAUGE

Figure 2-5B Control System Diagram- Modulation and Unload

UNLOAD

SOLENOID

SEQUENCING

SOLENOID

SPIRAL

VALVE

PRESSURE

REGULATOR

SULLICON

PRESSURE

REGULATOR

SULLICON

PRESSURE

LIMITING

REGULATOR

(HH & XH MODELS ONLY)

UNLOAD

SOLENOID

SEQUENCING

SOLENOID

SPIRAL

VALVE

PRESSURE

REGULATOR

SULLICON

PRESSURE

REGULATOR

SULLICON

PRESSURE

LIMITING

REGULATOR

(HH & XH MODELS ONLY)

CLOSED INLET

SOLENOID

(OPTIONAL)

CLOSED INLET

SOLENOID

(OPTIONAL)

Summary of Contents for LS-20S

Page 1: ...LS 20S OPERATOR S MANUAL AND Part Number 02250115 257 eSullair Corporation AIR COMPRESSOR INDUSTRIAL STANDARD AND 24KT 125 150HP 90 110KW PARTS LIST KEEP FOR FUTURE REFERENCE...

Page 2: ...t Sullair s corporate headquarters in Michigan City Indiana Instruction includes discussion of the function and installation of Sullair service parts troubleshooting of the most common problems and ac...

Page 3: ...TIONAL DESCRIPTION 6 2 4 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTIONAL DESCRIPTION 6 2 5 COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTION 10 2 6 CONTROL SYSTEM FUNCTIONAL DESCRIPTION 14 2 7 A...

Page 4: ...1 6 8 SUPERVISOR OUTPUT RELAYS 31 6 9 MAINTENANCE INTRODUCTION 32 6 10 DAILY OPERATION Section 7 MAINTENANCE 33 7 1 GENERAL 33 7 2 DAILY OPERATION 33 7 3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATIO...

Page 5: ...OOLER PIPING AIR COOLED AFTER JUNE 2000 60 8 11 AFTERCOOLER PIPING WATER COOLED 62 8 12 UNIT TUBING 64 8 13 SULLICON CONTROL 66 8 14 PNEUMATIC CONTROLS WITHOUT SPIRAL VALVE 68 8 15 PNEUMATIC CONTROLS...

Page 6: ...NOTES...

Page 7: ...t off throttle valve either at the compressor or at any other point along the air line when an air hose exceeding 1 2 13mm inside diameter is to be connected to the shut off throttle valve to reduce p...

Page 8: ...ags trash leaves litter or other com bustibles out of and away from the compressor J DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or w...

Page 9: ...ended with open electrical enclosures If necessary to do so then disconnect lock out and tag all power at source so others will not inadvertently restore power E Disconnect lock out and tag all power...

Page 10: ...ge enough to hold a person and if it is necessary to enter it to per form service adjustments inform other personnel before doing so or else secure and tag the access door in the open position to avoi...

Page 11: ...cludes compressor electric motor compressor inlet system compressor discharge system compressor cooling and lu brication system capacity control system and Supervisor control system all mounted on a h...

Page 12: ...ly open to the compressor unit when the fluid temperature is below 180_F 82_C The fluid passes through the thermal valve the main filter and directly to the com pressor unit where it lubricates cools...

Page 13: ...VALVE SILENCER CHECK VALVE PRESSURE REGULATOR CONTROL FILTER PRESSURE REGULATOR FOR HIGH PRESSURE MACHINES LOAD CONTROL SOLENOID VALVE SEQUENCING SOLENOID VALVE FLUID COOLER AFTERCOOLER AIR COOLED MAC...

Page 14: ...e requirement mes sage The receiver is a pressure vessel designed and built to codes administered by appropriate governing bo dies A combination minimum pressure check valve located downstream from th...

Page 15: ...LVE SUMP TANK MOISTURE SEPARATOR AFTERCOOLER FLUID FILL PLUG FLUID LEVEL SIGHT GLASS into the receiver on shutdown and during operation on the compressor in an unloaded condition A pressure relief val...

Page 16: ...icon Control a butterfly valve located on the compressor air in let a pressure switch pilot valve pressure reg ulator s and a control line filter The functional description of the control system is de...

Page 17: ...R FULL LOAD CHECK VALVE CONTROL LINE FILTER SULLICON CONTROL BLOWDOWN VALVE SPIRAL VALVE INLET CONTROL CYLINDER PRESSURE GAUGE CHECK VALVE UNLOAD SOLENOID CLOSED INLET SOLENOID SEQUENCING SOLENOID OPT...

Page 18: ...NTROL BLOWDOWN VALVE CHECK VALVE SPIRAL VALVE INLET CONTROL CYLINDER PRESSURE GAUGE Figure 2 5B Control System Diagram Modulation and Unload UNLOAD SOLENOID SEQUENCING SOLENOID SPIRAL VALVE PRESSURE R...

Page 19: ...h is being used As air demand keeps dropping further thespi ral valve keeps opening more and more until all the bypass ports are fully open At this point the spiral valve has moved into the unload min...

Page 20: ...imum position 2 7 AIR INLET SYSTEM FUNCTIONAL DESCRIP TION Refer to Figure 2 6 The compressor inlet system consists of a two stage heavy duty dry type filter with inertial dust separation and collecti...

Page 21: ...53 liters Duty Press 100 110 psig 6 9 7 6 bar Control Type Electro pneumatic Options Higher duty pressures up to 175 psig 12 1 bar spiral valve 24KT lubricant MOTOR 60Hz Size 125 150HP 90 110KW 4 pol...

Page 22: ...d use only Sullair 24KT fluid WARNING Mixing of other lubricants within the compressor unit will void all warranties Sullair recommends that a 24KT sample be taken at the first filter change and sent...

Page 23: ...Section 3 SPECIFICATIONS 17 Figure 3 1A Identification Air cooled Model Prior to June 1 2000...

Page 24: ...Section 3 SPECIFICATIONS 18 Figure 3 1B Identification Air cooled Model After June 1 2000...

Page 25: ...Section 3 SPECIFICATIONS 19 Figure 3 1C Identification Water cooled Model...

Page 26: ...20 NOTES...

Page 27: ...t that is radiated by the compressor This heat must be re moved to assure a normal operating temperature With air cooled compressors it is possible to use this heat for space heating providing no addi...

Page 28: ...ecks should be made to help as sure that the first start up will be trouble free DANGER Lethal shock hazard inside Disconnect all power at source before opening or servicing 1 Check incoming voltage B...

Page 29: ...t butterfly valve which throttles the air flow to the compressor inlet in order to match air sup ply to the demand SPIRAL VALVE OPTIONAL Internally bypasses and controls the air flow capacity of the c...

Page 30: ...This switch is not adjustable Used on water cooled packages only DRAIN VALVES Lubricant sump drain valve 5 3 INITIAL START UP PROCEDURE The following procedure should be used to make the initial star...

Page 31: ...25 NOTES...

Page 32: ...SSOR RUN LIGHT AUTOMATIC MODE RUN LIGHT DISPLAY MODE KEY PAD AUTOMATIC MODE KEY PAD LCD SELECTION PARAMETER VALUE CHANGE KEYPAD PROGRAMMING KEY PAD SULLAIR LOGO COMPRESSOR STOP RESET KEY PAD POWER ON...

Page 33: ...d See PA RAMETER SETUP PRG S Up arrow Used in status displays to change displays and in parameter setup mode to increment a value S Down arrow lamp test Used in status displays to change displays and...

Page 34: ...e and the maximum limit If the temperature exceeds the limit a T2 HI shutdown will occur T2 210 MAX 235 S Total hours that the compressor has been running HRS RUN 001234 0 S Total hours that the compr...

Page 35: ...ial below the unload pressure wherethe machine is loaded For example if the un load pressure is set to 110 psi 7 6 bar and the load differential is set to 10 psid 0 7 bar the machine will load when th...

Page 36: ...oad or emergency stop contacts are not tripped Press ing the I will turn on the compressor and put it in manual mode If the compressor is already running but in automatic mode pressing I will switch o...

Page 37: ...ds and unloads machines based on machine Com ID 6 7 PURPOSE OF CONTROLS SWITCH OPERATION EMERGENCY STOP SWITCH Pushing in this switch found adjacent to the Supervi sor cuts all AC outputs from the lat...

Page 38: ...d be made during all ex pected modes of operation i e full load no load different line pressures cooling water tempera tures etc During the initial start up or servicing of the pack age fluid may have...

Page 39: ...ys AIR MNTN and the LED display flashes or when corresponding maintenance message is dis played by the Supervisor II or once a year whichev er comes first If the filter needs to be replaced order repl...

Page 40: ...ENANCE Refer to Figure 7 3 The Supervisor indicates when the separator elements should be serviced this hap pens when the pressure drop across the elements has exceeded 10 psig 0 7 bar or once a year...

Page 41: ...ontrol lever and let link hang aside 3 Loosen remove the two 2 capscrew nut assem blies securing Sullicon to its mounting bracket and pull Sullicon away 4 Loosen remove remaining capscrew nut assem bl...

Page 42: ...torqued to 30 ft lbs 40 7Nm dry Please note that capscrews have self locking patches good for two re uses but the application of a thread locking adhesive increases this number NOTE DO NOT lubricate c...

Page 43: ...ads Tripped Reset after heater elements cool down Should trouble persist check whether motor starter contacts are functioning properly Low Incoming Line Voltage Check voltage Should voltage check low...

Page 44: ...n of solenoid valve to Operate See Section 7 5 Control Air Signal Leaks Check tubework feeding control signal for leaks Control Air Signal Filter Clogged Service filter assembly See Section 7 5 T1 HI...

Page 45: ...tion 7 5 Control Air Signal Leaks Check tubework feeding control signal for leaks Control Air Signal Filter Clogged Service filter assembly See Section 7 5 EXCESSIVE FLUID CONSUMPTION Clogged Return L...

Page 46: ...e the value The number on the left will in 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 savin...

Page 47: ...02250055 939 1 replacement coil for solenoid valve 250038 675 250038 730 1 repair kit for solenoid valve 250038 666 250038 672 1 replacement coil for solenoid valve 250038 666 250038 730 1 repair kit...

Page 48: ...Section 8 PARTS LIST 42 8 3 MOTOR COMPRESSOR AND FRAME 1 3 2 4 5 6 7 6 9 10 8 11 12 13 14 15 9 17 16 20 19 18 21 21 22...

Page 49: ...osure 12 x 10 x 6 250028 868 1 16 isolator vibration motor 250042 757 2 17 block mounting 125HP 90KW only 224511 2 18 washer reg 1 2 838208 112 2 19 washer springlock 1 2 837808 125 2 20 capscrew hex...

Page 50: ...Section 8 PARTS LIST 44 8 4 AIR INLET SYSTEM 1 2 3 4 1 5 6 7 8 9 10 11 9 7 12 13 14 15 16 17 18 15 19 20 21 22 23 WATER COOLED MACHINES ONLY WATER COOLED MACHINES ONLY...

Page 51: ...ir inlet air cooled only 02250047 270 1 11 adapter air inlet water cooled only 02250056 089 1 12 capscrew hex GR5 3 4 10 x 2 829112 200 8 13 washer springlock 3 4 837812 188 8 14 connector tube M 1 4...

Page 52: ...Section 8 PARTS LIST 46 8 5 COOLING AND LUBRICATION SYSTEM AIR COOLED 1 2 2 3 2 4 5 6 7 8 8 9 9 10 11 12 13 14 1516 2 17 18 5...

Page 53: ...20 2 10 valve fluid stop II 02250113 668 1 11 capscrew ferry 3 8 16 x 1 1 2 867306 150 4 12 washer springlock 3 8 837806 094 4 13 housing thermal valve 02250092 929 1 14 seal U cup viton 02250101 372...

Page 54: ...Section 8 PARTS LIST 48 8 6 COOLING AND LUBRICATION SYSTEM WATER COOLED 1 1 2 3 4 5 6 6 7 8 1 9 10 11 12 11 13 10 14 15 16 17 1819 7 1...

Page 55: ...8 02250055 015 2 11 reducer threaded viton 1 1 2 x 1 1 4 870024 020 2 12 valve fluid stop II 02250113 668 1 13 union tube hex 1 1 4 811320 125 1 14 capscrew ferry 3 8 16 x 1 1 2 867306 150 4 15 washer...

Page 56: ...Section 8 PARTS LIST 50 8 7 COOLER ASSEMBLY AIR COOLED 1 2 3 4 5 5 6 7 8 9 10 11 12 13 14 15 13 14...

Page 57: ...79 1 5 support cooler 02250043 287 2 6 fan 36 dia 405103 1 7 bushing split taper 249853 1 8 support cooler motor end 02250115 733 1 9 guard fan 38 dia 248744 1 10 support fan motor 015641 1 11 motor 5...

Page 58: ...E SYSTEM 1 2 3 4 5 6 6 7 7 8 8 9 9 9 10 11 11 12 13 14 1 15 16 17 14 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 36 37 37 38 39 40 41 42 43 44 45 A B C A TO CONTROL LINE FILTER B FROM LOA...

Page 59: ...2 802108 020 2 20 cross pipe 2 801315 080 1 21 nipple pipe 2 x close 822232 000 1 22 nipple pipe 2 x 10 822132 100 1 23 valve minimum pressure check valve 2 II 242405 1 24 bushing reducing hex 1 2 x 1...

Page 60: ...E SYSTEM 1 2 3 4 5 6 6 7 7 8 8 9 9 9 10 11 11 12 13 14 1 15 16 17 14 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 36 37 37 38 39 40 41 42 43 44 45 A B C A TO CONTROL LINE FILTER B FROM LOA...

Page 61: ...head pipe 1 2 841500 008 1 37 connector tube 1 2 x 1 2 250024 695 2 38 tube thermoplastic 1 2 250030 855 2 ft 39 valve ball 1 2 047117 1 40 nipple pipe 822108 030 1 41 nut hex flanged 1 2 13 825308 45...

Page 62: ...Section 8 PARTS LIST 56 8 9 AFTERCOOLER PIPING AIR COOLED BEFORE JUNE 2000 1 2 3 4 5 5 6 7 8 9 8 7 10 11 10 7 12 13 12...

Page 63: ...moisture 2 I 02250100 365 1 7 elbow pipe 2 801515 080 1 8 connector tube M 2 x 2 810232 200 2 9 tubing moisture separator to cooler 2 02250115 693 1 10 nipple pipe 2 x 5 822232 050 2 11 cooler fluid...

Page 64: ...Section 8 PARTS LIST 58 8 10 AFTERCOOLER PIPING AIR COOLED AFTER JUNE 2000 1 2 3 4 5 6 10 7 8 9 8 10...

Page 65: ...2 802208 082 1 3 U bolt 3 8 x 2 1 2 868306 250 1 4 support moisture separator 02250119 770 2 5 nipple pipe 2 x close 822232 000 1 6 separator moisture 2 02250100 365 1 7 cooler fluid 02250119 841 1 8...

Page 66: ...Section 8 PARTS LIST 60 8 11 AFTERCOOLER PIPING WATER COOLED 1 2 3 4 5 6 7 8 8 8 8 3 9 10 11 11 3 9 13 12 14 15 16 17 18 19 20 21 22 21 23 21 24 25 26 27 28 21 29...

Page 67: ...oler 043009 1 14 screw hex ser washer 3 8 16 x 1 829706 100 8 15 nut hex flange 3 8 16 825306 347 8 16 support cooler separator end 02250051 862 1 17 connector tube M 2 x 2 810232 200 1 18 tube minimu...

Page 68: ...Section 8 PARTS LIST 62 8 12 UNIT TUBING 1 1 1 1 2 3 4 5 6 6 7 8 9 10 14 15 1 18 17 8 20 19 20 13 13 22 21 11 12 10 13 16...

Page 69: ...x 562 02250044 297 1 8 elbow tube M 3 4 x 1 2 810512 050 2 9 tube injection 0 75 02250044 276 1 10 tube seal gear 38 02250045 058 1 11 tube bearing 38 02250045 057 1 12 tube bearing 38 02250045 056 1...

Page 70: ...Section 8 PARTS LIST 64 8 13 SULLICON CONTROL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 8 21 22 23 24 25 26 27 28 29...

Page 71: ...in yoke 1 4 040065 1 15 pin cotter 1 16 x 3 4 827101 075 1 16 plunger 020094 1 17 seal cup 042538 1 18 screw machine hex 5 16 24 x 2 831105 200 1 19 bracket sullicon 250031 765 1 20 screw machine shou...

Page 72: ...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 A C B D 12 9 19 1 2 3 5 4 3 6 3 7 20...

Page 73: ...4 810904 025 1 17 elbow tube M 1 4 x 1 4 810504 025 2 18 filter III 02250112 032 1 19 tee pipe 1 4 866815 010 2 20 nipple pipe 1 4 x 1 1 2 866304 015 1 21 elbow tube M 1 4 x 1 8 813704 125 1 22 valve...

Page 74: ...ROL 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 C B 1 2 2 2 2 2 2 3 3 3 4 5 6 7 8 9 10 6 6 6 6 6...

Page 75: ...egulator100psi IV 408275 1 20 valve press regulator V 406929 1 21 orifice pipe plug 1 4 232874 1 22 orifice 040381 1 23 elbow pipe 90q M 1 4 x 1 4 860504 025 1 24 elbow tube M 1 4 x 1 8 810504 012 4 2...

Page 76: ...Section 8 PARTS LIST 70 8 16 ELECTRICAL BOX 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 77: ...02250083 190 1 7 contactor size F 32A 250025 705 1 8 starter fan motor protector consult factory 1 9 switch push button operator 02250085 504 1 10 block contact normally closed 250027 125 2 11 plate a...

Page 78: ...Section 8 PARTS LIST 72 8 17 ENCLOSURE AIR COOLED 1 2 3 4 5 6 7 5 8 9 10 6 6 11 12 13 14 15 16 17 18 19 19 20 20 21 22 5 5...

Page 79: ...0049 723 1 10 baffle air inlet 02250046 858 1 11 panel canopy 02250116 308 1 12 screw hex ser washer 1 4 x 1 829704 100 10 13 washer springlock 1 4 838504 062 10 14 rivet tubular 1 4 049824 10 15 baff...

Page 80: ...Section 8 PARTS LIST 74 8 18 ENCLOSURE WATER COOLED 1 2 3 4 5 6 5 7 8 9 10 5 5 5 11 12 13 14 6 6 15 19 20 22 21 23 24 25 26 16 17 18...

Page 81: ...air inlet 02250046 858 1 11 panel canopy 02250116 308 1 12 screw hex ser washer 1 4 x 1 829704 100 10 13 washer springlock 1 4 838504 062 10 14 rivet tubular 1 4 049824 10 15 panel roof 02250116 309 1...

Page 82: ...Section 8 PARTS LIST 76 8 19 ACOUSTIC PANELS AIR COOLED MACHINES WATER COOLED MACHINES 1 2 2 3 4 5 6 4 5 7 8 9 10 7 11 12 13 14 15 7 12 11 10 WATER COOLED AIR COOLED MACHINES...

Page 83: ...er air cooled 02250118 827 1 7 panel fiberglass water air cooled 02250118 793 3 8 panel fiberglass water air cooled 02250118 796 1 9 panel fiberglass water air cooled 02250118 797 1 10 panel fiberglas...

Page 84: ...Section 8 PARTS LIST 78 8 20 DECAL GROUP 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 85: ...0 1 6 decal earth ground international 02250075 046 1 Sdecal PE designation international not shown 0225075 540 1 Sdecal protective earth ground international international not shown 0225075 045 1 7 s...

Page 86: ...Section 8 PARTS LIST 80 8 20 DECAL GROUP 15 16 17 18 19 20 21 22 23 24...

Page 87: ...17 decal danger high voltage 042218 1 18 decal water inlet outlet 049873 1 19 decal water in 250019 107 1 20 decal water out 250019 108 1 21 decal water drain 250022 810 1 22 decal actuator valve pos...

Page 88: ...Section 8 PARTS LIST 82 8 20 DECAL GROUP 25 26 27 28 29...

Page 89: ...25 decal ISO 9001 02250057 624 1 26 decal fluid sample 250022 675 1 27 sign warning food grade lube 250003 144 1 28 sign warning compressor fluid fill cap 049685 1 29 decal warning auto start 250017 9...

Page 90: ...Section 8 PARTS LIST 84 8 20 DECAL GROUP 30 31 32...

Page 91: ...r quantity 30 decal electrical component ID 02250109 734 1 31 decal LS 20S open 02250061 058 1 Sdecal LS 20S canopy 02250061 161 1 32 decal Sullair logo open 02250059 058 1 Sdecal Sullair logo canopy...

Page 92: ...Section 8 PARTS LIST 86 8 21 DECAL LOCATIONS 1 2 3 4 5 6 7 8 9 10 12 11 15 16 17 18 12 13 14...

Page 93: ...rning mixing fluids 02250110 891 1 9 decal fluid Sullube 02250069 389 1 Sdecal fluid 24 KT 02250069 395 1 Sdecal fluid CP 4600 F 02250118 342 1 10 sign warning compressor fluid fill cap 049685 1 11 si...

Page 94: ...Section 8 PARTS LIST 88 8 21 DECAL LOCATIONS 9 1 2 3 4 5 6 7 8 10 11 WATER COOLED MODEL 12 13...

Page 95: ...55 2 5 sign danger electrocution 049850 1 6 decal ISO 9001 02250057 624 1 7 decal fork lifting 241814 4 8 decal fluid 24 KT I 02250069 395 1 9 decal Sullair logo canopy 02250057 603 1 10 decal LS 20S...

Page 96: ...Section 8 PARTS LIST 90 8 21 DECAL LOCATIONS 1 2 3 5 6 7 4...

Page 97: ...ger high voltage 042218 1 4 decal voltage 460V 60Hz international 02250069 399 1 Sdecal 380 415 50Hz not shown 02250069 403 1 Sdecal 525V 50Hz not shown 02250069 415 1 Sdecal 575V 60Hz not shown 02250...

Page 98: ...Section 8 PARTS LIST 92 8 22 WIRING DIAGRAM STANDARD FULL VOLTAGE SUPERVISOR II DELUXE...

Page 99: ...Section 8 PARTS LIST 93 8 23 WIRING DIAGRAM STANDARD WYE DELTA SUPERVISOR II DELUXE...

Page 100: ...Section 8 PARTS LIST 94 8 24 WIRING DIAGRAM STANDARD WYE DELTA SUPERVISOR II DELUXE EUROPE...

Page 101: ...NOTES...

Page 102: ...an Boulevard Michigan City Indiana 46360 U S A Telephone 1 219 879 5451 Fax 219 874 1273 Fax 219 874 1835 Parts Fax 219 874 1288 Service SULLAIR ASIA LTD Sullair Road No 1 Chiwan Shekou Shenzhen Guang...

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