Sullair LS-25S Operator'S Manual And Parts List Download Page 1

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INDUSTRIAL ROTARY SCREW

LS---25S

200---350HP/150---261KW AND 24KT

OPERATOR’S

MANUAL AND

Part Number 02250059---710

Sullair Corporation, 1994

Effective 11/94

AIR COMPRESSOR

SUPERVISOR

PARTS LIST

Summary of Contents for LS-25S

Page 1: ...INDUSTRIAL ROTARY SCREW LS 25S 200 350HP 150 261KW AND 24KT OPERATOR S MANUAL AND Part Number 02250059 710 eSullair Corporation 1994 Effective 11 94 AIR COMPRESSOR SUPERVISOR I PARTS LIST...

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: ...COOLING AND LUBRICATION SYSTEM FUNCTIONAL DESCRIPTION 8 2 5 COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTION 10 2 6 CONTROL SYSTEM FUNCTIONAL DESCRIPTION 13 2 7 AIR INLET SYSTEM FUNCTIONAL DESCRIPT...

Page 4: ...CE 28 AIR FILTER MAINTENANCE 29 SEPARATOR ELEMENTS REPLACEMENT 30 CONTROL SYSTEM ADJUSTMENT 31 THERMAL VALVE MAINTENANCE 31 DRIVE COUPLING INSTALLATION AND MAINTENANCE 32 FLUID STOP VALVE MAINTENANCE...

Page 5: ...LING SYSTEM WATER COOLED 300 350HP 225 261K W 66 7 10 COMPRESSOR DISCHARGE SYSTEM 70 7 11 SULLICON CONTROL 74 7 12 COMPRESSOR ACTUATOR 76 7 13 ELECTRO PNEUMATIC CONTROL SYSTEM 80 7 14 ENCLOSURE 84 7 1...

Page 6: ...ompressor or at any other point along the air line when an air hose exceeding 2 13mm inside diameter is to be connected to the shut off throttle valve to reduce pressure in case of hose failure per OS...

Page 7: ...and confine long hair when working around this compressor especially when exposed to hot or moving parts D Keep access doors if any closed except when making repairs or adjustments E Make sure all pe...

Page 8: ...grounded conductors 1 9 LIFTING A If the compressor is provided with a lifting bail then lift by the bail provided If no bail is provided then lift by sling Compressors to be air lifted by helicopter...

Page 9: ...enter it to perform service adjustments inform other per sonnel before doing so or else secure and tag the access door in the open position to avoid the possi bility of others closing and possibly lat...

Page 10: ...mponents and assem blies of the air compressor are clearly shown The complete package includes compressor electric motor compressor inlet system compressor discharge system compressor cooling and lu b...

Page 11: ...Sullair compres sor unit a single stage positive displacement lu bricated type compressor This unit provides con tinuous pulse free air compression to meet your needs With a Sullair compressor there...

Page 12: ...Section 2 DESCRIPTION 7 Figure 2 3 Compressor Piping and nstrument Diagram...

Page 13: ...d stop valve to close and iso late the compressor unit from the cooling system Water cooled versions of the compressor have a water flow regulating valve not shown which op erates to conserve water du...

Page 14: ...prevents the re lief valve from opening and dumping fluid under normal conditions Also a high discharge tempera ture control with three 3 sensing probes is pro vided to shut down the compressor if the...

Page 15: ...ing returned back internally to suction end of the compressor unit Now the compressor is fully compressing only that amount of air which is being used As air demand keeps dropping further the spiral v...

Page 16: ...Section 2 DESCRIPTION 11 Figure 2 5A Control System Diagram Start Full Load...

Page 17: ...Section 2 DESCRIPTION 12 Figure 2 5B Control System Diagram Modulation Unload...

Page 18: ...TION Refer to Figure 2 7 The Supervisor I control panel consists of displays for pressure temperature and time as well as a status message display Default pressure is line pressure P2 which is normall...

Page 19: ...ad as a percent of run hours is available by pressing HR LOAD or HR respectively S Separator differential pressure can be dis played by pressing the P1 pad When a differ ential of 10 psid 0 7 bar is r...

Page 20: ...F use cursor key to select MAXIMUM PRESSURE P2A Use the cursor key to set the OFF LOAD pressure set ting Depressing the cursor pad for more than two se conds will initiate a fast scrolling mode to qui...

Page 21: ...preventive main tenance programs and customer DCS management packages Baud rates are factory settable from 150 to 4800 Consult factory for communication protocol SUPERVISOR I AUXILIARY DIGITAL INPUTS...

Page 22: ...UNLOAD SOLENOID VALVE Controls regulator bypass solenoid valve to load or unload the compressor as demand varies COMMON FAULT ALARM Initiates to provide a common signal for remote indi cation of a fau...

Page 23: ...81 300 225 1500 41 7 134 3404 87 2210 76 1930 9395 4281 H II 200 150 Air 900 25 5 134 3404 87 2210 76 1930 7845 3561 300 225 1300 36 8 134 3404 87 2210 76 1930 9395 4281 I Model L Maximum Pressure 110...

Page 24: ...compressor will void all warranties SRF 1 4000 fluid should be changed every 4000 hours or once a year whichever comes first The fluid should be changed more frequently under se vere operating condit...

Page 25: ...7KW L 55 208 LS 25S 300HP 225KW L 65 246 LS 25S 300HP 225KW H 67 254 LS 25S 350HP 261KW H 73 276 WATER FLOW LS 25S 350HP 261KW HH 73 276 The table below indicates the ventilation require ments necessa...

Page 26: ...isolate a compressor from the service line if re quired Also notice that the service line should be equipped with water legs and condensate drains throughout the system WARNING The Plastic Pipe Insti...

Page 27: ...ount of fluid However it is necessary to check the fluid level at installation The level is checked by looking at the sight glass located on the sump If the sump is properly filled the coolant level s...

Page 28: ...sure check valve Selectable alternate dis plays via touchpad include SUMP PRESSURE P1 displays receiver sump pressure at various ON LOAD and or OFF LOAD con ditions SEPARATOR DIFFERENTIAL P1 displays...

Page 29: ...falls to 40 psig 2 8 bar Prevents line pressure backflow into the sump during unload conditions and after shut down COMPRESSOR DISCHARGE The Supervisor will shut the compressor down when TEMPERATURE...

Page 30: ...lenoid valve to OFF LOAD the compressor The message ON LOAD or OFF LOAD will be dis played to indicate the status of the control P2 is also used to calculate separator differential pressure P1 BLOWDOW...

Page 31: ...fluid sight glass and simply press the ON OFF pad When the compressor is running observe the control panel for mainte nance indications 5 5 SHUTDOWN PROCEDURE To shut the compressor down simply press...

Page 32: ...other com ponents when compressor is running or pressur ized Stop compressor and relieve all internal pres sure before doing so 6 3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION After the initial 50...

Page 33: ...head to the canister 2 Pull the canister away from the filter head The fil ter elements will be attached to the head 3 Separate the element from the filter head 4 Remove the canister seal 5 Thoroughly...

Page 34: ...must be stored in a clean container 4 After the element has been installed inspect and tighten all air inlet connections prior to resuming operation PRIMARY ELEMENT REPLACEMENT 1 Place the element in...

Page 35: ...red Figure 6 4 Sullicon Control P N 011682 003 Repair Kit P N 250020 353 Figure 6 5 Standard Thermal Valve Repair Kit P N 001084 Standard Repair Kit P N 001149 24KT P N 041299 24KT Thermal Valve P N 0...

Page 36: ...ousing Figure 6 6 Drive Coupling Figure 6 7 Drive Coupling Alignment 5 Remove and replace the o rings between the upper and lower housings 6 Replace element 7 Reassemble the housing DRIVE COUPLING INS...

Page 37: ...y sized radiator hose clamp around the outer edge of the element as shown in Figure 6 6 Slide the ferry head capscrews with lockwashers through the holes in the hubs and ele ment Tighten the bolts to...

Page 38: ...s 5 to 7 Nm 6 Reconnect pilot tubing and make sure all joints are properly tightened before starting compres sor SOLENOID VALVE MAINTENANCE Refer to Figure 6 10 Solenoid valve P N 250038 668 maintenan...

Page 39: ...ousing from the body to al low access to internal parts 3 Next remove the spring button and the spring The dampener will stay inside the spring as it is removed Leave the dampener inside the spring as...

Page 40: ...nd retaining cover from the main body 3 Remove the flat washer and heavy spring from the main body 4 Tap the piston assembly with a screwdriver from the bottom of the main body and remove The o ring w...

Page 41: ...e filter P N 408389 maintenance normally requires replace ment of the filter element strainer gasket and o rings Use repair kit number 001692 and follow the procedure explained below for proper instal...

Page 42: ...andard 3 18 5 ft lbs 76 2mm 25 1 Nm 4 23 5 ft lbs 101 6mm 31 9 Nm I Tighten as shown in chart or a minimum of 16 1 5mm clearance between coupling lugs whichever comes first TABLE 3 GASKET RING SELECTI...

Page 43: ...ed from the power source and locked out for maintenance remove the cover to the motor conduit box 2 Inspect the rubber boots or connections insu lating materials covering the motor connections for sig...

Page 44: ...display Max P1 pressure may be set too low Consult factory for recalibration Defective solenoid valve solenoid valve should cause control lever to move to unload stop when the pressure switch contact...

Page 45: ...heck that sump pressure is exhausted to the atmosphere when in the OFF LOAD mode Repair or replace if necessary kit available Plugged Control Line Filter Clean or repair if necessary EXCESSIVE FLUID C...

Page 46: ...250034 129 secondary 250034 130 1 repair kit for regulator valve 406929 041742 1 repair kit for blowdown valve 409783 001667 1 repair kit for Sullicon Control 011682 003 250020 353 1 repair kit for co...

Page 47: ...Section 7 ILLUSTRATIONS AND PARTS LIST 42 7 3 MOTOR COMPRESSOR FRAME AND PARTS 150 KW 187 261 KW...

Page 48: ...set motor mounting 020293 4 12 frame 200HP 150KW 250007 796 1 S frame 250HP 187KW 250006 714 1 S frame 300HP 225KW 250006 714 1 S frame 350HP 261KW 250006 714 1 13 capscrew hex gr5 3 4 10 x 1 1 2 8286...

Page 49: ...Section 7 ILLUSTRATIONS AND PARTS LIST 44 7 4 COMPRESSOR AIR INTAKE SYSTEM...

Page 50: ...07 690 1 9 elbow rubber 90_ 8 043406 1 10 adpater compressor inlet 10 to 8 250003 378 1 11 capscrew hex gr5 7 8 9 x 3 1 2 828614 350 8 12 washer springlock regular 7 8 837514 219 8 13 gasket 1 16 x 10...

Page 51: ...Section 7 ILLUSTRATIONS AND PARTS LIST 46 7 5 FLUID COOLING PIPING SYSTEM AIR COOLED REMOTE COOLER...

Page 52: ...ypass tee filter 2 250008 381 1 18 tube tv bypass tee 2 250008 380 1 19 valve thermal 2 std V 041299 1 S valve thermal 2 24KT VI 02250043 433 1 20 clamp exhaust 040284 2 21 reinforcement flexible 13 2...

Page 53: ...Section 7 ILLUSTRATIONS AND PARTS LIST 48 7 5 FLUID COOLING PIPING SYSTEM AIR COOLED REMOTE COOLER...

Page 54: ...e 90_ 1 4 803515 015 1 37 clamp exhaust 044135 1 38 bracket 250026 878 1 39 support 250007 791 2 40 tee reducing 2 x 1 2 x 2 802208 028 2 41 valve check 1 2 042694 1 42 nipple pipe 2 x 7 822132 070 1...

Page 55: ...Section 7 ILLUSTRATIONS AND PARTS LIST 50 7 6 FLUID COOLING SYSTEM AIR COOLED REMOTE COOLER 200 250HP 150 187K W...

Page 56: ...860905 163 12 16 cooler fluid mod 040961 1 17 screw hex serrated washer 5 16 x 1 829705 100 12 18 aftercooler air to air 041807 1 19 panel right side 250001 203 1 20 tee reducing 2 x 1 2 x 2 802208 0...

Page 57: ...Section 7 ILLUSTRATIONS AND PARTS LIST 52 7 6 FLUID COOLING SYSTEM AIR COOLED REMOTE COOLER 200 250HP 150 187K W...

Page 58: ...ener suregrip 041516 2 41 capscrew hex gr5 1 2 13 x 2 828608 200 12 42 washer bevel 1 2 837008 125 10 43 decal fork lifting 241814 2 44 nipple pipe 2 x 16 822132 160 1 45 frame base 250001 191 1 46 de...

Page 59: ...Section 7 ILLUSTRATIONS AND PARTS LIST 54 7 7 FLUID COOLING SYSTEM AIR COOLED REMOTE COOLER 300 350HP 225 261K W...

Page 60: ...nut hex unfinished 3 8 16 824206 337 54 16 plug pipe 2 150 802815 080 4 17 panel top and bottom 250000 474 2 18 frame aftercooled base 250000 454 1 19 plug 1 2 807800 020 1 20 panel right side 250000...

Page 61: ...Section 7 ILLUSTRATIONS AND PARTS LIST 56 7 7 FLUID COOLING SYSTEM AIR COOLED REMOTE COOLER 300 350HP 225 261K W...

Page 62: ...0 8 44 nipple pipe 4 x 8 822164 080 1 45 nipple pipe 4 x 14 822164 140 1 46 elbow pipe 4 90_ 150 801515 160 1 47 decal fork lifting II 2 48 washer bevel 1 2 837008 125 10 49 washer springlock regular...

Page 63: ...Section 7 ILLUSTRATIONS AND PARTS LIST 58 7 8 FLUID COOLING SYSTEM WATER COOLED 200 250HP 150 187K W...

Page 64: ...oler 250HP 187KW 250009 333 1 17 tube aftercooler fluid cooler water 200HP 150KW 250009 335 1 S tube aftercooler fluid cooler water 250HP 187KW 250009 336 1 18 nut hex 3 8 824206 337 2 19 bushing redu...

Page 65: ...Section 7 ILLUSTRATIONS AND PARTS LIST 60 7 8 FLUID COOLING SYSTEM WATER COOLED 200 250HP 150 187K W...

Page 66: ...200HP 150KW 250007 792 1 S support aftercooler 250HP 187KW 250007 793 1 48 tube tv bypass tee water cooled 2 250009 328 1 49 aftercooler 8 x 36 200HP 150KW 042541 1 S aftercooler 8 x 60 250HP 187KW 0...

Page 67: ...Section 7 ILLUSTRATIONS AND PARTS LIST 62 7 9 FLUID COOLING SYSTEM WATER COOLED 300 350HP 225 261K W...

Page 68: ...hex head gr5 5 8 11 x 3 828610 300 8 18 capscrew hex head gr5 1 2 13 x 1 1 2 828608 150 4 19 washer springlock regular 5 8 837510 156 8 20 nut hex 5 8 11 unfinished 824210 559 8 21 separator 4 combina...

Page 69: ...Section 7 ILLUSTRATIONS AND PARTS LIST 64 7 9 FLUID COOLING SYSTEM WATER COOLED 300 350HP 225 261K W...

Page 70: ...132 120 1 51 tee pipe 2 150 802415 080 1 52 tube bypass tee water cooled 2 250023 074 1 53 support aftercooler 250007 793 1 54 elbow pipe reducing 4 x 3 90_ 801616 120 1 55 nipple pipe 4 x close 82226...

Page 71: ...Section 7 ILLUSTRATIONS AND PARTS LIST 66 7 10 COMPRESSOR DISCHARGE SYSTEM...

Page 72: ...17 elbow tube m 1 4 x 1 4 810504 025 1 18 tubing steel double braze 1 4 841015 004 10 ft 19 nipple pipe 1 1 2 x close 822224 000 1 20 element separator secondary III 250034 129 1 21 element plated pri...

Page 73: ...Section 7 ILLUSTRATIONS AND PARTS LIST 68 7 10 COMPRESSOR DISCHARGE SYSTEM...

Page 74: ...bow tube 90_ m 5 16 x 1 4 810505 025 1 43 elbow tube 90_ m 1 4 x 1 4 810504 025 1 44 tubing steel double bronze 5 16 841015 005 10 ft 45 connector tube 1 4 x 1 4 810204 025 1 46 fitting compression 25...

Page 75: ...Section 7 ILLUSTRATIONS AND PARTS LIST 70 7 11 SULLICON CONTROL 250 350 HP 187 261 KW ONLY 200HP 150KW ONLY...

Page 76: ...rod end 1 4 28 040138 1 17 plunger 020094 1 18 seal cup 042538 1 19 screw hex unmachined 5 16 24 x 2 831105 200 1 20 nut hex jam unfinished 5 16 24 right hand 824605 195 1 21 nut hex unfinished 5 16 1...

Page 77: ...Section 7 ILLUSTRATIONS AND PARTS LIST 72 7 11 SULLICON CONTROL 250 350 HP 187 261 KW ONLY 200HP 150KW ONLY...

Page 78: ...7 capscrew hex gr5 1 2 13 x 1 1 4 828608 125 2 38 bracket Sullicon 200HP 150KW 233402 1 39 rod link 5 16 24 x 8 3 4 020863 1 S rod link 5 16 24 x 9 1 2 021287 1 40 nut hex jam unfinished 5 16 24 82470...

Page 79: ...Section 7 ILLUSTRATIONS AND PARTS LIST 74 7 12 COMPRESSOR ACTUATOR...

Page 80: ...20 x 1 2 828204 050 4 15 cover adapter 250021 510 1 16 washer regular 18 838201 045 6 17 screw machine rod 8 32 x 1 2 831601 050 6 18 mount air cylinder 250016 188 1 19 capscrew ferry head 5 16 18 x...

Page 81: ...Section 7 ILLUSTRATIONS AND PARTS LIST 76 7 13 ELECTRO PNEUMATIC CONTROL SYSTEM...

Page 82: ...icro cntrlr II 250038 779 1 20 cord grip 250023 496 3 21 bulkhead pipe 1 8 841500 002 4 22 nipple pipe 1 4 x close 822204 000 12 23 tee pipe 1 4 804415 010 5 24 elbow pipe 90_ x 1 4 801515 010 2 25 co...

Page 83: ...Section 7 ILLUSTRATIONS AND PARTS LIST 78 7 13 ELECTRO PNEUMATIC CONTROL SYSTEM...

Page 84: ...41 washer springlock regular 1 2 837508 125 1 42 washer pl b regular unfinished 1 2 837308 112 1 43 connector tube m 1 4 x 1 8 813604 125 1 44 tubing plastic 1 4 250024 745 16 ft 45 valve differential...

Page 85: ...Section 7 ILLUSTRATIONS AND PARTS LIST 80 7 14 ENCLOSURE...

Page 86: ...4 17 support fan motor 014613 1 18 washer unfinished regular 3 8 837206 071 4 19 panel fiberglass 8 1 2 x 52 047823 162 2 20 motor 75HP 56KW 050288 1 21 screw hex serrated washer 5 16 x 3 4 829705 075...

Page 87: ...Section 7 ILLUSTRATIONS AND PARTS LIST 82 7 14 ENCLOSURE...

Page 88: ...number description number quantity 39 panel fiberglass 6 x 74 047823 179 4 40 panel access 33 x 50 Supervisor 02250058 224 1 41 panel fiberglass 8 1 2 x 62 047823 161 6 42 washer springlock 1 4 837504...

Page 89: ...Section 7 ILLUSTRATIONS AND PARTS LIST 84 7 15 UNIT TUBING...

Page 90: ...e M 1 x 1 810216 100 1 14 tube 250024 176 1 15 tube 250024 179 1 16 tube 250024 180 1 17 connector tube M 1 2 x 3 8 810208 038 1 18 elbow tube M 1 2 x 3 8 810508 038 4 19 plug pipe 1 4 807800 010 2 20...

Page 91: ...Section 7 ILLUSTRATIONS AND PARTS LIST 86 7 16 DECAL GROUP 1 2 3 4 5 6 7 8 9 10...

Page 92: ...250021 564 1 6 decal 460 volt 040631 1 Sdecal 380 volt I 241926 1 Sdecal 415 volt I 241927 1 Sdecal 525 volt I 02250047 898 1 Sdecal 575 volt I 041124 1 7 decal compressor fluid Sullube 32 250023 361...

Page 93: ...Section 7 ILLUSTRATIONS AND PARTS LIST 88 7 16 DECAL GROUP OIL STOP VALVE P N 16742 410239 11 12 13 14 15 16 17 18 19 20...

Page 94: ...836 1 13 decal danger high voltage 042218 1 14 decal water inlet outlet 049873 1 15 decal water in 250019 107 1 16 decal water out 250019 108 1 17 decal water drain 250022 810 1 18 decal compressor fl...

Page 95: ...Section 7 ILLUSTRATIONS AND PARTS LIST 90 7 16 DECAL GROUP 21 22 23 24 25...

Page 96: ...y 21 decal ISO 9001 02250057 624 1 22 decal actuator valve positioning 250029 784 1 23 sign warning food grade lube 250003 144 1 24 sign warning compressor fluid fill cap 049685 1 25 decal warning aut...

Page 97: ...Section 7 ILLUSTRATIONS AND PARTS LIST 92 7 16 DECAL GROUP 26 28 29 30 31...

Page 98: ...n number quantity 26 decal logo SRF 1 4000 250021 483 1 27 decal 24KT not shown 02250061 022 1 28 decal autostart 041065 1 29 decal LS 25S 02250061 361 1 30 decal fluid sample 250022 675 1 31 decal Su...

Page 99: ...ON INSTALLATION OF MACHINE UPON CUSTOMER REQUEST 4 ALL DIMENTIONS 1 ALLOW 4 FT 1 2 M CLEARANCE ALL AOUND FOR ACCESS 3 UNIT MAY BE FURNISHED WITHOUT SPIRAL VALVE AS AN OPTION 45 7 cm W O ENCL 76 2 cm W...

Page 100: ...in 3 8 cm N P T CONN 102 6 cm 110 2 cm 162 6 cm 3 4 in N P T 1 9 cm 30 5 cm 3 in 7 6 cm DIA LIFTING HOLES 4 7 8 in 2 2 cm DIA MTG 7 in 17 8 cm TYP 62 in 119 3 4 in 133 3 4 in 157 5 cm 304 2 cm 339 7 c...

Page 101: ...ME LENGTH SHIPPING LENGTH 24 in 70 0 cm 7 in 17 8 cm W O ENCL W O ENCL 80 in 108 in 203 2 cm 274 3 cm 87 1 2 in 222 3 cm O A GT 21 in 53 5 cm DOOR CLEARANCE 117 5 M min 3 52 7 cm 180 3 cm 76 in 193 0...

Page 102: ...Section 7 ILLUSTRATIONS AND PARTS LIST 97 7 20 WIRING DIAGRAM...

Page 103: ...Section 7 ILLUSTRATIONS AND PARTS LIST 98 7 21 WIRING DIAGRAM WYE DELTA...

Page 104: ...72232425 FAX 33 78907168 SULLAIR CORPORATION Subsidiary of Sundstrand Corporation 3700 East Michigan Boulevard Michigan City Indiana 46360 U S A Telephone 1 800 SULLAIR U S A Only or 1 219 879 5451 F...

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