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Section 8

ILLUSTRATIONS AND PARTS LIST

8.12 SULLICON CONTROL

key

part

number

description

number

quantity

rod, end spherical LH 5/16”

042004

lever, inlet valve

020687

screw, set sq head 5/16”

02250112-197

nut, hex jam LH 5/16”-24

866605-195

rod, control

222745

rod, link 5/16”-24 x 2 1/2”

045854

cylinder, air control 2” stroke

250016-990

orifice, .062”

040127

control, Sullicon

(I)

For maintenance on Sullicon control, order repair kit no. 250020-353.

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

Содержание LS-25

Страница 1: ...INDUSTRIAL AIR COMPRESSOR LS 25 150 200HP 112 149KW AIR COOLED AND WATER COOLED STANDARD 24KT OPERATOR S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250127 757 Sullair Corporation...

Страница 2: ...t Sullair s corporate head quarters in Michigan City Indiana Instruction includes discussion of the function and installation of Sullair service parts troubleshooting of the most common problems and a...

Страница 3: ...PTION OF COMPONENTS 5 2 3 SULLAIR COMPRESSOR UNIT FUNCTIONAL DESCRIPTION 6 2 4 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTIONAL DESCRIPTION 10 2 5 COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTIO...

Страница 4: ...PING 29 4 4 COUPLING ALIGNMENT CHECK 29 4 5 FLUID LEVEL CHECK 29 4 6 ELECTRICAL PREPARATION 30 4 7 MOTOR ROTATION DIRECTION CHECK Section 5 OPERATION 31 5 1 GENERAL 31 5 2 PURPOSE OF CONTROLS ELECTRO...

Страница 5: ...ELEMENT MAINTENANCE 43 CONTROL SYSTEM ADJUSTMENT 44 SULLICON ACTUATOR MAINTENANCE 45 SHAFT COUPLING MAINTENANCE 150HP 112KW 46 DRIVE COUPLING DISASSEMBLY AND REMOVAL 200HP 149KW 46 7 6 TROUBLESHOOTING...

Страница 6: ...EL ELECTRO MECHANICAL 90 8 18 INSTRUMENT PANEL SUPERVISOR 92 8 19 ELECTRICAL BOX 94 8 20 ENCLOSURE 98 8 21 DECAL GROUP 102 8 22 DECAL LOCATION REFERENCE AIR COOLED LESS ENCLOSURE 104 8 23 DECAL LOCATI...

Страница 7: ...uipment as well as noise ex posure administrative and or engineering controls and or personal hearing protective equipment 1 3 PRESSURE RELEASE A Install an appropriate flow limiting valve between the...

Страница 8: ...ce any wiring that has cracked cut abraded or other wise degraded insulation or terminals that are worn discolored or corroded Keep all terminals and pressure connectors clean and tight F Keep grounde...

Страница 9: ...an tifreeze systems contains methanol and is toxic harmful or fatal if swallowed Avoid contact with the skin or eyes and avoid breathing the fumes If swal lowed induce vomiting by administering a tab...

Страница 10: ...mpressor M Forklift no higher than necessary to clear obsta cles at floor level and transport and corner at mini mum practical speeds N Make sure pallet mounted compressors are firmly bolted or otherw...

Страница 11: ...system compressor cooling and lubrication system capacity con trol system and instrument panel all mounted on a structural steel frame On air cooled models a fan draws air over the fan motor and forc...

Страница 12: ...cooled in preparation for re injection 2 4 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTIONAL DESCRIPTION Refer to Figures 2 2 2 3A and 2 3B The cooling and lubrication system consists of a radiator...

Страница 13: ...Section 2 DESCRIPTION 7 Figure 2 2 Cooling and Lubrication System...

Страница 14: ...Section 2 DESCRIPTION 8 Figure 2 3A Compressor Piping and Instrumentation Diagram Electro mechanical...

Страница 15: ...Section 2 DESCRIPTION 9 Figure 2 3B Compressor Piping and Instrumentation Diagram Supervisor...

Страница 16: ...trument panel will be in the red zone or the display on Supervisor with prealarm will show indication when excessive pres sure drop through the separators develops At this time separator element repla...

Страница 17: ...Section 2 DESCRIPTION 11 Figure 2 4 Compressor Discharge System...

Страница 18: ...Section 2 DESCRIPTION 12 Figure 2 5A Compressor System Start Electro mechanical...

Страница 19: ...Section 2 DESCRIPTION 13 Figure 2 5B Compressor System Full Load Electro mechanical...

Страница 20: ...Section 2 DESCRIPTION 14 Figure 2 5C Compressor System Modulation Electro mechanical...

Страница 21: ...Section 2 DESCRIPTION 15 Figure 2 5D Compressor System Unload Electro mechanical...

Страница 22: ...Section 2 DESCRIPTION 16 Figure 2 6A Control System Start Supervisor with Spiral Valve...

Страница 23: ...Section 2 DESCRIPTION 17 Figure 2 6B Control System Full Load Supervisor with Spiral Valve...

Страница 24: ...Section 2 DESCRIPTION 18 Figure 2 6C Control System Modulation Supervisor with Spiral Valve...

Страница 25: ...Section 2 DESCRIPTION 19 Figure 2 6D Control System Unload Supervisor with Spiral Valve...

Страница 26: ...ates it starts opening the bypass ports gradually Excess air is then being returned back to suction Now the com pressor is compressing only that amount of air which is being used As air demand keeps d...

Страница 27: ...ensor bypass timing wye delta transition timing and facilitates selectable automat ic restart after power failure Two wire remote Stop Start input is provided Refer to Figures 2 8 and 2 9 for specific...

Страница 28: ...Section 2 DESCRIPTION 22 Figure 2 8 Typical Machine Connection Electro mechanical...

Страница 29: ...Section 2 DESCRIPTION 23 Figure 2 9 Instrument Panel Group and Controller Panel Electro mechanical Locations of pressure and temperature pick up points...

Страница 30: ...NOTES 24...

Страница 31: ...bar HH Model 150 psig 10 3 bar HH Model 175 psig 12 bar XH Model 175 psig 12 bar XH Model Bearing Type Anti Friction Anti Friction Ambient Temperature Max III 105 F 40 C 105 F 40 C Cooling Pressurized...

Страница 32: ...void all warranties Sullair recommends that 24KT sample be taken at the first filter change and sent to the factory for analysis This is a free service A sample kit with instructions and self addresse...

Страница 33: ...Section 3 SPECIFICATIONS 27 Figure 3 1A Compressor Identification Air cooled...

Страница 34: ...Section 3 SPECIFICATIONS 28 Figure 3 1B Compressor Identification Water cooled...

Страница 35: ...unt of heat that is radiated by the compressor This heat must be removed to assure a normal operating temperature With air cooled compressors it is possible to use this heat for space heating providin...

Страница 36: ...nergize the control circuits by pushing the START button and check all protective devices to be sure that they will de energize the starter coil when activated 5 Reconnect the three 3 motor leads and...

Страница 37: ...control is enabled by pressing the AUTO pad Selects between continuous or AUTO modes of operation Records accumulative hours of compressor operation useful for planning and logging service schedules C...

Страница 38: ...d to the unit on start up Cuts off the reverse flow of air fluid mixture through com pressor discharge system at compressor shutdown Regulates flow of fluid to and around the cooler Designed to mainta...

Страница 39: ...Reinspect the compressor for temperature and leaks the following day 5 4 SUBSEQUENT START UP PROCEDURE On subsequent start ups check that the proper level is visible in the fluid sight glass and simpl...

Страница 40: ...Section 6 SUPERVISOR 34 Figure 6 1 Supervisor Panel...

Страница 41: ...ode to increment a value Down arrow lamp test Used in status displays to change displays and in parameter setup mode to increment a value When in the default display the key will light all the lamps f...

Страница 42: ...ult occurred Next to last fault log This shows the fault on the first line and the run hours when the fault occurred 6 4 LAMP INDICATORS Embedded into the front panel schematic of the compressor are s...

Страница 43: ...7 bar the machine will load when the line pressure goes below 100 psi 6 9 bar P1 Max Maximum sump pressure An alarm and shut down will occur when the sump pressure rises above this pressure Wye to de...

Страница 44: ...tch operation to manual Pressing I while already run ning in manual mode will cause the Supervisor to turn off the common fault relay if engaged and clear any maintenance indicators To stop the compre...

Страница 45: ...and unloads machines based on sequencing hours COM ID Sends status message about once a second starts loads and unloads machines based on machine Com ID EMERGENCY STOP SWITCH Pushing in this switch fo...

Страница 46: ...vious records are very helpful in determining the normalcy of the measurements These observations should be made during all ex pected modes of operation i e full load no load different line pressures...

Страница 47: ...STMENT PROCEDURES Please familiarize yourself with the safety guide lines offered in Section 1 of this manual before at tempting any maintenance on the package AIR FILTER MAINTENANCE Refer to Figure 7...

Страница 48: ...asket 2 Clean the gasket seating surfaces 3 Apply a light film of fresh oil to the new gasket and hand tighten new element until gasket con tacts the seat 4 Continue tightening element an additional 1...

Страница 49: ...rating pressure which is stamped on the com pressor serial number nameplate The following ex planation applies to a typical installation with a de sired operating range of 100 to 110 psi 6 9 to 7 6 ba...

Страница 50: ...ttings SULLICON ACTUATOR MAINTENANCE Refer to Figure 7 5 The Sullicon actuator was ad justed at the factory and should require only peri odic lubrication of its links and pivot points to keep operatin...

Страница 51: ...t lbs 40 7Nm dry Please note that capscrews have self locking patches good for two re uses but the application of a thread locking ad hesive increases this number DO NOT lubricate capscrew threads Ple...

Страница 52: ...tightening the hex bolts tighten the shaft setscrews and remove the hose clamp from the flexible element At this time the coupling is ready for operation DRIVE COUPLING DISASSEMBLY AND RE MOVAL 200HP...

Страница 53: ...ad stop when the pres sure switch contacts open Repair if defective Defective blowdown valve blowdown valve should exhaust sump pressure to 25 to 35 psig 1 7 to 2 4 bar when maximum operating pressure...

Страница 54: ...ve or Out of Adjustment 135 psig 9 3 bar Defective Pressure Relief Valve High Separator Element Pressure Differential Check service lines for leaks or open valves Check the filter indicator and change...

Страница 55: ...heater elements cool down Should trouble persist check whether motor starter contacts are functioning properly Check voltage Should voltage check low consult power company Check connections from trans...

Страница 56: ...i e Blowdown Valve Sullicon Actuator Optional Spiral Valve Failed to Operate Pressure Regulator Maladjusted Solenoid Valve Failed to Operate Control Air Signal Leaks Control Air Signal Filter Clogged...

Страница 57: ...assembly See Section 7 5 Clean strainer screen and o ring replacement kit available Clean orifice Inspect separator elements and gaskets Replace if damaged Check tube pipework for leaks Drain excess...

Страница 58: ...l increase or decrease always showing the total amount of adjustment Maximum adjustment is 7 The DSP key exits wiping out changes to the cur rent item while saving changes to any previous items The PR...

Страница 59: ...rator element w gaskets 02250048 734 1 repair kit primary heavy duty air filter element 409853 1 repair kit secondary heavy duty air filter element 409854 1 repair kit for compressor shaft seal 600889...

Страница 60: ...Section 8 ILLUSTRATIONS AND PARTS LIST 54 8 3 MOTOR COMPRESSOR FRAME AND PARTS...

Страница 61: ...7 3 14 capscrew hex GR5 3 4 x 2 1 4 829112 225 4 15 washer wide 3 4 838312 174 4 I Motor may vary Consult factory with machine serial number II There is an exchange program whereby a remanufactured co...

Страница 62: ...Section 8 ILLUSTRATIONS AND PARTS LIST 56 8 4 AIR INLET SYSTEM...

Страница 63: ...1 2 049727 1 10 clamp hose 250020 159 3 11 tube aluminum 6 x 36 WC AC 200HP only 224953 1 tube aluminum 6 x 30 AC 150HP only 234367 1 12 elbow short rad WC only 242317 1 elbow AC 150HP AC 200HP 040304...

Страница 64: ...Section 8 ILLUSTRATIONS AND PARTS LIST 58 8 5 COOLING LUBRICATION AIR COOLED...

Страница 65: ...123 350 1 9 tube 02250123 344 1 10 filter fluid 1 5 8 I 02250054 605 1 11 adapter SAE 1 5 8 x 1 5 8 02250055 015 2 12 valve oil stop II 02250113 668 1 13 housing thermal valve 1 5 8 III 02250092 929 1...

Страница 66: ...Section 8 ILLUSTRATIONS AND PARTS LIST 60 8 6 COOLING AND LUBRICATION SYSTEM WATER COOLED...

Страница 67: ...connector tube 1 1 4 x 1 5 8 811820 163 2 12 filter fluid 1 5 8 I 02250054 605 1 13 O ring viton 2 1 2 x 3 32 826502 144 1 14 reducer straight thread 1 1 2 x 1 1 4 870024 020 2 15 valve oil stop II 02...

Страница 68: ...Section 8 ILLUSTRATIONS AND PARTS LIST 62 8 7 COOLER ASSEMBLY L MODEL...

Страница 69: ...25306 347 16 4 insert threaded 5 16 18 02250043 765 10 5 adapter venturi panel 02250043 027 1 6 panel venturi 36 245579 1 7 support cooler 02250126 597 1 8 bushing split taper 249853 1 9 fan 36 405103...

Страница 70: ...Section 8 ILLUSTRATIONS AND PARTS LIST 64 8 8 COOLER ASSEMBLY XH MODEL...

Страница 71: ...r venturi 250022 715 1 3 cover access venturi 02250117 117 1 4 gasket cover access 02250117 116 1 5 support cooler 017225 1 6 panel venturi 36 245579 1 7 fan 36 250022 605 1 8 angle 250022 720 1 9 gua...

Страница 72: ...Section 8 ILLUSTRATIONS AND PARTS LIST 66 8 9 WATER PIPING WATER COOLED...

Страница 73: ...lbow tube F 1 1 4 x 1 1 4 810420 125 2 7 elbow tube M 1 1 4 x 1 1 4 810520 125 2 8 tube 1 1 4 02250124 013 1 9 tube 1 1 4 02250124 009 1 10 tube 1 1 4 02250124 016 1 11 bushing reducing hex 2 x 1 1 4...

Страница 74: ...Section 8 ILLUSTRATIONS AND PARTS LIST 68 8 10 DISCHARGE SYSTEM AIR COOLED...

Страница 75: ...44 1 20 filter assembly II 02250117 782 2 21 glass sight 02250126 129 2 22 orifice plug brass 1 8 x 1 16 02250125 775 1 23 orifice plug brass 1 8 x 1 32 02250125 774 1 24 tee male pipe 1 4 869825 025...

Страница 76: ...Section 8 ILLUSTRATIONS AND PARTS LIST 70 8 10 DISCHARGE SYSTEM AIR COOLED...

Страница 77: ...le pipe 2 x close 150HP 822232 000 1 nipple pipe 2 x 2 1 2 200HP 822232 025 1 46 separator moisture 2 V 02250100 365 1 47 nipple pipe 2 x 6 150HP 822232 060 1 nipple pipe 2 x 4 200HP 822232 040 1 48 u...

Страница 78: ...Section 8 ILLUSTRATIONS AND PARTS LIST 72 8 11 DISCHARGE SYSTEM WATER COOLED...

Страница 79: ...fice plug brass 1 8 x 1 16 02250125 775 1 21 orifice plug brass 1 8 x 1 32 02250125 774 1 22 tee male pipe 1 4 869825 025 1 23 elbow pipe 90 M F 1 4 x 1 4 860704 025 1 24 elbow tube F 1 4 x 1 4 812304...

Страница 80: ...Section 8 ILLUSTRATIONS AND PARTS LIST 74 8 11 DISCHARGE SYSTEM WATER COOLED...

Страница 81: ...040 1 40 valve relief 1 x 1 1 4 02250047 679 1 41 bushing reducing hex 1 2 x 1 4 802102 010 1 42 tee reducing 2 x 2 x 1 2 802208 082 1 43 support bracket 02250122 857 1 44 separator moisture 2 V 02250...

Страница 82: ...Section 8 ILLUSTRATIONS AND PARTS LIST 76 8 12 SULLICON CONTROL...

Страница 83: ...l 021654 1 16 screw sealing 1 4 28 041264 1 17 washer back up 021172 1 18 diaphragm Sullicon 250020 028 1 19 washer springlock 5 16 837505 078 3 washer springlock 3 8 837506 094 4 20 nut hex 5 16 18 8...

Страница 84: ...Section 8 ILLUSTRATIONS AND PARTS LIST 78 8 12 SULLICON CONTROL...

Страница 85: ...1 41 screw set sq head 5 16 02250112 197 1 42 nut hex jam LH 5 16 24 866605 195 1 43 rod control 222745 1 44 rod link 5 16 24 x 2 1 2 045854 1 45 cylinder air control 2 stroke 250016 990 1 46 orifice...

Страница 86: ...Section 8 ILLUSTRATIONS AND PARTS LIST 80 8 13 ACTUATOR VALVE...

Страница 87: ...x 1 827404 100 1 14 capscrew hex GR8 1 4 20 x 1 2 828204 050 4 15 indicator actuator 250030 983 1 16 gear 250016 196 1 17 guide rack actuator 250016 199 1 18 mount air cylinder 250027 169 1 19 capscre...

Страница 88: ...Section 8 ILLUSTRATIONS AND PARTS LIST 82 8 14 CONTROL SYSTEM ELECTRO MECHANICAL...

Страница 89: ...T x 1 4 NPT 250018 430 1 15 nipple pipe 1 4 x 1 1 2 866304 015 1 16 nipple pipe 1 4 x 2 866304 020 1 17 elbow pipe 90 1 4 866215 010 1 18 valve check 1 4 II 049905 1 19 tee tube M 1 4 x 1 4 810904 025...

Страница 90: ...Section 8 ILLUSTRATIONS AND PARTS LIST 84 8 15 CONTROL SYSTEM SUPERVISOR...

Страница 91: ...ransducer pressure 0 250PSI 02250078 933 4 21 support pressure transducer 02250102 631 1 22 switch vacuum 02250078 249 1 23 elbow tube M 1 4 x 1 8 813704 125 1 24 bulkhead pipe 1 8 841500 002 4 25 val...

Страница 92: ...Section 8 ILLUSTRATIONS AND PARTS LIST 86 8 16 UNIT TUBING...

Страница 93: ...3 8 810508 038 1 12 connector tube M 1 2 x 3 8 810208 038 1 13 tube 250027 090 1 14 tube 250027 091 1 15 nipple pipe 3 4 x close 822212 000 1 16 connector tube M 3 8 x 1 4 810206 025 2 17 tube 250027...

Страница 94: ...Section 8 ILLUSTRATIONS AND PARTS LIST 88 8 17 INSTRUMENT PANEL ELECTRO MECHANICAL...

Страница 95: ...50125 073 1 2 panel instrument 02250125 351 1 3 gauge pressure 250005 185 2 4 gauge temp 042582 1 5 gauge differential pressure 250003 798 1 6 gauge differential pressure 250003 799 1 7 gauge vacuum 2...

Страница 96: ...Section 8 ILLUSTRATIONS AND PARTS LIST 90 8 18 INSTRUMENT PANEL SUPERVISOR...

Страница 97: ...0100 298 1 2 gasket control panel 02250071 093 1 3 panel cover Supervisor 02250054 854 1 4 gasket panel Supervisor 02250048 822 1 5 panel Supervisor 02250116 247 1 6 switch emergency shut down 250028...

Страница 98: ...Section 8 ILLUSTRATIONS AND PARTS LIST 92 8 19 ELECTRICAL BOX...

Страница 99: ...hf 250025 703 1 12 bar ground 5 post 02250101 721 1 13 starter size N 250038 283 1 starter size 5 250038 284 1 starter size K 250038 280 1 starter size 5DP 02250113 513 1 14 enclosure starter box 0225...

Страница 100: ...Section 8 ILLUSTRATIONS AND PARTS LIST 94 8 20 ENCLOSURE...

Страница 101: ...AC 200 HP WC 02250103 205 3 18 panel fiberglass 02250123 054 3 or 4 19 panel end 016887 2 20 corner member 230458 4 21 nut hex flange 5 16 825305 283 54 22 screw hex ser washer 5 16 x 3 4 829705 075...

Страница 102: ...Section 8 ILLUSTRATIONS AND PARTS LIST 96 8 20 ENCLOSURE...

Страница 103: ...mmet rubber 200 HP 040125 6 41 door instrument panel 200 HP 02250046 851 1 42 eyebolt reg 5 16 18 200 HP 839105 112 5 43 capscrew button hd 5 16 x 1 4 200 HP 250004 144 5 44 washer molded nylon 5 16 2...

Страница 104: ...Section 8 ILLUSTRATIONS AND PARTS LIST 98 8 21 DECAL GROUP...

Страница 105: ...250069 399 1 decal voltage 230 3 60 international not shown I 02250069 397 1 decal voltage 380 415 3 50 international not shown I 02250069 403 1 decal voltage 200 3 50 international not shown I 022500...

Страница 106: ...Section 8 ILLUSTRATIONS AND PARTS LIST 100 8 21 DECAL GROUP...

Страница 107: ...2250069 395 1 26 decal ISO 9001 02250057 624 1 27 decal electrical component ID 250038 457 1 28 decal LS 25 02250061 091 1 29 decal danger high voltage 042218 1 30 decal 24KT blk 1 75 4 ht 02250061 02...

Страница 108: ...Section 8 ILLUSTRATIONS AND PARTS LIST 102 8 22 DECAL LOCATION REFERENCE AIR COOLED LESS ENCLOSURE...

Страница 109: ...T blk 1 75 4 ht 02250061 022 1 14 sign warning hot surfaces 407408 4 15 decal auto start 041065 1 16 decal warning auto start 250017 903 1 17 decal warning actuator IV 250029 836 1 18 decal actuator v...

Страница 110: ...Section 8 ILLUSTRATIONS AND PARTS LIST 104 8 23 DECAL LOCATION REFERENCE WATER COOLED LESS ENCLOSURE...

Страница 111: ...decal auto start 041065 1 13 decal warning auto start 250017 903 1 14 decal warning sever fan 049855 1 15 decal warning actuator IV 250029 836 1 16 decal actuator valve positioning IV 250029 784 1 I T...

Страница 112: ...Section 8 ILLUSTRATIONS AND PARTS LIST 106 8 24 DECAL LOCATION REFERENCE TYPICAL ENCLOSURE...

Страница 113: ...91 1 4 decal 24KT blk 1 75 4 02250061 022 1 5 decal ISO 9001 02250057 624 1 6 decal fork lifting I 241814 4 7 decal Sullair logo 02250059 048 1 8 decal water in 250019 107 1 9 decal water out 250019 1...

Страница 114: ...Section 8 ILLUSTRATIONS AND PARTS LIST 108 8 25 WIRING DIAGRAM STANDARD FULL VOLTAGE ELECTRO MECHANICAL 02250125 969R1...

Страница 115: ...Section 8 ILLUSTRATIONS AND PARTS LIST 109 8 26 WIRING DIAGRAM WYE DELTA ELECTRO MECHANICAL 02250125 970R1...

Страница 116: ...Section 8 ILLUSTRATIONS AND PARTS LIST 110 8 27 WIRING DIAGRAM STANDARD FULL VOLTAGE SUPERVISOR 02250113 462R5...

Страница 117: ...Section 8 ILLUSTRATIONS AND PARTS LIST 111 8 28 WIRING DIAGRAM WYE DELTA SUPERVISOR 02250113 463R6...

Страница 118: ...Section 8 ILLUSTRATIONS AND PARTS LIST 112 8 29 WIRING DIAGRAM SOLID STATE STARTER SUPERVISOR 02250113 467R0...

Страница 119: ......

Страница 120: ...RATION 3700 East Michigan Boulevard Michigan City Indiana 46360 U S A Telephone 1 800 SULLAIR U S A Only or 1 219 879 5451 Fax 219 874 1273 Fax 219 874 1835 Parts Fax 219 874 1205 Service SULLAIR ASIA...

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