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Section 6

MAINTENANCE

43

the keys in position being sure that the end of the
key is flush with the end of the shaft. Secure the
compressor hub on the shaft with setscrews. Place
the element between the hubs and push the motor
hub to engage the element. After engaging the ele-
ment, set the motor hub for the proper gap as spec-
ified in

Table 6-1 Installation Data

, and secure the

motor hub with a setscrew. When the hub gap is
properly set, you will be able to move the element
in a slight back and forth motion (unless the cou-
pling is extremely out of alignment.

STEP 2 - ANGULAR ALIGNMENT

Clean fluid and dirt from the hubs in preparation for
angular alignment. Position the dial indicator on the
hubs as shown in Figure

. Rotate both hubs

equally to check alignment.

STEP 3 - PARALLEL OFFSET ALIGNMENT

Reposition the dial indicator as shown in Figure

. Rotate both hubs equally to check for misalign-

ment. Parallel offset alignment is equal to 1/2 the

Figure 6-5 Pressure Regulator Adjustments

Table 6-1 Installation Data

Max. Operating Misalignment

Parallel

Coupling Angular

Offset

Gap

inches/mm +.03 in./ .762mm

Degrees

inches/ mm

(I)

.008/ .02

1.38/ 35.0mm

.025

.005/ 127mm

(I)

Angular misalignment in inches equals maximum A minus mini-

mum B as shown in Figure

DO NOT

exceed values in Table

6-1 above.

Figure

6

-6 Drive Coupling Alignment

Figure 6-7 Drive Coupling

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47
48
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51
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Содержание LS16T

Страница 1: ...INDUSTRIAL AIR COMPRESSOR LS16T 100 200HP 75 149KW SUPERVISOR II OPERATOR S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250142 464 Sullair Corporation...

Страница 2: ...porate 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...

Страница 3: ...ONENTS 5 2 3 SULLAIR COMPRESSOR UNIT FUNCTIONAL DESCRIPTION 6 2 4 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTIONAL DESCRIPTION 7 2 5 COMPRESSOR DISCHARGE SYSTEM FUNCTIONAL DESCRIPTION 7 2 6 CONTRO...

Страница 4: ...SEQUENT START UP PROCEDURE 37 5 8 SHUTDOWN PROCEDURE Section 6 MAINTENANCE 39 6 1 MAINTENANCE INTRODUCTION 39 6 2 DAILY OPERATION 39 6 3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION 39 6 4 MAINTENA...

Страница 5: ...IR PIPING SYSTEM 100 125HP AIR COOLED 66 8 9 AIR PIPING SYSTEM 150 200HP AIR COOLED 70 8 10 FLUID PIPING SYSTEM 100 125HP AIR COOLED 72 8 11 FLUID PIPING SYSTEM 150 200HP AIR COOLED 74 8 12 DISCHARGE...

Страница 6: ......

Страница 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 eith...

Страница 8: ...the compressor J DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or with degraded lubricant K DO NOT attempt to operate the compressor in...

Страница 9: ...any hand held tools or other conductive objects away from exposed live parts of electrical system Maintain dry footing stand on insulating surfaces and DO NOT contact any other portion of the compress...

Страница 10: ...mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them NEVER attempt to forklift a compressor that is not secured to its pallet as u...

Страница 11: ...clearly shown The complete package includes compressor electric motor compressor inlet system compressor discharge system compressor cooling and lubrication system capacity control system and Supervi...

Страница 12: ...2 3B The cooling and lubrication system consists of a fluid cooler aftercooler full flow fluid filters fluid stop valve thermal valve and interconnection piping For water cooled models a shell and tu...

Страница 13: ...re on the digital display At a differential of 10 psid 0 7 bar or greater the operator will be told to service the separator element At this time separator ele ment replacement is necessary The receiv...

Страница 14: ...Section 2 DESCRIPTION 8 Figure 2 3A Compressor Piping and Instrumentation Diagram LS16T 100 125 Air cooled 02250138 815R01...

Страница 15: ...2250138 182 1 15 valve check 1 2 042694 1 16 valve minimum pressure 250022 735 1 17 regulator down stream 046556 2 18 element separator primary 250034 115 1 19 fltr coalescing 425 02250058 442 1 20 co...

Страница 16: ...Section 2 DESCRIPTION 10 Figure 2 3A Compressor Piping and Instrumentation Diagram LS16T 100 125 Air cooled 02250138 815R01...

Страница 17: ...scription number quantity 36 regulator back pressure 048059 1 37 valve relief gearbox 200psi 250039 222 1 38 glass sight 02250126 129 2 39 accumulator closed inlet 02250057 463 1 40 valve drain self c...

Страница 18: ...Section 2 DESCRIPTION 12 Figure 2 3B Compressor Piping and Instrumentation Diagram LS16T 150 200 Air cooled 02250135 209R01...

Страница 19: ...oler air 250008 938 1 15 valve check 1 2 042694 1 16 valve minimum pressure 250022 735 1 17 regulator down stream 046556 2 18 element separator primary 250034 115 1 19 fltr coalescing 425 02250058 442...

Страница 20: ...Section 2 DESCRIPTION 14 Figure 2 3B Compressor Piping and Instrumentation Diagram LS16T 150 200 Air cooled 02250135 209R01...

Страница 21: ...antity 36 regulator back pressure 048059 1 37 valve relief gearbox 200psi 250039 222 1 38 glass sight 02250126 129 2 39 accumulator closed inlet 02250057 463 1 40 valve drain self close 041111 1 41 ac...

Страница 22: ...ure regulator valve has an orifice which vents a small amount of air to the atmosphere when the control pressure regulator valve modulates the inlet poppet valve UNLOAD MODE EXCESS OF 360 PSIG 24 8 BA...

Страница 23: ...Section 2 DESCRIPTION 17 Figure 2 4A Control System Diagram Functional Components...

Страница 24: ...Section 2 DESCRIPTION 18 Figure 2 4B Control System Diagram START...

Страница 25: ...Section 2 DESCRIPTION 19 Figure 2 4C Control System Diagram MODULATION...

Страница 26: ...Section 2 DESCRIPTION 20 Figure 2 4D Control System Diagram FULL LOAD...

Страница 27: ...Section 2 DESCRIPTION 21 Figure 2 4E Control System Diagram UNLOAD...

Страница 28: ...D The keypad is used to control the machine as well as display status and change setpoints Refer to Figure 2 6 for following key descriptions Stop Used to put the machine into manual stop It is also u...

Страница 29: ...and stopped the machine The machine may start at any time STARTING Machine is trying to start OFF LOAD Machine is running and off loaded ON LOAD Machine is running and loaded FULL LD Machine is runnin...

Страница 30: ...ferential dP3 is defined as P3 P1 2 Unit discharge temperature and the maxi mum limit If the temperature exceeds the limit a T1 HI shutdown will occur Dry side discharge temperature and the maximum li...

Страница 31: ...being displayed For monitoring only T4 Interstage temperature If lit steady signifies that T4 is being displayed if flashing denotes the presence of an alarm For T1 T2 and T4 shutdown points are at 25...

Страница 32: ...NOTES 26...

Страница 33: ...compressor s fluid fill with the parts technician by using your compressor s serial number Mixing of other fluids within the compressor will void all warranties Sullube fluid should be changed every 1...

Страница 34: ...xposed plant piping I Sullube should not be used with PVC piping sys tems It may affect the bond at cemented joints Certain other plastic materials may also be affect ed I Plastic Pipe Institute Recom...

Страница 35: ...Section 3 SPECIFICATIONS 29 Figure 3 2 Identification LS16T 100 125 Air cooled 02250138 172R01...

Страница 36: ...Section 3 SPECIFICATIONS 30 Figure 3 3 Identification LS16T 150 200 Air cooled 02250134 200R02...

Страница 37: ...ejection requirement is the amount of heat that is radiated by the com pressor This heat must be removed to assure a normal operating temperature With air cooled com pressors it is possible to use thi...

Страница 38: ...at the incom ing voltage is the same voltage that the com pressor was wired for 2 Check starter and overload heater sizes see electrical parts in Parts Manual 3 Check all electrical connections for ti...

Страница 39: ...n and allows flow of fluid to the unit on startup Cuts off the reverse flow of air fluid mixture through compres sor discharge system at compressor shutdown Regulates flow of fluid to and around the c...

Страница 40: ...ifferential below the unload pressure where the machine is loaded For example if the unload pressure is set to 360 psi 24 8 bar and the load differential is set to 10 psid 0 7 bar the machine will loa...

Страница 41: ...Used only for sequencing see Sequencing Protocol Manual for details Machine Capacity Used only for sequenc ing see Sequencing Protocol Manual for details Sequence Hours Used only for sequenc ing see S...

Страница 42: ...et to a value the machine will go into standby after power up When the line pressure drops below the load setpoint the restart timer will start timing When the timer expires the machine will start SEQ...

Страница 43: ...P2 and pressure differen tial P2 are correctly programmed 7 Observe the operating temperature If the oper ating temperature exceeds 235 F 113 C the cooling system or installation environment should be...

Страница 44: ...NOTES 38...

Страница 45: ...compressor fluid 2 Replace the main fluid filter element 3 Clean the return line strainers and orifices 4 Clean or replace the control line filter element 6 5 FLUID CHANGE Standard models are filled w...

Страница 46: ...IR FILTER ELEMENT REPLACEMENT 1 Clean exterior of air filter housing 2 Unscrew the wing nut securing the cover 3 Carefully remove the element from the housing 4 Unscrew the wingnut assembly securing t...

Страница 47: ...ed to the separator cover return lines service lines etc to Allow lid removal 3 Loosen and remove the eighteen 18 hex head capscrews from the cover lid plate To assist with the removal of the tank lid...

Страница 48: ...wise to decrease the set ting The reference pressure regulator should be set to maintain a 60 psig 4 14 bar downstream pressure to the inlet poppet valve The unload pressure reg ulator should be set a...

Страница 49: ...LIGNMENT Clean fluid and dirt from the hubs in preparation for angular alignment Position the dial indicator on the hubs as shown in Figure 6 8 Rotate both hubs equally to check alignment STEP 3 PARAL...

Страница 50: ...shims under the motor feet while hori zontal parallel offset is corrected by sliding the motor sideways Angular alignment is indicated by the difference in indicator readings or by the difference in c...

Страница 51: ...hed Repair or replace as necessary kit available Readjust MAX P1 setpoint appropriately Cooling water temperature too high increase water flow water cooled Cooling water flow insufficient check water...

Страница 52: ...and or dP2 on controller indicates high dP Thermal valve not functioning properly replace element Cooling air flow restricted clean cooler and check for proper ventilation air cooled Ambient temperatu...

Страница 53: ...wdown Valve Defective Blowdown Solenoid Valve Plugged or Frozen Control Lines Defective Discharge Check Valve Defective Oil Stop Valve Defective Pressure Relief Valve Check all pipes connections and c...

Страница 54: ...NOTES 48...

Страница 55: ...r lid cover gasket no 250006 536 III When performing maintenance on inlet valve if required order gasket no 040708 IV When performing maintenance on inlet valve assembly discharge check valve if requi...

Страница 56: ...parts for thermal valve seal u cup 02250101 372 1 element 220 F 250001 349 1 o ring vition 826502 144 1 Repair kit for shaft seal 001934A 1 Sullube fluid 5 gal can 250022 669 30 gal Sullube fluid 55 g...

Страница 57: ...NOTES 51...

Страница 58: ...Section 8 ILLUSTRATIONS AND PARTS LIST 52 02250134 194R00 8 3 MOTOR FRAME COMPRESSOR AND PARTS 100 125HP...

Страница 59: ...3 3 4 829112 375 4 18 screw hex ser washer 5 16 18 x 3 4 829705 075 6 19 washer spr lock reg pltd 7 16 837807 112 12 20 washer spr lock reg pltd 1 2 837808 125 16 21 washer spr lock reg pltd 3 4 83781...

Страница 60: ...Section 8 ILLUSTRATIONS AND PARTS LIST 54 02250134 195R00 8 4 MOTOR FRAME COMPRESSOR AND PARTS 150 200HP...

Страница 61: ...9705 075 6 18 washer spr lock reg pltd 7 16 837807 112 12 19 washer spr lock reg pltd 1 2 837808 125 16 20 washer spr lock reg pltd 3 4 837812 188 14 I For maintenance on drive coupling sleeve order r...

Страница 62: ...Section 8 ILLUSTRATIONS AND PARTS LIST 56 02250134 187R00 8 5 AIR INLET SYSTEM...

Страница 63: ...elbow tube 90 deg m 3 8 x 1 2 810506 050 1 18 elbow tube 90 deg m 1 2 x 1 2 810508 050 1 19 nut hex f pltd 3 8 16 825306 347 4 20 capscr hex gr5 1 2 13 x 1 1 2 829108 150 4 21 screw hex ser washer 3 8...

Страница 64: ...Section 8 ILLUSTRATIONS AND PARTS LIST 58 02250138 173R00 8 6 FLUID COOLING SYSTEM 100 125HP AIR COOLED...

Страница 65: ...n 20 12 500 750 cfm 250042 676 1 13 nut hex pltd 1 2 13 825208 448 6 14 nut hex f pltd 5 16 18 825305 283 28 15 nut hex f pltd 3 8 16 825306 347 14 16 nut hex locking 3 8 16 825506 198 12 17 capscr he...

Страница 66: ...Section 8 ILLUSTRATIONS AND PARTS LIST 60 02250134 189R00 8 7 FLUID COOLING SYSTEM 150 200HP AIR COOLED...

Страница 67: ...16 nut hex f pltd 3 8 16 825306 347 22 17 nut hex locking 1 4 20 825504 145 8 18 nut hex locking 3 8 16 825506 198 12 19 capscr hex gr5 1 4 20 x 1 829104 100 8 20 capscr hex gr5 5 16 18 x 3 4 829105 0...

Страница 68: ...Section 8 ILLUSTRATIONS AND PARTS LIST 62 02250138 174R00 8 8 AIR PIPING SYSTEM 100 125HP AIR COOLED...

Страница 69: ...flange thrd 1 1 2 300 rf 820330 024 2 16 nut hex pltd 5 16 18 825205 273 2 17 nut hex pltd 1 2 13 825208 448 4 18 nut hex pltd 3 4 10 825212 665 8 19 u bolt 1 2 x 5 pipe 829008 500 2 20 capscr hex gr...

Страница 70: ...Section 8 ILLUSTRATIONS AND PARTS LIST 64 02250138 174R00 8 8 AIR PIPING SYSTEM 100 125HP AIR COOLED...

Страница 71: ...cription number quantity 35 bushing red pltd 1 x 3 4 867104 030 1 36 bushing red pltd 1 1 2 x 1 4 867106 010 1 37 tee pipe pltd 1 1 2 868430 060 1 38 elbow pipe 45 deg 300 plt 3 4 869430 030 1 39 elbo...

Страница 72: ...Section 8 ILLUSTRATIONS AND PARTS LIST 66 02250134 191R00 8 9 AIR PIPING SYTEM 150 200HP...

Страница 73: ...0532 200 2 15 flange thrd 1 1 2 300 rf 820330 024 2 16 nut hex pltd 5 16 18 825205 273 2 17 nut hex pltd 1 2 13 825208 448 4 18 nut hex pltd 3 4 10 825212 665 8 19 u bolt 1 2 x 5 pipe 829008 500 2 20...

Страница 74: ...Section 8 ILLUSTRATIONS AND PARTS LIST 68 02250134 191R00 8 9 AIR PIPING SYTEM 150 200HP...

Страница 75: ...art number description number quantity 34 bushing red pltd 1 1 2 x 1 4 867106 010 1 35 tee pipe pltd 1 1 2 868430 060 1 36 elbow pipe 45 deg 300 plt 3 4 869430 030 1 37 elbow tube 90 deg m 1 4 x 1 4 s...

Страница 76: ...Section 8 ILLUSTRATIONS AND PARTS LIST 70 02250138 175R01 8 10 FLUID PIPING SYSTEM 100 125HP...

Страница 77: ...vlv 220deg f I 250001 349 1 13 union tube hex 1 1 2 811324 150 1 14 elbow tube str thrd 1 1 2 x 1 7 8 811624 188 4 15 connector tube str thd 1 1 2 x 1 7 8 811824 188 4 16 nut hex pltd 3 8 16 825206 3...

Страница 78: ...Section 8 ILLUSTRATIONS AND PARTS LIST 72 02250134 199R00 8 11 FLUID PIPING SYSTEM 150 200HP WATER COOLED...

Страница 79: ...90 deg m 1 1 2 x 1 1 2 810524 150 2 13 elbow tube str thrd 1 1 2 x 1 7 8 811624 188 3 14 connector tube str thd 1 1 2 x 1 7 8 811824 188 3 15 nut hex pltd 3 8 16 825206 337 2 16 o ring viton 2 1 2 x...

Страница 80: ...Section 8 ILLUSTRATIONS AND PARTS LIST 74 02250134 197R00 8 12 DISCHARGE SYSTEM...

Страница 81: ...lifting 02250135 164 1 16 valve relief 1 npt 400psi 02250137 688 1 17 sleeve rtd 1 2 npt ls20t disch 02250138 457 2 18 plug o ring boss sae 1 1 4 040029 1 19 valve pneu nc 500 rn bdv III 045116 1 20...

Страница 82: ...Section 8 ILLUSTRATIONS AND PARTS LIST 76 02250134 197R00 8 12 DISCHARGE SYSTEM...

Страница 83: ...306 347 1 40 capscr hex gr5 3 8 16 x 1 1 4 829106 125 12 41 capscr hex gr5 1 2 13 x 2 3 4 829108 275 2 42 capscr hex gr5 5 8 11 x 2 829110 200 3 43 capscr hex gr5 3 4 10 x 2 829112 200 8 44 capscr hex...

Страница 84: ...Section 8 ILLUSTRATIONS AND PARTS LIST 78 02250134 197R00 8 12 DISCHARGE SYSTEM...

Страница 85: ...6408 025 1 59 nipple pipe xs plt 3 4 x 1 1 2 866412 015 1 60 nipple pipe xs plt 3 4 x 6 866412 060 1 61 plug pipe 1 4 3000 stl plt 866900 010 1 62 elbow pipe 90 deg 300 plt 1 2 867030 020 1 63 elbow p...

Страница 86: ...Section 8 ILLUSTRATIONS AND PARTS LIST 80 02250134 196R00 8 13 CONTROL START SYSTEM...

Страница 87: ...2 16 nipple pipe xs 316s 1 4 x cl 250019 142 3 17 support starter clr 200hp 250022 657 2 18 tee 1 4 t x m rn 316ss 250041 911 1 19 valve sol 3wno 1 8 8300 IV 407390 2 20 connector tube m 1 4 x 1 8 81...

Страница 88: ...Section 8 ILLUSTRATIONS AND PARTS LIST 82 02250134 196R00 8 13 CONTROL START SYSTEM...

Страница 89: ...x 1 4 867102 010 1 36 tee male pipe stainless 1 4 869925 025 1 37 elbow pipe 90 deg 1 4 300 ss 876630 010 2 38 tee pipe 300 1 4 ss 876730 010 1 39 connector tube m 1 4 x 1 8 ss 876804 012 2 40 connec...

Страница 90: ...Section 8 ILLUSTRATIONS AND PARTS LIST 84 02250137 724R02 8 14 CONTROL PANEL...

Страница 91: ...25 2 9 switch per red push pull e22 250028 588 1 10 control Supervisor II deluxe II 250042 023 1 11 nut hex f pltd 5 16 18 825305 283 4 12 nut hex metric m4 x 7 825904 070 8 13 screw hex ser washer 5...

Страница 92: ...Section 8 ILLUSTRATIONS AND PARTS LIST 86 02250138 176R00 8 15 ENCLOSURE 100 125HP...

Страница 93: ...516 2 14 angle formed 1 1 4 x 2 1 4 x 47 5 232876 2 15 grille enclosure end 249651 2 16 channel btm sill TS20 LS25S encl 250022 772 2 17 panel upper encl front 250041 072 1 18 panel upper encl rear 25...

Страница 94: ...Section 8 ILLUSTRATIONS AND PARTS LIST 88 02250134 193R00 8 16 ENCLOSURE 150 200HP...

Страница 95: ...876 2 14 grille enclosure end 249651 2 15 channel btm sill TS20 LS25S encl 250022 772 2 16 panel upper encl front 250041 072 1 17 panel upper encl rear 250041 073 1 18 panel upper encl end 250041 074...

Страница 96: ...Section 8 ILLUSTRATIONS AND PARTS LIST 90 8 17 DECAL GROUP...

Страница 97: ...rning food grade lube 250003 144 1 3 sign warning ground fault 049852 1 4 decal warning auto start 250017 903 1 5 sign danger electrocution 049850 1 6 sign warning hot surfaces 407408 3 7 sign warning...

Страница 98: ...Section 8 ILLUSTRATIONS AND PARTS LIST 92 8 17 DECAL GROUP...

Страница 99: ...mixing fluids 02250110 891 1 12 decal rotation 250021 286 1 13 decal rotation 250021 564 1 14 decal fluid Sullube 02250069 389 1 15 decal water inlet outlet 049873 1 16 decal water in 250019 107 1 17...

Страница 100: ...Section 8 ILLUSTRATIONS AND PARTS LIST 94 8 17 DECAL GROUP...

Страница 101: ...C decal V 575 3 60 international 02250069 400 1 22 decal ISO 9001 02250057 624 1 23 decal electrical component ID 250038 457 1 24 decal protective earth ground 02250075 045 1 25 decal earth ground 022...

Страница 102: ...Section 8 ILLUSTRATIONS AND PARTS LIST 96 8 18 DECAL LOCATIONS OPEN AIR COOLED...

Страница 103: ...drain 250022 810 1 7 sign danger electrocution 049850 1 8 decal autostart 041065 1 9 decal warning auto start 250017 903 1 10 decal LS20T black 4 ht 02250071 287 1 11 decal ISO 9001 02250057 624 1 12...

Страница 104: ...Section 8 ILLUSTRATIONS AND PARTS LIST 98 8 19 ENCLOSURE DECALS...

Страница 105: ...41814 4 6 decal Sullair logo 4 x 32 black 02250059 060 1 7 sign warning sever fan port 049965 2 8 sign warning compressor fluid fill cap 049685 1 9 decal rotation 250021 564 1 10 decal water in 250019...

Страница 106: ...Section 8 ILLUSTRATIONS AND PARTS LIST 100 8 20 DECAL LOCATIONS CONTROL BOX...

Страница 107: ...ecal danger high voltage 042218 1 3 decal V 460 3 60 international I 02250069 399 1 4 decal earth ground 02250075 046 1 I Due to custom voltage requests voltage decal may vary For positive identificat...

Страница 108: ...Section 8 ILLUSTRATIONS AND PARTS LIST 102 8 21 WIRING DIAGRAM LS16T AIR COOLED SUPERVISOR II DELUXE 02250138 816R01...

Страница 109: ...Section 8 ILLUSTRATIONS AND PARTS LIST 103 8 22 WIRING DIAGRAM LS16T AIR COOLED SSRV VFD COOLING FAN 02250135 132R02...

Страница 110: ...NOTES 104...

Страница 111: ......

Страница 112: ...ULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City Indiana 46360 U S A www sullair com Telephone 1 800 SULLAIR U S A Only or 1 219 879 5451 Fax 219 874 1273 PARTS DEPARTMENT Fax 219 874 183...

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