Professional Documents
Culture Documents
LS12-50&LS16-60/75LF
50&60HZ
thoroughly.
attempts will be made to update the manual, Sullair reserves the right to make
This manual describes in detail the system structure, function, usage and
Before installing and operating this machine, the customer shall carefully
read this manual. After fully understanding the structure and function of each
part of the machine set can they operate and maintain the machine set.
After certain period, there will be discrepancies between this manual and the
If there is any point that is not described in this manual but is unclear
during the operation and use by the user, you can contact your local distributor
Editor
Sep. 2004
TABLE OF CONTENTS
SECTION 1 SAFETY
1.1 General 1
1.2 Personal Protective Equipment 1
1.3 Fires and Explosion 1
1.4 Moving Parts 2
1.5 Hot Surfaces, Sharp Edges and Sharp Corners 2
1.6 Toxic and Irritating Substances 3
1.7 Electrical Shock 3
1.8 Lifting 3
1.9 Other Precautions 4
SECTION 6 SUPERVISOR II
6.1 Introduction 33
6.2 Keypad Description 33
6.3 Status Displays 33
6.4 Lamp Indicators 35
SECTION 7 MAINTENANCE
7.1 General 37
7.2 Daily Maintenance 37
7.3 Maintenance after Initial 50 Hours of Operation 37
7.4 Maintenance after Every 1000 Hours of Operation 37
7.5 Fluid Maintenance 37
7.6 Fluid Filter Maintenance 37
7.7 Maintenance of Fluid Air Separator 38
7.8 Parts Replacement and Adjustment 38
7.9 Troubleshooting – Instrument Type 45
7.10 Troubleshooting – Computer Type 47
7.11 Transducer Usage Description and Supervisor Parameter Calibration 50
7.12 Pipe Installation Diagram 50
SECTION 1 SAFETY
1. 1 GENERAL
Sullair Corporation designs and manufactures all of their products so they can be operated safely.
However, the responsibility for safe operation rests with those who use and maintain these products.
The following safety precautions are offered as a guide, which, if conscientiously followed, will
minimize the possibility of accidents thought the useful life of this equipment.
Only those who have been trained and delegated to do so, and who have read and understood this
Operator’s Manual should operate the compressor. Failure to follow the instructions, procedures and
safety precautions in this manual can result in accidents and injuries. Read this manual prior to
startup.
Never start the compressor unless it is safety to do so. Do not attempt to operate the compressor
with a known unsafe condition. Tag the compressor and render it inoperative by disconnecting and
locking out all power at source or otherwise disabling its prime mover, so others who may not know
of the unsafe condition, cannot attempt to operate it until the condition is corrected.
Install, use and operate the compressor and/or controls in full compliance with all pertinent
regulations and all applicable national and local laws, standards and regulations.
Do not modify the compressor and/or controls in any way except with written factory approval.
d. Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the
compressor or of the inside of the enclosure, if any.
e. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace
any wiring that has cracked, cut abraded or otherwise degraded insulation, or terminals that are
worn, discolored or corroded. Keep all terminals and pressure connectors clean and tight.
f. Keep grounded and/or conductive objects such as tools away from exposed live electrical parts such
as terminals to avoid arcing, which may serve as a source of ignition.
g. Remove any acoustical material or other material that may be damaged by heat or that may support
combustion and is in close proximity, prior to attempting weld repairs.
h. Keep suitable fully charged fire extinguisher or extinguishers nearby when servicing and operating
the compressor.
i. Keep oily rags, leaves, litter or other combustibles 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 fluid or with degraded lubricant.
k. Do not attempt to operate the compressor in any classification of hazardous environment unless the
compressor has been specially designed and manufactured for that duty.
1. 4 MOVING PARTS
a. Keep hands, arms and other parts of the body and also clothing away from couplings, fans and other
moving parts.
b. Do not attempt to operate the compressor with the fan, coupling or other guards removed.
c. Wear snug-fitting clothing 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 adjustment.
e. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or
operate it.
f. Disconnect and lock out all power at source and verify at the compressor that all circuits are
de-energized to minimize the possibility of accidental start-up or operation, prior to attempting
repairs or adjustments. This is especially important when compressor is remotely controlled.
g. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water, or other
liquids to minimize the possibility of slips and falls.
1. 7 ELECTRICAL SHOCK
a. This compressor should be installed and maintained in full compliance with any national or local
regulations, standards and laws, including those of the national electrical rules and also including
those relative to equipment grounding conductors, and only by personnel that are trained, qualified
and delegated to do so.
b.Keep all parts of the body and 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 compressor when making adjustments or repairs to expose 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 body.
c. Attempt repairs in clean, dry and well-lighted and ventilated areas only.
d. Do not leave the compressor unattended 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 at source prior to attempting repairs or adjustments to
rotating machinery and prior to handling any ungrounded conductors.
f. Dry test all shutdown circuits prior to starting the compressors after installation.
1. 8 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 must not be supported by the lifting
bail but by slings instead. In any event, lift and/or handle only in full compliance with the national
or local regulations and laws.
b. Inspect points of attachment for cracked welds and for cracked, bent, corroded or otherwise
degraded members and for loose bolts or nuts prior to lifting.
c. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition
and has a rated capacity of at least the weight of the compressor. If you are unsure of the weight,
then weigh compressor before lifting.
d. Make sure lifting hook has functional safety latch or equivalent, and is fully engaged and latched
LS12-50&LS16-60/75LF Series Screw Compressor O & M Manual Section 1 Safety
Enclosure
Blow down valve
Sump tank
Inlet air filter
Fluid filter
Motor
Fluid filter
Compressor discharge
Motor
Sump tank
Thermal valve
Air inlet valve
Fluid filter
Compressor discharge
Fluid cooler
Compressor unit
On air-cooled model, the fluid and compressed air are cooled with radiator-type cooler.
On water-cooled model, the fluid and compressed air are cooled with tube and shell cooler. The
cooling water first cools the air, then the fluid, and is finally discharged out of the machine.
Both air-cooled and water-cooled versions have easily accessible items such as fluid filter,
control valve, air filter, etc.
2. 2 Compressor Air-end
In the compressor machine set, the air-end is an important part, inside which there are a couple
of mutually fitting rotors, rotating at high speed driven under the electric motor and continuously
providing the stable and pulsation free compressed air.
When the rotor rotates to suck the air, the lubrication fluid is sprayed into the compressor body,
directly mixed with the air. Here, the fluid flow has three basic functions:
C. As coolant, it takes away the heat generated and reduces the internal leakage of the compressed
air;
C. Seals the leakage paths between the rotors and the stator and also between the rotors themselves;
C. 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 flows through the fluid air separator, the fluid and air are separated, the
air enters the service air piping, and the fluid is sprayed into the compressor once again after being
cooled.
regulating valve. It can regulate the cooling water flow based on different loads of the machine set.
When the machine is stopped, the valve is closed automatically, playing the role of shut-off valve.
Besides, the water-cooled machine set has one hydraulic switch to ensure the operation of the
compressor under appropriate water pressure.
Fluid Thermal
filter valve
Fluid/air cooler
Sump tank
Moisture separator
Separator element
Minimum pressure
/check valve
Fluid filter
Thermal
Valve
After cooler
Moisture separator
Straine Sump
ressure tank
regulator
valve
To separator dp gauge
Blowdown valve
Pressure switch
Solenoid valve
Shuttle valve
The air inlet valve is in the form of lifting valve, and its opening extent is regulated by the
pressure regulator based on the air demand volume. Please refer to 2.5 and 2.6 for details. When the
machine is stopped, the air inlet valve is closed, playing the role of check valve.
16 series
12 series
2. 8 Monitoring Instrument
Refer to Fig. 7. The location of each instrument is shown in the diagram, which includes line
pressure gage, pressure gage of sump tank, air discharge thermometer, separator pressure difference
meter, fluid filter dp gauge, switch button and hourmeter.
The function of each instrument is described as follows:
Line pressure gauge (P2): Located after minimum pressure valve, connecting with the dry side of
sump tank, indicating the air supplies pressure.
Pressure gauge of sump tank (P1): Indicating the pressure of sump tank.
Air discharge thermometer (T1): Monitoring the temperature of the compressor discharge air. In
normal case, the air discharge temperature through air cooling and
water cooling shall be between 180 F and 225 F (82 C – 107 C).
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 2: System Description
Separator dp gauge ( P1): Monitoring the status of fluid air separation element. If the separator
element has too high resistance, the indicator will point towards the red
area. At this time, the fluid air separation element will need to be
replaced.
Fluid filter dp gauge ( P2): Monitoring the status of the fluid filter. If the filter resistance is too high,
the indicator will point towards the red area. At this time, the filtering
element will need to be replaced.
Start button: Control the machine start.
Stop button: Control the stop.
Hourmeter: Reflecting the accumulated operation time of the compressor. This parameter can be
referenced during the operation and maintenance.
Amber light on: Indicating the machine in auto run status.
Red light on: Indicating the compressor is power energized.
Green light on: Indicating the compressor in operation.
Manual/auto switch: Choose manual or auto control mode.
Air filtering vacuum meter: Monitoring the status of the air filter. When the indicator points towards
the red area (20~30” water column 51~76cm), the filtering element must
be replaced.
Hourmeter
Power
Auto
Operation
Start Fluid filter dp gauge
Stop
Manual/auto
Fig. 7 Monitoring Instrument
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 3: Performance Parameter and Use of Fluid
Mixing of other fluid within the compressor unit will void all warranties!
If it is really necessary (or due to other reasons) to add other types of fluid, please follow the
instruction of 3.4.
! Note
Before replacing the fluid, first clean the fluid loop system. If the ambient temperature exceeds the
limit or the fluid exceeding the service life is used, please contact Sullair.
Before observing the machine, cut off the power. The electric circuit check can ensure no failure
before the initial starting of the compressor.
! Danger
High voltage inside. Be careful for electric shock. Before dismantling for maintenance,
disconnect all the power.
A Check if the incoming voltage meets the requirement;
B. Check the model of the starter and overload hot relay (see parts list);
C. Check to see if each electric circuit joint is reliable;
D. “Simulation operation”: Cut off the motor terminal line from the power, press the starting button,
and check if the contactor is in normal operation.
E. Re-connect the motor terminal, test run the motor as described in 4.8, and check if the rotating
direction is correct.
! Note
The wiring diagram for standard compressor is in the electric control box, and the wiring diagram
of the special compressor is different.
driving shaft is rotating clockwise, then the rotating direction is correct; if the rotating direction is
incorrect, cut off the power. Exchange any two power lines and try again after they are connected.
There is one decal on the coupling to indicate the rotating direction.
Checking if the electric motor is normal can be judged through if the sump pressure gauge on the
instrument panel has pressure indication. Press the starting button. If the gauge has pressure indication
immediately, it means the electric motor has normal rotating direction. In case of no pressure
indication, it means the motor has abnormal rotating direction. Press the stop button immediately, cut
off the power and test again based on the above method.
5. 3 Initial Start-up
1. Carefully read the preceding pages of this manual.
2. Ensure to complete the preparations and checks as described in the section of installation.
3. Open the shut-off valve to the service line.
4. Press start button to start the machine.
5. Check for possible leaks in piping.
6. Slowly close the shut-off valve, and check to see if the pressure switch unloads under set pressure.
If incorrect, please refer to the parts replacement and adjustment in 7.8.
7. Check the operation temperature. If the operation temperature exceeds 225 F (107 C), check the
cooling system and environment situation.
8. Check the fluid reflux status through the return line sight glass; check if there is signal for
maintenance requirement.
9. Open the shut-off valve to service line.
10. Check the operation temperature and leakage status the following day.
5. 4 Subsequent Start-up
After checking the fluid level, press the start button to start the machine set. During the operation
period, check each operation parameter.
5. 5 Shutdown
Press the stop button.
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 5: Compressor Operation
After pressing PRG key, the supervisor enters the programming mode. At this time, the set
values of some parameters can be changed. After entering the programming mode, PRG key is
used for selecting parameters. When resetting parameters, press up arrow or Sullair logo key to
increase the parameter. Press down arrow to reduce the parameter. When pressing the Sullair logo key,
the parameter increment is 10.
UNLD
100PSI
Load pressure difference --- Difference between load pressure and unload pressure. If the unload
pressure is set at 110 psig (7.6bar) and the load pressure difference is set at 10 psig (0.7bar), when the
line pressure is lower than 100 psig (6.9bar), the machine set will be loaded.
LOAD
10PSI
P1 Max --- Maximum pressure of the sump tank. If the sump pressure exceeds this value, the
supervisor will stop the machine and meanwhile indicate the warning signal.
P1 Max
135PSI
Y- Switching time (sec) --- If full voltage starter is used, this parameter is set at zero.
WYE DELT
10 SEC
Restart time --- Waiting time required for starting the machine set after power is connected.
Through setting this parameter, it can avoid simultaneous starting of several machine sets. Similarly, it
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 5: Compressor Operation
enables to start the machine set after other equipment is started. If there is no such a parameter, the
machine set won’t be started automatically after the power is re-connected.
RST TIME
10 SEC
Unload time lag (minute) --- If the machine set is in auto run mode, after the idle run exceeds the
set time, the supervisor will stop the machine. If the set value is less than 15 min (e.g. 5 min), the idle
run time before the machine stop may exceed the set value (5 min). This is because the machine set is
also equipped with one hourmeter, used for controlling the starting no more than 4 times within one
hour.
UNLD TLM
15MIN
Language selection --- Choose language used for display (English, Spanish, French, German or
Italian).
LANGUAGE
ENGLISH
UNITS
ENGLISH
Machine set number --- Network address of the machine. If more than two machines are used in
network, each machine has its exclusive number.
COM ID#
1
Communication speed (BAUD)--- Sequence control normally adopts 9600, and low speed can be
adopted for other controlling methods.
BAUDRATE
9600
Sequence control method --- Set the method for sequence control. The option has DISABLED,
REMOTE, SLAVE, HOURES, COMID#. For the details of each option, see sequence control and
communication protocol.
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 5: Compressor Operation
SEQUENCE
HOURS
Drain interval (min) --- Time for closing draining valve between two times of drainage.
DRN INTV
10MIN
DRN TIME
1 SEC
Max machine set number --- Only used during sequence control. See sequence control and
communication protocol.
LAST COM
3
Lowest allowable pressure --- Only used during sequence control. See sequence control and
communication protocol.
LOWEST
90 PSI
Recovery time --- Only used during sequence control. See sequence control and communication
protocol.
RECOVER
10 SEC
Rotating time --- Only used during sequence control. See sequence control and communication
protocol.
ROTATE
50HOURS
Machine set air supply capacity --- Only used during sequence control. See sequence control and
communication protocol.
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 5: Compressor Operation
CAPACITY
100
Sequence control time --- Only used during sequence control. See sequence control and
communication protocol.
SEQ HRS
1000
operation and at auto run mode, press I key to switch the operation mode to manual mode. If the
compressor is already in manual operation, press I key to make supervisor close the common
failure relay (if connected) and turn off the indication light to indicate the alarm signal.
To stop the machine, press O key. If the machine is already stopped when O key is
pressed, it will disconnect the common failure relay (if connected), remove alarm signal and turn off
the maintenance signal indication light. Whatever the compressor is doing, press O key to make
empty load, it will be stopped. To make the compressor at auto mode, press key. At this time, if
P2 is lower than “LOAD” value, the compressor will be started immediately; otherwise, the system
status displayed in the supervisor is “STANDBY”, while the display marked with “AUTO” will flash.
If the compressor is in operation but under manual mode, press key to switch the
operation mode to auto status. If the compressor is in auto operation, press key to make the
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 5: Compressor Operation
supervisor disconnect the common failure relay (if connected) and turn off the maintenance signal
indication light.
Under auto mode, press O key to stop the machine. The use of O key to stop the
5. 10 Relay Description
Peripheral Application
Operation relay (KI) Connect the compressor starter after closed.
* (K2) Timing close, being form starting and providing switching
time lag.
Unload/load (K3) Control the on load/off load operation of the solenoid valve.
Common failure (K4) Used for remote display of alarm signal or failure reason.
Draining valve (K5) Control the solenoid valve, and automatically remove the
condensing water.
Full load/regulation (K6) Used during sequence control.
After checking the fluid level, press the start button I (manual) or (auto) to start the
machine set. During the operation period, check each operation parameter.
5.13 Shutdown
Section 6 Supervisor II
6. 1 Introduction
Fig. 10 and Section 5 describe the basic knowledge of the compressor supervisor. The supervisor
displays the temperature, pressure, time and working status through LCD (liquid crystal display). LCD
can display two lines of data, the operator can control the compressor through keypad, set and control
parameter and choose the displayed parameter. The indication light on the system diagram shows the
location of the displayed parameters. When the light is on, it displays the parameter in this place; when
the light is flashing, then this location is in the alarming status.
6. 2 Keypad Description
See Fig. 7. In addition to used for controlling the machine set, the keypad is also used for displaying
parameters and modifying the set value of some parameters.
Manual --- Starts machine if no alarm conditions are present, and meanwhile choose manual
run mode. Also used to clear alarm conditions while machine is running.
Auto --- Starts machine and selects auto mode if no alarm conditions are present.
Display --- Used to display pressure, temperature and other status information.
Up arrow --- Change display item under the status display mode. Increase the value under
6. 3 Status Displays
By default the line pressure (P2) and discharge temperature (T1) are shown on the bottom line of the
display, and machine status on the top line. The following are the various machine status messages that
indicate the state of the compressor with LCD graphics listed below:
Stop (STOP) --- The compressor is off.
Standby (STANDBY) --- The machine set stops operation for the time being.
In case of power failure or unload timer had expired, the machine set enters the standby status.
Note that the machine set under this status may be started at any time.
Starting (STARTING) --- The machine set is trying to start.
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 6: Supervisor II
Off load (OFF LOAD) --- The machine is running and off loaded.
On load (ONLOAD) --- The machine is running and loaded.
Full load (FULL Ld) --- The machine set is in full load operation. This status is only displayed when the
Sequence control forces the full load solenoid valve to fully open.
Remote stop (RMT STOP) --- The machine set stops operation. After the remote starting contact is
closed, the machine set will be restarted. Note that the machine set under this status may be started
at any time.
SEQ stop (SEQ STOP) --- The machine set stops operation. After meeting the starting condition specified
by the program, the machine set will be restarted. Note that the machine set under this status may be
started at any time.
The default display appears as follows:
STIP
110 180
In case of failure signal, the failure signal will be displayed with default signal alternately, with 2
seconds for each display. The failure signal display is as follows:
T1 HI
110 180
To display other parameters, press DSPL key. Under this status, observe the temperature, pressure
value, operation time and other parameters. The user can choose the parameters to be displayed through
up arrow and down arrow. Press up arrow to display the parameter in the next screen, and press down
arrow to display the parameter in the previous screen. To return to the default status from the display
status, press DSPL key.
Pressure difference before and after the separator (dp1) and max allowable pressure difference (MAX).
If dp1 is greater than MAX, the supervisor will generate alarming signal.
P1 4
MAX 10
Sump tank pressure and line pressure.
P1 113
P2 108
Unit discharge temperature (T1) and max allowable value of T1 (MAX). If T1 exceeds MAX, the
supervisor will stop the machine and meanwhile display “T1 H1”.
T1 210
MAX 235
Total time that the compressor has been running (hour)
HRS RUN
1234.0
Total hours that the compressor has been loaded (hour)
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 6: Supervisor II
HRS LOAD
987. 0
Last fault log, and record the last fault signal activating the machine stop and the accumulated
running hours when it takes place.
T1 HI
@1234
Next to last fault log, and record the next to last fault signal activating the machine stop and the
accumulated running hours when it takes place.
T1 HI
@2 204
6. 4 Lamp Indicators
Embedded into the front panel schematic of the compressor are several lamps. To check the running
status of the lamp indicators, press the lamp test key, most of lamp indicators will be on for about 3
seconds. The function of each lamp is as follows:
P1 --- Indicating the sump tank pressure. If the light is stable, it displays P1. If it is flashing, it indicates
the supervisor has generated the alarm.
P2 --- Indicating the line pressure. If the light is stable, it displays P2. If it is flashing, it indicates the
supervisor has generated the alarm.
P1 --- (Pressure difference before and after separator). If the light is stable, it displays P1. If it is
flashing, it indicates the separation element needs to be replaced.
P2 --- (Pressure difference before and after fluid filter). If the light is stable, it displays P2. If it is
flashing, it indicates the separation element needs to be replaced.
T1 --- Indicating the main unit discharge temperature. If the light is stable, it displays T1. If the light is
flashing, it indicates the supervisor has generated the alarm.
T2 --- Indicating the dry side discharge temperature. If the light is stable, it displays T2. If the light is
flashing, it indicates the supervisor has generated the alarm.
MOTOR --- If the indication light is flashing, it indicates the main motor overloading contact is already
disconnected (main motor overloading).
INLET FILTER --- Air filter indication light. If the indication light is flashing, it indicates the inlet filter
needs maintenance.
POWER --- Power indication light. If the supervisor is connected with 120V AC power, this indication
light is always on.
ON --- Operation indication light. If the compressor is in operation, this light is illuminating stably. If the
indication light is flashing, it indicates the compressor is in the standby status and may be started at
any time. Restarting hourmeter not activated, remote stop or sequence stop will make the machine
set enter the standby status.
AUTO --- Auto run indication light. If the machine is in auto run status, this light is illuminating stably. If
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 6: Supervisor II
the indication light is flashing, it indicates the compressor is in the standby status and may be started
at any time. Restarting hourmeter not activated, remote stop or sequence stop will make the machine
set enter the standby status.
Fig. 10 Supervisor
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 7: Maintenance
Section 7 Maintenance
7. 1 General
As you proceed in reading this section, it will be easy to see that the Maintenance Program for the
air compressor is quite minimal. Such parts as air filter, fluid filter and fluid/air separator are monitored
with the relevant instrument. In case of problem, the monitoring instrument will generate the alarming
signal. Before the maintenance, refer to 7.8 parts replacement and adjustment.
7. 2 Daily Maintenance
Prior to starting the compressor, it is necessary to check the fluid level. If the fluid level is too low,
you need to add the fluid. If the machine needs to add the fluid frequently, then you need to check the
machine --- Refer to troubleshooting, find out the failure reason and take remedial measures.
After starting, check to see if each display value is normal. After the machine set temperature is
increased, it is better to check comprehensively the compressor and supervisor.
! Warning
Do not remove caps, plugs, and /or other components when compressor is running or pressurized.
Stop compressor and relieve all internal pressure before doing so.
7. 5 Fluid Maintenance
Based on the description of 3.2, 3.3 and 3.4, replace the fluid in the machine set.
Filter head
Gasket*
Element*
Cover
Sump tank
The pressure difference is the difference between the max operation pressure and min operation
pressure, normally set at 10 psig (0.7bar).
1. Set lowest operation pressure through pressure difference adjustment screw. Turn
counterclockwise to increase the pressure difference.
2. After the pressure switch is adjusted, adjust the pressure regulator and determine the pressure
starting the air volume regulation. In the example given, this pressure is 118 psig (8.2bar). After
loosening the lock nut at the bottom of the pressure regulator, turn the adjustment screw
clockwise to increase the set value and counterclockwise to decrease the set value.
Terminal B
Terminal C
Contact block
Terminal A
Range adjustment
3. Close the service valve. When the line pressure reaches 118 psig (8.2bar), the pressure regulator
shall send the controlling air into the air inlet valve, and reduce the openness of the air inlet valve.
If the line pressure continues to rise or the air inlet valve is not acted, adjust based on the Step 2.
After adjustment, the line pressure shall be around 118 psig (8.2ba), while the air inlet shall have
a vacuum extent of 1.00in.Hg (2.54cm).
4. Still don’t open the service valve, allowing the line pressure to go on increasing. When the line
pressure reaches 125 psig (8.6bar), the air inlet valve is closed completely. The vacuum extent at
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 7: Maintenance
air inlet is about 25.00 (63.5cmHg) in.Hg. The machine set starts to unload.
5. Open the service valve to reduce the line pressure to 115 psig (7.9bar), and check if the machine
set starts the load operation. Repeat the load and unload for several times, and check if the set
pressure is correct. Unload at 125 psig (8.6bar), and then check the pressure of sump tank during
unloading. Stop the machine, open the cover of the pressure switch, take out any one of the
conducting wire connecting the contact, and wrap with insulation tape. To get the correct reading,
the line shall be kept at the pressure of 80 psig (5.5bar).
! Danger
Do not touch the electrical contacts, terminal or leads with any metallic object. Severe electrical
shock may occur.
Turn on the machine to stabilize the pressure of sump tank. The correct reading is 12-20psig
(0.8-1.4bar).
Stop the machine after check. Connect the conducting wire and cover. Load and unload for
several repeated times, and check if the set pressure is correct.
Don’t hold the un-insulated metal conducting wire or directly use the body to touch the energized
contact, joint and conducting wire. Be careful of electric shock.
Gap
Refer to Fig. 15. Coupling installation and maintenance needs one measuring scale, one English
inner hexagonal wrench and one socket wrench. The installation procedure is as follows:
! Warning
Before installation and adjustment, please disconnect all power at source.
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 7: Maintenance
Note:
Don’t use other bolts to replace the flat-head bolts provided together with the coupling.
Tighten the bolt. After tensioning the screw, loosen the hose clamp. Check the coupling gap based
on Table 1 and Fig. 15.
Flexible element
Flange hub
Hose clamp
Flange hub
Fig. 16 Coupling
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 7: Maintenance
Dismantle coupling
See Fig. 16. The dismantling procedure is as follows:
1. As per drawing indication, use the hose clamp with appropriate tensioning size to compress the
volume of the flexible element.
2. Loosen the flat-head bolt.
3. Turn the flexible element till the screw on the hub is exposed.
4. Take out the flexible element with hose clamp still in place.
5. Loosen the screw on the shaft and take out the hub.
Fluid level in fluid air Check fluid level. When necessary, add fluid.
separator is too low
Thermal valve failure Check thermal valve and replace thermal control
element.
Cooler fin is too dirty (for Clean cooler fin
air-cooled machine set)
Fluid filter is plugged, and Replace fluid filter
bypass valve failure
Too high ambient Improve ventilation condition
Discharge temperature
temperature Too high resistance of user’s 1. Enlarge ventilation pipe.
T1 too high external ventilation pipe 2. Set exhaustion fan in the pipe.
Insufficient cooling water Check cooling water supply status.
flow (water-cooled machine
set)
Too high cooling water Increase cooling water flow and reduce water
temperature temperature
Cooler is plugged Clean tube and use clean cooling water
(water-cooled machine set)
Temperature RTD Check RTD connection. If connection is good, replace
malfunction RTD.
Unloading device (e.g. Check if unloading device action is proper
blowdown valve, air inlet
Too high air
valve, optional screw valve)
discharge
failure
pressure (tank
Pressure regulator failure Check pressure regulator
pressure) P1
Unload solenoid valve failure Check solenoid valve
Controlling air tube leakage Check if controlling tube is leaked
Controlling air tube filter is Repair filter assembly
clogged
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 7: Maintenance
Fluid air separator filtering Replace fluid air separator filtering element
element is clogged
Minimum pressure valve Check/repair minimum pressure valve
failure
Air consumption is greater (1) Reduce air consumption;
than air supply (2) Check if any leakage on the air transmission pipe
Air filter is clogged Replace filtering element
Air supply Air inlet valve can’t be fully Check the air inlet valve action and setting of pressure
pressure is opened regulator
lower than Loose pressure transducer Check transducer contact. If the joint is good, replace
rated joint pressure transducer
discharge Minimum pressure valve – Check / repair butterfly valve at fluid discharge
pressure butterfly valve failure connection
Optional screw valve is Check screw valve pressure regulator
opened
Fluid air separator filtering Check and replace fluid air separator filtering element
element is blocked
Pressure transducer P2 failure Check transducer contact. If the contact is good,
replace transducer
Unload device (e.g. Check operation of unload device
Line pressure
blowdown valve, air inlet
P2 higher than
valve, optional screw valve)
set value of
failure
unload
Unload solenoid valve failure Check operation of solenoid valve
pressure
Controlling air tube leakage Check if controlling air tube has air leakage
Controlling tube filter is Repair filter assembly
clogged
Return line strainer or orifice Clean strainer filtering net and orifice. If necessary,
is plugged. replace with spare part.
Excessive Filtering element or washer of Check filtering element and washer. If damaged, they
fluid fluid air separator is damaged must be replaced
consumption Lubricant system leakage Check fluid tube system
Too high fluid level Discharge excessive fluid.
Too much foam Discharge and replace fluid
LS12-50&LS16-60/75LF Screw Compressor O & M Manual Section 7: Maintenance
CAL P1
0 6.7
Take the above display as an example: “0” indicates regulation volume (with PSI or F as a unit).
6.7bar indicates current value of P1. To make adjustment, press “ ” key (up arrow) to increase value
and “ ” key (down arrow/indicator test) to reduce value. The value on left will be increased or
reduced and display the total regulation volume. The max regulation range is 7.
Press “DISPLY” key to exit the calibration mode, save all the previous option changes but don’t
save the change of current option. Press “PROG” key to save the current option and enter the next
option. All the temperature and pressure values can be calibrated separately.
Solenoid valve
Separator element Shuttle valve
dp gauge
Sump pressure gauge Minimum pressure/check
Control pressure valve
regulator valve
Control line orifice Shuttle valve
Sight glass
Air inlet valve
Check valve
Discharge
Compressor unit
temperature gauge Thermal valve
Water-cooled
after cooler
Pressure switch
Water-cooled
fluid cooler
Sight glass
Air inlet valve
Check
valve
Motor Fluid filter
dp p switch
Sump tank
Compressor unit
Compressor P3 Flulid pressure
temperature
RTD T1
Water-cooled
after cooler
Air-cooled
Moisture separator fluid and
after cooler
Note: When ordering spare parts, please indicate the compressor model, serial number and
BOM number so that we can provide better service for you.
Global Sales & Service
SULLAIR CORPORATION
Subsidiary of Hamilton-Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 001-219-879-5451 or1
1-800-Sullair (U.S.A. only )
Fax: 001-219-874-1273
Fax: 001-219-874-1835 (Part s)
Fax: 001-219-874-1805 (Service)
SULLAIR SINGAPORE
74Joo Koon,Circle,Jurong,Singapore 629093
Tel: (65)68611211 Fax:(65)68612967 68617163