Industrial Air Compressor Sullair

INDUSTRIAL
AIR COMPRESSOR
LS25S 250/300/350HP
STANDARD AND 24KT
OPERATOR’S
MANUAL AND
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Part Number 88290006-554
eSullair Corporation
AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are 3--day courses that provide hands--on instruction
in the proper operation, maintenance and service of Sullair equipment.
Individual seminars on Industrial compressors and compressor electrical
systems are presented at regular intervals throughout the year at a dedicated
training facility at 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 actual equipment
operation. The seminars are recommended for maintenance and service
personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1--888--SULLAIR or 219--879--5451 (ext. 5363)
-- Or Write --
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
Thank you for Choosing Sullair products. This manual cover the operation,
maintenance and trouble shooting of Sullair rotary screw compressors. Before
operating the compressor, please familiarize yourself with this manual
thoroughly.
At Sullair, we are committed to continuous product improvement. While all
attempt will be made to update the manual, Sullair reserves the right to make
changes to the product without prior notice.
Production license number: XK06-110-00019

Compressor model: ____________________
Compressor serial number:_________________
PREFACE
This manual describes in detail the system structure, function, usage and
maintenance method of Model LS25S-250/300/350 screw compressor
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.
Special fluid provided by Sullair Co. must be used. It is prohibited to mix
different brands of fluid. The user should be aware of it.
From time to time, the product is being redesigned to seek improvement.
After certain period, there will be discrepancies between this manual and the
product itself. The user should be aware of it.
---- Editor
May, 2003
TABLE OF CONTENTS
SECTION 1 COMPRESSOR SYSTEM

1.1 General -------------------------------------------------------------------------------------------- 1
1.2 Air Inlet System---------------------------------------------------------------------------------- 9
1.2.1 Operation Of Air Inlet System------------------------------------------------------------------ 9
1.2.2 Air Filter------------------------------------------------------------------------------------------- 9
1.2.3 Butterfly Valve ------------------------------------------------------------------------------------9
1.3 Discharge System ------------------------------- --------------------------------------------------9
1.3.1 Operation Of Discharge System-----------------------------------------------------------------9
1.3.2 Minimum Pressure Valve ------------------------------------------------------------------------9
1.3.3 Automatic Blow-Down Valve ------------------------------------------------------------------10
1.3.4 Pressure Relief Valve----------------------------------------------------------------------------10
1.3.5 Discharge System (Air-Cooled) ---------------------------------------------------------------10
1.4 Fluid Piping System ------------- --------------------------------------------------------------- 10
1.4.1 Operation Of Fluid Piping System ------------------------------------------------------------10
1.4.2 Thermal Valve --- ---------------------- ---------------------------------------------------------11
1.4.3 Fluid Stop Valve ---------------------------------------------------------------------------------11
1.4.4 Fluid Filter--------------------------------------------------------------------------------------- 11
1.4.5 Return Line -------------------------------------------------------------------------------------- 11
1.4.6 Fluid Piping System(A ir-Cooled)------------------------------------------------------------- 12
1.5 Fluid/Air Separator ------------------------------------------------------------------------------ 12
1.5.1 Functional Description------------------------------------------------------------------------- 12
1.5.2 Replacement Of Filter Element --------------------------------------------------------------- 12
1.5.3 Fluid Filling Pipe And Sight Glass --------------------------------------------------------- --13
1.6 Water Piping System ---------------------------------------------------------------------------- 13
1.6.1 Operation Of Water Piping System ----------------------------------------------------------- 13
1.6.2 After Cooler -------------------------------------------------------------------------------------13
1.6.3 Fluid Cooler -------------------------------------------------------------------------------- -----13
1.6.4 Automatic Moisture Separator ---------------------------------------------------------------- 13
1.6.5 Cooling Water Quality --------------------------------------------------------------------------13
1.6.6 Temperature, Pressure & Construction Of Water Inlet ---------------------------------------14
1.6.7 Shutdown And Drainage ---------------------------------------------------------------- ------ 14
1.7 I nstrumenatation And Control------------------------------------------------------------------14
1.8 Supervisor II --------------------------------------------------------------------------------------16
1.8.1 Functional Description ------------------------------------------------------------------------- 16
1.8.2 Keypad ------------- ------------------------------------------------------------------------------ 17
1.8.3 Status Display ----------------------------------------------------------------------------------- 18
1.8.4 Lamp Indicators --------------------------------------------------------------------------------- 20
1.8.5 Parameter Setup ---------------------------------------------------------------------------------21
SECTION 2 INSTALLATION
2.1 Mounting ----------------------------------------------------------------------------------------24
2.2 Vibration Absorption And Noise Reduction------------------------------------------------ 24
2.3 Ventilation And Cooling -------------------------------------------------------------------- ---24
2.4 Overall Arrangements A nd Mounting Illustration ------------------------------------------24
2.5 Installation (Air-Cooled Version) -------------------------------------------------------------24
2.6 Motor Rotation Direction Check-------------------------------------------------------- ----- 25
SECTION 3 OPERATION
3.1 Safety ---------------------------------------------------------------------------------------------31
3.2 Initial Start -Up Procedure --------------------------------------------------------------------- 31
3.3 Subsequent Start-Up Procedure ---------------------------------------------------------------31
3.4 Shutdown Procedure ---------------------------------------------------------------------------31
SECTION 4 MAINTENANCE
4.1 General ------------------------------------------------------------------------------------------- 32
4.2 Daily Maintenance ----------------------------------------------------------------------------- 32
4.3 Maintenance After Initial 50 Hours Of Operation ------------------------------------------32
4.4 Maintenance Every 1000 Hours --------------------------------------------------------------32
4.5 Fluid Replacement ------------------------------------------------------------------------------32
4.6 Fluid Filter Maintenance ----------------------------------------------------------------------- 32
4.7 Air Filter Maintenance ------------------------------------------------------------------------- 33
4.8 Fluid/Air Separator Maintenance -------------------------------------------------------------34
4.9 Fluid Stop valve Maintenance ---------------------------------------------------------------- 35
4.10 Pressure Regulator Maintenance------------------------------------------------------------- 35
4.11 Minimum P ressure Valve Maintenance ------------------------------------------------------36
4.12 Blow Down Valve Maintenance -------------------------------------------------------------- 36
4.13 Control Line Strainer Maintenance ---------------------------------------------------------- 37
4.14 Solenoid Valve Maintenance ------------------------------------------------------------------38
4.15 Coupling Installation And Maintenance -----------------------------------------------------39
4.16 Maintenance Of Special Motor On Sullair Compressor ----------------------------------- 40
SECTION 5 WIRING DIAGRAM

5.1 Wiring Diagram (Water-Cooled) ------------------------------------------------------------- 43
5.2 Wiring Diagram (Air-Cooled) ---------------------------------------------------------------- 44
5.3 Wiring Diagram For High-Voltage Machine (Air -Cooled/Water-Cooled) ------------- 45
SECTION 6 TROUBLESHOOTING AND REMEDY

6.1 General---------------------------------------------------------------------------- --------------- 46
6.2 Probable Problems And Troubleshooting------------------------------------------------------46
6.3 Transducers Operation And Supervisor Calibration -----------------------------------------47
SECTION 7 RECOMMENDED PARTS LIST ----------------------------------------------- 49

LS25S-250/300/350 Series Screw Compressor O & M Manual Section 1 Compressor systems
SECTION 1 COMPRESSOR SYSTEM

1.1 GENERAL
This machine is a motor -driven screw compressor of single-staged, fluid -injection,
water-cooled type featuring quiet operation. The machine mainly consists of compressor,
electric motor, separator, cooler, after cooler and frame, and is built in an acoustical enclosure,
on one side of which there is an instrumental panel. The machine features compact structure,
attractive appearance and ease of operation.
Either air-cooled or water-cooled version is available to meet your specific requirements.

For detailed specifications, refer to Table 1 below: Compressor Specifications.
Table 1 Compressor Specifications
TYPE 250 300 350

Motor Type 445TS 447TS 449TS
Rated Power kW(HP) 188(250) 225(300) 263(350)
Rated Revolution, 1480 1478 1480
rpm
Voltage/Frequency 380V/415V,50Hz 380V/50Hz 380V/50Hz
Service Factor 1. 15
Ambient Temp. ? =40
Start-Up Mode Y-?
Weight, Kg(Lb) 5200(11460) 5400(11900) 5420( 11950)
L×W×H, mm 3048×2210×2139
Compressor Type Fluid-Spraying Double Screw Compressor
Configuration Single Stage Displacement
Bearing Anti-friction
Fluid Makes Sullube32/ 24KT
Fluid Capacity (L) 189
See Fig. 1: Overall Arrangement of Type LS25S-250/300/350 (water-cooled, low-voltage)

See Fig. 2: Overall Arrangement of Type LS25S-250/300/350 (air-cooled, low -voltage)
See Fig. 3: Overall Arrangement of Type LS25S-250/300/350 (water-cooled, high-voltage)
See Fig. 4: Overall Arrangement of Type LS25S-250/300/350 (air-cooled, high -voltage)
See Fig. 5: System Flowchart of Type LS25S -250/300/350 (water-cooled)
See Fig. 6: System Flowchart of Type LS25S -250/300/350 (air -cooled)
A pair of preciously manufactured rotors engaged with each other is built in the
compressor unit, and the male rotor with 4 teeth is driven at high speed by the motor, while the
male rotor through a flexible coupling drives the female rotor with 6 teeth. With decreasing
1
volume of the enclosure between the teeth, air from the air filter is pressurized due to
compression until it is discharged when the enclosure is open to the discharge outlet. The
compressed air then goes through the separator, and then the minimum pressure valve, after
cooler and moisture separator in turn, before discharged to the service line for use. The fluid
separated subsides at the bottom of the separator and is brought back to the compressor under
pressure differential for recycling use.
2
Air supply
7 8 9 10 11 12 13 14
Water discharge
Water inlet
6
4 3 2 1
Fig. 1: Overall Arrangement of Type LS25S-250/300/350 (Water-cooled, Low-voltage)
1. Frame 2. Electrical Motor 3.Coupling 4. Compressor Unit 5. Fluid Cooler 6. Separator

7. Acoustical Enclosure 8. Pressure Relief Valve 9. Minimum Pressure Valve 10. Air Filter
11. Thermal Valve 12. After Cooler 13. Moisture Separator 14. Instrumental Panel
3
Ai r s u p p l y
7 8 9 10 11 12 13 14
Water discharge
6 Water inlet
4 3 2 1
Fig. 2: Overall Compressor Arrangement of Type LS25S-250/300/350 (Air-Cooled,

Low-Voltage)
1. Frame 2. Electrical Motor 3.Coupling 4.Compressor 5. Separator 6. Acoustical Enclosure
7. Pressure Relief Valve 8. Minimum Pressure Valve 9. Air Filter 10. Thermal Valve 11. After Cooler
12. Instrumental Panel
4
Air supply
6 7 8 9 10 11 12
Fluid inlet
Depressurized fluid
cooler return line
Fluid discharge
5
4 3 2 1
Fig. 3: Overall Arrangement of Type LS25S-250/300/350 (Water-Cooled, High-Voltage)

1. Frame 2. Electrical Motor 3.Coupling 4. Compressor 5. Cooler 6. Separator
7. Acoustical Enclosure 8. Inlet Fan 9. Pressure Relief Valve 10.Minimum Pressure Valve
11. Air Filters 12. Thermal Valve 13. After Cooler 14. Moisture Separator 15. Cord Stand
16. Instrumental Panels
5
Air supply
6 7 8 9 10 11 12
Fluid inlet
Depressurized fluid
cooler return line
Fluid discharge
5
4 3 2 1
Fig. 4: Overall Compressor Arrangement of Type LS25S-250/300/350 (Air-Cooled, High

-Voltage)
1. Frame 2. Electrical Motor 3.Coupling 4.Compressor 5. Separator 6. Acoustical Enclosure
7. Pressure Relief Valve 8. Minimum Pressure Valve 9. A ir Filter 10. Thermal Valve
11. Service Air Pipe 12. Instrumental Panel
6
8 1/4¡ ±tubing
Settings dependent on types of machine
1/4¡ t±ubing P2 23
4
1/4¡ ± tubing
32 A 32 YV3
41 7 11
YV1 B YV2
6 1 3 1/4¡ ±tubing 8
1/4¡ t±ubing
1 1
2
9 12 36
13 CYL 19
I N1¡ t±ubing 1¡ t±ubing
P
1/4¡ t±ubing
37
4
1/4¡ t±ubing
10 17 18 1/4¡ t±ubing
Water discharge
1/4¡ t±ubing
16 17 18
1/4¡ t±ubing
30
1/4¡ t±ubing
3
26
¡ £ Temperature
Temperature is set at 113 C
44 Pressure is set at 0.07MPa
15 P1 is set at ¡ £
1 24 T1 113 C
2 14
7
Air inlet T2 25
LS25S-250/300/350 Series Screw Compressor O & M Manual
42 27 22
20
28 21
5
40 29
Pressure is 560 mmH2O 32
Vacuum 38
34 P3 B A Water incoming
C (interfaceG1-1/2)
Pressure is set at 0.07MPa P4 35 H I
39 T3 33
15
Water outgoing
(interfance G1-1/2)
Section 1
Sequencing valve Solenoid valve in water

(optional) Customer supplied piping
piping (optional)
YV4 YV6 Fluid piping
43 31
Fluid/air mix piping
B A H I
Air piping
Fig. 5: System Flowchart of Type LS25S-250/300/350 (Water-Cooled)

control piping
Compressor systems
8 1/4¡ ±
t ubing
Setting dependent on type
1/4¡±
tubing P2 23
4
1/4¡ ±
t ubing
A
t ubing
32 41 32 7
11
B
6 1 3 1/4¡ ±
t ubing 8
1/4¡±
1 1
2
12 36
9 13 CYL 19
t ubing
tubing
I N 1¡ ± 1¡ ±
tubing
P
1/4¡±
37
4
1/4¡ ±
t ubing
10 17 1 / 4 ¡ ±
tubing 18
Drainage
t ubing
1/4¡ ±
t ubing
t ubing
16 17 18
30
1/4¡±
1/4¡ ±
3
26
Temp. Set at¡ £
44 113 0C degree
15 P1 ¡ ã
1 24 T1 Pressure set at0.98MPa Temp. Set at 113 C
Air inlet 2
T2 25
8
27 22
42
20
28 21
5 46
40 29
mmH2O 45 14
32
Pressure is 560 mm Hg 38 DN50tubing
B A
Vacuum 34 P3
Pressure set at 0.07MPa C
T3 33 P4
39 DN15tubing
15
47 35
Temp. set at
¡ £
46 0C degree
DN15tubing
Section 1
DN50tubing
Sequencing valve Service line

(Optional) Fluid line
43
Fluid/air mixture line
B A
Air line
Control line
Fig. 6: System Flowchart of Type LS25S-250/300/350 (Air -Cooled)

Compressor systems
1.2 AIR INLET SYSTEM

1.2.1 OPERATION OF AIR INLET SYSTEM
The air inlet system mainly consists of air filter, air modulating device, butterfly valve and
compressor unit.
During operation of the machine, the air intake from the air filter to the compressor enters
the compressor unit through opened butterfly valve after being filtrated. Male and female
rotors that rotate at high speed then compress the air, and the air pressure will rise. When the
enclosure between teeth is opened to outlet, the compressed air is discharged from the
compressor for use.
1.2.2 AIR FILTER
Air filter keeps air inlet clean by filtration. Any foreign material contained in the air inlet
will cause accelerating wear and tear of the rotor contours and contaminate the fluid.
1.2.3 BUTTERFLY VALVE
Butterfly valve functions to regulate the amount of air intake to the compressor. The
butterfly valve is fully opened as the compressor unit operates in full-load condition. When air
demand decreases, the air -modulating device will reduce openness of the butterfly valve to
reduce the amount of air intake. When there is no need of air, the butterfly valve is fully closed,
and the compressor runs in unload mode.
1.3 DISCHARGE SYSTEM

1.3.1 OPERATION OF DISCHARGE SYSTEM
The discharge system consists of compressor unit, fluid/air separator, minimum pressure
valve, blow -down valve, pressure relief valve , after cooler, moisture separator and
interconnections.
The compressed air/fluid mixture enters the separator through the check valve. Clean
compressed air is obtained after separated from the fluid.
The compressed air then enters, through minimum pressure valve, after cooler and
moisture separator. The after cooler lowers the temperature of the hot air down to normal
temperature. The moisture separator separates condensed water from the compressed air and
discharges the water outside the machine.
There is a spare flange of Rc4 external threads fixed at one end of the moisture separator.
Prior to operation of this machine, a piece of f 114×6 seamless steel pipe with one end R4 taper
threaded should be prepared beforehand and used to direct the compressed air outside the
machine. The user according to specific requirements may determine the length of the steel
pipe.
The user on the external line should equip a check valve.
1.3.2 MINIMUM PRESSURE VALVE

The minimum pressure valve, located on top cover of the separator, is to keep the
9
pressure within the separator no lower than 0.34 Mpa so that the fluid runs normally in the
fluid pipe s and the fluid consumption is reduced. The minimum pressure valve does not open
until the pressure within the separator is higher than 0.34 Mpa. This valve also acts as a check
valve when the compressor unit operates in connection with other units. The compressed air in
the pipelines is prevented from flowing back into the separator or compressor unit during
offload operation of the compressor unit.
1.3.3 AUTOMATIC BLOWDOWN VALVE

The blow-down valve, located near the minimum pressure valve, opens automatically
when the compressor is unloaded or shut down, to discharge the air and relieve the sump
pressure. There are two silencers attached on the blow-down valve to lower the noise.
1.3.4 PRESSURE RELIEF VALVE

There is a pressure relief valve on the separator tank, which opens to relieve the
pressure once the separator pressure exceeds the preset pressure for the sake of the machine.
The compressor is also equipped with a high-pressure shutdown switch to shut down the
compressor when the preset pressure is reached. The pressure relief valve does not open under
normal condition.
1.3.5 DISCHARGE SYSTEM (AIR-COOLED)

There are two separate units for the air-cooled version. External flanges are installed at
both discharge end of the compressor and the inlet/outlet of the after cooler, respectively . The
compressor unit and cooler should be positioned properly before proceed with connecting the
compressor unit and the cooler with a f 108×4 seamless steel pipe. The pipe should be
supported and positioned securely , to ensure no stress is transferred from connection pipe to
the compressor unit or cooler. Keep the distance between the compressor unit and the cooler
not less than 1 meter when mounted, to ensure good ventilation and ease of maintenance.
There is an external flange beneath the horizontal moisture separator. The flange should
be welded with a f 108×4 seamless steel pipe to direct the compressed air to working place.
Please note that user should install a check valve on service air pipe.
1.4 FLUID PIPING SYSTEM
1.4.1 OPERATION OF FLUID PIPING SYSTEM

This system consists of compressor unit, fluid/air separator, thermal valve, fluid filter,
fluid cooler, fluid stop valve and interconnections.
The fluid in the separator enters the cooler through the thermal valve first, and then to the
compressor unit through the Tee valve, stops valve and the fluid filter after being cooled. The
fluid together with the compressed air intake is compressed in the compressor unit and the
compressed fluid/air mixture is discharged and returned to the separator again for another
10
cycle.
The fluid flow has three basic functions:-
a. Cooling. It removes large amount of heat due to compression from the compressed air.
b. Lubricating. A film between the pair of rotor avoids one rotor directly contacting the
other, thus, reduce wear and tear. In addition, the fluid lubricates bearings and gears.
c. Sealing. The fluid of some viscous ness fills the gaps between the rotors and that
between the rotors and the stator, thus, reduces internal leak loss and improves
compressor output.
1.4.2 THERMAL VALVE

The thermal valve keeps the flu id temperature not lower than 91 ? to prevent
compressed air from condensation that may cause deterioration due to oxidation in the fluid.
There is a constant-open bypass valve in the thermal valve. When the fluid temperature is
lower than 91? , the fluid enters the compressor unit directly through bypass valve, fluid pipe,
Tee valve, fluid stop valve and filter. At this time, the fluid is not cooled, and when the fluid
temperature rises above 91? , the bypass valve closes and the fluid enters to the fluid cooler for
cooling before enters to the compressor unit through Tee valve, stop valve and fluid filter.
1.4.3 FLUID STOP VALVE

The function of STOP VALVE is to stop fluid from entering the compressor unit and
from injecting from air inlet while the machine is shut down.
1.4.4 FLUID FILTER

Fluid filter removes foreign substance from the fluid and maintain clean fluid flowing
inside the machine and through each lubrication points. Any foreign substance within the fluid
will cause the damage to the contour surface of the rotors, gears teeth and bearings, thus,
reduce the lifetime of the compressor unit.
Replace the filter elements periodically to keep the fluid pipe work properly.
A pressure differential gauge is installed on the top of the fluid filter. W hen the pressure
differential between the two ends of filter element is higher than the setting (0.14Mpa), the
message of FLUID FILTER MAINT REQD shown on the display will remind operators to
replace elements in time.
1.4.5 RETURN LINE

Two return lines located on the top of the separator collect small amount of fluid on the
bottoms of the primary and final elements back to the compressor unit, respectively.
Operator can check the flow through the sight glass on the return lines. The flow reaches
to a high level while full loaded, whereas, the flow decreases dramatically while unloaded,
even no flow at all. Therefore, if there is no flow or much less when full loaded, operator
should switch off the machine, and relieve the pressure inside to clean the filter.
11
1.4.6 FLUID PIPING SYSTEM (AIR - COOLED )

For air-cooled compressor, the cooler and compressor unit are installed separately and
an additional check valve is installed on the main fluid pipe to prevent the fluid from returning
to the sump tank when the machine is shut down or unloaded. In addition, a relief valve is
installed between the fluid cooler and sump tank to release pressure in the fluid cooler. Only
one direction flow is permitted by installing a check valve on the pipe to prevent air entering
into the fluid pipe.
There is an external spare flange at each fluid pipe. A piece off 50×3 seamless steel pipe
should be welded with the flange to connect to the radiator type fluid cooler. There is an
external flange at each end of fluid pipe connecting to the cooler. A steelf 56×3 pipe or DN50
metal hose can be used as the fluid pipe, however, in any case, no rubber or plastic pipe for
general purposes may be used. A steelf 56×3 pipe or DN50 metal hose can be used as the
unload pipe. It is recommended to connect the pipe with the hose to prevent damage to the
cooling system due to stress of connection and thermal deformation.
1.5 FLUID/AIR SEPARATOR
1.5.1 FUNCTIONAL DESCRIPTION

The separator consists of tank and filter elements, which comprise the primary element
for rough separation and the final element for refined separation.
The separator has four functions as explained below:
(1) A primary separator. The air/fluid mixture enters the separator and is directed against
the baffle. The direction of moveme nt is changed and its velocity significantly reduced,
thus causing large droplets of fluid to form and fall to the bottom of the separator
owing to their gravities.
(2) A fluid sump tank of the compressor: it stores fluid.
(3) Mounting of filter elements.
The fluid is separated from the mixture of fluid/air through the two filter elements,
gathering at the bottom of the filter. There are two filter elements: the primary element and the
final element. The fractional percentage of fluid remaining in the compressed air collects at the
bottoms of the filter elements as the compressed air flows through the separator. Two return
lines lead from the bottom of the separator elements to the inlet region of the compressor unit.
(4) To keep stable pressure.
There is some amount of air in the sump tank, which can effectively keep the pressure in the
service pipe from fluctuation, thus, stabilize the pressure.
1.5.2 REPLACEMENT OF FILTER ELEMENTS

After a period of operation, foreign substance in the fluid piping system will block the
pipes and cause resistance to compressed air passing through the filter elements, thus, affect
the normal operation. Operators should replace the filter elements timely according to the
12
message displayed on Supervisor II. Please Note: the filter elements should be replaced, no
service should be made.
1.5.3 FLUID FILLING PIPE AND SIGHT GLASS

The fluid filling pipe and sight glass are located on the outside end of the separator.
Some fluid contained in compressed air is discharged, more or less, therefore, after the
compressor runs over a period of time, the fluid level in the separator will drop and it is
necessary to add fluid. The fluid level is at the middle of the sign glass when the machine runs
in full-load mode.
1.6 WATER PIPING SYSTEM
1.6.1 OPERATION OF WATER PIPING SYSTEM

The water piping system consists of fluid cooler, after cooler, moisture separator and
interconnections. The cooling water enters the after cooler first, then the fluid cooler and,
ultimately is discharged outside the machine.
1.6.2 AFTER COOLER

The after cooler is a heat exchanger desig ned to cool the compressed air. The hot air
under high pressure coming from the minimum pressure valve enters the after cooler and
transfers large amount of heat to the cooling water, whereby, the compressed air obtains
normal temperature.
1.6.3 FLUID COOLER

The fluid cooler is also a heat exchanger designed to cool fluid. The fluid from the
fluid/air separator enters the fluid cooler through the thermal valve and removes some amount
of heat to the cooling water before enters the compressor unit.
1.6.4 AUTOMATIC MOISTURE SEPARATOR

Designed with a floating ball structure, the moisture separator separates condensed water
from compressed air and discharges it outside through a plastic hose periodically.
To periodically check the water discharge condition is necessary. Generally, more water
is discharged in summers, as it is hot and wet, whereas, less water is discharged outside in
winters. The moisture separator must be disassembled and cleaned if there is no water being
discharged, indicating that the separator is clogged.
1.6.5 COOLING-WATER QUALITY

Use clean cooling water to ensure exchange performance and long lifetime of the cooler. The
requirements are as explained below:
(1) The pH value of water should be in the range 6.5-9.5 to keep it neutral.
(2) The content of organic substance and suspension impurities should be lower than
13
25mg/L; and the fluid content lower than 5mg/L.

(3) The temporary hardness should be less than or equal to 10o (1o equivalent to 10 mg
CaO or 7.19 mg MgO).
1.6.6 TEMPERATURE, PRESSURE & CONSUMPTION OF WATER INLET
(1) The water temperature should be =30? . It is necessary to install separate water pipes
for both air cooler and fluid cooler respectively when water temperature is higher than
32? . No serial connection is allowed.
(2) The incoming water pressure should be equal to or higher than 0.2 MPa, and lower than
0.5MPa.
(3) When the water temperature is in the range between 27-29? , the water consumption of
the compressor is around 15T/h.
1.6.7 SHUTDOWN AND DRAINAGE

It is necessary to drain the water out of the cooler during wintertime or when the
machine is not in use for a long time, to prevent the cooler from damage due to freezing.
1.7 INSTRUMENTATION AND CONTROL
The purpose of the Instrumentation and Control is to regulate the amount of air being
compressed in response to the amount of compressed air being used.
When the amount of air being used is equal to the preset amount of air being exhausted,
the compressor will work in the full load mode. At this time, the butterfly valve that controls
amount of air intake keeps at the widest openness, and the pointer of the spiral valve points to
the MAX; while the amount of air being used is lower than the preset amount, this system will
regulate the openness automatically to decrease the inlet air amount; while there is no demand
of air being used, the butterfly valve will shut down automatically. (In fact, there is still a little
amount of air entering continuously to keep the low est pressure in the separator). The pointer
of the spiral valve points to the MIN when the machine runs under lower negative pressure in
unloaded mode.
The functional description is as below in four distinct phases of operation. For
explanation purpose, the following description will apply to a LS25S-300L compressor (See
Fig.7).
14
Pipe Pressure Gauge

Control Line Strainer
Air Discharge Gauge

Fluid Filter Pressure Gauge
Fluid Pressure Gauge
Pilot Valve
Pressure Regulator Minimum Pressure Valve
Shuttle Valve
Pressure Regulator
Control Line Strainer

Spiral Valve
Air Inlet Regulator

. Inlet Butterfly Valve
Fig. 7 Air Regulating System
(1) START-UP MODE (light load start -up process )

When the START buttons is pressed, the solenoid valve controlling the air supply of the
cylinder is energized. The butterfly valve is at the initial position (horizontal angle between
5-10 o) to allow a little amount of air to enter the compressor. The motor starts to work in a
lightly loaded mode (Y connection).
After the preset time (normally 6 seconds) is reached, the motor is switched to triangle
? connection. Meanwhile, the solenoid valve is de -energized. The compressed air enters the
cylinder and pushes the butterfly valve to open when the machine enters into subsequent
start-up mode.
(2) NORMAL OPERATING MODE
When the compressed air pressure rises above 3.4 bars, the minimum pressure valve
opens and delivers compressed air to the service line, and the openness of butterfly valve keeps
at the maximum position. The pointer of the spiral valve points to the MAX. The machine
remains running in a full load mode as long as the internal pressure is not higher than 7.0 bars.
15
(3) MODULATING MODE

If the amount of service air being used is less than the preset amount of air being used,
the pressure inside the system will rise. When it is above 7 Bar, the re gulator will be activated,
controlling air into the spiral valve to reduce the amount of air entering the compressor unit by
pushing spool with rack so that some amount of air being bypassed. The less the amount of air
being used, the wider the spiral valve opens. When the amount of service air being used is
50% of the rated amount, the pressure inside the system will rise to 7.4 bars. At this time, the
openness of the spiral valve will arrive to the maximum, and its level will point to the MIN.
therefore, the regulation range of air amount of spiral valve is between 100% and 50% of the
preset amount, the pressure of the system ranges accordingly is in the range from 7.0 to 7.4 bar,
the position of spiral valve varies from MAX to MIN.
If the amount of service air being used is less than 50% of the preset amount, the
pressure in the system will rise above 7.4 bars. The amount of inlet air will be reduced by the
pressure regulator (Sullicion), which regulates the openness of the butterfly valve. When the
amount of air being used is up to 40% of the preset amount, the pressure in the system will
reach to 7.6bar. Therefore, the regulation range of Sullion varies from 50% to 40% of the
preset inlet amount; accordingly, the pressure in the system varies from 7.4 to 7.6bar.
In this period, the spiral valve has remained at the MIN position.
(4) UNLOAD MODE
When the amount of service air being used is less than 40% of the preset amount, the
service line pressure will rise above 7.6 bar, then the supervisor II will switch off the solenoid
valve to prevent air from entering the Sullicion and blow down valve. The Sullicon closes the
butterfly valve to prevent air from entering and opens the blow -down valve to the atmosphere,
reducing the sump pressure to 2.1-3.4 Bar. At this time, the minimum pressure value closes,
disconnecting the sump and the service line. The machine runs at lower negative pressure in
energy saving mode.
If the consumption amount rises, the line pressure will decrease. When it is below 7.0 bar,
the Supervisor II will switch on the solenoid valve, and the Sullicion and spiral valve resume to
the initial positions with pointer indicating MAX position when the machine resume to the full
load mode again.
1.8 SUPERVISOR II
1.8.1 FUNCTIONAL DESCRIPTION

The temperature, pressure, running time and condition can be displayed on the LCD of
the supervisor. For the purpose of controlling the machine, setting the control parameters and
choosing the display of parameters, Operators can use the keypad on the panel. The lamp
indicators reflect the positions of parameters (See Fig. 8). Flashing lamp indicates alarm.
Operators should be acquainted with information of each signs on display of the Supervisor II
so as to make correct judgment accordingly in response to t he parameter and sign shown on the
panel.
16
1.8.2 KEYPAD
STOP -- Used to put the machine in manual stop. Also used to clear alarm
conditions.
CONTINUOUS -- starts machine if no alarm conditions are present. Also used

to clear condition while machine is running.
AUTO -- starts machine and selects auto mode if no alarm conditions are present. Also
used to clear alarm conditions while machine is running.
Fig. 8 SUPERVISOR II PANEL
DISPLAY-- Used to display temperature, pressure and other status information

(Details see section 1.8.3 Status Display).
LOGO -- Used for various functions described in later sections.
17
PROGRAM -- Used to enter the parameter mode where control parameters

may be displayed and changed (See Parameter Setup section).
UP ARROW—used in status displays to change and in parameter setup mode to

increase a value.
DOWN ARROW, LAMP TEST--- used in status displays to change displays

and in parameter setup mode to decrease a value. When in the fault display, the
key will light all the lamps for three seconds.
1.8.3 STATUS DISPLAY
By default the line pressure (p2) and discharge temperature (T1) are shown on the
bottom line of the display, and the system status on the top line. The following are the machine
status massages that indicate the state of the compressor.
The system modes may be displayed as below.(unit: temperature: ? , pressure: bar)
STOP- compressor is off.
STANDBY- Compressor is off but armed to start. This state may be entered because of a
power up, or the unload timer had expired and stop the machine. Note: the machine may start
at any time.
STARTING- machine is trying to start.
OFF LOAD- machine is running and off load.
ON LOAD- machine is running and load.
FULL LOAD -machine is running and fully loaded. This state is only displayed if the machine
is online.
RMT STOP- Compressor is off but armed to start. The machine will start when the remote
start contact is closed. Note: the machine may start at any time.
SEQ STOP- Compressor is off but armed to start. T he machine will start when the sequencing
conditions meet the criteria to start. Note: the machine may start at any time.
This default display appears as follows:
STOP
7.6 82
If there are alarms active they will alternately be shown with the default display. The machine
status will be displayed for two seconds then the alarms for two seconds each. For example:
T1 H1
7.6 82
To view other status parameters, press the DISPLY key. At this time, temperatures, pressures
and other status information can be displayed. To scroll through the displays press the up arrow
and down arrow keys. To return to the default display presses the DISPLAY key.
18
Separator differential pressure(? P 1) and the maximum limit (MAX)t. If the limit is exceeded, a
separator maintenance warning will be displayed.
? P1 0.3
MAX 0.7
Sump pressure P 1and line pressure P 2.:
P1 7.8
P2 7.4
Fluid filter differential pressure and the maximum limit.
? P2 0.3
MAX
If the limit is exceeded, a separator maintenance warning will be displayed.

Fluid filter inlet pressure P 4 and outlet pressure P 3 :
P3 7.4
P4 7.8
Fluid differential pressure(? P 3) and the minimum limited(MIN):
? P3 2.8
MIN 0.07
P1
Where, the pressure (? P 3) is defined as (P 3- )
2
If the limit is exceeded, the supervisor will s hutdown the machine and a P 3 LOW warning
will be displayed.
The compressor unit discharge temperature (T1) and the maximum limit(MAX):
T1 99
MAX 113
If the limit is exceeded, the supervisor will shutdown the machine and a T1 H1 warning will be
displayed.
Separator discharge temperature (T2 at the dry side) and the maximum limited (MAX):
T2 99
MAX 113
19
If the limit is exceeded, the supervisor will shutdown the machine and a T2 HI warning
will be displayed.
Fluid temperature T3 and the maximum limited (MAX):
T3 99
MAX 113
If the limit is exceeded, the supervisor will shutdown the machine and a T3 H1 warning
will be displayed.
Total hours that the compressor has been running:
HRS RUN
001234.0
Total hours that the compressor has been loaded:
HRS LOAD
00987.0
Last fault log. This shows the fault alarm and the total running hours till the moment the fault
occurred:
T1 HI
@1 112
Next to fault log. This shows the fault alarm and the total running hours till the moment the
fault occurred:
T1 HI
@2 96
1.8.4 LAMP INDICATORS

There are 10 lamp indicators on the panel. Press the testing keys of indicators to view the
running condition. All lights will flash for 3 seconds.
The functions of all lamp indicators are as below:
P1- (sump internal pressure) if lit steady, P1 is being displayed, if flashing denotes the
presence of an alarm.
P2- (line pressure) if lit steady, P2 is being displayed, if flashing denotes the presence of an
alarm.
T1 – (dry side discharge temperature) if lit steady, signifies that T1 is being displayed, if
flashing denotes the presence of an alarm.
T2 –(discharge temperature) if lit steady, signifies that T2 is being displayed, if flashing
denotes the presence of an alarm.
? P1- (separator differential pressure) if lit steady, signifies that dP1 is being displayed, if
flashing denotes replacement of filter element is needed.
20
? P2 – (filter differential pressure) if lit steady, signifies that dP2 is being displayed, if flashing
denotes replacement of fluid filter is needed.
an alarm.
MOTOR —if flashing denotes the overload contact is disconnected.
POWER –Lit if 120V AC power is applied to the supervisor.
ON – if lit steady, the compressor is running. If flashing, indicates that the compressor is
armed but stopped because of remote stop or sequence stop. The compressor may start at any
time.
AUTO -- if lit steady, the compressor is running in AUTO mode. If flashing, indicates that the
compressor is armed but stopped. The compressor may start at any time.
AIR FILTER - if flashing denotes the maintenance of air filter is needed
FLUID FILTER -- if flashing denotes the maintenance of fluid filter is needed.
1.8.5 PARAMETER SETUP

Press the ‘PROG’ button, the supervisor enters the ‘program’ mode to change some parameter
settings. For reset, press up arrow key or the LOGO key to increase the settings; or press down
arrow key to decrease the settings.
The parameter’s increment is 10 by pressing the LOGO key.
The display sequence is as following:
UNLOAD PRESSURE – if the value is set at 7.6 bars, the machine will unload when the
line pressure is above the set value 7.6bar:
UNLD
7.6 Bar
LOAD PRESSURE DIFFERENCE—difference between load pressure and unload
pressure. If the unload pressure is set at 7.6 bar and load pressure 0.7 bar, the machine will load
when line pressure is below 6.9 bar.
LOAD
0.7 Bar
P1 MAX-- the maximum separator pressure. P1- (sump and line pressure). If the pressure
within the separator exceeds this value, the Supervisor II will instruct the machine to shut
down and alarm signal will be displayed.
P1 MAX
9.3 Bar
Y-? EXCHANGE TIME (SECOND) -- set this parameter as 0 when using full voltage
starter.
WYE DELTA
10 SEC
RESTART TIME--time to start after switching on power. By this setting, all the
machines starting at the same time can be avoided, or ensure starting one after another. Without
21
this parameter, the machine does not start automatically when switch on again.
RST TIME
10 SEC
UNLOAD RELAY TIME (minute )-- in AUTO- mode, the machine will stop
automatically when run time in unload mode is above the set value. Note: owing to a hour
meter attached to the machine, which controls the start times lower than 4 in one hour, the
unload time may be higher than the set value (5mins) when it is lower than 15mins (e.g.
5mins).
UNLD TIM E
15 Min
LANGUAGE --English, Spanish, French, German and Italian are available
LANGUAGE
ENGLISH
UNITS--Metric and English are available.

UNITS
METRIC
COMMUNICATIONS ID # -- serial communication number or sequent control number.
COM ID#
1
COMMUNICATION BAUD RATE—This is to set serial communication baud rate.

1200,2400,4800,9600 may be selected.
BAUDRATE
9600
1.8.6 OPERATION MODES
The compressor may operate in several modes as explained below:-
(1) MANUAL OPERATION MODE

Pressing the “I” button will turn on the compressor and put it in manual mode. Pressing the “I”
button while the machine is already running in auto mode will switch operation to manual.
Pressing the button while the machine is already running in manual mode will cause the
supervisor to clear any maintenance Indicators.
To stop the compressor, press “O”.
If the compressor is already off when “O” is pressed, the supervisor will clear any maintenance
Indicators. Regardless of what the compressor is doing, pressing “O” puts the supervisor in
22
manual stop mode.
(2) AUTOMATIC OPERATION MODE
Pressing the “ “ button will turn on the compressor and put it in auto mode. Pressing the
“ “ button while the machine is already running in manual mode will switch operation to
auto mode. Pressing the“ “ button while the machine is already running in auto mode will
cause the supervisor to clear any maintenance Indicators. Pressing the “O” button while the
machine is already running in auto mode will cause the compressor to shutdown and puts the
supervisor in manual stop mode.
(3) SEQUENCING MODE

The following is a brief description of sequencing modes. For details see the Supervisor II
Sequencing & Protocol Manual (See Recommended Spare Parts List P /N02250057-696 or
02250057-697).
DISABLED- responds to status and parameter change massages via the network but will not
respond to start, stop, load and unload massages.
REMOTE- responds to status and parameter messages but will not respond to start, stop, load
and unload. The remote input and output are enabled ( start/stop,load/unload,master/local).
SLAVE- responds to all massages but will not start or load unless commanded to do so by a
message. This mode is used to control the machine from a master computer.
SEQUENCING HOURS- sends status message about once a second; starts, loads and unloads
machine based on sequencing hours.
COM ID#- sends status message about once a second; starts, loads and unloads machine based
on sequencing hours(COM ID#).
23
LS25S-250/300/350 Series Screw Compressor O & M Manual Section2 Installation
SECTION 2 INSTALLATION
2.1 MOUNTING
A foundation or mounting capable of supporting the weight of the compressor, and rigid
enough to maintain the compressor frame level and the compressor in alignment is required.
The compressor frame must be leveled and secured with foundation bolts to ensure normal
operation of the transmission parts and internal piping, and full uniform contact must be
maintained between the frame and foundation to prevent noise emission out of the machine
unit.
2.2 VIBRATION ABSORPTION AND NOISE REDUCTION
It is recommended to cushion the frame with rubber plate underneath with dimensions of
5~ 6mm thickness and 80mm width to prevent vibration/vibration and noise generated during
the machine running.
2.3 VENTILATION AND COOLING

It is necessary to select a location to permit sufficient unobstructed air flowing in and out
to the compressor to keep the operating temperature no higher than 40? . The minimum
distance that the compressor should be from the surroundings is not less than 1 meter for the
sake of ventilation and maintenance .
2.4 OVERALL ARRANGEMENTS AND MOUNTING ILLUSTRATION

Refer to Figure 9: Overall Arrangements And Mounting Illustration of Type
LS25S-250/300/350, 380V water-cooled version.
LS25S-250/300/350, 380V air-cooled version.
LS25S-250/300/350, 380V air-cooled version.
LS25S-250/300/350, 6kV water-cooled version.
LS25S-250/300/350, 6kV air -cooled version.
2.5 INSTALLATION (AIR-COOLED)

Installation of compressor unit of air-cooled version is separate from that of cooler.
Users may design and construct the piping system, including fluid piping and air piping
between the machine and cooler, with assistance of Sullair authorized dealer and service
24
department. In no case, the connection pipe may be longer than 5 m, to reduce flowing
resistance.
For details of piping, see section 1.3.5 Discharge System and section 1.4.6 Fluid Piping
System for air-cooled version. It is worth emphasis that when fluid piping is made, it is
recommended to use hose so as to avoid influence of pipe connection stress on the cooler.
The cooling fan airflow of air-cooled compressor is 764 M3/min. The arrangement of air inlet
and outlet positions should be done during construction of machine room.
2.6 MOTOR ROTATION DIRECTION CHECK

After the electrical wiring has been done, it is necessary to check the direction of the
motor rotation. This can be done by pulling out the EMERGENCY STOP button on the
supervisor panel, then jogging the ‘I’ (START) button, then ‘O’ (STOP) button, to run the
motor for a while. The shaft should be turning as the same direction as the arrow marked on the
adapter. If not, disconnect the power to the starter and exchange any two of the three power
input leads.
No reversed rotation is allowed!
25
Ai r s e r v i c e
Supervisor panel
Ai r s e r v i c e l i n e
outer diameter Rc4
ES Button
380V Water-Cooled Version.

Instrumental panel
Condensate water
26
Water pipe external
connections2-G1-1/2 external connection G1/2
Water outlet
Blow off
W
ater inlet
Section2 Installation
Figure 9 Overall Arrangements and Mounting Illustration of Type LS25S-250/300/350,

Power supply cable from base
1934
300
External connection
56X3
Reserved wire holes
piping2-
2166
152
1/2"NPT
1105
304
Ground bolt hole

4- 22
3048
1560
168
615
168
1105
1640
2210
Fluid discharge
Fluid inlet
2139
Air service
Figure 10: Overall Arrangements And Mounting Illustration of Type LS25S-250/300/350 ,

380V Air-Cooled Version
27
(Air inlet)
¡ °

380V Air-Cooled Version
28
water serve line
To drain pipe
To inlet/outlet
service line
1
2-G1 2
To air
Rc4
1
G2
Air discharge
¿Ø
µ çÄ Ô ° å
ÖÆ
Air incoming
Ai r s u p p l y
(Tunnel line)
Discharge
Water discharge
Water incoming

6kV Water-Cooled Version
29
To air service line
1/2 NPT
Rc4
Air discharge
Computer control panel

Air incoming
Cooler pressure
relief return line
Fluid discharge
Air supply
(Tunnel line)
Service line
Fluid inlet

6kV Air-Cooled Version
30
LS25S-250/300/350 Series Screw Compressor O & M Manual Section 3 Operation
SECTION 3 OPERATION
3.1 SAFETY
The following safety precautions are offered as a guide which, if conscientiously followed,
will minimize the possibility of accidents throughout the useful life of this equipment.
a. Only those who have been trained and delegated to do so, and who have read and
understood this Operator’s Ma nual should operate the compressor.
b. Install, use and operate the compressor only in full compliance withal pertinent
regulations and applicable national and local laws and regulations.
c. DO NOT modify the compressor and/or controls in any way except with factory written
approval.
d. Stop the machine and disconnect all power if anything is abnormal during the operation.
e. Avoid inflammable, explosive, toxic and irritating gases in the surrounding.
f. Shut off, depressurize, and disconnect all power before modify and maintain the machine.
3.2 INITIAL START-UP PROCEDURE

a. Set up parameters according to Section 1.8.5 :“Parameters Setup”;
b. Make sure the electrical wiring is safe and secure;
c. Fill fluid into the separator until the fluid level is around the middle of the sight glass;
d. For air-cooled compressor, fill in 5 gallon (19L) of specified fluid [Sulluble or 24KT] in
fluid cooler;
e. Connect to water piping;
f. Open the discharge shutdown valve;
g. Switch on the power supply and jog motor to check for correct rotation direction of motor
and make rewiring, if necessary;
h. Restart the compressor and slowly close the shutdown valve to assure unload pressure
setting is correct. If it is not, reset is necessary;
i. Check for possible leaks in piping and any abnormal noise;
j. For air-cooled compressor, in case of ambient temperature above -20? , user has to raise
ambient temperature as practical as possible to reduce viscosity of fluid in cooler and
pipes so that the machine may operate properly.
k. Open the discharge shutdown valve ;
l. Stop the machine.
3.3 SUBSEQUENT START -UP PROCEDURE

After init ial start up test for your new machine, proceed with the subsequent start up
procedure as following: On subsequent start –ups, check the proper level in the fluid sight glass,
and simply press the “I” button (manual mode), or ‘ ’ button. (Auto mode) to start the machine.
3.4 SHUTDOWN PROCEDURE

To shutdown the compressor, simply press the “O” button”.
31
LS25S-250/300/350 Series Screw Compressor O & M Manual Section 4 Maintenance
SECTION 4 MAINTENANCE
4.1 GENERAL
The maintenance program for air compressor is quite minimal. The Supervisor monitors
such parts as the fluid filter, air filter and fluid/air separator and once fault is found it sends
signal for maintenance by lamp indicator on the panel.
4.2 DAILY MAINTENANCE

P rior to starting the compressor, it is necessary to check the fluid level in the sump.
Should the level be low, simply add the necessary amount of fluid. After starting, check the
correctness of each reading. After the compressor has been warmed up, check for leakage or
abnormal noise.
4.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION

After the initial 50 hours of operation, observe and perform the following operations:
a. Clean the return line filters;
b. Clean the return line orifices.
c. Change the fluid filter elements.
d. Clean the control line strainers.
4.4 MAINTENANCE EVERY 1000 HOURS

After 1000 hours of ope ration, it will be necessary to perform the following:
a. Clean the return line filters;
b. Add fluid to the auxiliary drive in Sullicon;
c. Change the fluid filter elements, if necessary;
d. Change the air filter elements, if necessary.
4.5 FLUID REPLACEMENT

The fluid added to the compressor is SULLUBE 32. Fluid should be changed under the
following conditions, whichever occurs first:
a. Every 8000 hours.
b. Once a year.
c. As indicated by fluid analysis.
For 24 KT compressor, fluid need to be changed only as indicated by fluid analysis or as fluid
has been contaminated.
4.6 FLUID FILTER MAINTENANCE

For detailed structure of fluid filter, refer to figure 14.
The filter should be maintained or changed, if necessary, when the supervisor sends filter
maintenance alarm (the ? P2 flashes on the panel). The maintenance should be performed in
timely manner as explained below:
32
a. Using a strap wrench, remove the old elements and O-ring;

b. Clean the seal surface;
c. Apply a film of MO fluid to the O -ring of the new element;
d. Replace and tighten new element;
e. Restart machine and check for leaks.
f. Start the machine to check for fluid leakage;
g. Please note: only the filter elements identified by Sullair should be used. Only
replacement of filter elements is allowed.
Connector Bolt Hexagonal nut

Top cover
Seal ring Wing nut
Top cover Washer Buckle
Connector
Seal ring Primary element
Secondary element
Seal ring
Collection bag
Joint bolt
Filter eleme nt Body
Fig. 14 Fluid Filter Fig. 15 Air Filter

FILTER ELEMENTS P/N : 02250139-996
4.7 AIR FILTER MAINTENANCE

For detailed structure of air filter, refer to figure 15.
Having been used for a period of time, the air filter surface will be covered with dust,
which blocks the air flow. When the preset pressure differential of the air filter is reached, the
supervisor shows “alarm” signal. This indicates that it is necessary to remove the filter
elements, clean dust, or make replaceme nt. The maintenance should be made as explained
below:
a. Remove the latch and filter cover;
b. Unscrew the wing-nut and pull the primary element out;
c. Unscrew the hex nut and pull the final element out;
d. Clean the primary element by blowing out with compressed air from inside to outside,
from top to bottom along circle. The distance from air inlet to the element surface is
around 10mm. Alternative way is to put the element erectly on a flat table and lap the
33
top end of the element lightly;

e. Filter elements are made of paper and should not clean with water;
f. Change each element after 1500 hours, or earlier in dusty environment;
g. Lit bright lamp inside the element to check for any damage or leakage.
4. 8 FLUID/AIR SEPARATOR MAINTENANCE

Refer to figure 16. Maintenance of the separator requires mainly replacement of separator
elements.
Minimum pressure valve

Return line
Bolt (screw)
Anti-loosing washer
Return line
Primary element
Fig. 16 Fluid/Air Separator
The separator elements should be changed when the ? P1 flashes. Note: only replacement
rather than cleaning is allowed for separator elements.
The replacement should be performed as explained below :
a. Stop the machine and relieve all pressure from the sump tank and all compressor lines.
b. Disconnect all piping connected to the sump cover to allow removal.
c. Remove the primary and final elements, and change new elements.
Note: Do not peel off flange gasket on the element; do not remove cap screw on the gasket.
The cap screw is grounded for safety.
d. Clean the underside of the separator tank cover and put in new elements. Fasten the
screw and fix the cover cap.
e. Reconnect all piping.
Note: two return line tubes should extend to the bottom of the separator element. This will
34
assure proper fluid return flow to the compressor.
4.9 FLUID STOP VALVE MAINTENANCE

For detailed structure of stop valve, refer to figure 17. Maintenance of the separator requires
mainly replacement of O -ring and gasket as explained below:
a. Shut down the machine and relieve all pressures from the sump tank and all
compressor lines;
b. Disconnect the air pipe underneath, unscrew 6 screws and pull out the valve body;
c. Replace the “O” ring and washer with new ones, and apply a film of fluid to the new
O-ring;
d. Reassemble the valve body and tighten the screws;
e. Reconnect the air pipe. Inspect and tighten all connections prior to resuming operation.
Air tubing Cap

screw Washer
Piston housing
Diaphragm assembly
Screw
Retaining Diaphragm
ring
Locknut Valve body Disc

Lock
washer
Piston Nut
O-ring Valve seat Screw
Element nut Spring

Piston rod housing
Spring Adjustment spring
Locknut
Washer Spring holder
Adjustment
Cap screw
screw
Fig. 17 Fluid Stop Valve Fig. 18 Pressure Regulator
4.10 PRESSURE REGULATOR MAINTENANCE

For detailed structure of pressure regulator , refer to figure 17. Mainte nance of the regulator
requires only replacement of retaining ring, diaphragm and gasket, as explained below:
a. Loosen the locknut and turn the adjusting screw counterclockwise until the inner
spring is relieved;
b. Next remove the spring retainer, the spring and the diaphragm assembly.
c. Remove the gasket and retaining ring.
d. Loosen the locknut on the valve disc; remove the disc, diaphragm and screw.
e. Replace with new retaining ring, diaphragm and gasket.
35
f. Reassemble the pressure regulator valve.
4.11 MINIMUM PRESSURE VALVE MAINTENANCE

Refer to Figure 19. Maintenance of the regulator requires only replacement of of the O-ring, as
explained below:
a. Disconnect all piping connected to the minimum pressure valve and remove the valve
from the top cover of the fluid/air separator;
b. Remove the cap from the valve body. Tap and pull out the piston assembly;
c. Clean piston assembly and valve body thoroughly;
d. Replace with new O-ring and apply a film of fluid on the piston and O-ring;
e. Reassemble the piston assembly in reverse order before application of Luctite sealing
glue on the cap;
f. Reattach the valve to receiver cover and reconnect all piping.
Hex screw
Check valve spring
Lock washer
Washer
Caps
Check valve
assembly
Washer Pilot rod
Lock washer
Piston assembly
ALLEN fixing screw

Spring
Positioned
P iston assembly
Valve body
O-ring
Fig. 19 Minimum Pressure Valve
4.12 BLOWDOWN VALVE MAINTENANCE

Structure of the blowdown valve refers to figure 20. Maintenance of blowdown valve requires
replacement of O -rings and the Teflon washer, as explained below:
a. Take 4 1/4 3/4 screw and the cap end out;
b. Remove spring, piston, and o-ring;
c. Replace Teflon washer and all the O-rings with new ones;
36
d. Reassemble the blowdown valve.
4.13 CONTROL LINE STRAINER MAINTENANCE

Structure of the strainer refers to figure 21. Control line strainer maintenance normally requires
replacement of the filter element, gasket and O-ring, as explained below:
a. Loosen the body from the bowl and take all parts inside out;
b. Change the filter element and the O-rings on it;
c. Loosen and remove the nut on the bottom of the bowl and take the auto-discharge
system out, replace the gasket inside with new one;
d. Replace the O -ring on the top of the bowl;
e. Reassembly the filter.
Fig. 20 Blow Down Valve Fig . 21 Control Line Strainer
37
4.14 SOLENOID VALVE MAINTENANCE

Structure of the solenoid valve refers to figure 22. Solenoid valve maintenance is minimal. But
periodical clean is recommended. Generally, it needs to be cleaned whenever the valve
operates slowly or leaks, under proper working voltage. The maintena nce should be performed
as below:
a. Remove connector on the valve;
b. Unscrew the screw on the valve body, spool, spring and gasket.
c. Remove the end cap, gasket, spring and valve needle;
e. Clean all parts.
f. Change the spool or fluid;
g. Reassemble the valve.
Fixing screw
Top cover
Spool
Spring washer
Valve rod
Retaining ring
Spring
O-ring
Body
Needle
Spring
O-ring
Cap screw
Fig. 22 Solenoid Valve
38
4.15 COUPLING INSTALLATION AND MAINTENANCE
Fig. 23 Flexible Coupling Of Metal Laminate
Radial Run out

Angular Deflection
Fig. 24 Measuring Angular Deflection And Radial Run out With Micrometer Gauge
Structure of the coupling refers to figure 23.

(1) Installation and test refer to figure 19 and Table 2.
(2) Install folding hub kit and spacing axe.
Put folding hub kit and spacing axe between two discs follow ing the signs, then install
precision screws, bushing and locknut according to the signs. There is no requirement of
installation regarding angle or direction if no sign or marks on parts.
With a torque wrench, tighten the nuts in the diagonal sequence 3 times according to the
39
required torque shown on the table 2, first one end, then the other. Meanwhile keep the screw
still when tightening.
Use a little neutral grease when install locknuts, which can be used repeatedly. If the nuts are
loose or there are cracks on the end of nuts, the nuts should be scrapped.
Table 2
DISTANCE RADIAL RUNOUT ANGULAR TIGHTENING

mm DEFLECTION TORQUE
BETWEEN AXES
mm Nm
(mm)
120.2+0.40 0.05~ 0.10 0.08~ 0.12 80
4.16 MAINTENANCE OF SPECIAL MOTOR ON SULLAIR COMPRESSOR

4.16.1 LOW VOLTAGE MOTOR
4.16.1.1 Working conditions (export machines depend on country of destination):
Ambient Temperature =40?
Humidity <90%(free of condensed water)
Altitude =1000 m
Frequency see nameplate on the motor
Voltage see nameplate on the motor
System S1
Insulation class F
4.16.1.2 OPERATION
(1) The motor should be grounded properly. The grounded wire of the motor is generally
routed into the switch cabinet and the only thing you need to do is to connect the grounded
wire to the connection on the cabinet body securely.
(2) There are evident labels on the lead wire of Sullair motor:
Phase sequence A B C
Head T1 T2 T3
End T4 T5 T6
(3) The connection method of the motor is indicated clearly on the nameplate.
(4) When the voltage and frequency of the special motor for Sullair compressor remain
within the rated value shown on the nameplate, the motor runs continuously under the power
which equals to the rated power times the service factor. When the frequency deviation of
power supply exceeds 1% of the value on the nameplate, or the voltage deviation exceeds 5%,
the motor is not guaranteed to output such power continuously.
(5) When three phases supply is out of balance by less than 1%, the motor runs properly.
(6) Thermo relays are built in the cabinet for overload protection.
(7) There should be no intermittent or abnormal noise or vibration when the motor is
40
idling or loading.
4.16.1.3 LOW VOLTAGE MOTOR MAINTENANCE AND SERVICE

(1) Keep the working conditions dry, and the motor surface clean. The air inlet should
not be blocked with dust or fiber.
(2) When the thermo relay is actuated, check the cause of any fault. Put back into
operation only after the fault has been corrected.
(3) Maintain properly the bearings lubrication during the motor operation. Refill or
change the grease every 2000 hours operation (enclosed bearings need no replacement during
its lifetime). Immediately change the grease when the bearings are overheated or the grease has
deteriorated. The brand of grease is different from motor to motor. For details, please consult
Sullair service department.
(4) When a bearing is reaching the end of its lifetime the m otor’s noise and vibration are
increased considerably, which manifest that the bearing should be replaced.
(5) You are recommended to contact Sullair or local dealer in case of motor malfunction.
4.16.2 HIGH VOLTAGE MOTOR

4.16.2.1 Working conditions
Ambient Temperature =40?
Humidity <90%(free of condensed water)
Altitude =1000 m
Frequency see nameplate on the motor
Voltage see nameplate on the motor
System S1 (continuous)
Insulation class F
4.16.2.2 START-UP AND OPERATION

(1) INITIAL START -UP PROCEDURE
The initial start-up refers to operating the motor for the first time after it is newly installed,
overhauled, or out of service for over 1 month. It is recommended to proceed with initial
start-up with the compressor head unengaged, or unload start-up.
(2) The following procedure should be used to check the initial start-up of the
compressor.
a All temporary supports and gover plates have been cleared;
b Fluid level is normal;
c Resistance to ground is not less than 3(Un+1) mega ohm, Un in kV;
d Check for consistency of power supply phases, voltage, frequency with that on nameplate;
e Check for obstruction of ventilation opening and ducts;
41
f Check for noise in the motor ;

g Check correctness of wiring;
h Check other factors that may affect the normal operation of the motor.
(3) Jog the motor to check for correct rotation direction of the motor and make rewiring, if
necessary. Start the motor again after cooled down to ambient temperature; check for any
abnormal operation, if any, in the subsequent 2 hours. In case of abnormity, switch off the
power supply immediately, stop the motor, and find the cause.
(4) LOAD START -UP
Connect the coupling between the compressor head and the motor, according to section 4.15,
rotate the motor manually or with tools for several turns to check for sticking or any other
abnormal phenomenon and noise. When every thing is OK, start the machine , and check the
current of the motor and temperatures at each point frequently in the subseque nt 4 hours. Make
operation records of the motor and the machine. Stop the machine as soon as any problem is
spotted.
(5) NUMBER OF START-UP
The motor is permitted to start consecutively twice in cold state, and only once in hot state,
with interval time not less than 4 hours , to prevent damage to the insulation due to overheat.
4.16.2.3 MAINTENANCE DURING MOTOR OUT OF SERVICE
For the motor to be put out of service for over one month, regularly heat the motor or
warm up the motor with hot air (80? dry air), in order to keep the motor in dry state. Heating
is implemented by means of space heater attached on the motor. Otherwise when there is no
such a heater, place several lit lamps with rated power 100 w or 150 w inside the motor.
4.16.2.4 MAINTENANCE AND SERVICE
(1) Keep the environment and the motor clean and dry and ensure the ventilation opening
and duct free of obstruction due to accumulation of dust or the alike.
(2) Prepare a practical maintenance plan and check bearings of the motor regularly for
lubrication. Detailed instructions on greasing see the nameplate attached to the motor.
(3) In case of malfunction, please contact Sullair or its authorized dealer, never attempt to
tamper the motor.
42
Fluid flter pressure transducer 3¡ « 380V 50HZ
Higher pressure side Lower pressure side L1 L2 L3
BP4 BP3 SUPERVISOR II
P4 P3 DELUXE
S + - S + - J2 FU
J3 218
WHT(GRN) 301
RTN 18 5 TC1
217 To XT1 U3 FU3
1 P3 SIG - 17 100 101
WHT(GRN) 302 RS-485 Discharge temperature
2 P4 SIG + 16 216 at dry side To XT1
380V
BLK 303 215
110V
3 GND RTD2 + 15 WHT QF V3 102
To XT1 RED BLK 304 214 RTD2 BT2 Piping pressure Discharge pressure
208 RED 4 RTD2 - 14 RED
RED BP2 BP1 5
305 213 XB
Injection temperature 5 GND 13 GND
306 212 RED Discharge temperature P2 P1
WHT 6 RTD3 + RTD1 - 12 RED FU2
BT3 RTD3 307 211 RTD1 BT1 S + - S + -
RED 7 RTD3 - RTD1 + 11 WHT XT0
308 210 WHT(GRN)
8 RTD4 + P2 SIG 10
1L1
1L2
GND
309 209 WHT(GRN) 1L1
310
9 RTD4 - P1 SIG 9 RED
RED 208 RED 1L2
10 RTD GND +12V 8 BLK
311 207 BLK 1L3
11 RTD5 - GND 7
312 206
313
12 RTD5 + GND 6 P£¾
6 205
1L1
1L2
1L3
13 RTD6 - D5 5 SP1 Fluid filter plugged
1L1
1L2
1L1
1L2
1L3
1L3
SP2 P 314 204

14 RTD6 + D4 4
105
116
141
Water press gauge 315 203
15 D6 D3 3 FR2 Ventilator overload
316 202 KM1
16 D7 D2 2 FU1
317 201 SB1 FR1 Main motor overload
LOCAL/MASTER CONTROL 17 D8 D1 1 KA1 Force-loading
relay
102
141
117
318
3 REMOTE LOAD/UNLOAD 18 D9
319 Emergency stop button
SECTION 5
REMOTE START/STOP 19 D10 J1
U11
V11
W11
320 YV4 Force-loading solenoid valve
Parts in the dotted frame 20 GND K6 115
are for remote control modes only. FULL LOAD 15
202
U21
V21
W21
MODULATE 14 114
K5 113 1 YV5 Drainage
13 soenoid valve
ELECTRIC DRAIN FR1
12 112
K4 111 1 KA2 206
107
142
141
11 Alarm relay
COMMON FAULT 110
10 KM2
43
KM4
U12
V12
W12
K3 109 1
9 KA3 Loading signal sending relay

102
UNLOAD/LOAD
143
102
8 108
K2 107 T2
5.1 WIRING DIAGRAM (WATER-COOLED)
YV2 Loading/offload
7 solenoid valve T1 T3
*-DELTA 106
6
V22
K1 3
U22
W22
105 Emergency
W13
U13
V13
5 stop button
YV1 Start-up solenoid valve M1
RUN 104 ~
4 120 KM2 T4
103 143 KM3 Y contact T5 T6
AC GND 3
203
120V N 2 102 2
101 FR2
AC L 1
U13
V13
W13
KM3 141
206
KM1
Main contact
Note:
U23
V23
W23
KM1 KM3
1 Elements connected with dotted lines are optional. 142 KM2
¡ ÷contact
2 Jumpers should be removed before adding any optional.
141
105
143
3 For remote control mode, refer to SUPERVISOR II T2

Star-Delta mechanical interlock
KM4 KM3 T3 T1
SEQUENCING&PROTOCOL MANUAL,02250057-696and02250057-697 Ventilator contact M2 3
WIRING DIAGRAM
4 For networking SUPERVISOR II RS485 refer to Network ~

102
KA1
142
141
Control Wiring Diagram,88290002-027

Protection device should be supplied by user
122 YV3 Spiral
valve control solenoid valve
5 101 Discharge/fan motor
From XT1
6 Only for water-cooled machine Compressor main motor
102
From XT1 1 YV6 Water stop solenoid valve(optional)
From FU3
To KA1
KA2
KA3
From TC1
From KA1
1
101
101
120
102
102
102
102
102
104
105
105
106
107
107
108
109
110
111
112
113
114
115
115
116
117
122
90
91
92
93
94
95
XT1
101
101
120
102
102
102
102
102
105
105
106
107
107
108
110
111
112
113
114
116
117
122
202 202
204 204
205 205
206 206
206 206
206 206
208 208
208 208
209 209
210 210
211 211
212 212
213 213
214 214
215 215
216 216
217 217
218 218
301 301
302 302
303 303
306 306
307 307
308 308
309 309
310 310
315 315
317 317
318 318
319 319
320 320
90
91
92
93
94
95
64Î »
Machine Machine
To YV3
To YV4 115
YV5
alarming loading
From KM1
To SP2 320 320
From KM1
To KA1 115
BP1£¨WHT£©
To YV1
To YV2
To YV3
To YV4
To
From SB1 104
To KA1
To KM3
To YV1
To KM2
BT1£¨RED£©
From SP1
From FR1
From FR2 203 203
From FR1
From SP1
From SP2
+- GND 4 Wiring to user line

From BT2£¨RED£©
From BT3£¨WHT£©
From BT3£¨RED£©
From
From BT2£¨WHT£©
Section 5 Wiring Diagram
From
To YV2£¨KA3£© 109
From BP2£¨WHT£©
From BT1£¨WHT£©
To matching terminal
To BT3£¨RED¡¢GND£©
of next compressor
From BP1¡¢BP2(BLK) 207 207
From BP1¡¢BP2£¨RED£©
From BP3¡¢BP4£¨RED£©
BELDEN 9842 Shielded cables
To Supervisor II panel
From BT1¡¢BT2£¨RED¡¢GND£©
of 4 cores and 2 twisted

5.2
Fluid filter transducer NOTE:

Higher pressure side Lower pressure side
BP4 BP3 SUPERVISOR II 1 1.Elements connected with dotted lines are optional .
3¡ « 380V 50HZ
P4 P3 DELUXE 2 2.Jumpers should be removed before adding any optional.
J2 L3 L2 L1
S + - S + - 3 3.For remote control mode,refer to SUPERVISOR II
J3 218
RTN 18
WHT(GRN) 301 217 SEQUENCING&PROTOCOL MANUAL,02250057-696/697.
1 P3 SIG - 17 È ¥XT1
WHT(GRN) 302 RS-485 5
2 P4 SIG + 16 216 ¡ ¶SUPERVISOR II SEQUENCING & PROTOCOL MANUAL¡ · FU
BLK 303 215 Piping pressure Discharge pressure
To XT1 3 GND RTD2 + 15 WHT For networking SUPERVISOR II RS485 refer to Network
RED BLK 304 214 RTD2 BT2 4
208 RED 4 RTD2 - 14 RED
305 RED BP2 BP1 Control Wiring Diragram,88290002-027
213 GND 5
5 GND 13
Injection temperature 306 212 RED Discharge temperature P2 P1 5.Protection device should be supplied by user. QF
BT3 WHT 6 RTD3 + RTD1 - 12 RED 5
RTD3 307 211 RTD1 BT1 S + - S + -
RED 7 RTD3 - RTD1 + 11 WHT KM1
308 210 WHT(GRN)
8 RTD4 + P2 SIG 10 PE 102 141
309 209 WHT(GRN)
9 RTD4 - P1 SIG 9 XT0
GND RED 310 208 RED RED Compressor main motor FR1 117 116
10 RTD GND +12V 8
311 207 BLK BLK M
1 141 105
11 RTD5 - GND 7
312 206 U13 U12 U11 1L1
12 RTD5 + GND 6 P T4 T1
313 205 Air filter plugged V13 V12 V11 1L2
13 RTD6 - D5 5 SP1 T5 3 T2
314 204 W13 T6 ~ T3 W12 W11 1L3
Parts in the dotted frame are 14 RTD6 + D4 4
315 203 FR2 FR3 206 202
for remote control modes only 15 D6 D3 3 203A Ventilator overload
316 202 KM2
16 D7 D2 2
317 201 1 KA1 102 142
LOCAL/MASTER CONTROL 17 D8 D1 1 SB1 FR1 Main motor overload Force-loading relay
318
3 REMOTE LOAD/UNLOAD 18 D9 1L1
REMOTE START/STOP 19 D10 J1 1 Force-loading solenoid valve 1L2
320 YV4
20 GND K6 115 1L3
FULL LOAD 15
MODULATE 14 114 143 107
K5 113 YV5
13 Drainage solenoid valve
ELECTRIC DRAIN 141 105
12 112
K4 111 1 KA2
11 Alarm relay
COMMON FAULT 110
10
1
44
K3 109 KA3
WIRING DIAGRAM (AIR-COOLED)
9 Loading signal sending relay

UNLOAD/LOAD
8 108 142 141
K2 107 YV2
7 Loading/offload solenoid valve 102 143
*-DELTA
6 106 YV1
K1 105 Start-up solenoid valve KM4
5 KM3
RUN 104 KM2 102 105
4 143 KM3 Ventilator with enclosure FR2
103 120 Ycontact
AC GND 3 Emergency stop button M2 FU1
120V N 2 102 2 KM3 141 KM1 U23 U22 U21 1L1
101 Main contact T1
AC L 1 3 V23 V22 V21 1L2
T2
KM3 ~ W23 W22 W21 1L3
KM1 142 KM2 T3
¡ ÷contact
206 203
KM5
FU2 KM4
FU3 Sound enclosure Cooled ventilator 102 105
From XT0 1L1 U3 2 FR3
100 101 ventilator contact
KA1 M3 FU4
122 1 YV3
50/60HZ Spiral valve control U23 U22 U21 1L1
1 solenoid valve T1
380V/110V 3 T2 V23 V22 V21 1L2
~ T3 W23 W22 W21 1L3
1 YV6
102 Water stop solenoid PE 206 203
1L2 V3 valve(optional) 1L1
From XT0 TC1 XB Fluid temperature switch ST1 1L2
¦ ÈKM5 121 cooled ventilator contact To TC1
KM5
From XB
panel
panel
panel
panel
panel
panel
panel
panel
panel
panel
panel
panel
II panel
panel
panel
panel
panel
panel
panel
panel
panel
panel
panel
II panel
II panel
II panel
II
II
II
II
PE
To PE line
Supervisor
Supervisor
Supervisor
Supervisor
From FU3
To KA1
KA2
KA3
From TC1
From Supervisor II panel
To KM5
To
To
To
To
To Supervisor II
To Supervisor II
To Supervisor II
To Supervisor II
To Supervisor II
To Supervisor II
To Supervisor II
To Supervisor II
From Supervisor
1
To Supervisor II
To Supervisor II
From Supervisor
To Supervisor II
To Supervisor II
To Supervisor II
To Supervisor II
From Supervisor
To Supervisor II
To Supervisor II
To Supervisor II
To Supervisor II
From Supervisor
101
101
120
102
102
102
104
105
105
106
107
107
108
109
110
111
112
113
114
115
115
116
117
121
122
202
203
204
205
206
206
206
207
208
208
209
210
211
212
213
214
215
216
301
302
303
306
307
308
309
310
315
317
318
319
320
320
90
91
92
93
94
95
XT1 65 digit
101
101
120
102
102
102
105
105
106
107
107
108
109
110
111
112
113
114
115
115
116
117
122
203
204
205
206
206
206
208
208
210
211
212
213
214
215
216
217 217 From Supervisor II panel
218 218
302
303
306
307
308
309
310
315
317
318
319
320
320
90
91
92
93
94
95
KM2
To SB1
To YV1
To YV2
From SB1 104
From ST1 121
From FR1 202
FromFR2
FromSP1
FromFR1
FromSP1
ToYV1
only at chain end
Machine Machine
To KM3
Connection to machine case
GND
To ST1
To KM3
To
alarming loading
4
FromBT1£¨WHT£©
FromBT1£¨RED£©
FromBT2£¨RED£©
FromBT2£¨WHT£©
FromBT3£¨WHT£©
FromBT3£¨RED£©
-+
To YV2(KA3)
To matching Wiring to user line
FromBP1¡¢BP2(BLK) 207
FromBP1(WHT(GRN)) 209
FromBP2(WHT(GRN))
FromBP3(WHT(GRN)) 301
FromBP4(WHT(GRN))
FromBP3¡¢BP4(BLK)
terminal o f
FromBP1¡¢BP2£¨RED£©
FromBP3¡¢BP4£¨RED£©
To BT3£¨RED¡¢GND£©
next compressor
From BT1¡¢BT2£¨RED¡¢GND£©
BELDEN 9842 Shielded cables of

4 cores and twisted strands or
similar cables
3 ¡ «380V50HZ 3¡ «6KV/10KV
50HZ
Fluid filter pressure transducer
L13
L12
L3
L2
L1
L11
High pressure side Lower pressure side

BP4 BP3 SUPERVISOR II
DELUXE High voltage electrical
P4 P3 5 instrumental panel
S + - S + - J2
J3 218 is supplied by users.
RTN 18 217 To XT1
WHT(GRN) 301
1 P3 SIG
WATER-COOLED)
WHT(GRN) 302 RS-485 - 17 216 QF1

2 P4 SIG + 16 Recommendation
BLK 303 215 Discharge temperature at dry side
To XT1 3 GND RTD2 + 15 WHT
BLK 304 214 RTD2 BT2 Piping pressure Discharge pressure
208 RED RED 4 RTD2 - 14 RED
305 213 RED BP2 BP1
5 GND 13 GND
Injection temperature 306 212 RED Discharge temperature P2 P1
WHT 6 RTD3 + RTD1 - 12 RED
BT3 RTD3 307 211 RTD1 BT1 S + - S + -
RED 7 RTD3 - RTD1 + 11 WHT
308 210 WHT(GRN)
GND 8 RTD4 + P2 SIG 10 101
309 209 WHT(GRN) To XT2
9 RTD4 - P1 SIG 9 Failure signal of high
RED 310 208 RED RED XT0 voltage electrical motor
10 RTD GND +12V 8 BLK 124 S1
311 207 BLK To XT2
1L1
1L2
1L3
11 RTD5 - GND 7
312 206
12 RTD5 + GND 6 400
313 P From XT2
205 SP1 Air fluid plugged Start-up signal of
13 RTD6 - D5 5 voltage electrical motor
6 Water pressure gaugeSP2 314 204
P 14 RTD6 + D4 4
315 2 401 S3
203
electrical instrumental panel
15 D6 D3 3 Ventilator From XT2

316
FR1 FR2
202 220 overload
Secondary circuit of high voltage
16 D7 D2 2 402
From XT2
317 201 Shut down signal of high
LOCAL/MASTER CONTROL 17 D8 D1 1 7 FU2 FU1
318 KA4 High voltage electrical voltage electrical motor
3 REMOTE LOAD/UNLOAD 18 D9 SB1 instrumental panel protection 403 S4
319 From XT2
REMOTE START/STOP 19 D10
20 GND
Parts in the dotted frame
45
KA1
are for remote control modes only Froce-loading relay 90 From XT2
J1
U21
V21
W21
U11
V11
W11
NOTE: K6 115 YV4 Froce-loading solenoid valve Start/shut down status

FULL LOAD 15
114 KM2 KM1 (S2) signal of machines
1 Elements connected with dotted MODULATE 14 1
K5 113 YV5 91 From XT2
13 Drainage solenoid valve
lines are optional . ELECTRIC DRAIN
U22
V22
W22
U12
V12
W12
12 112
2 Jumpers should be removed K4 111 KA2 AC220V electrical source
11 Alarm relay
before adding any optional. COMMON FAULT 110
10 1
3 For remote control mode,refer K3 109 KA3 Loading signal sending relay
9
to SUPER-VISOR II SEQUENCING UNLOAD/LOAD 108
8 123
405
& PRO-TOCOL MANUAL,02250057-696/697 K2 107

YV2 Loading/offload solenoid valve
7 YV1
*-DELTA Start-up solenoid valve
220
203
4 For networking SUPERVISOR II 106

6
To XT2 404
K1 105
To XT2
RS485,refer to Network Control 5 KM1 Fan contact FR2 FR1

Wiring Diagram, 88290002-027 RUN 104 120
4
U23
V23
W23
206
U13
V13
W13
220
Emergency stop button Time relay for signal sending on

5 Protection device should 103 KT0
AC GND 3 compressor shutdown(0.1S)
be supplied by user. 102 2
120V N 2 Thermal control switch
6 Only for water-cooled machine 101 ST1
AC L 1
7 Only for air-cooled machine 1 ¦ È 121 KM2 Ventilator cooled contact T2
1 T2 T2 T1 T3
KM2 T1 T3 T1 T3
250VA 7 3 ~ 3~ 3~
FU3 50HZ FU4 KA1 M3 M2 M1
TC1 100 101 122 YV3 Spiral valve control
1L1 U1 solenoid valve
From XT0 1 YV6 Water stop solenoid 380V 50HZ 380V 50HZ
110V
380V valve(optional) 6KV/10KV
panel
panel
panel
panel
S1
II
II
II
II
1L2 V1 124 KA4 Failure signal of high 7 50Hz

From XT0 102 102 voltage electrical motor
KT0
XB 408
406
407
KT0
KT1
Time relay for signal

Supervisor
Supervisor
Supervisor
Supervisor
KT1 sending on compressor shutdown(0.1S)

KA2
KA3
II panel
KT0
KT1
From FU3
From TC1
To
To
To
To
2
KM£1 ¨ S 2 £ ©
To KA4
124
90
91
92
93
94
95
400
401
402
403
404
XT1 XT2
16 digits
101 101
101 101
120 120
102 102
102 102
102 102
103 103
104 104
105 105
105 105
106 106
107 107
108 108
109 109
110 110
111 111
112 112
113 113
114 114
115 115
115 115
116 116
117 117
121 121
122 122
123 123
124
202 202 From Supervisor II panel
205 205
206 206
206 206 To Supervisor II panel
206 206
207 207
211 211
215 215
216 216
217 217
218 218
220 220
301 301
302 302
303 303
306 306
307 307
308 308
309 309
310 310
315 315
317 317
318 318
319 319
320 320
320 320
90
92
93
94
95
404
405 405
66 digits
FR1
To FR1
To SP2
To KA4
To SB1
To SB1
To YV1
To YV2
To KM4
From SB1
To KM4
To YV1
To KA1
To YV4
To YV2
From FR1 203 203 To Supervisor II panel
From SP1 204 204 To Supervisor II panel
From
FromSB1
From SP1
Machine Loading
From SP2
From unite control S1

GND alarming machine
To KA2
5.3 WIRING DIAGRAM FOR HIGH-VOLTAGE MACHINE (AIR -COOLED/
4
From BT2(WHT)
electrical panel
electrical panel
Writing to
From BT2(RED) 214 214 To Supervisor II panel
From BT3(WHT)
From BT3(RED)
From BT1(WHT)
BP3(WHT(GRN))
instrumental panel
instrumental panel 401
instrumental panel
instrumental panel
-+
To matching terminal user side

instrumental panel
instrumental panel 91
S1
of next compressor
From BP3¡¢BP4(RED) 208 208 To Supervisor II panel
From BT3(RED¡¢GND)
From BP1¡¢BP2(BLK)
From BP1¡¢BP2(RED) 208 208
FromBP1(WHT(GRN)) 209 209 To Supervisor II panel
From BP2(WHT(GRN)) 210 210 To Supervisor II panel
From From BT1(RED) 212 212 To Supervisor II panel
From
From BP4(WHT(GRN))
From BP3¡¢BP4(BLK)
BT1¡¢BT2(RED¡¢GND) 213 213 To Supervisor II panel

To high voltage electrical
To high voltage electrical 400
To high voltage electrical 402
Connection to machine case BELDEN 9842 Shielded cables 4 cores and

S1 from high pressure panel only at chain end
2twisted strands or similar cables
From high voltage instrumental 403
From high voltage instrumental
LS25S-250/300/350 Series Screw Compressor O & M Manual Section 6 Troubleshooting & Remedy
SECTION 6 TROUBLESHOOTING AND REMEDY
6.1 GENERAL
The machine may experience troubles due to various reasons. It is important to collect
operation data systematically. Never tamper this machine without authorization. All available
data concerning the trouble should be systematically analyzed before undertaking any repairs
or component replacement procedure. Always remember to:
a. Check for loose wiring;
b. Check for damaged piping;
c. Check for parts damaged by overheat or an electrical short circuit, usually apparent by
discoloration or a burnt odor.
6.2 PROBABLE PROBLEMS AND TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE REMEDY
Low level of fluid in fluid/air Check fluid level and add, if
separator necessary
Malfunction of thermal control valve Check/c hange thermal controls
High discharge Deficient cooling water flowing Increase cooling water flow
temperature Water too hot Lower water temperature
(T1 HI) Clogged cooler element Clean pipes and bowl, if clogged
still exist, install water treatment
device
Malfunction RTD Check RTD connector , if it is good,
replace the RTD
Malfunction of unload parts (e.g. Check unload parts operation proper
High discharge blowdown valve , air inlet regulating or not
air pressure (in valve)
tank) Malfunction of unload solenoid valve Check solenoid valve
(P1 HI) Control air leak Check leakage in control line
Clogged control line strainer Service filter assembly
Air consumption exceeds air supply a. Reduce consumption;
b. Check leakage on service line
Air service Plugged air filter Change the filter elements
pressure lower Inlet butterfly valve can’t fully open Check the valve operation or reset
than rated the regulator
discharge Malfunction of pressure transducer P 2 Check the connector, or replace the
pressure transducer when necessary
Malfunction of pressure regulator Check pressure regulator , or change
when necessary
46
SYMPTOM PROBABLE CAUSE REMEDY

Malfunction of pressure transducer P 2 Check the connector, or change the
Line pressure transducer when necessary
P2 higher than Malfunction of unload parts (e.g. Check unload parts operation proper
unload pressure blowdown valve , air inlet regulating or not
valve)
Malfunction of unload solenoid valve Check solenoid valve
Control air leak Check leakage in control line
Clogged control line strainer Service filter assembly
Plugged return line filter or orifice Clean the filter, strainer and orifice
Damaged separator element or Check or replace when necessary
High fluid incorrect position of gasket
consumption
Leakage in the system Check the piping leakage
Fluid level too high Drain out excess fluid
Excess fluid foaming Change fluid
6.3 TRANSDUCERS OPERATION AND SUPERVISOR CALIBRATION

Whenever a transducer is suspected of fault, the recommended cause of action si to
measure the signal (pressure, temperature, etc.) with an alternative calibrated instrument and
compare readings. If readings conflict, the electrical and/or tubing connections should be
inspected, and if no faults are evident, then replace the TRANSDU CER and re-evaluate
against the calibrated instrument.
CALIBRATION
The Supervisor II has software calibration of the pressure and temperature probes. This
calibration affects the offset but not the slope of the pressure and temperature calculations.
Because of this, the most accurate method is to heat or pressurize the transducer to its operating
value. If this is too difficult, room temperature/open atmosphere calibration is adequate.
Calibration may only be done while machine is stopped and unarmed.
To enter calibration mode, you must press the following keys in sequence while in the default
status display mode: “ “, “ “ “ “, PROG. Once in calibration mode,
you will see a screen like the following:
CAL P1
0 6.7
In the above example, “0” refers to the amount of adjustment(in psi or ? ), 6.7 bar refers to
47
current value of P1). To make adjustment, press the” “ (UP ARROW) key to increase the
value, press the ” “ (DOWN ARROW/LAMP TEST) key to decrease the value. The
number on the left will increase or decrease always showing the total amount of adjustment.
Maximum adjustment is ±7.
The ”DISPLY” key exits, wiping out changes to the current item, while saving changes to
any previous items. The”PROG” key saves the current item and advances to the next. All
pressures and temperatures may be calibrated individually.
48
LS25S-250/300/350 Series Screw Compressor O & M Manual Section7 Recommended Parts List
SECTION 7 RECOMMENDED PARTS LIST
7.1 The parts necessary for maintenance of the compressor is shown below : -
No. Code Parts Name Part Number Qty Remark
1 016742 Fluid Stop Valve 001684 1

2 88290001-006 Thermal Valve 001084(24KT) 1
3 250034-123 Primary Separator Element 250034-124 1 Gasket
Inclusive
4 250034-129 Final Element 250034-130 1 Gasket
Inclusive
5 406929 P ressure Regulator 250028-693 1
6 409783 Blow Down Valve 001667 1
250020-353 1
7 011682-003 Sullicon
250006-526 1 Spring
02250112-031 1 Filter
8 02250112-032 Control Line Strainer
02250115-960 Floating Ball
9 Return Line Strainer 02250117-782 1
88290001-466 1 Primary
10 02250111-540 Air Filter Element
88290001-467 1 Safety E lement
11 250007-219 Filter Element of Fluid 02250139-996 1
Filter
250038-676 1 Spool
12 250038-755 Solenoid Valve
250038-730 1 Coil
250038-672 3 Spool
13 250038-666 Solenoid Valve
250038-730 3 Coil
14 408275 Pressure Regulator (Spiral 250028-693 1
Valve)
15 250038-821 Minimum Pressure Valve 250018-262 1
16 Compressor Shaft Seal 600893-001 1
17 Sullube32 Fluid 250022-669 1 5 Gallons
18 Sullube32 Fluid 250022-670 1 55 Gallons
19 24KT Fluid 02250051-153 1 5 Gallons
20 24KT Fluid 02250051-150 1 55 Gallons
Note: When Ordering Parts, Indicate Model, Serial Number Of Compressor And Part
Number (B.O.M).
49
Global Sales & Service
Head office in USA: SULLAIR CORPORATION

Subsidiary of Hamilton-Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 001-219-879-5451 or
1-800-Sullair (U.S.A. only )
Fax: 001-219-874-1273
Fax: 001-219-874-1835 (Parts)
Fax: 001-219-874-1805 (Service)
Head office in Europe: SULLAIR EUROPE, S .A.

Zone Des Granges BP 82
42602 Montbrison Cedex, France
Telephone: 0033-4-77968470
Fax: 0033-4-77968499
Head office in Asia: SULLAIR ASIA LIMITED

518068 Zuo Pao Tai Road, Chiwan, Shekou, Shenzhen, China
Tel: 0755-26851686
Fax: 0755-26853473, 26853475
Service hotline: 800-830-3977
Website: http://www.sullair -asia.c c

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INDUSTRIAL

maintenance and trouble shooting of Sullair rotary screw compressors. Before

operating the compressor, please familiarize yourself with this manual

At Sullair, we are committed to continuous product improvement. While all

changes to the product without prior notice.

Production license number: XK06-110-00019

maintenance method of Model LS25S-250/300/350 screw compressor

Special fluid provided by Sullair Co. must be used. It is prohibited to mix

different brands of fluid. The user should be aware of it.

From time to time, the product is being redesigned to seek improvement.

product itself. The user should be aware of it.

SECTION 1 COMPRESSOR SYSTEM

SECTION 5 WIRING DIAGRAM

SECTION 6 TROUBLESHOOTING AND REMEDY

SECTION 7 RECOMMENDED PARTS LIST ----------------------------------------------- 49

SECTION 1 COMPRESSOR SYSTEM

Either air-cooled or water-cooled version is available to meet your specific requirements.

TYPE 250 300 350

See Fig. 1: Overall Arrangement of Type LS25S-250/300/350 (water-cooled, low-voltage)

Fig. 1: Overall Arrangement of Type LS25S-250/300/350 (Water-cooled, Low-voltage)

1. Frame 2. Electrical Motor 3.Coupling 4. Compressor Unit 5. Fluid Cooler 6. Separator

Fig. 2: Overall Compressor Arrangement of Type LS25S-250/300/350 (Air-Cooled,

1. Frame 2. Electrical Motor 3.Coupling 4.Compressor 5. Separator 6. Acoustical Enclosure

12. Instrumental Panel

Fig. 3: Overall Arrangement of Type LS25S-250/300/350 (Water-Cooled, High-Voltage)

Fig. 4: Overall Compressor Arrangement of Type LS25S-250/300/350 (Air-Cooled, High

Sequencing valve Solenoid valve in water

Fig. 5: System Flowchart of Type LS25S-250/300/350 (Water-Cooled)

Sequencing valve Service line

Fig. 6: System Flowchart of Type LS25S-250/300/350 (Air -Cooled)

1.2 AIR INLET SYSTEM

1.3 DISCHARGE SYSTEM

1.3.2 MINIMUM PRESSURE VALVE

1.3.3 AUTOMATIC BLOWDOWN VALVE

1.3.4 PRESSURE RELIEF VALVE

1.3.5 DISCHARGE SYSTEM (AIR-COOLED)

1.4 FLUID PIPING SYSTEM

1.4.1 OPERATION OF FLUID PIPING SYSTEM

1.4.2 THERMAL VALVE

1.4.3 FLUID STOP VALVE

1.4.4 FLUID FILTER

1.4.5 RETURN LINE

1.4.6 FLUID PIPING SYSTEM (AIR - COOLED )

1.5 FLUID/AIR SEPARATOR

1.5.1 FUNCTIONAL DESCRIPTION

1.5.2 REPLACEMENT OF FILTER ELEMENTS

1.5.3 FLUID FILLING PIPE AND SIGHT GLASS

1.6 WATER PIPING SYSTEM

1.6.1 OPERATION OF WATER PIPING SYSTEM

1.6.2 AFTER COOLER

1.6.3 FLUID COOLER

1.6.4 AUTOMATIC MOISTURE SEPARATOR

1.6.5 COOLING-WATER QUALITY

25mg/L; and the fluid content lower than 5mg/L.

1.6.7 SHUTDOWN AND DRAINAGE

1.7 INSTRUMENTATION AND CONTROL

Pipe Pressure Gauge

Air Discharge Gauge

Pressure Regulator Minimum Pressure Valve

Control Line Strainer

Air Inlet Regulator

Fig. 7 Air Regulating System

(1) START-UP MODE (light load start -up process )

(3) MODULATING MODE