LS20-100 Sullair Manual.pdf

INDUSTRIALAIR COMPRESSOR LS--20 100HP (75KW) STANDARD AND 24KT OPERATOR’S MANUAL AND PARTS LIST KEEP FOR FUTURE REFERENCE Part Number 02250075--727 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 TABLE OF CONTENTS Section 1 SAFETY Page 1 1 1 2 2 2 2 3 3 4 1.1 GENERAL 1.2 PERSONAL PROTECTIVE EQUIPMENT 1.3 PRESSURE RELEASE 1.4 FIRE AND EXPLOSION 1.5 MOVING PARTS 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS 1.7 TOXIC AND IRRITATING SUBSTANCES 1.8 ELECTRICAL SHOCK 1.9 LIFTING 1.10 ENTRAPMENT Section 2 INSTALLATION 5 5 5 5 5 6 6 2.1 MOUNTING OF COMPRESSOR PACKAGE 7 8 8 8 3.1 TABLE OF SPECIFICATIONS 9 9 9 10 4.1 BASIC INTRODUCTION 13 13 14 5.1 INTRODUCTION 14 5.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION 2.2 VENTILATION AND COOLING 2.3 SERVICE AIR PIPING 2.4 SHAFT COUPLING CHECK 2.5 FLUID LEVEL CHECK 2.6 MOTOR ROTATION CHECK 2.7 ELECTRICAL PREPARATION Section 3 SPECIFICATIONS 3.2 LUBRICATION GUIDE -- STANDARD COMPRESSORS 3.3 LUBRICATION GUIDE -- 24KT COMPRESSORS 3.4 LUBRICATION GUIDE--OPTIONAL FLUID Section 4 SUPERVISOR II DESCRIPTION 4.2 KEYPAD -- ALL MODELS 4.3 STATUS DISPLAYS 4.4 LAMP INDICATORS-- ALL MODELS Section 5 COMPRESSOR SYSTEMS 5.2 DESCRIPTION OF COMPONENTS 5.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION 6 PURPOSE OF CONTROLS 6.1 INTRODUCTION 33 34 8.5 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES 29 30 30 AIR FILTER MAINTENANCE 31 SHAFT COUPLING MAINTENANCE FLUID FILTER MAINTENANCE SEPARATOR ELEMENT MAINTENANCE Section 8 TROUBLESHOOTING 33 8.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION 7.7 SUPERVISOR II OUTPUT RELAYS 6.3 SUPERVISOR II OPERATING PARAMETERS -.) Page 14 5.5 OPERATING THE COMPRESSOR 6.2 DAILY OPERATION 7.8 MOTOR ROTATION CHECK 6.TABLE OF CONTENTS (CONTINUED) Section 5 COMPRESSOR SYSTEMS (cont.6 CONTROL SYSTEM.3 CALIBRATION .11 SHUTDOWN PROCEDURE Section 7 MAINTENANCE 7.9 INITIAL SHUTDOWN PROCEDURE 6.1 INTRODUCTION 27 27 6. FUNCTIONAL DESCRIPTION Section 6 COMPRESSOR OPERATION 6.4 DELUXE PARAMETER SETUP 6.7 AIR INLET SYSTEM. FUNCTIONAL DESCRIPTION 23 23 24 25 25 26 26 27 27 6.2 PURPOSE OF CONTROLS 6. FUNCTIONAL DESCRIPTION 17 22 5.1 GENERAL 29 29 7.2 TROUBLESHOOTING 8.SETUP 6.4 MAINTENANCE EVERY 1000 HOURS OF OPERATION 5.10 SUBSEQUENT START--UP PROCEDURE 29 29 29 7.5 COMPRESSOR DISCHARGE SYSTEM. 20 DECAL GROUP 9.21 WIRING DIAGRAM LS--20 STANDARD 9.5 COMPRESSOR LUBRICATION SYSTEM (AIR--COOLED) 9. COMPRESSOR AND PARTS 9.14 ELECTRICAL CONTROL SYSTEM (AIR--COOLED) 9.17 MOTOR ASSEMBLY 9.9 COMPRESSOR COOLER ASSEMBLY (AIR--COOLED) 9.3 FRAME.6 COMPRESSOR LUBRICATION SYSTEM WITH SPIRAL VALVE (AIR--COOLED) 9.2 RECOMMENDED SPARE PARTS LIST 50 54 9.7 COMPRESSOR LUBRICATION SYSTEM (WATER--COOLED) 58 60 62 68 74 76 80 84 86 88 92 96 104 105 106 107 9.13 CONTROLS 9.1 PROCEDURE FOR ORDERING PARTS 35 38 40 42 46 9.18 ENCLOSURE ASSEMBLY (AIR--COOLED) 9.22 WIRING DIAGRAM WYE--DELTA STANDARD 9.15 ELECTRICAL CONTROL SYSTEM (WATER--COOLED) 9.4 AIR INLET ASSEMBLY 9.TABLE OF CONTENTS (CONTINUED) Section 9 PARTS LIST Page 35 9.8 COMPRESSOR LUBRICATION SYSTEM WITH SPIRAL VALVE (WATER--COOLED) 9.16 UNIT TUBING 9.10 COMPRESSOR WATER SYSTEM (WATER--COOLED) 9.24 WIRING DIAGRAM WYE--DELTA DELUXE .11 COMPRESSOR DISCHARGE SYSTEM (AIR--COOLED) 9.19 ENCLOSURE ASSEMBLY (WATER--COOLED) 9.23 WIRING DIAGRAM DELUXE STANDARD 9. MOTOR.12 COMPRESSOR DISCHARGE SYSTEM (WATER--COOLED) 9. NOTES . If the compressor is installed in an enclosed area. DO NOT change the factory setting of the relief valve. However. clogged. Failure to follow the instructions. chain or other suitable retaining devices to prevent tools or hose ends from being accidentally disconnected and expelled. Install an appropriate flow--limiting valve between the service air outlet and the shut--off (throttle) valve. most of the precautionary statements contained herein are applicable to most compressors and the concepts behind these statements are generally applicable to all compressors. cannot attempt to operate it until the condition is corrected. as well as noise exposure administrative and/or engineering controls and/or personal hearing protective equipment. pipes. of hose failure. respiratory protective equipment. either at the compressor or at any other point along the air line. State and Local codes. 1. and before attempting to refill optional air line anti--icer systems with antifreeze compound. J. Secure all hose connections by wire. valve. Use air at pressures less than 30 psig (2. DO NOT exceed manufacturer’s rated safe operating pressures for these items. fitting. Provide an appropriate flow--limiting valve at the beginning of each additional 75 feet (23m) of hose in runs of air hose exceeding 1/2” (13mm) inside diameter to reduce pressure in case of hose failure. M. procedures and safety precautions in this manual can result in accidents and injuries. air hoses. and other fittings accordingly. obstructed or otherwise disabled. DO NOT modify the compressor and/or controls in any way except with written factory approval. Flow--limiting valves are listed by pipe size and rated CFM. While not specifically applicable to all types of compressors with all types of prime movers.2 PERSONAL PROTECTIVE EQUIPMENT Prior to installing or operating the compressor. DO NOT use air tools that are rated below the maximum rating of the compressor. 1 . such as eye and face protective equipment. The following safety precautions are offered as a guide which. DO NOT tamper with sump and unit (if provided) relief valves. Tag the compressor and render it inoperative by disconnecting and locking out all power at source or otherwise disabling its prime mover. Select appropriate valves accordingly.3 PRESSURE RELEASE A. equipment intended to protect the extremities. DO NOT attempt to operate the compressor with a known unsafe condition. Keep personnel out of line with and away from the discharge opening of hoses or tools or other points of compressed air discharge. if conscientiously followed. employers and users should become familiar with. NEVER start the compressor unless it is safe to do so. I. hose. the responsibility for safe operation rests with those who use and maintain these products. protective shields and barriers and electrical protective equipment. Vent all internal pressure prior to opening any line. 1. G. will minimize the possibility of accidents throughout the useful life of this equipment. to reduce pressure in case B. Shut down the compressor and bleed the sump (receiver) to zero internal pressure before removing the cap. F. and who have read and understood this Operator’s Manual. owners.Section 1 SAFETY 1. per all applicable Federal. use and operate the compressor only in full compliance with all pertinent regulations and all applicable Federal. protective clothing.1 GENERAL Sullair Corporation and its subsidiaries design and manufacture all of their products so they can be operated safely. drain plug. standards and regulations. Install. when an air hose exceeding 1/2” (13mm) inside diameter is to be connected to the shut--off (throttle) valve. valves. standards. D. State and Local codes. Select air tools. C. so others who may not know of the unsafe condition. it is necessary to vent the relief valve to the outside of the structure or to an area of non--exposure. Read this manual prior to startup. K. connection or other component. standards and regulations. DO NOT engage in horseplay with air hoses as death or serious injury may result. L. all applicable regulations and any applicable Federal. Check the relief valve as recommended in the Maintenance Section of this manual or at a minimum of at least weekly to make sure it is not blocked. When the hose is to be used to supply a manifold. in accordance with their manufacturer’s recommendations. and then only with effective chip guarding and personal protective equipment. install an additional appropriate flow--limiting valve between the manifold and each air hose exceeding 1/2” (13mm) inside diameter that is to be connected to the manifold to reduce pressure in case of hose failure.1 bar) for cleaning purposes. and comply with. E. H. The compressor should be operated only by those who have been trained and delegated to do so. filters. Open fluid filler cap only when compressor is not running and is not pressurized. such as filters and line oilers. and Local codes. State. and regulations relative to personal protective equipment. D.17 & 18-. DO NOT ignore small cuts and burns as they may lead to infection. Clean up spills of lubricant or other combustible substances immediately. Keep hands. hot coolant. DO NOT permit fluids. if any. B. floors. hot surfaces and sharp edges and corners. B. DO NOT use air line anti--icer systems in air lines supplying respirators or other breathing air utilization equipment and DO NOT discharge air from these systems in unventilated or other confined areas. cut abraded or otherwise degraded insulation. D. Replace any wiring that has cracked. SHARP EDGES AND SHARP CORNERS A. Avoid bodily contact with hot fluid. if any. DO NOT attempt to operate the compressor with the fan. DO NOT use air from this compressor for respiration (breathing) except in full compliance with any Federal. 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. DO NOT use flammable solvents for cleaning purposes. F. 1. especially when exposed to hot or moving parts. A. 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. trash. H. Keep access doors. C. Wear snug--fitting clothing and confine long hair when working around this compressor. remove jumpers between 16-. Keep hands. or around acoustical material. including all terminals and pressure connectors in good condition. flames and other sources of ignition away and DO NOT permit smoking in the vicinity when checking or adding lubricant or when refilling air line anti--icer systems with antifreeze compound.19 (Dual Control Compressors) so the other compressor does not backfeed defeating the shutdown circuitry. including air line anti--icer system antifreeze compound or fluid film to accumulate on. DO NOT operate the compressor without proper flow of cooling air or water or with inadequate flow of lubricant or with degraded lubricant. under. or terminals that are worn.5 MOVING PARTS A. G. or on any external surfaces of the air compressor or on internal surfaces of the enclosure. Keep oily rags. E. feet. prior to attempting weld repairs. F.4 FIRE AND EXPLOSION ! WARNING When installing a Base Load Transfer (BLT) System. controls and walking surfaces clean and free of fluid. G. leaves. or other liquids to minimize the possibility of slips and falls. B. State or Local Codes or regulations. water. if such spills occur. Keep all terminals and pressure connectors clean and tight. C.Section 1 SAFETY 1. remove acoustical material. J.6 HOT SURFACES. D. prior to attempting repairs or adjustments. Keep suitable fully charged fire extinguisher or extinguishers nearby when servicing and operating the compressor. litter or other combustibles out of and away from the compressor. .7 TOXIC AND IRRITATING SUBSTANCES A. Keep grounded and/or conductive objects such as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition. 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. Remove any acoustical material or other material that may be damaged by heat or that may support combustion and is in close proximity. If necessary. Wear personal protective equipment including gloves and head covering when working in. This is especially important when compressors are remotely controlled. 1. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or operate it. clean all surfaces and then replace acoustical material. arms and other parts of the body and also clothing away from couplings. B. I. discolored or corroded. Keep a first aid kit handy. C. 2 K. Wipe down using an aqueous industrial cleaner or steam--clean as required. ! DANGER Death or serious injury can result from inhaling compressed air without using proper safety equipment. fans and other moving parts. E. Any acoustical material with a protective covering that has been torn or punctured should be replaced immediately to prevent accumulation of liquids or fluid film within the material. Shut off the compressor and allow it to cool. on or around the compressor. closed except when making repairs or adjustments. Then keep sparks. Keep all parts of the body away from all points of air discharge. Seek medical assistance promptly in case of injury. coupling or other guards removed. Keep electrical wiring. 1. Keep lift operator in constant attendance whenever compressor is suspended. noxious or corrosive fumes or substances. in each glass of clean. they should be washed with large quantities of clean water for 15 minutes. Consult the compressor operator’s manual lubrication section for information pertaining to compressor fluid fill. DO NOT store air line anti--icer system antifreeze compound in confined areas. and tag all power at source prior to attempting repairs or adjustments to rotating machinery and prior to handling any ungrounded conductors. and only by personnel that are trained. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been lifted clear of the ground. E. M. A physician. E. Make sure forklift truck forks are fully engaged and tipped back prior to lifting or transporting the compressor. Keep all parts of the body and any hand--held tools or other conductive objects away from exposed live parts of electrical system. B. as uneven floors or sudden stops may cause the compressor to tumble off. then weigh compressor before lifting. This compressor should be installed and maintained in full compliance with all applicable Federal. F. If you are unsure of the weight.9 LIFTING A. C. lock out. Keep all personnel out from under and away from the compressor whenever it is suspended. Make sure pallet--mounted compressors are firmly bolted or otherwise secured to the pallet prior to attempting to forklift or transport them. Locate the compressor or provide a remote inlet so that it is not likely to ingest exhaust fumes or other toxic. Call a physician immediately. then administer two teaspoons of baking soda in a glass of clean water. Wash with soap and water in the event of skin contact. 1. Maintain dry footing. then lift by the bail provided. possibly causing serious injury or property damage in the process. H. If neither fork pockets or pallet are provided. E. rigging and supporting structure has been inspected. lift and/or handle only in full compliance with Federal. DO NOT leave the compressor unattended with open electrical enclosures. Have patient lay down and cover eyes to exclude light. should be contacted immediately.Section 1 SAFETY C. standards and regulations. Compressors to be air lifted by helicopter must not be supported by the lifting bail but by slings instead. and also including those relative to equipment grounding conductors. then disconnect. and is fully engaged and latched on the bail or slings. Make sure entire lifting. If swallowed. utilize fork pockets if provided. H. Wear goggles or a full face shield when adding antifreeze compound to air line anti--icer systems. including those of the National Electrical Code. K. Operate the compressor only in open or adequately ventilated areas. G. bent. DO NOT attempt to lift in high winds. then lift by sling. If air line anti--icer system antifreeze compound enters the eyes or if fumes irritate the eyes. D. lock out and tag all power at source so others will not inadvertently restore power. 3 . If no bail is provided. Coolants and lubricants used in this compressor are typical of the industry. B. When moving compressors by forklift truck. seek medical treatment promptly. preferably an eye specialist. G. Inspect points of attachment for cracked welds and for cracked. then make sure compressor is secure and well balanced on forks before attempting to raise or transport it any significant distance. harmful. In any event. 1. warm water until vomit is clear. D. In the event of ingestion. The antifreeze compound used in air line antifreeze systems contains methanol and is toxic. If the compressor is provided with a lifting bail. Attempt repairs in clean. N. stand on insulating surfaces and DO NOT contact any other portion of the compressor when making adjustments or repairs to exposed live parts of the electrical system. C. I. qualified and delegated to do so. dry and well lighted and ventilated areas only. Make sure lifting hook has a functional safety latch or equivalent. is in good condition and has a rated capacity of at least the weight of the compressor. so as to minimize the possibility of creating a current path through the heart. induce vomiting by administering a tablespoon of salt. F. Set compressor down only on a level surface capable of safely supporting at least its weight and its loading unit. Avoid contact with the skin or eyes and avoid breathing the fumes. Care should be taken to avoid accidental ingestion and/or skin contact. Otherwise. Dry test all shutdown circuits prior to starting the compressor after installation. corroded or otherwise degraded members and for loose bolts or nuts prior to lifting. F. Disconnect. L. Forklift no higher than necessary to clear obstacles at floor level and transport and corner at minimum practical speeds.8 ELECTRICAL SHOCK A. If necessary to do so. State and Local codes. Make all such adjustments or repairs with one hand only. Lift compressor no higher than necessary. utilize pallet if provided. I. or fatal if swallowed. D. J. NEVER attempt to forklift a compressor that is not secured to its pallet. State and Local codes. B. 1. Make sure all personnel are out of compressor before closing and latching enclosure doors. If the compressor enclosure is large enough to hold a person and if it is necessary to enter it to perform service adjustments.Section 1 SAFETY O. DO NOT use the lifting eye bolt on the compressor motor. . to lift the entire compressor package. inform other personnel 4 before doing so.10 ENTRAPMENT A. if supplied. or else secure and tag the access door in the open position to avoid the possibility of others closing and possibly latching the door with personnel inside. With air--cooled compressors it is possible to use this heat for space heating.116 18.off valve should be installed to isolate the compressor from the service line if required. ! WARNING “The Plastic Pipe Institute recommends against the use of thermoplastic pipe to transport compressed air or other compressed gases in exposed above ground locations. A shut -. The water system must be capable of supplying the flow requirements listed in Table 1. 2. 1972.9 (75. Table 2 indicates the ventilation requirements necessary to keep the compressor running at a normal operating temperature.536 (I) Applies to compressors with canopy only (vent fan). No piping loads should be transmitted to the air and water connections provided with the package.WATER FLOW REQUIREMENTS WATER TEMP.4 cm).3) (water pressure should be between 25 and 75 psig [1. Poor leveling or excessive deflections may adversely affect the operation and longevity of these devices.Section 2 INSTALLATION 2. It is recommended that prior to initial startup. The fan air requirement is the volume of air which must flow through the compressor for proper ventilation.” (I) Sullube 32 should not be used with PVC piping systems. 5 .1 MOUNTING OF COMPRESSOR PACKAGE The compressor package should be placed over a surface or foundation that is capable of supporting its weight. while remaining level and free of deflections which may affect the driveline mounts or the inboard pipework. select a location to permit a sufficient unobstructed flow of air through the compressor to keep the operating temperature stable.2 bar).000/227 2. 2. Refer to the Coupling Service Procedures included in the Maintenance section of this manual. The specified heat rejection requirement is the amount of heat that is radiated by the compressor. 2. the fluid level should be visible in the sight glass. e. Adopted January 19. For water--cooled compressors. DO NOT install a water--cooled or an air--cooled/aftercooled compressor where it will be exposed to temperature less than 32_F(0_C).4 SHAFT COUPLING CHECK The compressor unit and motor are rigidly connected via a cast adaptor piece which maintains the shaft coupling in proper alignment. NOTE Water flow requirements are based on 80_F to 85_F (27_C to 29_C) water inlet temperature. The compressor/motor driveline is self--aligned by the use of a rigid distance piece and supported by flexible vibration isolation mounts.5 FLUID LEVEL CHECK The air compressor is also supplied with the proper amount of fluid. The minimum distance that the compressor should be from surrounding walls is three (3) feet (91. TABLE 2. it is imperative to provide adequate ventilation.000/4. It is recommended that the package frame be leveled and secured to the foundation with adequate anchorage.9 (56. 2.7 to 5.4) 19. Certain other plastic materials may also be affected. TABLE 1-. _F (_ _C) 70 (21) 80 (27) WATER FLOW GPM (LPM) 100HP 14. providing no additional pressure drop is created across the fan. The level is checked by looking at the sight glass located near the sump. and that a good grade grouting be used to insure full contact between the load bearing surfaces. However. If the sump is properly filled. Recommendation B.977/84 298. it is necessary to check the cooling water supply. This heat must be removed to assure a normal operating temperature. Also notice that the service line should be equipped with water legs and condensate drains throughout the system.VENTILATION REQUIREMENTS Cooling Type Air-cooled Water-cooled 100/75 100/75 Motor HP/KW Fan Air CFM/ M3/min (I) Heat Rejection BTU/hr / Kcal/hr 8.2 VENTILATION AND COOLING For air--cooled compressors.3 SERVICE AIR PIPING Service air piping should be installed as shown in Figure 2-. (I) Plastic Pipe Institute.1. all coupling fasteners are checked for proper tensioning. Recommended water pressure range is 25 to 75 psig (1. It may affect the bond at cemented joints.7 and 5. it is necessary to check the fluid level at installation.g. Consult a Sullair representative for assistance in utilizing this heat. To prevent excessive ambient temperature rise. in exposed plant piping.080/75.2 bar]). 6 ! DANGER Lethal shock hazard inside. etc. When looking at the motor rear end. NOTE Customer must provide electrical supply power disconnect within sight of machine. Disconnect all power at source before opening or servicing. the (START) “I” and (STOP) “O” pads. as explained in Section 2. then re-check rotation. Check incoming voltage.Section 2 INSTALLATION Figure 2-1 Service Air Piping (Typical Installation) 2. Pull out the EMERGENCY STOP button and press once. A few electrical checks should be made to help assure that the first start--up will be trouble free. 1. Required customer wiring is minimal. This action will “bump start” the motor for a very short time. it is necessary to check the direction of motor rotation. and/or any other applicable local electrical codes concerning isolation switches. 2. Check starter and overload heater sizes (see electrical parts in Parts Manual). 5. Be sure that the incoming voltage is the same voltage that the compressor was wired for. Energize the control circuits by pushing the (START) “I” pad and checking all protective devices to be sure that they will de--energize the starter coil when activated. but should be done by a qualified electrician in compliance with OSHA.7 ELECTRICAL PREPARATION Interior electrical wiring is performed at the factory. If the reversed rotation is noted. fuse disconnects. . quickly and in succession. National Electrical Code. disconnect the power to the starter and exchange any two of the three power input leads. “DRY RUN” the electrical controls by disconnecting the three (3) motor leads from the starter. A “Direction of Rotation” decal is located on the top of the compressor/motor adaptor piece.6 MOTOR ROTATION CHECK After the electrical installation has been done.6. 4. Check all electrical connections for tightness. Sullair provides a wiring diagram for use by the installer. 2. Reconnect the three (3) motor leads and jog the motor for a direction of rotation check. 3. the driveline should be rotating counterclockwise. 3 on Lubrication 9 gallons (34 liters) (Continued on page 8) 7 .) (I) 100-.45 2398 1219 1886 1483 75 WATER 13.H (ENCL.5 bar “H” -.) (I) 2640 (I) Model H Maximum Pressure: 125 psig/8.L (ENCL.) (I) 100-. (IV) The minimum distance that the compressor should be from surrounding walls and ceilings is 3 ft/915 mm.7. (V) The minimum height allowance needed to service the separator elements is 6 ft. COMPRESSOR: Type: Configuration: Bearing Type: Lubricant: Coolant: Sump Capacity: Positive displacement.2 and 3. (VI) Weight includes enclosure. 85 dBA (OPEN).H (W/O ENCL.6 bar (III) Includes standard and 24KT.) (I) 100-.H (W/O ENCL. NOTE: dBA RATINGS FREE FIELD NOISE LEVELS: 75 dBA (ENCLOSED).) LENGTH (MM) AIR (W/O ENCL.H (ENCL.L CAPACITY (M3/MIN) 100 100-. 3 in/1905 mm.1 TABLE OF SPECIFICATIONS DIMENSIONS (IV) (50 Hz) MODEL KW 100-.) (I) 100-.0 to 8.L HEIGHT (V) (MM) WEIGHT (VI) (KG) 75 AIR 13. and preferably 6 ft/1829 mm or more from the fan air discharge end of the compressor.45 2398 1219 1886 1483 75 AIR 13.H (W/O ENCL.H (ENCL.) (I) 100-.0 to 7.45 2002 1219 1525 1197 HP COOLING CAPACITY (ACFM) LENGTH (IN) WIDTH (IN) HEIGHT (V) (IN) WEIGHT (VI) (LB) 94 48 74 1/4 3270 (II) 100 AIR 500 79 48 60 WATER 500 94 48 74 1/4 3270 100 WATER 500 79 48 60 2640 100 AIR 460 94 48 74 1/4 3270 100 WATER 460 79 48 60 2640 100 AIR 460 94 48 74 1/4 3270 100 WATER 460 79 48 60 2640 (II) 100-.45 2002 1219 1525 1197 75 WATER 13.) 100-.) (I) 100-.H WIDTH (MM) 500 (II) 100 (W/O ENCL.8. fluid--lubricated. twin rotary screws Single--stage geared integral drive Anti--friction Pressurized Sullube 32 See Sections 3.) COOLING (W/O ENCL.) (II) 100-.L (ENCL.6 bar (II) Model L Maximum Pressure: 110 psig/7.5 bar. New series pressure range designations appearing after model number are as follows: “L” -.) (I) (60 Hz) (III) MODEL 100-.Section 3 SPECIFICATIONS 3.H (ENCL. . 3. various voltages 3. or when high particulate level. ! WARNING “The Plastic Pipe Institute recommends against the use of thermoplastic pipe to transport compressed air or other compressed gases in exposed above ground locations. such as high ambient temperatures coupled with high humidity. APPLICATION GUIDE Sullair encourages the user to participate in a fluid analysis program with the fluid suppliers. The fluid should be changed more frequently under severe operating conditions. e. Contact your Sullair dealer for details.Section 3 SPECIFICATIONS Duty Press: Control Type: Options: 100--110 psig (6. use only Sullair 24KT fluid. Certain other plastic materials may also be affected. The user will receive an analysis report with recommendations. corrosive gases or strong oxidizing gases are present in the air. P250SP--P250MP.3 LUBRICATION GUIDE--24KT COMPRESSORS Sullair 24KT compressors are filled with a lubricant which rarely needs to be changed. For extended life synthetic lubricants contact the nearest Sullair representative. Adopted January 19. various voltages 60 Hz MOTOR: Size: Service: Type: Options: 100 HP. whichever comes first. or when high particulate level. 104_F/40_C ambient Frame: IP23. Sullair recommends that a 24KT sample be taken at the first filter change and sent to the factory for analysis. This could result in a fluid change interval differing from that stated in the manual. 24KT lubricant 50 Hz MOTOR: Size: Service: Type: Options: 100 HP/ 75 KW. whichever comes first.9--7. 8 3.” (I) Sullube 32 should not be used with PVC piping systems. such as high ambient temperatures coupled with high humidity. 4--pole speed 3 ph. 4--pole speed 3 ph. 50 Hz. ! WARNING Mixing of other fluids within the compressor will void all warranties! SRF 1/4000 fluid should be changed every 4000 hours or once a year.4 LUBRICATION GUIDE--OPTIONAL FLUID Sullair compressors may use SRF 1/4000 fluid as an optional factory fill. ! WARNING ! WARNING Mixing of other lubricants within the compressor unit will void all warranties! Mixing of other lubricants within the compressor unit will void all warranties! Sullube 32 fluid should be changed every 8000 hours or once a year. 460 VAC. Mounting: IM1001 (Foot) IP55 enclosure. corrosive gases or strong oxidizing gases are present in the air. Recommendation B. 60 Hz. The fluid should be changed more frequently under severe operating conditions. 104_F/40_C ambient rise ODP enclosure. In the event a change of fluid is required. NEMA frame 404TSC TEFC enclosure.g.6 bar) Electro--pneumatic Higher duty pressures up to 175 psig (12. 400 VAC. This is a free service. Maintenance of all other components is still recommended as indicated in the Operator’s Manual.1 bar). Maintenance of all other components is still recommended as indicated in the Operator’s Manual. (I) Plastic Pipe Institute. 1972. in exposed plant piping.2 LUBRICATION GUIDE--STANDARD COMPRESSORS Sullair standard compressors are filled with Sullube 32 fluid as factory fill. spiral valve. A sample kit with instructions and self--addressed container is to be supplied by your Sullair Representative at start--up. It may affect the bond at cemented joints. Also used to clear alarm conditions while machine is running.Compressor is off but armed to start. S Display -.1 for following key descriptions. NOTE : the machine may start at any time. The machine will start when the sequencing conditions meet the criteria to start. S STARTING -. The Supervisor II has a two line display to show temperature. S SEQ STOP -. S Program -.2 KEYPAD--ALL MODELS The keypad is used to control the machine as well as display status and change setpoints. lamp test -.1. It has a keypad for operating the compressor. S OFF LOAD -. The lamps flash if that component is in an alarm condition.Used to enter the parameter change mode where control parameters may be displayed and changed (See PARAMETER SETUP).Starts machine if no alarm conditions are present. temperatures and other status information (See section on STATUS DISPLAYS). I S Auto -. NOTE : The machine may start at any time.Used in status displays to change displays and in parameter setup mode to increment a value. The machine will start when the remote start contact is closed. S ON LOAD -.1 BASIC INTRODUCTION Refer to Figure 4-.Used to put the machine into manual stop. pressure and status. There is a graphic illustration with lamps that light to show the item being displayed. 4. S RMT STOP -.Used to display pressures.Used in status displays to STOP 110 180 9 . This state may be entered because of a power up. and machine status on the top line. The following are the various machine status messages that indicate the state of the compressor: (Display graphics shown below.) S STOP -. It is also used to clear alarm conditions.3 STATUS DISPLAYS By default the line pressure (P2) and discharge temperature (T1) are shown on the bottom line of the display. or the unload timer had expired and stopped the machine. Refer to figure 4-. change displays and in parameter setup mode to increment a value. O S Continuous -.Machine is running and loaded. S FULL LD -. Also used to clear alarm conditions while machine is running. When in the default display the key will light all the lamps for three seconds.Compressor is off but armed to start. NOTE : the machine may start at any time.Used for various functions described in later sections. programming the control points and selecting displays. S Down arrow.Compressor is off.Starts machine and selects auto mode if no alarm conditions are present. This default display appears as follows: PROG S Up arrow -.Machine is running and off loaded.Section 4 SUPERVISOR II DESCRIPTION 4. S Stop -. This state is only displayed if the machine has a full load valve. S STANDBY -. 4.Machine is running and fully loaded.Compressor is off but armed to start.Machine is trying to start. DISPLY S Logo -. Section 4 SUPERVISOR II DESCRIPTION Figure 4-1 Supervisor II Panel MESSAGE DISPLAY SYSTEM GRAPHIC DISPLAY KEYPADS 10 . if flashing denotes the presence of an alarm.Section 4 SUPERVISOR II DESCRIPTION If there are alarms active they will alternately be shown with the default display. Each LED lamp has the following purpose.(Separate differential pressure) If lit steady.0 S Last fault log.If flashing. indicates the motor overload contact has opened. T4 -. S Separator differential pressure and the maximum limit. signifies that dP1 is being displayed.(Oil filter differential pressure) dP3 -. signifies that P1 is being displayed. indicates that oil filter maintenance is needed. if flashing denotes the presence of an alarm.(Sump and line pressure) If lit steady. signifies that T4 is being displayed.(Pressure before oil filter) dP1 -. If the temperature exceeds the limit a T1 HI shutdown will occur. The machine status will be displayed for two seconds then the alarms for two seconds each. if flashing denotes the presence of an alarm. If flashing. indicates that inlet filter maintenance is needed. HRS LOAD 000987. Embedded into the front panel schematic of the compressor are several lamps. the compressor is running.Lit if 120VAC power is applied to the Supervisor II.(Dry side discharge temperature) If lit steady. 11 .(Discharge temperature) If lit steady. P3 -. Pressing the lamp test key will light all the lamps for three seconds. For example: T1 HI 110 180 occurred.(Sump and line pressure) If lit steady. To return to the default display press the display key. signifies that T1 is being displayed.0 S Total hours that the compressor has been loaded.(Pressure after oil filter) Same as P1 & P2 except for P3.ALL MODELS To view other status press the DISPLY key. T5 -. dP 1 4 MAX 10 S Sump pressure and line pressure.(Package discharge temperature) MOTOR -.If flashing. POWER ON -. OIL FILTER -. if flashing denotes the presence of an alarm. P1 113 P2 108 S Unit discharge temperature and the maximum limit. T1 HI @1 234 S Next to last fault log.(Oil differential pressure) T1 -. T3 -. indicates that the compressor is armed but stopped because of restart timer not expired. All temperatures and pressures may be displayed as well as other status information. if flashing denotes the presence of an alarm. if flashing denotes the presence of an alarm. Up arrow moves to the next display. dP2 -. HRS RUN 001234. signifies that T3 is being displayed. signifies that T2 is being displayed. down arrow the previous display. INLET FILTER -. If the limit is exceeded. T1 210 MAX 235 S Total hours that the compressor has been running. T2 -. P2 -. The compressor may start at any time.(Interstage temperature) If lit steady.(Oil temperature) If lit steady. This shows the fault on the first line and the run hours when the fault occurred.4 LAMP INDICATORS -.If lit steady. ON -. signifies that P2 is being displayed. if flashing denotes replacement of separator is needed. T1 HI @2 204 4.If flashing. (Pressure after oil filter) P4 -. a separator maintenance warning will be displayed. remote stop or sequence stop. This shows the fault on the first line and the run hours when the fault P1 -. To scroll through the displays press the up arrow or down arrow keys. 12 . the compressor is running and in auto mode.Section 4 SUPERVISOR II DESCRIPTION AUTO -. indicates that the compressor is armed but stopped because of restart timer not expired. remote stop or sequence stop. If flashing. The compressor may start at any time.If lit steady. The components and assemblies of the air compressors are clearly shown. A fan is used to supply sufficient ventilating air to compressors equipped with a canopy. compressor discharge system.Section 5 COMPRESSOR SYSTEMS 5. On water--cooled models.1. Compared to other types of compressors. capacity control system. and Supervisor II control system. the Sullair rotary screw is unique in mechanical reliability.2 DESCRIPTION OF COMPONENTS Refer to Figure 5-. fluid is piped into a four-pass exchanger where the heat of compression is removed from the fluid. thereby removing the heat of compression from the cooling fluid. Both air--cooled and water--cooled versions have easily accessible items such as the fluid filters and control valves. with “no wear” and “no inspection” required of the working parts within the compressor unit. 5. call your nearest Sullair representative or the Sullair Corporation Service Department. electric motor. compressor inlet system. compressor cooling and lubrication system. Read Section 6 (Maintenance) to see how surprisingly easy it is to keep your air compressor in top operating condition. (See back cover). The complete package includes compressor. all mounted on a heavy gauge steel frame. On air--cooled models. The inlet air filters are also mounted for easy access and servicing.1 INTRODUCTION Your new Sullair lubricated rotary screw air compressor will provide you with a unique experience in improved reliability and greatly reduced maintenance. Should any questions arise which cannot be answered in the following text. Figure 5-1 Sullair Series LS-20 100HP/ 75KW Rotary Screw Compressor (Air-cooled) CONTROL PANEL BLOWDOWN VALVE MINIMUM PRESSURE/ CHECK VALVE FLUID/AFTER COOLER AIR FILTER SUMP TANK FLUID FILTER COMPRESSOR UNIT 13 . a separate motor--driven fan forces air through the cooler/aftercooler assembly. As the discharge temperature rises above 170_F (77_C). The compressed air/fluid mixture enters the receiver and is directed against a curved shroud. radiator--type cooler/aftercooler assembly. S Houses the final fluid separator elements. The receiver has three functions: S It acts as a primary fluid separator. the fluid flows to the main filter and on to the compressor unit. use only Sullair 24KT fluid. located downstream from the separator. A combination minimum pressure/check valve.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM. ! WARNING Mixing of other lubricants within the compressor unit will void all warranties! Sullair recommends that a 24KT sample be taken at the first filter change and sent to the factory for analysis. The cooling and lubrication system (air--cooled version) consists of a fan. Fluid is injected into the compressor unit in large quantities and mixes directly with the air as the rotors turn. 14 Fluid flows from the bottom of the receiver/sump to the thermal valve. With a Sullair compressor. a shell and tube fluid cooler. thermal valve and interconnecting piping. Fluid collecting on the bottom of each separator is returned to the compressor by a pressure difference between the receiver and the compressor inlet. The thermal valve is fully open to the compressor unit when the fluid temperature is below 170_F (77_C). an internal switch contact opens and the Supervisor II module displays a maintenance requirement message. assures a minimum receiver pressure of 50 psig (3. When the total pressure drop across the elements exceeds 10 psid (0. This valve automatically shuts off the water supply when the compressor is shut down. Sullair 24KT compressors are filled with a fluid which rarely needs to be changed. The filter has a replacement element and an integral pressure bypass valve. Its direction of movement is changed and its velocity significantly reduced. positive displacement. which is an idler.5 bar) during all conditions. In the event a change or make--up fluid is required. This valve also acts as a . cools and seals the rotors and the compression chamber. At this time. FUNCTIONAL DESCRIPTION Sullair air compressors feature the Sullair compressor unit. the Supervisor II module displays a maintenance requirement message.4 bar). S Acts as a lubricating film between the rotors allowing one rotor to directly drive the other. In addition. the air flows to the service line and the fluid is cooled in preparation for re--injection. 5. FUNCTIONAL DESCRIPTION Refer to Figures 5--2 and 5--3. a single--stage. From the cooler.5 COMPRESSOR DISCHARGE SYSTEM. lubricated--type compressor. Sight glasses are located in the return lines to observe this fluid flow. thus causing large droplets of fluid to form and fall to the bottom of the receiver/sump. The receiver is an ASME pressure vessel. The compressor unit discharges the compressed air/fluid moisture into the combination receiver/sump. due to the heat of compression. the fluid is separated from the air. The fluid flow has three primary functions: S Controls the rise of air temperature normally associated with the heat of compression. full--flow main line filter.7 bar). water--cooled models have a water pressure switch to prevent operation with inadequate water pressure. the thermal valve begins to close and a portion of the fluid then flows through the cooler. The user will receive an analysis report with recommendations. compressing the air. This unit provides continuous pulse--free air compression to meet your needs. This is a free service. S Serves as the compressor fluid sump. aftercooler and water--flow regulating valve are substituted for the radiator--type cooler on air-cooled compressors. The fluid also serves as lubricant for the anti--friction bearings and the drive gear sets. This pressure is necessary for proper air/fluid separation and proper fluid circulation while supplying air to the system. There are also orifices in these return lines (protected by strainers) to assure proper flow. After the air/fluid mixture is discharged from the compressor unit. 5. When the element pressure drop exceeds 20 psid (1. For the water--cooled models. The pressure in the receiver/sump causes fluid flow by forcing the fluid from the high pressure area of the sump to an area of lower pressure in the compressor unit. The fractional percentage of fluid remaining in the compressed air collects on the surface of the dual separator elements as the compressed air flows through them. S Seals the leakage paths between the rotors and the stator and also between the rotors themselves.3 SULLAIR COMPRESSOR UNIT. Two return lines (or scavenge tubes) lead from the bottom of each separator element to the inlet region of the compressor unit. The fluid passes through the thermal valve. The sample kit with instruction and self--addressed container is to be supplied by your Sullair representative at start--up. Water--cooled versions of the compressor have a water--flow regulating valve.Section 5 COMPRESSOR SYSTEMS 5. there is no maintenance or inspection of the internal parts of the compressor unit permitted in accordance with the terms of the warranty. the main filter and directly to the compressor unit where it lubricates. FUNCTIONAL DESCRIPTION Refer to Figure 5--3. Section 5 COMPRESSOR SYSTEMS Figure 5-2 Compressor Piping and Instrumentation Diagram 15 . is reached. above unload setting but below relief valve setting. b) A temperature level exceeding 240_F (116_C) is reached. A pressure relief valve (located on the wet side of the separator) is set to open if the sump pressure exceeds 200 psig (13. For added safety the Supervisor II module is programmed to shutdown the 16 package when: a) A pressure level. . See Supervisor II module functional description for further details on shutdown pressure levels.8 bar). Lubrication and Discharge Systems Diagram check valve preventing compressed air in the service line from bleeding back into the receiver on shutdown and during operation on the compressor in an unloaded condition.Section 5 COMPRESSOR SYSTEMS Figure 5-3 Compressor Cooling. Section 5 COMPRESSOR SYSTEMS All Sullair compressor models are equipped with a high pressure shutdown protection to shut down the compressor at 190 psig (13.1 bar). This prevents the pressure relief valve from opening under routine conditions, thereby preventing fluid loss through the pressure relief valve. A temperature switch will shut down the compressor if the discharge temperature reaches 240_F (115_C). ! 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. Fluid is added to the sump via a capped fluid filler opening, placed low on the tank to prevent overfilling of the sump. A sight glass enables the operator to visually monitor the sump fluid level. 5.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION Refer to Figures 5-- 4A through 5-- 4D. The purpose of the compressor control system is to regulate the amount of air being compressed to match the amount of compressed air being used. The capacity control system consists of a pressure switch, solenoid valve pressure regulator(s) and a control line filter. The functional description of the control system is described below in four distinct phases of operation. For explanatory purposes, this description will apply to a compressor with an operating range of 100 to 110 psig ( 6.9 to 7.6 bar). A compressor with any other pressure range would operate in the same manner except stated pressures. START MODE -- 0 TO 50 PSIG (0 TO 3.5 BAR) When the Supervisor II module “I” or “A” pad is depressed, the unit starts and the pressure quickly rises from 0 to 50 psig (0 to 3.5 bar). The pressure regulator(s) and the solenoid valve(s) remain closed, and the inlet poppet valve and spiral valve are inoperative. The spring loaded poppet is forced open by the intake air flow. The minimum pressure valve (MPV) isolates the compressed air from reaching the service line while building enough backpressure (40--50 psig [2.8--3.5 bar]) to maintain adequate lubricant fluid flow. If the optional Closed Inlet Start assembly is provided, an accumulated air signal is used to maintain the inlet poppet valve fully closed, minimizing the compression load for special drivers (i.e., Wye--Delta electric motors) during the start--up phase. After a pre--determined amount of time, the accumulated air signal is removed and the poppet is allowed to open by the air flow. NORMAL OPERATING MODE -- 50 TO 100 PSIG (3.5 to 6.9 BAR) When the compressed air pressure rises above 50 psig (3.5 bar), the minimum pressure valve opens and delivers compressed air to the service line. From this point on, the line air pressure is continually monitored by the Supervisor II. The pressure regulators and the solenoid valve remain closed during this phase, keeping the inlet poppet valve and spiral valve inactive. Both the spiral valve as well as the inlet poppet valve remain in the full load position as long as the compressor is running at 100 psig (6.9 bar) or below. MODULATING MODE (STANDARD CONTROL) -100 TO 110 PSIG (6.9 TO 7.6 BAR) If less than the rated capacity of compressed air is being used, the line pressure will rise above 100 psig (6.9 bar), and a pressure regulator starts feeding an air signal to close the inlet poppet valve, throttling the mass of air entering the compressor and thereby reducing the latter’s air delivery. The air throttling of the inlet poppet valve system increases proportionately with a rise of line pressure from 101 to 110 psig (7 to 7.6 bar). MODULATING MODE WITH OPTIONAL SPIRAL VALVE -- 100 to 110 PSIG (6.9 TO 7.6 bar) As air demand drops below the rated capacity of the compressor, the line pressure will rise above 100 psig (6.9 bar). As a result, the differential pressure regulator for the spiral valve gradually opens, applying air pressure to the spiral valve actuator. Air pressure at the actuator expands the diaphragm. The rack, in turn, engages with the pinion mounted on the spiral valve shaft assembly. This results in a rotary motion. As the spiral valve rotates, it starts opening the bypass ports gradually. Excess air is then being returned back internally to the suction end of the compressor unit. Now the compressor is fully compressing only that amount of air which is being used. As air demand keeps dropping further, the spiral valve keeps opening more and more until all the bypass ports are fully open. At this point, the spiral valve has moved into the unload (minimum) position. The spiral valve provides a modulation range from 100 to 50%. During this period, the pressure rises approximately from 100 to 105 psig (6.9 to 7.2 bar). As the air pressure exceeds 105 psig (7.2 bar), the differential pressure regulator controlling the inlet poppet valve starts opening and forcing the poppet closed, thus throttling inlet air flow to the compressor. The inlet poppet valve provides a modulation range from 50 to 40%. During this period, the pressure rises approximately from 106 to 110 psig (7.3 to 7.6 bar). During this range, the spiral valve remains in the unload position. UNLOAD MODE -- IN EXCESS OF 110 PSIG (7.6 BAR) LINE PRESSURE When little or no air demand is present, the line pressure increases beyond 110 psig (7.6 bar). At this point, the Supervisor II module energizes a solenoid valve which feeds an air signal to a) directly close the inlet poppet valve, and b) open the blowdown valve and depressurize the package to its unload level of 40 to 50 psig (2.8 to 3.5 bar). The minimum 17 Section 5 COMPRESSOR SYSTEMS Figure 5-4A Control System Diagram 18 Section 5 COMPRESSOR SYSTEMS Figure 5-4B Control System Diagram 19 Section 5 COMPRESSOR SYSTEMS Figure 5-4C Control System Diagram 20 . Section 5 COMPRESSOR SYSTEMS Figure 5-4D Control System Diagarm 21 . 9 bar) due to an increase in the air demand. dry--type filter with inertial dust separation and collection.Section 5 COMPRESSOR SYSTEMS Figure 5-5 Air Inlet System If the Supervisor II module is operating on an “I” mode.9 bar) level. and unless the line pressure falls below the 100 psig (6.7 AIR INLET SYSTEM. followed by package operation in the Load mode. is available for added air filtration and sound attenuation. of water column. Once the line pressure falls below the 100 psig (6. Supervisor II energizes the solenoid valve allowing the air pressure behind the inlet poppet valve to be vented through the solenoid valve exhaust port. a two--stage. dry--type air filter. the unit runs unloaded until the line pressure falls below 100 psig (6. 22 When the pressure drop across the filter element(s) exceeds a level of 15 in. and the inlet poppet valve opens. 5. heavy--duty. . the Supervisor II module is operating in the “A” mode. the unit runs unloaded for a pre--set length of time. Optionally. When the line pressure drops back to 100 psig (6. a switch contact opens in the Supervisor II module and a filter maintenance annunciation is displayed. an inlet poppet valve. and a spring in the actuator causes the spiral valve to return to the full load (maximum) position.5. the compressor automatically restarts. at which point it proceeds to the Normal Modulating Mode. Also the air pressure at the spiral valve actuator diaphragm is reduced through a vent hole at the spiral valve differential pressure regulator. If on the other hand. FUNCTIONAL DESCRIPTION Refer to Figure 5-. The compressor inlet system consists of a single--stage. it stops at the end of this period. The blowdown valve closes. and an adaptor piece which mounts both devices to the compressor inlet flange. pressure valve now isolates the sump vessel from the service line.9 bar).9 bar) level. thus preventing compressed air backflow during unloading or shutdown. re--closes the latter’s contacts after a current overload takes place.2.1 INTRODUCTION While Sullair has built into the 20 Series package a comprehensive array of controls and indicators to assure its proper operation. MINIMUM PRESSURE VALVE Maintains 50 psig (3.8 bar). Also prevents air/fluid backflow through compressor inlet during shutdown. Opens a pressure line between the service line and the spiral valve actuator allowing the spiral valve to regulate air delivery according to air demand. Before starting the unit. found adjacent to the Supervisor II. allowing it to regulate air delivery accord-ing to the air demand. the user should recognize and interpret readings which call for service or indicate the onset of a malfunction. and use. When pressure falls below 40 psig (2. INLET POPPET VALVE Throttles the air flow to the compressor inlet in order to match air supply to the demand. PRESSURE REGULATOR (INLET POPPET VALVE) PRESSURE REGULATOR (WITH OPTIONAL SPIRAL VALVE) Opens a pressure line between the sump and the inlet poppet valve. SOLENOID VALVE Electrically actuated. BLOWDOWN VALVE ASSEMBLY Vents the sump vessel to atmosphere during unloading and shutdown.5 bar) pressure in sump vessel. 3--way valve which controls the flow of pneumatic logic signals. so please refer to that section for your information. found on the starter’s thermal overload element housing. cuts all AC outputs from the latter and de--energizes the starter. 23 . PRESSURE RELIEF VALVE Vents the sump vessel to atmosphere if the compressed air pressure exceeds 200 psig (13. SClose the inlet poppet valve during shutdown opera-tion. Please be aware that the elements must be allowed to cool sufficiently before resetting. SPIRAL VALVE (OPTIONAL) Internally bypasses and controls the air flow capacity of the compressor. Used throughout package to: SOpen the blowdown valve.2 PURPOSE OF CONTROLS All Supervisor II module (Supervisor) related functions and indicators are presented in Section 4. in order to match air supply to the demand. A fault message (E STOP) is displayed by the Supervisor II until the button is pulled out and the “O” pad is depressed.8 bar). SClose the spiral valve during shutdown operation. This device is optional.Section 6 COMPRESSOR OPERATION 6. it closes and isolates the sump vessel from the air service line. location. Additional indicators and functions included in the package are as follows: CONTROL OR INDICATOR PURPOSE EMERGENCY STOP SWITCH Pushing in this switch. Its operation indicates fault with the Supervisor II operation or its programming. THERMAL O/L RESET Momentarily pushing this button. 6. the user should become familiar with the controls and indicators -.their purpose. 3 SUPERVISOR II OPERATING PARAMETERS-SET UP Pressing the program key enters parameter display and edit mode. The parameters are displayed in the following order: S Unload pressure -.7 bar). as well as shuts the water flow off when the package is not running.Section 6 COMPRESSOR OPERATION CONTROL OR INDICATOR PURPOSE THERMAL MIXING VALVE Bypasses fluid flow around the cooler until the former reaches a temperature of 170_F (77_C). If disabled the machine will not automatical- .7 bar). Useful for fast warm--up during start.The pressure differential below the unload pressure where the machine is loaded. Also used as lubricant sump drain valve. WYE DELT 10 SEC S Restart time -. UNLOAD 100 PSI S Load differential -.For full voltage starters this parameter is set to zero. if the water pressure falls below 10 psig (0.9 bar). Used on water--cooled packages only. DRAIN GLOBE VALVES Furnished as manual backup and bypass for the automatic (float--type) drain valve used in the condensate separator vessel. An alarm and shut down will occur when the sump pressure rises above this pressure.6 bar) the machine will unload when the line pressure is above 110 psi (7. the machine will load when the line 24 pressure goes below 100 psi (6. it should show half--full (compressor stopped) for proper fluid level. The logo key will increment by 10. For example if this parameter is set to 110 psi (7. This parameter is used to keep several machines from starting at the same time after power up.6 bar) and the load differential is set to 10 psid (0. SEPARATOR RETURN LINE SIGHT GLASSES Indicate fluid flow in the separator return lines. P1 MAX 135 PSI S Wye to delta transition timer -. Located on the sump side. Sluggish flow during full load operation indicates the need to clean the strainers fitted to the return lines. WATER REGULATOR VALVE Regulates the amount of water used. or to delay start until other equipment is started. SUMP SIGHT GLASS Indicates level of lubricant in the sump. via the Supervisor II. 6.The pressure where the machine is unloaded.6 bar). Large flow should be visible during full load operation.Time to wait after powerup before starting machine. For example if the unload pressure is set to 110 psi (7. little to no flow during unloaded operation. To move to the next parameter press the program key. WATER PRESSURE SWITCH De--energizes the starter. Used on water--cooled packages only. To increment a parameter press the up arrow key or logo key. To decrement the value press the down arrow key.Maximum sump pressure. This switch is not adjustable. Maintains a minimum temperature of 180_F (82_C) during periods of low load or low ambient temperatures. LOAD 10 PSI S P1 Max -. ROTATE 50 S Machine Capacity -.Used only for sequencing. LOWEST 90 PSI S Recovery Time -. each machine must have a unique number.Used only for sequencing. RST TIME 10 SEC S Unload Stop Timer -.This should always be selected to 9600 baud for all sequencing modes. see Sequencing & Protocol Manual for details. This is because there is another timer that keeps the machine from being started more than four times an hour. see Sequencing & Protocol Manual for details. HOURS. It may be lower for slave or monitoring modes.English. see Sequencing & Protocol 25 . BAUDRATE 9600 6. DRN TIM 1 SEC S Last Communication Number -. If there is more than one machine connected to the network. SLAVE. CAPACITY 100 S Sequence Hours -. for example).If the machine is running in AUTO mode. UNITS ENGLISH S Communications ID # -.The amount of time that the drain valve is actuated. COM ID # 1 S Communications Baud Rate -. REMOTE. RECOVER 10 SEC S Rotate Time -.Used only for sequencing.4 DELUXE PARAMETER SETUP The following parameters are only available on deluxe model Supervisor II.The time between actuation of the drain valve.Used only for sequencing. DRN INTV 10 MIN S Drain Time -. If the time is set less than 15 minutes (five minutes. Italian and French may be selected for display language. LANGUAGE ENGLISH S Units -.Used only for sequencing. see Sequencing & Protocol Manual for details. German.This is the network address of a machine. S Sequence Method -.Section 6 COMPRESSOR OPERATION ly start after power up.Used only for sequencing.English or metric units may be selected. See the Se- quencing & Protocol Manual (P/N 02250057--696) for details about these modes. SEQUENCE HOURS S Drain Interval -.This parameter sets the method used for sequencing. there may be times when the machine will run unloaded for more than five minutes. UNLD TIM 15 MIN S Language select -. this parameter specifies the amount of time that the machine will run unloaded before shutting off. The choices are DISABLED. see Sequencing & Protocol Manual for details. LAST COM 3 S Lowest Allowable Pressure -. see Sequencing & Protocol Manual for details. Spanish. COM ID#. master/local). See the previous section on operating parameter setup. S REMOTE -. If the compressor is already running. stop.Section 6 COMPRESSOR OPERATION Manual for details. S DISABLED -. To stop the compressor. SEQ HRS 1000 6. Pressing “I” while already running in manual mode will cause the Supervisor to turn off the common fault relay. and the motor overload or emergency stop contacts are not tripped. A fault message (E STOP) is displayed by the Supervisor until the button is pulled out and the “O” pad is depressed. Pressing “ ” while already running in automatic mode will cause the Supervisor II to turn off the common fault relay. S HOURS -. . To put the compressor in automatic mode press “ ”. for details see the Supervisor II Sequencing & Protocol Manual (P/N 02250057--696). This operation is as follows: P2 > UNLD ----> load solenoid turned off P2 < LOAD ----> load solenoid turned on POWER FAILURE RESTART If the restart timer (RST TIME parameter) is disabled the compressor will not try to start after a power up. pressing “ ” will switch operation to automatic. When the line pressure drops below the load setpoint. Pressing the “I”will turn on the compressor and put it in manual mode. Stopping the compressor using “O” will put the Supervisor II in manual stop mode. press “O”. pressing “I” will switch operation to manual. as long as temperatures and pressure remain within the valid operating ranges.Responds to status and parameter change messages via the RS485 network but will not respond to start. loads and unloads machines based on machine Com ID#. 6. the restart timer will start timing. starts.Sends status message about once a second. MANUAL OPERATION MODE In this mode the compressor will run indefinitely. Regardless of what the compressor is doing. load/unload.Sends status message about once a second. It will stop if the compressor runs unloaded for the number of minutes indicated by the UNLD TIM parameter . and clear any maintenance indicators. but will not start or load unless commanded to do so by a message. If the compressor is already running. but in continuous mode.Will respond to all messages. loads and unloads machines based on sequencing hours. and clear any maintenance indicators. and it will try to clear the alarm and maintenance indicators. found adjacent to the Supervisor. cuts all AC outputs from the latter and de--energizes the starter. load or unload messages. When the timer expires the machine will start. otherwise the system status will indicate STANDBY and the LED marked AUTO will flash. starts. The remote inputs and outputs are enabled (start/stop. if engaged. If P2 is already less than LOAD the compressor will start immediately. AUTOMATIC OPERATION MODE In this mode the compressor will start if line pressure (P2) is less than the LOAD parameter. This mode is used to control the machine from a master computer.5 OPERATING THE COMPRESSOR Before operating the compressor the operating parameters must be setup. In automatic mode the compressor can be stopped manually by pressing “O”. Regardless of whether in “automatic” or “manual” mode. pressing “O” puts the Supervisor II in manual stop mode. if engaged. if engaged. but in automatic mode. the common fault relay will be turned off. load or unload messages. SEQUENCING MODES The following is a brief description of sequencing modes. If the compressor is already off when “O” is pressed. If this time is set to a value the machine will go into standby after power up. S COM ID # -. S SLAVE -.6 PURPOSE OF CONTROLS 26 SWITCH OPERATION EMERGENCY STOP SWITCH Pushing in this switch.Responds to status and parameter change messages but will not respond to start. control of the load solenoid will be based on the parameters UNLD and LOAD. stop. check that the proper levThe following procedure should be used to make the el is visible in the fluid level sight glass and simply initial start--up of the compressor. May be used to provide remote indication of any pre-alarm. 5. disconnect the power to the starter and exchange any two of the three power input leads. Deluxe only -. the (START) “I” and (STOP) “O” pads. This action will bump start the motor for a very short time. see Control System Adjustments. A “Direction of Rotation” decal is located on the top of the compressor/motor adaptor piece. the driveline should be rotating in the direction indicated by the “Direction of Rotation” decal located on the top of the compressor/motor adapter piece.10 SUBSEQUENT START--UP PROCEDURE 6.Section 6 COMPRESSOR OPERATION 6. 3. oughly. Reinspect the compressor for temperature and leaks the following day. maintenance or fault shutdown condition. press “I” for manual or “ ” for automatic operation. it is necessary to check the direction of motor rotation. Observe the operating temperature. 6. 8. Check for possible leaks in piping. If the reversed rotation is noted. Open the shut--off valve to the service line. 7.used with sequencing feature. Open shut--off valve to the service line. Slowly close the shut--off valve to assure proper nameplate pressure unload setting is correct. observe the vari1. 27 .11 SHUTDOWN PROCEDURE made. 4. UNLOAD/LOAD (K3) COMMON FAULT (K4) DRAIN VALVE (K5) FULL LOAD/MODULATE (K6) NOTE: All output relays will handle 8 amperes at 120/240 VAC. When looking at the motor rear end. then re--check rotation. The compressor will unload at nameplate pressure. When the compressor is running. If adjustments are necessary.9 INITIAL START--UP PROCEDURE On subsequent start--ups. If the operating temperature exceeds 200_F (93_C). push “O” pad. 9.7 SUPERVISOR II OUTPUT RELAYS RELAY OPERATION RUN RELAY (K1) *--DELTA (K2) Contact closure energizes the compressor starter. Deluxe only -. 6. Jog motor to check for correct rotation of fan. the cooling system and installation environment should be checked. To shut the compressor down. Read the preceding pages of this manual thorous parameter displays. Pull out the EMERGENCY STOP button and press once. Controls ON LOAD/OFF LOAD operation of the load control solenoid valve. Be sure that all preparations and checks described in the Installation Section have been 6.8 MOTOR ROTATION CHECK After the electrical installation has been done.controls a solenoid valve to provide automatic condensate removal. A timed contact used to provide Wye--delta transition time. quickly and in succession. 2. 6. NOTES 28 . and/or other components when compressor is running or pressurized. Should faulty gaskets be evident.the optional heavy--duty filter adds a secondary element.3 MAINTENANCE AFTER INITIAL 50 HOURS OF OPERATION After the initial 50 hours of operation. 1. Place a bright light inside the element to inspect for damage or leak holes. The Supervisor II monitors the status of the air filter.e. 7. 7. 2. Your filter assembly includes a single element -.previous records are very helpful in determining the normalcy of the measurements. of water column.1. 2. different line pressures. it must be stored in a clean container.1 GENERAL As you proceed in reading this section. When maintenance to these devices is required. no--load. 4. 3. observe the various Supervisor II displays to check that normal readings are being made -.2 DAILY OPERATION Following a routine start. etc. fluid filter. Change the fluid filter element. cooling water temperatures. These observations should be made during all expected modes of operation (i. fluid may have to be added to the sump vessel to restore to an adequate level. DO NOT blow dirt out with compressed air.5 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES Please familiarize yourself with the safety guidelines offered in Section 1 of this manual before attempting any maintenance on the package. Clean the exterior of the filter housing. 7. ! Figure 7-1 Air Filter (Std.). it will be easy to see that the maintenance program for the air compressor is quite minimal. Air filter maintenance should be performed when the corresponding maintenance message is displayed by the Supervisor II -.this corresponds to a pressure loss condition across the unit of 15 in.Section 7 MAINTENANCE 7. 2. a few maintenance requirements are needed to rid the system of any foreign materials. Clean the return line strainers. ELEMENT REMOVAL 1. Inspect all gaskets and gasket contact surfaces of the housing. and should be investigated -. ELEMENT INSPECTION 1. Loosen the corresponding nut and sealing washer assemblies and pull the element(s) from the housing. During the initial start--up or servicing of the package. plugs. 7. If the clean element is to be stored for later use. Change the fluid filter element. Perform the following maintenance operations to prevent unnecessary problems. 29 . Clean the return line orifices.4 MAINTENANCE EVERY 1000 HOURS OF OPERATION 1. Stop compressor and relieve all internal pressure before doing so. Frequent fluid additions to maintain said level would be indicative of excessive fluid consumption. correct the condition immediately. and separator elements.see the Troubleshooting Section 8 of this manual for probable cause and remedy.) (P/N 02250060-554) WARNING * DO NOT remove caps. Concentrated light will shine through the element and disclose any holes. 3. Clean the interior of the housing with a damp cloth. Clean the return line strainers. 2. * Element Kit P/N 040899 AIR FILTER MAINTENANCE Refer to Figure 7-. the Supervisor II will display the appropriate maintenance message and flash the location LED on the graphics map as a visual reminder. full load. 3. Remove the cover assembly by loosening the wingnut securing it. 6. Element replacement is performed by reversing the removal instructions. 5. SEPARATOR ELEMENT MAINTENANCE Refer to Figure 7-. FLUID FILTER MAINTENANCE Refer to Figure 7-.Section 7 MAINTENANCE 4.this corresponds to a pressure loss condition across the units of 20 psig (1. 5. . whichever occurs first. Apply a light film of fresh oil to the new gasket and hand--tighten new element until gasket contacts the seat. 3. Disconnect all pipework connected to the sump cover. Using a strap wrench. Fluid filter maintenance should be performed when one or more of the following items occurs: S when corresponding maintenance message is displayed by the Supervisor II -.4 bar). Element service can be provided as follows: 1. DO NOT strike element(s) against a hard surface to dislodge dirt -. Clean the gasket seating surfaces.7 bar]). S every 6 months. S every 1000 hours. Make sure that the sealing washers and cover gasket are fully seated by their corresponding nuts. After the element has been installed.this may damage the sealing surfaces and/or rupture the element. Your fluid filter includes a proprietary replaceable element available solely from Sullair and its agents -. inspect and tighten all air inlet connections prior to resuming operation. 1.DO NOT substitute. 2. remove the old element and gasket. ELEMENT REPLACEMENT 1. DO NOT oil the element(s).2. Loosen and remove the twelve (12) hex head capscrews (3/4” x 2 1/2”) from the cover plate. 4. or once a year. S every fluid charge change -. Figure 7-3 Separator Element Replacement SECONDARY ELEMENT ** PRIMARY ELEMENT * Figure 7-2 Compressor Fluid Filter (P/N 02250054-605) * Replacement element P/N 02250061-137 (primary) ** Replacement element P/N 02250061-138 (secondary) * Repair Kit P/N 250025-526 30 3. Restart package and check for leaks. 2. Relieve all pressure from the sump tank and package pipework.3.STANDARD MACHINES ONLY. The separator elements should be serviced when indicated by the Supervisor II (this happens when the pressure drop across the elements has exceeded 10 psig [0. Continue tightening element an additional 1/2 to 3/4 turn. etc. 9. Loosen fasteners securing wireform guard to the distance piece and remove to allow access to the coupling assembly. 2. Loosen and remove all capscrews securing each flexible element half to the shaft hubs. INSPECTION/REMOVAL OF FLEXIBLE ELEMENT 1. with gasket attached. dirt. (40. 10. 11. which may be accessed as follows: ! DANGER Disconnect all power at source before attempting maintenance or adjustments. Remove the two (2) nested separator elements.4mm) from the bottom of each element. The compressor unit and motor are rigidly connected via a rigid adaptor piece. into the sump. 7. Clean the return line strainers.5. Reinsert the separator element. 6. 3. Re--connect all pipework. an operation best handled by Sullair personnel. (211Nm). This will insure proper fluid return during operation. Capscrews must be re--torqued to 30 ft. Figure 7-4 Drive Coupling RADIAL BOLTS (TORQUE TO 360 IN-LBS.Section 7 MAINTENANCE 4. the allowable angular and parallel shaft misalignments are presented in Figure 7-. Scrape the old gasket material from the cover and sump flange -. Reassemble in reverse order. taking care not to dent the former against the tank opening. Please note that capscrews have self--locking patches good for two re--uses. but the application of a thread--locking adhesive increases this number.4. making sure the return lines extend within 1/4” (6. Doing so will interfere with grounding circuit and may cause severe shock. 5. SHAFT COUPLING MAINTENANCE Refer to Figure 7-. 4. The only component requiring regular inspection or servicing is the coupling flexible element. elements must be replaced and Sullair contacted for further assistance. ! WARNING DO NOT remove grounding staples from the gaskets.67 NM]) ELEMENT (HALF) HUB HUB ELEMENT (HALF) RADIAL BOLTS 31 .7Nm) (dry).--lbs. Inspect the sump vessel for rust. DO NOT use any type of gasket eliminator. For reference only. thus the shafts are maintained in proper alignment at assembly. Replace the cover plate and re--fasten washer/ capscrew assemblies to 155 ft. Lift the cover plate from the sump.--lbs. [40. Inspect each element body for signs of tears or separation away from the metal flanges -. DO NOT LUBRICATE CAPSCREW THREADS! Please note that replacement of either shaft hub requires the removal of the motor.if any faults are found.avoid dropping any scraps into the sump. 8. R.50 Parallel Angular Offset Inches Degrees Inches (I) T.005 .005 (I) Angular misalignment in inches equals maximum A minus minimum B.5 . 32 .--in. . DO NOT exceed values in table above. 360 1.I.030 Torque Inches lb.Section 7 MAINTENANCE Figure 7--5 Drive Coupling Alignment Table 1 .Installation Data Max Operating Misalignment Coupling Capscrew Tightening Gap  . but NOT ALL of those possible.2 TROUBLESHOOTING SYMPTOM PROBABLE CAUSE T1 HI Message Discharge Temperature Exceeded 225_ F (107 _ C) for Pre--Alarm REMEDY Discharge Temperature Exceeded 235_ F (113_C) for Shutdown P1 HI Message Ambient Temperature Exceeded 105_ F (41 _C) Improve local ventilation (i. as it may give evidence of the presence (or not) of a fault before it turns into a serious breakdown -.2 bar) Exceeded for Pre--Alarm P1 MAX Exceeded for Shutdown Discharge Pressure Exceeded Shutdown Level Because: SEP MNTN Message COMPRESSOR DOES NOT BUILD FULL DISCHARGE PRESSURE Unloading Device (i. Inlet Poppet Valve. or the efficiency decrease of a dirty heat exchanger. provide cleaner water.. 3. If adequate. Fluid Level in Sump is Too Low Thermal Valve Malfunctioned Check/correct fluid level.e. It identifies symptoms and diagnosis of SEVERAL probable difficulties. Check for parts damaged by heat or an electrical short circuit. remote intake of process and/or cooling air. Water Flow is Low (water--cooled packages only) Check cooling water supply (i.e.3psi (. Optional Spiral Valve) Failed to Operate Check operation of unloading device.1 INTRODUCTION The foregoing information has been compiled from operational experience with your package.. Temperature RTD Malfunction Check connections from RTD. Air Demand Exceeds Supply Check air service lines for open valves or leaks.e. Check for damaged piping. Plugged Separator Replace separator elements.Section 8 TROUBLESHOOTING 8. Cooler is Plugged (water--cooled packages only) Clean tubes and/or shell -. dP1 > 10 psi (0. Solenoid Valve Failed to Operate Check operation of solenoid valve. Pressure Regulator Maladjusted Check operation of pressure regulator. replace RTD. The systematic collection of operational data cannot be over--emphasized. 33 . Control Air Signal Leaks Check tubework feeding control signal for leaks. Check/replace thermal valve. Always remember to: 1.if tube plugging persists. Cooler Fins are Dirty Clean cooler fins. P1 MAX -. Should your problem persist after making the recommended check. the vibrations signature increase of a damaged bearing.for example. closed valves). lower water temperature. 2. Water Temperature is High (water-cooled packages only) Increase water flow. 8. Check for loose wiring. usually apparent by discoloration or a burnt odor.. A detailed visual inspection is worth performing for almost all problems and may avoid unnecessary additional damage to the compressor. Blowdown Valve.7 bar) Check P1 & P2 pressure transducers. Control Air Signal Filter Clogged Service filter assembly. consult your nearest Sullair representative or the Sullair Corporation factory toll free at 1--800--SULLAIR. Inlet Valve Not Fully Open Check actuation of inlet poppet valve. Re-- Damaged or Improperly Gasketed Separator Elements Inspect separator elements and gaskets. If adequate. 8.2 TROUBLESHOOTING (Continued) SYMPTOM PROBABLE CAUSE COMPRESSOR DOES NOT BUILD FULL DISCHARGE PRESSURE (CONT.To make adjustments. you must press the following keys in sequence while in the default status display mode: “ ”.) Inlet Air Filter Clogged OIL MNTN Message REMEDY Check for maintenance message on Supervisor II display. The number on the left will increase or decrease always showing the total amount of adjustment. switch open or if machine has P3 & P4 pressure transducer. Inspect and/ or change element.ring.4 bar) LINE PRESSURE RISES ABOVE UNLOAD SETTING EXCESSIVE FLUID CONSUMPTION Pressure Sensor P2 at Fault Check connections from trans-ducer.3 CALIBRATION The Supervisor II has software calibration of the pressure and temperature probes. Press the “Y” (UP ARROW) key to increase the value. Control Air Signal Leaks Check tubework feeding control signal for leaks. “97” (6. This calibration affects the offset but not the slope of the pressure and temperature calculations. wiping out changes to the current item. Oil Differential Check oil differential switch. Blowdown Valve. press the ” (DOWN ARROW / LAMP TEST) key “B to decrease the value. The DISPLY key exits.e. while saving changes to any previous items. the electrical and/or tubing connections should be inspected. Fluid Level Too High Drain excess fluid. Because of this. “Y”. NOTE ON TRANSDUCERS: Whenever a sensor is suspected of fault.) with an alternate calibrated instrument and compare readings. Excessive Fluid Foaming Drain and change fluid. and if no faults are evident. All temperatures and pressures may be calibrated individually. The PROG key saves the current item and advances to the next. Clean strainer screen and o -. If conflicting. Optional Spiral Valve) Failed to Operate Check operation of unloading device Solenoid Valve Failed to Operate Check operation of solenoid valve. .Section 8 TROUBLESHOOTING 8. Replace if damaged. Maximum adjustment is ¦ 7. check transducers.7 bar) refers to the current value of P1). If adequate. Clean orifice.“B ” . etc. room temperature/open atmosphere calibration is adequate. See compressor Operator’s Manual for Clogged Return Line Strainer or Orifice placement kit available. Calibration may only be done while machine is stopped and unarmed. Fluid System Leaks Check tube/pipework for leaks. Pressure Sensor and/or Connections at Fault Check connections from trans-ducer. temperature. the most accurate method is to heat or pressurize the transducer to its operating value. you will see a screen like the following:In the above example. Inlet Poppet Valve. If this is too difficult. Unloading Device (i. 34 To enter calibration mode. the recommended cause of action is to measure the signal (pressure. Once in calibration mode.. “0” refers to the CAL 0 P1 97 amount of adjustment (in psi or _F. Control Air Signal Filter Clogged filter assembly service. Plugged Oil Filter Replace oil filter. PROG. dP2 > 20 psi (1. replace transducer. replace trans-ducer. then replace the sensor and re--evaluate against the calibrated instrument. fax or phone numbers below.A. No. INDICATE SERIAL NUMBER OF COMPRESSOR. France Shenzhen. Use of replacement parts other than those approved by Sullair Corporation may lead to hazardous conditions over which Sullair Corporation has no control.2 RECOMMENDED SPARE PARTS LIST DESCRIPTION KIT NUMBER QUANTITY element for air filter 02250060--554 repair kit for blowdown valve 250030--276 repair kit for thermal valve repair kit for solenoid valve 250035--291 replacement coil for solenoid valve 250035--291 repair kit for solenoid valve 250038--674 replacement coil for solenoid valve 250038--674 repair kit for solenoid valve 250031--695 replacement coil for solenoid valve 250031--695 repair kit for solenoid valve 250038--675 replacement coil for solenoid valve 250038--675 repair kit for solenoid valve 250038--755 replacement coil for solenoid valve 250038--755 replacement solenoid for solenoid valve 250038--163 replacement valve for solenoid valve 250038--163 replacement timer for solenoid valve 250038--163 repair kit for separator/trap 410143 repair kit for fluid filter 02250054--605 repair kit for air inlet valve 02250060--988 repair kit for pressure regulator 250017--280 repair kit for return line strainer 241771 repair kit primary separator element w/gaskets repair kit secondary separator element w/gaskets 040899 02250045--132 001168 250038--848 250035--292 250038--673 250031--738 250031--737 250031--738 250038--672 250038--730 250038--676 250038--730 250031--322 250031--278 250038--164 250033--038 250025--526 02250053--273 250019--453 241772 02250061--137 02250061--138 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (Continued on page 36) PLEASE NOTE: WHEN ORDERING PARTS. but are not limited to. Shekou 42602 Montbrison Cedex. SULLAIR ASIA. S. LTD. Guangdong PRV.Section 9 ILLUSTRATIONS AND PARTS LIST 9. Such conditions include. When ordering parts always indicate the Serial Number of the compressor.A.S. contact the factory directly at the address. The genuine Sullair service parts listed meet or exceed the demands of this compressor. 35 .1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the compressor was purchased. Phone: 1-800-SULLAIR (U. If for any reason parts cannot be obtained in this manner. SULLAIR EUROPE.A. Only) or 1-219-879-5451 Fax: (219) 874-1273 Fax: (219) 874-1835 (Parts) Fax: (219) 874-1205 (Service) 9. Sullair Road. 1 Zone Des Granges BP 82 Chiwan. Indiana 46360 U. This can be obtained from the Bill of Lading for the compressor or from the Serial Number Plate located on the compressor. bodily injury and compressor failure.S. Telephone: 33-477968470 PRC POST CODE 518068 Fax: 33-477968499 Telephone: 755-6851686 SULLAIR CORPORATION Fax: 755-6853473 3700 East Michigan Boulevard Michigan City. Sullube 32 (55 gallon drum) repair kit for pressure regulator 408275 (spiral valve) repair kit for minimum pressure/check valve 242405 document. Sullube 32 (5 gallon container) lubricant.2 RECOMMENDED SPARE PARTS LIST (CONTINUED) DESCRIPTION replacement element for heavy duty filter (primary) replacement element for heavy duty filter (secondary) repair kit for air cylinder removal repair kit for compressor shaft seal lubricant. Protocol (I) KIT NUMBER 409853 409854 606174--001 02250045--161 046850--001 250022--669 250022--670 250028--693 001176 02250057--696 QUANTITY 1 1 1 1 1 1 1 1 1 1 (I) This document is required to program your personal computer to communicate with the Supervisor II panel. 36 . PLEASE NOTE: WHEN ORDERING PARTS. INDICATE SERIAL NUMBER OF COMPRESSOR.Section 9 ILLUSTRATIONS AND PARTS LIST 9. 24KT (5 gallon container) lubricant. Section 9 ILLUSTRATIONS AND PARTS LIST NOTES 37 . 3 FRAME.Section 9 ILLUSTRATIONS AND PARTS LIST 9. COMPRESSOR AND PARTS 38 . MOTOR. lock reg 1/2” capscr. compr/motor support. For shaft seal repairs. hex 5/8” capscr.3 FRAME. For information regarding the unit exchange program. hex gr5 5/8”--11 x 3 1/4” washer. hex gr5 5/8”--11 x 1 3/4” capscrew. hex gr5 1/2”--13 x 2” part number quantity 250042--541 250042--756 02250052--233 consult factory 02250052--232 250042--486 250042--454 407986 consult factory 407985 406631 02250050--131 250015--817 828610--325 837510--156 837508--125 828610--200 824210--559 828610--400 829706--200 829706--075 834206--075 829705--075 828610--175 828608--200 3 2 1 1 1 1 1 1 1 1 1 2 1 2 13 9 2 1 1 2 10 12 8 8 9 (I) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sullair distributors or the factory at less cost than the owner could repair the unit. coupling frame. coupling 2” e50 element. PLEASE NOTE: WHEN ORDERING PARTS. dxx204170 (I) hub. lock reg 5/8” washer. 100hp 460/3/60 odp support. hex gr5 5/8”--11 x 4” screw. contact your nearest Sullair representative or the Sullair Corporation.Section 9 ILLUSTRATIONS AND PARTS LIST 9. hex ser wash 3/8” x 3/4” screw. order shaft seal repair kit no. coupling 2 1/8” e50 unit. MOTOR. hex ser wash 1/2” x 2” screw. coupling e50 guard. unit adapter. 02250045--161. hex gr5 5/8”--11 x 2” nut. vibration compr isolator. motor 20--100 motor. INDICATE SERIAL NUMBER OF COMPRESSOR 39 . unit 20--100 back foot hub. ser wash 5/16” x 3/4” capscr. The shaft seal is not considered part of the compressor unit in regard to the 2 year warranty. tc--hex 3/8”--16 x 3/4” screw. The normal Sullair parts warranty applies. COMPRESSOR AND PARTS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 description isolator. vibration 670--7 support. main 12/16 capscrew. 4 AIR INLET ASSEMBLY 40 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. 040899. tube m 1/4” x 1/4” capscrew. air inlet 20--100 (I) gasket. lock reg 1/2” valve. lock reg 3/4” part number quantity 02250060--554 040696 02250060--988 810204--025 828608--150 837508--125 -02250065--044 040422 828412--150 837512--188 1 1 1 3 8 8 1 1 1 8 8 (I) For maintenance on air inlet filter no. 02250053--273. (II) For maintenance on air linlet valve no.Section 9 ILLUSTRATIONS AND PARTS LIST 9.’s 8--11. (III) Spiral valve option includes parts’ key no. PLEASE NOTE: WHEN ORDERING PARTS. 1/32” x 6 1/2” x 8 1/4” valve. 02250060--988. spiral (option) (III) adapter. ferry head hd 3/4”--10 x 1 1/2” washer. order repair kit no. 8” inlet valve capscrew. hex gr 5 1/2” x 1 1/2” washer. 02250060--554. air inlet ls--20 gasket. air inlet 20--100 (II) connector. INDICATE SERIAL NUMBER OF COMPRESSOR 41 . order replacement element no.4 AIR INLET ASSEMBLY key number 1 2 3 4 5 6 7 8 9 10 11 description filter. 5 COMPRESSOR LUBRICATION SYSTEM (AIR--COOLED) 42 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. fluid level sight elbow. quad element. fluid 1 5/8”--12 (I) connector. pipe 1/2” steel elbow. sae 1 5/8”--12 tube. tube 1 1/2” tee. thermal valve orifice. 1/2” glass. order repair kit no. pipe 1/4” nipple. (II) For maintenance on thermal valve. tube 1 5/8”--12 x 1 1/4” hose. v--type (III) nipple. order replacement element no. thermal valve (II) gasket. sae 1 7/8”--12 x 1 7/8”--12 o--ring. sight valve. thermal valve adapter. pipe 90_ 1 1/2” plug. o--ring boss sae connector.1 7/8” x 1 7/8” x 1 5/8” housing. pipe 1/2” plug. 001168. INDICATE SERIAL NUMBER OF COMPRESSOR 43 . order repair kit no. pipe 1/2” x cl sc 80 tee. (III) For maintenance on strainer no 241771.red 2” x 1/4” 150# elbow.Section 9 ILLUSTRATIONS AND PARTS LIST 9. 02250054--605. PLEASE NOTE: WHEN ORDERING PARTS. straight 1/4” galv part number quantity 02250053--884 811615--150 046559 041007 040279 801515--060 040029 811820--125 02250055--088 02250054--605 020169 02250055--015 02250054--019 810520--125 811324--150 02250055--013 02250054--601 049812 02250055--014 046425 049542 022033 040381 241771 822204--000 802108--010 801515--020 807800--020 801515--010 822208--000 804415--010 2 4 5 1 2 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 (Continued on page 45) (I) For maintenance on flulid filter no.1 1/2” therm vlv/ fluid cool elbow.assy corrugated filter. 1/32” strainer. 241772. 250024--520.pipe 1/4” x cl sc 80 bushing. tube str thred 1 1/2” glass. flex 1/4” x 1/4” adapter. tube 1 1/4” union. corrugated 1 1/2” stl st elbow. 3/32” orifice.5 COMPRESSOR LUBRICATION SYSTEM (AIR--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 description hose. Section 9 ILLUSTRATIONS AND PARTS LIST 9.5 COMPRESSOR LUBRICATION SYSTEM (AIR--COOLED) 44 . pipe 1/2” x 4.5 COMPRESSOR LUBRICATION SYSTEM (AIR--COOLED) (CONTINUED) key number 32 33 34 35 36 37 description nipple. pipe 1--1/2” x cl sc 40 adapter.Section 9 ILLUSTRATIONS AND PARTS LIST 9. INDICATE SERIAL NUMBER OF COMPRESSOR 45 . filler washer. hex gr5 3/8”--16 x 1 1/2” nipple. lock reg 3/8” connector.0” sc 40 capscrew. tube m 1/4” x 1/4” part number quantity 822108--040 828606--150 822124--000 020044 837506--094 810204--025 1 4 1 1 4 2 PLEASE NOTE: WHEN ORDERING PARTS. Section 9 ILLUSTRATIONS AND PARTS LIST 9.6 COMPRESSOR LUBRICATION SYSTEM WITH SPIRAL VALVE (AIR--COOLED) 46 . order repair kit no. tube 1 1/2” tee. 1/2” glass. sae 1 7/8”--12 o--ring.1 1/2” therm vlv/oilcool union. PLEASE NOTE: WHEN ORDERING PARTS. red 2” x 1/4” 150# elbow. hex gr5 3/8”--16 x 1 1/2” part number quantity 02250060--571 811615--150 046559 041007 040279 801515--060 040029 02250054--605 020169 02250055--015 02250054--019 811324--150 02250055--013 02250054--601 049812 02250055--014 046425 049542 022033 040381 241771 02250064--784 822204--000 802108--010 801515--020 807800--020 801515--010 822208--000 804415--010 822108--040 828606--150 2 4 2 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 4 1 1 1 1 1 1 1 4 (Continued on page 49) (I) For maintenance on flulid filter no. sae 1 5/8”--12 tube. tube str thrd 1 1/2” glass. INDICATE SERIAL NUMBER OF COMPRESSOR 47 . thermal valve adapter. thermal valve orifice. (III) For maintenance on strainer no 241771. o--ring boss sae filter. v--type (III) hose. (II) For maintenance on thermal valve. pipe 1/2” steel elbow. pipe 1/2” x cl sc 80 tee. 1 7/8” x 1 7/8” x 1 5/8” housing.0” sc 40 capscrew. fluid level sight elbow. 1/32” strainer. 3/32” orifice. 250024--520.Section 9 ILLUSTRATIONS AND PARTS LIST 9. flex 1/4” x 1/4” adapter. pipe 1/2” x 4. straight 1/4” galv nipple. pipe 1/2” plug. fluid 1 5/8”--12 (I) connector. tv to cooler ac 1 1/2” elbow. 241772. assy corrugated st stl 1 nipple. pipe 1/4” x cl sc 80 bushing. pipe 1/4” nipple. 02250054--605.6 COMPRESSOR LUBRICATION SYSTEM WITH SPIRAL VALVE (AIR--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 description tube. quad element. 001168. order replacement element no. pipe 90_ 1 1/2” plug. sight valve. order repair kit no. thermal valve (II) gasket. Section 9 ILLUSTRATIONS AND PARTS LIST 9.6 COMPRESSOR LUBRICATION SYSTEM WITH SPIRAL VALVE (AIR--COOLED) 48 . 6 COMPRESSOR LUBRICATION SYSTEM WITH SPIRAL VALVE (AIR--COOLED) (CONTINUED) key number 32 33 34 35 36 37 description nipple. pipe 1 1/2” x cl sc 40 adapter.Section 9 ILLUSTRATIONS AND PARTS LIST 9. tube m 1 1/4” x 1 1/4” part number quantity 822124--000 020044 837506--094 810204--025 811615--125 810220--125 1 1 4 3 1 1 PLEASE NOTE: WHEN ORDERING PARTS. filler washer. lock reg 3/8” connector. tube m 1/4” x 1/4” elbow. tube str thrd 1 1/4” connector. INDICATE SERIAL NUMBER OF COMPRESSOR 49 . Section 9 ILLUSTRATIONS AND PARTS LIST 9.7 COMPRESSOR LUBRICATION SYSTEM (WATER--COOLED) 50 . 241772.pipe 1 1/2” x 3. order repair kit no. 250024--520. tube 1 5/8”--12 x 1 1/4” hose. 001168. fluid 1 5/8”--12 (I) connector. pipe 1 1/2” elbow. quad element. 1/2” glass. tube 1 1/4” tee. heat (fluid) nipple. order replacement element no. flex 1/4” x 1/4” adapter. 1/32” strainer.7 COMPRESSOR LUBRICATION SYSTEM (WATER--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 description elbow. thermal valve (II) gasket. pipe 1/4” part number quantity 811615--150 046559 041007 040279 040029 811820--125 02250055--088 02250054--605 020169 02250055--015 810520--125 02250055--013 02250054--601 049812 02250055--014 046425 049542 022033 040381 241771 829008--600 802208--026 250018--411 822204--000 802108--010 801515--060 801608--060 822124--030 801515--020 807800--020 801515--010 2 2 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1 4 1 2 1 1 1 1 1 (Continued on page 53) (I) For maintenance on flulid filter no. pipe 1/2” steel elbow. sae 1 7/8”--12 o--ring. reducing 2” x 1/2” x 1 1/2” exchanger. o--ring boss sae connector. red 2” x1 1/2” 150# nipple. 3/32” orifice. (II) For maintenance on thermal valve. pipe 1/4” x cl sc 80 bushing. tube str thrd 1 1/2” glass. INDICATE SERIAL NUMBER OF COMPRESSOR 51 . 1 7/8” x 1 7/8” x 1 5/8” housing. order repair kit no. thermal valve orifice. thermal valve adapter. (III) For maintenance on strainer no 241771. v--type (III) u--bolt. red 2” x1/4” 150# elbow.0” sc 40 elbow. pipe 1/2” plug.Section 9 ILLUSTRATIONS AND PARTS LIST 9. sae 1 5/8”--12 elbow. PLEASE NOTE: WHEN ORDERING PARTS. 02250054--605. fluid level sight plug. 6” pipe tee. assy corrugated filter. sight valve. Section 9 ILLUSTRATIONS AND PARTS LIST 9.7 COMPRESSOR LUBRICATION SYSTEM (WATER--COOLED) 52 . INDICATE SERIAL NUMBER OF COMPRESSOR 53 . fluid cooler to by pass tee connector. pipe 2 x 4. lock reg 3/8” capscrew. filler tube. pipe 2” x cl sc 80 part number quantity 822208--000 804415--010 822108--040 822124--000 020044 02250061--579 810224--150 837208--112 810204--025 822132--040 837506--094 828606--150 02250061--577 801515--080 822232--000 1 1 1 1 1 1 2 4 2 1 4 4 1 1 2 PLEASE NOTE: WHEN ORDERING PARTS.7 COMPRESSOR LUBRICATION SYSTEM (WATER--COOLED) (CONTINUED) key number 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 description nipple. pipe 1/2” x 4. fluid therm vlv to fluid clr elbow. pipe 2” nipple. b r 1/2” connector. pl.Section 9 ILLUSTRATIONS AND PARTS LIST 9. hex gr5 3/8”--16 x 1 1/2” tube. tube m 1/4” x 1/4” nipple. pipe 1 1/2” x cl sc 40 adapter.0 sc 40 washer. straight 1/4” galv nipple. tube m 1 1/2” x 1 1/2” washer.0” sc 40 nipple.pipe 1/2” x cl sc 80 tee. 8 COMPRESSOR LUBRICATION SYSTEM WITH SPIRAL VALVE (WATER--COOLED) 54 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. o--ring boss sae filter. pipe 1 1/2” elbow. corrugated 1 1/4” st. order replacement element no. sae 1 7/8”--12 o--ring. sight valve. red 2” x1 1/2” 150# nipple. order repair kit no. (III) For maintenance on strainer no 241771. pipe 1/2” plug. 02250054--605.Section 9 ILLUSTRATIONS AND PARTS LIST 9. INDICATE SERIAL NUMBER OF COMPRESSOR 55 . tube str thrd 1 1/2” glass. pipe 1/4” x cl sc 80 bushing. thermal valve orifice. thermal valve (II) gasket.0” sc 40 elbow. sae 1 5/8”--12 tee. st glass. reducing 2” x 1/2” x 1 1/2” heat exchanger (fluid) nipple. flex 1/4” x 1/4” adapter.8 COMPRESSOR LUBRICATION SYSTEM WITH SPIRAL VALVE (WATER--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 description elbow. straight 1/4” galv part number quantity 811615--150 046559 041007 02250064--784 040279 040029 02250054--605 020169 02250055--015 02250055--013 02250054--601 049812 02250055--014 046425 049542 022033 040381 241771 829008--600 802208--026 250018--411 822204--000 802108--010 801515--060 801608--060 822124--030 801515--020 807800--020 801515--010 822208--000 804415--010 2 2 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 2 2 1 1 4 1 2 1 1 1 1 1 1 1 (Continued on page 57) (I) For maintenance on flulid filter no. pipe 1/2” steel elbow. 241772. red 2” x 1/4” 150# elbow. (II) For maintenance on thermal valve. thermal valve adapter. v--type (III) u--bolt. fluid 1 5/8”--12 (I) connector. 6” pipe tee. 250025--526. pipe 1/4” nipple. order repair kit no. 3/32” orifice.1 7/8” x 1 7/8” x 1 5/8” housing. pipe 1/2” x cl sc 80 tee. PLEASE NOTE: WHEN ORDERING PARTS. 1/2” hose. 001168. fluid level sight plug. quad element. pipe 1 1/2” x 3. 1/32” strainer. Section 9 ILLUSTRATIONS AND PARTS LIST 9.8 COMPRESSOR LUBRICATION SYSTEM WITH SPIRAL VALVE (WATER--COOLED) 56 . 0” sc 40 washer. tube m 1 1/4” x 1 1/4” elbow. b r 1/2” connector. pipe 2” x 4. pipe 1 1/2” x cl sc 40 adapter.8 COMPRESSOR LUBRICATION SYSTEM WITH SPIRAL VALVE (WATER--COOLED) (CONTINUED) key number 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 description nipple. filler tube. tube m 1 1/2” x 1 1/2” washer. pipe 2” nipple. hex gr5 3/8”--16 x 1 1/2” tube. INDICATE SERIAL NUMBER OF COMPRESSOR 57 . tube str thrd 1 1/4” part number quantity 822108--040 822124--000 020044 02250061--579 810224--150 837208--112 810204--025 822132--040 837506--094 828606--150 02250061--577 801515--080 822232--000 810220--125 811615--125 1 1 1 1 2 4 3 1 4 4 1 1 2 1 1 PLEASE NOTE: WHEN ORDERING PARTS. fluid therm vlv to fluid clr elbow. fluid cooler to by pass tee connector. pipe 1/2” x 4. lock reg 3/8” capscrew.0” sc 40 nipple. pl. pipe 2” x cl sc 80 connector. tube m 1/4” x 1/4” nipple.Section 9 ILLUSTRATIONS AND PARTS LIST 9. Section 9 ILLUSTRATIONS AND PARTS LIST 9.9 COMPRESSOR COOLER ASSEMBLY (AIR--COOLED) 58 . h. hex locking 3/8” capscrew. fan 26” dia blade washer. lock reg 3/8” nut. cooler 20--100 support. hx gr5 5/16”--18 x 1” capscrew. venturi /cooler cooler. hex 7/16” capscrew.h. fan motor motor nut. INDICATE SERIAL NUMBER OF COMPRESSOR 59 . adapter.Section 9 ILLUSTRATIONS AND PARTS LIST 9. 5/16”--18 unc--2b thrd. starter l. lock reg 7/16” part number quantity 250017--630 250017--631 250017--977 250017--996 250017--978 02250062--046 02250053--915 consult factory consult factory consult factory 861405--092 consult factory 250006--220 837505--078 02250043--765 828605--100 828608--125 829705--075 825305--283 837206--071 825506--198 828606--125 837508--125 837506--094 824207--385 828607--100 837507--109 1 1 1 1 1 1 1 1 1 1 4 1 1 1 15 1 4 38 20 8 8 13 4 9 2 2 2 PLEASE NOTE: WHEN ORDERING PARTS. hx gr5 3/8”--16 x 1 1/4” washer. pl b r 3/8” nut. angle. venturi support. ser wash 5/16”--18 x 3/4” nut. hex flanged 5/16” washer.9 COMPRESSOR COOLER ASSEMBLY (AIR--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 description support. starter r. hex gr5 1/2”--13 x 1 1/4” lg screw. air/fluid comb 20--100 panel. blind capscrew. retainer 5/16”--18 fan guard. lock reg 5/16” insert. lock reg 1/2” washer. hex gr5 7/16”--14 x 1” washer. support cooler support. cooler 20--100 support. Section 9 ILLUSTRATIONS AND PARTS LIST 9.10 COMPRESSOR WATER SYSTEM (WATER--COOLED) 60 . pipe 1 1/4” x cl sc 40 part number 250017--978 250017--977 841215--004 049474 802102--010 810204--025 828608--125 837508--125 02250061--567 810520--125 802106--050 02250061--569 02250061--572 822120--040 801515--050 810220--125 822120--030 822220--000 822120--060 802515--050 -846400--050 846315--050 250035--291 822120--000 quantity 1 1 1 ft.0 sc 40 elbow. solenoid shut--off (option) (I) connector. support. 250035--292. sol 2--way nc 1 1/4” (II) nipple.10 COMPRESSOR WATER SYSTEM (WATER--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 description support. water reg 1 1/4” bushing. pipe 1 1/4” x 3.s. water inlet ls--20 1 1/4” elbow. flex--1/2” valve. pipe 1 1/4” connector. 250035--291. starter r.h.’s 22--25. and replacement coil no. conduit strt--1/2” conduit. tube m 1/4 x 1/4 capscrew. water flulid clr to wtr reg ls--20 nipple. pipe 1 1/4” x 6.0” sc 40 nipple. tube--m 1 1/4” x 1 1/4” bushing. red 1/2” x 1/4” 150# connector. starter l.h. 1/4” s. INDICATE SERIAL NUMBER OF COMPRESSOR 61 . 250038--848. lock reg 1/2” tube. pipe 1 1/4” x 4. order repair kit no. PLEASE NOTE: WHEN ORDERING PARTS. water aftclr to fluid clr ls--20 tube. valve.0” sc 40 union. tube m 1 1/4” x 1 1/4” nipple. pipe 1 1/4” 150# valve. 1 1 1 4 4 1 3 4 1 1 2 3 3 1 1 1 1 1 2 4 1 1 (I) Solenoid valve option includes parts’ key no. hex gr5 1/2”--13 x 1 1/4” lg washer. red 1 1/2”x 1 1/4” 150# tube. (II) For maintenance on solenoid valve no. tubing.Section 9 ILLUSTRATIONS AND PARTS LIST 9. pipe 1 1/4” x cl sc 80 nipple. 11 COMPRESSOR DISCHARGE SYSTEM (AIR--COOLED) 62 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. viton 3/4” x 1/8” gasket. (II) For maintenance on separator/trap no. sep/trap 2” to cust. relief 500 cfm valve. 1/2”m x 1/2”f . tube. 02250061--138 (secondary). air clr/sep 2” elbow. 1 1 1 1 1 1 1 1 4 1 1 1 1 3 4 1 (Continued on page 65) (I) For maintenance on blowdown valve no. rtd 100ohm tubing. air fluid sep 14” hose. thermoplastic 3/8” 0d cross.Section 9 ILLUSTRATIONS AND PARTS LIST 9. tube 2” x 2” 90_ support. 2” npt min press check u--bolt 6” separator./trap combination sep/trap. corrugated st stl 3” flange. order repair kit no. red 2” x 1/2” 150# connector. 2” mpv to cooler silencer.156 tube. probe.11 COMPRESSOR DISCHARGE SYSTEM (AIR--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 description tank. and no. pipe 2” x 2 1/2” sc 40 plug. threaded 2 1/2” tube. pipe 1/4” steel part number 02250054--125 02250059--184 819315--040 02250053--700 041006 250030--276 234125--156 02250053--698 810532--200 02250053--355 410143 02250054--613 02250053--869 250039--909 841215--004 242405 829008--600 02250060--462 826502--240 240621--7 02250060--463 02250055--464 047116 250024--746 801315--080 822132--025 807800--020 802108--020 810232--200 828610--275 807800--010 quantity 1 1 1 1 1 1 1 1 3 1 1 1 1 2 15 ft. 02250045--132. ball 3/8” tubing. pipe 150# 2” nipple. brk cust. order replacement element kits no. 250033--038. combination (II) support. PLEASE NOTE: WHEN ORDERING PARTS. 250030--276. (III) For separator maintenance. tube m 2” x 2” capscr. INDICATE SERIAL NUMBER OF COMPRESSOR 63 . air/fluid prim (III) o--ring. air 1/2” valve. conn. 02250061--137 (primary). 410143. air/flulid second (III) valve. asa 2 1/2” 150# separator. pipe 1/2” steel bushing. blowdown 2--way pneu (I) orifice. hex gr5 5/8”--11 x 2 3/4” plug. order repair kit no. sep. stl steel 1/4” valve. conn. Section 9 ILLUSTRATIONS AND PARTS LIST 9.11 COMPRESSOR DISCHARGE SYSTEM (AIR--COOLED) 64 . straight 3/8” coupling. pl b r 7/16” washer. csa flex 1/2” coupling. hex 5/8” fitting. pipe 1/2” x cl sc 80 nipple. pipe 3/4” steel part number quantity 828608--150 837508--125 837510--156 824210--559 250028--635 802100--005 822232--000 802103--015 813606--375 802415--015 801215--030 802102--005 822112--025 824208--448 822208--000 822206--000 837208--112 810204--025 828608--200 824207--385 837207--071 837507--109 828607--125 810504--012 822212--000 801515--030 -245572 846400--050 846600--050 847303--050 846315--050 801215--020 822108--015 807800--030 3 9 4 4 2 1 1 2 4 1 1 1 1 2 1 2 2 3 4 4 4 4 4 1 1 1 1 1 1 1 1 3 1 1 1 (Continued on page 67) (IV) Trap heater option includes parts’ key no. 90_ lq--tite 1/2” bushing. hex gr 5 1/2” x 1 1/2” washer. pipe 3/4” x cl sc 80 elbow. pipe 1/2” steel nipple. lock reg 7/16” capscrew. red 1/4” x 1/8” 150# nipple. hex 1/2” nipple. hex gr5 7/16”--14 x 1 1/4” elbow. hex gr5 1/2”--13 x 2” nut. compression probe bushing. red 1/2” x 1/8” 150# nipple. pipe 2” x cl sc 80 bushing. straight lq--tite 1/2” elbow. tube m 3/8” x 3/8” tee. trap (option) (IV) heater. red 3/4” x 3/8” 150# connector. pipe 3/4” steel bushing.11 COMPRESSOR DISCHARGE SYSTEM (AIR--COOLED) (CONTINUED) key number 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 description capscrew. trap 50 watt 120v connector. pipe 3/4” heater. pl. tube--m 1/4” x 1/8” nipple.Section 9 ILLUSTRATIONS AND PARTS LIST 9. INDICATE SERIAL NUMBER OF COMPRESSOR 65 . pipe 3/8” x cl sc 80 washer. PLEASE NOTE: WHEN ORDERING PARTS. b r 1/2” connector. hex 7/16” washer. red cond 3/4” x 1/2” conduit. pipe 3/4” x 2 1/2” sc 40 nut. lock reg 1/2” washer. tube m 1/4” x 1/4” capscrew.’s 59--66. lock reg 5/8” nut. pipe 1/2” x 1 1/2” sc 40 plug. 11 COMPRESSOR DISCHARGE SYSTEM (AIR--COOLED) 66 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. 31 cable valve. 250038--163. PLEASE NOTE: WHEN ORDERING PARTS. (VIII) Electric condensate drain option includes parts’ key no. order replacement solenoid no. v--type 300psi (IX) valve. sol--1/4” w/ timer 120v (X) bushing. corrugated st stl 3” drain.7 oz tube (VI) heater. sump (option) (V) adhesive. (VII) Spiral valve option includes parts’ key no. 241772. 241771. order repair kit no.Section 9 ILLUSTRATIONS AND PARTS LIST 9. rtv108 4. (IX) For maintenance on strainer no. electric condensate (option) (VIII) valve.’s 72 and 73. 250031--322. (VI) Apply adhesive to mating surface of heater before installing on tank. spiral (option) (VII) hose. replacement valve no. red 3/8” x 1/4” 150# part number quantity -02250054--398 02250069--938 241585 -02250064--754 -047115 241771 250038--163 802101--010 822204--000 801003--002 1 1 1 1 1 1 1 1 1 1 1 4 1 (V) Sump heater option includes parts’ key no. (X) For maintenance on solenoid valve no. INDICATE SERIAL NUMBER OF COMPRESSOR 67 . cord . 250031--278. red 3/8” x1/4” 150# nipple. sump 120v connector.’s 68--70. pipe 1/4” x cl sc 80 coupling.11 COMPRESSOR DISCHARGE SYSTEM (AIR--COOLED) (CONTINUED) key number 67 68 69 70 71 72 73 74 75 76 77 78 79 description heater. and replacement timer 250038--164.’s 74--79. ball 1/4” strainer. 12 COMPRESSOR DISCHARGE SYSTEM (WATER--COOLED) 68 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. air/fluid second (III) valve. and no. 410143. air/fluid prim (III) o--ring. 3 3/4” x 1/8” gasket. sep/trap combo sep/trap. bracket water in/out cust con heat exchanger. (II) For maintenance on separator/trap no. pipe 2” x 2 1/2” sc 40 plug. combination (II) probe. 2” npt min press check u--bolt 6” separator. lock reg 3/8” part number 02250054--125 02250059--184 819315--040 041006 250030--276 234125--156 02250053--355 410143 250039--909 841215--004 242405 829008--600 02250060--462 826502--240 240621--7 02250060--463 02250055--464 047116 250024--746 02250061--876 02250061--758 043008 801315--080 822132--025 807800--020 810204--025 802108--020 828610--275 828606--125 824206--337 837506--094 quantity 1 1 1 1 1 1 1 1 2 15 ft. blowdown 2--way pneu (I) orifice. hex 3/8” washer. order repair kit no. corrugated st stl 3” flange. bracket aftclr ls--20 support. tube m 1/4” x 1/4” bushing. (III) For separator maintenance. PLEASE NOTE: WHEN ORDERING PARTS. 02250045--132. hx gr 5 3/8” x 1 1/4” nut. order replacement element kits no. 02250061--138 (secondary). relief 500cfm valve. 250030--276. pipe 150# 2” nipple.156 support. stl steel 1/4” valve. air 1/2” valve. 02250061--137 (primary). air fluid sep 14” hose. aftercooler cross. 250033--038. order repair kit no. threaded 2 1/2” silencer. thermoplastic 3/8” od support. 1 3 1 1 1 1 1 1 4 2 1 1 1 1 1 4 1 4 4 4 4 (Continued on page 71) (I) For maintenance on blowdown valve no. hex gr5 5/8”--11 x 2 3/4” capscrew.12 COMPRESSOR DISCHARGE SYSTEM (WATER--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 description tank. ball 3/8” tubing. pipe 1/2” steel connector. 1/2”m x 1/2”f .Section 9 ILLUSTRATIONS AND PARTS LIST 9. INDICATE SERIAL NUMBER OF COMPRESSOR 69 . rtd 100ohm tubing. red 2” x 1/2” 150# capscr. asa 2 1/2” 150# separator. 12 COMPRESSOR DISCHARGE SYSTEM (WATER--COOLED) 70 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. hex 7/16” washer. red 1/2” x 1/8” 150# nipple. hex gr 5 1/2” x 1 1/2” washer. hex gr5 1/2”--13 x 2” nut. spiral valve (IV) hose. hex gr5 7/16”--14 x 1 1/4” option. hex 1/2” nipple.12 COMPRESSOR DISCHARGE SYSTEM (WATER--COOLED) (CONTINUED) key number 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 description washer. hex 5/8” nipple. pipe 3/8” x cl sc 80 washer. sump heater (V) part number quantity 837206--071 02250061--573 801515--080 810532--200 807800--010 828608--150 837508--125 837510--156 824210--559 822232--000 250028--635 802100--005 810232--200 802103--015 813606--375 802415--015 801215--030 02250061--575 802102--005 822112--025 824208--448 822208--000 822206--000 837208--112 828608--200 824207--385 837207--071 837507--109 828607--125 -02250064--754 810904--025 -- 4 1 1 2 1 3 9 4 4 2 2 1 2 2 4 1 1 1 1 1 2 1 2 2 4 4 4 4 4 1 1 1 1 (Continued on page 73) (IV) Spiral valve option includes items 62 and 63. 66 and 67. pl b r 7/16” washer. lock reg 1/2” washer. tube m 3/8” x 3/8” tee. tube m 2” x 2” bushing. tube--male run 1/4” x 1/4” option. red 1/4” x1/8” 150# connector. aftercooler to sep. pl. straight 3/8” coupling. pipe 2 x cl sc 80 fitting.Section 9 ILLUSTRATIONS AND PARTS LIST 9. lock reg 7/16” capscrew. lock reg 5/8” nut. pipe 2” elbow. tee. mpv to aftclr ls--20 2” elbow. tube--m 2” x 2” plug. assy corrugated st stl. (V) Sump heater option includes items 65. pipe 1/2” x cl sc 80 nipple. pl b r 3/8” tube. pipe 3/4” steel tube. ls--20 2” bushing. compression probe bushing. b r 1/2” capscrew. PLEASE NOTE: WHEN ORDERING PARTS. pipe 1/4” steel capscrew. pipe 3/4” x 2 1/2” sc 40 nut. red 3/4” x 3/8” 150# connector. INDICATE SERIAL NUMBER OF COMPRESSOR 71 . Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 COMPRESSOR DISCHARGE SYSTEM (WATER--COOLED) 72 Section 9 ILLUSTRATIONS AND PARTS LIST 9.12 COMPRESSOR DISCHARGE SYSTEM (WATER--COOLED) (CONTINUED) key number 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 description heater, sump 120vac adhesive, rtv108 4.7 oz tube (VI) conector, cord .31 cable option, trap heater (VII) heater, trap 50 watt 120v elbow, 90_ lq--tite 1/2 nipple, pipe 1/2” x 1 1/2” sc 40 coupling, pipe 1/2” steel plug, pipe 3/4” steel bushing, red cond 3/4” x 1/2” connector, straight lq--tite 1/2” conduit, csa flex 1/2” option, electric cond drain (VIII) valve, sol--1/4”w/ timer 120v (IX) strainer, v--type 300psi 1/4” (X) valve, ball 1/4” coupling, red 3/8” x 1/4” 150# nipple, pipe 1/4” x cl sc 80 bushing, red 3/8” x 1/4” 150# part number quantity 02250069--938 02250054--398 241585 -245572 846600--050 822108--015 801215--020 807800--030 847303--050 846400--050 846315--050 -250038--163 241771 047115 801003--002 822204--000 802101--010 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 4 1 (VI) Apply adhesive to mating surface of heater before installing on tank. (VII) Trap heater option includes items 69--76. (VIIII) Electric condensate drain option includes items 78--83. (IX) For maintenance on solenoid valve no. 250038--163, order replacement solenoid no. 250031--322, replacement valve no. 250031--278, and replacement timer 250038--164. (X) For maintenance on strainer no. 241771, order repair kit no. 241772. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR 73 Section 9 ILLUSTRATIONS AND PARTS LIST 9.13 CONTROLS 74 (IV) For maintenance on pressure regulator valve no.s. pressure regulator (IV) elbow. 241772. straight 1/4” s. elbow. heat tracing (V) connector.s. connector. nipple.s.31 cable insulation. stainless steel 1/4” nipple. cord . pipe 1/4” steel tee. stainless steel 1/4” valve. straight 1/4” s. pipe 1/4” swaglock 316s option. (III) Spiral valve option includes parts’ key no. pipe plug 1/32” valve.Section 9 ILLUSTRATIONS AND PARTS LIST 9. order repair kit no. PLEASE NOTE: WHEN ORDERING PARTS. tube m 1/4” x 1/4” tee. tube--m 1/4” x 1/4” orifice.s. order repair kit no. pipe 1/4” x cl s. terminal & track part number quantity 810904--025 250017--280 241771 049905 841215--004 02250052--363 250019--143 810204--025 250000--060 810504--025 232874 -241771 841215--004 408275 810504--025 02250052--363 810204--025 807800--010 250000--060 232874 250209--007 -241585 250022--693 407403 041493 1 1 1 1 12 6 1 3 4 1 2 1 1 8 1 1 5 1 1 2 1 1 1 1 50 25 1 (I) For maintenance on pressure regulator valve no. pipe 7/8” tape. (V) Heat tracing option includes parts’ key no. pressure regulator (I) strainer. 250019--453. INDICATE SERIAL NUMBER OF COMPRESSOR 75 . check 1/4” tubing. tube m 1/4” x 1/4” plug. (II) For maintenance on strainer no. v--type (II) valve. tube--m 1/4” x 1/4” nipple. heat self lim 120v block. tube m--run 1/4” valve. spiral (option) (III) strainer. 241771.’s 24--27.s.’s 13--22. pipe 1/4” x cl s. connector. order repair kit no. pipe plug 1/32” elbow. 250028--693.13 CONTROLS key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 description tee. v--type (II) tubing. 250017--280. pipe 1/4” x 1 1/2” s. orifice. 408275. Section 9 ILLUSTRATIONS AND PARTS LIST 9.14 ELECTRIC CONTROL SYSTEM (AIR--COOLED) 76 . assy Supervisor II (I) block. electrical Supervisor II harness.26 wire. conduit plastic--1/2” gasket. ring bulkhead. washer 5/16 bushing. cord for so 12/4 str 3/4” decal. panel Supervisor II controller. instrument Supervisor II assembly. contact 1 nc switch. cord g-. sol 3-. wire dx pwr reg panel.09--.5v (I) switch. washer locknut. (II) For decal part number. scrulug kpa--25 4--1/0 screw. snap 1 3/4” id connector. type g-. consult factory.14 ELECTRIC CONTROL SYSTEM (AIR--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 description wire. starter (I) assembly. INDICATE SERIAL NUMBER OF COMPRESSOR 77 . decal (II) valve. ground lug (II) transducer. cord grip . cc td 600vac (I) grip. tc--f rd 5/16” x 1/2” lug. PLEASE NOTE: WHEN ORDERING PARTS. tc--f pan #8--32 x1/2” part number quantity 850604--012 consult factory consult factory 250018--497 -consult factory 250014--656 250023--496 consult factory 250019--557 847200--050 848815--050 02250048--822 consult factory 250027--125 250028--588 02250053--117 02250054--329 02250054--328 02250054--853 consult factory -consult factory 250021--176 250042--243 813604--125 849303--010 841500--002 835705--050 849215--025 835601--050 6 3 1 1 1 2 1 3 5 2 3 1 1 1 2 1 1 1 1 1 1 1 1 4 2 1 1 2 1 1 4 (Continued on page 79) (I) To determine the proper part number for your compressor. consult electrical component decal listing in the Decal Section. oper red push/pull e22 panel.way no (I) gasket.gc (I) gasket. neoprene #12--4 so fuse. vac 22” wc n4 connector. tube--m 1/4” x 1/8” terminal. pressure 1-. wire dx ctl reg harness.Section 9 ILLUSTRATIONS AND PARTS LIST 9. pipe 1/8” npt screw.gc (I) grip. conduit--1/2” bushing. 14 ELECTRIC CONTROL SYSTEM (AIR--COOLED) 78 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. spiral (option) (III) locknut. ser wash 5/16” x 3/4” valve. springlck reg m4 nipple. enclosure 120v 30w part number quantity 810204--012 849106--002 825205--273 838405--034 825904--070 838804--090 250007--168 825305--283 829705--075 -847200--050 848815--050 consult factory 810904--012 250007--168 htr_encl_opt 250010--253 2 2 1 1 8 8 1 4 4 1 3 1 1 1 1 1 1 (III) Spiral valve option includes parts’ key no. hylug nut.14 ELECTRIC CONTROL SYSTEM (AIR--COOLED) (CONTINUED) key number 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 description connector. conduit--1/2” bushing. plated 5/16”--18 washer.Section 9 ILLUSTRATIONS AND PARTS LIST 9.7 washer. hex flanged 5/16” screw. tube--male run 1/4” x 1/8” nipple.way no tee. tube m 1/4” x 1/8” lug. conduit 1/2” x close nut. lock ext 5/16” nut. conduit plastic--1/2” valve. heater enclosure heater. PLEASE NOTE: WHEN ORDERING PARTS. hex metric m4 x . INDICATE SERIAL NUMBER OF COMPRESSOR 79 . sol 3-.’s 42--48. conduit 1/2” x close option. 15 ELECTRIC CONTROL SYSTEM (WATER--COOLED) 80 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. (III) For decal part number.15 ELECTRIC CONTROL SYSTEM (WATER--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 description fuse. tube--m 1/4” x 1/8” terminal. wire dx ctl reg harness. wire dx pwr reg panel. instrument Supervisor II assembly. and replacement coil no. washer 5/16” bushing. contact 1 nc switch. PLEASE NOTE: WHEN ORDERING PARTS. consult factory. INDICATE SERIAL NUMBER OF COMPRESSOR 81 . tc--f pan #8--32 x1/2” part number quantity various various 045433 various 250038--674 250014--656 250023--496 various 250030--037 250019--557 02250048--822 various 250027--125 250028--588 02250054--854 02250054--329 02250054--328 02250054--853 various 250017--992 -250021--176 250042--243 813604--125 849303--010 841500--002 810204--012 835705--050 849215--025 835601--038 835602--050 835601--050 3 1 1 2 1 1 3 5 1 2 1 1 2 1 1 1 1 1 1 1 1 4 2 1 1 2 2 1 1 2 2 8 (Continued on page 83) (I) To determine the proper part number for your compressor. ring bulkhead. cord #1 (I) decal. pipe 1/8” npt connector. cc td 2a 600ac (I) grip. vac 22” wc n4 connector.09--. tube--m 1/4 x 1/8 screw. self tap 10--24 x 1/2” screw. scrulug kpa--25 4--1/0 screw. washer gasket. ground lug transducer. sol valve supt gasket. (II) For maintenance on solenoid valve no. panel Supervisor II controller. pressure 0--200# 1--5v (I) valve. low water pressure assembly.26 wire. cord grip . 250038--673.Section 9 ILLUSTRATIONS AND PARTS LIST 9. starter n4 mfv nc n12 sup (I) switch. 250038--674. snap 1 3/4” id connector. type g--gc 1ga (I) bracket. tc--f pan 8”--32 x 3/8” screw. decal (III) gasket. 250031--738. consult electrical component decal listing in the Decal Section. electrical Supervisor II harness. tc--f rd 5/16” x 1/2” lug. order repair kit no. sol 3--way no 150p (II) switch. assy Supervisor II basic (I) block. oper red push/pull e22 panel. Section 9 ILLUSTRATIONS AND PARTS LIST 9.15 ELECTRIC CONTROL SYSTEM (WATER--COOLED) 82 . INDICATE SERIAL NUMBER OF COMPRESSOR 83 . springlck reg m4 locknut. enclosure 120v 30w part number quantity 849106--002 847008--000 825205--273 838405--034 825904--070 838804--090 847200--050 810204--025 825305--283 829705--075 -250010--253 2 1 1 1 8 8 1 1 4 4 1 1 Heat enclosure option includes item 44.7 washer.hex metric m4 x .15 ELECTRIC CONTROL SYSTEM (WATER--COOLED) (CONTINUED) key number 33 34 35 36 37 38 39 40 41 42 43 44 (IV) description lug. conduit red nut. conduit 1/2” connector. hylug washer. heater enclosure (IV) heater. ser wash 5/16” x 3/4” option. lock ext 5/16” nut. plated 5/16”--18 washer. tube m 1/4” x 1/4” nut. PLEASE NOTE: WHEN ORDERING PARTS.Section 9 ILLUSTRATIONS AND PARTS LIST 9. hex flanged 5/16” screw. Section 9 ILLUSTRATIONS AND PARTS LIST 9.16 UNIT TUBING 84 . 062” x .38” tube. 1. . 1/2” x 1/2”F x .Section 9 ILLUSTRATIONS AND PARTS LIST 9. pipe 1/2” x 2” orifice. tube--M 3/8” x 1/4” tube.313” bushing.38” tube.38” elbow. . . . reducing hex 1 1/4” x 1/2” tube.16 UNIT TUBING key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 description manifold.38” support orifice. INDICATE SERIAL NUMBER OF COMPRESSOR 85 . 1/8”M x 1/4”F x .25” x 1. tube--M 3/4” x 1/2” elbow.25”M x . tube--M 3/8” x 1/8” capscrew. . .188” elbow. ferry hd 1/2”--13 x 1 part number quantity 02250045--432 810206--025 02250045--056 02250045--057 810506--025 02250044--276 810506--012 828205--705 220959 810512--050 806530--020 822208--020 234125--313 802105--020 02250045--279 02250045--060 02250045--059 02250044--911 028831 828408--100 1 5 1 1 3 1 2 4 1 2 1 1 1 1 1 1 1 1 2 2 PLEASE NOTE: WHEN ORDERING PARTS.25”F capscrew.38” elbow.25” out connector. pipe 90_ 1/2” nipple.38” tube. tube--M 3/8” x 1/4” tube. . hex gr 8 5/16”--18 x 3/4” orifice. 17 MOTOR ASSEMBLY 86 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. type g--gc 3ga (575V) wire. springlock unfin 5/16” (460V & 575V) connector. cord #2 (575V) grip. burndy ya4--L4--4--3/8” (460V) lug. cord #1 (460V) washer. wire yellow (575V) grip. hex 5/16” x 1 1/4” (230V) lug.Section 9 ILLUSTRATIONS AND PARTS LIST 9. springlock unfin 5/16” (230V) Swasher. cord #250mcm (230V) lug. hex plated 5/16”--18 (460V & 575V) wire. burndy 1/0 x 3/8” (460V) grip. conduit red 3 1/2” x 2” (460V) insulator. conduit reducing 3 1/2” x 2 1/2” (230V) grip. conduit reducing 3” x 1 1/2” (575V) washer. splice t & b msc (460V & 575V) washer. burndy--hylug 350mcm x 1/2” (230V) wire. neoprene #12--4 so terminal. pl--b plated 5/16” (460V & 575V) washer. burndy ya2c--l #2--5/16” (575V) washer. wire red (230V) screw. INDICATE SERIAL NUMBER OF COMPRESSOR 87 . type g--gc 250mcm (230V) lug.17 MOTOR ASSEMBLY key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 description connector. burndy ya2c--l #2--3/8” (230V) part number quantity 851000--074 851000--074 250018--495 828605--100 849106--100 250014--560 847014--080 250006--113 824205--273 824205--273 250014--309 850604--012 849304--010 849106--002 250006--112 838205--071 838205--071 837505--078 6 3 1 6 3 2 2 3 3 6 7 6 1 1 3 6 12 3 837505--078 891000--076 828605--125 849108--035 250014--307 250014--314 849105--002 847012--060 6 3 3 3 7 7 3 2 847014--100 250014--559 250014--565 849106--004 849106--002 2 2 2 1 1 PLEASE NOTE: WHEN ORDERING PARTS. pl--b plated 5/16” (230V) Swasher. burndy ya2c--l #2--3/8” (575V) insulator. hex 5/16” x 1” (460V & 575V) lug. cord for so 12/4 st screw. wire yellow (460V) Sconnector. ring 1/4” x 12ga lug. hex plated 5/16”--18 (230V) Snut. type g--gc 1ga (460V) wire. splice t & b msc nut. 18 ENCLOSURE ASSEMBLY (AIR--COOLED) 88 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. 75” panel.18 ENCLOSURE ASSEMBLY (AIR--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 description panel. roof ls--20 panel. baffle sound panel.25” x 43. fibgs 2” x 55.00” x 68.25” weatherstrip. front seal panel. felt 1/8” x 1” part number 250018--646 02250060--284 02250053--970 02250053--969 02250059--926 02250062--531 02250062--530 02250060--287 049764 250017--312 250017--310 250018--667 02250064--130 250020--015 02250064--012 02250064--009 02250064--007 02250064--006 02250064--010 02250064--005 02250062--532 02250062--535 02250062--533 02250064--278 02250062--534 02250062--537 02250062--536 02250064--340 02250069--602 02250064--408 043502 quantity 2 1 2 2 2 2 2 2 6 1 6 2 4 12 1 2 1 1 2 1 2 1 2 1 1 1 1 1 1 1 13 ft.00” x 12. fibgs 2” x 66.5” x 41. roof ls--20 unit side panel.75” x 2.00” x 13.Section 9 ILLUSTRATIONS AND PARTS LIST 9. adj trigger lock 1” panel.50” panel.5” panel. fibgs 2” x 33. (Continued on page 91) PLEASE NOTE: WHEN ORDERING PARTS.5” panel. encl back side panel. fibgs 2” x 12” x 23” catch. end assy panel. fibgs 2” x 43. fibgls 2” x 46.50” panel. fibgls 1” x 15.75” x 7. fibgs 2” x 33.00” panel. INDICATE SERIAL NUMBER OF COMPRESSOR 89 . motor end seal panel.00” panel. end seal panel. fibgs 2” x 43.00” panel.00” x 13. corner rh panel. front/back assy grille. end 12/16 panel. fibgs 2” x 66. access side grille. bottom end panel.50” panel. corner lh panel. roof center ac grille. back seal panel. fibgs 2” x 33.5” x 23” panel. encl end 12/16 panel. compr.00” x 34.00” x 18. fibgls 2” x 16. 18 ENCLOSURE ASSEMBLY (AIR--COOLED) 90 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. self drill 1/4” x 3/4” hanger. 3/16” x 3/8” washer. hex gr5 1/4”--20 x 1” screw. hex flanged plated 5/16”--18 nut. pl b r pltd 1/4” nut. hx ser wash 5/16” x 3/4” clamp. hex unfinished 1/4”--20 panel. wire rivet. sprlock reg pltd 1/4” washer. encl front side nut. insulation part number 250022--436 838504--062 838204--071 861405--092 829104--100 829705--075 043194 049824 825305--283 824204--226 250017--311 861505--140 834504--075 02250054--281 quantity 76 ft. 16 8 8 16 96 20 8 82 8 1 8 12 61 PLEASE NOTE: WHEN ORDERING PARTS. retainer 5/16”--18 capscrew.Section 9 ILLUSTRATIONS AND PARTS LIST 9.18 ENCLOSURE ASSEMBLY (AIR--COOLED) (CONTINUED) key number 32 33 34 35 36 37 38 39 40 41 42 43 44 45 description weatherstrip. tubular int tap 1/4”--20 nut. INDICATE SERIAL NUMBER OF COMPRESSOR 91 . retainer 5/16”--18 screw. Section 9 ILLUSTRATIONS AND PARTS LIST 9.19 ENCLOSURE ASSEMBLY (WATER--COOLED) 92 . fibgs 2” x 66. fibgls 2” x 16. access side grille.00” panel.19 ENCLOSURE ASSEMBLY (WATER--COOLED) key number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 description panel. end assy panel. fibgls 2” x 46. roof center ac grille.25” x 43. fibgs 2” x 12” x 23” catch.00” panel.25 hp weatherstrip. compr. fan support ls--20. front/back assy grille.00” x 13. fibgs 2” x 55. (Continued on page 95) PLEASE NOTE: WHEN ORDERING PARTS.50” panel. motor end seal panel. roof ls--20 panel.00” x 34. 3/16” x 3/8” part number 250018--646 02250060--284 02250053--970 02250053--969 02250059--926 02250062--531 02250062--530 02250060--287 049764 250017--312 250017--310 250018--667 02250064--130 250020--015 02250064--009 02250064--007 02250064--010 02250064--005 02250062--532 02250062--535 02250062--533 02250064--278 02250062--534 02250064--340 02250069--602 02250073--906 02250064--408 410358 410179 consult factory 250022--436 quantity 2 1 2 2 2 2 2 2 6 1 6 2 4 12 2 1 2 1 2 1 2 1 1 1 1 1 1 1 1 1 76 ft.5” x 41. INDICATE SERIAL NUMBER OF COMPRESSOR 93 . corner lh panel. end seal panel.5” x 23” panel. corner rh panel.Section 9 ILLUSTRATIONS AND PARTS LIST 9.00” x 68. fibgs 2” x 33. baffle sound panel. encl end 12/16 panel.5” panel.00” panel. adj trigger lock 1” panel.50” panel. end 12/16 panel.00” x 18.5” panel. fibgs 2” x 66. encl back side panel. fibgls 1” x 15. fibgs 2” x 43. vent 18” guard. bottom end panel. exhaust fan motor.100wc panel.00” x 13. .00” x 12. roof ls--20 unit side panel. fibgs 2” x 43.25” fan. Section 9 ILLUSTRATIONS AND PARTS LIST 9.19 ENCLOSURE ASSEMBLY (WATER--COOLED) 94 . hx ser wash 5/16” x 3/4” clamp. pl b r 5/16” hanger. cord 1/2” screw. hex flanged plated 5/16”--18 nut.Section 9 ILLUSTRATIONS AND PARTS LIST 9. retainer 5/16”--18 grip. INDICATE SERIAL NUMBER OF COMPRESSOR 95 . insulation part number 838504--062 838204--071 861405--092 829104--100 829705--075 043194 049824 825305--283 824204--226 250017--311 861505--140 250018--497 834504--075 837205--071 02250054--281 quantity 16 8 8 16 104 20 8 90 8 1 8 1 12 12 56 PLEASE NOTE: WHEN ORDERING PARTS. self drill 1/4” x 3/4” washer. sprlock reg pltd 1/4” washer. retainer 5/16”--18 capscrew. hex gr5 1/4”--20 x 1” screw. pl b r pltd 1/4” nut. wire rivet. hex unfinished 1/4”--20 panel.19 ENCLOSURE ASSEMBLY (WATER--COOLED) (CONTINUED) key number 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 description washer. tubular int tap 1/4--20 nut. encl front side nut. 20 DECAL GROUP ! DANGER 3 1 2 4 9 5 6 8 7 96 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. voltage international (460V) (I) decal. rotation 7” decal. INDICATE SERIAL NUMBER OF COMPRESSOR 97 . danger air breathing sign. danger electrocution decal.20 DECAL GROUP key number 1 2 3 4 5 6 7 8 9 description sign.Section 9 ILLUSTRATIONS AND PARTS LIST 9. PLEASE NOTE: WHEN ORDERING PARTS. warning compressor fluid fill part number quantity 049855 049965 049850 250021--286 02250069--399 041065 250023--361 250027--935 049685 1 1 1 1 1 1 1 1 1 (Continued on page 99) (I) For machine with voltage other than 460V. warning sever fan port sign. consult factory for decal part number. compressor fluid Sullube 32 sign. warning sever fan sign. caution auto start/stop decal. Section 9 ILLUSTRATIONS AND PARTS LIST 9.20 DECAL GROUP 12 11 13 14 15 16 10 18 17 20 OIL STOP VALVE P/N 16742 21 98 410239 19 . water out (I) decal. water in (I) decal. rotation 3 1/2” decal. protective earth ground (not shown) Sdecal. earth ground Sdecal.Section 9 ILLUSTRATIONS AND PARTS LIST 9. water in/out (I) decal. fork lifting part number quantity 250003--144 250017--903 042218 250019--107 250019--108 049873 250022--810 250021--564 02250075--046 02250075--045 02250075--540 046540 410239 241814 1 1 1 1 1 1 1 1 2 1 1 1 1 2 (Continued on page101) (I) For water--cooled compressors only. warning food grade decal. warning auto start decal. fluid stop valve decal. INDICATE SERIAL NUMBER OF COMPRESSOR 99 .20 DECAL GROUP (CONTINUED) key number 10 11 12 13 14 15 16 17 18 19 20 21 description sign. water drain decal. PLEASE NOTE: WHEN ORDERING PARTS. danger high voltage decal. compressor lubrication decal. PE designation (not shown) decal. Section 9 ILLUSTRATIONS AND PARTS LIST 9.20 DECAL GROUP 22 24 23 R 46415 26 27 100 28 . Figure 4--1.Section 9 ILLUSTRATIONS AND PARTS LIST 9. Sullair decal. LS Supervisor II front (II) decal.20 DECAL GROUP (CONTINUED) key number 22 23 24 25 26 27 28 description decal. Supervisor II Description. PLEASE NOTE: WHEN ORDERING PARTS. INDICATE SERIAL NUMBER OF COMPRESSOR 101 . 24 KT decal. actuator decal. SRF 1/4000 fluid part number quantity 02250057--624 046415 250029--836 02250073--284 02250059--054 02250061--085 250022--839 1 2 1 1 1 1 1 (Continued on page 103) (II) See Section 4. LS--20 decal. ISO 9001 decal. 20 DECAL GROUP 30 29 31 32 102 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. 20 DECAL GROUP (CONTINUED) key number 29 30 31 32 33 description decal.Section 9 ILLUSTRATIONS AND PARTS LIST 9. electrical component (not shown) part number quantity 250009--383 250022--725 02250073--941 250021--483 250038--457 1 1 1 1 1 PLEASE NOTE: WHEN ORDERING PARTS. INDICATE SERIAL NUMBER OF COMPRESSOR 103 . Sullube label. LS std Supervisor II information decal. fluid monitor program decal. logo SRF 1/4000 decal. Section 9 ILLUSTRATIONS AND PARTS LIST 9.21 WIRING DIAGRAM LS--20 STANDARD 104 . 22 WIRING DIAGRAM WYE--DELTA STANDARD 105 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. 23 WIRING DIAGRAM DELUXE STANDARD 106 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. 24 WIRING DIAGRAM WYE--DELTA DELUXE 107 .Section 9 ILLUSTRATIONS AND PARTS LIST 9. S.WORLDWIDE SALES AND SERVICE R SULLAIR ASIA. Indiana 46360 U.A. PRC POST CODE 518068 Telephone: 755--6851686 Fax: 755--6853473 SULLAIR EUROPE. Shekou Shenzhen. France Telephone: 33--477968470 Fax: 33--477968499 SULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City. Zone Des Granges BP 82 42602 Montbrison Cedex. Sullair Road.S. Guangdong PRV. No. LTD.S.A.A. 1 Chiwan. Specifications Subject To Change Without Prior Notice . Telephone: 1--219--879--5451 Fax: (219) 874--1273 Fax: (219) 874--1835 (Parts) Fax: (219) 874--1288 (Service) Printed in U.