Sullair LS-32, Operator'S Manual And Parts List

Page 1: ...EEP FOR FUTURE REFERENCE Part Number 02250142 816 Sullair Corporation OPERATOR S MANUAL AND PARTS LIST INDUSTRIAL ROTARY SCREW AIR COMPRESSOR LS 3 32 350 400HP LOW PRESSURE AIR COOLED STANDARD and 24K...

Page 2: ...porate headquarters in Michigan City Indiana Instruction includes discussion of the function and installation of Sullair service parts troubleshooting of the most common problems and actual equipment...

Page 3: ...ON 5 2 2 DESCRIPTION OF COMPONENTS 6 2 3 SULLAIR COMPRESSOR UNIT FUNCTIONAL DESCRIPTION 6 2 4 COMPRESSOR COOLING AND LUBRICATION SYSTEM FUNCTIONAL DESCRIPTION 7 2 5 COMPRESSOR DISCHARGE SYSTEM FUNCTIO...

Page 4: ...TEMPERATURE AND TIMER SETTINGS 29 5 6 MAINTENANCE PREVENTIVE MAINTENANCE INFORMATION AND TIMERS 29 5 7 SEQUENCING SEQUENCING COMMUNICATION PARAMETERS 30 5 8 SYSTEM DISPLAY DISPLAY OF MODES OF MACHINE...

Page 5: ...PROCEDURES 39 MAIN FILTER MAINTENANCE 40 AIR FILTER MAINTENANCE 41 SEPARATOR ELEMENTS REPLACEMENT 42 OIL RETURN SIGHT GLASS MAINTENANCE 42 DIFFERENTIAL PRESSURE REGULATOR ADJUSTMENT 42 COMPRESSOR DRI...

Page 6: ...NOTES...

Page 7: ...trols and or personal hearing protective equipment 1 3 PRESSURE RELEASE A Install an appropriate flow limiting valve between the service air outlet and the shut off throttle valve either at the compre...

Page 8: ...uch as tools away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition G Remove any acoustical material or other materi al that may be damaged...

Page 9: ...CAL SHOCK A This compressor should be installed and main tained in full compliance with all applicable Federal State and Local codes standards and regulations including those of the National Electrica...

Page 10: ...ssor M Forklift no higher than necessary to clear obsta cles at floor level and transport and corner at mini mum practical speeds N Make sure pallet mounted compressors are firm ly bolted or otherwise...

Page 11: ...e air compressors are clearly shown The complete package includes compres sor electric motor compressor inlet system compressor discharge system compressor cooling and lubrication system capacity con...

Page 12: ...lubricating film between the rotors allowing one rotor to directly drive the other which is an idler After the air fluid mixture is discharged from the compressor unit the fluid is separated from the...

Page 13: ...d against an internal baffle The direction of movement is changed and its velocity significantly reduced thus causing the large droplets of fluid to fall to the bottom of the receiv er sump The fracti...

Page 14: ...Section 2 DESCRIPTION 8 Figure 2 2 Compressor Piping and Instrument Diagram 02250140 998R02...

Page 15: ...4 orifice 094 02250125 776 1 15 glass sight 1 4 02250126 129 2 16 strainer v type 3000 psi 1 4 02250117 782 2 17 trap automatic 042034 1 18 tank fluid sep 02250129 137 1 19 unit compressor 32 series 1...

Page 16: ...Section 2 DESCRIPTION 10 Figure 2 2 Compressor Piping and Instrument Diagram 02250140 998R02...

Page 17: ...ay univ 115v 020250125 679 2 37 valve check 1 4 nptf 02250110 557 2 38 valve thermal 2 5 170 deg 02250120 955 1 39 orf cap 031 x 1 4 02250132 934 2 40 orf 03 02250101 191 1 41 valve shuttle 1 4 408893...

Page 18: ...range of 60 to 70 psig 4 2 to 4 8 bar A compressor with any other pressure range would operate in the same manner except for the stated pressures START MODE 0 TO 40 PSIG 0 TO 2 8 BAR When the compress...

Page 19: ...al valve actuator Air pres sure 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...

Page 20: ...and the butterfly valve remain in the unload position When the line pressure drops back to 60 psig 4 2 bar due to an increase in the air demand Supervisor Controller energizes the solenoid valve allow...

Page 21: ...Section 2 DESCRIPTION 15 Figure 2 5A Control System KEY COMPONENTS...

Page 22: ...Section 2 DESCRIPTION 16 Figure 2 5B Control System START...

Page 23: ...Section 2 DESCRIPTION 17 Figure 2 5C Control System MODULATION...

Page 24: ...Section 2 DESCRIPTION 18 Figure 2 5D Control System UNLOAD...

Page 25: ...Section 2 DESCRIPTION 19 Figure 2 5E Control System FULL LOAD...

Page 26: ...e The vacuum switch located in the compressor Supervisor Controller control system indicates the condition of the air filter When the message AIR FILTER MAINT RQD is displayed maintenance is required...

Page 27: ...e Figure 3 1 Sullair 24KT compressors are filled with a lubricant which rarely ever needs to be changed In the event a change of fluid or make up fluid is required use only Sullair 24KT fluid Mixing o...

Page 28: ...Section 3 SPECIFICATIONS 22 Figure 3 2 Identification LS 32 Air cooled 02250140 997R01...

Page 29: ...assure a normal operating tem perature With air cooled compressors it is possible to use this heat for space heating providing exces sive pressure drop is not created across the fan Consult a Sullair...

Page 30: ...trical Parts in Parts Manual 3 Check all electrical connections for tightness 4 DRY RUN the electrical controls by disconnect ing the three 3 motor leads from the starter Pull out the EMERGENCY STOP b...

Page 31: ...compressor unit the shaft should be turning clockwise on all gear driven models and counterclockwise on direct drive models If the motor shaft is not turning in the proper direction disconnect the po...

Page 32: ...Section 5 SUPERVISOR CONTROLLER 26 Figure 5 1 Supervisor Control Panel...

Page 33: ...arning blank means no fault or warning is present If there are multiple alarms they will be shown for 2 seconds each If an alarm is active pressing the key will give troubleshooting information on tha...

Page 34: ...ne pressure is above 110 psi 7 6 bar Load delta The pressure differential below the unload pressure where the machine is loaded For example if the unload pressure is set to 110 psi 7 6bar and the load...

Page 35: ...etc Sensor Log Log of sensor readings leading up to a fault The sensor log shows the sensor readings leading up to a fault The top line shows the last fault The following lines show T1 T2 P1 P2 Each l...

Page 36: ...be calibrated The system pressure transducers on all machines should read within 1 psi of one another The calibration function can be used to set the readings to be the same 5 9 CALIBRATION CORRECTIO...

Page 37: ...r damaged piping c Check for parts damaged by heat or an electrical short circuit usually apparent by discoloration or a burnt odor Should your problem persist after making the rec ommended check cons...

Page 38: ...r High The Factory Setup Information Needs to be Reviewed for Correct Values Sump Pressure High Make sure unload pressure set below limit of compressor Check motor starter contacts for proper operatio...

Page 39: ...check operation and wiring Pressure regulator check adjust ment and operation Check minimum pressure check valve Check pressure sensor wiring and tubing Machine may have failed to start Ambient above...

Page 40: ...P1Max High Fault 0 5 0 When Running dP1Max P1Max P1 dP1Max High Warn 3 5 0 When Running dP1Max P1Max P1 P_1 High Inhibit 5 0 0 At Start High sump psi at start P_1 Low Fault 5 5 0 When Running Immediat...

Page 41: ...y pushing this button found on the starter s ther mal overload element housing re closes the starter s con tacts after a current overload takes place Please be aware that the elements must be allowed...

Page 42: ...ump Located on the sump side fluid level should be maintained at a level between the high and low sight glass Indicate fluid flow in the separator return lines Large flow should be visible during full...

Page 43: ...emperature and leaks the following day 6 4 SUBSEQUENT START UP PROCEDURE On subsequent start ups check that the proper level is visible in the fluid sight glass and simply press the START or AUTO MODE...

Page 44: ...38 NOTES...

Page 45: ...nte nance requirements are needed to rid the system of any foreign materials if any Perform the following maintenance operations to prevent unnecessary problems 1 Clean the return line strainers 2 Cle...

Page 46: ...changed after every sixth primary element change DO NOT clean the secondary element ELEMENT REMOVAL 1 Clean the exterior of the air filter housing 2 Remove the cover assembly by loosening the wingnut...

Page 47: ...r and flange on the sump being careful not to let the scraps fall in the sump 7 Inspect the separator tank for rust dirt etc 8 Reinsert the separator elements with gaskets attached into the sump takin...

Page 48: ...ted meet requirements of Section 4 1 The drive coupling must be aligned after installation and prior to ini tial start up of the compressor The use of stainless steel shims under the motor feet is rec...

Page 49: ...C melt temperature Direct flame towards hub bore using constant motion to avoid overheating an area If an oil bath is used the oil must have a flash point of 350 F 177 C or higher Do not rest hubs on...

Page 50: ...when adjusting motor position Tighten the spacer mounting bolts and recheck off set and angular alignment within the limits speci fied in Table 7 1 Installation Data If the vertical angular alignment...

Page 51: ...kit no 02250044 346 1 Remove old discpacks from adapters and spac er and discard 2 Install overload washers onto half of the new drive bolts provided and dip threads of ALL drive bolts with overload w...

Page 52: ...ghten them slightly until the inner ring can still just be turned 3 Slide shrink disc over the hub The hub outside surface can be greased Never tighten locking screws before shaft is inside the hub 4...

Page 53: ...ricated with a multipurpose grease as Molykote BR 2 or similar Table 7 2 Tapered Surface Lubricants COMPRESSOR WILL NOT START COMPRESSOR SHUTS DOWN WITH AIR DEMAND PRESENT Main Disconnect Switch Open...

Page 54: ...ssure differential Cooler plugged clean tubes If plugging persists install water conditioner or water filter water cooled only Cooling air flow restricted clean cooler and check for proper ventilation...

Page 55: ...ns in the Maintenance Section Check diaphragm and replace if necessary kit available Replace Check for leaks Check that Sullicon Control lever is moved to unload stop when Supervisor is in NO LOAD mod...

Page 56: ...50 NOTES...

Page 57: ...NDICATE SERIAL NUMBER OF COMPRESSOR 8 1 PROCEDURE FOR ORDERING PARTS Parts should be ordered from the nearest Sullair Representative or the Representative from whom the com pressor was purchased If fo...

Page 58: ...ng 046999 1 diaphragm repair kit for spiral valve air cylinder 250016 183 608311 001 1 repair kit for SCD zero loss drain 02250130 866 02250131 044 1 o ring for 2 1 2 12 SAE tube fittings 250042 649 1...

Page 59: ...53 NOTES...

Page 60: ...Section 8 ILLUSTRATIONS AND PARTS LIST 54 8 3 MOTOR COMPRESSOR FRAME AND PARTS 02250140 989R01...

Page 61: ...hrink rfn 4071 250009 242 1 17 elbow 90deg m swvl 1 4t x 1 4 npt 250025 850 2 18 hub coupling 3 625 bore III 2500339 610 1 19 connector tube f 1 4 x 1 4 810104 025 1 20 connector tube m 1 4 x 1 2 8102...

Page 62: ...Section 8 ILLUSTRATIONS AND PARTS LIST 56 8 3 MOTOR COMPRESSOR FRAME AND PARTS 02250140 989R01...

Page 63: ...ass 1 4 869825 025 1 41 LS32S air end gd sae IV 1 26 sign warning sever fan 049855 1 IV There is an exchange program whereby a remanufactured compressor unit can be obtained from Sullair distributors...

Page 64: ...Section 8 ILLUSTRATIONS AND PARTS LIST 58 8 4 AIR INLET SYSTEM 02250140 990R02...

Page 65: ...dia air II 250006 718 2 17 cap air inlet 10 250007 712 2 18 bracket ctl mtg 32 25 250014 397 1 19 lever inl vlv 3 4 shft adj 250019 036 1 20 connector tube strt 1 4mnpt x1 4 t 250024 685 1 21 connecto...

Page 66: ...Section 8 ILLUSTRATIONS AND PARTS LIST 60 8 4 AIR INLET SYSTEM 02250140 990R02...

Page 67: ...pltd 7 8 838214 174 2 33 nut hex jam lh pltd 5 16 24 866605 195 1 34 plug pipe 1 4 3000 stl plt 866900 010 1 35 capscrew ferry head hd pltd 5 16 18 x 1 1 4 867305 125 1 36 capscrew ferry head hd pltd...

Page 68: ...Section 8 ILLUSTRATIONS AND PARTS LIST 62 8 5 FLUID COOLING SYSTEM AIR COOLED 02250140 994R00...

Page 69: ...022 1 15 grommet rubber 040125 17 16 bushing taper brq iti 1 7 8 042520 1 17 guard fan 1600q 241347 2 18 fan 48 dia 25hp 1200rpm 250000 847 1 19 nut hex pltd 1 2 13 825208 448 12 20 nut hex f pltd 5 1...

Page 70: ...Section 8 ILLUSTRATIONS AND PARTS LIST 64 8 5 FLUID COOLING SYSTEM AIR COOLED 02250140 994R00...

Page 71: ...eg pltd 1 2 837808 125 16 35 washer pl b reg pltd 5 16 838205 071 18 36 washer pl b reg pltd 3 8 838206 071 20 37 washer pl b reg pltd 1 2 838208 112 16 38 eyebolt 5 16 18 x 1 1 8 pltd 839105 112 8 39...

Page 72: ...Section 8 ILLUSTRATIONS AND PARTS LIST 66 8 6 AIR PIPING SYSTEM AIR COOLED 02250140 992R01...

Page 73: ...g m 1 4 x 1 4 810504 025 1 17 flange thrd 4 150 rf 819315 064 2 18 nut hex pltd 1 2 13 825208 448 2 19 nut hex pltd 5 8 11 825210 559 20 20 o ring viton 5 3 8 x 1 8 826502 253 1 21 capscr hex gr5 5 8...

Page 74: ...Section 8 ILLUSTRATIONS AND PARTS LIST 68 8 6 AIR PIPING SYSTEM AIR COOLED 02250140 992R01...

Page 75: ...2 nipple pipe xs plt 1 x cl 866416 000 3 33 nipple pipe xs plt 1 x 2 1 2 866416 025 2 34 nipple pipe xs plt 1 1 4 x cl 866420 000 1 35 tee pipe 150 plt 1 866815 040 1 36 bushing red pltd 3 4 x 1 2 867...

Page 76: ...Section 8 ILLUSTRATIONS AND PARTS LIST 70 02250140 993R01 8 7 FLUID PIPING SYSTEM AIR COOLER...

Page 77: ...union LS32 lp 02250141 384 1 17 tube thrmvlv union LS32 lp 02250141 386 1 18 tube union unit LS32 lp 02250141 388 1 19 tube union thrmvlv LS32 lp 02250142 869 1 20 valve control 3 way III 043877 1 21...

Page 78: ...Section 8 ILLUSTRATIONS AND PARTS LIST 72 02250140 993R01 8 7 FLUID PIPING SYSTEM AIR COOLER...

Page 79: ...13 x 1 1 4 829108 125 1 43 screw hex ser washer 1 4 20 x 3 4 829704 075 2 44 screw hex ser washer 5 16 18 x 1 829705 100 3 45 washer spr lock reg pltd 3 8 837806 094 10 46 washer spr lock reg pltd 1 2...

Page 80: ...Section 8 ILLUSTRATIONS AND PARTS LIST 74 02250140 991R00 8 8 SUMP AND PARTS...

Page 81: ...LS32 lp 02250141 365 1 17 plug o ring boss sae 1 1 4 040029 2 18 gasket 6 125 flg full face 242437 012 2 19 connector tube f 1 4 x 1 4 810104 025 1 20 connector tube m 1 4 x 1 4 810204 025 1 21 elbow...

Page 82: ...Section 8 ILLUSTRATIONS AND PARTS LIST 76 02250140 991R00 8 8 SUMP AND PARTS...

Page 83: ...1 4 860704 025 1 32 elbow pipe 90 deg plt 2 866215 080 1 33 nipple pipe pltd 2 x 3 866332 030 1 34 plug pipe 1 4 3000 stl plt 866900 010 1 35 nipple pipe hx pltd 3 4 x 3 4 868512 075 1 36 tee male pi...

Page 84: ...Section 8 ILLUSTRATIONS AND PARTS LIST 78 8 9 SULLICON CONTROL 02250134 158R00...

Page 85: ...ocking 5 16 18 825505 166 1 17 pin cotter ep sc 1 16 x 3 4 827101 075 1 18 capscrew ferry head hd 3 8 16 x 2 828406 200 1 19 capscr hex gr5 5 16 18 x 2 1 4 829105 225 2 20 capscr hex gr5 5 16 18 x 2 1...

Page 86: ...Section 8 ILLUSTRATIONS AND PARTS LIST 80 8 10 COMPRESSOR ACTUATOR...

Page 87: ...50 4 15 cover adapter 250016 195 1 16 washer regular 8 838201 045 6 17 screw machine rod 8 32 x 1 2 831601 050 6 18 mount air cylinder 250016 188 1 19 capscrew ferry head 1 2 18 x 1 1 4 828405 125 3 2...

Page 88: ...Section 8 ILLUSTRATIONS AND PARTS LIST 82 8 11 PNEUMATIC CONTROLS 02250140 996R00...

Page 89: ...l ctl tubing supt 02250127 559 1 16 angle support 02250133 550 2 17 bracket support 02250133 551 1 18 bracket supt 02250133 552 1 19 bracket tubing manifold 02250133 564 1 20 valve drain self close 1...

Page 90: ...Section 8 ILLUSTRATIONS AND PARTS LIST 84 8 11 PNEUMATIC CONTROLS 02250140 996R00...

Page 91: ...x 1 1 2 829108 150 4 44 screw hex ser washer 5 16 18 x 3 4 829705 075 10 45 screw hex ser washer 5 16 18 x 1 829705 100 2 46 washer spr lock reg pltd 3 8 837806 094 5 47 washer spr lock reg pltd 1 2 8...

Page 92: ...Section 8 ILLUSTRATIONS AND PARTS LIST 86 8 11 PNEUMATIC CONTROLS 02250140 996R00...

Page 93: ...00 010 3 61 bushing red pltd 3 8 x 1 8 867101 005 1 62 cross pipe 1 4 plt 867615 010 1 63 nipple pipe hx pltd 3 8 x 1 4 868506 025 1 64 tee male pipe brass 1 4 869825 025 4 65 starter assy supv ctl VI...

Page 94: ...Section 8 ILLUSTRATIONS AND PARTS LIST 88 8 12 CONTROL BOX SOLID STATE 02250122 005R04...

Page 95: ...50120 644 1 12 relay 45496 1 13 relay base 46467 1 14 ground bus 02550110 334 1 15 ground bar 02550101 721 1 16 240A IT starter 02250122 042 1 17 304A IT starter 02250120 789 18 360A IT starter 022501...

Page 96: ...Section 8 ILLUSTRATIONS AND PARTS LIST 90 8 13 CONTROL BOX FULL VOLTAGE 02250122 511R04...

Page 97: ...0083 190 11 primary fuse 4 amp 250026 649 12 secondary fuse 6 a 250019 762 13 ground bus 02550110 334 1 14 ground bar 02550101 721 1 15 display module 02550119 330 1 16 display label 02550130 344 1 17...

Page 98: ...Section 8 ILLUSTRATIONS AND PARTS LIST 92 8 14 CONTROL BOX WYE DELTA 02250122 516R08...

Page 99: ...O module 02550141 089 1 14 display module 02550119 330 1 15 transformer 24v 02250135 283 1 16 size 5 contactor 02250083 824 1 17 size 4 contactor 02550083 823 1 18 size 5dp contactor 02550113 514 19 s...

Page 100: ...Section 8 ILLUSTRATIONS AND PARTS LIST 94 8 15 ENCLOSURE AIR COOLED 02250140 995R00...

Page 101: ...942 1 16 support corner wtr sep end TS32S 02250131 945 1 17 support canopy cntr post TS32S 02250133 839 2 18 strap bustle support TS32S ac wc 02250133 840 1 19 panel canopy header TS32S 02250134 127 2...

Page 102: ...Section 8 ILLUSTRATIONS AND PARTS LIST 96 8 15 ENCLOSURE AIR COOLED 02250140 995R00...

Page 103: ...25505 166 2 37 capscr hex gr5 1 4 20 x 3 4 829104 075 2 38 capscr hex gr5 5 16 18 x 3 4 829105 075 6 39 screw hex ser washer 5 16 18 x 3 4 829705 075 11 40 screw self drill 1 4 x 1 2 834504 050 43 41...

Page 104: ...Section 8 ILLUSTRATIONS AND PARTS LIST 98 8 16 DECAL GROUP...

Page 105: ...gn danger electrocution 049850 1 5 sign warning food grade lube 250003 144 1 6 decal warning actuator 250029 836 1 7 sign warning compressor fluid fill cap 049685 1 8 sign air breathing danger 250027...

Page 106: ...Section 8 ILLUSTRATIONS AND PARTS LIST 100 8 16 DECAL GROUP...

Page 107: ...95 1 17C decal fluid CP 4600 32 F 02250118 342 1 18 decal water drain 250022 810 1 19A decal V 460 3 60 international 02250069 399 1 19B decal V 575 3 60 international 02250069 400 1 19C decal V 380 3...

Page 108: ...Section 8 ILLUSTRATIONS AND PARTS LIST 102 8 16 DECAL GROUP...

Page 109: ...28 decal ISO 9001 I 1 29 decal fluid sample 250022 675 1 30 decal electrical component ID 250038 457 1 31 sign power energized 249544 049 1 32 decal fork lifting 241814 4 I ISO decal may vary per mach...

Page 110: ...Section 8 ILLUSTRATIONS AND PARTS LIST 104 8 17 DECAL LOCATIONS...

Page 111: ...er drain 250022 810 1 14 sign warning sever fan door closed 02250131 539 4 15 sign warning sever fan port 049965 2 16 decal rotation 250021 564 1 17 sign warning food grade lube 250003 144 1 18 sign a...

Page 112: ...Section 8 ILLUSTRATIONS AND PARTS LIST 106 8 18 DECAL LOCATIONS ENCLOSURE...

Page 113: ...5 decal warning auto start 250017 903 1 6 sign warning sever fan 049855 2 7 decal autostart 041065 1 8 decal ISO 9001 I 1 9 decal LS 32 02250061 371 1 10 decal Sullair logo 02250059 048 2 I ISO decal...

Page 114: ...Section 8 ILLUSTRATIONS AND PARTS LIST 108 8 19 DECAL LOCATIONS CONTROL BOX...

Page 115: ...l V 460 3 60 international 02250069 399 1 decal V 575 3 60 international 02250069 400 1 decal V 380 3 50 international 02250069 412 1 decal V 230 3 60 international 02250069 397 1 4 decal PE designati...

Page 116: ...Section 8 ILLUSTRATIONS AND PARTS LIST 110 02250140 999R00 8 20 WIRING DIAGRAM AIR COOLED CUSTOMER SUPPLIED STARTER...

Page 117: ...111 NOTES...

Page 118: ...ULLAIR CORPORATION 3700 East Michigan Boulevard Michigan City Indiana 46360 U S A www sullair com Telephone 1 800 SULLAIR U S A Only or 1 219 879 5451 Fax 219 874 1273 PARTS DEPARTMENT Fax 219 874 183...