STATIONARY SCREW COMPRESSOR
OPERATION & MAINTENANCE MANUAL
LS12-50&LS16-60/75LF
50&60HZ
SHENZHEN SULLAIR ASIA INDUSTRIAL CO., LTD.
Part No. : 88290007-828
Date : Sep. 2004 Rev. 02
Thank you for Choosing Sullair products. This manual cover the operation,
maintenance and trouble shooting of Sullair rotary screw compressors. Before
operating the compressor, please familiarize yourself with this manual
thoroughly.
At Sullair, we are committed to continuous product improvement. While all
attempts will be made to update the manual, Sullair reserves the right to make
changes to the product without prior notice.
Production license number: XK06-110-00019
C o mp r e s s o r mo d e l :
C o mp r e s s o r s e r i a l n u mb e r : _________________
Preface
This manual describes in detail the system structure, function, usage and
maintenance method for Model LS12-50&LS16-60/75LF screw compressor.
Before installing and operating this machine, the customer shall carefully
read this manual. After fully understanding the structure and function of each
part of the machine set can they operate and maintain the machine set.
Special fluid provided by Sullair Co. must be used. It is prohibited to mix
different brands of fluid.
From time to time, the product is being redesigned to seek improvement.
After certain period, there will be discrepancies between this manual and the
product itself. The user should be aware of it.
If there is any point that is not described in this manual but is unclear
during the operation and use by the user, you can contact your local distributor
of Sullair Co. or Customer Service Dept. of Sullair Co.
᱋᱋Editor
Sep. 2004
TABLE OF CONTENTS
SECTION 1 SAFETY
1.1
General ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ1
1.2
Personal Protective Equipment ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 1
1.3
Fires and Explosion ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ1
1.4
Moving PartsĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ2
1.5
Hot Surfaces, Sharp Edges and Sharp Corners ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 2
1.6
Toxic and Irritating Substances ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ3
1.7
Electrical Shock ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ3
1.8
Lifting ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 3
1.9
Other Precautions ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ4
SECTION 2
SYSTEM DESCRIPTION
2.1
Outline ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ5
2.2
Compressor Air-end ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 6
2.3
Cooling and Lubrication System ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 6
2.4
Compressor Discharge System ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 7
2.5
Control System – Instrument TypeĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ10
2.6
Control System – Computer TypeĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 11
2.7
Air Inlet SystemĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ13
2.8
Monitoring InstrumentĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ14
SECTION 3 PERFORMANCE PARAMETER AND USE OF FLUID
3.1
Main Performance Parameters of the Compressor ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ16
3.2
Lubrication Guide ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ16
3.3
Application GuideĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ17
3.4
Lubrication Change Recommendations and Maintenance ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ17
SECTION 4 COMPRESSOR INSTALLATION
4.1
Mounting of Compressor ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 18
4.2
Ventilation and Cooling ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 20
4.3
Installation of Service Air Piping ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ20
4.4
Coupling Alignment Check ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ20
4.5
Fluid Level CheckĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ20
4.6
Electric Circuit Check – Instrument Type ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ20
4.7
Electric Circuit Check – Computer Type ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ21
4.8
Motor Rotation Direction Check – Instrument TypeĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ21
4.9
Motor Rotation Direction Check – Computer TypeĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 22
SECTION 5 COMPRESSOR OPERATION
5.1
General Introduction – Instrument Type ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ23
5.2
Purpose of Controls – Instrument Type
5.3
Initial Start-upĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ24
5.4
Subsequent Start-up ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ25
5.5
ShutdownĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ25
5.6
Brief Introduction to Computer-type Machine Set ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ25
5.7
Setting of Supervisor Operation ParameterĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ25
5.8
Operation of Computer-type Machine Set ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ28
5.9
Controller’s Function – Computer Type ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ30
5.10
Relay DescriptionĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ31
5.11
Initial Start-upĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 31
5.12
Subsequent Start-upĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ32
5.13
Shutdown ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ32
ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ23
SECTION 6 SUPERVISOR II
6.1
Introduction ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 33
6.2
Keypad Description ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ33
6.3
Status Displays ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ33
6.4
Lamp Indicators ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ35
SECTION 7 MAINTENANCE
7.1
General ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 37
7.2
Daily Maintenance ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ37
7.3
Maintenance after Initial 50 Hours of Operation ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ37
7.4
Maintenance after Every 1000 Hours of OperationĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 37
7.5
Fluid Maintenance ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ37
7.6
Fluid Filter Maintenance ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ37
7.7
Maintenance of Fluid Air Separator ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ38
7.8
Parts Replacement and Adjustment ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ38
7.9
Troubleshooting – Instrument Type ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 45
7.10
Troubleshooting – Computer TypeĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ 47
7.11
Transducer Usage Description and Supervisor Parameter Calibration ĂĂĂĂĂĂĂĂ50
7.12
Pipe Installation DiagramĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ50
SECTION 8 ELECTRICAL WIRING DIAGRAM
8.1
Electrical Wiring Diagram of Instrumentation Control ĂĂĂĂĂĂĂĂĂĂĂĂĂĂ53
8.2
Electrical Wiring Diagram of Computer Board Control ĂĂĂĂĂĂĂĂĂĂĂĂĂĂ54
SECTION
9
RECOMMENDED PARTS LIST ĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂĂ55
LS12-50&LS16-60/75LF Series Screw Compressor
O & M Manual
Section 1 Safety
SECTION 1 SAFETY
1. 1 GENERAL
Sullair Corporation designs and manufactures all of their products so they can be operated safely.
However, the responsibility for safe operation rests with those who use and maintain these products.
The following safety precautions are offered as a guide, which, if conscientiously followed, will
minimize the possibility of accidents thought the useful life of this equipment.
Only those who have been trained and delegated to do so, and who have read and understood this
Operator’s Manual should operate the compressor. Failure to follow the instructions, procedures and
safety precautions in this manual can result in accidents and injuries. Read this manual prior to
startup.
Never start the compressor unless it is safety to do so. Do not attempt to operate the compressor
with a known unsafe condition. Tag the compressor and render it inoperative by disconnecting and
locking out all power at source or otherwise disabling its prime mover, so others who may not know
of the unsafe condition, cannot attempt to operate it until the condition is corrected.
Install, use and operate the compressor and/or controls in full compliance with all pertinent
regulations and all applicable national and local laws, standards and regulations.
Do not modify the compressor and/or controls in any way except with written factory approval.
1. 2 PERSONAL PROTECTIVE EQUIPMENT
Prior to installing or operating the compressor, owners, employers and users should become
familiar with, and comply with, all applicable regulations and any applicable national and local laws,
standards and regulations relative to personal protective equipment, such as eye and face protective
equipment, respiratory protective equipment, equipment intended to protect the extremities, protective
clothing, protective shields ad barriers and electrical protective equipment, as well as noise exposure
administrative and/or engineering controls and/or personal hearing protective equipment.
1. 3 FIRES AND EXPLOSION
a. Clean up spills of fluid or other combustible substances immediately, if such spills occur.
b. Shut off the
compressor and allows it to cool. Then keep sparks, flames and other sources of
ignition away and Do Not permit smoking in the vicinity when checking or adding fluid or when
refilling air line anti-icier systems with antifreeze compound.
c. Do not permit fluids, including airline anti-icier system antifreeze compound or fluid film to
accumulate on, under, or around acoustical material, or on any external surfaces of the air
compressor or on internal surfaces of the enclosure. Wipe down using an aqueous industrial cleaner
or steam-clean as required. If necessary, remove acoustical material, clean all surfaces and then
replace acoustical material. 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. Do not use flammable solvents for cleaning purposes.
ˍ
LS12-50&LS16-60/75LF Series Screw Compressor
O & M Manual
Section 1 Safety
d. Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the
compressor or of the inside of the enclosure, if any.
e. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace
any wiring that has cracked, cut abraded or otherwise degraded insulation, or terminals that are
worn, discolored or corroded. Keep all terminals and pressure connectors clean and tight.
f. Keep grounded and/or conductive objects such as tools away from exposed live electrical parts such
as terminals to avoid arcing, which may serve as a source of ignition.
g. Remove any acoustical material or other material that may be damaged by heat or that may support
combustion and is in close proximity, prior to attempting weld repairs.
h. Keep suitable fully charged fire extinguisher or extinguishers nearby when servicing and operating
the compressor.
i. Keep oily rags, leaves, litter or other combustibles out of and away from the compressor.
j. Do not operate the compressor without proper flow of cooling air or water or with inadequate flow
of fluid or with degraded lubricant.
k. Do not attempt to operate the compressor in any classification of hazardous environment unless the
compressor has been specially designed and manufactured for that duty.
1. 4 MOVING PARTS
a. Keep hands, arms and other parts of the body and also clothing away from couplings, fans and other
moving parts.
b. Do not attempt to operate the compressor with the fan, coupling or other guards removed.
c. Wear snug-fitting clothing and confine long hair when working around this compressor, especially
when exposed to hot or moving parts.
d. Keep access doors, if any, closed except when making repairs or adjustment.
e. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or
operate it.
f. Disconnect and lock out all power at source and verify at the compressor that all circuits are
de-energized to minimize the possibility of accidental start-up or operation, prior to attempting
repairs or adjustments. This is especially important when compressor is remotely controlled.
g. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water, or other
liquids to minimize the possibility of slips and falls.
1. 5 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
a. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners.
b. Keep all parts of the body away from all points of air discharge.
c. Wear personal protective equipment including gloves and head covering when working in, or around
the compressor.
d. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. Do not ignore small
cuts and burns as they may lead to infection.
ˎ
LS12-50&LS16-60/75LF Series Screw Compressor
O & M Manual
Section 1 Safety
1. 6 TOXIC AND IRRITATING SUBSTANCES
a. Do not use air from this compressor for respiration (breathing) except in full compliance with any
national or local regulations and laws.
b. Operate the compressor only in open or adequately ventilate areas.
c. Locate the compressor so that there is no toxic or irritating substances in the vicinity around the
compressor.
d. Coolants and fluids used in this compressor are typical of the industry. Care should be taken to the
event of ingestion, seek medical treatment promptly. Wash with soap and water in the event of skin
contact.
1. 7 ELECTRICAL SHOCK
a. This compressor should be installed and maintained in full compliance with any national or local
regulations, standards and laws, including those of the national electrical rules and also including
those relative to equipment grounding conductors, and only by personnel that are trained, qualified
and delegated to do so.
b.Keep all parts of the body and any hand-held tools or other conductive objects away from exposed
live parts of electrical system. Maintain dry footing, stand on insulating surfaces and Do Not
contact any other portion of the compressor when making adjustments or repairs to expose live
parts of the electrical system. Make all such adjustments or repairs with one hand only, so as to
minimize the possibility of creating a current path through the body.
c. Attempt repairs in clean, dry and well-lighted and ventilated areas only.
d. Do not leave the compressor unattended with open electrical enclosures. If necessary to do so, then
disconnect, lock out and tag all power at source so others will not inadvertently restore power.
e. Disconnect, lock out, and tag all power at source prior to attempting repairs or adjustments to
rotating machinery and prior to handling any ungrounded conductors.
f. Dry test all shutdown circuits prior to starting the compressors after installation.
1. 8
LIFTING
a. If the compressor is provided with a lifting bail, then lift by the bail provided. If no bail is provided,
then lift by sling. Compressors to be air lifted by helicopter must not be supported by the lifting
bail but by slings instead. In any event, lift and/or handle only in full compliance with the national
or local regulations and laws.
b. Inspect points of attachment for cracked welds and for cracked, bent, corroded or otherwise
degraded members and for loose bolts or nuts prior to lifting.
c. Make sure entire lifting, rigging and supporting structure has been inspected, is in good condition
and has a rated capacity of at least the weight of the compressor. If you are unsure of the weight,
then weigh compressor before lifting.
d. Make sure lifting hook has functional safety latch or equivalent, and is fully engaged and latched
ˏ
LS12-50&LS16-60/75LF Series Screw Compressor
O & M Manual
Section 1 Safety
on the bail of the ground.
e.
Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been
lifted clear of the ground.
f.
Do not attempt to lift in high winds.
g.
Keep all personnel out from under and away from the compressor whenever it is suspended.
h.
Lift compressor no higher than necessary.
i.
Keep lift operator in constant attendance whenever compressor is suspended.
j.
Set compressor down only on a level surface capable of safely supporting at least its weight and
its loading unit.
k.
When moving compressors by forklift truck, utilize fork pockets if provided. Otherwise, utilize
pallet if provided. If neither fork pockets nor pallet are provided, then make sure compressor is
secure and well balanced on forks before attempting to raise or transport it any significant
distance.
l.
Make sure forklift truck forks are fully engaged and tipped back prior to lifting or transporting the
compressor.
m. Forklift no higher than necessary to clear obstacles at floor level and transport and corner at
minimum practical speeds.
n.
Make sure pallet-mounted compressors are fully bolted or otherwise secured to the pallet prior to
attempting to forklift or transport them. Never attempt to forklift a compressor that is not secured
to its pallet, as uneven floors or sudden stops may cause the compressor to tumble off, possibly
causing serious injury or property damage in the process.
o.
Do not use the lifting eyebolt on the compressor motor, if supplied, to lift the entire compressor
package.
1. 9
OTHER SAFETY PRECAUTIONS
a
If the compressor enclosure is large enough to hold a person and if it is necessary to enter it to
perform service adjustments, inform other personnel before doing so, 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.
b.
Make sure all personnel are out of compressor before closing and latching enclosure doors.
ː
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 2
Section 2: System Description
System Description
2.1 Outline
LS12 series of machine set consists of compressor, electric motor, starter, compressor inlet system,
compressor discharge system, cooling and lubrication system, capacity control system, instrument
panel, cooler, combination separator and trap. Refer to Fig. 1 and Fig. 2. All the parts are mounted on
the same base. Refer to Fig. 1 and Fig. 2.
Fluid/air cooler
Minimum pressure/check valve
Enclosure
Blow down valve
Sump tank
Fluid
Inlet air filter
filter
Motor
Fluid filter
Compressor discharge
Compressor
Air inlet valve
unit
Fig. 1 Air-Cooled Machine Set
After cooler
Minimum pressure/check valve
Inlet air filter
Blow down valve
Motor
Sump tank
Thermal valve
Air inlet valve
Fluid filter
Compressor discharge
Fluid cooler
Compressor unit
Fig. 2 Water-Cooled Machine Set
ˑ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 2: System Description
On air-cooled model, the fluid and compressed air are cooled with radiator-type cooler.
On water-cooled model, the fluid and compressed air are cooled with tube and shell cooler. The
cooling water first cools the air, then the fluid, and is finally discharged out of the machine.
Both air-cooled and water-cooled versions have easily accessible items such as fluid filter,
control valve, air filter, etc.
2. 2 Compressor Air-end
In the compressor machine set, the air-end is an important part, inside which there are a couple
of mutually fitting rotors, rotating at high speed driven under the electric motor and continuously
providing the stable and pulsation free compressed air.
When the rotor rotates to suck the air, the lubrication fluid is sprayed into the compressor body,
directly mixed with the air. Here, the fluid flow has three basic functions:
C. As coolant, it takes away the heat generated and reduces the internal leakage of the compressed
air;
C. Seals the leakage paths between the rotors and the stator and also between the rotors themselves;
C. Acts as a lubricating film between the rotors allowing one rotor to directly drive the other, which
is an idler.
After the air/fluid mixture flows through the fluid air separator, the fluid and air are separated, the
air enters the service air piping, and the fluid is sprayed into the compressor once again after being
cooled.
2. 3 Cooling and Lubrication System ( Refer to Fig. 3 and Fig. 4 )
The cooling and lubrication system (air-cooled models) consists of fan, electric motor,
radiator-type aftercooler, fluid cooler, thermal valve, and interconnecting piping and tubing.
For water-cooled models, shell and tube cooler and water-flow regulating valve are substituted
for the radiator-type cooler in the air-cooled machine set. The fluid flow is pushed through the
pressure difference in the system, flowing to each working point of the machine set from sump tank.
When the fluid temperature is below 170qF(77qC), the thermal valve is fully open, and the fluid
flows to each working point directly through the fluid filter without cooling. Due to the heat generated
in the absorption and compression process, the fluid temperature is rising gradually. When the fluid
temperature is higher than 170qF (77qC), the thermal valve starts to close. A portion of the fluid flows
into the cooler. The fluid after cooling flows into the fluid filter and then enters the compressor unit.
In all the models, some fluids are sent to support the wearing bearing of the rotor. Before entering
the compressor, the fluid first passes through the fluid filter to ensure the cleanliness of the fluid
flowing to the bearing. The fluid filter general assembly consists of one replaceable filtering element
and internal pressure bypass valve. When the pressure differential meter indicator on the instrument
panel points towards the red area, the filter must be replaced. When the compressor is in operation,
regularly check the pressure gage reading. The water-cooled machine set is equipped with water-flow
˒
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 2: System Description
regulating valve. It can regulate the cooling water flow based on different loads of the machine set.
When the machine is stopped, the valve is closed automatically, playing the role of shut-off valve.
Besides, the water-cooled machine set has one hydraulic switch to ensure the operation of the
compressor under appropriate water pressure.
2. 4 Compressor Discharge System (See Fig. 3 and Fig. 4)
The pressurized fluid air mixture comes out from the compressor and enters the sump tank. The
sump tank has the three functions:
As primary fluid air separator;
As compressor fluid sump;
Installed with secondary fluid air separation element.
The fluid air mixtures enter the sump tank, strike against the arc surface, the flow rate is greatly
reduced, and the flow direction is changed to form large droplets of fluid. Since they are heavy, most
of them fall into the tank bottom, and the remaining small amount of fluid is separated when flowing
through the separation element, deposited at the bottom of the separation element. One fluid reflux
pipe is introduced out from the bottom of the separation element and connected into the compressor
inlet; the fluid reflux pipe is installed with the sight glass and orifice (pre-filter) to ensure the stable
fluid reflux.
The fluid content of the compressed air after separation is lower than 2ppm. The fluid air
separator pressure difference indicator is installed on the instrument panel. When the pointer points
towards the red area, the fluid air separator element must be replaced. When the compressor is in
operation under full load, the pressure difference reading must be checked regularly.
Install the minimum pressure valve after the fluid air separator to ensure the sump tank pressure
is no lower than 50psig (3.5bar) under the load. This pressure is the minimum pressure to ensure the
normal pressure of the fluid loop.
The minimum pressure valve is set with check valve, capable of preventing the compressed air
reflux when the machine is stopped or unloaded.
The sump tank is installed with pressure relief valve. When the pressure of the sump tank exceeds
the tank pressure set value, the pressure relief valve is opened automatically. Besides, the temperature
switch stops the machine when the discharge temperature is higher than 235qF (113qC).
!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.
To prevent the excessive lubricant injection, the fluid injection connection is set at the lower
position outside the sump tank. Check the fluid level in the sump tank through the fluid sight glass.
˓
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 2: System Description
Minimum pressure/check valve
Fluid
filter
Thermal
valve
Fluid/air cooler
Sump tank
Moisture separator
Separator element
Fig. 3 Cooling Lubrication And Discharge System – Air-Cooled
˔
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 2: System Description
Minimum pressure
/check valve
Fluid filter
Thermal
Valve
After cooler
Water control valve
Sump tank
(Optional)
Fluid cooler
Separator element
Moisture separator
Fig. 4 Cooling Lubrication And Discharge System – Water-Cooled
˕
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 2: System Description
2. 5 Control System – Instrument Type
As indicated in Fig. 5, the control system can regulate the air inlet quantity of the compressor
based on the required compressed air volume. When the line pressure exceeds the load pressure for
about 10psig (0.7bar), under the action of the control system, the machine set is vented and unloaded,
which can greatly reduce the energy consumption. The control system includes air inlet valve (at the
compressed air inlet), blowdown valve, solenoid valve, pressure switch, and pressure regulator. The
following describes the function of the control system through four different statuses during the
compressor operation. For explanatory purposes, this description will apply to a compressor with an
operating pressure range of 115-125psig (7.9-8.6bar). Except for different working pressure, its
principle is applicable for all LS12 and LS16 leak free series of machine sets, and the compressors in
other pressure ranges have the same operation mode.
Start – 0 to 50 psig (0 to 3.5bar)
After the starting button is depressed, the compressor is started, the control air is released from
the small air storage tank, and the air inlet valve is closed. The compressor is started at light load.
When the setting time is reached (normally in 6 seconds), it will be switched to the full-load status
automatically. During this process, the pressure regulator and solenoid valve are closed, the air inlet
valve is slightly opened through suction vacuum action, and the machine set is in operation at empty
load. The pressure in the sump tank rises from 0 to 50 psig (0-3.5 bar). At this time, the minimum
pressure valve is closed, the compressed air and service air piping are cut off, ensuring the lubricant
flow pressure; and the set pressure of the minimum pressure valve is normally around 50 psig (3.5
bar).
Normal operation mode – 50 to 115 psig (3.5 to 7.9 bar)
After the system pressure exceeds 50 psig (3.5 bar), the minimum pressure valve is opened, and
the compressed air enters the service air piping. Starting from it, the line pressure is monitored with
pressure switch (normally set as 125 psig [8.6bar]) and line pressure meter. Under this status, the
pressure regulator and solenoid valve are still closed, and the air inlet valve is not actuated and is at
fully open status.
Modulating mode – 115 to 125 psig (7.9 to 8.6bar)
If the air volume required is lower than the rated air discharge volume, the air discharge pressure
rises. When it exceeds 115 psig (7.9bar), the pressure regulator is actuated. Transport the control air to
the air inlet valve, and partly close the air inlet valve and reduce the air inlet volume through the piston
in the air inlet valve, balancing the air supply and consumption and maintaining the pressure between
115-125psig (7.9-8.6bar). The control system continuously regulates the air supply volume based on
the needs of the line pressure.
There is one small hole on the pressure regulator, capable of releasing small amount of control air
when regulating the air inlet valve; meanwhile, release the water vapor in the control pipe loop.
ˍˌ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 2: System Description
Unload – in excess of 125psig (8.6 bar) line pressure
When no air is being used, the line pressure will rise. When exceeding the set value of the
pressure switch, the pressure switch is tripped and the solenoid valve is powered off. Then the control
air enters the air inlet valve directly, closing the air inlet connection; meanwhile, the blowdown valve
is opened under the action of the control air, discharging the compressed air in the sump tank,
maintaining the pressure in the sump tank at 25-27 psig (1.7-1.9 bar), and the minimum pressure valve
on the service air piping prevents the line air from returning to the sump tank. When the air
consumption volume is increased, the line pressure is reduced. When it is lower than 115 psig (7.9bar),
the pressure switch is closed and the solenoid valve is powered on. At this time, the control air leading
to the air inlet valve and blowdown valve is cut off, so air inlet valve is fully opened, the blowdown
valve is closed, and the machine set is in operation at full load. After the pressure rises, the pressure
regulator will play the regulation function again.
If the user doesn’t need the compressed air all the time, it can choose two-level controller, putting
the machine set in operation under automatic mode. The machine operated under this mode can be
stopped automatically when no air supply is needed; when the user needs the compressed air, the
machine will be started automatically and loaded to supply air.
2. 6 Control System – Computer Type
As indicated in Fig. 5, the control system can regulate the air inlet quantity of the compressor
based on the required compressed air volume. The control system includes solenoid valve, pressure
regulator and air inlet valve.
The following describes the function of the control system through four different statuses during
the compressor operation. For explanatory purposes, this description will apply to a compressor with
an operating range of 100-110 psig (6.9-7.6 bars). Except for different working pressure, its principle
is applicable for all LS12 and LS16 leak free series of machine sets, and the compressors in other
pressure ranges have the same operation mode.
ˍˍ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Blow down valve
Air inlet valve
To separator
dp gauge
Section 2: System Description
Check
valve
Shuttle
valve
Straine
Sump
ressure
regulator
valve
tank
To separator dp gauge
Blowdown valve
Air inlet valve
To line
pressure switch
To separator
dp gauge
Strainer
Check
valve
To air filter gauge
Pressure
regulator
valve
Sump tank
Shuttle
valve
To line
pressure switch
Solenoid valve
To separator dp gauge
Pressure switch
Shuttle valve
Fig. 5 Control
System
Start – 0 to 50 psig ( 0 to 3.5bar )
After the starting button is depressed, the compressor is started, the control air is released from
the small air storage tank, and the air inlet valve is closed. The compressor is started at light load.
When the setting time is reached (normally in 6 seconds), it will be switched to the full-load status
automatically. During this process, the pressure regulator and solenoid valve are closed, the air inlet
valve is slightly opened through suc
tion vacuum action, and the
machine set is in operation at empty load. The pressure in the sump tank rises from 0 to 50 psig (0-3.5
bar). At this time, the minimum pressure valve is closed, the compressed air and service air piping are
cut off, ensuring the lubricant flow pressure; and the set pressure of the minimum pressure valve is
normally around 50 psig (3.5 bar).
ˍˎ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 2: System Description
Normal operation mode – 50 to 115 psig ( 3.5 to 7.9 bar)
After the system pressure exceeds 50 psig (3.5 bar), the minimum pressure valve is opened, and
the compressed air enters the service air piping. Starting from it, the line pressure is monitored with
computer board. Under this status, the pressure regulator and solenoid valve are still closed, and the air
inlet valve is not actuated and is at fully open status till the compressor pressure reaches 100psig (6.9
bar).
Modulation mode – 100 to 110 psig ( 6.9 to 7. 6 bar)
If the air volume required is lower than the rated air discharge volume, the air discharge pressure
rises. When it exceeds 100 psig (6.9bar), the pressure regulator is actuated. Transport the control air to
the air inlet valve, and reduce the air inlet volume, balancing the air supply and consumption. Within
the pressure range between 100-110psig (6.9-7.6bar), the control system makes relevant regulation
based on the needs of the line pressure.
Unload – in excess of 110psig ( 7. 6 bar)
If the air volume required for the user is reduced or not used, the line pressure will rise. When the
pressure exceeds the set value 110 psig (7.6bar), the computer board generates the electric signal,
opening the solenoid valve. The control air enters the air inlet valve and blowdown valve, thus closing
the air inlet valve and opening the blowdown valve. At this time, the machine is in operation under
low backpressure to reduce the energy consumption. The minimum pressure valve in the pipe loop
will prevent the compressed air reflux back to the tank.
When the line pressure is reduced to the minimum set pressure, the computer board energizes the
solenoid valve, and the blowdown valve is closed. At this time, the solenoid valve cuts off the control
on the air inlet valve and the air inlet suctions the air again. After the pressure rises, the pressure
regulator plays the function again.
The setting of the line minimum pressure (i.e. loading pressure) is as follows:
Low pressure: “L” 100 psig (6.9bar)
High pressure: “H” 115 psig (7.9bar)
Medium high pressure: “HH” 140 psig (9.7 bar)
Super high pressure: “XH” 175 psig (12.0 bar)
Auto operation mode
The “Auto” mode button of the computer control board can meet the user’s requirement for air at
any time. When you press the “Auto” button, the compressor will be started or stopped at any time
based on the air consumption needs.
2.7 Air Inlet System ( Refer to Fig. 6 )
The compressor air inlet system includes air filter, restriction gauge and air inlet valve.
There is restriction gauge on the instrument panel, reflecting the status of the air filter. If the air
filter resistance is too high, the vacuum meter pointer (restriction gauge) will point towards the red
area. At this time, the filter element will need to be replaced.
ˍˏ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 2: System Description
The air inlet valve is in the form of lifting valve, and its opening extent is regulated by the
pressure regulator based on the air demand volume. Please refer to 2.5 and 2.6 for details. When the
machine is stopped, the air inlet valve is closed, playing the role of check valve.
Air inlet valve
Air filter
16 series
Air filter
Air inlet valve
12 series
Fig. 6 Air Inlet System
2. 8 Monitoring Instrument
Refer to Fig. 7. The location of each instrument is shown in the diagram, which includes line
pressure gage, pressure gage of sump tank, air discharge thermometer, separator pressure difference
meter, fluid filter dp gauge, switch button and hourmeter.
The function of each instrument is described as follows:
Line pressure gauge (P2): Located after minimum pressure valve, connecting with the dry side of
sump tank, indicating the air supplies pressure.
Pressure gauge of sump tank (P1): Indicating the pressure of sump tank.
Air discharge thermometer (T1): Monitoring the temperature of the compressor discharge air. In
normal case, the air discharge temperature through air cooling and
water cooling shall be between 180qF and 225qF (82qC – 107qC).
ˍː
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 2: System Description
Separator dp gauge (ƸP1): Monitoring the status of fluid air separation element. If the separator
element has too high resistance, the indicator will point towards the red
area. At this time, the fluid air separation element will need to be
replaced.
Fluid filter dp gauge (ƸP2): Monitoring the status of the fluid filter. If the filter resistance is too high,
the indicator will point towards the red area. At this time, the filtering
element will need to be replaced.
Start button: Control the machine start.
Stop button: Control the stop.
Hourmeter: Reflecting the accumulated operation time of the compressor. This parameter can be
referenced during the operation and maintenance.
Amber light on: Indicating the machine in auto run status.
Red light on: Indicating the compressor is power energized.
Green light on: Indicating the compressor in operation.
Manual/auto switch: Choose manual or auto control mode.
Air filtering vacuum meter: Monitoring the status of the air filter. When the indicator points towards
the red area (20~30” water column 51~76cm), the filtering element must
be replaced.
Discharge
thermometer
Line pressure gauge
gauge
Separator dp gauge
System pressure gauge
Hourmeter
Power
Auto
Operation
Start
Fluid filter dp gauge
Air filter vacuum meter
Stop
Manual/auto
Fig. 7
Monitoring Instrument
ˍˑ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 3: Performance Parameter and Use of Fluid
Section 3 Performance Parameter and Use of Fluid
3.1 Main Performance Parameters of the Compressor
LS12-50 Series Performance Parameters ---50HZ
Model
LS12-50H
LS12-50HH
LS12-50XH
6.1
5.6
4.3
flow m /min(CFM)
(215.4)
(197.8)
(151.9)
Rated air discharge
8.0
10
12
pressure bar (psi)
(116)
(145)
(175)
Max
8.7
10.7
12.7
(125)
(155)
(185)
10
12
14
(145)
(175)
(200)
Nominal
volume
3
working
pressure bar (psi)
Pressure relief valve
opening pressure bar
(psi)
Machine set weight
̚1280(2820)
kg(Lb)
L x W x H mm
1829x1219x1581
Compressor unit
Type
Fluid spray dual screw compressor
Configuration
Single-stage gear drive
Bearing
Wear resistance type
Lubricant brand
Sullube 32 or 24KT
Lubricant volume, L
30
Electric motor
Model
Rated
326TSC-4
power
kW
37˄50˅
(HP)
Rated rotating speed
1475
rpm
Voltage/frequency
380/415V 50HZ
Usage coefficient
1.15
Usage
ambient
İ40
temperature ć
Starting mode
Y-Ƹ
ˍ˒
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 3: Performance Parameter and Use of Fluid
LS12-50 Series Performance Parameters ---60HZ
Model
LS12-50L
LS12-50H
LS12-50HH
LS12-50XH
6.66
6.1
5.3
4.4
flow m /min(CFM)
(235)
(215)
(187)
(154)
Rated air discharge
7.0
8.0
10
12
pressure bar (psi)
(110)
(116)
(145)
(175)
Max
7.7
8.7
10.7
12.7
(110)
(125)
(155)
(185)
9
10
12
14
(130)
(145)
(175)
(200)
Nominal
volume
3
working
pressure bar (psi)
Pressure relief valve
opening pressure bar
(psi)
Machine set weight
̚1280(2820)
kg(Lb)
L x W x H mm
1829x1219x1581
Compressor unit
Type
Fluid spray dual screw compressor
Configuration
Single-stage gear drive
Bearing
Wear resistance type
Lubricant brand
Sullube 32 or 24KT
Lubricant volume, L
30
Electric motor
Model
Rated
326TSC-4
power
kW
37˄50˅
(HP)
Rated rotating speed
1770
rpm
Voltage/frequency
380/415V 50HZ
Usage coefficient
1.15
Usage
ambient
İ40
temperature ć
Starting mode
Y-Ƹ
ˍ˓
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 3: Performance Parameter and Use of Fluid
LS16-60/75 Series Performance Parameters ---50&60HZ
Model
LS16-60H
LS16-60HH
LS16-60XH
LS16-75H
LS16-75HH
LS16-75XH
7.7
6.7
5.5
9.4
8.5
7.3
flow m /min(CFM)
(270)
(238)
(194)
(332)
(300)
(258)
Rated air discharge
8.0
10
12
8.0
10
12
pressure bar (psi)
(115)
(145)
(175)
(115)
(145)
(175)
Max
9.0
11
12.7
9
11
12.7
(130)
(160)
(185)
(130)
(160)
(185)
10
12
14
10
12
14
(145)
(175)
(200)
(145)
(175)
(200)
Nominal
volume
3
working
pressure bar (psi)
Pressure relief valve
opening pressure bar
(psi)
Machine set weight
̚1140(3175)
kg(Lb)
L x W x H mm
1829x1219x1581
Compressor unit
Type
Fluid spray dual screw compressor
Configuration
Single-stage gear drive
Bearing
Wear resistance type
Lubricant brand
Sullube 32 or 24KT
Lubricant volume, L
30
Electric motor
Model
Rated
power
kW
(HP)
364TSC-4
365TSC-4
45(60)
55(75)
Rated rotating speed
50HZ:1475
rpm
60HZ:1770
Voltage/frequency
380/415V 50HZ or 230/460 60HZ
Usage coefficient
1.15
Usage
ambient
İ40
temperature ć
Starting mode
Y-Ƹ
ˍ˔
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
3.2
Section 3: Performance Parameter and Use of Fluid
Lubrication Guide
To reduce the maintenance work and reduce the cost, LS-12/16 series compressor has been tested
and filled with long service life lubricant before delivered ex-factory.
!Warning
Mixing of other fluid within the compressor unit will void all warranties!
If it is really necessary (or due to other reasons) to add other types of fluid, please follow the
instruction of 3.4.
Do not mix different types of fluids.
If unclean mineral fluid is used, it will cause bad operation of the main unit. In addition, there
will be foaming, filtering element blockage, orifice or line plugging, etc. during the operation.
! Note
Before replacing the fluid, first clean the fluid loop system. If the ambient temperature exceeds the
limit or the fluid exceeding the service life is used, please contact Sullair.
3.3
Application Guide
Sullair encourages the user to participate in a fluid analysis program with the fluid suppliers. This
could result in a fluid change interval differing from that stated in the manual. Contact your Sullair
dealer for details.
3.4
Lubrication Change Recommendations and Maintenance
Lubricant
Fluid change
Fluid filter change
Fluid air separation element change
Sullube32
A,E
F,B
A,C
24KT
E,D
F,B
A,C
A- One year or 8000hr
B- Pressure difference exceeds 20psig (1.4bar)
C- Pressure difference exceeds 10psig (0.7bar)
D- Through fluid sample analysis or known contamination
E- No need to replace within the normal service life
F- Every 1000 hours
ˍ˕
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 4: Compressor Installation
Section 4 Compressor Installation
4.1 Mounting of Compressor
The machine set shall be installed on the supporting face or foundation with enough strength. To
enable the normal work of the driving part and internal pipe, ensure the machine set is laid horizontally.
No pipe load can be transmitted to the joint and connecting pipe of air/water pipe in the machine set.
See Fig. 8 for outline installation diagram of air-cooled machine set.
See Fig. 9 for outline installation diagram of water-cooled machine set.
Fig. 8 Outline Installation Diagram Of Air-Cooled Machine Set
ˎˌ
9HQWLODWLRQMRLQW
˄,QVWDOODWLRQKROH˅
%DVHUHVHUYHGKROH &DEOHHQWU\
(OHFWURPHFKDQLFDOGXDOFRQWURO
RUPLFURFRPSXWHUFRQWUROSDQHO
9HQWLODWLRQMRLQW
9HQWLODWLRQMRLQW
137
&RROLQJZDWHULQOHW
137
&RROLQJZDWHURXWOHW
137
([WHUQDOFRQQHFWLRQ
RIFRQGHQVDWH
137
([WHUQDO
FRQQHFWLRQ
RIVHUYLFHDLU
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
ˎˍ
Section 4: Compressor Installation
Fig. 9 Outline Installation Diagram Of Water-Cooled Machine Set
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
4.2
Section 4: Compressor Installation
Ventilation and Cooling
To enable stable working temperature of the air-cooled compressor, make sure the air can come in
and out of the compressor smoothly. During installation, one end of the fan is at least 3 feet (1.00m)
away from the wall. To prevent the ambient temperature rise, it is necessary to ensure sufficient
ventilation.
Cooling air flow required for air-cooled machine set:
Horsepower ˄HP/kW˅
3
Cooling air flow ˄CFM / m /h˅
50/37
60/45
75/55
6000/10200
7500/12700
7500/12700
For water-cooled compressor, ensure the cooling water supply.
Cooling water flow of water-cooled machine set:
Cooling water temperature
Cooling water flow (T/h)
qF (qC)
50HP˄37 kW˅ 60HP˄45 kW˅ 75HP˄55 kW˅
70˄21˅
1.59
2.04
2.38
80˄26.6˅
2.38
2.61
3.18
The water pressure is normally 1.7~5.2bar (25~75psig).
If the application ambient temperature is lower than 32qF (0qC), don’t use water-cooled
compressor or air-cooled compressor with after-cooling.
4.3
Installation of Service Air Piping
The service air connection of the machine set shall be installed with one shut-off valve. The
service air piping shall be equipped with draining valve and water discharge pipe.
4.4
Coupling Alignment Check
No coupling alignment is required (because it is already aligned before ex-factory).
4. 5
Fluid Level Check
The air compressor is supplied with the proper amount of fluid. However, it is still necessary to
check the fluid level before use. The fluid sight glass is beside the sump tank. If the fluid level can be
seen after the machine is stopped, then the fluid level is appropriate.
4.6
Electric Circuit Check – Instrument Type
Interior electrical wiring is performed at the factory. Required customer wiring is minimal.
During the wire connection, follow the relevant state and local electrical regulations for the insulation
switch and fuse as well as OSHA and NEC. Sullair will provide electric wiring diagram.
! Note
ˎˎ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 4: Compressor Installation
Before observing the machine, cut off the power. The electric circuit check can ensure no failure
before the initial starting of the compressor.
! Danger
High voltage inside. Be careful for electric shock. Before dismantling for maintenance,
disconnect all the power.
A
Check if the incoming voltage meets the requirement;
B.
Check the model of the starter and overload hot relay (see parts list);
C. Check to see if each electric circuit joint is reliable;
D.
“Simulation operation”: Cut off the motor terminal line from the power, press the starting button,
and check if the contactor is in normal operation.
E.
Re-connect the motor terminal, test run the motor as described in 4.8, and check if the rotating
direction is correct.
! Note
The wiring diagram for standard compressor is in the electric control box, and the wiring diagram
of the special compressor is different.
4.7 Electric Circuit Check – Computer Type
Interior electrical wiring is performed at the factory. Required customer wiring is minimal.
During the wire connection, follow the relevant state and local electrical regulations for the insulation
switch and fuse as well as OSHA and NEC. Sullair will provide electric wiring diagram.
The electric circuit check can ensure no failure before the initial starting of the compressor.
! Danger
High voltage inside. Be careful for electric shock. Before dismantling for maintenance, cut off all
the power.
A. Check if the incoming voltage meets the requirement;
B.
Check the model of the starter and overload hot relay (see parts list);
C.
Check to see if each electric circuit joint is reliable;
D. “Simulation operation”: Cut off the motor terminal line from the power, press the starting button,
and check if the contactor is in normal operation.
E. Re-connect the motor terminal, test run the motor as described in 4.8, and check if the rotating
direction is correct.
4.8
Motor Rotation Direction Check – Instrument Type
! Note
The motor rotating direction must be checked before the compressor is started. If necessary,
remove the compressor cover to observe the motor rotating direction.
After electric circuit is connected, check the rotating direction of the electric motor. Press the
starting button, then press the stop button, and make the motor jogging. If seen from the motor end, the
ˎˏ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 4: Compressor Installation
driving shaft is rotating clockwise, then the rotating direction is correct; if the rotating direction is
incorrect, cut off the power. Exchange any two power lines and try again after they are connected.
There is one decal on the coupling to indicate the rotating direction.
Checking if the electric motor is normal can be judged through if the sump pressure gauge on the
instrument panel has pressure indication. Press the starting button. If the gauge has pressure indication
immediately, it means the electric motor has normal rotating direction. In case of no pressure
indication, it means the motor has abnormal rotating direction. Press the stop button immediately, cut
off the power and test again based on the above method.
4.9
Motor Rotation Direction Check – Computer Type
! Note
The motor rotating direction must be checked before the compressor is started. If necessary,
remove the compressor cover to observe the motor rotating direction.
After electric circuit is connected, check the rotating direction of the electric motor. Pull out the
emergency stop button, press the starting button, then press the stop button immediately, and make the
motor jogging. If seen from the motor end, the driving shaft is rotating clockwise, then the rotating
direction is correct; if the rotating direction is incorrect, cut off the power. Exchange any two power
lines and try again after they are connected. There is one decal on the coupling to indicate the rotating
direction.
Checking if the electric motor is normal can also be judged through sump pressure gauge
indication on the computer panel. Pull out the emergency stop button, and press the starting button. If
the sump pressure gauge has pressure indication, it means the electric motor has normal rotating
direction. In case of no pressure indication, it means the motor has abnormal rotating direction. Stop
the machine immediately, cut off the power and repeat the above operation after reversing the phase.
ˎː
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 5
5.1
Section 5: Compressor Operation
Compressor Operation
General Introduction – Instrument Type
Sullair has assembled a series of complete controllers and indication instruments in the
instrument-type machine set. To ensure the normal operation of the machine set, the operator also
needs to make correct judgment based on each display value. Before starting the machine set, get
familiar with the controlling and indication instruments – their function, location and use.
5.2
Purpose of Controls – Instrument Type
Controller or indicator
Start button
Stop button
Manual / auto button
(dual control button)
Hourmeter
Line pressure gage
Sump pressure gage
Discharge
temperature
gauge
Air filter vacuum indicator
Fluid filter dp gauge
Separator dp gauge
Power light (red)
Fluid sight glass
Return line sight glass
Thermal valve
Minimum pressure valve
High-temperature protection
switch
Purpose
Depress to turn the compressor on.
Depress to turn the compressor off.
Choose manual or auto operation mode. When this button is located at “Auto”
position, the compressor can be stopped automatically after 15-30 minutes of
continuous unloaded operation. When the line pressure (P2) decreases below
the set value, the compressor can be started automatically.
Indicating the accumulated running time of the compressor. This parameter
can be referenced during the maintenance.
The probe of the line pressure gage is located after the discharge check valve,
reflecting the air supply pressure.
Reflecting the sump tank pressure under different working conditions.
Monitor the fluid/air mixture temperature at the exhaustion connection of the
main unit. The normal temperature range is about at 180qF~225qF
(82qC~107qC)
When the indicator points towards the red area, it indicates the air filter flow
resistance is too high, and the filtering element needs to be replaced.
When the indicator points towards the red area, it indicates the fluid filter
flow resistance is too high, and the filtering element needs to be replaced.
When the indicator points towards the red area, it indicates the separator flow
resistance is too high, and the filtering element needs to be replaced.
When the light is on, it indicates the power is connected.
Used for checking fluid level. After the machine is stopped, the fluid level is
near the center of sight glass. Don’t add too much fluid.
Used for checking the fluid reflux. At full load, there should be great flow;
when unloaded, the flow should be small or even no flow. If the flow is slow
at full load, then the return line strainer will need to be cleaned.
Regulate the fluid volume flowing through cooler. When the fluid
temperature is lower than 170qF (77qC), the valve is closed, the fluid loop is
bypassed, and the fluid doesn’t flow through cooler so as to rapidly increase
the fluid temperature during the starting.
Keep the pressure of sump tank at 50psig (3.5bar). When the pressure is
lower than 50 psig (3.5bar), the pressure valve is closed, cutting off the sump
and service air piping and preventing the compressed air reflux during
unloading or machine stop.
When the discharge temperature exceeds 235qF (113qC), the machine is
stopped.
ˎˑ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Controller or indicator
Water pressure switch (only
for water-cooled model)
Pressure relief valve
Air inlet valve
Pressure regulator
Solenoid valve
Pressure switch
Blowdown valve
Water volume regulating
valve (only for water-cooled
machine set)
Section 5: Compressor Operation
Purpose
When the water pressure is insufficient, the compressor won’t be started.
When the sump pressure is too high, this valve is actuated, and the sump is
connected with the atmosphere. The action of this valve shows the
high-pressure switch fails or is damaged.
Regulate the air volume entering the main unit based on the air consumption.
It is closed when the machine is stopped (acting as check valve).
Transmit the pressure signal to the air inlet valve. Control the air inlet volume
based on the air consumption needs.
When the machine set reaches the highest set pressure, bypass the pressure
regulator, and close the air inlet valve. It can also actuate the blowdown
valve.
After the line pressure reaches the set value, control the solenoid valve
unloading.
Open when unloaded and the machine is stopped, connecting the sump tank
with the atmosphere.
Regulate the cooling water flow and ensure normal operation temperature.
5.
3 Initial Start-up
1.
Carefully read the preceding pages of this manual.
2.
Ensure to complete the preparations and checks as described in the section of installation.
3.
Open the shut-off valve to the service line.
4.
Press start button to start the machine.
5.
Check for possible leaks in piping.
6.
Slowly close the shut-off valve, and check to see if the pressure switch unloads under set pressure.
If incorrect, please refer to the parts replacement and adjustment in 7.8.
7.
Check the operation temperature. If the operation temperature exceeds 225qF (107qC), check the
cooling system and environment situation.
8.
Check the fluid reflux status through the return line sight glass; check if there is signal for
maintenance requirement.
9.
Open the shut-off valve to service line.
10. Check the operation temperature and leakage status the following day.
5.
4 Subsequent Start-up
After checking the fluid level, press the start button to start the machine set. During the operation
period, check each operation parameter.
5.
5 Shutdown
Press the stop button.
ˎ˒
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
5.
Section 5: Compressor Operation
6 Brief Introduction to Computer-type Machine Set
Refer to Section 6 supervisor. Sullair has assembled a series of complete controllers and indication
instruments in the computer-type machine set. To ensure the normal operation of the machine set, the
operator also needs to make correct judgment based on each display value. Before starting the machine
set, get familiar with the controlling and indication instruments – their function, location and use.
5.
7 Setting of Supervisor Operation Parameter
After pressing PRG key, the supervisor enters the programming mode. At this time, the set
values of some parameters can be changed. After entering the programming mode, PRG key is
used for selecting parameters. When resetting parameters, press up arrow or Sullair logo key to
increase the parameter. Press down arrow to reduce the parameter. When pressing the Sullair logo key,
the parameter increment is 10.
The parameters will be indicated based on the following sequence.
Unload pressure --- Unload pressure of the machine set. If this parameter is set at 110psig(7.6bar),
when the line pressure exceeds 110 psig (7.6bar), the machine set will be unloaded.
UNLD
100PSI
Load pressure difference --- Difference between load pressure and unload pressure. If the unload
pressure is set at 110 psig (7.6bar) and the load pressure difference is set at 10 psig (0.7bar), when the
line pressure is lower than 100 psig (6.9bar), the machine set will be loaded.
LOAD
10PSI
P1 Max --- Maximum pressure of the sump tank. If the sump pressure exceeds this value, the
supervisor will stop the machine and meanwhile indicate the warning signal.
P1 Max
135PSI
Y-Ƹ Switching time (sec) --- If full voltage starter is used, this parameter is set at zero.
WYE DELT
10 SEC
Restart time --- Waiting time required for starting the machine set after power is connected.
Through setting this parameter, it can avoid simultaneous starting of several machine sets. Similarly, it
ˎ˓
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 5: Compressor Operation
enables to start the machine set after other equipment is started. If there is no such a parameter, the
machine set won’t be started automatically after the power is re-connected.
RST TIME
10 SEC
Unload time lag (minute) --- If the machine set is in auto run mode, after the idle run exceeds the
set time, the supervisor will stop the machine. If the set value is less than 15 min (e.g. 5 min), the idle
run time before the machine stop may exceed the set value (5 min). This is because the machine set is
also equipped with one hourmeter, used for controlling the starting no more than 4 times within one
hour.
UNLD TLM
15MIN
Language selection --- Choose language used for display (English, Spanish, French, German or
Italian).
LANGUAGE
ENGLISH
Unit selection --- Choose English system or metric system.
UNITS
ENGLISH
Machine set number --- Network address of the machine. If more than two machines are used in
network, each machine has its exclusive number.
COM ID#
1
Communication speed (BAUD)--- Sequence control normally adopts 9600, and low speed can be
adopted for other controlling methods.
BAUDRATE
9600
Sequence control method --- Set the method for sequence control. The option has DISABLED,
REMOTE, SLAVE, HOURES, COMID#. For the details of each option, see sequence control and
communication protocol.
ˎ˔
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 5: Compressor Operation
SEQUENCE
HOURS
Drain interval (min) --- Time for closing draining valve between two times of drainage.
DRN INTV
10MIN
Drain time (sec) --- Drain time of the draining valve.
DRN TIME
1 SEC
Max machine set number --- Only used during sequence control. See sequence control and
communication protocol.
LAST COM
3
Lowest allowable pressure --- Only used during sequence control. See sequence control and
communication protocol.
LOWEST
90 PSI
Recovery time --- Only used during sequence control. See sequence control and communication
protocol.
RECOVER
10 SEC
Rotating time --- Only used during sequence control. See sequence control and communication
protocol.
ROTATE
50HOURS
Machine set air supply capacity --- Only used during sequence control. See sequence control and
communication protocol.
ˎ˕
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 5: Compressor Operation
CAPACITY
100
Sequence control time --- Only used during sequence control. See sequence control and
communication protocol.
SEQ HRS
1000
5. 8
Operation of Computer-type Machine Set
Before the machine is started, the operation parameters must be set first. See 5.7 for setting of
operation parameters.
Manual operation mode
Under this mode, as long as the temperature and pressure are in the normal range, the motor is not
overloaded and the emergency stop button is not pressed, the compressor will not be stopped. Press
I
key to start the machine, and put at manual operation mode. If the compressor is already in
operation and at auto run mode, press
I
key to switch the operation mode to manual mode. If the
compressor is already in manual operation, press
I
key to make supervisor close the common
failure relay (if connected) and turn off the indication light to indicate the alarm signal.
To stop the machine, press
O key. If the machine is already stopped when O key is
pressed, it will disconnect the common failure relay (if connected), remove alarm signal and turn off
the maintenance signal indication light. Whatever the compressor is doing, press
O key to make
supervisor at manual stop mode.
Auto run mode
Under this mode, when the line pressure P2 is lower than set value of “LOAD”, the compressor
will be started. If the compressor run time reaches the set time of the parameter “UNLD TIM” under
empty load, it will be stopped. To make the compressor at auto mode, press
key. At this time, if
P2 is lower than “LOAD” value, the compressor will be started immediately; otherwise, the system
status displayed in the supervisor is “STANDBY”, while the display marked with “AUTO” will flash.
If the compressor is in operation but under manual mode, press
key to switch the
operation mode to auto status. If the compressor is in auto operation, press
key to make the
ˏˌ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 5: Compressor Operation
supervisor disconnect the common failure relay (if connected) and turn off the maintenance signal
indication light.
Under auto mode, press
O key to stop the machine. The use of O key to stop the
machine will make the supervisor at manual stop mode.
Whether at auto mode or manual mode, the control of load solenoid valve shall be based on the
set value of “UNLD” and “LOAD”. Its operation is as follows:
When P2˚UNLD, the load solenoid valve is de-energized.
When P2˘LOAD, the load solenoid valve is energized.
Restarting after power failure
If the restarting time (RST TIME) is not set, the machine set won’t be started automatically after
the power recovery. If this parameter is already set, the machine set will enter standby mode after
power recovery. When the line pressure is lower than the set load pressure, the hourmeter starts
timekeeping, and the machine set will be started at the end of timekeeping.
Sequence control mode
The following gives brief introduction to the sequence control mode. Please see sequence control
and communication protocol (P/N02250057-696 or 02250057-697) for details.
Suspension ---- Respond to parameter, status change inquiry command, but doesn’t respond to
start, stop, load and unload command. The communication port is RS-485 serial interface.
Remote control ---- Respond to parameter, status change inquiry command, but doesn’t respond
to start, stop, load and unload command. Under this status, allow remote control input and output
(control command includes Start/Stop, load/unload, master/local).
Subsidiary unit ---- Respond to all the commands. Note under this status, if the subsidiary unit
doesn’t receive the command sent from the main unit, it can’t be started or loaded; that is to say, the
supervisor is controlled through upper computer (main unit).
Sequence time ---- Basically send the status message once a second. Control the machine set
(starting, load and unload) based on the sequence control time.
Communication number ---- Basically send the status message once a second. Control the
machine set (starting, load and unload) based on the machine set number (Com ID#).
ˏˍ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 5: Compressor Operation
5. 9 Controller’s Function – Computer Type
Controlling element
Emergency stop button
Discharge
Application
Located near the supervisor. Press this button to cut off all the AC
output of the supervisor and cut off the starter’s power. Before
pulling out the button and pressing O key, the supervisor will
display failure message (E-STOP)
temperature When the discharge temperature exceeds 235qF (113qC), the
transducer --- T1
Air discharge
----P1
compressor is stopped. Meanwhile, monitor the temperature of the
pressure
Line pressure----P2
Fluid pressure ----P3
Fluid
filter
pressure
difference switch
Inlet air filtering element
vacuum switch
Fluid level sight glass
Thermal valve
Minimum pressure valve
Pressure relief valve
Air inlet valve
Solenoid valve
Water volume regulator
(only for water-cooled
machine set)
fluid air mixture discharged from the main unit.
When the air discharge pressure exceeds the max value of P1, the
compressor is stopped. Meanwhile, monitor the sump pressure, and
determine if the motor rotating direction is correct through sump
pressure display.
Monitoring the line pressure. When the line pressure reaches the set
value, the computer board controlling solenoid valve will unload the
machine.
Monitoring the pressure of the fluid injected into the machine. When
the pressure is too low, the compressor will be stopped.
Monitoring the fluid filter pressure difference. If the pressure
difference is too high, it will alarm automatically.
Monitoring the inlet air filter. If the pressure difference is too high, it
will alarm automatically.
Indicating the fluid level in the tank. When the machine is stopped,
if the fluid level can be seen, it means normal. Don’t add excessive
fluid.
Control the fluid volume flowing through cooler. This valve sets the
lowest fluid temperature at 170qF (77qC). After started, it can
increase the fluid temperature quickly.
Keep the pressure of the sump tank at 50PSIG (3.5bar). When the
pressure is lower than 50PSIG (3.5bar), the pressure valve is closed,
disconnecting the sump tank and service air piping, and preventing
the reflux of the compressed air during the unloading or stop.
When the sump pressure exceeds the set value of the pressure relief
valve opening pressure, this valve is opened, connecting the air in
the tank with the atmosphere.
Regulate the air volume entering the main unit based on the air
consumption. Closed when the machine is stopped (playing the
function of check valve)
When the machine set reaches the set unload pressure, bypass the
pressure regulator to close the air inlet valve.
Regulate the cooling water flow and ensure the normal operation
temperature.
ˏˎ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 5: Compressor Operation
5. 10 Relay Description
Peripheral
Application
Operation relay (KI)
Connect the compressor starter after closed.
*üƸ (K2)
Timing close, being üƸ form starting and providing switching
time lag.
Unload/load (K3)
Control the on load/off load operation of the solenoid valve.
Common failure (K4)
Used for remote display of alarm signal or failure reason.
Draining valve (K5)
Control the solenoid valve, and automatically remove the
condensing water.
Full load/regulation (K6)
Used during sequence control.
Note: The voltage of all the control relays is 120/240VAC
5.11 Initial Start-up
Before the initial starting of the compressor, the following procedures must be referenced:
1.
Carefully read the preceding pages of this manual.
2.
Start the motor to check the rotating direction (4.9).
3.
Ensure to complete the preparations and checks as described in the section of installation.
4.
Open the shut-off valve to the service line.
5.
Check for possible leaks in piping.
6.
Slowly close the shut-off valve, and check to see if the pressure switch unloads under set pressure.
If incorrect, please refer to the parts replacement and adjustment in 7.8.
7.
Check the operation temperature. If the operation temperature exceeds 225qF (107qC), check the
cooling system and environment situation.
8.
Open the shut-off valve to service line.
9.
Check the operation temperature and leakage status the following day.
5.12 Subsequent Start-up
After checking the fluid level, press the start button
I
(manual) or
machine set. During the operation period, check each operation parameter.
5.13 Shutdown
Press stop button
O .
ˏˏ
(auto) to start the
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 6
Section 6: Supervisor II
Supervisor II
6. 1 Introduction
Fig. 10 and Section 5 describe the basic knowledge of the compressor supervisor. The supervisor
displays the temperature, pressure, time and working status through LCD (liquid crystal display). LCD
can display two lines of data, the operator can control the compressor through keypad, set and control
parameter and choose the displayed parameter. The indication light on the system diagram shows the
location of the displayed parameters. When the light is on, it displays the parameter in this place; when
the light is flashing, then this location is in the alarming status.
6. 2 Keypad Description
See Fig. 7. In addition to used for controlling the machine set, the keypad is also used for displaying
parameters and modifying the set value of some parameters.
Stop --- Manual stop and eliminate the alarming signal.
Manual --- Starts machine if no alarm conditions are present, and meanwhile choose manual
run mode. Also used to clear alarm conditions while machine is running.
Auto --- Starts machine and selects auto mode if no alarm conditions are present.
Display --- Used to display pressure, temperature and other status information.
Sullair logo --- Its application is described in the following sections.
Program --- Enter the programming mode to modify the set value of some control
parameters. Please see the section of parameter setting for details.
Up arrow --- Change display item under the status display mode. Increase the value under
the parameter set mode.
Down arrow --- Change display item under the status display mode. Decrease the value
under the parameter set mode.
6. 3 Status Displays
By default the line pressure (P2) and discharge temperature (T1) are shown on the bottom line of the
display, and machine status on the top line. The following are the various machine status messages that
indicate the state of the compressor with LCD graphics listed below:
Stop (STOP) --- The compressor is off.
Standby (STANDBY) --- The machine set stops operation for the time being.
In case of power failure or unload timer had expired, the machine set enters the standby status.
Note that the machine set under this status may be started at any time.
Starting (STARTING) --- The machine set is trying to start.
ˏː
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 6: Supervisor II
Off load (OFF LOAD) --- The machine is running and off loaded.
On load (ONLOAD) --- The machine is running and loaded.
Full load (FULL Ld) --- The machine set is in full load operation. This status is only displayed when the
Sequence control forces the full load solenoid valve to fully open.
Remote stop (RMT STOP) --- The machine set stops operation. After the remote starting contact is
closed, the machine set will be restarted. Note that the machine set under this status may be started
at any time.
SEQ stop (SEQ STOP) --- The machine set stops operation. After meeting the starting condition specified
by the program, the machine set will be restarted. Note that the machine set under this status may be
started at any time.
The default display appears as follows:
STIP
110
180
In case of failure signal, the failure signal will be displayed with default signal alternately, with 2
seconds for each display. The failure signal display is as follows:
T1
HI
110
180
To display other parameters, press DSPL key. Under this status, observe the temperature, pressure
value, operation time and other parameters. The user can choose the parameters to be displayed through
up arrow and down arrow. Press up arrow to display the parameter in the next screen, and press down
arrow to display the parameter in the previous screen. To return to the default status from the display
status, press DSPL key.
gPressure difference before and after the separator (dp1) and max allowable pressure difference (MAX).
If dp1 is greater than MAX, the supervisor will generate alarming signal.
ƸP1
4
MAX
10
P1
113
P2
108
gSump tank pressure and line pressure.
gUnit discharge temperature (T1) and max allowable value of T1 (MAX). If T1 exceeds MAX, the
supervisor will stop the machine and meanwhile display “T1 H1”.
T1
210
MAX
235
gTotal time that the compressor has been running (hour)
HRS
RUN
1234.0
gTotal hours that the compressor has been loaded (hour)
ˏˑ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
HRS
Section 6: Supervisor II
LOAD
987. 0
Last fault log, and record the last fault signal activating the machine stop and the accumulated
running hours when it takes place.
T1
HI
@1234
gNext to last fault log, and record the next to last fault signal activating the machine stop and the
accumulated running hours when it takes place.
T1
HI
@2
204
6. 4 Lamp Indicators
Embedded into the front panel schematic of the compressor are several lamps. To check the running
status of the lamp indicators, press the lamp test key, most of lamp indicators will be on for about 3
seconds. The function of each lamp is as follows:
P1 --- Indicating the sump tank pressure. If the light is stable, it displays P1. If it is flashing, it indicates
the supervisor has generated the alarm.
P2 --- Indicating the line pressure. If the light is stable, it displays P2. If it is flashing, it indicates the
supervisor has generated the alarm.
Ƹ P1 --- (Pressure difference before and after separator). If the light is stable, it displays ƸP1. If it is
flashing, it indicates the separation element needs to be replaced.
Ƹ P2 --- (Pressure difference before and after fluid filter). If the light is stable, it displays ƸP2. If it is
flashing, it indicates the separation element needs to be replaced.
T1 --- Indicating the main unit discharge temperature. If the light is stable, it displays T1. If the light is
flashing, it indicates the supervisor has generated the alarm.
T2 --- Indicating the dry side discharge temperature. If the light is stable, it displays T2. If the light is
flashing, it indicates the supervisor has generated the alarm.
MOTOR --- If the indication light is flashing, it indicates the main motor overloading contact is already
disconnected (main motor overloading).
INLET FILTER --- Air filter indication light. If the indication light is flashing, it indicates the inlet filter
needs maintenance.
POWER --- Power indication light. If the supervisor is connected with 120V AC power, this indication
light is always on.
ON --- Operation indication light. If the compressor is in operation, this light is illuminating stably. If the
indication light is flashing, it indicates the compressor is in the standby status and may be started at
any time. Restarting hourmeter not activated, remote stop or sequence stop will make the machine
set enter the standby status.
AUTO --- Auto run indication light. If the machine is in auto run status, this light is illuminating stably. If
ˏ˒
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 6: Supervisor II
the indication light is flashing, it indicates the compressor is in the standby status and may be started
at any time. Restarting hourmeter not activated, remote stop or sequence stop will make the machine
set enter the standby status.
Fig. 10
Supervisor
ˏ˓
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 7
7. 1
Section 7: Maintenance
Maintenance
General
As you proceed in reading this section, it will be easy to see that the Maintenance Program for the
air compressor is quite minimal. Such parts as air filter, fluid filter and fluid/air separator are monitored
with the relevant instrument. In case of problem, the monitoring instrument will generate the alarming
signal. Before the maintenance, refer to 7.8 parts replacement and adjustment.
7. 2
Daily Maintenance
Prior to starting the compressor, it is necessary to check the fluid level. If the fluid level is too low,
you need to add the fluid. If the machine needs to add the fluid frequently, then you need to check the
machine --- Refer to troubleshooting, find out the failure reason and take remedial measures.
After starting, check to see if each display value is normal. After the machine set temperature is
increased, it is better to check comprehensively the compressor and supervisor.
! Warning
Do not remove caps, plugs, and /or other components when compressor is running or pressurized.
Stop compressor and relieve all internal pressure before doing so.
7. 3 Maintenance after Initial 50 Hours of Operation
After the initial 50 hours of operation, the machine needs to have small maintenance to remove the
impurities in the system.
1.
Clean the return line strainer;
2.
Clean the return line orifice.
7. 4 Maintenance after Every 1000 Hours of Operation
1.
Clean the fluid return line strainer;
2.
Replace fluid filter element and gasket based on the needs.
3.
Replace air filter element based on the needs.
7. 5 Fluid Maintenance
Based on the description of 3.2, 3.3 and 3.4, replace the fluid in the machine set.
7. 6 Fluid Filter Maintenance
In any of the following cases, replace the fluid filter element and gasket.
ˏ˔
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 7: Maintenance
Filter head
Gasket*
Element*
*Part No.:P/N 250025-526
Fig. 11 Fluid Filter
1.
After 1000~4000 hours of operation (depending on the environment);
2.
Every 6 months;
3.
Pressure difference meter indicator points towards the red area.
7.7 Maintenance of Fluid/Air Separator
When the indicator of the pressure difference gage of fluid/air separator points towards the red area,
or one year later, replace the fluid air separator-filtering element. Note: The filtering element can only
be replaced instead of being cleaned.
7. 8 Parts Replacement and Adjustment
Please refer to Fig. 11 for the fluid filter maintenance.
1. Use strap wrench to take out the filtering element and gasket;
2. Clean the gasket seating surface;
3. Apply a light film of fluid to the new gasket;
4. Use hand to install the new filtering element, and put new gasket in place to avoid gasket deformation,
damage and extrusion;
5. Then use hand to tighten for 1/2-3/4 turn;
6. Turn on the unit to check if there is any leakage.
! Warning
To minimize the possible filtering element damage, only use Sullair products, because other
substitutes may not match the machine set pressure.
ˏ˕
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Air
Section 7: Maintenance
filtering element*
Cover
Wing nut
Clamp
Fig. 12 Air Filter Replacement
Air filter maintenance
As shown in Fig. 12, when the air filter maintenance meter points towards the red area when the
machine set is in full load operation or half a year later, the filtering element of the air filter will need
to be replaced. The replacement procedure is shown as follows:
Filtering element replacement
1.
Clean the filter housing;
2.
Loosen the clamp;
3.
Turn to remove the rubber ring from the dust cover and dump the dust in the dust cover;
4.
Turn loose the wing nut and take out the filtering element;
5.
After taking out the filtering element, clean the inner chamber of the housing. Don’t use
compressed air to blow;
6.
Replace with new filtering element;
7.
Re-install the filter;
8.
Reset the restriction gauge (only for instrument type).
Filtering element check
1.
Put one bright light source in the filtering element. If the filtering element is damaged, the light
will irradiate from the small hole of the filtering net.
2.
Check all the gaskets and contact surface between the gasket and enclosure; in case of obvious
ːˌ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 7: Maintenance
damage, replace immediately;
3.
The spare clean filtering element must be stored in the clean vessel;
4.
After the filtering element is installed, check and fasten all the connection parts before use.
Replacement of fluid air separation element
Refer to Fig. 13. The separation element needs to be replaced every the other year or when the
monitoring instrument points towards the red area.
The replacement procedure is as follows:
1.
Release the pressure in the sump tank and line;
2.
Dismantle the pipe connecting with the top cover of sump tank;
3.
Remove the hexagonal screw on the top cover;
4.
Remove the top cover;
5.
Take out the separation element;
6.
Clean the dust, dirt, etc. on the tank body;
7.
Clean the old sealing gasket and other dust on the top cover and flange. Pay attention not to
letting the dust fall into the tank body;
8.
Install separator element (coat one layer of clean grease on the upper and lower sealing face of the
filtering element);
9.
Clean the part below the top cover and remove the dust;
10. The top cover anti-loosening gasket and screw are reinstalled and tightened. The tightening torque
is 55ft-Ibs (75Nm).
11. Reinstall the pipe. Note that the return line shall be shall be inserted to the bottom of the
separation element; otherwise it will affect the fluid reflux;
12. Before turning on the machine, clean the return line strainer.
ːˍ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 7: Maintenance
Secondary separator element*
Primary separator element*
Sump tank
* Part number of primary separator element: 02250100-755
* Part number of secondary separator element: 02250100-756
Fig. 13
Replacement Of Separator Element
Control system adjustment
Before adjusting the control system, you must first determine the max operation pressure and
pressure range of the machine set (i.e. determine the unload pressure and load pressure). The max set
operation pressure can’t exceed the max pressure specified by the manufacturer (see nameplate). The
following will introduce the adjustment method of the control system. For the convenience, select one
compressor with the pressure range of 115-125psig (7.9-8.6bar).
Take out the cover of the pressure switch, close the service valve(or slightly open), and then turn
on the machine. Observe the line pressure gage, and check if the switch acts under the set pressure.
When the line reaches 125 psig (8.6bar), the switching contact shall be tripped. If the contact has no
action or acts in advance, make appropriate adjustment. See Fig. 14.
Pressure range adjustment
1.
Take out the cover of the pressure switch;
2.
Choose max operation pressure through pressure range adjustment screw. Reduce the set value
through counterclockwise rotation.
Pressure difference adjustment
ːˎ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 7: Maintenance
The pressure difference is the difference between the max operation pressure and min operation
pressure, normally set at 10 psig (0.7bar).
1.
Set
lowest
operation
pressure
through
pressure
difference
adjustment
screw.
Turn
counterclockwise to increase the pressure difference.
2.
After the pressure switch is adjusted, adjust the pressure regulator and determine the pressure
starting the air volume regulation. In the example given, this pressure is 118 psig (8.2bar). After
loosening the lock nut at the bottom of the pressure regulator, turn the adjustment screw
clockwise to increase the set value and counterclockwise to decrease the set value.
Terminal B
Terminal C
Contact block
Terminal A
Range adjustment
Differential adjustment screw
Fig. 14 Pressure Switch (P/N 040694)
3.
Close the service valve. When the line pressure reaches 118 psig (8.2bar), the pressure regulator
shall send the controlling air into the air inlet valve, and reduce the openness of the air inlet valve.
If the line pressure continues to rise or the air inlet valve is not acted, adjust based on the Step 2.
After adjustment, the line pressure shall be around 118 psig (8.2ba), while the air inlet shall have
a vacuum extent of 1.00in.Hg (2.54cm).
4.
Still don’t open the service valve, allowing the line pressure to go on increasing. When the line
pressure reaches 125 psig (8.6bar), the air inlet valve is closed completely. The vacuum extent at
ːˏ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 7: Maintenance
air inlet is about 25.00 (63.5cmHg) in.Hg. The machine set starts to unload.
5.
Open the service valve to reduce the line pressure to 115 psig (7.9bar), and check if the machine
set starts the load operation. Repeat the load and unload for several times, and check if the set
pressure is correct. Unload at 125 psig (8.6bar), and then check the pressure of sump tank during
unloading. Stop the machine, open the cover of the pressure switch, take out any one of the
conducting wire connecting the contact, and wrap with insulation tape. To get the correct reading,
the line shall be kept at the pressure of 80 psig (5.5bar).
! Danger
Do not touch the electrical contacts, terminal or leads with any metallic object. Severe electrical
shock may occur.
Turn on the machine to stabilize the pressure of sump tank. The correct reading is 12-20psig
(0.8-1.4bar).
Stop the machine after check. Connect the conducting wire and cover. Load and unload for
several repeated times, and check if the set pressure is correct.
Don’t hold the un-insulated metal conducting wire or directly use the body to touch the energized
contact, joint and conducting wire. Be careful of electric shock.
Adjustment of pressure regulator
Start compressor, regulate the line air supply valve, and maintain the compressor’s line pressure
within the set range (e.g. 115psig). Turn the pressure adjustment screw till the air discharged from the
orifice.
Drive coupling installation and maintenance
Gap
Fig. 15 Coupling Gap Adjustment
Refer to Fig. 15. Coupling installation and maintenance needs one measuring scale, one English
inner hexagonal wrench and one socket wrench. The installation procedure is as follows:
! Warning
Before installation and adjustment, please disconnect all power at source.
ːː
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 7: Maintenance
Table 1 Installation data
Horse power
Elastomer
Hub gap
Tightening torque (net)
50HP
250004-641
46mm
75N·m
60HP(45kW)/75HP(55kW)
250018-551
52mm
110N·m
First step: Install coupling
Respectively install motor hub and main unit hub.
Second step: Adjust the hub gap
First fix the main unit hub onto the driving shaft of the main unit. Then put the motor hub on the
motor shaft and don’t fix so as to adjust the gap.
Third step: Install flexible element
Install flexible element between the two hubs. Before installation, first compress its volume
through the hose clamp around the flexible element, as shown in Fig. 16.
Install lock gasket. Use flat-head bolt to fix the hub and flexible element. See Table 1 for bolt
torque.
Note:
Don’t use other bolts to replace the flat-head bolts provided together with the coupling.
Tighten the bolt. After tensioning the screw, loosen the hose clamp. Check the coupling gap based
on Table 1 and Fig. 15.
Flexible element
Flange hub
Flange hub
Hose clamp
Fig. 16 Coupling
ːˑ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 7: Maintenance
Dismantle coupling
See Fig. 16. The dismantling procedure is as follows:
1.
As per drawing indication, use the hose clamp with appropriate tensioning size to compress the
volume of the flexible element.
2.
Loosen the flat-head bolt.
3.
Turn the flexible element till the screw on the hub is exposed.
4.
Take out the flexible element with hose clamp still in place.
5.
Loosen the screw on the shaft and take out the hub.
7. 9 Troubleshooting – Instrument Type
The content in the troubleshooting table is established based on the actual application condition
of the instrumentation-type compressor and extensive test of the manufacturer. This table includes the
symptom, normal reason causing the failure and remedy.
Before repairing or replacing the parts, make comprehensive system analysis on various
possibilities generating failure. To avoid meaningless damage of the compressor, it is very necessary to
check carefully with eyes first. Normally the following points shall be observed closely:
a. Check for loose wiring;
b. Check for damaged piping;
c. Check for parts damaged by heat or electric short circuit, usually apparent by discoloration or a
burnt odor.
After checking based on the recommended method, if the failure still can’t be eliminated, please
consult Sullair distributor or directly consult Sullair.
Symptom
Probable cause
Remedy
Main disconnect switch open
Close switch
Line fuse blown
Replace fuse
Control
Compressor
blown
will not start
Motor
transformer
starter
fuse Replace fuse
overloads Reset. Should trouble persist, check whether motor
tripped
starter contacts are functioning properly.
Low incoming line voltage
Check voltage. Should voltage check low, consult
power company.
Compressor
shuts down
with air
demand
present
Reset. If trouble persists, check that line pressure
Loss of control voltage
does not exceed maximum operating pressure of the
compressor (specified on nameplate).
Low incoming voltage
Excessive operating pressure
Contact power company
Defect in line pressure switch; check pressure at
which contact points open.
ː˒
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Symptom
Probable cause
Section 7: Maintenance
Remedy
Separator requires maintenance; check maintenance
indicator under full load condition.
High-pressure shutdown switch is defective; replace.
Defective solenoid valve; regulator valve should
cause inlet valve to close when the pressure switch
contacts open. Repair if defective.
Defective blowdown valve; blowdown valve should
exhaust sump pressure to 10-15 psig (0.7-1.0 bar)
when maximum operating pressure is reached.
Repair if defective.
Cooling water temperature is too high (only for
water-cooled machine). Increase the water flow.
Cooling water flow is insufficient (only for
water-cooled machine). Check the supply of cooling
water.
Cooler is plugged (only for water-cooled machine).
Clean the tube --- if plugging persists, install water
conditioner.
Cooling airflow restricted; clean cooler and check
Discharge temperature switch for proper ventilation.
open
Ambient temperature is too high; provide sufficient
ventilation.
Low fluid level; check/adjust the fluid level.
Clogged fluid filter; Based on the indication of
maintenance indicator, replace filtering element.
Thermal valve not functioning properly; replace
element. Water flow regulating valve not functioning
properly; change (only for water-cooled machine).
Defective discharge temperature switch; check for a
short or open circuit to probe and correct wiring.
Air demand is too great
Compressor
will not build
Check service lines for leaks or open valves up.
Check the filter indicator and inspect and/or change
Dirty air filter
element if required.
full discharge
Pressure
pressure
adjustment
Maintenance section)
Defective pressure regulator
Check diaphragm and replace if necessary
regulator
out
of Adjust pressure regulator (see instructions in the
ː˓
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Symptom
Probable cause
Leak
Line pressure
rises
above
cut-out
in
causing
control
loss
of
Section 7: Maintenance
Remedy
system Check for leaks
pressure
signals
Defective pressure switch
Check that diaphragm and contacts are not damaged.
Replace if necessary.
pressure
setting
on
pressure
Defective pressure regulator
Check that sump pressure is exhausted to the
Defective blowdown valve
switch
Check diaphragm. If damaged, replace.
atmosphere when the pressure switch contacts open.
Repair or replace if necessary (kit available).
Plugged control line strainer
Clean strainer or replace with spare part
Clogged return line or orifice
Clean strainer --- replace O ring (kit available)
Excessive
Separator element damaged Clean strainer.
compressor
or not functioning properly
fluid
Leak in lubrication system
Check if the piping system has fluid leakage.
consumption
Fluid level too high
Discharge excessive fluid
Excessive fluid foaming
Replace fluid.
Pressure relief Defective
valve
pressure
relief Replace pressure relief valve.
open valve
repeatedly
Plugged separator
Water
Liquid
water from
vapor
Check separator differential
condensation Remove the water vapor from compressed air prior
cooling
and to distribution through the air system. Check
in compressed compression occurs naturally
operation of aftercooler and moisture separator.
air lines
Install a compressed air dryer. Check all drain traps
routinely.
7. 10 Troubleshooting – Computer Type
The content in the troubleshooting table is established based on the actual application condition
of the computer-type compressor and extensive test of the manufacturer. This table includes the
symptom, normal reason causing the failure and remedy.
Before repairing or replacing the parts, make comprehensive system analysis on various
possibilities generating failure. To avoid meaningless damage of the compressor, it is very necessary to
check carefully with eyes first. Normally the following points shall be observed closely:
a. Check for loose wiring;
b. Check for damaged piping;
c. Check for parts damaged by heat or electric short circuit, usually apparent by discoloration or a
burnt odor.
After checking based on the recommended method, if the failure still can’t be eliminated, please
consult Sullair distributor or directly consult Sullair.
ː˔
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 7: Maintenance
Troubleshooting – Computer Type
Symptom
Probable cause
Fluid
level
in
Remedy
fluid
air Check fluid level. When necessary, add fluid.
separator is too low
Thermal valve failure
Check thermal valve and replace thermal control
element.
Cooler fin is too dirty (for Clean cooler fin
air-cooled machine set)
Fluid filter is plugged, and Replace fluid filter
bypass valve failure
Too high ambient
Improve ventilation condition
Discharge
temperature
temperature
Too high resistance of user’s
1. Enlarge ventilation pipe.
T1 too high
external ventilation pipe
2. Set exhaustion fan in the pipe.
Insufficient
water Check cooling water supply status.
cooling
flow (water-cooled machine
set)
Too
high
cooling
water Increase cooling water flow and reduce water
temperature
Cooler
temperature
is
plugged Clean tube and use clean cooling water
(water-cooled machine set)
Temperature
Too high air
discharge
pressure (tank
pressure) P1
RTD Check RTD connection. If connection is good, replace
malfunction
RTD.
Unloading device (e.g.
Check if unloading device action is proper
blowdown valve, air inlet
valve, optional screw valve)
failure
Pressure regulator failure
Check pressure regulator
Unload solenoid valve failure
Check solenoid valve
Controlling air tube leakage
Check if controlling tube is leaked
Controlling air tube filter is
Repair filter assembly
clogged
ː˕
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Symptom
Section 7: Maintenance
Probable cause
Remedy
Fluid air separator filtering
Replace fluid air separator filtering element
element is clogged
Minimum
pressure
valve Check/repair minimum pressure valve
failure
Air
Air consumption is greater
(1) Reduce air consumption;
than air supply
(2) Check if any leakage on the air transmission pipe
Air filter is clogged
Replace filtering element
supply Air inlet valve can’t be fully
is opened
pressure
lower
Check the air inlet valve action and setting of pressure
regulator
than Loose pressure transducer
Check transducer contact. If the joint is good, replace
rated
joint
pressure transducer
discharge
Minimum pressure valve –
Check / repair butterfly valve at fluid discharge
pressure
butterfly valve failure
connection
Optional screw valve is
Check screw valve pressure regulator
opened
Fluid air separator filtering
Check and replace fluid air separator filtering element
element is blocked
Pressure transducer P2 failure
Check transducer contact. If the contact is good,
replace transducer
Line pressure
P2 higher than
set value of
unload
pressure
Check operation of unload device
Unload device (e.g.
blowdown valve, air inlet
valve, optional screw valve)
failure
Unload solenoid valve failure
Check operation of solenoid valve
Controlling air tube leakage
Check if controlling air tube has air leakage
Controlling tube filter is
Repair filter assembly
clogged
Return line strainer or orifice Clean strainer filtering net and orifice. If necessary,
is plugged.
replace with spare part.
Excessive
Filtering element or washer of
Check filtering element and washer. If damaged, they
fluid
fluid air separator is damaged
must be replaced
consumption
Lubricant system leakage
Check fluid tube system
Too high fluid level
Discharge excessive fluid.
Too much foam
Discharge and replace fluid
ˑˌ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 7: Maintenance
7. 11 Transducer Usage Description and Supervisor Parameter Calibration
Transducer usage description:
Whenever the transducer is suspected of failure, it is better to choose other standard instruments
for calibration (pressure, temperature, etc.). If the reading is incorrect, first check the wire joint or pipe
joint. If the joint is good and correct, replace transducer and use standard instrument for the
calibration.
Parameter calibration
The supervisor is equipped with the calibration software of pressure transducer and temperature
transducer. This calibration method can affect the deviation of the pressure and temperature
calculation, but won’t affect the curve slope. For this reason, the most accurate method is to heat or
pressurize the transducer to its operation value. If this is too difficult, calibration under room
temperature/atmosphere can be made. The calibration can only be made when the machine is stopped
and external control is released.
To enter calibration mode, you must press sequence key “
”, “ ”, “DISPLY”, “
” PROG
under display default mode. Once in calibration mode, you will be able to see on the screen:
CAL
P1
0
6.7
Take the above display as an example: “0” indicates regulation volume (with PSI or qF as a unit).
6.7bar indicates current value of P1. To make adjustment, press “ ” key (up arrow) to increase value
and “
” key (down arrow/indicator test) to reduce value. The value on left will be increased or
reduced and display the total regulation volume. The max regulation range isf7.
Press “DISPLY” key to exit the calibration mode, save all the previous option changes but don’t
save the change of current option. Press “PROG” key to save the current option and enter the next
option. All the temperature and pressure values can be calibrated separately.
7. 12
Pipe Installation Diagram
See Fig. 17 for pipe installation diagram of standard machine.
See Fig. 18 for pipe installation diagram of computer-type machine.
ˑˍ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Solenoid valve
Separator element
dp gauge
Sump pressure gauge
Section 7: Maintenance
Shuttle valve
Minimum pressure/check
Control pressure valve
regulator valve
Shuttle valve
Control line orifice
Air filter gauge
Blow down valve
Strainer
Pressure relief valve
Fluid filter
Air filter
dp gauge
Orifice
Sight glass
Air inlet valve
Check valve
Motor
Sump tank
Fluid filter dp gauge
Compressor unit
Discharge
temperature gauge
Thermal valve
Water-cooled
after cooler
Pressure switch
Water-cooled
fluid cooler
Water control valve
Line pressure gauge
Moisture separator
Fig. 17 Pipe installation principle diagram - Standard type
ˑˎ
Air-cooled
fluid and afercooler
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 7: Maintenance
Compressor
unit
discharge pressure P1
Shuttle valve
Control air orifice
Solenoid valve
Minimum pressure/
Control pressure check valve
regulator valve
Shuttle valve
Solenoid valve
Air filter
dp P switch
Strainer
Blowdown valve
Pressure relief valve
Fluid filter
Thermal valve
Air
Orifice
filter
Air inlet valve
Sight glass
Check
valve
Motor
Fluid filter
dp p switch
Sump tank
Compressor
Compressor
temperature
RTD T1
unit
P3 Flulid
pressure
Water-cooled
after cooler
Water cooled
fluid cooler
Package discharge
pressure P2
Water control valve
Moisture separator
Fig. 18 Pipe Installation Principle Diagram - Computer Type
ˑˏ
Air-cooled
fluid and
after cooler
̚9+=
$
$
S
S
6WRS
6%
)DQPRWRU
RYHUORDG
)5
)URP;7
)URP)8
)5
0DLQPRWRU
RYHUORDG
)URP7&
©
'LVFKDUJH
DLUWHPSHUDWXUH
WRRKLJK
67
'LVFKDUJH
DLUSUHVVXUH
WRRKLJK
63
:DWHUSUHVVXUH
WRRORZ
63
)URP;7
7R.0
.0
6WDUWXS
6%
.0
;7
7
7
a 7
77
7
.$
.0
.7
63
S
<Ƹ
)URP6%
7R.0
)URP6%
)URP)5
)URP)5
7R)5
)URP63
7R67
)URP67
7R<9ǃ<9
7R+/
.7
7RRKLJK
OLQHYROWDJH
.0
0
)5
.0
)8
:LULQJWRXVHUOLQH
0DFKLQH
ORDGLQJ
.7
.$
$XWRPDWLFVWRS <9
+/
2IIORDG
GHOD\UHOD\
$XWRPDWLF
FRQWUROYDOYH
LQGLFDWRUODPSV
6HOHFWLRQRI
RSHUDWLRQPRGHV
6$
0
)5
+/
.$
2SHUDWLRQ 6WDUWXS
LQGLFDWRUODPSV UHOD\
/
/
/
3(
7R)5
4)
7R6%
7R6%
/
/
/
3(
)URP6$
$
7R+0
)URP.7
$
7R<9
)URP.0
)URP6$
7R+/ǃ.0
3(
$
7R63
0(&
0(&
;
8
9
:
8
9
:
$
$
)URP63
$
7R63
$
7R.7
8
9
:
8
9
:
$
+0
7
7
7
a
8
9
:
3(
<9
3(
.0
.7
)8
8
9
:
8
9
7R<9
)URP.7
7R.$
:
9
8
.$
ˑː
7&
)8
+=
.0
.0
.0
99
9$
;%
;
;
$
+/
3KDVHVHTXHQFHSURWHFWRU
1& 12 12 6$FRQWDFW
7R;7
7R;7
&RQQHFW
5HIHUWR(QJOLVKYHUVLRQGUDZLQJQXPEHU
2SWLRQDO
'LVFRQQHFW
1RWH
&RQQHFW
'LVFRQQHFW
0DQXDO
$XWRPDWLF
PRGH
PRGH
'LVFRQQHFW
&RQQHFW
3URWHFWLRQGHYLFHLQIURQWRIWKH
HOHFWULFDOLQVWUXPHQWDOSDQHOLVVXSSOLHGE\XVHU
-XPSHUVVKRXOGEHUHPRYHGSULRUWRDGGLQJDQ\RSWLRQDO
6$FRQWDFWVWDWXVGHVFULSWLRQ
3RZHU
LQGLFDWRU
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 8: Electrical Wiring Diagram
Section 8 Electrical Wiring Diagram
8. 1 Electrical Wiring Diagram of Instrumentation Control
FRQWUROYDOYH
/2&$/0$67(5&21752/
5(027(/2$'81/2$'
5(027(67$576723
-PSHUVVKRXOGEHUHPRYHGEHIRUHDGGLQJDQ\RSWLRQDO
35272&2/0$18$/
2QO\IRUZDWHUFRROHGPDFKLQH
GLJLWV
;7
3URWHFWLRQGHYLFHVKRXOGEHVXSSOLHGE\XVHU
&RQWURO:LULQJ'LDJUDP
)RUQHWZRUNLQJ683(59,625,,56UHIHUWR1HWZRUN
)URP)8
)RUUHPRWHFRQWUROPRGHUHIHUWR683(59,625,,6(48(1&,1*
(OHQHQWVFRQQHFWHGZLWKGRWWHGOLQHVDUHRSWLRQDO
)URP7&
7R<9
7R<9
7R.0
-
)URP;7 )URP;7
571 36,*
56 36,*
*1'
57' 57' *1' 57'
57' 57'
57' 57'
36,* 57'
36,* 57'*1'
9 57'
*1' 57'
*1' ' 57'
' 57'
' '
' '
' '
'
'
-
*1'
.
)8///2$'
02'8/$7(
.
(/(&75,&'5$,1
.
&20021)$8/7
.
81/2$'/2$'
.
'(/7$
.
581
$&*1'
91
$&/
1RWH
IRUUHPRWHFRQWUROPRGHVRQO\
3DUWVLQWKHGRWWHGIUDPHDUH
7R.0
5('
:+7 *51
:+7 *51
'LVFKDUJHWHPSHUDWXUH
57'
6
%7
.0
.0
.0
0DLQPRWRURYHUORDG
(PHUJHQF\VWRSEXWWRQ
5('
*1'
.0
6
6%
.$ /RDGLQJVLJQDOVHQGLQJUHOD\
.$
7
7
7
a
7
7
7
/
/
/
.0
7RPDFKLQHWHUPLQDORIQH[WFRPSUHVVRU
%(/'(16KLHOGHGFDEOHVRI
FRUHVDQGWZLVWHGVWDQGVRUVLPLODUFDEOHV
:LULQJWRXVHUVLGH
6WDUW 0DFKLQH /RDGLQJ
VLJQDODODUPLQJ PDFKLQH
RIPDFKLQHV
.0
)8
&RPSUHVVRUPDLQPRWRU
<9 :DWHUVWRSVROHQRLGYDOYH RSWLRQDO
9HQWLODWRUFRQWDFW
ƸFRQWDFW
0DLQFRQWDFW
0
)5
.0
;7
4)
)8
/ / /
̚9+=
.0
.0
.0
.$ 6WDUWXSVLJQDOUHOD\
<9 6WDUWXSVROHQRLGYDOYH
.0 <FRQWDFW
<9 /RDGLQJRIIORDGVROHQRLGYDOYH
$ODUPUHOD\
<9 (OHFWULFDOPRLVWXUHVROHQRLGYDOYH
<9 )RUFHORDGLQJVROHQRLGYDOYH
)5
%/.
3
5('
)5
%/.
3
%7 3LSLQJWHPSHUDWXUH 'LVFKDUJHSUHVVXUH
%3
%3
63 3
63 3
)OXLGILOWHU
SOXJJHG
$LUILOWHUSOXJJHG
9HQWLODWRURYHUORDG
*1'
57'
(PHUJHQF\VWRSEXWWRQ
5('
5('
:+7
:+7
5('
7R;7
'LVFKDUJHWHPSHUDWXUHDWGU\VLGH
.$
63 3
:DWHUSUHVVXUHJDXJH
7R<9
7R.0
.$
7R<9 .$
7R6XSHUYLVRU
,,SDQHO
7R6XSHUYLVRU
,,SDQHO
)URP.0
)URP.0
7R<9
)URP63
.$
/
/
9
8
/
/
/
:
8
9
-
)URP)5 )URP)5 )URP63 )URP63
)URP)5
)URP63
)URP63
)URP%3ǃ%3 %/. )URP%3ǃ%3 5('
)URP%3 :+7 *51
)URP%3 :+7 *51 )URP%7 :+7
)URP)URP%7 5(' %7ǃ%7 5('ǃ*1' )URP%7 5('
)URP%7 :+7
7&
;%
9
683(59,625,,
'(/8;(
&RQQHFWLRQWRPDFKLQH
FDVHRQO\DWFKDLQHQG
)URP63
/
/
/
8
9
:
8
9
:
8
9
:
9
.0
)8
0
7R;7
7
a
7
7
'LVFKDUJHIDQPRWRU
)5
)8
/
/
/
8
9
:
8
9
:
8
9
:
ˑˑ
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 8: Electrical Wiring Diagram
8. 2 Electrical Wiring Diagram of Computer Board Control
6WDU'HOWDPHFKDQLFDOLQWHUORFN
LS12-50&LS16-60/75LF Screw Compressor O & M Manual
Section 9
Section 9: Recommended Parts List
Recommended Parts List
Name
Fluid filter 02250054-605 filtering element
Part number
250025-526
Qty
1
Heavy-duty air filter 88290006-012 filtering element
(LS12)
88290006-013
1
Heavy-duty air filter 02250091-634 filtering element
(LS16)
02250131-499
1
Primary separator filtering element
02250100-755
1
Secondary separator filtering element
02250100-756
1
Minimum pressure valve 02250097-598 repair kit
001177
1
Minimum pressure valve 02250097-598 cap repair kit
02250046-396
1
Minimum pressure valve 02250097-598 O-ring repair
kit
02250048-363
1
Minimum pressure 02250097-598 piston repair kit
02250051-337
1
Thermal valve 02250092-929 repair kit
02250105-553
1
Pressure regulator 02250084-027 repair kit (LS12)
250019-453
1
Pressure regulator 250017-280 repair kit (LS16)
250019-453
1
Blowdown valve 02250100-042 repair kit
02250045-132
1
Solenoid valve 250038-666 repair kit
250038-672
1
Solenoid valve 250038-666 fluid repair kit
250031-730
1
Air inlet valve 250030-612 repair kit (LS12)
250031-438
1
Air inlet valve 02250083-783 repair kit (LS16)
250029-249
1
Repair kit of return line strainer
02250117-782
1
Shaft seal repair kit (LS12)
02250050-363
1
Shaft seal repair kit (LS16)
02250050-364
1
Shaft seal installation and maintenance tool
602542-001
1
Moisture separator repair kit (50HP/37KW)
88290003-833
1
Sequence control and communication protocol manual
02250057-696
1
250022-669
1
02250051-153
1
(I)
Sullube 32 fluid (5 gal)
24KT lubricant (5 gal)
Note: When ordering spare parts, please indicate the compressor model, serial number and
BOM number so that we can provide better service for you.
ˑ˒
Global Sales & Service
SULLAIR CORPORATION
Subsidiary of Hamilton-Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 001-219-879-5451 or1
1-800-Sullair (U.S.A. only )
Fax: 001-219-874-1273
Fax: 001-219-874-1835 (Part s)
Fax: 001-219-874-1805 (Service)
SULLAIR EUROPE, S.A.
Zone Des Granges BP 82
42602 Montbrison Cedex, France
Telephone: 0033-4-77968470
Fax: 0033-4-77968499
SULLAIR ASIA LIMITED
Zuo Pao Tai Road, Chiwan, Shekou, Shenzhen 518068, PRC
Telephone: 0755-26851686
Fax: 0755-26853473, 26853475
Hotline: 800-830-3977
Website: http://www.sullair-asia.com
SULLAIR TAIWAN LIMITED
3F1, 2/3 Chung San Road, Lin Kou Hsiang,Taipei Hseing,Taiwan
Tel: (02)2601-3500
Fax: (02)2601-3032
SULLAIR SINGAPORE
74Joo Koon,Circle,Jurong,Singapore 629093
Tel: (65)68611211
Fax:(65)68612967
68617163