Sullair LS-25S-257KW Installation and maintenance instructions

INDUSTRIAL ROTARY SCREW
LS---25S---257KW
EQUIPMENT NO.
OPERATOR’S
MANUAL AND
Part Number 02250127---759
eSullair Corporation
AIR COMPRESSOR
SUPERVISOR II
PARTS LIST
1 --- M C --- Q B 0 0 1
0 --- M C --- Q B 0 0 1
2 --- M C --- Q B 0 0 1

AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are 3--day courses that provide hands--on instruction
in the proper operation, maintenance and service of Sullair equipment.
Individual seminars on Industrial compressors and compressor electrical
systems are presented at regular intervals throughout the year at a dedicated
training facility at Sullair’s corporate headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service
parts, troubleshooting of the most common problems, and actual equipment
operation. The seminars are recommended for maintenance and service
personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1--888--SULLAIR or 219--879--5451 (ext. 5363)
-- O r W r i t e --
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department

TABLE OF CONTENTS
Section 1 PAGE
SAFETY 11.1 GENERAL
11.2 PERSONAL PROTECTIVE EQUIPMENT
11.3 PRESSURE RELEASE
21.4 FIRE AND EXPLOSION
21.5 MOVING PARTS
21.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
21.7 TOXIC AND IRRITATING SUBSTANCES
31.8 ELECTRICAL SHOCK
31.9 LIFTING
41.10 ENTRAPMENT
Section 2
DESCRIPTION 52.1 INTRODUCTION
52.2 DESCRIPTION OF COMPONENTS
62.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
72.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
72.5 COMPRESSOR DISCHARGE SYSTEM,
FUNCTIONAL DESCRIPTION
82.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
11 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
11 2.8 SUPERVISOR II PANEL BASIC INSTRUCTION
11 2.9 KEYPAD
13 2.10 STATUS DISPLAYS
14 2.11 LAMP INDICATORS
Section 3
SPECIFICATIONS 15 3.1A IDENTIFICATION --- LS25S
16 3.1B LS25S COOLER PACK
17 3.2 LUBRICATION GUIDE---STANDARD COMPRESSORS
17 3.3 APPLICATION GUIDE
Section 4
INSTALLATION 19 4.1 MOUNTING OF COMPRESSOR
19 4.2 VENTILATION AND COOLING
19 4.3 SERVICE AIR PIPING
19 4.4 FLUID PIPING (AIR---COOLED ONLY)
20 4.5 COUPLING ALIGNMENT CHECK
20 4.6 FLUID LEVEL CHECK

TABLE OF CONTENTS
(CONTINUED)
Section 4 PAGE
INSTALLATION (CONT) 20 4.7 ELECTRICAL PREPARATION
21 4.8 MOTOR ROTATION CHECK
Section 5
OPERATION 23 5.1 GENERAL
23 5.2 PURPOSE OF CONTROLS
24 5.3 PARAMETER SETUP
25 5.4 OPERATING THE COMPRESSOR
26 5.5 SUPERVISOR OUTPUT RELAYS
27 5.6 INITIAL START---UP PROCEDURE
27 5.7 SUBSEQUENT START---UP PROCEDURE
27 5.8 SHUTDOWN PROCEDURE
Section 6
MAINTENANCE 29 6.1 MAINTENANCE INTRODUCTION
29 6.2 DAILY OPERATION
29 6.3 MAINTENANCE AFTER INITIAL 50 HOURS
OF OPERATION
29 6.4 MAINTENANCE EVER 1000 HOURS
29 6.5 FLUID CHANGE
29 6.6 SEPARATOR MAINTENANCE
29 6.7 PARTS REPLACEMENT AND
ADJUSTMENT PROCEDURES
29 MAIN FILTER MAINTENANCE
30 AIR FILTER MAINTENANCE
31 SEPARATOR ELEMENTS REPLACEMENT
32 DIFFERENTIAL PRESSURE REGULATOR ADJUSTMENT
32 PRESSURE REGULATOR MAINTENANCE
32 DRIVE COUPLING INSTALLATION AND ALIGNMENT
35 6.8 TROUBLESHOOTING INTRODUCTION
35 6.9 TROUBLESHOOTING GUIDE
Section 7
ILLUSTRATIONS
AND PARTS LIST 37 7.1 PROCEDURE FOR ORDERING PARTS
37 7.2 RECOMMENDED SPARE PARTS LIST
38 7.3 MOTOR, COMPRESSOR, FRAME AND PARTS

TABLE OF CONTENTS
(CONTINUED)
Section 7 PAGE
ILLUSTRATIONS
AND PARTS LIST 40 7.4 COMPRESSOR AIR INTAKE SYSTEM
(CONT) 42 7.5 FLUID COOLING PIPING SYSTEM --- AIR---COOLED
REMOTE COOLER
44 7.6 FLUID COOLING SYSTEM --- AIR --- COOLED
REMOTE COOLER
46 7.7 FLUID COOLING SYSTEM --- AIR --- COOLED
REMOTE (LOW NOISE)
48 7.8 COMPRESSOR DISCHARGE SYSTEM
52 7.9 SULLICON CONTROL
54 7.10 COMPRESSOR ACTUATOR
56 7.11 ELECTRO---PNEUMATIC CONTROL SYSTEM
60 7.12 ENCLOSURE
64 7.13 UNIT TUBING
66 7.14 DECAL GROUP
72 7.15 DECAL LOCATIONS
74 7.16 PIPING AND INSTRUMENTATION
76 7.17 WIRING DIAGRAM

Section 1
SAFETY
1
1.1 GENERAL
Sullair Corporation and its subsidiaries design and
manufacture all of their products so they can be op-
erated 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 fol-
lowed, will minimize the possibility of accidents
throughout the useful life of this equipment.
The compressor should be operated only by those
who have been trained and delegated to do so, and
who have read and understood this Operator’s Man-
ual. 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 safe 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 un-
safe condition, cannot attempt to operate it until the
condition is corrected.
Install, use and operate the compressor only in full
compliance with all pertinent regulations and all ap-
plicable Federal, State, and Local codes, standards
and regulations.
DO NOT modify the compressor and/or controls in
any way except with written factory approval.
While not specifically applicable to all types of com-
pressors with all types of prime movers, most of the
precautionary statements contained herein are ap-
plicable to most compressors and the concepts be-
hind these statements are generally applicable to all
compressors.
1.2 PERSONAL PROTECTIVE EQUIPMENT
Prior to installing or operating the compressor, own-
ers, employers and users should become familiar
with, and comply with, all applicable regulations and
any applicable Federal, State and Local codes,
standards, and regulations relative to personal pro-
tective equipment, such as eye and face protective
equipment, respiratory protective equipment,
equipment intended to protect the extremities, pro-
tective clothing, protective shields and barriers and
electrical protective equipment, as well as noise ex-
posure administrative and/or engineering controls
and/or personal hearing protective equipment.
1.3 PRESSURE RELEASE
A. Install an appropriate flow--limiting valve between
the service air outlet and the shut--off (throttle)
valve, either at the compressor or at any other point
along the air line, when an air hose exceeding 1/2”
(13mm) inside diameter is to be connected to the
shut--off (throttle) valve, to reduce pressure in case
of hose failure, per all applicable Federal, State and
Local codes, standards and regulations.
B. When the hose is to be used to supply a manifold,
install an additional appropriate flow--limiting valve
between the manifold and each air hose exceeding
1/2” (13mm) inside diameter that is to be connected
to the manifold to reduce pressure in case of hose
failure.
C. Provide an appropriate flow--limiting valve at the
beginning of each additional 75 feet (23m) of hose in
runs of air hose exceeding 1/2” (13mm) inside di-
ameter to reduce pressure in case of hose failure.
D. Flow--limiting valves are listed by pipe size and
rated CFM. Select appropriate valves accordingly,
in accordance with their manufacturer’s recommen-
dations.
E. DO NOT use air tools that are rated below the
maximum rating of the compressor. Select air tools,
air hoses, pipes, valves, filters, and other fittings ac-
cordingly. DO NOT exceed manufacturer’s rated
safe operating pressures for these items.
F. Secure all hose connections by wire, chain or
other suitable retaining devices to prevent tools or
hose ends from being accidentally disconnected
and expelled.
G. Open fluid filler cap only when compressor is not
running and is not pressurized. Shut down the
compressor and bleed the sump (receiver) to zero
internal pressure before removing the cap.
H. Vent all internal pressure prior to opening any
line, fitting, hose, valve, drain plug, connection or
other component, such as filters and line oilers, and
before attempting to refill optional air line anti--icer
systems with antifreeze compound.
I. Keep personnel out of line with and away from the
discharge opening of hoses or tools or other points
of compressed air discharge.
J. Use air at pressures less than 30 psig (2.1 bar) for
cleaning purposes, and then only with effective chip
guarding and personal protective equipment.
K. DO NOT engage in horseplay with air hoses as
death or serious injury may result.
L. DO NOT tamper with sump and unit (if provided)
relief valves. Check the relief valve as recom-
mended in the Maintenance Section of this manual
or at a minimum of at least weekly to make sure it is
not blocked, clogged, obstructed or otherwise dis-
abled. DO NOT change the factory setting of the re-
lief valve.
M. If the compressor is installed in an enclosed
area, it is necessary to vent the relief valve to the
outside of the structure or to an area of non--expo-
sure.

Section 1
SAFETY
2
1.4 FIRE AND EXPLOSION
WARNING
!
When installing a Base Load Transfer (BLT) Sys-
tem, remove jumpers between 16--17 & 18--19
(Dual Control Compressors) so the other com-
pressor does not backfeed defeating the shut-
down circuitry.
A. Clean up spills of lubricant or other combustible
substances immediately, if such spills occur.
B. Shut off the compressor and allow 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 lubricant or when refilling
air line anti--icer systems with antifreeze compound.
C.DO NOT permit fluids, including air line anti--icer
system antifreeze compound or fluid film to accu-
mulate 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 re-
quired. If necessary, remove acoustical material,
clean all surfaces and then replace acoustical mate-
rial. Any acoustical material with a protective cover-
ing that has been torn or punctured should be re-
placed immediately to prevent accumulation of liq-
uids or fluid film within the material.DONOTuse
flammable solvents for cleaning purposes.
D. Disconnect and lock out all power at source prior
to attempting any repairs or cleaning of the com-
pressor 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, dis-
colored or corroded. Keep all terminals and pres-
sure 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 might 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 at-
tempting weld repairs.
H. Keep suitable fully charged fire extinguisher or
extinguishers nearby when servicing and operating
the compressor.
I. Keep oily rags, trash, leaves, litter or other com-
bustibles 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
lubricant 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.
1.5 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 adjustments.
E. Make sure all personnel are out of and/or clear of
the compressor prior to attempting to start or oper-
ate it.
F. Disconnect and lock out all power at source and
verify at the compressor that all circuits are de--en-
ergized to minimize the possibility of accidental
start--up or operation, prior to attempting repairs or
adjustments. This is especially important when
compressors are remotely controlled.
G. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water, or other liq-
uids to minimize the possibility of slips and falls.
1.6 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, on or
around the compressor.
D. Keep a first aid kit handy. Seek medical assis-
tance promptly in case of injury. DO NOT ignore
small cuts and burns as they may lead to infection.
1.7 TOXIC AND IRRITATING SUBSTANCES
A. DO NOT use air from this compressor for respira-
tion (breathing) except in full compliance with any
Federal, State or Local Codes or regulations.
DANGER
!
Death or serious injury can result from inhaling
compressed air without using proper safety
equipment.
B. DO NOT use air line anti--icer systems in air lines
supplying respirators or other breathing air utiliza-
tion equipment and DO NOT discharge air from
these systems in unventilated or other confined ar-
eas.

Section 1
SAFETY
3
C. Operate the compressor only in open or ade-
quately ventilated areas.
D. Locate the compressor or provide a remote inlet
so that it is not likely to ingest exhaust fumes or other
toxic, noxious or corrosive fumes or substances.
E. Coolants and lubricants used in this compressor
are typical of the industry. Care should be taken to
avoid accidental ingestion and/or skin contact. In
the event of ingestion, seek medical treatment
promptly. Wash with soap and water in the event of
skin contact. Consult the compressor operator’s
manual lubrication section for information pertaining
to compressor fluid fill.
F. Wear goggles or a full face shield when adding an-
tifreeze compound to air line anti--icer systems.
G. If air line anti--icer system antifreeze compound
enters the eyes or if fumes irritate the eyes, they
should be washed with large quantities of clean
water for 15 minutes. A physician, preferably an eye
specialist, should be contacted immediately.
H. DO NOT store air line anti--icer system antifreeze
compound in confined areas.
I. The antifreeze compound used in air line anti-
freeze systems contains methanol and is toxic,
harmful, or fatal if swallowed. Avoid contact with the
skin or eyes and avoid breathing the fumes. If swal-
lowed, induce vomiting by administering a table-
spoon of salt, in each glass of clean, warm water un-
til vomit is clear, then administer two teaspoons of
baking soda in a glass of clean water. Have patient
lay down and cover eyes to exclude light. Call a phy-
sician immediately.
1.8 ELECTRICAL SHOCK
A. This compressor should be installed and main-
tained in full compliance with all applicable Federal,
State and Local codes, standards and regulations,
including those of the National Electrical Code, 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 ex-
posed 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 exposed 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
heart.
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
compressor after installation.
1.9 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 heli-
copter must not be supported by the lifting bail but by
slings instead. In any event, lift and/or handle only in
full compliance with Federal, State and Local codes.
B. Inspect points of attachment for cracked welds
and for cracked, bent, corroded or otherwise de-
graded 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 a functional safety
latch or equivalent, and is fully engaged and latched
on the bail or slings.
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 when-
ever compressor is suspended.
J. Set compressor down only on a level surface ca-
pable of safely supporting at least its weight and its
loading unit.
K. When moving compressors by forklift truck, util-
ize fork pockets if provided. Otherwise, utilize pallet
if provided. If neither fork pockets or pallet are pro-
vided, 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 obsta-
cles at floor level and transport and corner at mini-
mum practical speeds.
N. Make sure pallet--mounted compressors are
firmly 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 caus-
ing serious injury or property damage in the process.

Section 1
SAFETY
4
O. DO NOT use the lifting eye bolt on the compres-
sor motor, if supplied, to lift the entire compressor
package.
1.10 ENTRAPMENT
A. If the compressor enclosure is large enough to
hold a person and if it is necessary to enter it to per-
form 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.

Section 2
DESCRIPTION
5
2.1 INTRODUCTION
Your new Sullair lubricated rotary screw air com-
pressor will provide youwithaunique experience in
improved reliability and greatly reduced mainte-
nance.
Compared to other types of compressors, the Sul-
lair rotary screw is unique in mechanical reliability,
with “no wear” and “no inspection” required of the
working parts within the compressor unit.
Read Section 6 (Maintenance) to see how surpris-
ingly easy it is to keep your air compressor in top
operating condition. Should any questions arise
which cannot be answered in the following text, call
your nearest Sullair representative or the Sullair
Corporation Service Department.
2.2 DESCRIPTION OF COMPONENTS
Refer to Figure2---1.The components and assem-
blies of the air compressor are clearly shown. The
complete package includes compressor,electric
motor,compressor inlet system,compressor
discharge system,compressor cooling and lu-
brication system,capacity control system and
“Supervisor II Control System” all mounted on a
structural steel frame.
On air---cooled models, the cooling package is re-
mote---mounted and shipped as a separate unit.
The separate motor---driven fan cooling package
forces air through the coolers, which removes the
heat of compression from the cooling fluid.
Both air---cooled and water---cooled versions have
easily accessible items such as the fluid filters and
control valves. The inlet air filters are also mounted
for easy access and servicing.
2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL
DESCRIPTION
Sullair aircompressors feature theSullair compres-
sor unit, a single---stage, positive displacement, lu-
bricated---type compressor. This unit provides con-
tinuous pulse---free air compression to meet your
Figure 2 --- 1 Sullair Series LS --- 25S Rotary Screw Compressor

Section 2
DESCRIPTION
6
Figure 2---2 Compressor Piping and Instrument Diagram

Section 2
DESCRIPTION
7
needs. With a Sullair compressor, there is no
maintenance or inspection of the internal parts of
the compressor unit permitted in accordance with
the terms of the warranty.
Fluid is injected into the compressor unit in large
quantities and mixes directly with the air as the ro-
tors turn, compressing the air. The fluid flow has
three main functions:
SAs coolant, it controls the rise of air tem-
perature normally associated with the heat
of compression.
SSeals the leakage paths between the ro-
tors and the stator and also between the
rotors themselves.
SActs as a lubricating film between the ro-
tors allowing one rotor to directly drive the
other,whichisanidler.
After the air/fluid mixture is discharged from the
compressor unit, the fluid is separated from the air.
At this time, the air flows to the service line and the
fluid is cooled in preparation for reinjection.
2.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
Referto Figure2---2.The cooling and lubrication
system consists of a fluid cooler,aftercooler,full
flow fluid filters,fluid stop valve,thermal valve
and interconnection piping. For water---cooled
models, a shell and tube fluid cooler and after-
cooler are mounted on the compressor package.
For air --- cooled models, they are radiator --- type
coolers which are mounted on separate cooling
packages.
Thepressure inthereceiver/sump causes fluidflow
by forcing the fluid from the high pressure area of
the sump to an area of lower pressure in the com-
pressor unit.
Fluid flows from the bottom ofthe receiver/sump to
the thermal valve. The thermal valve is fully open
when the discharge temperature is below 170_F
(77_C). The fluid passes through the thermal valve,
the main fluid filter and directly to the compressor
unit.
As the discharge temperature rises above 170_F
(77_C), due to the heat of compression, the ther-
mal valve begins to close and a portion of the fluid
then flows through the cooler. In the case of 24KT
compressors, as the injection fluid temperature
risesabove 140_F(60_C), the thermal valve begins
to close and a portion of the fluid begins to flow
through the cooler. From the cooler, the fluid flows
tothe main filter and on tothe compressor unit. The
fluid filter has a replacement element and an inte-
gral pressure bypass valve.
The fluid stop valve prevents fluid from filling the
compressor unit when the compressor is shut
down. When the compressor is operating, the fluid
stop valve is held open by air pressure from the
compressor unit allowing a free flow of fluid from
the receiver/sump back to the compressor unit. On
shutdown, the compressor unit pressure is re-
duced, causing the fluid stopvalve toclose andiso-
late the compressor unit from the cooling system.
2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC-
TIONAL DESCRIPTION
Refer to Figure2---2.The compressor unit dis-
charges the compressed air/fluid moisture through
a discharge check valve into the combination re-
ceiver/sump. The discharge check valve prevents
air in the receiver from returning to the compres-
sion chamber after the compressor has been shut
down. The receiver has three functions:
SIt acts as a primary fluid separator.
SServes as the compressor fluid sump.
SHouses the final fluid separator elements.
The compressed air/fluid mixture enters the re-
ceiver and is directed against the ends of the tank.
The direction of movement is changed and its ve-
locity significantly reduced, thus causing large
droplets of fluid to form and fall to the bottom of the
receiver/sump. The fractional percentage of fluid
remaining in the compressed air collects on the
surfaces of the dual separator elements as the
compressed air flows through them. Two return
lines (or scavenge tubes) lead from the bottom of
each separator element to the inlet region of the
compressor unit. Fluid collecting on the bottom of
each separator is returned to the compressor by a
pressure difference between the receiver and the
compressor inlet. Sight glasses are located in the
return lines toobserve this fluid flow.There are also
orifices in this return line (protected by strainers) to
assure proper flow.By pressing the ΔP1pad onthe
Supervisor,the operator may monitor the condition
of the separator elements by reading differential
pressure on the digital display.At a differential of 10
psid (0.7 bar) or greater, the operator will be told to
service the separator element. At this time, separa-
tor element replacement is necessary.
The receiver is an ASME pressure vessel. A combi-
nation minimum pressure/check valve, located
downstream from the separator, assures a mini-
mum receiver pressure of 50 psig (3.4 bar) during
full load operation. This pressure is necessary for
proper air/fluid separation and proper fluid circula-
tion while supplying air to the system. This valve
also acts as a check valve preventing compressed
air inthe service line frombleeding back into there-
ceiver on shutdown and during operation on the
compressor in an unloaded condition.
A pressure relief valve (located on the wet side of
the separator) is set to open if the sump pressure
exceeds 150 psig (10.3 bar).

Section 2
DESCRIPTION
8
The compressor is also equipped with high pres-
sure shutdown protection to shut down the com-
pressor at 135 psig (9.3 bar). This prevents the re-
lief valve from opening and dumping fluid under
normal conditions. Also, a highdischarge tempera-
ture control with three (3) sensing probes is pro-
vided toshut downthe compressor if thedischarge
temperature reaches 235_F (113_C).
WARNING
!
DO NOT remove caps, plugs, and/or other com-
ponents when compressor is running or pressur-
ized.
Stop compressor and relieve all internal pres-
sure before doing so.
Fluid is added to the sump via a capped fluid filler
opening, located on the tank to prevent overfilling
of the sump. A sight glass enables the operator to
visually monitor the sump fluid level.
2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIP-
TION
RefertoFigures2--- 3Aand2--- 3B.Thepurposeof
the compressor control system is to regulate the
amount of air being compressed to match the
amount of compressed air being used. The capac-
ity control system consists of a spiral valve and an
inlet butterfly valve. The functional description of
the control system is described below in four dis-
tinct phases of operation. The following description
text applies to all LS---25S Series compressors
ranging from200 --- 350HP/150 --- 261KWmodels.
For explanatory purposes, this description will ap-
ply to acompressor withan operating range of 100
to 110 psig (6.9 to 7.6 bar). A compressor with any
other pressure range would operate in the same
manner except at stated pressures.
START MODE --- 0 TO 50 PSIG (0 TO 3.4 BAR)
When the compressor ON/OFF pad is depressed,
thesump pressure willquickly risefrom0to50psig
(0to 3.4bar). During this period, both thepressure
regulator and the solenoid valve areclosed and the
Sullicon Control is inoperative. The spring on the
control holds the butterfly valve fully open while the
spiral valve is fully closed (maximum) position and
the compressor pumps at full rated capacity. The
rising compressor air pressure is isolated from the
service line in this phase by the minimum pressure
valve set at approximately 50 psig (3.4 bar).
FULL LOADMODE --- 50 TO100 PSIG(3.4 TO 6.9
BAR)
When the compressed air pressure in the sump
rises above 50 psig (3.4 bar), the minimum pres-
sure valve opens, allowing compressed air to flow
into the service line. From this point on, the line air
pressure is continually monitored by the Supervi-
sor. The pressure regulator and the solenoid valve
remain closed during this phase, keeping the Sulli-
con Control inactive. Both the spiral valve, as well
as the inlet butterfly valve, remain in the full load po-
sition as long as the compressor is running at 100
psig (6.9 bar) or below.
MODULATION --- 100 to 110 PSIG (6.9 TO 7.6
BAR)
As air demand drops below the rated capacity of
the compressor, the line pressure will rise above
100 psig (6.9 bar). As a result, the differential pres-
sure regulator for the spiral valve gradually opens,
applying air pressure tothe spiral valveactuator.Air
pressure at the actuator expands the diaphragm.
The rack, in turn, engages with the pinion mounted
on the spiral valve shaft assembly. This results in a
rotary motion. As the spiral valve rotates, it starts
opening the bypass ports gradually. Excess air is
then being returned back internally to suction end
ofthe compressor unit. Nowthe compressor isfully
compressing only that amount of air which is being
used. As air demand keeps dropping further, the
spiral valve keeps opening more and more until all
the bypass ports are fully open. At this point, the
spiral valve has moved into the unload (minimum)
position.
The spiral valve provides a modulation range from
100 to 50%. During this period, the pressure rises
approximately from100to108 psig (6.9to 7.4 bar).
As the air pressure exceeds 108 psig (7.4 bar), the
differential pressure regulator controlling the Sul-
licon Control opens. This allows the air pressure to
expand the diaphragm chamber of the Sullicon
Control, which starts partially closing the inlet but-
terfly valve. The inlet butterfly valve provides modu-
lation range from 50 to40%. During this period, the
pressure rises approximately from 108 to 110 psig
(7.4 to 7.6 bar). During this range, the spiral valve
remains in the unload position.
UNLOAD MODE --- IN EXCESS OF 110 PSIG (7.6
BAR)
When a relatively small amount or no air is being
used, the service line pressure continues to rise.
When it exceeds 110 psig (7.6 bar), Supervisor
de---energizes the solenoid valve allowing line
pressure to be supplied directly to the Sullicon dia-
phragm keeping the inlet butterfly closed; the spiral
valve is fully open (minimum) position. Simulta-
neously,the solenoid valve sends a pneumatic sig-
nal to the blowdown valve. The blowdown valve
opens the sump to the atmosphere. This reduces
the sump pressure to approximately 30 to 50 psig
(2.1 to 3.4 bar) which results in low horsepower
consumption. The check valve in theair service line
prevents line pressure from returning to sump
while the compressor is running in the unloaded
mode. Both the spiral valve and the butterfly valve
remain in the unload position.
Whenthelinepressuredropsbackto100psig(6.9
bar) due to an increase in the air demand, the Su-
pervisor energizes the solenoid valve allowing the
air pressure behind the Sullicon Control to be

Section 2
DESCRIPTION
9
Figure 2---3A Control System Diagram (Start/ Full Load)

Section 2
DESCRIPTION
10
Figure 2---3B Control System Diagram (Modulation/ Unload)

Section 2
DESCRIPTION
11
Figure 2---4 Air Inlet System
vented through the solenoid valve exhaust port.
The blowdown valve closes, and the inlet butterfly
valve opens. Also the airpressure at the spiral valve
actuator diaphragm isreduced through a vent hole
at the spiral valve differential pressure regulator,
and a spring in the actuator causes the spiral valve
to return to the full load (maximum) position.
AUTOMATIC OPERATION
For applications with varied periods of time when
there are no air requirements, Supervisor’s Auto-
matic mode allows the compressor to shut down
(time delayed) when no compressed air require-
ment is present, and restart as compressed air is
needed.
2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIP-
TION
Refer toFigure2---4.The compressor inlet systems
consists ofa dry---type air filter,avacuum switch,
and an air inlet valve.
The vacuum switch, located on the compressor
Supervisor Control System, indicates the condition
of the air filter. When the message “AIR FILTER
MAINT RQD” is displayed,maintenance is re-
quired.
The butterfly---type air inlet valve directly controls
the amount of air intake to the compressor in re-
sponse tothe operation ofthe Sullicon Control (see
Section 2.6,Control System, Functional Descrip-
tion).
2.8. SUPERVISOR ΙΙ PANEL BASIC INTRODUCTION
RefertoFigure2---5.TheSupervisorΙΙ has atwo
linedisplay toshowtemperature, pressure andsta-
tus. It has a keypad for operating the compressor,
programming the control points and selecting dis-
plays. There isa graphic illustration with lamps that
light to show the item being displayed. The lamps
flash if that component is in an alarm condition.
2.9 KEYPAD
The keypad is used to control the machine as well
as display status and change setpoints. Refer to
figure 2---5for following keydescriptions.
SStop --- Used to put the machine into
manual stop. It is also used to clear alarm
conditions.
O

Section 2
DESCRIPTION
12
Figure 2---5 Supervisor II Panel
SContinuous --- Starts machine if no alarm
conditions are present. Also used to clear
alarm conditions while machine isrunning.
I
SAuto --- Starts machine and selects auto
mode if no alarm conditions are present.
Also used to clear alarm conditions while
machine is running.
S Display --- Used to display pressures,
temperatures and other status information
(See section on STATUS DISPLAYS).
DSP
SLogo --- Used for various functions de-
scribed in later sections
SProgram --- Used to enter the parameter
change mode where control parameters
may be displayed and changed (See PA-
RAMETER SETUP).
PRG
SUp arrow --- Used in status displays to
change displays and in parameter setup
mode to increment a value.
SDown arrow, lamp test --- Used in status
displays to change displays and in param-

Section 2
DESCRIPTION
13
eter setup mode to increment a value.
When inthe default display the key will light
all the lamps for three seconds.
2.10 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 mes-
sages that indicate the state of the compressor:
(Display graphics shown below.)
SSTOP --- Compressor is off.
SSTANDBY --- Compressor is off but armed
tostart. This state may beentered because
of a power up, or the unload timer had ex-
pired and stopped the machine. NOTE :
The machine may start at any time.
SSTARTING --- Machine is trying to start.
SOFF LOAD --- Machine is running and off
loaded.
SON LOAD --- Machine is running and
loaded.
SFULL LD --- Machine is running and fully
loaded. This state is only displayed if the
machine has a full load valve.
SRMT STOP --- Compressor is off but
armed to start. The machine will start when
the remote start contact is closed. NOTE :
the machine may start at any time.
SSEQSTOP --- Compressor isoffbutarmed
to start. The machine will start when the se-
quencing conditions meet the criteria to
start. NOTE : the machine may start at any
time.
This default display appears as follows:
STOP
110 180
If there are alarms active they will alternately be
shown withthe default display.The machine status
will bedisplayed for 2seconds then the alarms for 2
seconds each. For example:
T1 HI
110 180
To view other status press the DISPLY key. All tem-
peratures and pressures may be displayed as well
as other status information. To scroll through the
displays press the up arrow or down arrow keys.
Up arrow moves to the next display, down arrow
the previous display.Toreturn tothe default display
press the display key.
SSeparator differential pressure and the
maximum limit. If the limit is exceeded, a
separator maintenance warning will bedis-
played.
MAX 10
ΔP1 4
SSump pressure and line pressure.
P1 113
P2 108
SOil filter differential pressure and the maxi-
mum limit. If the limit is exceeded oil main-
tenance warning will be displayed.
P2 4
MAX 20
Δ
SPressure before(P4)and after(P3)oilfilter.
P3 108
P4 113
SOil differential pressure and the minimum
limit. If the pressure goes below the limit a
P3LOWshutdown will occur.Oildifferential
(ΔP3) is defined as P3---P1/2
P3 40
MIN 1
Δ
SUnit discharge temperature and the maxi-
mum limit. If the temperature exceeds the
limit a T1 HI shutdown will occur.
T1 210
MAX 235
SDry side discharge temperature and the
maximum limit. If the temperature exceeds
the limit a T2 HI shutdown will occur.
T2 210
MAX 235
SOil temperature and the maximum limit.
If the temperature exceeds the limit a T3 HI
shutdown will occur.
T3 210
MAX 235
STotal hours that the compressor has been

Section 2
DESCRIPTION
14
running.
HRS RUN
001234.0
STotal hours that the compressor has been
loaded.
HRS LOAD
000987.0
SLast fault log. This shows the fault on the
first line and the run hours when the fault
occurred.
T1 HI
@1 234
SNext to last fault log. This shows the fault
on the first line and the run hours when the
fault occurred.
T1 HI
@2 204
2.11 LAMP INDICATORS
Embedded into the front panel schematic of the
compressor are several lamps. Pressing the lamp
test key will light all the lamps for 3 seconds. Each
LED lamp has the following purpose.
P1 --- (Line pressure) If lit steady, signifies that P1 is
being displayed, if flashing denotes the presence
of an alarm.
P2 --- (Sump pressure) If lit steady, signifies that P2
isbeing displayed, ifflashing denotes the presence
of an alarm.
P3 --- Injection oil pressure (Pressure after oil filter)
Same as P1 & P2 except for P3.
P4 --- (Pressure before oil filter)
ΔP1 --- (Separate differential pressure) If lit steady,
signifies that ΔP1 is being displayed, if flashing de-
notes replacement of separator is needed.
ΔP2 --- (Oil filter differential pressure)
ΔP3 --- (Oil differential pressure)
T1 --- (Dry side discharge temperature) If lit steady,
signifies that T1 is being displayed, if flashing de-
notes the presence of an alarm.
T2 --- (Discharge temperature) If lit steady,signifies
that T2 is being displayed, if flashing denotes the
presence of an alarm.
T3 --- (Oil temperature) If lit steady, signifies that T3
isbeing displayed, ifflashing denotes the presence
of an alarm.
MOTOR --- If flashing, indicates the motor overload
contact has opened.
INLET FILTER --- Ifflashing, indicates that inlet filter
maintenance is needed.
OIL FILTER --- If flashing, indicates that oil filter
maintenance is needed.
POWER ON --- Litif120VAC power isapplied tothe
Supervisor ΙΙ.
ON --- If lit steady, the compressor is running. If
flashing, indicates that the compressor is armed
but stopped because of restart timer not expired,
remote stop or sequence stop. The compressor
may start at any time.
AUTO --- Iflitsteady,the compressor is running and
in auto mode. If flashing, indicates that the com-
pressor is armed but stopped because of restart
timer not expired, remote stop or sequence stop.
The compressor may start at any time.

Section 3
SPECIFICATIONS
15
3.1A Identification--- LS25S
02250122---158R2