Sullair LS-25S Installation and maintenance instructions

INDUSTRIAL ROTARY SCREW
L S --- 2 5 S
200---350HP/150---261KW AND 24KT
OPERATOR’S
MANUAL AND
Part Number 02250059---710
eSullair Corporation, 1994
Effective 11/94
AIR COMPRESSOR
SUPERVISOR I
PARTS LIST

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---800---SULLAIR or 219---879---5451 (ext. 1816)
--- 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
11.4 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
82.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
82.5 COMPRESSOR DISCHARGE SYSTEM,
FUNCTIONAL DESCRIPTION
10 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
13 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
13 2.8 INSTRUMENTATION, FUNCTIONAL DESCRIPTION
14 2.9 SUPERVISOR IMICROCONTROLLER PROGRAMMING
Section 3
SPECIFICATIONS 18 TABLE OF SPECIFICATIONS
19 LUBRICATION GUIDE
Section 4
INSTALLATION 20 4.1 MOUNTING OF COMPRESSOR
20 4.2 VENTILATION AND COOLING
20 4.3 SERVICE AIR PIPING
20 4.4 FLUID PIPING (AIR---COOLED ONLY)
22 4.5 COUPLING ALIGNMENT CHECK
22 4.6 FLUID LEVEL CHECK
22 4.7 ELECTRICAL PREPARATION
22 4.8 MOTOR ROTATION DIRECTION CHECK

TABLE OF CONTENTS
(CONTINUED)
Section 5 PAGE
OPERATION 23 5.1 GENERAL
23 5.2 PURPOSE OF CONTROLS
25 5.3 INITIAL START---UP PROCEDURE
26 5.4 SUBSEQUENT START---UP PROCEDURE
26 5.5 SHUTDOWN PROCEDURE
Section 6
MAINTENANCE 27 6.1 GENERAL
27 6.2 DAILY OPERATION
27 6.3 MAINTENANCE AFTER INITIAL 50 HOURS
OF OPERATION
27 6.4 MAINTENANCE EVERY 1000 HOURS
27 6.5 FLUID CHANGE
27 6.6 SEPARATOR MAINTENANCE
28 6.7 PARTS REPLACEMENT AND
ADJUSTMENT PROCEDURES
28 MAIN FILTER MAINTENANCE
28 AIR FILTER MAINTENANCE
29 SEPARATOR ELEMENTS REPLACEMENT
30 CONTROL SYSTEM ADJUSTMENT
31 THERMAL VALVE MAINTENANCE
31 DRIVE COUPLING INSTALLATION AND MAINTENANCE
32 FLUID STOP VALVE MAINTENANCE
33 SOLENOID VALVE MAINTENANCE
34 PRESSURE REGULATOR VALVE MAINTENANCE
34 MINIMUM PRESSURE/CHECK VALVE MAINTENANCE
36 BLOWDOWN VALVE MAINTENANCE
36 CONTROL LINE MAINTENANCE
36 FLEXIBLE COUPLING MAINTENANCE
38 6.8 TROUBLESHOOTING
Section 7
ILLUSTRATIONS
AND PARTS LIST 41 7.1 PROCEDURE FOR ORDERING PARTS
41 7.2 RECOMMENDED SPARE PARTS LIST
42 7.3 MOTOR, COMPRESSOR, FRAME AND PARTS
44 7.4 COMPRESSOR AIR INTAKE
46 7.5 FLUID COOLING PIPING SYSTEM --- AIR---COOLED
REMOTE COOLER

TABLE OF CONTENTS
(CONTINUED)
Section 7
ILLUSTRATIONS
AND PARTS LIST
(Continued)
54 7 . 7 F L U I D C O O L I N G S Y ST E M --- A I R --- C O O L ED
REMOTE COOLER (300---350HP/225---261K W)
58 7 . 8 F L U I D C O O L I N G S Y ST E M --- W A T E R --- C O O L E D
(200---250HP/150---187K W)
62 7 . 9 F L U I D C O O L I N G S Y ST E M --- W A T E R --- C O O L E D
(300---350HP/225---261K W)
66 7.10 COMPRESSOR DISCHARGE SYSTEM
70 7.11 SULLICON CONTROL
74 7.12 COMPRESSOR ACTUATOR
76 7.13 ELECTRO---PNEUMATIC CONTROL SYSTEM
80 7.14 ENCLOSURE
84 7.15 UNIT TUBING
86 7.16 DECAL GROUP
94 7.17 DIMENSIONS --- 200HP/150KW (WATER---COOLED)
95 7.18 DIMENSIONS --- 250---350HP/187---261K W (WATER---COOLED)
96 7.19 DIMENSIONS --- 300HP/225KW (AIR---COOLED)
97 7.20 WIRING DIAGRAM
98 7 . 2 1 W I R I N G D I A G R A M --- W Y E --- D E LT A

Section 1
SAFETY
1
1.1 GENERAL
Sullair Corporation and its subsidiaries designs
and manufactures all of its products so they can be
operated safely. However, the responsibility for
safe operation rests with those who use and main-
tain these products. The following safety precau-
tions are offered as a guide which, if conscien-
tiously followed, will minimize the possibility of acci-
dents throughout the useful life of this equipment.
The compressor should be operated only by those
whohavebeentrainedanddelegatedtodoso,and
who have read and understood this Operator’s
Manual. Failure to follow the instructions, proce-
dures and safety precautions in this manual may
result in accidents and injuries.
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 compres-
sor and render it inoperative by disconnecting and
locking out all power at source or otherwise dis-
abling 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 only in full
compliance with all pertinent OSHA regulations
and/or any applicable 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
behind these statements are generally applicable
to all compressors.
1.2 PERSONAL PROTECTIVE EQUIPMENT
Prior to installing or operating the compressor,
owners, employers and users should become fa-
miliar with, and comply with, all applicable OSHA
regulations and/or any applicable Federal, State
and Local codes, standards, and regulations rela-
tive to personal protective equipment, such as eye
and face protective equipment, respiratory protec-
tive equipment, equipment intended to protect the
extremities, protective clothing, protective shields
and barriers and electrical protective equipment,
as well as noise exposure administrative and/or en-
gineering controls and/or personal hearing protec-
tive equipment.
1.3 PRESSURE RELEASE
A. Install an appropriate flow---limiting valve be-
tween the service air outlet and the shut---off (throt-
tle) valve, either at the compressor or at any other
point along the air line, when an air hose exceeding
!@2” (13mm) inside diameter is to be connected to
the shut---off (throttle) valve, to reduce pressure in
case of hose failure, per OSHA Standard 29 CFR
1926.302(b)(7) and/or any applicable Federal,
State and Local codes, standards and regulations.
B. Whenthehoseistobeusedtosupplyamani-
fold, install an additional appropriate flow---limiting
valve between the manifold and each air hose ex-
ceeding !@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 !@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 recom-
mendations.
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 device to prevent tools or
hose ends from being accidentally disconnected
and expelled.
G. Open fluid filter 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 bar) for
cleaning purposes, and then only with effective
chip guarding and personal protective equipment
per OSHA Standard 29 CFR 1910.242 (b) and/or
any applicable Federal, State, and Local codes,
standards and regulations.
K. DO NOT engage in horseplay with air hoses as
death or serious injury may result.
1.4 FIRE AND EXPLOSION
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 ig-
nition away and DO NOT permit smoking in the vi-
cinity when checking or adding lubricant or when
refilling air line anti---icer systems with antifreeze
compound.

Section 1
SAFETY
2
C. DO NOT permit fluids, including air line anti---
icer system antifreeze compound or fluid film to ac-
cumulate 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 mate-
rial, 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.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 other-
wise 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 might
serve as a source of ignition.
G. Remove any acoustical material or other mate-
rial that may be damaged by heat or that may sup-
port combustion and is in close proximity, prior to
attempting weld repairs.
H. Keep suitable fully charged Class BC or ABC fire
extinguisher or extinguishers nearby when servic-
ing 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 respi-
ration (breathing) except in full compliance with
OSHA Standards 29 CFR 1910 and/or any applica-
ble Federal, State or Local codes or regulations.
DANGER
!
Death or serious injury can result from inhaling
compressed air without using proper safety
equipment. See OSHA standards and/or any ap-
plicable Federal, State, and Local codes, stan-
dards and regulations on safety equipment.
B. DO NOT use air line anti---icer systems in air
lines supplying respirators or other breathing air
utilization equipment and DO NOT discharge air
from these systems in unventilated or other con-
fined areas.
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 sub-
stances.
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 Material Safety Data Sheet for
information pertaining to fluid of fill.

Section 1
SAFETY
3
F. Wear goggles or a full face shield when adding
antifreeze 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 anti-
freeze 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
until vomit is clear, then administer two teaspoons
of baking soda in a glass of clean water. Have pa-
tient lay down and cover eyes to exclude light. Call
a physician 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 ground-
ing 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 adjust-
ments or repairs with one hand only, so as to mini-
mize 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 rotat-
ing machinery and prior to handling any un-
grounded conductors.
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
helicopter must not be supported by the lifting bail
but by slings instead. In any event, lift and/or han-
dle only in full compliance with OSHA standards 29
CFR 1910 subpart N and/or any applicable Feder-
al, State, and Local codes, standards and regula-
tions.
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. D O N O T 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 the compressor by forklift truck,
utilize fork pockets if provided. Otherwise, utilize
pallet if provided. If neither fork pockets or 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 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 proc-
ess.

Section 1
SAFETY
4
1.10 ENTRAPMENT
A. If the compressor enclosure, if any, is large
enough to hold a man and if it is necessary to enter
it to perform service adjustments, inform other per-
sonnel before doing so, or else secure and tag the
access door in the open position to avoid the possi-
bility 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 you with a unique 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 IControl 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.
On water---cooled models, fluid is piped into a heat
exchanger where the heat of compression is re-
moved from the fluid. A fan is used to supply suffi-
cient ventilating air to the compressors equipped
with a canopy.
Both air---cooled and water---cooled versions have
easily accessible items such as the fluid filters and
Figure 2 ---1 Sullair Series LS ---25S 200HP/150KW Rotary Screw Compressor

Section 2
DESCRIPTION
6
control valves. The inlet air filters are also mounted
for easy access and servicing.
2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL
DESCRIPTION
Sullair air compressors feature the Sullair compres-
sor unit, a single---stage, positive displacement, lu-
bricated---type compressor. This unit provides con-
tinuous pulse---free air compression to meet your
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.
F i g u r e 2 --- 2 C o o l i n g a n d L u b r i c a t i o n S y s t e m --- Ty p i c a l ( W a t e r --- c o o l e d )

Section 2
DESCRIPTION
7
Figure 2---3 Compressor Piping and /nstrument Diagram

Section 2
DESCRIPTION
8
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 temperature
normally associated with the heat of compres-
sion.
SSeals the leakage paths between the rotors and
the stator and also between the rotors them-
selves.
SActs as a lubricating film between the rotors al-
lowing one rotor to directly drive the other, which
is an idler.
After the air/fluid mixture is discharged from the
compressor unit, the fluid is separated from the 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
R e fe rt oF i g u re s2--- 2a n d2--- 3.T h eco o li n ga n dlu-
brication system consists of a fluid cooler,after-
cooler,full flow fluid filters,fluid stop valve,
thermal valve and interconnection piping.For
water---cooled models, a shell and tube fluid cooler
and aftercooler are mounted on the compressor
package. For air---cooled models, they are radia-
tor---type coolers which are mounted on separate
cooling packages.
The pressure in the receiver/sump causes fluid flow
by forcing the fluid from the high pressure area of
the sump to an area of lower pressure in the com-
pressor unit.
Fluid flows from the bottom of the receiver/sump to
the thermal valve. The thermal valve is fully open
when the discharge temperature is below 170_F
(77_C). In the case of 24KT compressors, the ther-
mal valve is fully open when the fluid temperature is
below 140_F(60_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
rises above 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
to the main filter and on to the 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 stop valve to close and iso-
late the compressor unit from the cooling system.
Water---cooled versions of the compressor have a
water---flow regulating valve (not shown) which op-
erates to conserve water during periods of varying
load on the compressor. This same valve automati-
cally shuts off the water supply when the compres-
sor is shut down. In addition, water---cooled mod-
els have a water pressure switch to prevent opera-
tion with inadequate water pressure.
2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC-
TIONAL DESCRIPTION
Refer to Figure2---4.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 to observe this fluid flow. There are also
orifices in this return line (protected by strainers) to
assure proper flow. By pressing the ∆P1 pad on the
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 in the service line from bleeding back into the re-
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
9
F i g u r e 2 --- 4 C o m p r e s s o r D i s c h a r g e S y s t e m --- Ty p i c a l ( W a t e r --- c o o l e d )
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 high discharge tempera-
ture control with three (3) sensing probes is pro-
vided to shut down the compressor if the discharge
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.

Section 2
DESCRIPTION
10
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
RefertoFigure2---5.Thepurposeofthecompres-
sor control system is to regulate the amount of air
being compressed to match the amount of com-
pressed air being used. The capacity control sys-
tem consists of a spiral valve and an inlet butterfly
valve. The functional description of the control sys-
tem is described below in four distinct phases of
operation. The following description text applies to
all LS---25S Series compressors ranging from 200
--- 350 HP/150 --- 261 KW models. For explanatory
purposes, this description will apply to a compres-
sor with an operating range of 100 to 110 psig (6.9
to 7.6 bar). A compressor with any other pressure
range would operate in the same manner except at
stated pressures.
START MODE --- 0 TO 50 PSIG (0 TO 3.4 BAR)
When the compressor ON/OFF pad is depressed,
the sump pressure will quickly rise from 0 to 50 psig
(0 to 3.4 bar). During this period, both the pressure
regulator and the solenoid valve are closed 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 LOAD MODE --- 50 TO 100 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 to the spiral valve actuator. Air
pressure at the actuator expands the diaphragm.
The rack, in turn, engages with the pinion mounted
on the spiral valve shaft assembly. This results in a
rotary motion. As the spiral valve rotates, it starts
opening the bypass ports gradually. Excess air is
then being returned back internally to suction end
of the compressor unit. Now the compressor is fully
compressing only that amount of air which is being
used. As air demand keeps dropping further, the
spiral valve keeps opening more and more until all
the bypass ports are fully open. At this point, the
spiral valve has moved into the unload (minimum)
position.
The spiral valve provides a modulation range from
100 to 50%. During this period, the pressure rises
approximately from 100 to 108 psig (6.9 to 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 to 40%. 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-
teously, 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 the air 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
vented through the solenoid valve exhaust port.
The blowdown valve closes, and the inlet butterfly
valve opens. Also the air pressure at the spiral valve
actuator diaphragm is reduced 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. AUTOMATIC also incorporates the 60 sec-
ond unloaded STOP MODE feature which allows
the motor to stop from an unloaded condition when
the ON/OFF pad is pressed or after the timed stop
period. If immediate stop is required when operat-

Section 2
DESCRIPTION
11
Figure 2---5A Control System Diagram (Start/Full Load)

Section 2
DESCRIPTION
12
Figure 2---5B Control System Diagram (Modulation/Unload)

Section 2
DESCRIPTION
13
Figure 2---6 Air Inlet System
ing in AUTOMATIC mode, press the EMERGENCY
STOP button on the control panel.
2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIP-
TION
Refer to Figure2---6.The compressor inlet systems
consists of a 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 to the operation of the Sullicon Control (see
Section 2.6, Control System, Functional Descrip-
tion).
2.8 INSTRUMENTATION, FUNCTIONAL DESCRIP-
TION
RefertoFigure2---7.TheSupervisorIcontrolpanel
consists of displays for pressure, temperature and
time, as well as a status message display. Default
pressure is line pressure (P2) which is normally dis-
played with pad selections for sump pressure, fluid
pressure, separator differential and fluid filter differ-
ential. Default temperature is unit discharge tem-
perature (T1) which is normally displayed with a
pad selection for injection fluid temperature. An
LED map provides a graphic illustration of the
points being monitored. Operator controls consist
of EMERGENCY STOP, ON/OFF, monitor display
pads and programming pads. All compressor con-
trol and pressure and temperature displays are
provided in the Supervisor.
SThe line (terminal) pressure transducer (P2) is
connected to the dry side of the receiver down-
stream from the check valve and continually moni-
tors the plant air pressure.
SThe sump pressure transducer (P1) monitors

Section 2
DESCRIPTION
14
Figure 2 --- 7 Supervisor IControl Panel
the sump pressure at the various load and/or off---
load conditions.
SThe discharge temperature probe (T1) moni-
tors the temperature of the air leaving the compres-
sor unit. For both air---cooled and water---cooled
compressors the normal reading is approximately
180_F(82_C) based on 80_F(27_C) ambient tem-
perature.
SThe injection temperature probe (T2) monitors
the temperature of the fluid just before it is injected
into the unit.
SThe air filter maintenance switch monitors the
condition of the air intake filter. When the Supervi-
sor displays the message “AIR FILTER MAINT
RQD”, filter serviceis required (see Figure2---3).
SThe ON/OFF pad turns the compressor on and
off.
SThe hour display records cumulative hours of
operation for the compressor and is useful for plan-
ning and logging service operations. A selectable
display of “load” hours or “load” as a percent of
“run” hours is available by pressing “HR LOAD” or
“HR%” respectively.
SSeparator differential pressure can be dis-
played by pressing the “∆P1” pad. When a differ-
ential of 10 psid (0.7 bar) is reached, the message
“SEPARATOR MAINT RQD” is displayed and the
∆P1 LED will flash.
SOil filter differential pressure can be displayed
by pressing the “∆P2” pad. When a differential of
20 psid (1.4 bar) is reached, the message “OIL FIL-
TER MAINT RQD” will be displayed and the ∆P2
LED will flash.
SThe “ON” LED indicates when the compressor is
running.
SThe amber light on the control panel indicates
when power to the compressor is supplied.
SThe green message display indicates the status
of the compressor.
2.9 SUPERVISOR IMICROCONTROLLER
PROGRAMMING
Several display and operational functions are user
programmable from the Supervisor keypad. Re-
peatedly pressing the “PROG” pad will scroll the
message display through the various program-
mable parameters. The cursor pad (∆)isusedto
change parameter values. A built--- in timed delay
feature returns the message display to operation
mode after 5 seconds of inactivity.

Section 2
DESCRIPTION
15
PROGRAMMABLE PARAMETERS
PARAMETER OPERATION
LANGUAGE Press the cursor pad for 2 seconds to change to next
language for the message display. Languages in or-
der are: French, German, Italian, Spanish and En-
glish.
AUTOMATIC/MANUAL The controller default state is AUTOMATIC operation.
If line pressure is adequate and/or the sump pressure
is greater than 5 to 10 psig (0.3 to 0.7 bar), pressing
the ON/OFF pad will put the control in STANDBY
mode until line pressure drops to the programmed
differential value and the sump pressure is low
enough to permit a START. AUTOMATIC mode pro-
vides a timed STOP with automatic restart operation.
Automatic restart after power failure is also included
in AUTOMATIC mode.
MANUAL mode ignores the line pressure permissive
of AUTOMATIC and starts the compressor with ON/
OFF as long as the minimum sump pressure and oth-
er fault conditions are satisfied. The compressor is
only stopped manually with no time stop and no auto-
matic restart after power failure.
PRESSURE UNITS Selects bar or psig; use cursor key to select. 1 bar =
14.5 psig.
TEMPERATURE UNITS _COR_F; use cursor key to select.
MAXIMUM PRESSURE P2A Use the cursor key to set the OFF LOAD pressure set-
ting. Depressing the cursor pad for more than two se-
conds will initiate a fast scrolling mode to quickly
reach the desired setpoint for all programmable set-
points. A wraparound feature (on all functions) re-
turns the value to its lowest limit if scrolling exceeds
the high limit. Typically set for 110 psig (7.6 bar).
PRESSURE DIFFERENTIAL P2A Selects the OFF LOAD setting by subtracting the dif-
ferential from P2A. Normally set for 10 psid (0.7 bar).
MAXIMUM PRESSURE P2B Same as P2A, but provides a second OFF LOAD set-
ting for base/load operation.
PRESSURE DIFFERENTIAL P2B Same as P2A, but provides a second ON LOAD set-
ting for base/load operation.
UNLOAD TIME Adjusts timed stop function if compressor is running
in OFF LOAD mode. Adjustment range is 1 to 60 min-
utes.
WYE TO DELTA TIME Adjusts transitions timer for Wye---Delta starters from
0 to 30 seconds. ON LOAD function is delayed by the
value of Wye to Delta time. A separate relay contact is
provided with this function.
DRAIN TIME AND DRAIN INTERVAL A timed contact is furnished to control a condensate
(OPTIONAL) removal solenoid valve. Both the drain duration time
(1 to10 seconds) and the time interval between drains
(1 to 10 minutes) may be set from these modes.