INDUSTRIAL AIR

COMPRESSOR
LS---10
25, 30 & 40 HP
18, 22 & 30 KW
STANDARD & 24 KT

OPERATOR’S
MANUAL AND
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Part Number 02250105--- 114
eSullair Corporation
 AIR CARE
SEMINAR TRAINING

Sullair Air Care Seminars are 3---day courses that provide hands---on instruction
in the proper operation, maintenance and service of Sullair equipment.
Individual seminars on Industrial compressors and compressor electrical
systems are presented at regular intervals throughout the year at a dedicated
training facility at Sullair’s corporate headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service
parts, troubleshooting of the most common problems, and actual equipment
operation. The seminars are recommended for maintenance and service
personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department
1---800---SULLAIR or 219---879---5451 (ext. 1816)
--- Or Write ---
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
 TABLE OF CONTENTS
Section 1 PAGE
SAFETY 1 1.1 GENERAL
1 1.2 PERSONAL PROTECTIVE EQUIPMENT
1 1.3 PRESSURE RELEASE
2 1.4 FIRE AND EXPLOSION
2 1.5 MOVING PARTS
2 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
2 1.7 TOXIC AND IRRITATING SUBSTANCES
3 1.8 ELECTRICAL SHOCK
3 1.9 LIFTING
4 1.10 ENTRAPMENT

Section 2
DESCRIPTION 5 2.1 INTRODUCTION
5 2.2 DESCRIPTION OF COMPONENTS
5 2.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
6 2.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION
6 2.5 COMPRESSOR DISCHARGE SYSTEM,
FUNCTIONAL DESCRIPTION
8 2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION---
STANDARD ELECTRO/MECHANICAL
10 2.7 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION---
SUPERVISOR II
10 2.8 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION
11 2.9 INSTRUMENT PANEL GROUP,
FUNCTIONAL DESCRIPTION--- STANDARDELECTRO/
MECHANICAL

Section 3
SPECIFICATIONS 13 3.1 TABLE OF SPECIFICATIONS

14 3.2 LUBRICATION GUIDE

14 3.3 APPLICATION GUIDE
15 3.4 LUBRICATION CHANGE RECOMMENDATIONS AND
MAINTENANCE

Section 4
INSTALLATION 17 4.1 MOUNTING OF COMPRESSOR
17 4.2 VENTILATION AND COOLING
17 4.3 SERVICE AIR PIPING
18 4.4 COUPLING ALIGNMENT CHECK
18 4.5 FLUID LEVEL CHECK
18 4.6 ELECTRICAL PREPARATION--- STANDARD ELECTRO/
MECHANICAL
 TABLE OF CONTENTS
(CONTINUED)

Section 4 PAGE
INSTALLATION 19 4.7 ELECTRICAL PREPARATION--- SUPERVISOR II
(CONTINUED) 19 4.8 MOTOR ROTATION DIRECTION CHECK--- STANDARD
ELECTRO/MECHANICAL
19 4.9 MOTOR ROTATION DIRECTION CHECK---
SUPERVISOR II

Section 5
OPERATION 21 5.1 GENERAL
21 5.2 PURPOSE OF CONTROLS--- STANDARD ELECTRO/
MECHANICAL
22 5.3 INITIAL START--- UP PROCEDURE--- STANDARD ELECTRO/
MECHANICAL
23 5.4 SUBSEQUENT START--- UP PROCEDURE--- STANDARD ELECTRO/
MECHANICAL
23 5.5 SHUTDOWN PROCEDURE--- STANDARD ELECTRO/
MECHANICAL
23 5.6 GENERAL INTRODUCTION--- SUPERVISOR II
23 5.7 SUPERVISOR II PARAMETER SETUP
24 5.8 OPERATING THE COMPRESSOR
25 5.9 PURPOSE OF CONTROLS--- SUPERVISOR II
26 5.10 SUPERVISOR II OUTPUT RELAYS
27 5.11 INITIAL START--- UP PROCEDURE
27 5.12 SUBSEQUENT START--- UP PROCEDURE
27 5.13 SHUTDOWN PROCEDURE

Section 6
SUPERVISOR II 29 6.1 INTRODUCTION--- SUPERVISOR II
29 6.2 KEYPAD
29 6.3 STATUS DISPLAYS
30 6.4 LAMP INDICATORS

Section 7
MAINTENANCE 33 7.1 GENERAL
33 7.2 DAILY OPERATION
33 7.3 MAINTENANCE AFTER INITAL 50 HOURS OF
OPERATION
33 7.4 MAINTENANCE EVERY 1000 HOURS
33 7.5 FLUID MAINTENANCE
33 7.6 FILTER MAINTENANCE
33 7.7 SEPARATOR MAINTENANCE
33 7.8 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES
36 7.9 TROUBLESHOOTING--- STANDARD ELECTRO/
MECHANICAL
 TABLE OF CONTENTS
(CONTINUED)

Section 7 PAGE
MAINTENANCE 38 7.10 TROUBLESHOOTING--- SUPERVISOR II
(CONTINUED) 40 7.11 CALIBRATION

Section 8
ILLUSTRATIONS AND
PARTS LIST 45 8.1 PROCEDURE FOR ORDERING PARTS
45 8.2 RECOMMENDED SPARE PARTS LIST
46 8.3 MOTOR, COMPRESSOR, FRAME AND PARTS
50 8.4 COOLER ASSEMBLY
52 8.5 AIR INLET SYSTEM
54 8.6 COOLING AND LUBRICATION SYSTEM
58 8.7 DISCHARGE SYSTEM
62 8.8 CONTROL SYSTEM AND ELECTRICAL PARTS
66 8.9 INSTRUMENT PANEL
68 8.10 ENCLOSURE
70 8.11 DECAL GROUP
78 8.12 WIRING DIAGRAM--- ELECTRO/MECHANICAL
(AIR--- COOLED/WATER--- COOLED)
79 8.13 WIRING DIAGRAM--- SUPERVISOR II DELUXE
(AIR--- COOLED/WATER--- COOLED)
80 8.14 WIRING DIAGRAM--- WYE--- DELTA ELECTRO/MECHANICAL
(AIR--- COOLED/WATER--- COOLED)
81 8.15 WIRING DIAGRAM--- WYE--- DELTA SUPERVISOR II DELUXE
(AIR--- COOLED/WATER--- COOLED)
NOTES
 Section 1
SAFETY

1.1 GENERAL pressure in case of hose failure, per all applicable

Sullair Corporation and its subsidiaries design and Federal, State and Local codes, standards and
manufacture all of their products so they can be op- regulations.
erated safely. However, the responsibility for safe
operation rests with those who use and maintain B. When the hose is to be used to supply a man-
these products. The following safety precautions ifold, install an additional appropriate flow ---limiting
are offered as a guide which, if conscientiously fol- valve between the manifold and each air hose ex-
lowed, will minimize the possibility of accidents ceeding 1/2” (13mm) inside diameter that is to be
throughout the useful life of this equipment. connected to the manifold to reduce pressure in
case of hose failure.
The compressor should be operated only by those
who have been trained and delegated to do so, and C. Provide an appropriate flow ---limiting valve at the
who have read and understood this Operator’s beginning of each additional 75 feet (23m) of hose
Manual. Failure to follow the instructions, proce- in runs of air hose exceeding 1/2” (13mm) inside di-
dures and safety precautions in this manual can re- ameter to reduce pressure in case of hose failure.
sult in accidents and injuries. Read this manual
prior to startup. D. Flow ---limiting valves are listed by pipe size and
rated CFM. Select appropriate valves accordingly,
NEVER start the compressor unless it is safe to do in accordance with their manufacturer’s recom-
so. DO NOT attempt to operate the compressor mendations.
with a known unsafe condition. Tag the compres- E. DO NOT use air tools that are rated below the
sor and render it inoperative by disconnecting and maximum rating of the compressor. Select air tools,
locking out all power at source or otherwise disab- air hoses, pipes, valves, filters, and other fittings ac-
ling its prime mover, so others who may not know of cordingly. DO NOT exceed manufacturer’s rated
the unsafe condition, cannot attempt to operate it safe operating pressures for these items.
until the condition is corrected.
F. Secure all hose connections by wire, chain or
Install, use and operate the compressor only in full other suitable retaining devices to prevent tools or
compliance with all pertinent regulations and all ap- hose ends from being accidentally disconnected
plicable Federal, State, and Local codes, stan- and expelled.
dards and regulations.
G. Open fluid filler cap only when compressor is
DO NOT modify the compressor and/or controls in not running and is not pressurized. Shut down
any way except with written factory approval. the compressor and bleed the sump (receiver) to
zero internal pressure before removing the cap.
While not specifically applicable to all types of com-
pressors with all types of prime movers, most of the H. Vent all internal pressure prior to opening any
precautionary statements contained herein are ap- line, fitting, hose, valve, drain plug, connection or
plicable to most compressors and the concepts other component, such as filters and line oilers,
behind these statements are generally applicable and before attempting to refill optional air line anti---
to all compressors. icer systems with antifreeze compound.
1.2 PERSONAL PROTECTIVE EQUIPMENT I. Keep personnel out of line with and away from the
Prior to installing or operating the compressor, discharge opening of hoses or tools or other points
owners, employers and users should become fa- of compressed air discharge.
miliar with, and comply with, all applicable regula-
tions and any applicable Federal, State and Local J. Use air at pressures less than 30 psig (2.1 bar) for
codes, standards, and regulations relative to per- cleaning purposes, and then only with effective
sonal protective equipment, such as eye and face chip guarding and personal protective equipment.
protective equipment, respiratory protective equip- K. DO NOT engage in horseplay with air hoses as
ment, equipment intended to protect the extremi- death or serious injury may result.
ties, protective clothing, protective shields and bar-
riers and electrical protective equipment, as well as L. DO NOT tamper with sump and unit (if pro-
noise exposure administrative and/or engineering vided) relief valves. Check the relief valve as rec-
controls and/or personal hearing protective equip- ommended in the Maintenance Section of this
ment. manual or at a minimum of at least weekly to make
sure it is not blocked, clogged, obstructed or other-
1.3 PRESSURE RELEASE wise disabled. DO NOT change the factory setting
A. Install an appropriate flow ---limiting valve be- of the relief valve.
tween the service air outlet and the shut ---off
(throttle) valve, either at the compressor or at any M. If the compressor is installed in an enclosed
other point along the air line, when an air hose ex- area, it is necessary to vent the relief valve to the
ceeding 1/2” (13mm) inside diameter is to be con- outside of the structure or to an area of non---expo-
nected to the shut ---off (throttle) valve, to reduce sure.

1
Section 1
SAFETY

1.4 FIRE AND EXPLOSION K. DO NOT attempt to operate the compressor in

any classification of hazardous environment unless
! WARNING the compressor has been specially designed and
manufactured for that duty.
When installing a Base Load Transfer (BLT) Sys- 1.5 MOVING PARTS
tem, remove jumpers between 16---17 & 18---19
(Dual Control Compressors) so the other com- A. Keep hands, arms and other parts of the body
pressor does not backfeed defeating the shut- and also clothing away from couplings, fans and
down circuitry. other moving parts.
B. DO NOT attempt to operate the compressor
A. Clean up spills of lubricant or other combustible with the fan, coupling or other guards removed.
substances immediately, if such spills occur.
C. Wear snug---fitting clothing and confine long hair
B. Shut off the compressor and allow it to cool. when working around this compressor, especially
Then keep sparks, flames and other sources of when exposed to hot or moving parts.
ignition away and DO NOT permit smoking in the
vicinity when checking or adding lubricant or when D. Keep access doors, if any, closed except when
refilling air line anti---icer systems with antifreeze making repairs or adjustments.
compound. E. Make sure all personnel are out of and/or clear of
the compressor prior to attempting to start or oper-
C. DO NOT permit fluids, including air line anti--- ate it.
icer system antifreeze compound or fluid film to ac-
cumulate on, under, or around acoustical material, F. Disconnect and lock out all power at source and
or on any external surfaces of the air compressor or verify at the compressor that all circuits are de---en-
on internal surfaces of the enclosure. Wipe down ergized to minimize the possibility of accidental
using an aqueous industrial cleaner or steam--- start---up or operation, prior to attempting repairs
clean as required. If necessary, remove acoustical or adjustments. This is especially important when
material, clean all surfaces and then replace compressors are remotely controlled.
acoustical material. Any acoustical material with a
protective covering that has been torn or punc- G. Keep hands, feet, floors, controls and walking
tured should be replaced immediately to prevent surfaces clean and free of fluid, water, or other liq-
accumulation of liquids or fluid film within the mate- uids to minimize the possibility of slips and falls.
rial. DO NOT use flammable solvents for cleaning 1.6 HOT SURFACES, SHARP EDGES AND SHARP
purposes. CORNERS
D. Disconnect and lock out all power at source prior A. Avoid bodily contact with hot fluid, hot coolant,
to attempting any repairs or cleaning of the com- hot surfaces and sharp edges and corners.
pressor or of the inside of the enclosure, if any. B. Keep all parts of the body away from all points of
E. Keep electrical wiring, including all terminals and air discharge.
pressure connectors in good condition. Replace C. Wear personal protective equipment including
any wiring that has cracked, cut abraded or other- gloves and head covering when working in, on or
wise degraded insulation, or terminals that are around the compressor.
worn, discolored or corroded. Keep all terminals
and pressure connectors clean and tight. D. Keep a first aid kit handy. Seek medical assis-
tance promptly in case of injury. DO NOT ignore
F. Keep grounded and/or conductive objects such small cuts and burns as they may lead to infection.
as tools away from exposed live electrical parts
such as terminals to avoid arcing which might 1.7 TOXIC AND IRRITATING SUBSTANCES
serve as a source of ignition. A. DO NOT use air from this compressor for respi-
ration (breathing) except in full compliance with
G. Remove any acoustical material or other materi- any Federal, State or Local Codes or regulations.
al that may be damaged by heat or that may sup-
port combustion and is in close proximity, prior to
attempting weld repairs. ! DANGER
H. Keep suitable fully charged fire extinguisher or Death or serious injury can result from inhaling
extinguishers nearby when servicing and operat- compressed air without using proper safety
equipment.
ing the compressor.
I. Keep oily rags, trash, leaves, litter or other com-
bustibles out of and away from the compressor. B. DO NOT use air line anti---icer systems in air
lines supplying respirators or other breathing air
J. DO NOT operate the compressor without proper utilization equipment and DO NOT discharge air
flow of cooling air or water or with inadequate flow from these systems in unventilated or other con-
of lubricant or with degraded lubricant. fined areas.

2
 Section 1
SAFETY

C. Operate the compressor only in open or ade- E. Disconnect, lock out, and tag all power at source
quately ventilated areas. prior to attempting repairs or adjustments to rotat-
ing machinery and prior to handling any un-
D. Locate the compressor or provide a remote inlet grounded conductors.
so that it is not likely to ingest exhaust fumes or oth-
er toxic, noxious or corrosive fumes or substances. F. Dry test all shutdown circuits prior to starting the
compressor after installation.
E. Coolants and lubricants used in this compressor
are typical of the industry. Care should be taken to 1.9 LIFTING
avoid accidental ingestion and/or skin contact. In A. If the compressor is provided with a lifting bail,
the event of ingestion, seek medical treatment then lift by the bail provided. If no bail is provided,
promptly. Wash with soap and water in the event of then lift by sling. Compressors to be air lifted by he-
skin contact. Consult the compressor operator’s licopter must not be supported by the lifting bail but
manual lubrication section for information pertain- by slings instead. In any event, lift and/or handle
ing to compressor fluid fill. only in full compliance with Federal, State and Lo-
cal codes.
F. Wear goggles or a full face shield when adding
antifreeze compound to air line anti---icer systems. B. Inspect points of attachment for cracked welds
and for cracked, bent, corroded or otherwise de-
G. If air line anti---icer system antifreeze compound graded members and for loose bolts or nuts prior to
enters the eyes or if fumes irritate the eyes, they lifting.
should be washed with large quantities of clean
water for 15 minutes. A physician, preferably an C. Make sure entire lifting, rigging and supporting
eye specialist, should be contacted immediately. structure has been inspected, is in good condition
and has a rated capacity of at least the weight of
H. DO NOT store air line anti---icer system anti- the compressor. If you are unsure of the weight,
freeze compound in confined areas. then weigh compressor before lifting.
I. The antifreeze compound used in air line anti- D. Make sure lifting hook has a functional safety
freeze systems contains methanol and is toxic, latch or equivalent, and is fully engaged and
harmful, or fatal if swallowed. Avoid contact with the latched on the bail or slings.
skin or eyes and avoid breathing the fumes. If swal-
lowed, induce vomiting by administering a table- E. Use guide ropes or equivalent to prevent twisting
spoon of salt, in each glass of clean, warm water or swinging of the compressor once it has been
until vomit is clear, then administer two teaspoons lifted clear of the ground.
of baking soda in a glass of clean water. Have pa- F. DO NOT attempt to lift in high winds.
tient lay down and cover eyes to exclude light. Call
a physician immediately. G. Keep all personnel out from under and away
from the compressor whenever it is suspended.
1.8 ELECTRICAL SHOCK
A. This compressor should be installed and main- H. Lift compressor no higher than necessary.
tained in full compliance with all applicable Federal, I. Keep lift operator in constant attendance when-
State and Local codes, standards and regulations, ever compressor is suspended.
including those of the National Electrical Code, and
also including those relative to equipment ground- J. Set compressor down only on a level surface ca-
ing conductors, and only by personnel that are pable of safely supporting at least its weight and its
trained, qualified and delegated to do so. loading unit.
B. Keep all parts of the body and any hand---held K. When moving compressors by forklift truck, uti-
tools or other conductive objects away from ex- lize fork pockets if provided. Otherwise, utilize pal-
posed live parts of electrical system. Maintain dry let if provided. If neither fork pockets or pallet are
footing, stand on insulating surfaces and DO NOT provided, then make sure compressor is secure
contact any other portion of the compressor when and well balanced on forks before attempting to
making adjustments or repairs to exposed live raise or transport it any significant distance.
parts of the electrical system. Make all such adjust- L. Make sure forklift truck forks are fully engaged
ments or repairs with one hand only, so as to mini- and tipped back prior to lifting or transporting the
mize the possibility of creating a current path compressor.
through the heart.
M. Forklift no higher than necessary to clear ob-
C. Attempt repairs in clean, dry and well lighted and stacles at floor level and transport and corner at
ventilated areas only. minimum practical speeds.
D. DO NOT leave the compressor unattended with N. Make sure pallet---mounted compressors are
open electrical enclosures. If necessary to do so, firmly bolted or otherwise secured to the pallet prior
then disconnect, lock out and tag all power at to attempting to forklift or transport them. NEVER
source so others will not inadvertently restore pow- attempt to forklift a compressor that is not secured
er. to its pallet, as uneven floors or sudden stops may

3
Section 1
SAFETY

cause the compressor to tumble off, possibly caus- form service adjustments, inform other personnel
ing serious injury or property damage in the pro- before doing so, or else secure and tag the access
cess. door in the open position to avoid the possibility of
others closing and possibly latching the door with
O. DO NOT use the lifting eye bolt on the compres- personnel inside.
sor motor, if supplied, to lift the entire compressor
package.
1.10 ENTRAPMENT
A. If the compressor enclosure is large enough to B. Make sure all personnel are out of compressor
hold a person and if it is necessary to enter it to per- before closing and latching enclosure doors.

4
 Section 2
DESCRIPTION

2.1 INTRODUCTION tion separator and trap, all mounted on a heavy

Your new Sullair flood---lubricated rotary screw air gauge steel frame.
compressor will provide you with a unique experi- On air---cooled models, a fan draws air over the mo-
ence in improved reliability and greatly reduced tor and forces it out through the combined after-
maintenance. cooler and fluid cooler thereby removing the com-
pression heat from the compressed air and the
Compared to other types of compressors, the Sull- cooling fluid.
air rotary screw is unique in mechanical reliability,
with “no wear” and “no inspection” required of the On water---cooled models, a shell and tube heat ex-
working parts within the compressor unit. changer is mounted on the compressor frame.
Fluid is piped into the heat exchanger where com-
Read Section 7 (Maintenance) to see how surpris- pression heat is removed from the fluid. Another
ingly easy it is to keep your air compressor in top similar heat exchanger cools the compressed air.
operating condition. Both air---cooled and water---cooled versions have
2.2 DESCRIPTION OF COMPONENTS easily accessible items such as the fluid filters and
control valves. The inlet air filter is also easily acces-
Refer to Figure 2---1. The components and assem- sible for servicing.
blies of the air compressor are clearly shown. The
complete package includes compressor, electric 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL
motor, starter, compressor inlet system, com- DESCRIPTION
pressor discharge system, compressor lubrica- Sullair air compressors feature the Sullair compres-
tion and cooling system, capacity control sys- sor unit, a single---stage, positive displacement,
tem, instrument panel, aftercooler, a combina- flood lubricated---type compressor. This unit pro-

Figure 2 ---1 Sullair Rotary Screw Air Compressor

5
Section 2
DESCRIPTION

vides continuous pulse---free compression to meet pressor unit.

your needs.
Fluid flows from the bottom of the receiver/sump to
the thermal valve. The thermal valve is fully open
NOTE when the fluid temperature is below 170_F (77_C).
The fluid passes through the thermal valve, the
With a Sullair compressor, there is no mainte- main filter and directly to the compressor unit
nance or inspection of the internal parts of the where it lubricates, cools and seals the rotors and
compressor unit permitted in accordance with the compression chamber.
the terms of the warranty.
As the discharge temperature rises above 170_F
(77_C), due to the heat of compression, the ther-
Sullair 24KT compressors are filled with a fluid mal valve begins to close and a portion of the fluid
which rarely needs to be changed. In the event a then flows through the cooler. From the cooler the
change of fluid is required, use only Sullair 24KT fluid flows to the main filter and then on to the com-
fluid. pressor unit.
A portion of the fluid flowing to the compressor is
! WARNING routed to the anti---friction bearings which support
the rotors inside the compressor unit. Prior to enter-
Mixing of other lubricants within the compressor
unit will void all warranties! ing the compressor unit, this fluid is taken through
the fluid filter, thus assuring properly filtered lubri-
Sullair recommends that a 24KT sample be taken cant for bearing supply.
at the first filter change and sent to the factory for
analysis. This is a free service. The sample kit with The fluid filter has a replacement element and an in-
instructions and self---addressed container is to be tegral pressure bypass valve. A gauge on the in-
supplied by your Sullair dealer at start ---up. The strument panel shows red when the filter needs
user will receive an analysis report with recommen- servicing. This gauge has a pressure setting lower
dations. than that of the bypass valve. The gauge should be
checked with compressor running at full system
Fluid is injected into the compressor unit in large pressure.
quantities and mixes directly with the air as the ro-
tors turn, compressing the air. The fluid flow has Water---cooled versions of the compressor have a
three basic functions: water---flow regulating valve (not shown) which op-
erates to conserve water during periods of varying
1. As coolant, it controls the rise of air temperature load on the compressor. This same valve automati-
normally associated with the heat of compres- cally shuts off the water supply when the compres-
sion. sor is shut down. In addition, water---cooled mod-
2. Seals the leakage paths between the rotors and els have a water pressure switch to prevent opera-
the stator and also between the rotors them- tion with inadequate water pressure.
selves.
3. Acts as a lubricating film between the rotors al- 2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC-
lowing one rotor to directly drive the other, which TIONAL DESCRIPTION
is an idler. Refer to Figure 2---2. The compressor unit dis-
charges the compressed air/fluid mixture into the
After the air/fluid mixture is discharged from the combination receiver/sump.
compressor unit, the fluid is separated from the air.
At this time, the air flows through an aftercooler and The receiver has three basic functions:
separator then to your service line while the fluid is 1. It acts as a primary fluid separator.
being cooled in preparation for reinjection. 2. Serves as the compressor fluid sump.
3. Houses the final fluid separator.
2.4 COMPRESSOR COOLING AND LUBRICATION
SYSTEM, FUNCTIONAL DESCRIPTION The compressed air/fluid mixture enters the receiv-
Refer to Figure 2---2. The Cooling and Lubrication er and is directed against the internal baffle. The
System (air---cooled version) consists of a fan, direction of movement is changed and its velocity
double shaft drive motor, radiator-- type after- significantly reduced, thus causing large droplets
cooler and fluid cooler, full flow fluid filter, ther- of fluid to form and fall to the bottom of the receiver/
mal valve, and interconnecting piping and tub- sump. The fractional percentage of fluid remaining
ing. For water---cooled models, two shell and tube in the compressed air collects on the surface of the
heat exchangers and a water-- flow regulating separator element as the compressed air flows
valve are substituted for the radiator---type cooler through the separator. A return line (or scavenge
listed above. tube) leads from the bottom of the separator ele-
ment to the inlet region of the compressor unit.
The pressure in the receiver/sump causes fluid flow Fluid collecting on the bottom of the separator is re-
by forcing the fluid from the high pressure area of turned to the compressor by a pressure differential
the sump to an area of lower pressure in the com- between the receiver and the compressor inlet. A

6
 Section 2
DESCRIPTION

Figure 2 ---2 Compressor Fluid Cooling/Lubrication and Discharge System

COOLING/LUBRICATION
SYSTEM

DISCHARGE SYSTEM

7
Section 2
DESCRIPTION

visual sight glass is located on the return line to ob- same manner excepting stated pressures.
serve this fluid flow. There is also an orifice in this
return line (protected by a strainer) to assure prop- START -- 0 TO 50 PSIG (0 TO 3.5 BAR)
er flow. This separation will reduce the fluid carry--- When the compressor START button is depressed,
over to less than 2 ppm (parts per million). A the sump pressure will quickly rise from 0 to 50 psig
gauge, located on the instrument panel, shows red (0 to 3.5 bar). During this period both the pressure
if abnormal pressure drop through the separator regulator and the solenoid valve are closed, the in-
develops. At this time, separator element replace- let valve is fully open due to inlet air flow, and the
ment is necessary. This gauge must be checked compressor pumps at full rated capacity. The rising
with the compressor running fully loaded. compressor air pressure is isolated from the ser-
vice line in this phase by the minimum pressure
A minimum pressure/check valve, located down- valve, set at approximately 50 psig (3.5 bar).
stream from the separator, assures a minimum re-
ceiver pressure of 55 psig (3.8 bar) during loaded NORMAL OPERATING MODE -- 50 TO 115 PSIG
conditions. This pressure is necessary for proper (3.5 TO 7.9 BAR )
air/fluid separation and proper fluid circulation. When the pressure air rises above 50 psig (3.5 bar),
the minimum pressure/check valve opens and de-
A terminal check valve is incorporated into the mini- livers compressed air to the service line. From this
mum pressure/check valve to prevent compressed point on, the line air pressure is continually moni-
air in the service line from bleeding back into the re- tored by a line pressure gauge and a pressure
ceiver on shutdown and during operation of the switch usually set at 125 psig (8.6 bar). The pres-
compressor in an unloaded condition. sure regulator and the solenoid valve remain
closed during this phase. The inlet valve remains
A pressure relief valve (located on the wet side of fully open for maximum capacity.
the separator) is set to open if the sump pressure
exceeds the sump tank rating. A temperature MODULATING MODE -- 115 TO 125 PSIG (7.9
switch will shut down the compressor if the dis- TO 8.6 BAR)
charge temperature reaches 235_F (113_C). If less than the rated capacity of compressed air is
being used, the service line pressure will rise above
115 psig (7.9 bar). The pressure regulator valve
! WARNING gradually opens, applying air pressure through the
control line to the inlet valve piston. This causes the
DO NOT remove caps, plugs, and/or other com- inlet valve to partially close reducing the amount of
ponents when compressor is running or pressur-
ized. air entering the compressor until it matches the
amount of air being used. The control system func-
Stop compressor and relieve all internal pres- tions continually in this manner, between the limits
sure before doing so.
of 115 to 125 psig (7.9 to 8.6 bar), in response to
varying demands from the service line.
Fluid is added to the sump via a capped fluid filler The pressure regulator has an orifice which vents a
opening, placed low on the tank to prevent overfil- small amount of air to the atmosphere when the
ling of the sump. A sight glass enables the operator pressure regulator controls the inlet valve. The ori-
to visually monitor the sump fluid level. fice also bleeds any accumulated moisture from
2.6 CONTROL SYSTEM, FUNCTIONAL DE- the control lines.
SCRIPTION-- STANDARD ELECTRO/MECHAN- UNLOAD -- IN EXCESS OF 125 PSIG (8.6 BAR)
ICAL LINE PRESSURE
Refer to Figure 2---3. The purpose of the compres- When no air is being used,the service line pressure
sor Control System is to regulate the compressor rises to the setting (cut ---out pressure) of the pres-
air intake to match the amount of compressed air sure switch. the pressure switch opens, interrupt-
being used. At approximately 10 psig (0.7 bar) air ing the electrical power to the solenoid valve. At this
line over---pressure, the control system will auto- time, the solenoid valve allows dry sump tank air
matically blow down the compressor and greatly pressure or service air pressure through a shuttle
reduce the unload power consumption. The Con- valve to be applied directly to the inlet valve piston
trol System consists of an inlet valve, (located on and keep it closed. Simultaneously, the solenoid
the compressor air inlet), blowdown valve, sole- valve sends a pneumatic signal to the blowdown
noid valve, pressure switch, and a pressure reg- valve. The blowdown valve opens the sump to the
ulator. The functional descriptions of the Control compressor intake reducing the sump pressure to
System are given below in four distinct phases of approximately 25 to 27 psig (1.7to 1.9 bar). The
compressor operation. The following guidelines check valve in the air service line pressure prevents
apply to all LS---10 Series compressors. For ex- line pressure from returning to the sump.
planatory purposes this description will apply to a
compressor with an operating pressure range of When the line pressure drops to the low setting
115 to 125 psig (7.9 to 8.6 bar). A compressor with (cut ---in pressure) of the pressure switch (usually
any other pressure range would operate in the 115 psig [7.9 bar]), the pressure switch closes, re---

8
 Section 2
DESCRIPTION

Figure 2 ---3 Control System

9
Section 2
DESCRIPTION

energizing the 3---way solenoid valve and allowing 100 psig (6.9 bar). The pressure regulator valve
the blowdown valve to close. The re---energized so- gradually opens, directing air pressure to the inlet
lenoid valve again prevents pressure from reaching control valve, reducing air entering the compressor
the inlet valve. The inlet valve is fully open and the until it matches the amount of air being used. The
compressor delivers full rated capacity. Should the control system functions continually in this manner
pressure begin to rise, the pressure regulator will between the limits of 100 to 110 psig (6.9 to 7.6 bar)
resume its normal function as previously de- in response to varying demands from the service
scribed. line.

To accomodate varied periods of time when there The pressure regulator has an orifice which vents a
are not any air requirements, “Dual---Control” is uti- small amount of air to the atmosphere when the
pressure regulator controls the inlet control valve.
lized. This feature allows you to set the compressor The orifice also bleeds any accumulated moisture
in an automatic position whereby the compressor from the pressure regulator.
will shut down when no compressed air require-
ment is present and restart as compressed air is UNLOAD MODE -- IN EXCESS OF 110 PSIG (7.6
needed. BAR)
When a relatively small amount or no air is being
2.7 CONTROL SYSTEM, FUNCTIONAL DE- used, the service line pressure continues to rise.
SCRIPTION-- SUPERVISOR II When it exceeds 110 psig (7.6 bar), the Supervisor
Control System de---energizes the solenoid valve
Refer to Figure 2.3. The purpose of the compressor allowing sump air pressure to be supplied directly
Control System is to regulate the amount of air be- to close the inlet valve. Simultaneously, the sole-
ing compressed to match the amount of com- noid valve sends a pneumatic signal to the blow-
pressed air being used. The Capacity control sys- down valve. The blowdown valve opens to the at-
tem consists of a solenoid valve, regulator valve mosphere, reducing the sump pressure to approxi-
and an inlet valve. The functional description of the mately 25 to 27 psig (1.7 to 1.9 bar). The check
Control System is described below in four distinct valve in the air service line prevents line pressure
phases of operation. The following description text from returning to the sump.
applies to all LS---10 Series compressors with op-
tional Supervisor II. For explanatory purposes, this When the line pressure drops to the low setting
description will apply to a compressor with an oper- (cut ---in pressure; usually 100 psig [6.9 bar] on low
ating range of 100 to 110 psig (6.9 to 7.6 bar). A pressure [“L”] compressors and 115 psig [8.0 bar]
compressor with any other pressure range would on high pressure [“H”] compressors, 140 psig [9.7
operate in the same manner except stated pres- bar] on [“HH”] compressors, 175 psig [12.0 bar]
sures. [“XH”] . Supervisor energizes the solenoid valve
and allows the blowdown valve to close. The re---
START MODE -- 0 TO 50 PSIG (0 TO 3.5 BAR) energized solenoid valve again prevents line pres-
When the compressor “I” (START) pad is de- sure from reaching the inlet control valve. Should
pressed, the sump pressure will quickly rise from 0 the pressure begin to rise, the pressure regulator
to 50 psig (0 --- 3.4 bar). The compressor initially will resume its normal function as previously de-
starts unloaded, then switches to full load when full scribed.
rpm has been achieved. During this period, both AUTOMATIC OPERATION
the pressure regulator and the solenoid valve are For applications with varied periods of time when
closed, the inlet valve is fully open and the com- there are no air requirements, Supervisor’s AUTO-
pressor pumps at full rated capacity. The rising MATIC mode allows the compressor to shutdown
compressor air pressure is isolated from the ser- (time delayed) when no compressed air require-
vice line in this phase by the minimum pressure ment is present and restart as compressed air is
valve set at approximately 50 psig (3.4 bar). needed.
FULL LOAD MODE -- 50 TO 100 PSIG (3.4 TO 6.9 2.8 AIR INLET SYSTEM, FUNCTIONAL DE-
BAR) SCRIPTION
When the compressed air pressure rises above 50 Refer to Figure 2---4. The Compressor Inlet System
psig (3.4 bar), the minimum pressure valve opens consists of a dry -- type air filter, a restriction
allowing compressed air to flow into the service gauge and an air inlet valve.
line. From this point on, the line air pressure is con-
tinually monitored by the Supervisor. The pressure The restriction gauge (located on the instrument
regulator and the solenoid valve remain closed dur- panel), indicates the condition of the air filter by
ing this phase. The inlet valve is in the fully open showing red when filter maintenance is required.
position as long as the compressor is running at
100 psig ( 6.9 bar) or below. The poppet ---type modulating air inlet valve directly
controls the amount of air intake to the compressor
MODULATING MODE -- 100 TO 110 PSIG (6.9 in response to the operation of the pressure regula-
TO 7.6 BAR) tor (see Modulating Mode, Section 2.6 [Standard
If less than the rated capacity of compressed air is Electrol/Mechanical] or Section 2.7 [Optional Su-
being used, the service line pressure will rise above pervisor Il]). The inlet valve also acts as a check

10
 Section 2
DESCRIPTION

Figure 2 ---4 Air Inlet System S The sump pressure gauge continually monitors
the sump pressure at the various load and/or un-
load conditions.
S The discharge temperature gauge monitors
the temperature of the air leaving the compressor
unit. For both air---cooled and water---cooled com-
pressors the normal reading is approximately
180_F to 205_F (82_C to 96_C).
S The separator maintenance gauge monitors
condition of the separator element and shows in
the red zone when the element restriction is exces-
sive.
S The fluid filter maintenance gauge monitors
the condition of the bearing lube filter element and
shows in the red zone when the element should be
changed.
S The START pushbutton turns the compressor on.
S The STOP pushbutton turns the compressor off.
S The hourmeter records accumulative hours of
operation for the compressor and is useful for plan-
ning and logging service operations.
S The red light on the instrument panel indicates
when power to the compressor is supplied.
S The green light indicates when the compressor is
running.
S The HAND/AUTO switch provides selection be-
tween hand operation and automatic control.
valve, thus preventing reverse rotation when the
compressor is shut down. Figure 2 ---5 Instrument Panel Group

! WARNING
“The Plastic Pipe Institute recommends against the
use of thermoplastic pipe to transport compressed
air or other compressed gases in exposed above
ground locations, e.g. in exposed plant piping.” (I)

Sullube 32 should not be used with PVC piping sys-

tems. It may affect the bond at cemented joints. Cer-
tain other plastic materials may also be affected.

(I) Plastic Pipe Institute, Recommendation B,

Adopted January 19, 1972.

2.9 INSTRUMENT PANEL GROUP, FUNCTIONAL

DESCRIPTION-- STANDARD ELECTRO/ME-
CHANICAL
Refer to Figure 2---5 for specific location of parts de-
scribed. The Instrument Panel group consists of a
panel containing the line pressure, sump pres-
sure and discharge temperature gauges, the
separator element and the fluid filter, restriction
gauges, along with START and STOP pushbut-
tons and an hourmeter.
Refer to Figure 2---5 for locations of the following in-
dicators and controls:
S The line (terminal) pressure gauge is con-
nected to the dry side of the receiver downstream
from the check valve and continually monitors the
air pressure.

11
 NOTES

12
 Section 3
SPECIFICATIONS
3.1 TABLE OF SPECIFICATIONS

LS-- 10 SERIES 60 Hz
MODEL HP/KW CAPACITY LENGTH WIDTH HEIGHT(I) WEIGHT(II) MOTOR
(ACFM/M3/MIN) (IN/MM) (IN/MM) (IN/MM) (LB/KG) ENCLOSURE

H 25/18 100/2.83 57.0/1448 33.0/838 39.0/991 1015/2238 ODP/TEFC

(115 psig/ 30/22 114/3.22 57.0/1448 33.0/838 39.0/991 1035/2282 ODP/TEFC
8 bar) 40/30 151/4.28 57.0/1448 33.0/838 39.0/991 1140/2513 ODP
40/30 151/4.28 62.5/1588 33.0/838 39.0/991 1165/2568 TEFC

HH 25/18 83/2.35 57.0/1448 33.0/838 39.0/991 1015/2238 ODP/TEFC

(140 psig/ 30/22 100/2.83 57.0/1448 33.0/838 39.0/991 1035/2282 ODP/TEFC
19.7 bar) 40/30 142/4.02 57.0/1448 33.0/838 39.0/991 1140/2513 ODP
40/30 142/4.02 62.5/1588 33.0/838 39.0/991 1165/2568 TEFC

XH 25/18 76/2.15 57.0/1448 33.0/838 39.0/991 1015/2238 ODP/TEFC

(175 psig/ 30/22 90/2.55 57.0/1448 33.0/838 39.0/991 1035/2282 ODP/TEFC
12 bar) 40/30 119/3.37 57.0/1448 33.0/838 39.0/991 1140/2513 ODP
40/30 119/3.37 62.5/1588 33.0/838 39.0/991 1165/2568 TEFC

LS-- 10 SERIES 50 Hz
MODEL HP/KW CAPACITY LENGTH WIDTH HEIGHT(I) WEIGHT MOTOR
(ACFM/M3/MIN) (IN/MM) (IN/MM) (IN/MM) (LB/KG) ENCLOSURE

H 25/18 93/2.63 57.0/1448 33.0/838 39.0/991 1015/2238 ODP/TEFC

(115 psig/ 30/22 118/3.34 57.0/1448 33.0/838 39.0/991 1035/2282 ODP/TEFC
8 bar) 40/30 160/4.53 57.0/1448 33.0/838 39.0/991 1140/2513 ODP
40/30 160/4.53 62.5/1588 33.0/838 39.0/991 1165/2568 TEFC

HH 25/18 82/2.32 57.0/1448 33.0/838 39.0/991 1015/2238 ODP/TEFC

(140 psig/ 30/22 99/2.80 57.0/1448 33.0/838 39.0/991 1035/2282 ODP/TEFC
19.7 bar) 40/30 137/3.88 57.0/1448 33.0/838 39.0/991 1140/2513 ODP
40/30 137/3.88 62.5/1588 33.0/838 39.0/991 1165/2568 TEFC

XH 25/18 73/2.07 57.0/1448 33.0/838 39.0/991 1015/2238 ODP/TEFC

(175 psig/ 30/22 90/2.55 57.0/1448 33.0/838 39.0/991 1035/2282 ODP/TEFC
12 bar) 40/30 115/3.26 57.0/1448 33.0/838 39.0/991 1140/2513 ODP
40/30 115/3.26 62.5/1588 33.0/838 39.0/991 1165/2568 TEFC

ENCLOSURE
25---30 HP/
18---22 KW - 60.0/1524 36.0/914 41.88/1064 (II) ODP/TEFC
40 HP/30 KW (ODP) - 60.0/1524 36.0/914 41.88/1064 (II) ODP
40 HP/30 KW (TEFC) - 64.5/1638 36.0/914 41.88/1064 (II) TEFC

(I) An additional length of 4 in./102mm is needed for servicing the separator; 9 in./229mm for enclosure models.
(II) Add 250 lbs/ 113.4 kgs for the enclosure to the total package weight.

13
Section 3
SPECIFICATIONS
COMPRESSOR: STANDARD MODELS
Type: Rotary Screw
Standard Operating Pressure (IV): 100 psig (6.9bar) (L) 140 psig (9.7 bar) (HH)
115 psig (7.9bar) (H) (XH) 175 psig (12 bar) (XH)
Bearing Type: Anti---Friction
Ambient Temperature (Max.) (V): 105_F (41_C)
Cooling: Pressurized Fluid
Compressor Fluid: Sullair Sullube 32
Sump Capacity: 3.5 U.S. gallons (14.8 liters)
Control: Electro---Pneumatic
Supervisor II (optional)
MOTOR (VI): STANDARD MODELS
Size: 25, 30 and 40HP
Type: C---Flanged, Open Dripproof, Premium Efficiency
Three Phase, 230/460 60 Hz, 380/415 50 Hz
40_C Maximum Ambient Temperature
Options Available: 200V and 575V
T.E.F.C. Also Available: IP54
Starter: Full Voltage Magnetic or Wye Delta
Options Available: 200V and 575V
Speed: 60 Hz: 1770 RPM
50 Hz: 1475 RPM
40HP: 3000 RPM

(IV) Special compressors are available for operation at higher pressures.

(V) Special compressors are available for operation in higher ambient temperature.
(VI) Multi--frequency and voltage motors are used. The compressors must be used only with the specified electrical frequency and voltage.

3.2 LUBRICATION GUIDE For light ---duty high---humidity service where

condensed moisture and emulsification (may-
For best value and longest uninterrupted ser- onnaise) may occur, the fluid change interval
vice, the LS---10 Series compressors are factory must be reduced to 300 hours maximum. A
filled and tested with a long life lubricant. non---detergent fluid with rust, oxidation and
foam inhibitors and good water separation char-
! WARNING acteristics should be used.

Mixing of other lubricants within the compres- DO NOT MIX DIFFERENT TYPES OF FLUIDS.
sor unit will void all warranties!
Contamination of non---detergent mineral fluids
with traces of detergent motor fluids may lead to
If, due to availability or other reasons, other fluids operational problems such as foaming, filter
are required, follow Lubrication Guide 3.4 below. plugging, orifice or line plugging.

! WARNING
NOTE
“The Plastic Pipe Institute recommends
against the use of thermoplastic pipe to trans- Flush system when switching lubricant
port compressed air or other compressed brands.
gases in exposed above ground locations, e.g.
in exposed plant piping.” (I)
Sullube 32 should not be used with PVC piping When ambient conditions exceed those noted
systems. It may affect the bond at cemented or if conditions warrant use of “extended” life lu-
joints. Certain other plastic materials may also bricants contact Sullair for recommendation.
be affected.
(I) Plastic Pipe Institute, Recommendation B,
Adopted January 19, 1972. 3.3 APPLICATION GUIDE
Sullair encourages the user to participate in a
fluid analysis program with the fluid suppliers.
Maintenance of all other components is still rec- This could result in a fluid change interval differ-
ommended as indicated in the Operator’s ing from that stated in the manual. Contact your
Manual. Sullair dealer for details.

14
 Section 3
SPECIFICATIONS
3.4 LUBRICATION CHANGE RECOMMENDATIONS AND MAINTENANCE

LUBRICANT FLUID CHANGE FLUID FILTER CHANGE SEPARATOR CHANGE

Sullube 32 A,E G,C A,D
Sullair LLL--4--32 A,E G,C A,D
SRF 1/4000 B,E G,C B,D
24KT F,E G,C A,D
CP--4600--32--F B,E G,C B,D

A - 8,000 Hours or once a year.

B - 4,000 Hours or more frequently if conditions so require.
C - When measured pressure loss exceeds 20 psig (1.3 bar).
D - When measured pressure loss exceeds 10 psig (0.7 bar).
E - When required by fluid analysis or known contamination.
F - Does not require replacement during normal service conditions.
G - Every 1000 hours.

15
 NOTES

16
 Section 4
INSTALLATION

4.1 MOUNTING OF COMPRESSOR ature. The fan air requirement is the volume of air
A foundation or mounting capable of supporting which must flow through the compressor for proper
the weight of the compressor, and rigid enough to ventilation. The specified heat rejection require-
maintain the compressor frame level and the com- ment is the amount of heat that is radiated by the
pressor in alignment is required. The compressor compressor. This heat must be removed to assure
frame must be leveled and secured with foundation a normal operating temperature. With air---cooled
bolts, and full uniform contact must be maintained compressors it is possible to use this heat for space
between the frame and foundation. No piping heating, providing no additional pressure drop is
loads shall be transmitted to the compressor at the created across the fan. Consult a Sullair office for
external connections. assistance in utilizing this heat.
4.2 VENTILATION AND COOLING DO NOT install a water---cooled or an air---cooled/
For air---cooled compressors, select a location to aftercooled compressor where it will be exposed to
permit sufficient unobstructed air flowing in and out temperatures less than 32_F(0_C).
to the compressor to keep the operating tempera-
ture stable. The minimum distance that the com- 4.3 SERVICE AIR PIPING
pressor should be from surrounding walls is three Service air piping should be installed as shown in
(3) feet (1m). To prevent excessive ambient tem- Figure 4---1. A shut---off valve should be installed to
perature rise, it is imperative to provide adequate isolate the compressor from the service line if re-
ventilation. quired. Also notice that the service line should be
equipped with water legs and condensate drains
For water---cooled compressors, it is necessary to throughout the system.
check the cooling water supply. The water system
must be capable of supplying the flows shown in
Table I ---Water Supply Requirements (Water--- ! WARNING
cooled), and must be maintained at all times.
These figures apply to a compressor running at full “The Plastic Pipe Institute recommends against the
load with an aftercooler. For cooler water or a par- use of thermoplastic pipe to transport compressed
air or other compressed gases in exposed above
tially loaded compressor, slightly less water is re- ground locations, e.g. in exposed plant piping.” (I)
quired. However, for hotter water the flow require-
ments are significantly greater. Sullube 32 should not be used with PVC piping sys-
tems. It may affect the bond at cemented joints. Cer-
Table 2---Ventilation Requirements indicates the tain other plastic materials may also be affected.
ventilation requirements necessary to keep the (I) Plastic Pipe Institute, Recommendation B,
compressor running at a normal operating temper- Adopted January 19, 1972.

TABLE 1-- WATER SUPPLY REQUIREMENTS (WATER-- COOLED)

WATER FLOW (I)
WATER TEMP. GMP (LITERS)
0˚F (˚C) 25HP (18KW) 30HP (22KW) 40HP (30KW)
70 (21) 3.75 (14.2) 4.50 (17.0) 5.75 (21.8)
80 (26.6) 5.00 (18.9) 6.00 (22.7) 7.50 (28.4)
(I) Water pressure should be between 25 and 75 psig (1.7 and 5.2 bar).

TABLE 2-- VENTILATION REQUIREMENTS (I)

Cooling Type Air ---cooled with Aftercooler Water---cooled
Motor HP/KW 25/18 30/22 40/30 25/18 30/22 30/40

Fan Air CFM 2500/4250 2500/4250 3500/5950 720/1220 720/1220 720/1220

M3/Hr (II)
Ventilating Air/
Heat Rejection
BTU/Hour 76980/ 88800/ 118320/ 8500/ 10000/ 13000
KCal/Hour 19500 22500 29900 2150 2550 3300
Cooling Water/
Heat Rejection
BTU/Hour
Kcal/Hour
(I) Values based on: 100% RH, 85˚F Ambient
(II) Applies to compressor with canopy only (vent fan).

17
Section 4
INSTALLATION

Figure 4 ---1 Service Air Piping with Aftercooler and Optional Air Dryer (Typical)

4.4 COUPLING ALIGNMENT CHECK

No coupling alignment is required. NOTE
Customer must provide electrical supply power
disconnect within sight of machine.
4.5 FLUID LEVEL CHECK
The air compressor is also supplied with the proper
amount of fluid. However, it is necessary to check A few electrical checks should be made to help as-
the fluid level at installation. The level is checked by sure that the first start---up will be trouble---free.
looking at the sight glass located near the sump. If
the sump is properly filled, fluid should be visible in ! WARNING
the sight glass. The maximum fluid level is the level
Lethal shock hazard inside. Disconnect all power
of the filler port. at source before opening or servicing.

1. Check incoming voltage. Be sure that compres-

4.6 ELECTRICAL PREPARATION-- STANDARD sor is wired for the correct incoming voltage.
ELECTRO/MECHANICAL 2. Check starter for correct size, proper overload
Interior electrical wiring is performed at the factory. relay, and heaters.
Required customer wiring is minimal, but should 3. Check all electrical connections for tightness.
be done by a qualified electrician in compliance 4. “DRY RUN” the electrical controls by discon-
with OSHA, National Electrical Code, and/or any necting the three (3) motor leads from the start-
other applicable State, Federal and local electrical er. Energize the control circuits by turning the
codes concerning isolation switches, fused dis- “O/I” STOP/START switch to “I” START and
connects, etc. Sullair provides a wiring diagram for check all protective devices to be sure that they
use by the installer. will de---energize the starter coil when tripped.

18
 Section 4
INSTALLATION

5. Reconnect the motor leads and jog the motor for the end opposite the compressor unit, the shaft
a direction of rotation check as explained in Sec- should be turning clockwise. If the motor shaft is
tion 4.8. not turning clockwise, disconnect the power to the
starter and exchange any two of the three power in-
NOTE put leads, then re---check rotation. A “Direction of
Rotation” decal is located on the motor to show
Wiring diagram for standard compressors is sup-
proper motor/compressor rotation.
plied on the inside cover of the Control Center. An alternative to this procedure is to monitor the
Optional compressor wiring diagrams will vary. sump pressure gauge when toggling the “I”
(START) switch. If immediate pressure is shown
4.7 ELECTRICAL PREPARATION-- SUPERVISOR II on the sump pressure gauge when the compres-
Interior electrical wiring is performed at the factory. sor is started, then the proper motor rotation has
Required customer wiring is minimal, but should been achieved. If no pressure is indicated, turn
be done by a qualified electrician in compliance switch to the “O” (STOP) position immediately.
with OSHA, National Electric Code and/or any ap- This indicates improper motor rotation. Discon-
plicable local electrical code concerning isolation nect the power to the starter and exchange any two
switches, fused disconnects, etc. Sullair provides a of the three power input leads. Recheck rotation as
wiring diagram for use by the installer. outlined above.

An electrical check should be made to help assure

that the first start---up will be trouble---free.
4.9 MOTOR ROTATION DIRECTION CHECK --
SUPERVISOR II
! DANGER
Lethal shock hazard inside. Disconnect all power
at source, before opening or servicing. NOTE

1. Check incoming voltage. Be sure that the incom- Motor rotation check must be made at compressor
ing voltage is the same voltage that the com- start---up. Remove compressor panel as needed to
view motor rotation.
pressor was wired for.
2. Check starter and overload heater sizes.
3. Check all electrical connections for tightness. After the electrical wiring has been done, it is nec-
4. “DRY RUN” the electrical controls by discon- essary to check the direction of the motor rotation.
necting the three (3) motor leads from the start- Pull out the EMERGENCY STOP button and press
er. Energize the control circuits by pushing the once, quickly and in succession, the “I” (START)
“I” (START) pad and check all protective de- and “O” (STOP) pads. This action will bump start
vices to be sure that they will de---energize the the motor for a very short time. When looking at the
starter coil when tripped. motor from the end opposite the compressor unit,
5. Reconnect the three (3) motor leads and jog the the shaft should be turning clockwise. If the re-
motor for a direction of rotation check, as ex- versed rotation is noted, disconnect the power to
plained in Section 4.9. the starter and exchange any two of the three pow-
4.8 MOTOR ROTATION DIRECTION CHECK -- er input leads, then re---check rotation. A “Direction
STANDARD ELECTRO/MECHANICAL of Rotation” decal is located on the motor to show
proper motor/compressor rotation.
NOTE An alternative to this procedure is to set the Super-
visor to display P1. Pull out the EMERGENCY
Motor rotation check must be made at compressor STOP button and press once, quickly and in suc-
start---up. Remove compressor panel as needed to cession, the “I” (START) and “O” (STOP) pads.
view motor rotation.
This action will bump start the motor for a very short
time. If motor rotation is correct there will be imme-
After the electrical wiring has been done, it is nec- diate pressure shown. If no pressure is present, re-
essary to check the direction of the motor rotation. verse rotation is occurring. Disconnect the power
This can be done by toggling the “I” (START) and to the starter and exchange any two of the three
“O” (STOP) positions of the rotary switch on the power imput leads. Recheck rotation as outlined
control box door. When looking at the motor from above.

19
 NOTES

20
 Section 5
OPERATION

5.1 GENERAL call for service or indicate the beginning of a mal-

While Sullair has built into this compressor a com- function. Before starting your Sullair compressor,
prehensive array of controls and indicators to as- read this section thoroughly and familiarize your-
sure you that it is operating properly, you will want self with the controls and indicators --- their pur-
to recognize and interpret the reading which will pose, location and use.

5.2 PURPOSE OF CONTROLS-- STANDARD ELECTRO/MECHANICAL

CONTROL OR INDICATOR PURPOSE

START PUSHBUTTON Depress to turn the compressor ON.

STOP PUSHBUTTON Depress to turn the compressor OFF and reset the com-
mon fault circuit.
HAND AUTO SWITCH (DUAL CONTROL) To select between continuos (HAND) operation and au-
tomatic stop/start (AUTO) operation. Shuts off com-
pressor automatically after the compressor runs un-
loaded for a specified time (ranging from 15---30 min-
utes). Restarts compressor when the pressure switch
trips to the reload setting. Dual control is enabled by
placing the control switch in the “AUTO” position.
HOURMETER Records cumulative hours of compressor operation;
useful for planning and logging service schedules.
LINE PRESSURE GAUGE Continually monitors service line air pressure. It is lo-
cated on dry side of receiver downstream from check
valve.
SUMP PRESSURE GAUGE Continually monitors receiver/sump pressure at vari-
ous load and/or unloaded conditions.
DISCHARGE TEMPERATURE GAUGE Monitors temperature of the air leaving the compres-
sor unit. For both air and water---cooled compressors,
the normal reading should be approximately 180_F to
205_F (82_C to 96_C ).
AIR FILTER RESTRICTION GAUGE Indicates when the air filter element change is re-
quired. The gauge shows the red zone when drop
through the filter is excessive. The compressor must
be running full load for an accurate indication.
FLUID FILTER MAINTENANCE GAUGE Indicates when a fluid filter element change is re-
quired. It shows red when the pressure drop through
the filter is excessive.
SEPARATOR MAINTENANCE GAUGE Indicates when separator element change is required.
Shows red when the pressure drop through the filter is
excessive. The compressor must be running full load
for an accurate indication.
“POWER ON” LIGHT (RED) Indicates when the starter is receiving power.
“RUNNING” LIGHT (GREEN) Indicates when compressor is in operation.
“RUNNING” LIGHT (AMBER) Indicates when compressor is in auto mode.
FLUID LEVEL SIGHT GLASS Monitors fluid level in the sump. The fluid must be vis-
ible in the glass. Check the level when the compressor
is shut down. Maximum fill level is the level of the fill
port, minimizing the risk of overfilling.

21
Section 5
OPERATION

5.2 PURPOSE OF CONTROLS-- STANDARD ELECTRO/MECHANICAL (CONTINUED)

CONTROL OR INDICATOR PURPOSE

SEPARATOR RETURN LINE SIGHT GLASS Used to indicate fluid flow in the return line. When the
compressor is running at full load, fluid flow should be
visible in this sight glass. There may be little or no flow
when the compressor is running unloaded, but a slug-
gish flow at full load indicates a need to clean the re-
turn line strainer.
THERMAL VALVE Regulates flow of fluid to and around the cooler. It is de-
signed to maintain a minimum operating temperature
of 180_F (82_C); use for fast warm---up on start---up.
MINIMUM PRESSURE/CHECK VALVE Maintains minimum of 55 psig (3.8 bar) in the com-
pressor sump. Valve piston restricts receiver air dis-
charge from receiver/sump when pressure falls to 55
psig (3.8 bar). Also prevents backflow into the sump
during unload conditions and after shutdown.
COMPRESSOR DISCHARGE Designed to shut the compressor down when the
TEMPERATURE SWITCH discharge temperature reaches 235_F (113_C).
WATER PRESSURE SWITCH It prevents operation when water pressure of
(water---cooled compressors only) compressor is inadequate.
PRESSURE RELIEF VALVE Opens sump pressure to the atmosphere should pres-
sure inside the sump become too high. Operation of
this valve indicates that the high pressure switch is ei-
ther faulty or out of adjustment.
MODULATING INLET VALVE Regulates the amount of air allowed to enter the air
compressor. This regulation is determined by the
amount of air being used at the service line. Also acts
as a check valve to prevent reverse compressor rota-
tion at shut down.
PRESSURE REGULATOR Allows a pressure signal to reach the air inlet valve to
control air delivery according to demand.
SOLENOID VALVE Bypasses the pressure regulator valve causing the in-
let valve to close when the compressor reaches maxi-
mum operating pressure. Also activates blow ---down
valve.
PRESSURE SWITCH Senses service line pressure. When line pressure
reaches maximum setting the pressure switch signals
the pilot valves to unload the compressor.
BLOWDOWN VALVE Vents sump pressure to the atmosphere during un-
load conditions and shutdown.
WATER REGULATING VALVE Regulates the amount of cooling water used to keep
(water---cooled only) the compressor running at a normal operating tem---
perature.

5.3 INITIAL START-- UP PROCEDURE-- STANDARD 2. Be sure that all preparations and checks de-
ELECTRO/MECHANICAL scribed in the Installation Section have been
The following procedure should be used to make made.
the initial start ---up of the compressor: 3. Crack open the shut off valve to the service line.
4. Start the compressor by pushing the START but-
1. Read the preceding pages of this manual thor- ton.
oughly. 5. Check for possible leaks in piping.

22
 Section 5
OPERATION

6. Slowly close the shut ---off valve and check that S Load differential --- The pressure differ-
the setting on the pressure switch is set correct- ential below the unload pressure where the
ly. If set correctly, the compressor will unload at machine is loaded. For example, if the un-
the desired unload pressure. If adjustments are load pressure is set to 110 psi (7.6 bar) and
necessary, see Control System Adjustment in the load differential is set to 10 psi (0.7 bar),
the Maintenance Section 7.7 of this manual. the machine will load when the line pres-
7. Observe the operating temperature. If the oper- sure goes below 100 psi (6.9 bar).
ating temperature exceeds 205_F (96_C), the
cooling system or installation environment
should be checked. LOAD
8. Observe return line sight glass and maintenance 10 PSI
indicators.
9. Open shut---off valve to service line. S P1 Max --- Maximum sump pressure. An
10. Reinspect the compressor for temperature and alarm and shut down will occur when the
leaks the following day. sump pressure rises above this pressure.
5.4 SUBSEQUENT START-- UP PROCEDURE--
STANDARD ELECTRO/MECHANICAL P1 MAX
On subsequent start ---ups, check that fluid level is 135 PSI
visible in the fluid sight glass and simply press the
START button. When the compressor is running, S Wye to delta transition timer --- For full
observe the instrument panel and maintenance in- voltage starters this parameter is set to 0.
dicators.

5.5 SHUTDOWN PROCEDURE-- STANDARD ELEC- WYE DELT

TRO/MECHANICAL 10 SEC
To shut the compressor down, simply press the
STOP button. S Restart time --- Time to wait after power up
before starting machine. This parameter is
used to keep several machines from start-
5.6 GENERAL INTRODUCTION -- SUPERVISOR II ing at the same time after power up, or to
delay start until other equipment is started.
Reference Section 6, Supervisor II . While Sullair If disabled the machine will not automati-
has built into this compressor a comprehensive cally start after power up.
array of controls and indicators to assure you that it
is operating properly, you will want to recognize
and interpret the readings which will call for service RST TIME
or indicate the beginning of a malfunction. Before 10 SEC
starting your Sullair compressor, read this section
thoroughly and familiarize yourself with the con- S Unload Stop Timer --- If the machine is
trols and indicators --- their purpose, location and running in AUTO mode, this parameter
use. specifies the amount of time that the ma-
chine will run unloaded before shutting off.
5.7 SUPERVISOR II PARAMETER SETUP If the time is set less than 15 minutes (for
example five minutes), there may be times
Pressing the program key enters parameter dis- when the machine will run unloaded for
play and edit mode. To move to the next parameter more than five minutes. This is because
press the program key. To increment a parameter there is another timer that keeps the ma-
press the up arrow key or logo key. The logo key chine from being started more than four
will increment by 10. To decrement the value press times an hour.
the down arrow key.
The parameters are displayed in the following or-
der: UNLD TIM
15 MIN
S Unload pressure --- The pressure where
the machine is unloaded. For example if S Language select --- English, German,
this parameter is set to 110 psi (7.6 bar) the Spanish, Italian and French may be se-
machine will unload when the line pressure lected for display language.
is above 110 psi (7.6 bar).
LANGUAGE
UNLOAD ENGLISH
100 PSI
S Units --- English or metric units may be se-

23
Section 5
OPERATION

lected. col Manual for details.

UNITS LOWEST
ENGLISH 90 PSI

S Communications ID # --- This is the net- S Recovery Time --- Used only for sequenc-
work address of a machine. If there is more ing, see Sequencing & Protocol Manual for
than one machine connected to the net- details.
work, each machine must have a unique
number. RECOVER
10 SEC
COM ID # SRotate Time --- Used only for sequencing
1 --- units in HOURS, see Sequencing & Pro-
tocol Manual for details.
S Communications baud rate --- This
should always be selected to 9600 baud
for all sequencing modes. It may be lower ROTATE
for slave or monitoring modes. 50 HOURS

SMachine Capacity --- Used only for se-

BAUDRATE quencing --- units in CFM (M3/min), see Se-
9600 quencing & Protocol Manual for details.

S Sequence method --- This parameter sets CAPACITY

the method used for optional sequencing. 100
The choices are DISABLED, REMOTE,
SLAVE, HOURS, COM ID#. See the Se- S Sequence Hours --- Used only for se-
quencing & Protocol Manual (See Recom- quencing, see Sequencing & Protocol
mended Spare Parts List) for details about Manual for details.
these modes.

SEQ HRS
SEQUENCE 1000
HOURS

S Drain interval --- The time between actua-

tion of the drain valve. 5.8 OPERATING THE COMPRESSOR
Before operating the compressor the operating pa-
rameters must be setup. See the previous section
DRN INTV on operating parameter setup.
10 MIN
MANUAL OPERATION MODE
S Drain time --- The amount of time that the In this mode the compressor will run indefinitely, as
drain valve is actuated. long as temperatures and pressure remain within
the valid operating ranges, and the motor overload
or emergency stop contacts are not tripped. Press-
DRN TIM ing the “I” will turn on the compressor and put it in
1 SEC manual mode. If the compressor is already run-
ning, but in automatic mode, pressing “I” will
S Last Communication Number --- Used switch operation to manual. Pressing “I” while al-
only for sequencing, see Sequencing & ready running in manual mode will cause the Su-
Protocol Manual for details. pervisor to turn off the common fault relay, if en-
gaged, and clear any maintenance indicators.
To stop the compressor, press “O” If the compres-
LAST COM sor is already off when “O” is pressed, the common
3 fault relay will be turned off, if engaged, and it will try
to clear the alarm and maintenance indicators. Re-
S Lowest Allowable Pressure --- Used only gardless of what the compressor is doing, pressing
for sequencing, see Sequencing & Proto- “O” puts the Supervisor in manual stop mode.

24
 Section 5
OPERATION

AUTOMATIC OPERATION MODE timer will start timing. When the timer expires the
In this mode the compressor will start if line pres- machine will start.
sure (P2) is less than the LOAD parameter. It will
stop if the compressor runs unloaded for the num- SEQUENCING MODES
ber of minutes indicated by the UNLD TIM parame- The following is a brief description of sequencing
ter. To put the compressor in automatic mode press modes. For details see the Supervisor II Sequenc-
“ ”. If P2 is already less than LOAD the compres- ing & Protocol Manual (See Recommended Spare
sor will start immediately, otherwise the system sta- Parts List).
tus will indicate STANDBY and the LED marked S DISABLED --- Responds to status and
AUTO will flash. parameter change messages via the
RS485 network but will not respond to
If the compressor is already running, but in continu- start, stop, load or unload messages.
ous mode, pressing “ ” will switch operation to
automatic. Pressing “ ” while already running in S REMOTE --- Responds to status and pa-
automatic mode will cause the Supervisor to turn rameter change messages but will not re-
off the common fault relay, if engaged, and clear spond to start, stop, load or unload mes-
any maintenance indicators. sages. The remote inputs and outputs are
In automatic mode the compressor can be enabled (start/stop, load/unload, master/
stopped manually by pressing “O”. Stopping the local).
compressor using “O” will put the Supervisor in
manual stop mode. S SLAVE --- Will respond to all messages,
Regardless of whether in “automatic” or “manual” but will not start or load unless command-
mode, control of the load solenoid will be based on ed to do so by a message. This mode is
the parameters UNLD and LOAD. This operation is used to control the machine from a master
as follows: computer.
P2 > UNLD -- -- > load solenoid turned off S HOURS --- Sends status message about
P2 < LOAD -- -- > load solenoid turned on once a second; starts, loads and unloads
POWER FAILURE RESTART machines based on sequencing hours.
If the restart timer (RST TIME parameter) is dis-
abled the compressor will not try to start after a S COM ID # --- Sends status message
power up. If this time is set to a value, the machine about once a second; starts, loads and un-
will go into standby after power up. When the line loads machines based on machine COM
pressure drops below the load setpoint, the restart ID#.

5.9 PURPOSE OF CONTROLS -- SUPERVISOR II

CONTROL OR INDICATOR PURPOSE

EMERGENCY STOP SWITCH Pushing in this switch, found adjacent to the Supervi-
sor, cuts all AC outputs from the latter and de---ener-
gizes the starter. A fault message (E STOP) is dis-
played by the Supervisor until the button is pulled out
and the “O” pad is depressed.
DISCHARGE TEMPERATURE PROBE---T1 Shuts the compressor down when the compressor
discharge temperature exceeds 240_F (116_C). Con-
tinually monitors air/fluid mixture discharged from the
compressor unit.
AIR END DISCHARGE PRESSURE---P1 Shuts the compressor down when the compressor dis-
charge pressure exceeds P1 MAX. Continually moni-
tors the discharge pressure of the compressor unit. In-
dicates pressure in compressor sump upon start---up to
verify rotor motor rotation.
PACKAGE OUTLET PRESSURE---P2 Continually monitors service line pressure. When line
(Service Line Pressure) pressure reaches the UNLOAD setting, the Supervisor
control signals the solenoid valve to unload the com-
pressor.

25
Section 5
OPERATION

5.9 PURPOSE OF CONTROLS -- SUPERVISOR II (CONTINUED)

CONTROL OR INDICATOR PURPOSE

FLUID PRESSURE---P3 Continually monitors injection fluid pressure and shuts

down the compressor in the event of low fluid pressure.
FLUID FILTER DIFFERENTIAL SWITCH Continually monitors fluid filter differential and gener-
ates an alarm when the fluid filter needs replacement.
INLET FILTER MAINTENANCE SWITCH Monitors condition of compressor inlet air filter and indi-
cates when replacement is required.
FLUID LEVEL SIGHT GLASS Indicates fluid level in the sump. Proper level is not to
fall below the center of the sight glass. Check level
when compressor is shut down. DO NOT OVERFILL.
COOLER BYPASS VALVE Regulates flow of fluid to and around the cooler. De-
signed to maintain a minimum operating temperature of
180_F (82_C); used for fast warm---up on start ---up.
MINIMUM PRESSURE/CHECK VALVE Maintains minimum of 50 psig (3.4 bar) in the com-
pressor sump. Valve piston restricts receiver air dis-
charge from receiver/sump when pressure falls to 50
psig (3.4 bar). Also incorporated in this valve is a ter-
minal check valve which prevents line pressure back-
flow into the sump during unload conditions and after
shutdown.
PRESSURE RELIEF VALVE Protects compressor by venting compressed air in
excess of 200 psig (13.8 bar) to atmosphere.
MODULATING INLET VALVE Regulates the amount of air allowed to enter the air
compressor. This regulation is determined by the
amount of air being used at the service line. Also acts
as a check valve to prevent reverse compressor rota-
tion at shut down.
SOLENOID VALVE Bypasses the pressure regulator valve causing the in-
let valve to close when the compressor reaches maxi-
mum operating pressure. Also activates blowdown
valve.
WATER REGULATING VALVE Regulates the amount of cooling water used in the
(water---cooled only) cooler to keep the compressor running at a normal op-
erating temperature of 170_F (77_C).

5.10 SUPERVISOR II OUTPUT RELAYS

RELAY OPERATION

RUN RELAY (K1) Contact closure energizes the compressor starter.

*---DELTA (K2) A timed contact used to provide wye---delta transition
time.
UNLOAD/LOAD (K3) Controls ON LOAD/OFF LOAD operation of the load
control solenoid valve.
COMMON FAULT (K4) May be used to provide remote indication of any pre---
alarm, maintenance or fault shutdown condition.
DRAIN VALVE (K5) Controls optional solenoid valve to provide automatic
condensate removal.

26
 Section 5
OPERATION

5.10 SUPERVISOR II OUTPUT RELAYS (CONTINUED)

RELAY OPERATION

FULL LOAD/MODULATE (K6) Used with optional sequencing feature.

NOTE: All output relays will handle eight (8) amps at 120/240 VAC.

5.11 INITIAL START-- UP PROCEDURE-- SUPERVI- 7. Observe the operating temperature. If the oper-
SOR II ating temperature exceeds 200_F (93_C), the
The following procedure should be used to make cooling system and installation environment
the initial start ---up of the compressor. should be checked.
1. Read the preceding pages of this manual thor- 8. Open shut ---off valve to the service line.
oughly. 9. Reinspect the compressor for temperature and
2. Jog motor to check for correct rotation of motor leaks the following day.
(refer to Section 4.9). 5.12 SUBSEQUENT START-- UP PROCEDURE-- SU-
3. Be sure that all preparations and checks de- PERVISOR II
scribed in the Installation Section have been
made. On subsequent start ---ups, check that the proper
4. Open the shut---off valve to the service line. level is visible in the fluid level sight glass and sim-
5. Check for possible leaks in piping. ply press “I” for manual or “ ” for automatic op-
6. Slowly close the shut---off valve to assure proper eration. When the compressor is running, observe
nameplate pressure unload setting is correct. the various parameter displays.
The compressor will unload at nameplate pres-
sure. If adjustments are necessary, see Control 5.13 SHUTDOWN PROCEDURE-- SUPERVISOR II
System Adjustments. To shut the compressor down, push “O” pad.

27
 NOTES

28
 Section 6
SUPERVISOR II

6.1 INTRODUCTION-- SUPERVISOR II

Refer to Figure 6---1 and Section 5 for information
regarding your compressor with Supervisor II. The S Up arrow --- Used in status displays to
Supervisor II has a two line display to show tem- change displays and in parameter setup
perature, pressure and status. It has a keypad for mode to increment a value.
operating the compressor, programming the con-
trol points and selecting displays. There is a graph-
ic illustration with lamps that light to show the item
being displayed. The lamps flash if that component
is in an alarm condition.
S Down arrow, lamp test --- Used in status
6.2 KEYPAD displays to change displays and in param-
The keypad is used to control the machine as well eter setup mode to increment a value.
as display status and change setpoints. Refer to When in the default display the key will light
figure 6---1 for following key descriptions. all the lamps for three seconds.
S Stop --- Used to put the machine into
manual stop. It is also used to clear alarm
conditions.

O 6.3 STATUS DISPLAYS

By default the line pressure (P2) and discharge
temperature (T1) are shown on the bottom line of
S Continuous --- Starts machine if no alarm the display, and machine status on the top line.
conditions are present. Also used to clear The following are the various machine status mes-
alarm conditions while machine is running. sages that indicate the state of the compressor with
LCD graphics listed below:

I S STOP --- Compressor is off.

S STANDBY --- Compressor is off but armed

S Auto --- Starts machine and selects auto to start. This state may be entered because
mode if no alarm conditions are present. of a power up, or the unload timer had ex-
Also used to clear alarm conditions while pired and stopped the machine. NOTE :
machine is running. The machine may start at any time.

S STARTING --- Machine is trying to start.

S OFF LOAD --- Machine is running and off

S Display --- Used to display pressures, loaded.
temperatures and other status information
(See section on STATUS DISPLAYS). S ON LOAD --- Machine is running and
loaded.
DSP S FULL LD --- Machine is running and fully
loaded. This state is only displayed if the
S Logo --- Used for various functions de- machine has a full load valve and under se-
scribed in later sections. quence control.

S RMT 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.
S Program --- Used to enter the parameter
change mode where control parameters S SEQ STOP --- Compressor is off but armed
may be displayed and changed (See PA- to start. The machine will start when the se-
RAMETER SETUP). quencing conditions meet the criteria to
start. NOTE : the machine may start at any
time.
PRG
This default display appears as follows:

29
Section 6
SUPERVISOR II
S Total hours that the compressor has been
STOP loaded.
110 180

If there are alarms active they will alternately be HRS LOAD

shown with the default display. The machine status 000987.0
will be displayed for two seconds, then the alarms
for two seconds each. For example: S Last fault log. This shows the fault on the
first line and the run hours when the fault
T1 HI occurred.
110 180
T1 HI
To view other status press the DSP key. All temper- @1 234
atures and pressures may be displayed as well as
other status information. To scroll through the dis- S Next to last fault log. This shows the fault
plays press the up arrow or down arrow keys. Up on the first line and the run hours when the
arrow moves to the next display, down arrow the fault occurred.
previous display. To return to the default display
press the display key.
T1 HI
S Separator differential pressure and the @2 204
maximum limit. If the limit is exceeded, a
separator maintenance warning will be dis- 6.4 LAMP INDICATORS
played. Embedded into the front panel schematic of the
compressor are several lamps. Pressing the lamp
nP1 4 test key will light all the lamps for three seconds.
Each LED lamp has the following purpose.
MAX 10
P1 --- If lit steady, signifies that P1 is being dis-
S Sump pressure and line pressure. played; if flashing denotes the presence of an
alarm.
P1 113 P2 --- If lit steady, signifies that P2 is being dis-
P2 108 played; if flashing denotes the presence of an
alarm.
S Pressure after (P3) oil filter.
nP1 --- If lit steady, signifies that nP1 is being dis-
played; if flashing denotes replacement of separa-
P3 108 tor is needed.
nP2 --- If lit, indicates replacement of fluid filter is
S Oil differential pressure and the minimum needed.
limit. If the pressure goes below the limit a
P3 LOW shutdown will occur. Oil differential T1 --- If lit steady, signifies that T1 is being dis-
(dP3) is defined as P3---P1/2 played; if flashing denotes the presence of an
alarm.
INLET FILTER --- Same as nP2.
dP3 40
MIN 1 MOTOR --- If flashing, indicates the motor overload
contact has opened.
S Unit discharge temperature and the maxi-
mum limit. If the temperature exceeds the POWER ON --- Lit if 120VAC power is applied to the
limit a T1 HI shutdown will occur. Supervisor II.
ON --- If lit steady, the compressor is running. If
T1 210 flashing, indicates that the compressor is armed
MAX 235 but stopped because of restart timer not expired,
remote stop or sequence stop. The compressor
S Total hours that the compressor has been may start at any time.
running. AUTO --- If lit steady, the compressor is running and
in auto mode. If flashing, indicates that the com-
HRS RUN pressor is armed but stopped because of restart
001234.0 timer not expired, remote stop or sequence stop.
The compressor may start at any time.

30
 Section 6
SUPERVISOR II

Figure 6 ---1 Supervisor II Panel

SYSTEM GRAPHIC DISPLAY

MESSAGE DISPLAY

KEYPADS

31
 NOTES

32
 Section 7
MAINTENANCE
7.1 GENERAL Figure 7 ---1 Fluid Filter (P/N 02250096 ---783)
As you proceed in reading this section, it will be easy
to see that the Maintenance Program for the air
compressor is quite minimal. The use of the service
indicators provided for the bearing filter, air filter and
fluid separator, will alert you when service mainte-
nance is required. When the maintenance gauge
shows red, maintenance for that specific item is re-
quired. See instructions for each item in Section 7.8,
Parts Replacement and Adjustment procedures.

7.2 DAILY OPERATION

Prior to starting the compressor, it is necessary to
check the fluid level in the sump. Should the level be
low, simply add the necessary amount. If the addi-
tion of fluid becomes too frequent, a simple problem
has developed which is causing this excessive loss.
See the Troubleshooting Section under Excessive
Fluid Consumption for a probable cause and reme-
dy.
After a routine start has been made, observe the in-
strument panel gauges and be sure they monitor
the correct readings for their particular phase of op-
eration. After the compressor has warmed up, it is
recommended that a general check on the overall
compressor and instrument panel be made to as- * Repair Kit P/N 250025--- 525
sure that the compressor is running properly.
7.6 FILTER MAINTENANCE
Replace your fluid filter element and the gasket un-
der any of the following conditions, whichever oc-
! WARNING curs first:
1. As indicated by the maintenance gauge.
DO NOT remove caps, plugs, and/or other compo- 2. Every 1000 hours.
nents when compressor is running or pressur- 3. Every 6 months.
ized.
7.7 SEPARATOR MAINTENANCE
Stop compressor and relieve all internal pressure Replace the separator elements when your separa-
before doing so. tor maintenance gauges show red or after one (1)
year, whichever comes first. The separator ele-
ments must be replaced. DO NOT clean the separa-
tor elements.
7.3 MAINTENANCE AFTER INITIAL 50 HOURS OF 7.8 PARTS REPLACEMENT AND ADJUSTMENT
OPERATION PROCEDURES
After the initial 50 hours of operation, a few mainte- FLUID FILTER ELEMENT REPLACEMENT
nance requirements are needed to clean the system Refer to Figure 7---1.
of any foreign materials. Perform the following main-
tenance operations to prevent unnecessary prob- 1. Using a strap wrench, remove the old element
lems. and gasket.
2. Clean gasket seating surface.
1. Clean the return line strainer. 3. Apply a light film of fluid to the new gasket.
2. Clean the return line orifice. 4. Hand tighten new element until new gasket is
seated in the gasket groove. Avoid any nicks,
7.4 MAINTENANCE EVERY 1000 HOURS cuts or pinches to the gasket.
After 1000 hours of operation, it will be necessary to 5. Continue tightening element by hand an addition-
perform the following: al 1/2 to 3/4 turn.
1. Clean the return line strainer. 6. Restart compressor and check for leaks.
2. Replace the fluid filter element and gasket.
7.5 FLUID MAINTENANCE ! CAUTION
Drain the sump and change the compressor fluid To minimize the possibility of filter element rup-
using instructions shown in sections 3.2, 3.3, and ture, it is important that ONLY replacement ele-
3.4. ments identified with the Sullair name, logo and

33
Section 7
MAINTENANCE

Figure 7 ---2 Air Filter Replacement 8. Reset the air filter restriction indicator if equipped
(P/N 02250107 ---327) --- 25 ---30HP/ 18 ---22KW (electro---mechanical models only).
(P/N 040595) --- 40HP/30KW ELEMENT INSPECTION
1. Place a bright light inside the element to inspect
for damage or leak holes. Concentrated light will
shine through the element and disclose any
holes.
2. Inspect all gaskets and gasket contact surfaces
of the housing. Should faulty gaskets be evident,
correct the condition immediately.
3. If the clean element is to be stored for later use, it
must be stored in a clean container.
4. After the element has been installed, inspect and
tighten all air inlet connections prior to resuming
operation.
SEPARATOR ELEMENT REPLACEMENT
Refer to Figure 7---3. The separator elements must
be changed when the maintenance gauge shows
* red with the compressor running full load, or once a
year, whichever occurs first. Follow the procedure
explained below for separator element replace-
ment.
Figure 7 ---3 Separator Element Replacement
(P/N 250034 ---113)

*
CAPSCREW

LOCK WASHER
* Replacement Element P/N 043334 (25--- 30HP/18--- 22KW)
Replacement Element P/N 040596 (40HP/30KW)
COVER

appropriate part number be used and that substi-

tuted elements not be used, due to the fact that SEPARATOR
such filters may have inadequate or questionable ELEMENT*
working pressure ratings.

AIR FILTER MAINTENANCE

Refer to Figure 7---2. Air filter maintenance should
be performed when the maintenance gauge shows
red with the compressor running full load, or once a
year, whichever comes first. If the filter needs to be
replaced, order replacement elements. Below you
will find procedures on how to replace the air filter RECEIVER/SUMP
elements. TANK
AIR FILTER ELEMENT REPLACEMENT
1. Clean exterior of air filter housing.
2. Release tension on cover retaining ring.
3. Remove the rubber baffle from the inside dust cup
and empty the dirt from the dust cap.
4. Remove air filter element by loosening the wing-
nut securing the element.
5. Remove element and clean interior of housing us-
ing a damp cloth. DO NOT blow dirt out with
compressed air.
6. At this time replace the element.
7. Reassemble in the reverse order of the disassem- * Replacement Kit for Primary Element P/N 250034--- 114
bly.

34
 Section 7
MAINTENANCE
1. Relieve all pressure from the sump tank and all wise widens the differential by lowering the reset
compressor lines. (lower) setting only.
2. Disconnect all piping connected to the sump cov- 2. When the pressure switch adjustment is com-
er to allow removal (return lines, service lines, plete, the pressure regulator should be adjusted
etc.). for the pressure at which modulation of air deliv-
3. Loosen and remove the eight (8) hex head caps- ery should begin. In this case that pressure will
crews (1/2---13 x 1 1/2”) from the cover plate. be 118 psig (8.2 bar). The regulator is adjusted
4. Lift the cover plate from the sump. by loosening the jam nut on the end of the cone
5. Remove the separator element. shaped cover of the pressure regulator. When
6. Inspect the receiver/sump tank for rust, dirt, etc. the jam nut is loose, turn the adjusting screw
7. Scrape the old gasket material from the cover clockwise to increase or counterclockwise to de-
and flange on the sump. Be careful not to let the crease the setting.
scraps fall in the sump.
8. Reinsert the separator element into the sump tak- 3. To set the regulator, continue closing the service
ing care not to dent the element against the tank valve until the line pressure is 118 psig (8.2 bar).
opening. At this point regulator should pass a signal to the
9. Clean the underside of the receiver/sump tank inlet valve to start closing it. If the line pressure
cover and remove any rust. keeps on rising or if the modulation does not be-
10. Replace the cover plate, washers and caps- gin, adjust the regulator valve as described
crews. Torque to 55 ft ---lbs. (75 Nm). above. After adjustment, line pressure should be
11. Reconnect all piping making sure return line approximately 118 psig (8.2 bar) and 1.00 in. Hg
tubes extend to the bottom or 1/4” (6mm) above (2.54 cm Hg.) vacuum below the inlet.
the bottom of the separator element. This will as- 4. Next, close the service valve; line pressure will
sure proper fluid return flow to the compressor. start rising. When line pressure reaches 125 psig
12. Clean the return line strainers before restarting (8.6 bar), the inlet valve will be closed to its maxi-
the compressor. mum position. The inlet vacuum at this point will
be around 25 in. Hg (63.5 cm Hg.). The machine
CONTROL SYSTEM ADJUSTMENT should unload at this point.
Refer to Figure 7---4. Prior to adjusting the Control
System, it is necessary to determine the desired op-
erating pressure range and also the maximum pres- Figure 7 ---4 Pressure Switch
sure at which your compressor is to operate. The P/N 040694 --- Standard
pressure must not exceed the maximum operating P/N 407778 --- High Pressure
pressure which is stamped on the compressor seri-
al number nameplate. The following explanation ap-
plies to a typical installation with a desired operating
range of 115 to 125 psig (7.9 to 8.6 bar). This infor-
mation will apply to a compressor with any other op-
erating range excepting the stated pressures.
Remove the cover of the pressure switch. With the
shut ---off valve closed (or slightly cracked open)
start the compressor. Observe the line pressure
gauge and pressure switch contacts. When the line
pressure reaches 125 psig (8.6 bar), the pressure
switch contacts should open. If the pressure switch
contacts do not open or they open prior to the de-
sired pressure, the pressure switch setting will re-
quire adjustment (refer to Figure 7---4).
FOR PRESSURE RANGE ADJUSTMENT:
1. Remove cover to pressure switch.
2. Turn the range adjusting screw to the high pres-
sure setting. Turning the screw counterclockwise
lowers both the high and low pressure equally.
FOR DIFFERENTIAL ADJUSTMENT:
Differential is the difference between the high and
low pressure settings. 10 psig (0.7 bar) is typical.
1. Turn the differential adjusting screw to the lower
(reset) setting. Turning the screw counterclock-

35
Section 7
MAINTENANCE
5. Open the service valve so the line pressure is 115 TABLE 1 INSTALLATION DATA
psig (7.9 bar). Machine is now set for operation. SERIES 10 (25---40HP/ 18---30 KW)
Recheck the unload pressure by closing of the Coupling Coupling Tightening
service valve. Machine should unload via the Horsepower Element Hub Gap Torque (Wet)
pressure switch at 125 psig (8.6 bar).
25 & 30 HP/ 045672 .09--- .125 in 55 ft.--- lbs.
After the control pressures have been adjusted, the 18 & 22 KW 2.4--- 3.2 mm (75Nm)
“unloaded” sump pressure should be checked. It 60, 75, 100 250004--- 638 .09--- .125 in 110 ft.--- lbs.
will be necessary to shut the compressor down, re- (45, 55, 75 KW) 2.4--- 3.2 mm (149Nm)
move the pressure switch cover, and disconnect
one of the two lead wires that are connected to the
micro---switch (contact block). After disconnecting Figure 7 ---5 Drive Coupling “Hub” Gap Check
the lead, tape the exposed wire with electrician’s
tape to make sure that it does not come in contact
with any metallic surface.

! DANGER
DO NOT touch the electrical contacts, terminal or
leads with any metallic object. Severe electrical
shock may occur.

With the lead taped, you may start the compressor

again. Allow the sump pressure to stabilize.
The sump pressure should read 30 to 35 psig (2.1 to
2.8 bar).
Once this is checked, shut the compressor down
once again and reconnect the taped lead and re-
place the pressure switch cover. At this time, start STEP 1 -- COUPLING GUARDS
the compressor and cycle the Control System sev- There are three 5/16” screws from each of the wire
eral times and re---check all pressure settings and guards located on each side of the unit/motor adap-
adjustments. tor for the 25/30 HP (18/22 KW) packages, or the two
3/8” bolt/nut/washer assemblies from the plate
! DANGER guard and adaptor located on the top side.

DO NOT touch the pressure switch, electrical con-

STEP 2 -- MOUTING HUBS/ELEMENT
tacts, terminal board or leads with any part of the The coupling halves have a unique bore for the mo-
body or any un---insulated metallic object. Severe tor and the air---end. The air---end half is to be lo-
electrical shock may occur. cated so that the hub is positioned against the shaft
shoulder and secured in place by two set ---screws.
The motor half should remain free floating until the
PRESSURE REGULATOR ADJUSTMENT element is in its proper location. The motor half is
Start the compressor and adjust the service valve to then positioned within assembly maintaining an ax-
maintain service air pressure at rated pressure (115 ial coupling gap as listed in Figure 7---5. There are
psig for example). Turn the adjusting screw on the two set ---screws located on the motor coupling half
regulator until air just begins to escape from the also. Prior to starting of package, assure the set ---
control air orifice. The regulator is now properly set. screws are secure to eliminate potential movement
of the hub.
DRIVE COUPLING INSTALLATION AND MAIN-
TENANCE 7.9 TROUBLESHOOTING -- STANDARD ELECTRO/
Refer to Figures 7---5 and 7---6. For coupling installa- MECHANICAL
tion and maintenance the tools required will be a The information contained in the Standard Electro-
measuring scale, one set of standard Allen Mechanical Troubleshooting chart has been com-
wrenches, and one set of standard socket piled from field report data and factory experience. It
wrenches. contains symptoms and usual causes for the de-
For installation and maintenance of the drive cou- scribed problems. However, DO NOT assume that
pling, follow the steps explained below. these are the only problems that may occur. All avail-
able data concerning a problem should be system-
atically analyzed before undertaking any repairs or
! DANGER component replacement procedures.
Disconnect all power at source, before attempting A detailed visual inspection is worth performing for
maintenance or adjustments. almost all problems and may avoid unnecessary

36
 Section 7
MAINTENANCE
additional damage to the compressor. Always re- short circuit, usually apparent by discoloration or
member to: a burnt odor.
1. Check for loose wiring. Should your problem persist after making the rec-
2. Check for damaged piping. ommended check, consult your nearest Sullair rep-
3. Check for parts damaged by heat or an electrical resentative.

TROUBLESHOOTING -- STANDARD ELECTRO/MECHANICAL

SYMPTOM PROBABLE CAUSE REMEDY

COMPRESSOR WILL NOT START Main Disconnect Switch Open Close switch.

Line Fuse Blown Replace fuse.

Control Transformer Fuse Blown Replace fuse.

Motor Starter Overloads Tripped Reset. Should trouble persist, check

whether motor starter contacts are
functioning properly.

Low Incoming Line Voltage Check voltage. Should voltage check low,
consult power company.

COMPRESSOR SHUTS DOWN WITH Loss of Control Voltage Reset. If trouble persists, check that line
AIR DEMAND PRESENT pressure does not exceed maximum oper---
ating pressure of the compressor (specified
on nameplate).
Low Incoming Voltage Consult power company.

Excessive Operating Pressure Defect in line pressure switch; check pressure

at which contact points open.
Separator requires maintenance; check
maintenance indicator under full load condi---
tions.
High pressure shutdown switch is defective;
replace.
Defective 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 to
15 psig (0.7 to 1.0 bar) when maximum
operating pressure is reached. Repair if
defective.
Discharge Temperature Switch Open Cooling water temperature too high;
increase water flow (water--- cooled only).
Cooling water flow insufficient; check water
lines and valves (water--- cooled only).
Cooler plugged; clean tubes. If plugging
persists, install water conditioner
(water--- cooled only).
Cooling air flow restricted; clean cooler and
check for proper ventilation.
Ambient temperature is too high; provide
sufficient ventilation.
Low fluid level; add fluid.
Clogged filter; change the fluid filter element
and change the bearing filter element if
maintenance indicator shows red.
Thermal valve not functioning properly;
replace element.
Water flow regulating valve not functioning
properly; change (water--- cooled only).
Defective discharge temperature switch;
check for a short or open circuit to probe
and correct wiring.

37
 Section 7
MAINTENANCE
TROUBLESHOOTING -- STANDARD ELECTRO/MECHANICAL
SYMPTOM PROBABLE CAUSE REMEDY

COMPRESSOR WILL NOT BUILD Air Demand is Too Great Check service lines for leaks or open valves up
FULL DISCHARGE PRESSURE.
Dirty Air Filter Check the filter indicator and inspect and/or
change element if required.
Pressure Regulator Out of Adjustment Adjust regulator according to control
adjustment instructions in the Maintenance
section.
Defective Pressure Regulator Check diaphragm and replace if necessary
(kit available).

LINE PRESSURE RISES ABOVE Leak in Control System Causing Check for leaks.
CUT--- OUT PRESSURE SETTING Loss of Pressure Signals
ON PRESSURE SWITCH
Defective Pressure Switch Check that diaphragm and contacts are not
damaged. Replace if necessary.
Defective Regulator Valve Check that air bleeds from control orifice
when the pressure switch contacts open.
Readjust; Repair or replace it if necessary (kit avail
able).
Plugged Control Line Strainer Clean strainer (screen and o’ring replacement kit
available).
Defective Blowdown Valve Check that sump pressure is exhausted to
the atmosphere when the pressure switch
contacts open. Repair or replace if neces---
sary (kit available).
High Pressure Shutdown Switch is Readjust or replace.
Defective or Incorrectly Adjusted

EXCESSIVE COMPRESSOR FLUID Clogged Return Line or Orifice Clean strainer (screen and o--- ring replace---
CONSUMPTION ment kit available).
Clean orifice.
Separator Element Damaged or
Not Functioning Properly Change separator.
Leak in the Lubrication System Check all pipes, connections and compo---
nents.
Excess Fluid Foaming Drain and change.
Fluid Level Too High Drain and change.

PRESSURE RELIEF VALVE OPEN Defective Pressure Relief Valve Replace.

REPEATEDLY
Plugged Separator Check separator differential.

LIQUID WATER IN COMPRESSED Water Vapor Condensation from Cooling Remove the water vapor from compressed air prior
AIR LINES and Compression Occurs Naturally to distribution through the air system. Check opera---
tion of aftercooler and moisture separator. Install a
compressed air dryer sized for the flow and dryness
level required. (Note: Filters may also be required to
remove particulates, liquid oil aerosols or for oil vapor
removal. Change cartridges as recommended by the
filter manufacturerer). Check all drain traps routinely
to insure their proper operation. Maintain them regu---
lary.

7.10 TROUBLESHOOTING -- SUPERVISOR II It contains symptoms and usual causes for the de-
The information contained in the Supervisor II Trou- scribed problems. However, DO NOT assume that
bleshooting chart is based upon both the actual ap- these are the only problems that may occur. All avail-
plied situations and extensive testing at the factory. able data concerning a problem should be system-

38
 Section 7
MAINTENANCE
atically analyzed before undertaking any repair or b. Check for damaged piping.
component replacement procedures. c. Check for parts damaged by heat or an electrical
short circuit, usually apparent by discoloration or
A detailed visual inspection is worth performing for a burnt odor.
almost any problems which may prevent unneces-
sary damage to the compressor. Always remember Should your problem persist after making the rec-
to: ommended check, consult your nearest Sullair rep-
a. Check for loose wiring. resentative or the Sullair Corporation factory.

TROUBLESHOOTING -- SUPERVISOR II
SYMPTOM (DISPLAY) PROBABLE CAUSE REMEDY

T1 HI Message Discharge Temperature Exceeded

225_F (107_C) for Pre--- Alarm
Discharge Temperature Exceeded
235_F (113_C) for Shutdown
Ambient Temperature Exceeded Improve local ventilation (i.e.,
105_F (41_C) remote intake of process and/or
cooling air).
Fluid Level in Sump is Too Low Check/correct fluid level.
Thermal Valve Malfunctioned Check/replace thermal valve.
Cooler Fins are Dirty (Air--- cooled only) Clean cooler fins.
Water Flow is Low (Water--- cooled Check cooling water supply (i.e.,
Packages Only) closed valves).
Water Temperature is High (Water--- Increase water flow, lower water
Cooled Packages Only) temperature.
Cooler is Plugged (Water--- Cooled Clean tubes and/or shell --- if tube
Packages Only) plugging persists, provide cleaner
water.

T1 FAIL Temperature RTD Malfunction Check connections from RTD.

If connection is good, replace RTD.

P1 HI Message Discharge Pressure Exceeded

Shutdown Level Because:
P1 MAX--- 3psi (0.2 Bar) Exceeded
for Pre--- Alarm
P1 MAX Exceeded for Shutdown
Unloading Device (i.e., Blowdown Check operation of unloading device.
Valve) Failed to Operate
Pressure Regulator Adjusted Incorrectly Check operation of pressure regulator.
Solenoid Valve Failed Check operation of solenoid valve.
to Operate
Control Air Signal Leaks Check tubework feeding control
signal for leaks.
Control Air Signal Filter Clogged Service filter assembly.

P1, P2, P3 FAIL Pressure Transducer Malfunction Check connections from transducer.
If connections are good, replace transducer.

P3 LOW Oil Pressure Falls Below 10 psig (0.7 bar)

or Less than 1/2 of P1 while Compressor
is Running Because:
Oil Filter Clogged Replace filter element.
Sump Oil Level Too Low Replenish oil level.

SEP MNTN Message Plugged Separator Replace separator element.

nP1 > 10 psi (0.7 Bar) Check P1 & P2 pressure transducers.

39
 Section 7
MAINTENANCE
TROUBLESHOOTING -- SUPERVISOR II (CONTINUED)
SYMPTOM (DISPLAY) PROBABLE CAUSE REMEDY

COMPRESSOR DOES NOT Air Demand Exceeds Supply Check air service lines for open
BUILD FULL DISCHARGE valves or leaks.
PRESSURE
Inlet Air Filter Clogged Check for maintenance message
on Supervisor display. Inspect and/or
change element.
Inlet Valve Not Fully Open Check actuation and position.
Pressure Sensor and/or Connections Check connections from trans---
at Fault ducer. If adequate, replace trans---
ducer.

LINE PRESSURE RISES ABOVE Pressure Sensor P2 at Fault Check connections from trans---
UNLOAD SETTING ducer. If adequate, replace
transducer.
Unloading Device (i.e., Blowdown Check operation of unloading device.
Valve) Failed to Operate
Solenoid Valve Failed Check operation of solenoid
to Operate valve.
Control Air Signal Leaks Check tubework feeding control
signal for leaks.
Control Air Signal Filter Clogged Service filter assembly.

EXCESSIVE FLUID CONSUMPTION Damaged or Improperly Gasketed Inspect separator element and
Separator Element gasket. Replace if damaged.
Fluid System Leaks Check tube/pipework for leaks.
Fluid Level Too High Drain excess fluid.
Excessive Fluid Foaming Drain and change fluid.

LIQUID WATER IN COMPRESSED Water Vapor Condensation From Cooling Remove the water vapor from compressed
AIR LINES and Compression Occurs Naturally air prior to distribution through the air system.
Check operation of aftercooler and moisture
separator. Install a compressed air dryer sized
for the flow and dryness level required. (Note:
Filters may also be required to remove
particulates, liquid oil aerosols or for oil vapor
removal. Change cartridges as recommended
by the filter manufacturer). Check all drain traps
routinely to insure their proper operation. Main---
tain them regularly.

NOTE ON TRANSDUCERS: tion is adequate. Calibration may only be done while

Whenever a sensor is suspected of fault, the recom- machine is stopped and unarmed.
mended cause of action is to measure the signal To enter calibration mode, you must press the fol-
(pressure, temperature, etc.) with an alternate cali- lowing keys in sequence while in the default status
brated instrument and compare readings. If read- display mode: “ ”, “Y”, DSP, “B ”, PRG.
ings conflict, the electrical and/or tubing connec- Once in calibration mode, you will see a screen like
tions should be inspected, and if no faults are evi- the following:
dent, then replace the sensor and re---evaluate
against the calibrated instrument. CAL P1
0 97
7.11 CALIBRATION
The Supervisor II has software calibration of the In the above example, “0” refers to the amount of ad-
pressure and temperature probes. This calibration justment (in psi or _F, “97” refers to the current value
affects the offset but not the slope of the pressure of P1).
and temperature calculations. Because of this, the To make adjustments, Press the “Y” (UP ARROW)
most accurate method is to heat or pressurize the key to increase the value, press the “B ” (DOWN
transducer to its operating value. If this is too diffi- ARROW / LAMP TEST) key to decrease the value.
cult, room temperature/open atmosphere calibra- The number on the left will increase or decrease al-

40
 Section 7
MAINTENANCE
ways showing the total amount of adjustment. Maxi-
mum adjustment is ¦ 7.
The DSP key exits, wiping out changes to the cur-
rent item, while saving changes to any previous
items. The PRG key saves the current item and ad-
vances to the next. All temperatures and pressures
may be calibrated individually.

41
 Section 7
MAINTENANCE

Figure 7 ---7 Piping and Instrumentation Diagram --- Standard

42
 Section 7
MAINTENANCE

Figure 7---8 Piping and Instrumentation Diagram--- Supervisor II

43
 NOTES

44
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.1 PROCEDURE FOR ORDERING PARTS

Parts should be ordered from the nearest Sullair Representative or the Representative from whom the com-
pressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly
at the addresses, phone or fax numbers listed below.
When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the Bill
of Lading for the compressor or from the Serial Number Plate located on the compressor.

SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A.

Sullair Road, No. 1 Zone Des Granges BP 82
Chiwan, Shekou 42602 Montbrison Cedex, France
Shenzhen, Guangdong PRV. Telephone: 33-- 477968470
PRC POST CODE 518068 Fax: 33 -- 477968499
Telephone: 755-- 6851686
Fax: 755 -- 6853473
SULLAIR CORPORATION
Subsidiary of Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 1-- 219-- 879-- 5451
Fax: (219) 874 -- 1273
Fax: (219) 874-- 1835 (Parts)
Fax: (219) 874-- 1288 (Service)

8.2 RECOMMENDED SPARE PARTS LIST

DESCRIPTION KIT NUMBER QTY
element, compressor fluid filter 02250096---783 250025-- 525 1
element, heavy duty air filter 02250107---327 (25---30HP/ 19---22KW) 043334 1
element, heavy duty air filter 040595 (40HP/ 30 KW) 040596 1
element, primary replacement for separator 250034---113 250034-- 114 1
kit, repair for air inlet valve 02250088---348 250019-- 451 1
kit, repair springs for air inlet valve 02250088---348 250029-- 315 1
kit, repair for minimum pressure/check valve 02250097---609 250026-- 758 1
kit, repair cap for minimum pressure/check valve 02250097---609 02250046-- 397 1
kit, repair o---ring for minimum pressure/check valve 02250097---609 02250048-- 362 1
kit, repair piston for minimum pressure/check valve 02250097---609 02250051-- 338 1
kit, repair thermal valve 02250096---738 (170˚F) 250025-- 621 1
kit, repair thermal valve 02250103---509 (190˚F) 02250103-- 562 1
kit, repair for pressure regulator 250017---280 250019-- 453 1
kit, repair for blowdown valve 250025---655 250031-- 772 1
kit, repair for solenoid valve 250038---674 (<= 140 psi/ 9.7 bar) 250038-- 673 1
kit, replacement for solenoid valve coil 250038---674 (<= 140 psi/ 9.7 bar) 250031-- 738 1
kit, repair for solenoid valve 250038---675 (>140 psi/ 9.7 bar) 02250055-- 939 1
kit, replacement for solenoid valve coil 250038---675 (>140 psi/ 9.7 bar) 250038-- 730 1
kit, repair inlet valve 02250088---348 250019-- 451 1
kit, repair for v---type strainer 241771 241772 1
kit, repair for shaft seal 001836-- 007 1
element, replacement for combination separator/trap 02250078---841 02250081-- 108 1
kit, repair automatic drain for combination separator/trap 02250078---841 02250087-- 422 1
manual, Sequencing & Protocol (I) 02250057-- 696 1
fluid, SRF 1/4000 (5 gallons) 250019-- 662 (II)
lubricant, Sullube 32 (std.) (5 gallons) 250022-- 669 (II)
lubricant, 24 KT (5 gallons) 046850-- 001 (II)

(I) This document is required to program your personal computer to communicate with the Supervisor II
panel.
(II) For proper amount of fluid fill, please consult Lubrication Guide in Section 3, Specifications.

PLEASE NOTE: WHEN ORDERING PARTS, ALWAYS INDICATE SERIAL NUMBER OF COMPRESSOR

45
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.3 MOTOR, COMPRESSOR, FRAME AND PARTS

46
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.3 MOTOR, COMPRESSOR, FRAME AND PARTS

key part
number description number quantity

1 adapter, motor (25, 30HP) 250038---448 1

2 washer, springlock reg pltd 1/2”
(25, 30HP) 837808---125 4
•washer, springlock reg pltd 5/8”(40HP) 837810---156 4
3 capscrew, ferry head 1/2”---13 x 1---1/4”
(25, 30HP) 867308---125 4
•capscrew, ferry head 5/8”---11 x 1---1/4”
(40HP) 867310---150 4
4 hub, motor (25, 30HP) 045671 1
•hub, motor (40HP) 250004---640 1
5 element, drive coupling (25, 30HP) 045672 1
•element, drive coupling (40HP) 250004---638 1
6 coupling, hub (25, 30HP) 045673 1
•coupling, hub (40HP) 250004---639 1
7 capscrew, hex gr5 1/2---13 x 1---1/2” 829108---150 2
8 washer, pl---b reg plated 1/2” 838208---112 4
9 capscrew, hex gr5 3/8”---16 x 2” 829106---200 2
10 washer, pl---b reg plated 3/8” 838206---112 2
11 angle, compressor mounting 02250103---594 1
12 screw, ser washer 5/16” x 3/4” 829705---075 6
13 grille, coupling guard 250038---863 2
14 washer, springlock reg plated 3/8”
(25, 30HP) 837806---094 9
•washer, springlock reg plated 3/8” (40HP) 837806---094 12
15 capscrew, hex gr5 3/8”---16 x 1---1/4” 829106---125 7
16 nut, hex plated 3/8”---16 (25, 30HP) 825206---337 2
•nut, hex plated 3/8”---16 (40HP) 825206---337 5
17 compressor unit consult factory 1
18 angle, compressor mounting 02250107---610 1
19 capscrew, hex gr5 3/8”---16 x 1---3/4” 829106---175 3

(Continued on page 49)

(I) There is an exchange program whereby a remanufactured compressor unit can be obtained from
Sullair distributors or the factory at less cost than the owner could repair the unit. For information
regarding the unit exchange program, contact your nearest Sullair representative or the Sullair Cor-
poration.
The shaft seal is not considered part of the compressor unit in regard to the two year warranty. The
normal Sullair parts warranty applies. For shaft seal repairs, order shaft seal repair kit no.
001836---007.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

47
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.3 MOTOR, COMPRESSOR, FRAME AND PARTS

48
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.3 MOTOR, COMPRESSOR, FRAME AND PARTS (CONTINUED)

key part
number description number quantity

20 block, spacer 1 x 2 x 3 (25,30HP) 250001---798 2

21 adapter, compressor (40HP) 250009---542 1
22 plate, motor/compressor 225980 1
23 adapter, motor (40HP) 231977 1
24 motor consult factory 1
25 capscrew, hex gr5 1/2”---13 x 2---3/4”
(25, 30HP) 829108---275 2
•capscrew, hex gr5 1/2”---13 x 1---3/4”
(40HP) 829108---175 2
26 frame 02250097---328 1
27 washer, springlock reg plated 1/2” 837808---125 4
28 nut, hex plated 1/2”---13 825208---448 4

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

49
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.4 COOLER ASSEMBLY

50
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.4 COOLER ASSEMBLY

key part
number description number quantity

1 screw, ser washer 5/16”---18 x 3/4” 829705---075 17

2 panel, cooler adapter (25, 30HP) 02250107---473 1
•panel, cooler adapter (40HP) 02250107---548 1
3 nut, hex flanged plated 5/16”---18 825305---283 8
4 cooler, fluid ls---10 1---1/16” SAE 02250096---704 1
5 plate, cooler mtg frame extension 02250105---536 1
6 cooler, air/aftercooler (25, 30HP) 407106 1
•cooler, air/aftercooler (40HP) 250006---931 1
7 shroud, fan---17” (25, 30HP) 011994 1
•shroud, fan---18” (40HP) 013315 1
8 nut, retainer---u 5/16”---18 .140 861505---140 5
9 fan, 18”dia rh blower (25, 30HP) 042492 1
•fan, 17”dia rh blower (40HP) 249012 1
10 nut, hex locking plated 5/16”---18 (25, 30HP) 825505---166 4
•nut, hex locking plated 3/8”---16 (40HP) 825506---198 4
11 guard, fan shroud 225962 1
12 hub, fan mounting (25, 30HP) 023350 1
•hub, fan mounting (40HP) 231981 1
13 capscrew, ferry head 5/16”---18 x 1---1/2”
(25, 30HP) 828405---150 4
•capscrew, ferry head 3/8”---16 x 1---3/4”
(40HP) 828406---175 4
14 screw, set 5/16”---18 x 1/2” 250010---322 2
15 nut, hex flanged plated 5/16”---18 825305---283 2
16 screw. ser washer 5/16”---18 x 3/4” 829705---075 2
17 nut, retainer---u 5/16”---18 861505---140 4

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

51
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.5 AIR INLET SYSTEM

52
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.5 AIR INLET SYSTEM

key part
number description number quantity

1 filter, air inlet heavy duty (25, 30HP) (I) 02250107---327 1

•filter, air inlet heavy duty (40HP) (II) 040595 1
2 indicator, maintenance 045757 1
3 band, mounting---inlet filter (25, 30HP) 043370 1
•band, mounting---inlet filter (40HP) 040598 1
4 clamp, inlet elbow 250018---550 1
5 screw, ser washer 5/16”---18 x 3/4” 829705---075 2
6 connector, 1/4”tube x 1/8”npt 250018---427 1
7 tubing, nylon 1/4” black 02250054---861 ---
8 support, filter heavy duty 02250100---529 1
9 nut, hex flanged plated 5/16”---18 825305---283 2
10 elbow, rubber 90˚ red 2---1/2” x 3” (25, 30HP) 250032---462 1
•elbow, rubber 90˚ 3” (40HP) 040599 1
11 capscrew, hex gr5 5/8”---11 x 1---1/2” 829110---150 4
12 washer, springlock reg plated 5/8” 837810---156 4
13 valve, inlet control (III) 02250088---348 1
14 elbow, 1/4”tube x 1/4”npt 250018---430 1
15 o---ring, viton 826502---238 1
16 support, filter heavy duty 02250100---528 1
17 capscrew, hex gr5 5/16”---18 x 1---3/4” 829105---175 1
18 nut, hex flanged plated 5/16”---18 825305---283 1
19 lug, scrulug---ground 849215---025 1
20 capscrew, hex gr5 3/8”---16 x 1---3/4” 829106---175 1
21 washer, springlock reg plated 3/8” 837806---094 1
22 nut, hex plated 3/8”---16 825206---337 1
23 capscrew, hex gr5 3/8”---16 x 1---1/2” 829106---150 2
24 washer, springlock reg plated 3/8” 837806---094 2
25 nut, hex plated 3/8”---16 825206---337 2
26 clamp, inlet elbow (25, 30HP) 040083 1
Sclamp, inlet elbow (40HP) 250018---550 1

(I) For maintenance on air filter no. 02250107---327, order replacement element no. 043334.
(II) For maintenance on air filter no. 040595, order replacement element no. 040596.
(III) For maintenance on air inlet valve no. 02250088---348, order repair kit no. 250019---451, and/or repair kit
for springs no. 250029---315.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

53
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.6 COOLING AND LUBRICATION SYSTEM

54
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.6 COOLING AND LUBRICATION SYSTEM

key part
number description number quantity

1 cooler, fluid ls---10 1---1/16” SAE 02250096---704 1

2 elbow, tube straight thread 3/4” x 1---1/16” 811612---106 4
3 tube, 3/4” cooler/fluid filter 02250099---370 1
4 elbow, tube---m 1” x 3/4” (25, 30HP) 810516---075 2
•elbow, tube---m 1” x 1” (40HP) 810516---100 2
5 cooler, air/aftercooler (25, 30HP) 407106 1
•cooler, air/aftercooler (40HP) 250006---931 1
6 tube, aftercooler/moisture separator 02250100---730 1
7 tube, minimum pressure valve/aftercooler 02250099---372 1
8 connector, tube---m 1” x 1” 810216---100 1
9 bushing, reducing hex 1---1/2” x 1” plated 868906---040 1
10 separator, moisture 1---1/2”npt (I) 02250078---841 1
11 U ---bolt, 3/8” x 1---1/2” pipe plated 868306---150 1
12 nipple, pipe 1---1/2” x 3---1/2” plated 866324---035 1
13 tee, reducing 1---1/2” x 1/2” x 1---1/2” plated 867506---026 1
14 transducer, pressure 0---250psi 1---5dvc N4 02250078---933 1
15 bushing, reducing 1/2” x 1/8” plated 868902---005 1
16 connector, tube---m 1/4” x 1/8” nylon 250018---427 1
17 tubing, nylon 1/4” black 02250054---861 ---
18 washer, springlock reg plated 3/8” 837806---094 2
19 clamp, tube rubber center 1---3/8” dia 2500025---638 1
20 support, bracket moisture separator ls10 02250100---634 1
21 screw, ser washer 5/16”---18 x 3/4” 829705---075 3
22 connector, SAE x ORFS 0.75” 02250099---765 2
23 hose, mp ORFS f---swivel end .75” x 45” 02250099---175 1
24 reducer, straight thread 1---1/4” x 3/4” viton 870020---012 2
25 filter, fluid 1---5/8” SAE connection (II) 02250096---783 1
26 connector, tube 1/8M x 1/4T stainless steel 250139---024 1
27 elbow, tube 1/8M x 1/4T stainless steel 250211---013 1
28 tubing, stainless steel 1/4” 20ga 841215---004 ---
29 tee, tube---run straight thread 3/4” x 1---1/16” 811912---106 1
30 tube, fluid filter/thermal valve 02250099---367 1
31 connector, tube straight thread
3/4” x 1---1/16” 811812---106 2
32 tube, thermal valve/oil cooler 02250099---369 1

(Continued on page 57)

(I) For maintenance on moisture separator no. 02250078---841, order replacement element no.
02250081---108, and automatic drain no. 02250087---422.
(II) For maintenance on fluid filter no. 02250096---783, order replacement element no. 250025---525.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

55
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.6 COOLING AND LUBRICATION SYSTEM

56
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.6 COOLING AND LUBRICATION SYSTEM (CONTINUED)

key part
number description number quantity

33 valve, thermal (170˚F) (III) 02250096---738 1

•valve, thermal (190˚F) (IV) 02250103---509 1
34 tube, flexible tank/thermal valve ls10 02250100---616 1
35 screw, ser washer 5/16”---18 x 3/4” 829705---075 4
36 support, bracket oil filter 02250103---970 1
37 transducer, pressure 0---250psi 1---5dvc N4 02250078---933 1
38 switch, pressure differential 20psid 02250050---154 1
39 elbow, tube 1/8”M x 1/4”T stainless steel 250211---013 2
40 tee, tube 1/8F x 1/8M x 1/8F 02250077---903 1
41 connector, tube 1/8”M x 1/4”T stainless steel 250139---024 2

(III) For maintenance on thermal valve (170˚F) no. 02250096---738, order repair kit no. 250025---621.
(IV) For maintenance on thermal valve (190˚F) no. 02250103---509, order repair kit no. 02250103---562.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

57
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.7 DISCHARGE SYSTEM

3 TO AIR
11 FILTER
9 TO SOLENOID
VALVE 4
10 12 13
9
8 14
4 13
4 17 15
2 7
54 1
6
3 21 18 16
22
23 19
5
20
4

25 11

12
24
4
30 13
43
26

SUPERVISOR II
MACHINES TO CONTROL
SYSTEM
48 TO PRIMARY STRAINER
49 45
50 X SEPARATOR 27
51 GAUGE 28
46
45
47
3 44

30
ELECTRO--MECHANICAL 29
MACHINES
42
38
52
X 31
40 39

41 46
47

37 X 32
ELECTRO--MECHANICAL
MACHINES 53
SUPERVISOR II 35
MACHINES 36 34 33

58
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.7 DISCHARGE SYSTEM

key part
number description number quantity

1 connector, 1/4”tube x 1/4”npt 250018---428 1

2 elbow, tube---m 1/4”t x 1/8”p stainless steel 250211---013 1
3 tube, stainless steel 1/4” 20ga 841215---004 ---
4 tube, nylon 1/4” black 02250054---861 ---
5 elbow, tube---m 1/4” stainless steel 250211---005 1
6 glass, sight ---in line 1/4”npt 046559 1
7 orifice, .094” 1/4”npt steel 022033 1
8 strainer, v---type 300psi x 1/4”npt (I) 241771 1
9 connector, tube---male bulkhead 1/4”t x 1/4”p
ststl 870204---025 1
10 support, bracket---oil return 02250101---192 1
11 capscrew, hex gr5 1/2”---13 x 1---1/4” plated 829108---125 8
12 washer, springlock reg plated 1/2” 837808---125 8
13 elbow, 1/4”tube x 1/4”npt 250018---430 3
14 valve, ball check in---line 1/4” 045244 1
15 tee, pipe 1/4” male npt 869825---025 1
16 elbow, female 1/4”npt x 1/4”T 250041---287 1
17 orifice, .125” x 1/4”mnpt x 1/4”fnpt 02250046---537 1
18 valve, blowdown 1/4”npt (II) 250025---655 1
19 nipple, pipe 1/4”npt hex 868504---025 1
20 connector, flex 1/4”t x 1/4”p 020169 1
21 plug, pipe 1/8”npt 3000# plated 866900---005 1
22 valve, minimum pressure check 1---5/8”
SAE (III) 02250097---609 1
23 connector, tube---straight thread 1” x 1---5/8” 811816---163 1
24 tube, minimum pressure valve/aftercooler 02250099---372 1
25 adapter, SAE 1---5/8”---12 x 1---5/8”---12 02250055---015 1
26 element, separator---primary (IV) 250034---113 1
27 tank, separator air/oil 10”dia SAE/ISO 02250096---708 1
28 valve, pressure relief 1/2”npt 200# 250006---938 1
29 elbow, tube---m straight thread ss 1/4” x 7/16” 870807---025 1
30 elbow, tube straight thread 1---1/2” x 1---7/8” 811624---188 2

(Continued on page 61)

(I) For maintenance on strainer no. 241771, order repair kit no. 241772.
(II) For maintenance on blowdown valve no. 250025---655, order repair kit no. 250031---772.
(III) For maintenance on minimum pressure check valve no. 02250097---609, order repair kit no.
250026---758; repair kit (for cap) no. 02250046---397; repair kit (for o---ring) no. 02250048---362; repair kit
(for piston) no. 02250051---338.
(IV) For maintenance on separator, order replacement element no. 250034---114.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

59
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.7 DISCHARGE SYSTEM

3 TO AIR
11 FILTER
9 TO SOLENOID
VALVE 4
10 12 13
9
8 14
4 13
4 17 15
2 7
54 1
6
3 21 18 16
22
23 19
5
20
4

25 11

12
24
4
30 13
43
26

SUPERVISOR II
MACHINES TO CONTROL
SYSTEM
48 TO PRIMARY STRAINER
49 45
50 X SEPARATOR 27
51 GAUGE 28
46
45
47
3 44

30
ELECTRO--MECHANICAL 29
MACHINES
38 42
52
X 31
40 39

41 46
47

37 X 32
ELECTRO--MECHANICAL
MACHINES 53
SUPERVISOR II 35
MACHINES 36 34 33

60
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.7 DISCHARGE SYSTEM (CONTINUED)

key part
number description number quantity

31 plug, sight glass 1---5/16”SAE 02250097---610 1

32 valve, ball 3/8”m x 3/8”f nptf 02250100---094 1
33 elbow, 90_ 3/4”SAE x 3/8”f nptf 02250100---093 1
34 capscrew, hex gr5 1/2”---13 x 1---1/4” plated 829108---125 4
35 washer, springlock reg plated 1/2” 837808---125 4
36 plug, straight thread 3/4”---16 SAE viton 250042---623 1
37 gauge, temperature---sump 100_ ---250_ 02250100---096 1
38 switch, temperature 240_ 3/4” SAE 02250100---095 1
39 coupling, conduit 1/2” 250007---179 1
40 elbow, 90_ conduit 1/2” 846600---050 1
41 conduit, csa flex 1/2” 846315---050 2.5 ft.
42 plug, o---ring 1---1/4” 040029 1
43 joint, expansion ls10 unit/tank 02250097---823 1
44 support, tank brace ls10 02250107---906 1
45 capscrew, hex gr5 3/8”---16 x 1” 829106---100 2
46 washer, springlock reg plated 3/8” 837806---094 2
47 nut, hex plated 3/8”---16 825206---337 2
48 adapter, pipe---f 1/2”SAE x 1/4”npt 811504---025 1
49 bushing, reducing 1/4” x 1/8” plated 867100---005 1
50 fitting, compression adjustable 250028---635‘ 1
51 probe, rtd 100 ohm platinum 250039---909 1
52 locknut, conduit 1/2” 847200---050 1
53 plug, pipe 3/8” 3000# steel 807800---015 1
54 orifice, 1/8 m x 1/8 f x .062 224427 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

61
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.8 CONTROL SYSTEM AND ELECTRICAL PARTS

62
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.8 CONTROL SYSTEM AND ELECTRICAL PARTS

key part
number description number quantity

1 tee, tube 1/4” male branch 250028---582 1

2 tubing, nylon 1/4” black 0225054---861 ---
3 strainer, v---type 300 psi x 1/4” npt (I) 241771 1
4 tee, pipe 1/4” male npt 869825---025 2
5 connector, 1/4” tube x 1/4” female npt 250041---084 1
6 nut, hex plated #10---24 825202---130 2
7 washer, springlock reg plated #10 837802---047 2
8 support, bracket pneumatic cntrls 02250104---420 1
9 screw, machine---round #10---24 x 1/2” 831602---050 2
10 bulkhead, pipe 1/4” npt 841500---025 1
11 elbow, 90˚ conduit 1/4 846600---050 1
12 conduit, csa flex 1/2” 846315---050 0.4 ft.
13 nipple, ipe 1/4” hex 868504---025 1
14 elbow, 1/4” tube x 1/4” npt 250018---430 4
15 valve, shuttle 1/4” npt 408893 1
16 valve, pressure regulator (II) 250017---280 1
17 orifice, .040 x 1/4” fnpt x 1/4” mnpt 02250091---395 1
18 switch, pressure (<= 140 psi/ 9.7 bar) 040694 1
Sswitch, pressure (< 140 psi/ 9.7 bar) 407778 1
19 tee, tube 1/4” male run 250038---059 2
20 support, bracket strtr box ls 10 lh 02250106---969 1
21 nut, hex flanged plated 5/16”---18 825305---283 4
22 support, bracket strtr box ls 10 rh 02250104---194 1
23 elbow, 45˚ conduit 1/2” 846500---050 1
24 locknut, conduit seal N4 1/2” 02250071---362 1
25 valve, solenoid 1/4” 3---way
(<= 140 psi/ 9.7 bar) (III) 250038---674 1
Svalve, solenoid 1/4” 3--- way
(> 140 psi/ 9.7 bar) (IV) 250038---675 1
26 elbow, 45˚conduit1/2” 846500---050 1
27 nipple, chase 1/2” 847815---050 1
28 box, electrical strtr ls 10 consult factory 1

(Continued on page 65)

(I) For maintenance on strainer no. 241771, order repair kit no. 241772.
(II) For maintenance on pressure regulator valve no. 250017---280, order repair kit no. 250019---453.
(III) For maintenance on solenoid valve no. 250038---674, order repair kit no. 250038---673, and replacement
coil no. 250031---772.
(IV) For maintenance on solenoid valve no. 250038---675, order repair kit no. 02250055---939, and replace-
ment coil no. 250038---730.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

63
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.8 CONTROL SYSTEM AND ELECTRICAL PARTS

64
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.8 CONTROL SYSTEM AND ELECTRICAL PARTS (CONTINUED)

key part
number description number quantity

29 nut, hex metric m4 x 0.7 825904---070 8

30 decal, instrument panel e/m dc 02250105---186 1
31 panel, elec/instrument e/m dc 02250105---187 1
32 hourmeter, 2 1/2” 120v 60 hz 042988 1
Shourmeter 2 1/2” 110v 50hz 250042---010 1
33 gasket, hourmeter 410353 1
34 light, unit f.v. 120c 250027---122 2
35 gasket, panel Supervisor II 02250048---822 1
36 switch, pushbutton green no N4 250016---351 1
37 switch, operator selector 2---position 250034---647 1
38 controller, Supervisor II dlx 02250048---822 1
39 switch, emergency shut---off 02250085---504 1
40 washer, springlock m4 838804---090 8
41 lens, indicating light green 250028---129 1
42 lens, indicating light red 250028---128 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

65
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.9 INSTRUMENT PANEL

66
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.9 INSTRUMENT PANEL

key part
number description number quantity

1 elbow, 90_ 1/4”t x 1/8” female npt 250041---286 2

2 tubing, nylon 1/4” black 02250054---861 ---
3 connector, tube---f 1/4”t x 1/8”p stainless steel 250139---050 2
4 tubing, stainless steel 1/4” 20ga 841215---004 ---
5 tee, adaptor 1/4”t x 1/8”m x 1/8”f 869704---012 1
6 elbow, tube---f 1/4”t x 1/8”p stainless steel 250211---030 1
7 connector, female 1/4”t x 1/8”npt 250021---379 1
8 panel, mounting gauge e/mdc 02250104---355 1
9 decal, instrument panel 10 series universal 02250060---034 1
10 gauge, differential pressure 0---30psi 250003---799 1
11 gauge, temperature 100_ ---250_F---3/4” SAE 02250100---096 1
12 gauge, differential pressure 0---15psi 250003---798 1
13 gauge, pressure 2” dia 0---230# 250005---185 2
14 nut, hex flanged plated 5/16”---18 825305---283 2

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

67
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.10 ENCLOSURE

30 5 15
11 1

14
13
7
12
2
10 2
9

4 7 2
2 6
12 18
WATER COOLED MACHINES 21
9
6

7 18
7

19 31
5 5

5
27
AIR COOLED 20
MACHINES 25
5
30 7

18 8 19
8
26
18 8
3
5
24
28
20
12 16
29
11 21
17
23 22

68
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.10 ENCLOSURE
key part
number description number quantity

1 panel, roof ls10 250018---316 2

2 panel, fiberglass 5” x 35---1/2” 4
3 connector, tube---f ¼”t x 1/8”p stainless steel 242095 1
4 nut, retainer “j” 5/16”---18 861505---140 14
5 screw, ser washer 5/16” x ¾” 829705---075 40
screw, ser washer 5/16” x ¾” 829705---075 36
6 panel, access 014620 2
7 panel, fiberglass 15---1/4” x 32---1/2” 4
8 weatherstrip, felt 02250058---345 75
9 panel, enclosure center 224585 3
10 guard, fan 13” 241579 1
11 washer, springlock reg plated ¼”(ac) 837804---062 8
washer, springlock reg plated ¼”(wc) 837804---062 12
12 capscrew, hex gr5 ¼”---20 x 1”(ac) 829104---100 8
capscrew, hex gr5 ¼”---20 x 1”(wc) 829104---100 12
13 panel, wc end 02250043---677 1
14 fan, enclosure wc 241580 1
15 nut, hex plated ¼”---20 825204---226 4
16 rivet, tubular ¼”---20 049824 8
17 nut, hex plated ½”---13 825208---448 4
18 panel, fiberglass 13” x 36---1/2” 250020---059 4
19 panel, enclosure – right hand corner 224583 2
20 nut, hex ser washer 5/16”---18 plated 825305---283 28
nut, hex ser washer 5/16”---18 plated 825305---283 24
21 panel, enclosure---left hand corner 224584 2
22 frame, enclosure---sub 014790 1
23 panel, cooler end(ac) 02250105---122 1
24 clamp, wire 043194 4
25 latch, door black 02250094---632 4
26 panel, access front 02250105---123 1
27 panel, enclosure instrument access(e/m dc) 02250104---191 1
panel, enclosure center(supervisor) 224585 1
28 capscrew, hex gr5 pltd ½”---13 x 1---1/2” 829108---150 4
29 washer, springlock reg plated ½” 837808---125 4
30 nut, retainer 5/16”---18 861405---092 4
31 panel, fiberglass 250034---038 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

69
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.11 DECAL GROUP

2 1 3

4
9

7 8

10

11

70
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.11 DECAL GROUP

key part
number description number quantity

1 decal, fork lifting 241814 4

2 decal, electrical component 250038---457 1
3 sign, warning sever fan 049855 2
4 sign, warning sever fan port 049965 1
5 sign, danger electrocution 049850 1
6 decal, warning auto start 041065 1
7 decal, 460 voltage international (I) 02250069---399 1
8 decal, earth ground 02250075---046 1
9 decal, warning ground fault 049852 1
10 decal, water drain 250022---810 1
11 decal, LS---10 2” high 02250060---916 1

(Continued on page 73)

(I) Compressor voltage may vary. Consult Factory with machine serial number.

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

71
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.11 DECAL GROUP

12

14
13

15

17

18

16

19

20

72
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.11 DECAL GROUP (CONTINUED)

key part
number description number quantity

12 sign, warning “food grade” lube 250003---144 1

13 sign, danger air breathing 250027---935 1
14 sign, warning compressor fluid fill cap 049685 1
15 decal, compressor fluid Sullube 32 250023---361 1
16 decal, SRF 1/4000 fluid 250022---839 1
17 decal, danger high voltage 042218 1
18 decal, “water in” 250019---107 1
19 decal, “water out” 250019---108 1
20 decal, water inlet/outlet 049873 1

(Continued on page 75)

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

73
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.11 DECAL GROUP

21
22

23

24

25

26

27

74
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.11 DECAL GROUP (CONTINUED)

key part
number description number quantity

21 decal, ground lug 045433 1

22 decal, Sullube 250009---383 1
23 decal, SRF 1/4000 logo 250021---483 1
24 decal, compressor lubricant 046540 1
25 decal, 24 KT 02250061---016 1
26 decal, ISO 9001 02250057---624 1
27 decal, Sullair 02250059---054 2

(Continued on page 77)

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

75
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.11 DECAL GROUP

FULL

28

29 ADD

30

31

76
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.11 DECAL GROUP (CONTINUED)

key part
number description number quantity

28 decal, fluid sample 250022---675 1

29 decal, gauge fluid level 250020---730 1
30 decal, warning auto start 250017---903 1
31 decal, electrocution hazard international 02250077---472 1
32 plate, rotation arrow (not shown) 02250057---737 1
33 decal, instrument pnl
universal (not shown) 02250051---301 1
34 decal, instument pnl
universal (not shown) 02250051---303 1
35 decal, instrument pnl
universal---dual cntrl (not shown) 02250059---410 1
36 decal, instrument pnl 10 Series
universal (see Section 8.9) 02250060---034 1

PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR

77
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.12 WIRING DIAGRAM -- ELECTRO/MECHANICAL (AIR-- COOLED/WATER-- COOLED)

78
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.13 WIRING DIAGRAM -- SUPERVISOR II DELUXE (AIR-- COOLED/WATER-- COOLED)

79
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.14 WIRING DIAGRAM -- WYE-- DELTA ELECTRO/MECHANICAL (AIR-- COOLED/WATER-- COOLED)

80
 Section 8
ILLUSTRATIONS AND PARTS LIST

8.15 WIRING DIAGRAM -- WYE-- DELTA SUPERVISOR II DELUXE (AIR-- COOLED/WATER-- COOLED)

81
NOTES
NOTES
WORLDWIDE SALES AND SERVICE

SULLAIR ASIA, LTD. SULLAIR EUROPE, S.A.

Sullair Road, No. 1 Zone Des Granges BP 82
Chiwan, Shekou 42602 Montbrison Cedex, France
Shenzhen, Guangdong PRV. Telephone: 33-- 477968470
PRC POST CODE 518068 Fax: 33 -- 477968499
Telephone: 755-- 6851686
Fax: 755 -- 6853473

SULLAIR CORPORATION
Subsidiary of Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 1-- 219-- 879-- 5451
Fax: (219) 874 -- 1273
Fax: (219) 874-- 1835 (Parts)
Fax: (219) 874-- 1288 (Service)

Printed in U.S.A.
Specifications Subject To
Change Without Prior Notice
E98