Sullair Compressor Manual LS25S (EN)

STATIONARY AIR COMPRESSOR
OPERATION & MAINTENANCE MANUAL
NEW LS25S-250/300/350
STATIONARY SCREW COMPRESSOR
OPERATION & MAINTENANCE MANUAL
LS25S-250/300/350
(Generation II Model)
SHENZHEN SULLAIR ASIA INDUSTRIAL CO., LTD.
P/N: 88290016-736
Rev. 00, January 2008
Thank you very much for purchasing and using
stationary screw compressors manufactured by
Sullair Asia
We hope that our stationary screw compressors of all the sizes will play the
expected role in your work.
Please read through this manual carefully before you and your employees
operate and maintain the stationary screw compressors.
Sullair Asia reserves the right to make continuous research and improvement
on its products, and has no obligations of modifying and improving the
products delivered by it before.
Compressor Model:
Compressor Serial Number:
PREFACE
This operation and maintenance manual describes in detail the safety precautions,
structural functions of each system and component, and operation & maintenance method
for the 2nd generation of LS25S series stationary screw compressors designed and
manufactured by Shenzhen Sullair Asia.
The compressor should be operated only by those who have been trained and delegated
to do so, and who have read and understood this Operator’s Manual. Failure to follow the
instructions, procedures and safety precautions in this manual can result in accidents and
injuries. Read this manual prior to startup.
This manual doesn’t include illustration and parts list. If you need to order parts to our
company, please consult for the parts list manual (88290016-737).Please note that Shenzhen
Sullair Asia makes continuous product research and improvement. There may be some
changes in the content of the manual and actual products after certain days. Please verify it
before ordering with the Aftermarket Dept. of Sullair first.
While there are inquiries which are not mentioned in this manual, please contact the
local Sullair distributor, or directly contact Sullair Asia branch or Aftermarket Dept. of
Sullair Asia listed in the back cover of this manual.
--- Editor
January 2008
ＴＡＢＬＥＯＦＣＯＮＴＥＮＴＳ
Chapter I Safety.............................................................................................................................. 1
1.1 General ........................................................................................................................... 1
1.2 Personal protective equipment ....................................................................................... 1
1.3 Fire and explosion .......................................................................................................... 1
1.4 Moving parts .................................................................................................................. 2
1.5 Hot surfaces, sharp edges and sharp corners:................................................................. 2
1.6 Toxic and Irritating substances: ..................................................................................... 2
1.7 Electrical shock .............................................................................................................. 3
1.8 High-voltage protection (for high-voltage machine) ..................................................... 3
1.9 Lifting............................................................................................................................. 4
1.10 Other precautions ......................................................................................................... 4
Chapter II Compressor Structure.................................................................................................... 5
2.1 General ........................................................................................................................... 5
2.2 Inlet system .................................................................................................................. 13
2.3 Discharge system.......................................................................................................... 13
2.4 Fluid piping system ...................................................................................................... 14
2.5 Air/fluid separator ........................................................................................................ 15
2.6 Air-cooling system (air-cooled machine only)............................................................. 15
2.7 Water piping system (water-cooled machine only)...................................................... 16
2.8 Air volume adjustment system..................................................................................... 17
2.9 Microprocessor controller ............................................................................................ 18
Chapter III Installation of Compressor ........................................................................................ 19
3.1 Frame............................................................................................................................ 19
3.2 Vibration absorption and noise reduction .................................................................... 19
3.3 Equipment room environment...................................................................................... 19
3.4 Dimension and mounting illustration........................................................................... 19
3.5 Installation.................................................................................................................... 19
3.6 Remove transportation support parts (air-cooled machine only) ................................. 19
3.7 Motor rotation direction check..................................................................................... 20
Chapter IV Compressor Operation............................................................................................... 25
4.1 Safety operation procedure .......................................................................................... 25
4.2 Preparation before initial starting................................................................................. 25
4.3 Normal operation.......................................................................................................... 25
4.4 Shutdown procedure..................................................................................................... 25
Chapter V Maintenance and Service ............................................................................................ 26
5.1 General ......................................................................................................................... 26
5.2 Daily operation............................................................................................................. 26
5.3 Maintenance after initial 50 hours of operation ........................................................... 26
5.4 Maintenance every 1000 hours of operation ................................................................ 26
5.5 Lube fluid replacement................................................................................................. 26
5.6 Maintenance of fluid filter............................................................................................ 27
5.7 Maintenance of air filter............................................................................................... 28
5.8 Maintenance of air/fluid separator ............................................................................... 29
5.9 Maintenance of pressure regulator ............................................................................... 30
5.10 Maintenance of Minimum pressure valve.................................................................. 30
5.11 Maintenance of vent valve ......................................................................................... 31
5.12 Maintenance of control pipe filter.............................................................................. 32
5.13 Maintenance of solenoid ............................................................................................ 32
5.14 Disassemble and maintenance of coupling ................................................................ 33
5.15 Maintenance of VVVF ............................................................................................... 35
5.16 Maintenance of Sullair compressor specific motor.................................................... 35
5.17 Maintenance of acid removal filter (only for SULLUBE unit).................................. 38
Chapter VI Schematics................................................................................................................. 39
6.1 Air-cooled machine wiring diagram - Low-voltage (Deluxe Microprocessor Controller
I) ............................................................................................................................................ 39
6.2 Wiring Diagram between high voltage starter and low voltage starter........................ 41
6.3 Air-cooled machine wiring diagram –high -voltage (Deluxe Microprocessor Controller
I) ............................................................................................................................................ 42
6.4 Water-cooled machine wiring diagram - Low-voltage (Deluxe Microprocessor
Controller I)........................................................................................................................... 45
6.5 Water-cooled machine wiring diagram – High-voltage (Deluxe Microprocessor
Controller I)........................................................................................................................... 46
Chapter VII Troubleshooting ....................................................................................................... 49
7.1 General ......................................................................................................................... 49
7.2 Troubleshooting are listed in the following table ........................................................ 49
7.3 Transmitter operation description and controller parameter calibration - Deluxe
Microprocessor Controller I .................................................................................................. 50
7.4 Transmitter operation description and controller parameter calibration – Sullair
Supervisor II.......................................................................................................................... 51
Chapter VIII Parts Order .............................................................................................................. 52
LS25S-250/300/350 Series Screw Compressor Operator’s Manual Chapter I Safety
Chapter I Safety
1.1 General
Sullair Corporation and its subsidiaries design and manufacture all of their products so they can be
operated safely. However, the responsibility for safe operation rests with those who use and maintain
these products. The following precautions are offered as a guide which, if conscientiously followed, will
minimize the possibility of accidents throughout the useful life of this equipment.
The compressor should be operated only by those who have been trained and delegated to do so, and who
have thoroughly read and understood this operator’s manual. Failure to follow the instructions,
procedures and safety precautions in this manual can result in accidents and injuries. Read this manual
prior to startup.
NEVER start the compressor unless it is safe to do so. DO NOT attempt to operate this compressor with
a known unsafe condition. Install, use and operate the compressor only in full compliance with all
pertinent regulations and all applicable Federal, State and Local codes, standards and regulations.
Do not modify the compressor and/or controls in anyway except with written factory of approval.
1.2 Personal protective equipment
Prior to installing or operating the compressor, owners, employers and users should become familiar with,
and comply with, all applicable regulations and any applicable national and local laws, standards and
regulations relative to personal protective equipment, such as eye and face protective equipment,
respiratory protective equipment, equipment intended to protect the extremities, protective clothing,
protective shields ad barriers and electrical protective equipment, as well as noise exposure
administrative and/or engineering controls and/or personal hearing protective equipment.
1.3 Fire and explosion

A. Clean up spills of fluid or other combustible substances immediately, if such spills occur.
B. Shut off the compressor and allows it to cool. Then keep sparks, flames and other sources of
ignition away and Do Not permit smoking in the vicinity when checking or adding fluid or when refilling
air line anti-icier systems with antifreeze compound.
C. Do not permit fluids, including airline anti-icier system antifreeze compound or fluid film to
accumulate on, under, or around acoustical material, or on any external surfaces of the air compressor or
on internal surfaces of the enclosure. Wipe down using an aqueous industrial cleaner or steam-clean as
required. If necessary, remove acoustical material, clean all surfaces and then replace acoustical material.
Any acoustical material with a protective covering that has been torn or punctured should be replaced
immediately to prevent accumulation of liquids or fluid film within the material. Do not use flammable
solvents for cleaning
D. Disconnect and lock out all power at source prior to attempting any repairs or cleaning of the
compressor or of the inside of the enclosure, if any.
E. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace
any wiring that has cracked, cut abraded or otherwise degraded insulation, or terminals that are worn,
discolored or corroded. Keep all terminals and pressure connectors clean and tight.
F. Keep grounded and/or conductive objects such as tools away from exposed live electrical parts
such as terminals to avoid arcing, which may serve as a source of ignition.
G. Remove any acoustical material or other material that may be damaged by heat or that may support
1
combustion and is in close proximity, prior to attempting weld repairs.
H. Keep suitable fully charged fire extinguisher or extinguishers nearby when servicing and operating
the compressor.
I. Keep fluidly rags, leaves, litter or other combustibles out of and away from the compressor.
J. Do not operate the compressor without proper flow of cooling air or water or with inadequate flow
of fluid or with degraded lubricant.
K. Do not attempt to operate the compressor in any classification of hazardous environment unless the
compressor has been specially designed and manufactured for that duty.
1.4 Moving parts

A. Keep hands, arms and other parts of the body and also clothing away from couplings, fans and other
moving parts.
B. Do not attempt to operate the compressor with the fan, coupling or other guards removed.
C. Wear snug-fitting clothing and confine long hair when working around this compressor, especially
when exposed to hot or moving parts.
D. Keep access doors, if any, closed except when making repairs or adjustment.
E. Make sure all personnel are out of and/or clear of the compressor prior to attempting to start or
operate it.
F. Disconnect and lock out all power at source and verify at the compressor that all circuits are de-
energized to minimize the possibility of accidental start-up or operation, prior to attempting repairs
or adjustments. This is especially important when compressor is remotely controlled.
G. Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water, or other liquids
to minimize the possibility of slips and falls.
1.5 Hot surfaces, sharp edges and sharp corners:

A. Avoid bodily contact with hot fluid, hot coolant, hot surfaces and sharp edges and corners.
B. Keep all parts of the body away from all points of air discharge.
C. Wear personal protective equipment including gloves and head covering when working in, or around
the compressor.
D. Keep a first aid kit handy. Seek medical assistance promptly in case of injury. Do not ignore small
cuts and burns as they may lead to infection.
1.6 Toxic and Irritating substances:

A. Do not use air from this compressor for respiration (breathing) except in full compliance with any
national or local regulations and laws.
B. Operate the compressor only in open or adequately ventilate areas.
C. Locate the compressor so that there is no toxic or irritating substances in the vicinity around the
compressor.
D. Coolants and fluids used in this compressor are typical of the industry. Care should be taken to the
event of ingestion, seek medical treatment promptly. Wash with soap and water in the event of skin
contact.
2
1.7 Electrical shock

A. Besides the Electrical shock precautions specified in this paragraph 1.7, national and local laws,
regulations, ordinates and codes on Electrical shock should also be complied with. Electrical shock codes
and post responsibility mechanism for specific situations should also be enacted.
B. The installation and operation should follow national and local laws, standards and regulations
(including national electric codes and other regulations on safe grounding). It should be carried out by
qualified person.
C. Electric working site should be clean, dry and well lighted. Insulation boots and gloves must be
provided. Arrange dry rubber blanket and insulation lectern on the ground.
D. The selection of machine power supply breaker provided by user and the integration of various
protection current coefficients should be based on actual machine capacity. Sufficient electric insulation
gap should be provided between power terminals.
E. Cable distribution, servicing and maintenance may only be carried out when power supply is
disconnected and compressor is not powered on. Meanwhile service warning mark and other procedures
to prevent switch closing should be prepared.
F. Each machine should be properly grounded. Ground line should firmly connect to the ground pole in
power distribution cubicle. Ground line between the terminal of user side and the grounding pole of
distribution cubicle should be free of splitting, damage or patching. Ground line of each machine should
be connected to the ground terminal of user side separately with impedance less than 4 ohms.
G. Do not put your hand or other objects into the inlet/discharge ports to avoid electric shock.
H. Do not remove or damage the electric protection devices, such as protection cover inside the
distribution cubicle.
I. Electric components or devices to be replaced or removed by user must be provided or certified by
Sullair.
J. If user needs to modify schematic or wiring, it must be approved by Sullair before implementation.
K. Once installation is completed, please dehumidify and test all electric circuits before starting the
compressor.
L. Fire extinguisher should be suitable for electric (including rotating motor) and fluid equipment.
Corresponding Personal should be familiar with the operation of fire extinguishing equipment and the
fire fighting programs of electric devices.
M. The power distribution cubicle of air compressor room should be placed well away from the
equipment and near janitor's room and the exit to cut off power supply in emergency.
1.8 High-voltage protection (for high-voltage machine)

A. The requirements in 1.7 Electrical shocks also apply to high-voltage machine.
B. The selection, cabling and wiring of high-voltage machine's power cable must comply with and be
approved by the regulations of local electric authorities.
C. The electric protection equipment of high-voltage power distribution cubicle should be sufficient
and in good condition. Reasonable protection integration coefficient should be given. The design and
production of high-voltage distribution cubicle interface should comply with relevant requirement of
Sullair.
D. Each high-voltage motor should be equipped with separate ground line with line impedance less
than 0.1 ohm. Grounding impedance should be less than 0.5 ohm.
E. Do not touch the insulation part and enclosure of high-voltage motor while it is powered on. If
online test is required for high-voltage motor, it should be carried out by authorized Personal.
3
F. When the machine is stopped, the High-voltage Closing Allow handle must be rotated to "Closing
Forbidden".
G. To service the machine, the High-voltage Closing Allow handle must be rotated to "Closing
Forbidden". Press emergency stop switch to cut off power supply to high-voltage motor. Take procedures
to lock the handle in corresponding high-voltage cubicle and set obvious service warning marks.
H. The janitor of air compressor and janitor of high-voltage room should keep good communication.
In case of high-voltage motor fault or unable to stop the machine, janitor of high-voltage room should be
informed in time.
I. Accident Break button should be provided in compressor janitor room to bread the high-voltage
switch in case of motor fault.
1.9 Lifting
A. Air-cooled all-in-one machine is equipped with flexible lug pole. Pull the lug pole to its extremity
before hoisting. After hoisting, return the pole back and lock. Please comply with governmental and local
regulations and relevant laws under any circumstances.
B. Check connection parts before hoisting. See if there is crevice in weld. See if there is crevice,
deformation or erosion on parts. See if bolt and nut are loose.
C. For air-cooled all-in-one machine, make sure compressor air-end strut is securely fastened.
D. Lug hook should be equipped with safe buckle to securely fasten the lug pole during hoisting.
E. Drag the machine with rope to avoid hoisted machine revolve or swing. Do not hoist in strong wind.
F. No person is allowed under hoisted compressor. Hoist operator should not leave the site.
G. If a forklift is used for transporting, the forklift hole should be used. Make sure the folk is secure
and leaning backward.
H. If a trailer is used for transporting, hold the compressor with bolts or other means to avoid accident
in case of bumping road or machine stop.
1.10 Other precautions

A. If the compressor enclosure is large enough to hold a person and if it is necessary to enter it to
perform service adjustments, inform other persons before doing so, or else secure and tag the access
door in the open position to avoid the possibility of others closing and possibly latching the door
with personal inside.
B. Make sure all personnel are out of compressor before closing and latching enclosure doors.
4
LS25S-250/300/350 Series Screw Compressor Operator’s Manual Chapter II Compressor Structure
Chapter II Compressor Structure
2.1 General
The machine is a single stage stationary rotary screw compressor for power applications. It features fluid
injection, air/water-cooling, motor driven and low noise. The machine is composed of air-end, motor,
air/fluid separator, fluid cooler, after cooler and machine base, etc., enclosed in a soundproof enclosure.
Electric control cubicle is mounted on one side of the enclosure. The structure is compact, elegant and
convenient for service.
There are two structures, i.e. air-cooled and water-cooled. Customer may choose according to field
requirement.
Machine specifications are listed in Table. 1.
Table 1 Major compressor specifications (standard configuration)
Model 250L 250H 250HH 300L 300H 300HH 300XH 350L 350H 350HH 350XH
Nominal capacity 35 31.7 27.6 41.8 38.6 33.8 29.6 48 44.6 41 32.5
m3/min (CFM) (1236.7) (1120) (975) (1475) (1363.9) (1194.3) (1046) (1696) (1576) (1447) (1175)
Rated pressure
bar (psi) 7.0(100) 8.0(115) 10(140) 7.0(100) 8.0(115) 10(140) 12(175) 7.0(100) 8.0(115) 10(140) 12(175)
Safety valve open

pressure bar (psi) 9.0(130) 10(145) 12(175) 9.0(130) 10(145) 12(175) 14(200) 9.0(130) 10(145) 12(175) 14(200)
5920(13050)(380V air-
6190(13650)(380V air-cooled) 6300(13900)(380V air-cooled)
cooled)
4800(10580)(380V water-
5050(11130)(380V water-cooled) 5200(11460)(380V water-cooled)
cooled)
6640(14638)(6kV air-cooled)
Weight kg(Lb)
5400(11905)(6kV water-cooled)
6600(14550)(10kV water-cooled)
4200x2210x2200(380V/6kV air-cooled)
3265x2210x2200(380V/6kV water-cooled)
LxWxH mm
4000x2210x2200(10kV water-cooled)
Compressor air-end
Type Fluid injection double rotary screw compressor
Configuration Single stage gear transmission
Bearing Wear resistant
Lube fluid brand Sullube32 or 24KT
Lube fluid capacity (L) 155
Motor
Rated power HP 250 300 350
Rated RPM 1487 1487 1487
Voltage/Frequency 380V/50Hz, 6kV/50Hz, 10kV/50Hz
Application coefficient 1.15
Ambient temperature ℃ ≤40
Starting mode Y-△start/full-voltage start
5
Figure 1 - LS25S-250/300/350 (380V/6kV ODP) air-cooled machine layout

Figure 2 - LS25S-250/300/350 (380V/6kV ODP) water-cooled machine layout
Figure 3 - LS25S-250/300/350 (6KV/10kV TEFC) air-cooled machine layout
Figure 4 - LS25S-250/300/350 (6KV/10kV TEFC) water-cooled machine layout
Figure 5 - LS25S-250/300/350 air-cooled machine system flowchart
Figure 6 - LS25S-250/300/350 water-cooled machine system flowchart
A pair of preciously manufactured rotors engaged with each other is built in the compressor unit, and the
male rotor with four teeth is driven through a flexible coupling at high speed by the motor, while the
male rotor drives the female rotor with six teeth. With decreasing volume of the enclosure between the
teeth, air from the air filter is pressurized due to compression until it is discharged when the enclosure is
open to the discharge outlet. The compressed air then goes through the separator, and then the minimum
pressure valve, after cooler and moisture separator in turn, before discharged to the service line for use.
The fluid separated subsides at the bottom of the separator and is brought back to the compressor under
pressure differential for recycling use.
6
AIR OUT AIR IN

12 13 14 15
←
←
←
←
←
←
Compressed Air
←
2200
AIR IN
←
10 08 04
06 03 02 01
09 07 05
11
OIL OUT
2210
OIL IN
4,200
Figure 1 - LS25S-250/300/350 (380V/6kV ODP) Air-cooled Compressor Installation Illustration

01. Motor 02. Frame
03. Vibration absorber 04. Compressor/Motor Frame
05. Starter 06. Coupling
07. Air filter 08. Air-end
09. Air/fluid separator 10. Air/fluid cooler
11. Drain valve 12. Fan motor
13. Inlet valve 14. Minimum pressure valve
15. Safety valve
7
11 12 AIR OUT 13 15 16 17 AIR IN
←
←
←
←
←
EXHAUST AIR
2,200
08 14 07 06 04 03 02 01
09
456
WATER IN/OUT
←
2,210
DRAIN OUT
3,265
Figure 2 - LS25S-250/300/350 (380V/6Kv ODP) Water-Cooled Compressor Installation

Illustration
01. Motor 02. Frame 03. Starter 04. Coupling 05. Fluid cooler
06. Air filter 07. Air/fluid separator 08. Air-end 09.Canopy
10. Fluid filter 11. Inlet valve 12. Minimum pressure valve 13. Ventilation fan
14. Safety valve 15. Thermal valve 16. After cooler 17. Drain valve
8
← 10 11 12 13
←
←
←
←
← Compressed Air
2200
08 06
09 04 02 01
07 05 03
OIL OUT
2210
OIL IN
4750
Figure 3 - LS25S-250/300/350 (6 kV /10kV TEFC) air-cooled machine layout
01. Motor 02. Machine base 03. Starter 04. Coupling

05. Air filter 06. Air-end 07. Air/fluid separator 08. Air/fluid cooler 09. Drain valve
10. Fan motor 11. Minimum pressure valve 12. Inlet valve 13. Safety valve
9
11 12 13 16 17
←
←
←
←
←
08 07 14 15 06 06 04 03 02 01
09
10
←
Figure 4 - LS25S-250/300/350 (6 kV /10kV TEFC) water-cooled machine layout
01. Motor 02. Machine Frame 03. Starter 04. Coupling

05. Fluid cooler 06. Air filter 07. Air/fluid separator 08. Air-end 09. Canopy
10. Fluid filter 11. Inlet valve 12. Minimum pressure valve 13. Ventilation fan
14. Safety valve 15. Thermal valve 16. After cooler 17. Drain valve
10
NOTE:
PLEASE REFER TO ORDER
TO SET P2 VALUE
8 1/4”Tube F
A 18 P2
26 YV4 8
2
3
1/4”Tube
32 9
32
1
YV2 24
10
1/4”Tube
5 7
1 17 Air Outlet
IN 1/2”Tube
YV1 2 3 P
36 35 20
30
1
P 3/4”Tube Water Drain
38 37 13
39 12 1/4”Tube
11 1/4”Tube
be
13
1/4”Tube
Tu
14 12
37
4”
11
1/
NOTES:
LS25S-250/300/350 Series Screw Compressor Operator’s Manual
15
1/2”Tube
1.Parts Numbers are for reference only.Refer
。
TEMP. Setpoint 113 C TEMP. Setpoint to BOM and/or face of order for actual parts.
29 18 P1 。
22 16 T1 113 C
3 T2 16
25
2 6 27 L
4 G G
28 Spiral Valve(Optional)
Vaccum OIL PIPE
560mmH2O 1 F
18 1-1/2”Tube 23 OIL/AIR MIX PIPE
P3 YV3 AIR PIPE
Pressure Setpoint Min 0.07MPa 24 CONTROL PIPE
Air Inlet 31 3
16 T3 DP Setpoint 0.14MPa
1 WATER PIPE
2 4
34
Figure 5 - LS25S-250/300/350 air-cooled system flow chart

21
P4
18
NOTE:
PLEASE REFER TO ORDER
TO SET P2 VALUE
A 8 1/4”TUBE F
18 P2
26 YV4 8
2
3
32 9
1/4”TUBE
1
32 YV2 24
1/4”TUBE
5 10
7 1/2”TUBE
17 AIR OUT
1 IN
YV1 2 3
P
36 35 20
30
1
P 3/4”TUBE
DRAIN COND.
39 37 12 13
40 1/4”TUBE
11 13 1/4”TUBE
1/4”TUBE
14 12
37
15
1/2”TUBE
TEMP. SETPOINT PRESS SETPOINT
113℃ TEMP. SETPOINT 0.07MPa
18 P1
12
22 16 T1 113℃
19
3 T2 16
25
2 6 27 L
4 G
28
VACUUM ALARM
41 WATER IN
SETPOINT 560mmH2O 18 * 1-1/2”TUBE B A G1-1/2 PIPE
P3
C H I
1 PRESS SETPOINT 31 42
AIR INLET 0.07MPa 16 T3 SET @ 0.14MPa
WATER OUT
P4 G1-1/2 PIPE
G WATER SOLENOID ** 18
ELEC. DRAIN
VALVE(OPTION) NOTES:
F (OPTION)
YV6 OIL PIPE 1.PART NUMBERS ARE FOR REFERENCE ONLY,REFER TO BILL
Figure 6 - LS25S-250/300/350 water-cooled system flow chart

23 43 OF MATERIAL AND FACE OF ORDER FOR ACTUAL PARTS.
YV3 OIL/AIR MIX PIPE
2.SECTION BETWEEN LETTERED PIONTS ARE TO BE REPLACED
H I AIR PIPE WITH CORRESPONDING OPTION, PICTURED BELOW AS
3 1 CONTROL PIPE REQUIRED BY FACE OF ORDER.
2 4 3.MARK'*'INDICATED PARTS MATCH SUPERVISOR II.
WATER PIPE MARK'**'INDICATED PARTS MATCH SUPERVISOR II DELUXE.
34 21
2.2 Inlet system

2.2.1 Operation of inlet system.
Inlet system consists of air filter, inlet valve, compressor air-end and elbow, connection pipe, etc.
During operation of machine, the air intakes from the air filter to the compressor enters the compressor
unit through open butterfly valve after being filtrated. It is compressed by male/female rotors rotate at
high speed, and the air pressure will rise. The compressed air is discharged for use when the enclosure
between teeth is open to outlet.
2.2.2 Air filter
Air filter keeps inlet air clean by filtration. Any foreign material contained in the air inlet will cause
accelerating wear and tear of the rotor contours and contaminate the fluid.
2.2.3 Inlet valve
Butterfly valve functions to regulate the amount of air intake to the compressor. The butterfly valve is
fully opened as the compressor unit operates in full-load condition. When air demand decreases, the air-
modulating device will reduce openness of the butterfly valve to reduce the amount of air intake. When
there is no need of air inlet, the butterfly valve is fully closed, and the compressor runs in unload mode.
2.3 Discharge system

2.3.1 Operation of discharge system
The discharge system consists of compressor unit, fluid/air separator, minimum pressure valve, blow-
down valve, pressure relief valve, after cooler, moisture separator and interconnections.
The compressed air/fluid mixture enters the separator through the check valve. Clean compressed air is
obtained after separated from the fluid.
The compressed air then enters, through minimum pressure valve, after cooler and moisture separator.
The after cooler lowers the temperature of the hot air down to normal temperature. The moisture
separator separates condensed water from the compressed air and discharges the water outside the
machine.
There is a spare flange of Rc4 external threads fixed at one end of the moisture separator. Prior to
operation of this machine, a piece ofφ114×6 seamless steel pipe with one end R4 taper threaded should
be prepared beforehand and used to direct the compressed air outside the machine. The user according to
specific requirements may determine the length of the steel pipe.
The user on the external line should be equipped with a check valve.
2.3.2 Minimum pressure valve
The minimum pressure valve, located on top cover of the separator, is to keep the pressure within the
separator no lower than 0.34 Mpa so that the fluid runs normally in the fluid pipes and the fluid
consumption is reduced. The minimum pressure valve does not open until the pressure within the
separator is higher than 0.34 Mpa. This valve also acts as a check valve when the compressor unit
operates in connection with other units. The compressed air in the pipelines is prevented from flowing
back into the separator or compressor unit during offload operation of the compressor unit.
2.3.3 Automatic blow down valve
The blow-down valve, located near the minimum pressure valve, opens automatically when the
compressor is unloaded or shut down, to discharge the air and relieve the sump pressure. There are two
silencers attached on the blow-down valve to lower the noise.
2.3.4 Drain valve
Drain valve is used to separate condensed water from compressed air, and drain the water out off the
13
machine through a plastic hose. Operator should observe regularly. Generally more water is drained in
summer due to higher temperature and humidity. Less water is drained in winter due to lower
temperature and humidity. If no water is observed, it means that the dispersion valve is clogged up and
should be removed and cleaned.
2.3.5 Safety valve
A safety valve is equipped on air/fluid separator. When pressure in separator exceeds threshold, safety
valve will open to discharge pressure and make sure the machine is safe.
The machine also features a high pressure stop switch. When pressure in separator exceeds threshold, the
machine will stop automatically. Therefore safety valve will not open under normal circumstances.
2.4 Fluid piping system

2.4.1 Operation of fluid piping system
Fluid piping system consists of compressor, air/fluid separator, thermal valve (water-cooled machine
only), fluid cooler and fluid filter and connection pipeline.
Lube fluid in air/fluid separator flows into fluid cooler through thermal valve (water-cooled machine
only). Cooled fluid enters air-end working chamber through tee connector and fluid filter. Then it is
compressed along with inlet air and enters air/fluid separator for a complete cycle. Lube fluid serves for
three roles:
(1) Coolant - Lube fluid injected into the machine absorbs large amount of heat generated during
compressing as a coolant.
(2) Lubricant - Lube fluid forms a fluid layer between the rotors, avoiding direct contact between male
and female rotors. Therefore the wear between rotor surfaces is minimized. In addition, lube fluid flows
to lubrication positions through internal fluid way to lubricate bearings and gears.
(3) Sealant - Lube fluid with appropriate viscosity can fill up the gaps between rotors and between rotor
and enclosure. It reduces leakage loss and enhances the cubage efficiency of compressor.
2.4.2 Thermal valve
Thermal valve (water-cooled machine only) adjusts the temperature of injected fluid and prevents water
from being condensed under low temperature, which will cause fluid deterioration.
A normally open bypass valve resides in thermal valve inner chamber. When fluid temperature is low,
thermal valve does not function and lube fluid flows through bypass valve, bypass fluid pipe, tee
connector, fluid filter and enters air-end working chamber without being cooled. When fluid is heated,
thermal valve opens and bypass valve closes gradually. Lube fluid enters fluid cooler. Cooled fluid then
enters air-end working chamber through tee connector and fluid filter.
2.4.3 Fluid filter
Fluid filter clears the impurity in lube fluid and ensures that clean fluid flows to air-end working chamber
and lubrication positions. Impurity in lube fluid will cause wear on rotor/gear engaging surfaces and bear,
and reduces the product life of compressor.
Fluid filter elements should be replaced regularly to ensure fluid circulation in good condition.
Pressure difference transmitter is equipped at the top of fluid filter. If pressure difference between the
two sides of filter element exceeds threshold (0.14MPa), a service signal (FLUID FILTER MAINT
REQD) will be displayed on the monitor to remind operator of filter elements replacement.
2.4.4 Fluid return pipe
Two ways of fluid return pipe on the cap of air/fluid separator. Small amount of fluid on the bottom of
primary filter element and secondary filter element is recycled to compressor through two ways.
Fluid sight glass on fluid return pipe is used by operator to observe fluid return condition. More fluid can
be seen when the compressor is running at full load. Less fluid will be observed when the compressor is
14
unloaded. If no fluid or little fluid is observed at full load, please clean fluid return filter after the
machine is blown down.
2.4.5 Acid removal filter (only for SULLUBE unit)
After out of air/fluid separator, most of SULLUBE lubricant enters fluid cooler while small portion enters the
acid removal filter and the fluid filter via bypass line before directly returning to the working chamber of the
compressor air end.
The acid removal filter is used to filter out the acidic substances in the lubricant to ensure the clean lubricant
enters the working chamber of the air end and each lubrication point. When the content of the acidic substance
in the lubricant reaches certain level, it will cause the acidic property of SULLUBE lubricant, affect the
SULLUBE lubricant performance and service life, corrode the compressor air end, shorten the SULLUBE
lubricant replacement time, and reduce the normal service life of the compressor.
The acid adsorbent of the acid removal filter should be replaced periodically to ensure the acid removal effect
of SULLUBE fluid.
2.5 Air/fluid separator

2.5.1 Function of air/fluid separator
The separator consists of tank and filter elements, which comprise the primary element for rough
separation and final element for refined separation.
The separator has for four functions as explained below:
(1) A primary separator – The air/fluid mixture enters the separator and is directed against the baffle.
The direction of movement is changed and its velocity significantly reduced, thus causing large droplets
of fluid to form and fall to the bottom of separator owing to their gravities.
(2) A fluid sump tank of the compressor: it stores fluid
(3) Mounting of the filter elements. Two filter elements are mounted in the separator, i.e. primary filter
element and secondary filter element.
The fluid is separated from the mixture through the two filter elements. The fractional percentage of the
fluid remaining in the compressed air collected at the bottom of the filter elements as the compressor air
flows through the separator. Two return lines lead from the bottom of the separator elements to the inlet
region of the compressor unit.
(4) To keep stable pressure. There is some amount of air inside the sump tank, which can effectively
keep the pressure in the service pipe from fluctuation, thus, stabilize the pressure.
2.5.2 Filter element replacement
Impurities exist in the fluid piping system. Filter element will be clogged up after a period. Resistance of
filter element to compressed air will increase and machine operation will be compromised. Operator
should replace filter element according to the signal on monitor on time. Note: filter element may not be
repaired.
2.5.3 Fluid fill and sight glass
Fluid fill and sight glass are equipped on the outer side of air/fluid separator.
Since air supply contains fluid more or less, the fluid level of separator will drop and need to be added.
The normal fluid level when compressor is not running should be at the lower center of upper sight glass.
2.6 Air-cooling system (air-cooled machine only)

Air-cooled machine's cooling system includes fluid cooler, after cooler, cooling fan, fan motor and
connection parts.
15
2.6.1 Operation of cooling system
Air-cooled machine equips two fans to cool fluid cooler and after cooler respectively. The motor of the
fan facing fluid cooler is driven by a VVVF, while the other fan motor is driven by utility power supply.
VVVF working procedure is described below. Set required air discharge temperature value. Air
discharge temperature will fluctuate due to the variation of ambient temperature and load. VVVF
automatically adjusts its output frequency based on air discharge temperature to change motor speed,
thus cooling air flux. Air discharge temperature is therefore compensated. Result discharge temperature
will fluctuate within a narrow range around original setting. VVVF plays an important role in the reliable
operation of compressor under various circumstances and load conditions. In case of low fan and motor
speed, VVVF is conducive to noise reduction and energy saving.
If the ambient temperature during unloading operation is low, and air discharge temperature is not
maintained under lowest VVVF frequency output, please contact Sullair after-sales market department or
Sullair dealer.
2.6.2 After cooler
After cooler is a fin/plate heat exchanger used to cool the compressed air.
High temperature/pressure air from Minimum pressure valve enters after cooler and passes large amount
of heat to cooling air. Therefore low temperature compressed air is obtained.
2.6.3 Fluid cooler
Fluid cooler is also a fin/plate heat exchanger which cools the lube fluid.
Lube fluid from air/fluid separator enters fluid cooler and passes some heat to the cooling air, and then
flows to compressor working region.
2.7 Water piping system (water-cooled machine only)

2.7.1Operation of Water piping system
Water piping system includes fluid cooler, after cooler, supporting parts and connection pipeline. Cooling
water enters after cooler first, and then enters fluid cooler before drained out of the machine.
2.7.2 After cooler
After cooler is a tube/shell heat exchanger used to cool the compressed air.
High temperature/pressure air from Minimum pressure valve enters after cooler and passes large amount
of heat to cooling water. Therefore low temperature compressed air is obtained.
2.7.3 Fluid cooler
Fluid cooler is also a tube/shell heat exchanger. It cools the lube fluid. Lube fluid from air/fluid separator
enters fluid cooler through thermal valve and passes some heat to the cooling air, and then flows to
compressor working chamber.
2.7.4 Quality of cooling water
To maintain good heat exchange performance and lifetime of the cooler, clean cooling water must be
used. See the following for specific requirement:
(1) Cooling water should be neutral, i.e. PH value 6.5~9.5.
(2) Organic and suspended mechanical impurities should be less than 25mg/L; fluid content less than
5mg/L.
(3) Temporary hardness≤10° (1°hardness means 10mg CaO or 7.19mg MgO in 1L water).
2.7.5 Water inlet temperature, pressure and consumption
(1) Temperature of cooling water should be ≤30℃. If temperature is above 32℃, water in/out pipe
should be equipped to air cooler and fluid cooled separately instead of serial link;
(2) Water inlet pressure should be no less than 0.2MPa but less than 0.5MPa;
16
(3) If water temperature is 27 to 29℃, machine's water consumption should be around 15T/h.
2.7.6 Discharge water when the machine is not in use
In winter, discharge water in cooler after the machine is stopped to avoid fissure on cooler caused by
icing. Discharge water also when the machine is not in use for a period.
2.8 Air volume adjustment system

Air volume adjustment system automatically adjusts compressor's inlet air volume based on customer
demand to maintain balanced supply and demand. When air demand equals to rated air supply, machine
runs in full load mode. In such case, inlet valve that controls inlet volume fully opens and the pointer of
spiral valve is in its maximum position (MAX). If air demand is less than rated air discharge, system will
control the openness of inlet valve automatically and reduces inlet volume correspondingly. When
customer stops to use air, inlet valve is closed automatically to stop air inlet. In such case, machine will
run under lower back pressure in no-load mode, and the pointer of the spiral valve is in its minimum
position (MIN).
Illustrated by LS25S-300L, the functions of air volume adjustment system in four different modes are
detailed below.
(1) Start-up mode (light load start-up procedure)
The open and close of inlet valve is controlled by two ways of air: opening air way and closing air way.
The opening air way mainly comprises pressure reduction valve and starting solenoid, while the closing
air way includes load/unload solenoid and part of the load pressure regulator, etc.
Press start button and the starting solenoid and load/unload solenoid are still not powered on. Starting air
way is closed and closing air way is opened. Now the inlet valve is partly open by vacuum and small
amount of air enters compressor. Separated compressed air is led back to inlet valve by circulation valve
to establish pressure in the separator. Motor is now running in Y connection mode under light load.
After a set period (normally 6 seconds), the system switch to △ connection mode. Starting solenoid and
load/unload solenoid are switched on simultaneously. Starting air way is opened and closing air way is
closed. Recirculation valve is closed and inlet valve is fully opened. Machine enters normal operation.
(2) Normal operation
When pressure in air/fluid separator reaches 3.4Bar, Minimum pressure valve will open and compressor
will start to supply air. Now the inlet valve keeps fully openness and spiral valve pointer is in its MAX
position. Machine runs at full load mode. This mode is maintained unless system pressure exceeds 7.0Bar.
(3) Air volume adjustment
If customer air demand is lower than machine's capacity, system pressure will build up. When pressure
reaches 7.0Bar, the pressure regulator that controls spiral valve is activated. Control air enters spiral
valve and pushes valve plug through a rack and bypass some output air to inlet port, thus reducing
machine air supply. The more air demand, the more spiral valve opens. If air demand is 50% of
machine's rating capacity, system pressure will increase to 7.4Bar. Now the spiral valve opens the most
and the pointer of spiral valve points MIN. Therefore spiral valve adjusts air supply from 100% rating to
50%, corresponding to 7.0~7.4Bar system pressure and MAX to MIN pointer position.
If air demand is less than 50% of machine's rating capacity, system pressure will exceed 7.4Bar. Now
partial load pressure regulator starts to work and pressure is transmitted to the closing air way of inlet
valve to diminish inlet valve openness, reducing inlet air volume. If air demand is 40% of rating capacity,
system pressure reaches 7.6Bar. Therefore partial load pressure regulator adjusts air supply from 50%
rating to 40%, corresponding to 7.4~7.6Bar system pressure, and spiral valve pointer stays in MIN.
position.
Note: for machine without spiral valve, air supply volume is adjusted by partial load regulator only.
Adjustment range is 100% to 40%.
(4) Unload operation
If customer air demand is lower than 40% of machine's rating capacity, system pressure will exceed
17
7.6Bar. In such case, controller will cut off power supply to starting solenoid and load/unload solenoid.
The starting air way of inlet valve is discharged and closing air way is filled with high pressure air of
unload pressure value immediately. Inlet valve now is closed completely.
Meanwhile recirculation valve and vent valve are opened to discharge the compressed air in separator to
lowest can pressure. Air circulates among inlet valve, air-end and separator. In such case, Minimum
pressure valve is closed to isolate user's pipeline from the machine. Machine is running under a low back
pressure without load to save energy.
If air demand increases, system pressure will drop. When pressure drops to 7.0Bar, controller will power
on the starting solenoid and load/unload solenoid. Inlet regulator and spiral valve return to original
position. Spiral valve's pointer points MAX. Now the machine enters full load mode again.
2.9 Microprocessor controller

Sullair provides Deluxe Microprocessor Controller or Sullair Supervisor II according to customer needs.
For detail information on controller, see 88920010-484 Deluxe Microprocessor Controller I Operation
Manual.
18
LS25S-250/300/350 Series Screw Compressor Operator’s Manual Chapter III Installation of Compressor
Chapter III Installation of Compressor
3.1 Frame
A foundation or mounting capable of supporting the weight of compressor and rigid enough to maintain
the compressor frame level and the compressor in alignment is required. The compressor frame must be
leveled and secured with foundation bolts to ensure normal operation of the transmission parts and
internal piping, and full uniform contact must be maintained between the frame and foundation to prevent
noise emission out of the machine unit. Concrete foundation construction shown in Figure (7).
3.2 Vibration absorption and noise reduction

It is recommended to cushion the frame with rubber plate underneath with dimension of 5~6mm
thickness and 80mm width to prevent vibration and noise generated during the machine running.
3.3 Equipment room environment

To ensure compressor's normal operation, equipment room must be well ventilated with room
temperature no more than 40℃. No object should be placed within 1m range of the compressor for the
convenience of ventilation and operation. Room design should also satisfy ambient temperature
requirement for starting in winter, which is 32°F (0℃).
3.4 Dimension and mounting illustration

a) Figure. 8 - Dimension and mounting illustration of LS25S-250/300/350 (380V/6kVODP) air-cooled
machine.
b) Figure. 89- Dimension and mounting illustration of LS25S-250/300/350 (380V/6kV ODP) water-
cooled machine.
c) Figure. 10 - Dimension and mounting illustration of LS25S-250/300/350 6kV/10kV TEFC air-cooled
machine.
d) Figure. 11 - Dimension and mounting illustration of LS25S-250/300/350 6kV/10kV TEFC water-
cooled machine.
3.5 Installation
Air-cooled machine features all-in-one design. Air in/out interfaces has been prepared on enclosure. See
dimension and mounting illustration for details. The flux of cooling fan in air-cooled machine is
764m3/min. User should arrange ventilation tunnel in designing equipment room. Check valve or leaf
window that closes automatically when the machine is stopped must be equipped in the ventilation tunnel
to make sure that machine temperature is higher than 0℃ before restarting in winter.
Water piping of water-cooled machine should be prepared according to 2.7 Water piping System.
3.6 Remove transportation support parts (air-cooled machine only)

To prevent potential damage to the vibration absorber under motor bracket during transportation, Sullair
provides additional strut to motor bracket of air-cooled all-in-one machine before delivery. Strut is
marked in red. User must make sure that the strut is removed before tuning up.
19
LS25S-250/300/350 Series Screw Compressor Operator’s Manual Chapter III Installation of Compressor
3.7 Motor rotation direction check

After the electrical wiring has been done, it is necessary to check the direction of the motor rotation. Pull
out emergency stop button on supervisor panel, then jogging "I" button (start), then by "O" button (stop)
immediately. Let motor revolve for a moment. If motor rotates in the same direction of marked arrow, it
means wiring is correct. If not, disconnect the power and exchange any two of the three power inlet leads.
Then test again.
No reversed rotation is allowed!
Figure. 7 - Basic Construction Plans
20
VENT AIR IN VENT AIR OUT A VIEW
2210
Emergency A
Shut down
2200
CONN.4" PIPE
(WELDING)
8- 18
200
R81.5
295
36
120
370 1730 1730 435 345

78 DRAIN
CONN.? 10x1 HOSE
4200
21
8-?22
795 CONN. FOUNDATION BOLT:M20 865

63 98
5X134=670 5x134=670
40 40
40
NOTES:
1.The minimum distance that the compressor should be from
surrouding walls and top is 1m.
2.The stability of foundation of supporting the weight of the
200 compressor is required and full uniform contact must be maintained
80-M8
POWER SUPPLY
between the frame and foundation.
1100
IN GROUND/ 6KV
3.No piping loads shall be transmitted to the compressor at the external
connections.
300 105
Figure. 8 - Dimension and mounting illustration of

50 TOTAL WEIGHT OF LS25S/AC(UNIT:KG)
Main cable in through
2050
2160
2050
2130
LS25S-250/300/350 (380V/6kV ODP) air-cooled machine

frame(TOP) / 6KV MOTOR 250HP 300HP 350HP 250HP/300HP/350HP
(2 PLACES)
13X150=1950
SPEC.
2- 120 HOLE 380V ODP 380V TEFC 380V ODP 380V TEFC 380V ODP 380V TEFC 6KV
CANOPY YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO
WEIGHT/KG 5920/5180 6240/5500 6190/5450 6540/5800 6300/5560 6740/6000 6640/5900
900
TOP & Bottom/380V
150
40
362
90
743 813
968
3
THE VENTILATION OF EXHAUST:103m3/min
WIND SPEED：～9m/s
EMG.STOP
CONTROL
PANEL
WATER OUT
2200
STARTER INTERNAL THREAD G1/2
1290
40
150
75
300
2511 HOLE OF BARD BOLT 6- 22 2160
22
DRAIN OUT
WATER IN
1224 INTERNAL THREAD G1/2 INTERNAL THREAD G1/2
VENT AIR IN
ROUND THE MOTOR
INLET AREA:0.42m 2
WIND SPEED:6m/s Notes:
650
THE POSITION OF THE
HIGH-VOLTAGE WIRE
surrounding walls and top is 1 meter.
200(BOTTOM)
compressor is required and full uniform contact must be
STEEL TUBE 114X6
(WELD) maintained between the frame and foundation.
THE POSITION OF THE 3.No piping load shall be trasmitted to the compressor at the
COMPRESSED AIR OUT
HIGH-VOLTAGE WIRE

50(TOP) external connections.
VENT AIR IN 4.The design od air compressor station must accord with the standard
2210
THE POSITION OF THE
LS25S-250/300/350 (380V/6kV ODP) water-cooled machine

LOW-VOLTAGE WIRE ROUND THE TANK
2- 120(TOP&BOTTOM) GBJ29《THE DESIGN SPCIFICATION OF AIR COMPRESSOR STATION》.
300 THE LIST OF THE LS25S-WC WEIGHT(UNITS：KG)
900
250HP 300HP 350HP 250HP/300HP/350HP
MOTOR
380V ODP 380V TEFC 380V ODP 380V TEFC 380V ODP 380V TEFC 6KV
382
CANOPY YES NO YES NO YES NO YES NO YES NO YES NO YES NO
968 WEIGHT 4800 4200 5100 4500 5050 4450 5400 4800 5200 4600 5600 5000 5400 5000
3265
A VIEW
COOLER AIR IN COOLER AIR OUT
2210
CONTROL
PANEL
A VIEW
2200
CONN.4"STEEL TUBE 8- 18
200
（WELD）
105 173
120
118
295
36
1202 2068
78 1050
500 800 2150 800 435 345
CONN.DRAIN OUT 10x1
RUBBER
4750
23
795 NOTES:
865
63 97
5X134=670 5x134=670 1.The minimum distance that the compressor should be from
40
40
40
maintained between the frame and foundation.
200
80-M8
REFERENCE POSITION FOR
3.No piping load shall be trasmitted to the compressor at the
HIGH-VOLTAGE INLET( BOTTOM)
1105
external connections.
4.The design od air compressor station must accord with the standard
300 GBJ29《THE DESIGN SPCIFICATION OF AIR COMPRESSOR STATION》.

2050
2160
2050
2130
LS25S-250/300/350(6kV/10kV TEFC) air-cooled machine

105 THE LIST OF THE LS25S-WC WEIGHT(UNITS：KG)
13X150=1950
(TWO PLACES)
50
REFERENCE POSITION FOR
LOW-VOLTAGE INLET(TOP) 250HP/300HP/350HP
MOTOR
6KV TEFC 10KV TEFC 10KV ODP
900
WEIGHT/kg 7230 7530 7030
150
362
743 813
90
40
10- 22
965
CONN.FOUNDATION BOLT M20
3
THE VENTILATION OF EXHAUST ：103m /min
MAIN MOTOR CONNECTION HOLE
WIND SPEED：～9m/s
←
←
←
←
←
A VIEW
EMG.STOP
CONTROL
PANEL
MAIN MOTOR JUNCTION BOX
M ax 1 6 0 0
VENT AIR IN ROUND THE MOTOR 125 CONN.4"STEEL TUBE(WELD)
Notes:
24
A VIEW
THE POSITION OF THE

2.Make sure no materials prevent the air hole to let the air out,
AUX.VENT AIR IN 380 LOW-VOLTAGE WIRE(BOTTOM) 2210 prevent the hot wind flow back into the air inlet hole.
300
3.The air,water joint should keep distance of 55mm to the out board.
330
250
VENT AIR IN
maintained between the frame and foundation.
5.No piping load shall be trasmitted to the compressor at the
external connections.
6.The design od air compressor station must accord with the standard
200
THE POSITION OF THE HIGN-VOLTAGE WIRE (BOTTOM)
GBJ29《THE DESIGN SPCIFICATION OF AIR COMPRESSOR STATION》.
2210
2200
4- 12.5

600
THE LIST OF THE LS25S-WC WEIGHT(UNITS：KG)
Max1250 POWER INLET HOLE
2- 75 250HP/300HP/350HP
LS25S-250/300/350(6kV/10kV TEFC) water-cooled machine

300
35 MOTOR
? 50
6KV TEFC/10KV ODP&TEFC

ACOUSTIC
ENCLOSURE YES NO
1000
648
650
WEIGHT 6160 5500
280
200
314
WATER OUT 605
INTERNAL THREAD G1-1/2
681
1959 DRAIN OUT
INTERNAL THREAD G1/2 757
4000 955
WATER IN
INTERNAL THREAD G1-1/2
LS25S-250/300/350 Series Screw Compressor Operator’s Manual Chapter IV Compressor Operation
Chapter IV Compressor Operation
4.1 Safety operation procedure

To avoid personal injury and machine damage, customer should make detailed safety operation
procedure. Please reference to the following:
(1) Operator must be well trained before operation, and has read and understood this manual.
(2) The installation and operation of machine should comply with national and local laws and regulations.
(3) Never modify machine structure and control mode, unless with written approval by the manufacturer.
(4) If abnormal condition is encountered, stop the machine immediately and disconnect all power supply.
(5) No inflammable, explosive, toxic and erosive gas should be stored in the vicinity.
(6) Blow down the compressor and shut down all power supply before maintenance or adjustment
operation.
(7) For air-cooled machine, if machine or fluid cooler is in a place where ambient temperature is below
0℃, user must increase temperature to above 0℃ to reduce fluid viscosity in cooler, air/fluid separator
and connection pipe and make the machine be able to start.
4.2 Preparation before initial starting

(1) Check if electric connection is safe and reliable;
(2) Set operation parameters according to the manual of accompanied computer controller;
(3) Observe air/fluid separator level. Normally fluid level should be at the lower center of upper sight
glass;
(4) If ventilation tunnel is installed, make sure it is clean and clear;
(5) Open discharge stop valve;
(6) Power on the machine. Start the machine then stop immediately to check if motor rotates in the same
direction of marked arrow. Reset the machine if the direction is wrong;
(7) Start the compressor again and close stop valve gradually. Check if unloading pressure coincides with
settings. Reset the machine if not.
(8) Check if all systems work properly. Check for fluid, air and water leakage and abnormal sound;
(9) Open discharge stop valve;
(10)Stop the machine.
4.3 Normal operation

After a new purchased unit has passed the initial starting test procedure, it can be used for normal
operation.Check the fluid level before start,then press "I" button (manual mode) or " " button (auto
mode) to start the compressor.
4.4 Shutdown procedure

To shut the compressor down, Push "O" pad.
25
LS25S-250/300/350 Series Screw Compressor Operator’s Manual Chapter V Maintenance and Service
Chapter V Maintenance and Service
5.1 General
As you proceed in reading this section, it will be easy to see that the Maintenance Program for the air
compressor is quite minimal. Air filter, fluid filter and air/fluid separator, etc. are monitored by the
controller. Once there is a problem, controller will send corresponding signal through the indicators on
panel system schematics.
5.2 Daily operation

Check fluid level before starting the machine. Add lube fluid if level is low. Check if displayed
parameters are correct after the machine is started. Check operation condition of various systems after the
machine is warmed up, and check for leakage and abnormal sound.
5.3 Maintenance after initial 50 hours of operation

Check and proceed with the following after 50 operation hours of a new machine:
(1) Clean fluid return pipe filter;
(2) Clean fluid return pipe nozzle;
(3) Replace fluid filter element;
(4) Clean filter on control pipeline.
5.4 Maintenance every 1000 hours of operation

(1) Clean fluid return pipe filter;
(2) Replace fluid filter element if needed;
(3) Replace air filter element if needed.
5.5 Lube fluid replacement

(1) In order to minimize service operation and reduce cost, LS25S series compressor has been tested and
filled with long life lube fluid before delivery. Standard machine is filled with Sullube 32 lube fluid.
(2) For 24KT machine, change fluid only when chemical analysis indicates fluid need to be changed or the
lube fluid is contaminated.
(3) Use non-Sullair lube fluid in compressor will void all Sullair warranties.
(4) Do not mix different type lube fluid. Mix dirty mineral fluid may cause poor performance of the air-
end. It could also cause bubble, filter element clogging and nozzle or pipe clogging.
(5) Note: Clean fluid piping system before fluid replacement. If ambient temperature exceeds range or use
lube fluid above its life, please contact Sullair dealer.
(6) Tips on using lube fluid
Sullair encourages user to participate in the fluid sample analysis program of Sullair dealer. Fluid
replacement interval may vary from case to case. Please contact Sullair dealer for details.
26
(7) Lube fluid replacement and service instruction

Lube fluid replacement Fluid change Fluid filter replacement Air/fluid separator element
Sullube32 A,D F,B A,C
24KT E,D F,B A,C
A - One year or 8000 hours
B - Pressure difference over 20psig (1.4bar)
C - Pressure difference over 10psig (0.7bar)
D - Sample analysis or confirmed contamination
E - Need no change during normal life
F - Every 1000 hours
5.6 Maintenance of fluid filter

See Figure 12 for fluid filter structure.
Filter head
Gasket
Filter element
Figure 12 Fluid filter

Filter element part number: 02250139-996
27
When controller sends fluid filter service signal (△P2 on panel flashes), operator should service fluid
filter and replace filter element immediately as described below:
(1) Remove filter element and O-ring with a belt wrench;
(2) Clean sealing surface;
(3) Apply a layer of clean lube fluid on the O-ring of new filter element;
(4) Screw up and fasten the new filter element;
(5) Start the machine and see if there is fluid leakage;
(6) Be noted that the filter element is Sullair specific. Do not use other products. Filter element may not be
cleaned. Replace the filter element only.
5.7 Maintenance of air filter

See Figure 13 for air filter element. Surface of air filter will be covered by dust after a period and air flow
resistance will rise. If pressure difference between the two sides of filter element exceeds threshold, a
"service needed" signal will display on the monitor. You should remove the filter element and dedust or
replace it as described below:
(1) Screw off the nut and remove back cap;
(2) Screw off the filter element fixing nut and washer assembly to remove the filter element;
(3) To service filter element, blow it inside out using compressed air. Keep blow nozzle 10mm away from
the inner surface of filter element and blow along its perimeter from top to bottom. Another way to service
filter element is put it on a platform vertically and tap the top of filter element to dust off;
(4) Do not wash the filter element because it is paper made;
(5) Besides dust cleaning, user should also check for damages. Put a lighted bulb inside the filter element
and observe for light leakage from outside.
Figure 13 Air filter
28
5.8 Maintenance of air/fluid separator

Maintenance of air/fluid separator means the replacement of air/fluid separator element. See Figure 14.
Replace air/fluid separator element every year or when controller is sending the service signal
(△P1flashes).
Note: Air/fluid separator element may be replaced only. Do not clean it.
Replace air/fluid separator element as described below:
(1) Stop the machine and discharge pressure;
(2) Disconnect the pipeline linked to top cap. Pop up top cap using the bottom bolt of side suspension arm
beside the can and screw it to proper position. During the process and when the cap is screwed open,
operator should not stay behind the top cap;
Figure 14 Air/fluid separator

(3) Take out the two elements and replace with new ones. Note: do not touch the sealing pad on filter
element flange. Do not remove the metal holding screw from sealing pad. Metal holding screw also serves
as grounding function to prevent fire in separator caused by static;
(4) Clean the inside surface of top cap and put in the new filter. Fasten bolts and pressing cap;
(5) Connect pipelines linked to top cap.
29
Note: Two fluid return pipes must be inserted to the bottom of filter element to ensure fluid return.
5.9 Maintenance of pressure regulator

See Figure 15 for the structure of pressure regulator. Normally only the fencing ring, membrane and
sealing pad need to be replaced. Maintenance procedure is described below:
(1) Screw off the locking nut and turn the adjustment screw counterclockwise until spring is loose;
(2) Remove spring base, spring and membrane assembly;
(3) take out sealing pad and fencing ring;
(4) Loosen the nuts on valve disk and remove valve disk, membrane and bolts, etc;
(5) Install new fencing ring, membrane and sealing pad;
(6) Reassemble the pressure regulator.
Figure 15 Pressure regulator
5.10 Maintenance of Minimum pressure valve

See Figure 16 for the structure of Minimum pressure valve. Normally only O-ring needs to be replaced.
Maintenance procedure is described below:
30
(1) Disconnect pipelines linked to Minimum pressure valve and remove it from the top cap of air/fluid
separator;
(2) Screw off the top cap of valve and remove the piston assembly in the valve;
(3) clean the valve and piston assembly carefully;
(4) Replace with a new O-ring. Apply a film of fluid on O-ring and piston;
(5) Apply a layer of Lucite sealing glue on top cap and then reassemble the piston in reverse order;
(6) Reattach the Minimum pressure valve to receiver cover and reconnect pipelines.
Figure 16 Minimum pressure valves
5.11 Maintenance of vent valve

See Figure 17 for the structure of vent valve. Vent valve needs little maintenance. Repair the blowdown as
follows if the valve is not acting fluently or is leaking.
(1) Pressure must be discharged completely before maintenance. Remove related control air pipe and
silencer pipe, etc., and remove the vent valve from machine.
(2) Open the cap.
31
(3) Screw off piston assembly (hex bolt, washer and locking nut). User needs to remove the bolt and tap
the head. Remember the disassembling order.
(4) Check, clean or replace worn parts.
(5) Reassemble in reverse order.
Figure 17 Vent valve

*Service part no.: 02250045-132
5.12 Maintenance of control pipe filter

See Figure 18 for the structure of control pipe filter. Service mainly refers to filter element, washer and O-
ring replacement as described below:
(1) Screw off the shell and remove inner parts;
(2) Replace with new filter element and O-ring;
(3) Screw off nuts on the sump and remove the auto discharge device. Replace the washer;
(4) Replace O-ring on the top of shell;
(5) Reassemble the filter.
5.13 Maintenance of solenoid

See Figure 19 for structure of solenoid. Solenoid needs little service. However it should be cleaned
regularly. Generally if working voltage is right and the solenoid is acting slow or is leaking, it should be
cleaned as described below:
(1) Detach terminals on solenoid winding;
32
(2) Remove fixing nuts and take out the solenoid;

(3) Screw off screws on valve and remove valve plug, element spring and sealing ring;
(4) Screw off bottom cap and remove sealing ring, spring and valve needle;
(5) Clean each component;
(6) Replace winding or valve plug;
(7) Reassemble the solenoid.
Figure 18 Control pipe filter Figure 19 Solenoid
5.14 Disassemble and maintenance of coupling
1. Disassemble and maintenance of coupling (see above figure for structure of coupling) ,see Figure 20
33
(1) Among all parts of coupling, only the elastomeric needs to be replaced when it has failed. Release the
studs and locking screw on one side of flange to replace the elastomeric.
(2) If air-end bearing or sealing parts need to be serviced, you do not need to move the motor but coupling
needs to be removed.
2. Installation requirement of coupling
(1) Adjust distance between motor axle and air-end axle and the co-axial property by tools such as dial
indicator and adjustment washer (022031). The following co-axial requirement on should be met. See
Figure 21.
Axle distance of 380V/6kV Axle distance of 10kV

Radial offset (mm) Angle offset (mm)
machine (mm) machine (mm)
116.8±0.5 113.8±0.5 0.05～0.10 0.1～0.2
Figure 20 Coupling
Figure 21 Coupling
(2) Once the above listed requirements are met, fasten the locking bolts of motor and re-check shape &
34
position tolerance to avoid later movement. Re-adjust if necessary.

(3) Place the intermediate coupling and elastomer between the two flanges of coupling and fasten the bolts
by hand before using torque wrench for balanced fastening. Apply some neutral lube fluid on the bolts.
5.15 Maintenance of VVVF

Please operate according to Schneider Altivar 38 Asynchronous Motor VVVF Operation Manual.
5.16 Maintenance of Sullair compressor specific motor

5.16.1 Low-voltage motor
5.16.1.1 Operation condition (Exported model may vary by its country)
Ambient temperature ≤40℃
Humidity <90% (no condense)
Altitude ≤1000m
Frequency see motor nameplate
Voltage see motor nameplate
Operation standard S1 (continuous)
Insulation class F
5.16.1.2 Motor operation
(1) Motor should be properly grounded. The ground line of Sullair compressor specific motor is normally
linked to electric cubicle and is connected to the cubicle. Securely attach user ground line to the terminal.
(2) Sullair compressor specific motor leads are cleared marked:
Phase A B C
Head T1 T2 T3
Tail T4 T5 T6
(3) Wiring of Sullair compressor specific motor is clearly marked on nameplate.
(4) When voltage and frequency of Sullair compressor specific motor are maintained as described on
nameplate, motor may output a power of power rating multiplied by utilization coefficient. If frequency
variation exceeds 1%, or voltage variation exceeds 5% of the value on nameplate, aforesaid power output
is not guaranteed.
(5) Sullair compressor specific motor works well when imbalance among three phases does not exceed
1%.
(6) Thermal relay is normally equipped in Sullair compressor electric distribution cubicle as motor
overload protection component.
(7) Intermittent or abnormal sound and vibration should not be observed when motor is running with or
without load.
5.16.1.3 Maintenance and service of low-voltage motor
1) Environment should be dry. Motor surface should be clean and air-in port should not be obstructed by
dust or fiber, etc.
2) If thermal relay is activated, find and correct fault causes before restarting.
3) Make sure bearings are well lubricated during operation. Generally, grease should be added or replaced
every 2000H (enclosed bearing does not need grease replacement during its life). If grease is too hot or is
deteriorated during operation, it should be replaced. Add grease after cleaning bearing and cap slot.
35
Different motor uses different type of grease. See motor nameplate or call Sullair Service Department at
0755-26851686-270, 271 and 272 for grease detail.
4) When bearing life is coming to its end, vibration and noise will increase drastically, and the bearing
should be replaced.
5) See Three-phase Asynchronous Motor Operation and Maintenance Manual for motor inspection and
maintenance.
6) User is recommended to contact Sullair or Sullair dealer when motor has problem.
5.16.1.4 Regular inspection
Motor should be inspected every year or half a year based on its condition. If the motor is exposed to one
of the following conditions, it should be inspected every half a year.
1) Caustic or conducting dust.
2) Velveteen or extremely dirty environment. Accumulated dust may impede normal ventilation.
3) Chemical smoke, steam, salt mist or fluid mist.
4) Humid or extremely dry, radiation heat, bug hazard or mildew cultivating atmosphere.
or running under one of the following conditions:
1) Variation to voltage and/or frequency ratings regulated in Sullair Compressor Specific Motor Operation
section is constantly out of limit.
2) Poor room ventilation or ambient temperature exceeds 40℃.
3) Motor is started frequently due to air demand fluctuation.
Checklist:
1) Discharge, clean and refill lube fluid (grease) to bearing. If bearing is already found abnormal, then
check the bearing. See motor nameplate for lube fluid (grease) type.
2) Take procedures to deal with leaked fluid at bearing sealing position.
3) Check end cap and top cover for condensation or accumulated water, rust or erosion. Remove end cap
and top cover if necessary.
4) Note if there is dust or other external objects accumulation.
5) Check all non-insulated electric connections for loose, over heat, arcing or erosion. Make correction if
necessary.
6) Check all bolts and nuts and make sure they are securely fastened.
7) Check all leads and see there is over heat or corona.
5.16.1.5 Check and clean the winding
Based on the type and amount of dust accumulated on winding, the following methods are listed for
reference. (If too much dust is accumulated on winding, or the winding needs to be checked and cleaned
thoroughly, the rotor must be removed from the stator.)
1) Wipe with dry rag
If the surface is easily accessible and there is dust only, then use a clean and dry down less rag to wipe
will do the work. Do not use "cotton waste" because fluff will stick to insulation and cause more dust
accumulation. Fluff is also damaging insulation of high-voltage motor due to the tendency of corona
vibration.
2) Brush and vacuum clean
Brush off dry dust with a short and hard brush and then use vacuum (do not use metal brush). This is
favorable because dust will not scatter onto other equipment.
3) Blow
36
Blow the dust off with dry compressed air only in inaccessible gap while the motor is not humid. Blow
direction should not cause the dust being brought to deep inside of the motor, which is hard to clean and
may block air way.
Caution: Pressure of compressed air should be no more than 0.2MPa to avoid damaging insulation.
Do not blow dust when insulation is loose. Make sure air is dry and contains no condensed water
from air pipeline.
4) Solvent clean
Solvent clean is especially effective for the pitch, grease, wax and fluid on electric devices. Wipe with a
rag containing solvent. Then wipe with a dry rag. (Do not use "cotton waste" because fluff will stick to
insulation.)
Sullair suggests inorganic volatile solvent or petroleum solvent. In a fire protection area, use fire retarding
methyl-chloroform, because this solvent will burn under normal conditions and is mildly toxic. Local
ventilation is required when the odor of solvent vapor is strong.
5.16.2 High-voltage motor
5.16.2.1 Operation condition (Exported model may vary by its country)
Ambient temperature ≤40℃
Humidity <90% (no condense)
Altitude ≤1000m
Frequency see motor nameplate
Voltage see motor nameplate
Operation standard S1 (continuous)
Insulation class F
5.16.2.2 Motor starting and operation
(1) Initial starting
Initial starting means the first time motor is powered on after installation, overhaul or not being used for
over 1 month. It is recommended to detach motor from compressor air-end before initial starting, i.e. start
on no load.
(2) Checklist of initial starting:
a Temporary struts and cover boards are removed;
b Lube fluid level is normal;
c Insulation resistance to ground is no less than 3(Un+1) mega ohms (Un is in Kv);
d Check if power supply phases, voltage and frequency coincide with the nameplate;
e Ventilation port and way are clear;
f Turning the motor should not generate abnormal sound;
g Cables are connected correctly;
h Other factors that may influence the operation of motor.
(3) Start the motor for a second and see if the rotation direction complies with the mark. Switch phases if
not to correct the direction. Restart the motor when it is cooled to ambient temperature and check if the
motor is running properly within the next two hours. Cut off the power if there is a problem and find
causes.
(4) Start on load
Connect the coupling between air-end and motor according to 4.15. Turn several circles with hand or tool
to check if it is stuck or if there is problem or sound. Start the machine when everything is normal. Check
37
motor current and temperatures of various positions frequently in the next 4 hours and record the
operation condition of motor and compressor. Stop the machine immediately if there is a problem.
(5) Start times
Motor can be started twice consecutively in cold status, while only once in hot status within four hours to
avoid motor insulation damaged by heat.
5.16.2.3 Maintenance when the motor is not in use
If the motor is not in use for over one month, the motor should be heated or ventilated by hot wind (80℃
dry air) regularly to keep the motor dry. User may use the space heater on the motor. If space heater is not
available, put several bulbs of 100 or 150watt inside the motor and turn them on.
5.16.2.4 Maintenance and service of motor
(1) Environment should be kept dry. Motor surface should be kept clean. Ventilation port and way should
be kept clear without dust and fiber, etc.
(2) Make a practical service program. Check if motor bearings are well lubricated regularly. See motor
nameplate on how to add grease.
(3) User is suggested to contact Sullair or Sullair dealer if there is a problem. Do not disassemble by
yourself.
(4) Do not block air in/out ports of motor. Check and clean air in/out ports regularly to ensure heat
radiation.
5.17 Maintenance of acid removal filter (only for SULLUBE unit)
After certain period of usage, the acid removal adsorbent in the acid removal filter will need replacement. In
principle, the replacement time takes 1000hour as the unit, subject to the total time required for TAN to reach
1.0 after fresh fluid is added to the local machine.
During the replacement, the following procedures can be followed for maintenance:
(1) Before installation of acid removal adsorbent, the inside of the filter tank must be cleaned. Check if the
screws of the filter screen plate in the tank are tightened;
(2) Open the top cover of the fluid filter;
(3) Install acid absorbent (88290013-633), with volume of 2000g.
The absorbent replacement can only be carried out after closing the bypass ball valve and shutting down the
unit with pressure released!
38
I)
Line Voltage QF7 160
L1 L2 L3 TC1
U3 KA7
100
QF3 101
161
To XT1 KA7
110V
QF1 V3 102 NOTES:
5 162
QF2 1 OPTIONS.
XB YV6
2 REMOVE JUMPER TO ADD OPTIONS.
XT0 Bypass Sol.Valve
1L1
1L2
3 REFERENCE 02250057-696/697《SUPERVISOR II SEQUENCING &
QF5
1L3 2L3 PROTOCOL MANUAL》FOR REMOTE CONTROL MODE.
1L2 2L2 4 REFERENCE DRAWING 88290007-919 FOR DELUXE MICROPROCESSOR
1L1 2L1 CONTROLLER I RS485 NET.
PE 5 CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT
410 PE PRIOR TO STARTER AS REQUIRED BY LOCAL WIRING CODES.
1L1
1L2
1L3
UA1 CT1
305 101 411
To XT1
1 2 3 4
8 7 6 5
303 102 Current
Current
Transformer
1 Transmitter
1L3
1L2
1L1
1L1
1L2
1L3
1L2
1L3
1L1
QF6
PE
2L1
2L2
2L3
Analog input(0～20mA)
-100～+200℃ REAL TIME

Control voltage output
Relay output
+10V interior power

I/O Ground
Forward start/low-speed running
PID Function active
Max. rpm running
I/O Ground
Start/Stop Control(B)
Gogging
Control source A/B select
ready
ready
Relay output
erorr
Current output，analog output

24V boost input voltage
DIN1-DIN3's common terminal

Serial bus input/output
3L3
3L2
3L1
QF4
KM1 L1 L2 L3 PE
39
5 6 7
AU1 VSD
KA6
11 14
NXL
W11
V11
U11
U V W PE
+10 1
A11+ 2
A11- 3
A12+ 4
A12- 5
+24V 6
GND 7
DIN1 8
DIN2 9
DIN3 10
GND 11
AO1+ 18
AO1- 19
RS485 A
RS485 B
+24V 30
R01 23
+24V 1
GND 2
DIN1 3
DIN2 4
DIN3 5
D01 6
R01 24
R01 25
R01 26
NXOPTAA
V21
U21
W21
154
153
150
151
152
155
153
203A R01 21
206 211 211 R01 22
FR1 KM4
V22
U22
W22
KM2 PE
U12
W12
V12
Chapter VI Schematics
PID Function active order

Start/Low-speed/Stop order
T2 T3
T1
T2 3 -KM1
-KA3
T1 T3 T2 ~ Temp. of Oil Cooler

T1 T3
WHT
153 RED RTD4 BT4
V13
U13
W13
3 3 RED
~ ~ M3 154
PT100
T4 T6
T5 M1 Oil Cooler Motor Fan PE
Y-△
Main Motor M2
After Cooler Fan Motor
W13
V13
U13
1 Wiring Diagram of motor's space heater
AC220~240V AC110~120V
L N L N
HT1 HT2 HT3 HT4 HT1 HT2 HT3 HT4
KM3 KM1 KM1

EH1 EH2 EH1 EH2
Note:
For Power 220-240V：N JUMP TO HT4。
For Power 110-120V：N JUMP TO HT3，
HT2 JUMP TO HT4。
6.1 Air-cooled machine wiring diagram - Low-voltage (Deluxe Microprocessor Controller

Oil Filter Pressure sensor
High-Pressure Low-Pressure
BP4 BP3 DELUXE MICROPROCESSOR J2
219 Dry Disch. Air Temp.
RTD2 + 19 WHT Discharge
P4 P3 CONTROLLER I 218 RTD2 BT2 Line Pressure Pressure
S + - S + - RTD2 - 18 RED BP2 BP1
J3 217 RED
GND 17 GND
WHT(GRN) 301 216 RED Discharge Temp. P2 P1
1 P3 SIG AP RTD1 - 16 RED
WHT(GRN) 302 215 RTD1 BT1 S + - S + -
2 P4 SIG RTD1 + 15 WHT
To XT1 BLK 303 214 WHT(GRN)
212 3 GND P2 SIG 14
BLK 304 213 WHT(GRN)
RED 4 Td P1 SIG 13
To UA1 305 212 RED RED
5 Ic +12V 12
Oil injection Temp. 306 211 BLK BLK
WHT 6 RTD3 + GND 11
RTD3 307 210
BT3 RED 7 RTD3 - D10 10
308 209
8 RTD4 + D9 9
309 208
9 RTD4 - D8 8
GND RED 310 207
10 RTD GND D7 7 2
311 206 KA6
11 RTD5 - D6 6
312 205 1
12 RTD5 + D5 5
313 204 P
13 RTD6 - D4 4 SP1 Air Filter
314 203
14 RTD6 + D3 3
315 202 QF4 203A AU1 Fan overload
15 D11 D2 2
316 201
16 D12 D1 1
317 FR1 Air-end overload
LOCAL/MASTER CONTROL 17 D13 SB1
318 Emergency Stop KA1
3 REMOTE LOAD/UNLOAD 18 D14 J1 Full Load Relay
319 K8
REMOTE START/STOP 19 D15 115 1 YV4
320 15 Full Load Sol.Valve
20 GND EXTEND 114
Only for remote control mode 14 YV5
K7 113 Electric drain Sol.Valve
J4 13
361 EXTEND 112 KA2
1 A1 OUT 0-10V(P2 REAL TIME) 12 Alarm Relay
analog output + 111
362 A2 OUT 0-10V(T1&P2 LOAD) FULL LOAD MODULATE 11
2
40
+ K6 110 KA3
363 3 + ELECTRIC DRAIN 10 Load Relay
Sequential control communication 1/RS-485 K5 109
364 4 - COMMON FAULT 9 YV2 Load/Unload Sol.Valve

365 K4 108
5 + 8
Modbus Communication 2/RS-485 107 YV1 Start Control Sol.Valve
366 6 - UNLOAD/LOAD 7
367 K3 106 KM2
7 GND *-DELTA 6 143 KM3 Y Contactor
K2 105
RUN 5
K1 104 KM3 141
4 Emg. Stop
KM1 Main(Line) Contactor
103 KM3
AC GND 3 KM1 142 KM2 △ Contactor
120V N 2 102
101 KM4
AC L 1 Fan Contactor
KA7 Bypass Sol.Valve Relay
101 KA1 YV3
122 SPV Control Sol.Valve
1
102
101
101
120
102
102
102
104
105
105
106
107
108
109
110
111
122
162
-XT1
101
101
101
101
120
120
102
102
102
102
102
102
104
104
105
105
105
105
106
106
107
107
108
108
109
109
110
110
111
111
122
122
162
162
209
210
211
211
211
212
213
214
215
216
217
218
219
202
203
204
205
206
207
208
-XT2
202
202
203
203
204
204
205
205
206
206
207
207
208
208
209
209
210
210
211
211
211
211
211
211
212
212
213
213
214
214
215
215
216
216
217
217
218
218
219
219
KA7
KA2
KA3
KM1
301
302
303
305
306
307
310
315
316
317
318
319
320
90
91
92
93
94
95
HT1
HT4
HT2
HT3
pt11
pt12
pt13
PE
pt21
pt22
pt23
PE
pt31
pt32
pt33
PE
-XT3 -XT4 -XT5
1
90
91
92
93
94
95
301
301
302
302
303
303
305
305
306
306
307
307
310
310
315
315
316
316
317
317
318
318
319
319
320
320
6.1 Air-cooled machine wiring diagram - Low-voltage (Deluxe Microprocessor Controller I) (Continued)
pt11
pt12
pt13
PE
pt21
pt22
pt23
PE
pt31
pt32
pt33
PE
Reference to
RUNNING ALARM wiring diagram
LOAD of motor's
space heater
RTD-M1
RTD-M2
RTD-M3
CUSTOMER INTERFACE
LS25S-250/300/350 Series Screw Compressor Operator’s Manual Chapter VI Schematics
6.2 Wiring Diagram between high voltage starter and low voltage starter
COMPRESSOR STARTER
SB2
403
405
404
406
412
413
415
501
414
505
407
402
500
411
504
502
503
507
506
401
410
400
408
409
508 +
509 -
DC4-20mA
S14 MAIN MOTOR CURRENT
S5 COMPRESSOR RUNNING
S6 COMPRESSOR STOPPED
AUXILIARY TERMINAL
AUXILIARY TERMINAL
S4 COMPRESSOR FAULT
S12 HI-VOLT SWITCH
S13 HI-VOLT SWITCH

S7 ACCIDENT BUTTON
S8 COMPRESSOR LOAD
S10 HI-VOLT READY
S11 HI-VOLT FAULT

S1 STARTING PULSE
S3 START ALLOW
S2 STOP PULSE
main motor current
～
measure sig.
DC4-20mA
(user configure
HI-VOLT STARTER the transmitter) option only for
SCN monitor
Notes：
Typical connecting method for S1、S2、S3、S7 1.Design high voltage starter interface according to this drawing.
signal in high voltage starter 2.Compressor S1 signal is the only one to turn on high voltage starter
switch,no else can be.
Q 3.The signal to compressor from high voltage starter must be responsible.
4.To cut off main high voltage motor when it have an accident, set a
400 S1 401 404 S3 405

Q START manual turn off button in the field like dutyroom where there are
people on duty.
HQ 5.If high voltage starter can not cut down high voltage motor when a
GENERAL signal from compressor were send,a severs accident would be happened.
STARTING PULSE START ALLOW
RELAY The high voltage starter must be responsibe to turn off high voltage power.
PROTECTOR 6.The interfaces between high voltage starter and compressor must be
S2 approved by sullair company.
402 403 Q STOP 7.The compressor output terminal heat current:6A
8.Use yellow conduct wire to connect compressor and high voltage starter.
TQ
STOP PULSE
S7(SB2)
412 413
ACCIDENT BUTTON
THE INTERFACE BETWEEN COMPRESSOR AND HI-VOLTAGE STARTER

CONTACTOR LOW-VOLT SIGNAL MEANING
SIGNAL DESCRIPTION NOTES
(VOLT. FREE) TERMINAL NUMBER CLOSED OPEN
S1 STARTING PULSE N.O. 400、401 IMPULSE START COMMAND
S2 STOP PULSE N.O. 402、403 IMPULSE STOP COMMAND
DISABLE PROHIBIT HI-VOLT SWITCH CLOSE
S3 START ALLOW N.O. 404、405 ENABLE STARTING
STARTING WHEN THIS SIGNAL OPEN
COMPRESSOR
S4 COMPRESSOR ALARM N.O. 406、407 COMPRESSOR OK CLOSED WHEN COMPRESSOR FAULT
ALARM
COMPRESSOR COMPRESSOR COMPRESSOR
S5 N.O. 408、409 CLOSED AFTER COMPRESSOR STARTED
RUNNING RUNNING STOPED
COMPRESSOR COMPRESSOR
S6 COMPRESSOR STOP N.C. 410、411 CLOSED AFTER COMPRESSOR STOPPED
STOPED RUNNING
PRESS ACCIDENT BUTTON WHEN
S7 ACCIDENT BUTTON N.O. 412、413 ACCIDENT ---
AUTOMATIC STOP FAULT
COMPRESSOR
S8 COMPRESSOR LOAD N.O. 414、415 COMPRESSOR LOAD ---
UNLOADED
HI-VOLT. HI-VOLT. SW. CLOSED WHILE HI-VOLTAGE SWITCH
S10 HI-VOLTAGE READY N.O. 500、501
SW.RDY. NOT RDY. GEAR IS OK
CLOSED WHEN HI-VOLTAGE SWITCH
S11 HI-VOLTAGE FAULT N.C. 502、503 HI-VOLT. OK HI-VOL FAULT
GEAR FAULTS
HI-VOLT. SW.
S12 HI-VOLTAGE SWITCH N.O. 504、505 --- ---
CLOSED
HI-VOLT. SW.
S13 HI-VOLTAGE SWITCH N.C. 506、507 --- ---
OPENED
MAIN MOTOR
S14 AI 508、509 --- DC4~20mA
CURRENT
41
I)
6.3
NOTES:
LOW VOLTAGE POWER SUPPLY
PLEASE CONSULATE SULLAIR FOR REQUIRMENTS
1 OPTIONS.
2 REMOVE JUMPER TO ADD OPTIONS.
PE
L1
L2
L3
3 REFERENCE 02250057-696/697《SUPERVISOR II SEQUENCING &
PROTOCOL MANUAL》FOR REMOTE CONTROL MODE. 3～3KV/6KV/10KV
PE
4 REFERENCE DRAWING 88290007-919 FOR DELUXE MICROPROCESSOR L13
L12
L11
CONTROLLER I RS485 NET.
QF1 5 REFERENCE 88290009-787 FOR THE REQUEST OF HI-VOLT STARTER. 5 CUSTOMER FURNISHED
PROPOSE INTERLOCK HI-VOLTAGE STARTER
412
CUSTOMER FURNISH C.B.
SB2 a ACCIDENT BUTTON S7
QF7 160 413
TC1 SA1 KM1 KA2
U3 KA7
QF3
1L1
1L2
1L3
100 101 435 437 439 KA11 404
161
去XT1 KA7
110V
V3 102
162
START ALLOW S3
QF2 XB 405
YV6
Bypass Sol.Valve
101 500
1L1
1L2
QF5 HIGH VOLTAGE READY
1L3 2L3 124 501 S10
1L2 2L2
2L1 506
1L1 PE
HI-VOLT SWITCH SIGNAL
KA0 507 S13
1L1
1L2
1L3
42
QF6 433
400
QF4
KA0 431 KA12 401

START SIGNAL S1
2L1
2L2
2L3
504
5 6 7 HI-VOLT SWITCH SIGNAL S12
PE
2L1
2L2
2L3
SB1 505
Analogue input(0～20mA)
KA6
-100～+200℃ REAL TIME

Reference voltage
I/O Ground
Digital input 1
Digital input 2
Digital input 3
Relay output
Analogue signal output

Digital input common A
L1 L2 L3 PE KM1 KA0 402
V21
W21
U21
AU1 VSD STOP SIGNAL S2
403
101 125
KM1 101 502
HIGH VOLTAGE FAULT S11
NXL
U V W PE 126 503
RS485 A
RS485 B
+10 1
A11+ 2
A11- 3
A12+ 4
A12- 5
+24V 6
GND 7
DIN1 8
DIN2 9
DIN3 10
CMA 11
AO1+ 18
AO1- 19
R01 22
R01 23
V22
W22
U22
CONTROL PART IN HI-VOLTAGE STARTER
154
153
150
151
152
155
153
508 508 MAIN MOTOR CURRENT S14
203A R01 21
211
+
XT-M3 CT OUT DC4-20mA
T2 509 509 -
T1 T3
VSD alarm
3
~ PE
T2 T3 T2
PID Function active order

T1
Start/Low-speed/Stop order
M2 T1 T3
3 M1 3～
After Cooler Fan Motor ~ Temp. of Oil Cooler
-KM1
-KA3
WHT MAIN MOTOR
153 RED RTD4 BT4
RED
154
M3 PT100
PE
Oil Cooler Motor Fan
XB2
Air-cooled machine wiring diagram –high -voltage (Deluxe Microprocessor Controller

Oil Filter Pressure sensor
High-Pressure Low-Pressure
J2
BP4 BP3
Dry Disch. Air Temp.
219 Discharge
P4 P3 RTD2 + 19 WHT Line Pressure Pressure
DELUXE MICROPROCESSOR 218 RTD2 BT2
S + - S + - RTD2 - 18 RED
J3 RED BP2 BP1
CONTROLLER I GND 217 GND
WHT(GRN) 301 17 Discharge Temp.
1 P3 SIG 216 RED P2 P1
WHT(GRN) 302 RTD1 - 16 RED
2 P4 SIG 215 RTD1 BT1 S + - S + -
BLK 303 RTD1 + 15 WHT
TO XT2 AP 214 WHT(GRN)
212 BLK 304
3 GND P2 SIG 14
RED RED 4 Td 213 WHT(GRN)
+ DC4～20mA 305 P1 SIG 13
8 1 5 Ic 212 RED RED
7 306 +12V 12
2 - 211 BLK
508 UA1 3 6 RTD3 + GND 11 BLK
DC4～20mA + 6 102 307 COMPRESSOR OUTPUT(OPTIONS)
- 509 5 4 101 7 RTD3 - 210
308 D10 10
ISOLATOR FROM XT1 8 RTD4 + 209
WHT 309 D9 9 406 414
BT3 9 RTD4 - 208
RTD3 RED D8 8
RED 310 COMPRESSOR COMPRESSOR
10 RTD GND 207
GND 311 D7 7 KA2 FAULT LOADING
11 RTD5 - 206 KA3
312 D6 6
12 RTD5 + 205 407 S4 415 S8
313
D5 5
13 RTD6 - 204 KA11
314
D4 4 POWER INSPECT
HIGH-VOLT. SIGNAL 14 RTD6 + 203 408
KA10 315
D3 3 410
15 D11 202
D2 2
316 201 P KM1
16 D12 D1 1 SP1 COMPRESSOR
317 Air Filter COMPRESSOR
LOCAL/MASTER CONTROL 17 D13 KM1 KA0
318 441 RUNNING STOPPED
3 REMOTE LOAD/UNLOAD 18 D14 QF4 203A AU1
319 Fan overload S5 S6
REMOTE START/STOP 19 D15 KA0
320
20 GND 409 411
Only for remote control mode a
SB1 SB2
J1 201A
J4 K8 Emergency Stop
361 115 Emg. Stop ACCIDENT
1 + A1 OUT 0-10V 15
analogue output 362 EXPAND 114
43
2 + A2 OUT 0-10V 14
K7 113
363 3 + 13
1/RS-485 EXPAND
Sequential control protocol 112

364 4 - 12
111 1 YV4 Full Load Sol.Valve
365 5 + FULL LOAD MODULATE 11
Modbus protocol 2/RS-485 K6 110
366 6 - ELECTRIC DRAIN 10 KA1 Full Load Relay
367 K5 109
7 GND COMMON FAULT 9
K4 108 1 KA7
8 Electric drain Sol.Valve
107
UNLOAD/LOAD 7 KA2
K3 106 Alarm Relay
*-DELTA 6
K2 105 KA3 Load Relay
RUN 5
K1 104 Emg. Stop 120 120A
4 YV2 Load/Unload Sol.Valve
103 2
AC GND 3 YV1
102 KA11 Start Control Sol.Valve
120V N 2
101 101
AC L 1 KM1
Fan Contactor
105 KA0
START/STOP RELAY
KA1
122 1 YV3 SPV Control Sol.Valve
KA7 Bypass Sol.Valve Relay
S11
101 101 101 502 503 5 126 KA10 HIGH VOLTAGE STARTER FAULT RELAY
FROM XT1
101 KA6 125 KA11

LOW VOLTAGE POWER READY RELAY
KA11 KA12 5
130 131 S10
500 501 124 KA12 HIGH VOLTAGE STARTER READY RELAY
6.3 Air-cooled machine wiring diagram - high-voltage (Deluxe Microprocessor Controller I) (Continued)
POWER SHOW(RED)
HIGH VOLTAGE READY(GREEN)
LOW VOLTAGE READY(WHITE)

102
FROM XT1
HL1 HL2 HL3
44
-XT1
-XT4
101
400 400 101
START PULSE 101
S1
401 401 101

402 402 101
STOP PULSE 101
S2
403 403 120

120
404 404 120
S3
START ALLOW
405 405 120A
406 406 120A
COMPRESSOR 120A
S4
FAULT 407 407 102

408 408 102
COMPRESSOR 102
S5
RUNNING 409 409 102

102
COMPRESSOR 410 410 102
S6
STOP 411 411 102

CUSTOMER CONNECTION
ACCIDENT 412 412 102 102

S7
BUTTON 413 413 104

104
414 414 104
COMPRESSOR
S8
LOAD 415 415 105

105 105
105
105 105
106
106 106
-XT5
107
107
500 500 107
HIGH VOLTAGE
S10
READY 501 501 108

108
502 502 108
HIGH VOLTAGE
109
S11
FAULT 503 503 109

109
HI-VOLTAGE 504 504
110
S12
N.O OF SWITCH 505 505

110 110
HI-VOLTAGE 506 506
N.C OF SWITCH 111
S13
507 507 111

111
HI-VOLTAGE MOTOR 508 508 112
CURRENT TRANSFORMER
CUSTOMER CONNECTION
S14
509 509 112

112
113
113
113
114
114
114
-XT3
301 115
301 115
-XT2
301 115
302 202 124
302 302 202 124
202 124
303 203 126
303 303 203 126
203 126
304 204 162
304 304 204 162
204 162
305 205
305 305 205
205
306 206
306 306 206
206
307 207
307 307 207
207
308 208
308 308 208
208
309 209
309 309 209
209
310 210
310 310 210
210
311 211
311 311 211
211
312 211
312 312 211
211
313 211
313 313 211
211
314 212
314 314 212
212
315 213
315 315 213
213
316 214
316 316 214
214
317 215
317 317 215
215
318 216
318 318 216
216
319 217
319 319 217
217
320 218
320 320 218
218
219
219
219
6.3 Air-cooled machine wiring diagram - high-voltage (Deluxe Microprocessor Controller I) (Continued)
Chapter VI Schematics LS25S-250/300/350 Series Screw Compressor Operator’s Manual
OIL FILTER PRESS. SENSOR
UPSTREAM DISCH.
BP4 BP3
P4 P3 NOTES:
S + - S + -
J3 J2
WHT(GRN) 301 1 OPTIONS.
1 P3 SIG
WHT(GRN) 302 219 DRY DISCH. AIR TEMP. 2 REMOVE JUMPER TO ADD OPTIONS. L3 L2 L1 TC1
2 P4 SIG RTD2 + 19 WHT U3
TO XT1 BLK 303 DELUXE MICROPROCESSOR 218 RTD2 BT2 DRY DISCH. AIR PRESS QF2 101
3 GND RTD2 - 18 RED 3 REFERENCE 02250057-696/697《SUPERVISOR II SEQUENCING & 100
212 BLK 304 RED BP2 BP1 UNIT DISCH PRESS
Controller I)
RED RED 4 Td CONTROLLER I 217 GND

GND 17 TO XT1
305 216 RED UNIT DISCH. AIR TEMP. P2 P1 PROTOCOL MANUAL》FOR REMOTE CONTROL MODE.
110V
INJECTION OIL TEMPERATURE RTD 5 Ic RTD1 - 16 RED QF V3 102
306 215 RTD1 BT1 S + - S + - 4 REFERENCE DRAWING 88290007-919 FOR SUPERVISOR DELUXE
WHT 6 RTD3 + RTD1 + 15 WHT 1
BT3 RTD3 307 AP 214 WHT(GRN)
RED 7 RTD3 - P2 SIG 14 QF1 XB
308 MICROPROCESSOR CONTROLLER I RS485 NET.
8 RTD4 + 213 WHT(GRN)
309
P1 SIG 13
212 RED RED 5 CUSTOMER TO FURNISH FUSED OR CIRCUIT BREAKER DISCONNECT
9 RTD4 - +12V 12 XT0
1L1
1L2
GND RED 310 211 BLK BLK
10 RTD GND GND 11 PRIOR TO STARTER AS REQUIRED BY LOCAL WIRING CODES.
311 210
11 RTD5 - D10 10
312 209
12 RTD5 + D9 9
313 208
13 RTD6 - D8 8
314 207 PE
14 RTD6 + D7 7 P 410
315 206 SP3 LO. WATER PRESS
HIGH-VOLT. SIGNAL 15 D11 1L3
1L2
1L1
316 D6 6
16 D12 205 2 UA1 CT1
317 D5 5 TO XT1 305 101 411
1 2 3 4
204
8 7 6 5
LOCAL/MASTER CONTROL 17 D13 D4 4 KA6 POWER MONITOR 303 102
318 203
3 REMOTE LOAD/UNLOAD 18 D14 D3 3 1 CURRENT TRANSDUCER CURRENT TRANSFORM
319 202 1 1L1
REMOTE START/STOP 19 D15 D2 2
320 201
20 GND D1 1 P 1L2
ONLY REMOTE CONTROL MODE SP1 INLET FILTER
1L3
QF3 203A TK FAN O.L.
J4 K8
J1
361 115
1L3
1L2
1 15 SB1 FR1 MAIN MOTOR O.L. 1L1
1L2
1L1
1L3
ANALOG OUTPUT 362
+ A1 OUT 0-10V(P2 REAL TIME) EXTEND 114 QF5
2 + A2 OUT 0-10V(T1&P2 LOAD) 14 EMG. STOP
K7
3L1
3L2
3L3
363 13 113 QF3
3 + EXTEND
SEQUENCE CONTROL COMMUNICATION 1/RS-485 112 KM1
364 4 - 12
111 KA1
365 5 + FULL LOAD MODULATE 11 FULL LOAD RELAY(OPT'L)
Modbus COMMUNICATION 2/RS-485 K6 110
366 6 - ELECTRIC DRAIN 10 1 YV4 5 6 7
K5 109 FULL LOAD VALVE(OPT'L)
367 7 GND COMMON FAULT 9 KA6
K4 108 KA7 11 14
W11
V11
8
U11
REMOTE
107 KA2
V21
7
U21
UNLOAD/LOAD
W21
K3 106 ALARM RELAY(OPT'L)

*-DELTA 6 KA3
K2 105 LOAD CTL. SOL. VALVE 206 211
RUN 5
K1 104 YV2 FR1 KM4
4 LOAD RELAY(OPT'L)
45
103 E-STOP
AC GND 3 YV1
V22
U22
W22
120V N 2 102 START CONTROL SOL. VALVE

101 KM2 KM2
W12
V12
U12
AC L 1 143 KM3 Y CONTACTOR

KM3 141 KM1
MAIN(LINE) CONTACTOR
KM3 T2
KM1 142 KM2 T1 T3 T2
△ CONTACTOR T1 T3
V13
U13
W13
KM4 3 3
FAN CONTACTOR ~
2 T6
~
T4
KA1 T5
122 YV3 SPIRAL VLV. CTL. SOL. VLV.(OPT'L)
Y-△
1 M1
W13
V13
U13
YV5 MAIN MOTOR

ELECTRONIC DRAIN VALVE
101
1 YV6 WATER SHUTOFF SOL. VALVE(OPT'L)
102 KM3
101
101
120
102
102
102
104
105
105
106
107
108
109
110
111
122
209
210
211
211
211
212
213
214
215
216
217
218
219
202
203
204
205
206
207
208
203A
-XT1 -XT2
101
101
101
101
120
120
102
102
102
102
102
102
104
104
105
105
105
105
106
106
107
107
108
108
109
109
110
110
111
111
122
122
202
202
203
203
204
204
205
205
206
206
207
207
208
208
209
209
210
210
211
211
211
211
211
211
212
212
213
213
214
214
215
215
216
216
217
217
218
218
219
219
203A
203A
KA1
KA2
KA3
90
91
92
93
94
95
365
367
367
301
361
364
366
362
302
303
306
307
310
315
316
317
318
319
320
363
-XT3 -XT4 -XT5
90
91
92
93
94
95
301
301
302
302
303
303
306
306
307
307
310
310
315
315
316
316
317
317
318
318
319
319
320
320
365
367
367
361
364
366
362
363
FULL
ALARM LOAD
LOAD
4 TO MATCHING TERMINALS
ON NEXT COMPRESSOR
6.4 Water-cooled machine wiring diagram - Low-voltage (Deluxe Microprocessor

LOW VOLTAGE POWER SUPPLY
PLEASE CONSULT SULLAIR FOR THE REQUIRMENTS
CUSTOMER FURNISH C.B.
PE
L1
L2
L3
3～3KV/6KV/10KV
Controller I)
PE
L13
L12
L11
QF1 5 CUSTOMER FURNISHED
PROPOSE INTERLOCK HI-VOLTAGE STARTER
412
TC1 SB2 a ACCIDENT BUTTON S7
U3 QF3
100 101 413
SA1 KM1 KA2
去XT1
1L1
1L2
1L3
435 437 439 KA11 404
110V
V3 102
START ALLOW S3
QF2 XB1 405
101 500
1L1
1L2
HIGH VOLTAGE READY HIGH VOLTAGE READY
124 501 S10
506
507 S13
1L1
1L2
1L3
KA0
QF6 433
400
46
QF4
KA0 431 KA12 START SIGNAL S1
401
2L1
2L2
2L3
504
5 6 7 S12
505
CONTROL PART IN HI-VOLTAGE STARTER
SB1
KA6
KM1 KA0 402
V21
W21
U21
STOP SIGNAL S2
403
101 125
KM1 101 502
HIGH VOLTAGE FAULT S11
HIGH VOLTAGE FAULT
V22
W22
U22
126 503
508 508
+
MAIN MOTOR CURRENT MAIN MOTOR CURRENT S14
T2 509 509 -CT OUT DC4-20mA
T1 T3
3
~
T2
M2 T1 T3
Fan Motor M1 3～
MAIN MOTOR
XB2
6.5 Water-cooled machine wiring diagram – High-voltage (Deluxe Microprocessor

Oil Filter Pressure Sensor
High-Pressure Low-Pressure J2
BP4 BP3
Dry Disch. Air Temp.
P4 P3 219 WHT
DELUXE MICROPROCESSOR RTD2 + 19 Line Pressure Discharge
218 RTD2 BT2 Pressure
S + - S + - RTD2 - 18 RED
J3 RED BP2 BP1
CONTROLLER I GND 217 GND
WHT(GRN) 301 17 RED
1 P3 SIG 216 Discharge Temp. P2 P1
WHT(GRN) 302 RTD1 - 16 RED
2 P4 SIG 215 RTD1 BT1 S + - S + -
BLK 303 RTD1 + 15 WHT
TO XT2 3 GND AP 214 WHT(GRN)
212 BLK 304 P2 SIG 14
RED RED 4 Td 213 WHT(GRN)
+ DC4～20mA 305 P1 SIG 13
8 1 5 Ic 212 RED RED
7 306 +12V 12
2 - 211 BLK BLK
+ 508 6 UA1 3
102
6 RTD3 + GND 11
DC4～20mA 307
- 509 5 4 101 7 RTD3 - 210
308 D10 10
ISOLATOR FROM XT1 8 RTD4 + 209
WHT 309 D9 9
BT3 9 RTD4 - 208
RTD3 RED D8 8
RED 310 207
Oil injection Temperature 10 RTD GND D7 7
GND 311 206 SP2 P
11 RTD5 - D6 6 Water Pressure Switch
312 205
12 RTD5 + D5 5
313 204 KA11
13 RTD6 - D4 4 Power Inspect
HIGH-VOLT. SIGNAL 314 203
14 RTD6 + D3 3
KA10 315 202
15 D11 D2 2 COMPRESSOR OUTPUT(OPTIONS)
316 201 P
16 D12 D1 1 SP1
317 Air Filter
LOCAL/MASTER CONTROL 17 D13
318 QF4 406 414
3 REMOTE LOAD/UNLOAD 18 D14
319 Fan overload COMPRESSOR COMPRESSOR
REMOTE START/STOP 19 D15
320
20 GND KA2 FAULT LOADING
Only for remote control mode a KA3
SB1 SB2 S4 S8
201A 407 415
J4 K8 J1 Emergency Stop
361 115 Accident
1 15
47
Analogue Output + A1 OUT 0-10V EXPAND 114 Emgergency Stop Button
362 14 408 410
2 + A2 OUT 0-10V K7 113
363 3 13
Sequential Control Protocol + EXPAND

1/RS-485 112
364 4 - 12 KM1 COMPRESSOR
111 1 YV4 COMPRESSOR
365 5 + FULL LOAD MODULATE 11 Full Load Control Solenoid Valve
Modbus Protocol 2/RS-485 K6 110 RUNNING KM1 KA0 STOPPED
366 6 - ELECTRIC DRAIN 10 KA1 441
367 K5 109 Full Load Control Relay
7 GND COMMON FAULT 9
K4
8 108 1 KA7 Electric drain Sol.Valve
KA0 S5 S6
107
J5 UNLOAD/LOAD 7 KA2 Alarm Relay
409
K3 106 411
*-DELTA 6 KA3
381 K2 105 Load Relay
1 RUN 5
382 K1 104 Emg. Stop 120 120A YV2
2 4 Load/Unload Sol.Valve
383 EXPAND 103 2
3 AC GND 3 YV1
384 KA11 Start Control Sol.Valve
4 120V N 2 102
101
AC L 1 KM1 Fan Contactor
101
105 KA0 START/STOP RELAY
YV5 Electric drain Sol.Valve
KA1
122 1 YV3 Spiral Control Volve
S11
101 101 101 502 503 5 126 KA10 High Voltage Starter Fault Relay
FROM XT1
101 KA6 125 KA11 Low Voltage Power Ready Relay

KA11 KA12 5
130 131 S10
500 501 124 KA12 High Voltage Starter Ready Relay
POWER SHOW(RED)
HIGH VOLTAGE READY(GREEN)
LOW VOLTAGE READY(WHITE)

FROM XT1
102
HL1 HL2 HL3
6.5 Water-cooled machine wiring diagram – High-voltage (Deluxe Microprocessor Controller I) (Continued)
48
-XT1
-XT4
101
400 400 101
S1
START PULSE 101

401 401
101
STOP PULSE
402 402 101
S2
101
403 403
120
404 404 120
2
START ALLOW
S3
120
405 405
120A
COMPRESSOR 406 406 120A
S4
FAULT 120A
407 407 102
COMPRESSOR 408 408 102 102
S5
RUNNING
409 409 102
CUSTOMER CONNECTION
COMPRESSOR 410 410 102

STOP
102
S6
411 411 102

ACCIDENT 412 412 102 102
BUTTON
S7
413 413 104

COMPRESSOR 414 414 104 104
LOAD
S8
415 415 105

105
105
105
105 105
106
106 106
-XT5
500 500 107

HIGH VOLTAGE
107 107
S10
READY 501 501

108
HIGH VOLTAGE
502 502 108
108
S11
FAULT 503 503

109
HI-VOLTAGE 504 504 109 109
N.O OF SWITCH
S12
505 505 110

HI-VOLTAGE 506 506 110 110
N.C OF SWITCH
S13
507 507
CUSTOMER CONNECTION
111
HI-VOLTAGE MOTOR 508 508 111
111
CURRENT TRANSFORMER
S14
509 509 112

112
112
113
113
113
114
114
114
115
115
115
124
124
124
126
126
126
-XT3
301
-XT2
301 301 202

302 202
202
302 302
203
303 203
203
303 303
204
304 204
204
304 304
205
305 205
205
305 305
206
306 206
206
306 306
207
307 207
207
307 307
208
308 208
208
308 308
209
309 209
209
309 309
210
210
310 210
310 310
211
311 211
211
311 311
211
312 211
211
312 312
211
313 211
211
313 313
212
314 212
212
314 314
213
315 213
213
315 315
214
316 214
214
316 316
215
317 215
215
317 317
216
318 216
216
318 318
217
319 217
217
319 319
218
320 218
218
320 320
219
219
219
6.5 Water-cooled machine wiring diagram – High-voltage (Deluxe Microprocessor Controller I) (Continued)
Chapter VI Schematics LS25S-250/300/350 Series Screw Compressor Operator’s Manual
LS25S-250/300/350 Series Screw Compressor Operator’s Manual Chapter VII Troubleshooting
Chapter VII Troubleshooting
7.1 General
Compressor's fault may be caused by multiple reasons. Therefore a systematic analysis on all causes of
the fault should be carried out before service or parts replacement. Do not disassemble the machine
without purpose. To avoid damage, visual check is necessary. Keep the following in mind:
a. Check if cable leads are loose or disconnected;
b. Check if pipeline is damaged;
c. Check if there is part damaged by over heat or short circuit. Normally phenomena are color changing
or scorch odor.
7.2 Troubleshooting are listed in the following table

Trouble Possible causes Actions
Low fluid level in air/fluid separator Check fluid level, add fluid if necessary
High cooling air temperature (air-cooled machine Increase ventilation, reduce air-in
only) temperature
Thermal valve failure (water-cooled machine only) Check/replace thermal components
See Schneider Altivar 38 Asynchronous

VVVF that drives fluid cooler fan motor is faulted
Motor VVVF Operation Manual for
(air-cooled machine only)
troubleshooting
High air discharge Insufficient cooling water flux (water-cooled
temperature Increase cooling water flux
machine only)
(T1 HI)
High water temperature (water-cooled machine
Decrease water temperature
only)
Clean pipe and shell. If it is still clogged
Water cooler element clogged up
up, water treatment device should be
equipped
Air cooler clogged up Clean cooler element fin plate
Thermal resistor temperature transmitter RTD Check RTD connector. If the connector is
failure good, replace RTD
Unloading components (e.g. vent valve, inlet

Check if unloading components are normal
regulator valve) are not working properly
High air discharge
pressure (can Load/unload solenoid failure Check solenoid condition
pressure)
(P1 HI) Control air leakage Check if control pipeline is leaking
Control pipeline filter clogged up Repair filter assembly
(1) Reduce air demand;

Air demand higher than air supply (2) Check for leakage on pipeline.
Air supply pressure
Air filter clogged up Replace filter element
lower than rated
discharge pressure Check motion of inlet valve; check the
Inlet valve unable to open completely setting of pressure reducing valve and
pressure regulator
49
Check transmitter's contacts. Replace

Pressure transmitter P2 fault transmitter if contacts are normal.
Check pressure regulator, replace with

Pressure regulator failure
spare parts if necessary
Trouble Possible causes Actions
Check transmitter's contacts. Replace

Pressure transmitter P2 fault transmitter if contacts are normal.
Unloading components (e.g. vent valve, inlet Check if unloading components are normal
regulator valve) are not working properly
Pipeline pressure P2 Unload solenoid failure Check solenoid

higher than Control air leakage Check if control pipeline is leaking
unloading pressure
Control pipeline filter clogged up Repair filter assembly
Fluid return pipe filter or nozzle blocked Clean filter, sieve and nozzle
Separator element damaged or washer displaced Check separator components and washer.
Replace if necessary.
System is leaking fluid Check if system pipeline is leaking fluid
Fluid consumption Fluid level too high Discharge some lube fluid
too high
Too much fluid foam Change lube fluid
7.3 Transmitter operation description and controller parameter calibration - Deluxe

Microprocessor Controller I
Transmitter operation description:
Whenever a transmitter is suspected to be faulted, use other standard gauge to measure and calibrate
(pressure and temperature, etc.). If readings are incorrect, check cable terminals or pipe connectors. If
terminals and connectors are in good condition, replace the transmitter and calibrate again with standard
gauge.
Parameter calibration
Controller is equipped with calibration software for pressure transmitter and temperature transmitter. The
software may modify pressure and temperature calculation offset, but not the slope of conversion curve.
Therefore the most accurate method is to heat or pressurize the transmitter to its operation value. If this is
too hard to do, then calibrate under room temperature/atmospheric pressure. Calibration can be carried
out only when the machine is stopped and external control is deactivated.
To enter calibration mode, you must enter User Parameter Setting screen (see Deluxe Microprocessor
Controller I Operation Manual on how to enter and modify) and find corresponding transmitter
calibration screen. For example:
NO: 57P1 CAL
P1:00
0 Bar
In the above illustration: "NO: 57" represents parameter code; P1: 00 represents the actual value of P1; 0
50
bar represents the current revision value of P1 transmitter. Press " " button (Up arrow) to increase
the value, and press " " button (Down arrow/indicator test) to decrease. Value on the left will
increase or decrease, and adjustment total value is always displayed. Maximum adjustment range is
±2.0Bar. Press "DISPLY" button to exit calibration mode and previous items except current item are
saved. Press "PROG" button to save current item and enter next item. Each temperature and pressure
value can be calibrated separately.
7.4 Transmitter operation description and controller parameter calibration – Sullair

Supervisor II
Transmitter operation description:
Whenever a transmitter is suspected to be faulted, use other standard gauge to measure and calibrate
(pressure and temperature, etc.). If readings are incorrect, check cable terminals or pipe connectors. If
terminals and connectors are in good condition, replace the transmitter and calibrate again with standard
gauge.
Parameter calibration
Controller is equipped with calibration software for pressure transmitter and temperature transmitter. The
software may modify pressure and temperature calculation offset, but not the slope of conversion curve.
Therefore the most accurate method is to heat or pressurize the transmitter to its operation value. If this is
too hard to do, then calibrate under room temperature/atmospheric pressure. Calibration can be carried
out only when the machine is stopped and external control is deactivated.
To enter calibration mode, you must press the following keys in sequence under default status display
mode: “ ”, “ ”, “DISPLAY”, “ ” and “PROG”. Once it is in calibration mode, you will see
the following screen on display:
CAL P1
0 6.7
Press " " button (Up arrow) to increase the value, and press " " button (Down
arrow/indicator test) to decrease. Value on the left will increase or decrease, and adjustment total value is
always displayed. Maximum adjustment range is ±7.
Press "DISPLY" button to exit calibration mode and previous items except current item are saved. Press
"PROG" button to save current item and enter next item. Each temperature and pressure value can be
calibrated separately.
51
LS25S-250/300/350 Series Screw Compressor Operator’s Manual Chapter VIII Parts Order
Chapter VIII Parts Order
Parts ordering procedure:

You can order required spare parts at local division of Sullair Asia or your dealer. If you cannot get the
spare parts from them due to some reasons, please contact the After-sales Market Department of Sullair
Asia at the address listed at the end of this manual.
Model and serial number of your machine must be specified when you order parts because Sullair
product is constantly updating. You may find discrepancies between manual and your actual situation
after a period. See machine nameplate or bill of lading for machine model and serial number.
Check parts schematics thoroughly before ordering. See LS25S-250/300/350 Parts List (The Second
Generation Model), Sullair part number: 88290016-737.
52
Global Sales and Sercive
Headquarter in US: SULLAIR CORPORATION

Subsidiary of Hamilton-Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 001-219-879-5451 or 1-800-Sullair (U.S.A. only)
Fax: 001-219-874-1273
Headquarter in Asia: SULLAIR ASIA

website: http://www.sullair-asia.com Hotline: 800-830-3977
Sullair Singapore: 74 Joo Koon Circle, Jurong Singapore 629093
Telephone: 65-68611211 Fax: 65-68612967
Sullair Taipei: No. 1, 3rd Floor, 248 Zhongshan Road, Linkou Village,
Taipei County
Tel: 02-26013500 Fax: 02-26013032
Shenzhen Factory: Zuo Paotai Road, Chiwan, Shekou, Shenzhen, P. R.
China 518068
Tel: 0755-26851686 Fax: 0755-26853475
Suzhou Factory: 266 Changyang Street, Singapore Industrial Park,
Suzhou, 215000
Tel: 0512-87162388 Fax: 0512-87162389, 87162387
Shanghai Branch: Room 2903, Laifushi Plaza, 268 Xizang Road Central,
Shanghai City 200001
Tel: 021-53852036, 53852038 Fax: 021-53852035
Beijing Branch: Room 1506, Block B, Xingfu Building, 3 Eastern Third
Ring Road North, Beijing City 100027
Tel: 010-64629770, 64629768 Fax: 010-64629773
Chengdu Branch: Room H, 28/F, Guancheng Plaza, 308 Shuncheng
Street, Chengdu City 610017
Tel: 028-86527506, 86527507 Fax: 028-86527505
Shenyang Branch: Room 1601, Gaodeng International Building, 355
Zhongshan Road, Shenhe District, Shenyang City 110014
Tel: 024-22818450, 22818550 Fax: 024-22818590
Xi’an Branch: Room 701A, Jinxin Building, 99 Heping Road, Xi’an City
710001
Tel: 029-87206201, 87206202 Fax: 029-87206204
Wuhan Branch: Room 2909, Block B, Zhongshang Plaza, 7 Zhongnan
Road, Wuchang, Wuhan City 430071
Tel: 027-87322745Fax: 027-87322546
Xinjiang Branch: Unit J, 9th Floor, National Development Bank Tower,
339 Zhongshan Road, Urumqi, 830002
Tel: 0991-2308451, 2308452 Fax: 0991-2308450
(P/N): 88290016-736
(E/N): 01

Sullair Compressor Manual LS25S (EN)

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Sullair Compressor Manual LS25S (EN)

Загружено:

Авторское право:

Доступные форматы

STATIONARY AIR COMPRESSOR

OPERATION & MAINTENANCE MANUAL

SHENZHEN SULLAIR ASIA INDUSTRIAL CO., LTD.

1.2 Personal protective equipment

1.3 Fire and explosion

1.4 Moving parts

1.5 Hot surfaces, sharp edges and sharp corners:

1.6 Toxic and Irritating substances:

1.7 Electrical shock

1.8 High-voltage protection (for high-voltage machine)

1.10 Other precautions

Chapter II Compressor Structure

Safety valve open

Figure 1 - LS25S-250/300/350 (380V/6kV ODP) air-cooled machine layout

AIR OUT AIR IN

Figure 1 - LS25S-250/300/350 (380V/6kV ODP) Air-cooled Compressor Installation Illustration

11 12 AIR OUT 13 15 16 17 AIR IN

Figure 2 - LS25S-250/300/350 (380V/6Kv ODP) Water-Cooled Compressor Installation

Figure 3 - LS25S-250/300/350 (6 kV /10kV TEFC) air-cooled machine layout

01. Motor 02. Machine base 03. Starter 04. Coupling

Figure 4 - LS25S-250/300/350 (6 kV /10kV TEFC) water-cooled machine layout

01. Motor 02. Machine Frame 03. Starter 04. Coupling

Figure 5 - LS25S-250/300/350 air-cooled system flow chart

Figure 6 - LS25S-250/300/350 water-cooled system flow chart

2.2 Inlet system

2.3 Discharge system

2.4 Fluid piping system

2.4.5 Acid removal filter (only for SULLUBE unit)

2.5 Air/fluid separator

2.6 Air-cooling system (air-cooled machine only)

2.7 Water piping system (water-cooled machine only)

2.8 Air volume adjustment system

2.9 Microprocessor controller

Chapter III Installation of Compressor

3.2 Vibration absorption and noise reduction

3.3 Equipment room environment

3.4 Dimension and mounting illustration

3.6 Remove transportation support parts (air-cooled machine only)

3.7 Motor rotation direction check

Figure. 7 - Basic Construction Plans

370 1730 1730 435 345

795 CONN. FOUNDATION BOLT:M20 865

Figure. 8 - Dimension and mounting illustration of

LS25S-250/300/350 (380V/6kV ODP) air-cooled machine

CANOPY YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO

WEIGHT/KG 5920/5180 6240/5500 6190/5450 6540/5800 6300/5560 6740/6000 6640/5900

2511 HOLE OF BARD BOLT 6- 22 2160

Figure. 9 - Dimension and mounting illustration of

LS25S-250/300/350 (380V/6kV ODP) water-cooled machine

300 THE LIST OF THE LS25S-WC WEIGHT(UNITS：KG)

Figure. 10 - Dimension and mounting illustration of

LS25S-250/300/350(6kV/10kV TEFC) air-cooled machine

MAIN MOTOR JUNCTION BOX

1.The minimum distance that the compressor should be from

THE POSITION OF THE

Figure. 11 - Dimension and mounting illustration of

LS25S-250/300/350(6kV/10kV TEFC) water-cooled machine

6KV TEFC/10KV ODP&TEFC

Chapter IV Compressor Operation

4.1 Safety operation procedure

4.2 Preparation before initial starting

4.3 Normal operation

4.4 Shutdown procedure