LS25 S Manual PDF

INDUSTRIAL ROTARY SCREW
AIR COMPRESSOR
LS25S
200-350HP/
149-261KW
AIR-COOLED & WATER-COOLED
STANDARD AND 24KT
OPERATOR’S
MANUAL AND
PARTS LIST
KEEP FOR
FUTURE
REFERENCE
Part Number 02250137-621
©Sullair Corporation
AIR CARE
SEMINAR TRAINING
Sullair Air Care Seminars are 3-day courses that provide hands-on instruction in the proper operation, mainte-
nance and service of Sullair equipment. Individual seminars on Industrial compressors and compressor electrical
systems are presented at regular intervals throughout the year at a dedicated training facility at Sullair’s corporate
headquarters in Michigan City, Indiana.
Instruction includes discussion of the function and installation of Sullair service parts, troubleshooting of the most
common problems, and actual equipment operation. The seminars are recommended for maintenance and serv-
ice personnel.
For detailed course outlines, schedule and cost information contact:
Sullair Corporate Training Department

1-800-SULLAIR or 219-879-5451 (ext. 5630)
www.sullair.com/training.shtm
- Or Write -
Sullair Corporation
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department
TABLE OF CONTENTS
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL
Section 1 Page
SAFETY 1 1.1 GENERAL
1 1.2 PERSONAL PROTECTIVE EQUIPMENT
1 1.3 PRESSURE RELEASE
2 1.4 FIRE AND EXPLOSION
2 1.5 MOVING PARTS
2 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
3 1.7 TOXIC AND IRRITATING SUBSTANCES
3 1.8 ELECTRICAL SHOCK
3 1.9 LIFTING
4 1.10 ENTRAPMENT
Section 2
DESCRIPTION 5 2.1 INTRODUCTION
5 2.2 DESCRIPTION OF COMPONENTS
5 2.3 SULLAIR COMPRESSOR UNIT,
FUNCTIONAL DESCRIPTION
6 2.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM,
8 2.5 COMPRESSOR DISCHARGE SYSTEM,
10 2.6 CONTROL SYSTEM, FUNCTIONAL
DESCRIPTION
13 2.7 AIR INLET SYSTEM, FUNCTIONAL
DESCRIPTION
Section 3
SPECIFICATIONS 15 3.1 SULLAIR SERIES LS25S SPECIFICATIONS
15 3.2 LUBRICATION GUIDE- STANDARD COMPRESSORS
15 3.3 LUBRICATION GUIDE- 24KT COMPRESSORS
15 3.4 APPLICATION GUIDE
15 3.5 LUBRICATION CHANGE RECOMMENDATIONS
AND MAINTENANCE
TABLE OF CONTENTS
Section 4
INSTALLATION 45 4.1 MOUNTING OF COMPRESSOR
45 4.2 VENTILATION AND COOLING
45 4.3 SERVICE AIR PIPING
45 4.4 COUPLING ALIGNMENT CHECK
45 4.5 FLUID LEVEL CHECK
46 4.6 FLUID PIPING (REMOTE AIR-COOLED OPTION ONLY)
47 4.7 ELECTRICAL PREPARATION
47 4.8 MOTOR ROTATION DIRECTION CHECK
Section 5
SUPERVISOR 48 FIGURE 5-1 SUPERVISOR CONTROL PANEL
Section 6
COMPRESSOR
OPERATION 49 6.1 INTRODUCTION
49 6.2 PURPOSE OF CONTROLS
50 6.3 INITIAL START-UP PROCEDURE
51 6.4 SUBSEQUENT START-UP PROCEDURE
51 6.5 SHUTDOWN PROCEDURE
Section 7
MAINTENANCE 53 7.1 GENERAL
53 7.2 DAILY OPERATION
53 7.3 MAINTENANCE AFTER INITIAL 50 HOURS
OF OPERATION
53 7.4 MAINTENANCE AFTER 1000 HOURS
53 7.5 FLUID CHANGE
53 7.6 SEPARATOR MAINTENANCE
53 7.7 PARTS REPLACEMENT AND ADJUSTMENT
PROCEDURES
53 FLUID FILTER MAINTENANCE
54 AIR FILTER MAINTENANCE
55 SEPARATOR ELEMENTS REPLACEMENT
56 OIL RETURN/SIGHT GLASS MAINTENANCE
56 DIFFERENTIAL PRESSURE REGULATOR
ADJUSTMENT
57 PRESSURE REDUCING REGULATOR
57 DRIVE COUPLING INSTALLATION AND ALIGNMENT
(200-350HP/ 149-261KW)
59 7.8 TROUBLESHOOTING
TABLE OF CONTENTS
Section 7
MAINTENANCE
(Continued) 59 7.9 TROUBLESHOOTING GUIDE
Section 8
ILLUSTRATION AND
PARTS LIST 63 8.1 PROCEDURE FOR ORDERING PARTS
63 8.2 RECOMMENDED SPARE PARTS LIST-
200-250HP/ 149-186KW
65 8.3 RECOMMENDED SPARE PARTS LIST-
300-350HP/ 224-261KW
66 8.4 MOTOR, COMPRESSOR, FRAME AND PARTS
68 8.5 AIR INLET SYSTEM
70 8.6 INLET VALVE
72 8.7 FLUID COOLING SYSTEM- AIR-COOLED
200-250HP/ 149-186KW
76 8.8 FLUID COOLING SYSTEM- AIR-COOLED
300-350HP/ 224-261KW
80 8.9 WATER COOLER PIPING- 200-350HP/ 149-261KW
82 8.10 AIR PIPING SYSTEM- AIR-COOLED 200-250HP/
149-186KW
86 8.11 AIR PIPING SYSTEM- WATER-COOLED300-350HP/
224-261KW
88 8.12 AIR PIPING SYSTEM- REMOTE-COOLED 200-250HP/
149-186KW
90 8.13 AIR PIPING SYSTEM- AIR-COOLED 300-350HP/
224-261KW
94 8.14 AIR PIPING SYSTEM- WATER-COOLED 300-350HP/
224-261KW
96 8.15 AIR PIPING SYSTEM- REMOTE-COOLED 300-350HP/
224-261KW
98 8.16 AIR PIPING SYSTEM- 24KT 350HP/ 261KW
102 8.17 FLUID PIPING SYSTEM- AIR-COOLED
200-250HP/ 149-186KW
104 8.18 FLUID PIPING SYSTEM- WATER-COOLED
200-250HP/ 149-186KW
106 8.19 FLUID PIPING SYSTEM- REMOTE-COOLED
200-250HP/ 149-186KW
110 8.20 FLUID PIPING SYSTEM- AIR-COOLED
300-350HP/ 224-261KW
112 8.21 FLUID PIPING SYSTEM- WATER-COOLED
300-350HP/ 224-261KW
TABLE OF CONTENTS
Section 8
ILLUSTRATION AND
PARTS LIST (Cont.) 114 8.22 FLUID PIPING SYSTEM- REMOTE-COOLED
300-350HP/ 224-261KW
116 8.23 SUMP AND PARTS 200-250HP/ 149-186KW
118 8.24 SUMP AND PARTS 300-350HP/ 224-261KW
120 8.25 COMPRESSOR SPIRAL VALVE
ACTUATOR (OPTIONAL)
122 8.26 ZERO-LOSS MOISTURE DRAIN (OPTIONAL)
124 8.27 PNEUMATIC CONTROLS
130 8.28 CONTROL BOX- SOLID STATE
132 8.29 CONTROL BOX- FULL VOLTAGE
134 8.30 CONTROL BOX- WYE-DELTA
136 8.31 ENCLOSURE- AIR-COOLED
200-250HP/ 149-186KW
140 8.32 ENCLOSURE- AIR-COOLED
300-350HP/ 224-261KW
144 8.33 ENCLOSURE- WATER-COOLED
200-350HP/ 149-261KW
148 8.34 DECAL GROUP
154 8.35 DECAL LOCATIONS- AIR-COOLED/OPEN
156 8.36 DECAL LOCATIONS- WATER-COOLED/OPEN
158 8.37 DECAL LOCATIONS- ENCLOSURES
160 8.38 DECAL LOCATIONS- CONTROL BOX INTERIOR
162 8.39 WIRING DIAGRAM- AIR-COOLED FULL VOLTAGE
WITH SUPERVISOR CONTROLLER
163 8.40 WIRING DIAGRAM- WATER-COOLED FULL VOLTAGE
164 8.41 WIRING DIAGRAM- WYE-DELTA AIR- AND REMOTE-
COOLED WITH SUPERVISOR CONTROLLER
165 8.42 WIRING DIAGRAM- WYE-DELTA WATER-COOLED
166 8.43 WIRING DIAGRAM- SOLID STATE AIR- AND REMOTE-
COOLED WITH SUPERVISOR CONTROLLER
167 8.44 WIRING DIAGRAM- SOLID STATE WATER-COOLED
Section 1
SAFETY
1.1 GENERAL the service air outlet and the shut-off (throttle)
Sullair Corporation and its subsidiaries design and valve, either at the compressor or at any other point
manufacture all of their products so they can be along the air line, when an air hose exceeding 1/2”
operated safely. However, the responsibility for (13mm) inside diameter is to be connected to the
safe operation rests with those who use and main- shut-off (throttle) valve, to reduce pressure in case
tain these products. The following safety precau- of hose failure, per all applicable Federal, State and
tions are offered as a guide which, if conscientious- Local codes, standards and regulations.
ly followed, will minimize the possibility of accidents B. When the hose is to be used to supply a mani-
throughout the useful life of this equipment. fold, install an additional appropriate flow-limiting
The compressor should be operated only by those valve between the manifold and each air hose
who have been trained and delegated to do so, and exceeding 1/2” (13mm) inside diameter that is to be
who have read and understood this Operator’s connected to the manifold to reduce pressure in
Manual. Failure to follow the instructions, proce- case of hose failure.
dures and safety precautions in this manual can C. Provide an appropriate flow-limiting valve at the
result in accidents and injuries. Read this manual beginning of each additional 75 feet (23m) of hose
prior to startup. in runs of air hose exceeding 1/2” (13mm) inside
NEVER start the compressor unless it is safe to do diameter to reduce pressure in case of hose failure.
so. DO NOT attempt to operate the compressor D. Flow-limiting valves are listed by pipe size and
with a known unsafe condition. Tag the compressor rated CFM. Select appropriate valves accordingly,
and render it inoperative by disconnecting and lock- in accordance with their manufacturer’s recommen-
ing out all power at source or otherwise disabling its dations.
prime mover, so others who may not know of the
unsafe condition, cannot attempt to operate it until E. DO NOT use air tools that are rated below the
the condition is corrected. maximum rating of the compressor. Select air tools,
air hoses, pipes, valves, filters, and other fittings
Install, use and operate the compressor only in full accordingly. DO NOT exceed manufacturer’s rated
compliance with all pertinent regulations and all safe operating pressures for these items.
applicable Federal, State, and Local codes, stan-
dards and regulations. F. Secure all hose connections by wire, chain or
other suitable retaining devices to prevent tools or
DO NOT modify the compressor and/or controls in hose ends from being accidentally disconnected
any way except with written factory approval. and expelled.
While not specifically applicable to all types of com- G. Open fluid filler cap only when compressor is not
pressors with all types of prime movers, most of the running and is not pressurized. Shut down the com-
precautionary statements contained herein are pressor and bleed the sump (receiver) to zero inter-
applicable to most compressors and the concepts nal pressure before removing the cap.
behind these statements are generally applicable to
all compressors. H. Vent all internal pressure prior to opening any
line, fitting, hose, valve, drain plug, connection or
1.2 PERSONAL PROTECTIVE EQUIPMENT other component, such as filters and line oilers, and
Prior to installing or operating the compressor, own- before attempting to refill optional air line anti-icer
ers, employers and users should become familiar systems with antifreeze compound.
with, and comply with, all applicable regulations and
any applicable Federal, State and Local codes, I. Keep personnel out of line with and away from the
standards, and regulations relative to personal pro- discharge opening of hoses or tools or other points
tective equipment, such as eye and face protective of compressed air discharge.
equipment, respiratory protective equipment, equip- J. Use air at pressures less than 30 psig (2.1 bar)
ment intended to protect the extremities, protective for cleaning purposes, and then only with effective
clothing, protective shields and barriers and electri- chip guarding and personal protective equipment.
cal protective equipment, as well as noise exposure K. DO NOT engage in horseplay with air hoses as
administrative and/or engineering controls and/or death or serious injury may result.
personal hearing protective equipment.
L. DO NOT tamper with sump and unit (if provid-
1.3 PRESSURE RELEASE ed) relief valves. Check the relief valve as recom-
A. Install an appropriate flow-limiting valve between mended in the Maintenance Section of this manual
1
Section 1
SAFETY
or at a minimum of at least weekly to make sure it al that may be damaged by heat or that may sup-
is not blocked, clogged, obstructed or otherwise port combustion and is in close proximity, prior to
disabled. DO NOT change the factory setting of the attempting weld repairs.
relief valve. H. Keep suitable fully charged fire extinguisher or
M. If the compressor is installed in an enclosed extinguishers nearby when servicing and operating
area, it is necessary to vent the relief valve to the the compressor.
outside of the structure or to an area of non-expo- I. Keep oily rags, trash, leaves, litter or other com-
sure. bustibles out of and away from the compressor.
1.4 FIRE AND EXPLOSION J. DO NOT operate the compressor without proper
flow of cooling air or water or with inadequate flow
of lubricant or with degraded lubricant.
When installing a Base Load Transfer (BLT)
System, remove jumpers between 16-17 & 18-19
K. DO NOT attempt to operate the compressor in
(Dual Control Compressors) so the other com- any classification of hazardous environment unless
pressor does not backfeed defeating the shut- the compressor has been specially designed and
down circuitry. manufactured for that duty.
A. Clean up spills of lubricant or other combustible 1.5 MOVING PARTS
substances immediately, if such spills occur. A. Keep hands, arms and other parts of the body
B. Shut off the compressor and allow it to cool. and also clothing away from couplings, fans and
Then keep sparks, flames and other sources of igni- other moving parts.
tion away and DO NOT permit smoking in the vicin- B. DO NOT attempt to operate the compressor with
ity when checking or adding lubricant or when refill- the fan, coupling or other guards removed.
ing air line anti-icer systems with antifreeze com- C. Wear snug-fitting clothing and confine long hair
pound. when working around this compressor, especially
C. DO NOT permit fluids, including air line anti-icer when exposed to hot or moving parts.
system antifreeze compound or fluid film to accu- D. Keep access doors, if any, closed except when
mulate on, under, or around acoustical material, or making repairs or adjustments.
on any external surfaces of the air compressor or
on internal surfaces of the enclosure. Wipe down E. Make sure all personnel are out of and/or clear of
using an aqueous industrial cleaner or steam-clean the compressor prior to attempting to start or oper-
as required. If necessary, remove acoustical mate- ate it.
rial, clean all surfaces and then replace acoustical F. Disconnect and lock out all power at source and
material. Any acoustical material with a protective verify at the compressor that all circuits are de-
covering that has been torn or punctured should be energized to minimize the possibility of accidental
replaced immediately to prevent accumulation of start-up or operation, prior to attempting repairs or
liquids or fluid film within the material. DO NOT use adjustments. This is especially important when
flammable solvents for cleaning purposes. compressors are remotely controlled.
D. Disconnect and lock out all power at source prior G. Keep hands, feet, floors, controls and walking
to attempting any repairs or cleaning of the com- surfaces clean and free of fluid, water, or other liq-
pressor or of the inside of the enclosure, if any. uids to minimize the possibility of slips and falls.
E. Keep electrical wiring, including all terminals and 1.6 HOT SURFACES, SHARP EDGES AND SHARP
pressure connectors in good condition. Replace CORNERS
any wiring that has cracked, cut abraded or other- A. Avoid bodily contact with hot fluid, hot coolant,
wise degraded insulation, or terminals that are hot surfaces and sharp edges and corners.
worn, discolored or corroded. Keep all terminals
and pressure connectors clean and tight. B. Keep all parts of the body away from all points of
air discharge.
F. Keep grounded and/or conductive objects such
as tools away from exposed live electrical parts C. Wear personal protective equipment including
such as terminals to avoid arcing which might serve gloves and head covering when working in, on or
as a source of ignition. around the compressor.
G. Remove any acoustical material or other materi- D. Keep a first aid kit handy. Seek medical assis-
tance promptly in case of injury. DO NOT ignore
2
Section 1
SAFETY
small cuts and burns as they may lead to infection. tained in full compliance with all applicable Federal,
1.7 TOXIC AND IRRITATING SUBSTANCES State and Local codes, standards and regulations,
A. DO NOT use air from this compressor for respi- including those of the National Electrical Code, and
ration (breathing) except in full compliance with any also including those relative to equipment ground-
Federal, State or Local Codes or regulations. ing conductors, and only by personnel that are
trained, qualified and delegated to do so.
B. Keep all parts of the body and any hand-held
Death or serious injury can result from inhaling tools or other conductive objects away from
compressed air without using proper safety exposed live parts of electrical system. Maintain dry
equipment. footing, stand on insulating surfaces and DO NOT
contact any other portion of the compressor when
B. DO NOT use air line anti-icer systems in air lines making adjustments or repairs to exposed live parts
supplying respirators or other breathing air utiliza- of the electrical system. Make all such adjustments
tion equipment and DO NOT discharge air from or repairs with one hand only, so as to minimize the
these systems in unventilated or other confined possibility of creating a current path through the
areas. heart.
C. Operate the compressor only in open or ade- C. Attempt repairs in clean, dry and well lighted and
quately ventilated areas. ventilated areas only.
D. Locate the compressor or provide a remote inlet D. DO NOT leave the compressor unattended with
so that it is not likely to ingest exhaust fumes or open electrical enclosures. If necessary to do so,
other toxic, noxious or corrosive fumes or sub- then disconnect, lock out and tag all power at
stances. source so others will not inadvertently restore
E. Coolants and lubricants used in this compressor power.
are typical of the industry. Care should be taken to E. Disconnect, lock out, and tag all power at source
avoid accidental ingestion and/or skin contact. In prior to attempting repairs or adjustments to rotating
the event of ingestion, seek medical treatment machinery and prior to handling any ungrounded
promptly. Wash with soap and water in the event of conductors.
skin contact. Consult the compressor operator’s
manual lubrication section for information pertaining F. Dry test all shutdown circuits prior to starting the
to compressor fluid fill. compressor after installation.
F. Wear goggles or a full face shield when adding 1.9 LIFTING

antifreeze compound to air line anti-icer systems. A. If the compressor is provided with a lifting bail,
then lift by the bail provided. If no bail is provided,
G. If air line anti-icer system antifreeze compound then lift by sling. Compressors to be air lifted by hel-
enters the eyes or if fumes irritate the eyes, they icopter must not be supported by the lifting bail but
should be washed with large quantities of clean by slings instead. In any event, lift and/or handle
water for 15 minutes. A physician, preferably an eye only in full compliance with Federal, State and Local
specialist, should be contacted immediately. codes.
H. DO NOT store air line anti-icer system antifreeze B. Inspect points of attachment for cracked welds
compound in confined areas. and for cracked, bent, corroded or otherwise
I. The antifreeze compound used in air line degraded members and for loose bolts or nuts prior
antifreeze systems contains methanol and is toxic, to lifting.
harmful, or fatal if swallowed. Avoid contact with the C. Make sure entire lifting, rigging and supporting
skin or eyes and avoid breathing the fumes. If swal- structure has been inspected, is in good condition
lowed, induce vomiting by administering a table- and has a rated capacity of at least the weight of
spoon of salt, in each glass of clean, warm water the compressor. If you are unsure of the weight,
until vomit is clear, then administer two teaspoons then weigh compressor before lifting.
of baking soda in a glass of clean water. Have
patient lay down and cover eyes to exclude light. D. Make sure lifting hook has a functional safety
Call a physician immediately. latch or equivalent, and is fully engaged and latched
on the bail or slings.
1.8 ELECTRICAL SHOCK E. Use guide ropes or equivalent to prevent twisting
A. This compressor should be installed and main-
3
Section 1
SAFETY
or swinging of the compressor once it has been lift- mum practical speeds.
ed clear of the ground. N. Make sure pallet-mounted compressors are firm-
F. DO NOT attempt to lift in high winds. ly bolted or otherwise secured to the pallet prior to
G. Keep all personnel out from under and away attempting to forklift or transport them. NEVER
from the compressor whenever it is suspended. attempt to forklift a compressor that is not secured
to its pallet, as uneven floors or sudden stops may
H. Lift compressor no higher than necessary. cause the compressor to tumble off, possibly caus-
I. Keep lift operator in constant attendance whenev- ing serious injury or property damage in the
er compressor is suspended. process.
J. Set compressor down only on a level surface O. DO NOT use the lifting eye bolt on the compres-
capable of safely supporting at least its weight and sor motor, if supplied, to lift the entire compressor
its loading unit. package.
K. When moving compressors by forklift truck, uti- 1.10 ENTRAPMENT
lize fork pockets if provided. Otherwise, utilize pal- A. If the compressor enclosure is large enough to
let if provided. If neither fork pockets or pallet are hold a person and if it is necessary to enter it to per-
provided, then make sure compressor is secure form service adjustments, inform other personnel
and well balanced on forks before attempting to before doing so, or else secure and tag the access
raise or transport it any significant distance. door in the open position to avoid the possibility of
L. Make sure forklift truck forks are fully engaged others closing and possibly latching the door with
and tipped back prior to lifting or transporting the personnel inside.
compressor. B. Make sure all personnel are out of compressor
M. Forklift no higher than necessary to clear obsta- before closing and latching enclosure doors.
cles at floor level and transport and corner at mini-
4
Section 2
DESCRIPTION
2.1 INTRODUCTION trol system and Supervisor ControllerTM, micro-
Refer to Figures 2-1A and 2-1B. Your new Sullair processor system and starter all mounted on a
lubricated rotary screw air compressor provides you structural steel frame
with a unique experience in improved reliability and On air-cooled models, a fan draws air over the fan
greatly reduced maintenance. motor and forces it through the combined aftercool-
Compared to other types of compressors, the er and fluid cooler, thereby removing the heat of
Sullair rotary screw is unique in its mechanical reli- compression from the cooling fluid.
ability and lack of “wear”. The compressor requires On water-cooled models, fluid is piped into a water-
absolutely no inspection of its internal parts. cooled heat exchanger where the heat of compres-
By reading through Section 6, you will notice the sion is removed from the fluid. A fan is used to sup-
easy process of caring and maintaining this Sullair ply sufficient ventilating air to compressors
manufactured product. Should any questions arise equipped with an optional enclosure.
which cannot be answered in this text, call your Both air-cooled and water-cooled versions have
nearest Sullair representative or the Sullair easily accessible items such as the fluid filters and
Corporation Service Department. control valves. The inlet air filters are also mounted
2.2 DESCRIPTION OF COMPONENTS for easy access and servicing.
Refer to Figures 2-1A and 2-1B. The components 2.3 SULLAIR COMPRESSOR UNIT, FUNCTIONAL
and assemblies of the air compressors are clearly DESCRIPTION
shown. The complete package includes compres- Sullair air compressors feature the Sullair compres-
sor, electric motor, compressor inlet system, sor unit, a positive displacement fluid lubricated-
compressor discharge system, compressor type compressor. This unit provides continuous air
cooling and lubrication system, capacity con- compression to meet your needs.
Figure 2-1A Sullair Series LS25S Rotary Screw Compressor (Air-cooled Version)
5
Section 2
DESCRIPTION
Figure 2-1B Sullair Series LS25S Rotary Screw Compressor (Water-cooled Version)
Fluid is injected into the compressor unit where it 2.4 COMPRESSOR COOLING AND LUBRICATION
mixes directly with the air as the internal rotors turn, SYSTEM, FUNCTIONAL DESCRIPTION
compressing the air. The fluid flow has three basic Refer to Figures 2-2, 2-3, 2-4, 2-5A, 2-5B, 2-5C and
functions: 2-5D. The cooling and lubrication system con-
1. As coolant, it controls the rise of air temperature sists of a fluid cooler, full flow fluid filter and
normally associated with the heat of compression. thermal valve.
2. Seals the clearance between the rotors and the The pressure in the receiver/sump causes fluid flow
stator and also between the rotors themselves. by forcing the fluid from the high pressure area of
the sump to an area of lower pressure in the com-
3. Acts as a lubricating film between the rotors pressor unit.
allowing one rotor to directly drive the other, which
is an idler. After the air/fluid mixture is discharged Fluid flows from the receiver/sump to the thermal
from the compressor unit, the fluid is separated valve. The thermal valve is fully open to the com-
from the air. At this time, the air flows to the serv- pressor unit when the discharge temperature is
ice line and the fluid is cooled in preparation for re- below 170°F (77°C) for all compressors, except
injection. water-cooled 24KT models, which is fully open up
to 195°F (91°C). The fluid passes through the ther-
mal valve, the main fluid filter and directly to the
compressor unit.
With a Sullair compressor, there is no mainte-
nance or inspection of the internal parts of the
As the discharge temperature rises above 170°F
compressor unit permitted in accordance with (77°C) for all compressors (195°F [91°C] for water-
the terms of the warranty. cooled 24KT models), due to the heat of compres-
6
Section 2
DESCRIPTION
Figure 2-2 Compressor Piping and Instrument Diagram (200 -350HP/ 149-261KW)
7
Section 2
DESCRIPTION
Figure 2-3 Compressor Cooling and Lubrication System (Air-cooled)
sion, the thermal valve begins to close and a portion ments.

of the fluid then flows through the cooler. From the The compressed air/fluid mixture enters the receiv-
cooler, the fluid flows to the main filter, and on to the er and is directed against an internal baffle. The
compressor unit. The fluid filter has a replacement direction of movement is changed and its velocity
element and an integral pressure bypass valve. significantly reduced, thus causing the large
Water-cooled models have a water pressure switch droplets of fluid to fall to the bottom of the receiv-
to prevent operation with inadequate water pres- er/sump. The fractional percentage of fluid remain-
sure. ing in the compressed air collects on the surface of
2.5 COMPRESSOR DISCHARGE SYSTEM, FUNC- the nested separator elements (primary and sec-
TIONAL DESCRIPTION ondary) as the compressed air flows through them.
Refer to Figures 2-2 and 2-4. The compressor unit Two return lines (or scavenge tubes) lead from the
discharges the compressed air/fluid mixture into the bottom of each separator element to the low pres-
combination receiver/sump. The receiver has three sure inlet region of the compressor unit. Fluid col-
functions: lecting on the bottom of each separator is returned
to the compressor by a pressure difference
1. It acts as a primary fluid separator. between the receiver and the compressor inlet.
2. It serves as the compressor fluid sump. Sight glasses are located in the return lines to
3. It houses the final fluid/air separator ele- observe this fluid flow. dP1 on the Supervisor
8
Section 2
DESCRIPTION
Figure 2-4 Compressor Discharge System (Air-cooled)
ControllerTM microprocessor control monitors the air in the service line from bleeding back into the
condition of the separator elements by reading the receiver on shutdown and during operation of the
differential pressure on the digital display. At a dif- compressor in an unloaded condition.
ferential of 10 psig (0.7 bar), or greater, the opera- A pressure relief valve (located on the wet side of
tor will be told to service the separator elements. At the separator) is set to open if the sump pressure
this time, separator element replacement is neces- exceeds the rated pressure of the tank.
sary.
All Sullair compressor models are equipped with
high pressure shutdown protection to shut down the
compressor at 20-35 psi above rated pressure. This
Calibration of dP1 is required at start-up. Consult
Supervisor manual.
prevents the pressure relief valve from opening
under normal conditions, thereby preventing fluid
The receiver is an ASME pressure vessel. A combi- loss through the pressure relief valve. The
nation minimum pressure/check valve, located Supervisor will shut down the compressor if the dis-
downstream from the separator, assures a mini- charge temperature reaches 235°F (113°C).
mum receiver pressure of 50 psig (3.4 bar) during
full load operation. This pressure is necessary for
proper air/fluid separation and proper fluid circula-
DO NOT remove caps, plugs, and/or other com-
tion while supplying air to the system. This valve ponents when compressor is running or pres-
also acts as a check valve preventing compressed surized.
9
Section 2
DESCRIPTION
Figure 2-5A Control System- START Stage (200-350HP/ 149-261KW)
Stop compressor and relieve all internal pressure ic inlet valve. The functional description of the con-
before doing so. trol system is described below in four distinct phas-
Fluid is added to the sump via a capped fluid filler es of compressor operation. The following applies
opening, placed low on the receiver tank to prevent to LS25S Series compressors ranging from 200
over-filling of the sump. Two sight glasses enable through 350HP/ 149-261KW. For explanatory pur-
the operator to visually monitor the sump fluid level. poses, this description applies to any compressor
with an operating range of 100 to 110 psig (6.9 to
2.6 CONTROL SYSTEM, FUNCTIONAL DESCRIP- 7.6 bar). A compressor with any other pressure
TION range would operate in the same manner except for
Refer to Figures 2-5A, 2-5B, 2-5C and 2-5D. The the stated pressures.
purpose of the compressor control system is to reg-
ulate the amount of air being compressed to match START MODE - 0 TO 50 PSIG (0 TO 3.4 BAR)
the amount of compressed air being used. When the compressor (ON) pad is depressed,
The capacity control system consists of a pneumat- the sump pressure will quickly rise from 0 to 50 psig
10
Section 2
DESCRIPTION
Figure 2-5B Control System MODULATION Stage (200-350HP/ 149-261KW)
(0 to 3.4 bar). During this period, both of the pres- rises above 50 psig (3.4 bar), the minimum pres-
sure regulators and the solenoid valve are closed sure valve opens, allowing compressed air to flow
and the pneumatic inlet valve is inoperative. The into the service line. From this point on, the line air
internal spring holds the inlet valve fully closed to pressure is continually monitored by the Supervisor.
reduce motor torque for starting. After eight (8) sec- A load signal is provided through a pressure reduc-
onds the solenoid valve will open, opening the inlet ing regulator set at 70 psig (4.8 bar) to maintain the
valve, and the compressor will run at full rated inlet valve in an open position. The inlet valve will
capacity. The rising compressor air pressure is iso- remain in the full load position as long as the com-
lated from the service line in this phase by the min- pressor is running at 100 psig (6.9 bar) or below.
imum pressure valve set at approximately 50 psig MODULATION - 100 TO 110 PSIG (6.9 TO 7.6
(3.4 bar). BAR)
FULL LOAD MODE - 50 TO 100 PSIG (3.4 TO 6.9 As air demand drops below the rated capacity of the
BAR) compressor, the line pressure will rise above 100
When the compressed air pressure in the sump psig (6.9 bar). As the air pressure exceeds 100 psig
11
Section 2
DESCRIPTION
Figure 2-5C Control System FULL LOAD Stage (200-350HP/ 149-261KW)
(6.9 bar), the differential pressure regulator con- used, the service line pressure continues to rise.
trolling the inlet valve opens. This allows the air When it exceeds 110 psig (7.6 bar), Supervisor
pressure into the unload chamber of the inlet valve, energizes the solenoid valve, applying pressure to
which starts partially closing the inlet valve, provid- the unload chamber of the inlet valve, which fully
ing modulation. During this period, the pressure closes the valve. Simultaneously, the solenoid valve
rises approximately from 100 to 110 psig (6.9 to 7.6 sends a pneumatic signal to the blowdown valve.
bar). When equipped with optional spiral valve, the The blowdown valve opens the sump to the atmos-
differential pressure regulator controlling the spiral phere. This reduces the sump pressure to approxi-
valve will operate to unload the spiral valve from mately 25 psig (1.7 bar), which results in low horse-
100-105 psi (6.9-7.2 bar) with the inlet valve acting power consumption. The check valve in the air
from 105-110 psig (6.9 -7.6 bar). service line prevents line pressure from returning to
UNLOAD MODE - IN EXCESS OF 110 PSIG (7.6 sump while the compressor is running in the
BAR) unloaded mode. The inlet valve remains in the
When a relatively small amount or no air is being unload position.
12
Section 2
DESCRIPTION
Figure 2-5D Control System UNLOAD Stage (200-350HP/ 149-261KW)
When the line pressure drops back to 100 psig (6.9 ulation can be disabled in the Supervisor
bar) due to an increase in the air demand, ControllerTM in the “Control Parameters” menu. If
Supervisor de-energizes the solenoid valve remov- modulation is disabled, the unload pressure must
ing air pressure from the unload chamber, opening be reset to the rated load pressure of the machine.
the inlet valve. The blowdown valve closes, and the For example, an L model rated for 100 psig full load
inlet valve opens. operation and 110 psig unload must have the
AUTOMATIC OPERATION unload pressure reset to 100 psig. This ensures
For applications with varied periods of time when that the motor will not run in an overload condition.
there are no air requirements, Supervisor’s Auto 2.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIP-
mode allows the compressor to shut down (time TION
delayed) when no compressed air requirement is Refer to Figure 2-6. The compressor inlet system
present and restart as compressed air is needed. consists of a dry-type air filter, a vacuum switch
LOAD/ NO LOAD OPERATION and an air inlet valve.
If applications call for load/no load operation, mod- The vacuum switch, located in the compressor
13
Section 2
DESCRIPTION
Figure 2-6 Compressor Air Inlet System Supervisor control system, indicates the condition
of the air filter. When the message “AIR FILTER
MAINT RQD” is displayed, maintenance is required.
The pneumatic-type air inlet valve directly controls
the amount of air intake to the compressor (Section
2.6).
14
Section 3
SPECIFICATIONS
3.1 SULLAIR SERIES LS25S SPECIFICATIONS
60 HZ MODEL LENGTH WIDTH HEIGHT (I) WEIGHT
(AC & WC) (IN) (IN) (IN) (LB)
154 78 86 (II)
50Hz MODEL LENGTH WIDTH HEIGHT (I) WEIGHT

(AC & WC) (CM) (CM) (CM) (KG)
392 198 218 (II)
(I) Add 7 in./18 cm for enclosure. Add 27.5 in./70 cm (200-350HP/149-261KW) for servicing the separator.
(II) For data on package weights, consult Sullair Factory Sales Department.
For noise level information, please contact the Sullair Factory Service Department.
3.2 LUBRICATION GUIDE-STANDARD COMPRES- 3.4 APPLICATION GUIDE

SORS Sullair encourages the user to participate in a fluid
Refer to Figure 3-1. Sullair LS25S Series standard analysis program with the fluid suppliers. This could
compressors are filled with Sullube fluid as factory result in a fluid change interval differing from that
fill. stated in the manual. Contact your Sullair dealer for
details.
3.5 LUBRICATION CHANGE RECOMMENDATIONS
Mixing of other lubricants within the compres- AND MAINTENANCE
sor unit will void all warranties. LUBRICANT FLUID FLUID FILTER SEPARATOR
Sullube fluid should be changed every 8000 hours CHANGE CHANGE CHANGE
Sullube A, D F, B A, C
or once a year, whichever comes first. The fluid 24KT E, D F, B A, C
should be changed more frequently under severe
A - 8,000 Hours or once a year
operating conditions, such as high ambient temper- B - When measured pressure loss exceeds 20 psig (1.3 bar).
atures coupled with high humidity, or when high C - When measured pressure loss exceeds 10 psig (0.7 bar).
particulate level, corrosive gases or strong oxidizing D - When required by fluid analysis or known contamination.
E - Does not require replacement during normal service condi-
gases are present in the air.
tions.
Maintenance of all other components is still recom- F- Every 1000 hours.
mended as indicated in the Maintenance section of
this manual. Figure 3-1 Fluid Fill Location
3.3 LUBRICATION GUIDE- 24KT COMPRESSORS
Refer to Figure 3-1. Sullair 24KT compressors are
filled with a lubricant which rarely ever needs to be
changed. In the event a change of fluid or make-up
fluid is required, use only Sullair 24KT fluid.
Mixing of other lubricants within the compressor

unit will void all warranties.
Sullair recommends that 24KT sample be taken at
the first filter change and sent to the factory for
analysis. This is a free service. A sample kit with
instructions and self addressed container is sup-
plied by your Sullair representative at start-up. The
user will receive an analysis report with recommen-
dations.
A 24KT sample should be sent in annually, after

the first year.
15
Section 3
SPECIFICATIONS
Figure 3-2 Identification- LS25S 200-250HP/ 149-186KW Air-cooled (Typical)
02250136-148R01
16
Section 3
SPECIFICATIONS
Figure 3-3 Identification- LS25S 200-250HP/ 149-186KW Water-cooled (Typical)
02250136-151R01
17
Section 3
SPECIFICATIONS
Figure 3-4 Identification- LS25S 200-250HP/ 149-186KW Remote-cooled (Typical)
02250136-150R01
18
Section 3
SPECIFICATIONS
Figure 3-5 Identification- LS25S 200-350HP/ 149-261KW EES (Typical)
02250136-149R00
19
Section 3
SPECIFICATIONS
Figure 3-6 Identification- LS25S 300-350HP/ 224-261KW Air-cooled (Typical)
02250136-156R00
20
Section 3
SPECIFICATIONS
Figure 3-7 Identification- LS25S 300-350HP/ 224-261KW Water-cooled (Typical)
02250136-159R00
21
Section 3
SPECIFICATIONS
Figure 3-8 Identification- LS25S 300-350HP/ 224-261KW Remote-cooled (Typical)
02250136-158R01
22
Section 8
ILLUSTRATIONS AND PARTS LIST
Figure 3-9 Identification- LS25S 300-350HP/ 224-261KW EES (Typical)
02250136-157R01
23
Section 3
SPECIFICATIONS
Figure 3-10 Piping and Instrumentation Diagram- LS25SC-200/250 Remote-cooled Supervisor with Pneumatic
Control
02250136-141R03
24
Section 3
SPECIFICATIONS
Control
key part
number description number quantity
1 filter, assy air inlet (heavy duty) 250006-718 -

2 vlv, inlet 8” 02250137-084 -
3 gauge, pressure 02250117-009 -
4 vlv, check 1/2” 042694 -
5 vlv, spiral - -
6 regulator, backpressure control 1/4” 02250052-358 -
7 vlv, sol 3wno 1/4” 115vac 02250125-657 -
8 filter, control 1/4” npt 02250112-032 -
9 vlv, press. reg. 406929 -
10 orifice, .032” 02250125-774 -
11 orifice, .03” 02250101-191 -
12 vlv, blowdown 1” nc 2-way 409783 -
13 vlv, check 1/4” 045244 -
14 regulator, reducing 1/4npt 02250046-568 -
15 pressure transducer n4 02250078-933 -
16 orifice, .094 02250125-776 -
17 glass, sight 1/4” 02250126-129 -
18 strainer,in line sae 02250117-782 -
19 vlv, min. press. check 3” npt 250033-821 -
20 vlv, sol 2way nc 1/4” 02250125-674 -
21 element, secondary separator 250034-133 -
22 element, primary separator 250034-121 -
23 strainer, y 1/2” 406480 -
24 probe, 100 ohm rtd 20’ 02250044-985 -
25 trap, condensate 3/4” 042034 -
26 vlv, relief 1-1/2” 150# 02250119-109 -
27 tank, fluid sep. 02250120-350 -
28 glass, fluid level sight 02250097-611 -
29 vlv, ball 3/4” 02250125-221 -
30 orifice, .094” 022033 -
31 heater, moisture separator 02250087-631 -
32 hsg, thrmvlv 1 7/8sae 4 port 02250127-119 -
33 filter, fluid 02250121-658 -
(Continued on page 27)
25
Section 3
SPECIFICATIONS
Control
02250136-141R03
26
Section 3
SPECIFICATIONS
Control (Continued)
key part
34 vlv, sol ees 1/4” 4-way 02250056-983 -

35 cooler, fluid w/ 1 -7/8-12 sae oil ports 02250122-858 -
36 aftercooler, air to air 02250121-098 -
37 separator, combo trap 02250111-105 -
38 heater, sump 047226 -
39 vlv,ball 1/2” npt 047117 -
40 switch, vac. 22” w.c. n4 02250078-249 -
41 drain,elec.conds. scd2400 115 vac 02250130-866 -
42 unit, compressor - -
43 vlv, sol 2way no 1/4” 02250125-667 -
44 vlv, oil stop w/sae ports 02250113-668 -
45 valve, check 1/2” 042694 -
46 valve, check 2” 040671 -
47 switch, temp n.o. 115f 043239 -
48 orifice, cap 1/4” npt .031 dia. 02250132-934 -
49 orf, 1/4”npt .046 dia (w/o spiral vlv) 02250137-619 -
49 orf, 1/4”npt .03 dia (w/spiral vlv) 02250101-191 -
27
Section 3
SPECIFICATIONS
Control
02250136-142R03
28
Section 3
SPECIFICATIONS
Control
key part
1 filter, assy air inlet (heavy duty) 250006-718 -

2 vlv, inlet 8” 02250137-084 -
3 gauge, pressure 02250117-009 -
4 vlv, check 1/2” 042694 -
5 vlv, spiral - -
6 regulator, backpressure control 1/4” 02250052-358 -
7 vlv, sol 3wno 1/4” 115vac 02250125-657 -
8 filter, control 1/4” npt 02250112-032 -
9 vlv, press. reg. 406929 -
10 orifice, .032” 02250125-774 -
11 orifice, .03” 02250101-191 -
12 vlv, blowdown 1” nc 2-way 409783 -
13 vlv, check 1/4” 045244 -
14 regulator, reducing 1/4npt 02250046-568 -
15 pressure transducer n4 02250078-933 -
16 orifice, .094 02250125-776 -
17 glass, sight 1/4” 02250126-129 -
18 strainer,in line sae 02250117-782 -
19 vlv, min. press. check 3” npt 250033-821 -
20 vlv, sol 2way nc 1/4” 02250125-674 -
21 element, secondary separator 250034-129 -
22 element, primary separator 250034-123 -
23 strainer, y 1/2” 406480 -
24 probe, 100 ohm rtd 20’ 02250044-985 -
25 trap, condensate 3/4” 042034 -
26 vlv, relief 1-1/2” 150# 02250119-109 -
27 tank, fluid sep. 02250120-612 -
28 glass, fluid level sight 02250097-611 -
29 vlv, ball 3/4” 02250125-221 -
30 orifice, .094” 022033 -
31 heater, moisture separator 02250087-631 -
32 vlv, thermal assy w/ sae ports 02250120-955 -
33 filter, fluid 02250121-638 -
34 vlv, sol EES 1/4” 4-way 02250056-983 -
29
Section 3
SPECIFICATIONS
Control
02250136-142R03
30
Section 3
SPECIFICATIONS
Control (Continued)
key part
35 cooler, fluid w/ 1-7/8”-12 sae oil ports 02250122-218 -

36 aftercooler, air to air 02250122-219 -
37 separator, combo trap 02250111-105 -
38 heater, sump 047226 -
39 vlv,ball 1/2” npt 047117 -
40 switch, vac. 22” w.c. n4 02250078-249 -
41 drain,elec.conds. scd2400 115 vac 02250130-866 -
42 unit, compressor - -
43 vlv, sol 2way no 1/4” 02250125-667 -
44 switch, temp n.o. 115f 043239 -
45 vlv, oil stop w/sae ports 02250122-004 -
46 vlv, check 1/4” 02250110-557 -
47 vlv, inline check 2-1/2” 02250125-617 -
48 strainer, oil pump suction 250038-912 -
49 pump, fluid sys 250018-782 -
50 mtr, 5hp VARIOUS -
51 valve, control 3 way 043877 -
52 orifice, cap 1/4” npt .031 dia. 02250132-934 -
53 orf, 1/4”npt .046 dia (w/o spiral vlv) 02250137-619 -
53 orf, 1/4”npt .031 dia (w/spiral vlv) 02250101-191 -
31
Section 3
SPECIFICATIONS
Figure 3-12 Piping and Instrumentation Diagram- LS25SC-200/350 ACAC Supervisor with Pneumatic Control
02250136-143R02
32
Section 3
SPECIFICATIONS
key part no. part no.

number description 250HP 300/350HP qty
1 filter, assy air inlet (heavy duty) 250006-718 250006-718 1

2 vlv, inlet 8” 02250137-084 02250137-084 1
3 gauge, pressure 02250117-009 02250117-009 1
4 vlv, check 1/2” 042694 042694 1
5 vlv, spiral - - 1
6 regulator, backpressure control 1/4” 02250052-358 02250052-358 1
7 vlv, sol 3wno 1/4” 115vac 02250125-657 02250125-657 2
8 filter, control 1/4” npt 02250112-032 02250112-032 1
9 vlv, press. reg. 406929 406929 1
10 orifice, .032” 02250125-774 02250125-774 1
11 orifice, .03” 02250101-191 02250101-191 2
12 vlv, blowdown nc 2-way 409783 409783 1
13 vlv, check 1/4” 045244 045244 4
14 regulator, reducing 1/4npt 02250046-568 02250046-568 1
15 pressure transducer n4 02250078-933 02250078-933 4
16 orifice, .094 02250125-776 02250125-776 1
17 glass, sight 1/4” 02250126-129 02250126-129 2
18 strainer,in line sae 02250117-782 02250117-782 2
19 vlv, min. press. check 3” npt 250033-821 250033-821 1
20 vlv, sol 2way nc 1/4” 02250125-674 02250125-674 1
21 element, secondary separator 250034-133 250034-129 1
22 element, primary separator 250034-121 250034-123 1
23 strainer, y 1/2” 406480 406480 1
24 probe, 100 ohm rtd 20’ 02250044-985 02250044-985 3
25 trap, condensate 3/4” 042034 042034 1
26 vlv, relief 1-1/2” 150# 02250119-109 02250119-109 1
27 tank, fluid sep. 02250120-350 02250120-612 1
28 glass, fluid level sight 02250097-611 02250097-611 2
29 vlv, ball 3/4” 02250125-221 02250125-221 1
30 orifice, .094” 022033 022033 1
31 heater, moisture separator 02250087-631 02250087-631 1
32 vlv, thermal assy w/sae ports 02250127-119 02250120-955 1
33 filter, fluid 02250121-658 02250121-638 1
34 vlv, sol ees 1/4” 4-way 02250056-983 02250056-983 1
35 cooler, fluid w/1-7/8”-12 sae oil ports 02250122-858 02250122-218 1
33
Section 3
SPECIFICATIONS
02250136-143R02
34
Section 3
SPECIFICATIONS
(Continued)

36 aftercooler, air to air 02250121-098 02250122-219 1

37 separator, combo trap 02250111-105 02250111-105 1
38 heater, sump 047226 047226 1
39 vlv,ball 1/2” npt 047117 047117 1
40 switch, vac. 22” w.c. n4 02250078-249 02250078-249 1
41 drain,elec.conds. scd2400 115 vac 02250130-866 02250130-866 1
42 unit, compressor - - 1
43 vlv, sol 2way no 1/4” 02250125-667 02250125-667 1
44 orifice, cap 1/4” npt .031 dia. 02250132-934 02250132-934 1
45 orifice, 1/4” npt .070 dia. - 02250137-477 1
45 orifice, 1/4” npt .062 dia. 027443 - 1
35
Section 3
SPECIFICATIONS
Figure 3-13 Piping and Instrumentation Diagram- LS25SC-200/350 WCAC Supervisor with Pneumatic Control
02250136-144R02
36
Section 3
SPECIFICATIONS


2 vlv, inlet 8” 02250137-084 02250137-084 1
3 gauge, pressure 02250117-009 02250117-009 1
4 vlv, check 1/2” 042694 042694 1
5 vlv, spiral - - 1
7 vlv, sol 3wno 1/4” 115vac 02250125-657 02250125-657 2
9 vlv, press. reg. 406929 406929 1
10 orifice, .032” 02250125-774 02250125-774 1
11 orifice, .03” 02250101-191 02250101-191 2
12 vlv, blowdown 1” nc 2-way 409783 409783 1
13 vlv, check 1/4” 045244 045244 4
16 orifice, .094 02250125-776 02250125-776 1
17 glass, sight 1/4” 02250126-129 02250126-129 2
20 vlv, sol 2way nc 1/4” 02250125-674 02250125-674 1
23 strainer, y 1/2” 406480 406480 1
24 probe, 100 ohm rtd 20’ 02250044-985 02250044-985 3
25 trap, condensate 3/4” 042034 042034 1
26 vlv, relief 1-1/2” 150# 02250119-109 02250119-109 1
27 tank, fluid sep. 02250120-350 02250120-612 1
29 vlv, ball 3/4” 02250125-221 02250125-221 1
30 orifice, .094” 022033 022033 1
33 filter, fluid 02250121-658 02250121-638 1
35 clr, fluid w/s.a.e. oil ports 02250126-003 02250126-002 1
37
Section 3
SPECIFICATIONS
02250136-144R02
38
Section 3
SPECIFICATIONS
(Continued)

36 aftercooler, < = 150# 042950 042950 1

36 aftercooler, > = 150# 02250053-383 02250053-383 1
38 heater, sump 047226 047226 1
39 vlv,ball 1/2” npt 047117 047117 1
40 switch, vac. 22” w.c. n4 02250078-249 02250078-249 1
43 vlv, sol 2way no 1/4” 02250125-667 02250125-667 1
44 switch, press n.o. 10psi 250017-992 250017-992 1
45 vlv, water regulator 1-1/4” 248743 248743 1
46 vlv, sol 2wnc 1-1/2” 02250125-653 02250125-653 1
48 orifice, 1/4” npt .070 dia. - 02250137-477 1
48 orifice, 1/4” npt .062 dia. 027443 - 1
39
Section 3
SPECIFICATIONS
Figure 3-14 Piping and Instrumentation Diagram- LS25SC-200/350 WCAC Supervisor with Pneumatic Control &
Parallel Piping
02250136-145R02
40
Section 3
SPECIFICATIONS
Parallel Piping


2 vlv, inlet 8” 02250137-084 02250137-084 1
3 gauge, pressure 02250117-009 02250117-009 1
4 vlv, check 1/2” 042694 042694 1
5 vlv, spiral - - 1
7 vlv, sol 3wno 1/4” 115vac 02250125-657 02250125-657 2
9 vlv, press. reg. 406929 406929 1
10 orifice, .032” 02250125-774 02250125-774 1
11 orifice, .03” 02250101-191 02250101-191 2
12 vlv, blowdown 1” nc 2-way 409783 409783 1
13 vlv, check 1/4” 045244 045244 4
16 orifice, .094 02250125-776 02250125-776 1
17 glass, sight 1/4” 02250126-129 02250126-129 2
20 vlv, sol 2way nc 1/4” 02250125-674 02250125-674 1
23 strainer, y 1/2” 406480 406480 1
24 probe, 100 ohm rtd 20’ 02250044-985 02250044-985 3
25 trap, condensate 3/4” 042034 042034 1
26 vlv, relief 1-1/2” 150# 02250119-109 02250119-109 1
27 tank, fluid sep. 02250120-350 02250120-612 1
29 vlv, ball 3/4” 02250125-221 02250125-221 1
30 orifice, .094” 022033 022033 1
33 filter, fluid 02250121-658 02250121-638 1
35 clr, fluid w/s.a.e. oil ports 02250126-003 02250126-002 1
41
Section 3
SPECIFICATIONS
Parallel Piping
02250136-145R02
42
Section 3
SPECIFICATIONS
Parallel Piping (Continued)

36 aftercooler, < = 150# 042950 042950 1

36 aftercooler, > = 150# 02250053-383 02250053-383 1
38 heater, sump 047226 047226 1
39 vlv,ball 1/2” npt 047117 047117 1
40 switch, vac. 22” w.c. n4 02250078-249 02250078-249 1
43 vlv, sol 2way no 1/4” 02250125-667 02250125-667 1
44 switch, press n.o. 10psi 250017-992 250017-992 1
45 vlv, water regulator 1-1/4” 248743 248743 1
46 vlv, sol 2wnc 1-1/2” 02250125-653 02250125-653 1
47 vlv, globe 1-1/2” 047834 047834 1
49 orifice, 1/4” npt .070 dia. - 02250137-477 1
49 orifice, 1/4” npt .062 dia. 027443 - 1
43
NOTES
44
Section 4
INSTALLATION
4.1 MOUNTING OF COMPRESSOR Table 4-1 Ventilation Requirements below indicates
A foundation or mounting capable of supporting the the ventilation requirements necessary to keep the
weight of the compressor, and rigid enough to main- compressor running at a normal operating temper-
tain the compressor frame level and the compres- ature. The fan air requirement is the volume of air
sor in alignment is required. The compressor frame which must flow through the compressor and/or
must be leveled and secured with foundation bolts, cooling package for proper ventilation. The speci-
and full uniform contact must be maintained fied heat rejection requirement is the amount of
between the frame and foundation. It is recom- heat that is radiated by the compressor. This heat
mended that the frame be grouted to the founda- must be removed to assure a normal operating tem-
tion. The compressor unit and driver must be perature. With air-cooled compressors it is possible
aligned after installation as specified in the to use this heat for space heating, providing exces-
Operator’s Manual. No piping loads shall be trans- sive pressure drop is not created across the fan.
mitted to the compressor or the cooling package at Consult a Sullair office for assistance in utilizing this
the external connections. heat.
4.2 VENTILATION AND COOLING DO NOT install a water-cooled or an air-
For air-cooled compressors, select a location to cooled/aftercooled compressor without adequate
permit sufficient unobstructed air to flow in and out freeze protection where it will be exposed to tem-
of the compressor cooling package to keep the perature less than 32°F(0°C).
operating temperature stable. The minimum dis- 4.3 SERVICE AIR PIPING
tance that the compressor should be from sur- Service air piping should be installed as shown in
rounding walls is three (3) feet (914mm). To prevent Figure 4-1. A shut-off valve should be installed to
excessive ambient temperature rise, it is imperative isolate a compressor from the service line if
to provide adequate ventilation. required. Also notice that the service line should be
For water-cooled compressors, it is necessary to equipped with water legs and condensate drains
check the cooling water supply. The water system throughout the system.
must be capable of supplying the following flows: 4.4 COUPLING ALIGNMENT CHECK
MODEL-HP/KW WATER FLOW (GPM) In preparation for the factory test, the coupling sup-
plied with your compressor is properly aligned for
LS25S 200HP/149KW 44
operation. Refer to Coupling Alignment procedure
LS25S 250HP/187KW 54
explained in the Maintenance section of this manu-
LS25S 300HP/225KW 65
al.
LS25S 350HP/260KW 76
4.5 FLUID LEVEL CHECK
Your air compressor is also supplied with the prop-
er amount of fluid. However, it is necessary to
check the fluid level at installation. The level is
Water flow requirements are based on 80°F to checked by looking at the sight glass located on the
85°F (27°C to 29°C) water inlet temperature.
sump. If the sump is properly filled, the coolant level
Recommended water pressure range is 40 to 75 should fill 1/2 of the upper sight glass when the
psig (2.8 to 5.2 bar). Water flow rates will vary compressor is shutdown. When the oil level falls
with operating conditions. For rates based on below the center of the lower sight glass, fluid must
criteria other than that listed, consult your local
Sullair representative. be added.
Table 4-1 Ventilation Requirements

WATER COOLED OR REMOTE COOLED AIR-COOLED (I)
COMPRESSOR PACKAGE COOLING PACKAGE
HEAT REJECTION VENT FAN FLOW (II) HEAT REJECTION AIR FLOW
MODEL MOTOR HP/KW BTU/HR CFM BTU/HR CFM
LS25S-200 200/149 47,570 4150 576,500 18,000

LS25S-250 250/187 57,360 4150 695,500 18,000
LS25S-300 300/225 64,170 4150 847,500 28,000
LS25S-350 350/260 74,320 4150 955,000 31,000
(I) Applicable to air-cooled models only.
(II) Applicable to compressors with enclosure.
45
Section 4
INSTALLATION
Figure 4-1 Service Air Piping (Typical Installation)
4.6 FLUID PIPING (REMOTE AIR-COOLED OPTION (usually lowest ambient). If the pressure drop is in
ONLY) excess of 10 psig (0.7 bar), a pump should be
To allow de-pressurization of the cooling package installed. Consult the Sullair Service Department for
and connecting piping between the compressor and recommendations.
the cooling package upon shutdown of the com- It is recommended that shutoff valves be installed in
pressor, a 1/2”(13 mm) de-pressurization line must the supply and return piping to facilitate compressor
be installed between the top of the fluid cooler and component’s maintenance.
the sump tank connection which is located on the
fluid supply and return line connection bracket. This Because of the variability in installations, the fluid
line must be maintained at a higher level than the necessary to fill the supply and return piping for the
supply and return piping for the fluid cooler. fluid cooler is not part of the standard scope of sup-
ply for the compressor. The fluid necessary to fill
The supply and return piping for the fluid cooler this piping may be ordered from the nearest Sullair
must be adequately sized to prevent excessive representative or the representative from whom the
pressure drop. The total pressure drop in the supply compressor was purchased. To assist in determin-
and return piping and associated fittings and ing the amount of fluid necessary to fill the piping,
valves, not including the cooler, shall not exceed 10 the following chart may be used.
psig (0.7 bar) at the worst case operating condition
46
Section 4
INSTALLATION
GALLONS/LITERS OF FLUID
PIPE SIZE PER 12 INCHES/304.8MM OF PIPE control panel, press STOP , then press
2 .1635/.62 START .
2 1/2 .2555/.97
3 .368/1.39
4 .6542/2.48
6 1.4719/5.57 Since some solid state starters have built-in power
monitoring, a dry run will only indicate compres-
4.7 ELECTRICAL PREPARATION sor overload when machine has this type of
Interior electrical wiring is performed at the factory. starter.
Required customer wiring is minimal, but should be
by a qualified electrician in compliance with OSHA, 5. Reconnect the three (3) motor leads and jog the
National Electrical Code, and any other applicable motor for a direction of rotation check, as
state or local electrical code concerning isolation explained in Section 4.8.
switches, fuse disconnects, etc. Sullair provides a 6. Verify all directions of rotations on all auxiliary
wiring diagram for use by the installer. motors.
A few electrical checks should be made to help 4.8 MOTOR ROTATION DIRECTION CHECK
assure that the first start-up will be trouble free. After the electrical wiring has been done, it is nec-
essary to check the direction of the motor rotation.
With the control system in MANUAL mode, press
Lethal shock hazard inside.
the and pads in succession to bump start
Disconnect all power at source, before opening
or servicing starter or control panel.
the compressor. When looking at the motor from the
end opposite the compressor unit, the shaft should
1. Check incoming voltage. Be sure that the incom- be turning clockwise on all gear driven models, and
ing voltage is the same voltage that the com- counterclockwise on direct drive models. If the
pressor was wired for. motor shaft is not turning in the proper direction,
2. Check starter and overload heater sizes (see disconnect the power to the starter and exchange
Electrical Parts in Parts Manual). any two of the three power input leads, then re-
3. Check all electrical connections for tightness. check rotation. A “Direction of Rotation” decal is
located on the coupling guard between the motor
4. “DRY RUN” the electrical controls by disconnect-
and compressor to show proper motor/compressor
ing the three (3) motor leads from the starter.
rotation.
Pull out the EMERGENCY STOP button on the
47
Section 5
SUPERVISOR
Figure 5-1 Supervisor Control Panel
For information concerning all aspects of the Supervisor Controller,

consult the Supervisor Controller manual no. 02250133-517.
48
Section 6
COMPRESSOR OPERATION
6.1 INTRODUCTION pose, location, and use.
While Sullair has built into the LS25S Series pack- 6.2 PURPOSE OF CONTROLS
age a comprehensive array of controls and indica- All Supervisor Controller related functions and indi-
tors to assure its proper operation, the user should cators are presented in the Supervisor Controller
recognize and interpret readings which call for Manual, so please refer to that manual for further
service or indicate the onset of a malfunction. information. Additional indicators and functions
Before starting the unit, the user should become included in the package are as follows:
familiar with the controls and indicators-their pur-
CONTROL OR INDICATOR PURPOSE

EMERGENCY STOP SWITCH Pushing in this switch, found adjacent to the Supervisor, cuts
all AC outputs from the Supervisor and de-energizes the
starter. A fault message (E STOP) is displayed by the
Supervisor until the button is pulled out and the “O” pad is
depressed.
THERMAL O/L RESET Momentarily pushing this button, found on the starter’s ther-
mal overload element housing, re-closes the starter’s con-
tacts after a current overload takes place. Please be aware
that the elements must be allowed to cool sufficiently before
resetting.
SPIRAL VALVE Internally bypasses and controls the air flow capacity of the
compressor, in order to match air supply to the demand.
Maintains a maximum pilot pressure of 70 psig (4.8 bar).
PRESSURE REGULATOR
(LOAD CHAMBER)
PRESSURE REGULATOR Opens a pressure line between the sump and the inlet unload
(UNLOAD CHAMBER) chamber, allowing the inlet valve to regulate air delivery
according to air demand. Works in conjunction with solenoid
valve #3.
SOLENOID VALVE #1 Electrically actuated, 3-way valve which controls the flow of
pneumatic logic signals. Used throughout package to:
•Open the blowdown valve.
•Pressurize the unload port/close the inlet valve during shut-
down operation.
•Open the (optional) spiral valve.
SOLENOID VALVE #2 Opens when the Wye-delta timer closes; closes when the
Wye-delta timer is open. Opens a pressure line between the
sump and inlet load chamber allowing the inlet valve to deliv-
er air. This prevents any air system loss and de-pressurizes
the controls when the compressor is shut off.
SOLENOID VALVE #3 Opens pressure line between sump and inlet unload chamber
for modulation.
Serves to control machine during sequencing with multiple
machines. Designates whether machine is at full load or mod-
ulating.
49
Section 6
CONTROL OR INDICATOR (CONT.) PURPOSE (CONT.)
PNEUMATIC INLET VALVE Blocks the reverse flow of air/fluid through the compressor
unit during shutdown, and opens to allow air intake to the
compressor during normal load.
Maintains 50 psig (3.5 bar) in the receiver tank when the
MINIMUM PRESSURE VALVE
compressor is running loaded. Also incorporates a check
valve, which prevents compressed air backflow from the sys-
tem when unloaded or shutdown.
PRESSURE RELIEF VALVE Vents the sump vessel to atmosphere before the com-
pressed air pressure exceeds rated tank pressure. Its oper-
ation indicates fault with the Supervisor operation unload
pressure set too high or failure of solenoid valve #1.
BLOWDOWN VALVE ASSEMBLY Vents the sump vessel to atmosphere during unloading and
shutdown.
THERMAL MIXING VALVE Bypasses fluid flow around the cooler until the fluid reaches
a temperature of 170°F, 77°C (195°F for water cooled KT and
> 150 psi/ 10.3 bar). Useful for fast warm-up during start.
Maintains a minimum temperature during periods of low load
or low ambient temperatures.
FLUID STOP VALVE Blocks the flow of cooler fluid to the sump during shutdown,
(remote-cooler package only) thus preventing the overfill of fluid in the sump.
SUMP SIGHT GLASSES Indicates level of lubricant in the sump. Located on the sump
side, fluid level should be maintained at a level between the
high and low sight glass.
SEPARATOR RETURN LINE SIGHT Indicate fluid flow in the separator return lines. Large flow
GLASSES should be visible during full load operation; little to no flow
during unloaded operation. Sluggish flow during full load
operation indicates the need to clean the strainers fitted to
the return lines.
WATER PRESSURE SWITCH De-energizes the starter, via the Supervisor, if the water pres-
sure falls below 10 psig (0.7 bar). This switch is not
adjustable. Used on water-cooled packages only.
DRAIN VALVES Lubricant sump drain valve.
6.3 INITIAL START-UP PROCEDURE described in the Installation Section have been
The following procedure should be used to make made.
the initial start-up of the compressor. 4. Open the shut-off valve to the service line.
1. Read the preceding pages of this manual thor- 5. Check for possible leaks in piping.
oughly.
6. Slowly close the shut-off valve to assure proper
2. Jog motor to check for correct rotation of fan nameplate pressure unload setting is correct.
(refer to Section 4.8). The compressor will unload at nameplate pres-
3. Be sure that all preparations and checks sure. If adjustments are necessary, see Control
50
Section 6
System Adjustments. 6.4 SUBSEQUENT START-UP PROCEDURE
7. Observe the operating temperature. If the oper- On subsequent start-ups, check that the proper
ating temperature exceeds 200°F (93°C) [215°F level is visible in the fluid sight glass and simply
(102°C) for water-cooled 24KT and > 150 psi], press the START or AUTO MODE button.
the cooling system and installation environment When the compressor is running, observe the
should be checked. instrument panel and maintenance indicators.
8. Open shut-off valve to the service line. 6.5 SHUTDOWN PROCEDURE
9. Reinspect the compressor for temperature and To shut the compressor down, simply press the
leaks the following day.
STOP button.
51
NOTES
52
Section 7
MAINTENANCE
7.1 GENERAL 7.5 FLUID CHANGE
As you proceed in reading this section, it will be Standard models are filled with the long life lubri-
easy to see that the Maintenance Program for the cant Sullube.
air compressor is quite minimal yet important. The Sullube should be changed under the following con-
use of the service indicators provided for the fluid fil- ditions, whichever occurs first:
ter, air filter and fluid separator, will alert you when
service maintenance is required. When the mainte- 1. Every 8000 hours.
nance message is displayed by the Supervisor 2. Once a year.
ControllerTM, maintenance for that specific item is 3. As indicated by fluid analysis.
required. See instructions for each item in Section A fluid sample at every 1000 hours is recommend-
7.7, Parts Replacement and Adjustment proceed. For a free Sullube analysis, send fluid to:
dures. Dow Chemical
7.2 DAILY OPERATION Lubricant Technology Center
Prior to starting the compressor, it is necessary to Building B-1605
check the fluid level in the sump. Should the level Freeport, TX 77541
be low, simply add the necessary amount. If the To facilitate this, a sample bottle is included with the
addition of fluid becomes too frequent, a simple compressor.
problem has developed which is causing this
7.6 SEPARATOR MAINTENANCE
excessive loss. See the Troubleshooting Section
Replace the separator elements when a message is
(7.8) under Excessive Fluid Consumption for a
displayed or after one (1) year, whichever comes
probable cause and remedy.
first. The separator elements must be replaced. DO
After a routine start has been made, observe the NOT clean the separator elements.
Supervisor control panel and be sure it monitors the
7.7 PARTS REPLACEMENT AND ADJUSTMENT
correct readings for that particular phase of opera-
PROCEDURES
tion. After the compressor has warmed up, it is rec-
ommended that a general check of the overall com- FLUID FILTER MAINTENANCE
pressor and Supervisor be made to assure that the Refer to Figure 7-1. The fluid filter (P/N 02250128-
compressor is running properly. 717) is located schematically after the thermal
valve. When servicing the fluid filter, shut the com-
pressor down, be sure all pressure has been
DO NOT remove caps, plugs, and/or other com-
released, then follow the instructions below. For
ponents when compressor is running or pres-
surized. Figure 7-1 Fluid Filter (P/N 02250128-717)
Stop compressor and relieve all internal pres-
sure before doing so.
7.3 MAINTENANCE AFTER INITIAL 50 HOURS OF
OPERATION
After the initial 50 hours of operation, a few mainte-
nance requirements are needed to rid the system of
any foreign materials if any. Perform the following
maintenance operations to prevent unnecessary
problems.
1. Clean the return line strainers.
2. Clean the return line orifices.
3. Change the fluid filter element.
4. Clean the control line filters.
7.4 MAINTENANCE AFTER 1000 HOURS
After 1000 hours of operation, it will be necessary to
perform the following:
1. Clean the return line strainers.
2. Replace the fluid filter element.
*Repair Kit P/N 02250121-657
53
Section 7
MAINTENANCE
element replacement order kit number 02250121- sary. When removing the primary element, always
657. check the secondary element for visible dirt, grease
1. Drain the fluid from the canister by removing the or damage. The secondary element must be
bottom drain plug changed after every sixth primary element change.
DO NOT clean the secondary element.
2. Loosen the spin-on canister using a wrench on
the bottom canister hex. ELEMENT REMOVAL
3. Pull the canister away from the filter head. The 1. Clean the exterior of the air filter housing.
filter element will be attached to the head. 2. Remove the cover assembly by loosening the
4. Separate the element from the head. wingnut securing it.
5. Remove the canister seals. 3. Pull the element assembly out of the housing.
6. Thoroughly clean the filter head and canister in 4. On the inside of the element, you will notice a
solvent. wingnut which fastens the element to the hous-
ing. Remove the wingnut and pull the primary
7. Lubricate the new seals with the same type of element out.
fluid used in the compressor and position each
seal in its appropriate place. 5. Loosen and remove the hex nut securing the sec-
ondary element. Remove the secondary ele-
8. Slide the element into the canister. ment.
9. Thread the canister and element back on the fil- 6. Inspect the secondary element and replace if
ter head. necessary.
AIR FILTER MAINTENANCE 7. Clean the interior of the housing by using a damp
Refer to Figure 7-2. Air filter maintenance should cloth. DO NOT blow dirt out with compressor air.
be performed when the air filter maintenance mes-
sage is displayed. The air filter is equipped with a 8. Install the new secondary element and replace
primary element and a secondary element. As pre- the sealing washer and hex nut.
viously stated, the Supervisor will alert you as to 9. With the secondary element in place, replace the
when the primary element maintenance is neces- primary element.
Figure 7-2 Air Filter Replacement (P/N 250006-718)
*Primary Replacement Element P/N 250007-838

**Secondary Replacement Element P/N 250007-839
54
Section 7
MAINTENANCE
Figure 7-3 Separator Element Replacement shine through the element, revealing any holes.
2. Inspect all gaskets and gasket contact surfaces
of the housing. Should faulty gaskets be evident,
correct the condition immediately.
3. If the clean element is to be stored for later use,
it must be stored in a clean, closed container.
4. After the element has been installed, inspect and
tighten, if necessary, all air inlet connections
prior to resuming operation.
PRIMARY ELEMENT REPLACEMENT
1. Place the element in position over secondary ele-
ment. Replace the sealing washer and wingnut.
Tighten the wingnut so as to fully seat the ele-
ment gasket.
2. Install the cover/element assembly and replace
the wingnut.
SEPARATOR ELEMENTS REPLACEMENT
Refer to Figure 7-3. The separator elements must
be changed when “Separator Maintenance
Required” message is displayed, or once a year
whichever occurs first. Follow the procedure
explained below for separator element replace-
ment.
PROCEDURE FOR 200-350HP/149-261KW ELE-
MENT REPLACEMENT
1. Relieve all pressure from the separator and all
compressor lines prior to disconnecting any
pipes, tubing, etc.
2. Disconnect all piping connected to the separator
cover to allow removal (return lines, service
lines, etc.).
200-250HP/ 149-186KW: 3. Loosen and remove the twelve (12) 3/4” x 3” hex
*Primary Replacement Element P/N 250034-122 head capscrews from the cover plate.
**Secondary Replacement Element P/N 02250131-225 4. Lift the cover plate from the separator using a
3/4” jackscrew under the lifting arm post. The lid
300-350HP/ 224-261KW: can be pivoted to the side supported by the lift-
*Primary Replacement Element P/N 250034-124
ing arm.
**Secondary Replacement Element P/N 250034-130 5. Remove the primary and secondary separator
elements.
DO NOT strike the element against any hard sur- 6. Scrape the old gasket material from the cover
face to dislodge dust. This will damage the sealing and flange on the sump being careful not to let
surfaces and possibly rupture the element. the scraps fall in the sump.
DO NOT “blow” dirt out of the interior of the filter 7. Inspect the separator tank for rust, dirt, etc.
housing. This may introduce dust downstream of
8. Reinsert the separator elements with gaskets
the filter. Instead, use a clean damp cloth.
attached into the sump taking care not to dent
DO NOT oil the element. them against the tank opening. DO NOT remove
ELEMENT INSPECTION grounding staples. Check between separator
1. Place a bright light inside the element to inspect element flange and tank for continuity after
for damage or leak holes. Concentrated light will torquing bolts. DO NOT use anti-seize com-
55
Section 7
MAINTENANCE
Figure 7-4 Oil Return/Sight Glass
*Replacement Filter Assembly P/N 02250117-782

pound on gaskets.
9. Clean the underside of the separator tank cover
Always performing maintenance on both oil
and remove any rust.
return/sight glasses at the same time.
10. Replace the cover plate, washers and 3/4-10 1. Disconnect the tubes at the tops of the sight
capscrews. Lubricate and torque to 200 ft.-lbs. glass assemblies.
(271 Nm).
2. Unscrew male connector (for left-side glass), or
11. Reconnect all piping making sure return line the straight thread tube connector (for right-side
tubes extend to the bottom or 1/4” (6mm) above glass) from sight glass/orifice blocks.
the bottom of the separator element. This will
assure proper fluid return flow to the compres- 3. Remove used filter assembly, and replace with
sor. new assembly.
12. Check the return line strainers before restarting 4. Coat/lubricate the o-rings will silicone grease.
the compressor (order replacement kit no. 5. Reattach the connectors to the sight glass/orifice
02250117-782). blocks.
OIL RETURN/SIGHT GLASS MAINTENANCE DIFFERENTIAL PRESSURE REGULATOR
Refer to Figure 7-4. The oil return/sight glass sub- ADJUSTMENT
assembly is attached to the separator tank lid. Oil Refer to Figure 7-5. The differential pressure regu-
return/sight glass maintenance should be per- lators are adjusted by loosening the jam nut on the
formed on a routine basis parallel to that of the fluid end of the cone shaped cover of the pressure reg-
filter, or as indicated in the Troubleshooting ulator. When the jam nut is loose, turn the adjusting
Sections (both Supervisor and Maintenance) of this screw clockwise to increase or counterclockwise to
manual. The maintenance on an oil return/sight decrease the setting.
glass is mainly concerned with the condition of the Above 100 psig (6.9 bar), the inlet regulator should
filter assembly. Order filter assembly no. 02250117- allow pressure to flow into the unload chamber of
782, and use the following instructions as a guide. the inlet valve. Cycle the Control System several
times and recheck all pressure settings.
56
Section 7
MAINTENANCE
Figure 7-5 Pressure Regulator Adjustments
Above 100 psig (6.9 bar), the optional spiral valve pressure reducing regulator to maintain 70 psig (4.8
regulator should allow pressure to flow into the bar) signal to open the inlet valve.
chamber of the spiral valve actuator. The spiral DRIVE COUPLING INSTALLATION AND ALIGN-
valve should start to rotate at this time. MENT (200-350HP/ 149-261KW)
PRESSURE REDUCING REGULATOR Refer to Figures 7-6, 7-7 and 7-8. For coupling
When running with compressor loaded, adjust the installation and alignment, the tools required are a
straight edge, a measuring scale, one set of feeler
Figure 7-6 Drive Coupling (200-350HP/ 149-261KW) gauges, a set of standard Allen wrenches and one
set of standard socket wrenches.
Disconnect all power at source, before attempt-

ing maintenance or adjustments.
TABLE 7-1
INSTALLATION DATA (200-350HP/149-261KW)
Max. Operating Misalignment
Tightening Coupling Parallel Angular
Torque Gap Offset
ft.-lbs./Nm inches/cm inches/cm inches/cm (I)
200 2.969 + .030 .010 .010
- .000
271Nm 7.5 + .08 .03 .03
- .000
(I) Angular misalignment in inches equals maximum A minus
minimum B as shown in Figure 7-7. DO NOT exceed val-
*Replacement Element P/N 046999 ues in Table above.
57
Section 7
MAINTENANCE
Figure 7-7 Drive Coupling Alignment rately to correct. Recheck the vertical offset.
STEP 4 INSTALL THE FLEXIBLE ELEMENT -
Position the motor and compressor keyways 180°
apart. Insert the flexible element between the two
hubs. The element should be compressed prior to
insertion. The element can be compressed by tight-
ening a suitably sized radiator hose clamp around
the outer edge of the element as shown in Figure 7-
8. Slide the ferry head capscrews with lockwashers
through the holes in the hubs and element. Tighten
the capscrews to 200 ft.-lbs. (271 Nm).
For installation and alignment of the drive coupling,
follow the steps explained below.
Capscrews are 3/4-10 x 4” LG ASTM A354 Grade
STEP 1 MOUNT HUBS - Mount the motor hub and BD yellow zinc di-chromate. DO NOT substitute
the compressor hub onto respective shaft. Position with any other bolts.
the hubs to establish the correct gap specified in After tightening the capscrews, tighten the shaft
Table 7-1 Installation Data. Secure each hub with a setscrews and remove the hose clamp from the
setscrew. flexible element. At this time, the coupling is ready
STEP 2 OFFSET ALIGNMENT - Clean any oil, for operation.
grease, dirt or paint from coupling faces and the
other surfaces of the drive flanges. Rotate shafts so
that a straight edge will rest squarely (or within the
0.010 inch maximum limit shown in Table 7-1
Installation Data) on both flanges and at a point 90° Figure 7-8 Parallel/ Angular Offset Alignment
away. The vertical offset alignment is adjusted by
the addition or removal of motor mounting shims.
Loosen the motor mounting bolts and slide the
motor sideways to correct the horizontal offset.
STEP 3 COUPLING GAP AND ANGULAR ALIGN-
MENT - Position the hubs to establish the proper
gap and angular alignment as indicated in Table 7-
1 Installation Data. To determine the angular mis-
alignment in inches, measure the maximum space
between the hub flanges and the minimum space
180° away, and then subtract. To adjust the hori-
zontal angular misalignment, loosen the motor
mounting bolts and adjust the motor position until
the angular alignment is within tolerance.
DO NOT upset the offset alignment or hub gap

when adjusting motor position.
When within the limits specified in Table 7-1
Installation Data, tighten the motor mounting bolts
and recheck the offset and angular alignment. If the
vertical angular alignment is not within .010 inch tol-
erance, shim the front or rear of the motor sepa-
58
Section 7
MAINTENANCE
7.8 TROUBLESHOOTING A detailed visual inspection is worth performing for
The information contained in the Troubleshooting almost any problems which may prevent unneces-
chart is based upon both the actual applied situa- sary damage to the compressor. Always remember
tions and extensive testing at the factory. It contains to:
symptoms and usual causes for the described prob- a. Check for loose wiring.
lems. However DO NOT assume that these are the b. Check for damaged piping.
only problems that may occur. All available data c. Check for parts damaged by heat or an electrical
concerning the trouble should be systematically short circuit, usually apparent by discoloration or a
analyzed before undertaking any repair or compo- burnt odor.
nent replacement.
Should your problem persist after making the rec-
ommended check, consult your nearest Sullair rep-
For additional information on troubleshooting, resentative or the Sullair Corporation.
consult the Supervisor Controller manual.
7.9 TROUBLESHOOTING GUIDE

SYMPTOM PROBABLE CAUSE REMEDY
COMPRESSOR WILL NOT START Main Disconnect Switch Open Close switch.
Line Fuse Blown Replace fuse.
Control Transformer Fuse Blown Replace fuse.
Motor Starter Overloads Tripped Reset. Should trouble persist, check whether
motor starter contacts are functioning properly.
Low Incoming Line Voltage Check voltage. Should voltage check low, consult
power company.
Replace Supervisor display module if no display

or erratic display.
COMPRESSOR SHUTS DOWN Loss of Control Voltage Check incoming power.

WITH AIR DEMAND PRESENT
Low Incoming Voltage Check control fuses and wiring.
Consult power company. The Sullair Supervisor
will provide indication of most maintenance prob-
lems if control power has not been lost. Shutdowns
will occur upon a faulty condition or a bad sender
condition.
Excessive Operating Pressure Check maximum P2 pressure setting.
HIGH PRESS P1 display; Max P1 pressure may

be set too low. Consult factory for recalibration.
Defective solenoid valve; solenoid valve should

cause inlet to unload when unload pressure is
exceeded. Repair if defective.
Defective blowdown valve; blowdown valve

should exhaust sump pressure to 25 psig (1.7 bar)
for integrated coolers; 50 psig (3.4 bar) for remote
coolers when maximum operating pressure is
reached. Repair if defective.
Open or shorted P1, P2, P3 or P4 sender mes-

sage; replace sender indicated.
59
Section 7
MAINTENANCE
7.9 TROUBLESHOOTING GUIDE (CONTINUED)
COMPRESSOR SHUTS DOWN HIGH TEMP T1 or T3 Message Displayed Cooling water temperature too high; increase
WITH AIR DEMAND PRESENT water flow (water-cooled only).
(CONTINUED)
Cooling water flow insufficient; check water lines,
valves (water-cooled only) and available water
pressure differential.
Cooler plugged; clean tubes. If plugging persists,

install water conditioner or water filter(water-
cooled only).
Cooling air flow restricted; clean cooler and check

for proper ventilation.
Ambient temperature is too high; provide suffi-

cient ventilation.
Cooling air ductwork, if installed, may restrict air

flow. High static fan must be specified with cus-
tomer-supplied ductwork, and ductwork must be
sized to minimize flow restriction.
Low fluid level; add fluid.
Clogged filter; change the fluid filter element as

indicated by Supervisor control.
Thermal valve not functioning properly; replace

element.
Optional Water flow regulating valve not function-

ing properly; change (water-cooled only).
Open or shorted T1 or T2 sender; check for a

short or open circuit to probe and correct wiring.
Excessive pressure drop in supply and return

lines of remote air-cooled cooling package.
Consult paragraph 4.6 of this manual.
Low Fluid Pressure Check fluid level.

(LOW PRESSURE P3 display)
Check for clogged fluid filter.
Low Water Pressure Check the cooling fan motor or water flow sys-
(FAN OL/LOW WATER display) tem.
COMPRESSOR WILL NOT BUILD Air Demand is Too Great Check service lines for leaks or open valves.
UP FULL DISCHARGE PRESSURE
Dirty Air Filter Check for filter maintenance message on supervi-
sor panel and change or clean element if
required.
Pressure Regulator Out of Adjustment Adjust regulator according to control adjustment

instructions in the Maintenance Section.
Defective Pressure Regulator Check diaphragm and replace if necessary (kit

available).
LINE PRESSURE RISES ABOVE Leak in Control System Causing Loss of Check for leaks.
UNLOAD P2 PRESSURE SETTING Pressure Signals
ON THE SUPERVISOR
Defective Blowdown Valve Check that sump pressure is exhausted to the
atmosphere when in the OFF LOAD mode.
Repair or replace if necessary (kit available).
60
Section 7
MAINTENANCE
7.9 TROUBLESHOOTING GUIDE (CONTINUED)
LINE PRESSURE RISES ABOVE Plugged Control Line Filter Clean or repair if necessary.
UNLOAD P2 PRESSURE SETTING
ON THE SUPERVISOR (CONT.)
EXCESSIVE FLUID CONSUMP- Clogged Return Line Strainer or Orifice Clean strainer (screen with o-ring replacement kit
TION available)
Clean orifice.
Separator Element Damaged or Not Check Separator Differential (plugged) dP1.

Functioning Properly
Change Separator
Leak in the Lubrication System Check all pipes, connections and components.
Excess Fluid Foaming Drain and change.
Fluid Level Too High Drain excess fluid.
PRESSURE RELIEF VALVE Defective Pressure Relief Valve Replace pressure relief valve.
OPENS REPEATEDLY
LIQUID WATER IN COMPRESSED Water Vapor Condensation From Cooling Remove the water vapor from compressed air
AIR SERVICE LINE and Compression Occurs Naturally prior to distribution through the air system. Check
operation of aftercooler and moisture separator.
Install a compressed air dryer sized for the flow
and dryness level required. (Note: Filters may also
be required to remove particulates, liquid oil
aerosols or for oil vapor removal. Change car-
tridges as recommended by the filter manufactur-
er.) Check all drain traps routinely to insure their
proper operation. Maintain them regularly.
61
NOTES
62
Section 8
ILLUSTRATION AND PARTS LIST
8.1 PROCEDURE FOR ORDERING PARTS
Parts should be ordered from the nearest Sullair Representative or the Representative from whom the com-
pressor was purchased. If for any reason parts cannot be obtained in this manner, contact the factory directly
at the address or phone numbers listed below.
When ordering parts always indicate the Serial Number of the compressor. This can be obtained from the Bill
of Lading for the compressor or from the Serial Number Plate located on the compressor. For compressor unit
parts only, order parts by the unit serial number place located on the compressor unit.
For ordering parts other than those pertaining to the compressor unit, use serial number located on nameplate
mounted on control panel.
SULLAIR ASIA, LTD. SULLAIR CORPORATION SULLAIR EUROPE, S.A.

Sullair Road, No. 1 3700 East Michigan Boulevard Zone Des Granges BP 82
Chiwan, Shekou Michigan City, Indiana 46360 U.S.A. 42602 Montbrison Cedex, France
Shenzhen, Guangdong PRV. Telephone: 33-477968470
www.sullair.com
PRC POST CODE 518068 Fax: 33-477968499
Telephone: 1-800-SULLAIR (U.S.A. Only)
Telephone: 755-6851686 www.sullaireurope.com
or 1-219-879-5451
Fax: 755-6853473
Fax: (219) 874-1273
www.sullair-asia.com
PARTS DEPARTMENT
Fax: (219) 874-1835
www.sullair.com/parts.shtm
SERVICE DEPARTMENT
Fax: (219) 874-1205
www.sullaircompressors.com
8.2 RECOMMENDED SPARE PARTS LIST - 200-250HP/ 149-186KW

DESCRIPTION KIT NUMBER QTY
element for 18” diameter air filter 250006-718 (primary) 250007-838 1

element for 18” diameter air filter 250006-718 (secondary) 250007-839 1
element for separator with gaskets (primary) 250034-122 1
element for separator with gaskets (secondary) 02250131-225 1
repair kit for thermal valve (175°F) 02250127-119 02250105-553 1
repair kit for thermal valve (195°F) 02250127-962 (I) 02250112-709 1
repair kit for regulator valve 02250046-568 02250055-911 1
repair kit for blowdown valve 409783 001667 1
repair kit for control line filter 02250112-032 02250112-031 1
replacement kit for fluid return strainer 02250117-782 1
repair kit for fluid stop valve 02250113-668
(Remote Cooler only) 02250116-697 1
repair kit for water separator 02250111-105 Consult Factory 1
(I) For 24KT water-cooled, and ≥ 150 psig compressors.
PLEASE NOTE: WHEN ORDERING PARTS, INDICATE SERIAL NUMBER OF COMPRESSOR
63
Section 8
8.2 RECOMMENDED SPARE PARTS LIST - 200-250HP/ 149-186KW (CONTINUED)
replacement kit for fluid filter 02250121-658 02250139-995 1

repair kit for solenoid valve 02250125-657 02250125-829 (valve) 1
replacement coil for solenoid valve 02250125-657 02250125-861 (coil) 1
repair kit for solenoid valve 02250125-667 02250125-826 1
repair kit for regulator valve 02250052-358 048409 1
repair kit for minimum pressure valve 250033-821 250018-262 1
repair kit for pressure regulator 406929 041742 1
repair kit with o-rings and and springs for inlet valve assembly 02250141-645 1
rebuild kit for inlet valve assembly 02250141-648 1
repair kit for shaft seal 067329-001 1
element for drive coupling 046999 1
diaphragm repair kit for spiral valve air cylinder 250016-183 608311-001 1
o-ring for 2 1/2 -12 SAE tube fittings 250042-649 -
compressor Sullube fluid (5 gallons) 250022-669 -
compressor 24KT fluid (5 gallons) 02250051-153 -
compressor CP-4600-32-F fluid (5 gallons) 250029-008 -
64
Section 8
8.3 RECOMMENDED SPARE PARTS LIST- 300-350HP/ 224-261KW
element for 18” diameter air filter 250006-718 (primary) 250007-838 1

element for 18” diameter air filter 250006-718 (secondary) 250007-839 1
element for separator with gaskets 250034-123 (primary) 250034-124 1
element for separator with gaskets 250034-129 (secondary) 250034-130 1
repair kit for water separator 02250111-105 Consult Factory 1
repair kit for thermal valve (170°F) 02250120-955 02250120-957 1
repair kit for thermal valve (195°F) 02250127-962 (I) 02250127-963 1
repair kit for regulator valve 02250046-568 02250055-911 1
repair kit for blowdown valve 409783 001667 1
repair kit for control line filter 02250112-032 02250112-031 1
repair kit for fluid return strainer 02250117-782 1
replacement kit for fluid filter 02250128-717 02250121-657 1
repair kit for solenoid valve 02250125-657 02250125-829 (valve) 1
repair kit for solenoid valve 02250125-667 02250125-826 1
repair kit for regulator valve 02250052-358 048409 1
repair kit for minimum pressure valve 250033-821 250018-262 1
repair kit for pressure regulator 406929 041742 1
repair kit with o-rings and and springs for inlet valve assembly 02250141-645 1
rebuild kit for inlet valve assembly 02250141-648 1
repair kit for fluid stop valve 02250122-004
(Remote Cooler only) 001684 1
repair kit for shaft seal 067329-001 1
element for drive coupling 046999 1
diaphragm repair kit for spiral valve air cylinder 250016-183 608311-001 1
o-ring for 2 1/2 -12 SAE tube fittings 250042-649 1
compressor Sullube fluid (5 gallons) 250022-669 -
compressor 24KT fluid (5 gallons) 02250051-153 -
compressor CP-4600-32-F fluid (5 gallons) 250029-008 -
(I) For 24KT water-cooled, and ≥ 150 psig compressors.
65
Section 8
8.4 MOTOR, COMPRESSOR, FRAME AND PARTS
02250134-871R00
66
Section 8
8.4 MOTOR, COMPRESSOR, FRAME AND PARTS
key part
1 screw, sqhd 0.5 x 3.5 cup set pt 02250112-193 6

2 frame, main LS25S/32-200/350hp 02250134-870 1
3 nut, assy compr mtg 32/25 02250135-358 4
4 guard, coupling LS25S 02250136-316 1
5 block, motor adjusting 02250137-596 4
6 angle, mtr adjust bolt on 02250137-597 2
7 element, drive cplg - saga 34a 046999 1
8 hub, coupling saga 34a 2-3/8 x 5/8 250004-635 1
9 nut, hex pltd 3/4-10 825212-665 8
10 capscr, hex gr5 1/2-13 x 1 829108-100 2
11 capscr, hex gr5 1/2-13 x 1 1/2 829108-150 4
12 capscr, hex gr5 1/2-13 x 2 829108-200 4
13 capscr, hex gr5 3/4-10 x 2 1/4 829112-225 8
14 capscr, hex gr5 3/4-10 x 2 1/2 829112-250 4
15 washer, bevel 3/4 837012-150 8
16 washer, spr lock reg pltd 1/2 837808-125 10
18 washer, pl-b reg pltd 1/2 838208-112 4
19 stud, with 2 nuts 3/4-10x5 1/2 842812-055 4
20 capscrew, ferry head hd pltd 3/4-10 x 4 867312-400 8
21 unit, compr dxr25 (I) - 1
22 hub, compressor (II) - 1
23 motor, main (III) - 1
24 support, motor (III) - 2
(I) There is an exchange program whereby a remanufactured compressor unit can be obtained from Sullair
distributors or the factory at less cost than the owner could repair the unit. For information regarding
the unit exchange program, contact your nearest Sullair representative or the Sullair Corporation.
The shaft seal is not considered part of the compressor unit in regard to the two year warranty.
The normal Sullair parts warranty applies. For shaft seal repairs order repair kit no. 067329-001.
(II) For maintenance on drive coupling element, order drive coupling replacement no. 046999.
(III) Motor and motor support may vary. Consult factory with machine serial number.
67
Section 8
8.5 AIR INLET SYSTEM
02250134-881R01
68
Section 8
8.5 AIR INLET SYSTEM
key part
1 adapter, compressor inlet 8” inl vlv 02250044-615 1

2 support, 18” filter LS25SC 02250134-882 1
3 sub assembly, 8” inlet valve (I) 02250137-084 1
4 gasket, 8-1/2” x 10-1/2” x 1/32” 040422 1
5 gasket, .06 x 10.5id x 13.25od 041079 1
6 hose, hump 8 x 5” 043596 1
7 clamp, hose 8” 043598 2
8 filter, 18” dia air (II) 250006-718 1
9 cap, air inlet 10” 250007-712 1
10 nut, jam rh unfin 3/4-10 824912-446 2
11 nut, hex pltd 3/8-16 825206-337 4
12 nut, hex locking 3/8-16 825506-198 1
13 capscr, hex gr5 3/8-16 x 1 1/4 829106-125 4
14 capscr, hex gr5 3/8-16 x 1 1/2 829106-150 1
15 capscr, hex gr5 3/4-10 x 2 1/2 829112-250 6
18 stud, threaded 3/4-10 x 3 839412-030 2
(I) For maintenance on inlet valve no. 02250137-084, order repair kit with o-rings and springs no.
02250141-645, or rebuild kit no. 02250141-648.
When performing maintenance on the inlet valve, gasket no. 040422 and gasket no. 041079 may also
need to be replaced.
(II) For maintenance on air filter no. 250006-718, order primary replacement element no. 250007-838, and
secondary replacement element no. 250007-839.
69
Section 8
8.6 INLET VALVE
02250137-085R00
70
Section 8
8.6 INLET VALVE
key part
1 housing, body 8” inlet valve (I) 250042-276 1

2 cover, assembly 8” inlet valve 02250048-491 1
3 plate, flow control 8” inlet valve 250042-297 1
4 cover, inter 8” inlet valve 250042-301 1
5 piston, 8” inlet valve 250042-299 1
6 spring, comp. 144 lbs inter 250042-384 1
7 shaft, 8” inlet valve 250042-305 1
8 spring, comp. 109 lbs outer 250042-383 1
9 spring, comp. 2.61 lbs 250042-656 1
10 capscr hx. gr.5 1/4-20 x 3/4 829104-075 1
11 washer, sprlock reg. 1/4 837804-062 1
12 o-ring, viton 4 5/8 x 1/4 826502-426 1
13 o-ring, viton 1 x 1/8 826502-214 1
14 screw, ferry hd, 3/8-16 x 13/4 lg 867306-175 18
15 plug, pipe 1/4-18 npt; stl 3000# 866900-010 2
(I) For maintenance on inlet valve no. 02250137-084, order repair kit with o-rings and springs no.
02250141-645, or rebuild kit no. 02250141-648.
When performing maintenance on the inlet valve, gasket no. 040422 and gasket no. 041079 may also
need to be replaced.
71
Section 8
8.7 FLUID COOLING SYSTEM- AIR-COOLED 200-250HP/ 149-186KW
02250134-080R02
72
Section 8
key part
1 cooler, air after 200/250hp 200psi 02250121-098 1

2 fan, 42” 250hp clr pk hi static 02250121-101 1
3 plate, clean out cover (I) 02250121-123 4
4 panel, venturi 42”fan TS20-250hpac 02250122-381 1
5 support, fan motor TS20-250hpacac (256t 02250122-428 1
6 cooler, oil(ac)200/250hp 200psi 02250122-858 1
7 guard, fan 42” TS20-150/250hpacac 02250123-366 1
8 bar, back-up horizontal clr pk 02250123-797 2
9 adapter, venturi panel 200/250hpac part 02250123-920 2
10 adapter, venturi panel 200/250hpac part 02250124-924 2
11 hinge, door 02250125-402 4
12 support, cooler TS32A-200/250 intac 02250126-432 3
13 support, cooler TS32A-200/250 intac spc 02250126-433 1
14 lug, lifting clr pk - 90deg bend 02250132-040 4
15 grommet, rubber 040125 16
16 nut, hex pltd 1/2-13 825208-448 14
17 nut, hex f pltd 5/16-18 825305-283 44
18 nut, hex f pltd 3/8-16 825306-347 4
19 nut, hex locking 5/16-18 825505-166 8
20 nut, hex locking 1/2-13 825508-262 4
21 capscr, hex gr5 1/2-13 x 1 3/4 829108-175 14
22 screw, hex ser washer 5/16-18 x 3/4 829705-075 50
23 screw, hex ser washer 5/16-18 x 1 829705-100 10
26 screw, hex ser washer 3/8-16 x 1 1/ 829706-125 22
(I) DO NOT operate compressor without cooler access panles in place.
73
Section 8
02250134-080R02
74
Section 8
8.7 FLUID COOLING SYSTEM- AIR-COOLED 200-250HP/ 149-186KW (CONTINUED)
key part

32 eyebolt, 5/16-18 x 1 1/8” pltd 839105-112 8
33 nut, retainer 5/16-18 .092 861405-092 6
34 bushing (I) - 1
35 screw. hex ser washer 1/2-13 x various (I) - 4
36 motor (I) - 1
(I) This item may vary with machine. Consult factory with machine serial number.
75
Section 8
02250128-959R02
76
Section 8
key part
1 panel, adapter 400hp clr pk 02250121-117 2

2 panel, adapter 400hp clr pk w/clean 02250121-118 2
3 saddle, motor supt 300/400hp clr pk 02250121-119 1
4 support, mtr 300/400hp clr pk 02250121-120 1
5 plate, clean out cover (I) 02250121-123 4
6 panel, venturi 48” TS32-300-450 02250121-343 1
7 cooler, oil 300/350 hp 02250122-218 1
8 cooler, air aft 300/350 hp 02250122-219 1
9 bar, back-up horizontal clr pk 02250123-797 2
10 support, cooler TS32A-300/350 intac mtrside 02250123-834 2
11 support, cooler TS32A-300/350 intac strside 02250123-835 2
12 hinge, door 02250125-402 4
13 lug, lifting clr pk - 90deg bend 02250132-040 4
15 guard, fan (1600q) 241347 2
16 nut, hex pltd 1/2-13 825208-448 15
17 nut, hex f pltd 5/16-18 825305-283 20
18 nut, hex locking 5/16-18 825505-166 8
19 capscr, hex gr5 3/8-16 x 1 1/4 829106-125 14
20 capscr, hex gr5 1/2-13 x 1 3/4 829108-175 12
30 eyebolt, 5/16-18 x 1 1/8” pltd 839105-112 8
31 nut, retainer 5/16-18 .092 861405-092 10
(I) DO NOT operate compressor without cooler access panles in place.
77
Section 8
02250128-959R02
78
Section 8
8.8 FLUID COOLING SYSTEM- AIR-COOLED 300-350HP/ 224-261KW (CONTINUED)
key part
32 bushing (I) - 1
33 capscr, hex gr5 1/2-13 x various len (I) - 4
34 bushing (I) - 1
35 motor (I) - 1
79
Section 8
8.9 WATER COOLER PIPING- 200-350HP/ 149-261KW
02250127-756R01 & 02250128-479R01
80
Section 8
8.9 WATER COOLER PIPING- 200-350HP/ 149-261KW
key part
1 support, aftercooler 02250124-430 2

2 tube, water in/aftclr 1-1/2” o.d. 02250124-618 1
3 tube, aftclr/oilclr 1-1/2” o.d. 02250124-619 1
4 support,wc aftclr/ac discharge pipe 02250128-850 1
5 tube, TS32-200/250wc serpp wtrout to 02250134-267 1
•tube, TS32-300/350wc serpp wtrout to 02250134-347 1
6 bracket, 2” npt oil in/out 250008-245 1
7 elbow, red 2 x 1 1/2 150# 801608-060 1
8 bushing, red hx 3 x 1 1/2 802112-060 2
9 connector, tube-m 1 1/2 x 1 1/2 810224-150 5
10 elbow, tube 90 deg m 1 1/2 x 1 1/2 810524-150 1
11 nipple, pipe 1 1/2 x 6 1/2 822124-065 1
12 nipple, pipe 2 x 13 (250 only) 822132-130 1
13 nut, hex pltd 1/2-13 825208-448 16
14 capscr, hex gr5 1/2-13 x 1 1/2 829108-150 16
17 elbow, pipe 90 deg plt 1 1/2” 866215-060 4
18 nipple, pipe pltd 1 1/2 x 3 866324-030 1
19 nipple, pipe pltd 1 1/2 x 5 866324-050 2
20 bushing, red pltd 2 x 1 1/2 867108-060 3
21 u-bolt, 1/2” x 8” pipe pltd 868308-800 2
22 cooler, fluid (I) - 1
23 aftercooler (I) - 1
24 nipple, pipe-xs plt 2 x cl (300-350 only) 866432-000 1
25 decal, water inlet-outlet 049873 1
26 decal, water in 250019-107 1
27 decal, water out 250019-108 1
81
Section 8
8.10 AIR PIPING SYSTEM- AIR-COOLED 200-250HP/ 149-186K
02250137-569R02
82
Section 8
key part
1 separator, water dh ws800 3”npt (I) 02250111-105 1

2 bracket, seperator mount 02250121-831 1
3 joint, expansion TS32A-200/250ac mpv/intac 02250127-208 1
4 valve, check 1/2” 042694 1
5 gasket, asa flange 150# 3” 240621-008 3
6 valve, min press check 3” (spl) (II) 250033-821 1
7 valve, blwdwn 1”nc 2way #c6654 (III) 409783 1
8 connector, tube-m 5/8 x 1/2 810210-050 2
9 connector, tube-m 1 x 3/4 810216-075 1
10 elbow, tube 90 deg m 1 x 1 810516-100 1
11 flange, thrd 3” 150# rf 819315-048 3
12 nipple, pipe 3 x 3 1/2 822148-035 2
13 nipple, pipe 3 x 7 822148-070 1
14 nipple, pipe 3 x 14 822148-140 1
15 nipple, pipe-xs 1 x cl 822216-000 1
16 nut, hex pltd 5/8-11 825210-559 12
17 capscr, hex gr5 5/16-18 x 1 829105-100 2
18 capscr, hex gr5 3/8-16 x 1 829106-100 2
19 capscr, hex gr5 5/8-11 x 3 829110-300 4
20 capscr, hex gr5 5/8-11 x 3 1/4 829110-325 8
28 elbow, pipe-90m 1/2 x 1/2 860508-050 1
29 elbow, pipe 90 deg plt 1/2” 866215-020 1
(I) For maintenance on water separator no. 02250111-105, consult factory for replacement parts.
(II) For maintenance on minimum pressure check valve no. 250033-821, order repair kit no. 250018-262.
(III) For maintenance on blowdown valve no. 409783, order repair kit no. 001667.
83
Section 8
02250137-569R02
84
Section 8
8.10 AIR PIPING SYSTEM- AIR-COOLED 200-250HP/ 149-186K (CONTINUED)
key part
30 nipple, pipe pltd 1/2 x 3 866308-030 1

31 nipple, pipe-xs plt 1/2 x cl 866408-000 1
32 tee, reducing pltd 3/4 x 1/2 x 1/2 867503-022 1
33 u-bolt, 1/2” x 3” pipe pltd 868308-300 1
34 nipple, pipe-hx pltd 1/2 x 1/2 868508-050 2
35 elbow, red 1 x 1/2 150# plt 869204-020 1
36 union, pipe-brs seat 1/2 150# 871615-020 1
85
Section 8
8.11 AIR PIPING SYSTEM- WATER-COOLED 200-250HP/ 149-186KW
02250137-571R02
86
Section 8
key part

2 joint, expansion mpv to aftclr 3” dia. 02250124-433 1
3 valve, check 1/2” 042694 1
5 gasket, 4” 125# flg full face 242437-010 2
10 elbow, tube 90 deg m 1 x 1 810516-100 1
11 flange, thrd 3” 150# rf 819315-048 2
12 flange, thrd red 3 x 9” 819548-090 1
13 nipple, pipe 3 x 8 822148-080 1
14 nipple, pipe 3 x 16 822148-160 2
16 nut, hex pltd 5/8-11 825210-559 20
17 capscr, hex gr5 5/8-11 x 3 1/4 829110-325 20
19 elbow, pipe-90m 1/2 x 1/2 860508-050 1
23 nipple, pipe-xs plt 3 x cl 866448-000 1
26 elbow, red 1 x 1/2 150# plt 869204-020 1
87
Section 8
8.12 AIR PIPING SYSTEM- REMOTE-COOLED 200-250HP/ 149-186KW
02250137-570R02
88
Section 8
key part

2 support, wc aftclr/ac discharge pipe 02250128-850 1
3 clamp, exhaust 3 1/2” 040284 2
4 valve, check 1/2” 042694 1
5 valve, min press check 3” (spl) (I) 250033-821 1
6 valve, blwdwn 1”nc 2way #c6654 (II) 409783 1
9 elbow, tube 90 deg m 1 x 1 810516-100 1
10 flange, thrd 3” 150# rf 819315-048 1
11 nipple, pipe 3 x 7 1/2 822148-075 2
12 nipple, pipe 3 x 20 822148-200 1
13 nipple, pipe 3 x 96 822148-960 1
15 nut, hex pltd 1/2-13 825208-448 10
16 capscr, hex gr5 1/2-13 x 1 1/2 829108-150 10
19 elbow, pipe-90m 1/2 x 1/2 860508-050 1
21 elbow, pipe 90 deg plt 3” 866215-120 1
23 nipple, pipe pltd 3 x 15 1/2 866348-155 1
27 elbow, red 1 x 1/2 150# plt 869204-020 1
29 union, pipe-brs seat 3 150# 871615-120 2
(I) For maintenance on minimum pressure check valve no. 250033-821, order repair kit no. 250018-262.
(II) For maintenance on blowdown valve no. 409783, order repair kit no. 001667.
89
Section 8
8.13 AIR PIPING SYSTEM- AIR-COOLED 300-350HP/ 224-261KW
02250137-572R00
90
Section 8
key part

3 joint, expansion ts32a-300/350 mpv/intac 02250123-836 1
4 valve, check 1/2” 042694 1
6 valve, min press check 3” (spl)(II) 250033-821 1
10 connector, tube-m 1 x 1 810216-100 1
11 flange, thrd 3” 150# rf 819315-048 3
12 nipple, pipe 1 x 2 1/2 822116-025 1
14 nut, hex pltd 1/2-13 825108-448 2
15 nut, hex pltd 5/8-11 825210-559 12
16 capscr, hex gr5 5/16-18 x 1 829105-100 2
17 capscr, hex gr5 3/8-16 x 3/4 829106-075 2
18 capscr, hex gr5 5/8-11 x 3 829110-300 4
19 capscr, hex gr5 5/8-11 x 3 1/4 829110-325 8
27 elbow, pipe-90m 1/2 x 1/2 860508-050 1
30 nipple, pipe pltd 3 x 3 866348-030 2
91
Section 8
02250137-572R00
92
Section 8
8.13 AIR PIPING SYSTEM- AIR-COOLED 300-350HP/ 224-261KW (CONTINUED)
key part
31 nipple, pipe pltd 3 x 5 1/2 866348-055 1

32 nipple, pipe pltd 3 x 12 866348-120 1
34 u-bolt, 1/2” x 3” pipe pltd 868308-300 1
93
Section 8
02250137-575R00
94
Section 8
key part

2 joint, expansion mpv to aftclr 3” dia. 02250124-433 1
3 valve, check 1/2” 042694 1
5 gasket, 4” 125# flg full face 242437-010 2
10 elbow, tube 90 deg m 1 x 1 810516-100 1
11 flange, thrd 3” 150# rf 819315-048 2
12 flange, thrd red 3 x 9” 819548-090 1
13 nipple, pipe 3 x 3 1/2 822148-035 1
14 nipple, pipe 3 x 6 1/2 822148-065 1
15 nipple, pipe 3 x 20 822148-200 1
16 nut, hex pltd 5/8-11 825210-559 20
17 capscr, hex gr5 5/8-11 x 3 1/4 829110-325 20
19 elbow, pipe-90m 1/2 x 1/2 860508-050 1
22 nipple, pipe-xs plt 1 x 2 866416-020 3
95
Section 8
02250137-574R00
96
Section 8
key part

2 support,wc aftclr/ac discharge pipe 02250128-850 1
3 clamp, exhaust 3 1/2” 040284 2
4 valve, check 1/2” 042694 1
5 valve, min press check 3” (spl) (I) 250033-821 1
6 valve, blwdwn 1”nc 2way #c6654 (II) 409783 1
9 elbow, tube 90 deg m 1 x 1 810516-100 1
10 flange, thrd 3” 150# rf 819315-048 1
11 nipple, pipe 3 x 3 822148-030 1
12 nipple, pipe 3 x 7 1/2 822148-075 2
13 nipple, pipe 3 x 20 822148-200 1
14 nipple, pipe 3 x 96 822148-960 1
15 nut, hex pltd 1/2-13 825208-448 10
16 capscr, hex gr5 1/2-13 x 1 1/2 829108-150 10
19 elbow, pipe-90m 1/2 x 1/2 860508-050 1
24 nipple, pipe-xs plt 1 x 2 1/2 866416-025 1
(I) For maintenance on minimum pressure check valve no. 250033-821, order repair kit no. 250018-262.
(II) For maintenance on blowdown valve no. 409783, order repair kit no. 001667.
97
Section 8
8.16 AIR PIPING SYSTEM- 24KT 350HP/261KW
02250137-580R00
98
Section 8
key part

3 joint, expansion 3” x 4” ts32a-350/400hp 02250131-110 1
4 valve, check 1/2” 042694 1
12 flange, thrd 3” 150# rf 819315-048 2
13 flange, thrd red 3 x 9” 819548-090 1
14 nipple,pipe 3 x 3 822148-030 2
15 nipple,pipe 3 x 5 1/2 822148-055 1
16 nipple,pipe 3 x 12 822148-120 1
17 nut,hex pltd 5/8-11 825210-559 20
18 capscr, hex gr5 5/16-18 x 1 829105-100 2
19 capscr, hex gr5 3/8-16 x 3/4 829106-075 2
20 capscr, hex gr5 5/8-11 x 3 829110-300 8
21 capscr, hex gr5 5/8-11 x 3 1/4 829110-325 12
29 elbow, pipe-90m 1/2 x 1/2 860508-050 1
99
Section 8
02250137-580R00
100
Section 8
8.16 AIR PIPING SYSTEM- 24KT 350HP/261KW (CONTINUED)
key part

32 nipple,pipe-xs plt 1 x cl 866416-000 2
33 nipple,pipe-xs plt 1 x 2 1/2 866416-025 1
35 u-bolt,1/2” x 3” pipe pltd 868308-300 1
36 nipple,pipe-hx pltd 1/2 x 1/2 868508-050 2
37 union,pipe-brs seat 1 150# 871615-040 1
101
Section 8
8.17 FLUID PIPING SYSTEM- AIR-COOLED 200-250HP/ 149-186KW
02250135-894R01
102
Section 8
key part
1 adapter, sae 1 7/8-12 x 1 7/8-12 02250055-014 1

2 seal, u-cup therm vlv 02250101-372 1
3 filter, 1 7/8-12 sae coreless (I) 02250121-658 1
4 housing, therm vlv 1 7/8”-12 conn w/ ext (II) 02250127-119 1
5 tube, 1-1/2” thrmvlv/clr TS32A-200/25 02250127-347 1
6 tube, 1-1/2” clr/thrmvlv TS32A-200/25 02250127-349 1
7 elbow, sae 90 1 7/8m x 1 7/8f 02250136-054 1
8 tube, filter-elbow LS25SC-200 02250136-055 1
9 tube, elbow/unit LS25SC-200 02250136-056 1
10 element, thermal vlv 049542 1
11 elbow, tube union 1 1/2 811224-150 1
12 elbow, tube str thrd 1 1/2 x 1 7/8 811624-188 5
13 connector, tube str thd 1 1/2 x 1 7/8 811824-188 1
14 o-ring, viton 2 1/2 x 3/32” 826502-144 1
16 capscrew, ferry head hd pltd 3/8-16 x 1 1/2 867306-150 4
(I) For maintenance on coreless filter no. 02250121-658, order replacement filter no. 02250139-995.
(II) For maintenance on thermal valve (175ºF), order repair kit no. 02250105-553.
103
Section 8
8.18 FLUID PIPING SYSTEM- WATER-COOLED 200-250HP/ 149-186KW
02250135-895R01
104
Section 8
key part
1 adapter, sae 1 7/8-12 x 1 7/8-12 02250055-014 1

3 filter, 1 7/8-12 sae coreless 02250121-658 1
4 tube, thermal valve to oil cooler 02250126-426 1
5 housing, therm vlv 1 7/8”-12 conn w/ ext (I) 02250127-119 1
6 tube, oc/thrmvlvTS32-200/250 1-1/2”w 02250134-340 1
7 elbow, sae 90 1 7/8m x 1 7/8f 02250136-054 1
8 tube, oilfltr/elbow LS25SC-200 02250136-055 1
11 elbow, tube union 1 1/2 811224-150 1
14 o-ring, viton 2 1/2 x 3/32” 826502-144 1
(I) For maintenance on thermal valve (175ºF), order repair kit no. 02250105-553.
105
Section 8
8.19 FLUID PIPING SYSTEM- REMOTE-COOLED 200-250HP/ 149-186KW
02250135-896R01
106
Section 8
key part
1 housing, therm vlv 1 7/8”-12 sae ports (I) 02250054-601 1

2 adapter, sae 1 7/8-12 x 1 7/8-12 02250055-014 4
4 tee, sae str. thrd 1-7/8 x 12 02250113-549 1
5 valve, oil stop (II) 02250113-668 2
6 filter,1 7/8-12 sae coreless 02250121-658 1
7 tube, thermal valve/oil out 02250134-554 1
8 tube, oil in/tee block 02250134-556 1
9 tube, 1-1/2” oilfltr/tube elbow 02250134-558 1
11 valve, check 1/2” 042694 1
12 switch, temp n.o. 115f 043239 1
15 valve, check-swing 2” npt 40671 1
17 connector, tube-m 1 1/2 x 1 1/2 810224-150 2
18 elbow, tube 90 deg m 1/2 x 1/2 810508-050 1
19 elbow, tube union 1 1/2 811224-150 1
22 nut, hex pltd 1/2-13 825208-448 2
23 o-ring, viton 2 1/2 x 3/32” 826502-144 1
24 capscr, hex gr5 1/2-13 x 1 1/2 829108-150 2
31 bushing, red pltd 1/2 x 1/4 867102-010 1
(I) For maintenance on thermal valve (175ºF), order repair kit no. 02250105-553.
(II) For mainteinance on fluid stop vavle no. 02250113-668, order repair kit no. 02250116-697.
107
Section 8
02250135-896R01
108
Section 8
8.19 FLUID PIPING SYSTEM- REMOTE-COOLED 200-250HP/ 149-186KW (CONTINUED)
key part

33 tee, reducing pltd 2 x 1 1/2 x 1 867508-064 1
34 bushing, red hex pltd 1 x 1/2 868904-020 1
35 bushing, red hex pltd 2 x 1 1/2 868908-060 1
109
Section 8
02250134-950R00
110
Section 8
key part
1 adapter, sae 2-1/2-12 x 2-1/2-12 02250110-661 1

2 valve, thermal 2.5” sae 170deg (I) 02250120-955 1
3 tube, thrmvlv/intac 2” o.d. 02250124-662 1
4 tube,intac/thrmvlv 2” o.d. 02250124-663 1
5 filter, 2-1/2 sae coreless 80cn-1(II) 02250128-717 1
6 tube, oil elbow/unit ls25sc-300 02250135-660 1
7 tube, oil flt-el ls25sc-300 02250136-890 1
8 elbow, tube union 2 811232-200 1
9 elbow, tube str thrd 2 x 2 1/2 811632-250 5
10 connector, tube str thd 2 x 2 1/2 811832-250 1
11 o-ring, viton 2 3/4 x 1/8” 826502-232 1
14 reducer, str thrd viton 1 1/2 x 2 870024-032 1
(I) For maintenance on thermal valve (170ºF) no. 02250120-955, order repair kit no. 02250120-957.
(II) For maintenance on coreless filter no. 02250128-717, order replacement kit no. 02250121-657.
111
Section 8
02250135-878R00
112
Section 8
key part
1 adapter, sae 2-1/2-12 x 2-1/2-12 02250110-661 1

3 tube, oilclr/thrmvlv 2” o.d. 02250124-633 1
4 tube, thrmvlv/oilclr 2” o.d. 02250124-634 1
5 filter. 2-1/2 sae coreless 80cn-1 02250128-717 1
6 tube, oil elbow/unit LS25SC-300 02250135-660 1
7 tube, oil fltr-elb LS25SC-300wc 02250136-900 1
10 connector, tube str thd 2 x 2 1/2 811832-250 1
11 o-ring, viton 2 3/4 x 1/8” 826502-232 1
(I) For maintenance on thermal valve (170ºF) no. 02250120-955, order repair kit no. 02250120-957.
113
Section 8
02250135-879R01
114
Section 8
key part
1 adapter, sae 2-1/2-12 x 2-1/2-12 02250110-661 2

3 valve, oil stop 2.5” sae (II) 02250122-004 1
4 2-1/2” sae check valve insert 02250125-617 1
5 filter. 2-1/2 sae coreless 80cn-1 02250128-717 1
6 tube, 2”dia TS32-300rc thrmvlv to un 02250129-215 1
7 tube, 2”dia TS32-300rc union to oil 02250129-219 1
8 tube, 2”dia TS32-300rc oil in to uni 02250129-221 1
9 tube, 2”dia TS32-300rc union to thrm 02250129-223 1
10 tube, oil elbow/unit LS25SC-300 02250135-660 1
11 tube, oil fltr-elb LS25SC-300rc 02250136-893 1
12 valve, check 1/2” 042694 1
13 switch, temp n.o. 115f 043239 1
15 tee, reducing 2 x 2 x 1/2 802208-082 1
18 elbow, tube 90 deg m 1/2 x 1/2 810508-050 1
20 union, tube hex 2” 811332-200 2
23 nut, hex pltd 1/2-13 825208-448 2
24 o-ring, viton 2 3/4 x 1/8” 826502-232 1
25 capscr, hex gr5 1/2-13 x 1 1/2 829108-150 2
28 bushing, red pltd 1/2 x 1/4 867102-010 1
(I) For maintenance on (170ºF) thermal valve no. 02250120-955, order repair kit no. 02250120-957.
(II) For maintenance on oil stop valve no. 02250122-004, order repair kit no. 001684.
115
Section 8
8.23 SUMP AND PARTS 200-250HP/ 149-186KW
02250135-451R01
116
Section 8
key part
1 connector, flex 1/4t x 1/4p 020169 2

2 plug, sight glass 1-7/8” sae 02250097-611 2
3 valve, ball 3/4”sae x 3/4”npt 02250125-221 1
4 sub assembly, oil return/sightglass line (I) 02250126-164 1
5 tube, sump drain 3/4” 02250126-483 1
6 boom, lid lifting 02250127-249 1
7 support, oil rtn sight glass TS32A-200/ 02250129-872 1
8 element, secondary separator (II) 02250131-223 1
9 joint, expansion LS25SC 200/250 02250135-447 1
10 plug, o-ring boss sae 1 1/4 040029 1
12 gasket, discharge flange 4” n.p.t. 250002-379 1
13 element, primary 25-200 (II) 250034-121 1
14 connector, tube str thd 3/4 x 1 1/16 811812-106 2
15 flange, slp-on 4” 150# 819215-064 2
16 nut, hex pltd 1/2-13 825208-448 4
17 nut, hex pltd 5/8-11 825210-559 8
18 nut, hex pltd 3/4-10 825212-665 1
19 capscr, hex gr5 1/2-13 x 2 829108-200 4
20 capscr, hex gr5 1/2-13 x 2 3/4 829108-275 2
21 capscr, hex gr5 5/8-11 x 3 1/4 829110-325 8
22 capscr, hex gr5 3/4-10 x 2 1/2 829112-250 1
26 plug, pipe 1/4” 3000# stl plt 866900-010 1
27 plug, pipe 3/4” 3000# stl plt 866900-030 1
30 tank, oil sump 24” vert std (III) - 1
31 valve, relief 1-1/2” 1950cfm viton s (III) - 1
(I) Consult Oil Return Sight Glass Maintenance information in Section 7, and Figure 7-4 for maintenance
and repair kit on oil return/sight glass sub-assembly.
(II) For maintenance on separator elements, order (primary) replacement kit no. 250034-122, and (second-
ary) replacement kit no. 02250131-225.
(III) This item may vary with machine. Consult factory with machine serial number.
117
Section 8
02250134-913R00
118
Section 8
key part
1 connector, flex 1/4t x 1/4p 020169 2

2 plug, sight glass 1-7/8” sae 02250097-611 2
3 valve, ball 3/4”sae x 3/4”npt 02250125-221 1
4 tube, 3/4” sump drain 02250125-918 1
5 sub assembly, oil return/sightglass line (I) 02250126-164 1
6 boom, lid lifting 02250127-249 1
7 support, oil rtn sight glass TS32A-200/ 02250129-872 1
8 joint, expansion LS25SC 300/350 02250134-912 1
9 plug,o-ring boss sae 1 1/4 040029 2
11 gasket, discharge flange 4” n.p.t. 250002-379 1
12 element, sep/pri (II) 250034-123 1
13 element, sep/sec (II) 250034-129 1
14 connector, tube str thd 3/4 x 1 1/16 811812-106 2
15 nut, hex pltd 5/8-11 825210-559 8
16 nut, hex pltd 3/4-10 825212-665 5
17 capscr, hex gr5 1/2-13 x 2 3/4 829108-275 2
18 capscr, hex gr5 5/8-11 x 3 1/4 829110-325 8
19 capscr, hex gr5 3/4-10 x 2 1/2 829112-250 5
20 washer, bevel 3/4 837012-150 2
26 plug, pipe 1/4” 3000# stl plt 866900-010 1
27 plug, pipe 3/4” 3000# stl plt 866900-030 1
30 tank, oil separator 30”dia - 1
31 valve, relief 1-1/2” 1950cfm viton s (III) - 1
(I) Consult Oil Return Sight Glass Maintenance information in Section 7, and Figure 7-4 for maintenance
and repair kit on oil return/sight glass sub-assembly.
(I) For maintenance on separator elements, order (primary) replacement kit no. 250034-124, and (second-
ary) replacment kit no. 250034-130.
(II) This item may vary with machine. Consult factory with machine serial number.
119
Section 8
8.25 COMPRESSOR SPIRAL VALVE ACTUATOR (OPTIONAL)
120
Section 8
8.25 COMPRESSOR SPIRAL VALVE ACTUATOR (OPTIONAL)
key part
1 shaft, valve - direct 250030-981 1

•shaft, valve - geared 250030-982 1
2 valve, weight counterbalance 250016-193 1
3 capscrew, socket 3/8”-16 x 1” 828906-100 2
4 ring, retaining 499068-005 1
5 bearing, ball 499002-207 1
6 seal, lip 250016-200 1
7 screw, set 1/2”-13 x 1.62 br 250024-465 1
8 adapter, air cylinder 250016-182 1
9 capscrew, ferry head 1/2”-13 x 1 1/2” 828408-150 6
10 guide, rack 250016-199 1
11 gear, pinion 250016-196 1
12 indicator, actuator 250030-983 1
13 pin, roll unfinished 1/4”x 1” 827404-100 1
14 capscrew, hex head gr8 1/4”-20 x 1/2” 828204-050 4
15 cover, adapter 250016-195 1
16 washer, regular #8 838201-045 6
17 screw, machine rod #8-32 x 1/2” 831601-050 6
18 mount, air cylinder 250016-188 1
19 capscrew, ferry head 1/2”-18 x 1 1/4” 828405-125 3
20 spring, seal 2 1/4” 250016-394 1
21 rack, gear 250016-197 1
22 nut, hex jam 3/8”-16 824906-227 1
23 shaft, air cylinder 250016-194 1
24 cylinder, air (I) 250016-183 1
25 orifice, .062 x .25m x .25f 028831 1
26 nut, hex unfinished 1/2”-13 824208-448 1
27 screw, machine hex 1/4”-20 x 1 3/4” 830104-175 1
28 nut, hex jam 1/4”-20 824904-164 1
29 decal, warning actuator 250029-836 1
30 decal, actuator valve positioning 250029-784 1
(I) For maintenance on air cylinder no. 250016-183, order diaphragm repair kit no. 608311-001.
121
Section 8
8.26 ZERO-LOSS MOISTURE DRAIN (OPTIONAL)
02250131-040R02
122
Section 8
8.26 ZERO-LOSS MOISTURE DRAIN (OPTIONAL)
key part
1 drain, electric condensate - scd300 02250130-866 2

2 valve, ball 1/2”npt 047117 2
3 connector, tube-strt 1/2”mnpt x 1/2”tube 250024-695 1
4 connector, tube-el 3/8”npt x 1/2”tube 250024-713 2
5 connector, tube-el 1/2”npt x 1/2”tube 250024-714 1
6 bulkhead, pipe 1/2” npt 841500-008 1
9 decal, water drain 250022-810 1
123
Section 8
8.27 PNEUMATIC CONTROLS
02250138-038R01
124
Section 8
key part
1 regulator, reducing 1/4 npt (I) 02250046-568 1

2 regulator, back press control 1/4” (II) 02250052-358 1
3 locknut, n4 conduit sealing 02250071-362 6
4 grip, cord n4 .125-.187 x 1/2” 02250071-379 3
5 grip, cord n4 .250-.375 x 1/2” 02250071-381 5
6 switch, vacuum 22”wc n4 6ft cable 5a 02250078-249 1
7 transducer, pressure 0-25psi 1-5vdc n4 02250078-933 4
8 orifice, .031” x .25m x .25m nptf 02250101-191 1
9 support, bracket transducer mounting 02250110-132 1
10 filter, control air 1/4”npt (III) 02250112-032 1
11 gage, air press 2 1/2” 0-200 psi 02250117-009 1
12 valve, solenoid 3wno 1/4 235# n4 (IV) 02250125-657 2
13 valve, solenoid 2wno 1/4 130# n4 (V) 02250125-667 1
14 support, str box LS20S ac 02250127-380 2
15 channel, ctl tubing supt 02250127-559 3
16 angle, support 02250133-550 2
17 bracket, support 02250133-551 3
18 bracket, supt 02250133-552 3
19 bracket, tubing manifold 02250133-564 3
20 orifice, .070 brass 1/4 npt 02250137-477 1
21 valve, inline check(1/4”npt)dc 045244 3
22 nipple, conduit 1/2 x 1.5” 250007-169 2
23 nipple, conduit 1/2” x 2” 250007-170 1
24 elbow, 90 1/4t pls x 1/4 npt m 250018-430 2
25 grip, cord so 12/4 st 1/2” 250018-495 1
26 connector, tube-strt 1/8”mnpt x 1/4”tube 250024-684 1
(I) For maintenance on reducing pressure regulator no. 02250046-568, order repair kit no. 02250055-911.
(II) For maintenance on back pressure control regulator no. 02250052-358, order repair kit no. 048409.
(III) For maintenance on control air filter no. 02250112-032, order repair kit no. 02250112-031.
(IV) For maintenance on solenoid valve no. 02250125-657, order repair kit no. 02250125-829(valve), and
replacement coil no. 02250125-861.
(V) For maintenance on solenoid valve no. 02250125-667, order repair kit no. 02250125-826(valve), and
replacement coil no. 02250125-858.
125
Section 8
02250138-038R01
126
Section 8
8.27 PNEUMATIC CONTROLS (CONTINUED)
key part
27 valve, diff press reg 1/4”npt (VI) 406929 1

28 connector, tube-f 1/4 x 1/4 810104-025 3
32 elbow, tube -f 1/4 x 1/4 810404-025 1
33 elbow, tube 90 deg m 1/4 x 1/4 810504-025 5
34 tee, tube-male run 1/4 x 1/4 810904-025 1
35 union, tube bhd 1/4” 811104-025 21
36 union, tube bhd 5/16” 811104-031 3
37 nut, hex pltd 1/4-20 825204-226 2
38 nut,hex pltd 3/8-16 825206-337 4
39 nut, hex pltd 1/2-13 825208-448 7
40 nut, hex f pltd 5/16-18 825305-283 18
41 capscr, hex gr5 1/4-20 x 1/2 829104-050 2
42 capscr, hex gr5 3/8-16 x 1 3/4 829106-175 4
43 capscr, hex gr5 1/2-13 x 1 1/2 829108-150 7
49 bulkhead, pipe 1/8” npt 841500-002 4
50 locknut, conduit 1/2 847200-050 3
51 bushing, conduit plastic 1/2 848815-050 3
52 elbow, pipe-90m 1/4 x 1/4 860504-025 3
53 elbow, pipe 90m/f 1/4 x 1/4 860704-025 1
55 tee, pipe 150# plt 1/4 866815-010 2
56 plug, pipe 1/4” 3000# stl plt 866900-010 1
57 cross, pipe 1/4” plt 867615-010 1
(VI) For maintenance on differential pressure regulator no. 406929, order repair kit no. 041742.
127
Section 8
02250138-038R01
128
Section 8
8.27 PNEUMATIC CONTROLS (CONTINUED)
key part
59 tee, male pipe brass 1/4 869825-025 3

60 starter, assy TS32A (VII) - 1
(VII) This item may vary with machine. Consult factory with machine serial number.
129
Section 8
8.28 CONTROL BOX- SOLID STATE
02250122-005R04
130
Section 8
8.28 CONTROL BOX- SOLID STATE
key part
1 enclosure 02550108-859 1
2 door 02550109-465 1
3 bezel 02250089-302 1
4 beze; gasket 02550090-872 1
5 I/0 module 02250141-089 1
6 display module 02250119-330 1
7 display gasket 02250048-822 2
8 primary fuse 305 amp 250026-648 1
9 secondary fuse 5 amp 250019-751 1
10 univ. 250 va trans 02250083-189 1
11 power supply 24v 0250120-644 1
12 relay 45496 1
13 relay base 46467 1
14 ground bus 02550110-334 1
15 ground bar 02550101-721 1
16 240A IT starter 02250122-042 1
17 304A IT starter 02250120-789 -
18 360A IT starter 02250120-792 -
19 420A IT starter 02250122-043 -
20 500A IT starter 02250122-044 -
21 650A IT starter 02250120-645 -
22 850A IT starter 02250122-046 -
23 display label 02250130-344 1
24 E-stop decal 02550086-259 1
25 E-stop operator 02550085-504 1
26 contact block 250027-125 1
27 plate 02550086-265 1
131
Section 8
8.29 CONTROL BOX- FULL VOLTAGE
02250122-511R04
132
Section 8
8.29 CONTROL BOX- FULL VOLTAGE
key part
1 enclosure 02550108-859 1
2 door 02550109-465 1
3 bezel 02250129-958 1
4 bezel gasket 02550090-872 1
5 I/O module 02550141-089 1
6 transformer 24v 02250135-283 1
7 primary fuse 3.5 amp 250026-648 2
9 univ. 250 va trans 02250083-188 1
10 univ. 350 va trans 02250083-190 -
11 primary fuse 4 amp 250026-649 -
12 secondary fuse 6 a 250019-762 -
13 ground bus 02550110-334 1
14 ground bar 02550101-721 1
16 display label 02550130-344 1
17 starter9 size 5 250038-284 1
18 starter9 size 5dp 02250113-513 -
19 starter9 size 6 250038-285 -
20 display module gasket 02250048-822 2
21 E-stop operator 02250085-504 1
22 contact block I-NC 250027-125 1
23 E-stop decal 02250086-259 1
24 plate 02250086-265 1
133
Section 8
8.30 CONTROL BOX- WYE-DELTA
02250122-516R08
134
Section 8
8.30 CONTROL BOX- WYE-DELTA
key part
1 ground bus 02550110-334
2 univ. 250 va trans 02250083-188 -

3 primary fuse 2.5 amp 250026-646 -
4 secondary fuse 3 amp 250019-758 -
5 ground bar 02550101-721 1
6 univ. 350 va trans 02250083-190 1
7 primary fuse 3.5 amp 250026-648 2
9 door 02550109-465 1
10 enclosure 02550108-859 1
11 bezel 02250089-302 1
12 bezel gasket 02550090-872 1
13 I/O module 02550141-089 1
15 transformer 24v 02250135-283 1
16 size 5 contactor 02250083-824 1
17 size 4 contactor 02550083-823 1
18 size 5dp contactor 02550113-514 -
19 size 5dp starter 02550113-513 -
20 starter size 5 250038-284 1
21 starter size n 250038-283 -
22 rev contactors size n 250041-589 -
23 display label 02550130-344 1
24 E-stop operator 02550085-504 1
25 contact block 250027-125 1
26 plate 02550086-265 1
27 E-stop decal 02550086-259 1
28 current transformer (optional) - 1
29 ammeter (optional) - 1
135
Section 8
8.31 ENCLOSURE- AIR-COOLED 200-250HP/ 149-186KW
02250128-119R01
136
Section 8
key part
1 panel, sill short TS32A 02250124-938 1

2 panel, header side TS32A 02250124-939 2
3 panel, header end TS32A 02250124-940 4
4 panel, header 60” str ts32 encl 02250124-942 1
5 angle, roof seal TS32A-200/250ac 02250125-070 4
6 panel, roof end TS32A-200/250ac 02250126-923 1
7 panel, roof mid TS32A-200/250ac 02250126-924 1
8 panel, roof side TS32A-200/250ac 02250126-925 2
9 panel, sill TS32A 02250129-475 5
10 support, center TS32A 02250129-478 2
11 hinge, separator access door 02250129-761 1
12 panel, baffle sep access door TS32A 02250129-762 1
13 panel, baffle unit end TS32A 02250129-838 1
14 hinge, 180deg. screw-on lift-off rh 02250129-863 33
15 support, canopy TS32A 02250130-219 5
16 support, starter side TS32A 02250130-221 1
17 support, corner TS32A 02250130-222 3
18 support, corner spcl TS32A 02250130-223 1
19 panel, roof sump end TS32A 02250130-224 1
20 cover, separator access 02250130-226 1
21 panel, access assy 30” x 57” 02250130-227 11
23 handle, canopy 042262 1
24 nut, hex pltd 1/4-20 825104-226 2
25 nut, hex f pltd 5/16-18 825305-283 13
26 nut, hex locking 5/16-18 825505-166 2
27 capscr, hex gr8 1/4-20 x 3/4 827904-075 2
28 capscr, hex gr5 5/16-18 x 3/4 829105-075 6
31 screw, self-drill 1/4 x 1/2 834504-050 44
(Contiued on page 139)
137
Section 8
02250128-119R01
138
Section 8
8.31 ENCLOSURE- AIR-COOLED 200-250HP/ 149-186KW (CONTINUED)
key part

34 eyebolt, 5/16-18 x 1 1/8” pltd 839105-112 2
35 nut, retainer 5/16-18 .092 861405-092 16
139
Section 8
02250128-122R01
140
Section 8
key part

4 panel, header 60” str TS32 encl 02250124-942 1
5 panel, roof center TS32A-300/350ac 02250127-099 1
6 panel, roof motor side TS32A-300/350ac 02250127-100 1
7 panel, roof starter side TS32A-300/350 02250127-101 1
8 panel, roof end TS32A-300/350ac 02250127-102 1
11 panel, sill TS32A 02250129-475 5
23 roof, TS32-350 intclr rmtinl 02250133-148 1
26 nut, hex pltd 1/4-20 825104-226 2
27 nut, hex f pltd 5/16-18 825305-283 13
28 nut, hex locking 5/16-18 825505-166 2
29 capscr, hex gr5 1/4-20 x 3/4 829104-075 2
30 capscr, hex gr5 5/16-18 x 3/4 829105-075 6
141
Section 8
02250128-122R01
142
Section 8
8.32 ENCLOSURE- AIR-COOLED 300-350HP/ 224-261KW (CONTINUED)
key part

36 eyebolt, 5/16-18 x 1 1/8” pltd 839105-112 2
37 nut, retainer 5/16-18 .092 861405-092 16
143
Section 8
8.33 ENCLOSURE- WATER-COOLED 200-350HP/ 149-261KW
02250128-124R02
144
Section 8
key part
1 support, fan motor 014613 1

2 fan, blower 20”-30 deg 185q8f 02250107-474 1
6 panel, header 60” str TS32 encl 02250124-942 1
7 panel, roof center TS32A-200/350 wc 02250126-834 1
8 panel, sill TS32A 02250129-475 4
14 support, canopy spcl TS32A 02250129-995 1
15 panel, sill spcl TS32A-200/350 wc & rc 02250130-216 1
20 panel, roof sump end TS32A 02250130-224 1
21 panel, roof mtr end TS32A-200/350 wc 02250130-225 1
25 panel, baffle mtr end TS32A-200/350wc 02250131-583 1
26 panel, baffle mtrend-r TS32C-200/350wc 02250138-258 1
28 guard, fan 24” 041765 1
30 clamp, speed tube 1/4” 043357 1
31 motor, .75hp 230/460v tefc 050288 1
32 spacer, fan support 227267 3
33 nut, hex pltd 1/4-20 825104-226 2
145
Section 8
02250128-124R02
146
Section 8
8.33 ENCLOSURE- WATER-COOLED 200-350HP/ 149-261KW (CONTINUED)
key part
34 nut, hex pltd 3/8-16 825106-337 7

35 nut, hex pltd 1/2-13 825108-448 4
36 nut, hex f pltd 5/16-18 825305-283 14
37 nut, hex locking 5/16-18 825505-166 2
38 capscr, hex gr5 3/8-16 x 1 1/4 828606-125 4
39 capscr, hex gr5 3/8-16 x 4 828606-400 3
40 capscr, hex gr5 1/2-13 x 1 828608-100 4
41 capscr, hex gr5 1/4-20 x 3/4 829104-075 2
42 capscr, hex gr5 5/16-18 x 3/4 829105-075 6
51 eyebolt, 5/16-18 x 1 1/8” pltd 839105-112 2
147
Section 8
8.34 DECAL GROUP
148
Section 8
8.34 DECAL GROUP
key part
1 sign, warning sever-fan port 049965 1

2 sign, warning hot surfaces 407408 1
3 sign, warning sever - fan 049855 2
4 sign, danger electrocution 049850 1
5 sign, warning “food grade” lube 250003-144 1
6 decal, warning actuator 250029-836 1
7 sign, warning “compressor fluid fill cap” 049685 1
8 sign, air breathing (danger) 250027-935 1
9 decal, Sullair logo 02250059-048 2
149
Section 8
8.34 DECAL GROUP
150
Section 8
8.34 DECAL GROUP (CONTINUED)
key part
10 sign, warning ground fault 049852 1

11 decal, warning auto start 250017-903 1
12 decal, autostart 041065 1
13 decal, danger high voltage 042218 1
15 decal, water in 250019-107 1
17A decal, fluid Sullube 02250069-389 1
17B decal, fluid 24KT 02250069-395 1
17C decal, fluid CP-4600-32-F 02250118-342 1
19A decal, V 460/3/60 international 02250069-399 1
19B decal, V 575/3/60 international 02250069-400 1
19C decal, V 380/3/50 international 02250069-412 1
19D decal, V 230/3/60 international 02250069-397 1
20 decal, protective earth ground 02250075-045 1
21 decal, PE designation 02250075-540 1
22 decal, earth ground 02250075-046 1
23 decal, warning mixing fluids 02250110-891 1
151
Section 8
8.34 DECAL GROUP
152
Section 8
8.34 DECAL GROUP (CONTINUED)
key part
24 decal, LS25S 02250061-363 1

25 decal, compressor fluid 24KT 02250061-022 1
26 decal, rotation 250021-564 1
28 decal, ISO 9001 (I) - 1
29 decal, fluid sample 250022-675 1
30 decal, electrical component ID 250038-457 1
31 sign, power energized 249544-049 1
32 decal, fork lifting 241814 4
(I) ISO decal may vary per machine. To determine the proper part number of this decal, consult factory
with machine serial number.
153
Section 8
8.35 DECAL LOCATIONS- AIR-COOLED/OPEN
154
Section 8
8.35 DECAL LOCATIONS- AIR-COOLED/OPEN
key part

9 decal, LS25S 02250061-363 1
10 decal, 24KT (I) 02250061-022 1
11 decal, ISO 9001 (II) - 1
14 decal, fluid (III) - 1
15 decal, warning-actuator (IV) 250029-836 1
16 decal, actuator- valve positioning (IV) 250029-784 1
17 sign, warning sever fan door closed 02250131-539 2
(I) This decal is used with 24KT fluid option fill only.
(II) ISO decal may vary per machine. To determine the proper part number of this decal, consult factory with
machine serial number.
(III) Fluid decal will vary per machine fill. To determine the compressor’s proper fill decal, consult factory
(IV) This decal is used with actuator option only.
155
Section 8
8.36 DECAL LOCATIONS- WATER-COOLED/OPEN
156
Section 8
8.36 DECAL LOCATIONS- WATER-COOLED/OPEN
key part

6 decal, water in 250019-107 1
12 decal, LS25S 02250061-363 1
13 decal, 24KT (I) 02250061-022 1
14 decal, ISO 9001 (II) - 1
16 decal, fluid (III) - 1
15 decal, warning-actuator (IV) 250029-836 1
16 decal, actuator- valve positioning (IV) 250029-784 1
17 sign, warning sever fan door closed 02250131-539 2
(I) This decal is used with 24KT fluid option fill only.
(II) ISO decal may vary per machine. To determine the proper part number of this decal, consult factory with
machine serial number.
(III) Fluid decal will vary per machine fill. To determine the compressor’s proper fill decal, consult factory
(IV) This decal is used with actuator option only.
157
Section 8
8.37 DECAL LOCATIONS- ENCLOSURES
158
Section 8
8.37 DECAL LOCATIONS- ENCLOSURES
key part

10 decal, ISO 9001 (I) - 1
(I) ISO decal may vary per machine. To determine the proper part number of this decal, consult factory
159
Section 8
8.38 DECAL LOCATIONS- CONTROL BOX INTERIOR
160
Section 8
8.38 DECAL LOCATIONS- CONTROL BOX INTERIOR
key part
1 decal, protective earth ground 02250075-045 2

2 decal, danger high voltage 042218 1
3 decal, V 460/3/60 international 02250069-399 1
•decal, V 575/3/60 international 02250069-400 1
4 decal, PE designation 02250075-540 1
5 sign, warning ground fault 049852 1
161
Section 8
8.39 WIRING DIAGRAM- AIR-COOLED FULL VOLTAGE WITH SUPERVISOR CONTROLLER
02250136-109R03
162
Section 8
8.40 WIRING DIAGRAM- WATER-COOLED FULL VOLTAGE WITH SUPERVISOR CONTROLLER
02250136-114R02
163
Section 8
8.41 WIRING DIAGRAM- WYE-DELTA AIR- AND REMOTE-COOLED WITH SUPERVISOR CONTROLLER
02250136-108R03
164
Section 8
8.42 WIRING DIAGRAM- WYE-DELTA WATER-COOLED WITH SUPERVISOR CONTROLLER
02250136-113R02
165
Section 8
8.43 WIRING DIAGRAM- SOLID STATE AIR- AND REMOTE-COOLED WITH SUPERVISOR CONTROLLER
02250136-107R02
166
Section 8
8.44 WIRING DIAGRAM- SOLID STATE WATER-COOLED WITH SUPERVISOR CONTROLLER
02250136-112R02
167
WORLDWIDE SALES AND SERVICE
SULLAIR ASIA, LTD.

SULLAIR EUROPE, S.A.
Sullair Road, No. 1
Zone Des Granges BP 82
Chiwan, Shekou
42602 Montbrison Cedex, France
Shenzhen, Guangdong PRV.
Telephone: 33-477968470
PRC POST CODE 518068
Fax: 33-477968499
Telephone: 755-6851686
www.sullaireurope.com
Fax: 755-6853473
www.sullair-asia.com
SULLAIR CORPORATION
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
www.sullair.com
Telephone: 1-800-SULLAIR (U.S.A. Only)
or 1-219-879-5451
Fax: (219) 874-1273
PARTS DEPARTMENT
Fax: (219) 874-1835
www.sullair.com/parts.shtm
SERVICE DEPARTMENT
Fax: (219) 874-1205
www.sullaircompressors.com
Printed in the U.S.A.

Specifications Subject To
Change Without Prior Notice
E03SF

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INDUSTRIAL ROTARY SCREW

For detailed course outlines, schedule and cost information contact:

Sullair Corporate Training Department

F. Wear goggles or a full face shield when adding 1.9 LIFTING

sion, the thermal valve begins to close and a portion ments.

50Hz MODEL LENGTH WIDTH HEIGHT (I) WEIGHT

3.2 LUBRICATION GUIDE-STANDARD COMPRES- 3.4 APPLICATION GUIDE

Mixing of other lubricants within the compressor

A 24KT sample should be sent in annually, after

1 filter, assy air inlet (heavy duty) 250006-718 -

(Continued on page 27)

34 vlv, sol ees 1/4” 4-way 02250056-983 -

1 filter, assy air inlet (heavy duty) 250006-718 -

(Continued on page 31)

35 cooler, fluid w/ 1-7/8”-12 sae oil ports 02250122-218 -

key part no. part no.

1 filter, assy air inlet (heavy duty) 250006-718 250006-718 1

(Continued on page 35)

key part no. part no.

36 aftercooler, air to air 02250121-098 02250122-219 1

key part no. part no.

1 filter, assy air inlet (heavy duty) 250006-718 250006-718 1

(Continued on page 39)

key part no. part no.

36 aftercooler, < = 150# 042950 042950 1

key part no. part no.

1 filter, assy air inlet (heavy duty) 250006-718 250006-718 1

(Continued on page 43)

key part no. part no.

36 aftercooler, < = 150# 042950 042950 1

Table 4-1 Ventilation Requirements

LS25S-200 200/149 47,570 4150 576,500 18,000

For information concerning all aspects of the Supervisor Controller,

CONTROL OR INDICATOR PURPOSE

Figure 7-2 Air Filter Replacement (P/N 250006-718)

*Primary Replacement Element P/N 250007-838

*Replacement Filter Assembly P/N 02250117-782

Disconnect all power at source, before attempt-

DO NOT upset the offset alignment or hub gap

7.9 TROUBLESHOOTING GUIDE

Line Fuse Blown Replace fuse.

Control Transformer Fuse Blown Replace fuse.

Replace Supervisor display module if no display

COMPRESSOR SHUTS DOWN Loss of Control Voltage Check incoming power.

Excessive Operating Pressure Check maximum P2 pressure setting.

HIGH PRESS P1 display; Max P1 pressure may

Defective solenoid valve; solenoid valve should

Defective blowdown valve; blowdown valve

Open or shorted P1, P2, P3 or P4 sender mes-

Cooler plugged; clean tubes. If plugging persists,

Cooling air flow restricted; clean cooler and check

Ambient temperature is too high; provide suffi-

Cooling air ductwork, if installed, may restrict air

Low fluid level; add fluid.

Clogged filter; change the fluid filter element as

Thermal valve not functioning properly; replace

Optional Water flow regulating valve not function-

Open or shorted T1 or T2 sender; check for a

Excessive pressure drop in supply and return