As90&110 Operation & Maintenance Manual 88291010-131 (01) - en

STATIONARY AIR COMPRESSOR
OPERATION & MAINTENANCE MANUAL

STATIONARY SCREW COMPRESSOR
AS90/110
OPERATION & MAINTENANCE MANUAL
LS32-400/450
固定式螺杆压缩机
操作手册
LS32-400/450
深圳寿力亚洲实业有限公司
SHENZHEN SULLAIR ASIA IND. CO., LTD.
零件号：88290013-606
2010 年 3 月第 01 版
Thank you very much for purchasing and using
stationary screw compressors manufactured by
Shenzhen Sullair Asia Industrial Co., Ltd.
We hope that our stationary screw compressors of all the sizes will play the
expected role in your work.
Please read through this manual carefully before you and your employees operate
and maintain the stationary screw compressors.
Sullair Asia reserves the right to make continuous research and improvement on
its products, and has no obligations of modifying and improving the products
delivered by it before.
Compressor Model:
Compressor Serial Number:
I
II
Foreword
This manual provides the instructions on the construction, functions, use and maintenance of
all the systems of AS90-110 stationary screw compressors.
Before installing and operating this compressor, users should read through this manual
carefully, and should not start the operation and maintenance of the unit until they have a full
understanding of the construction and functions.
It is necessary to use the special fluid supplied by Sullair for the compressor. It is prohibited to
use the fluids of different brands.
We remind the users that due to continuous improvement of the product construction, the
information provided in this manual may not completely reflect the actual details of the
product.
If there is any point not mentioned in this manual and the user has some unclear points during
the operation and use, you can contact the local dealer of Sullair or the After-sales Marketing
Dept. of Sullair.
―Editor
May 2015
III
Table of Contents
Foreword
CHAPTER I SAFETY ............................................................................................................................................ 1
1.1 OVERVIEW ........................................................................................................................................ 1
1.2 SAFETY EQUIPMENT .......................................................................................................................... 1
1.3 FIRE AND EXPLOSION PROTECTION .................................................................................................... 1
1.4 MOVING PARTS ................................................................................................................................. 1
1.5 HOT SURFACES, SHARP EDGES AND CORNERS .................................................................................... 2
1.6 TOXIC AND IRRITATIVE SUBSTANCES ................................................................................................. 2
1.7 ELECTRIC SHOCK PROTECTION .......................................................................................................... 2
1.8 HOISTING AND TRANSPORTATION ...................................................................................................... 2
1.9 MISCELLANEOUS ............................................................................................................................... 3
CHAPTER II COMPRESSOR STRUCTURE ............................................................................................................. 4
2.1 OVERVIEW ........................................................................................................................................ 4
2.2 AIR SUCTION SYSTEM ...................................................................................................................... 13
2.2.1 Working procedure of air suction system ..................................................................................... 13
2.2.2 Air filter ..................................................................................................................................... 13
2.2.3 Air inlet valve ............................................................................................................................. 13
2.3 AIR DISCHARGE SYSTEM ................................................................................................................. 13
2.3.1 Working procedure of air discharge system .................................................................................. 13
2.3.2 Minimum pressure valve ............................................................................................................. 13
2.3.3 Automatic blowdown valve ......................................................................................................... 13
2.3.4 Relief valve ................................................................................................................................ 13
2.4 FLUID LOOP SYSTEM ........................................................................................................................ 13
2.4.1 Working procedure of fluid loop system ...................................................................................... 13
2.4.2 Fluid filter................................................................................................................................... 14
2.4.3 Fluid return pipe ......................................................................................................................... 14
2.5 COOLING SYSTEM .................................................................................................................................. 14
2.6 FLUID/AIR SEPARATOR .................................................................................................................... 14
2.6.1 Function of fluid/air separator ..................................................................................................... 14
2.6.2 Filter element replacement .......................................................................................................... 15
2.6.3 Fluid filling port and sight glass .................................................................................................. 15
2.7 CONTROL SYSTEM ........................................................................................................................... 15
2.7.1 Line frequency model ................................................................................................................. 15
2.7.2 VSD model ................................................................................................................................. 15
2.8 MICROCOMPUTER CONTROLLER ...................................................................................................... 15
CHAPTER III INSTALLATION OF COMPRESSOR ................................................................................................ 16
3.1 MACHINE INSTALLATION.................................................................................................................. 16
3.2 VENTILATION AND TEMPERATURE REDUCING ................................................................................... 16
3.3 COOLING WATER SYSTEM - WATER-COOLED MODEL ......................................................................... 16
3.4 AIR SUPPLY PIPE .............................................................................................................................. 17
3.5 CHECK COUPLING ........................................................................................................................... 17
3.6 CHECK FLUID LEVEL ....................................................................................................................... 17
3.7 CHECK DRAIN PLUG OF COOLER (FOR WATER-COOLED MODEL ONLY) .............................................. 17
3.8 CHECK ELECTRIC CIRCUIT ............................................................................................................... 17
3.9 ROTATION DIRECTION OF THE MOTOR ............................................................................................... 18
3.9.1 Line frequency model .................................................................................................................. 18
3.9.2 VSD model ................................................................................................................................. 18
3.10 CHECK THE AIR OUTLET .................................................................................................................. 18
3.11 RELEASING OF SUPPORT BOLT FOR THE AIR END ............................................................................... 19
CHAPTER IV COMPRESSOR OPERATION ......................................................................................................... 24
IV
4.1 SAFETY OPERATION PROCEDURE ..................................................................................................... 24
4.2 PREPARATION BEFORE INITIAL STARTING ......................................................................................... 24
4.3 NORMAL OPERATION ....................................................................................................................... 24
4.4 STOP ............................................................................................................................................... 24
4.5 LOADING/UNLOADING SETTING AND ADJUSTMENT OF PRESSURE REGULATOR .................................. 25
CHAPTER V MAINTENANCE AND SERVICE ...................................................................................................... 26
5.1 OVERVIEW ...................................................................................................................................... 26
5.2 DAILY MAINTENANCE ..................................................................................................................... 26
5.3 SERVICE AFTER 50 OPERATION HOURS ............................................................................................ 26
5.4 SERVICE AFTER EVERY 1000 OPERATION HOURS ............................................................................. 26
5.5 CHANGING FLUID ............................................................................................................................ 26
5.6 MAINTENANCE OF FLUID FILTER ...................................................................................................... 27
5.7 MAINTENANCE OF AIR FILTER .......................................................................................................... 27
5.8 MAINTENANCE OF FLUID/AIR SEPARATOR ......................................................................................... 29
5.9 MAINTENANCE OF MINIMUM PRESSURE VALVE ................................................................................ 29
5.10 MAINTENANCE OF PRESSURE REGULATOR ........................................................................................ 30
5.11 MAINTENANCE OF THERMAL VALVE ................................................................................................. 31
5.12 INSTALLATION AND MAINTENANCE OF COUPLING ............................................................................. 31
5.13 MAINTENANCE OF THE MOTOR FOR SULLAIR COMPRESSOR .............................................................. 32
CHAPTER VI WIRING DIAGRAM ...................................................................................................................... 34
6.1 WD FOR STANDARD MODEL ............................................................................................................. 34
6.2 WD FOR VSD MODEL ...................................................................................................................... 35
7.1 OVERVIEW ...................................................................................................................................... 36
7.2 POSSIBLE COMPRESSOR FAULT AND ACTIONS ARE LISTED IN THE FOLLOWING TABLE .......................... 36
CHAPTER VIII SPARE PARTS LIST ..................................................................................................................... 38
CHAPTER IX PARTS LIST .................................................................................................................................. 39

9.1 MOTOR - COMPRESSOR SYSTEM ....................................................................................................... 39
9.2 MOTOR - COMPRESSOR SYSTEM (VSD MODEL) ................................................................................ 43
9.3 AIR INLET SYSTEM .......................................................................................................................... 45
9.4 FLUID LOOP SYSTEM (AIR-COOLED MODEL) .................................................................................... 47
9.5 FLUID LOOP SYSTEM (WATER-COOLED MODEL) ............................................................................... 49
9.6 COOLING FAN SYSTEM (AIR-COOLED MODEL).................................................................................. 51
9.7 COOLING WATER SYSTEM (WATER-COOLED MODEL) ....................................................................... 53
9.8 FLUID/AIR SEPARATOR SYSTEM ....................................................................................................... 55
9.9 AIR DISCHARGE SYSTEM (AIR-COOLED MODEL) .............................................................................. 59
9.10 AIR DISCHARGE SYSTEM (WATER-COOLED MODEL) ......................................................................... 61
9.11 CONTROL SYSTEM ........................................................................................................................... 63
9.12 CONTROL SYSTEM (VSD MODEL) .................................................................................................... 67
9.13 AIR COOLING ACOUSTICAL ENCLOSURE SYSTEM ............................................................................. 71
9.14 WATER COOLING ACOUSTICAL ENCLOSURE SYSTEM ........................................................................ 73
9.15 AIR COOLING ACOUSTICAL ENCLOSURE SYSTEM (VSD MODEL) ...................................................... 75
9.16 WATER COOLING ACOUSTICAL ENCLOSURE SYSTEM (VSD MODEL) ................................................. 77
9.17 DECAL SYSTEM (AIR-COOLED MODEL) ............................................................................................ 79
9.18 DECAL SYSTEM (WATER-COOLED MODEL)....................................................................................... 83
9.19 DECAL SYSTEM (AIR-COOLED VSD MODEL) .................................................................................... 87
9.20 DECAL SYSTEM (WATER-COOLED VSD MODEL) .............................................................................. 91
V
AS90/110 Series Screw Compressor Operation Manual Chapter I Safety
Chapter I Safety
1.1 Overview
Sullair designs and manufactures its products so that they can be operated safely. However, the
responsibility for safe operation rests with those who use and maintain these products. The following safety
precautions are offered as a guide, which, if conscientiously followed, will minimize the possibility of
accidents throughout the useful life of this equipment.
Only those who have been trained and delegated to do so, and who have read and understood this manual
should operate the air compressor. Failure to follow the instructions, procedures and safety precautions in
this manual can result in accidents and even injuries or death. Read this manual prior to start-up. Never
start the air compressor unless it is safe to do so. Do not attempt to operate the compressor with a known
unsafe condition. Tag the compressor and render it inoperative by disconnecting all source of power so that
others who may not know of the unsafe condition will not attempt to operate it until the condition is
corrected.
Installation and operation of the machine shall follow national and local laws and regulations.
Do not modify the devices and control unless approved by the manufacturer in writing.
1.2 Safety Equipment

Before installation and operation, all installers and operators shall be familiar with and follow the safety
regulations, national and local laws and standards. Safety equipment shall be provided, such gears to
protect eyes, faces and respiration, protection clothes, boards and electrician protection devices, noise
monitoring & control system, sound insulation equipment, etc.
1.3 Fire and Explosion Protection

1.3.1. Clean up spills of fluid or inflammable substances immediately;
1.3.2. Avoid spark, flame or inflammable substance. Never smoke near the machine when observing or
filling fluid. Service shall be carried out when the machine is stopped and compressor completely
cools down;
1.3.3. Do not permit fluid to splash on acoustical material or accumulate on compressor, lower surfaces
and inside of fence. Wipe down using an aqueous industrial cleaner or steam – clean as required. If
necessary, replace acoustical material and clean all surfaces. Any acoustical material with a
protective covering that has been damaged should be replaced immediately to prevent
accumulation of fluid within the material. Do not use inflammable detergent;
1.3.4. Disconnect all power supplies prior to attempting any repairs or cleaning inside the machine;
1.3.5. Keep the electrical system (including terminals and contactors) in good condition. If the cable is
damaged, scratched, deteriorating in insulation performance, lead aging, fading in color or
corroded, replace immediate. Keep the wire lead and contactor clean;
1.3.6. Keep grounded and/or conductive objects (such as tools) away from exposed live electrical parts
(such as terminals) to avoid arcing, which might serve as a source of ignition;;
1.3.7. In case welding is necessary when repairs, clear acoustical materials and other inflammables or
heat sensitive articles out of site;
1.3.8. Sufficient fire extinguishers shall be provided when servicing or operating the compressor;
1.3.9. Clean inflammable materials such as oil cloth or scrap of paper near the compressor;
1.3.10. If the cooling system or fluid system is not working property (poor circulation of cooling air or
fluid), do not start the machine;
1.3.11. Do not operate the compressor in a dangerous circumstance unless it is designed to do so.
1.4 Moving Parts

1.4.1. Keep hands, arms and other parts of the body and also clothing away from couplings, fans and
other moving parts;
1.4.2. Do not attempt to operate the compressor with the fan, coupling or other guards removed;
1.4.3. Wear snug-fitting clothing and confine long hair when working around this compressor, especially
when exposed to hot or moving parts;
1
1.4.4. Keep access doors closed except when making maintenance;

1.4.5. Make sure all personnel are out of the compressor prior to attempting to start or operate it;
1.4.6. Disconnect all power supplies and make sure all circuits are powered off when servicing or
adjusting the machine. This is especially important in remote control mode;
1.4.7. Keep hands, feet, floors, and controls and walking surfaces clean and free of fluid, water, or other
liquids.
1.5 Hot Surfaces, Sharp Edges and Corners

1.5.1. Do not contact hot oil, coolant, surface or sharp edge/corner;
1.5.2. Keep your body away from the air discharge outlet;
1.5.3. Wear safety equipment such as gloves or helmet, etc. when operating within or around the
machine;
1.5.4. Keep a first-aid kit handy. Seek medical assistance promptly in case of injury. Do not ignore small
cuts and burns as they may lead to infection.
1.6 Toxic and Irritative Substances

1.6.1. Do not use discharged air for breathing purpose unless it meets the requirement of relevant laws;
1.6.2. Operate the compressor only in open or well-ventilated areas;
1.6.3. No toxic or caustic gas shall be present around the compressor;
1.6.4. The fluid is unique in the industry. Avoid skin contact or swallow. In case of swallow, see a doctor
immediately. In case of skin contact, wash with soap and water.
1.7 Electric Shock Protection

1.7.1. Installation and maintenance of the compressor shall follow national and local laws, standards and
regulations (including national electric codes and other regulations on safety grounding), and shall
be down by qualified personnel;
1.7.2. Keep all parts of the body and any hand-held tools or other conductive objects away from exposed
live parts of electrical system. Maintain dry footing, stand on insulating surface and do not contact
any other portion of the compressor when making adjustment or repairs to expose live parts of the
electrical system. Operate with only one hand such that the current will not flow through your
heart even if the electric shock occurs;
1.7.3. Maintain the compressor at a clean, dry and well lighting place;
1.7.4. Do not leave the machine until the electric box is wired up. Set up notification labels to avoid
unintentional operation if leaving the machine is inevitable;
1.7.5. Before servicing or adjusting moving parts or handling ungrounded conductors, disconnect the
power and set up notification on the power supply;
1.7.6. Once installation is completed, please dry and test all electrical circuits before starting the
compressor.
1.8 Hoisting and Transportation

1.8.1. A forklift is recommended for transportation. If forklift is used, forklift hole or dedicated tray shall
be used. Remove the baffle for forklift on the chassis and secure the compressor motor and
fluid/air separator as required to avoid damage to shock absorber during transportation;
1.8.2. Make sure the forklift is secure and slanting backward before moving. Inspect and make sure the
supporting bolts on the fluid/air separator plate are secured against bottom surface;
1.8.3. The unit on the forklift should not be lifted up higher than necessary for crossing over the barriers.
The forklift should run at the lowest speed when it turns around;
1.8.4. If a plate support is used, secure the compressor with bolts or other means to prevent the
compressor from dropping in case of bumping road or sudden brake;
2
1.8.5. Do not use the bolt eyes on compressor for hoisting. Hoist the entire compressor body. Use chain
when hoisting with a helicopter. Be aware that governmental and local regulations and laws shall
always be complied with;
1.8.6. Make sure entire hoisting, rigging and supporting structure has been inspected, is in good
condition and has a rated capacity of at least the weight of the compressor. If you are unsure of the
weight, then weigh compressor before hoisting;
1.8.7. Make sure entire hoisting, rigging and supporting structure has been inspected, is in good
condition and has a rated capacity of at least the weight of the compressor. If you are unsure of the
weight, then weigh compressor before hoisting;
1.8.8. The hook should be equipped with a safety buckle, which securely locks lugs or hoist chain during
hoisting;
1.8.9. Use guide ropes or equivalent to prevent twisting or swinging of the compressor once it has been
lifted clear of the ground;
1.8.10. Do not hoist in case of strong wind;
1.8.11. No person is allowed under the compressor or crane once the compressor has been lifted;
1.8.12. Lift the compressor no higher than necessary;
1.8.13. The operator may not leave the site once the compressor has been lifted;
1.8.14. Set compressor down only on a level surface capable of safely supporting it.
1.9 Miscellaneous
1.9.1. If it is necessary to enter the enclosure to perform service adjustments, inform other personnel
before doing so and setup notification. Block the door to avoid the possibility of others closing the
door;
1.9.2. Make sure all personnel are out of compressor before closing the door.
3
AS90/110 Series Screw Compressor Operation Manual Chapter II Compressor Structure
Chapter II Compressor Structure
2.1 Overview
Presented to you is a stationary screw compressor for power purpose. It has single stage compressing unit,
oil injecting, air cooled (or water cooled) and driving motor. The machine comprises the air end, motor,
fluid/air separator, fluid cooler, after cooler, cooling fan assembly, chassis assembly, etc. enclosed in a
soundproof cover. An electric control cabinet is equipped on one side of the acoustical enclosure. The
machine is compact, elegant and easy to operate.
The machine has two kinds of structure which are water cooled and air cooled. The users could choose freely
depending on situations.
The stationary screw compressor not only has high efficiency and reliability, maintenance is seldom needed.
Compared with other brands of compressors, it’s unique in supreme reliability abrasion proof and the parts in
the main engine meets the technique requirements without verifying.
In order to maintain the compressor in the best condition, please refer to the Chapter 6(maintenance). If there
are any complicated problems can’t be solved in the manual, please contact local Sullair agency or after sale
department.
Main specifications of the machine are listed in the table below.
Main specifications of AS90 compressor—Standard model:
Model AS9007 AS9008 AS9010 AS9012
16.9(596.9) 15.5(547.4) 14.2(501.5) 12.8(452)
Nominal capacity flow 50Hz 50Hz 50Hz 50Hz
m3/min (CFM) 16.4(579) 15.3(540) 14.3(505) 12.8(452)
60Hz 60Hz 60Hz 60Hz
Rated discharge
7(100) 8(115) 10(145) 12(175)
pressure(psi)
Maximum working
7.6(110) 8.6(125) 10.7(155) 12.7(185)
pressure bar (psi)
Opening pressure of
9 (130) 10 (145) 12.1 (175) 14.1 (200)
relief valve bar (psi)
Input power 380-415V 50Hz, 220-480V/60Hz
Motor rated power kW
90 (125)
(HP)
Motor rated speed rpm 1480(50Hz)/1785(60Hz)
Starting mode Y-△
Ambient temperature
0<T≤40
T℃
Fluid capacity L (GA) 55(14.5)
Air service connector Rc2
Moisture separator
G1/2
draining connector
Machine weight kg 2100
L×W ×H mm 2500×1400×1800
4
Main specifications of the AS110 compressor—Standard model:

Model AS11007 AS11008 AS11010 AS11012
20.1(710) 19.6(692) 16.5(583) 14.6(516)
Nominal capacity flow 50Hz 50Hz 50Hz 50Hz
m3/min (CFM) 20.3(719) 19.4(685) 16.7(589) 14.3(505)
60Hz 60Hz 60Hz 60Hz
Rated discharge
7(100) 8(115) 10(145) 12(175)
pressure(psi)
Maximum working
7.6(110) 8.6(125) 10.7(155) 12.7(185)
pressure bar (psi)
Opening pressure of relief
9(130) 10(145) 12.1(175) 14.1(200)
valve bar (psi)
Input power 380-415V 50Hz, 220-480V/60Hz
90(125)
(HP)
Motor rated speed rpm 1480(50Hz)/1800(60Hz)
Starting mode Y-△
Ambient temperature T ℃ 0<T≤40
Fluid capacity L (GA) 55(14.5)
Moisture separator
G1/2
draining connector
L×W ×H mm 2500×1400×1800
Main specifications of AS90 compressor—VSD model:
Model AS9007V AS9008V AS9010V AS9012V

Nominal capacity flow
16.9(597) 15.5(547) 14.2(501) 12.8(452)
m3/min (CFM)
Capacity Regulating 4.2-16.9 4.0-15.5 3.4-14.2 3.6-12.8
Range - m3/min (CFM) (148.3-597) (141.3-547) (120-501) (127-452)
Rated discharge
7 (100) 8 (115) 10 (145) 12 (175)
pressure(psi)
Maximum working
7.6 (110) 8.6 (125) 10.7 (155) 12.7 (185)
pressure bar (psi)
9 (130) 10 (145) 12.1 (175) 14.1 (200)
valve bar (psi)
Input power 380-415V/380-420V 50/60Hz
125(90)
(HP)
Motor rated speed rpm 600-3000(As per model)
Starting mode VSD
Ambient temperature
0＜T≤40
T℃
Fluid capacity L (GA) 55（14.5）
Moisture separator
G1/2
draining connector
L×W ×H mm 3100x1400x1890
5
Main specifications of AS110 compressor—VSD model:
Model AS11007V AS11008V AS11010V AS11012V

Nominal capacity flow 20.1(710) 19.6(692) 16.5(583) 14.6(516)
m3/min (CFM)
Capacity Regulating 5.5-20.1 5.4-19.6 4.0-16.5 4.0-14.6
Range - m3/min (CFM) (194.2-710) (190.7-692) (141.3-583) (141.3-516)
Rated discharge
7 (100) 8 (115) 10 (145) 12 (175)
pressure(psi)
Maximum working
7.6 (110) 8.6 (125) 10.7 (155) 12.7 (185)
pressure bar (psi)
9 (130) 10 (145) 12.1 (175) 14.1 (200)
valve bar (psi)
Input power 380-415V/380-420V 50/60Hz
150(110)
(HP)
Motor rated speed rpm 600-3000(As per model)
Starting mode VSD
Ambient temperature
0＜T≤40
T℃
Fluid capacity L (GA) 55（14.5）
Moisture separator
G1/2
draining connector
L×W ×H mm 3100x1400x1890
See Figure 1-4 for the layout and Figure 5-6 for the system flowchart of AS90/110 unit.
A pair of delicately machined rotors engages each other inside compressor's body. The male rotor has four
teeth, while the female rotor has six teeth. Motor drives the male rotor through an elastomer coupling and the
male rotor drives the female one at high speed. As the space between teeth is getting smaller, air from air
filter is compressed and pressure increased. When the teeth chamber reaches discharge port of compressor,
compressed air is pushed into fluid/air separator through discharge port for separation. Separated air then
flows through minimum pressure valve, after cooler and drain valve until it is utilized by user. Separated
fluid is settled to the bottom of fluid/air separator. Once cooled, it is recycled to air end working chamber
under pressure difference.
6
Control System
Air Cooling Acoustical

Enclosure System
Decal System
Cooling Fan System
Fluid Loop System
Air Inlet System

Air Discharge System
Motor-Compressor System
Fluid/air Separator System
Figure 1 General Layout of AS90/110 Air-cooled Unit
7
Control System
Water Cooling Acoustical

Enclosure System
Decal System
Fluid Loop System
Air Discharge System
Air Inlet System

Cooling Water Loop System
Motor-Compressor System
Fluid/air Separator System
Figure 2 General Layout of AS90/110 Water-cooled Unit
8
Figure 3 General Layout of AS90/110 VSD Air-cooled Unit
9
Figure 4 General Layout of AS90/110 VSD Water-cooled Unit
10
No. P/N No. P/N

1 Air filter 18 Fluid bleeding plug
2 Indicator 19 Sight glass
3 Capacity control integrated system 20 Thermal valve element
4 Compressor air end 21 Fluid filter element
Fluid filter pressure difference
5 Temperature sensor 22
indicator
6 Pressure gauge 23 Pressure sensor
7 Fluid/air separator tank 24 Water-cooled after cooler
Single stage fluid separating &
8 25 Water-cooled fluid cooler
filtering element
9 Minimum pressure valve 26 Pressure switch
10 Fluid/air cooler 27 Check valve
11 Moisture separator 28 Orifice
12 Relief valve 29 Orifice
13 Filtering connector 30 Filtering
14 Sight glass 31 Solenoid valve
15 Orifice 32 Pressure regulator
16 Y type filter 33 Orifice
17 Ball valve 34 Spiral valve
Figure 5 System Flow Chart of AS90/110 Unit
11
No. P/N No. P/N

1 Air filter 15 Orifice
2 Indicator 16 Y type filter
3 Capacity control integrated system 17 Ball valve
4 Compressor air end 18 Fluid bleeding plug
5 Temperature sensor 19 Sight glass
6 Pressure gauge 20 Thermal valve element
7 Fluid/air separator tank 21 Fluid filter element
Single stage fluid separating & Fluid filter pressure difference
8 22
filtering element indicator
9 Minimum pressure valve 23 Pressure sensor
10 Fluid/air cooler 24 Water-cooled after cooler
11 Moisture separator 25 Water-cooled fluid cooler
12 Relief valve 26 Pressure switch
13 Filtering connector 27 Check valve
14 Sight glass 28 Orifice
Figure 6 System Flow Chart of AS90/110 VSD Unit
12
2.2 Air Suction System

2.2.1 Working procedure of air suction system
Air inlet system is composed of air filter, air intake elbow, air inlet valve and compressor air end, etc.
When the machine is running, air is sucked from air filter and flows to compressing chamber through air
inlet valve. It is compressed by male/female rotors revolving at high speed and its pressure is increased.
When the teeth chamber reaches discharge port of compressor, compressed air is discharged through
discharge port.
2.2.2 Air filter
Air filter is used to filter intake air and provide clean air to compressor. Impurities in air will cause wear on
rotor surface and pollution in fluid. Not following the air filter service requirement or not using original filter
element will cause early failure of fluid and fluid/air separator element and warranty void.
2.2.3 Air inlet valve
Air inlet valve of this series of compressor is integrated into the air end. Inlet valve is used to control intake
air volume using loading/unloading mechanism.
2.3 Air Discharge System
2.3.1 Working procedure of air discharge system
Air discharge system is composed of compressor, fluid/air separator, minimum pressure valve, relief valve,
blowdown valve, after cooler, moisture separator and connection pipeline.
Compressed oil/air mixture from compressor enters fluid/air separator through the discharge port of
compressor. Fluid in compressed air is separated and clean compressed air is obtained.
Compressed air after oil/air separation flows through minimum pressure valve, after cooler and discharges in
sequence. After cooler is used to cool hot air. Moisture separator is equipped with automatic water discharge
device. It separates the condensate water from the compressed air, and discharges it out of the machine.
Service connector of the machine is Rc2 with inner thread. User shall prepare a check valve on external air
pipeline. Do not expose after cooler to stress when piping.
Air tank is recommended to reduce the loading/unloading action of the compressor and extend the life of
components.
2.3.2 Minimum pressure valve
The minimum pressure valve is located on the top cap of fluid/air separator. It is used to maintain pressure in
fluid/air separator above 0.34MPa to ensure fluid flow in oil pipeline. It also reduces oil consumption.
Therefore only when pressure in fluid/air separator is above 0.34MPa and higher than pipeline pressure, the
minimum pressure valve will be opened. In parallel working mode, minimum pressure valve works as a
check valve to prevent compressed air from back flowing to separator and air end during compressor
blowdown.
2.3.3 Automatic blowdown valve
An automatic blowdown valve is equipped in the control line. When the compressor is unloading or being
stopped, blowdown valve opens automatically to allow compressed air in fluid/air separator into inlet pipe,
thus release pressure.
2.3.4 Relief valve
A relief valve is equipped on fluid/air separator. When pressure in separator exceeds threshold, relief valve
will open to discharge pressure and make sure the machine is safe.
The machine also features a high pressure stop switch. When pressure in separator exceeds threshold, the
machine will stop automatically.
2.4 Fluid loop system
2.4.1 Working procedure of fluid loop system
Fluid loop system is composed of compressor, fluid/air separator, thermal valve, fluid cooler, fluid filter and
connection pipeline.
Fluid in fluid/air separator flows into fluid cooler through thermal valve. Cooled oil enters air end working
chamber through fluid filter. Then it is compressed along with intake air and enters fluid/air separator for a
13
complete cycle. Fluid serves for three roles:

(1) Cooling - Fluid injected into the machine absorbs large amount of heat generated during
compressing as a coolant.
(2) Lubricant - Fluid forms an oil layer between the rotors, avoiding direct contact between male and
female rotors. Therefore the wear between rotor surfaces is minimized. In addition, fluid flows to
lubrication positions through internal lubrication to lubricate bearings and gears.
(3) Sealant - Fluid with appropriate viscosity can fill up the gaps between rotor-rotor and between
rotor-casing. It reduces leakage loss and enhances the cubage efficiency of compressor.
2.4.2 Fluid filter
Fluid filter clears the impurity in fluid and ensure that clean oil is transported to air end working chamber
and lubrication positions. Impurity in fluid will cause wear on rotor/gear engaging surfaces and bearing, and
reduces the life of compressor.
Fluid filter element should be replaced regularly to ensure good oil circulation.
2.4.3 Fluid return pipe
A fluid return pipe is located on the cap of fluid/air separator. Small amount of oil on the bottom of filter
element is recycled to compressor through the pipe.
2.5 Cooling System
The machine is composed with fluid cooler and after cooler. Please refer to the cooling system chart in the
components manual.
A. Water-cooled model: the users should pay attention to the following in setting external water loop
system.
(1) Cooling is after the water inlet pipeline connecting, that’s cool the air first and then cool the fluid.
(2) In order to keep the cooler in good condition of transferring heat persistently and extend the using
life of the cooler. Clean cooling water and necessary cooling water flow is needed. The requirements of
the quality and the flow of the cooling water can be found in the 3.3 Cooling system-water-cooled
model.
(3) In winter, the accumulated water in the cooler should be discharged when the machine stops or the
unit hasn’t been used for a long time in order to protect the cooler from cracking.
B. Air-cooled model:
The cooling system fan equipped within the system is the axial fan. The cooling air comes in the engine from
the blinds of two sides and then passes the cooler, after transferring heat, it was discharged out of the engine.
2.6 Fluid/air Separator
2.6.1 Function of fluid/air separator
Fluid/air separator is composed of a tan and a filter element. It has the following four functions:
(1) Primary separator.
Oil/air mixture from air end enters the fluid/air separator and crashes on the wall of separator to lower
its speed. Large oil drops are formed due to lower speed. Most of the oil drops set to the bottom of
separator under gravity.
(2) As oil reservoir of the compressor to store fluid.
(3) Filter element.
After collision separation, oil/air mixture flows through filter element for fine separation. Minor fluid
residue in compressed air is separated and accumulated on the bottom of filter element. Then the oil is
returned back to compressor's intake port and working chamber through the oil return pipe.
(4) Pressure regulation.
Certain amount of air inside the fluid/air separator effectively stabilizes pipeline pressure.
14
2.6.2 Filter element replacement

Impurities exist in the fluid loop system. Fluid separator element will be clogged up after a period.
Resistance of filter element to compressed air will increase and machine operation will be compromised.
Operator should replace filter element according to the signal on monitor on time.
Caution: Fluid separator element may only be replaced instead of being repaired.
2.6.3 Fluid filling port and sight glass
Fluid filling port and sight glass are equipped on the outer side of fluid/air separator.
Since discharged air contains oil more or less, the oil level of separator will drop and need to be added. The
normal oil level shall be observable from the sight glass when the compressor is running at full load.
2.7 Control System
2.7.1 Line frequency model

Air capacity adjustment system automatically adjusts the open/close of inlet valve based on air demand to
minimize fluctuation in service pressure.
The control system loads/unloads the compressor based on air demand. The control system comprises
solenoid valve, air inlet valve, and blowdown valve and control line.
When air demand equals to or is higher than machine rating, the machine will run at full load. In such a case,
the starting/unloading solenoid valve is energized, cutting off the control line. Inlet valve of the air end is
fully opened under vacuum.
When air demand is lower than rating, line pressure of the machine builds up slowly. Once the pressure
exceeds rated pressure, pressure regulator will be activated, sending control air to inlet valve to reduce air
intake and keep the balance between supply and demand. If air demand is less than 50% of the rated
capacity, system pressure will continue to rise, once the discharge pressure reaches unloading setting of the
machine, the compressor will change into unloading mode. The starting/unloading solenoid valve is de-
energized, opening the control line. In such a case, the inlet valve is closed through the control line.
Meanwhile, the blowdown valve is opened to release the pressure in fluid/air separator tank (to intake port)
until pressure in separator is stabilized to 15-25PSI. Now the machine runs at a lower pressure with no load.
The machine will keep running for a preset time period at unloading mode before stop. Once the pressure in
user airline drops to the lower limit set in the microprocessor controller, the compressor will enter loading
mode from unloading mode again, i.e. the starting/unloading solenoid valve is energized, cutting off the
control line. Air inlet valve of the air end is fully opened under vacuum.
2.7.2 VSD model
Air capacity adjustment system of VSD model varies the speed of electric motor via frequency variation to
match the fluctuation of air demand, and keep the balance between supply and demand. Minimum motor
frequency of WS45-75 series VSD machines is 20Hz and the maximum frequency varies from model to
model. Reference frequency of electric motor is 75Hz. Each VSD model has its own maximum output
frequency for VSD and maximum speed for motor. When air demand equals to rated capacity, the machine
runs in full load mode and the frequency of motor VSD is at rated value. If air demand is lower than rated
capacity, motor frequency will be reduced to lower the speed or air end, thus reducing air intake. If there is
no demand, motor frequency will be reduced to minimum, meanwhile inlet valve will be closed to stop air
intake. In such a case the machine runs on a lower back pressure in no-load mode.
2.8 Microcomputer Controller

The machine is equipped with microprocessor controller. For detail information on controller, see 88290022-
798 EC2000 Controller Operation Manual.
The line frequency model may have the option, and VSD model is equipped with deluxe microprocessor
controller. For detail information on controller, see 88290010-484 Deluxe Microprocessor Controller I –
Operation Manual.
15
AS90/110 Series Screw Compressor Operation Manual Chapter III Installation of Compressor
Chapter III Installation of Compressor
3.1 Machine Installation

The machine should be mounted on supporting ground or foundation with sufficient strength. To ensure that
the transmission and internal piping work properly, the machine should be level and firmly contacting the
ground, and there must be less than 15% space of contacting area to control the vibration within technology
range; A rubber plate with thickness of 20~50mm, width of 80 mm is suggested on the contacting plate
between the machine (base frame and intermediate bearing beam) and ground.
Elastomeric coupling is used for transmission. Note that the level error or large deflection could affect the
machine and reduce its lifespan.
No load from the piping shall be transferred to air/water connectors within the machine.
The machine should be in the ambient of 0-40 ℃.Under any circumstance, make sure the ambient
temperature is above 0 ℃.
See Figure 8 and Figure 11 for the outline and installation of the machine.
3.2 Ventilation and Temperature Reducing

To provide reliable ambient temperature for air-cooled model, air should be able to flow in and out of the
compressor smoothly. Exhaust of the compressor should be at least 1m away from wall and top cover should
be at least 1.5m away from ceiling. Take measures to prevent hot exhaust being drawn back into the
compressor. Ventilation facility should be in place to avoid abrupt temperature rise. Air in/out interface is
ready on the enclosure. See Dimension and Installation Diagram for detailed size. Arrange ductworks when
designing the equipment room. Total pressure loss of all external ducts shall be no more than 3mm water
column. On the other hand, room design should also satisfy ambient temperature requirement for starting in
winter, which is 32°F (0℃) or above.
Ventilation volume and ventilation heat exchange volume can be referred to the following form:
Air inlet Ventilation Ventilation heat
Items
temperature volume exchange volume
AS90 air-cooled model ≤32℃ 305m3/min 1670kcal/min
3
AS110 air-cooled model ≤32℃ 305m /min 2004kcal/min
AS90 water-cooled model ≤32℃ 80m3/min 118kcal/min
3
AS110 water-cooled model ≤32℃ 80m /min 141kcal/min
Note: The form listed air volume needed for keeping compressor working temperature stable. The
“ventilation volume” in the form refers to the least amount of air volume for cooling; “ventilation heat
exchange volume” means heat generated in the working process of the compressor. The compressor can’t be
installed in the place with diffusely explosive, toxic, corrosive air (substance). More detailed information,
please contact the Sullair after sale department.
3.3 Cooling Water System - Water-cooled Model

According to the Code for Design of Industrial Circulating Cooling Water Treatment GB50050 and Code for
Design of Industrial Circulating Cooling Water GB/T50102-2003, as well as requirements for both Sullair
air compressor and water-cooled refrigerated dryer, requirements for cooling water quality are set out below:
PH 6.5-9
CL 20-50 mg/L
SO4 50-100 mg/L
CL2 0.5-1.0 mg/L
CaCO3 70-100 mg/L
Total solid substance 25-50 mg/L
Fe2+ <0.5 mg/L
16
Ca2+ 30-200 mg/L

Not with Nitrogen or mercury
For water cooling compressor, supply of cooling water should be ensured. Cooling water system
specifications are as follows:
Water flow T/h

Water temperature℃
AS90 AS110
21 4.0 4.8
27 5.3 6.4
(The water pressure going through the machine can’t overpass 1.4Bar)
Accumulated water of after cooling and in the oil cooling should be discharged to prevent frozen
cracking.
3.4 Air Supply Pipe

Air / water separator outside the motor is the screw connection of Rc2, and users could discharge the
condensed air out of machine by equipping it with correspondent sealed screw pipe. A stop valve is needed
outside of the external pipeline.
3.5 Check Coupling

Air end of compressor is connected with electric motor through elastomer coupling. Before starting the
machine for the first time, make sure each fastener is properly fastened according to the procedures of
coupling in the Manual.
3.6 Check Fluid Level

Sufficient fluid has been added at Sullair factory. There is a sight glass in the fluid reservoir. Fluid level
should be normal when the compressor is running at full load. Otherwise, stop the machine and add fluid. It
is proper for the fluid level to be seen at 1/2 – 3/4 of the sight glass when fluid is filled to full-load running.
3.7 Check Drain Plug of Cooler (For Water-cooled Model Only)

Drain plug of the cooler is already in place before the machine leaves factory. However, user shall check
each plug to make sure they are secured to avoid coolant leak upon start-up.
3.8 Check Electric Circuit

Internal circuits are wired at factory. There is little wiring work for user to carry out. When wiring the
machine, observe national and local regulations on insulation switch, fuse, etc. Sullair provides the
schematics.
Danger
High-voltage inside. Be careful of electric shock.

Cut off all power supplies before servicing.
17
1. Check if input voltage is conforming.

2. Check the model of starter and overload heater.
3. Check if all electric terminals are securely fastened.
4. Re-wire the terminal of motor and check the rotation direction of motor according to 4.10.
3.9 Rotation direction of the motor
3.9.1 Line frequency model

User should check if motor rotation direction matches the mark of coupling guard as follows once the
machine is powered on.
Pull out emergency stop button from Microprocessor Controller and press "I" button (start) followed by "O"
button (stop) immediately. Let motor revolve for a moment. If motor rotates in the same direction of marked
arrow, it means wiring is correct. If not, cut off power and exchange any two power cables. Then test again.
Machine with phase sequence protector may not be started if the phase sequence is wrong. Please observe
the message shown on the controller.
3.9.2 VSD model
User should check rotation direction of main motor and fan motor separately once the wiring the completed.
Check main motor rotation direction:
Pull out emergency stop button from monitor's control panel and press "I" button (start) followed by "O"
button (stop) immediately. Let motor revolve for a moment. Looking from the rear end of the motor, if the
spindle rotates clockwise, then it is correct. If not, cut off power and exchange the phase on the output side
of VSD and test again. There is a sign on the barrel between motor and compressor to indicate rotation
direction.
Check fan motor rotation direction:
Check the rotation direction of fan motor together with the main motor. Both motor and fan have direction
indicator. If the direction is wrong, adjust fan motor contactor.
Never put the motor in reverse rotation direction!
3.10 Check the Air Outlet

A sealing plate in red paint was put on the air outlet of the fluid/air separator at ex-works for the purpose not
to let foreign matters fall inside and it shall be removed before the unit starts work, see Figure7.
Seal plate
Figure 7 Air Discharge System Sealing Plate

18
3.11 Releasing of Support Bolt for the Air End

There is a standing bolt under the air end, which makes the support plate connected with the air end. It
functions to protect rubber shock pad against damage due to bump up and down during transportation of the
whole unit. In view of this, it is required to release the connecting bolt between this red support plate and the
air end prior to the first operation. Customers are recommended to keep this part for using as the support
during maintenance of air end.
The support plate of

the air end
painted in red Standing bolt of
the air end
19
Figure 8 Dimension and Installation Diagram of AS90/110 Air- Cooled Model

20
Figure 9 Dimension and Installation Diagram of AS90/110 Water-Cooled Model
21
AS90/110 Series Screw Compressor Operation Manual Chapter IV Compressor Operation
Figure 10 Dimension and Installation Diagram of AS90/110 VSD Air- Cooled Model
22
Figure 11 Dimension and Installation Diagram of AS90/110 VSD Water- Cooled Model
23
Chapter IV Compressor Operation
4.1 Safety Operation Procedure

To avoid injury and machine damage, customer shall make detailed safety operation procedure. Please refer
to the following:
(1) Operator must be well trained before operation, and has read and understood this manual;
(2) The installation and operation of machine shall comply with national and local laws and regulations;
(3) Never modify machine structure and control mode, unless approved by manufacturer in written.
(4) If abnormal condition is encountered, stop the machine immediately and shut down all power supply.
(5) No inflammable, explosive, toxic and erosive gas shall be stored in the vicinity.
(6) Blowdown the compressor and shut down all power supply before maintenance or adjustment operation.
4.2 Preparation before Initial Starting

(1) Check if electric connection is safe and reliable;
(2) Set operation parameters according to the manual of accompanied computer controller;
(3) Check fluid level. It is required, at stop, for the fluid level to be visible from the sight glass or over
the sight glass;
(4) Connect the water pipe(water-cool model)
(5) If ventilation tunnel is installed, make sure it is clean and clear;
(6) Open air discharge check valve;
(7) Power on the machine. Start the machine then stop immediately to check if motor rotates in the
same direction of marked arrow. Reset the machine if direction is wrong;
(8) The fluid level shall be visible from the sight glass at full-load running and the fluid, if insufficient
therein, shall be filled, with the motor stopped first, enough to have the fluid level visible at 1/2 to 3/4
of the sight glass at full-load running.
(9) Restart the compressor and close check valve gradually. Check if unloading pressure coincides with
settings. Reset the machine if not.
(10) Check if all systems work properly. Check for oil, air and water leakage and abnormal sound;
(11) If ambient temperature is too low, user must increase room temperature above 0℃ to start the
machine and keep its operation;
(12) Stop the machine.
4.3 Normal Operation

Once a new machine has been tested according to the first starting test procedures, it may be used for normal
operation. Check fluid level before starting. Press "I" button to start the compressor.
4.4 Stop
Press “O” button to stop the machine.
24
4.5 Loading/Unloading Setting and Adjustment of Pressure Regulator
Actual discharge pressure of the compressor can be adjusted according to field condition to meet
pressure/delivery requirements and save energy at the same time, provided that the discharge pressure at
maximum delivery is reduced, i.e. lower than rated discharge pressure. This is realized by adjusting the
loading/unloading setting and pressure regulator
Warning
Loading/unloading setting and pressure regulator shall be adjusted by Sullair’s service engineer,
Sullair dealer’s service personnel or trained operator.
25
AS90/110 Series Screw Compressor Operation Manual Chapter V Maintenance and Service
Chapter V Maintenance and Service
5.1 Overview
Besides daily maintenance and inspections every 1000 hours, maintenance works are grouped according to
time interval (operation hours). The microprocessor controller has a programmable service timer. Once the
setting in the service timer has been reached, LCD status column of the controller will give corresponding
minor fault alarm message in rotation, reminding user of service. Reset the service timer after service
operation. See 88290021-984 EC2000 Compressor Controller Operation Manual for detail. Normal
operation of the machine relies on good maintenance and service.
Warning
Do not carry out maintenance or service work when the power supply has not been cut off.
Do not disassemble any part when the compressor is running or pressurized. Shut down the machine,
bleed internal pressure to zero and cut off external pressure before disassembling.
Sullair genuine parts must be used when servicing Sullair compressor in accordance with the
requirements in Operation Manual. Otherwise, warranty may void.
5.2 Daily Maintenance

Check fluid level before starting the machine. Add fluid if level is too low. Once the machine is started,
check if displayed parameters are correct to make sure the machine is normal. Check operation condition of
various systems after the machine is warmed up, and check for leakage and abnormal sound.
5.3 Service After 50 Operation Hours

Check and proceed with the following after 50 operation hours:
(1) Clean oil return pipe filter;
(2) Replace fluid filter element;
5.4 Service After Every 1000 Operation Hours

(1) Clean oil return pipe filter;
(2) Replace fluid filter element, upon the necessity;
(3) Replace the air filter element, upon the necessity;
5.5 Changing Fluid

(1) In order to minimize service operation and reduce cost, AS90/110 series compressor has been tested
and filled with SRF fluid before delivery;
(2) Use non-Sullair fluid in compressor will void all Sullair warranties;
(3) Do not mix different type fluid. Mix dirty mineral oil may cause poor performance of the air end. It
could also cause bubble, filter element clogging and nozzle or pipe clogging;
(4) Note: Clean oil way system before changing oil. If ambient temperature exceeds range or use fluid
above its life, please contact Sullair dealer.
(5) Maintenance interval and guidance
Fluid filter Fluid/air separator

Fluid Fluid change interval Air filter
change interval element change interval
6 months or 4000 hours
SRF 1/4000 1000 hours 6 months or 4000 hours 2000 hours
or assay
(Whichever comes first) In case the compressor is running in a dusty environment, service the filter more
frequently.
26
5.6 Maintenance of Fluid filter

Replace fluid filter element and gasket every 1000 hours or if indicated so by the pressure drop indicator of
fluid filter.
Top cover
Washer *
Filter element *
Figure 12 Fluid Filter

Spare Part No.: 250025-526
See Figure 12 for the maintenance of fluid filter.

(1) Remove the filter element and washer using a belt wrench;
(2) Clean the sealing surface;
(3) Coat the new washer with clean compressor oil.
(4) Screw up the new element with hand. Make sure the new washer is in place. Avoid deformation,
damage or press to the washer;
(5) Tighten another 1/2-3/4 circle with hand;
(6) Start the machine and check for leak.
5.7 Maintenance of Air Filter

See Figure 13 and Figure 14, in case the service indicator of air filter is in red zone when the machine is
running at full load, or the machine has been operated for 2000 hours, replace air filter element as described
below:
27
Air filter maintenance

indicator
Figure 13 Air filter repair indicator

Replacing filter element:
1. Stop the machine and bleed pressure;
2. Clean the shell of filter;
3. Screw out the airfoil nut to remove the shell and pour out the dust therein;
4. Screw out the nut to remove the sealing washer and the filter element;
5. Clean the inside of the shell after removing the filter element. Do not use compressed air;
6. Use the steps reversed to those of removal to set on the filter element. Securely fix the sealing washer
and the gasket on the shell;
7. Reassemble the filter;
8. Reset the service indicator.
Filter Rear
Housing element cover
Figure 14 Air Filter

Spare Number of Air filter element: 88290001-469
Check filter element

1. Place a shining light source in the filter element and, when the light sends out of the filtering
screen, view it from outside to check if it gets damaged;
2. Check all gaskets and mounting surface of the gasket. Replace damaged gasket immediately;
3. Spare filter element should be stored in a clean container;
4. With the element installed, check and tighten all connection parts before starting the machine.
5. When to clean the dirt on the filter element, never knock it on a hard object, or both sealing surface
and filter element would be made damaged;
28
6. Do not oil the filter element.
5.8 Maintenance of Fluid/air Separator

The maintenance of fluid/air separator is the replacement of the elements. See Figure 15.
Replace fluid/air separator element every 4000 hours or in case pressure drop is greater than 10psi (0.7bar).
Caution: This element can be replaced only and can not be cleaned.
Steps to replace the fluid-air separating element:
(1) Stop the machine and discharge pressure;
(2) Disconnect the pipeline linked to top cap and remove the top cap;
(3) Take out the element and replace with new one.
(4) Clean the inside surface of top cap and put in the new filter. Fasten bolts and pressing cap;
(5) Connect pipelines linked to top cap.
Caution: The oil return pipe shall be inserted to the bottom of the filter element in order not to affect the
back oil.
Primary filter element P/N: 250034-085

Secondary filter element P/N: 02250048-734
Figure 15 Fluid/air separation System
5.9 Maintenance of Minimum Pressure Valve

See Figure 16 for the structure of minimum pressure valve. Normally only O-ring needs to be replaced.
Maintenance procedure is described below:
1. Separate the pipeline connected with the minimum pressure valve to remove the valve from the top of
the oil-gas separating tank;
2. Screw out the top cover to take out the primary spring;
3. Turn the valve upside-down and slightly knock the check valve assembly with a screwdriver till both
piston and said assembly fall off;
4. Clean the valve body and the undamaged parts;
5. Coat the new check valve with a layer of oil and put it into the body lightly, then mount a new check
spring in;
6. Coat the new “O”-ring with a layer of lubricating grease, put on the piston and the new piston spring,
remount the top cover and connect the pipeline.
29
Spring
Top
cover
Check valve
assembly
Spring
Gasket
Spring lock
washer
Hexhead set * O ring
screw
Piston
Valve
body
Figure 16 Minimum Pressure Valve 242405

Maintenance kit P/N: 001176
5.10 Maintenance of Pressure Regulator
See Figure 17. The regulator is equipped in the capacity control integrated system.
Procedures:
1. Unscrew the locknut, and turn the
adjusting screw counterclockwise until the
spring is relaxed. Now the spring screw is not
Valve body
under pressure;
Valve bolt *
2. Screw off spring chamber;
3. Take out the spring seat, spring and
diaphragm assembly; Stop ring *
Membrane *
4. Remove the gasket;
5. Unscrew the nut on the valve disc,
remove the valve disc, diaphragm and bolts; Valve plate *
6. Remove retain ring and discard; Spring lock washer *

7. Replace with parts and reinstall; Valve disc nut *
8. Replace with new retain ring; Seal
9. Replace with new gasket; washer *
10. Replace with new spring if damaged;

11. Put in the spring seat; Spring
chamber Adjusting spring
12. Assemble other parts and install in the
spring chamber;
13. Tighten adjusting screw until it is under Lock nut Spring seat
force from spring; Adjusting
14. Readjust pressure regulator according to screw
control system procedures.

Figure 17 Pressure Regulator 250017-280
Maintenance kit P/N: 250019-453
30
5.11 Maintenance of Thermal Valve

The structure of thermal valve, see Fig.18.
Dismantlement:
1. Remove the pipe connecting with the valve
2. Remove four bolts connecting with the upper and down
valve
3. Take down the pad
4. Remove the thermal element
Seal ring *
Installation:
1. Grease the new sealing ring and put it into the valve Thermal element*
Spring lock
2. Push the thermal element into the upper valve till the Washer *
washer
sealing ring is completely connected with the top.
3. Put a new pad.
4. Align the bolt of the upper and down valve and then fix
it. The tightening torque of bolt is 30－40N.M.
Bolt
5. Reconnect the pipe Valve body
Figure 18 Thermal Valve
5.12 Installation and Maintenance of Coupling

See Figure 19 the structure of the coupling. Compress shaft and spindle of motor are rigidly connected to
their respective mounting plates and the mounting plates are connected through an elastomer. Normally
only the elastomer needs maintenance. Maintenance should be carried out as follows:
Warning
Cut off all the power supply prior to repair and adjustment.
Compressor shaft Fixing Motor spindle
mounting plate Elastomer cap mounting plate
Figure 19 Coupling
1. Remove the cover on connection tube;

2. Release the connecting bolt and setscrew at one flange side and then you can start to replace the elastic
body;
3. Check the surface whether it is worn, deformed or torn, please replace the elastic body, if any, and
31
contact with Sullair for more services;

Under normal circumstance, no maintenance is needed for the coupling.
5.13 Maintenance of the Motor for Sullair Compressor

1. Operating conditions of Motor for Sullair Compressor (For exported units, they change with
different countries):
Ambient temperature ≤46℃
Altitude ≤1000m
See the name plate of motor and the following requirements for other conditions.
2. Operation of the Motor for Sullair Compressor
(1) Motor should be grounded correctly. Generally, the ground wire of the motor for Sullair
compressors is connected in the electric cabinet. Users only need to connect the earth ground wire
securely to this point.
(2) Clear markings are provided on the lead wires of the motor for Sullair compressors
(3) For connection of the motor for Sullair compressors, a connection diagram is provided on the
nameplate.
(4) If the voltage and frequency of power source for the motor for a Sullair compressor are as
indicated on the nameplate, the motor can operate continuously at the rated power × utility coefficient.
If the frequency of the power source deviates from the rating value indicated on the nameplate by 1%
of this value or undervoltage/overvoltage exceeds 10%, it cannot be guaranteed that the motor will
deliver such output power.
(5) Sullair compressor specific motor works well when imbalance among three phases does not
exceed 1%.
(6) Generally, a current detection device is mounted in the electric cabinet of a Sullair compressor and
it is used as motor overload protection.
(7) There should be no intermittent or unusual noises or vibrations when the motor runs at no load or
at loads.
3. Maintenance and repair of Motor for Sullair Compressor

(1) Operating environment should be kept dry, the motor surface should be clean and its air inlet should
not be obstructed by dust or fibers.
(2) Find out where the fault comes from, when the thermal relay acts, and do not start working until
settling the fault.
(3) Make sure bearings are well lubricated during operation. Generally, grease should be added or
replaced every 2000H (enclosed bearing does not need grease replacement during its life). If grease is
too hot or is deteriorated during operation, it should be replaced. Add grease after cleaning bearing and
cap slot. Different motor uses different type of grease. See motor nameplate or call Sullair After-sales
Marketing Department.
(4) When the service life of the bearing ends, shock and noises generated during motor operation will be
increased significantly, and in this case, the bearing should be replaced.
(5) After motor faults occur, we recommend that the user contact Sullair or its agents.
4. Periodic check
The motor shall be checked per year or six months upon the conditions of use, the irregular conditions for
the check per six-month to be surely done are:
Exposed to one of the followings:
(1) Corrosive or conductive dust.
(2) Velveteen or a very dirty condition of use. The accumulated dust may affect the normal ventilation.
(3) Chemical smoking, steam, salt mist or oil mist.
(4) The atmosphere moisture or vary dry, radiation heated, pest intruded or mold caused to grow up.
Or working with one of the following conditions:
32
(1) The deviation to the rated voltage and (or) frequency is often over the limit set in the clause “Operation
of the motor special for Sullair compressor.
(2) In a room of poor ventilation or the ambient temperature is over 40℃.
(3) The motor is caused to frequently start due to the frequent fluctuation of the air volume being used.
List for check-up:
(1) Discharge, clean and fill bearing again with fluid (grease). Check the bearing if it is found abnormal.
Refer to the nameplate on the motor for the brand of the fluid (grease).
(2) Take some measure to settle the oil leak at the bearing seal.
(3) Check if there is condensation, deposited water, iron rust or corrosion on the end-cover or the top
mantle, which can be removed if necessary.
(4) Check if there is deposited dust or other foreign matters.
(5) Check if the non-insulated electric connections are contacted tightly, overheated, arc-over or corroded
and use the measures for remedy, if necessary.
(6) Check all the nuts and bolts and make sure of them secured.
(7) Check if there is overheat or corona with the main led-out wiring.
5. Check and sort-out of windings
The adoptable ways are listed below for reference upon the kind and quantity of the dust deposited on the
winding. (The rotor needs to be drawn out of the stator, in case of much dust deposited on the winding or
for all-respect check and clean of it).
(1) Drying wipe
When a surface which needs to be cleaned is accessible and what needs to get rid of is dust only, a
satisfactory effect can be made just by way of drying wipe with a clean lint-free cloth. “Cotton waste” shall
not be used, as the floss may be adhered on the insulation to get much more dust gathered and is adverse
particularly to the insulation on the high voltage motor, as corona discharge tendency would be caused.
(2) Way of cleaning by brush-off and suck-out
It is a satisfactory way that to get rid of dust by the way of brush-off with a short and hard brush (not a
metal brush) first and then to suck it out completely with vacuum, as there is no possibility for the dust to
be scattered and deposited on any other equipments.
(3) Blow-off
The way to blow off the dust with sprayed dry air is applicable only for the gap almost unable to access and
when the motor is kept dried and the direction for the air to blow off shall not make the dust blown into the
deep inside of the motor, causing it difficultly removed and the air duct possibly blocked.
Especially, the pressure of the air used therein shall not be over 0.2MPa, this is for preventing the insulation
from getting injury and that to blow off the dust with the insulation loosened and making sure of the air to
be dried and without containing the condensed water from the air pipeline.
(4) Way of cleaning with solvent
This way is more effective to get rid of the bitumen, grease, wax and oil on electric equipments and works
like that to wipe the surface with a cloth soaked in a solvent and then with a dry cloth (no “cotton waste”
shall be used to let no floss deposited on the insulation).
Sullair suggests to use a volatile solvent of inorganic or petroleum category to clean the insulation. At the
fire danger place, methyl chloroform of suppression can be adopted to clean. Because this solvent is
combustible in the general condition, and gently toxic, therefore partial ventilation is required when the
smell of the solvent steam becomes thicker.
6. See 3-phase Asynchronous Motor Maintenance Manual for other inspection and service of motor.
33
AS90/110 Series Screw Compressor Operation Manual Chapter VI Wiring Diagram
Chapter VI Wiring Diagram

6.1 WD for standard model
34
AS90/110 Series Screw Compressor Operation Manual Chapter VI Wiring Diagram
6.2 WD for VSD model
35
AS90/110 Series Screw Compressor Operation Manual Chapter VII Troubleshooting
Chapter VII Troubleshooting
7.1 Overview
Compressor’s fault may be caused by multiple reasons. Therefore, a systematic analysis on all causes of the
fault should be carried out before service or parts replacement. Do not disassemble the machine without
purpose. To avoid damage, visual check is necessary. Keep the following in mind:
a. If cable leads are loose or disconnected;
b. If pipeline is damaged;
c. If there is part damaged by over heat or short circuit. Phenomena are color changing or scorch odor.
7.2 Possible compressor fault and actions are listed in the following table
Symptom Possibly generated causes Actions
Low fluid level in fluid/air separator Check fluid level, add fluid if necessary
Cooler fin dirty Clean the cooler fins
Fluid filter clogged up and bypass
Replace the fluid filter
valve failed
Ambient temperature high Improve ventilation
High resistance in exhaust duct (air- 1. Enlarge exhaust duct
High discharge cooled unit) 2. Install exhaust fan in the duct
air temperature Thermal resistor temperature Check RTD connector. If the connector is good,
transducer RTD failure replace RTD
Fan motor damaged Check and repair fan motor
Insufficient cooling water flow
Check the cooling water supply condition
(water-cooled unit)
Add cooling water flow, reducing the water
Cooling water overheat
temperature
Cooler clogged (water-cooled unit) Clean the pipe with the clean cooling water
(1) Reduce air demand;
Air demand higher than air supply
(2) Check for leakage on pipeline.
Air supply Air filter clogged up Replace filter element
pressure lower
Air inlet valve unable to open Check motion of inlet valve, pressure reducing
than rated
completely valve and the setting of pressure regulator
discharge
pressure Check transducer's contacts. Replace transducer
Pressure transducer fault
if contacts are normal.
Minimum pressure valve failure Check/repair minimum pressure valve
Check transducer's contacts. Replace transducer
Pressure transducer fault
if contacts are normal.
Line pressure Unloading devices (such as blow-off
Check the operation of unloading components
higher than valve, inlet regulation valve) failure
unloading Unloading solenoid valve failure Check the operation of solenoid valve
pressure
Control air pipe leak Check if control pipeline is leaking
Control pipe filter clogged Repair filter assembly
36
AS90/110 Series Screw Compressor Operation Manual Chapter VII Troubleshooting
Symptom Possibly generated causes Actions

Fluid return line filter or orificeClean filter screen and orifice, replace with spare
blocked parts if necessary
Fluid Check separator components and washer. Replace
Separator element or washer damaged
consumption too if necessary.
high System is leaking Check if system pipeline is leaking
Fluid level too high Discharge excess fluid
Too much oil froth Change fluid
Vibration and Isolator damaged; Replace isolator
noise increased Fan or box fault; Check fan
37
AS90/110 Series Screw Compressor Operation Manual Chapter VIII Spare Parts List
Chapter VIII Spare Parts List
Item Maintenance kit No. Quantity

Fluid filter element 250025-526 1
Air filter 88290001-251 spare part of filter element 88290001-469 1
Primary separator element 250034-085 1
Secondary separator element 02250048-734
Air inlet valve sealing maintenance kit 02250169-607 1
Air inlet valve maintenance kit 02250169-608 1
Pressure regulator maintenance kit in capacity control
250017-280 1
integrated system 88291010-087
Solenoid valve maintenance kit in capacity control integrated
88290021-950 1
system 88291010-087
Blowdown valve service kit in capacity control integrated
88291008-364 1
system 88291010-087
Solenoid valve maintenance kit in ON/OFF control
88290021-950 1
integrated system 88291009-363
Blowdown valve service kit in ON/OFF control integrated
88291008-364 1
system 88291009-363
Minimum pressure valve 242405 maintenance kit 88290018-146 1
Thermal valve maintenance kit (Non-XH Model) 049542 1
Thermal valve maintenance kit (XH Model) 88290019-737 1
Fluid return pipe filter maintenance kit 02250117-782 1
Shaft seal maintenance kit 02250169-605 1
Coupling 88291010-113 elastomer 88291010-114 1
SRF Fluid (5 gallon) 250019-662 1
SRF Fluid (55 gallon) 250016-663 1
Sullube Fluid (5gallon) 87250022-669 1
Sullube Fluid (55gallon) 87250022-670 1
Note: Please notify compressor model, series number and B.O.M number in ordering spare parts to
facilitate our service.
38
A90/110 Series Screw Compressor Operation Manual Chapter IX Parts List
Chapter IX Parts List
9.1 Motor - Compressor System
39
9.1 Motor - Compressor System Parts List
S/N P/N Name Qty. Remarks

1 250042-785 Isolator 2
2 829108-250 Bolt 2
3 837808-125 Gasket 2
4 838208-112 Large Spacer 2
AS90 08 50Hz Model
88250184-826 Compressor Air End 1
AS110 08 60Hz Model
AS90 10 50Hz Model
AS110 10 60Hz Model
88250184-841 Compressor Air End 1 AS110 07 Model
AS90 07 50Hz Model
AS110 07 60Hz Model
AS90 12/13 50Hz Model
5 88250206-665 Compressor Air End 1
AS90 08 60Hz Model
88250206-666 Compressor Air End 1 AS110 10 50Hz Model
88250206-667 Compressor Air End 1 AS110 12/13 50Hz Model
6 88290003-464 Guard 2
88290004-855 Motor 1 AS110 IP23 380-415V 50Hz
88290004-952 Motor 1 AS90 IP23 380-415V 50Hz
88290005-410 Motor 1 AS110 IP55 380-415V 50Hz
88290005-790 Motor 1 AS90 IP55 380-415V 50Hz
88290008-834 Motor 1 AS90 IP23 220-240V 60Hz
7
88290008-835 Motor 1 AS90 IP23 380-420V 60Hz
88290008-836 Motor 1 AS90 IP23 440-480V 60Hz
88290008-837 Motor 1 AS110 IP23 220-240V 60Hz
88290008-838 Motor 1 AS110 IP23 380-420V 60Hz
88290008-839 Motor 1 AS110 IP23 440-480V 60Hz
8 88290020-283 Isolator 2
9 88291008-847 Base 1
10 88291008-904 Support Plate B 1
11 88291008-905 Support Plate A 1
12 88291009-124 Sleeve 1
13 88291010-113 Coupling 1
14 88812110-020 Full Thread Bolt 6
40
9.1 Motor - Compressor System (Continued)
41
9.1 Motor - Compressor System Parts List (Continued)

20 88813108-016 Flanged Bolt 8
21 88831110-020 Flat Washer 16
22 88831112-025 Flat Washer 2
23 88832110-026 Spring Washer 10
24 88832112-031 Spring Washer 2
25 88832116-041 Spring Washer 8
42
9.2 Motor - Compressor System (VSD Model)
43
9.2 Motor - Compressor System (VSD Model) Parts List

1 250042-785 Isolator 2
2 829108-250 Bolt 2
3 837808-125 Gasket 2
4 838208-112 Large Spacer 2
AS9007/AS9008/AS11010/
5 AS11012 Model
88250174-577 Compressor Air End 1 AS9010/AS9012 Model
88250184-821 Compressor Air End 1 AS11007/AS11008 Model
6 88290003-464 Guard 2
88290020-111 Motor 1 AS90 380V IP55 Model
7
8 88290020-283 Isolator 2
9 88291008-904 Support Plate B 1
10 88291008-905 Support Plate A 1
11 88291009-124 Sleeve 1
12 88291010-113 Coupling 1
13 88291010-483 Base 1
20 88813108-016 Flanged Bolt 8
21 88831110-020 Flat Washer 16
22 88831112-025 Flat Washer 2
23 88832110-026 Spring Washer 10
24 88832112-031 Spring Washer 2
25 88832116-041 Spring Washer 8
44
9.3 Air Inlet System
45
9.3 Air Inlet System Parts List

1 88290001-251 Air Filter 1
2 88290001-649 Air Filter Fixing Belt 1
3 88290004-721 T-shape Clamp 2
4 88291008-924 Air Filter Support 1
5 88291009-325 Air Inlet Elbow 1
6 88811108-060 Bolt 1
8 88821108-068 Nut 1
9 88821110-084 Nut 2
10 88831108-016 Flat Washer 1
11 88831110-020 Flat Washer 4
12 88832108-021 Spring Washer 1
13 88832110-026 Spring Washer 4
46
9.4 Fluid Loop System (Air-cooled Model)
47
9.4 Fluid Loop System (Air-cooled Model) Parts List

1 02250101-372 Seal Ring 1
2 02250112-477 Valve Seat 1
For the model with pressure
049542 Thermal Valve Element 1
<12bar
3
For the model with pressure ≥
88290019-737 Thermal Valve Element 1
12bar
4 250019-661 SRF 1/4000 Fluid (GA) 14.5
5 250025-526 Fluid Filter Element 1
6 826502-144 O Seal Ring 1
7 88290001-578 Connector 1
8 88290005-241 Straight Connector 1
Adjustable Rectangle
9 88290005-242 2
Elbow
Differential Pressure
88290023-074 Switch Fluid Filter Holder 1 Visual Indicator
Integration
10
Differential Pressure
88291010-165 Switch Fluid Filter 1 Equipped with signal generator
Holder Integration
13 88291010-208 Metal Hose A 1
14 88291010-332 Fluid Pipe B 1
15 88291010-333 Fluid Pipe C 1
16 88818210-040 Socket Head Cap Screw 4
17 88832110-026 Spring Washer 4
18 88842026-040 O Ring 5
19 88842035-037 O Ring 5
20 88842035-045 O Ring 2
48
9.5 Fluid Loop System (Water-cooled Model)
49
9.5 Fluid Loop System (Water-cooled Model) Parts List

1 02250101-372 Seal Ring
2 02250112-477 Valve Seat
1 For the model with pressure
049542 Thermal Valve Element
<12bar
3
1 For the model with pressure ≥
88290019-737 Thermal Valve Element
12bar
4 250019-661 SRF 1/4000 Fluid (GA) 14.5
5 250025-526 Fluid Filter Element 1
6 826502-144 O Seal Ring 1
7 88290001-578 Connector 1
8 Differential Pressure 2
88290004-863 Switch Fluid Filter Holder
Integration
Adjustable Rectangle 1
10 88290005-242
Elbow
11 Differential Pressure
88290023-074 Switch Fluid Filter Holder 1
Integration
13 88291009-953 Metal Hose B 1
14 88291009-954 Metal Hose C 1
15 88291010-208 Metal Hose A 1
16 88818210-040 Socket Head Cap Screw 4
17 88832110-026 Spring Washer 4
18 88842018-037 O Ring 1
19 88842026-040 O Ring 4
20 88842026-051 O Ring 2
21 88842035-037 O Ring 5
50
9.6 Cooling Fan System (Air-cooled Model)
51
9.6 Cooling Fan System (Air-cooled Model) Parts List

015641 Support Plate 1 60Hz Model
1
88290001-942 Motor Support 1 50Hz Model
02250117-715 Fan 1 50Hz Model
2
405103 Fan 1 60Hz Model
3 245579 Air Guard 1
4 248744 Guard 1
5 250022-436 Sealing Strip (FT) 14.5
88290004-950 Motor 1 50Hz Model
6
88290008-694 Motor 1 60Hz Model
7 88290006-312 Clip Nut 8
8 88291008-861 Fluid/air Cooler 1
9 88291009-265 Cooler Support 1
12 88813108-016 Flanged Bolt 6
13 88813108-020 Flanged Bolt 18
14 88823010-119 Lock Nut 6
15 88831110-020 Flat Washer 18
16 88821110-084 Nut 12
17 88822108-076 Flanged Nut 2
52
9.7 Cooling Water System (Water-cooled Model)
53
9.7 Cooling Water System (Water-cooled Model) Parts List

Water Transport Rubber
1 88290001-425 1
Tube A
2 88290005-234 Connector 2
3 88290005-235 4
Elbow
4 88291009-926 Cooler Support 2
5 88291009-949 Water-cooled After Cooler 1
6 88291009-966 Water Pipe Support 1
Water Discharge Rubber
7 88291009-969 1
Tube
8 88291009-970 Water Inlet Rubber Tube 1
9 88291010-170 Water-cooled Fluid Cooler 1
10 88291010-370 1
Elbow
12 88821112-108 Nut 8
13 88831112-025 Flat Washer 14
14 88832112-031 Spring Washer 14
15 88842026-040 O Ring 4
16 88842035-038 O Ring 4
54
9.8 Fluid/air Separator System
55
9.8 Fluid/air Separator System Parts List

1 020169 Connector 2
2 02250048-734 Secondary filter element 1
3 02250101-490 Connector 2
4 02250117-782 Filtering Connector 2
For the model with pressure
5 02250125-775 Orifice 1
≥12bar
For the model with pressure ＜
6 02250125-776 Orifice 1
12bar
7 02250126-129 Sight Glass 2
8 250034-085 Primary filter element 1
9 869825-025 Connector 1
10 810104-025 Connector 1
11 811505-025 Connector 1
12 841215-004 Stainless Steel Pipe (FT) 6
13 860704-025 Elbow 1
14 810504-025 Elbow 1
15 88290001-031 Oiler Plug 1
16 88290001-219 Sight Glass 1
88290001-329 Fluid/air Separator Tank 1 GB150
17
88291008-477 Fluid/air Separator Tank 1 ASME
88290001-950 Relief Valve 1 For AS90/110 12/13 model
88290005-471 Relief Valve 1 For AS90 07 model
18 88290005-472 Relief Valve 1 For AS90/110 08 model
88290005-473 Relief Valve 1 For AS90/110 10 model
88290012-883 Relief Valve 1 For AS110 07 model
19 88290005-475 Connection Base 1 For AS110 07 model
20 88290002-435 Ball Valve 1
21 88290002-637 Mounting plate 1
22 88290002-688 Half flange 1
23 88290002-836 Drain plug 1
24 88290008-847 Grommet 1
25 88291008-871 Air Discharge Pipe A 1
56
9.8 Fluid/air Separator System (Continued)
57
9.8 Fluid/air Separator System Parts List (Continued)
29 88832108-021 Spring Washer 4

30 88832112-031 Spring Washer 4
31 88832116-041 Spring Washer 4
32 88834233-027 Combined Gasket 1
33 88834242-029 Combined Gasket 1 For AS110 07 model
34 88842026-051 O Ring 1
35 88842035-047 O Ring 1
36 88842035-069 O Ring 1
37 88842035-106 O Ring 1
38 88871008-044 Inner Connector 1
58
9.9 Air Discharge System (Air-cooled Model)
To the fluid/air separator tank
59
9.9 Air Discharge System (Air-cooled Model) Parts List

1 242405 Minimum pressure valve 1
2 88290001-541 Connector 1
3 88291006-087 Moisture Separator 1
4 88291009-198 Air Discharge Pipe B 1
7 88291009-281 Flange Connector A 1
8 88291009-282 Flange Connector B 1
9 88291010-132 Sealing Plate of Air Outlet 1 Special for transportation
11 88821112-108 Nut 4
12 88831112-025 Flat Washer 4
13 88832112-031 Spring Washer 4
14 88842026-056 O Ring 2
15 88842035-056 O Ring 1
16 88842035-065 O Ring 1
17 88842035-075 O Ring 1
60
9.10 Air Discharge System (Water-cooled Model)
61
9.10 Air Discharge System (Water-cooled Model) Parts List

1 242405 Minimum pressure valve 1
2 88290001-541 Connector 1
3 88291006-087 Moisture Separator 1
5 88291009-281 Flange Connector A 1
6 88291009-282 Flange Connector B 1
7 88291009-947 Air Discharge Pipe 1
8 88291010-002 Flange Elbow 1
9 88291010-132 Sealing Plate of Air Outlet 1 Special for transportation
12 88821112-108 Nut 12
13 88831112-025 Flat Washer 4
14 88832112-031 Spring Washer 12
15 88842035-069 O Ring 2
16 88842035-075 O Ring 1
62
9.11 Control System
63
9.11 Control System Parts List

1 02250052-841 Pipe Core 5
2 02250054-861 Nylon Tube (FT) 6
3 02250099-052 Pipe Core 6
4 02250099-626 Elbow 4
5 02250099-630 Nylon Tube (FT) 3.3
6 02250112-032 Filter 1 For Spiral valve model
7 049905 Check Valve 1
8 250003-869 Indicator 1
9 250017-992 Pressure Switch 1 For water-cooled model
11 250018-430 Elbow 5
12 250023-496 Connector 1
13 250038-755 Solenoid valve 1 For Spiral valve model
14 408275 pressure regulator 1 For Spiral valve model
15 807600-005 Reducing Connector 1
16 810904-025 Tee 1 For Spiral valve model
17 811504-025 Connector 1
18 823202-000 Connector 2
19 846400-050 Pipe 1
20 847200-050 Locknut 2 For Spiral valve model
21 848815-050 Bushings 1 For Spiral valve model
22 860108-050 Connector 1
23 860208-050 Elbow 1
24 866408-000 Connector 1
25 868504-025 Connector 4
Plastic-coated Metal Hose
26 88290001-267 1
(MT)
27 88290001-272 2
Connector
28 88290002-119 Pressure Gauge 1
29 88290002-284 Cable Joint 1
64
9.11 Control System (Continued)
65
9.11 Control System Parts List (Continued)

30 88290002-751 Cable Pipe Joint 1 For water-cooled model
31 88290002-754 Cable Pipe Joint 2 For air-cooled model
32 88290002-774 Cable (MT) 1.5
33 88290014-514 Pressure Transducer 1
34 88290017-335 Hose 1
35 88290021-801 Connector 1
36 88291003-279 Orifice 1
Electric Control Panel
88291009-305 1
Assembly
37
88291010-163 1
Assembly
38 88291009-352 Electric Cabinet 1
39 88291010-070 Control Panel 1
Capacity Control Integrated
40 88291010-087 1
System
41 88291010-094 Y-shape Filter 1
42 88291010-144 Temperature Sensor 1
45 88816055-013 Self-Tapping Screw 4
46 88831110-020 Flat Washer 4
47 88831112-025 Flat Washer 1
48 88832110-026 Spring Washer 4
49 804415-010 Tee 1 For Spiral valve model
50 232874 Orifice 1 For Spiral valve model
66
9.12 Control System (VSD Model)
67
9.12 Control System Parts List (VSD Model)

1 02250052-841 Pipe Core 6
2 02250054-861 Nylon Tube (FT) 3
3 02250099-052 Pipe Core 4
4 02250099-626 Elbow 4
5 02250099-630 Nylon Tube (FT) 2
6 049905 Check Valve 1
7 250003-869 Indicator 1
8 250017-992 Pressure Switch 1 For water-cooled model
10 250018-430 Elbow 1
11 250023-496 Connector 2
12 250028-635 Connector 1
13 250039-909 Temperature probe 2
17 811504-025 Connector 1
18 823202-000 Connector 2
19 860108-050 Connector 1
20 860208-050 Elbow 1
21 866408-000 Connector 1
22 868504-025 Connector 1
23 88290001-267 1
(MT)
24 88290001-272 2
Connector
25 88290001-535 Emergency stop button 1
26 88290001-536 Contact 1
27 88290002-284 Cable Joint 1
30 88290002-774 Cable (MT) 1
31 88290003-806 Pressure sensor 2
32 88290004-495 Emergency stop alarm ring 1
Deluxe microprocessor
33 88290007-999 1
controller
68
9.12 Control System (VSD Model) (Continued)
69
9.12 Control System Parts List (VSD Model) (Continued)

34 88290017-335 Hose 1
35 88290021-801 Connector 2
36 88291005-494 Orifice 1
88291009-298 1 AS110 AC 380-420V VSD SCNS
Assembly
88291010-975 1 AS90 AC 380-420V VSD SCNS
Assembly
37
88291011-407 1 AS110 WC 380-420V VSD SCNS
Assembly
88291011-408 1 AS90 WC 380-420V VSD SCNS
Assembly
Capacity Control
38 88291009-363 1
Integrated System
39 88291010-094 Y-shape Filter 1
40 88291011-142 Cable Joint 1
42 88821104-032 Nut 9
43 88831112-025 Flat Washer 1
44 88832104-011 Spring Washer 9
45 88813108-016 Flange bolt 8
46 88831110-020 Flat Washer 4
47 88832110-026 Spring Washer 4
49 88290015-219 Solenoid valve 1 Option
50 88291008-364 Blowdown valve 1 Option
70
9.13 Air Cooling Acoustical Enclosure System
71
9.13 Air Cooling Acoustical Enclosure System Parts List

1 02250048-520 Plastic Cap 17
2 250022-436 Sealing Strip (FT) 155
3 88290005-094 Hinge 6
4 88290006-895 Hinge 6
5 88291008-881 Beam E 1
6 88291008-882 Beam D 1
7 88291009-150 Door A 3
8 88291009-153 Standing Plate A 1
9 88291009-157 Pillar A 1
10 88291009-159 Door B 1
11 88291009-160 Pillar B 1
12 88291009-161 Beam F 1
13 88291009-162 Top Plate A 1
14 88291009-164 Top Plate B 1
15 88291009-165 Door D 1
16 88291009-166 Door E 1
17 88291009-222 Standing Plate B 1
18 88291009-286 Pillar C 1
19 88291009-287 Beam B 1
20 88291009-288 Pillar D 1
21 88291009-289 Beam A 1
22 88291009-291 Beam C 1
23 88291009-366 Door C 2
24 88291009-468 Beam G 1
25 88291009-469 Beam H 1
26 88291009-944 Angle Plate A 2
27 88291009-945 Angle Plate B 2
29 88813108-016 Flanged Bolt 84
72
9.14 Water Cooling Acoustical Enclosure System
73
9.14 Water Cooling Acoustical Enclosure System Parts List

1 02250048-520 Plastic Cap 16
2 250007-835 Square Lock 2
4 829704-100 Flanged Bolt 2
5 88290001-669 Fan 1
6 88290005-094 Hinge 6
7 88290006-895 Hinge 6
8 88291008-882 Beam D 1
9 88291009-150 Door A 3
10 88291009-159 Door B 1
11 88291009-161 Beam F 1
12 88291009-162 Top Plate A 1
13 88291009-286 Pillar C 1
14 88291009-287 Beam B 1
15 88291009-288 Pillar D 1
16 88291009-289 Beam A 1
17 88291009-291 Beam C 1
18 88291009-366 Door C 2
19 88291009-468 Beam G 1
20 88291009-469 Beam H 1
21 88291009-960 Baffle G 1
22 88291009-961 Door E 1
23 88291009-965 Top Plate B 1
24 88291010-004 Beam E 1
25 88291010-201 Door D 1
26 88291010-202 Pillar B 1
27 88291010-203 Pillar A 1
31 88813108-016 Flanged Bolt 70
74
9.15 Air Cooling Acoustical Enclosure System (VSD Model)
75
9.15 Air Cooling Acoustical Enclosure System (VSD Model) Parts List

1 02250048-520 Plastic Cap 19
3 88290005-094 Hinge 6
4 88290006-895 Hinge 6
5 88291009-150 Door A 2
7 88291009-166 Door E 1
9 88291009-287 Beam B 1
10 88291009-469 Beam H 1
11 88291009-944 Angle Plate A 2
12 88291009-945 Angle Plate B 2
13 88291010-485 Beam F 1
14 88291010-486 Column A 1
15 88291010-487 Column B 1
16 88291010-488 Beam E 1
17 88291010-489 Beam C 1
18 88291010-491 Cover A 1
19 88291010-494 Door B 2
20 88291010-496 Door C 1
21 88291010-498 Standing Plate C 1
22 88291010-521 Beam G 1
23 88291010-522 Beam A 1
24 88291010-577 Cover B 1
25 88291010-643 Standing Plate D 1
26 88291010-779 Door D 1
28 88813108-016 Flanged Bolt 77
76
9.16 Water Cooling Acoustical Enclosure System (VSD Model)
77
9.16 Water Cooling Acoustical Enclosure System (VSD Model) Parts List

1 02250048-520 Plastic Cap 19
2 250007-835 Square Lock 2
4 829704-100 Flanged Bolt 2
5 88290001-669 Fan 1 220-270V/380-480V 50/60Hz
6 88290005-094 Hinge 6
7 88290006-895 Hinge 6
8 88291009-150 Door A 2
9 88291009-287 Beam B 1
10 88291009-469 Beam H 1
11 88291009-960 Baffle G 1
12 88291009-965 Top Plate B 1
15 88291010-485 Beam F 1
16 88291010-489 Beam C 1
17 88291010-491 Cover A 1
18 88291010-494 Door B 2
19 88291010-496 Door C 2
20 88291010-498 Standing Plate C 1
21 88291010-521 Beam G 1
22 88291010-522 Beam A 1
23 88291010-643 Standing Plate D 1
24 88291011-403 Beam E 1
25 88291011-404 Door E 1
26 88291011-410 Column B 1
27 88291011-412 Column B 1
28 88813108-016 Flanged Bolt 75
78
9.17 Decal System (Air-cooled Model)
79
9.17 Decal System (Air-cooled Model) Parts List
For domestic model:

1 88290001-279 Warning Decal 3
2 88290001-281 Hoisting position decal 2
Electric Shock Warning
3 88290001-282 1
Decal
Auto Start/Stop Warning
4 88290001-283 1
Decal
High Pressure Risk Warning
5 88290001-292 1
Decal
6 88290001-321 Rotation Direction Decal 1
7 88290001-322 Grounding Decal 1
8 88290001-324 Initial Start Label 1
9 88290004-160 Fluid Fill Warning Decal 1
10 88290004-161 Breathing Warning Decal 1
11 88290004-162 Food Warning Decal 1
12 88290005-334 Nameplate 1
13 88290011-431 Website Decal 1
14 88290013-723 Rivet 4
15 88290016-001 SRF Reminder Decal 1
Voltage Warning Combined
16 88290016-067 1
Decal
88291010-169 AS90 Model Decal 1 For AS90 model
17
18 88291010-096 Sullair Logo Decal 1
80
9.17 Decal System (Air-cooled Model) (Continued)
81
9.17 Decal System (Air-cooled Model) Parts List (Continued)
For foreign model:

1 049855 Warning Decal 3
2 241814 Hoisting position decal 2
3 049850 1
Decal
4 250017-903 1
Decal
5 042218 1
Decal
Grounding Fault Warning
7 049852 1
Decal
9 049685 Fluid Fill Warning Decal 1
12 88290013-683 Nameplate 1
13 88290011-431 Website Decal 1
14 88290013-723 Rivet 4
16 88290016-067 1
Decal
17
82
9.18 Decal System (Water-cooled Model)
83
9.18 Decal System (Water-cooled Model) Parts List
For domestic model:

2 88290001-281 Lifting Position Decal 2
3 88290001-282 1
Decal
4 88290001-283 1
Decal
5 88290001-292 1
Decal
6 88290001-316 Water-in Decal 1
7 88290001-318 Water-out Decal 1
11 88290002-325 Antifreeze Decal 3
Water-cooled Model Initial
12 88290003-238 1
Start Reminder
16 88290005-334 Nameplate 1
17 88290011-431 Website Decal 1
18 88290013-723 Rivet 4
20 88290016-067 1
Decal
21
84
9.18 Decal System (Water-cooled Model) (Continued)
85
9.18 Decal System (Water-cooled Model) Parts List (Continued)
For foreign model:

2 241814 Lifting Position Decal 2
3 049850 1
Decal
4 250017-903 1
Decal
5 042218 1
Decal
6 250019-108 Water-in Decal 1
9 049852 1
Decal
12 88290013-349 1
Start Reminder
16 88290013-683 Nameplate 1
17 88290011-431 Website Decal 1
18 88290013-723 Rivet 4
20 88290016-067 1
Decal
21
86
9.19 Decal System (Air-cooled VSD Model)
87
9.19 Decal System (Air-cooled VSD Model) Parts List
For domestic model:

2 88290001-281 Hoisting position decal 2
3 88290001-282 1
Decal
4 88290001-283 1
Decal
5 88290001-292 1
Decal
12 88290005-334 Nameplate 1
13 88290011-431 Website Decal 1
14 88290013-723 Rivet 4
16 88290016-067 1
Decal
17 88290020-725 VSD Decal 1
18
88
9.19 Decal System (Air-cooled VSD Model) (Continued)
89
9.19 Decal System (Air-cooled VSD Model) Parts List (Continued)
For foreign model:

2 241814 Hoisting position decal 2
3 049850 1
Decal
4 250017-903 1
Decal
5 042218 1
Decal
7 049852 1
Decal
12 88290013-683 Nameplate 1
13 88290011-431 Website Decal 1
14 88290013-723 Rivet 4
16 88290016-067 1
Decal
17 88290020-725 VSD Decal 1
18
90
9.20 Decal System (Water-cooled VSD Model)
91
9.20 Decal System (Water-cooled VSD Model) Parts List
For domestic model:

2 88290001-281 Lifting Position Decal 2
3 88290001-282 1
Decal
4 88290001-283 1
Decal
5 88290001-292 1
Decal
6 88290001-316 Water-in Decal 1
12 88290003-238 1
Start Reminder
16 88290005-334 Nameplate 1
17 88290011-431 Website Decal 1
18 88290013-723 Rivet 4
20 88290016-067 1
Decal
21 88290020-725 VSD Decal 1
22
92
9.20 Decal System (Water-cooled VSD Model) (Continued)
93
9.20 Decal System (Water-cooled VSD Model) Parts List (Continued)
For foreign model:

2 241814 Lifting Position Decal 2
3 049850 1
Decal
4 250017-903 1
Decal
5 042218 1
Decal
6 250019-108 Water-in Decal 1
9 049852 1
Decal
12 88290013-349 1
Start Reminder
16 88290013-683 Nameplate 1
17 88290011-431 Website Decal 1
18 88290013-723 Rivet 4
20 88290016-067 1
Decal
21 88290020-725 VSD Decal 1
22
94
Global Sales and Service
Headquarter in US: SULLAIR CORPORATION

Subsidiary of Hamilton-Sundstrand Corporation
3700 East Michigan Boulevard
Michigan City, Indiana 46360 U.S.A.
Telephone: 001-219-879-5451 or 1-800-Sullair (U.S.A. only)
Fax: 001-219-874-1273
SULLAIR ASIA: SULLAIR ASIA
Website: http://www.sullair-asia.com Hotline: 800-830-3977
SULLAIR Singapore: 74 Joo Koon Circle, Jurong Singapore 629093
Telephone：65-68611211 Fax：65-68612967
SULLAIR Taipei: No.1, 3/F., No.248 Zhongshan Road, Linkou Town,
Taipei
Tel: 02-26013500 Fax: 02-26013032
Shenzhen Factory: Zuopaotai Road, Chiwan, Shekou, Shenzhen 518068
Tel: 0755-26851686 Fax: 0755-26835157
Suzhou Factory: No.266 Changyang Street, Singapore Industrial Park,
Suzhou 215000
Tel: 0512-87162388 Fax: 0512-87162389, 87162387
Shanghai Branch: Room 1504, Harbour Ring Plaza, No.18 Xizang
Middle Road, Shanghai City 200001
Tel: 021-53852036, 53852038 Fax: 021-53852035
Beijing Branch: Room 1506, Block B, Xingfu Building, No. 3 East 3rd
Ring Road, Beijing City 100027
Tel: 010-64629770, 64629768 Fax: 010-64629773
Chengdu Branch: Block H, 28/F., Guancheng Plaza, No.308 Shuncheng
Street, Chengdu City 610017
Tel: 028-86527506, 86527507 Fax: 028-86527505
Shenyang Branch: Room 1601, Golden International Building, No.355
Zhongshan Road, Shenhe District, Shenyang City 110014
Tel: 024-22818450, 22818550 Fax: 024-22818590
Xi’an Branch: Room 701A, Jinxin International Building, No.99 Heping
Road, Xi’an City 710001
Tel: 029-87206201, 87206202 Fax: 029-87206204
Wuhan Branch: Room 2909, Block B, Zhongshang Plaza, No.7
Zhongnan Road, Wuchang District, Wuhan City 430071
Tel: 027-87322745 Fax: 027-87322546
Xinjiang Branch: Unit J, 9/F., National Development Bank Tower,
No.339 Zhongshan Road, Urumqi 830002
Tel: 0991-2308451, 2308452 Fax: 0991-2308450
P/N: 88291010-131
E/N: 01

As90&110 Operation & Maintenance Manual 88291010-131 (01) - en

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STATIONARY AIR COMPRESSOR

OPERATION & MAINTENANCE MANUAL

CHAPTER IX PARTS LIST .................................................................................................................................. 39

1.2 Safety Equipment

1.3 Fire and Explosion Protection

1.4 Moving Parts

1.4.4. Keep access doors closed except when making maintenance;

1.5 Hot Surfaces, Sharp Edges and Corners

1.6 Toxic and Irritative Substances

1.7 Electric Shock Protection

1.8 Hoisting and Transportation

Chapter II Compressor Structure

Main specifications of the AS110 compressor—Standard model:

Main specifications of AS90 compressor—VSD model:

Model AS9007V AS9008V AS9010V AS9012V

Main specifications of AS110 compressor—VSD model:

Model AS11007V AS11008V AS11010V AS11012V

Air Cooling Acoustical

Cooling Fan System

Fluid Loop System

Air Inlet System

Fluid/air Separator System

Figure 1 General Layout of AS90/110 Air-cooled Unit

Water Cooling Acoustical

Fluid Loop System

Air Discharge System

Air Inlet System

Fluid/air Separator System

Figure 2 General Layout of AS90/110 Water-cooled Unit

Figure 3 General Layout of AS90/110 VSD Air-cooled Unit

Figure 4 General Layout of AS90/110 VSD Water-cooled Unit

No. P/N No. P/N

Figure 5 System Flow Chart of AS90/110 Unit

No. P/N No. P/N

Figure 6 System Flow Chart of AS90/110 VSD Unit

2.2 Air Suction System

complete cycle. Fluid serves for three roles:

2.6.2 Filter element replacement

2.7 Control System

2.7.1 Line frequency model

2.8 Microcomputer Controller

Chapter III Installation of Compressor

3.1 Machine Installation

3.2 Ventilation and Temperature Reducing

3.3 Cooling Water System - Water-cooled Model

Ca2+ 30-200 mg/L

Water flow T/h

3.4 Air Supply Pipe

3.5 Check Coupling

3.6 Check Fluid Level

3.7 Check Drain Plug of Cooler (For Water-cooled Model Only)

3.8 Check Electric Circuit

High-voltage inside. Be careful of electric shock.

1. Check if input voltage is conforming.

3.9 Rotation direction of the motor

3.9.1 Line frequency model

Never put the motor in reverse rotation direction!

3.10 Check the Air Outlet

Figure 7 Air Discharge System Sealing Plate

3.11 Releasing of Support Bolt for the Air End

The support plate of

Figure 8 Dimension and Installation Diagram of AS90/110 Air- Cooled Model