ROTARY SCREW AIR COMPRESSORS - Welcome to … manuals/2. Mini-screw Compressors/2... · STATEMENT...

54
COAIRE M-Series Microprocessor Control System MAINTENANCE MANUAL AND PARTS LIST MODELS : CHSA-7.5M CHSA-10M CHSA-15M CHSA-20M CHSA-25M CHSA-30M COAIRE TECHNOLOGIES, CORPORATION All rights reserved Printed in U.S.A. ROTARY SCREW AIR COMPRESSORS For proper and safe use of the compressor, please follow all instructions and safety precautions as identified in this manual, along with general safety regulations and practices.

Transcript of ROTARY SCREW AIR COMPRESSORS - Welcome to … manuals/2. Mini-screw Compressors/2... · STATEMENT...

COAIRE M-Series

Microprocessor Control System

MAINTENANCE MANUAL AND PARTS LIST

MODELS

CHSA-75M

CHSA-10M

CHSA-15M

CHSA-20M

CHSA-25M

CHSA-30M

COAIRE TECHNOLOGIES CORPORATION

All rights reserved Printed in USA

ROTARY SCREW AIR COMPRESSORS

For proper and safe use of the compressor please follow all instructions and safety precautions as identified in this manual along with general safety regulations and practices

SAFETY AND PRECAUTIONS Before you install the air compressor you should take the time to carefully read all the instructions contained in this manual Electricity and compressed air have the potential to cause severe personal injury or property damage Before installing wiring starting operating or making any adjustments identify the components of the air compressor using this manual as a guide The operator should use common sense and good working practices while operating and maintaining this unit Follow all procedures and piping accurately Understand the starting and stopping sequences Check the safety devices in accordance with the following procedures contained in this manual Maintenance should be done by qualified personnel accurately with proper tools Follow the maintenance schedule as outlined in the manual to ensure problem free operation after start up

SAFETY PRECAUTIONS BEFORE INSTALLING THE COMPRESSOR OR PERFORMING ANY MAINTENANCE READ THIS MANUAL

CAREFULLY

WARNINGS COMPRESSED AIR AND ELECTRICITY ARE DANGEROUS BEFORE DOING ANY WORK ON THIS UNIT BE SURE THE

ELECTRICAL SUPPLY HAS BEEN SHUT OFF(LOCKED AND TAGGED) AND THE ENTIRE COMPRESSOR SYSTEM HAS

BEEN VENTED OF ALL PRESSURE

1 Do not remove the cover loosen or remove any fittings connections or devices when this unit is operating or in

operation Hot liquid and air that are contained within this unit under pressure can cause severe injury or death 2 The compressor has high and dangerous voltage in the motor the starter and control box All installations must be in

accordance with recognized electrical procedure Before working on the electrical system ensure that the systems power has been shut off by use of a manual disconnect switch A circuit breaker or fuse switch must be provided in the electrical supply line to be connected to the compressor The preparation work for installation of this unit must be done in suitable grounds maintenance clearance and lighting arrestors for all electrical components

3 Do not operate the compressor at a higher discharge pressure than those specified on the compressor nameplate If so an overload will occur This condition will result in electric motor compressor shutdown

4 Use only safety solvent for cleaning the compressor and auxiliary equipment 5 Install a manual shut off valve(isolation type) in the discharge line for service work 6 Whenever pressure is released through the safety valve during operation it is due to excessive pressure in the

system The cause of excessive pressure should be checked and immediately corrected 7 Before doing any mechanical work on the compressor a) Shut down the unit b) Electrically isolate the compressor by use of the manual disconnect switch in the power line to the unit Lock and

tag the switch so that it cannot be operated c) Release all compressed air within the system and isolate the unit from any other sources of air 8 Allowing the unit lubricants to enter into the plant air system must be avoided at all times Air line separators which

are properly selected and installed can reduce any liquid carry-over close to zero 9 Before starting the compressor the maintenance instructions should be thoroughly read and understood 10 After maintenance work is completed covers must be securely closed 11 For questions contact your distributor before proceeding

STATEMENT OF WARRANTY TERMS amp CONDITIONS COAIRErsquos screw air compressors are warranted to be free of defects in materials and workmanship under proper use installation and application This warranty shall be for a period of 15 months from date of shipment from our factory or other stocking facilities or 12 months from date of installation Proof of installation date will be required All air compressors outside the US and Canada carry a parts only warranty ALL FREIGHT DAMAGE CLAIMS ARE NOT THE RESPONSIBILITY OF THE MANUFACTURER AND ARE NOT COVERED UNDER WARRANTY AS ALL PRODUCTS ARE SHIPPED FOB SHIPPER

PLEASE DIRECT ALL FREIGHT CLAIMS TO THE SHIPPER IN QUESTION

MAINTENANCE AND ADJUSTMENTS

ADJUSTMENTS PRESSURE SETTINGS AND MAINTENANCE OF FLOAT AND AUTOMATIC DRAINS AND OIL COOLER COILS ARE CONSIDERED TO BE ROUTINE MAINTENANCE AND THEREFORE NON-WARRANTABLE ITEMS AND ARE THE SOLE RESPONSIBILITY OF THE END USER CONSULT THE INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR THE ADJUSTMENT AND MAINTENANCE PROCEDURES

This warranty does not apply to any unit damaged by accident modification misuse negligence or misapplication Damage to heat exchangers by exposure to ammonia any other corrosive substance or sub-freezing environment will be considered misuse

Any air compressors part or material found defective will be repaired replaced or refunded at the sellers option free of charge provided that COAIRE is notified within the above stated warranty period All returns of allegedly defective equipment must have prior written authorization Said authorization may be obtained through our air compressor service department All air compressors parts materials must be returned freight prepaid to the Manufacturerrsquos factory within 30 days of return authorization date Any shipment returned to the factory collect will be refused

If an item is found to be warrantable the repaired item or replacement will be returned normal ground freight prepaid within the continental United States and Canada Expedited shipment costs are the responsibility of the requestor

Any replacement part or material is warranted only to the extent of the remaining warranty period of the air compressor or to the extent as provided by the supplier whichever is longer

Identification Plate The identification plate is located on the side of the air compressor and shows all the primary data of the machine Upon installation fill in the table on the previous page with all the data shown on the identification plate This data should always be referred to when calling the manufacturer or distributor The removal or alteration of the identification plate will void the warranty rights

DISCLAIMER The warranty does not cover any responsibility or liability for direct or indirect damages to persons or equipment caused by improper usage or maintenance and is limited to manufacturing defects only Refer to COAIRE Warranty policy manual for travel mileage and special charge considerations The warranty will be immediately voided if there are changes or alterations to the air compressor

WHO TO CONTACT IF YOU HAVE A WARRANTY CLAIM COAIRE Technologies Corporation Phone (562) 463-3935

Fax (562) 463-4928

All freight damage claims should be filed within 15 working days and should be directed to the carrier

TABLE OF CONTENTS

Chapter Ⅰ General information

1-1 Instruction 1

1-2 Screw compression process 1

1-3 Compressed air flow 2

1-4 Cooling air flow 2

1-5 Oil separation 2

1-6 Oil flow 2

1-7 Oil scavenge flow 2

1-8 Standard Specifications 3

1-9 Installation and wiring 4

Chapter Ⅱ Operating instructions

2-1 Operating panel 8

2-2 Initial start-up 9

2-3 Daily operation 10

2-4 Standard factory settings of control components 11

2-5 Operation and control sequence 12

2-6 Microprocessor Controller 14

Chapter Ⅲ Functional Description

3-1 Compressor air-end 19

3-2 Drive motor 20

3-3 V-Belt drive 20

3-4 Capacity control 20

3-5 Lubrication system 20

3-6 After cooleroil cooler 20

3-7 Oil separator 20

3-8 Oil Filter 20

3-9 Thermostatic Valve 20

3-10 Min Pressure Valve 20

3-11 Air Intake Filter 20

3-12 Instrument Panel 21

3-13 Starter and control box 21

3-14 Safety device 21

Chapter Ⅳ Scheduled Maintenance

4-1 Standard maintenance schedule 22

4-2 Control of lubrication 23

Chapter Ⅴ Trouble shooting

5-1 Trouble symptoms and solutions 25

5-2 Operation record form 26

Chapter Ⅵ Corrective maintenance

6-1 Oil filter 28

6-2 Suction filter 29

6-3 Oil separator element 29

6-4 Oil seal 29

6-5 Min Pressure valve 30

6-6 Suction control valve 30

6-7 Cooling fan 30

6-8 Oil temperature regulating valve 30

6-9 V-Belt 31

6-10 Pressure transmitter 32

6-11 Safety valve 32

Appendix

A Compressor Part List 33

B Parts List 36

C PC Board 44

D Wiring Diagram 45

E Outline Drawing 47

1

CHAPTER I

GENERAL INFORMATION 1-1 INSTRUCTION COAIRE screw air compressor unit is a complete package type driven by an electric motor It is single stage oil injected rotary screw type with all components full piped wired and mounted on a common base it is a very self-contained air compressor package

1-2 SCREW COMPRESSION PROCESS

1-2-1 SUCTION PROCESS Along with the rotation of the rotor air is admitted fully into the void of two rotors through the suction port The void is then isolated from the suction port with the casing wall thereby completing the suction process

Fig 1-1 Suction Process

1-2-2 COMPRESSION PROCESS The air in the void is compressed as the male rotor lobe meshes between the female rotor lobes and squeezes the air against discharge cover

Fig 1-2 Compression Process

1-2-3 OIL INJECTION PROCESS As pressure builds oil is injected into the compression area and onto the bearings and shaft seal serving to lubricate absorb compression heat and seal the rotors

Fig 1-3 Oil Injection Process

1-2-4 DISCHARGE PROCESS Compression continues as the rotor rotates When the void comes to the discharge port provided in the discharge chamber the compressed air is discharged through the port While this process is occurring with one inter-lobe space the other spaces are following the same cycle Therefore air is compressed continuously

Fig 1-4 Discharge Process

2

1-3 COMPRESSED AIR FLOW The panel has an intake duct through which air is drawn into the enclosure Airflows through an air intake filter intake silencer and suction control valve to the air-end suction port Air then is compressed by the rotation of the male rotor and oil is injected into the air-end during compression process The injected oil performs various functions such as sealing cooling as well as lubricating The airoil mixture leaves the air-end through the discharge port and flows into the oil separator where the oil is separated from the compressed air Compressed air leaves the oil separator and is supplied to discharge connection of the unit via minimum pressure valve after-cooler and liquid separator

1-4 COOLING AIR FLOW The air-cooled unit comprises a forced ventilation system with a cooling fan which is driven by an electric motor First the cooling air removes the heat generated from the main motor air end etc The cooling air is then forced into the oil and after-cooler by cooling fan After the heat exchange the hot air flows through the ventilation duct and is exhausted from the ventilation louvers in the panel

1-5 OIL SEPARATION Primary separation Most of the oil is separated from air by the impact at the inner wall of the oil separator and by the fluid cyclonic effect After primary separation the heavy oil falls and is collected in the oil sump at the bottom of the oil separator Secondary separation The air which still contains fine oil particles flows through the oil separator element where the oil forms into large particles and is collected at the bottom of the element shell Then clean air leaves the oil separator 1-6 OIL FLOW The oil which is collected in the oil sump at the bottom of the oil separator is circulated through the lubrication system by the pressure differential existing between the oil separator and the air-end The oil temperature control valve is a bypass valve When the oil is cold the oil bypasses the oil cooler partly or completely and is sent to the oil filter When the oil is hot 185 lsquoF(85rsquoC) or more the oil flows into the oil cooler unless by-pass the compression chamber and lubrication parts of the air-end Oil injected via the internal oil hole is provided into the intermesh among male rotor female rotor and the rotor casing the shaft seal suction side and discharge side bearings 1-7 OIL SCAVENGE FLOW After oil is separated from the air and collected in the element shell of the oil separator it is scavenged to the compression chamber of the air-end by the internal pressure differential so that the oil carry-over in the discharged air can be controlled within the allowable limit

3

M

TS PI

PT

Fig 1-5 Operating flow diagram

1-8 STANDARD SPECIFICATIONS MODEL

ITEM CHSA-75M CHSA-10M CHSA-15M

Motor output Kw(HP) 55(75) 75(10) 11(15) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 290 265 230 385 360 310 570 520 460 Compressor speed RPM 5250 4720 4350 6950 6380 5950 6450 6200 5550 Oil flow rate gpm 40 53 80 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph(1Ph) 208-230V 3Ph 208-230460V Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 07 07 11 Noise level dB(A) 68 70 71 Weight lbs 300 310 420 Dimensions(WtimesDtimesH) in 17times2458x3258 2834x4138x4218 Air outlet piping size in 34rdquo 1rdquo

Air

Cleaner

Solenoid

Valve

Only

15 ~ 30HP

Oil Filter

Oil Cooler

Thermostat

Valve

Oil

Separator

Min

Pressure

After Cooler

Oil Separator

Tank

Symbol PT Pressure Transmitter

TS Temperature Sensor

PI Pressure Indicator

M Motor

4

MODEL

ITEM CHSA-20M CHSA-25M CHSA-30M

Motor output Kw(HP) 15(20) 19(20) 22(30) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 734 680 640 1253 1150 1080 Compressor speed RPM 8280 7900 7500 5700 5380 5160 Oil flow rate gpm 85 119 119 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph 208-230 460 Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 11 13 13 Noise level dB(A) 72 73 73 Weight lbs 450 550 630 Dimensions(WtimesDtimesH) in 2834x4138x4218 3112x4714x4978 Air outlet piping size in 1rdquo 1rdquo

1-9 INSTALLATION AND WIRING Upon delivery carefully check the air compressor unit(s) for damage during transportation 1-9-1 HANDLING When handling by a forklift make sure that forks completely extend through the width of the unit When handling by a shop crane use the openings provided on common base where slings or steel wire ropes can be use for lifting

Fig 1-6 Handling by forklift truck

Fig 1-7 Handling by shop crane

1-9-2 LOCATION The unit should be installed in a dry well ventilated area dust-free environment The unit should not be installed outdoors Consideration must be given to the need for clearance around the unit to avoid the re-circulation of air-end for easy maintenance access

5

(Unit Inch)

Fig 1-8 The space clearance example

CAUTION

- Install the unit in a dust-free room of low humidity and on a level concrete floor

- Never install the unit on timbers or block High humidity may result in electrical shorts and corrosion

- Dust particles containing iron or sand may result in poor resistance of the motor and air-end damage

- A ventilation fan should be provided to keep the ambient temperature 115 or lower

- operation at ambient temperature of higher than 115 may cause compressor shutdown or severe

damage to the unit

HEAT GENERATION amp VENTILATION FAN CAPACITY MODEL

CAPACITY CHSA-75M CHSA-10M CHSA-15M CHSA-20M CHSA-25M CHSA-30M

CAPACITY (Btuh) AIR VOLUME (cfm) 1165 1235 1900 2120 2330 2540 Note 1 The room ventilation capacity is based on (1) Compressor room Temperature rise which is controlled within the 9 (2) Static pressure of ventilation air should be 0 inchWG 2 Consult the distributor for more information on ventilation capacity when the air exhaust duct is installed

A B C D CHSA-75M 24 42 42 24 CHSA-10M 24 42 42 24 CHSA-15M 24 42 42 24 CHSA-20M 42 42 42 24 CHSA-25M 24 42 42 24 CHSA-30M 24 42 42 24

6

1-9-3 PIPING WORK

CAUTION

- All service piping must be installed so as to exert zero force of movement on the system

- A drain valve and isolation valve should be mounted near the compressor discharge section

- Water condensation can affect the operation of pneumatic devices After-coolers and the addition of

air dryers can eliminate this hazard Similarly avoid allowing compressor coolant to enter the plant air

systems Air line separators properly selected and installed will reduce any liquid carry-over

- When installed in parallel operation you must provide an isolation valve and drain trap for each

compressor unit before the common receiver Screw air compressors should not be installed in air

systems with reciprocating compressors without a means of isolation such as a common receiver It

is recommend that both types of compressor units are piped to a common receiver utilizing individual

air lines

- In case of a lead fluctuation or a very small volume in pipe from discharge connection of compressor

unit to the end of the piping the use of air receiver is recommended

- In case the discharge piping has to be unusually long you should select the diameter of the piping in

considering the pressure drop in the piping

- Consult your distributor for proper technical support

Fig 1-9 Parallel installation Fig 1-10 Installation with reciprocating compressor

1-9-4 ELECTRICITY This extensive line of Coaire screw air compressors has been designed to provided all the conveniences of air supply system especially for the stats of the art manufacturing industries These units are composed of compressor motor protection devices and control equipment The applicable voltage range for each unit is given in the electrical data The working voltage among the three phases must be balanced within 2 deviation from each voltage at the compressor terminals Voltage range limit is to be 90~110 of regular voltage described in proportional frequency Unbalance of voltage measured in motor terminals should be within 3 in accordance with the following formula

(V)max - (V)mean ---------------------------- times 100 () (V)mean where (V)max Maximum voltage among three terminals (V)mean Average voltage among three terminals

CAUTION

7

ELECTRICAL WIRING

- Read all related topics in this manual

- Comply to the National Electric Code(NEC) and any other local codes

- Utilize a qualified licensed electrical contractor

1-9-5 ELECTRICAL SPECIFICATION

3 Phase Motor

MODEL

AIR-END MOTOR NO FUSE

BREAKER

OVER

CURRENT

RELAY

MAIN CABLE

OUTPUT

[kWHp]

INPUT

[kW]

POWER[V]

3oslash60Hz

FLA

[A]

LRA[A] POWER

FACTOR

[]

FRAME

[AF]

TRIP

[A]

TRIP

[A]

POWER

[]

KIV

GROUND

[]

GV DIRECT Y-DELTA

CHSA-75M 55975 208 190 708 -

94

230 170 640 - 460 85 320 -

CHSA-10M 74610 208 256 741 -

91

230 232 670 - 460 116 385 -

CHSA-15M 111915 208 387 1371 -

90

230 350 1240 - 460 175 620 -

CHSA-20M 149220

208 520 1680 -

88

230 470 1520 -

460 235 760 -

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

SAFETY AND PRECAUTIONS Before you install the air compressor you should take the time to carefully read all the instructions contained in this manual Electricity and compressed air have the potential to cause severe personal injury or property damage Before installing wiring starting operating or making any adjustments identify the components of the air compressor using this manual as a guide The operator should use common sense and good working practices while operating and maintaining this unit Follow all procedures and piping accurately Understand the starting and stopping sequences Check the safety devices in accordance with the following procedures contained in this manual Maintenance should be done by qualified personnel accurately with proper tools Follow the maintenance schedule as outlined in the manual to ensure problem free operation after start up

SAFETY PRECAUTIONS BEFORE INSTALLING THE COMPRESSOR OR PERFORMING ANY MAINTENANCE READ THIS MANUAL

CAREFULLY

WARNINGS COMPRESSED AIR AND ELECTRICITY ARE DANGEROUS BEFORE DOING ANY WORK ON THIS UNIT BE SURE THE

ELECTRICAL SUPPLY HAS BEEN SHUT OFF(LOCKED AND TAGGED) AND THE ENTIRE COMPRESSOR SYSTEM HAS

BEEN VENTED OF ALL PRESSURE

1 Do not remove the cover loosen or remove any fittings connections or devices when this unit is operating or in

operation Hot liquid and air that are contained within this unit under pressure can cause severe injury or death 2 The compressor has high and dangerous voltage in the motor the starter and control box All installations must be in

accordance with recognized electrical procedure Before working on the electrical system ensure that the systems power has been shut off by use of a manual disconnect switch A circuit breaker or fuse switch must be provided in the electrical supply line to be connected to the compressor The preparation work for installation of this unit must be done in suitable grounds maintenance clearance and lighting arrestors for all electrical components

3 Do not operate the compressor at a higher discharge pressure than those specified on the compressor nameplate If so an overload will occur This condition will result in electric motor compressor shutdown

4 Use only safety solvent for cleaning the compressor and auxiliary equipment 5 Install a manual shut off valve(isolation type) in the discharge line for service work 6 Whenever pressure is released through the safety valve during operation it is due to excessive pressure in the

system The cause of excessive pressure should be checked and immediately corrected 7 Before doing any mechanical work on the compressor a) Shut down the unit b) Electrically isolate the compressor by use of the manual disconnect switch in the power line to the unit Lock and

tag the switch so that it cannot be operated c) Release all compressed air within the system and isolate the unit from any other sources of air 8 Allowing the unit lubricants to enter into the plant air system must be avoided at all times Air line separators which

are properly selected and installed can reduce any liquid carry-over close to zero 9 Before starting the compressor the maintenance instructions should be thoroughly read and understood 10 After maintenance work is completed covers must be securely closed 11 For questions contact your distributor before proceeding

STATEMENT OF WARRANTY TERMS amp CONDITIONS COAIRErsquos screw air compressors are warranted to be free of defects in materials and workmanship under proper use installation and application This warranty shall be for a period of 15 months from date of shipment from our factory or other stocking facilities or 12 months from date of installation Proof of installation date will be required All air compressors outside the US and Canada carry a parts only warranty ALL FREIGHT DAMAGE CLAIMS ARE NOT THE RESPONSIBILITY OF THE MANUFACTURER AND ARE NOT COVERED UNDER WARRANTY AS ALL PRODUCTS ARE SHIPPED FOB SHIPPER

PLEASE DIRECT ALL FREIGHT CLAIMS TO THE SHIPPER IN QUESTION

MAINTENANCE AND ADJUSTMENTS

ADJUSTMENTS PRESSURE SETTINGS AND MAINTENANCE OF FLOAT AND AUTOMATIC DRAINS AND OIL COOLER COILS ARE CONSIDERED TO BE ROUTINE MAINTENANCE AND THEREFORE NON-WARRANTABLE ITEMS AND ARE THE SOLE RESPONSIBILITY OF THE END USER CONSULT THE INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR THE ADJUSTMENT AND MAINTENANCE PROCEDURES

This warranty does not apply to any unit damaged by accident modification misuse negligence or misapplication Damage to heat exchangers by exposure to ammonia any other corrosive substance or sub-freezing environment will be considered misuse

Any air compressors part or material found defective will be repaired replaced or refunded at the sellers option free of charge provided that COAIRE is notified within the above stated warranty period All returns of allegedly defective equipment must have prior written authorization Said authorization may be obtained through our air compressor service department All air compressors parts materials must be returned freight prepaid to the Manufacturerrsquos factory within 30 days of return authorization date Any shipment returned to the factory collect will be refused

If an item is found to be warrantable the repaired item or replacement will be returned normal ground freight prepaid within the continental United States and Canada Expedited shipment costs are the responsibility of the requestor

Any replacement part or material is warranted only to the extent of the remaining warranty period of the air compressor or to the extent as provided by the supplier whichever is longer

Identification Plate The identification plate is located on the side of the air compressor and shows all the primary data of the machine Upon installation fill in the table on the previous page with all the data shown on the identification plate This data should always be referred to when calling the manufacturer or distributor The removal or alteration of the identification plate will void the warranty rights

DISCLAIMER The warranty does not cover any responsibility or liability for direct or indirect damages to persons or equipment caused by improper usage or maintenance and is limited to manufacturing defects only Refer to COAIRE Warranty policy manual for travel mileage and special charge considerations The warranty will be immediately voided if there are changes or alterations to the air compressor

WHO TO CONTACT IF YOU HAVE A WARRANTY CLAIM COAIRE Technologies Corporation Phone (562) 463-3935

Fax (562) 463-4928

All freight damage claims should be filed within 15 working days and should be directed to the carrier

TABLE OF CONTENTS

Chapter Ⅰ General information

1-1 Instruction 1

1-2 Screw compression process 1

1-3 Compressed air flow 2

1-4 Cooling air flow 2

1-5 Oil separation 2

1-6 Oil flow 2

1-7 Oil scavenge flow 2

1-8 Standard Specifications 3

1-9 Installation and wiring 4

Chapter Ⅱ Operating instructions

2-1 Operating panel 8

2-2 Initial start-up 9

2-3 Daily operation 10

2-4 Standard factory settings of control components 11

2-5 Operation and control sequence 12

2-6 Microprocessor Controller 14

Chapter Ⅲ Functional Description

3-1 Compressor air-end 19

3-2 Drive motor 20

3-3 V-Belt drive 20

3-4 Capacity control 20

3-5 Lubrication system 20

3-6 After cooleroil cooler 20

3-7 Oil separator 20

3-8 Oil Filter 20

3-9 Thermostatic Valve 20

3-10 Min Pressure Valve 20

3-11 Air Intake Filter 20

3-12 Instrument Panel 21

3-13 Starter and control box 21

3-14 Safety device 21

Chapter Ⅳ Scheduled Maintenance

4-1 Standard maintenance schedule 22

4-2 Control of lubrication 23

Chapter Ⅴ Trouble shooting

5-1 Trouble symptoms and solutions 25

5-2 Operation record form 26

Chapter Ⅵ Corrective maintenance

6-1 Oil filter 28

6-2 Suction filter 29

6-3 Oil separator element 29

6-4 Oil seal 29

6-5 Min Pressure valve 30

6-6 Suction control valve 30

6-7 Cooling fan 30

6-8 Oil temperature regulating valve 30

6-9 V-Belt 31

6-10 Pressure transmitter 32

6-11 Safety valve 32

Appendix

A Compressor Part List 33

B Parts List 36

C PC Board 44

D Wiring Diagram 45

E Outline Drawing 47

1

CHAPTER I

GENERAL INFORMATION 1-1 INSTRUCTION COAIRE screw air compressor unit is a complete package type driven by an electric motor It is single stage oil injected rotary screw type with all components full piped wired and mounted on a common base it is a very self-contained air compressor package

1-2 SCREW COMPRESSION PROCESS

1-2-1 SUCTION PROCESS Along with the rotation of the rotor air is admitted fully into the void of two rotors through the suction port The void is then isolated from the suction port with the casing wall thereby completing the suction process

Fig 1-1 Suction Process

1-2-2 COMPRESSION PROCESS The air in the void is compressed as the male rotor lobe meshes between the female rotor lobes and squeezes the air against discharge cover

Fig 1-2 Compression Process

1-2-3 OIL INJECTION PROCESS As pressure builds oil is injected into the compression area and onto the bearings and shaft seal serving to lubricate absorb compression heat and seal the rotors

Fig 1-3 Oil Injection Process

1-2-4 DISCHARGE PROCESS Compression continues as the rotor rotates When the void comes to the discharge port provided in the discharge chamber the compressed air is discharged through the port While this process is occurring with one inter-lobe space the other spaces are following the same cycle Therefore air is compressed continuously

Fig 1-4 Discharge Process

2

1-3 COMPRESSED AIR FLOW The panel has an intake duct through which air is drawn into the enclosure Airflows through an air intake filter intake silencer and suction control valve to the air-end suction port Air then is compressed by the rotation of the male rotor and oil is injected into the air-end during compression process The injected oil performs various functions such as sealing cooling as well as lubricating The airoil mixture leaves the air-end through the discharge port and flows into the oil separator where the oil is separated from the compressed air Compressed air leaves the oil separator and is supplied to discharge connection of the unit via minimum pressure valve after-cooler and liquid separator

1-4 COOLING AIR FLOW The air-cooled unit comprises a forced ventilation system with a cooling fan which is driven by an electric motor First the cooling air removes the heat generated from the main motor air end etc The cooling air is then forced into the oil and after-cooler by cooling fan After the heat exchange the hot air flows through the ventilation duct and is exhausted from the ventilation louvers in the panel

1-5 OIL SEPARATION Primary separation Most of the oil is separated from air by the impact at the inner wall of the oil separator and by the fluid cyclonic effect After primary separation the heavy oil falls and is collected in the oil sump at the bottom of the oil separator Secondary separation The air which still contains fine oil particles flows through the oil separator element where the oil forms into large particles and is collected at the bottom of the element shell Then clean air leaves the oil separator 1-6 OIL FLOW The oil which is collected in the oil sump at the bottom of the oil separator is circulated through the lubrication system by the pressure differential existing between the oil separator and the air-end The oil temperature control valve is a bypass valve When the oil is cold the oil bypasses the oil cooler partly or completely and is sent to the oil filter When the oil is hot 185 lsquoF(85rsquoC) or more the oil flows into the oil cooler unless by-pass the compression chamber and lubrication parts of the air-end Oil injected via the internal oil hole is provided into the intermesh among male rotor female rotor and the rotor casing the shaft seal suction side and discharge side bearings 1-7 OIL SCAVENGE FLOW After oil is separated from the air and collected in the element shell of the oil separator it is scavenged to the compression chamber of the air-end by the internal pressure differential so that the oil carry-over in the discharged air can be controlled within the allowable limit

3

M

TS PI

PT

Fig 1-5 Operating flow diagram

1-8 STANDARD SPECIFICATIONS MODEL

ITEM CHSA-75M CHSA-10M CHSA-15M

Motor output Kw(HP) 55(75) 75(10) 11(15) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 290 265 230 385 360 310 570 520 460 Compressor speed RPM 5250 4720 4350 6950 6380 5950 6450 6200 5550 Oil flow rate gpm 40 53 80 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph(1Ph) 208-230V 3Ph 208-230460V Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 07 07 11 Noise level dB(A) 68 70 71 Weight lbs 300 310 420 Dimensions(WtimesDtimesH) in 17times2458x3258 2834x4138x4218 Air outlet piping size in 34rdquo 1rdquo

Air

Cleaner

Solenoid

Valve

Only

15 ~ 30HP

Oil Filter

Oil Cooler

Thermostat

Valve

Oil

Separator

Min

Pressure

After Cooler

Oil Separator

Tank

Symbol PT Pressure Transmitter

TS Temperature Sensor

PI Pressure Indicator

M Motor

4

MODEL

ITEM CHSA-20M CHSA-25M CHSA-30M

Motor output Kw(HP) 15(20) 19(20) 22(30) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 734 680 640 1253 1150 1080 Compressor speed RPM 8280 7900 7500 5700 5380 5160 Oil flow rate gpm 85 119 119 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph 208-230 460 Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 11 13 13 Noise level dB(A) 72 73 73 Weight lbs 450 550 630 Dimensions(WtimesDtimesH) in 2834x4138x4218 3112x4714x4978 Air outlet piping size in 1rdquo 1rdquo

1-9 INSTALLATION AND WIRING Upon delivery carefully check the air compressor unit(s) for damage during transportation 1-9-1 HANDLING When handling by a forklift make sure that forks completely extend through the width of the unit When handling by a shop crane use the openings provided on common base where slings or steel wire ropes can be use for lifting

Fig 1-6 Handling by forklift truck

Fig 1-7 Handling by shop crane

1-9-2 LOCATION The unit should be installed in a dry well ventilated area dust-free environment The unit should not be installed outdoors Consideration must be given to the need for clearance around the unit to avoid the re-circulation of air-end for easy maintenance access

5

(Unit Inch)

Fig 1-8 The space clearance example

CAUTION

- Install the unit in a dust-free room of low humidity and on a level concrete floor

- Never install the unit on timbers or block High humidity may result in electrical shorts and corrosion

- Dust particles containing iron or sand may result in poor resistance of the motor and air-end damage

- A ventilation fan should be provided to keep the ambient temperature 115 or lower

- operation at ambient temperature of higher than 115 may cause compressor shutdown or severe

damage to the unit

HEAT GENERATION amp VENTILATION FAN CAPACITY MODEL

CAPACITY CHSA-75M CHSA-10M CHSA-15M CHSA-20M CHSA-25M CHSA-30M

CAPACITY (Btuh) AIR VOLUME (cfm) 1165 1235 1900 2120 2330 2540 Note 1 The room ventilation capacity is based on (1) Compressor room Temperature rise which is controlled within the 9 (2) Static pressure of ventilation air should be 0 inchWG 2 Consult the distributor for more information on ventilation capacity when the air exhaust duct is installed

A B C D CHSA-75M 24 42 42 24 CHSA-10M 24 42 42 24 CHSA-15M 24 42 42 24 CHSA-20M 42 42 42 24 CHSA-25M 24 42 42 24 CHSA-30M 24 42 42 24

6

1-9-3 PIPING WORK

CAUTION

- All service piping must be installed so as to exert zero force of movement on the system

- A drain valve and isolation valve should be mounted near the compressor discharge section

- Water condensation can affect the operation of pneumatic devices After-coolers and the addition of

air dryers can eliminate this hazard Similarly avoid allowing compressor coolant to enter the plant air

systems Air line separators properly selected and installed will reduce any liquid carry-over

- When installed in parallel operation you must provide an isolation valve and drain trap for each

compressor unit before the common receiver Screw air compressors should not be installed in air

systems with reciprocating compressors without a means of isolation such as a common receiver It

is recommend that both types of compressor units are piped to a common receiver utilizing individual

air lines

- In case of a lead fluctuation or a very small volume in pipe from discharge connection of compressor

unit to the end of the piping the use of air receiver is recommended

- In case the discharge piping has to be unusually long you should select the diameter of the piping in

considering the pressure drop in the piping

- Consult your distributor for proper technical support

Fig 1-9 Parallel installation Fig 1-10 Installation with reciprocating compressor

1-9-4 ELECTRICITY This extensive line of Coaire screw air compressors has been designed to provided all the conveniences of air supply system especially for the stats of the art manufacturing industries These units are composed of compressor motor protection devices and control equipment The applicable voltage range for each unit is given in the electrical data The working voltage among the three phases must be balanced within 2 deviation from each voltage at the compressor terminals Voltage range limit is to be 90~110 of regular voltage described in proportional frequency Unbalance of voltage measured in motor terminals should be within 3 in accordance with the following formula

(V)max - (V)mean ---------------------------- times 100 () (V)mean where (V)max Maximum voltage among three terminals (V)mean Average voltage among three terminals

CAUTION

7

ELECTRICAL WIRING

- Read all related topics in this manual

- Comply to the National Electric Code(NEC) and any other local codes

- Utilize a qualified licensed electrical contractor

1-9-5 ELECTRICAL SPECIFICATION

3 Phase Motor

MODEL

AIR-END MOTOR NO FUSE

BREAKER

OVER

CURRENT

RELAY

MAIN CABLE

OUTPUT

[kWHp]

INPUT

[kW]

POWER[V]

3oslash60Hz

FLA

[A]

LRA[A] POWER

FACTOR

[]

FRAME

[AF]

TRIP

[A]

TRIP

[A]

POWER

[]

KIV

GROUND

[]

GV DIRECT Y-DELTA

CHSA-75M 55975 208 190 708 -

94

230 170 640 - 460 85 320 -

CHSA-10M 74610 208 256 741 -

91

230 232 670 - 460 116 385 -

CHSA-15M 111915 208 387 1371 -

90

230 350 1240 - 460 175 620 -

CHSA-20M 149220

208 520 1680 -

88

230 470 1520 -

460 235 760 -

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

STATEMENT OF WARRANTY TERMS amp CONDITIONS COAIRErsquos screw air compressors are warranted to be free of defects in materials and workmanship under proper use installation and application This warranty shall be for a period of 15 months from date of shipment from our factory or other stocking facilities or 12 months from date of installation Proof of installation date will be required All air compressors outside the US and Canada carry a parts only warranty ALL FREIGHT DAMAGE CLAIMS ARE NOT THE RESPONSIBILITY OF THE MANUFACTURER AND ARE NOT COVERED UNDER WARRANTY AS ALL PRODUCTS ARE SHIPPED FOB SHIPPER

PLEASE DIRECT ALL FREIGHT CLAIMS TO THE SHIPPER IN QUESTION

MAINTENANCE AND ADJUSTMENTS

ADJUSTMENTS PRESSURE SETTINGS AND MAINTENANCE OF FLOAT AND AUTOMATIC DRAINS AND OIL COOLER COILS ARE CONSIDERED TO BE ROUTINE MAINTENANCE AND THEREFORE NON-WARRANTABLE ITEMS AND ARE THE SOLE RESPONSIBILITY OF THE END USER CONSULT THE INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR THE ADJUSTMENT AND MAINTENANCE PROCEDURES

This warranty does not apply to any unit damaged by accident modification misuse negligence or misapplication Damage to heat exchangers by exposure to ammonia any other corrosive substance or sub-freezing environment will be considered misuse

Any air compressors part or material found defective will be repaired replaced or refunded at the sellers option free of charge provided that COAIRE is notified within the above stated warranty period All returns of allegedly defective equipment must have prior written authorization Said authorization may be obtained through our air compressor service department All air compressors parts materials must be returned freight prepaid to the Manufacturerrsquos factory within 30 days of return authorization date Any shipment returned to the factory collect will be refused

If an item is found to be warrantable the repaired item or replacement will be returned normal ground freight prepaid within the continental United States and Canada Expedited shipment costs are the responsibility of the requestor

Any replacement part or material is warranted only to the extent of the remaining warranty period of the air compressor or to the extent as provided by the supplier whichever is longer

Identification Plate The identification plate is located on the side of the air compressor and shows all the primary data of the machine Upon installation fill in the table on the previous page with all the data shown on the identification plate This data should always be referred to when calling the manufacturer or distributor The removal or alteration of the identification plate will void the warranty rights

DISCLAIMER The warranty does not cover any responsibility or liability for direct or indirect damages to persons or equipment caused by improper usage or maintenance and is limited to manufacturing defects only Refer to COAIRE Warranty policy manual for travel mileage and special charge considerations The warranty will be immediately voided if there are changes or alterations to the air compressor

WHO TO CONTACT IF YOU HAVE A WARRANTY CLAIM COAIRE Technologies Corporation Phone (562) 463-3935

Fax (562) 463-4928

All freight damage claims should be filed within 15 working days and should be directed to the carrier

TABLE OF CONTENTS

Chapter Ⅰ General information

1-1 Instruction 1

1-2 Screw compression process 1

1-3 Compressed air flow 2

1-4 Cooling air flow 2

1-5 Oil separation 2

1-6 Oil flow 2

1-7 Oil scavenge flow 2

1-8 Standard Specifications 3

1-9 Installation and wiring 4

Chapter Ⅱ Operating instructions

2-1 Operating panel 8

2-2 Initial start-up 9

2-3 Daily operation 10

2-4 Standard factory settings of control components 11

2-5 Operation and control sequence 12

2-6 Microprocessor Controller 14

Chapter Ⅲ Functional Description

3-1 Compressor air-end 19

3-2 Drive motor 20

3-3 V-Belt drive 20

3-4 Capacity control 20

3-5 Lubrication system 20

3-6 After cooleroil cooler 20

3-7 Oil separator 20

3-8 Oil Filter 20

3-9 Thermostatic Valve 20

3-10 Min Pressure Valve 20

3-11 Air Intake Filter 20

3-12 Instrument Panel 21

3-13 Starter and control box 21

3-14 Safety device 21

Chapter Ⅳ Scheduled Maintenance

4-1 Standard maintenance schedule 22

4-2 Control of lubrication 23

Chapter Ⅴ Trouble shooting

5-1 Trouble symptoms and solutions 25

5-2 Operation record form 26

Chapter Ⅵ Corrective maintenance

6-1 Oil filter 28

6-2 Suction filter 29

6-3 Oil separator element 29

6-4 Oil seal 29

6-5 Min Pressure valve 30

6-6 Suction control valve 30

6-7 Cooling fan 30

6-8 Oil temperature regulating valve 30

6-9 V-Belt 31

6-10 Pressure transmitter 32

6-11 Safety valve 32

Appendix

A Compressor Part List 33

B Parts List 36

C PC Board 44

D Wiring Diagram 45

E Outline Drawing 47

1

CHAPTER I

GENERAL INFORMATION 1-1 INSTRUCTION COAIRE screw air compressor unit is a complete package type driven by an electric motor It is single stage oil injected rotary screw type with all components full piped wired and mounted on a common base it is a very self-contained air compressor package

1-2 SCREW COMPRESSION PROCESS

1-2-1 SUCTION PROCESS Along with the rotation of the rotor air is admitted fully into the void of two rotors through the suction port The void is then isolated from the suction port with the casing wall thereby completing the suction process

Fig 1-1 Suction Process

1-2-2 COMPRESSION PROCESS The air in the void is compressed as the male rotor lobe meshes between the female rotor lobes and squeezes the air against discharge cover

Fig 1-2 Compression Process

1-2-3 OIL INJECTION PROCESS As pressure builds oil is injected into the compression area and onto the bearings and shaft seal serving to lubricate absorb compression heat and seal the rotors

Fig 1-3 Oil Injection Process

1-2-4 DISCHARGE PROCESS Compression continues as the rotor rotates When the void comes to the discharge port provided in the discharge chamber the compressed air is discharged through the port While this process is occurring with one inter-lobe space the other spaces are following the same cycle Therefore air is compressed continuously

Fig 1-4 Discharge Process

2

1-3 COMPRESSED AIR FLOW The panel has an intake duct through which air is drawn into the enclosure Airflows through an air intake filter intake silencer and suction control valve to the air-end suction port Air then is compressed by the rotation of the male rotor and oil is injected into the air-end during compression process The injected oil performs various functions such as sealing cooling as well as lubricating The airoil mixture leaves the air-end through the discharge port and flows into the oil separator where the oil is separated from the compressed air Compressed air leaves the oil separator and is supplied to discharge connection of the unit via minimum pressure valve after-cooler and liquid separator

1-4 COOLING AIR FLOW The air-cooled unit comprises a forced ventilation system with a cooling fan which is driven by an electric motor First the cooling air removes the heat generated from the main motor air end etc The cooling air is then forced into the oil and after-cooler by cooling fan After the heat exchange the hot air flows through the ventilation duct and is exhausted from the ventilation louvers in the panel

1-5 OIL SEPARATION Primary separation Most of the oil is separated from air by the impact at the inner wall of the oil separator and by the fluid cyclonic effect After primary separation the heavy oil falls and is collected in the oil sump at the bottom of the oil separator Secondary separation The air which still contains fine oil particles flows through the oil separator element where the oil forms into large particles and is collected at the bottom of the element shell Then clean air leaves the oil separator 1-6 OIL FLOW The oil which is collected in the oil sump at the bottom of the oil separator is circulated through the lubrication system by the pressure differential existing between the oil separator and the air-end The oil temperature control valve is a bypass valve When the oil is cold the oil bypasses the oil cooler partly or completely and is sent to the oil filter When the oil is hot 185 lsquoF(85rsquoC) or more the oil flows into the oil cooler unless by-pass the compression chamber and lubrication parts of the air-end Oil injected via the internal oil hole is provided into the intermesh among male rotor female rotor and the rotor casing the shaft seal suction side and discharge side bearings 1-7 OIL SCAVENGE FLOW After oil is separated from the air and collected in the element shell of the oil separator it is scavenged to the compression chamber of the air-end by the internal pressure differential so that the oil carry-over in the discharged air can be controlled within the allowable limit

3

M

TS PI

PT

Fig 1-5 Operating flow diagram

1-8 STANDARD SPECIFICATIONS MODEL

ITEM CHSA-75M CHSA-10M CHSA-15M

Motor output Kw(HP) 55(75) 75(10) 11(15) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 290 265 230 385 360 310 570 520 460 Compressor speed RPM 5250 4720 4350 6950 6380 5950 6450 6200 5550 Oil flow rate gpm 40 53 80 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph(1Ph) 208-230V 3Ph 208-230460V Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 07 07 11 Noise level dB(A) 68 70 71 Weight lbs 300 310 420 Dimensions(WtimesDtimesH) in 17times2458x3258 2834x4138x4218 Air outlet piping size in 34rdquo 1rdquo

Air

Cleaner

Solenoid

Valve

Only

15 ~ 30HP

Oil Filter

Oil Cooler

Thermostat

Valve

Oil

Separator

Min

Pressure

After Cooler

Oil Separator

Tank

Symbol PT Pressure Transmitter

TS Temperature Sensor

PI Pressure Indicator

M Motor

4

MODEL

ITEM CHSA-20M CHSA-25M CHSA-30M

Motor output Kw(HP) 15(20) 19(20) 22(30) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 734 680 640 1253 1150 1080 Compressor speed RPM 8280 7900 7500 5700 5380 5160 Oil flow rate gpm 85 119 119 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph 208-230 460 Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 11 13 13 Noise level dB(A) 72 73 73 Weight lbs 450 550 630 Dimensions(WtimesDtimesH) in 2834x4138x4218 3112x4714x4978 Air outlet piping size in 1rdquo 1rdquo

1-9 INSTALLATION AND WIRING Upon delivery carefully check the air compressor unit(s) for damage during transportation 1-9-1 HANDLING When handling by a forklift make sure that forks completely extend through the width of the unit When handling by a shop crane use the openings provided on common base where slings or steel wire ropes can be use for lifting

Fig 1-6 Handling by forklift truck

Fig 1-7 Handling by shop crane

1-9-2 LOCATION The unit should be installed in a dry well ventilated area dust-free environment The unit should not be installed outdoors Consideration must be given to the need for clearance around the unit to avoid the re-circulation of air-end for easy maintenance access

5

(Unit Inch)

Fig 1-8 The space clearance example

CAUTION

- Install the unit in a dust-free room of low humidity and on a level concrete floor

- Never install the unit on timbers or block High humidity may result in electrical shorts and corrosion

- Dust particles containing iron or sand may result in poor resistance of the motor and air-end damage

- A ventilation fan should be provided to keep the ambient temperature 115 or lower

- operation at ambient temperature of higher than 115 may cause compressor shutdown or severe

damage to the unit

HEAT GENERATION amp VENTILATION FAN CAPACITY MODEL

CAPACITY CHSA-75M CHSA-10M CHSA-15M CHSA-20M CHSA-25M CHSA-30M

CAPACITY (Btuh) AIR VOLUME (cfm) 1165 1235 1900 2120 2330 2540 Note 1 The room ventilation capacity is based on (1) Compressor room Temperature rise which is controlled within the 9 (2) Static pressure of ventilation air should be 0 inchWG 2 Consult the distributor for more information on ventilation capacity when the air exhaust duct is installed

A B C D CHSA-75M 24 42 42 24 CHSA-10M 24 42 42 24 CHSA-15M 24 42 42 24 CHSA-20M 42 42 42 24 CHSA-25M 24 42 42 24 CHSA-30M 24 42 42 24

6

1-9-3 PIPING WORK

CAUTION

- All service piping must be installed so as to exert zero force of movement on the system

- A drain valve and isolation valve should be mounted near the compressor discharge section

- Water condensation can affect the operation of pneumatic devices After-coolers and the addition of

air dryers can eliminate this hazard Similarly avoid allowing compressor coolant to enter the plant air

systems Air line separators properly selected and installed will reduce any liquid carry-over

- When installed in parallel operation you must provide an isolation valve and drain trap for each

compressor unit before the common receiver Screw air compressors should not be installed in air

systems with reciprocating compressors without a means of isolation such as a common receiver It

is recommend that both types of compressor units are piped to a common receiver utilizing individual

air lines

- In case of a lead fluctuation or a very small volume in pipe from discharge connection of compressor

unit to the end of the piping the use of air receiver is recommended

- In case the discharge piping has to be unusually long you should select the diameter of the piping in

considering the pressure drop in the piping

- Consult your distributor for proper technical support

Fig 1-9 Parallel installation Fig 1-10 Installation with reciprocating compressor

1-9-4 ELECTRICITY This extensive line of Coaire screw air compressors has been designed to provided all the conveniences of air supply system especially for the stats of the art manufacturing industries These units are composed of compressor motor protection devices and control equipment The applicable voltage range for each unit is given in the electrical data The working voltage among the three phases must be balanced within 2 deviation from each voltage at the compressor terminals Voltage range limit is to be 90~110 of regular voltage described in proportional frequency Unbalance of voltage measured in motor terminals should be within 3 in accordance with the following formula

(V)max - (V)mean ---------------------------- times 100 () (V)mean where (V)max Maximum voltage among three terminals (V)mean Average voltage among three terminals

CAUTION

7

ELECTRICAL WIRING

- Read all related topics in this manual

- Comply to the National Electric Code(NEC) and any other local codes

- Utilize a qualified licensed electrical contractor

1-9-5 ELECTRICAL SPECIFICATION

3 Phase Motor

MODEL

AIR-END MOTOR NO FUSE

BREAKER

OVER

CURRENT

RELAY

MAIN CABLE

OUTPUT

[kWHp]

INPUT

[kW]

POWER[V]

3oslash60Hz

FLA

[A]

LRA[A] POWER

FACTOR

[]

FRAME

[AF]

TRIP

[A]

TRIP

[A]

POWER

[]

KIV

GROUND

[]

GV DIRECT Y-DELTA

CHSA-75M 55975 208 190 708 -

94

230 170 640 - 460 85 320 -

CHSA-10M 74610 208 256 741 -

91

230 232 670 - 460 116 385 -

CHSA-15M 111915 208 387 1371 -

90

230 350 1240 - 460 175 620 -

CHSA-20M 149220

208 520 1680 -

88

230 470 1520 -

460 235 760 -

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

TABLE OF CONTENTS

Chapter Ⅰ General information

1-1 Instruction 1

1-2 Screw compression process 1

1-3 Compressed air flow 2

1-4 Cooling air flow 2

1-5 Oil separation 2

1-6 Oil flow 2

1-7 Oil scavenge flow 2

1-8 Standard Specifications 3

1-9 Installation and wiring 4

Chapter Ⅱ Operating instructions

2-1 Operating panel 8

2-2 Initial start-up 9

2-3 Daily operation 10

2-4 Standard factory settings of control components 11

2-5 Operation and control sequence 12

2-6 Microprocessor Controller 14

Chapter Ⅲ Functional Description

3-1 Compressor air-end 19

3-2 Drive motor 20

3-3 V-Belt drive 20

3-4 Capacity control 20

3-5 Lubrication system 20

3-6 After cooleroil cooler 20

3-7 Oil separator 20

3-8 Oil Filter 20

3-9 Thermostatic Valve 20

3-10 Min Pressure Valve 20

3-11 Air Intake Filter 20

3-12 Instrument Panel 21

3-13 Starter and control box 21

3-14 Safety device 21

Chapter Ⅳ Scheduled Maintenance

4-1 Standard maintenance schedule 22

4-2 Control of lubrication 23

Chapter Ⅴ Trouble shooting

5-1 Trouble symptoms and solutions 25

5-2 Operation record form 26

Chapter Ⅵ Corrective maintenance

6-1 Oil filter 28

6-2 Suction filter 29

6-3 Oil separator element 29

6-4 Oil seal 29

6-5 Min Pressure valve 30

6-6 Suction control valve 30

6-7 Cooling fan 30

6-8 Oil temperature regulating valve 30

6-9 V-Belt 31

6-10 Pressure transmitter 32

6-11 Safety valve 32

Appendix

A Compressor Part List 33

B Parts List 36

C PC Board 44

D Wiring Diagram 45

E Outline Drawing 47

1

CHAPTER I

GENERAL INFORMATION 1-1 INSTRUCTION COAIRE screw air compressor unit is a complete package type driven by an electric motor It is single stage oil injected rotary screw type with all components full piped wired and mounted on a common base it is a very self-contained air compressor package

1-2 SCREW COMPRESSION PROCESS

1-2-1 SUCTION PROCESS Along with the rotation of the rotor air is admitted fully into the void of two rotors through the suction port The void is then isolated from the suction port with the casing wall thereby completing the suction process

Fig 1-1 Suction Process

1-2-2 COMPRESSION PROCESS The air in the void is compressed as the male rotor lobe meshes between the female rotor lobes and squeezes the air against discharge cover

Fig 1-2 Compression Process

1-2-3 OIL INJECTION PROCESS As pressure builds oil is injected into the compression area and onto the bearings and shaft seal serving to lubricate absorb compression heat and seal the rotors

Fig 1-3 Oil Injection Process

1-2-4 DISCHARGE PROCESS Compression continues as the rotor rotates When the void comes to the discharge port provided in the discharge chamber the compressed air is discharged through the port While this process is occurring with one inter-lobe space the other spaces are following the same cycle Therefore air is compressed continuously

Fig 1-4 Discharge Process

2

1-3 COMPRESSED AIR FLOW The panel has an intake duct through which air is drawn into the enclosure Airflows through an air intake filter intake silencer and suction control valve to the air-end suction port Air then is compressed by the rotation of the male rotor and oil is injected into the air-end during compression process The injected oil performs various functions such as sealing cooling as well as lubricating The airoil mixture leaves the air-end through the discharge port and flows into the oil separator where the oil is separated from the compressed air Compressed air leaves the oil separator and is supplied to discharge connection of the unit via minimum pressure valve after-cooler and liquid separator

1-4 COOLING AIR FLOW The air-cooled unit comprises a forced ventilation system with a cooling fan which is driven by an electric motor First the cooling air removes the heat generated from the main motor air end etc The cooling air is then forced into the oil and after-cooler by cooling fan After the heat exchange the hot air flows through the ventilation duct and is exhausted from the ventilation louvers in the panel

1-5 OIL SEPARATION Primary separation Most of the oil is separated from air by the impact at the inner wall of the oil separator and by the fluid cyclonic effect After primary separation the heavy oil falls and is collected in the oil sump at the bottom of the oil separator Secondary separation The air which still contains fine oil particles flows through the oil separator element where the oil forms into large particles and is collected at the bottom of the element shell Then clean air leaves the oil separator 1-6 OIL FLOW The oil which is collected in the oil sump at the bottom of the oil separator is circulated through the lubrication system by the pressure differential existing between the oil separator and the air-end The oil temperature control valve is a bypass valve When the oil is cold the oil bypasses the oil cooler partly or completely and is sent to the oil filter When the oil is hot 185 lsquoF(85rsquoC) or more the oil flows into the oil cooler unless by-pass the compression chamber and lubrication parts of the air-end Oil injected via the internal oil hole is provided into the intermesh among male rotor female rotor and the rotor casing the shaft seal suction side and discharge side bearings 1-7 OIL SCAVENGE FLOW After oil is separated from the air and collected in the element shell of the oil separator it is scavenged to the compression chamber of the air-end by the internal pressure differential so that the oil carry-over in the discharged air can be controlled within the allowable limit

3

M

TS PI

PT

Fig 1-5 Operating flow diagram

1-8 STANDARD SPECIFICATIONS MODEL

ITEM CHSA-75M CHSA-10M CHSA-15M

Motor output Kw(HP) 55(75) 75(10) 11(15) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 290 265 230 385 360 310 570 520 460 Compressor speed RPM 5250 4720 4350 6950 6380 5950 6450 6200 5550 Oil flow rate gpm 40 53 80 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph(1Ph) 208-230V 3Ph 208-230460V Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 07 07 11 Noise level dB(A) 68 70 71 Weight lbs 300 310 420 Dimensions(WtimesDtimesH) in 17times2458x3258 2834x4138x4218 Air outlet piping size in 34rdquo 1rdquo

Air

Cleaner

Solenoid

Valve

Only

15 ~ 30HP

Oil Filter

Oil Cooler

Thermostat

Valve

Oil

Separator

Min

Pressure

After Cooler

Oil Separator

Tank

Symbol PT Pressure Transmitter

TS Temperature Sensor

PI Pressure Indicator

M Motor

4

MODEL

ITEM CHSA-20M CHSA-25M CHSA-30M

Motor output Kw(HP) 15(20) 19(20) 22(30) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 734 680 640 1253 1150 1080 Compressor speed RPM 8280 7900 7500 5700 5380 5160 Oil flow rate gpm 85 119 119 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph 208-230 460 Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 11 13 13 Noise level dB(A) 72 73 73 Weight lbs 450 550 630 Dimensions(WtimesDtimesH) in 2834x4138x4218 3112x4714x4978 Air outlet piping size in 1rdquo 1rdquo

1-9 INSTALLATION AND WIRING Upon delivery carefully check the air compressor unit(s) for damage during transportation 1-9-1 HANDLING When handling by a forklift make sure that forks completely extend through the width of the unit When handling by a shop crane use the openings provided on common base where slings or steel wire ropes can be use for lifting

Fig 1-6 Handling by forklift truck

Fig 1-7 Handling by shop crane

1-9-2 LOCATION The unit should be installed in a dry well ventilated area dust-free environment The unit should not be installed outdoors Consideration must be given to the need for clearance around the unit to avoid the re-circulation of air-end for easy maintenance access

5

(Unit Inch)

Fig 1-8 The space clearance example

CAUTION

- Install the unit in a dust-free room of low humidity and on a level concrete floor

- Never install the unit on timbers or block High humidity may result in electrical shorts and corrosion

- Dust particles containing iron or sand may result in poor resistance of the motor and air-end damage

- A ventilation fan should be provided to keep the ambient temperature 115 or lower

- operation at ambient temperature of higher than 115 may cause compressor shutdown or severe

damage to the unit

HEAT GENERATION amp VENTILATION FAN CAPACITY MODEL

CAPACITY CHSA-75M CHSA-10M CHSA-15M CHSA-20M CHSA-25M CHSA-30M

CAPACITY (Btuh) AIR VOLUME (cfm) 1165 1235 1900 2120 2330 2540 Note 1 The room ventilation capacity is based on (1) Compressor room Temperature rise which is controlled within the 9 (2) Static pressure of ventilation air should be 0 inchWG 2 Consult the distributor for more information on ventilation capacity when the air exhaust duct is installed

A B C D CHSA-75M 24 42 42 24 CHSA-10M 24 42 42 24 CHSA-15M 24 42 42 24 CHSA-20M 42 42 42 24 CHSA-25M 24 42 42 24 CHSA-30M 24 42 42 24

6

1-9-3 PIPING WORK

CAUTION

- All service piping must be installed so as to exert zero force of movement on the system

- A drain valve and isolation valve should be mounted near the compressor discharge section

- Water condensation can affect the operation of pneumatic devices After-coolers and the addition of

air dryers can eliminate this hazard Similarly avoid allowing compressor coolant to enter the plant air

systems Air line separators properly selected and installed will reduce any liquid carry-over

- When installed in parallel operation you must provide an isolation valve and drain trap for each

compressor unit before the common receiver Screw air compressors should not be installed in air

systems with reciprocating compressors without a means of isolation such as a common receiver It

is recommend that both types of compressor units are piped to a common receiver utilizing individual

air lines

- In case of a lead fluctuation or a very small volume in pipe from discharge connection of compressor

unit to the end of the piping the use of air receiver is recommended

- In case the discharge piping has to be unusually long you should select the diameter of the piping in

considering the pressure drop in the piping

- Consult your distributor for proper technical support

Fig 1-9 Parallel installation Fig 1-10 Installation with reciprocating compressor

1-9-4 ELECTRICITY This extensive line of Coaire screw air compressors has been designed to provided all the conveniences of air supply system especially for the stats of the art manufacturing industries These units are composed of compressor motor protection devices and control equipment The applicable voltage range for each unit is given in the electrical data The working voltage among the three phases must be balanced within 2 deviation from each voltage at the compressor terminals Voltage range limit is to be 90~110 of regular voltage described in proportional frequency Unbalance of voltage measured in motor terminals should be within 3 in accordance with the following formula

(V)max - (V)mean ---------------------------- times 100 () (V)mean where (V)max Maximum voltage among three terminals (V)mean Average voltage among three terminals

CAUTION

7

ELECTRICAL WIRING

- Read all related topics in this manual

- Comply to the National Electric Code(NEC) and any other local codes

- Utilize a qualified licensed electrical contractor

1-9-5 ELECTRICAL SPECIFICATION

3 Phase Motor

MODEL

AIR-END MOTOR NO FUSE

BREAKER

OVER

CURRENT

RELAY

MAIN CABLE

OUTPUT

[kWHp]

INPUT

[kW]

POWER[V]

3oslash60Hz

FLA

[A]

LRA[A] POWER

FACTOR

[]

FRAME

[AF]

TRIP

[A]

TRIP

[A]

POWER

[]

KIV

GROUND

[]

GV DIRECT Y-DELTA

CHSA-75M 55975 208 190 708 -

94

230 170 640 - 460 85 320 -

CHSA-10M 74610 208 256 741 -

91

230 232 670 - 460 116 385 -

CHSA-15M 111915 208 387 1371 -

90

230 350 1240 - 460 175 620 -

CHSA-20M 149220

208 520 1680 -

88

230 470 1520 -

460 235 760 -

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

1

CHAPTER I

GENERAL INFORMATION 1-1 INSTRUCTION COAIRE screw air compressor unit is a complete package type driven by an electric motor It is single stage oil injected rotary screw type with all components full piped wired and mounted on a common base it is a very self-contained air compressor package

1-2 SCREW COMPRESSION PROCESS

1-2-1 SUCTION PROCESS Along with the rotation of the rotor air is admitted fully into the void of two rotors through the suction port The void is then isolated from the suction port with the casing wall thereby completing the suction process

Fig 1-1 Suction Process

1-2-2 COMPRESSION PROCESS The air in the void is compressed as the male rotor lobe meshes between the female rotor lobes and squeezes the air against discharge cover

Fig 1-2 Compression Process

1-2-3 OIL INJECTION PROCESS As pressure builds oil is injected into the compression area and onto the bearings and shaft seal serving to lubricate absorb compression heat and seal the rotors

Fig 1-3 Oil Injection Process

1-2-4 DISCHARGE PROCESS Compression continues as the rotor rotates When the void comes to the discharge port provided in the discharge chamber the compressed air is discharged through the port While this process is occurring with one inter-lobe space the other spaces are following the same cycle Therefore air is compressed continuously

Fig 1-4 Discharge Process

2

1-3 COMPRESSED AIR FLOW The panel has an intake duct through which air is drawn into the enclosure Airflows through an air intake filter intake silencer and suction control valve to the air-end suction port Air then is compressed by the rotation of the male rotor and oil is injected into the air-end during compression process The injected oil performs various functions such as sealing cooling as well as lubricating The airoil mixture leaves the air-end through the discharge port and flows into the oil separator where the oil is separated from the compressed air Compressed air leaves the oil separator and is supplied to discharge connection of the unit via minimum pressure valve after-cooler and liquid separator

1-4 COOLING AIR FLOW The air-cooled unit comprises a forced ventilation system with a cooling fan which is driven by an electric motor First the cooling air removes the heat generated from the main motor air end etc The cooling air is then forced into the oil and after-cooler by cooling fan After the heat exchange the hot air flows through the ventilation duct and is exhausted from the ventilation louvers in the panel

1-5 OIL SEPARATION Primary separation Most of the oil is separated from air by the impact at the inner wall of the oil separator and by the fluid cyclonic effect After primary separation the heavy oil falls and is collected in the oil sump at the bottom of the oil separator Secondary separation The air which still contains fine oil particles flows through the oil separator element where the oil forms into large particles and is collected at the bottom of the element shell Then clean air leaves the oil separator 1-6 OIL FLOW The oil which is collected in the oil sump at the bottom of the oil separator is circulated through the lubrication system by the pressure differential existing between the oil separator and the air-end The oil temperature control valve is a bypass valve When the oil is cold the oil bypasses the oil cooler partly or completely and is sent to the oil filter When the oil is hot 185 lsquoF(85rsquoC) or more the oil flows into the oil cooler unless by-pass the compression chamber and lubrication parts of the air-end Oil injected via the internal oil hole is provided into the intermesh among male rotor female rotor and the rotor casing the shaft seal suction side and discharge side bearings 1-7 OIL SCAVENGE FLOW After oil is separated from the air and collected in the element shell of the oil separator it is scavenged to the compression chamber of the air-end by the internal pressure differential so that the oil carry-over in the discharged air can be controlled within the allowable limit

3

M

TS PI

PT

Fig 1-5 Operating flow diagram

1-8 STANDARD SPECIFICATIONS MODEL

ITEM CHSA-75M CHSA-10M CHSA-15M

Motor output Kw(HP) 55(75) 75(10) 11(15) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 290 265 230 385 360 310 570 520 460 Compressor speed RPM 5250 4720 4350 6950 6380 5950 6450 6200 5550 Oil flow rate gpm 40 53 80 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph(1Ph) 208-230V 3Ph 208-230460V Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 07 07 11 Noise level dB(A) 68 70 71 Weight lbs 300 310 420 Dimensions(WtimesDtimesH) in 17times2458x3258 2834x4138x4218 Air outlet piping size in 34rdquo 1rdquo

Air

Cleaner

Solenoid

Valve

Only

15 ~ 30HP

Oil Filter

Oil Cooler

Thermostat

Valve

Oil

Separator

Min

Pressure

After Cooler

Oil Separator

Tank

Symbol PT Pressure Transmitter

TS Temperature Sensor

PI Pressure Indicator

M Motor

4

MODEL

ITEM CHSA-20M CHSA-25M CHSA-30M

Motor output Kw(HP) 15(20) 19(20) 22(30) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 734 680 640 1253 1150 1080 Compressor speed RPM 8280 7900 7500 5700 5380 5160 Oil flow rate gpm 85 119 119 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph 208-230 460 Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 11 13 13 Noise level dB(A) 72 73 73 Weight lbs 450 550 630 Dimensions(WtimesDtimesH) in 2834x4138x4218 3112x4714x4978 Air outlet piping size in 1rdquo 1rdquo

1-9 INSTALLATION AND WIRING Upon delivery carefully check the air compressor unit(s) for damage during transportation 1-9-1 HANDLING When handling by a forklift make sure that forks completely extend through the width of the unit When handling by a shop crane use the openings provided on common base where slings or steel wire ropes can be use for lifting

Fig 1-6 Handling by forklift truck

Fig 1-7 Handling by shop crane

1-9-2 LOCATION The unit should be installed in a dry well ventilated area dust-free environment The unit should not be installed outdoors Consideration must be given to the need for clearance around the unit to avoid the re-circulation of air-end for easy maintenance access

5

(Unit Inch)

Fig 1-8 The space clearance example

CAUTION

- Install the unit in a dust-free room of low humidity and on a level concrete floor

- Never install the unit on timbers or block High humidity may result in electrical shorts and corrosion

- Dust particles containing iron or sand may result in poor resistance of the motor and air-end damage

- A ventilation fan should be provided to keep the ambient temperature 115 or lower

- operation at ambient temperature of higher than 115 may cause compressor shutdown or severe

damage to the unit

HEAT GENERATION amp VENTILATION FAN CAPACITY MODEL

CAPACITY CHSA-75M CHSA-10M CHSA-15M CHSA-20M CHSA-25M CHSA-30M

CAPACITY (Btuh) AIR VOLUME (cfm) 1165 1235 1900 2120 2330 2540 Note 1 The room ventilation capacity is based on (1) Compressor room Temperature rise which is controlled within the 9 (2) Static pressure of ventilation air should be 0 inchWG 2 Consult the distributor for more information on ventilation capacity when the air exhaust duct is installed

A B C D CHSA-75M 24 42 42 24 CHSA-10M 24 42 42 24 CHSA-15M 24 42 42 24 CHSA-20M 42 42 42 24 CHSA-25M 24 42 42 24 CHSA-30M 24 42 42 24

6

1-9-3 PIPING WORK

CAUTION

- All service piping must be installed so as to exert zero force of movement on the system

- A drain valve and isolation valve should be mounted near the compressor discharge section

- Water condensation can affect the operation of pneumatic devices After-coolers and the addition of

air dryers can eliminate this hazard Similarly avoid allowing compressor coolant to enter the plant air

systems Air line separators properly selected and installed will reduce any liquid carry-over

- When installed in parallel operation you must provide an isolation valve and drain trap for each

compressor unit before the common receiver Screw air compressors should not be installed in air

systems with reciprocating compressors without a means of isolation such as a common receiver It

is recommend that both types of compressor units are piped to a common receiver utilizing individual

air lines

- In case of a lead fluctuation or a very small volume in pipe from discharge connection of compressor

unit to the end of the piping the use of air receiver is recommended

- In case the discharge piping has to be unusually long you should select the diameter of the piping in

considering the pressure drop in the piping

- Consult your distributor for proper technical support

Fig 1-9 Parallel installation Fig 1-10 Installation with reciprocating compressor

1-9-4 ELECTRICITY This extensive line of Coaire screw air compressors has been designed to provided all the conveniences of air supply system especially for the stats of the art manufacturing industries These units are composed of compressor motor protection devices and control equipment The applicable voltage range for each unit is given in the electrical data The working voltage among the three phases must be balanced within 2 deviation from each voltage at the compressor terminals Voltage range limit is to be 90~110 of regular voltage described in proportional frequency Unbalance of voltage measured in motor terminals should be within 3 in accordance with the following formula

(V)max - (V)mean ---------------------------- times 100 () (V)mean where (V)max Maximum voltage among three terminals (V)mean Average voltage among three terminals

CAUTION

7

ELECTRICAL WIRING

- Read all related topics in this manual

- Comply to the National Electric Code(NEC) and any other local codes

- Utilize a qualified licensed electrical contractor

1-9-5 ELECTRICAL SPECIFICATION

3 Phase Motor

MODEL

AIR-END MOTOR NO FUSE

BREAKER

OVER

CURRENT

RELAY

MAIN CABLE

OUTPUT

[kWHp]

INPUT

[kW]

POWER[V]

3oslash60Hz

FLA

[A]

LRA[A] POWER

FACTOR

[]

FRAME

[AF]

TRIP

[A]

TRIP

[A]

POWER

[]

KIV

GROUND

[]

GV DIRECT Y-DELTA

CHSA-75M 55975 208 190 708 -

94

230 170 640 - 460 85 320 -

CHSA-10M 74610 208 256 741 -

91

230 232 670 - 460 116 385 -

CHSA-15M 111915 208 387 1371 -

90

230 350 1240 - 460 175 620 -

CHSA-20M 149220

208 520 1680 -

88

230 470 1520 -

460 235 760 -

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

2

1-3 COMPRESSED AIR FLOW The panel has an intake duct through which air is drawn into the enclosure Airflows through an air intake filter intake silencer and suction control valve to the air-end suction port Air then is compressed by the rotation of the male rotor and oil is injected into the air-end during compression process The injected oil performs various functions such as sealing cooling as well as lubricating The airoil mixture leaves the air-end through the discharge port and flows into the oil separator where the oil is separated from the compressed air Compressed air leaves the oil separator and is supplied to discharge connection of the unit via minimum pressure valve after-cooler and liquid separator

1-4 COOLING AIR FLOW The air-cooled unit comprises a forced ventilation system with a cooling fan which is driven by an electric motor First the cooling air removes the heat generated from the main motor air end etc The cooling air is then forced into the oil and after-cooler by cooling fan After the heat exchange the hot air flows through the ventilation duct and is exhausted from the ventilation louvers in the panel

1-5 OIL SEPARATION Primary separation Most of the oil is separated from air by the impact at the inner wall of the oil separator and by the fluid cyclonic effect After primary separation the heavy oil falls and is collected in the oil sump at the bottom of the oil separator Secondary separation The air which still contains fine oil particles flows through the oil separator element where the oil forms into large particles and is collected at the bottom of the element shell Then clean air leaves the oil separator 1-6 OIL FLOW The oil which is collected in the oil sump at the bottom of the oil separator is circulated through the lubrication system by the pressure differential existing between the oil separator and the air-end The oil temperature control valve is a bypass valve When the oil is cold the oil bypasses the oil cooler partly or completely and is sent to the oil filter When the oil is hot 185 lsquoF(85rsquoC) or more the oil flows into the oil cooler unless by-pass the compression chamber and lubrication parts of the air-end Oil injected via the internal oil hole is provided into the intermesh among male rotor female rotor and the rotor casing the shaft seal suction side and discharge side bearings 1-7 OIL SCAVENGE FLOW After oil is separated from the air and collected in the element shell of the oil separator it is scavenged to the compression chamber of the air-end by the internal pressure differential so that the oil carry-over in the discharged air can be controlled within the allowable limit

3

M

TS PI

PT

Fig 1-5 Operating flow diagram

1-8 STANDARD SPECIFICATIONS MODEL

ITEM CHSA-75M CHSA-10M CHSA-15M

Motor output Kw(HP) 55(75) 75(10) 11(15) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 290 265 230 385 360 310 570 520 460 Compressor speed RPM 5250 4720 4350 6950 6380 5950 6450 6200 5550 Oil flow rate gpm 40 53 80 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph(1Ph) 208-230V 3Ph 208-230460V Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 07 07 11 Noise level dB(A) 68 70 71 Weight lbs 300 310 420 Dimensions(WtimesDtimesH) in 17times2458x3258 2834x4138x4218 Air outlet piping size in 34rdquo 1rdquo

Air

Cleaner

Solenoid

Valve

Only

15 ~ 30HP

Oil Filter

Oil Cooler

Thermostat

Valve

Oil

Separator

Min

Pressure

After Cooler

Oil Separator

Tank

Symbol PT Pressure Transmitter

TS Temperature Sensor

PI Pressure Indicator

M Motor

4

MODEL

ITEM CHSA-20M CHSA-25M CHSA-30M

Motor output Kw(HP) 15(20) 19(20) 22(30) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 734 680 640 1253 1150 1080 Compressor speed RPM 8280 7900 7500 5700 5380 5160 Oil flow rate gpm 85 119 119 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph 208-230 460 Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 11 13 13 Noise level dB(A) 72 73 73 Weight lbs 450 550 630 Dimensions(WtimesDtimesH) in 2834x4138x4218 3112x4714x4978 Air outlet piping size in 1rdquo 1rdquo

1-9 INSTALLATION AND WIRING Upon delivery carefully check the air compressor unit(s) for damage during transportation 1-9-1 HANDLING When handling by a forklift make sure that forks completely extend through the width of the unit When handling by a shop crane use the openings provided on common base where slings or steel wire ropes can be use for lifting

Fig 1-6 Handling by forklift truck

Fig 1-7 Handling by shop crane

1-9-2 LOCATION The unit should be installed in a dry well ventilated area dust-free environment The unit should not be installed outdoors Consideration must be given to the need for clearance around the unit to avoid the re-circulation of air-end for easy maintenance access

5

(Unit Inch)

Fig 1-8 The space clearance example

CAUTION

- Install the unit in a dust-free room of low humidity and on a level concrete floor

- Never install the unit on timbers or block High humidity may result in electrical shorts and corrosion

- Dust particles containing iron or sand may result in poor resistance of the motor and air-end damage

- A ventilation fan should be provided to keep the ambient temperature 115 or lower

- operation at ambient temperature of higher than 115 may cause compressor shutdown or severe

damage to the unit

HEAT GENERATION amp VENTILATION FAN CAPACITY MODEL

CAPACITY CHSA-75M CHSA-10M CHSA-15M CHSA-20M CHSA-25M CHSA-30M

CAPACITY (Btuh) AIR VOLUME (cfm) 1165 1235 1900 2120 2330 2540 Note 1 The room ventilation capacity is based on (1) Compressor room Temperature rise which is controlled within the 9 (2) Static pressure of ventilation air should be 0 inchWG 2 Consult the distributor for more information on ventilation capacity when the air exhaust duct is installed

A B C D CHSA-75M 24 42 42 24 CHSA-10M 24 42 42 24 CHSA-15M 24 42 42 24 CHSA-20M 42 42 42 24 CHSA-25M 24 42 42 24 CHSA-30M 24 42 42 24

6

1-9-3 PIPING WORK

CAUTION

- All service piping must be installed so as to exert zero force of movement on the system

- A drain valve and isolation valve should be mounted near the compressor discharge section

- Water condensation can affect the operation of pneumatic devices After-coolers and the addition of

air dryers can eliminate this hazard Similarly avoid allowing compressor coolant to enter the plant air

systems Air line separators properly selected and installed will reduce any liquid carry-over

- When installed in parallel operation you must provide an isolation valve and drain trap for each

compressor unit before the common receiver Screw air compressors should not be installed in air

systems with reciprocating compressors without a means of isolation such as a common receiver It

is recommend that both types of compressor units are piped to a common receiver utilizing individual

air lines

- In case of a lead fluctuation or a very small volume in pipe from discharge connection of compressor

unit to the end of the piping the use of air receiver is recommended

- In case the discharge piping has to be unusually long you should select the diameter of the piping in

considering the pressure drop in the piping

- Consult your distributor for proper technical support

Fig 1-9 Parallel installation Fig 1-10 Installation with reciprocating compressor

1-9-4 ELECTRICITY This extensive line of Coaire screw air compressors has been designed to provided all the conveniences of air supply system especially for the stats of the art manufacturing industries These units are composed of compressor motor protection devices and control equipment The applicable voltage range for each unit is given in the electrical data The working voltage among the three phases must be balanced within 2 deviation from each voltage at the compressor terminals Voltage range limit is to be 90~110 of regular voltage described in proportional frequency Unbalance of voltage measured in motor terminals should be within 3 in accordance with the following formula

(V)max - (V)mean ---------------------------- times 100 () (V)mean where (V)max Maximum voltage among three terminals (V)mean Average voltage among three terminals

CAUTION

7

ELECTRICAL WIRING

- Read all related topics in this manual

- Comply to the National Electric Code(NEC) and any other local codes

- Utilize a qualified licensed electrical contractor

1-9-5 ELECTRICAL SPECIFICATION

3 Phase Motor

MODEL

AIR-END MOTOR NO FUSE

BREAKER

OVER

CURRENT

RELAY

MAIN CABLE

OUTPUT

[kWHp]

INPUT

[kW]

POWER[V]

3oslash60Hz

FLA

[A]

LRA[A] POWER

FACTOR

[]

FRAME

[AF]

TRIP

[A]

TRIP

[A]

POWER

[]

KIV

GROUND

[]

GV DIRECT Y-DELTA

CHSA-75M 55975 208 190 708 -

94

230 170 640 - 460 85 320 -

CHSA-10M 74610 208 256 741 -

91

230 232 670 - 460 116 385 -

CHSA-15M 111915 208 387 1371 -

90

230 350 1240 - 460 175 620 -

CHSA-20M 149220

208 520 1680 -

88

230 470 1520 -

460 235 760 -

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

3

M

TS PI

PT

Fig 1-5 Operating flow diagram

1-8 STANDARD SPECIFICATIONS MODEL

ITEM CHSA-75M CHSA-10M CHSA-15M

Motor output Kw(HP) 55(75) 75(10) 11(15) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 290 265 230 385 360 310 570 520 460 Compressor speed RPM 5250 4720 4350 6950 6380 5950 6450 6200 5550 Oil flow rate gpm 40 53 80 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph(1Ph) 208-230V 3Ph 208-230460V Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 07 07 11 Noise level dB(A) 68 70 71 Weight lbs 300 310 420 Dimensions(WtimesDtimesH) in 17times2458x3258 2834x4138x4218 Air outlet piping size in 34rdquo 1rdquo

Air

Cleaner

Solenoid

Valve

Only

15 ~ 30HP

Oil Filter

Oil Cooler

Thermostat

Valve

Oil

Separator

Min

Pressure

After Cooler

Oil Separator

Tank

Symbol PT Pressure Transmitter

TS Temperature Sensor

PI Pressure Indicator

M Motor

4

MODEL

ITEM CHSA-20M CHSA-25M CHSA-30M

Motor output Kw(HP) 15(20) 19(20) 22(30) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 734 680 640 1253 1150 1080 Compressor speed RPM 8280 7900 7500 5700 5380 5160 Oil flow rate gpm 85 119 119 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph 208-230 460 Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 11 13 13 Noise level dB(A) 72 73 73 Weight lbs 450 550 630 Dimensions(WtimesDtimesH) in 2834x4138x4218 3112x4714x4978 Air outlet piping size in 1rdquo 1rdquo

1-9 INSTALLATION AND WIRING Upon delivery carefully check the air compressor unit(s) for damage during transportation 1-9-1 HANDLING When handling by a forklift make sure that forks completely extend through the width of the unit When handling by a shop crane use the openings provided on common base where slings or steel wire ropes can be use for lifting

Fig 1-6 Handling by forklift truck

Fig 1-7 Handling by shop crane

1-9-2 LOCATION The unit should be installed in a dry well ventilated area dust-free environment The unit should not be installed outdoors Consideration must be given to the need for clearance around the unit to avoid the re-circulation of air-end for easy maintenance access

5

(Unit Inch)

Fig 1-8 The space clearance example

CAUTION

- Install the unit in a dust-free room of low humidity and on a level concrete floor

- Never install the unit on timbers or block High humidity may result in electrical shorts and corrosion

- Dust particles containing iron or sand may result in poor resistance of the motor and air-end damage

- A ventilation fan should be provided to keep the ambient temperature 115 or lower

- operation at ambient temperature of higher than 115 may cause compressor shutdown or severe

damage to the unit

HEAT GENERATION amp VENTILATION FAN CAPACITY MODEL

CAPACITY CHSA-75M CHSA-10M CHSA-15M CHSA-20M CHSA-25M CHSA-30M

CAPACITY (Btuh) AIR VOLUME (cfm) 1165 1235 1900 2120 2330 2540 Note 1 The room ventilation capacity is based on (1) Compressor room Temperature rise which is controlled within the 9 (2) Static pressure of ventilation air should be 0 inchWG 2 Consult the distributor for more information on ventilation capacity when the air exhaust duct is installed

A B C D CHSA-75M 24 42 42 24 CHSA-10M 24 42 42 24 CHSA-15M 24 42 42 24 CHSA-20M 42 42 42 24 CHSA-25M 24 42 42 24 CHSA-30M 24 42 42 24

6

1-9-3 PIPING WORK

CAUTION

- All service piping must be installed so as to exert zero force of movement on the system

- A drain valve and isolation valve should be mounted near the compressor discharge section

- Water condensation can affect the operation of pneumatic devices After-coolers and the addition of

air dryers can eliminate this hazard Similarly avoid allowing compressor coolant to enter the plant air

systems Air line separators properly selected and installed will reduce any liquid carry-over

- When installed in parallel operation you must provide an isolation valve and drain trap for each

compressor unit before the common receiver Screw air compressors should not be installed in air

systems with reciprocating compressors without a means of isolation such as a common receiver It

is recommend that both types of compressor units are piped to a common receiver utilizing individual

air lines

- In case of a lead fluctuation or a very small volume in pipe from discharge connection of compressor

unit to the end of the piping the use of air receiver is recommended

- In case the discharge piping has to be unusually long you should select the diameter of the piping in

considering the pressure drop in the piping

- Consult your distributor for proper technical support

Fig 1-9 Parallel installation Fig 1-10 Installation with reciprocating compressor

1-9-4 ELECTRICITY This extensive line of Coaire screw air compressors has been designed to provided all the conveniences of air supply system especially for the stats of the art manufacturing industries These units are composed of compressor motor protection devices and control equipment The applicable voltage range for each unit is given in the electrical data The working voltage among the three phases must be balanced within 2 deviation from each voltage at the compressor terminals Voltage range limit is to be 90~110 of regular voltage described in proportional frequency Unbalance of voltage measured in motor terminals should be within 3 in accordance with the following formula

(V)max - (V)mean ---------------------------- times 100 () (V)mean where (V)max Maximum voltage among three terminals (V)mean Average voltage among three terminals

CAUTION

7

ELECTRICAL WIRING

- Read all related topics in this manual

- Comply to the National Electric Code(NEC) and any other local codes

- Utilize a qualified licensed electrical contractor

1-9-5 ELECTRICAL SPECIFICATION

3 Phase Motor

MODEL

AIR-END MOTOR NO FUSE

BREAKER

OVER

CURRENT

RELAY

MAIN CABLE

OUTPUT

[kWHp]

INPUT

[kW]

POWER[V]

3oslash60Hz

FLA

[A]

LRA[A] POWER

FACTOR

[]

FRAME

[AF]

TRIP

[A]

TRIP

[A]

POWER

[]

KIV

GROUND

[]

GV DIRECT Y-DELTA

CHSA-75M 55975 208 190 708 -

94

230 170 640 - 460 85 320 -

CHSA-10M 74610 208 256 741 -

91

230 232 670 - 460 116 385 -

CHSA-15M 111915 208 387 1371 -

90

230 350 1240 - 460 175 620 -

CHSA-20M 149220

208 520 1680 -

88

230 470 1520 -

460 235 760 -

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

4

MODEL

ITEM CHSA-20M CHSA-25M CHSA-30M

Motor output Kw(HP) 15(20) 19(20) 22(30) Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 Air delivery cfm 734 680 640 1253 1150 1080 Compressor speed RPM 8280 7900 7500 5700 5380 5160 Oil flow rate gpm 85 119 119 Ambient temperature 32 115sim Discharge air temperature Inlet air temperature + 27 (MAX) Driving method - V-Belt V-Belt Voltage V 3Ph 208-230 460 Frequency Hz 60 Starting method - Direct on Start Oil sump capacity gal 11 13 13 Noise level dB(A) 72 73 73 Weight lbs 450 550 630 Dimensions(WtimesDtimesH) in 2834x4138x4218 3112x4714x4978 Air outlet piping size in 1rdquo 1rdquo

1-9 INSTALLATION AND WIRING Upon delivery carefully check the air compressor unit(s) for damage during transportation 1-9-1 HANDLING When handling by a forklift make sure that forks completely extend through the width of the unit When handling by a shop crane use the openings provided on common base where slings or steel wire ropes can be use for lifting

Fig 1-6 Handling by forklift truck

Fig 1-7 Handling by shop crane

1-9-2 LOCATION The unit should be installed in a dry well ventilated area dust-free environment The unit should not be installed outdoors Consideration must be given to the need for clearance around the unit to avoid the re-circulation of air-end for easy maintenance access

5

(Unit Inch)

Fig 1-8 The space clearance example

CAUTION

- Install the unit in a dust-free room of low humidity and on a level concrete floor

- Never install the unit on timbers or block High humidity may result in electrical shorts and corrosion

- Dust particles containing iron or sand may result in poor resistance of the motor and air-end damage

- A ventilation fan should be provided to keep the ambient temperature 115 or lower

- operation at ambient temperature of higher than 115 may cause compressor shutdown or severe

damage to the unit

HEAT GENERATION amp VENTILATION FAN CAPACITY MODEL

CAPACITY CHSA-75M CHSA-10M CHSA-15M CHSA-20M CHSA-25M CHSA-30M

CAPACITY (Btuh) AIR VOLUME (cfm) 1165 1235 1900 2120 2330 2540 Note 1 The room ventilation capacity is based on (1) Compressor room Temperature rise which is controlled within the 9 (2) Static pressure of ventilation air should be 0 inchWG 2 Consult the distributor for more information on ventilation capacity when the air exhaust duct is installed

A B C D CHSA-75M 24 42 42 24 CHSA-10M 24 42 42 24 CHSA-15M 24 42 42 24 CHSA-20M 42 42 42 24 CHSA-25M 24 42 42 24 CHSA-30M 24 42 42 24

6

1-9-3 PIPING WORK

CAUTION

- All service piping must be installed so as to exert zero force of movement on the system

- A drain valve and isolation valve should be mounted near the compressor discharge section

- Water condensation can affect the operation of pneumatic devices After-coolers and the addition of

air dryers can eliminate this hazard Similarly avoid allowing compressor coolant to enter the plant air

systems Air line separators properly selected and installed will reduce any liquid carry-over

- When installed in parallel operation you must provide an isolation valve and drain trap for each

compressor unit before the common receiver Screw air compressors should not be installed in air

systems with reciprocating compressors without a means of isolation such as a common receiver It

is recommend that both types of compressor units are piped to a common receiver utilizing individual

air lines

- In case of a lead fluctuation or a very small volume in pipe from discharge connection of compressor

unit to the end of the piping the use of air receiver is recommended

- In case the discharge piping has to be unusually long you should select the diameter of the piping in

considering the pressure drop in the piping

- Consult your distributor for proper technical support

Fig 1-9 Parallel installation Fig 1-10 Installation with reciprocating compressor

1-9-4 ELECTRICITY This extensive line of Coaire screw air compressors has been designed to provided all the conveniences of air supply system especially for the stats of the art manufacturing industries These units are composed of compressor motor protection devices and control equipment The applicable voltage range for each unit is given in the electrical data The working voltage among the three phases must be balanced within 2 deviation from each voltage at the compressor terminals Voltage range limit is to be 90~110 of regular voltage described in proportional frequency Unbalance of voltage measured in motor terminals should be within 3 in accordance with the following formula

(V)max - (V)mean ---------------------------- times 100 () (V)mean where (V)max Maximum voltage among three terminals (V)mean Average voltage among three terminals

CAUTION

7

ELECTRICAL WIRING

- Read all related topics in this manual

- Comply to the National Electric Code(NEC) and any other local codes

- Utilize a qualified licensed electrical contractor

1-9-5 ELECTRICAL SPECIFICATION

3 Phase Motor

MODEL

AIR-END MOTOR NO FUSE

BREAKER

OVER

CURRENT

RELAY

MAIN CABLE

OUTPUT

[kWHp]

INPUT

[kW]

POWER[V]

3oslash60Hz

FLA

[A]

LRA[A] POWER

FACTOR

[]

FRAME

[AF]

TRIP

[A]

TRIP

[A]

POWER

[]

KIV

GROUND

[]

GV DIRECT Y-DELTA

CHSA-75M 55975 208 190 708 -

94

230 170 640 - 460 85 320 -

CHSA-10M 74610 208 256 741 -

91

230 232 670 - 460 116 385 -

CHSA-15M 111915 208 387 1371 -

90

230 350 1240 - 460 175 620 -

CHSA-20M 149220

208 520 1680 -

88

230 470 1520 -

460 235 760 -

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

5

(Unit Inch)

Fig 1-8 The space clearance example

CAUTION

- Install the unit in a dust-free room of low humidity and on a level concrete floor

- Never install the unit on timbers or block High humidity may result in electrical shorts and corrosion

- Dust particles containing iron or sand may result in poor resistance of the motor and air-end damage

- A ventilation fan should be provided to keep the ambient temperature 115 or lower

- operation at ambient temperature of higher than 115 may cause compressor shutdown or severe

damage to the unit

HEAT GENERATION amp VENTILATION FAN CAPACITY MODEL

CAPACITY CHSA-75M CHSA-10M CHSA-15M CHSA-20M CHSA-25M CHSA-30M

CAPACITY (Btuh) AIR VOLUME (cfm) 1165 1235 1900 2120 2330 2540 Note 1 The room ventilation capacity is based on (1) Compressor room Temperature rise which is controlled within the 9 (2) Static pressure of ventilation air should be 0 inchWG 2 Consult the distributor for more information on ventilation capacity when the air exhaust duct is installed

A B C D CHSA-75M 24 42 42 24 CHSA-10M 24 42 42 24 CHSA-15M 24 42 42 24 CHSA-20M 42 42 42 24 CHSA-25M 24 42 42 24 CHSA-30M 24 42 42 24

6

1-9-3 PIPING WORK

CAUTION

- All service piping must be installed so as to exert zero force of movement on the system

- A drain valve and isolation valve should be mounted near the compressor discharge section

- Water condensation can affect the operation of pneumatic devices After-coolers and the addition of

air dryers can eliminate this hazard Similarly avoid allowing compressor coolant to enter the plant air

systems Air line separators properly selected and installed will reduce any liquid carry-over

- When installed in parallel operation you must provide an isolation valve and drain trap for each

compressor unit before the common receiver Screw air compressors should not be installed in air

systems with reciprocating compressors without a means of isolation such as a common receiver It

is recommend that both types of compressor units are piped to a common receiver utilizing individual

air lines

- In case of a lead fluctuation or a very small volume in pipe from discharge connection of compressor

unit to the end of the piping the use of air receiver is recommended

- In case the discharge piping has to be unusually long you should select the diameter of the piping in

considering the pressure drop in the piping

- Consult your distributor for proper technical support

Fig 1-9 Parallel installation Fig 1-10 Installation with reciprocating compressor

1-9-4 ELECTRICITY This extensive line of Coaire screw air compressors has been designed to provided all the conveniences of air supply system especially for the stats of the art manufacturing industries These units are composed of compressor motor protection devices and control equipment The applicable voltage range for each unit is given in the electrical data The working voltage among the three phases must be balanced within 2 deviation from each voltage at the compressor terminals Voltage range limit is to be 90~110 of regular voltage described in proportional frequency Unbalance of voltage measured in motor terminals should be within 3 in accordance with the following formula

(V)max - (V)mean ---------------------------- times 100 () (V)mean where (V)max Maximum voltage among three terminals (V)mean Average voltage among three terminals

CAUTION

7

ELECTRICAL WIRING

- Read all related topics in this manual

- Comply to the National Electric Code(NEC) and any other local codes

- Utilize a qualified licensed electrical contractor

1-9-5 ELECTRICAL SPECIFICATION

3 Phase Motor

MODEL

AIR-END MOTOR NO FUSE

BREAKER

OVER

CURRENT

RELAY

MAIN CABLE

OUTPUT

[kWHp]

INPUT

[kW]

POWER[V]

3oslash60Hz

FLA

[A]

LRA[A] POWER

FACTOR

[]

FRAME

[AF]

TRIP

[A]

TRIP

[A]

POWER

[]

KIV

GROUND

[]

GV DIRECT Y-DELTA

CHSA-75M 55975 208 190 708 -

94

230 170 640 - 460 85 320 -

CHSA-10M 74610 208 256 741 -

91

230 232 670 - 460 116 385 -

CHSA-15M 111915 208 387 1371 -

90

230 350 1240 - 460 175 620 -

CHSA-20M 149220

208 520 1680 -

88

230 470 1520 -

460 235 760 -

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

6

1-9-3 PIPING WORK

CAUTION

- All service piping must be installed so as to exert zero force of movement on the system

- A drain valve and isolation valve should be mounted near the compressor discharge section

- Water condensation can affect the operation of pneumatic devices After-coolers and the addition of

air dryers can eliminate this hazard Similarly avoid allowing compressor coolant to enter the plant air

systems Air line separators properly selected and installed will reduce any liquid carry-over

- When installed in parallel operation you must provide an isolation valve and drain trap for each

compressor unit before the common receiver Screw air compressors should not be installed in air

systems with reciprocating compressors without a means of isolation such as a common receiver It

is recommend that both types of compressor units are piped to a common receiver utilizing individual

air lines

- In case of a lead fluctuation or a very small volume in pipe from discharge connection of compressor

unit to the end of the piping the use of air receiver is recommended

- In case the discharge piping has to be unusually long you should select the diameter of the piping in

considering the pressure drop in the piping

- Consult your distributor for proper technical support

Fig 1-9 Parallel installation Fig 1-10 Installation with reciprocating compressor

1-9-4 ELECTRICITY This extensive line of Coaire screw air compressors has been designed to provided all the conveniences of air supply system especially for the stats of the art manufacturing industries These units are composed of compressor motor protection devices and control equipment The applicable voltage range for each unit is given in the electrical data The working voltage among the three phases must be balanced within 2 deviation from each voltage at the compressor terminals Voltage range limit is to be 90~110 of regular voltage described in proportional frequency Unbalance of voltage measured in motor terminals should be within 3 in accordance with the following formula

(V)max - (V)mean ---------------------------- times 100 () (V)mean where (V)max Maximum voltage among three terminals (V)mean Average voltage among three terminals

CAUTION

7

ELECTRICAL WIRING

- Read all related topics in this manual

- Comply to the National Electric Code(NEC) and any other local codes

- Utilize a qualified licensed electrical contractor

1-9-5 ELECTRICAL SPECIFICATION

3 Phase Motor

MODEL

AIR-END MOTOR NO FUSE

BREAKER

OVER

CURRENT

RELAY

MAIN CABLE

OUTPUT

[kWHp]

INPUT

[kW]

POWER[V]

3oslash60Hz

FLA

[A]

LRA[A] POWER

FACTOR

[]

FRAME

[AF]

TRIP

[A]

TRIP

[A]

POWER

[]

KIV

GROUND

[]

GV DIRECT Y-DELTA

CHSA-75M 55975 208 190 708 -

94

230 170 640 - 460 85 320 -

CHSA-10M 74610 208 256 741 -

91

230 232 670 - 460 116 385 -

CHSA-15M 111915 208 387 1371 -

90

230 350 1240 - 460 175 620 -

CHSA-20M 149220

208 520 1680 -

88

230 470 1520 -

460 235 760 -

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

7

ELECTRICAL WIRING

- Read all related topics in this manual

- Comply to the National Electric Code(NEC) and any other local codes

- Utilize a qualified licensed electrical contractor

1-9-5 ELECTRICAL SPECIFICATION

3 Phase Motor

MODEL

AIR-END MOTOR NO FUSE

BREAKER

OVER

CURRENT

RELAY

MAIN CABLE

OUTPUT

[kWHp]

INPUT

[kW]

POWER[V]

3oslash60Hz

FLA

[A]

LRA[A] POWER

FACTOR

[]

FRAME

[AF]

TRIP

[A]

TRIP

[A]

POWER

[]

KIV

GROUND

[]

GV DIRECT Y-DELTA

CHSA-75M 55975 208 190 708 -

94

230 170 640 - 460 85 320 -

CHSA-10M 74610 208 256 741 -

91

230 232 670 - 460 116 385 -

CHSA-15M 111915 208 387 1371 -

90

230 350 1240 - 460 175 620 -

CHSA-20M 149220

208 520 1680 -

88

230 470 1520 -

460 235 760 -

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

8

CHAPTER II

OPERATING INSTRUCTIONS

2-1 OPERATING PANEL The schematic figure and the names of each part in the operating panel are as follows

Fig 2-1 Operating panel

DESCRIPTION FUNCTION Start Switch for Running Stop Switch for stopping Pressure Indicates the discharge pressure Temperature Indicates the discharge temperature Run Signal lamp for running Alarm Signal lamp for alarm ResetEnter Switch for the alarm reset and input value Menu Switch for selecting the message on the LCD screen Up Switch for increasing the input value Down Switch for decreasing the input value Hour Indicates the running time

ENTERDOWN UP

RUN

PRESSURE(kgcm )

MENU

ALARM

M

HOUR

H

STOP

TEMPERATURE(degC)

START

RESET

2

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

9

2-2 INITIAL START-UP Before starting the unit for the first time all operators must become familiar with all parts and assemblies Only qualified personnel are to start the machine(Contact your distributor)

2-2-1 BEFORE OPERATION Make sure that

All installation piping and electrical work has been properly installed and completed The main power is disconnected The voltage of the power source is at a regular level Tightness of all electrical connections and wirings Tightness of all joints fasteners covers plugs and caps are inspected Tightness of all grounding connections are inspected V -belt tensions are inspected The oil level is a t the proper point Isolation stop valve in the discharge air line is completely open

WARNING

CHECK PROPER ROTATION

There is no the reverse phase relay in the unit Operator should open the front belt guard and

check proper rotation visually You can see rotation arrow on the belt guard Reinstall guard

prior to any further running 2-2-2 STARTING

Turn on the main disconnection switch Power lamp on air compressor instrument panel lights up

Press start key on operating panel of the uni t The running lamp on the unit-operating panel lights up

Check the rotation While checking proper rotation you should not run the machine for 5 sec or more If you do not the air-end will be damaged Reinstall guard prior to any further operation

WARNING

REVERSE ROTATION

Upon initial operation check proper rotation If reverse rotation disconnect the main power

and interchange two of three main cables on terminal board installed in the control box Check oil level and run the unit for a short period Oil level may drop as

oil circulates into the system Add oil if the level during operation should be below the lower centerline of lower oil level gauge Press stop button to stop the motor After confirming that the discharge pressure gauge reads 0 psig(approximately 90 seconds after stopping the motor) add oil as necessary

Check the unit for any abnormal noise or vibration Run the unit at the discharge pressure 57 to 71 psig for approximately one hour gradually close the isolation stop valve until the discharge pressure gauge

indicates the same pressure as the oil sump pressure

WARNING

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

10

Do not loosen the oil-filling plug before the internal pressure is vented completely Make sure

that the oil-filling plug is tightly fastened after oil has been added Restart the unit Check the

oil piping for any oil leak and correct as required

Check the safety valve Pull the attached ring to operate the safety valve use caution and appropriate

safety equipment Check the capacity control system Gradually close the stop valve at the external air receiver As discharge

pressure rises stop closing when the discharge pressure reaches the cutout pressure 2-2-3 STOPPING

Press STOP key Machine is stopped after 30 second stop control time Make sure that the blow -off solenoid valve operates

The blow-off air sounds for approximately 90 seconds Make sure that the discharge pressure gauge reads 0 psig

2-3 DAILY OPERATION

BEFORE EACH DAY OF OPERATION Drain the condensation from after-cooler

Check oil level Proper oil level is at centerline of upper oil level gage w ith machine not running STARTING Press START key

DURING THE OPERATION Check oil level gauge Make sure that all gauges in compressor instrument panel indicates normal status and followings

SPECIFICATION UNIT Limit Remarks Discharge temperature Less Than 203 Ambient Temperature Less Than 115 Indicating Lamps - Run Voltage Volt Normal Power plusmn10 Current Amp Less than Normal Current+15 Pressure Differential unit and line PSID Max 15

STOPPING

Press STOP key Make sure that th e discharge pressure gauge reads 0 psig Operate the toggle switch for oil heater as follows(if option is installed)

For ambient temperature consistently over 50 when the unit is idled place the toggle switch to OFF position For ambient temperature consistently below 50 when unit is not running place the toggle switch to ON position

2-4 STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150 Minimum pressure valve Psi 57 Discharge pressure switch Psi 11090 125105 150130 Oil separator element diff switch Psi 10 Oil filter diff switch Psi 25 Discharge temperature switch 220

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

11

2-5 OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM

POWER ON

rarr

darr

(Check rotation) START

darr (No alarm) darr larr

POWER OFF

IF REVERSE

ROTATION

Y-Δ START

(IF APPLICABLE DELTA RUN

AFTER Y-START)

uarr

darr

EXCHANGE 3

OF 2 MAIN

CABLE

LOAD OPERATION

(AFTER 5 SEC IDLING

OPERATION)

rarr larr

larr darr darr

LINE PRESSURE MONITORING

(PRESSURE SWITCH)

SET PRESSURE

OR LESS LOAD OPERATION

(Loading Valve ON)

uarr

SET PRESSURE OR MORE

uarr

OFF LOAD OPERATION

(Loading Valve OFF)

darr

uarr

LINE PRESSURE MONITORING

(Pressure Transmitter)

SET PRESSURE

OR MORE OFF LOAD

OPERATION

(Loading Valve OFF)

SET PRESSURE MINUS 21

PSIG

darr

RETURN LOAD OPERATION

(Loading Valve ON)

OFF LOADING TIME

CHECK

uarr darr darr

STAND-BYMODE

(AFTER STOPPING

OPERATION)

AUTO-RESTART

BY LINE PRESSURE

darr

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

12

(2) STOP CONTROL SYSTEM

WHILE

MACHINE IS

RUNNING

darr PUSH STOP BUTTON darr

MONITORING WHEN IN OFF-LOAD

OPERATION

WHEN IN

LOAD

OPERATION darr rarr darr

OFF-LOAD OPERATION

OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER) darr (IF SET TIME IS ON)

STOP CONTROL

OPERATION

WHILE SET TIME

(SET TIME30~60SEC)

darrOFF-LOAD OPERATION

WHILE REMINING TIME

darr darr larr MACHINE STOP

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD HIGH DISCHARGE

TEMPERATURE

OIL FILTER or

OIL SEPARATOR

CLOGGED

OCR(ITH) TEMPERATURE SENSOR DIFF PRESSURE

SWITCH

FLASH ALARM LAMP ON SWITCH PANEL

ALARM MESSAGE ON LCD

BUZZER

RESET AND STOP DISCONNECT POWER AND RELEASE PRESSURE

CHECK AND REPLACE

RESTART

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

13

2-6 MICROPROCESSOR CONTROLLER 2-6-1 ALARM MESSAGE

DISPLAY DISCRIPTION COP ocr Indicates the COMPRESSOR MOTOR OVERLOAD Fan ocr Indicates the COOLING FAN MOTOR OVERLOAD OIL FLt Indicates the OIL FILTER CLOGGED OIL SPt Indicates the OIL SEPARATOR CLOGGED OHt HI Indicates the HIGH DISCHARGE TEMPERATURE SEn Err Indicates the TEMPERATURE SENSOR ABNORMAL Pt Err Indicates the PRESSURE TRANSMITTER ABNORMAL PrS HI Indicates the ABNORMAL DISCHARGE PRESSURE

2-6-2 SET VALUE CHANGING MENUS Various data values showing the running status of the unit can set or display

Y-DELTA START

SET TIME XX [SEC] Displays the Y-Delta delay time (Applicable to Y-Delta units only)

IDELING START

SET TIME XX [SEC] Displays the idling delay time

UNLOADING CONTROL

SET TIME XX [MIN] Displays the idling delay time

STOP CONTROL

SET TIME XX [SEC] Displays the stop control time

DISCHARGE AIR

SET TEMP XXX [] Displays the discharge temperature

DISCHARGE PRESS

SET XXX [PSI] Displays the discharge air pressure

DRAIN ON-TIME

SET XX [SEC] Displays the auto drain valve on-time(open)

DRAIN OFF-TIME

SET XX [MIN] Displays the auto drain valve off-time(close)

MACHINE TYPE

MINI SCREW or RECIPROCATING Displays the current set machine type

UNITS CHANGE

METRIC LBS Displays the current set units

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

14

2-6-3 CHANGING SET VALUES It is highly recommended that the following procedures be conducted by qualified factory trained personnel Consult your distributor The running mode of the unit is programmed upon delivery However the operator may amend it depending on conditions and needs To amend the set value operator has to release the system key lock first Mode selection may be reset in the following way HOW TO RELEASE SYSTEM KEY LOCK

Press [MENU] key one time Machine will ask the operatorrsquos password and following message will be appeared ldquoPSd ldquo letter will light on and last three digits will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make password of 111 by using the arrow keys and press enter key When password input the screen to be

amend is to be display Once the password is installed it lasts for about 5 minutes CAUTION The operatorrsquos password is 111

2-6-3-1 CHANGING THE PASSWORD 1) Release the system key lock 2) Press [MENU] key two times Following message will appear And ldquoPSd - - -ldquo will flash to input password step by step On the screen

TEMPERATURE

PSd - - -

Make new password by using the arrow keys and press enter key Password should be three digits numeric only

2-6-3-2 CHANGING THE WORKING PRESSURE 1) Release the system key lock 2) Press [MENU] key Three times The working pressure can be amended after releasing the engineerrsquos password The engineeringrsquos password is used at factory only

PRESSURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) PSI increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) PSI decrements

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

15

2-6-3-3 CHANGING THE DISCHARGE ALARM TEMPERATURE 1) Release the system key lock 2) Press [MENU] key four times On the following screen last digit will be flashed to be able to input valve

TEMPERATURE

X X X

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) lsquoF increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) lsquoF decrements 2-6-3-4 CHANGING THE IDLING START TIME 1) Release the system key lock 2) Press [MENU] key five times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Idl 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-5 CHANGING THE UNLOADING CONTROL TIME 1) Release the system key lock 2) Press [MENU] key six times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

Uld 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

16

2-5-3-6 CHANGING THE STOP CONTROL TIME 1) Release the system key lock 2) Press [MENU] key seven times On the following screen last digit will be flashing to be able to input valve

TEMPERATURE

StP 000

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically

Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press (Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements

2-6-3-7 CHANGING THE DRAIN VALVE OFF-TIME(CLOSE TIME)

1) Release the system key lock 2) Press [MENU] key eight times On the following screen last digit will flash to be able to input value

TEMPERATURE

Drn F00

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) minute increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) minute decrements 2-6-3-8 CHANGING THE DRAIN VALVE ON-TIME(OPEN TIME)

1) Release the system key lock 2) Press [MENU] key nine times On the following screen last digit will flash to be able to input valve

TEMPERATURE

Drn o-0

3) Amend the set value by using (Up) and (Down) Keys Input the set value at flashing digit by using the arrow keys and press enter key Flashed digit will be moved to the next digit automatically Press (Up) Key to increase the set point Increases are displayed in 1(one) second increments Press

(Down) Key to decrease the set point Decreases are displayed in 1(one) second decrements 2-6-3-9 Factory Set Values No Items Factory set point Adjustable Range 1 Compressor discharge shut down temperature 220 176 ~ 230 2 Start idling time 5 Sec 5 ~ 10 Sec 3 Unloading control time 5 Min 5 ~ 10 Min 4 Stop control time 30 Sec 20 ~ 50 Sec 5 Drain valve off-time 5 Min 1 ~ 45 Min 6 Drain valve on-time 1 sec 1 ~ 5 Sec 7 Discharge pressure 110 Psi 80 ~ 190 PSI

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

17

2-6-3-10 DIP SWITCH

No Items FUNCTION

Items ON OFF 1 MACHINE M-screw Scrolloil-less

2 PU Pressure switch By-pass Oil-less type only for capacity control

3 REMOTE Remote Non-remote 4 AUTO RESTORE Auto restart Manual restart After restoring power 5 UNITS Metric units Lbs-inch UNITS

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

18

CHAPTER III

FUNCTIONAL DESCRIPTIONS

3-1 COMPRESSOR AIREND Oil injected single stage rotary screw type that primarily consists of rotors housing and shaft seal along with other component parts Features Precision grind rotors provide close inter-lobe clearance This minimizes leakage and increases efficiency

Long service life and high reliability of bearings achieved by application of 5+7 profile rotors At the discharge end of the compressor angular contact ball bearings for the male and female rotors are located to support axial thrust loads and to position the rotor Cylindrical roller bearings are also located to support radial loads

With a differential pressure lubrication system the compress or can dispense with an oil pump thus dramatically simplifying the oil supply system

The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance

3-1-1 ROTORS The male rotor has five lobes and the female rotor has seven grooves This is patented SRM designed profiles

Fig 3-2 Pair of rotor

3-1-2 HOUSING The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads

3-1-3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil leakage

Fig 3-3 Detail of mechanical seal

3-2 DRIVE MOTOR IEC or NEMA standard drip-proof 3-phase 2 or 4 pole induction motor

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

19

3-3 V-BELT DRIVE Motor speed is increased by V-belt drive to the male rotors driving speed

Fig 3-4 V-Belt drive

3-4 CAPACITY CONTROL All models provide capacity control on-lineoff-line control Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features 3-5 LUBRICATION SYSTEM The lubrication system consists of oil cooler oil separator and controls the oil temperature within an allowable limit The oil circulates through the system by differential pressure

3-6 AFTER COOLER OIL COOLER The cooler assembly is consisting in heat exchanger cooling fan fan motor and bracket After-cooler and oil-cooler are composed of corrugated fin and tube type with aluminum material Those fins remove the compression heat efficiently Cooling fan exhausts the heat-exchanged air through a ventilation duct to the outside of the enclosure 3-7 OIL SEPARATOR Spin-on type Oil separator is located at the air-end which efficiently separates the oil from discharged air 3-8 OIL FILTER Oil filter element is located at the air-end which efficiently filtering foreign material from circulating oil The oil filter has from 5 to 10 micron paper cartridge and it should be replaced every 1000 run hours normally 3-9 THERMOSTATIC VALVE This is the oil by-pass valve Located in the oil cooler outlet pipe in order to maintain adequate system temperature for efficient compression and protect to making water from compressed air The operating temperature is set 160

3-10 MINIMUM PRESSURE VALVE Located in air-end discharge in order to maintain adequate system pressure for efficient separation of oil pressure setting is 57 psig If less than 57 psig adjust the screw to maintain pressure on 57 psig or more

3-11 AIR INTAKE FILTER The air intake filter is replaceable dry-type filter with two-stage design It consists of an outside element of urethane and inside element of polyester 3-12 INSTRUMENT PANEL Consists of start button stop button indicating lamps synoptic display control panel and pressure gauge

3-13 STARTER AND CONTROL BOX Consists of pre-wired direct starter for model CHSA-75M through CHSA-30M and star-delta starter useable for model CHSA-30M optionally

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

20

3-14 SAFETY DEVICE Shutdown switch for discharge high air temperatures Differential shutdown switch for oil filter Differential shutdown switch for oil separator element Overload for motor Overload for cooling fan motor Safety valve

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

21

CHAPTER IV

SCHEDULED MAINTENANCE 4-1 STANDARD MAINTENANCE SCHEDULE Maintenance schedule is instructed as below The intervals are a guide based on normal operating conditions If operated in a severe environment necessary maintenance service should be performed on a more frequent basis User should carry out the maintenance work based on either the running hours or the calendar time whichever comes first Please be advised that Items marked with

should be performed by a user while the other marked with should be maintained by an authorized distributor

Part Action Taken

Maintenance Interval

Remark Daily

Monthly 6 Monthly Annually 2 yearly 4 yearly

1000 Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs

Oil

Sepa

rato

r

Oil Level Check

Condensation Drain

Oil Sampling

Replace

Oil Tank Clean

Level Gauge Clean

O-ring Gasket Replace

Monitor Check

Air Filter Element Replace

Separator Cartridge Replace

Oil Filter Cartridge Replace

After Cooler Clean

Intake Suction Valve Clean

Repair

Safety Valve Clean

Solenoid Valve Check

Min Pressure Valve Clean

Repair

V-belt Tension

Replace

Elec wire terminal Check

Cooling fan Clean

Indication of control panel Check

4-2 CONTROL OF LUBRICATION The control of lubrication is critical Neglecting it may cause varnish or

Mot

or

Insulation Check

Bearing Replace

Grease Refill

Air-

end

Bearing Replace

Oil Seal Replace

O-ring Gasket Replace

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

22

sludge deposits in the system resulting in severe damage or breakdown of the unit The major causes of such deposits are Mixing of different types or brands of oil Use of unsuitable oil Failure to drain the condensation which will result in oil deterioration Failure to change oil within a scheduled maintenance interval

WARNING

Use of inappropriate oil andor improper maintenance may result in catastrophic damage to the air

compressor or may result in a oil separator element fire

CONSULT YOUR DISTRIBUTOR FOR MAINTENANCE SERVICE AND COLUBE 68 COMPRESSOR OIL

4-2-1 FUNCTIONS OF OIL Oil is an essential factor in the oil flooded rotary screw compressor Use COAIRE COLUBE 68 only which is developed for pressurized circulation system containing rust foam oxidation and wear inhibitors along with effective water release characteristics Oil performs the following functions Lubrication Oil lubricates the bearing and other internal components Sealing Oil seals the clearance between the two rotors and clearance between the rotors and inner wall

of casing This prevents air leakage above the inter mesh during compression to increase compression process efficiency

Cooling Oil is injected during compression process to remove the heat of compression

WARNING

Never mix different brands or types of oils each other Blending of oils may cause a formation of varnish

or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil must be

replaced with another be sure to flush out the oil system first Consult your distributor for the

procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil

COAIRE-COLUBE 68

4-2-2 OIL CHANGE A practical way is to change the oil at the following intervals

First oil change 500 hours after initial start -up Second oil change 1500 hours after the first oil change( 2000 hours after the initial start-up) Third and consequent oil changes Every 3000 hours after the previous oil change Oil life is related to working environment High operating temperature or dirty ambient conditions will

require more frequent oil changes The above intervals are based on normal operating conditions If condensation is not drained from the unit the

oil will be deteriorated and required more frequent oil changes Proceed as follows

Run the unit loaded mode long enough to have the oil warm up Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at

the discharge outlet and disconnect the main electrical Place a drain pan unde r the oil drain valve of the unit and open the valve Open the plug of oil filling port

on oil separator to speed up draining For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down Drain the oil as completely as possible Then close the drain valve of the oil separator and drain plug of oil cooler Return the plug to the drain outlet and tighten

Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

23

After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks

4-2-3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start-up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve

NOTE

If a compressor operation can be suspended (for example during lunchtime) it is a wise practice to

drain the condensate once again after the suspension time Thirty(30) minutes may be enough for

sufficient separation of oil from condensation

WARNING

Even if the unit is in 24 hour continuous service it is still recommended to perform a draining

procedure Normally in such an operation mode an extra stand-by compressor has to be installed at

the same time to allow for better draining of condensation

CAUTION

LUBRICANT

Avoid prolonged breathing of vapors Always use adequate ventilation contact with eyes should be

avoided Avoid prolonged periods of skin contact

If excessive vapors are inhaled remove person to fresh air area In the event of contact with eyes

flush with water and consult a physician if serious irritation persists

In the event of contact with skin wash contacted area with soap and water Wash clothing before

reusing

Oil is flammable Use water fog foam dry chemical or carbon dioxide to extinguish Avoid use of

direct stream of water since the oil may float and re-ignite

Dispose of oil by using an recycling service Do not dump oil into drain or onto the ground Do not

place oil or partially filled oil containers in trash Keep out of sewers and water systems

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

24

CHAPTER V

TROUBLE SHOOTING As a guide the most likely problems are listed in the table below Before doing any work on this unit be sure the electrical supply has been shut off and the entire compressor system has been vented of all pressure In case of the automatic safety shutdown the operating panel will indicate the shutdown mode Inspect the cause of shutdown correct it and reset emergency switch on operating panel 5-1 TROUBLE SYMPTOMS AND SOLUTIONS

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1 Failure to start or restart a Main breaker opened a Reset

b Power Failure or low voltage b Inspect power source c Control circuit fuses blown c Replace d Failure of electric components(motor starter coil start button sol valve etc)

d Repair or Replace

e Loose wiring or wires too small or disconnected e Tighten or replace 2 Unscheduled shutdowns a Automatic safety shutdowns

a-1 Main motor overload a-1 See CONDITION 3 a-2 High discharge air temperature a-2 See CONDITION 4 b Control circuit fuses blows b Replace

3 Main motor over load (Safety shutdown)

a Difficulty of air-end rotation a Consult the distributor a-1 Foreign material in air-end a-2 For oil separator filter element a-3 Oil viscosity too high(oil deterioration or oil heater not switched ON at stopping

b Low voltage b Inspect source voltage 4 High discharge temperature (safety shutdowns)

a high ambient temperature a Improve room ventilation b Low oil Level b Add oil as necessary c Oil cooler c-1 Clogged inside tube c-1 Clean or replace c-2 Dirt accumulation on fins c-2 Clean d Oil filter clogged d Clean or replace element e Failure of oil temperature regulating valve e Check or replace f Insufficient cooling air flow f Check or replace the fan

and filter g Deterioration of oil g Change oil

5 High Discharge pressure a Failure of suction throttle valve a Repair or replace b Failure of pressure Transmitter b Repair or replace

6 Low discharge pressure a Too high air demand a Install a new compressor b Leak in discharge line b Check the air line c Air intake valve clogged c Clean or replace d Oil separator element clogged d Replace e Suction Throttle valve plugged e Disassemble and clean f Failure of blow-off solenoid valve f Replace g Failure of pressure Transmitter g Check or replace h Other failure of capacity control h Consult the distributor I Failure of minimum pressure valve I Clean or replace j Indication failure of discharge pressure gage j Replace k Drive belt loose k Tighten or replace

CONDITION POSSIBLE CAUSE SUGGESTED REMEDY

7 Failure to unload property a Failure of pressure setting a Adjust setting b Other failure of capacity control b Consult the distributor c Control line filter clogged c Clean or replace

8 High oil consumption or a Too high oil level in separator tank a Removal oil

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

25

discharge air contains oil mist

b Oil leak b-1 From mechanical seal(Too much leak) b-1 Consult the distributor b-2 From joint b-2 Retighten c Failed or clogged oil separator element c Replace d Faulty installation of separator element d Correct e Failure of minimum pressure valve e Replace f Use of improper oil f Change the oil after flushing g Too frequent unload and load g Readjust setting points

9 Oil deterioration

a Use of improper oil a See CONDITION 8-f b Mixing of different oil b See CONDITION 8-f c High ambient temperature c See CONDITION 4-a d Water included in oil d See CONDITION 8-f e Scheduled oil change neglected e See CONDITION 8-f

10 Noise and vibration

a Loose components and joints a Retighten b From air end b Consult the distributor b-1 Bearing demand or worn b-2 Foreign material c V-belt slip c Adjust tension or replace d Wrong installation of the unit d Correct the installation e Unbalanced cooling fan(Dust collection) e Clean the fan

11 Blow-back of oilair

a Failure of Intake check valve a Replace b Minimum pressure valve leak b Replace c failure of capacity control c Consult the distributor e V-belt broken during running d Replace f Coupling broken during running e Replace

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

26

5-2 OPERATION RECORD FORM

Repla

ced p

arts a

nd

oth

er

partic

ula

rs

Tota

l

runnin

g h

ours

Quantity

of

refill

oil

(gal)

Am

bie

nt

Tem

pera

ture

(lsquoF)

Dis

charg

e

pre

ssure

(Psig

)

Oil

Tem

pera

ture

(lsquoF)

Moto

r Voltage

(V)

Am

p

(A)

Date

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

27

CHAPTER VI

CORRECTIVE MAINTENANCE

6-1 OIL FILTER If the differential pressure between inlet and outlet of the oil filter reaches 185 psig it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately The replacement of oil filter element under normal operating conditions should be performed every 1000 hours or once a monthly whichever comes first

NOTE

In cold ambient temperature conditions the oil tends to have a high viscosity Therefore checking the

oil temperature must be carried out only after the unit has run for a while and warmed-up properly

To replace the oil filter element please take the following steps Stop the unit and make sure that the discharge pressure gauge indicates 0 psig Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter Remove the filter element and make certain the seal is also removed Clean the i nner surface of filter head Reinstall the filter element and seal

Fig 6-2 Oil filter

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

28

6-2 SUCTION FILTER Whenever the operating time is over 500 hours or as required in service operating conditions clean the suction filter To clean the suction filter please follow the steps as described below

After stopping the unit remove the cover Unscrew the wing nut off and take out the element and the silencer

Remove the first stage element Gently knock the t wo end faces of second stage element alternately on a flat surface to remove most of heavy dry dirt

Using an air nozzle held at a suitable distance between

the nozzle and the inside pleats of second stage element blast up and down the pleats in a reverse flow action Clean the first stage element by using an air nozzle

Inspect the element by placing a bright light nearby it If there are thin spots pin holes or ruptures show up discard the element

Reinstall the element Make sure that the ele ment has seated tightly without any gap between the filter and the silencer

Tighten the wing nut

Fig 6-4 Suction Filter

CAUTION

The second stage polyester element may be washable five times at a maximum Do not fail to discard the

used element and replace it with a new one

6-3 OIL SEPARATOR CARTRIDGE Oil separator cartridge is located at the upper part of air-end Oil separator cartridge separates the fine oil mist from the air Separated oil is collected at the bottom of the cartridge and is scavenged to the air-end Under normal operating conditions the oil carry over in the discharge air is controlled within the design limits If the oil separator element is clogged the oil carry-over is increased Check every 3000 hours or six(6) month to check whether excessive oil consumption exists Replace the oil separator cartridge and clean the inside of oil separator every 6000 hours or yearly whichever comes first To replace the element please follow the steps as described below Stop the unit and make sure that the discharge pressure gauge indicates 0 psig

Rotate the oil filter in a counter clockwise rotation when viewed from the bottom of the filter

Remove the filter element and make certain the seal is also removed Clean the inner surface of filter head

Reinstall the filter element and seal

6-4 AIREND MECHANICAL SEAL Mechanical seal is located on the suction side of male rotor shaft The contact surfaces are lubricated by oil which is fed through a port in the oil seal housing The drain tube for this oil is routed back to the air intake via a check valve This system must be inspected cleaned or replaced if necessary every 24000 operating hours or every 4 years whichever comes first Oil seal wear may be monitoredtested Maximum oil leakage 3 cch Consult your distributor

CAUTION

Do not install anything to block the drain tube such as a stop valve The drain tube should be open to the

atmosphere in order to check for the mount oil leak in the event of such incident

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

29

6-5 MINIMUM PRESSURE VALVE Minimum pressure valve is located on the compressor discharge line after the separator tank The valve is set at 57 psig for maintaining adequate system pressure for effective separation of oil If the set pressure is not proper readjust as follows

WARNING

The correct minimum pressure is vital for the function of the compressor Tampering with the

adjustment may cause a compressor breakdown Valves should be adjusted by authorized personnel

Contact your distributor

6-6 SUCTION CONTROL VALVE Service the suction control valve every 6000 hours of operation or yearly whichever comes first Proceed as follows

Stop the unit and disconnect the electrical mains Close the isolation stop valve Make sure that the unit is completely depressurized Remove the suction filter and silencer Disconnect all the piping on suction control valve Remove the bolts fixing the su ction control valve with air-end Take out the suction control valve with care not to damage the surrounding equipment Protect the air-end inlet against the entry of dust by covering it

Disassemble the suction control valve Remove the gasket(or o -ring) from groove Use care so the gasket surface or the groove is not damaged

Inspect the Butterfly valve and non -return valve for any damage or scratches Mount the suction control valve on the air -end Tighten the bolts and set screws Reconnect all the piping Make sure that the installation positions are correct Open the isolation stop valve and start the unit Make sure that the suction control valve is operating correctly

6-7 OIL AFTER COOLER amp COOLING FAN It is important to keep the fins of oil cooler and after cooler free from dust accumulation to ensure optimum efficiency of heat exchange Therefore the coolers and cooling fan should be cleaned every 3000 hours or six(6) month whichever comes first To clean the cooler fins use an air nozzle or steam jettier Wipe the accumulated dust off the cooling fan to prevent unbalanced rotation(Extreme environments may require more frequent servicing)

6-8 OIL TEMPERATURE REGULATING VALVE Service the oil temperature regulating valve every 6000 hours of operation or at once a year whichever comes first Please proceed as follows

Stop the unit and disconnect the electrical mains Make sure that the unit is completely depressurized Prepare the oil pan to catch dripping oil Disconnec t the oil pipings to take out the assembly of the oil temperature regulating valve assembly

Disassemble the oil temperature regulating valve assembly Using a new o -ring reassemble the oil temperature regulating valve and connect it to the piping

6-9 V-BELTS

6-9-1 TENSION CHECK Inspect belts every 50 hours of operation when new and adjust tension and alignment as required until 200 hours Then inspect every 2000 hours or four months whichever comes first For inspection of belt tension proceed as follow

As illustrated below push and pull each V -belt in both in and outward with a spring balancer or tension meter

Check the average deflections measured Make sure that the average deflections are approximately the same value as in the table below

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

30

Fig 6-14 V-Belt tension

6-9-2 TENSION READJUSTMENT AND ALIGNMENT If necessary readjust the tension as follow Isolate main power Loosen the lock bolts located at the motor base Loosen the tightening nuts of adjusting bolts Tighten the adjusting bolts until the correct tension is

obtained If necessary inspect the alignment as follows

Motor shaft and air -end rotor shaft must be parallel and motor sheave and pulley must be exactly opposite each other Put the end of a string into the groove between pulley and V-belts Holding the other end of the string stretch the string onto the end surface of motor sheave and pulley Make sure that no gap exists at the points amp If there is a gap slightly loosen or retighten either of adjusting bolts

Tighten the nuts Tighten the lock bolts and check the tension a gain for confirmation Manually turn the pulleys and make sure that they can turn smoothly

WARNING

Loosely tensioned V-belts may develop problems such as slipping of V-belts premature wearing of

V-belts and pulley grooves abnormal heat generation loss of pressure etc

Too tightly tensioned V-belts may develop the problems such as shaft damage short service life of

bearings etc

NOTE

Consult with distributor in your area for V-belts replacement if any of the followings has occurred before

the normal replacement interval (12000 hours)

V-belts are elongated too much to get the correct tension

Any one of V-belts is worn damaged or broken Neglecting it may cause all of V-belts to break

MODEL NEW INSTALLATION READJUSTMENT

TENSION P lbs

DEFLECTION δ inch

TENSION P lbs

DEFLECTION δ inch

CHSA-7510M 55 0267 48 0267 CHSA-1520M 59 0276 53 0276

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

31

Fig 6-15 V-Belt alignment

6-10 PRESSURE TRANSMITTER Check the settings of the pressure switch every 500 hours of operation or monthly basis whichever comes first If cut-out pressure settings are not proper readjust as follows Differential = Cut-out pressure - cut-in pressure Therefore the value of standard factory setting is 256 psig

NOTE

Generally the narrower differential needs a larger air receiver and vice versa However please be advised

that using an unnecessarily larger air receiver is not generally recommended

6-11 SAFETY VALVE Make sure that safety valve is operative every 500 hours of operation or monthly whichever comes first To operate the safety valve pull the attached ring while the unit is running Thereby the collected condensate and rust will be relieved Use caution and appropriate safety equipment and procedures

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

32

Appendix-A

COMPRESSOR PART LIST

1 Part List for Model CHSA-7510M(NK40)

Item Part Number Description QTY

1 CHSA-7510M-3-1 Air-end 1

2 CHSA-7510M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-7510M-3-3 Separator Cartridge 1

4 CHSA-7510M-3-4 Oil Filter 1

5 CHSA-7510M-3-5 Temperature Prove Connection 1

6 CHSA-7510M-3-6 Oil Circuit Out 1

7 CHSA-7510M-3-7 Oil Reservoir 1

8 CHSA-7510M-3-8 Oil Circuit In 1

9 CHSA-7510M-3-9 Safety Valve 1

10 CHSA-7510M-3-10 Air Intake 1

11 CHSA-7510M-3-11 Compressed Air Outlet 1

12 CHSA-7510M-3-12 Port For Pressure Transmitter 1

13 CHSA-7510M-3-13 Oil Filler Plug 1

14 CHSA-7510M-3-14 Minimum Pressure Valve 1

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

33

2 Part List for Model CHSA-1520M(NK60)

Item Part Number Description QTY

1 CHSA-1520M-3-1 Air-end 1

2 CHSA-1520M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-1520M-3-3 Separator Cartridge 1

4 CHSA-1520M-3-4 Oil Filter 1

5 CHSA-1520M-3-5 Temperature Prove Connection 1

6 CHSA-1520M-3-6 Oil Circuit Out 1

7 CHSA-1520M-3-7 Oil Reservoir 1

8 CHSA-1520M-3-8 Oil Circuit In 1

9 CHSA-1520M-3-9 Safety Valve 1

10 CHSA-1520M-3-10 Air Intake 1

11 CHSA-1520M-3-11 Compressed Air Outlet 1

12 CHSA-1520M-3-12 Port For Pressure Transmitter 1

13 CHSA-1520M-3-13 Minimum Pressure Valve 1

14 CHSA-1520M-3-14 Oil Filler Plug 1

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

34

3 Part List for Model CHSA-2530M(NK100)

Item Part Number Description QTY

1 CHSA-2530M-3-1 Air-end 1

2 CHSA-2530M-3-2 Intake Control Valve wAir Filter 1

3 CHSA-2530M-3-3 Separator Cartridge 1

4 CHSA-2530M-3-4 Oil Filter 1

5 CHSA-2530M-3-5 Temperature Prove Connection 1

6 CHSA-2530M-3-6 Oil Circuit Out 1

7 CHSA-2530M-3-7 Oil Reservoir 1

8 CHSA-2530M-3-8 Oil Circuit In 1

9 CHSA-2530M-3-9 Safety Valve 1

10 CHSA-2530M-3-10 Air Intake 1

11 CHSA-2530M-3-11 Compressed Air Outlet 1

12 CHSA-2530M-3-12 Port For Pressure Transmitter 1

13 CHSA-2530M-3-13 Minimum Pressure Valve 1

14 CHSA-2530M-3-14 Oil Filler Plug 1

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

35

Appendix-B

1 PART LIST FOR MODEL CHSA-75M(12)

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

36

1 PART LIST FOR MODEL CHSA-75M(22)

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

37

2 PART LIST FOR MODEL CHSA-10M(12)

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

38

2 PART LIST FOR MODEL CHSA-10M(22)

3 PART LIST FOR MODEL CHSA-15M(12)

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

39

3 PART LIST FOR MODEL CHSA-15M(22)

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

40

4 PART LIST FOR MODEL CHSA-20M(12)

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

41

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

42

4 PART LIST FOR MODEL CHSA-20M(22)

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

43

Appendix-C

1 DISPLAY PC BOARD

2 CONTROL PC BOARD

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

44

D Wiring Diagram(1) for Model CHSA-75101520M

START

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COM

P DISCH

ARGE

TEMP

RTD

Pt 10

0ohm

-+

DC

12V

4~2

0 mADC

PT

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

45

4 Wiring Diagram(2) for Model CHSA-30M

STA

RT

STO

P

DO

WN

UP

RU

N

MEN

UEN

TERALAR

M

RESET

HO

UR

PRESSU

RE(k

gc

m )2

TEM

PER

ATU

RE(deg

C)

COMP D

ISCH

ARGE

TEM

P

RTD

Pt 100

ohm

-+

DC 1

2V

4~20

mADC

PT

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

46

Appendix-E

1 Outline Drawing for Model CHSA-7510M

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

47

2 Outline Drawing for Model CHSA-1520M

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

48

Warranty Claim Report Please complete the following claim form your claim will be confirmed by our sales representative

To Coaire Technologies Corporation 12226 Coast Drive Whittier CA 90601 Tel(562)463-3935Fax(562)463-4928

Distributor Company Date

Address Model Serial No

Customer Company Run Hours Hrs

Address Setting Press PSIG

OPERATING CONDITIONS Percent() on load Ambient Temperature F No of days of operation weekly Days Discharge temperature F Hours per day Hours Compressor area temperature F Machine setting OLOL or Mod Environment 1)

1) 1 to 10 1 being clean 10 very dirty Incoming Voltages Full load amperage at _______ PSIG Unload amperage at ______ PSIG L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3 L1 - L2 L2 - L3 L1 - L3

Volts Amp Amp Amp Amp Amp Amp Amp Amp

Symptom

Fault Diagnosis

Resolution

Parts required Labor Cost No Item Number DescriptionMFGR Part Number Quantity Labor Time Hrs x $Hrs= $ 01 Travel Time Hrs x $Hrs= $

02 Total Amount $

03 04 Technicians name

WRITTEN BY SIGNATURE X

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

49

STARTUP REPORT FOR ROTARY SCREW AIR COMPRESSOR Please fill out completely and return to the factory to validate warranty

CUSTOMER AND MACHINE INFORMATION CUSTOMER FACTORY SHIP DATE ADDRESS DATE STARTED UP CITYSTATE MODEL NUMBER CHSA- S PHONE SERIAL NUMBER WRITTTEN BY HOURS ON MACHINE Hrs

MACHINE INFORMATIONS AND INITIAL STARTUP Compressor Environment- excellent good fair poor Machine Location ndash indoors outdoors if outdoors protected from rain Yes No

Approx ambient temperature______ adequate ventilation - Yes No Did you check for correct rotation Yes No Nameplate amperage for voltage used ________ Incoming Voltages

L1‐L2 L2‐L3 L1‐L3 Volts Volts Volts

Full load amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Unload amperage at _________ PSIG

L1 L2 L3 Amp Amp Amp

Is the machine on a level and stable surface Yes No Did you have to add lubricant oil ndash Yes No if yes please indicate amount and exact name and type (Amount _______ Name _______ Type _______ ) Was a flexible connector used to connect piping ndash Yes No Approx time spent during startup procedure ___________ Hrs Did you advice customer on operation and maintenance of machine Yes No Application and installation comments__________________________________________________________ ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Machine Sold By(Company) __________________ Sales Person ___________________________ Startup performed by ____________________ Date _________________________________

THERE IS NO WARRANTY WITHOUT THIS REPORT

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802

50

QUALITY AND RELIABILITY WITHOUT COMPROMISE

WARRANTY

COAIRE compressors are thoroughly tested at the factory and warranted against defects in workmanship and material for a period of 12 months The entire compressor package is warranted for a period of 12 months from the date of installation or 18 months from the date of factory shipment including parts and labor The requirements are the use of genuine COAIRE maintenance fluid replacement parts and annual oil sample sent to COAIRE The warranty is void if the product is modified without COAIREs approval or use of maintenance fluids and parts other than genuine COAIRE products

TECHNOLOGIES CORP

12226 COAST DRIVE WHITTIER CA 90601 TEL(562)463-3935 ㆍ FAX(562)463-4928

COAIRE reserves the right to make changes at any time without notice as

a result of our commitment to continuous improvement

COAIRE-CHSA-0802