• Author / Uploaded
• Mauricio Gómez

Citation preview

ROTARY SCREW AIR COMPRESSORS Microprocessor Control System

MAINTENANCE MANUAL AND PARTS LIST

MODELS : CHSA-20S CHSA-25S CHSA-30S CHSA-50S CHSA-60S CHSA-75S CHSA-100S

COAIRE TECHNOLOGIES, CORPORATION All rights reserved

Printed in U.S.A.

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 system's 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.

Coaire Technologies, Corp.

1

CHSA-M0211

TABLE OF CONTENTS Chapter Ⅰ. General information 1-1. Instruction ............................................................................................................................................ 1-2. Screw compression process ............................................................................................................... 1-3. Compressed air flow ........................................................................................................................... 1-4. Cooling air flow .................................................................................................................................. 1-5. Oil separation ..................................................................................................................................... 1-6. Oil flow .............................................................................................................................................. 1-7. Oil scavenge flow .............................................................................................................................. 1-8. Standard Specifications ..................................................................................................................... 1-9. Installation and wiring ........................................................................................................................ Chapter Ⅱ. Operating instructions 2-1. Operating panel ................................................................................................................................... 2-2. Initial start-up ..................................................................................................................................... 2-3. Daily operation ................................................................................................................................... 2-4. Standard factory settings of control components .................................................................................... 2-5. Microprocessor controller ..................................................................................................................... Chapter Ⅲ. Functional Description 3-1. Compressor air-end ............................................................................................................................... 3-2. Drive motor ......................................................................................................................................... 3-3. Compressor drive ................................................................................................................................. 3-4. Capacity control .................................................................................................................................. 3-5. After cooler/oil cooler ........................................................................................................................ 3-6. Lubrication system ................................................................................................................................ 3-7. Oil separator ...................................................................................................................................... 3-8. Air intake filter ................................................................................................................................... 3-9. Minimum pressure valve ....................................................................................................................... 3-10. Instrument panel ................................................................................................................................. 3-11. Starter and panel ............................................................................................................................... 3-12. Safety device ..................................................................................................................................... Chapter Ⅳ. Scheduled Maintenance 4-1. Standard maintenance schedule ............................................................................................................. 4-2. Control of lubrication ........................................................................................................................... Chapter Ⅴ. Trouble shooting 5-1. Trouble symptoms and solutions ............................................................................................................. 5-2. Operation record form ........................................................................................................................ Chapter Ⅵ. Corrective maintenance 6-1. Oil level gage ..................................................................................................................................... 6-2. Oil Filter ............................................................................................................................................. 6-3. Oil scavenge filter ............................................................................................................................. 6-4. Suction filter ....................................................................................................................................... 6-5. Oil separator element .......................................................................................................................... 6-6. Air-end mechanical seal ........................................................................................................................ 6-7. Minimum pressure valve ....................................................................................................................... 6-8. Pressure switch .................................................................................................................................... 6-9. Differential pressure switch ................................................................................................................... 6-10. Suction control valve .......................................................................................................................... 6-11. Oil/after cooler and cooling fan ........................................................................................................ 6-12. Oil temperature regulating valve ......................................................................................................... 6-13. Coupling ........................................................................................................................................... 6-14. Coupling alignment ............................................................................................................................. 6-15. V-Belts ............................................................................................................................................. 6-16. Safety valve .................................................................................................................................... Chapter Ⅳ. Parts list 7-1. Machinery parts ................................................................................................................................... 7-2. Electric parts ....................................................................................................................................... Appendix A. Solid State Board ............................................................................................. B. Electric Connecting Diagram ...................................................................................... C. Electric Wiring Diagram .......................................................................................... D. Open Protocol for PC Monitoring .......................................... ...............................................

Coaire Technologies, Corp.

2

CHSA-M0211

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 totally 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

Coaire Technologies, Corp.

3

CHSA-M0211

1-3. COMPRESSED AIR FLOW. The panel has an intake duct through which air is drawn into the enclosure. Air flows 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 air/oil 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, the oil flows into the oil cooler, 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.

Coaire Technologies, Corp.

4

CHSA-M0211

Fig 1-5. Operating flow diagram

Coaire Technologies, Corp.

5

CHSA-M0211

1-8. STANDARD SPECIFICATIONS MODEL ITEM Motor output Discharge pressure Air delivery Compressor speed Ambient temperature Discharge air temperature Driving method Voltage Frequency Starting method Oil sump capacity Weight Dimensions(W×D×H) Air outlet piping size MODEL ITEM Motor output Discharge pressure Air delivery Compressor speed Ambient temperature Discharge air temperature Driving method Voltage Frequency Starting method Oil sump capacity Weight Dimensions(W×D×H) Air outlet piping size

CHSA-20S Kw(HP) psi(g) cfm RPM ℉ ℉ V Hz gal lbs in in

110 84 2450

15(20) 125 77 2250

CHSA-25S

CHSA-30S

19(25) 22(30) 125 150 110 125 96 87 125 115 2900 2650 3900 3505 32∼115℉ Inlet air temperature + 27℉(MAX) V-Belt (3V×3) V-Belt (3V×4) 230, 460 60 Direct Start 5.0 5.5 1056 1232 59.½×40.⅜×45.⅝ 59.½×40.⅜×50.⅜ 1 150 66 1900

CHSA-50S

110 104 3100

CHSA-60S

CHSA-75S

Kw(HP) 37(50) 45(60) 55(75) psi(g) 110 125 150 110 125 150 110 125 150 cfm 207 193 170 269 246 203 337 309 264 RPM 1900 1750 1500 2350 2150 1770 2810 2600 2270 ℉ 32∼115℉ ℉ Inlet air temperature + 27℉(MAX) V-Belt (3V×7) V-Belt (3V×9) V 230, 460 Hz 60 Star-Delta Start gal 8 13 lbs 1716 2530 in 67×50×57.⅞ 68.½×51.½×57.⅞ in 1½ 1½

150 100 3050

CHSA-100S 75(100) 110 434 3540 Coupling

15 3320 83.⅛×48.⅜×59.⅞ 2

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

Coaire Technologies, Corp.

6

CHSA-M0211

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 recirculation of air-end for easy maintenance access.

CHSA-20S CHSA-25S CHSA-30S CHSA-50S CHSA-60S CHSA-75S CHSA-100S

A 24 24 24 42 60 60 60

B 42 42 42 42 60 60 60

C 42 42 42 36 60 60 60

D 24 24 24 36 60 60 60

(Unit : Inch)

Fig 1-8. The space clearance example

Coaire Technologies, Corp.

7

CHSA-M0211

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 104℉ or lower. - operation at ambient temperature of higher than 104℉ may cause compressor shutdown or severe damage to the unit.

HEAT GENERATION & VENTILATION FAN CAPACITY MODEL CAPACITY

CAPACITY (Btu/h) AIR VOLUME (cfm)

CHSA-20S CHSA-25S CHSA-30S CHSA-50S CHSA-60S CHSA-75S CHSA-100S

51981 5474

75790 7945

125790 13250

197610 20840

266650 28080

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.

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.

Coaire Technologies, Corp.

8

CHSA-M0211

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 ---------------------------- × 100 (％) (V)mean where, (V)max : Maximum voltage among three terminals (V)mean : Average voltage among three terminals

CAUTION 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

MODEL

Coaire Technologies, Corp.

NO FUSE BREAKER

AIR-END MOTOR

9

OVER CURRENT RELAY

MAIN CABLE

CHSA-M0211

L.R.A.[A] POWER[V] F.L.A. FRAME TRIP POWER 3ø60Hz [A] DIRECT Y-DELTA [AF] [A] OUTPUT INPUT FACTOR [kW/Hp] [kW] [%] 380 22 138.6 50 50 440 19 119.7 50 40 220 54.3 353 100 100 CHSA-20S 15/20 17 82 380 31.4 203.8 100 60 440 27.2 176.5 100 50 220 59.0 378 100 100 CHSA-25S 19/25 20.2 88.5 380 440 220 81.5 163 225 150 CHSA-30S 22/30 25.2 81 380 47.2 94.3 100 75 440 40.8 81.5 100 75 220 133.1 274.7 225 225 CHSA-50S 37/50 41.4 81.5 380 77.1 159 225 150 440 66.6 137.3 225 125 220 CHSA-60S 45/60 48.1 380 440 75.0 155.0 220 196.7 393.3 400 350 CHSA-75S 55/75 61.5 82 380 113.9 227.7 225 200 440 98.4 196.6 225 175 220 252.9 505.3 400 400 380 146.4 292.3 400 300 CHSA-100S 75/100 82.9 86 440 126.4 252.5 225 225 380 288 768 600 600 440 248.7 663.3 600 500

Coaire Technologies, Corp.

10

TRIP [A] 27 23 65 38 33 66

POWER GROUND [㎟] [㎟] KIV GV 5.5 3.5 5.5 3.5 22 5.5 14 3.5 8 3.5

57 33 28 92 53 46

50 22 14 100 38 30

5.5 3.5 3.5 14 5.5 5.5

136 79 68 175 101 88 200 172

150 80 60 250 125 100 325 250

22 14 14 22 14 14 22 22

CHSA-M0211

CHAPTER II OPERATING INSTRUCTIONS

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

Fig 2-1. Operating panel DESCRIPTION Discharge pressure Emergency stop Power Run Reset Start Stop Menu Up Down Reverse Phase Over Current Discharge Temp HI Check Oil Separator Check Oil Filter

FUNCTION Indicates the discharge pressure Push button switch for emergency stop Signal lamp for power on/off Signal lamp for running Switch for the alarm reset Switch for Running Switch for stopping Switch for selecting the message on the LCD screen Switch for increasing the input value Switch for decreasing the input value Alarm, Signal lamp for Reverse Phase Alarm, Signal lamp for cut-out at over current Alarm, Signal lamp for high discharge temperature Alarm, Signal lamp for the separator element differential Pressure Alarm, Signal lamp for the oil filter differential pressure

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). Coaire Technologies, Corp.

11

CHSA-M0211

WARNING DIRECTION OF ROTATION

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 at the proper point. Oil level should be at the center line of the upper oil level gage. ⒤ Isolation stop valve in the discharge air line is completely open. 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 unit. The running lamp on the unit operating panel lights up.

CAUTION REVERSE PHASE CONNECTION In case of the reverse phase connection, the unit does not start and the reverse phase signal lamp of the operating panel of the unit lights up. If this happens, 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 of time. Oil level may drop as oil circulates into the system. Add oil if the level during operation should be below the lower center line 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 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. Coaire Technologies, Corp.

12

CHSA-M0211

⒢ 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 cut-out 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 center line of upper oil level gage with 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. STOPPING ⒜ Press STOP key. ⒝ Make sure that the 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 Discharge pressure Minimum pressure valve Discharge pressure switch Oil separator element diff. switch Oil filter diff. switch Discharge temperature switch

Coaire Technologies, Corp.

UNIT Psi Psi Psi Psi Psi ℉

STANDARD FACTORY SETTING VALVE

110 110/90

13

125 57 125/105 10 25 220

150 150/130

CHSA-M0211

2-5. OPERATION AND CONTROL SEQUENCE (1) CAPACITY CONTROL SYSTEM POWER ON → ↓ (REVERSE HASE)

START

↓

(Normal)

CHECHING ROTATION

←

Y-Δ START (DELTA RUN AFTER Y-START)

↑

↓ LOAD OPERATION (AFTER 10 SEC. IDLING OPERATION)

EXCHANGE 3 OF 2 MAIN CABLE → ←

↓

← ↓ SET PRESSURE

LINE PRESSURE MONITORING (PRESSURE SWITCH)

↑

OR LESS

↑

LOAD OPERATION (Loading Valve ON)

COMING SET PRESSURE OR MORE

OFF LOAD OPERATION (Loading Valve OFF) ↓ ↑ SET PRESSURE

LINE PRESSURE Monitoring (Pressure Switch)

OR MORE

COMING SET PRESSURE OR LESS

RETURN LOAD OPERATION (Loading Valve ON)

↑

↓

OFF LOAD OPERATION (Loading Valve OFF)

↓ OFF LOADING TIME CHECK

↓ STAND-BYMODE (AFTER STOPPING OPERATION)

AUTO-RESTART BY LINE PRESSURE ↓ Coaire Technologies, Corp.

14

CHSA-M0211

(2) STOP CONTROL SYSTEM WHILE MACHINE IS RUNNING ↓ PUSH STOP BUTTON ↓ MONITORING WHEN LOAD OPERATION

WHEN OFF-LOAD OPERATION →

↓

OFF-LOAD OPERATION

↓ OFF-LOAD OPERATION TIME COUNT

(IF SET TIME IS OVER)

STOP CONTROL OPERATION WHILE SET TIME (SET TIME:30~60SEC.)

↓

(IF SET TIME IS ON)

OFF-LOAD OPERATION WHILE REMINING TIME

↓

↓ ↓ MACHINE STOP

←

(3) TROUBLE MONITORING SYSTEM

MOTOR OVERLOAD

HIGH DISCHARGE TEMPERATURE

OIL FILTER or OIL SEPARATOR CLOGGY

O.C.R.(ITH)

TEMPERATURE SWITCH

DIFF. PRESSURE SWITCH

▶ FLASH ALARM LAMP ON SWITCH PANEL ▶ ALARM MESSAGE ON L.C.D. ▶ BUZZER RESET AND STOP DISCONNECT POWER AND RELEASE PREASE CHECK AND REPLACE RESTART Coaire Technologies, Corp.

15

CHSA-M0211

2-6. MICROPROCESSOR CONTROLLER. The unit uses DDC(Direct Digital Control) to obtain maximum efficiency(of its function), realize precision control and save energy. It also perfectly deals with, stores, and displays various data during operation to ensure running convenience. 2-6-1. STRUCTURE OF FRONT SIDE OF DISPLAY CONTROL PANEL.

2-6-2. STATUS MENUS DURING THE NORMAL OPERATION. 1] POWER-ON MODE

COAIRE ROTARY SCREW Displays the status of the initial power on for 3 sec.

ALARM STATUS NO ALARM

ALARM STATUS ABNORMAL

Displays the status after 3 sec. of the initial power on for 2 sec.

Displays the status after 3 sec. of the initial power on for 2 sec. And will be indicate the alarm message on alarm mode.

POWER ON RUN TIME xxxxx H Displays the status of be ready to start machine. The operator can start the unit and the power lamp will indicate. Displays the total run time. Coaire Technologies, Corp.

16

CHSA-M0211

2] STARTING MODE

STARTING DIRECT STARTING

STARTING Y-DELTA STARTING

Displays the status of the direct starting.

Displays the status of the Y-delta starting.

WYE STARTING TIME xx SEC Displays the Y-Delta starting time. The running lamp will be flashed during Y-Starting mode and the running lamp will indicate there after. The running time of the Y-Starting mode is counted on the display screen.

IDLING OPERATION TIME xx SEC Displays the idling running time. The running lamp will be flashed during idling operation mode and the running lamp will indicate there after. The running time of the idling mode is counted on the display screen.

3] RUNNING MODE

xxx PSI xxx ℉ RUN TIME xxxxx H

xxx PSI xxx ℉ UNLOAD xx MIN

Displays the status of the loading operation.

Displays the operation.

status

of

the

unloading

4] STAND-BY MODE

xxx PSI xxx ℉ STAND-BY xxxxx H Displays standby status, machine will automatically restart when set pressure is achieved.

Coaire Technologies, Corp.

17

CHSA-M0211

5] STOPPING MODE

xxx PSI xxx ℉ STOP CNT XX SEC Displays stopping status when stop switch is pressed. Displays stopping time, machine stops.

POWER ON RUN TIME xxxxx H Displays the status of be ready to start machine. The operator can start the unit and the power lamp will indicate. Displays the total run time.

2-6-3. ALARM STATUS MENUS. Various alarm statuses of the unit are displayed.

ALARM STATUS ABNORMAL Displays the error status.

1] REVERSE PHASE ALARM

CHECK MESSAGE REVERSE PHASE Displays status of reverse phase for main power source of #1~#3. Following messages will be scrolled automatically

REVERSE PHASE CHECK POWER LINES AND INTERCHANGE TWO OF THREE MAIN CABLES IN TERMINAL BLOCK.

2] END MOTOR OVERLOAD ALARM Coaire Technologies, Corp.

18

CHSA-M0211

CHECK MESSAGE AIR-END MOTOR Displays status of overload for air-end motor. Following messages will be scrolled automatically

AIR-END MOTOR CHECK THE MAIN MOTOR OVERLOAD AND THE LOW VOLTAGE, CONSULT WITH THE DISTRIBUTOR. 3] FAN MOTOR OVERLOAD ALARM

CHECK MESSAGE COOLING FAN OCR Displays status of overload for cooling fan motor. Following messages will be scrolled automatically

COOLING FAN OCR CHECK THE COOLING FAN OCR AND THE LOW VOLTAGE, CONSULT WITH THE DISTRIBUTOR. 4] OIL FILTER CLOGGED ALARM

CHECK MESSAGE OIL FILTER Displays the status that oil filter is clogged. Following messages will be scrolled automatically

OIL FILTER CHECK THE OIL FILTER SERVICE TIME. REPLACE OIL FILTER AS NECESSARY, 5] OIL SEPARATOR CLOGGED ALARM

CHECK MESSAGE OIL SEP. ELEMENT Displays the status that element of the oil separator is clogged. Following messages will be scrolled automatically

OIL SEP. ELEMENT FAILED OR CLOGGED OIL SEPARATOR ELEMENT. REPLACE THE ELEMENT, 6] HIGH DISCHARGE AIR TRMPERATURE ALARM

CHECK MESSAGE Coaire Technologies, Corp.

19

CHSA-M0211

DISCHARGE TEMP. Displays the status of the high discharge air temperature

COOLING FAN OCR CHECK THE DISCHARGE TEMP. AND REFER THE MANUAL. 7] PRESSURE TRANSMITTER FAIL ALARM

CHECK MESSAGE PRESS TRANSMITTER Displays the status of the pressure transmitter fail

PRESSURE TRANSMITTER CHECK THE PRESSURE TRANSMITTER WIRES. CONSULT WITH THE DISTRIBUTOR. 8] PRESSURE SWITCH(FOR UNLOADING)

CHECK MESSAGE PRESS SWITCH Displays the status of the pressure switch fail(if installed)

PRESSURE TRANSMITTER CHECK THE PRESSURE SWITCH AND WIRES. REPLACE THE PRESSURE SWITCH AS NECESSARY 9] RTD SENSOR(DIS. TEMPERATURE SENSOR)

CHECK MESSAGE PRESS SWITCH Displays the status of the RTD sensor.

PRESSURE TRANSMITTER CHECK THE RTD SENSOR WIRES. REPLACE THE RTD SENSOR AS NECESSARY 2-6-4. SET VALUE CHANGING MENUS. Various data values showing the running status of the unit can set or display.

Y-DELTA START Coaire Technologies, Corp.

20

CHSA-M0211

IDELING START SET TIME XX [SEC] Displays the idling delay time.

UNLOADING CONTROL SET TIME XX [MIN]

STOP CONTROL SET TIME XX [SEC]

Displays the idling delay time.

Displays the stop control time.

DISCHARGE AIR SET TEMP XXX [℉]

OIL HEATER ON SET TEMP XX [℉]

Displays the discharge temperature.

Displays the oil heater on time(optionally)

DISCHARGE PRESS SET XXX [PSI]

DRAIN ON-TIME SET XX [SEC]

Displays the discharge air pressure

Displays the auto drain valve on-time(open)

SET TIME XX [SEC] DRAIN OFF-TIME SET XX [MIN]

Displays the Y-Delta delay time. (Applicable to Y-Delta units only)

Displays the auto drain valve off-time(close)

Coaire Technologies, Corp.

21

CHSA-M0211

UNITS CHANGE ? METRIC / LBS Displays the current set units

LANGUAGE ? ENGLISH

MACHINE TYPE ? STANDARD(or MINI SCREW)

Displays the current set language

Displays the current set machine type

2-6-5. It is highly recommended that the following procedures be conducted by qualified factory trained personnel. Consult your distributor. HOW TO CHANGE SET VALUES. The running mode of the unit is programmed upon delivery. However, the operator may amend it depending on conditions and needs. Mode selection may be reset in the following way : 2-6-5-1 CHANGING THE 'Y-DELTA DELAY TIME' 1) Select the STARTING mode. Operator can amend the set value in this mode only.

STARTING MODE Y-DELTA START/DIRECT START 2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System key lock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the Y-Delta delay time, Press [MENU] key one time after system key-lock release. The menu will be displayed :

Y-DELTA START SET TIME XX [SEC] 4) Amend the set value by using ▲(Up) and ▼(Down) Keys. Display Returns to initial mode after 10 sec. 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 increments 2-5-5-2 CHANGING THE 'IDLING START TIME' 1) Select the STARTING mode. Operator can amend the set value in this mode only.

STARTING MODE Y-DELTA START/DIRECT START 2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System key-lock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the idling start time, Press [MENU] key two times. The following menu will be displayed :

IDELING START SET TIME XX [SEC] Coaire Technologies, Corp.

22

CHSA-M0211

4) Amend the set value by using ▲(Up) and ▼(Down) Keys. Display Returns to initial mode after 10 sec. 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 increments 2-6-5-3 CHANGING THE 'UNLOADING CONTROL TIME' 1) Select the STARTING mode. Operator can amend the set value in this mode only.

STARTING MODE Y-DELTA START/DIRECT START 2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System key-lock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the unloading control time, Press [MENU] key three times. The following menu will be displayed :

UNLOADING CONTROL SET TIME XX [MIN] 4) Amend the set point value by using ▲(Up) and ▼(Down) Keys. Returned to initial mode after 10 sec. 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 increments. 2-5-5-4 INCASE OF CHANGING THE 'STOP CONTROL TIME' 1) Select the STARTING mode. Operator can amend the set value in this mode only.

STARTING MODE Y-DELTA START/DIRECT START 2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System keylock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the stop control time, Press [MENU] key four times. The following menu will be displayed :

STOP CONTROL SET TIME XX [SEC]

4) Amend the set point value by using ▲(Up) and ▼(Down) Keys. Returned to initial mode after 10 sec. 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 increments. 2-6-5-5 CHANGING THE 'AIR-END DISCHARGE AIR TEMP.' 1) Select the STARTING mode using MENU key. Operator can amend the set value in this mode only.

STARTING MODE Coaire Technologies, Corp.

23

CHSA-M0211

Y-DELTA START/DIRECT START 2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System key-lock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the compressor discharge shut down temperature, Press [MENU] key five times. The following menu will be displayed :

DISCHARGE AIR SET TEMP XXX [℉] 4) Amend the set point value by using ▲(Up) and ▼(Down) Keys. Returned to initial mode after 10 sec. Press ▲(Up) Key to increase the set point. Increases are displayed in 1(one) ℉ increments. Press ▼(Down) Key to decrease the set point. Decreases are displayed in 1(one) ℉ increments. 2-6-5-6 CHANGING THE 'OIL HERTER ON-TEMPERATURE.'(OPTIONALLY) 1) Select the STARTING mode using MENU key. Operator can amend the set value in this mode only.

STARTING MODE Y-DELTA START/DIRECT START 2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System key-lock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the compressor discharge shut down temperature, Press [MENU] key six times. The following menu will be displayed :

OIL HEATER ON SET TEMP XX [℉] 4) Amend the set point value by using ▲(Up) and ▼(Down) Keys. Returned to initial mode after 10 sec. Press ▲(Up) Key to increase the set point. Increases are displayed in 1(one) ℉ increments. Press ▼(Down) Key to decrease the set point. Decreases are displayed in 1(one) ℉ increments. 2-6-5-7 CHANGING THE 'DRAIN VALVE OFF-TIME(CLOSE TIME).' 1) Select the STARTING mode using MENU key. Operator can amend the set value in this mode only.

STARTING MODE Y-DELTA START/DIRECT START 2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System key-lock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the compressor discharge shut down temperature, Press [MENU] key seven times. The following menu will be displayed :

DRAIN OFF-TIME Coaire Technologies, Corp.

24

CHSA-M0211

SET XX [MIN] 4) Amend the set point value by using ▲(Up) and ▼(Down) Keys. Returned to initial mode after 10 sec. 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 increments. 2-6-5-8 CHANGING THE 'DRAIN VALVE ON-TIME(OPEN TIME).' 1) Select the STARTING mode using MENU key. Operator can amend the set value in this mode only.

STARTING MODE Y-DELTA START/DIRECT START 2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System key-lock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the compressor discharge shut down temperature, Press [MENU] key eight times. The following menu will be displayed :

DRAIN ON-TIME SET XX [SEC] 4) Amend the set point value by using ▲(Up) and ▼(Down) Keys. Returned to initial mode after 10 sec. 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 increments. 2-6-5-9 CHANGING THE ‘DRAIN VALVE OFF-TIME(CLOSE TIME).' 1) Select the STARTING mode using MENU key. Operator can amend the set value in this mode only.

STARTING MODE Y-DELTA START/DIRECT START 2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System key-lock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the compressor discharge shut down temperature, Press [MENU] key nine times. The following menu will be displayed :

DRAIN OFF-TIME SET XX [MIN] 4) Amend the set point value by using ▲(Up) and ▼(Down) Keys. Returned to initial mode after 10 sec. 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 increments. 2-6-5-10 CHANGING THE 'DISPLAY UNITS.' 1) Select the STARTING mode using MENU key. Operator can amend the set value in this mode only.

STARTING MODE Y-DELTA START/DIRECT START Coaire Technologies, Corp.

25

CHSA-M0211

2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System key-lock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the compressor discharge shut down temperature, Press [MENU] key ten times. The following menu will be displayed :

UNITS CHANGE ? METRIC / LBS 4) Amend the set point value by using ▲(Up) and ▼(Down) Keys. Returned to initial mode after 10 sec. Press ▲(Up) Key to increase the set point. Unit is changed Metric or Lbs. 2-6-5-11 CHANGING THE 'DISPLAY LANGUAGE.' 1) Select the STARTING mode using MENU key. Operator can amend the set value in this mode only.

STARTING MODE Y-DELTA START/DIRECT START 2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System key-lock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the compressor discharge shut down temperature, Press [MENU] key eleven times. The following menu will be displayed :

LANGUAGE ? ENGLISH 4) Amend the set point value by using ▲(Up) and ▼(Down) Keys. Returned to initial mode after 10 sec. Press ▲(Up) Key to increase the set point. Language is changed in English or Korean.

Coaire Technologies, Corp.

26

CHSA-M0211

2-6-5-12 CHANGING THE 'MACHINE TYPE.' 1) Select the STARTING mode using MENU key. Operator can amend the set value in this mode only.

STARTING MODE Y-DELTA START/DIRECT START 2) Press and hold ▲(Up) and ▼(Down) Keys simultaneously for 1 second. Message of the 'System key-lock Release ..... ' will appear on the LCD screen. If operator does not select a mode within 10 second after above message, the message will terminate. 3) To find the mode of the compressor discharge shut down temperature, Press [MENU] key twelve times. The following menu will be displayed :

MACHINE TYPE ? STANDARD(or MINI SCREW) 4) Amend the set point value by using ▲(Up) and ▼(Down) Keys. Returned to initial mode after 10 sec. Press ▲(Up) Key to change the set point. Machine type, controlled is changed for Coaire standard screw compressors.(CHSA-20S through CHSA-100 models) or mini-screw compressors.

[ Note ] Set Values No. Items 1 Y-Delta delay time 2 Start idling time 3 Unloading control time 4 Stop control time 4 Compressor discharge shut down temperature 5 Oil heater on-temperature(optionally) 6 Discharge pressure 8 Drain valve on-time 9 Drain valve off-time

Coaire Technologies, Corp.

Factory set point 5 Sec. 10 Sec. 5 Min. 30 Sec. 220 ℉ 41 ℉ 110 Psi 2 sec. 10 Min.

27

Adjustable Range 3 ~ 10 Sec. 5 ~ 10 Sec. 5 ~ 10 Min. 20 ~ 50 Sec. 176 ~ 230 ℉ 32 ~ 50 ℉ 80 ~ 190 PSI 1 ~ 5 Sec. 1 ~ 45 Min.

CHSA-M0211

CHAPTER III FUNCTIONAL DESCRIPTIONS 3-1. COMPRESSOR AIREND. Oil injected, single stage, rotary screw type which primarily consists of rotors, housing, 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 and 4+6 profile rotors. At the discharge end of the compressor, double 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 compressor 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 for model CHSA-20S, CHSA-25S and CHSA-30S has five lobes and the female rotor has seven grooves. The male rotor for model CHSA-50S, CHSA-60S, CHSA-75S and CHSA-100S has four lobes Coaire Technologies, Corp.

28

CHSA-M0211

and the female rotor has six grooves, both are 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.

3-3. COMPRESSOR DRIVE. 3-3-1. V-BELT DRIVE. Motor speed is increased by V-belt drive to the male rotor's driving speed. Coaire Technologies, Corp.

29

CHSA-M0211

Fig 3-4. V-Belt drive 3-3-2. COUPLING DRIVE.

Motor speed is transferred by coupling drive to the male rotor's driving speed.

Fig 3-5. Coupling drive 3-4. CAPACITY CONTROL. All models provide capacity control, on-line/off-line control with upper range modulation. Internal pressure is vented to atmosphere at partially loaded or unload conditions whereby the motor idles for power saving features. 3-5. AFTER COOLER / OIL COOLER. After cooler and oil cooler is composed of corrugated fin and tube type with aluminium 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. 3-6. 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. 3-7. OIL SEPARATOR. Oil separator element is located at the upper part of oil separator, which efficiently separates the oil from discharged air. The lower part of the oil separator housing is the oil sump. 3-8. AIR INTAKE FILTER. The air intake filter is replaceable, dry-type filter with two stage design. It consist of an outside element of urethane and inside element of polyester. Coaire Technologies, Corp.

30

CHSA-M0211

3-9. MINIMUM PRESSURE VALVE. Located in oil separator air outlet in order to maintain adequate system pressure for efficient separation of oil, pressure setting is 57 psig. 3-10. INSTRUMENT PANEL. Consists of start button, stop button, indicating lamps, synoptic display, control panel and pressure gauge. 3-11 STARTER AND CONTROL BOX. Consists of pre-wired direct starter for model CHSA-20S through CHSA-30S and star-delta starter for model CHSA-50S through CHSA-100S. 3-12. SAFETY DEVICE ⒜ Shutdown switch for discharge high air temperatures ⒝ Differential shutdown switch for oil filter ⒞ Differential shutdown switch for oil separator element ⒟ Internal overload thermostat for motor ⒠ Over current relay for cooling fan motor ⒡ Safety valve

Coaire Technologies, Corp.

31

CHSA-M0211

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. Times Interval Part or Item

Action Taken

Condensation from oil separator Drain out Oil level Check Indication of control panel Check Air intake filter Clean Oil(COAIRE recommended brands) Replace Oil scavenge filter Clean Capacity control system properly Check working Check Safety valve properly working Clean Suction filter Replace Oil filter element Oil(COAIRE advised brands) Replace Excessive oil consumption Check Oil scavenge filter Clean Oil level gauge Clean Oil & after cooler Clean V-belts Check for tension Electric components & gauge Check Mechanical seal(Air-end) Check for leak Oil separator element Replace Inside oil separator Clean & Check Oil filter element Replace Oil scavenge filter Replace Suction filter Replace Suction throttle valve Clean Gasket(Suction control valve) Replace Minimum pressure valve Clean Air return filter(Capacity control system) Clean Valve for capacity control system Clean Coupling Clean Cooling fan Clean Oil temperature regulator properly Check working Check Oil heater Check Oil piping line Check Compressed air piping line V-belt or Coupling Replace & Check Check valve Replace Oil heater(if installed) Replace Air-end(Bearing & Mech. Seal) Replace

Run hours 8 8 8 200 500 500 500 500 500 500 3000 3000 3000 3000 3000 3000 3000

Daily

Monthly

6 Eve. 4 Yearly Monthly years

○ ○ ○ ○ (1st check only)

○ ○ ○ ○ ○ ○

(Subsequent replace)

○ ○ ○ ○ ○ ○ ○

(Subsequent replace)

6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000

○ ● ○ ○ ● ● ○ ● ○ ○ ○ ○ ○ ○ ○ ○ ○

12000 24000 24000 30000

○

(Every 2 years) ● ○ ●

4-2. CONTROL OF LUBRICATION. The control of lubrication is critical. Neglecting it may cause varnish or 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. Coaire Technologies, Corp.

32

CHSA-M0211

⒞ Failure to drain the condensation, which will result in an oil deterioration. ⒟ Failure to change oil within a scheduled maintenance interval. WARNING Use of inappropriate oil and/or 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 : 1,500 hours after the first oil change.(4,000 hours after the initial start-up) ⒞ Third and consequent oil changes : Every 4,000 hours after the previous oil change. 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 under 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 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. ⒢ 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 Coaire Technologies, Corp.

33

CHSA-M0211

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 lunch time), 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. Contents will burn. Use water fog, foam, dry chemical or carbon dioxide to extinguish. Avoid use of direct stream of water since product may float and reignite. 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

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 1. Failure of start or restart

2. Unscheduled shutdowns Coaire Technologies, Corp.

POSSIBLE CAUSE a. Main breaker opened b. Power Failure or low voltage c. Control circuit fuses blown d. Failure of electric components(motor, starter coil, start button, sol. valve etc.) e. Loose wiring or wires too small or disconnected a. Automatic safety shutdowns

34

SUGGESTED REMEDY a. Reset b. Inspect power source c. Replace d. Repair or Replace e. Tighten or replace CHSA-M0211

3. Main motor over load (Safety shutdown)

4. High discharge temperature (safety shutdowns)

5. High Discharge pressure 6. Low discharge pressure

CONDITION 7. Failure to unload property 8. High oil consumption or discharge air contains oil mist

9. Oil deterioration

10. Noise and vibration

Coaire Technologies, Corp.

a-1. Main motor overload a-2. High discharge air temperature b. Differential pressure switch shutdowns b-1. For oil filter b-2. For oil separator filter element c. Control circuit fuses blows a. Difficulty of air-end rotation 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 a. high ambient temperature b. Low oil temperature c. Oil cooler c-1. Clogged inside tube c-2. Dirt accumulation on fins d. Oil filter clogged e. Failure of oil temperature regulating valve f. Insufficient cooling air flow g. Deterioration of oil a. Failure of suction throttle valve b. Failure of pressure switch a. Too high air demand b. Leak in discharge line c. Air intake valve clogged d. Oil separator element clogged e. Suction Throttle valve plugged f. Failure of blow-off solenoid valve g. Failure of pressure switch h. Other failure of capacity control I. Failure of minimum pressure valve j. Indication failure of discharge pressure gage

POSSIBLE CAUSE a. Failure of pressure switch setting b. Other failure of capacity control c. Control line filter clogged a. Too high oil level in separator tank b. Oil leak : b-1. From mechanical seal(Too much leak) b-2. From joint c. Scavenge filter or orifice clogged d. Failed or clogged oil separator element e. Faulty installation of separator element f. Failure of minimum pressure valve g. Use of improper oil h. Too frequent unload and load a. Use of improper oil b. Mixing of different oil c. High ambient temperature d. Water included in oil e. Scheduled oil change neglected a. Loose components and joints b. From air end b-1. Bearing demand or worn b-2. Foreign material c. V-belt slip d. Wrong installation of the unit

35

a-1. See CONDITION 3. a-2. See CONDITION 4. b-1. Replace b-2. Replace c. Replace a. Consult the distributor

b. Inspect source voltage a. Improve room ventilation b. Add oil as necessary c-1. Clean or replace c-2. Clean d. Clean or replace element e. Check or replace f. Check or replace the fan and filter g. Change oil a. Repair or replace b. Repair or replace a. Install a new compressor b. Check the air line c. Clean or replace d. Replace e. Disassemble and clean f. Replace g. Check or replace h. Consult the distributor I. Clean or replace j. Replace

SUGGESTED REMEDY a. Adjust setting b. Consult the distributor c. Clean or replace a. Removal oil b-1. Consult the distributor b-2. Retighten c. Clean or replace d. Replace e. Correct f. Replace g. Change the oil after flushing h. Readjust setting points a. See CONDITION 8-g b. See CONDITION 8-g c. See CONDITION 4-a d. See CONDITION 8-g e. See CONDITION 8-g a. Retighten b. Consult the distributor

c. Adjust tension or replace d. Correct the installation CHSA-M0211

11. Blow-back of oil/air

Coaire Technologies, Corp.

e. Unbalanced cooling fan(Dust collection) a. Failure of check valve b. Minimum pressure valve leak c. failure of capacity control e. V-belt broken during running f. Coupling broken during running

36

e. Clean the fan a. Replace b. Replace c. Consult the distributor d. Replace e. Replace

CHSA-M0211

Date

Amp. (A)

Voltage (V)

Motor Oil Temperature (‘ F)

Discharge pressure (Psig)

Ambient Temperature (‘ F)

Quantity of refill oil (gal.) Total running hours

Replaced parts and other particulars

5-2. OPERATION RECORD FORM

Coaire Technologies, Corp.

37

CHSA-M0211

CHAPTER VI CORRECTIVE MAINTENANCE 6-1. OIL LEVEL GAUGE Oil level gauge is mounted on the oil separator shell. The proper oil level should be checked, so that it is between the center line of upper oil level gauge when machine is stopped and the center line of lower level gauge when machine running. NOTE A quick drop of oil level may be caused by a loosened joint in oil piping, ruptured or clogged oil separator element, clogged oil scavenge filter, oil leak from air-end shaft seal, failure of minimum pressure valve and so on. If this happens, take corrective action and add oil, refer to the relevant section of this manual.

Oil level gages may become clouded, resulting in inability to read oil level. Clean the oil level gauge every 3,000 hours or six(6) monthly whichever comes first, under normal operating conditions. To clean or change the oil level gauge, proceed as follows : ⒜ Make sure that the pressure has been released completely to 0 psig in the oil separator. ⒝ Drain the oil from the system(Please refer to the previous section on oil draining) ⒞ Remove the oil level gauge by rotating counter clockwise. ⒟ Clean the gauge. Discard the oil gauge, if it is too dirty and replace it with a new one. ⒠ Reinstall the gauge using the appropriate sealant on threads. ⒡ Tighten to appropriate torque, (52Lb.ft-in) ⒢ Fill the oil and run the unit. Make sure that the oil does not leak from the oil level gauge.

Fig 6-1. Oil level gauge

Coaire Technologies, Corp.

Fig 6-2. Oil filter

38

CHSA-M0211

6-2. OIL FILTER. If the differential pressure between inlet and outlet of the oil filter reaches 18.5 psig, it means that an oil filter is in a severe clogging state and you must clean the oil filter immediately. If the differential pressure is over 25.6 psig, the compressor is stopped by the differential pressure switch. The replacement of oil filter element under normal operating conditions should be performed every 4,000 hours or once a year whichever comes first. NOTE In cold ambient temperature conditions, the oil tends to have a high viscosity. Therefore, checking the ambient 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 inner surface of filter head. ⒠ Reinstall the filter element and seal. 6-3. OIL SCAVENGE FILTER. Orifice and screen are combined into one scavenge filter block. If the scavenge filter clogs or the oil is accumulated on oil separator element, the oil will be carried over with discharge air. To avoid this problem, the scavenge filter must be cleaned or replaced. The cleaning interval is 3,000 hours or six month whichever comes first. The replacement interval is 6,000 hours or yearly whichever comes first. To clean the scavenge filter, please follow the steps as described below: ⒜ Relieve air pressure from separator tank. ⒝ Disconnect the tube from the filter. ⒞ Unscrew the filter from the filter socket. ⒟ Clean the filter by using an air nozzle. ⒠ Install the filter into the tube and filter socket. Fig 6-3. Oil scavenge filter NOTE Change the whole filter block when : ⒜ Micro screen is excessively dirty or greasy. ⒝ Too many fine dust particles found inside the screen.

6-4. SUCTION FILTER. Whenever the operating time is over 500 hours, 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 two 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. Coaire Technologies, Corp.

39

CHSA-M0211

⒟ 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 element 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 with a new one.

6-5. OIL SEPARATOR ELEMENT. Oil separator element is located at the upper part of oil separator sump. Oil separator element separates the fine oil mist from the air. Separated oil is collected at the bottom of the element, and is scavenged to the air-end by the oil scavenged pipe. 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 3,000 hours or six(6) month to check whether excessive oil consumption exists. Replace the oil separator element and clean the inside of oil separator every 6,000 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. ⒝ Disconnect the discharge piping flange and all the other piping and wiring on top of oil separator. ⒞ Remove the bolts holding the oil separator cover. ⒟ Remove the cover and gasket. ⒠ Clean the inner surfaces of oil separator tank by using clean rags. ⒡ Check the coating of inner surface for any crack or separation. ⒢ Discard the used oil separator element, and install the new element. Make sure that the end of oil scavenge pipe touches the bottom plate of oil separator element. ⒣ Install the new gasket, and securely tighten the bolts of cover. ⒤ Make sure that separator ground is properly installed. ⒥ Connect all the pipings and wiring. Fig 6-5. Oil separator element 6-6. 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 3000 operating hours or every 3 months whichever comes first. Oil seal wear may be monitored/tested. Maximum oil leakage 3 cc/h. 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. Coaire Technologies, Corp.

40

CHSA-M0211

Fig 6-6. Mechanical seal 6-7. MINIMUM PRESSURE VALVE. Minimum pressure valve is located between the oil separator sump and after-cooler and installed on the top of the oil separator. 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 : ⒜ Stop the unit. ⒝ Remove the plastic plug(9) and the pin(10) with a pair of pliers. ⒞ Increase first the opening/minimum pressure by turning the ring(3) clockwise, one or two turns of the wrench. Then decrease the opening/minimum pressure by turning the ring(3) slowly and gradually counter-clockwise. ⒟ Secure the new setting by inserting the pin(10) into a new hole(to be drilled 0.1" into the ring 3). Under normal operating conditions, clean lubricate and change the parts of minimum pressure valve as follows ⒜ Stop the unit and disconnect the electrical mains. ⒝ Remove the plastic plug(9) on top of the screw(3). ⒞ Screw the threaded bolt(31) and lock out(32) into thread J of the position(4). ⒟ Tighten the lock nut(32), 3 turns. ⒠ Disassemble the upper body(2). ⒡ Release tension of the spring(7) by loosening the lock out(32). ⒢ Remove the threaded bolt(31) and lock nut(32). ⒣ Check the spring, if the spring is broken or spring force is lost, use a new O-ring. ⒤ Use cleaning agents for metal surfaces. Do not scratch guide and sealing surface. ⒥ Lubricate all threads, guide and sealing surface with compressor oil before reassembling. 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.

Coaire Technologies, Corp.

41

CHSA-M0211

Fig 6-7. Minimum pressure valve 6-8. PRESSURE SWITCH. 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 : ⒜ Start the unit, and let the unit operate under the loaded operation for more than 30 minutes. ⒝ Loosen the cover bolt, and turn the adjusting screw(A, Fig 6-8). Turning counter-clockwise lowers the setting of unload pressure and vice versa. ⒞ Be sure that the cover bolt is tightened. Pressure switch operation is detected by a change in the unit's operating sound or ammeter reading. If cut-in pressure settings are not proper, readjust as follows : ⒜ Start the unit, and let the unit operate under the loaded condition for more than 30 minutes. ⒝ Loosen the cover bolt, turn the "pressure differential adjustment screw(B, Fig 6-8)" counter-clockwise with a slotted blade screw driver for a narrower differential and vice versa. The differential is calculated by the following formula ; Differential = Cut-out pressure － cut-in pressure Therefore, the value of standard factory setting is 25.6 psig ⒞ Make sure the cut-in pressure is reset by referring to the pressure gauge on the operating panel. ⒟ After the adjustment, mount the cover plate and tighten the cover bolt. 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.

Coaire Technologies, Corp.

42

CHSA-M0211

Fig 6-8. Pressure switch 6-9. DIFF. PRESSURE SWITCH. Check the settings of the pressure switch every 500 hours of operation or on a monthly basis whichever comes first. If cut-out pressure differential settings are not proper, readjust as follows : ⒜ Start the unit, and let the unit operate under the loaded operation for longer than 30 minutes. ⒝ Read the oil separator element inlet pressure and outlet pressure. ⒞ Subtract the inlet pressure reading from the outlet pressure reading. This is the net differential pressure across element. ⒟ To increase the cut-out pressure, turn the adjusting disk of the pressure switch clockwise. To decrease, turn counter-clockwise. ⒠ To raise the pressure differential, turn the adjusting disk to the left when viewing the front of switch. Turn the adjusting disk to the right to lower the pressure differential. Fig 6-9. Diff. pressure switch 6-10. SUCTION CONTROL VALVE. Service the suction control valve every 6,000 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 suction 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.

Coaire Technologies, Corp.

43

CHSA-M0211

Fig 6-10. Suction control valve

6-10-1. SERVO CYLINDER. The service life depends upon the total number of cylinder strokes, the control mode(proportional or on/off) and the signal pressure. Inspection and service intervals are similar to intervals for sealing and filters of compressors. CAUTION Never attempt to disassemble a cylinder under pressure.

Fix cylinder rod by means of a vice for dismantling of the cover 2 - spring 5 is tensioned. Clean polished surfaces with liquid cleaning agent and soft cloth. Do not scratch polished surfaces. Assemble the new diaphragm on dry surfaces.

NOTE 2 3 5 6 14 E

Cylinder cover Piston and rod Control spring Rolling Diaphragm Inlet nozzle Inlet

Fig 6-11. Servo cylinder 6-10-2. PROPORTIONAL CONTROLLER. No maintenance is required if the air supplied to the controller is clean and dry. Controller have to be protected from dirt in the pressure lines and installed in a position for easy drainage of the condensate. Controller can be cleaned with petrol, paraffin, cleaning agent. If possible, cleaned controller should be fitted with a new diaphragm. The set point is adjusted by turning the hand wheel. To a higher pressure turn clockwise, to a lower pressure is counter-clockwise rotation. Coaire Technologies, Corp.

44

CHSA-M0211

Fig 6-12. Proportional controller 6-11. OIL & AFTER COOLER & 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 3,000 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. 6-12. OIL TEMPERATURE REGULATING VALVE. Service the oil temperature regulating valve every 6,000 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. Disconnect 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. 6-13. COUPLING. Check the coupling or tolerance every 3,000 hours of operation or six(6) months whichever comes first. For the tolerance check, proceed as follows : ⒜ Stop the unit and disconnect the electrical mains. ⒝ Make sure that the unit is completely depersonalized. ⒞ Remove the front panel of enclosure. ⒟ Remove the bolts holding the coupling cover. ⒠ Clean the inner surface of coupling and cover with clean rags. ⒡ Check the tolerance both side of coupling. ⒢ Reassemble the coupling and the front panel of enclosure. (Grease name is ALVANIA GREASE EP. NO 2) 6-14. COUPLING ALIGNMENT. A minimum distance of 1/8 inches is required between coupling flanges so that the coupling can be removed without moving either component. ⒜ Secure parallel alignment first. Attach a dial indicator to the motor hub with its sensing pointer resting on the end of a lobe of the air-end hub as shown in figure. Use a loose bolt or stud between the lobes of the air-end and motor hubs to ensure that the lobes rotate together. Rotate the air-end and motor shafts together(use a box wrench on the bolt head on the end of the air-end shaft to facilitate turning) and note the total indicator reading. Adjust the position of the air end or motor using shims where necessary to bring the alignment to within the tolerance(H), 0.006 inch or less.(shown in figure 6-13) ⒝ Secure angular alignment by setting indicator (steel attached to the motor coupling half) to read the point on the smooth back of the air-end hub. Rotate the air-end and motor shafts together noting the change in reading during one revolution. Adjust the position of the air-end or motor using shims where necessary until indicator readings are within the tolerance(V), 0.008 inch or less.(shown in figure 6-10) ⒞ Repeat steps ⒜ and ⒝ until angular and parallel alignments are correct. NOTE Coaire Technologies, Corp.

45

CHSA-M0211

The importance of correct alignment cannot be overemphasized. Angular alignment assures that the shafts are parallel to each other. Parallel alignment assures that both shafts are in the same horizontal and vertical plans. Therefore, it is not possible to have correct alignment unless both the angular and parallel alignments are correct. Step ⒜ and ⒝ must be repeated as often as necessary to adjust the position of the motor or air-end. Obtaining parallel alignment may destroy the angular alignment and vice versa.

⒟ When alignment is complete, tighten the motor and air-end mounting bolts. Then recheck the alignment to be sure it was not altered while tightening. ⒠ Loosen the set screw of the motor hub and slide the motor hub toward the motor. This allows space to assemble the coupling discs and center pieces. ⒡ Rotate the motor shaft so that the two keys are 180°apart. ⒢ Bolt the flexible discs to the coupling hubs. Bolt the center piece in place. ⒣ Be sure the hub properly placed on the motor shaft so that it does not exert any push or pull on the coupling discs. Then tighten the motor hub setscrew. ⒤ After correct alignment has been attached, the air-end and motor must be doweled to preserve correct alignment. Drill and ream any two diagonally opposite mounting feet of the air-end and motor, using the proper sized drill and reamer with respect to the dowel pins to be used. The holes should be drilled completely through the base and they should be reamed until the dowel pin drives tight when it is seated full depth. ⒥ Install the coupling cover.

Fig 6-13. Allowable tolerance for coupling 6-15. V-BELTS 6-15-1. 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. Coaire Technologies, Corp.

46

CHSA-M0211

⒞ Make sure that the average deflections are approximately the same value as in the table below.

NEW INSTALLATION TENSION DEFLECTION P lbs δ inch 5.5 0.267

MODEL CHSA-20S CHSA-25S CHSA-30S CHSA-50S CHSA-60S CHSA-75S

READJUSTMENT TENSION DEFLECTION P lbs δ inch 4.8 0.267

5.9

0.276

5.3

0.276

5.9

0.276

5.3

0.276

6.2

0.267

5.3

0.267

Fig 6-14. V-Belt tension

6-15-2. TENSION READJUSTMENT AND ALIGNMENT. If necessary, readjust the tension as follow : ⒜ 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 ⓐⓑⓒ&ⓓ. If there is a gap, slightly loosen or retighten either of adjusting bolts. ⒝ Tighten the nuts. ⒞ Tighten the lock bolts, and check the tension again 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 (12,000 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.

Coaire Technologies, Corp.

47

CHSA-M0211

Fig 6-15. V-Belt alignment 6-16. 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.

Coaire Technologies, Corp.

48

CHSA-M0211

CHAPTER VII PARTS LIST 7-1. MACHINERY PARTS 7-1-1. PIPING ASSEMBLY FOR MODEL CHSA-20S

AC210088

Coaire Technologies, Corp.

49

CHSA-M0211

7-1-2. PART LIST FOR MODEL CHSA-20S Item

Part Number

1

CHSA-20-1-1

Description Minimum Pressure Valve

Qty Item 1

31

Part Number

Description

Qty

CHSA-20-1-31

Capacity Control Valve

1

2

CHSA-20-1-2

Oil Temperature Reg. Valve

1

32

CHSA-20-1-32

Temperature Sensor

2

3

CHSA-20-1-3

Air Discharge Valve

1

33

CHSA-20-1-33

Drain Cock

2

4

CHSA-20-1-4

Oil/Air Hose(1)

1

34

CHSA-20-1-34

Copper Tube(3/8")

2

5

CHSA-20-1-5

Oil/Air Hose(2)

1

35

CHSA-20-1-35

Half Union

2

6

CHSA-20-1-6

Oil/Air Hose(3)

1

36

CHSA-20-1-36

Flare Nut w/ Seat

4

7

CHSA-20-1-7

Oil/Air Hose(4)

1

37

CHSA-20-1-37

Socket

1

8

CHSA-20-1-8

Oil Filter

1

38

CHSA-20-1-38

Half Union

2

9

CHSA-20-1-9

Safety Valve

1

39

CHSA-20-1-39

Venting Nozzle

1

10

CHSA-20-1-10

Pipe Nipple

1

40

CHSA-20-1-40

Air Hose

3

11

CHSA-20-1-11

Mesh Filter

1

41

CHSA-20-1-41

Push To Connector

2

12

CHSA-20-1-12

Ball Check Valve

1

42

CHSA-20-1-42

Push To Connector

4

13

CHSA-20-1-13

L-Connector

2

43

CHSA-20-1-43

Pipe Nipple

1

14

CHSA-20-1-14

Steel Pipe

1

44

CHSA-20-1-44

Orifice

1

15

CHSA-20-1-15

Copper Tube

4

45

CHSA-20-1-45

Tee

2

16

CHSA-20-1-16

Half Union

1

46

CHSA-20-1-46

90D Elbow Nipple

2

17

CHSA-20-1-17

Flare Nut w/ Seat

6

47

CHSA-20-1-47

Nipple

1

18

CHSA-20-1-18

90D Elbow Nipple

4

48

CHSA-20-1-48

Nipple

3

19

CHSA-20-1-19

Flare Nut w/o Seat

2

49

CHSA-20-1-49

Air Outlet Filter

1

20

CHSA-20-1-20

Copper Tube(1/2")

5

50

CHSA-20-1-50

Auto Drain Valve

1

21

CHSA-20-1-21

Half Union

2

51

CHSA-20-1-51

U-Bolt

1

22

CHSA-20-1-22

Flare Nut w/ Seat

2

52

CHSA-20-1-52

Pipe Supporting Leg

1

23

CHSA-20-1-23

Pipe Nipple

1

53

CHSA-20-1-53

Venting Valve

1

24

CHSA-20-1-24

Globe Valve

1

54

CHSA-20-1-54

Proportional Valve

1

25

CHSA-20-1-25

Pipe Nipple

1

55

26

CHSA-20-1-26

Ball Valve

1

56

27

CHSA-20-1-27

Air Hose(2)

1

57

28

CHSA-20-1-28

Panel

1

58

29

CHSA-20-1-29

Oil Filter Differential Switch

1

59

30

CHSA-20-1-30

Capacity Control Switch

1

60

Coaire Technologies, Corp.

50

CHSA-M0211

7-1-3. BASIC ASSEMBLY FOR MODEL CHSA-20S

Coaire Technologies, Corp.

51

CHSA-M0211

7-1-4. PART LIST, BASIC ASSEMBLY FOR MODEL CHSA-20S

Coaire Technologies, Corp.

52

CHSA-M0211

7-1-4. CABINET MODEL CHSA-20S Item

1 2 3 4 5 6 7 8 9 10 11 12

Part Number CHSA-20-2-1 CHSA-20-2-2 CHSA-20-2-3 CHSA-20-2-4 CHSA-20-2-5 CHSA-20-2-6 CHSA-20-2-7 CHSA-20-2-8 CHSA-20-2-9 CHSA-20-2-10 CHSA-20-2-11 CHSA-20-2-12

Coaire Technologies, Corp.

Description

Aluminum profile frame Common base Front cover - Left Front cover - Right Side cover - Right Wire net Side cover - Left Suction grille Air inlet filter Switch panel assembly Upper cover Rear cover

53

Q'ty

1 1 1 1 1 1 1 1 1 1 1

CHSA-M0211

7-2-1. PIPING ASSEMBLY FOR MODEL CHSA-25S & CHSA-30S

Coaire Technologies, Corp.

54

CHSA-M0211

7-2-2. PART LIST FOR MODEL CHSA-25S & 30S

Item 1

Part Number

Description

CHSA-25/30-1-1 Minimum Pressure Valve

Qty Item 1

Part Number

Description

Qty

31 CHSA-25/30-1-31 Capacity Control Valve 1

2

CHSA-25/30-1-2 Oil Temperature Reg. Valve 1

32 CHSA-25/30-1-32 Temperature Sensor

2

3

CHSA-25/30-1-3 Air Discharge Valve

1

33 CHSA-25/30-1-33 Drain Cock

2

4

CHSA-25/30-1-4 Oil/Air Hose(1)

1

34 CHSA-25/30-1-34 Copper Tube(3/8")

2

5

CHSA-25/30-1-5 Oil/Air Hose(2)

1

35 CHSA-25/30-1-35 Half Union

2

6

CHSA-25/30-1-6 Oil/Air Hose(3)

1

36 CHSA-25/30-1-36 Flare Nut w/ Seat

4

7

CHSA-25/30-1-7 Oil/Air Hose(4)

1

37 CHSA-25/30-1-37 Socket

1

8

CHSA-25/30-1-8 Oil Filter

1

38 CHSA-25/30-1-38 Half Union

2

9

CHSA-25/30-1-9 Safety Valve

1

39 CHSA-25/30-1-39 Venting Nozzle

1

10 CHSA-25/30-1-10 Pipe Nipple

1

40 CHSA-25/30-1-40 Air Hose

3

11 CHSA-25/30-1-11 Mesh Filter

1

41 CHSA-25/30-1-41 Push To Connector

2

12 CHSA-25/30-1-12 Ball Check Valve

1

42 CHSA-25/30-1-42 Push To Connector

4

13 CHSA-25/30-1-13 L-Connector

2

43 CHSA-25/30-1-43 Pipe Nipple

1

14 CHSA-25/30-1-14 Steel Pipe

1

44 CHSA-25/30-1-44 Orifice

1

15 CHSA-25/30-1-15 Copper Tube

4

45 CHSA-25/30-1-45 Tee

2

16 CHSA-25/30-1-16 Half Union

1

46 CHSA-25/30-1-46 90D Elbow Nipple

2

17 CHSA-25/30-1-17 Flare Nut w/ Seat

6

47 CHSA-25/30-1-47 Nipple

1

18 CHSA-25/30-1-18 90D Elbow Nipple

4

48 CHSA-25/30-1-48 Nipple

3

19 CHSA-25/30-1-19 Flare Nut w/o Seat

2

49 CHSA-25/30-1-49 Air Outlet Filter

1

20 CHSA-25/30-1-20 Copper Tube(1/2")

5

50 CHSA-25/30-1-50 Auto Drain Valve

1

21 CHSA-25/30-1-21 Half Union

2

51 CHSA-25/30-1-51 U-Bolt

1

22 CHSA-25/30-1-22 Flare Nut w/ Seat

2

52 CHSA-25/30-1-52 Pipe Supporting Leg 1

23 CHSA-25/30-1-23 Pipe Nipple

1

53 CHSA-25/30-1-53 Venting Valve

1

24 CHSA-25/30-1-24 Globe Valve

1

54 CHSA-25/30-1-54 Proportional Valve

1

25 CHSA-25/30-1-25 Pipe Nipple

1

55

26 CHSA-25/30-1-26 Ball Valve

1

56

27 CHSA-25/30-1-27 Air Hose(2)

1

57

28 CHSA-25/30-1-28 Panel

1

58

29 CHSA-25/30-1-29 Oil Filter Differential Switch 1

59

30 CHSA-25/30-1-30 Capacity Control Switch

60

Coaire Technologies, Corp.

1

55

CHSA-M0211

7-2-3. BASIC ASSEMBLY FOR MODEL CHSA-25S & CHSA-30S

Coaire Technologies, Corp.

56

CHSA-M0211

7-2-4. PART LIST, BASIC ASSEMBLY FOR MODEL CHSA-25S & CHSA-30S

Coaire Technologies, Corp.

57

CHSA-M0211

7-2-5. CABINET MODEL CHSA-25S & CHSA-30S Item

1 2 3 4 5 6 7 8 9 10 11 12

Part Number CHSA-25/30-2-1 CHSA-25/30-2-2 CHSA-25/30-2-3 CHSA-25/30-2-4 CHSA-25/30-2-5 CHSA-25/30-2-6 CHSA-25/30-2-7 CHSA-25/30-2-8 CHSA-25/30-2-9 CHSA-25/30-2-10 CHSA-25/30-2-11 CHSA-25/30-2-12

Coaire Technologies, Corp.

Description

Aluminum profile frame Common base Front cover - Left Front cover - Right Side cover - Right Wire net Side cover - Left Suction grille Air inlet filter Switch panel assembly Upper cover Rear cover

58

Q'ty

1 1 1 1 1 1 1 1 1 1 1

CHSA-M0211

7-3-1. PIPING ASSEMBLY FOR MODEL CHSA-50S

Coaire Technologies, Corp.

59

CHSA-M0211

7-3-2. PART LIST FOR MODEL CHSA-50S Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Part Number CHSA-50-1-1 CHSA-50-1-2 CHSA-50-1-3 CHSA-50-1-4 CHSA-50-1-5 CHSA-50-1-6 CHSA-50-1-7 CHSA-50-1-8 CHSA-50-1-9 CHSA-50-1-10 CHSA-50-1-11 CHSA-50-1-12 CHSA-50-1-13 CHSA-50-1-14 CHSA-50-1-15 CHSA-50-1-16 CHSA-50-1-17 CHSA-50-1-18 CHSA-50-1-19 CHSA-50-1-20 CHSA-50-1-21 CHSA-50-1-22 CHSA-50-1-23 CHSA-50-1-24 CHSA-50-1-25 CHSA-50-1-26 CHSA-50-1-27 CHSA-50-1-28 CHSA-50-1-29 CHSA-50-1-30

Description Air Discharge Hose Minimum Pressure Valve Assy. Pipe Nipple Safety Valve Mesh Filter Push to Connector Nozzle Oil Hose 3 Drain Cock Pressure Switch Nozzle Push to Connector Oil Hose 2 Connector Connector Oil Heater(Option) Oil Hose 4 Oil Hose 1 Ball Valve Pipe, Copper Stop Valve, Globe Pipe Nipple Socket Push to Connector Push to Connector Air Hose Solenoid Valve Tee Nipple Nipple

Coaire Technologies, Corp.

Qty Item Part Number Description 1 31 CHSA-50-1-31 Flare Nut w/Seat 1 32 CHSA-50-1-32 Socket 1 33 CHSA-50-1-33 Half Union 2 34 CHSA-50-1-34 Pipe, Copper 3/8" 2 35 CHSA-50-1-35 Venting Nozzle 6 36 CHSA-50-1-36 Nipple, 90D Elbow 37 CHSA-50-1-37 Proportional Controller 1 38 CHSA-50-1-38 Venting Valve 2 39 CHSA-50-1-39 Diff. Pressure Switch 1 40 CHSA-50-1-40 Half Union 41 CHSA-50-1-41 Flare Nut Without Seat 3 42 CHSA-50-1-42 Panel 43 CHSA-50-1-43 Pipe, Copper 1/2" 2 44 CHSA-50-1-44 Plug Flare Nut w/Seat 2 45 CHSA-50-1-45 Nipple, 90D Elbow 1 46 CHSA-50-1-46 Pipe Nipple 1 47 CHSA-50-1-47 Tee 1 48 CHSA-50-1-48 Elbow, Street 1 49 1 50 1 51 1 52 1 53 2 54 4 55 3 56 1 57 2 58 1 59 3 60

60

Qty 4 1 2 2 1 2 1 1 4 2 2 1 4 6 4 1 1 2

CHSA-M0211

7-3-3. BASIC ASSEMBLY FOR MODEL CHSA-50S

Coaire Technologies, Corp.

61

CHSA-M0211

7-3-4. PART LIST, BASIC ASSEMBLY FOR MODEL CHSA-50S

Coaire Technologies, Corp.

62

CHSA-M0211

7-3-5. CABINET ASSEMBLY FOR MODEL CHSA-50S Item

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part Number CHSA-50-2-1 CHSA-50-2-2 CHSA-50-2-3 CHSA-50-2-4 CHSA-50-2-5 CHSA-50-2-6 CHSA-50-2-7 CHSA-50-2-8 CHSA-50-2-9 CHSA-50-2-10 CHSA-50-2-11 CHSA-50-2-12 CHSA-50-2-13 CHSA-50-2-14 CHSA-50-2-15

Coaire Technologies, Corp.

Description

Aluminum profile frame Common base Front cover - Left Front cover - Right Side cover - Right(1) Side cover - Right(2) Side cover - Left(1) Side cover - Left(2) Top cover - Left Top cover - Right Rear cover Air inlet filter Suction grill Wire net Switch panel ass'y

63

Q'ty

1 1 1 1 1 1 1 1 1 1 1 2 2 1 1

CHSA-M0211

7-4-1. PIPING ASSEMBLY FOR MODEL CHSA-60S & CHSA-75S

Coaire Technologies, Corp.

64

CHSA-M0211

7-4-2. PART LIST FOR MODEL CHSA-60S & CHSA-75S Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Part Number CHSA-60/75-1-1 CHSA-60/75-1-2 CHSA-60/75-1-3 CHSA-60/75-1-4 CHSA-60/75-1-5 CHSA-60/75-1-6 CHSA-60/75-1-7 CHSA-60/75-1-8 CHSA-60/75-1-9 CHSA-60/75-1-10 CHSA-60/75-1-11 CHSA-60/75-1-12 CHSA-60/75-1-13 CHSA-60/75-1-14 CHSA-60/75-1-15 CHSA-60/75-1-16 CHSA-60/75-1-17 CHSA-60/75-1-18 CHSA-60/75-1-19 CHSA-60/75-1-20 CHSA-60/75-1-21 CHSA-60/75-1-22 CHSA-60/75-1-23 CHSA-60/75-1-24 CHSA-60/75-1-25 CHSA-60/75-1-26 CHSA-60/75-1-27 CHSA-60/75-1-28 CHSA-60/75-1-29 CHSA-60/75-1-30 CHSA-60/75-1-31

Description Qty Item Part Number Description Minimum Pressure Valve Assy. 1 32 CHSA-60/75-1-32 Temperature Sensor Pipe Nipple 1 33 CHSA-60/75-1-33 Ball Valve Air Discharge Hpse 1 34 CHSA-60/75-1-34 Pipe Nipple Temperature Reg. Valve Assy. 1 35 CHSA-60/75-1-35 Globe Valve Oil Hose 1 1 36 CHSA-60/75-1-36 Pipe Nipple Oil Hose 2 1 37 CHSA-60/75-1-37 Drain Cock Oil Hose 3 1 38 CHSA-60/75-1-38 Nipple, 90D Elbow Oil Filter Hose 1 39 CHSA-60/75-1-39 Half Union Tee 1 40 CHSA-60/75-1-40 Tee Pipe Nipple 1 41 CHSA-60/75-1-41 Nipple Pipe Nipple 2 42 CHSA-60/75-1-42 Solenoid Valve Bush for Oil Filter 2 43 CHSA-60/75-1-43 Bush Safety Valve Assembly 1 44 CHSA-60/75-1-44 Plug Pipe Nipple 1 45 CHSA-60/75-1-45 Fixing Bracket Elbow, Street 1 46 CHSA-60/75-1-46 Fixing Ring Pipe, Steel 1 47 CHSA-60/75-1-47 Venting Nozzle Check Valve, Ball 1 48 CHSA-60/75-1-48 Air Hose Push to Connector, 1/4" 2 49 CHSA-60/75-1-49 Push to Connector, 1/4" Filter 1 50 CHSA-60/75-1-50 Push to Connector, 1/8 Pipe, Copper 6 51 CHSA-60/75-1-51 Flare Nut w/Seal Half Union 3 52 CHSA-60/75-1-52 Orifice Flare Nut w/Seat 8 53 CHSA-60/75-1-53 Half Union Flare Nut without Seat 4 54 CHSA-60/75-1-54 Pipe, Copper 1/2" Nipple, 90D Elbow 2 55 CHSA-60/75-1-55 Bush Pipe, Copper 3/8" 2 56 CHSA-60/75-1-56 Nipple Nipple, 90D Elbow 2 57 CHSA-60/75-1-57 Auto Drain Valve Half Union 1 58 CHSA-60/75-1-58 Elbow, Street Flare Nut w/ Seat 6 59 CHSA-60/75-1-59 Pipe Nipple Panel 1 60 CHSA-60/75-1-60 Pressure Gage Nipple, 90D Elbow 2 61 CHSA-60/75-1-61 Diff. Pressure Switch Oil Heater(Option) 62 CHSA-60/75-1-62 Pressure Switch

Coaire Technologies, Corp.

65

Qty 1 1 1 1 1 2 1 4 2 2 1 1 1 1 1 1 4 6 2 2 1 2 1 1 2 1 4 1 1 2 1

CHSA-M0211

7-4-3. BASIC ASSEMBLY FOR MODEL CHSA-60S & CHSA-75S

Coaire Technologies, Corp.

66

CHSA-M0211

7-4-4. PART LIST, BASIC ASSEMBLY FOR MODEL CHSA-60S & CHSA-75S

Coaire Technologies, Corp.

67

CHSA-M0211

7-4-5. CABINET ASSEMBLY FOR MODEL CHSA-60S & CHSA-75S Item

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part Number CHSA-60/75-2-1 CHSA-60/75-2-2 CHSA-60/75-2-3 CHSA-60/75-2-4 CHSA-60/75-2-5 CHSA-60/75-2-6 CHSA-60/75-2-7 CHSA-60/75-2-8 CHSA-60/75-2-9 CHSA-60/75-2-10 CHSA-60/75-2-11 CHSA-60/75-2-12 CHSA-60/75-2-13 CHSA-60/75-2-14 CHSA-60/75-2-15 CHSA-60/75-2-16 CHSA-60/75-2-17

Coaire Technologies, Corp.

Description

Aluminum profile frame Common base Front cover - Left Front cover - Right Side cover - Right(1) Side cover - Right(2) Side cover - Left(1) Side cover - Left(2) Top cover(1) Top cover(2) Rear cover(1) Rear cover(2) Suction grill Air inlet filter Wire net(1) Wire net(2) Switch panel ass'y

68

Q'ty

1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1

CHSA-M0211

7-5-1. PIPING ASSEMBLY FOR MODEL : CHSA-100S

Coaire Technologies, Corp.

69

CHSA-M0211

7-5-2. PART LIST FOR MODEL CHSA-100S Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Part Number CHSA-100-1-1 CHSA-100-1-2 CHSA-100-1-3 CHSA-100-1-4 CHSA-100-1-5 CHSA-100-1-6 CHSA-100-1-7 CHSA-100-1-8 CHSA-100-1-9 CHSA-100-1-10 CHSA-100-1-11 CHSA-100-1-12 CHSA-100-1-13 CHSA-100-1-14 CHSA-100-1-15 CHSA-100-1-16 CHSA-100-1-17 CHSA-100-1-18 CHSA-100-1-19 CHSA-100-1-20 CHSA-100-1-21 CHSA-100-1-22 CHSA-100-1-23 CHSA-100-1-24 CHSA-100-1-25 CHSA-100-1-26 CHSA-100-1-27 CHSA-100-1-28 CHSA-100-1-29 CHSA-100-1-30

Description Qty Item Part Number Description Minimum Pressure Valve Assy. 1 31 CHSA-100-1-31 Oil Heater(Option) Air Discharge Hose 1 32 CHSA-100-1-32 Temperature Sensor Air Discharge Pipe 1 33 CHSA-100-1-33 Ball Valve Temperature Reg. Valve Assy. 1 34 CHSA-100-1-34 Pipe Nipple Oil Hose 1 1 35 CHSA-100-1-35 Globe Valve Oil Hose 2 1 36 CHSA-100-1-36 Pipe Nipple Oil Filter Assembly 1 37 CHSA-100-1-37 Drain Cock Oil Filter Hose 1 38 CHSA-100-1-38 Filter, Scavenge Tee 1 39 CHSA-100-1-39 Half Union Pipe Nipple 1 40 CHSA-100-1-40 Tee Pipe Nipple 2 41 CHSA-100-1-41 Nipple Bush for Oil Filter 2 42 CHSA-100-1-42 Solenoid Valve Safety Valve Assembly 1 43 CHSA-100-1-43 Bush Pipe Nipple 1 44 CHSA-100-1-44 Plug Elbow, Street 1 45 CHSA-100-1-45 Fixing Bracket Pipe, Steel 1 46 CHSA-100-1-46 Fixing Ring Check Valve, Ball 1 47 CHSA-100-1-47 Venting Nozzle Push to Connector, 1/4" 2 48 CHSA-100-1-48 Air Hose Pipe Nipple 1 49 CHSA-100-1-49 Push to Connector, 1/4" Pipe, Copper 6 50 CHSA-100-1-50 Push to Connector, 1/8 Half Union 3 51 CHSA-100-1-51 Push to Connector, 3/8" Flare Nut w/Seat 8 52 CHSA-100-1-52 Orifice Flare Nut without Seat 4 53 CHSA-100-1-53 Nipple Nipple, 90D Elbow 2 54 CHSA-100-1-54 Pipe, Copper 1/2" Pipe, Copper 3/8" 2 55 CHSA-100-1-55 Filter, Control Line Nipple, 90D Elbow 2 56 CHSA-100-1-56 Half Union Half Union 1 57 CHSA-100-1-57 Diff. Pressure Switch Flare Nut w/ Seat 6 58 CHSA-100-1-58 Pressure Switch Panel 1 59 Nipple, 90D Elbow 2 60

Coaire Technologies, Corp.

70

Qty 1 1 1 1 1 2 1 4 2 2 1 1 1 1 1 1 4 6 1 1 1 1 1 1 2 2 1

CHSA-M0211

7-5-3. BASIC ASSEMBLY FOR MODEL : CHSA-100S

Coaire Technologies, Corp.

71

CHSA-M0211

7-5-4. PART LIST, BASIC ASSEMBLY FOR MODEL : CHSA-100S

Coaire Technologies, Corp.

72

CHSA-M0211

7-5-5. CABINET FOR MODEL CHSA-100S Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Part Number CHSA-100-2-1 CHSA-100-2-2 CHSA-100-2-3 CHSA-100-2-4 CHSA-100-2-5 CHSA-100-2-6 CHSA-100-2-7 CHSA-100-2-8 CHSA-100-2-9 CHSA-100-2-10 CHSA-100-2-11 CHSA-100-2-12 CHSA-100-2-13

Coaire Technologies, Corp.

Description Aluminum Profile Frame Common Base Front Cover - Left Front Cover - Right Side Cover - Right Wire Net Side Cover - Left Suction Grille Air Inlet Filter Switch Panel Assembly Top Cover(1) Top Cover(2) Rear Cover

73

Qty 1 1 2 1 1 1 1 1 1 1 1 1 1

CHSA-M0211

7-6. ELECTRIC PARTS 7-6-1. CONTROLLER FOR MODEL CHSA-20S, CHSA-25S & CHSA-30S

Item 51F EF1,2 52C NF TR-C TR-P 46 TB E

Part Number CHSA-20/25/30-3-1 CHSA-20/25/30-3-2 CHSA-20/25/30-3-3 CHSA-20/25/30-3-4 CHSA-20/25/30-3-5 CHSA-20/25/30-3-6 CHSA-20/25/30-3-7 CHSA-20/25/30-3-8 CHSA-20/25/30-3-9

Coaire Technologies, Corp.

Description Fan Motor Overload Relay Fuse For Control Circuit Magnetic Contactor Noise Filter Transformer, Control Transformer, PCB Negative Phase Relay Terminal Base(Main/Control) Ground

74

QTY. 1 1 1 1 1 1 1 1 1

CHSA-M0211

7-6-2. CONTROLLER FOR MODEL CHSA-50S, CHSA-60S, CHSA-75S & CHSA-100S

Item Part Number Description 51F CHSA-50/60/75/100-3-1 Fan Motor Overload Relay EF1,2 CHSA-50/60/75/100-3-2 Fuse For Control Circuit 52C CHSA-50/60/75/100-3-3 Magnetic Contactor 42C CHSA-50/60/75/100-3-4 Magnetic Contactor 6C CHSA-50/60/75/100-3-5 Magnetic Contactor NF CHSA-50/60/75/100-3-6 Noise Filter TR-C CHSA-50/60/75/100-3-7 Transformer, Control TR-P CHSA-50/60/75/100-3-8 Transformer, PCB 46 CHSA-50/60/75/100-3-9 Negative Phase Relay TB CHSA-50/60/75/100-3-10 Terminal Base(Main/Control) E CHSA-50/60/75/100-3-11 Ground Coaire Technologies, Corp.

75

QTY. 1 1 1 1 1 1 1 1 1 1 1 CHSA-M0211

Appendix-A Solid State Board

Coaire Technologies, Corp.

76

CHSA-M0211

Appendix-B Connecting Diagram

Coaire Technologies, Corp.

77

CHSA-M0211

Appendix-C Wiring Diagram(1) for Model CHSA-20S/25/30

Coaire Technologies, Corp.

78

CHSA-M0211

Wiring Diagram(2) for Model CHSA-50/60/75/100

Coaire Technologies, Corp.

79

CHSA-M0211

Appendix-D OPEN PROTOCOL

PROTOCOL-MODBUS 1. GENERAL ① Transmission Mode = RTU mode ② Baud rate=9600 ③ Coding System:

8-bit binary, hexadecimal 0-9, A-F Two hexadecimal characters contained in each 8-bit field of the message

④ Bits per Byte:

1 start bit 8 data bit, least significant bit sent first - no parity bit 2 stop bit

⑤ Error Check Field: Cyclic Redundancy Check(CRC) ⑥ RTU Message Framing START

ADDRESS FUNCTION

at least 3.5

8 BITS

Character Times

8BIT

DATA

CRC CHECK

N x 8 BITS

16BIT

END at least 3.5 Character Times

⑦ RTU Bit Order start

1

2

3

4

5

6

7

8

stop

stop

Example Function code 03h (Read Holding Registers) QUERY Field Name

Example(Hex)

Slave Address Function Starting Addr. Hi Starting Addr. Lo No. of Points Hi No. of Points Lo Error Check

Coaire Technologies, Corp.

11h 03h 00h 6Bh 00h 03h (CRC)

80

CHSA-M0211

RESPONSE Field Name

Example(Hex)

Slave Address Function Byte Count Data Hi (Register # 40108) Data Lo (Register # 40108) Data Hi (Register # 40109) Data Lo (Register # 40109)

11h 03h 06h 02h 2Bh 00h 00h

Data Hi (Register # 40110) Data Lo (Register # 40110) Error Check

00h 64h (CRC)

Note * Current sample has the response of the function code 03 only

2. RAM MAP FOR MODBUS COMMUNICATIONS

LABEL

ADDRESS

RunMode

equ 000h

bit

DESCRIPTIONS ; Status of the unit operations

Runf

equ 0

; “ RUN” status

Readyf

equ 1

; Flashing lamp while 1 sec., after starting

Ydeltaf

equ 2

; Y-Delta running status

Idlingf

equ 3

; “ IDLING” status

StandByf

equ 4

; “ STAND-BY” status

Stopf

equ 5

; “ STOP” Status

Loadf

equ 6

; Loading operation

Unldf

equ 7

; Unloading operation

MnuMode

equ 001h

Coaire Technologies, Corp.

; Display Menu Set Mode

81

CHSA-M0211

SetMode

equ 002h

; Value Set Mode

KeyFlag

equ 003h

; Key Check flag

Keyinf

equ 0

OKkeyf

equ 1

NOkeyf

equ 2

Continuef

equ 3

RemoCtrlf

equ 4

; START(1)/STOP(0) set bit on remote operation. If REM switch set to “ 1” on SW1 and REM terminal, remote mode of the unit will be set to “ ON” . (“ 0” is OFF).

Passwordf

equ 5

; Password bit. To set, push Up/Down key

Securityf

equ 6

; To set password, set on-mode Security Dip Switch on P.C.B. If off-mode the dip switch, could not adjust pressure on Set Value Mode

BzMaskf

equ 7

; If push reset button one time at alarm mode, will be set, and then alarm buzzer will be off.

Mnukey

equ 0

; Key value, Not Need for Modbus

DecKey

equ 5

; Key value, Not Need for Modbus

IncKey

equ 7

; Key value, Not Need for Modbus

PswKey

equ 9

; Key value, Not Need for Modbus

TimFlag

equ 004h

;Not Need for Modbus

OneSecf

equ 0

OneMinf

equ 1

BLINKF

equ 2

DSPF

equ 3

TOGF

equ 4

BlkDspf

equ 5

Err1stf

equ 6

ErrMode

equ 005h

;Alarm mode set when alarm is occurred

SP1_Err

equ 0

;Alarm for Spare Switch(Extra alarm switch)

PHASE_Err

equ 1

;Reverse Phase Alarm (Checking while stop mode and 1 second after starting)

MOCR_Err Coaire Technologies, Corp.

equ 2

;Air-end Motor Over Current Alarm

82

CHSA-M0211

(Checking from 2 second after starting motor) FOCR_Err

equ 3

;Fan Motor Over Current Alarm (Checking from 2 second after starting motor)

SOIL_Err

equ 4

;Oil Separator Cloggy Alarm (Checking from 2 second after starting motor)

FOIL_Err

equ 5

;Oil Filter Cloggy Alarm (Checking from 2 second after starting motor)

DCHG_Err

equ 6

; Discharge Air High Temperature Alarm (Checking from 1 second after starting motor)

RTD_Err

equ 7

;Temperature Sensor Trouble Alarm

PS_Err

equ 0

;Checking Pressure Switch Alarm

PRS_Err

equ 1

;Pressure Transmitter Alarm

ErrMode1

equ 006h

Set Alarm when does not work after starting EOCR_Err

equ 2

;EOCR error

* When PSWF=1(when pressure switch is installed), display alarm if PS_Err=1 and PRS_Err=1 * When PSWF=0(when pressure switch is not installed), display alarm if PRS_Err=1 * in case MINI-SCREW(EOCR Only) : standby- set EOCR Alarm : while 1 second after starting – set PHASE Alarm : From 1 second after starting – set MOCR Alarm * In case STANDARD-SCREW(46,51C ) : 46 : set PHASE(reverse Phase) Alarm when power on : 51c: set MOCR(Overload) Alarm after starting

ErrFlag

equ 007h

;Not Need for Modbus

ErrBuff

equ 008h

;Not Need for Modbus

ErrFlag1

equ 009h

;Not Need for Modbus

ErrBuff1

equ 00ah

;Not Need for Modbus

RlyFlag

equ 00bh

;Relay Set

RLY_DRN

equ 0

RLY_EXF

equ 1

RLY_OH

equ 2

Coaire Technologies, Corp.

83

CHSA-M0211

RLY_ARM

equ 3

RLY_LOD

equ 4

RLY_SP

equ 5

RLY_C52

equ 6

RLY_C06

equ 7

LedFlag

equ 00ch

;Not Need for Modbus

RxDFlag

equ 00dh

;Not Need for Modbus

RxDinF

equ 0

TxDinF

equ 1

DspFlag

equ 00eh

;Not Need for Modbus

NextDspf

equ 0

Continuf

equ 1

ExitDspf

equ 2

ADC_endf

equ 3

RTDminerf

equ 4

PRSminerf

equ 5

Initialf

equ 6

LOCKF

equ 7

DswFlag

equ 00fh

PSWF

equ 0

;Checking that Pressure Switch installed or not

REMO

equ 2

;checking Status of the DIP SWITCH setting

CLR

equ 3

;checking Status of the DIP SWITCH setting

MODE

equ 4

;checking Status of the DIP SWITCH setting

AUTO

equ 5

;checking Status of the DIP SWITCH setting

MKS

equ 6

;checking Status of the DIP SWITCH setting

;

GrdSn_Pointer

equ 010h

KeyIn_Counter

equ 011h

ErrDp_Counter

equ 012h

ErrSt_Counter

equ 013h

RemSn_Counter

equ 014h

MnuDp_Counter

equ 015h

ATRun_Counter

equ 016h

Key_Buf

equ 017h

Coaire Technologies, Corp.

;Not Need for Modbus

84

CHSA-M0211

Key_Reg

equ 018h

Reg_1msec

equ 019h

Reg_10msec

equ 01ah

Reg_1000msec

equ 01bh

Dly_100msec

equ 01ch

Scrol_100msec

equ 01dh

TimeDecBuf

equ 01eh

TimeDecReg

equ 01fh

AddresBuf

equ 020h

;Not Need for Modbus

;Not Need for Modbus

;Address of the Unit Controller(DSW2) From #0 to #15 for connecting 16 air compressors

Adcnt

equ 021h

;Not Need for Modbus

adbuf0H

equ 022h

adbuf0L

equ 023h

adbuf2H

equ 024h

adbuf2L

equ 025h

adbuf3H

equ 026h

adbuf3L

equ 027h

RTD_Temper

equ 028h

;Temperature sensor output(0V~5V=0~255)

RTD_Buffer

equ 029h

;Not Need for Modbus

RTD_Register

equ 002ah

;units equivalent values(LBS or Metric)

* When Unit=1(LBS units on the option)

32~302('F), display "---" when 32‘ F or less

* When Unit=0(Metric units on the option)

0~150('C), display "---" when 0 ‘ C or less

RTD_Temper

equ 02bh

;Pressure transmitter output(0V~5V=0~255)

RTD_Buffer

equ 02ch

;Not Need for Modbus

RTD_Register

equ 002dh

;units equivalent value(LBS or Metric)

* when Unit=1(LBS units on the option)

0~200,

If 0 PSI or less, display "---"on L.C.D.

* when Unit=0(Metric units on the option)

0~140,

If 0 kg/cm2 or less, display "---" on L.C.D

MasterOrder

***

0~140 have to set 0~14.0(kg/cm2)

***

Example, 68 comes to 6.8(kg/cm2)

equ 02fh

;Signal for PC control

MasterRunf

equ 0

;If set, machine run(equal to Run Key function on panel)

MasterStop

equ 1

;If set, machine stop(equal to Stop Key function on panel)

ContinRunf

equ 2

;If set, machine run(equal to Remote Run signal)

ContinStop

equ 3

;If set, machine stop(equal to Remote Stop signal)

MasterReset

equ 7

;Equal to Reset Key function on panel

Coaire Technologies, Corp.

85

CHSA-M0211

•

To operate machine on Key Panel, MasterRunf and MasterStop have to be cleared.

BinDatacntr

equ 030h

DrainOnBuf

equ 031h

;Drain On time Counter

DrainOfBuf

equ 032h

;Drain Off time Counter

SilentTime

equ 033h

;SilentTime for communication

CommErr

equ 034h

;Communication Erroir counter

InitSW_Counter

equ 035h

;Not Need for Modbus

BinDataBuf

equ 036h

BinDataBuf1

equ 037h

Data_Counter

equ 038h

Word_Counter

equ 03ah

Line_Counter

equ 03bh

Word_Buffer

equ 03ch

Line_Buffer

equ 03dh

LCD_Index_Buf

equ 03eh

;LCD_Index_Buf+1

equ 03fh

LCD_Index_Buf0

equ 040h

LCD_Index_Buf1

equ 042h

LCD_Index_Buf2

equ 044h

LCD_Index_Buf3

equ 046h

LCD_Index_Buf4

equ 048h

LCD_Index_Buf5

equ 04ah

LCD_Index_Buf6

equ 04ch

LCD_Index_Buf7

equ 04eh

Start_Addr_Buf

equ 050h

Start_Addr_Buf1

equ 052fh

Start_Addr_Buf2

equ 054h

Start_Addr_Buf3

equ 056h

Start_Addr_Buf4

equ 058h

Start_Addr_Buf5

equ 05ah

Start_Addr_Buf6

equ 05ch

Coaire Technologies, Corp.

;For LCD Display ,Not Need for Modbus

;Not Need for Modbus

86

CHSA-M0211

Start_Data_Buf

equ 060h

Start_Data_Buf1

equ 061h

Start_Data_Buf2

equ 062h

Start_Data_Buf3

equ 063h

Start_Data_Buf4

equ 064h

Start_Data_Buf5

equ 065h

Start_Data_Buf6

equ 066h

Cusor_Data_Buf

equ 06ah

Finsh_Data_Buf

equ 06bh

Cusor_Addr_Buf

equ 06ch

Finsh_Addr_Buf

equ 06eh

RxBuffer_Head

equ 070h

RxBuffer_Tail

equ 07eh

;Not Need for Modbus

;Not Need for Modbus

;Not Need for Modbus

; RxData0

equ 070h

RxData1

equ 071h

RxData2

equ 072h

RxData3

equ 073h

RxData4

equ 074h

RxData5

equ 075h

RxData6

equ 076h

RxData7

equ 077h

RxData8

equ 078h

RxData9

equ 079h

RxData10

equ 07ah

RxData11

equ 07bh

RxData12

equ 07ch

RxData13

equ 07dh

RxData14

equ 07eh

; RxBufferIndex

Coaire Technologies, Corp.

equ 07fh

87

CHSA-M0211

TxBuffer_Head

equ 080h

TxBuffer_Tail

equ 08eh

;Not Need for Modbus

; TxData0

equ 080h

TxData1

equ 081h

TxData2

equ 082h

TxData3

equ 083h

TxData4

equ 084h

TxData5

equ 085h

TxData6

equ 086h

TxData7

equ 087h

TxData8

equ 088h

TxData9

equ 089h

TxData10

equ 08ah

TxData11

equ 08bh

TxData12

equ 08ch

TxData13

equ 08dh

TxData14

equ 08eh

; TxBufferIndex

equ 08fh

; TempRxBuffer

equ 05eh

TempTxBuffer

equ 05fh

BackUP_SRT_ADDRS

equ 090H

BackUP_END_ADDRS

equ 0AFH

Add_Run_Time_Reg

equ 090h

;total run time calculation(Decimal Value)

*** 90h: 100000

;00000~99999

*** 91h: 1000 *** 92h: 100 *** 93h: 10 *** 94h: 1

Coaire Technologies, Corp.

88

CHSA-M0211

Loading_Time_Reg

equ 095h

;Total Loading time calculation(Decimal Value)

*** 95h: 10000 units

;00000~99999

*** 96h: 1000 units *** 97h: 100 units *** 98h: 10 units *** 99h: 1 unit Unlding_Time_Reg

;Total Unloading time calculation(Decimal

equ 09ah

Value) *** 9Ah: 10000 units

;00000~99999

*** 9Bh: 1000 units *** 9Ch: 100 units *** 9Dh: 10 units *** 9Eh: 1 unit Option

;Set value of the Option and Dip Switch

equ 09fh

LAN

equ 0 equ 1

;Language set value(0=English, 1=Korean) ;units set value(0=Metric, 1=LBS)

TYPE

equ 6

;"1"=MINISCREW, "0"=STANDARD

ATRunf

equ 7

UNIT ;

Y_Delta_Time_Reg

equ 0a0h

;restart automatically when set AUTO mode and stand-by mode ;Y_Delta starting time set (3sec~10sec)

Idling_Time_Reg

equ 0a1h

;Idling time set (5sec~10sec)

UnldCtl_Time_Reg

equ 0a2h

;Unload control time set (5min~10min)

StopCtl_Time_Reg

equ 0a3h

;Stop control time set(20sec~50sec)

DchgAir_Temp_Reg

equ 0a4h

;Discharge air temperature set

equ 0a5h

;Oil heater On-temperature set

equ 0a6h

;Discharge air temperature set

*when Metric units, 80'C~110'C *when LBS units, 176'F~230'F OilHtOn_Temp_Reg * when Metric units, 0'C~10'C * when LBS units, 32'F~50'F Dcharge_Pres_Reg

* when Metric units, 60~135 (6.0kg/cm2~13.5kg/cm2) * when LBS units, 85PSI~192PSI

Coaire Technologies, Corp.

89

CHSA-M0211

DrainOn_Time_Reg

equ 0a7h

;Drain On time set(1sec~5sec)

DrainOf_Time_Reg

;Drain Off time set(1min~45min)

LoadMin60Counter

equ 0a8h equ 0a9h

UnldMin60Counter

equ 0aah

;Unloading operation Counter

SysFlag

equ 0afh

;Not Need for Modbus

TempReg

equ 0b0h

;Not Need for Modbus

LoopVar

equ 0b1h

IndexVar

equ 0b2h

Parameter

equ 0b3h

CRC_regH

equ 0b4h

CRC_regL

equ 0b5h

Coaire Technologies, Corp.

90

;Loading operation Counter

;Not Need for Modbus

CHSA-M0211

Coaire Technologies, Corp.

91

CHSA-M0211

MODEL SERIAL NO. RUN HOURS

WARRANTY CLAIM REPORT

DATE : DISTRIBUTOR ADDRESS

CHSAHrs. /

/

PHONE FAX

CUSTOMER ADDRESS

PHONE FAX

SYMPTOM:

FAULT DIAGNOSIS:

RESOLUTION:

PARTS REQUIRED No. PART NAME/DESCRIPTIONS 1 2 3 LABOR COST TRAVEL TIME Hrs x LABOR TIME Hrs x TOTAL COST WRITTEN BY

Coaire Technologies, Corp.

Q'TY

$/Hr$ $/Hr$ $ SIGNATURE

92

X

CHSA-M0211

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 five(5) year air-end warranty includes parts only. 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 COAIRE's 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 Technologies, Corp.

93

CHSA-M0211