Rotary Screw Manual-Jan 2008

TECHNOLOGIES CORP.
OIL INJECTION
AND
AIR COOLED
ROTARY SCREW AIR COMPRESSORS
MAINTENANCE MANUAL AND PARTS LIST
MODELS :
CHSA-20
CHSA-25
CHSA-30
CHSA-50
CHSA-60
CHSA-75
CHSA-100
All right reversed

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.
TECHNOLOGIES CORP. Maintenance Manual and Parts List
TABLE OF CONTENTS
Safety and warnings ............................................................................... 3
Chapter Ⅰ. General information

4
1. Screw compression process ............................................................... 4
2. Air-end ............................................................................................... 5
3. Major components .............................................................................. 6
4. Outside view ....................................................................................... 11
5. Standard specification ......................................................................... 13
6. Installation and wiring ........................................................................ 14
7. Operating instructions ......................................................................... 21
8. Functional description of control system ............................................ 23
Chapter Ⅱ. Operation
Maintenance ............................................................................................ 25
1. standard maintenance schedule .......................................................... 25
2. Management of lubrication ................................................................ 26
3. Maintenance and repair of main parts ................................................ 27
Chapter Ⅲ. Functional Description

Trouble shooting ..................................................................................... 36
1. Trouble lists & remedy ....................................................................... 36
2. Operation record form ........................................................................ 38
Chapter Ⅳ. Scheduled Maintenance

Chapter Ⅴ. Trouble shooting

Chapter Ⅵ. Corrective maintenance

Chapter Ⅳ. Parts list

Parts ....................................................................................................... 39
1. Model: CHSA-20, CHSA-25 & CHSA-30 .............................................. 39
2. Model: CHSA-50, CHSA-60, CHSA-75 & CHSA-100 ............................ 43
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 the 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
immediately.
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.
2
CHAPTER 1
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 interlobe space, the other spaces are following the
same cycle. Therefore air is compressed continuously.
Fig 1-4. Discharge Process
3
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 airend suction port. Air then is compressed by the rotation of the male rotor, and oil is
injected into the airend during compression process. The injected oil performs various functions,
such as, sealing, cooling as well as lubricating. The air/oil mixture leaves the airend 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, aftercooler 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
aftercooler 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 airend. 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
airend. 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 airend by the
internal pressure differential so that the oil carry-over in the discharged air can be controlled
within the allowable limit.
4
Fig 1-5. Operating flow diagram
5
Fig 1-6. Operating flow diagram
6
1-4. STANDARD SPECIFICATION
MODEL
CHSA-20 CHSA-25 CHSA-30
ITEM
Motor output Kw(HP) 15(20) 19(25) 22(30)
Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150
Air delivery cfm 84 77 66 104 96 87 125 115 100
Compressor speed RPM 2450 2250 1900 3100 2900 2650 3900 3505 3050
Ambient temperature ℉ 32∼115℉
Discharge air temperature ℉ Inlet air temperature + 27℉(MAX)
Driving method - V-Belt (3V×3) V-Belt (3V×4)
Voltage V 230, 460
Frequency Hz 60
Starting method - Direct
Oil sump capacity gal 3.7 5
Weight lbs 1056 1232
Dimensions(W×D×H) in 55.½×40.⅜×43.¾ 55.½×40.⅜×48.½
Air outlet piping size in 1
MODEL
CHSA-50 CHSA-60 CHSA-75 CHSA-100
ITEM
Motor output Kw(HP) 37(50) 45(60) 55(75) 75(100)
Discharge pressure psi(g) 110 125 150 110 125 150 110 125 150 110
Air delivery cfm 207 193 170 269 246 203 337 309 264 434
Compressor speed RPM 1900 1750 1500 2350 2150 1770 2810 2600 2270 3540
Ambient temperature ℉ 32∼115℉
Discharge air temperature ℉ Inlet air temperature + 27℉(MAX)
Driving method - V-Belt (3V×7) V-Belt (3V×9) Coupling
Voltage V 230, 460
Frequency Hz 60
Starting method - Star-Delta
Oil sump capacity gal 8 13 17
Weight lbs 1716 2530 3320
Dimensions(W×D×H) in 56.⅝×46⅛×57.⅞ 68.⅛×51.⅝×57.⅞ 82.¾×48.½×59.⅞
Air outlet piping size in 1 ½ 1 ½ 2
7
1-8. INSTALLATION AND WIRING. Upon delivery, carefully check the air compressor unit(s) for
damage during transportation.
1-8-1. 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 1-7. Handling by forklift truck
Fig 1-8. Handling by shop crane
1-8-2. 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 airend for easy maintenance access.
8
A B C D
CHSA-20 24 42 42 24
CHSA-25 24 42 42 24
CHSA-30 24 42 42 24
CHSA-50 42 42 36 36
CHSA-60 60 60 60 60
CHSA-75 60 60 60 60
CHSA-100 60 60 60 60
(Unit : Inch)
Fig 1-9. The space clearance example
CAUTION
- Install the unit in a dust-free room of low humidity and on a level concrete floor.
- Never install the unit on timbers or block. High humidity may result in electrical shorts
and corrosion.
- Dust particles containing iron or sand may result in poor resistance of the motor and
airend 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
CHSA-20 CHSA-25 CHSA-30 CHSA-50 CHSA-60 CHSA-75 CHSA-100
CAPACITY
CAPACITY (Btu/h) 51981 75790 125790 197610 266650
AIR VOLUME (cfm) 5474 7945 13250 20840 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.
9
1-8-3. PIPING WORK
CAUTION
- All service piping must be installed so as to exert zero force of moment 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. Aftercoolers 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 can reduce any liquid carry-over.
- In case of 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 to be
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.
Fig 1-10. Parallel installation Fig 1-11. Installation with reciprocating compressor
10
1-8-4. 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
ꠏꠏꠏꠏꠏꠏꠏꠏꠏꠏꠏꠏꠏꠏꠏꠏꠏ × 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
1-8-5. ELECTRICAL SPECIFICATION

NO FUSE
ELECTRIC OVER
COMPRESSOR MOTOR BREAKER CAPACITORS
CURRENT RELAY
(N.F.B) FOR POWER
MODEL MAIN START'G FACTOR
RUNNING POWER
OUTPUT INPUT POWER CURRENT TRIP TIME LOAD CORRECTION
CURRENT FACTOR FRAME
(KW/HP) (KW) (V) (A) (SEC) TRIP(A) (㎌/kvar)
(A) DIRECT Y-DELTA (%) (AF)
3Φ, 60Hz
CHSA-20 15/20 16.64 230 52 336 - 88.5 100 100 5 61 175/2.97
CHSA-25 19/25 20.21 230 59 378 - 88.5 100 100 5 66 200/3.76
CHSA-30 22/30 24.40 230 76 390 - 89.5 225 150 5 91 200/3.74
CHSA-50 37/50 39.90 460 60 - 118 84 225 125 7 41 150/11.73
CHSA-60 45/60 48.13 460 75 - 155 82 225 150 7 52 200/13.73
CHSA-75 55/75 59.27 460 88 - 177 82 225 175 10 65 250/20.35
CHSA-100 75/100 79.90 460 109 - 262 94 225 225 12 76 40/2.63
11
CHAPTER 2
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
NO DESCRIPTION FUNCTION
1 Discharge pressure gauge Indicate The discharge pressure
2 Indicating Lamp Signal lamp for unloading
3 Indicating Lamp Signal lamp for high discharge temperature
4 Indicating Lamp Signal lamp for separator high temperature
5 Indicating Lamp Signal lamp for reverse phase
6 Indicating Lamp Signal lamp for cut-out at over current
7 Indicating Lamp Signal lamp for checking the separator element
8 Indicating Lamp Signal lamp for checking the oil filter
9 Hour Meter The running time display
10 Oil heater switch(if need) Switch for the heater on/off
11 Buzzer switch Switch for the buzzer on/off
12 Indicating Lamp Signal for running
13 Indicating Lamp Signal for power on/off
14 Start button Push button switch for running
15 Stop button Push button switch for stopping
16 Emergency stop switch Push button switch for emergency stop
17 Buzzer Trouble Warning
12
2-2. INITIAL START-UP. Before starting the unit for the first time, all operators must become familiar
with all parts and assemblies.
WARNING
DIRECTION OF ROTATION
2-2-1. BEFORE OPERATION

Make sure that :
⒜ All installation piping and electrical work has been properly performed 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 upper 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-on/off lamp on air compressor instrument panel lights up.
⒝ Press start button 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 upper 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 stably indicates the
corresponding pressure.
13
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.
⒢ Check the safety valve ; Pull the attached ring to operate the safety valve.
⒣ Check the capacity control system. ; Gradually close the stop valve at external air receiver.
As discharge pressure rises, stop closing when the discharge pressure reaches the cut-out pressure.
2-2-3. STOPPING
⒜ Press STOP button.
⒝ 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 aftercooler.
⒝ Oil level should is checked to maintain between upper and lower center lines of the oil gauge.
STARTING
Press START button.
DURING THE OPERATION.

⒜ Check oil level gauge.
⒝ Make sure that the all gauges in compressor instrument panel indicates normal status.
STOPPING
⒜ Press STOP button.
⒝ Make sure that the discharge pressure gauge reads 0 psig.
⒞ Operate the toggle switch for oil heater as follows(if necessary) :
For ambient temperature consistently over 50℉ when the unit is idled, place the toggle switch to "OFF"
position. For ambient temperature consistently below 50℉ when unit is not running, place the toggle
switch to "ON" position.
2-4. STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS
SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Discharge pressure Psi 110 125 150
Minimum pressure valve Psi 57
Discharge pressure switch Psi 110/90 125/105 150/130
Oil separator element diff. switch Psi 10
Oil filter diff. switch Psi 25
Discharge temperature switch ℉ 212(100℃)
Oil separator temperature switch ℉ 221(105℃)
14
CHAPTER 3
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.
Fig 3-1. Cross Section of Airend
NO NAME NO. NAME

1 ROTOR HOUSING 7 MALE ROTOR
2 INLET CASING 8 FEMALE ROTOR

CYLINDRICAL ROLLER BEARING(INLET
3 OUTLET CASING 9
SIDE)
CYLINDRICAL ROLLER
4 BEARING COVER 10
BEARING(OUTLET SIDE)
5 SEAL COVER 11 ANGULAR CONTACT BALL BEARING
6 MECHANICAL SEAL 12 DISTANCE RING
Features
■ Precision grind rotors provide close interlobe 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.
16
3-1-1. ROTORS. The male rotor for model CHSA-20, CHSA-25 and CHSA-30 has five lobes and the
female rotor has seven grooves. The male rotor for model CHSA-50, CHSA-60, CHSA-75 and CHSA-100
has four lobes and the female rotor has six grooves, which is a patented SRM original 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 from 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.
17
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.
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 a range
modulation. Internal pressure is vented to the 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.
18
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 provides oil sump.
3-8. AIR INTAKE FILTER. The air intake filter is replaceable, dry-type filter with two stage design. It
consist of outside element of urethane and inside element of polyester.
3-9. MINIMUM PRESSURE VALVE. Located in oil separator air outlet in order to maintain adequate
system pressure for efficient separation of oil and setting pressure is 57 psig.
3-10. INSTRUMENT PANEL. Consists of start button, stop button, indicating lamp, hour meter and
pressure gauge.
3-11 STARTER AND CONTROL BOX. Consists of pre-wired direct starter for model CHSA-20 through
CHSA-30 and star-delta starter for model CHSA-50 through CHSA-100.
3-12. SAFETY DEVICE

⒜ Shutdown switch for discharge high air temperatures
⒝ Shutdown switch for oil separator high air temperatures
⒞ Differential shutdown switch for oil filter
⒟ Differential shutdown switch for oil separator element
⒠ Internal thermostat for airend motor
⒡ Over current relay for cooling fan motor
⒢ Safety valve
19
CHAPTER 4
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 Run 6 Eve. 4 Remarks
Daily Monthly Yearly
hours Monthly years
Condensation from oil separator Drain out 8 ○
Oil level Check 8 ○
Indication of control panel Check 8 ○
Air intake filter Clean 200 ○
Oil(k&C recommended brands) Replace 500 ○ (1st check only)
Oil scavenge filter Clean 500 ○
Capacity control system properly working Check 500 ○
Safety valve properly working Check 500 ○
Suction filter Clean 500 ○
Oil filter element Replace 500 ○
Oil(k&C advised brands) Replace 3000 ○ (Subsequent replace)
Excessive oil consumption Check 3000 ○
Oil scavenge filter Clean 3000 ○ (Subsequent replace)
Oil level gauge Clean 3000 ○
Oil & after cooler Clean 3000 ○
V-belts Check for tension 3000 ○
Electric components & gauge Check 3000 ○
Mechanical seal(Airend) Check for leak 6000 ○

Oil separator element Replace 6000 ●
Inside oil separator Clean & Check 6000 ○
Oil filter element Replace 6000 ○
Oil scavenge filter Replace 6000 ●
Suction filter Replace 6000 ●
Suction throttle valve Clean 6000 ○
Gasket(Suction controlvalve) Replace 6000 ●
Minimum pressure valve Clean 6000 ○
Air return filter(Capacity control system) Clean 6000 ○
Valve for capacity control system Clean 6000 ○
Coupling Clean 6000 ○
Cooling fan Clean 6000 ○
Oil temperature regulator properly working Check 6000 ○
Oil heater Check 6000 ○
Oil piping line Check 6000 ○
Compressed air piping line Check 6000 ○
V-belt or Coupling Replace & Check 12000 ○ (Every 2 years)

Check valve Replace 24000 ●
Oil heater(if installed) Replace 24000 ○
Airend(Bearing & Mech. Seal) Replace 30000 ●
20
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.
⒞ Failure to drain the condensation, which will result in an oil deterioration.
⒟ Failure to change oil within a scheduled maintenance interval.
WARNING
Varnish or sludge deposits may cause serious problems on the unit such as catching fire
from a separator element arid etc.
4-2-1. FUNCTIONS OF OIL. Oil is an essential factor in the oil flooded rotary screw compressor. Use a
high grade synthetic oil with ISO viscosity grade 68, which is developed for pressurized circulation system,
containing rust, form, oxidation and wear inhibitors along with effective water release characteristics. Oil
performs the following functions :
⒜ Lubrication : Oil seals the clearance between the male and female rotors, the clearance between shaft
and shaft seal.
⒝ 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-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.(2,000 hours after the initial start-up)
⒞ Third and consequent oil changes : Every 2,000 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.
21
⒟ For draining of oil cooler, remove the plug at the drain outlet of the oil cooler to let the oil run down.
⒠ Drain the oil as complete 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 the original state.
⒡ Fill with new oil through the oil filling port of oil separator. Refer to the table of specification for the
appropriate oil amount.
⒢ After securely tightening the plug at oil filling port, run the unit to make sure there aren't any oil leaks.
4-2-3 DRAINING CONDENSATION. Moisture contained in intake air can be condensed into water
especially during a longer a unloading time or when the unit is stopped, and is accumulated in a separator
sump, Since the water in a compressor system can cause deterioration of oil and internal rusting, do not
neglect draining the condensation at least on a daily basis. Draining should be performed before start-up
since oil and condensation have been sufficiently separated from each other. Open the drain valve at outlet
of oil separator sump. Use a pan to store the condensation being drained. Closely watch the draining
condensation, and close the valve.
NOTE
If a compressor operation can be suspended (for example, during 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 continuos service, it is still recommended to perform a
draining procedure although oil is wastefully drained out together with the condensation.
Normally in such an operation mode, an extra stand-by compressor has to be installed at
the same time to allow for better draining condensation.
CAUTION
LUBRICANT
Avoid prolonged breathing of vapors. Always use with 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 of
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 this oil by using an intended 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
22
CHAPTER 5
TROUBLE SHOOTING
As a guide, the most likely problems causes 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 press emergency switch on operating panel.
CONDITION POSSIBLE CAUSE SUGGESTED REMEDY
a. Main breaker opened a. Reset

b. Power Failure or low voltage b. Inspect power source
c. Control circuit fuses blown c. Replace
1. Failure of start or restart
d.Failure of electric components(motor, starter coil,
d. Repair or Replace
start button, sol. valve etc.)
e. Loose wiring or wires too small or disconnected e. Tighten or replace
a. Automatic safety shutdowns
a-1. Main motor overload a-1. See CONDITION 3.
a-2. High discharge air temperature a-2. See CONDITION 4.
2. Unscheduled shutdowns b. Differential pressure switch shutdowns
b-1. For oil filter b-1. Replace
b-2. For oil separator filter element b-2. Replace
c. Control circuit fuses blows c. Replace
a. Difficulty of airend rotation a. Consult the distributor
a-1. Foreign material in airend
3. Main motor over load a-2. For oil separator filter element
(Safety shutdown) a-3. Oil viscosity too high(oil deterioration or oil
heater not switched ON at stopping
b. Low voltage b. Inspect source voltage
a. high ambient temperature a. Improve room ventilation
b. Low oil temperature b. Add oil as necessary
c. Oil cooler
c-1. Clogged inside tube c-1. Clean or replace
4. High discharge temperature c-2. Dirt accumulation on fins c-2. Clean
(safety shutdowns) d. Oil filter clogged d. Clean or replace element
e. Failure of oil temperature regulating valve e. Check or replace
f. Check or replace the fan
f. Insufficient cooling air flow
and filter
g. Deterioration of oil g. Change oil
a. Failure of suction throttle valve a. Repair or replace
5. High Discharge pressure
b. Failure of pressure switch b. Repair or replace
a. Too high air demand a. Install a new compressor
b. Leak in discharge line b. Check the air line
c. Air intake valve clogged c. Clean or replace
d. Oil separator element clogged d. Replace
e. Suction Throttle valve plugged e. Disassemble and clean
6. Low discharge pressure
f. Failure of blow-off solenoid valve f. Replace
g. Failure of pressure switch g. Check or replace
h. Other failure of capacity control h. Consult the distributor
I. Failure of minimum pressure valve I. Clean or replace
j. Indication failure of discharge pressure gage j. Replace
23
CONDITION POSSIBLE CAUSE SUGGESTED REMEDY
a. Failure of pressure switch setting a. Adjust setting
7. Failure to unload property b. Other failure of capacity control b. Consult the distributor
c. Control line filter clogged c. Clean or replace

a. Too high oil level in separator tank a. Removal oil
b. Oil leak :
b-1. From mechanical seal(Too much leak) b-1. Consult the distributor
b-2. From joint b-2. Retighten
8. High oil consumption or c. Scavenge filter or orifice clogged c. Clean or replace
discharge air contains oil
mist d. Failed or clogged oil separator element d. Replace
e. Faulty installation of separator element e. Correct
f. Failure of minimum pressure valve f. Replace
g. Use of improper oil g. Change the oil after flushing
h. Too frequent unload and load h. Readjust setting points
a. Use of improper oil a. See CONDITION 8-g
b. Mixing of different oil b. See CONDITION 8-g
9. Oil deterioration
c. High ambient temperature c. See CONDITION 4-a
d. Water included in oil d. See CONDITION 8-g
e. Scheduled oil change neglected e. See CONDITION 8-g
a. Loose components and joints a. Retighten
b. From air end b. Consult the distributor
b-1. Bearing demand or worn
10. Noise and vibration
b-2. Foreign material
c. V-belt slip c. Adjust tension or replace
d. Wrong installation of the unit d. Correct the installation
e. Unbalanced cooling fan(Dust collection) e. Clean the fan
a. Failure of check valve a. Replace
b. Minimum pressure valve leak b. Replace
11. Blow-back of oil/air
c. failure of capacity control c. Consult the distributor
e. V-belt broken during running d. Replace
f. Coupling broken during running e. Replace
24
CHAPTER 6
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 and the center line of lower
level gauge.
NOTE
A quick drop of oil level may be caused by loosened joint of oil piping, ruptured or clogged oil
separator element, clogged oil scavenge filter, oil leak from airend 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.
Cloudy oil level gauge results in the failure to notice the reduced oil amount. 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 an oil separator.
⒝ Drain the oil from the system(Please refer to the previous section on Oil Draining)
⒞ Remove the three bolts holding oil level gauge.
⒟ Clean the gauge. Discard the oil gauge, if it is too dirty and replace it with a new one.
⒠ Reinstall the gauge by using the new packing.
⒡ Tighten the bolts, the appropriate tightening torque should be 52Lbf-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 Fig 6-2. Oil filter
25
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 cloging 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 6,000 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 :
① Stop the unit, and make sure that the discharge pressure gauge indicates 0 psig.
② Turn the oil filter element by using a belt to a counter clockwise rotation.
③ Remove the filter element and packing.
④ Clean the inner surfaces of filter head by using an air nozzle.
⑤ Reinstall the filter element and packing.
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 such a problem, the scavenge filter must be cleaned
and changed. 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
scanenge filter, please follow the steps as described below:
⒜ 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.
26
⒞ 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 also by using an air nozzle.
⒟ Inspect the element by placing a bright light nearby it
If thin spots, pin holes or raptures show up, discard
the element.
⒠ Reinstall the elements. Make sure that the element
have 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 airend by the oil scavenged pipe. Under the normal operating
condition, the oil carry over in the discharge air is
controlled with in 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 the
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 wirings on the 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 touchs 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 wirings.
Fig 6-5. Oil separator element
27
6-6. AIREND MECHANICAL SEAL. Mechanical seal is located on the suction side of male rotor shaft.
The contact surfaces between fixed part and rotating part of the mechanical seal are lubricated by the oil
injected through the hole at seal cover. Oil is oozes slightly through the mechanical seal to the drain tube.
Oozing of oil is to lubricate the mechanical seal normally. If the amount of oozing is more than 3 cc/h, It is
due to the failure of the mechanical seal, and there must be a leak. Consult the distributor in this instance,
for the replacement of mechanical seal.
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.
Fig 6-6. Mechanical seal
6-7. MINIMUM PRESSURE VALVE. Minimum pressure valve is located between oil separator sump and
coolers 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 setting pressure is not proper, readjust as follows :
⒜ Stop the unit.
⒝ Remove the plastic plug(9) and the pin(10) with a pair of pliers.
⒞ Inclease first the openning/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 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).
28
⒢ Remove the threaded bolt(31) and lock nut(32).

⒣ Check the spring, if the spring is broken or spring force is lost, use the 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
of the distributor by using an accurate pressure gage.
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 loading operation for longer than 30 minutes.
⒝ Loosen the cover bolt, and turn the adjusting screw(A, Fig 6-8) of the pressure switch. Turning
counter-clockwise provides the lower setting of unload pressure and vice versa.
⒞ Be sure that the cover bolt is tightened. The starting of pressure switch 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 loading operation for longer than 30 minutes.
⒝ Loosen the cover bolt, turn the "pressure differential adjustment screw(B, Fig 6-8)" counter-clockwise by
a slotted blade screw driver for a narrower differential and vice versa. The differential is calculated by
the following formula ;
29
Differential = Cut-out pressure － cut-in pressure

Therefore, the valve 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
Fig 6-8. Pressure switch
6-9. DIFF. PRESSURE SWITCH. Check the settings of the pressure switch every 500 hours of
operation or 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 loading 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 in 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
30
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 airend. Take out the suction control valve with
care not to damage the surrounding equipment. Protect the airend inlet against the entering of dust by
covering it.
⒠ Disassemble the suction control valve. Remove the gasket(or o-ring) from groove. Be cautious that 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 airend. Tighten the bolts and set screws.
⒣ Reconnect all the pipings. 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.
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 dried up surfaces.
31
NOTE
2 Cylinder cover
3 Piston and rod
5 Control spring
6 Rolling Diaphragm
14 Inlet nozzle
E 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 is clockwise, to a lower pressure is counter-clockwise rotation.
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 jetter. 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.
⒞ Disassemble the assembly of the oil temperature regulating valve.
⒟ Using a new o-ring, reassemble the oil temperature regulating valve and connect it to the pipings.
32
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 depressurized.
⒞ Remove the front panel of enclosure.
⒟ Remove the blots 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 between coupling flanges is required so that the
coupling can be assembled or disassembled without moving the motor.
⒜ 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 airend hub as shown in figure. Use a loose bolt or stud between the
lobes of the airend and motor hubs to ensure that the lobes rotate together. Rotate the airend and
motor shafts together(use a box wrench on the bolt head on the end of the airend 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 airend hub. Rotate the airend and motor shafts together noting the
change in reading during one revolution. Adjust the position of the airend 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
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 airend to obtain parallel alignment may destroy the
angular alignment and vice versa.
⒟ When alignment is complete, tighten the motor and airend 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 airend and motor must be doweled to preserve correct
alignment. Drill and ream any two diagonally opposite mounting feet of the airend 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.
33
Fig 6-13. Allowable tolerance for coupling
6-15. V-BELTS
6-15-1. TENSION CHECK. Check the V-belt for tension, wear and damage every 3,000 hours of
operation or six(6) months whichever comes first. For inspection on 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 which are measured.
⒞ Make sure that the average deflections are approximately the same value as in the table below.
NEW INSTALLATION READJUSTMENT

MODEL
TENSION DEFLECTION TENSION DEFLECTION
P lbs δ inch P lbs δ inch
CHSA-20 5.5 0.267 4.8 0.267
CHSA-25
5.9 0.276 5.3 0.276
CHSA-30
CHSA-50 5.9 0.276 5.3 0.276
CHSA-60
6.2 0.267 5.3 0.267
CHSA-75
Fig 6-14. V-Belt tension
34
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 airend 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 V-belts, and make sure that they can turn smoothly.
WARNING
ⓐ Loosely tensed V-belts may develop problems such as slip of V-belts, premature wearing of
V-belts and pulley grooves, abnormal heat generation, pressure and so on.
ⓑ Too tightly tensed V-belts may develop the problems such as shaft damage, short service life of
bearings and so on.
NOTE
Consult with distributor in your area for V-belts replacement, if any of the followings has occurred
even 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.
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 ring attached while the unit is running. Thereby
the collected condensate and rust will be relieved.
35
CHAPTER 7
PARTS LIST
7-1. BASIC/PIPING ASSEMBLY FOR MODEL CHSA-20, CHSA-25 & CHSA-30
39
7-2. PART LIST FOR MODEL CHSA-20, CHSA-25 & CHSA-30
Item Part Number Description Q'ty
1 CHSA-20/25/30-1-1 Commom base 1

2 CHSA-20/25/30-1-2 Basic compressor 1
3 CHSA-20/25/30-1-3 Comp. bracket 1
4 CHSA-20/25/30-1-4 Pad for anti-vibration 2
5 CHSA-20/25/30-1-5 Unload ass'y 1
6 CHSA-20/25/30-1-6 Suction filter & Silencer ass'y 1
7 CHSA-20/25/30-1-7 Comp. pulley 1
8 CHSA-20/25/30-1-8 Motor pulley 1
9 CHSA-20/25/30-1-9 Pulley end plate 1
10 CHSA-20/25/30-1-10 V-Belt 4
11 CHSA-20/25/30-1-11 Motor 1
12 CHSA-20/25/30-1-12 Motor base 1
13 CHSA-20/25/30-1-13 Oil separator ass'y 1
14 CHSA-20/25/30-1-14 Temp. Regulating valve & Oil filter 1
15 CHSA-20/25/30-1-15 Discharge pipe 1
16 CHSA-20/25/30-1-16 Oil & After cooler 1
17 CHSA-20/25/30-1-17 Cooler base 2
18 CHSA-20/25/30-1-18 Fan motor 1
19 CHSA-20/25/30-1-19 Cooler fan ass'y 1
20 CHSA-20/25/30-1-20 Fan casing 1
21 CHSA-20/25/30-1-21 Fan guard 1
22 CHSA-20/25/30-1-22 Non return valve 1
23 CHSA-20/25/30-1-23 Fan motor base 1
24 CHSA-20/25/30-1-24 Control box 1
25 CHSA-20/25/30-1-25 Pad for anti-vibration 2
26 CHSA-20/25/30-1-26 Pipe coupling 1
27 CHSA-20/25/30-1-27 Air discharge pipe 1
28 CHSA-20/25/30-1-28 Minimum pressor valve 1
29 CHSA-20/25/30-1-29 Safety valve 1
30 CHSA-20/25/30-1-30 Mesh filter 1
31 CHSA-20/25/30-1-31 ψ6 copper tube
32 CHSA-20/25/30-1-32 Oil hose 3 ass'y 1
33 CHSA-20/25/30-1-33 Capacity control piping ass'y 1
34 CHSA-20/25/30-1-34 Drain cock 1
35 CHSA-20/25/30-1-35 Temperature sensor 2
36 CHSA-20/25/30-1-36 Oil separator drain hose ass'y 1
38 CHSA-20/25/30-1-38 ψ12.7 copper tube
39 CHSA-20/25/30-1-39 Bush for heater 1
40 CHSA-20/25/30-1-40 Cartridge heater 1
41 CHSA-20/25/30-1-41 Oil stop valve 1
44 CHSA-20/25/30-1-44 Air hose
45 CHSA-20/25/30-1-45 Ball valve 1
46 CHSA-20/25/30-1-46 Globe valve 1
47 CHSA-20/25/30-1-47 Pressure gauge 1
39
7-3. CABINET MODEL CHSA-20, CHSA-25 & CHSA-30

1 CHSA-20/25/30-2-1 Aluminium profile frame
2 CHSA-20/25/30-2-2 Common base 1
3 CHSA-20/25/30-2-3 Front cover - Left 1
4 CHSA-20/25/30-2-4 Front cover - Right 1
5 CHSA-20/25/30-2-5 Side cover - Right 1
6 CHSA-20/25/30-2-6 Wire net 1
7 CHSA-20/25/30-2-7 Side cover - Left 1
8 CHSA-20/25/30-2-8 Suction grille 1
9 CHSA-20/25/30-2-9 Air inlet filter 1
10 CHSA-20/25/30-2-10 Switch panel assembly 1
11 CHSA-20/25/30-2-11 Upper cover 1
12 CHSA-20/25/30-2-12 Rear cover 1
39
7-5. CONTROL BOX ASSEMBLY FOR MODEL CHSA-20, CHSA-25 & CHSA-30
Item Part Number Description QTY.

X1 CHSA-20/25/30-3-1 Control Relay
X2 CHSA-20/25/30-3-2 Control Relay 1
X3 CHSA-20/25/30-3-3 Control Relay 1
XA CHSA-20/25/30-3-4 Control Relay 1
XB CHSA-20/25/30-3-5 Control Relay 1
XC CHSA-20/25/30-3-6 Control Relay 1
2C CHSA-20/25/30-3-7 Timmer For Energy Saving 1
2U CHSA-20/25/30-3-8 Timmer For Unload 1
2G CHSA-20/25/30-3-9 Timmer For Time Guard 1
26TS1 CHSA-20/25/30-3-10 Temperature Control For Discharge 1
26TS2 CHSA-20/25/30-3-11 Temperature Control For Oil Separator Out 1
52C CHSA-20/25/30-3-12 Magnetic Contactor 1
F CHSA-20/25/30-3-13 Fuse For Control Circuit 1
51F CHSA-20/25/30-3-14 Fan Motor Overload Relay 1
TR CHSA-20/25/30-3-15 Control Transformer 1
46 CHSA-20/25/30-3-16 Negative Phase Relay 1
TB CHSA-20/25/30-3-17 Terminal Base(Main/Control) 1
E CHSA-20/25/30-3-18 Ground 1
39
7-6. BASIC/PIPING ASSEMBLY FOR MODEL CHSA-50, CHSA-60 & CHSA-75
40
7-7. PART LIST FOR MODEL CHSA-50, CHSA-60 & CHSA-75
1 CHSA-50/60/75-1-1 Commom base 1

2 CHSA-50/60/75-1-2 Basic compressor 1
3 CHSA-50/60/75-1-3 Unload ass'y 1
4 CHSA-50/60/75-1-4 Suction filter & Silencer ass'y 1
5 CHSA-50/60/75-1-5 Comp. pulley 1
6 CHSA-50/60/75-1-6 Pulley end plate 1
7 CHSA-50/60/75-1-7 V-Belt 7
8 CHSA-50/60/75-1-8 Cooler hanger 1
9 CHSA-50/60/75-1-9 Motor 1
10 CHSA-50/60/75-1-10 Motor base 1
11 CHSA-50/60/75-1-11 Motor pulley 1
12 CHSA-50/60/75-1-12 Oil separator ass'y 1
13 CHSA-50/60/75-1-13 Temp. Regulating valve & Oil filter 1
14 CHSA-50/60/75-1-14 Discharge pipe 1
15 CHSA-50/60/75-1-15 Pipe coupling 1
16 CHSA-50/60/75-1-16 Oil & After cooler 1
17 CHSA-50/60/75-1-17 Fan motor 1
18 CHSA-50/60/75-1-18 Fan casing 1
19 CHSA-50/60/75-1-19 Fan guard 1
20 CHSA-50/60/75-1-20 Cooler fan ass'y 1
21 CHSA-50/60/75-1-21 Fan motor bracket 1
22 CHSA-50/60/75-1-22 Fan motor base 1
23 CHSA-50/60/75-1-23 Control box 1
24 CHSA-50/60/75-1-24 Air discharge pipe 1
25 CHSA-50/60/75-1-25 Minimum pressor valve 1
26 CHSA-50/60/75-1-26 Safety valve 2
27 CHSA-50/60/75-1-27 Mesh filter 2
28 CHSA-50/60/75-1-28 ψ6 copper tube
30 CHSA-50/60/75-1-30 Capacity control piping ass'y 1
31 CHSA-50/60/75-1-31 Drain cock 2
33 CHSA-50/60/75-1-33 ψ12.7 copper tube
34 CHSA-50/60/75-1-34 Wire heater 1
35 CHSA-50/60/75-1-35 Oil stop valve 1
38 CHSA-50/60/75-1-38 Ball valve 1
39 CHSA-50/60/75-1-39 Globe valve 1
41 CHSA-50/60/75-1-41 Pressure gauge 1
41
7-8. CABINET ASSEMBLY FOR MODEL CHSA-50, CHSA-60 & CHSA-75

1 CHSA-50/60/75-2-1 Aluminium profile frame
2 CHSA-50/60/75-2-2 Common base 1
3 CHSA-50/60/75-2-3 Front cover - Left 1
4 CHSA-50/60/75-2-4 Front cover - Right 1
5 CHSA-50/60/75-2-5 Side cover - Right 1
6 CHSA-50/60/75-2-6 Wire net 1
7 CHSA-50/60/75-2-7 Side cover - Left 1
8 CHSA-50/60/75-2-8 Suction grill 1
9 CHSA-50/60/75-2-9 Air inlet filter 1
10 CHSA-50/60/75-2-10 Switch panel ass'y 1
11 CHSA-50/60/75-2-11 Upper cover 1
12 CHSA-50/60/75-2-12 Rear cover 1
42
7-9. CONTROL BOX ASSEMBLY FOR MODEL CHSA-50, CHSA-60 & CHSA-75
X1 CHSA-100-3-1 Control Relay 1
XA CHSA-100-3-4 Control Relay 1
XB CHSA-100-3-5 Control Relay 1
XC CHSA-100-3-6 Control Relay 1
2C CHSA-100-3-7 Timmer 1
2U CHSA-100-3-8 Timmer 1
2G CHSA-100-3-9 Timmer 1
26TS1 CHSA-100-3-10 Temperature Controller 1
51F CHSA-100-3-12 Fan Motor Overload Relay 1
F CHSA-100-3-13 Control Circuit Fuse 1
52C CHSA-100-3-14 Compressor Motor Circuit(Main) 1
42C CHSA-100-3-15 Compressor Motor Circuit(Delta) 1
6C CHSA-100-3-16 Compressor Motor Circuit(Star) 1
51C CHSA-100-3-17 Compressor Motor Overload Relay 1
TR CHSA-100-3-18 Control Transformer 1
46 CHSA-100-3-19 Negative Phase Relay 1
TB CHSA-100-3-20 Terminal Base(Main Control) 1
E CHSA-100-3-21 Ground 1
43
7-10. BASIC/PIPING ASSEMBLY FOR MODEL : CHSA-100
39
7-11 PART LIST FOR MODEL CHSA-100

1 CHSA-100-1-1 Common Base 1
2 CHSA-100-1-2 Basic Compressor 1
3 CHSA-100-1-3 Unload Assembly 1
4 CHSA-100-1-4 Suction Filter & Silencer Assembly 1
5 CHSA-100-1-5 Coupling Assembly 1
6 CHSA-100-1-6 Cooler Hanger 1
7 CHSA-100-1-7 Motor 1
8 CHSA-100-1-8 Motor Base 1
9 CHSA-100-1-9 Oil Separator Assembly 1
10 CHSA-100-1-10 Temperature Regulating Valve 1
11 CHSA-100-1-11 Oil Filter 1
12 CHSA-100-1-12 Discharge Pipe 1
13 CHSA-100-1-13 Pipe Coupling 1
14 CHSA-100-1-14 Oil & After Cooler 1
15 CHSA-100-1-15 Fan Motor 1
16 CHSA-100-1-16 Fan Guard 1
17 CHSA-100-1-17 Cooler Fan Assembly 1
18 CHSA-100-1-18 Fan Motor Bracket 1
19 CHSA-100-1-19 Fan motor Base 1
20 CHSA-100-1-20 Control Box 1
21 CHSA-100-1-21 Air Discharge Pipe 1
22 CHSA-100-1-22 Minimum Pressure Valve 1
23 CHSA-100-1-23 Safety Valve 1
24 CHSA-100-1-24 Mesh Filter 1
25 CHSA-100-1-25 OD 0.24" Copper Tube
26 CHSA-100-1-26 Oil Hose 3 Assembly 1
27 CHSA-100-1-27 Capacity Control Piping Assembly 1
28 CHSA-100-1-28 Drain Cock 2
29 CHSA-100-1-29 Temperature sensor 1
30 CHSA-100-1-30 OD 0.5" Copper Tube
31 CHSA-100-1-31 Wire Heater -
32 CHSA-100-1-32 Oil Stop Valve -
35 CHSA-100-1-35 Ball Valve 1
36 CHSA-100-1-36 Globe Valve 1
37 CHSA-100-1-37 Temperature Sensor 1
38 CHSA-100-1-38 Pressure Gage 1
40
5-12 CABINET FOR MODEL CHSA-100

1 CHSA-100-2-1 Aluminum Profile Frame 1
2 CHSA-100-2-2 Common Base 1
3 CHSA-100-2-3 Front Cover - Left 1
4 CHSA-100-2-4 Front Cover - Right 1
5 CHSA-100-2-5 Side Cover - Right 1
6 CHSA-100-2-6 Wire Net 1
7 CHSA-100-2-7 Side Cover - Left 1
8 CHSA-100-2-8 Suction Grille 1
9 CHSA-100-2-9 Air Inlet Filter 1
10 CHSA-100-2-10 Switch Panel Assembly 1
11 CHSA-100-2-11 Upper Cover 1
12 CHSA-100-2-12 Rear Cover 1
41
5-13 CONTROL BOX ASSEMBLY FOR MODEL CHSA-100

XA CHSA-100-3-4 Control Relay 1
XB CHSA-100-3-5 Control Relay 1
XC CHSA-100-3-6 Control Relay 1
2C CHSA-100-3-7 Timmer 1
2U CHSA-100-3-8 Timmer 1
2G CHSA-100-3-9 Timmer 1
51F CHSA-100-3-12 Fan Motor Overload Relay 1
F CHSA-100-3-13 Control Circuit Fuse 1
52C CHSA-100-3-14 Compressor Motor Circuit(Main) 1
42C CHSA-100-3-15 Compressor Motor Circuit(Delta) 1
6C CHSA-100-3-16 Compressor Motor Circuit(Star) 1
51C CHSA-100-3-17 Compressor Motor Overload Relay 1
TR CHSA-100-3-18 Control Transformer 1
46 CHSA-100-3-19 Negative Phase Relay 1
TB CHSA-100-3-20 Terminal Base(Main Control) 1
E CHSA-100-3-21 Ground 1
42
QUALITY AND RELIABILITY
WITHOUT COMPROMISE
WARRANTY
COAIRE compressors are thoroughly tested at the factory and warran-
ted against defects in workmanship and material for a period of 12
months. The entire compressor package is warrented for a period of
12 months from the date of installation or 18 months the date of
factory shipment including parts and labor. The five(5) year air end
warrenty includes parts only. The requirments are the use of genuine
COAIRE maintenance fluid, replacement parts and annual oil sample
sent to COAIRE. The warrenty 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.
16655 KOALA ROAD, ADELANTO, CA 92301 TEL.(760)246-1600 FAX(760)246-1605
COAIRE reserves the right to make changes, at any time without notice as
a result of our commitment to continuous improvement.
COAIRE-AC-1198
43
ELECTRICAL SEQUENCE DIAGRAM
44
45
46

Rotary Screw Manual-Jan 2008

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TECHNOLOGIES CORP.

MAINTENANCE MANUAL AND PARTS LIST

All right reversed

Safety and warnings ............................................................................... 3

Chapter Ⅰ. General information

Chapter Ⅲ. Functional Description

Chapter Ⅳ. Scheduled Maintenance

Chapter Ⅴ. Trouble shooting

Chapter Ⅵ. Corrective maintenance

Chapter Ⅳ. Parts list

SAFETY AND PRECAUTIONS

1-2. SCREW COMPRESSION PROCESS

1-2-1. SUCTION PROCESS. Along with the rotation of the

Fig 1-1. Suction Process

1-2-2. COMPRESSION PROCESS. The air in the void is

Fig 1-2. Compression Process

1-2-3. OIL INJECTION PROCESS. As pressure builds, oil is

Fig 1-3. Oil Injection Process

1-2-4. DISCHARGE PROCESS. Compression continues as the

Fig 1-4. Discharge Process

1-5. OIL SEPARATION.

Fig 1-5. Operating flow diagram

Fig 1-6. Operating flow diagram

1-4. STANDARD SPECIFICATION

Motor output Kw(HP) 15(20) 19(25) 22(30)

Air delivery cfm 84 77 66 104 96 87 125 115 100

Ambient temperature ℉ 32∼115℉

Discharge air temperature ℉ Inlet air temperature + 27℉(MAX)

Driving method - V-Belt (3V×3) V-Belt (3V×4)

Voltage V 230, 460

Starting method - Direct

Oil sump capacity gal 3.7 5

Weight lbs 1056 1232

Dimensions(W×D×H) in 55.½×40.⅜×43.¾ 55.½×40.⅜×48.½

Air outlet piping size in 1

Motor output Kw(HP) 37(50) 45(60) 55(75) 75(100)

Ambient temperature ℉ 32∼115℉

Discharge air temperature ℉ Inlet air temperature + 27℉(MAX)

Driving method - V-Belt (3V×7) V-Belt (3V×9) Coupling

Voltage V 230, 460

Starting method - Star-Delta

Oil sump capacity gal 8 13 17

Weight lbs 1716 2530 3320

Dimensions(W×D×H) in 56.⅝×46⅛×57.⅞ 68.⅛×51.⅝×57.⅞ 82.¾×48.½×59.⅞

Air outlet piping size in 1 ½ 1 ½ 2

Fig 1-7. Handling by forklift truck

Fig 1-8. Handling by shop crane

Fig 1-9. The space clearance example

HEAT GENERATION & VENTILATION FAN CAPACITY

CAPACITY (Btu/h) 51981 75790 125790 197610 266650

AIR VOLUME (cfm) 5474 7945 13250 20840 28080

1-8-3. PIPING WORK

- Read all related topics in this manual.

1-8-5. ELECTRICAL SPECIFICATION

Fig 2-1. Operating panel

2-2-1. BEFORE OPERATION

⒟ Check the unit for any abnormal noise or vibration.

2-3. DAILY OPERATION

BEFORE EACH DAY OF OPERATION

DURING THE OPERATION.

2-4. STANDARD FACTORY SETTINGS OF CONTROL COMPONENTS

SPECIFICATION UNIT STANDARD FACTORY SETTING VALVE

Fig 3-1. Cross Section of Airend