MAINTENANCE MANUAL AND PARTS LIST
Contents
1. IRE Authonzed Distributor Only ROTARY SCREW AIR END MAINTENANCE MANUAL AND PARTS LIST MODEL BC S 130 FOR C HSA 20 25 30 BC S 168 FOR C HSA 50 75 100 COAIRE TEC HNOLOGIES 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 ELECTRIC2. in the system The cause of excessive pressure should be checked and immediately corrected 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 MO211 STATEMENT OF WARRANTY TERMS amp CONDITIONS COAIRE s screw air compressors are warranted to be free of defects in materials and workmanship under proper use installation and application This warranty shall be for a period of 15 months from date of shipment from our factory or other stocking facilities or 12 months from date of installation Proof of installation date will be required All air compressors outside the U S and Canada carry a parts only warranty ALL FREIGHT DAMAGE CLAIMS ARE NOT THE RESPONSIBILITY OF THE MANUFACT
3. rotor casing 4 9 Inner Ring of Roller Bearing Required Tools Acetylene Oxygen Burner Thick Gloves File Procedure D Remove the rising portions with a file 2 Hold the male screw rotor vertically on the workbench Note In the case of the female screw rotor hold the female screw rotor on the workbench utilizing a small steel piece as shown in Fig 2 9 in order that the inner ring can be removed easily Coaire Technologies Corp 2 CHSA MO211 htt Bing af Haller Bearing Fig 2 9 Caution D Heat one point of the ring Do not move the flame of the burner 2 Do not heat the screw rotor and do not heat the inner ring for longer than five seconds because the wrap of the screw can occur Removing the inner ring in a short period of time is the important point regarding this 3 The same manner can be applied to the other inner rings of roller bearings 11 12 and 13 on the male screw rotor and female screw rotor Coaire Technologies Corp 22 CHSA MO211 CHAPTER V REASSEMBLY Reassemble all the parts of the screw Air End including replacement parts at the same positions as before disassembly as already mentioned in chapter IV 5 1 PREPARATION Before starting reassembling work thoroughly perform the following preparation work D Clean the working location before starting the reassembling work 2 Check and clean the required tools and facility 3 Check to confirm the parts to be replaced accordi
4. If an adjusting washer with an appropriate thickness is selected at this stage the discharge gap will be correct 5 3 7 4 Ball Bearings Required Tools Ball Bearing Inserting Jig Rotor Stopper Jig 2 500 kg cm Torque Wrench Oil with Oilier Heater with Oil Pan Replacing Parts Ball Bearing 14 Procedure D Insert new adjusting washer 9 and after spreading oil on their surfaces 2 Heat ball bearings 14 to a range of 60 C to 80 C with an oil pan and insert it into the hole for the male rotor of the outlet casing with ball bearing inserting jig Caution Check the direction of the ball bearings as shown in Fig 5 4 3 Check to confirm that the ball bearings are inserted to the extreme interior utilizing the ball bearing inserting jig and slightly tapping with a hammer 4 The same procedure can be performed for the female screw rotor as shown in Fig 5 5 Coaire Technologies Corp 31 CHSA MO211 5 Insert lock washers 23 and screw lock nuts 22 to the male screw rotor and the female screw rotor by hand until they reach the surface of the ball bearings 6 Attach rotor stopper jig to the motor side of the male screw rotor shaft and fix it with M12 bolt 7 Tighten lock nuts 22 by inserting the bearing lock nut jig into the notch of the lock nut 5 3 8 OUTLET BEARING COVER Required Tools 8 mm Hexagon Wrench 2 500kg cm Torque Wrench Oil with Oilier Coaire Technologies Corp 32 CHSA M0211 Replacing
5. Parts Gasket 17 Procedure D Insert spring pin 25 to sleeve 10 for male and female screw rotors 2 Insert sleeve 10 with spring pin 25 to both sides male and female screw rotors of outlet casing 2 3 Insert cup spring 24 to the sleeve 10 of both sides male and female screw rotors 4 Tighten bolts 18 with washers 27 6 Attach the gasket 17 with refrigeration oil on the top position of outlet casing 2 6 Tighten bolts 20 with 2 500 kg cm torque wrench after attach the outlet bearing cover 6 on the gasket 17 5 3 9 OIL SEAL AND SEAL COVER Required Tools 8 mm Hexagon Wrench 2 500kg cm Torque Wrench Oil with Oilier Replacing Parts Gasket 16 Coaire Technologies Corp 33 CHSA MO211 Procedure D Thoroughly clean all remaining parts 2 Insert wave spring 14 and suction sleeve 15 to female screw rotor side of rotor casing 2 3 Lubricate the new seal face with clean compressor oil CAUTION Be careful not to scratch the seal face or mating ring scratch or break the carbon ring of the seal assembly Wipe the lapped mating surfaces of the mating ring and carbon ring with a clean lint free cloth before installing the seal retainer assembly 4 Insert seal retainer to the male rotor shaft 18 securely 5 Check retainer assembly to be inserted properly Make sure that there is no gap between end face of the bellows and bearing surface Install the o ring and mating ring in the bearin
6. Corp 36 CHSA M0211 Exploded View Model BCS 168 FOR CHSA 50S through CHSA 100S Coaire Technologies Corp 37 CHSA M0211 Specification PartNo Qty Unit 1 Female Cover AC4M39 o eeoa 1 2 Rotor Casing AC20800 BCS 6 amp O2 1 outlet casing AC e 1 6 3 BCS 6B06 2 8 AWOZ KSB 20 BC amp 6B08 2 9 Angular Contact Ball Brg 73098 EGAP Bome 4 MG 12760 G6 ASVGG BURGMANN 22 Gasket Outlet Brg Cover AC20688 BCS 168 22 1 23 Hex Socket Bolt moo BCS6823 4 4 ORm 35 H 08 STB 25 Suction Fange BCS 6825 1 27 Gasket Seal Cover BCS 68 27 1 Coaire Technologies Corp 38 CHSA MO211 WARRANTY CLAIM REPORT MODEL CHSA SERIAL NO RUN HOURS Hrs DATE DISTRIBUTOR ADDRESS PHONE FAX CUSTOMER ADDRESS PHONE FAX SYMPTOM FAULT DIAGNOSIS RESOLUTION PARTS REQUIRED No PART NAME DESCRIPTIONS 1 QTY 2 3 LABOR COST TRAVEL TIME Hrs x LABOR TIME Hrs x TOTAL COST S Hr S Hr WRITTEN BY Coaire Technologies Corp SIGNATURE 39 CHSA MO211 QUALITY AND RELIABILITY WITHOUT COMPROMISE COAIRE compressors are thoroughly tested at the factory and warranted against de
7. ITY 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 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 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 Use only safety solvent for cleaning the compressor and auxiliary equipment Install a manual shut off valve isolation type in the discharge line for service work Whenever pressure is released through the safety valve during operation it is due to excessive pressure
8. Inner Ring for Roller Bearing Female rotor Discharge side Procedure D Place the new roller bearings on the steel plate Then heat the bearings to 80 C 90 C with a heater Caution Check the temperature of the refrigeration oil with a thermometer 2 Insert one of the hot inner rings of new roller bearing to the suction side of male screw rotor 3 The same manner can be applied to the other inner rings as follows Inner ring of roller bearing for discharge side of male screw rotor Inner ring of roller bearing for suction side of female screw rotor Inner ring of roller bearing for discharge side of female screw rotor Caution D The inner rings are interchangeable among the same models of roller bearings 2 Place the inner rings in the direction as shown in Fig 3 3 so that the model numbers of the bearings can be confirmed after the inner rings are inserted 3 If the inner rings cannot be smoothly inserted into the screw rotor repeat the entire procedure Coaire Technologies Corp 25 CHSA MO211 Bari Wedel H ID E L L FIG 3 9 Beyin Wrei 5 3 4 SCREW ROTOR Required Tools Refrigeration Oil with Oilier Procedure 1 Adequately spread refrigeration oil on the surface of the inner rings of roller bearings 11 13 on the female screw rotor 2 Adequately spread refrigeration oil on the surface of the inner rings of roller bearings 11 12 on the male screw roto
9. Measure the thickness of the adjusting washers with a micrometer and record the actual thicknesses in the record sheet 5 3 7 2 Total Gap Required Tools Dial Gauge with Magnet Base Procedure D Attach the magnet base of the dial gauge to the surface of the outlet casing and contact the spindle of the dial gauge with the end of the male screw rotor 2 Depress the male screw rotor to the discharge side and adjust the dial to the zero position 5 Depress the male screw rotor to the suction side and read the dial This reading T indicates the total gap between the male screw rotor the rotor casing and the outlet casing Record T in the record sheet Suction Slide Yj fee te Y yy f Bius a Ui 7 77 Wf 0 W EE 7 We Fig 5 3 4 This procedure should also be performed for the female screw rotor to measure the total gap between the female screw rotor the rotor casing and outlet casing Record T in the record sheet 5 Insert adjusting washer 9 into the hole for male screw rotor of the outlet casing after spreading refrigeration oil on their surfaces and record actual thickness T1 of the adjusting washer 9 6 Insert ball bearing measuring jig into the hole for male rotor of the outlet casing 7 Insert M12 bolt and nut into the hole of the rotor gap measuring jig After inserting this jig into the hole for male screw rotor of the outlet casing insert M12 bolt to the end of the mal
10. ORS Coaire Technologies Corp DISTANCE RING 7 CHSA MO211 With high precision and high grade finishing rotors mechanical vibration sources have been eliminated thus ensuring smooth and quiet operation The lobe combinations are two types In case of model BCS 130 the lobe combinations of male and female rotors have 5 7 rotor profile In case of model BCS 168 the lobe combinations of male and female rotors have 5 7 profile Fig 2 2 Newly Developed 5 7 Profile Screw Rotors 2 1 2 HOUSING Screw air end incorporates the low noise design with double housing construction With this design the noisy male rotor is located at the center of double housing minimizing the noise liable to occur during low temperature operation The cylindrical roller bearings support the radial loads whereas the angular ball bearings support the axial loads 2 1 3 SHAFT SEAL Mechanical seal is fitted on the male rotor shaft to prevent oil and air leakage 2 1 4 BEARINGS At the discharge end the outlet casing of the Air End double angular contact ball bearings and a cylindrical roller bearing for the male rotor and the female rotor are located to support axial thrust loads and radial loads Moreover the springs for reducing the axial loads is located assuring long life and high reliability Oil for lubrication is supplied to each bearing by the pressure difference without oil pump 2 2 DRIVE 2 2 1 V BELT DRIVE Rg 2 3 Motor sp
11. URER AND ARE NOT COVERED UNDER WARRANTY AS ALL PRODUCTS ARE SHIPPED F O B SHIPPER PLEASE DIRECT ALL FREIGHT CLAIMS TO THE SHIPPER IN QUESTION MAINTENANCE AND ADJUSTMENTS ADJUSTMENTS TO THE HOT GAS AND MAINTENANCE OF FLOAT AND AUTOMATIC DRAINS AND CONDENSER COILS ARE CONSIDERED TO BE ROUTINE MAINTENANCE AND THEREFORE NON WARRANTABLE ITEMS AND ARE THE SOLE RESPONSIBILITY OF THE END USER CONSULT THE INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR THE ADJUSTMENT AND MAINTENANCE PROCEDURES This warranty does not apply to any unit damaged by accident modification misuse negligence or misapplication Damage to heat exchangers by exposure to ammonia any other corrosive substance or sub freezing environment will be considered misuse Any air compressors part or material found defective will be repaired replaced or refunded at the sellers option free of charge provided that COAIRE is notified within the above stated warranty period All returns of allegedly defective equipment must have prior written authorization Said authorization may be obtained through our air compressor service department All air compressors parts materials must be returned freight prepaid to the Manufacturer s factory within 30 days of return authorization date Any shipment returned to the factory collect will be refused If an item is found to be warrantable the repaired item or replacement will be returned normal ground freight prepaid within the continental Unit
12. ae we os ce ees ame 5 2 CCAR ING ax E 22 A Exploded view for 34 BES o Exploded view for 36 BOSH NOB sce rasa rece PIE MEE ies cet a Lui at BAR Se Dee ae Coaire Technologies Corp 4 CHSA MO211 CHAPTER GENERAL INFORMATION 1 1 SCOPE This manual shall be applied to air end models for COAIRE screw Air End as follows BCS 130 BCS 168 Screw Air End driven by an electric motor is the important part of screw air compressor unit It is single stage oil injected rotary screw type Screw Air End have been developed to meet higher performance including high efficiency high reliability low noise and low vibration and have been introduced to the market since 1988 with our long manufacturing experiences 1 2 COMPRESSION PROCESS 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 Fig 1 3 Oil Injection Process Fig 1 4 Discharge Process 1 2 1 SUCTION PROCESS Coaire Technologies Corp 5 CHSA M0211 Along with the rotation of the rotor air is admitted fu
13. and remove roller bearings 11 Coaire Technologies Corp 20 CHSA MO211 4 7 SCREW Required Tools None Procedure D Rotate female screw rotor counter clockwise by holding the shaft portion of the female screw rotor and remove it from the rotor casing 2 Slowly rotate male screw rotor clockwise by holding the shaft portion of the male screw rotor and remove it from the rotor casing Caution Rotate the screw rotor by hand while holding the shaft portion Before drawing out the screw rotor from rotor casing 1 hold the screw rotor with your hand by holding the lobe portion of the screw rotor Note 8 The weights of the screw rotors are as follows Compressor Model Male Rotor kg Female Rotor kg BCS 130 12 6 BCS 168 15 7 D The male rotor can be removed from the rotor casing together with the inner rings of roller bearing 11 and the female rotor can be also removed together with the inner ring of roller bearings 11 The four inner rings of the roller bearings remain on the male and female rotors Remove these inner rings according to the instructions in section 9 of the chapter 4 4 8 SUCTION SIDE BEARINGS Required Tools Copper Tube 22mm O D x 200mm Length Procedure D Lightly knock roller bearing 12 from the rear side of rotor casing 1 and remove roller bearing 12 2 Lightly knock roller bearing 13 from the rear side of rotor casing 1 and remove roller bearing 13 from
14. aution The edge inside the rotor casing is sharp edge Therefore pay attention that your hand does not come into contact with this edge 5 2 2 Outlet Casing Seal Cover and Other Covers Required Tools Gasket Remover Oilstone Cleaning Oil Oil Pan for Cleaning Sponge Wire Brush Compressed Air Waste Cloth Procedure Coaire Technologies Corp 23 CHSA MO211 Remove the gaskets and finish the gasket surfaces of the following casing and covers D Outlet Bearing Cover 2 Outlet Casing 3 Seal Cover 4 Discharge End Cover Flange Note All covers should be open for reassembling rotor set replacement The reassembling of the rotor set replacement goes forward the section as next step 5 2 3 Male Rotor and Female Rotor Required Tools Cleaning Oil Oil Pan for Cleaning Sponge Sand Paper 280 Compressed Air Waste Cloth Procedure D Clean male screw rotor with cleaning oil and sponge After cleaning work blow the male screw rotor with compressed air 2 Clean female screw rotor with cleaning oil and sponge After cleaning work blow the female screw rotor with compressed air 3 Check and inspect the screw rotors surface according to the maintenance policy If there are any sight scratches repair the screw rotor surface with a sheet of sand paper 7280 5 2 4 Other Internal Components Required Tools Cleaning Oil Oil Pan for Cleaning Sponge Sand Paper 7280 Compressed Air Waste Cloth Procedure Clean all o
15. bearings achieved by application of 5 7 and 4 6 profile rotors At the discharge end of the Air End 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 1 4 3 With a differential pressure lubrication system the Air End can dispense with an oil pump thus dramatically simplifying the oil supply system 1 4 4 The wedge construction of the secondary sealing element of the mechanical seal naturally eliminates leakage This seal is highly reliable and excellent performance CHAPTER FUNCTIONAL DESCRIPTIONS Coaire Technologies Corp 6 CHSA M0211 2 1 CONSTRUCTIONS Oil injected single stage rotary screw Air End primarily consists of rotors housing shaft seal along with other component parts LX SSS SSS gt T D 7 m ANS in Fig 2 1 Cross Section of Air end Model NAME O aq a TES S ps FE 19 N 225 S BEZA lr T d Ok GY TT 73 R A TT WM M m m em BCS 130 ROTOR HOUSING MALE ROTOR INLET CASING FEMALE ROTOR OUTLET CASING CYLINDRICAL ROLLER BEARING INLET SIDE BEARING COVER CYLINDRICAL ROLLER BEARING OUTLET SIDE SEAL COVER ANGULAR CONTACT BALL BEARING MECHANICAL SEAL 2 1 1 ROT
16. e outlet and disconnect the main electrical 3 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 4 For draining the oil cooler remove the plug at the drain outlet of the oil cooler to let the oil run down 5 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 6 Fill with new oil through the oil filling port of oil separator Refer to the specification table for appropriate oil amount 7 After securely tightening the plug at the oil filling port run the unit to make sure there are no oil leaks 3 2 3 DRAINING CONDENSATION Moisture contained in intake air can be condensed into water during long unloading time or when the unit is stopped and this moisture is accumulates in the separator sump Since the water in a compressor system can cause deterioration of oil and internal rusting do not neglect draining the condensation at least on a daily basis Draining should be performed before start up since oil and condensation have been sufficiently separated from each other Open the drain valve at outlet of oil separator sump Use a pan to store the condensation being drained Closely watch the draining condensation and close the valve WARNING Even ifthe unitis in 24 hour continuous service it is still recommended to perform a dra
17. e rotor by hand and tighten nut Attach the magnet base of the dial gauge to the surface of the outlet casing and pull the jig towards you And then depress the male rotor to the outlet side 9 Attach the magnet base of the dial gauge to the surface of the outlet casing and adjust the dial to the zero position Coaire Technologies Corp 29 CHSA MO211 Depress the jig to the suction side and read the dial and record 1 in the record sheet Caution Repeat the measurement with a dial gauge three or four times to confirm an accurate reading Coaire Technologies Corp 30 CHSA MO211 5 3 7 3 Selection of Adjusting Washer Required Tools Oilstone Procedure D Calculate the difference between the recommended gap that is 0 05mm 0 07mm and actual gap to be measured by the dial gauge as follows T2 0 05 T3 Gap Difference Record T3 in the record sheet 2 Select one of the adjusting washer in consideration of the gap difference T4 Thickness of New Adjusting Washer T1 Thickness of Initial Adjusting Washer T3 Gap Difference Example If there are T1 6 1mm T2 0 08mm T2 0 08 0 05 T3 0 03 T4 T1 6 1 T3 0 03 6 13mm 3 If an appropriate thickness of a new adjusting washer 9 is not available reduce the thickness of a slightly thicker adjusting washer by utilizing an oilstone until an appropriate thickness is achieved 4 Exchange the final selected adjusting washer and measure the discharge side gap
18. ed States and Canada Expedited shipment costs are the responsibility of the requestor Any replacement part or material is warranted only to the extent of the remaining warranty period of the dryer or to the extent as provided by the supplier whichever is longer Identification Plate The identification plate is located on the side of the air compressor and shows all the primary data of the machine Upon installation fill in the table on the previous page with all the data shown on the identification plate This data should always be referred to when calling the manufacturer or distributor The removal or alteration of the identification plate will void the warranty rights DISCLAIMER The warranty does not cover any responsibility or liability for direct or indirect damages to persons or equipment caused by improper usage or maintenance and is limited to manufacturing defects only Refer to COAIRE Warranty policy manual for travel mileage and special charge considerations The warranty will be immediately voided if there are changes or alterations to the dryer WHO TO CONTACT IF YOU HAVE A WARRANTY CLAIM COAIRE Technologies Corporation Phone 562 463 3935 Fax 562 463 4928 All freight damage claims should be filed within 15 working days and should be directed to the carrier Coaire Technologies Corp CHSA MO211 SAFETY AND PRECAUTIONS STATEMENT OF WARRANTY TERMS AND CONDITIONS Chapter General information 1 1 1 2 Comp
19. eed is increased by V belt drive to the male rotor s driving speed 2 2 2 COUPLING DRIVE Hg 2 4 Motor speed is transferred by coupling drive to the male rotor s driving speed Coaire Technologies Corp 8 CHSA MO211 Fig 2 3 V Belt drive Fig 2 4 Coupling drive 2 3 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 Coaire Technologies Corp 9 CHSA M0211 CHAPTER SCHEDULED MAINTENANCE 3 1 STANDARD MAINTENANCE SC HEDULE The maintenance of the air compressor unit equipped with these screw air end should be performed based on the following standard maintenance schedule 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 e should be maintained by an authorized distributor Maintenance Interval Part 5 Em Monthly 6 Monthly Annually 2 yearly 4 yearly pomo y soHs Hrs 3000 Hrs 6K HRS 12K HRS 24K Hrs of control Oil recommended Replace 1st et brands SE Oi
20. fects 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 COAIRE TECHNOLOGIES CORP 12226 COAST DRIVE WHITTIER CA 90601 TEL 562 463 3935 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 40 CHSA MO211
21. g cover 1 7 Attach gasket 27 with oil on the top position of rotor casing 2 8 Tighten bolts 28 with 2 500 kg cm torque wrench after attach the seal cover 1 on the gasket 27 RETAINER ASSEMBLY MATING RING SEAL COVER COVER BOLT COVER GASKET Coaire Technologies Corp 34 CHSA MO211 Exploded View Model BCS 130 FOR CHSA 208 through CHSA 30S Coaire Technologies Corp 35 CHSA MO211 1 AC3246 8543007 2 Rotor Casing 10105 1805130021 Outlet Casing AC0163 eean OO o 4 Outlet Bearing Cover BCS13004 1 5 Cup spring 3 Boao 2 6 sewe AC3013 BCS13006 2 7 lokNu ANOZ SE Q004j BC913007 2 Lock Washer _ AWO7 KSEB 2005 BC913008 2 9 Angular Contact Ball Brg 7307BEGAP BCS13009 4 10 Adjusting Washer __ BCS13010 2 11 Cylindrical Roller Brg NUZUSETVPZ Bawn 2 12 Female Rotor _ aono Bonon 1 13 Cylindrical Roller Brg NUZU ETVP2 BCS13013 1 14 Wave Spring OD 4x64kio BCS30d4 1 15 Female Suction Sleeve BCe13015 1 MG12 60 G6 ASVGG 16 BURGMANN BCS 130 16 1 Gasket Outlet Brg Cover 23 Hex Socket Modo 86513023 8 ORng 35 Hs 08 Benoa 1 BCS 130 35 e e NINI Coaire Technologies
22. hould be overhauled according to the following guide Overhaul the screw Air Ends within the following years of operation hours which ever case first occurs 1 Ever five years from the date of starting operation 2 Every 20 000 operation hours for applications to air cooled units or every 30 000 operation hours for applications of water cooled units Note The purpose of the overhauling is to exchange roller bearings and ball bearings with new ones The exchange of gaskets O rings and oil are also required 3 4 COMPONENT REPLAC EMENT GUIDE Coaire Technologies Corp 13 CHSA MO211 3 4 1 Components to be replaced Securely replace the following components when the screw Air Ends are overhauled Name of Component Item Number BCS 130 Item Number BCS 168 Cylindrical Roller Bearing 11 12 13 12 13 14 Angular Contact Ball Bearing 14 15 Adjusting Washer 9 10 Gasket 16 17 17 18 19 20 O Ring 28 31 Wave Spring 8 9 Cup Spring 24 27 Washer 27 30 3 4 2 Inspection and Replacement of Components Check the following components and exchange them with new ones if required Name of Component Item Number BCS 130 Item Number BCS 168 Male Rotor 4 5 Female Rotor 5 6 Mechanical Seal 15 16 3 4 3 Screw Rotors Basically it is not recommended that the male screw rotors and the female screw rotors be exchanged with new ones However in order to maintain the screw c
23. ining procedure Normally in such an operation mode an extra stand by compressor has to be installed atthe same time to allow for better draining of condensation Coaire Technologies Corp 12 CHSA MO211 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 suffic ient separation of oil from 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 imitation persists In the event of contact with skin wash contacted area with soap and water Wash clothing before reusing Contents will bum 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 3 3 SIANDARD OVERHAUL PERIOD When the periodic checking and inspections mentioned on the previous page are appropriately performed and the Air Ends have been operated under normal conditions the Air Ends s
24. l filter element Replace mememe m e Oil recommended fea IT s We aa replace Oil vom filter i E Mechanical seal Check for leak Gasket Suction control Replace valve Air end gasket and Check amp o ring Replace Air end Bearing amp Replace Mech Seal Coaire Technologies Corp 10 CHSA MO211 3 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 1 Mixing of different types or brands of oil 2 Use of unsuitable oil 3 Failure to drain the condensation which will result in an oil deterioration 4 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 MAINTENANC E SERVIC E AND C OLUBE 68 COMPRESSOR OIL 3 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 D Lubrication Oil lubricates the bearing and other internal components 2 Sealing Oil seals the clea
25. lly 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 1 2 2 COMPRESSION PROCESS The air in the void is compressed by meshes between the male rotor and the female rotor lobes and squeezes the air against discharge cover 1 2 3 OILINJ ECTION 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 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 continuously compressed 1 3 OILFLOW 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 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 4 FEATURES 1 4 1 Precision grind rotors provide close inter lobe clearance This minimizes leakage and increases efficiency 1 4 2 Long service life and high reliability of
26. lts The right hand side is for the male screw rotor and left hand side is for the female screw rotor 6 Turn the special bolts slowly with an adjustable wrench of 300mm length Note Turn the bolts alternating with every two turns Then do not make the gap between the rotor casing and the outlet casing greater than 100mm If the gap becomes greater than 100mm the outlet casing can drop 4 6 OUTLET CASING AND BEARINGS 1 Outlet casing with Bearings Required Tools None Coaire Technologies Corp 19 CHSA MO211 Caution The disassembling work of outlet casing 2 with bearings requires two people a chain block or lift for suspending them Procedure D Remove outlet casing 2 including the jig together with bearings 2 Transport the outlet casing to a clean workbench Notes D The weight of the outlet casing is as follows Compressor Model Weight of Outlet Casing kg BCS 130 25 BCS 168 50 2 The inner rings of the roller bearings are fixed on the screw rotors Therefore the main bodies of roller bearing 11 are removed together with the outlet casing but inner rings of the roller bearings remain on the screw rotor 2 Male and Female Screw Rotor Bearings Required Tools Copper Tube 22mm O D x 200mm Length Procedure D Remove angular contact ball bearings 14 adjusting washer 9 from the outlet casing 2 2 Lightly knock roller bearing 11 from the rear side of the outlet casing 2
27. ng to the maintenance guide mentioned in chapter IV Especially check to confirm the types and the sizes of bearings Remove the inner rings of roller bearings from the bearing bodies The inner rings provide interchangeability among the bearings of the same size However in order to avoid confusion place the bearing bodies and the inner rings in sequence on a clean sheet of paper or a cloth prior to reassembly 4 Clean all the parts with cleaning oil spray cleaning oil and then dry the parts with compressed air 5 After drying the parts spread adequate oil on the surfaces of all the parts Especially in order to avoid air leakage spread oil on both of the surfaces of the gasket 5 2 CLEANING 5 2 1 Rotor Casing Required Tools Gasket Remover Oilstone Cleaning Oil Oil Pan for Cleaning Sponge Wire Brush Compressed Air Waste Cloth Procedure D Remove gasket which is stuck to the seal cover side surface of the rotor casing utilizing a gasket remover Then finish the surface utilizing an oil stone 2 Finish the gasket surface of the suction side of the rotor casing in the same manner 8 Finish the O ring surface of the flange side of the outlet casing in the same manner 4 Clean the rotor casing with a wire brush if some adhesive material is detected 5 Clean the inside of the rotor casing with cleaning oil and sponge After the cleaning work blow out foreign materials and dry the rotor casing using compressed air C
28. ompressor s performance including capacity suppression of noise and vibration the replacement of the screw rotors can be performed according to the following guide A file or rough sand paper must not touch the surfaces of the screw rotors However the small scratches can be required with an oilstone or 280 sand paper 3 4 4 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 Coaire Technologies Corp 14 CHSA M0211 CAUTION Do not install anything to block the drain tube such asa 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 3 5 STANDARD SPECIFICATIONS Type Unit BCS 130 BCS 168 Power source size 125 psig kW 15 29 35 89 Capacity e 125 psig scfm 72 160 195 495 Max Operating Pressure psig 190 190 Rotor speed 125 psig RPM 2200 4400 1500 4000 Rotor Diameter Male mm 130 168 23 Female mm 126 88 168 23 Rotor Length mm 150 281 Center Di
29. ools special jigs necessary spare parts and materials in accordance with the lists in this service manual The general tools special tools and materials which are necessary for the overhauling work are listed in this manual The necessary spare parts are listed in this manual maintenance guide 4 1 4 Tightening Torque List Tighten the bolts and nuts in the screw compressor according to the following tightening torque standard Name M8 M10 M12 M14 M16 M35 M45 M50 Socket Head Bolt 450 800 Lock Nut 2200 2800 3000 4 2 DISASSEMBLY FOR AIR END All the parts of the air end must be reassembled to the same locations of the air end as before disassembly excluding consumption articles such as gaskets oil and replacement parts which are indicated in the maintenance guide Therefore in order to avoid confusion all covers and casings must be marked with a marking pen and all disassembled parts must be positioned on a clean sheet of paper or cloth in the order of disassembly This service manual has been complied for the overhauling work of screw air end model CHSA 20S 30S This air end must be brought into the workshop After pumping down or purging compressed air from the receiver remove the screw air end from the unit according to the following procedures Coaire Technologies Corp 16 CHSA MO211 D Check to ensure that the pressure in the screw air compressor unit is near to zero in gauge
30. pins 25 from the both sides of the male amp female screw rotors 5 Release lock washers 23 from the both sides of the male and female screw rotors with a flat head screw driver 6 Remove lock washers 23 D Insert the rotor stopper jig to the shaft end of male screw rotor 4 and fix the screw rotors to prevent rotation with M12 bolt Attach the bearing lock nut jig to the groove of lock nuts 22 Then insert a 2 500 kg cm torque wrench into the square hole of the jig and loosen lock nuts 22 9 Remove lock nuts 22 by hand Remove the rotor stopper jig Coaire Technologies Corp 18 CHSA MO211 4 5 OUTLET CASING Required Tools Bearing Removal Jig 1 Bearing Removal Jig 2 Dowel Pin Removal Jig 14mm Hexagon Wrench 300mm Length Adjustable Wrench 300mm Length Procedure D Loosen M10 hexagon socket bolts 21 with a 8mm hexagon wrench and remove the bolts by hand 2 Remove the dowel pins 26 with dowel pin removal jig 3 Attach the jig 1 to outlet casing 3 at the location of removed bearing cover 5 utilizing six M10 bolts with the length of 45mm These bolts are included in the jig 4 Attach the two special M24 bolts to the screw holes of the jig 1 and check to confirm that the points of these special bolts lightly touch the end of the screw rotors through the jig 1 as shown in Fig 2 5 Fig 2 5 Note The confirmation must be performed through the holes of the jig at the position under the special bo
31. pressure and then purge compressed air from the receiver 2 Disconnect all electric wiring 3 Loosen the suction and discharge piping connections and check to confirm that the pressure of the connection part is zero in gauge pressure then disconnect all the piping 4 Remove the V Belt from motor shaft and air end rotor shaft Lift the air end utilizing wire rope The weight of the screw air end is shown in the below table Air End Model Weight kg BCS 130 90 BCS 168 208 4 3 SEALCOVER AND OIL SEAL Required Tools 8 mm Hexagon Wrench 2 500kg cm Torque Wrench Plastic Hammer Procedure D Loosen all M10 hexagon socket bolts 28 with 8mm hexagon wrench 2 Remove the bolts 28 the seal cover 1 and the gasket 27 3 Remove the female suction sleeve 15 and the wave spring 14 4 Remove the mechanical seal 16 Fig 2 3 Oil seal CAUTION Be careful not to scratch or damage the air end shaft Coaire Technologies Corp 17 CHSA MO211 4 4 OUTLET BEARING COVER amp LOCK NUT WASHER Required Tools 8 mm Hexagon Wrench Rotor Stopper Jig Bearing Lock Nut Jig 2 500kg cm Torque Wrench Flat Head Screwdriver Plastic Hammer Procedure 1 Loosen all M10 hexagon socket bolts 20 with 8mm hexagon wrench 2 Remove the bolts 20 the outlet bearing cover 6 and the gasket 17 3 Remove the female and male cup springs 24 4 Remove the bolts 18 the washers 27 sleeves 10 and spring
32. r 3 Insert male screw rotor 4 to the rotor casing by supporting it by hand while rotating the male screw rotor clockwise Coaire Technologies Corp 26 CHSA MO211 Caution The edge of the rotor casing is extremely sharp and dangerous like a razor Pay careful attention that your hands do not touch the edge 4 Insert female screw rotor 5 into the rotor casing and slightly rotate the female screw rotor counterclockwise which is combined with the male screw rotor 5 3 5 OUTLET CASING Required Tools 2 M10 Stud Bolts Steel Hammer 8mm Hexagon Wrench Plastic Hammer Liquid Gasket Loctite No 573 O ring Procedure D Attach two M10 stud bolts to the top position of the discharge side of the rotor casing 2 Insert O ring 28 with grease 3 Insert one of the outer rings of new roller bearings for male and female screw rotors in the outlet casing 4 Adequately coat liquid gasket around O ring 28 on the surface of the rotor 1 to be connected with the outlet casing 2 6 Attach the outlet casing 2 to the rotor casing along the two stud bolts Insert two knock dowel pins 26 to the knock pin holes of the outlet casing with the steel hammer 6 Tighten the outlet casing to the rotor casing with the M10 bolts 21 Coaire Technologies Corp 27 CHSA MO211 5 3 6 DISCHARGE SIDE ROLLER BEARINGS Required Tools Roller Bearing Inserting Jig Rotor Stopper Jig Oil with Oilier Plastic Hammer Replacing Pa
33. rance 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 3 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 vamish or sludge deposits in the system If oils have been carelessly mixed or if a certain brand of oil mustbe replaced with another be sure to flush outthe oil system first Consult your distributor for the procedures We highly recommended the use of Genuine COAIRE Screw Compressor Oil COAIRE C OLUBE 68 3 2 2 OILCHANGE A practical way is to change the oil at the following intervals D First oil change 500 hours after initial start up 2 Second oil change 1 500 hours after the first oil change 4 000 hours after the initial start up Coaire Technologies Corp 11 CHSA MO211 3 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 D Run the unit loaded mode long enough to have the oil warm up 2 Stop the unit confirm that the pressure has been released completely and close the isolation stop valve at the discharg
34. ression Cea m EE 1 3 Oil Chapter 1 Functional descriptions 2 1 EE 2 3 Capacity ee E M D E D DE IP iD noe Chapter Ill Scheduled maintenance 3 1 Maintenance scheduled ME 3 2 Control of FICATION S RT TO RT NOE 3 3 Standard overhaul M 3 4 Component replacement DUNG esa saws cameo OPER ND CRT REN TR RUE 3 5 Standard SDeCITCablOn scuto tee vetu edes tool rn et ed aon aa evades cog PARTURIENT Chapter IV Disassembly 4 1 Preparation for a GF 4 2 Disassembly for CIE sh TU ETT TT UT ue whee eb abe hae aes Seg i eek a oes 4 3 Seal 4 5 Outlet CASINO tios he kate teeny ce ot A E 4 6 Outlet casing and gt oes Cand a Mol ILE E PE 4 7 Screw 4 8 Suction side Dearil9 EINE MM LP DEUM PEL P EDI ESL tree eae an a en aU 4 9 nner ring of roller DENO PETENTE Coaire Technologies Corp TABLE OF CONTENTS 20 20 20 CHSA MO211 Chapter V Reassembly 5 1 e 22 5 2 GI UU UT 22 5 3 Suction side 24 DENO T ID S I TT
35. rts 2 Roller Bearing 11 without Inner Ring Procedure D Fix male rotor with rotor stopper jig 2 Adequately spread refrigerant oil on roller bearing 11 and insert it into the male screw rotor of the outlet casing 3 Adequately spread refrigerant oil on roller bearing 11 and insert it into the female screw rotor of the outlet casing 4 Depress roller bearings 11 to the extreme interior with the roller bearing inserting jig Face the roller bearing surface for which the bearing model number is denoted towards you 5 3 7 ADJUSTING WASHERS AND BALL BEARINGS Etc This procedure is the most important when performing screw air end reassembling work because the gap between the screw rotors and the rotor casing in screw rotor shaft direction must be adjusted within a range of 0 05mm to 0 070mm for model BC S201 5301 and within a range of 0 07mm to 0 10mm for model BC S501 1001 The movement of the screw in the axial direction is supported with ball bearings Accordingly the gap can be adjusted by changing the thicknesses of adjusting washers 9 5 3 7 1 Thickness of Adjusting Washers Required Tools Ball Bearing Measuring Jig Rotor Gap Measuring Jig Micrometer with Measuring Range of Omm to 25mm Record Sheet for Gap Adjustment Coaire Technologies Corp 2 CHSA MO211 Replacing Parts Adjusting Washer 9 for Male Rotor Adjusting Washer 9 for Female Rotor Procedure D Prepare a record sheet for gap adjustment 2
36. stance mm 104 132 L Dm 1 154 1 670 Displacement Volume cb in rev 68 7 234 8 Lobe Combination M F 5 7 4 6 Driven By rotor male Male Suction size Bore inch 3 9 64 7 7 8 Discharge size Bore inch 1 37 64 2 3 4 Weight lbs 203 474 Coaire Technologies Corp 15 CHSA MO211 CHAPTER IV DISASSEMBLY 4 1 PREPARATION FOR OVERHAUL Thoroughly perform the following preparation work before starting the overhauling work of the air ends 4 1 1 Air ends According to the procedures indicated in the instructions of the unit remove the unit remove the air end to be overhauled from the unit Observe the following air end handling rules D The air end must not be left flange open for longer than 24 hours 2 If the air end is required to be left open for longer than 24 hours close the covers of the air end to avoid rust and dust accumulation and dip the parts of the air end in oil 3 If the air end is required to be left open for longer than one week before the next procedures into the air end dehydrate the air end 4 Oil remains in the screw air end 5 The air end has been placed on the workbench 4 1 2 Location and Facility The location where the overhauling work of the air end is performed should be clean clear dry and be provided with a wide service space The necessary facilities for the overhauling work of the air end are listed in this manual 4 1 3 General Tools special Jigs and Replacement parts Prepare general t
37. ther internal components with cleaning oil and sponge After cleaning work blow them with compressed air Coaire Technologies Corp 24 CHSA MO211 5 3 SUCTION SIDE BEARING 5 3 1 Inserting Roller Bearings without Inner Rings Required Tools Bearing Inserting Jig Replacing Parts 1 Cylindrical Roller Bearing without Inner Ring Male rotor 1 Cylindrical Roller Bearing without Inner Ring Female rotor Procedure D Insert new cylindrical roller bearing without inner ring into the male rotor hole of the rotor casing for model CHSA 20S 25S 30S by grasping the inside of the bearing 2 Insert new roller bearing without an inner ring into the female rotor hole of the rotor casing in the same manner 3 Slightly tap the bearings to the correct place with the roller bearing with roller bearing inserting jig and by hand Note Face the roller bearing surface on which the bearing model number is denoted towards the rotor casing Model BCS 130 BCS 168 Suction side Discharge side Suction side Discharge side Male rotor side Nu208 Nu209 Nu212 Nu211 Female rotor side Nu207 Nu209 Nu2209 Nu211 5 3 2 Inserting Inner Rings of Roller Bearings Required Tools Steel Plate Thermometer Heater Thick Glove Replacing Parts 1 Inner Ring for Roller Bearing Male rotor Suction side 1 Inner Ring for Roller Bearing Female rotor Suction side 1 Inner Ring for Roller Bearing Male rotor Discharge side 1
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