OIL INJECTION

SCREW COMPRESSOR

AS SERIES

USER MANUAL
AS21(20)B, AS31(30)B
AS26(25), AS31(30), AS41(40)

Before install the air compressor you should take the time
to carefully read all the instructions contained in this manual.

AGENCY

HEAD OFFICE
3BL 602LT, 1280-1 Jungwang-dong, Sihung-si, Geonggi-do, Korea
TEL. 82-31-496-2031~2
FAX. 82-31-319-4910
www.coaire.co.kr / www.ekyungwon.co.kr
NG0SP03335

CONTENTS

1.0 CONTENTS

1.0
2.0

Contents

-------1

SAFETY AND WARNINGS

2-1 Safety instructions

4.0

5.0

------22

6-11 Bypass valve

------22

6-12 Oil

------22

-------2

2-2 Safety precautions

3.0

6-10 Oil filter

7.0

CONTROL

2-3 Symbols

-------3

7-1 Controller

------24

2-4 Decals

-------4

7-2 General function

------24

7-3 Controller setup

------31

7-4 Running log

------34

COMPRESSOR GENERAL
3-1 Specification

-------8

3-2 Major component

-------9

3-3 P&ID

------11

8.0

INSTALLATION

MAINTENANCE
8-1 Maintenance procedure

------36

8-2 Belt

------39

8-3 Scheduled maintenance

------41

4-1 Inspection

------13

4-2 Handling

------13

4-3 Location

------14

9-1 General

------42

4-4 Piping work

------15

9-2 Trouble shooting

------42

4-5 Electricity

------16

9-3 Cause and remedy

------46

9.0

OPERATION

TROUBLE SHOOTING

10.0 OUTLINE DRAWING

5-1 Initial start-up

------17

5-2 Daily operation

------19

10-1 AS21(20)B, AS31(30)B

------47

AS26(25), AS31(30),
AS41(40)

6.0

FUNTIONAL DESCRIPTION
6-1 Airend

------20

11.0 ELECTRICAL WIRING DWG.

6-2 Motor

------20

11-1 AS21(20)B, AS31(30)B

------48

6-3 Coupling

------20

11-2 AS26(25), AS31(30),

------51

6-4 Suction control V/V

------20

6-5 Suction filter

------20

6-6 Separator tank

------21

6-7 Separator element

------21

6-8 MPV

------21

PRODUCT GUARANTEE

6-9 Cooler

------21

COMPRESSOR INSTALLATION REPORT

AS41(40)

SAFETY AND WARNINGS

2.0 SAFETY AND WARNINGS

2-1 Safety instructions
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.

2-2 Safety precautions

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 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 read & understood.
10. After maintenance work is completed, covers must be securely closed.

SAFETY AND WARNINGS

2-3 Symbols

CAUTION

Caution is used to indicate the presence of a hazard which will or can cause
minor personal injury or property damage if the warning is ignored.

Warning is used to indicate the presence of a hazard which can cause severe

WARNING

personal injury, death, or substantial property damage if the warning is

ignored.
Danger is used to indicate the presence of a hazard which will cause severe

DANGER

personal injury, death, or substantial property damage if the warning is

ignored.

Hazardous voltage. Can cause severe injury or death.

Only use factory supplied for incoming power.
See Operators/Instruction manual.

Moving parts. Can cause severe injury.

Do not operate with covers removed.
Service only with machine blocked to prevent turn over.

High pressure air. Can cause severe injury or death.

Relieve pressure before removing filter plugs/caps, fitting or covers.

Hot surface. Can cause severe injury.

Do not touch. Allow to cool before servicing.

SAFETY AND WARNINGS

2-4 Decals
AS21(20)B, AS31(30)B

WARNING
Do not touch!
Hot surface.
Will cause injury or death.

1. Installation of an air receiver tank is

highly recommended when air demand
has wide fluctuation
2. For easy maintenance, please use the union
or the flange when connecting to air
discharge pipe line.

DANGER
High pressure. Safely depressure the
compressed air. Flying parts from
compressed air can cause injury or
death.

3. In cases where the discharge piping is

installed vertically, install the drain valve
on a drip leg and check the drain daily.

DANGER

4. It is necessary to install a condensate

drain on the piping.
Consult your distributor for further details.

Compressed air from this machine contains

oil mist which may cause severe nausea,
injury or death. Never use air from this
machine to supply breathing air and keep
unit in a well-ventilated area.

5. Adequate clearance around the unit is

required for ease of access when maintain
and provide proper airflow and cooling.
Consult the operator's manual for modelspecific details.

REQUIRED SEPERATOR
CONDENSATE DRAIN SCHEDULE
Condensate should be drained at least once a day
before starting or an hour after stopping the air
compressor. Refill oil if necessary, to the recommended
levels indicated in operator's manual.

USE ONLY GENUINE PARTS

Use of unauthorized parts will automatically void the
warranty and can cause dangerous and unstable
compressor operation

GENUINE LUBRICANT
FOR SCREW AIR COMPRESSOR

AIRLUBE-S

DANGER
Hazardous voltage inside.
Shut off power.
Will shock, cause injury or death.

[ Fig. 2-1 ] Front Side

SAFETY AND WARNINGS

WARNING

DANGER

Do not touch!
Hot surface.
Will cause severe injury.

Keep hands, feet and clothing

away from driven parts.
Will cause injury or death.

WARNING

DANGER

Do not touch!
Hot surface.
Will cause severe injury.

Keep hands, feet and clothing

away from driven parts.
Will cause injury or death.

[ Fig. 2-2 ] Rear Side

SAFETY AND WARNINGS

AS26(25), AS31(30), AS41(40)

WARNING
Do not touch!
Hot surface.
Will cause injury or death.

1. Installation of an air receiver tank is

highly recommended when air demand
has wide fluctuation
2. For easy maintenance, please use the union
or the flange when connecting to air
discharge pipe line.

DANGER
High pressure. Safely depressure the
compressed air. Flying parts from
compressed air can cause injury or
death.

3. In cases where the discharge piping is

installed vertically, install the drain valve
on a drip leg and check the drain daily.

DANGER

4. It is necessary to install a condensate

drain on the piping.
Consult your distributor for further details.

Compressed air from this machine contains

oil mist which may cause severe nausea,
injury or death. Never use air from this
machine to supply breathing air and keep
unit in a well-ventilated area.

5. Adequate clearance around the unit is

required for ease of access when maintain
and provide proper airflow and cooling.
Consult the operator's manual for modelspecific details.

REQUIRED SEPERATOR
CONDENSATE DRAIN SCHEDULE
Condensate should be drained at least once a day
before starting or an hour after stopping the air
compressor. Refill oil if necessary, to the recommended
levels indicated in operator's manual.

USE ONLY GENUINE PARTS

Use of unauthorized parts will automatically void the
warranty and can cause dangerous and unstable
compressor operation

GENUINE LUBRICANT
FOR SCREW AIR COMPRESSOR

AIRLUBE-S

DANGER
Hazardous voltage inside.
Shut off power.
Will shock, cause injury or death.

[ Fig. 2-3 ] Front Side

SAFETY AND WARNINGS

DANGER

WARNING

Keep hands, feet and clothing

away from driven parts.
Will cause injury or death.

Do not touch!
Hot surface.
Will cause severe injury.

WARNING

DANGER
Keep hands, feet and clothing
away from driven parts.
Will cause injury or death.

Do not touch!
Hot surface.
Will cause severe injury.

[ Fig. 2-4 ] Rear Side

GENERAL

3.0 COMPRESSOR GENERAL

3-1 Specification

AS21B
(AS20B)

MODEL

AS31B
(AS30B)

Type
U
N
I
T

Air
Delivery
(/min)

T
O
R

G
E
N
E
R
A
L

2.6

3.9

3.25

3.9

4.8

0.85 MPa

2.2

3.4

2.80

3.7

4.3

0.95MPa

2.1

3.0

2.55

3.0

3.8

Belt Drive
15/20

22/30

Direct Coupled
18/25

22/30

Voltage ( V )

220, 380, 440

Frequency ( Hz )

50 / 60

Poles

Starting Method

D.O.L.

Y-Delta

Air Outlet A(B)

25 (1)

Oil Sump Capacity (Liter)

10

Discharge Air Temp. ()

Inlet Air Temperature + 15 : Air-Cooled

Ambient Temp. ()

Max.40

AS41
(AS40)

0.7 Mpa

Output ( kW/HP )

AS31
(AS30)

Oil Injection and Rotary Screw

Driving Method

AS26
(AS25)

dB(A)

685

30/40

655

Length ( mm )

1400

Width ( mm )

830

Height ( mm )

1350

I
M.

Weight ( kg )

480

560

550

Note.
1. Noise level measured according to ISO 12127, Ed. 3, Annex C-1996.

590

610

GENERAL

3-2 Major component

3-2-1 AS21(20)B, AS31(30)B

#. DESCRIPTION
1. COMMON BASE
2. COVER & FRAME

15

3. AIREND
4. PULLEY & BELT
5. MOTOR

12

16

6. SUCTION FILTER
7. SUCTION VALVE
8. BYPASS VALVE & OILFILTER HEAD
9. OIL FILTER CARTIDGE

17
2

10. DISCHARGE PIPE

22

11. SEPARATOR TANK

12. SEPARATOR COVER & MPV
13. AIR DELIVERY PIPE
1

14. AIR COOLER SIDE

20

19

15. OIL COOLER SIDE

21

11

16. CONTROLLER

[ Fig. 3-3 ] Front View

17. CONTROL BOX

18. SIROCCO FAN
19. OIL DRAIN VALVE
20. OIL LEVEL GAUGE
21. OIL FILLER
22. PRESSURE GAUGE

14
6

10
18
9
13
8

5
3
4

[ Fig. 3-4 ] Rear View

GENERAL

3-2-2 AS26(25), AS31(30), AS41(40)

#. DESCRIPTION
1. COMMON BASE
2. COVER & FRAME

15
12

3. AIREND
4. COUPLING
5. MOTOR
6. SUCTION FILTER

16
2

7. SUCTION VALVE
8. BYPASS VALVE & OILFILTER HEAD

17

9. OIL FILTER CARTIDGE

10. DISCHARGE PIPE
11. SEPARATOR TANK
12. SEPARATOR COVER & MPV

13. AIR DELIVERY PIPE

22

14. AIR COOLER SIDE

15. OIL COOLER SIDE

20
11

21

19

[ Fig. 3-5 ] Front View

16. CONTROLLER
17. CONTROL BOX
18. SIROCCO FAN
19. OIL DRAIN VALVE
20. OIL LEVEL GAUGE
21. OIL FILLER

14
6

22. PRESSURE GAUGE

18

9
8

10
13

5
4

[ Fig. 3-6 ] Rear View

10

GENERAL

3-3 Piping and instrument diagram

3-3-1 Flow chart

ABBREVIATION
SF
SH
SCV
AE
ST
SP
MPV
SFV
AC
OC
THV
OF
OR
SC
VT

SUCTION FILTER
SUCTION HOSE
SUCTION VALVE
AIR END
SEPARATOR TANK
SPARATOR ELEMENT
MINIMUM PRESSURE VALVE
SAFETY VALVE
AIR COOLER
OIL COOLER
THERMOSTATIC VALVE
OIL FILTER
OIL RECOVERY VIEWER
SOL VALVE
AIR VENTING

SIMBOL LIST
TT

TEMPERATURE TRANSMETER

SUPPLY AIR LINE

PT

PRESSURE TRANSMETER

AIR LINE

PI

PRESSURE INDICATOR

AIR CONTROL LINE

LG

OIL LEVEL GAUGE

AIR MIXING LINE

CHECK VALVE

OIL RETURN LINE

ORIFICE

OIL LINE
BALL VALVE

[ Fig. 3-7 ] Flow Chart

1) Start and loading

At the same time of starting, suction valve is opened by vacuum pressure occurred by Airend rotation.
And, this time, in order to prevent the sudden load of Airend, the de-energized normal open type solenoid
valve make that the air is flowed into the valve seat of suction valve. The volume of air which flows into
the Airend is self-regulated by the balance of vacuum pressure and small compressed air.
After load delay time elapsed, output of load solenoid is energized. Then the normal open solenoid valve
starts normal loading operation. The oil is separated from compressed air by the oil separator.
And then compressed air is supplied to the line after getting cooled by air cooler & passing the MPV.

11

GENERAL

2) Unloading and stop

When the pressure transmitter senses the pressure of pipe reaches to the set pressure, the solenoid valve
is de-energized and the compressed air is flowed into the suction valve piston. At this time, suction valve is
closed by compressed air and the inside compressed air of the Separator tank is vented through the orifice
and suction filter which are had built-in suction valve. The pressure of separator tank inside is kept up the
minimum pressure (0.2~0.35Mpa) in order to circulate the oil.
The operation of suction valve during the stop is the same.

3-3-2 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.

12

INSTALLATION

4.0 INSTALLATION
4-1 Inspection
When you receive the compressor please inspect it closely.
Upon delivery, carefully check the compressor for damage

MODEL NO.

during transportation.

SERIAL NO.

If goods are received in damaged condition, it is important

that you notify the carrier and insist on a notation of loss or
damage across the freight bill.

kW

AS

Ph

MPa
Hz

KYUNGWON MACHINERY Co., Ltd.

3BL 602LT, 1280-1 JUNGWANG-DONG, SIHUNG-SI,
GYEONGGI-DO, KOREA
PHONE : +82-31-496-2031~8, FAX : +82-31-319-4910

[ Fig. 4-1 ] Name Plate

4-2 Handling
4-2-1 Handling by forklift
When handling by a forklift, make sure that forks completely extend through the width of the unit. [Fig. 4-2]
4-2-2 Handling by shop crane
When handling by a shop crane, use the openings provided on common base where slings or steel wire
ropes can be used for lifting. [Fig. 4-3]

[ Fig. 4-3 ] Handling by Shop Crane

[ Fig. 4-2 ] Handling by Forklift

13

INSTALLATION

4-3 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.

[ Fig. 4-4 ] Location

[ Table 4-1 ] Ventilation Fan Capacity
Air Volume

Hood Size

(/min)

[ mm x mm ]

AS21(20)B, AS26(25)

100

600 x 600

AS31(30)B, AS31(30)

110

600 x 600

AS41(40)

130

700 x 700

MODEL

[ Note ]
1. The room ventilation capacity is based on :
(1) Compressor room Temperature rise which is controlled within the 14 (-10).
(2) Static pressure of ventilation air should be 0 inch.
2. Consult the distributor for more information on ventilation capacity when the air exhaust
duct is installed.

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

14

INSTALLATION

4-4 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. After coolers and the addition
of air dryers can eliminate this hazard. Similarly, avoid allowing compressor coolant to enter the plant
air systems. Air line separators properly selected and installed 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.

DRAIN VALVE
CHECK VALVE
STOP VALVE

FLEXIBLE HOSE

[ Fig. 4-5 ] Installation with Reciprocating Compressor

15

INSTALLATION

4-5 Electricity
This extensive line of 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 90110 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
(V)max

100 ()
(V)mean

: 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.
[ Table 4-4 ] Electric Specification
MODEL
[Pole]
AS21B
(AS20B)
[4P]
AS31B
(AS30B)
[2P]
AS26
(AS25)
[2P]
AS31
(AS30)
[2P]
AS41
(AS40)
[2P]

OUTPUT

R.L.A.

L.R.A

[V]

[kw]

[A]

[A]

AF
[A]

TRIP
[A]

KIV
[]

CV 1C
[]

CV 3C
[]

GV
[]

54

310

100

100

16

16

16

31.2

202.8

50

50

440

27.0

155.0

50

50

220

73.6

488.7

225

125

25

25

25

42.6

283

100

75

10

10

10

440

36.8

244.4

100

60

10

10

10

220

62

415.4

100

100

16

16

16

31.7

212.4

50

50

440

31

207.7

50

50

220

73.6

488.7

225

125

25

25

25

42.6

283

100

75

10

10

10

440

36.8

244.4

100

60

10

10

10

220

97.6

496.7

225

150

35

35

35

56.5

287.7

100

100

16

16

16

48.8

248.4

100

75

16

16

10

220
380

380

380

380

380
440

15

22

18.5

22

30

MCCB

CABLE SPECIFICATION

POWER

16

GROUND

OPERATION

5.0

OPERATION INSTRUCTIONS

5-1 Initial start-up

5-1-1 Controller

MENU

START

RESET

STOP

CANCEL

E NTER

UP

DOWN

[ Fig. 5-1 ] Controller

5-1-2 Before operation
Make sure that :
(1) All installation piping and electrical work has been properly performed and completed.
(2) The voltage of the power source is at a regular level.
(3) The main power is disconnected.
(4) Tightness of all electrical connections and wirings.
(5) Tightness of all joints, fasteners, covers, plugs and caps are inspected.
(6) Tightness of all grounding connections are inspected.
(7) V-belt tensions are inspected.
(8) The oil level is at the proper point.
Oil level should be at the upper center line of the upper oil level gauge.
(9) Isolation stop valve in the discharge air line is completely open.

DANGER
This machine is remotely controlled and may start without warning.
As a further safeguard, persons switching on remotely controlled units shall take adequate
precautions to ensure that there is no one checking or working on the machine.
To this end, a suitable notice shall be affixed to the start equipment.

17

OPERATION

5-1-3 Starting
(1) Turn on the main MCCB. Then, LCD of compressor controller displays initial display.
(2) Press start keypad on controller of compressor. The start icon of controller lights up on green.

CAUTION
REVERSE PHASE CONNECTION
: In case of the reverse phase connection, the unit does not start and the reverse phase
fault message will be displayed on LCD. If this happens, disconnect the main power
and interchange two of three main cables on terminal block installed in the control box.
(3) Check oil level after starting. Oil level may drop as oil circulates into the system.
During operation, oil level should be nearby the center line of lower oil level gauge.
(4) Check the unit for any abnormal noise or vibration.
(5) In order to load & unload operation, gradually close the isolation stop valve of external receiver
tank. With the close of discharge vale, compressor automatically stop in 300 seconds. With open
discharge valve before automatically stop, compressor returns loading condition.
LCD displays current pressure value and current status of compressor.
(6) Press stop keypad to stop the compressor.
30 seconds after entering stop command, compressor and motor will be stopped.
(7) Please do not re-start the compressor with the condition over 0.05MPa pressure of separator tank.

AS21B
(AS20B)

AS31(30)B, AS26(25),
AS31(30), AS41(40)

ITEM

Unit

Discharge Pressure

MPa

0.7 , 0.85 , 0.95

Time to Maintenance

Hour

3000

Autostop Delay Time

min

Load Delay Time

sec

10

Discharge Temperature

Max. 110 ( @AIREND DISCHARGE)

Y- Time

sec

D.O.L.

[ Table 5-1 ] Factory Default of Control Parameters

18

OPERATION

5-2 Daily operation

5-2-1 Before operation
(1) Make sure the 0Mpa pressure of separator tank.
(2) Drain the condensation water from separator tank.
(3) Check the oil level. ( If necessary, refill the oil. )
(4) Open discharge valve and check all gauge indicating proper level.
(5) Check controller condition and press START button.
(6) After 10 seconds delay time to load, unit begin loading work with suction valve open.
(7) Check the unit for any abnormal noise or vibration.
5-2-2 During operation
(1) Make sure that all gauges of compressor indicating normal status.
(2) Make sure the proper working with pulling handle of safety valve. (check every 500hrs.)

ITEM

RATING

REMARKS

Discharge Temperature

Max.110

Alarm at 105

Ambient Temperature

0~40

Above -10

Controller Status

NORMAL

LCD & LED Display

Voltage

Rated Voltage 5 [%]

Differential Pressure

Max. 0.1 Mpa

Change Separator Element / Cartridge

[ Table 5-2 ] Check-list during Operation condition

5-2-3 Stopping
(1) Press STOP button.
(2) Disconnect main power.
(3) Make sure the discharge pressure is 0 MPa.

WARNING
1) Do not remove the cap of drain valve and oil filler, it can cause severe injury or death.
2) Make sure 0MPa of separator tank pressure before open drain valve.
3) After stopping air compressor, for the time being, the inner side temperature of compressor
is very high. Make sure not to touch discharged moisture or oil from the unit.
4) Do not approach to the revolutionary body during the working.

19

FUNCTIONAL DESCRIPTION

6.0 FUNCTIONAL DESCRIPTION

6-1 Airend
Oil injected, single stage, rotary screw type which primarily consists of
rotors, housing, shaft seal along with other component parts.
Precision rotors provide close inter lobe clearance. This minimizes
leakage and increases efficiency. 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

[ Fig. 6-1 ] Airend

loads. With a differential pressure lubrication system, the compressor can

dispense with an oil pump, thus dramatically simplifying the oil supply
System.

6-2 Motor
IEC or NEMA standard, DP or TE enclosure, 3-phase AC induction motor.
[ Fig. 6-2 ] Motor

6-3 Coupling [AS26(25), AS31(30), AS41(40)]

Motor speed is transferred by HRC flexible coupling drive to rotor driving speed. And adoption of taper
lock bush is easy maintenance and arrangement.

6-4 Suction control valve

Suction control valve controls load or unload condition. Internal pressure is vented to the atmosphere
at partially loaded or unload conditions whereby the motor idles for power saving features.

6-5 Suction 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.
GENUINE SUCTION FILTER ENSURES YOUR SYSTEM FOR LONG LIFE.

[ Fig. 6-3 ] Coupling

[ Fig. 6-4 ] Suction Control Valve

20

[ Fig. 6-5 ] Suction Filter

FUNCTIONAL DESCRIPTION

6-6 Separator tank

Oil injected screw compressor compress mixed air and oil.
Most of the oil is separated from air by the impact at the inner wall
of the separator tank. As the fluid cyclonic effect, the heavy oil falls
and collected in the oil sump at the bottom of the separator tank.
The function of separator tank are :
1) Oil separation
2) Oil storage and circulation
3) Buffer tank of air
4) Attachment of gauge and parts
[ Fig. 6-6 ] Separator Tank

6-7 Separator element

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.

GENUINE SEPARATOR ELEMENT ENSURES

YOUR SYSTEM FOR LONG LIFE.

[ Fig. 6-7 ] Separator Element

6-8 MPV (Minimum Pressure Valve)

It is located in oil separator air outlet in order to maintain adequate
system pressure for efficient separation of oil.
And the setting pressure is 0.4MPa.
[ Fig. 6-8 ] MPV

6-9 Cooler
After cooler and oil cooler is composed of corrugated fin
and tube type with aluminum material.
Those fins remove the compression heat efficiently.
Cooling fan exhausts the heat-exchanged air through
a ventilation duct to the outside of the enclosure.

[ Fig. 6-9 ] Cooler & Cooling Fan

21

FUNCTIONAL DESCRIPTION

6-10 Oil filter

Airend consists of precision processed rotors and other component.
And the internal clearance is well adjusted and very small.
If the injection oil involve some particle or dust, it may be cause of
airend trouble. Coaire airend uses a genuine cartridge filter with
5 ~ 10 micron. It should replace every 3000hrs. operating time, but
the time is reduced if it is more severe operating condition.

GENUINE OIL FILTER ENSURES YOUR SYSTEM FOR LONG LIFE.

[ Fig. 6-10 ] Oil Filter

6-11 Bypass valve (Thermostat valve)

The function of bypass valve reduce the condensate water in oil
separator tank by means of adjusting the discharge air temperature.
At initial operating, the oil passing thru the airend until the oil
temperature of 70C. If oil temperature is more then 71C, the
bypass valve open and the oil will pass through the oil cooler.
[ Fig. 6-11 ] Bypass Valve

6-12 Oil
Oil is an essential factor in the oil flooded rotary screw compressor.
Use a high grade synthetic oil with ISO viscosity grade 32, 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
[ Fig. 6-13 ] AIRLUBE-S

compression process efficiency.

Cooling : Oil is injected during compression process to remove the heat of
compression.
GENUINE OIL ENSURES YOUR SYSTEM FOR LONG LIFE.

22

FUNCTIONAL DESCRIPTION

[ Table 6-1 ] AIRLUBE-S

DESCRIPTION

SPECIFICATION

DESCRIPTION

SPECIFICATION

Viscosity Grade

ISO VG32

cSt@100

5.7

Density @ 15

0.854

Viscosity Index

119

Flash Point []

224

RBOT, Min.

3000

Flock Point []

-32.5

Demulsibility, Min. @ 54

40-40-0(10)

Color, ASTM

L0.5

Copper Corrosion Test

(100x3Hr)

Viscosity, cSt @ 40

1a

31.8

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 our distributor for the procedures.
We highly recommended the use of Genuine Screw Compressor Oil, AIRLUBE-S.

23

CONTROL

7.0 CONTROL
7-1 CONTROLLER
COAIRE controller efficiently controls SCREW AIR COMPRESSOR based on microprocessor, gives users
an alarm against trip by checking the status of the air compressor in advance and offers users the
information for maintenance and let them treat it quickly and easily.

7-1-1 Power supply & environment

1) Power Input : AC24V 10% 50/60Hz 40w
2) Transformer : 50[VA] - recommended minimum
3) Operation temperature : -10 ~ 60
4) Operation humidity

: below 95% @40

5) Storage Temperature

: -30 ~ 80

7-2 General function

7-2-1 LCD display

[ Fig. 7-1 ] LCD Display

24

CONTROL

7-2-2 Keypad

MENU

START

RESET

STOP

CANCEL

E NTER

UP

DOWN

[ Fig. 7-2 ] Keypad

START

Pressing START keypad, compressor will start.

STOP

Pressing STOP keypad, compressor will stop.

RESET

Pressing RESET keypad, to reset trip or alarm.

MENU

Pressing MENU keypad, to setup and status menu.

ENTER

To enter the set point procedure.

UP / DOWN

Upward (Increase) and/or Downward (Decrease)

Return to the .previous menu or initial screen

CANCEL

BRIGHTNESS

&

Press CANCEL keypad in initial status, and then

adjust screen using the UP / DOWEN keypad.

[ Table 7-1 ] Function of Keypad

25

CONTROL

7-2-3 LED lamp

OPERATION STATUS
[START LED]
FAULT STATUS
[RESET LED]

GREEN

ON / OFF according to operation status

RED

ON / OFF according to fault status

7-2-4 LED operation

STATUS

OPERATION STATUS LED

Initialization

OFF

Start Inhibit

OFF

Ready to Start

OFF

Stat Delay

SF
HF : if load request

Ready to Motor Start

SF

Motor Starting

SF

(Y-D Conversion)

Load Delay

Loading

Reload Delay

Normal : OFF

HF : if load request
SF
HF : if load request

SF
HF : if load request
SF

Stop Run On Time

LF

Trip

: HF

Alarm

: LF

Maintenance : SF
Start Inhibit : SF

ON

Standby Run On Time

Shutdown

FAULT STATUS LED

OFF

NOTE
1) ON : LED is always ON.
2) HF : High speed flickering - ON for 0.1 sec / OFF for 0.1 sec
3) LF : Low speed flickering - ON for 0.5 sec / OFF for 0.5 sec
4) SF : Spot flickering - ON for 0.1 sec / OFF for 4 sec
5) OFF : LED is always OFF.

26

CONTROL

7-2-5 Status Display

LOC
NET
REM
SCH

PRE
NET
REM

LOC STP
REM STP
NET STP
SCH STP
S.D STP

LOC RUN
REM RUN
NET RUN
SCH RUN

GOOD
MAINTEN
ALARM
S-DOWN
INHIBI

Start / Stop Mode Display

LOC : S tart /Stop using START / STOP key on the controller
NET : Start / Stop from PC or remote device using protocol [OPTION]
REM : Start / Stop remotely using digital input port on the controller
SCH : Start / Stop according to setup schedule of [Schedule] menu [OPTION]

Load Operation Mode Display

PRE : Load / Unload operation by press. value of sensor on the equipment
NET : Load / Unload operation from PC or remote device using protocol [OPTION]
REM : Load / Unload operation remotely using digital input port on the equipment

Stop Status Display - Display during equipments stop

LOC STP : Stop by stop button on the controller
REM STP : Stop by digital input signal
NET STP : Stop by communication function [OPTION]
SCH STP : Stop by setup time on SCHEDULE set-up [OPTION]
S.D STP : Stop by shutdown fault

Operation Status Display - Display during equipments operation

LOC RUN : Operate by start button on the equipment
REM RUN : Operate by digital input
NET RUN : Operate by communication function
SCH RUN : Operate by setup time on [Schedule] menu

Equipment Status Display

GOOD : Normal status
MAINTEN : Required maintenance
ALARM : Alarm status
S-DOWN : Sensing fault
INHIBIT : Start inhibit

SYSTEM LOCK

27

CONTROL

7-2-6 Digital Input Signal

Symbol

Description

Symbol

Description

EMS

Emergency Switch Signal

REV

Reverse Phase Signal

FAN

Fan Motor Overload Signal

AOS

Air Oil Separator High Temp. Signal

RES

Remote Start/Stop Control Signal

REN

Remote Enable Signal

REL

Remote Load/Unload Control Signal

MOL

Main Motor Overload Signal

OFP

Oil-Filter High DP Signal

7-2-7 Digital Output Signal

Symbol

Description

Symbol

Description

N1

Multi Function Port N1

N2

Multi Function Port N2

N3

Multi Function Port N3

N4

Multi Function Port N4

CM

Main Magnetic Contactor Signal

CY

Star Magnetic Contactor Signal

CD

Delta Magnetic Contactor Signal

SOL

28

Load Solenoid Control Signal

CONTROL

7-2-8 Message
[ Table 7-2 ] Trip Message
No.

Message

Description

System Fault

Emergency Stop

Fan Motor O.L.

Fan OCR is operated

Reverse Phase

Reverse phase protector is operated

AOS Temp.

Main Motor O.L.

Delivery Press. High

Delivery pressure is higher than trip set value

Delivery Temp. High

Delivery temperature is higher than trip set value

Delivery P-Sensor

Delivery pressure sensor is troubled

10

Delivery T-Sensor

Delivery temperature sensor is troubled

In case of unexpected trouble of the parameter value

Emergency stop switch is operated

Separator temperature is higher than set value

EOCR is operated

Fault message is reset by pushing RESET keypad after clearing related reason.

[ Table 7-3 ] Alarm Message

No.

Message

Description

Delivery Press. High

Delivery pressure is higher than alarm set value

Delivery Temp. High

Delivery temperature is higher than alarm set value

Alarm message is reset automatically when clearing related reason.

[ Table 7-4 ] Start Inhibit Message

No.

Message

Delivery Temp. Low

Description
Delivery temperature is lower than inhibit set value

Even if START command is entered, the compressor will not start under start inhibit condition.
And, the compressor automatically start when start inhibit condition is cleared.

29

CONTROL

[ Table 7-5 ] Running Log Message

No.

Message

Description

Initial Power On

Power On

Started

Operation Start Time

Stop

Operation Stop Time

Initial Power Input Time (It cannot be deleted.)

Power Input Time,(In case of system recovery by WATCH DOG timer)

Running log message is recorded in RUNNUNG LOG menu.

[ Table 7-6 ] Maintenance Message

No.

Message

Description

AOS Element Change

In case of exceeding separator element cleaning cycle

Suction Filter Change

In case of exceeding suction filter change cycle

Oil Filter Change

In case of exceeding oil filter change cycle

Lub. Oil Change

In case of exceeding lubricate oil change cycle

Maintenance cycle is 3,000 hours.

30

CONTROL

7-3 Controller setup

7-3-1 Compressor status

Press DOWN keypad in initial status,

REV

LCD display status of digital input / output, running time,

and loading time.

Press CANCEL keypad in any status, return to initial status.

1) Digital input
SYMBOL

SPECIFICATION

NORMAL

SYMBOL

SPECIFICATION

NORMAL

EMS

Emergency Stop

ON

RES

Remote Start / Stop

REV

Reverse Phase

ON

REN

Remote Enable

FAN

Fan Motor Trip

ON

REL

Remote Load / Unload

AOS

Separator Trip

OFF

MOL

Main Motor Trip

ON

2) Digital output
SYMBOL

SPECIFICATION

SYMBOL

SPECIFICATION

N1

Multi Function Relay N1

CM

Main Magnet Contactor

N2

Multi Function Relay N2

CY

Star Magnet Contactor

N3

Multi Function Relay N3

CD

Delta Magnet Contactor

N4

Multi Function Relay N4

SOL

SOL. V/V Control

31

CONTROL

7-3-2 Running Status

Total Run Hours records the duration of started state.

1) Press MENU keypad at initial status, then Access Code display.

2) When Access Code display, enter access code or press ENTER keypad.
3) When menu list display, press ENTER keypad again.
4) Using UP / DOWN keypad, check temperature, pressure, running hour and time.

32

CONTROL

7-3-3 Pressure set

1) Press MENU keypad. When Access Code display, enter access code or press ENTER keypad.
It is possible to changing load / unload pressure value without access code.
2) Move cursor to OPERATION menu using DOWN keypad, then press ENTER keypad.
3) Current set value of unloading pressure is displayed. To change set value, press ENTER keypad.
4) Change set value using UP / DOWN keypad, then press ENTER keypad.
5) Changed set value is displayed. Changing of unload pressure value is over.
6) Press DOWN keypad one time, current set value of load pressure is displayed.
7) To change set value, use ENTER and UP / DOWN keypad, then press ENTER keypad.
8) Changing of unload / load pressure value are over.
9) In order to display initial status, press CANCEL keypad two times.

33

CONTROL

7-3-4 Multi function output

No. 11 & No. 12 of terminal bock in electric control box are digital output for indicating of
compressor status, and No. 13 is common of No. 11 & No. 12.
How to set multi function output
Press MENU keypad at initial status menu, then ACCESS CODE input display.
After input ACCESS CODE (0100) using UP / DOWN keypad, press ENTER keypad.
Move cursor to CONFIGURATION using UP / DOWN keypad, press ENTER keypad.
In order to change function of No. 11, move to cursor to MULTI FUNCTION N1.
In order to change function of No. 12, move to cursor to MULTI FUNCTION N2.
In the each menu, change function regarding to TABLE 7-12.
Change function using UP / DOWN and press ENTER keypad to save changing value.
Pressing CANCEL two times after changing value, LCD display initial status menu.
FUNCTION

DESCRIPTION

OFF

ALARM

TRIP

AL+TRIP

ON : Trip, Alarm, Maintenance, Start inhibit

SERVICE

ON : Maintenance

READY

ON : Ready to motor start condition

START

ON : Started condition

MOTOR RUN

LOADED

10

COOLING

11

HEATER

12

DRAIN

13

REMOTE

Not use
ON : Alarm condition
ON : Trip condition

ON : Motor running condition

ON : Loading condition
ON : [Operation / Cooling Fan Run. Temp.] > Delivery Air Temp.
OFF : [Operation / Cooling Fan Stop. Temp.] < Delivery Air Temp.
ON : [Start Inhibit / Delivery Temp. Low] + 5 > Delivery Air Temp.
OFF : [Start Inhibit / Delivery Temp. Low] + 10 < Delivery Air Temp.
ON : [Operation / Drain Interval & Drain Time]
while motor running condition
ON : [Compressor / Starting Command Mode set to Remote]
[ Table 7-2 ] Multi Function Output

WARNING
Rated capacity of MULTI FUNCTION OUTPUT are 250[V], 10[A].
Using overload condition cause severe damage of controller and compressor.

34

CONTROL

7-4 Running log

1) When trip / alarm occurs (or resets), data and history of event are stored at non volatile memory.
2) The maximum number of storable event is 50EA and it is deleted the earliest event and stored
the latest one in case of over 50EA.
3) When event is occurred, the name of EVENT is recorded and display occur.
Also, when event is reset, , the name of EVENT is recorded and display reset.
4) When pressing ENTER keypad, you can see operation status, delivery pressure and temperature
when trip alarm occurs.

Press MENU keypad at initial status menu,

then ACCESS CODE input display.
ACCESS CODE is not necessary, press ENTER keypad again.

Move cursor to RUNNIG LOG UP / DOWN keypad,

then press ENTER keypad.

The latest event display automatically.

Check the other events using UP / DOWN keypad.

Pressing ENTER keypad, check status, pressure and

temperature when event occurred.

Pressing ENTER keypad again, check status of digital input

and output when event occurred.

35

MAINTENANCE

8.0 MAINTENANCE
8-1 Maintenance procedure
8-1-1 Airend
1) Before beginning any work on the compressor, check the vibration and abnormal noise
and if it occurs, should contact exclusive service technician.
2) Check the oil leakage for every month, and if it occurs, should contact exclusive service technician.
8-1-2 Motor lubrication
The induction type squirrel cage motors have antifriction ball or roller bearings front and rear.
At periodic intervals they require re-lubrication. Improper lubrication can be a cause of motor bearing
failure. The quantity of grease added should be carefully controlled.
1) Free drain hole of any hard grease.
2) Use a hand lever type grease gun. Determine in advance the quantity of grease delivered with
each stroke of the lever.
3) Add the recommended volume of the recommended lubricant.
4) Run motor for about 30 minutes before replacing outlet plugs or reliefs.
[ Table 8-1 ] Recharge Amount of Grease
Bearing Initial Recharge
No.
[g]
[g]

Period [M]
2 Pole 4 Pole

Bearing Initial Recharge

No.
[g]
[g]

Period [M]
2 Pole 4 Pole

6205

14

6311

100

30

6206

15

10

6312

100

30

6208

30

15

6313

100

30

6211

80

25

6314

200

50

6213

80

25

6315

200

50

6307

30

15

6316

200

50

6309

60

20

6317

200

50

6310

80

25

6318

300

50

[NOTE]

1) Cycle time is under the 24hr operating condition.

2) Heavy duty, long life grease.
3) Regarding the bearing number, refer to motor name plate.

WARNING
1. Grease should be added when the motor is stopped and power disconnected.
2. Over re-greasing can be a cause of bearing and motor failure.
Make sure dirt and contaminants are not introduced when adding grease.
3. Grease should be added when the unit storage time is to exceed 3 month or more.

36

MAINTENANCE

8-1-3 Separator element

COVER

1) Stop the unit, and make sure that the discharge pressure gauge
indicates 0 MPa.

GASKET
SEPARATOR
ELEMENT

2) Disconnect the discharge piping flange and all the other piping
and wirings on the top of oil separator.

GASKET

3) Remove the bolts holding the oil separator cover.

4) Discard the used oil separator element, and install the new element.

OIL INLET
PORT

Make sure that the end of oil scavenge pipe touches the bottom
plate of oil separator element.

SEPARATOR
TANK

5) Install the new gasket, and securely tighten the bolts of cover.
6) Install the new gasket, and securely tighten the bolts of cover.

DRAIN

8-1-4 Oil
1) 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,

[ Fig. 8-1 ] Separator Tank

and close the isolation stop valve at the discharge outlet and

Adequate amount

disconnect the main electrical power.

3) Open the drain valve.
4) Open the plug of oil filling port on oil separator to speed up draining.
5) For draining of oil cooler, remove the plug at the drain outlet of the
oil cooler to let the oil run down.
6) Drain the oil as complete as possible. Then, close the drain valve of
separator and drain plug of oil cooler.
7) Fill with new oil through the oil filling port of oil separator.
Refer to the table of specification for the appropriate oil amount.

[ Fig. 8-2 ] Oil Level Gauge

[Upper side]

8) After securely tightening the plug at oil filling port, run the unit to make sure there are not any oil leaks.

WARNING
1) Main power should shut down during the separator element replaced.
2) All parts should be genuine parts. If not, it may cause product damage and quality deterioration.
3) Oil level should be checked every 2-3days. In case of oil pipe blockage or oil separator efficiency
drop, oil level can be dropped drastically.
4) Drain condensate water through drain valve located separator tank before re-start compressor
after unit shut down for the time being. Water in oil mist can make lust to the unit or bearing.
5) Oil should be replaced first 500 hours operation, then replaced every 3,000hours.
User should check oil quality every 1,000hours. In case of oil contamination even before 3,000
hours, it should be replaced earlier than maintenance schedule.
6) In case of oil replacement, all oil should be drained before refuel.
7) Oil should not be mixed even under same specification but different manufacturer.
Different oil addictive can cause chemical reaction which may cause severe damage to airend.
8) In case of oil level reach up to oil level glass down side, refill oil up to middle of oil level glass
upper side before oil replacement schedule.

37

MAINTENANCE

8-1-6 Oil filter

1) Exchange with the same period of oil.
2) Use exclusive wrench to remove filter.
3) Spread oil on O-ring when exchange oil filter.

WARNING
GENUINE OIL FILTER ENSURES
YOUR SYSTEM FOR LONG LIFE.
[ Fig. 8-3 ] Oil Filter Replacement
8-1-7 Suction Filter
Clean the suction filter every 500 hours of operation time.
To clean the suction filter, please follow the steps as described belows.
1) After stopping the compressor, remove the cover. Unscrew the wing nut off, and take out the
element and the silencer.
2) 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.
3) 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.
4) Inspect the element by placing a bright light nearby it If thin spots, pin holes or raptures show up,
discard the element.
5) Reinstall the elements. Make sure that the element have seated tightly without any gap between
the filter and the silencer.
6) Tighten the wing nut.
FILTER BRACKET

FILTER BODY

FILTER COVER

FILTER ELEMENT

[ Fig. 8-4 ] Suction Filter Disassembling

[ Fig. 8-5 ] Suction Filter Cleaning

WARNING
GENUINE SUCTION FILTER ENSURES YOUR SYSTEM FOR LONG LIFE.

38

MAINTENANCE

8-2 Belt [AS21(20)B, AS31(30)B]

8-2-1 Belt tension
Check the belt tension after 500 hours of purchasing and every 3000 hours (or 6 months).
please follow the steps as described belows and [ Table 8-2 ].
1) Check the belt tension with tension-meter each belt and adjust as same tension between belts.
2) Loosen fixing bolt of motor base and adjust tension bolt equivalent with [ Table 8-2 ].
3) Array motor line and fasten motor fixing bolt.

MOTOR

ADJUST BOLT
AIREND PULLEY
BELT
MOTOR PULLEY
MOTOR MOUNTING BOLT

[ Fig. 8-6 ] Belt Driven

P [ kg ]
Deflection = [mm]

[ Table 8-2 ] Belt tension

MODEL

Brand New

Old one

P kg

mm

P kg

mm

AS21(20)B

2.3

5.8

2.0

5.8

AS31(30)B

2.1

5.4

1.9

5.4

39

[ Fig. 8-7 ] Belt Tension Test

MAINTENANCE

8-2-2 Belt array

Disarray of belt causes noise, vibration and abrasion of belt and belt pulley.
Check the array between belt and pulley during the belt tension check.
The gap between pulley and ruler using iron ruler with fixing compressor should be under 0.5mm [ Fig.
8-8 ].
Check pulley array with gradual motor bolt fixing.

Max. 0.5mm

After total fixing of bolt and check the pulley array and smooth working of pulley.

ADJUSTABLE PULLEY

FIXED PULLEY

MOTOR

AIREND
[ Fig. 8-8 ] Belt Array

WARNING
1) Should stop unit before check belt tension or exchange.
2) Use Genuine belt and change whole belts including damaged one.
3) High belt tension causes the damage of rotor shaft and lowering bearing life time.
Low belt tension causes belt slippery, so maintain the tension [ Table 8-2 ]

40

MAINTENANCE

8-3 Scheduled maintenance

Part or Item

Action taken

MOTOR
AIREND

Insulation

Check

Bearing

Replace

Grease

Supplement

Bearing

Replace

Lip Seal

Replace

Oring, Gasket

Replace

Monitor

Check

Belt tension

Check

Coupling

Check

Daily

6000
hr

12000
hr

24000
hr

2
monthly

6
monthly

1
yearly

2
yearly

4
yearly

( refer motor spec )

(first 500Hr)

BELT
TYPE

SEPARATOR TANK

Oil Drain

Drain

(3000Hr)

Replace

Tank Inside

Clean

Level Gauge

Clean

Oring, Gasket

Replace

Separator Element

Replace

(3000Hr)

Oil filter Cartridge

Replace

(3000Hr)

Oil & Air cooler

Clean

Suction v/v

Clean

Part replace

Suction filter

Replace

Safety v/v

Check

Sol. v/v

Check

Check

M.P.V.

Remarks

Check

Oil

3000
hr

Oil Level

Sampling

1000
hr

Part replace

41

TROUBLE SHOOTING

9.0 TROUBLE SHOOTING

9-1 General
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.

9-2 Trouble shooting

9-2-1 LCD Display
LCD OFF

- Check Circuit Breaker

Power Connection

- Check cable connection

N
Y

- Check the FUSE

Controller

- Check the TRANSFORMER

- Check the CONTROLLER

REQUEST AS

START

Clear trouble

9-2-2 Reverse phase

REVERSE PHASE

Power Connection

REVERSE PHASE message display on LCD

Interchange 2 of 3 main cables

N
Y
Reverse Phase Detector

- Check supplied power of RPD.

- Check REVERSE PHASE DETECTOR

N
START

REQUEST AS

42

Clear trouble

TROUBLE SHOOTING
9-2-3 Motor start failure

MOTOR SART FAILURE

Controller Message

- Check controller TRIP MESSAGE

Motor Cable

- Check MOTOR CABLE

- Check loose wiring and cable size

Magnet Contactor

- Check wiring of M/C coil

- Operation test of M/C

MOTOR

- Check resistance of cable

- Check bearing adhesion

AIREND

Y
- Check AIREND adhesion

CONTROLLER

- Check digital output

- Re-power up to CONTROLLER

N
REQUEST AS

START

Clear trouble

DANGER
This machine is remotely controlled and may start without warning while inspecting the unit.
As a further safeguard, persons inspecting units shall take adequate precautions to ensure
that machine may not start and running.
To this end, 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.

43

TROUBLE SHOOTING
9-2-4 Discharge pressure low
Discharge pressure decrease

Air consumption increase

- Check piping leakage

- System compressed air demand

Suction control valve

- Check SUCTION CONTROL VALVE

- Check solenoid, venting v/v, piston

MPV Control

- Suction valve control is disable,

while the pressure of separator
tank is lower than 0.1 Mpa.

N
Y

- Replace separator element,

Separator Diff.

if differential pressure is greater

than 0.1MPa.

N
REQUEST AS

START

Clear trouble

9-2-5 Discharge pressure high

Discharge pressure increase

Pressure Sensor

Discharge Press. High message display

Check PRESSURE SENSOR

N
Y
Suction control valve

Check venting v/v unloading system

N
Controller

Check solenoid control output

N
REQUEST AS

START

44

Clear trouble

TROUBLE SHOOTING

9-2-6 Discharge temperature high

Discharge Temperature High

Ambient Temp. high

Discharge Temp. High message display on LCD

- Keep Amb. temp. below 40

- Check ventilation system & duct

Bypass valve

- Bypass valve operation & temp.

- Replace wax-element

N
Y
Oil filter

- Check service interval

- Replace oil filter, if differential
pressure is greater than 0.08MPa.

Cooling system

- Check FAN MOTOR

- Cleaning cooler

Separator

- Check service interval

- Replace separator element,
if differential pressure is greater

than 0.08MPa.
Controller

- Check temp. sensor

- Check analog input value of temp.

sensor

REQUEST AS

START

Clear trouble

NOTICE

1) In case of bad air compressor room environment, Oil filter and Oil Separator can be contaminated
earlier than recommended maintenance schedule.
2) 85~95 of Air Outlet temperature is optimal when Air Inlet (Ambient) temperature is below 40.
3) When Air Outlet temperature drastically increased, air compressor should be checked any abnormal.

45

TROUBLE SHOOTING

9-3 Cause and remedy

CONDITION

POSSIBLE CAUSE

SUGGESTED REMEDY

1) Airend adhesion
MOTOR
OVER
CURRENT

1) Consult the distributor

- Foreign material in airend

- Airend [Rotor] damage
- Oil viscosity increase by oil damage
2) Unbalanced / under power

2) Power condition upgrade

3) Motor coil damage

3) Motor check

4) EOCR set value

4) Reset / replacement

ULOADING

1) Pressure sensor fault

1) Replacement

CONTROL

2) Suction control valve damage

2) Consult the distributor

3) Venting valve damage

3) Cleaning / replacement

1) Oil over-filling

1) Reduce oil level

2) Oil leakage

2)

FAILURE

OIL
CARRY OVER

OIL
DAMAGE

NOISE
&
VIBRATION

AIR / OIL
REVERSE
FLOW

- Oil leakage of LIP SEAL

- Consult the distributor

- Oil leakage of piping & joint

- Check

3) Separator element damage

3) Replacement

4) Incomplete assembling of Sep. element

4) Re-assembling

5) Using incongruent oil

5) Use GENUINE OIL

6) MPV damage

6) Replacement

1) Using incongruent oil

1) Use GENUINE OIL

2) Oil mixture

2) Use GENUINE OIL

3) Ambient temperature high

3) Vent condition upgrade

4) Mixed oil & moisture

4) Replace oil

5) Using damaged oil

5) Replace oil

1) Loosen bolt

1) Tightening bolt

2) Airend

2) Consult the distributor

- Bearing damage
- Foreign material in airend
3) Coupling unbalancing & damage

3) Balancing & replacement

4) Incomplete installing compressor

4) Re-install compressor

5) Cooling fan damage

5) Cleaning c& replacement

1) MPV leakage

1) Check & replacement

2) Suction control valve damage

2) Consult the distributor

46

OUTLINE DRAWING

10.0 OUTLINE DRAWING

10-1 AS21(20)B, AS31(30)B, AS26(25), AS31(30), AS41(40)

ENCOURAGEMENT SUBJECT
1. Main tai n ambie nt tem perature between
32 and 104 (0~40 ).
2. R emove dus t and steam ar ound equipement after
ins tall ation of compressor.

AS31B

47

ELECTRICAL WIRING DRAWING

11.0 ELECTRICAL WIRING DIAGRAM

11-1 AS21(20)B
11-1-1 POWER & MOTOR / 220V

48

ELECTRICAL WIRING DIAGRAM

11-1-2 POWER & MOTOR / 380V, 440V

49

ELECTRICAL WIRING DRAWING

11-1-3 CONTROL PARTS / 220V, 380V, 440V

50

ELECTRICAL WIRING DIAGRAM

11-2 AS31B(30), AS26(25), AS31(30), AS41(40)

11-2-1 POWER & MOTOR / 220V

51

ELECTRICAL WIRING DRAWING

11-2-2 POWER & MOTOR / 380V, 440V

52

ELECTRICAL WIRING DIAGRAM

11-2-3 CONTROL PARTS / 220V, 380V, 440V

53

Data

Hour

Total Running
2

(Kgf/Cm g)

Discharge
Pressure
Discharge
Temperature
(C)

Ambien t
Temperature
(C)
Voltage
Curren t

Electric

Quantity of refill
Oil
(Liter)

Replaced Parts
and other
Particulars

Operation Record Form

Product Guarantee
Thank you for purchasing our COAIRE Compressor.
KYUNGWON Limited guarantees the product as follows according to the consumers loss
compensation regulation for each category.
Upon request for service, we provide after service at KYUNGWON or assigned agency.
When requesting for the service, please check the following categories before contacting us.

Product Name

Model Name

Purchasing Date

Serial Number

Supplier

Installation Date

Product Guarantee Period: One year after installation, five years of parts possession
Free Service :
If the damage is found within one year of operation in standard usage condition after purchase and
installation of the product, repair service will be provided free of charge.
However, parts categorized as exhaustive parts in the manual are excluded from service.
Charged Service
Service will be charged if it is requested without any defect in the product.
Therefore, please read the manual. (We follow a separate standard for irreparable product damage.)
In case of the damage caused by the consumer
- In case damage is caused by consumer's mishandling or repair or reformation of the product
- In case of damage caused by someone other than KYUNGWON agency or serviceman
- In case of damage caused by using parts not provided by KYUNGWON Limited
- In case of damage caused by moving or dropping the product after installation
- In case of damage caused by power problem or defects in the connector attached to the product
Other Cases
- In case of the damage caused by natural calamities (fire, sea wind, flood, etc)
- When the lifespan of exhaustive parts had reached the end (oil, filter, etc)

Contact Us
3BL 602LT,1280-1 Jungwang-dong, Siheung-si, Gyeonggi-do, Korea
TEL: 031- 496 - 2060 ~ 4 FAX : 031 - 319 4910
Homepage : www.coaire.co.kr and www.ekyungwon.co.kr
This product guarantee is only valid in the country where product purchased
and cannot be re-published. Therefore, please store this product guarantee with the manual.

Compressor Installation Report

Record Item
Model Name
Serial Number
Manufacturing
Date
Customer
Information
Distributor

Company
Tel.

Operator

Installer

Company
Tel.

Check Point
Item

The result of the Check

Does the compressor installation condition satisfy the conditions specified

in the manual?

Yes

No

Was there any damage caused while moving or installing the compressor?

Yes

No

Is there a separate breaker installed exclusively for the compressor?

Yes

No

Is the grounding standard?

Yes

No

Is there oil residues or dampness during operation?

Yes

No

Are the noise and vibration in good condition when operating the
compressor?

Yes

No

Are there any flammable materials in the area of compressor installation?

Yes

No

Are the oil level, pressure, temperature, power voltage and electric current
normal during the compressor operation?

Yes

No

Did the installation serviceman provide you with sufficient cautions and
warnings
in regards to the safety and usage sufficiently?

Yes

No

Please make sure all items stated above meet the satisfactory level.
If not, please refer to the manual for corrections.
We hereby certify that the product installation has been completed based on the contents of
the product handling manual under the agreement from the customer.

Distributor

Customer

Company
:
Tel.
:
Person in Charge :

Company
:
Tel.
:
Person in Charge :

DATE :

KYUNGWON MACHINERY CO.,LTD.