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Kirloskar Pneumatic Co. LTD., Pune
Kirloskar Pneumatic Co. LTD., Pune
Kirloskar Pneumatic Co. LTD., Pune
, Pune
Kirloskar Pneumatic Co. Ltd., Pune
Replaces,
Document Number: 272100054000
Date: 25.02.2006
Contact Information:
Phone : 91 – 20 26870133/26870341
Toll free Number: 1800 301 00009 (directly accessible from all networks)
Kirloskar Pneumatic Co. Ltd., Pune
Address:___________________________________
Compressor Model:___________________________________
Year of Manufacture:____________________________________
Date of delivery:_____________________________________
Date of Commissioning:_____________________________________
NOTE: Always indicate Compressor Serial Number given above while communicating with KPCL
dealer / Service Centre/ Branch office regarding your compressor. The warranty on this compressor is
valid only if the dealer signs and stamps on the warranty card supplied along with the compressor.
Kirloskar Pneumatic Co. Ltd., Pune
Dear Customer,
KPCL operates from Pune factory with state of the art facilities for
Research & Development, Manufacturing, Metrology and other
Business processes. KPCL’s dedication in serving the customers
through its network of branch offices, dealers, distributors, service
providers and web based customer care system has earned excellent
reputation to the company and valuable customers and partners.
TABLE OF CONTENTS
Section 1 USER INFORMATION Page No.
1.1 General 1
1.2 Warranty 2
1.3 ISO Symbols 3-4
1.4 Receiving the Compressor 5
1.5 Lifting the Compressor 6-8
1.6 General Installation Guidelines 9
1.7 Installation requirements 10-14
Section 2 SAFETY 15
Section 3 DOs and DON’Ts 16
Section 4 COMMISSIONING
4.1 General 17
4.2 Points to be observed before Initial Start 17
4.3 Commissioning the compressor 18-19
Section 5 TECHNICAL SPECIFICATIONS AND SALIENT FEATURES
5.1 Technical Specifications 20-22
5.2 Salient Features 23-27
Section 6 SYSTEM OPERATION 28-29
Section 7 MAINTENANCE
7.1 General 30
7.2 Maintenance Schedule 30
7.3 List of Consumables and Spare parts 31
Section 8 DETAILS OF SUB-ASSEMBLIES
8.1 Air Intake System 32
8.2 Drive System 33-34
8.3 Discharge System 35-36
8.4 Air-oil Separator Tank Assembly 37-38
8.5 Cooling System 39-40
8.6 Lubrication System 41-42
8.7 Capacity Control System 43
8.8 Electrical System 44
8.9 Structure assembly 45-46
Kirloskar Pneumatic Co. Ltd., Pune
1. USER INFORMATION
1.1 GENERAL
The contents in this Manual are proprietary and confidential to Kirloskar
Pneumatic Company Ltd and should not be reproduced without prior written
permission of Kirloskar Pneumatic Company Ltd.
This Manual contains instructions and technical data to cover all routine
operation and scheduled maintenance tasks by operation and maintenance
staff. Major overhauls are outside the scope of this manual and should be
referred to authorized KPCL dealer / KPCL Service department.
The use of repair parts / lubricants / fluids other than those included within the
KPCL approved parts list may create hazardous conditions over which KPCL
has no control. Therefore KPCL cannot be held responsible for equipment in
which non–approved repair parts are installed.
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Kirloskar Pneumatic Co. Ltd., Pune
1.2 WARRANTY
The warranty applicable for the compressor purchased by you is given in
the Warranty Certificate sent along with the Compressor. Preserve it to get
warranty service from KPCL dealer/KPCL.
KPCL does not accept any liability for damages in transit and during handling in
transport. Inspect the physical conditions of the compressor on receipt and get the
transporter’s confirmation regarding the damages on receipt on the transporter
invoice to claim the insurance.
Any other complaint should be informed to the authorized dealer of KPCL or KPCL
branch or KPCL registered office, Pune in writing within 6 days from the receipt of
compressor. Preserve the Warranty Certificate sent along with the compressor.
KPCL will not accept the warranty for any problems/damages arising out of failures
to observe the instructions given in this Manual. The warranty will also expire if you
alter the compressor by yourself in anyway, perform improper repairs and
insufficient maintenance. Appropriate repair and maintenance means following the
instructions given in this manual and use of KPCL Genuine spare parts for the
compressor.
KPCL reserves the right for modifications without notice in the interest of
technology progress.
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On receipt of the compressor with packing case, the condition of the packing case
has to be checked immediately for any damages. In case of damages, the proof of
condition has to be obtained from the transporter on the transporter invoice and
then the details are to be reported to insurance authorities (if transit insurance is
done) and also to KPCL dealer / KPCL.
The condition of the compressor inside the packing case also has to be verified by
unpacking the case (except the base of the packing case). In case of damages,
follow the instructions given above.
The contents are to be verified with the packing list received with the invoice /
delivery note. Written complaint to be given to KPCL dealer / KPCL immediately, if
any item is found missing w.r.to packing list. Following items are sent with
Standard Compressor without spares /accessories:
1) One No. Key for the canopy doors
2) One no. Operation and Maintenance manual
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Kirloskar Pneumatic Co. Ltd., Pune
KPCL air compressors are shipped in wooden packing cases. Refer the
figures given below to lift the compressor with overhead crane or forklift. Wooden
frame shall to be used to keep the ropes away from the canopy while lifting the
compressor with overhead crane. Soft pad / wooden panel shall be used between
canopy and forklift arm to avoid damages to canopy while lifting the compressor
using forklift.
Prior to lifting, remove the red color brackets on the base frame; inspect the
bails, ropes and support frame for their capacity and condition to suit the
weight of the compressor.
Ensure lifting hook is with functional safety latch or equivalent and is fully
engaged.
Use guide ropes or an equivalent supports to avoid the lifted unit is swinging
in air.
Do not lift the compressor in open area with high wind speed.
Ensure all the personnel are out under the compressor when suspended.
Ensure the lift operator is kept under constant observation when
compressor is suspended.
Ensure the compressor is not lifted beyond the requirement of clearance
from floor.
Check the unit is firmly sitting on the forks when forklift is used for lifting.
Ensure the compressor is slightly tilted towards forklift by tilting the forks to
avoid slipping during movement.
Ensure the compressor is resting on forklift vertical beams with pad kept
between.
Ensure the speed of the forklift / crane does not cross 5 km/hr speed.
In case of shifting the compressor to site without forklift / overhead crane,
use pipes or cylindrical rods under the compressor with wooden base of
packing case.
Use tripods with adequate capacity chain & pulley blocks to lift the
compressor from the wooden base after removing the red color brackets
fitted on base frame to hold the compressor firmly.
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Kirloskar Pneumatic Co. Ltd., Pune
Quantity of hot air to be ventilated for KES37 to KES45 models is 6000 cfm (170
m3/min). The open area around the compressor has to be kept free for operating
& maintenance personnel movement for performing the routine checks and
maintenance activities.
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Kirloskar Pneumatic Co. Ltd., Pune
Site preparation: The compressor does not need any special foundation or
grouting. Normal shop floor suitable for installing metal cutting machines is
sufficient. The surface of installation area should be with minimum variation to
avoid non-uniform seating of the compressor base frame. Use shims to ensure the
base frame seating on floor at all corners to avoid vibrations during running. The
compressor suction side has to be positioned towards the open area or opening on
the wall to ensure fresh atmospheric air entry to the compressor. Exhaust fan /
ducting has to be installed to avoid the hot air recirculation and increase in
temperature in the compressor. Refer the figures given on the previous page and
the following page for general guidance. The exhaust fan sizing has to be done
such that the air velocity does not exceed 5 m/sec. Installation of higher capacity
fan may result in capacity problem in the compressor. The compressor positioning
also to be such that the hot air from other compressors or equipments is not
diverted to the compressor to be installed.
Failure to observe the instructions regarding installation and ventilation will
result in increase in discharge temperature which in-turn result in frequent
tripping and pre-matured failure of parts.
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Kirloskar Pneumatic Co. Ltd., Pune
Connect the earth line to the threaded hole next to the cable entry hole.
Follow the electrical safety norms as per local statutory regulations and electrical
standards for the safety of operating personnel and the compressor.
Refer the illustrations and drawings on the following pages for installation.
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Kirloskar Pneumatic Co. Ltd., Pune
Refer the illustrations given above for installing the air-cooled compressor.
Best installation is with hot air exhaust duct from compressor to atmosphere and
air inlet side is kept directly inline with the air intake opening from the atmosphere.
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2.0 SAFETY
The compressors designed and manufactured by KPCL are for safe operation at
the designated conditions. The safe operation of the compressor lies with the
personnel operating and maintaining it. Hence, those who are trained and
understood this OPERATION AND MAINTENANCE MANUAL only shall operate
the compressor.
Never start the compressor when it is not safe to do so. Never operate the
compressor with known unsafe conditions. When the compressor is unsafe, tag the
unit to indicate to other and disconnect the power supply either by removing the
fuses or removing the power wire connections to avoid accidents.
This air compressor is not explosion proof and hence it has to be installed away
from the explosion area. Do not use the air from this compressor for direct contact
with food & medicine substances and do not use for breathing purpose.
Do not modify the compressor without getting the written permission from KPCL.
Fire or Explosion: Install fire extinguishers near the compressor. Do not store
inflammable materials near the compressor. Keep the compressor clean from oil
spills to ensure safety to operating personnel and equipment.
Hot Surfaces: Do not handle/touch the hot surfaces on the compressor without
using proper protection & handling devices. Avoid body contact with hot surfaces,
oil and air.
Electrical safety: Ensure electrical safety standards are adhered for the safe
operation of the compressor and personnel. Do not store materials inside the
electrical panel even though free space is available. Attempt repairs after removing
the fuses in the incoming power supply lines and keep notice near the fuse box to
avoid accidental connections.
Waste disposal: Follow the local safety standards for disposing the used oil, filters
and other used parts of the compressor to protect the environment.
DANGER
Death or serious injury may result from inhaling compressed air without using proper
safety equipment.
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DOs
DON’Ts
Neglect the routine maintenance
Allow the leakages in the system
Clean the air filter with pressurized air
Change the settings on compressor parts
Use cleaning agents while changing the oil other than recommended
Keep tools & other material on compressor
Leave loose the free end of air line hoses
Use the air for breathing
Use the air for direct contact with food products without recommended filters
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Kirloskar Pneumatic Co. Ltd., Pune
4.0 COMMISSIONING
4.1 GENERAL
The instructions given in this Manual is for a Standard Air Compressor without
additional equipment. Check for the visual damages after completing the
installation has to be done. Each compressor is supplied with electrical circuit
diagram -pasted inside the electrical panel. Check the condition of the parts and
connections. Each compressor is subjected to test run before dispatch. There are
chances of settings get disturbed during transport or installation Verification of
firmness of all connections has to be done after installing compressor at site. The
commissioning of the compressor has to be done by the KPCL dealer only after
the installation and connections are done.
Remove all supports / brackets painted in red color used for support during
transit.
Ensure the airline connections from compressor to air network are done without
gaps or loose bolts.
Ensure the electrical connections are firm and correct as per recommendations.
Ensure the moisture drain lines are connected and auto drain line ball valve is
kept open.
Ensure the oil drain ball valve on Air-oil separator tank is closed and fitted with a
threaded plug at open end of the valve.
Remove the air filter and pour 500 ml of recommended oil inside the intake valve
by pressing the tappet plate. This is to ensure the lubrication oil is present inside
the airend at the time of starting.
Check and ensure the oil level in the Air-oil Separator tank of the compressor is
filled to middle level of the sight glass fitted on tank. Use the Servo system
HLP68 only. Though oil fill capacity is 16 litres, actual fill may be low since other
points in the oil line may not be filled. Further oil fill-up to be done during the
commissioning process. Fix threaded plug at pour point and tighten it fully.
Ensure the air filter is firmly fitted on the intake valve with the clamp.
Ensure the electrical connections are done as per circuit.
Ensure the power supply line is with adequate capacity for the compressor with
Wye-delta (Star –delta) starting system for the main motor.
Ensure the ball valve on air outlet line is kept open.
If the compressor was stored for more than 3 months from the date of
manufacturing, the KPCL dealer has to be informed to do additional checks to
confirm all the moving parts like motors, airend, valves etc and critical parts are
in good conditions.
Ensure the motors are with stickers on fan cover or body to indicate direction of
rotation.
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Switch ON the main power supply and confirm “Healthy” LED is glowing on the
microcontroller after displaying Date & Time and Welcome message.
Press key on the microcontroller to confirm the display “PT-1 DIS. AIR PR” is
00.0. This display to indicate the air pressure at compressor outlet.
Press again to get the display “PT-2 BEF. OIL PR” with value 00.0 to confirm
no pressure in the Air oil separator tank.
Remove the canopy door below the electrical panel to view the motor.
Press Start button (green color) on the microcontroller to make the main motor ON.
If motor is energized, switch off the compressor by pressing Off button (red color)
on microcontroller. Check and confirm the direction of the rotation is in line with the
direction arrow mark sticker pasted on the fan cover. If the direction of rotation is
wrong, check the main power supply lines and correct them. If the direction of
rotation is correct, fit the canopy cover in position.
Close the ball valve at the compressor air outlet line.
Switch ON the compressor and confirm, “Comp. ON” LED is ON. Now the
compressor will get loaded with “Load” LED in ON condition.
Run the compressor for ONE minute and switch OFF to make the oil in the oil lines
to flow back to the tank.
Check and ensure the display for PT-2 is 00.0 when the compressor is in OFF
condition. This is to ensure there is no pressurized air in air-oil separator tank
when compressor is in OFF condition after Blow-off valve releases the air from
tank.
Check the oil level on the sight glass after 5 mins. Add oil till the level reaches to
middle level of the sight glass.
Ensure the threaded plug provided on oil pour point is tightened fully.
The compressor will go to “Unload” mode once the pressure reaches maximum
pressure/unload pressure. This is when “PT-1 DIS AIR PR” display is unloading
pressure value of the model. When the compressor is in Unload mode, the “Load”
LED will go OFF.
Open the canopy panels and confirm no air and oil leakages during this run at the
joints/fittings.
Open the ball valve slowly till the pressure PT-1 value on microcontroller display is
the working pressure of the model.
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Run the compressor on load to confirm the fan motor is getting switched ON and
OFF based on the oil temperature required for the satisfactory performance of
compressor. The settings for making the fan motor ON/OFF is already done in the
microcontroller program.
Run the compressor and record the values from the microcontroller display by
pressing button.
Refer the specifications given in Section 5 of this Manual for each model to confirm
the compressor performance is within the limits.
Ensure the temperature inside the compressor room is not more than 5 degC
above the temperature outside the room during the continuous run.
Refer Trouble –shooting guide given in this manual for any abnormalities found.
Report to KPCL, if problem persists after applying remedial actions given in the
trouble-shooting guide.
- Control . . . µ-control
SR. NO.-
D1 D2 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
P N
COM.
COM.
M O DIFIED E
NO
NO
0V OUT
CO M.
NO
12V OUT
NOT USED
COMP. MOTOR O/L
START LOAD FAN
RELAY RELAY
REMOTE START
RELAY
COMMON
RTD WHITE
RTD WHITE
FAN O /L
SPP/ RVP
PRES.T.-II
RTD RED
PRES.T.-I
E. STOP
OFF
ON
C1 C2 C3 C4 C5 C6 A1 A2 A3 A4 A5
12 34
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Air Quality: The cyclone separation system optimized over the years of research
and tests along with the best quality coalescent type oil mist separation filter
element ensure efficient separation of oil particles from the compressed air with
minimum pressure drop. This optimally designed system ensures consistent quality
of air is delivered during all modes operating cycles.
Safety systems: The compressor is provided with multiple safety systems and
elements to protect the equipment and operating personnel. The software logic
built in the microcontroller, temperature sensor, overload relay, single-phase
preventor, Reverse rotation protection, alarm messages and safety valve provided
ensures the unit runs with adequate protections.
Pulsation – free airflow: The helical fluted rotors in the airend with optimum
Length to Diameter ratio of rotors ensures pulsation free flow of compressed air.
This gives a great advantage of getting continuous flow of air.
High Reliability: The airend with only rotating parts mounted on oil lubricated
rolling bearings and minimum number of best quality moving parts is air
compression system ensures the system operates trouble-free for longer period of
time.
Low operating costs: With rotating parts of the airend, Motor and all moving
parts well lubricated, amply sized consumables of the compressor, best suitable oil
and low operating temperature of the entire system ensures the operating costs
are much lower than conventional compressors.
Airend: This is the main component of the compressor package called as Airend.
Free atmospheric air is being compressed during the rotation of optimally designed
twin helical screws in the airend. The air end is coupled directly to the electric
motor through flexible claw coupling. Both air-end & motor is mounted an anti
vibration pads placed on the base frame. With this arrangement we ensure less
vibrations and longer life of the compressor.
High efficiency air-end and reliable arrangement for transmission of power makes
the compressor energy efficient and reliable performance machine.
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Air Intake: Trouble free operation of this close tolerance, screw type compressor
is achieved by suction air filtration system. It is with Dry, Paper type filter element
in cartridge form for easy replacement. Complete filter assembly is within canopy
of the compressor, which avoids entry of heavy particles in the compressor.
Lube oil Filtration: Spin-on type oil filter is used to filter Lube oil before injecting to
the airend. This enhances long life of the compressor and reliable operation.
Air/Oil Separation: Compressed air and lube oil is separated in a multistage air/oil
separator tank. The separator also acts as an oil reservoir. High efficient air/oil
separator element, limits oil carryover to desired level in the delivered air from
compressor package.
Canopy & Base Frame: All components of the compressor package are mounted
on a single base frame. It does not require any foundation. The complete
package can be shifted with forklift or hydraulic lift trolleys by using the provision
given in the base frame.
Powder Coated Metallic Canopy of the compressor is of modular design. It is
acoustically designed to limit sound pressure level of the package to 75 dB (A) at a
distance of one meter. The noise measurement is as per Pneurop / Cagi
PN8NTC2 standard. Easily removable doors with locks are provided for easy
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Safety Devices: Following mechanical safety devices are provided to ensure safe
operation of the compressor
Minimum Pressure Valve - Maintains minimum air pressure in air-oil separator tank
so that positive oil flow is ensured.
Blow Down Valve - Ensures proper pressure relief arrangement during the
unload condition of the compressor
Oil Level indicator - This is mounted on air/oil separator tank. It gives visual
indication of minimum & maximum level of oil present
in compressor system
Control Panel: This is auto star-delta starter cum microprocessor based control
panel packaged on the same base frame within canopy of the compressor. Panel
is wired and hooked up with main motor and all instruments with in the package.
The display of various operating parameters and setting is done on a man machine
interface (MMI) - microcontroller installed on easily accessible height on canopy
front part.
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Kirloskar Pneumatic Co. Ltd., Pune
Electrical circuit diagram sticker is pasted inside the Electrical panel for ready
reference during wiring or trouble-shooting.
Safety & Control: Following Trip signals are provided to protect the machine from
abnormal operating conditions:
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The Air Intake Valve provided is normally open type. As the supply to the motor is
on due to the vacuum created in the compressor, air enters in the bare compressor
from suction filter. The compressed air is delivered to Air/oil separator. The
pressure in Air/Oil separator starts rising. This air pressure signal passes through
the open type solenoid Valve & is given to the inside piston of Air Intake Valve.
This closes the air intake valve & supply of air to the compressor is cut off. Thus
compressor is immediately unloaded. This ensures that the starting torque required
is less thereby limiting the starting current of the motor. Also the motor is started in
star connection. After a set time the starter connects the motor in delta connection
& compressor runs smoothly in unloaded condition. After a set delay time, the
Solenoid Valve is energized & the signal line to air intake valve is cut off &
connected to exhaust. With this the Air Intake Valve is immediately open &
compressor comes on load. It takes few seconds for the compressor to come on
load depending on the motor rating. The moment the pressure rises in the Air Oil
Separator tank, the oil flow to compressor is started, irrespective of whether the
compressor is in loaded or unloaded condition.
Air / oil separator separates the oil from air/oil mixture down to 1 to 3 PPM by
mechanical as well as with the help of air-oil separator element as described
earlier. The minimum pressure valve starts opening at a pressure of 3.5 kg/cm²
(full open at 4.0 kg/cm2). The compressed air from receiver then passes through
the after-cooler part of the combi-cooler where it is cooled with air of fan driven by
motor. An efficient moisture separator then separates the condensed moisture in
the compressed & cooled air. The separated moisture is drained by mechanical
auto-drain valve of the Moisture Separator. Pressurized air is now available at the
air delivery valve for user’s network.
When the demand for air decreased or when there is no demand, pressure builds
up in the system. The pressure transmitter fitted after the Moisture Separator
senses this pressure. When the pressure in the system increases beyond a set
value, an electric signal is given to the Solenoid Valve & it is de-energized. The
pressure signal line from receiver is connected to the Air Intake Valve & the
compressor is immediately unloaded. At the same the pressure signal from
receiver through the Solenoid Valve is also given to Blow Down Valve. The BDV is
normally closed type. The pressure signal opens it & receiver is connected to the
suction side of the compressor. BDV has in-built spring resistance which helps to
maintain a minimum pressure of 2.0 kg/cm^2g during unloading. This not only
ensures that the power consumption during No-load running is minimum & but also
sufficient oil flow is maintained during No-load running.
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The heat of compression is absorbed by oil besides sealing the rotor gaps and
lubricating the moving parts including bearings. The oil collected at the bottom of
the Air-oil separator tank is pumped to oil cooler using the air pressure in the tank.
The oil is cooled by atmospheric air pumped by the axial flow fan & motor
assembly fitted at the bottom of the cooler assembly with fan cowl. Further, the
cooled oil is filtered in oil filter and supplied to compressor.
If the oil is overcooled, the moisture in the air condenses and condensed water
mixes with the oil. This affects the performance and life of oil. Compressor
performance & life also gets affected. To avoid this overcooling a thermal switch is
provided in the oil line after the oil cooler. This switch switches off the cooling fan if
the oil temperature falls below a set value.
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7.0 MAINTENANCE
7.1 GENERAL
Before carrying-out any maintenance activity, stop the compressor and wait for 1
minute for all the rotating parts to stop and air from the Air-oil separator tank is
relieved by Blow-off valve. Use proper tools during maintenance to avoid damage
to compressor parts. Ensure this Manual is read and understood. KPCL dealer /
KPCL servicing department shall be contacted to clarify the doubts and assist.
Daily – after Check pressure & temp. reading during running Microcontroller
starting Check moisture drain through auto drain Drain line
After first Change oil Servo system HLP68
100 hrs of Change Oil Filter Element 271.01.432.50
running
After every Change oil Servo system HLP68
1000 hrs of Change Oil Filter Element 271.01.432.50
running Clean the cooler assembly core area
Change Air Filter Element 273.03.772.50
After every Additional activities apart from changing the parts
2000 hrs of given above are:
running 1) Check the oil and air line fittings for leakage Refer Recommended Spares
2) Check the electrical wiring connections list for fittings and O-rings for
3) Check the condition of contacts on contactors fittings.
4) Check the condition of rubber hoses Hose Kit - 273.01.847.50.
.
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The Compressor oil Servo System HLP68 is not given in the consumable list
since it can be procured directly from the oil manufacturer by the
customer/user.
The rubber & non-metallic parts like O-rings, gaskets, hoses are not considered in
the list of consumables since the life depends on the operating temperature which
in-turn depends on the operating environment, operation & maintenance
conditions. Apart from this, the gaskets and O-rings are to be replaced when the
part is damaged during the maintenance/repair of compressor parts during
operation. Hence KPCL recommends user to maintain one set of gaskets and O-
rings as stand-by stock.
C. Kit of Spares after 8000 hrs run or ONE year - 273.01.865.50 consists of
10
8 9
4
2
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10
2
6
9
11
15
12 14
7
3
4
5
13
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Sl.
PART No. PART DESCRIPTION QTY. REMARKS
No.
1 211.08.101.50 ELECTRIC MOTOR-37kW 1 FOR KES-37
1 211.08.102.50 ELECTRIC MOTOR-45kW 1 FOR KES-45
1 211.08.103.50 ELECTRIC MOTOR-55.kW 1 FOR KES-55
2 --- AIR END 1
3 REF. PLATE – 8.12 COUPLING ASSEMBLY 1
4 REF. PLATE – 8.12 RUBBER ELEMENT 1 set
5 273.01.298.50 SPACER, MOTOR SIDE 1
6 997.00.023.04 KEY 1
7 271.00.252.50. ANTI VIBRATION MTG, AVM-200 2
8 273.01.446.50 ANTI VIBRATION MTG, AVM-400 1
9 273.01.299.50. ADAPTOR (MOTOR AND AIR END) 1 FOR KES-45 & 55
9 273.03.214.50. ADAPTOR (MOTOR AND AIR END) 1 FOR KES-37
10 999.01.694.50. BOLT HEX STD M16X2X55L E 8
11 999.11.286.50. WASHER SPRING STEEL ID16.2X 3.5TH 8
12 999.06.687.50. NUT HEX M16X2 8
13 999.01.936.50. BOLT HEX STD M10X1.5X40L E 12
14 3999.11.268.50. WASHER SPRING STEEL ID 10.2x2.2THK. 12
15 999.06.632.50. NUT HEX M10X1.5 12
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Kirloskar Pneumatic Co. Ltd., Pune
Sl.
PART No. PART DESCRIPTION QTY. REMARKS
No.
1 273.50.109.50. GASKET (FOR AIR END DELIVERY) 1
2 999.01.641.50. SCREW HEX STD M10X1.5X40L E 4
3 999.01.639.50. WASHER SPRING STEEL ID10.2X 2.0 TH 11
4 273.01.816.50. HOSE ASSLY. 2" x 900L 1
5 999.01.672.50. BOLT HEX HD M12X1.75X50L 2
6 273.01.491.50. 'O' RING ID 56 x 3.55 DIA 3
7 999.11.274.50. WASHER SPRING STEEL ID12.2X 2.5TH 4
8 999.06.650.50. NUT HEX M12X1.75 2
9 999.01.639.50. SCREW HEX STD M10X1.5X30L 3
10 999.01.643.50. BOLT HEX HD M10X1.5X50L 3
11 999.06.632.50. NUT HEX M10X1.5 4
12 273.01.817.50. HOSE ASSLY. 1-1/2" x 750L 1
13 274.02.329.50. SPL UNION 1-1/2"BSP X1-1/2"BSP 2
14 273.01.818.50. HOSE ASSLY. 1-1/2" x 560L 1
15 274.00.230.50. SPL UNION 1-1/2" BSP x 1-1/2" BSPT 1
16 REF. PLATE – 8.16 MOISTURE SEPARATOR ASSEMBLY G 1 1/2 1
17 999.01.680.50. BOLT HEX STD M12X1.75X150L 2
18 --- BRACKET FOR MOISTURE SEPARATOR -- PART OF CANOPY
19 273.01.866.50 DELIVERY PIPE 1-1/2" x 200 mm L 1
20 270.02.678.50. BALL VALVE-40NB (1 1/2" BSP) 1
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Kirloskar Pneumatic Co. Ltd., Pune
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6
2
7
3
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Sl.
PART No. PART DESCRIPTION QTY. REMARKS
No.
273.00.595.50 COMBI COOLER ASSLY. FOR KES-37 1 CONSISTS OF
273.00.596.50 COMBI COOLER ASSLY. FOR KES-45 1 BELOW
273.01.486.50 COMBI COOLER ASSLY. FOR KES-55 1 COMPONENTS
1 273.01.854.50 COMBI COOLER FOR KES-37 1 FOR KES-37
1 273.01.855.50 COMBI COOLER FOR KES-45 1 FOR KES-45
1 273.01.856.50 COMBI COOLER FOR KES-55 1 FOR KES-55
2 -- FAN COWL 1
3 273.01.857.50 FAN FOR KES-37 COMBICOOLER 1 FOR KES-37
3 273.01.858.50 FAN FOR KES-45 COMBICOOLER 1 FOR KES-45
3 273.01.859.50 FAN FOR KES-55 COMBICOOLER 1 FOR KES-55
4 273.01.860.50 FAN MOTOR FOR KES-37 COMBICOOLER 1 FOR KES-37
4 273.01.861.50 FAN MOTOR FOR KES-45 COMBICOOLER 1 FOR KES-45
4 273.01.862.50 FAN MOTOR FOR KES-55 COMBICOOLER 1 FOR KES-55
5 999.01.621.50. SCREW- HEX HEAD M8X1.25X20L E 6
6 999.11.262.50. WASHER- SPRING STEEL ID8.2X2.0 THK. 6
7 999.06.623.50. NUT -HEX M8X1.25 6
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Sl.
No. PART No. PART DESCRIPTION QTY.
1 271.00.591.50. SPL. UNION -3/4"BSP x 1"BSP 3
2 273.01.843.50. HOSE ASSLY- 1"X1050L 1
3 273.01.844.50. HOSE ASSLY- 1" X 540L 1
4 271.01.676.50. SPECIAL UNION- 1" BSP X 1 " BSP 2
5 REF PLATE – 8.15 OIL FILTER HEAD 1
6 REF. PLATE –8.15 OIL FILTER ELEMENT 2
7 273.01.845.50. HOSE ASSLY- 1" X 600L 1
8 273.01.846.50. ADAPTOR- ELBOW, 1/2"BSP x 1"BSP 1
9 271.00.554.50. SPECIAL UNION ASSLY. 3/8" BSP x 3/8" BSP 2
10 273.01.822.50. HOSE ASSLY- 3/8" x 400L 1
11 271.01.557.50. SPECIAL UNION ASSLY- 3/8" BSP x 3/8" BSP 2
12 REF. PLATE – 8.4 SCAVENGE PIPE 1
13 273.01.823.50. HOSE ASSLY- 1/4” x 700L 1
14 271.00.556.50. SPECIAL UNION ASSLY- 1/4” BSP x 1/4” BSP 1
15 273.01.849.50 BRACKET FOR LUBE OIL FILTER 1
16 999.01.636.50. SCREW- HEX HEAD M10X1.5X20L 2
17 999.11.268.50. WASHER –SPRING STEEL ID 10.2x2.2THK. 4
18 999.01.639.50. SCREW –HEX HEAD M10X1.5X30L 2
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Kirloskar Pneumatic Co. Ltd., Pune
Sl.
No. PART No. PART DESCRIPTION QTY.
1 271.00.367.50 ADAPTOR FOR SOLENOID VALVE 1
2 273.01.098.50. PIPE FOR SV AND BDV 1
3 271.00.554.50. SPECIAL UNION ASSLY- 3/8” BSP x 3/8” BSP 2
4 999.30.755.50. REDUCER BUSH HEX- 3/8X1/4 2
5 998.16.483.50. ASSLY OF ELBOW UNION – R1/4 HEAVY 1
6 999.37.103.00.01 TUBE- SS, OD6x1.0 TKK 2
ZA7 998.16.603.50. ASSLY OF UNION T- R1/4 HEAVY 1
8 271.01.550.50 REDUCER BUSH HEX -1/2X1/4 1
9 998.16.485.50 ASSLY OF ELBOW UNION- R1/4 1
10 999.37.717.00.01 TUBE SS OD6x1.0 THK 2
11 998.16.604.50 ASSLY OF UNION T - R1/4 1
12 998.16.247.50 ASSLY OF UNION - R1/4 HEAVY 1
13 999.30.683.00 HEX NIPPLE -1/4" 1
14 999.30.879.00 TEE FEMALE -1/4" 1
15 271.00.349.50 NRV -1/4" BSP 1
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Kirloskar Pneumatic Co. Ltd., Pune
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Kirloskar Pneumatic Co. Ltd., Pune
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Kirloskar Pneumatic Co. Ltd., Pune
1
2
5
4
3
6
8
10
7
10
11
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Kirloskar Pneumatic Co. Ltd., Pune
13
14 12
9
4
8 6
3
7
14
2
10
11
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Kirloskar Pneumatic Co. Ltd., Pune
1) Remove the Cover locking screw (5) and slide the cover to expose the element.
2) Remove the elements and clean the surfaces of claws with air jet & clean cloth
3) Slide the new elements in the slots and check for the axial gap of 1 to 3mm
4) Slide the cover to hold the elements in place and hold in position by fixing the screw.
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Kirloskar Pneumatic Co. Ltd., Pune
10
7
11 9
6
8
5
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Kirloskar Pneumatic Co. Ltd., Pune
11
12
10
9
5
6
4 3 2
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Kirloskar Pneumatic Co. Ltd., Pune
DRIVING RING
MECH.SEAL
SIDE VIEW OF SEAL
LOCKING PIN
BEFORE FITMENT
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Kirloskar Pneumatic Co. Ltd., Pune
FRONT VIEW:
- Control . . .
REAR VIEW:
µ-control
SR. NO.-
D1 D2 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
P N
COM.
COM.
M O DIFIED E
NO
NO
0V OUT
NO
CO M.
12V OUT
NOT USED
COMP. MOTOR O/L
RELAY
COMMON
RTD WHITE
RTD WHITE
FAN O /L
SPP/RVP
PRES.T.-II
RTD RED
E. STOP
PRES.T.-I
OFF
ON
C1 C2 C3 C4 C5 C6 A1 A2 A3 A4 A5
12 34
DIP
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Kirloskar Pneumatic Co. Ltd., Pune
FEATURES:
• Microcontroller based design
• 5 Digital inputs
• 2 Analogue inputs (4 – 20 mA)
• 1 RTD PT100 input
• 3 Relay outputs
• Automatic /Manual Compressor Start/Stop
• Auto stop on event of Fault
• Relay output for motor starter
• Status indications on LED
• Manual unload Push Button
• Event History
• Maintenance Warnings
TECHNICAL SPECIFICATIONS:
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Kirloskar Pneumatic Co. Ltd., Pune
ANALOGUE INPUTS :
DIGITAL INPUTS:
NOTE: All digital inputs are with respect to ground. COMMON should be connected to
12V.
OUTPUT DETAILS:
(All outputs are potential free outputs)
Sl. No. Name of Output Function of Output
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Kirloskar Pneumatic Co. Ltd., Pune
1 ON Programming Enable
OFF Programming Disable
2 ON Remote Mode
OFF Local Mode
4 - Not used
NOTE: New DIP setting will active only on next power ON.
To see DIP status on LCD screen press “ACCEPT “key at POWER ON.
Status Y means DIP SW is ON
Status N means DIP SW is OFF
Status X means DIP SW is NOT USED
Auto Restart Feature: If ACCEPT key is pressed when DIP status is being displayed
on the Screen e.g.
DIP : 1 2 3 4
Y N Y X
then following screen will appear
AUTO RESTART
DISABLE
This Auto-restart feature can be enabled or Disabled by pressing “ “ or “” key.
Enabling this feature will allow the Compressor to restart automatically when the
Discharge Air. Pressure (PT1) drops below the “Load Pressure Set Point” after the
UNLOAD TIME OVER error had occurred.
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Kirloskar Pneumatic Co. Ltd., Pune
LED DETAILS:
Comp. ON ON Compressor is ON
OFF Compressor is OFF
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Kirloskar Pneumatic Co. Ltd., Pune
PROGRAMMING DETAILS:
- Press “STOP” key for 15 second to set the parameter values.
- Press “ “ key to increment the parameter value.
- Press “ “ key to decrement the parameter value.
- Press “ACCEPT” key to save the parameter value and switch to next
parameter.
- Press “STOP” key to escape from programming mode.
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Kirloskar Pneumatic Co. Ltd., Pune
RTC SETTING:
CALIBRATION MODE:
- Press, “ACCEPT” key for switching to next calibration analog parameter. If the
parameter is last one then it will escape from CALIBRATION MODE.
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Kirloskar Pneumatic Co. Ltd., Pune
HOW TO OPERATE:
Test Modes:
This feature is used in fault diagnosis.
Press “Accept “ key when compressor is in OFF condition.
Note: Test modes are not for operator use.
Local Mode:
- Press, “START” key for 5 second to start the compressor.
- Press, “STOP” key to stop the compressor
- If any faulty condition occurs then display will show the reason and faulty LED
will be ON.
Remote Mode:
- Apply the REMOTE START (NC) digital input to start the compressor.
- Remove the REMOTE START digital input to stop the compressor.
- If any faulty condition occurs then display will show the reason and faulty LED
will be ON.
Note: Loading and unloading as per the auto/manual mode selection.
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Kirloskar Pneumatic Co. Ltd., Pune
Manual Mode: -
Auto Mode: -
- If the discharge air pressure is below the load pressure value (settable) then
compressor will get loaded if compressor is ON.
- If the discharge air pressure is above the unload pressure value (settable) then
compressor will get unloaded if compressor is ON.
FAULTS:
Different possible faults are as below-
1. High discharge air pressure.
2. High delta pressure (This fault will come only once after compressor is loaded.
It will not stop the compressor functionality).
3. PT1- air pressure sensor fault.
4. PT2- oil pressure sensor fault.
5. RTD-air temperature sensor fault.
6. Main motor overload.
7. Fan motor overload.
8. SPP/RVP.
9. Emergency Stop
10. Unload time over
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Kirloskar Pneumatic Co. Ltd., Pune
Safety Devices :
Following mechanical safety devices are provided to ensure safe operation of the package
Minimum Pressure Valve - Maintains minimum air pressure in air-oil separator tank
so that positive oil flow is ensured.
Excessive oil in air Scavenge line blocked Remove the scavenge pipe/hose,
line fittings and clean the passage.
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Kirloskar Pneumatic Co. Ltd., Pune
Oil throw through air Leakage across Air Intake Valve. Check for damages on tappet
filter during stopping plate and the sealing ring.
Replace the defective part.
Intake valve is not closing when
Check the parts and repair /
compressor stops due to the absence of Air replace.
flow to intake valve piston is not given due
to solenoid valve failure or line blockage
Compressor loading not -Intake valve is stuck Check and repair/replace the
happening parts.
Safety valve opening Pressure transmitter is defective Check the PT (0-20mA for 0-16
during operation bar)
Motor tripping during - Air pressure in the air-oil separator tank Release the air from the tank by
Starting. due to failure of blow-off valve to exhaust opening the safety valve
the air when compressor was switched off. manually. Then check the
- Motor damage/failure functioning of solenoid valve &
its circuit and Blow-off valve
- Airend damage with air connection.
- Loose connection in motor power line Check motor, airend & gears
- Gear failure
Motor tripping after Intake valve opens before the Star- delta Check the timer settings for
running few seconds changeover is completed. Star- Delta changeover
from start
Motor tripping after High starting current due to loose Check the connections and
few start /stops and connections or Intake Valve in open Intake Valve piston.
contactors jammed position during starting.
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Kirloskar Pneumatic Co. Ltd., Pune
DELHI 208 MEGHDOOT 011 30981341,42 011 26429685 kgkcldel@del6.vsnl.net.in ACR Division
BUILDING 94 NEHRU Reliance: 26417549
PLACE, NEW DELHI 30946820, 6821
110 019
BANGALORE NO 102, 1ST FLOOR, 080 22270029, 080 22270045 kpclblr@dataone.in Mr G Ramesh /
ANDREE CAPITOL, 22270079 vvreddy@vsnl.net Mr KVV Reddy
8/1 KH ROAD, Reliance: reddykv@kpcl.co.in
BANGALORE 560 027 30619331/ 9332
CHENNAI 1ST FLOOR, ELCANSO 044 28193066, 044 28194937 kpcl_chn@vsnl.net Mr KVV Reddy/
COMPLEX NO.10, 28190436, 28192092 sridhart@kpcl.co.in Mr Sridhar T
COSA MAJOR ROAD, Reliance :
EGMORE, CHENNAI 30910143/ 0144
600 008
VADODARA CHI CHI TOWER "A" 0265 2284604, 0265 2280095 kpclbrd@icenet.net Mr Dhaval Shah
KOLLOL CHILDREN 2284605, 2284606 shahdi@kpcl.co.in (Mobile 9898098098)
HOSPITAL LANE,TANA Reliance :
APPT, ELLORA PARK, 0265 30967
SUBHANPURA,
VADODARA 390 007
TIRUCHENGODE 3/100A, SALEM MAIN kishansuresh@rediffmail.com Mr Kishan Suresh
ROAD, T
KALASAMPALAYAM
TIRUCHENGODE (TK)
631 209 DIST.
NAMAKKAL DIST.
Kirloskar Pneumatic Co. Ltd., Pune
Notes
Kirloskar Pneumatic Co. Ltd., Pune
Notes
Kirloskar Pneumatic Co. Ltd., Pune
Contact your nearest dealer for any assistance or dial Toll free number 1800 301 00009