KOBELCO OIL-FLOODED SCREW COMPRESSOR

KS15A/KS22A

Instruction Manual

Thank you for your purchase of KOBELCO Oil-Flooded Screw Compressor "Kobelco KS series".
You are advised to read through this instruction manual carefully before you attempt to carry
out operation and maintenance.
Please keep the manual at hand for ready reference.

Accessories

Model
KS15A KS22A
Parts name

Fork hole cover 2 2

Fork hole cover

KOBELCO COMPRESSORS MANUFACTURING DWG No.4H50ZS1115P1

(SHANGHAI)CORPORATION ISSUE 01 Printed 2013.07
 ■ Copyright Reserved

Copyright ownership belongs to KOBELCO, shall not be reproduced, copied,

or used in other ways without permission.
Espeically trademark, name of models, parts name and drawings.
The manual is available to KS series.

KS15A/KS22A Ⅰ
 Contents
Contents ………………………………………………………………………… Ⅰ

1　Safety Information　　………………………………………………………………… 1
1.1 General Precautions ………………………………………………………………… 1
1.2 Alert Symbols and Safety Marks …………………………………………………… 2
1.3 Safety Rules ………………………………………………………………………… 4

2　Part Names and Functions ………………………………………………………… 11

2.1 Overview ……………………………………………………………………………… 11
2.2 Part names and Functions …………………………………………………………… 12
2.3 KS Controller ………………………………………………………………………… 14

3　Location for Installation …………………………………………………………… 16

3.1 Places to be Avoided ………………………………………………………………… 16
3.2 Environments to be Avoided ……………………………………………………… 16
3.3 Installation Space for Safe Operation ……………………………………………… 17
3.4 Installing the Machine in an Enclosed Room ……………………………………… 18

4　Precautions before Operation ……………………………………………………… 22

4.1 Unloading …………………………………………………………………………… 22
4.2 Precautions for Piping ……………………………………………………………… 23
4.3 Lubricating Oil ………………………………………………………………………… 25
4.4 Power Supply Wiring ………………………………………………………………… 27

5　Operation …………………………………………………………………………… 28
5.1 Pre-operation Inspection to Stop …………………………………………………… 28
5.2 Pre-operation Inspection …………………………………………………………… 29
Initial Settings for KS Controller (Factory default settings) ………………………………………… 30
5.3 Operation Procedure ………………………………………………………………… 31
5.4 Setting Control Pressure …………………………………………………………… 33
5.5 Operation Modes …………………………………………………………………… 35

KS15A/KS22A Ⅰ
 Contents

6　Troubleshooting …………………………………………………………………… 39
6.1 Emergency Stop ……………………………………………………………………… 39
6.2 Caution ………………………………………………………………………………… 40
6.3 Countermeasures …………………………………………………………………… 41
6.4 Interlock List ………………………………………………………………………… 42
6.5 Before You Suspect Failure ………………………………………………………… 44

7　Maintenance and Part Replacement ……………………………………………… 46

7.1 Guidelines for preventive maintenance …………………………………………… 46
7.2 List of preventive maintenance ……………………………………………………… 47
7.3 Insulation test Procedures for Compressor Unit ………………………………… 48
7.4 Cleaning of Suction Filter …………………………………………………………… 49

8　Shutdown for a Prolonged Period ………………………………………………… 51

9 Disposal ………………………………………………………………………………… 52

10 Remote Control …………………………………………………………………………… 53

11 Specifications …………………………………………………………………………… 55
11.1 Specifications ………………………………………………………………………… 55
11.2 Electric power facilities ……………………………………………………………… 58
11.3 Wiring Diagram ……………………………………………………………………… 60
11.4 Connection Diagram ………………………………………………………………… 61
11.5 System Diagram ……………………………………………………………………… 62

12 Warranty ………………………………………………………………………………… 63

13 Indemnity ………………………………………………………………………………… 64

KS15A/KS22A Ⅱ
 １．Safety Information

Safety Information

Please carefully read and understand the general precautions and the descriptions for alert
symbols and safety marks.
Then proceed to 1.3 Safety Rules on page 4 where you will find itemized safety instructions.

1.1 General Precautions

◎ Carrying-in work, installation, operation, maintenance and inspections of the machine

　 must be done by the well-trained personnel.

◎ We shall not be responsible for any personal injury and faults/damage of the machine
　 resulting from modification by the customer.
WARNING
◎ Strictly follow the local regulations and the safety standard established in the field.

KS15A/KS22A 1
 1.2 Alert Symbols and Safety Marks

For safety and trouble-free operation, the following alert symbols and safety marks are given
to the important items in order to call your attention. Please follow these instructions.

Alert signals

Meanings of signals

Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.
WARNING

Indicates a potentially hazardous situation which, if not

avoided, could result in minor or moderate injury or property
CAUTION damage. (*1)

Indicates supplemental information to the operation.

NOTE
((*1)) : Property
p y damage g means the loss of the machine itself and/or incidental or
consequential loss of peripheral equipment and facility.

Explanation of pictograms

The following marks are used together with alert symbols and pictographs to discriminatively
indicate actions which the operator must not take, and which the operator must take.

Pictograms Meaning of pictograms

Indicates the item to be prohibited.

Concrete information is given by picture or sentence in or
near the mark.

Indicates the forced (mandatory) item.

Concrete information is given by picture or sentence in or
near the mark.

KS15A/KS22A 2
 Check on Machine No. Name Plate

Make sure that the machine No. name plate is attached to the machine.
If the name plate is missing or not readable, contact our company or the distributor.

Machine No. name plate

SCREW COMPRESSOR

MPa
MPa
m 3/min
kW r/min
UUnity
nity Input
InputSpeci ficpower
Specific pow er kW/(m 3 /min)
mm
kg

PS-K A 03-513
03-5 07#(K)-(L)

Please let us know the model and

machine No. when asking for repair
or ordering spare parts.

KS15A/KS22A 3
 1.3 Safety Rules

1.3.1 General items

Fully understand the descriptions shown in the instruction

manual before operation / maintenance / inspection of the
machine.
The operators and the administrator must not allow those who
do not understand the manual to operate the machine.

Wear appropriate clothing and protectors during the work.

Especially when installing, disassembling or assembling the
machine, be sure to wear a helmet and safety shoes.
Also wear safety glasses to protect eyes from pressurized air.
It is necessary to establish and observe the safety standards
for the field where the machine is used.

FOREPERSON Inspection and maintenance must be done by experts.

Those who have little experience must be closely supervised.

Use only genuine KOBELCO parts.

GENUINE If not observed, it can cause malfunction and / or failure.

Be sure to earth the machine, or the electrical problems

including harmonics may damage the electric unit or cause electric
shock.

KS15A/KS22A 4
 1.3.2 Carrying in

When using a forklift

Carry the machine with fork arms into fork holes of the base
plate.

Put filler cloth between the sound proof cover and the fork lift
to prevent damage.

When using a crane

Pass nylon slings through fork holes of the base plate and
protect the front top surface of the sound proof cover with
cloth.

Lift the machine slowly keeping the slings at a 45 degree

g with the top
angle p of the sound proof
p cover.

*For detailed information, see 4.1 Unloading on page 22.

KS15A/KS22A 5
 1.3.3 Installation / Installation site

Transfer

When moving the machine using a forklift or a crane, protect

the sound proof cover with a pad cloth against damage.

CAUTION
Do not drop the machine or carry it at a slant of 45 degree
or more when moving it.

Installation site

This machine is designed for indoor use only.

Do not install the machine outdoors or semi-outdoors.

・Installation in a place exposed to rain or in a humid

CAUTION
　basement can cause an electric leak, drain and/or rust.

・Installation in a place where dust such as iron powder

p
　and sand is lifted can cause low insulation performance
　of electric parts and damage to the rotor.

・Installation in the atmosphere containing toxic gas can

　cause deterioration of lubricating oil and corrosion in
　parts.

Do not install the machine near a work place where flame

is used or the ambient temperature is over 40゜C {104゜F}.
Do not put inflammable objects near the compressor.
WARNING

Installation

When installing the compressor in a closed room, provide air

suction and exhaust openings, and equip the exhaust
opening with a ventilating fan having a proper capacity.

KS15A/KS22A 6
 1.3.4 Electric wiring

Electric wiring
Electric wiring must be performed by qualified electricians.

・Leading into the power source should be done not to

　expose wiring. Wiring in the starting board requires
ELECTRICIAN 　a protective bushing in the through hole in order to
　protect the wires.

CAUTION ・Electric leak, low insulation performance, overcurrent,

　short circuit, incorrectly phased operation and
　malfunction of the safety device can produce spark in
　the motor, wiring and electric circuit.

Breaker

Only knife switch Use an earth leakage breaker for the power source in
accordance with the machine model.
ON

OFF
Do not use the knife switch without anyy earth leakage
g
breaker in terms of protection.
CAUTION

Installation
Removal or modification of the safety device or any change
in the set value can cause an accident.

SAFETY DEVICE
Any change in the set value for the safety device and
M
operation without the safety device can abnormally heat
ON
CAUTION lubricating oil to start a fire. Never change the set value
or operate the machine without the safety device.

Earth Connect the earth wire with the earth terminal

(marked with PE) on the starting board in the compressor.
The earth resistance should be 10Ω or less.
A specialist should perform the earthing work.

CAUTION
Be sure to connect the earth wire directly to the ground.
Operation without earthing may cause electric shock and
failure in the compressor.

KS15A/KS22A 7
 1.3.5 Operation

Dangerous objects

Do not put any inflammables around the machine.

Never work using flame near the machine.

・The compressor can catch a fire from spark producing

　work carried out near the machine, including welding,
　which may result in a fire.
CAUTION

・Do not touch the exhaust outlet and the peripheral area
　which are heated up during the operation and may
　cause a burn.

Pressure

Operate the machine within the limits specified in this manual.

Rotating portions

When the power lamp is lit, never touch the rotating portions
even if the compressor is stopped.

・To contact any rotating part, such as ventilating fan,

CAUTION 　always turn off the main power.

・Note that the compressor is automatically started when

WARNING 　the pressure drops to the recovery pressure.

KS15A/KS22A 8
 1.3.6 Shutdown

Parallel operation
Close the stop valve of discharge pipe in the compressor
which is stopped and let the drain out.

Long-term shutdown

Turn off the power supply and close the discharge valve of
ON
the compressor.

OFF
Be sure to run the compressor (for 20 minutes) once a week.
This is essential to prevent rust in the compressor.
CAUTION

1.3.7 Inspection during shutdown

Pressure
Before inspecting the inside of compressor, or replenishing
g oil, stop
lubricating p the compressor
p byy pressing
p g the Stop
p
button on the controller, make sure that "OIL SEPA.
PRESSURE" on the controller is 0 [MPa], and turn off the
earth leakage breaker.

Power supply
To inspect the starting board, always turn off all the power
sources.

Safety valve
The safety valve has undergone the close function test, so it
does not require overhaul.
If any problem occurs, contact our service personnel.

KS15A/KS22A 9
 1.3.8 Lubrication

Lubricating oil

Use the KOBELCO EXTRA OIL or KOBELCO GENUINE SCREW OIL.

Never mix oils of different brands.
× L

OI○
OI

L
×

Degradation, insufficiency, discontinuous flow, and high

viscosity of lubricating oil induces unusual high temperature,
and it causes ignition.
CAUTION
Be sure to visually check the oil level on the oil gauge
and, if it is low, replenish or change the oil.

Replenishment
If the oil level is below the lower limit when in operation,
replenish oil.
・Before refilling the lubricating oil, press the STOP
　button on the KS controller and stop the compressor.
　Making sure that the indication of oil separator pressure
　on the KS controller is ０ MPa, turn off the leakage
H 　breaker, and then refill the lubricating oil.
　Residual pressure exists in the oil separator for
L
WARNING p
　2 minutes or more after the compressor pp
is stopped.
　Before refilling the lubricating oil, always make sure
　that the pressure in the oil separator has been relieved
　completely.

Oil change
Maximum service life of the lubricating oil is 4,000 hours,
though it depends on the operational conditions.
Be sure to change oil in the full amount.
GENUINE
Deteriorated oil requires immediate change in the full amount.
Oil deterioration will cause the deteriorated carbon to
GENUINE adhere to the separator element.
OIL
The deteriorated carbon may be partially heated up by
WARNING
oxidization heat to start a fire and explode.
When changing lubricating oil, be sure to replace the oil
element.

Overhaul
Overhaul shall be performed every 4 years.

ON

OFF To overhaul the compressor, cut all of the power supply.

WARNING

KS15A/KS22A 10
 ２．Part names and Functions

2.1 Overview

Introduction

KS15A,KS22A are one stage, air cooled oil injected compressors, and driven by motoring.
They are installed in noise insulation canopies.
KS15A,KS22A models are controlled by standard controller. User can also choose optional controller.
The controller and emergency button are mounted on the door plate of the electric cabinet.
Electrical power distributor mounted on the back side of front cover.
The standard compressor unit is rich in stereoscopic feeling as the cover of front side,left side
and right side with convex shape.

KS15A/KS22A 11
 ２．Part names and Functions

1 2.2 Part names and functions

KS15A/KS22A

Outside View

Compressor exhaust outlet

Discharges air heated through
heat exchange in oil cooler, after
cooler.

KS controller
Compressor air inlet
Used to run and stop the compressor, (Provided on the both sides)
perform various setting, and display Lets in air for oil cooler,
the status of compressor.
after cooler, and cooling motor.
(See page14)

Compressed air discharge outlet

Discharges compressed air.
Fork hole
Used to carryy or install the compressor.
p
After installation is completed, attach
accessory covers for sound insulation. Power cable inlet
Connect a cable of proper size
referring to the power (voltage)
specification. (See page 59.)

Air inlet

KS15A/KS22A 12
 Internal Construction

Oil separator element

Suction filter
Separates and recovers
lubricating oil in compressed air. Prevents foreign materials from
entering.

Combination  valves

Oil supply port Centrifugal impeller

Cools the oil cooler, the after
cooler and centrifugal impeller
using the intake air
Oil separator unit

Oil filter Electric  cabinet

Removes foreign materials in
lubricating oil.

Oil level gauge

Indicates the oil level in the oil
separator tank. Keep the oil level
between the red lines during operation.

Oil cooler
Cools lubricating oil
oil.

Fan motor
Drives fan impeller. After cooler
Cools compressed air.

Main motor Safety valve

Drives the compressor. Opens to discharge compressed
air when the pressure inside the
oil separator tank rises abnormally
load/unload solenoid valve
To control the working of the load Suction regulating valve
or unload.
Adjusts inlet air flow rate.
Closes to prevent reverse air flow
when the compressor is stopped.
Oil outlet
Used to drain lubricating oil in the
motor splitter. Compressor proper
Has rotors with ideal profiles to
reduce vibration and noise level
and improve performance.

Any modification without prior permission shall invalidate the warranty even
within the warranty period.
Please consult us whenever modification is required.
WARNING

KS15A/KS22A 13
 2.3 KS Controller
Construction of KS Controller
Message monitor Alert indicator lamps
① Indicates the operating condition setting and causes of alert indic- ② "Emergency" LED (red)
　 ations, i.e. Emergency, Caution, and Maintenance. (See page 39.) 　Indicates that the compressor has been stopped
　・Maintenance information 　 due to a failure.
　・Caution information ③ "Caution" LED (yellow)
　・Emergency stop information 　Indicates that an alert or maintenance
has been issued on the compressor.
④ "Start" LED (green)
① 　Indicates that the compressor is running or
④ standby.
③ ②

⑩ ⑪
⑤ ⑥ ⑦ ⑧ ⑨

Operation mode switch buttons

⑤ [Back] key "←" ⑨ "Reset" key
　Arrow key "←" is used to return to the previous screen. 　If the Reset key is pressed when the cursor is sitting
⑥ [UP] key "+" 　over the changeable item, the display will be put into

Arrow key"+" is used to move the cursor or increase 　the Reset mode.
the set values. 　Resets the Emergency and Caution lamps.
⑦ [DWON] key"-" ⑩ "Start" key
Arrow key"-" is used to move the cursor or decrease 　Pressing this key in the Local mode starts the compressor.
the set values. ⑪ "Stop" key
⑧ "Enter" key Shut down the compressor.
If the Enter key is pressed after inputting the set value,
　the input value will be registered.

KS15A/KS22A 14
 Lamp Indications
Lamp indication (● :On ◎: Blinking)

Status Emergency Caution Start

Normal load running ●

operation unload running ●
Normal stop
Maintenance ◎
Caution ●
Emergency stop ●
Maintenance LED has been on
for 100 hours or more ●

Restart after power ◎

outage(*)

Indicator light test ◎ ◎ ◎

*：If power comes back within the allowable time, the compressor will start automatically.

For details, see the separate volume, "KS Controller Instruction Manual".

KS15A/KS22A 15
 ３．Location for Installation

1 3.1 Places to be Avoided

・Avoid outdoors. This machine is designed for indoor use

only.
・Avoid rain. Use or store in locations where the machine is
　protected from rain. Exposure to rain may cause electrical
　leakage or rust, as the machine is equipped with electrical
　parts.
・Avoid places where the atmosphere contains a lot of dust
　such as iron powder and sand, or harmful gases such as
　chlorine, hydrogen sulfide, zinc oxide, and high
　concentration ozone. Such substrates may cause damage
KOBELCO
　to the compressor main body, poor insulation in electrical
　components, deterioration of lubricants, or corrosion in parts.
・Avoid places where the ambient temperature exceeds
　40℃ {104゜F}. It may cause serious accidents such as
　burning of the machine and fire.
・Install the machine on a flat and level floor.
　Placing the machine on blocks may hinder the proper
　operation.
・Avoid places where excessive vibration is expected.
・The noise level mayy changeg depending
p g on the building
g
　construction and the installation site.

2 3.2 Environments to be Avoided

Avoid environments where the unit may suck in:

・Mist of cutting fluids from machine tools,

・Exhaust/smoke from boilers,
・Cracked gases of plastics,
・Vapor of waste water/liquids in food processing plants,
・Emission from vehicles including trucks,
KOBELCO ・Any other harmful gases including NH3, SO2, and NOX.

Avoid installation in environments where the machine may suck

in harmful gases containing substances listed above.
Sucking in such gases may cause clogging of the oil separator
CAUTION
elements, resulting in malfunctional shutdown.

KS15A/KS22A 16
 Ventilation to avoid sucking harmful gases / mist

・Provide a suction or exhaust fan, or ventilation duct.

・Do not install the compressor in the downstream of gas flow.

● ●
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● ● ● ● ● ● ● ● ● ●
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● ● ● ● ● ● ● ● ● ● ● ●
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● ● ●

● ● ● ●

● ● ●

● ● ● ●
● ● ●

● ● ● ●

● ● ●

● ● ● ●

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● ● ●

KOBELCO

3 3.3 Installation Space for Safe Operation

・Secure sufficient space away from the outlet above the inlet on both side faces of the
p p functions.
　machine to ensure proper
・Secure sufficient space away from the front and upper faces of the machine to ensure
　proper opening and closing of doors, operation, and maintenance.

Ｄ or more

Width

Height

Depth

Ｅor more
KOBE LCO
Ｂor more
Ｃ or more
Ａor more

[ mm ]
Dimensions Minimum maintenance space
Model Front side Right side Left side Top Rear side
Width Depth Height
A B C D E
KS15A 600 600 600 1000 500
1400 879 1350
KS22A or more or more or more or more or more

KS15A/KS22A 17
 4 3.4 Installing the Machine in an Enclosed Room

Installation of Ventilating Fan and Duct

・Use in a closed room will increase the room temperature, causing

　the compressor to stop. To avoid this, provide an air supply
　opening to take fresh air in and an exhaust opening to discharge
Ventilating fan
　hot air, on the walls of the room. Also install a ventilating fan at
Exhaust
　the exhaust opening. (The exhaust outlet must be located in the
opening 　higher position, and the air supply opening in the lower position.)
Air ・The air supply opening must be wide enough to prevent negative
KOBELCO supply
　pressure in the room.
・Select a ventilating fan with a capacity higher than the value
　specified in the table below.
・Note that a lower ceiling may cause higher ambient temperature
　as the exhaust heat moves to the air supply side.
・Use at the room temperature of 40℃ {104゜F} or higher may cause
　the compressor to trip. In such a case, improvement is required to
　decrease the room temperature.
・ Do not attach the duct above the cover on top cover. It is used for
g g oil separator
exchanging p elements.

Ventilation Method and Fan Capacity

Items Compressor cooling air Minimum ventilation capacity(※1)

Generated
calories Allowable
Exhaust Ventilating Ventilating
pressure loss Entire ventilation
air volume duct duct & fan
in exhaust duct
[MJ/h] [kcal/h]
Model [m3/min] Pa(mmH2O) [m3/min] [m3/min] [m3/min]
KS15A
159 16 80
KS15A-H 57 13,674 64
or more or more or more
KS15A-GH
20(2)
KS22A
232 23 103
KS22A-H 84 19,952 80
or more or more or more
KS22A-GH

※1: Ventilation capacity indicates the value at the allowable room temperature of 5℃ {9゜F} higher than
the ambient temperature.

KS15A/KS22A 18
 Installation of Ventilating duct
The capacity of ventilating duct must be higher than exhaust volume of the compressor.
Otherwise, a serious damage of the machine may occur.
① Entire ventilation ② Ventilating duct ③ Ventilating duct & fan

Exhaust
Exhaust

Exhaust
Exhaust
Air inlet
Air inlet
Air inlet

The duct should The duct shoul d

be removable be removabl e CAUTION

H=300～
400mm

The ventilation capacity is for ventilating
the entire room.
(at the allowable room temperature of
5℃ {9゜F} higher than the ambient
temperature)
The air supply opening should be
adjusted so that the flow rate will be
2 m/s or less.
・Calculate the pressure loss (resistance) in ・The pressure loss (resistance)
　the ventilating duct based on the exhaust air 　 in the ventilating duct is over 20
　volume of the compressor. If the result is not 　Pa (2 mmH2O), install a ventilating
　more than 20 Pa (2 mmH 2O) for air cooling type, 　 fan with the specified capacity
　the exhaust from the compressor exhaust outlet 　 inside the duct taking the
　through the duct will be possible. pressure loss into consideration.
・Connect the ventilating duct referring to the duct
　installation mark at the top of the compressor. CAUTION
　The duct should be removable.
To choose a type of fan can
　Do not fix the duct with screws. endure much heat .
(high temperature )[80℃
　It may hinder repair and maintenance work.
{176゜F}]
　Use of KOBELCO genuine expansion duct is
　recommended, as shown on the next page.
・Minimize bents in the duct to avoid resistance.
・When installing the duct, provide a full radius. ・Turn on the ventilating fan while
　Duct resistance over 20 Pa (2 mmH 2O) could 　 the compressor is running, and
　reduce the exhaust volume, causing temperature 　turn it off when the compressor
　rise to stop the compressor. is stopped.
・Even if the duct is connected directly to ・The opening area of air inlet shall
　the compressor, the temperature will rise. 　be adjusted so that the flow rate
　In such a case, install a ventilating fan mentioned will be 2 m/s or less.
　in the previous page (at the allowable room
　temperature of 5℃{9゜F} higher than the
　 ambient temperature).
・Prevent rain water from entering the duct outlet.
・If the pressure loss in the ventilating duct is over
　20 Pa (2 mmH 2O), install a ventilating fan at
　the duct outlet. (See method ③.)
・Follow the same installation procedure to install
　a ventilating fan and air inlet as that of entire
　ventilation.
　The opening area for air supply shall be adjusted
　so that the flow rate will be 2 m/s or less.

KS15A/KS22A 19
KS15A/KS22A
CONTROL SIGNAL CABLE INLET
APPROX1459
63
26 A EXHAUST OUTLET

COOLING AIR INLET

EMERGENCY
STOP
External dimensions

560

13 24
138.2 40.5

APPRO X135 8

114 0. 5
51.2

233
Ø 48 POWER CABLE INLET
4×Ø18 BASE HOLE
1160

452
325 265

180
23 804(BASE HOLE) 23 350 649

60
850 1344
A SECTION
APPROX928 1400

20
100 0m m

AIR INLET AIR INLET

OIL SEPARATOR UNIT OIL SEPARATOR

PORT FOR OIL FILLING PORT FOR OIL FILLING

653
600
mm
176 COMPRESSOR
PROPER COMPRESSOR
SOR PROPER REACTOR
RE INVERTER mm
500
INTERIOR COLLOCATION(STANDARD UNIT ) INTERIOR
NTERIOR COLLOCATION(INVERTER
COLLO UNIT )

600
mm
m
0m
60
AIR DISCHARGE AIR DISCHARGE
OUTLET R21 OUTLET R21

MAINTENANCE SPACE

(UNIT:mm)

4H30ZS1026P1 01
 Foundation drawing

FOUNDATION DRAWING
(KS15A KS22A KS22AV)

※　SOLD SEPARATELY

1600

1400
1160

960

804

649

4×M12-6g ANCHOR BOLT ※ COMPRESSOR BASE PLATE

EFFECTIVE THREAD 40
30
300

FOUNDATION DRAWING

NOTE:
１．FOUNDAION TO BE FURNISHED WITH STEEL RODS.
２．FOUNDATION REQUIRED TO BE STRONG ENOUGH TO SUPPORT THE WEIGHT.
３．HORIZONTAL LEVEL SHOULD BE ±１／１０0.

( UNIT: mm)

KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION 4H31ZS1018P1 01

KS15A/KS22A 21
 ４．Precautions before Operation

4.1 Unloading

When unloading and carrying, use the openings on the base plate of the compressor.
The openings are large enough to fit forklift forks, which allows unloading and
carrying by a forklift.

NOTE Be sure to read the section "Carrying in" of 1.3.2 Safety Precautions on page 5
before starting work.

Forklift

Wire

Protecting
wood
Pad

In case of using a forklift In case of using a crane

CAUTION ･Make sure that the front cover is closed up to prevent it from opening
unexpectedly.
･The supplied fork covers are designed to reduce the noise level.
Attach the fork covers on both front and rear faces after the completion of installation.
･Figure(1): When lifting or moving, please attach the mounting plate as shown in figure (1).
･Figure(2): After installation and commissioning, please attach the mounting plate
and the fork hole cover as shown in figure (2)

Fork hole cover

Mounting plate
Front side Back side Front side Back side (carrying)
Figure(1) Figure(2)

KS15A/KS22A 22
 4.2 Precautions for Piping

Piping

・An unsupported long piping may cause for vibration and, as a result, the devices to
　which such piping is connected may be damaged.
　The piping must be properly supported (using hangers, fasteners, columns, etc.).

・When more than two units of compressors are installed and their discharge piping are
　connected to the same discharge main piping, be sure to provide the stop valves before
　the discharge main piping so that they can be closed when the operations of the
　compressors are stopped.

・Slope the main piping in the discharge air flow direction so that condensate does not
　gather in the middle of piping.

・Provide a drainage at the bottom part of pipe if there is a height difference.

・To prevent condensate reverse flow connect a discharge piping at the top of the main
　piping.

when connecting to the main

piping,connect the discharge
piping from the above.

Main piping

Emergency valve
Discharge air
（If you increase
the compressor）
Main piping To prevent the reverse
flow such as drain.
Hanger

Hanger Discharge air

Inclination
(Slope along
the air flow）

Stop valve Stop valve

Union Union

Drainage valve Drainage valve

or mor e or mor e

Connected by customer

Prevent drain from flowing back in the discharged air piping.

Prevent the reverse flow drain.
It may cause the drain separator clogging or coolers corrosion.
CAUTION
Keep a distance of at least 800mm from the side of unit when installing the drain separator.

KS15A/KS22A 23
 Air tank installation

In order to make pressure fluctuation small, install a proper capacity air receiver tank
with discharge piping.

When install separate dryer, a line filter and a check valve, please install in the down
stream of air tank. In addition, please shorten the piping from a compressor to air
tank as much as possible.

*If piping pressure loss from a compressor to air tank becomes big; of driving of load /
unload become frequent, and part life shortens.

◆Air tank capacity

Model Air tank capacity（m3）
KS15A Min 0.32
KS15A-H Min 0.28
KS15A-GH Min 0.23
KS22A Min 0.45
KS22A-H Min 0.43
KS22A-GH Min 0.36

p y of the case of load rate 50%, difference of upper

Note）This is the capacity pp and lower limit
pressure 0.1 MPa and a cycle time (load → unload → load) 30seconds.

PH VR ：Air tank capacity（m3）

t1 ：Unload time（min）
t2 ：Load time（min）
t1＋t2≧0.5min（more than 30sec.）
Qs ：Air discharge volume（m3/min）
Pa ：Suction pressure（MPa）
PL
D ：Difference of upper and lower limit pressure（MPa）
← t1 →← t2 →

(t1+t2)× Qs × Pa × x(1-x) x ：Load rate

VR =
D （Used air toward air discharge volume Qs）

《KS15A type calculation example》

t1+t2= 0.5 min　　Qs= 2.5 m3/min　　Pa= 0.101 MPa　　D= 0.70-0.60 = 0.10 MPa
x=50%（Air tank capacity is surely made the biggest at the time of load rate 50%）

0.5×2.5×0.101×0.5×(1－0.5)
VR = ≒ 0.32 m3
0.10

KS15A/KS22A 24
 4.3 Lubricating Oil

Precautions for lubrication

・Use our genuine brand lubricant,

Brand name Intervals(h)

Lubricating oil KOBELCO EXTRA OIL 4000
KOBELCO GENUINE SCREW OIL 2000

・Never mix different brands of lubricating oil.

・If accidental contact of compressed air with food is

　expected, vegetable oil "ANDEROL FGC 32" may be used.

　To use the above oil, please contact our company.

×

OI○
OIL

L
×

ANDEROL FGC 32 (19L) P-HD11-525 2000 hours

CAUTION

・Maintain the oil level between "H" and "L" during operation.

・Do not operate with the oil level higher than "H". Otherwise,
　oil may flow out into the discharged air and cause problems.
　(It is not abnormal that the oil level exceeds "H" when
　 operation is stopped oil returns to the oil separator.)

KOBELC0
　If the oil level is much higher than that in the previous run,
　shut down the compressor immediately, drain the oil
　completely and perform inspection.

Guide for refilling oil

Before refilling Refilled amount After refilling

1.5L

There has a green mark on the mark H of oil level.It to show the oiling height
when the whole oil system have no oil.

KS15A/KS22A 25
 Refilling oil

1 Stop the compressor by pressing the Stop button (red).

　　Make sure that "OIL SEPARATOR PRESSURE" on the
　　controller is 0 [MPa], and then turn off the power switch.

2 　Turn off the earth leakage breaker.

ON

OFF

CAUTION

Oil supply port Loose

3 　To open the oil supply port of the compressor(left,front side
　　 face), remove the front cover of the compressor and loosen
　　the plug with a wrench.

Tighten 4 　When closing the oil supply port, wipe off spilled oil
p
　　completelyy and tighten
g p g securely.
the plug y

The quantity of oil required for change in full is shown below.

Unit : (L)
MODEL KS15A KS22A
Quantity 7 7.5

・Pressure remains in the oil separator one minute or more after the compressor
　is stopped. Wait for about two minutes until the pressure is released, and
　then replenish oil.
CAUTION ・Oil must be supplied from the oil supply port. If oil were supplied from any
　other point, the oil level could not be checked.

Draining oil
1 Stop the compressor by pressing the Stop button (red).
　　Make sure that "OIL SEPARATOR PRESSURE" on the
　　controller is 0 [MPa].

2 　Turn off the earth leakage breaker.

3 　Open the drain valve at the bottom of the oil separator

　　to drain the lubricating oil.
oli exit port
　　Also drain the lubricating oil from the oil cooler using its
　　drain valve.

KS15A/KS22A 26
 4.4 Power Supply Wiring

KS15/KS22A

Controller

S10

14 15 16 17 18 19 20 21 22 23 24 25 26

CP1 CP2 CP3 1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26

TYPE:
SER NO :

POWER:

MS MD MC CT1 CT2
88A

TB-1

V2 W2 U2

OL1 THF
R/L1 S/L2 T/L3
U3 V3 W3

Recommend cable inlet U1 V1 W1

Earth cable

Power cable

connected by customer

KS15A/KS22A 27
 ５．Operation

5.1 Pre-operation Inspection to Stop

Ensure the safety of the compressor

and its peripheral that could be loads, ・Do not touch any rotating
and give an "All Clear" sign to the  parts or heated parts while
peop le around the compressor before  the compressor is running or
starting the operation.  immediately after the
 compressor is stopped as it is
 very dange rous.
 For safe operation and noise
 prevention, operate the
Before operation, always perform
"pre-operation inspection".
Startup  compressor with all the
(See page 31.)  covers closed.
・If any alert lamp comes on,
 inspect the faulty part.
・Check the running hours.
Before  Inspect each part accordingly.
operation During ・Perform oil level control,
(See page 29.) operation  check of controller display,
 check of abno rmal sound , etc.

St
Stop
(See page 32.)

Periodic
inspection
(See page 46.)
Shutdown for a
prolonged period
(See page 51.)
Perform inspection and
maintenan ce of each part
according to running hours or
operating time. In case of
storage for a prolonge d
period, store the compressor
indoo rs and keep it dry.
Pressure may remain inside
the compressor immediately
after shutdown.
In addition, voltage may still
exist in the inverter.
Before performing inspection
or maintenan ce, make sure
that the inner pressure of
the compressor has been
released completely and turn
Disposal off the breaker to reduce the
(See page 52.) voltage to 0.

KS15A/KS22A 28
 5.2 Pre-operation Inspection

Are the air inlets on the right side face, the one on
the left side face and the outlet on the upper face not blocked?
Clean!
　　

Is the oil level normal?

Before operation,check the oil level.

Please check and confim the oil level if found the oil level had
severe exceptional(above or lower than last time).

* At a stop of operation, the oil level in the tank varies

since the return oil flow rates from the oil cooler and
other related portions to the tank are different
depending on the running condition before the stop.
Check that the oil level is between H and L after
the compressor is started.
Avoid overfilling as it may deteriorate the oil recovery
performance and increase the oil consumption.

Ready?

KS15A/KS22A 29
 Initial Settings for KS Controller (Factory default settings.)

Initial Settings
Item KS15A KS15A-H KS15A-GH
KS22A KS22A-H KS22A-GH
Remote/Local Local
Load/Unload setting Local
Clock Real time
Running hour ０h
4000h
Replace suc. filter (*1)
Elapsed time: 0
4000h
Replace oil filter (*1)
Elapsed time: 0
4000h/2000h(*3)
Replace lube oil (*1)
Elapsed time: 0
4000h
Replace oil separator element (*1)
Elapsed time: 0
4000h
Inspect cooler (*1)
Elapsed time: 0
High temperature grease enclosed inside the bearings,
Fill motor grease (*1)
and it is replaced with the bearings together.
Annual inspection
p (*1)
( ) 4000h
Elapsed time: 0
Unloading pressure(*2) 0.72MPa 0.82MPa 1.02MPa
Loading pressure(*2) 0.60MPa 0.70MPa 0.90MPa
Auto start pressure 0.55MPa 0.65MPa 0.85MPa

(*1) The maintenance intervals (cleaning time) are based on general operating environment.
Your compressor must be maintained according to the operating conditions at your factory.

(*2) A change period of LOAD/UNLOAD shortens when make a difference of unloaing puressure
and loading pressure small.
Please set pressure so that a change period of LOAD/UNLOAD does not become less than
1 cycle 30sec.

(*3) Please refer to brands of lubricating oil. KOBELCO EXTRA OIL: 4000hours;
KOBELCO GENUINE SCREW OIL: 2000hours.

KS15A/KS22A 30
 5.3 Operation Procedure

Startup
1　 Turn on the main power.

2　 Turn on the earth leakage breaker.

　　At the same time, make sure that the POWER indicator
　　light is on.

3　 Check the set values on the SETUP OF COMPRESSOR

　　SETTING screen on page10.
　　To change the set value, see the separate volume,
　　"KS Controller Instruction Manual".

4 　Select local mode using the start

　　selector switch on page10.
g the load/unload
Select local mode using
selector switch on page10.

5 　Press the Start button (green) to start the compressor.

　　(When "Local" is selected using the start
　　 selector switch)

6 　Check the running condition.

　　・Oil level should be between red and yellow lines.
　　・Discharge pressure and temperature should be normal.

* If the alert lamp comes on and a warning message appears

on the message monitor on P00.01, see the separate volume,
"KS Controller Instruction Manual".
After the corrective action is taken, press the Reset button.

KS15A/KS22A 31
 Stop

1 Press the Stop button.

Make sure that the inner pressure of the compressor proper

drops on the message monitor of controller.

* The compressed air in the compressor will be discharged

automatically.

2 Turn off the earth leakage breaker switch.

Emergency
g y Stop
p

The compressor will stop in 10 seconds with unloading condition

after pressing the Stop button. Press the Emergency Stop button in
case the compressor needs to be stopped immediately.

* Emergency Stop button is used only in emergency case.

KS15A/KS22A 32
 5.4 Setting Control Pressure

To set the discharge pressure using the KS controller, follow the procedure shown below.

1 Press the back key "←" several times until the display
　　shown in the figure on the left (main menu screen)
　　appears.

2 Move the cursor to "SETUP OF COMPRESSOR

　　SETTING" by pressing the UP key [+] and press
　　the Enter key.

3 Move the cursor to "UNLOADING PRESSURE" by

　　pressing the DOWN key [-] and press the Enter key.
　　(The Reset mode is entered.)

4 The changeable digit is highlighted. Move the cursor to

　　the digit to be changed by pressing the arrow key "↓"
　　or "↑" and change the figure by pressing the arrow key
　　"Enter".
* The allowable setting ranges are as shown in the table
below.

５．After the pressure is changed as desired, press

　　the Enter key for registration.

Setting ranges
KS15A KS15A-H KS15A-GH
KS22A KS22A-H KS22A-GH
Factory Lower Upper Factory Lower Upper Factory Lower Upper
setting limit limlt setting limit limlt setting limit limlt
Unloading pressure(MPa) 0.72 0.56 0.75 0.82 0.56 0.85 1.02 0.56 1.05
Loading pressure(MPa) 0.60 0.55 0.74 0.70 0.55 0.84 0.90 0.55 1.04
Auto start pressure(MPa) 0.55 0.30 0.73 0.65 0.30 0.83 0.85 0.30 1.03

KS15A/KS22A 33
 *Confirmation of control pressure

Confirm that the capacity control function within the set range and that a cycle
(Unload Operation → Load Operation → Unload Operation) takes longer than 30 seconds.
Frequent driving narrow parts life.

Unloading Pressure
Discharge Pressure

Loading Pressure

TIME
０
More than 30 sec.

*About a driving mode

A compressor has driving mode with [Local]、[Remote] and [Communication] operation.
As for these mode choice effective onlyy in the case of LOCAL mode, a compressor
p p
please
LOAD/UNLOAD a compressor by a signal from remote or communication at the time of REMOTE
or COMMUNINATION operation.

KS15A/KS22A 34
KS15A/KS22A
Oil separator
element

Unload pressure perserve valve

5.5 Operation Modes

Safety valve

Load solenoid valve Blow-off valve

After cooler
Pressure sensor
Air filter

Suction
regulating
valve

35
Combination
valve

Compressor proper

Notes：All of configuration and quantity of parts in the drawings are only for reference.
 【AUTO】・【MANUAL】Mode

START SW ON

Star delta start

Unload lock released

(Load/Unload S/V : open)

Load operation

NO
Dis. press.＞Unloading press.

YES Judge whether quantity of use air decreased.

Unload operation Suction air flow is limited and the

pressure inside the oil separator is
minimized to perform economical
operation.
load S/V : Closed

KS15A/KS22A 36
 Auto running mode

NO

Lapsed time
after starting ＞15min

YES

NO
3 minutes Unloading

Determines there is no
YES air consumption.

Motor auto stop

NO NO
Dis. press. ＜Auto start press. Dis. press. ＜Loading press. Unloading
continued.

Y ES YE S

Star delta start

Unload lock released

Motor auto Start

Unload lock released Load S/V : Open

(Load S/V : Open)

Load operation Load operation

For detail of the controller, see the KS CONTROLLER INSTRUCTION MANUAL.

KS15A/KS22A 37
 Emergency Stop

Running

YES
Emergency condition occurs

NO

YES
Emergency Stop Operation

NO Emergency Stop 
NO
Stop Operation

YES
Unload starting 

NO
Starting Operation

YES NO
  To pass 10S
  
unload working
Unload lock released

YES

motor stop

KS15A/KS22A 38
 ６．Troubleshooting

If emergency stop occurs or a caution is given, restart the compressor after the corrective
action is taken following the countermeasures. (See page 41.)
The KS controller stores up to 50 latest failure records on page 03.

6.1 Emergency Stop

The Emergency LED on the controller comes on, and the cause is shown P00.01 on the message
monitor. The motor stops as soon as a failure is detected.

KS controller display
Counter
No. Message monitor display
measures
Major factor Possible causes
Pressure setting error KC-13
1 M Main motor Too many start & stop KC-11
a overcurrent Power supply error KC-06
i
n Motor failure KC-09
m Main motor Power supply error KC-06
2 o
t is clogging Motor failure KC-09
o
r Main motor phase Power supply error KC-06
3
imbalance Motor failure KC-09
e
r
Too many start & stop KC-11
r
o Motor coil Pressure setting error KC-13
4 r
temperature is high Power supply pp y failure KC-06
Motor failure KC-09
Fan motor error Power supply failure KC-06
5 machine halt Motor failure KC-09
　 Condenser fin clogged KC-08
Ambient temperature is high KC-03
Discharge air temp. Pressure setting error KC-13
6
is high Oil cooler clogged KC-02
Oil filter clogged KC-04
7 High discharge pressure
High pressure in (Call KOBELCO distributor.)
8
oil separator tank
Discharge air temper- Oil separator element is needed to replace.
9 ature switch Stop compressor and after pressure of oil separator is zero
replace oil separator element.
phase L1 Phase error
10 sequence L2 Phase error Break power supply and check if power supply wiring is correct.
L3 Phase error
11 Temperature sensor error
12 Discharge pressure sensor error (Call KOBELCO distributor.)
13 Oil separator tank pressure sensor error

Oil separator element is needed to replace.

14 Error of total psid high
(Call KOBELCO distributor.)

15 Emergency shut down Please check the EMERGENCY STOP Switches.

KS15A/KS22A 39
 6.2 Caution

The Caution LED on the controller comes on, and the cause is shown P00.01 on the message
monitor. In this case, the compressor does not stop.

KS controller display
Counter
No. Major factor Message monitor display
measures
Possible causes
Ambient temperature is high KC-03
Discharge air temper- Pressure setting error KC-13
1
ature is getting high Oil cooler clogged KC-02
Oil filter clogged KC-04
Error of total differential Oil separator element is needed to replace.
2
pressure (Call KOBELCO distributor.)
Alarm of air fifter Air separator element is needed to replace.
3
differential pressure (Call KOBELCO distributor.)
Ambient temp. Ambient temperature should be under 40℃ {104 F}.
4
is getting high Ventilate compressor room and improve air condition.
5 High discharge pressure
(Call KOBELCO distributor.)
6 Oil separator tank pressure high

q
When maintenance is required,The Caution LED on the controller comes on, and the cause is
shown P00.01 on the message monitor. In this case, the compressor does not stop.

KS controller display
Counter
No. Major factor Message monitor display
measures
Possible causes
Air separator element is needed to replace.
1 Air filter element service
(Call KOBELCO distributor.)
Oil fifter is needed to replace.
2 Oil filter service
(Call KOBELCO distributor.)
Oil separator element Oil separator element is needed to replace.
3
service (Call KOBELCO distributor.)

4 Cooler service (Call KOBELCO distributor.)

5 Oil change service (Call KOBELCO distributor.)

If 100 hours or more have passed without pressing the Reset button since
the Maintenance LED on the KS controller came on, the caution lamp will blink
CAUTION at the intervals of one second.

KS15A/KS22A 40
 6.3 Countermeasures
Troubleshoot the problem following the countermeasures in the table below.
Possible causes
No.
KC-02 Clogged cooler
KC-03 Ambient temp. is
getting high
KC-04 Replace oil filter
KC-06 Power supply failure
KC-08 Clogged condenser fin
KC-09 Motor failure
KC-11 Too many start & stop
frequency
KC-12 Circuit error
KC-13 Pressure setting error
KS15A/KS22A
Actions
Countermeasures
Stop compressor.
After confirming fan has stopped clean it by blowing air.
Ambient temperature should be under 40 ℃ {104°F}.
Ventilate compressor room and improve air condition.
Oil separator element is needed to replace.
Stop compressor and after pressure of oil separator is zero replace
oil separator element.
Stop compressor.
Check for voltage drop, voltage unbalance, single phase operation,
and reverse phase operation. Then improve defectives.
Stop compressor.
Clean condenser fin.
Stop compressor.
Check if motor constants is higher than 10MΩ.
If not call KOBELCO distributor.
Check if pressure fluctuation is not continuous occurred.
Compressor must be kept running more than 2 min and kept in
stopped state for more than 3 min.
Stop compressor.
Break power supply and check if power supply wiring is correct.
Compressor must be kept running more than 2 min and kept in
stopped state for more than 3 min.
41
 6.4 Interlock List

Emergency stop

Caution
Item Location where a failure is detected Detector Condition 1 Condition 2
1 Discharge temperature high In oil separator tank PT100 above 105℃{221゜F}
2 Discharge pressure high exhaust opening pipeline Controller Exceed
3 High pressure in oil separator tank In oil separator tank Controller Exceed
4 Startup frequency / hour Controller Controller Exceed (frequently startup)
5 Ambient temperature high Compressor air inlet Thermal Switch turned "ON"(above 43℃)
Differential pressure
Air fifter differential pressure alarm Switch turned "ON"
6 Compressor air inlet switch
7 Error of total psid high Controller Controller Exceed
8 Power error Controller X13 Connector Voltage exceed
9 timepiece error Controller Controller System self-check
10 System error Controller Controller System self-check

KS15A/KS22A 42
 Maintenance*

Item Location where a failure is detected Detector Condition 1 Condition 2

1 Air filter element service Running hours different pressure Controller 4000 hours -6.2kPa
2 Oil filter service Running hours Controller 4000 hours
3 Oil filter element service Running hours Controller 4000 hours
4 Motor grease service Running hours Controller 2000 hours
5 Oil change service Running hours Controller 4000 hours*1 2000 hours*2
6 Cooler service Running hours Controller 4000 hours

Start of operation to
7 Routine service Running hours Controller 4000 hours one year or yearly
inspection to one year

*Please refer to the manual of Part 7 for details.

*1 Use KOBELCO EXTRA OIL
*2 Use KOBELCO GENUINE SCREW OIL

KS15A/KS22A 43
 6.5 Before You Suspect Failure

If the compressor malfunctions, check the following items.

Problem Causes Countermeasures

Broken cable Replace the cable.
Motor is not Failure in circuit board, relays Replace the faulty part.
groaning. or magnetic contactor
Does not start

Motor failure Check the insulation, and repair or replace the motor.
Low voltage For low capacity power supply, change the capacity
of the transformer.
Motor is Thin cable Replace the cable with the specified size.
groaning. Motor failure Repair or replace the motor.
Compressor stall Overhaul the compressor proper.
Blow-off solenoid valve failure Readjust or replace the solenoid valve.
Low discharge Leakage from piping Tighten the fitting or replace the packing.
pressure Clogged suction filter Clean or replace the element.
Clogged oil separator Replace the element.
Blow-off from Pressure higher than the specified value Select an air reservoir with proper capacity.
safety valve Safety valve improper adjustment or failure Readjust, repair or replace the valve.
Clogged oil recovery line Clean or replace the recovery orifice.
High
g lubricating
g Clogged
gg oil separator
p Replace the element.
oil consumption Drain the oil so that the oil level will be between the red
Excessive lubrication
lines of the oil level gauge.
Volumetric Too short load cycle Increase the capacity of piping (air reservoir).
control failure Improper pressure setting Reset the pressure.

Use of oil other than Kobelco genuine oil. Replace the oil with Kobelco genuine oil.

Premature deteriorationHigh ambient temperature Lower the temperature by ventilation or other methods.
lubricating oil Mixture of water Inspect the air inlet and drain the oil.
Residual deteriorated lubricating oil Perform flushing at the replacement of lubricating oil.
Abnormal sound from Foreign material caught in the compressor Overhaul and repair.
compressor proper Wear or damage on the bearing Replace the bearing.
Other abnormal Loose bolt or screw Tighten the bolt or screw.
sound Improper installation Fill mortar and fix the compressor horizontally.
Loose bolt or screw Tighten the bolt or screw.
Excessive Improper installation
Fill mortar and fix the compressor horizontally.
vibration Unbalance due to
contaminated cooling fan Clean the blades.

KS15A/KS22A 44
 MEMO

KS15A/KS22A 45
 ７．Maintenance and Part Replacement

7.1 Guidelines for preventive maintenance

■ Warning Perform the following procedures before maintenance,

inspection or repair.
・ Stop the compressor
・ Emergency button
・ Lower the pressure inside oil separator to 0[Mpa]
・ Turn off the power supply

For details, please refer to Troubleshooting

The safety precautions must be conducted by experienced personnel.

■ Warranty

Use only authorized parts. We shall not be resposible for any faults or damages caused by
unauthorized parts.

■ Service contract
KOBELCO supplies several types'of service contracts to bring you peace of mind. Consult the
authorized service shop or the sales department of KOBELCO.

■ Overview

In maintenace, all gaskets, o-ring and washers which are dismantled should be replaced.

■ Intervals

Local sales department of KOBELCO can offer a preventive service plan for compressor
according to environment and operating conditions, especially maintenance intervals.
Long interval of service and inspection must include short interval of service
and inspection.

■ Service operation for compressor with controller

Besides daily inspection and three month inspection, the maintenance should be grouped
by intervals time (running hours). There is a maintenance timer which can be set in the controller.
When a timer reaches the interval time, it will indicate caution, in this case, checking running time
of the machine. Perform maintenance work in the plan based on running time.
Reset maintenance timer after maintenance. Please refer to the chapter of maintenance timer
in the controller instruction manual.

KS15A/KS22A 46
 7.2　List of preventive maintenance

■ Check list

Intervals Operation
Daily Check oil level
Check the data on the screen monitor

Every three month Check the cooler and clean it if required.

Dismantle the suction filter element and check it
Replace the element which has been damaged or polluted.

Yearly Test safety valve.

■ Interval
Frequency（running hours） Operation
4000（1） If using KOBELCO EXTRA OIL
p
Replace g oil
lubricating
Replace oil filter
Replace air filter
Replace oil separator element
Clean cooler
Check the data of pressure and temperature.
Perform test for lamp indication and screen monitor.
Inspect leakage.
Test the stop function of temperature.
Frequency(running hours)
2000
If using KOBELCO GENUINE SCREW OIL

（1）：Or once per year, perform the maintenance in accordance with

which one comes first.

·Please call KOBELCO distributor if timer set change required.

·Please call the customer service center of KOBELCO in case of replacing oil
and oil filter element in tough conditions.
WARNING ·Please pay attention to any leakage. Replace the damaged hose or nipple.

KS15A/KS22A 47
 · The warranty period shall be one year.
· The maintenance intervals listed above are based on normally expected practices, and are not
guaranteed.They may be shortened depending on the operating conditions and environment.
Therefore adjustment of intervals is required according to the operating conditions.

NOTE: The maintenance intervals in the table above are base on the 4000 running hours per year.
In the operation beyond this standard, maintenance is required when the preparation time is
reached before the maintenance period.

7.3 Insulation Test Procedures for Compressor Unit

This compressor has a KS controller, which consists of electronic parts.

Various kinds of serge absorbers are also equipped for noise prevention.
Therefore, if insulation tests are made on the unit at the voltage beyond the setting for
the serge absorbers, it could cause wrong test results and damage on the monitor.

Perform insulation tests following the procedures shown below.

Starting board

Test voltage： DC500V or less

Criteria for evaluation(at normal temperature)：
UVW
Each phase-FG 500VDC 10MΩ or more
Motor leadwire

FG

Base plate

【Insulation test for motor】

　1. Measure the insulation of terminals for the motor lead wires and the base plate
　 (FG: frame ground).

【Insulation test for control circuit】

　1. Disconnect all the connectors inserted into the controller.
　2. Measure the insulation of terminals on the terminal block of starting board and
　 the base plate (FG: frame ground).

KS15A/KS22A 48
 7.4 Cleaning of Suction Filter

Cleaning

・Open the maintenance door on the right side cover.

　Take out the element and clean it by blowing air from the inside.
　If the element is clogged severely, replace it.
・After cleaning（normal1000h）, fit the element into the body firmly and attach the cover.
・The suction filter may be clogged early under operating environments where the dust filter is
　 clogged early. In such cases, early replacement is recommended.
・Operation continued without replacing or cleaning the suction filter may cause damage to
the duct hose.

Part No.
Suction filter element PS-CE03-516

Suction
Suction filter
filter Element
Elem ent Cover
C over

KS15A/KS22A 49
 MEMO

KS15A/KS22A 50
 ８．Shutdown for a Prolonged Period

・When the compressor is not used for a prolonged period, be

　sure to turn off the earth leakage breaker.

・When the compressor is not used for a prolonged period, be

perfom a break-in 　sure to close the discharge air valve.
once a week.

・It is recommended to perform a break-in once a week for

　about 20 minutes to keep the machine in good order and to
　prepare for the next operation.
　Follow the steps described in 5.3 Operation Procedure on
　page 31 for break-ins.

Do not resume operation! ・If any abnormal conditions are detected, request a service in
　order to ensure a trouble-free run at the next operation.

・Follow the steps described in 5.3 Operation Procedure when

　on page 31 resuming operation.

・Never leave the compressor outdoors.

・Compressor is not running for a long time, lubricating oil of friction

pair may drain. When powered on again, prone to friction, lead units
CAUTION
severely damaged. So the unit is not running for a long time, before
power on again, please call Kobelco distributor.

KS15A/KS22A 51
 ９．Disposal

Disposal

To dispose of any KS series compressor, drain the lubricating oil.

For details, contact the designated service shop, distributor, or Customer
service of KOBELCO COMPRESSOR.

KS15A/KS22A 52
 １０．Remote Control

Remote Control Setting Procedure

Remote control can be selected following the procedure below.

1 Turn on the power.

2 Select remote mode using start selector

switch on menu P10.11 ;
Select remote mode using load/unload selector
switch on menu P10.12.

3 Turn off the power and wire the following

　　terminals as shown in the electric wiring diagram
　　on page 60.
　　C7: Remote Load/Unload switch (a contact: Closed - Load)
　　C8: Remote ON/OFF switch (a contact: Closed - ON)
　　COM1: Common （DC24V）

4 To return to the local operation.

Select local mode using start selector
se switch on menu P10.11;
Select local mode using load/unload selector
switch on menu P10.12.

NOTES
1) The stop operation using the Stop button on the control panel is
valid regardless of LOCAL / REMOTE selection.

2) LOCAL / REMOTE selection can be changed during operation.

○：Valid　×：Invalid
Selection Start button Stop button Remote ON Remote OFF
Local ○ ○ × ×
Remote × ○ ○ ○

KS15A/KS22A 53
 Handling External Signals

The following external signals are provided.

(See the electric wiring diagram on page 60.)

《Input signals to compressor》

・Remote・Run　 （Terminal C8-COM1 → Closed：Run）
・Remote・Stop　 （Terminal C9-COM1 → Open：Stop）
・Remote・Load　 （Terminal C7-COM1 → Closed：Load）
・Remote・Unload　 （Terminal C7-COM1 → Closed：Unload）

《Output signals from compressor》

・Emergency stop　（Terminal R7 - COM2 → Closed：Emergency stop）
・Caution and maintenance （Terminal R8 - COM3 → Closed：Caution and maintenance）

NOTES （１）Input signals to the compressor should be voltage contact input.

　　　Electric current of DC24V is supplied between the COM1~C7、C8
　　　terminals from the controller side.
　　　Voltage could damage the controller.
（２）The rated load to use the output signals from the compressor should be
　　　AC240V 4A or DC 30V 4A at maximum.
（３）The terminal COM1, C7, C8,COM2,R7,COM3 and R8 for remoteness is prepared
　　　in the starting panel terminal block TB2.

Any modification without prior permission of Kobelco Machinery Asia Pte. Ltd
or Kobelco Compressors Manufacturing (Shanghai) Corporation may invalidate
CAUTION the warranty even within the warranty period.

KS15A/KS22A 54
 １１．Specifications

1 11.1 Specifications

KS15A

Types
KS15A KS15A-H KS15A-GH
Items
Frequency （Hz） 50
Power supply voltage （V） 380,415　3-phase　3-wire type
Air discharge volume （m3/min） 2.5 2.25 1.86
Suction Pressure Atmospheric pressure (1 bar)
condition Temperature （℃(ﾟF)） 2～40（36～104）
Pressure （MPa） 0.7 0.8 1.0
Discharge
Max. discharge pressure （MPa） 0.75 0.85 1.05
condition
Temperature （℃(ﾟF)） 45 {113} below (Ambient temperature condition : 30℃ {86°F})
Output （kW） 15
Type 3-phase cage induction totally enclosed
Voltage （V） 380,415
Main motor

Number of poles 2P
Protection IP55
Cooling system Air cooling
Starter system Star-Delta
Insulation class F
Output （kW） 0.55
Fan motorr

Type 3-phase cage induction totally enclosed

Number of poles 4P
Insulation class F
Discharge pipe diameter R2 1
Initial lubricating oil charge （L） 7
Dimensions: W×D× H （mm） 1400×879×1350
Weight （kg） 560
Noise level （dB(A)） 68

NOTES:
(1)Measurement guidelines for air discharge volume in accordance with GB/T3853 (ISO1217 Appendix C).
The suction condition of compressor(body): 20 ℃{68゜F}, 1bar, 0％RH.
(2)The discharge pressure gauge indicates a package outlet pressure.
(3)Lubricating oil drained from a compressor at the factory.
　 Be sure to use『KOBELCO EXTRA OIL』or『KOBELCO GENUINE SCREW OIL』at the time of the exchange.
(4)The noise data is measured at a point of an anechoic room, which is 1.0 meter height from the floor and 1.5
meter length from all directions of the unit.
(5)The compressed air must not be used for respiratory equipment from which aspiration is directly made.
(6)As for the guaranteed values, consult with us separately.

KS15A/KS22A 55
 KS22A

Types
KS22A KS22A-H KS22A-GH
Items
Frequency （Hz） 50
Power supply voltage （V） 380,415　3-phase　3-wire type
3 3.7
Air discharge volume （m /min） 3.4 2.9
Suction Pressure Atmospheric pressure (1 bar)
condition Temperature （℃(ﾟF)） 2～40（36～104）
Pressure （MPa） 0.7 0.8 1.0
Discharge
Max. discharge pressure （MPa） 0.75 0.85 1.05
condition
Temperature （℃(ﾟF)） 45 {113} below (Ambient temperature condition : 30℃ {86°F})
Output （kW） 22
Type 3-phase cage induction totally enclosed
Voltage （V） 380,415
Main motor

Number of poles 2P
Protection IP55
Cooling system Air cooling
Starter system Star-Delta
Insulation class F
Output （kW） 1.1
n motor

Type 3-phase cage induction totally enclosed

Number of poles 4P
Fan

Insulation class F
Discharge pipe diameter R21
Initial lubricating oil charge （L） 7.5
Dimensions: W×D× H （mm） 1400×879×1350
Weight （kg） 620
Noise level （dB(A)） 69

NOTES:
(1)Measurement guidelines for air discharge volume in accordance with GB/T3853 (ISO1217 Appendix C).
The suction condition of compressor(body): 20 ℃{68゜F}, 1bar, 0％RH.
(2)The discharge pressure gauge indicates a package outlet pressure.
(3)Lubricating oil drained from a compressor at the factory.
　 Be sure to use『KOBELCO EXTRA OIL』or『KOBELCO GENUINE SCREW OIL』at the time of the exchange.
(4)The noise data is measured at a point of an anechoic room, which is 1.0 meter height from the floor and 1.5
meter length from all directions of the unit.
(5)The compressed air must not be used for respiratory equipment from which aspiration is directly made.
(6)As for the guaranteed values, consult with us separately.

KS15A/KS22A 56
 Fan properties

FAN AND FAN MOTOR

Type
Items KS15A KS22A

Frequency （Hz） 50
Voltage （V） 3-phase 380,415
Output （kW） 0.55 1.1
3 3
Input air 3850m /h@200Pa 5600m /h@220Pa
Cooling system Air cooling

KS15A/KS22A 57
 11.2 Electric power facilities

■ 380V,415V/50Hz (3-phase 3-wire type), should be supplied to the unit.

Remove the front cover and introduce the power cable through the opening on the right side,
then connect each cable correctly to the terminal panel in the starter box. For normal
operation, a suitable power source is required. Secure less than ±5 % of rated voltage
during operation. In order to suppress the imbalance of current, imbalance of the voltage
between phases as less than 2 % is required.

■ Selection of power supply transformer

If the transformer is too small or the wiring is too thin and too long, the motor may not accelerate
sufficiently or may fail to start because of a sharp voltage drop at the start.
Select a transformer of an adequate capacity for the motor considering proper wiring size and
routing.

Transformer capacity

Model Tansformer capacity

KS15A 30 kVA or more

KS22A 50 kVA or more

■ Selection of power supply breaker

When installing the breaker for the main power supply, select an earth leakage breaker.
Inrush current is supposed to flow at the moment when swiching from star cunnection
to delta connection.
Please be sure to choose and use an earth leakage breaker having a suitable electric
specification in order for it not to wark because of the inrush current flow.
Use of any breaker without high frequency measures may cause malfunction due to affection
of high frequency current.

Maximum rated current Star - delta starting current Inrush current (rms value) Recommended breaker model
Model
380V 415V 380V 415V 380V 415V Reference MITSUBISHI

KS15A 34 A 31 A 142 A 130 A 614 A 562 A NV63-SV/50A

KS22A 48 A 44 A 215 A 197 A 876 A 802 A NV125-SV/75A

*Current sensitivity: 200mA

・The power to be supplied is 3-phase 3-wire type 380V,415V/50Hz.

・The earth leakage breaker suitable for the machine should be mounted in the power unit.

KS15A/KS22A 58
 Selection of cables

For the power cables, select EV or CV or VV cables for 600V insulated by the polyvinyl chloride.
GB12706.1-2002/JIS C3605.

Earth cable: Connect the earth wire to the earth terminal (marked with PE) on the power supply
terminal block.
The earth resistance should be 10Ω or less.

Cable size
Power cable Earth cable screw size of terminal panel
Model Voltage
5m within 10m within 20m within 5m within power cable Earth cable

KS15A 10mm 2 10mm 2 16mm 2 16mm 2 M6 M6

380V
415V
KS22A 10mm 2 16mm 2 16mm 2 16mm 2 M6 M6

NOTE: 20 m or longer cables must have a sectional size more than those listed above.
　　　 Use a relay terminal so that the cable size on the local side will be as specified above.

KS15A/KS22A 59
 UA

CAUTION
CONTROLLER

KS15A/KS22A
1
UB
2 X12
UC 2
3
EARTH LEAKAGE BREAKE R S10 S20 S20 X01
L1/R AC380V/AC415V 2 1
L1 AC25V R10 R20 R20 X13
L2/S 1
L2 USER
AC220V R11
L3/T BREAKER 9 C8
L3 TRANSFORMER REMOTE START/STOP
TR BREAKER CP3 2A
11.3 Wiring Diagram

E E 8 C7
AC380V 50Hz CP3 3A CT1a CURRENT TRANSFORME R
1a 1a REMOTE LOAD/UNLOAD
AC415V 50Hz 1
7 C6
CT1b CURRENT TRANSFORME R WT3 DISCHARGE TEMP. SWITC H
User 1b 1b 2 X11
6 C5
CT1a CT1b WT2 AMBIENT TEMP. SWITC H
1c 1c X02
3
5 C4
OL1 MAIN MOTOR OVERCURREN T
1 MAIN MOTOR TEMP. SWITC H
X10 4 C3 WT1
WS WATER BREAK RELAY(BACKUP )
PB-EMS 2 FAN MOTOR OVERCURREN T
3 C2 THF
KL SUCTION PRESSURE DIFFERENCE SWITC
H
R31 1
88A 2 C1
R31 EMERGENCY STOP
03 R1 2

60
MD MC MC 1 COM1
MAIN MAGNETIC CONTACTO R PB-EMS
THF OL1 X09
MS OL1 MD 04 R2 3
MAGNETIC CONTACTOR FOR STA R MS

MS 05 R3 TE1
MAGNETIC CONTACTOR FOR DELT A MD 4
6 T1-
INSIDE OIL SEPARATOR TEMP .
5 T1+
V2 W2 U2 U3 V3 W3 1
CP33 2A
BREAKER
EAKER SUCTION SOLENOID VALV E
SUCT R4 4 P2- PT2
FAN MOTOR THF SV1 2
U1 V1 W1 IM X03 INSIDE OIL SEPARATOR PRESS .
01 X08
3 3 P2+
MC
IM E
MAIN MOTOR 02 R6 2 P1- PT1
SV3 4
E DISCHARGE PRESSURE
DRYER SOLENOID VALVE （BACKUP） 1 P1+

88A
R7
CONTACTOR FOR FAN MOTO R 1

To perform remote control, read Chapter 10 "Remote Control" (page 53).

ABNORMAL
NORMAL FAULT STOP
S OUTPU T
COM2 2
X07
R8 3
LARM MAINTENANCE
ALARM MAINTENANC OUTPU T
COM3 4

User
WIRING DIAGRAM(STANDARD COMPRESSOR )

KOBELCO COMPRESSORS MANUF A CTURING(SHANGHAI)CORPORAT I ON

 11.4 Connection Diagram

Back side of controll er

A-OUT
A GND

C OM1
T 1-
T 1+
P 2-
P 2+
P 1-
P 1+
C8
C7
C6
C5
C4
C3
C2
C1
X01 X02 X03

X13 X12 X11 X10 X09 X08 X07

L 1/ R
L 2/ S
L 3/ T

C OM 2

C OM 3
R31

R31
R20
S20

R1

R4
R5
R6

R7

R8
P1

P2

T1
X03 X02 X01

Front side
of controller

C OM1
R21
R3
C1
Emergen c y
stop sw it c h
X07 X08 X09 X11 X12 X13

Ambient t e m p.
swit c h

L1/R L2/S
C OM1

C OM1

C OM1

C OM1
S31
C2

C4

R4

C5

C6

380V 1 0
415V 2 0
S10

14 15 16 17 18 19 20 21 22 23 24 25 26
L 1/R
L 2/S
R 10
R 11
S10

CP1 CP2 CP3 1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26

11 0
12 1
13 2
PE

TYPE :

SER N O:

POW ER:

MS MD MC CT1 CT2
88 A

TB-1

V2 W2 U2

OL1 TH F

R/L1 S/L2 T/L3

U3 V3 W3
U1 V1 W1

V2 W2 U2 PE U1 V1 W1 U3 V3 W3 PE

KS15A/KS22A 61
 11.5 System Diagram

Exhaust air

P1

After cooler Drain separator

OL2

Cooling Compressed air

fan
Discharge outlet
Oil cooler
Load solenoid valve Unload pressure preserve valve Connected by
Blow-off customer
PD1 valve Oil separator
element
Saftey valve
Air filter
Suction regulating
valve
OL1 Oil return sight glass
TS1

Air
inlet TS2

Combination
valves
TS3 P2

Oil filter Oil level

OL
gauge
T1

Thermostatic
valve

Notes：All of configuration and quantity of parts in the drawing are only for reference.

MARK NAME
P1 PRESSURE SENSOR (DISCHARGE PRESSURE)
PRESSURE SENSOR (INSIDE OIL SEPARATOR） COMPRESSED AIR
P2
T1 TEMPERATURE SENSOR (INSIDE OIL SEPARATOR)
PD1 AIR FILTER PRESSURE DIFFERENTIAL SWITCH
COOLING AIR
TS1 SUCTION TEMP. SWITCH
TS2 TEMP. SWITCH (AFTER OIL SEPARATOR) LUBRICATING OIL
TS3 COIL TEMP. SWITCH
OL1 OVERCURRENT RELAY (MAIN MOTOR)
OL2 OVERCURRENT RELAY (FAN)

KS15A/KS22A 62
 １２．Warranty

Warranty

If the machine has a failure when in proper operation according to this instruction manual
or other instructions, we will repair on our expense for certain period and on certain
conditions. Consult with our distributor.

Warranty period

The warranty period of this machine shall be 12 months from a date of completion of the
test run or 18 months from the date of shipment, whichever comes earlier.
Note) “After completion of the test run” shall mean
　　　[At the time when the test run (procedure and activities of receiving materials test)
　　　 is completed after installation at site.]

Warranty conditions

If a failure occurs due to our design or workmanship within the warranty period, we will
make repair or change faulty parts promptly on our expense.

Exclusion of warranty

We shall not warrant any of the following faults even within the warranty period:

・Any faults caused by natural disasters or force majeure.

・Any faults caused by changes in design or materials made by the customer without
　prior permission.
・Any faults caused by repairs or modifications made by the customer without prior
　permission.
・Any faults caused by neglect to follow the instruction for proper operation, regular
　maintenance and inspection, and storage described in the specifications and the
　instruction manual.
・Any faults induced by defects in equipment other than the machine, foundation,

Consult with our distributor for repairs on the machine after the warranty period is
expired. Repairs will be made on the customer's expense upon request if the repairs
can maintain the performance.

KS15A/KS22A 63
 １３．Indemnity

Indemnity

Under no circumstances shall, including any illegality, Kobelco Machinery Asia Pte. Ltd
or Kobelco Compressors Manufacturing (Shanghai) Corporation be liable indirect,
incidental, or consequential damages, including, but not limited to,loss of production,
for special, loss of anticipated profits, loss of operational profits, loss of material and
products, or indirect losses, however same shall be caused.

KS15A/KS22A 64
 INDONESIA
PT KOBELINDO COMPRESSORS
Cilandak Commercial Estate 110S, JI. Cilandak KKO,P.O.BOX 7038 Jks/CCE Jakarta, 12560 Indonesia
Tel:+62-21-782-7002 Fax:+62-21-782-7025