KOBELCO INSTALLATION COMPRESSORS (AMERICA), INC .

KOBELCOCOMPRESSORS(AMERICA), INCDocument # K10-Z002 Rev. 2INSTALLATION ANDMAINTENANCE MANUAL

Page Intentionally Left Blank

WARNINGBE SURE TO COMPLETELY READ AND UNDERSTAND THECONTENTS OF THIS MANUAL BEFORE ANY ATTEMPT IS MADE TOINSTALL, OPERATE OR MAINTENANCE THIS AIR COMPRESSOR.NOTICETHE OPERATION OF A ROTARY SCREW AIR COMPRESSOR ISINHERITLY DANGEROUS.KOBELCO COMPRESSORS (AMERICA), INC. HAS MADE EVERYEFFORT TO PROVIDE YOU WITH A SAFE AIR COMPRESSOR.ONLY TRAINED PERSONNEL, WHO HAVE BEEN DESIGNATED,SHOULD OPERATE AND MAINTAIN THIS AIR COMPRESSOR.FAILURE TO FOLLOW THE ENCLOSED INSTRUCTIONS WILLGREATLY INCREASE THE RISK OF BODILY HARM AND/OR DEATH.A QUALIFIED INDIVIDUAL MUST INSPECT AND APPROVE THEELECTRICAL SYSTEM, AIR PIPING, FILTER ELEMENTS,COMPRESSOR SUCTION/ DISCHARGE, GAUGES, VALVES ANDHOSING AND ANY OTHER COMPONENTS NOT LISTED THAT ARERELATED TO THE OPERATION OF THIS AIR COMPRESSOR.DO NOT ATTEMPT TO BEGIN OR CONTINUE TO OPERATE THISCOMPRESSOR WHEN THERE IS RELATED DANGER PRESENT.ANY MODIFICATION TO THIS COMPRESSOR WITHOUT SPECIFICWRITTEN APPROVAL FROM THE FACTORY (NOT DISTRIBUTOR)WILL VOID WARRANTY AND COULD GREATLY INCREASE THE RISKOF INJURY.

ContentsGENERAL INFORMATION . 1General Safety . 1Installation / Installation site. 3Electrical . 5Operation. 7Shutdown . 7Shutdown Inspection . 8Lubrication . 9Rebuilding . 10Description of Components . 11Motor . 11Air End. 11Triple Lip Seal . 12Intake / Volume Control . 12Air Filter . 12Inlet Valve. 13Shuttle Valve . 13Primary Separator . 14Secondary Separator . 14Lubricant. 14Cooling System . 15Analog / Digital Electrical Cabinet . 17Instrumentation. 19Installation . 20

General. 20Handling . 20Location . 20Foundation . 23Ventilation. 23Aftercooler . 23Receiver . 24Air Piping . 24Electrical . 24Maintenance . 26How to decode the Model Number . 26Schedule . 27Inlet valve unload pressure regulator . 29Shaft Lip Seal / Shaft Wear Sleeve . 29Motor Coupling Installation . 32Replacing Air Filter . 34Replacing Lubricant (Oil) Filter . 37Lubricant Sampling . 38Replacing Coalescing (Separator) Filter . 40Replacing Lubricant (Oil) . 41Servicing Scavenger Return Valve . 43Lubricating the Motor . 45Adjusting Modulation . 47Microprocessor Error Codes. 49Microprocessor Reference . 50

Electric Schematic . 53Specifications . 54Data / Dimensions . 54Recommended Pipe and Receiver Sizes . 54Bolt Torque Specs . 54Flow Diagram . 55Troubleshooting . 56

GENERAL INFORMATIONGeneral SafetyThe following is provided to protect the customer from severe personal injury,dismemberment, death, property damage, fire or damage to the compressor. We cannotcover all dangerous situations, thus all users must exercise caution and common sense.All persons working on and operating compressor should only do so after reading thisentire manual. READ AND UNDERSTAND THE ENTIRE CONTENTS OF THIS MANUALBEFORE INSTALLING, OPERATING OR MAINTAINING THIS COMPRESSOR. Never maintenance machine or attempt to remove guards unless the machine isturned off and the power has been locked out. The compressor is equipped with an automatic start control. Never assume it issafe to start maintenance or remove guards. THE MACHINE MAY START ATANY TIME. Inspect compressor daily to insure proper operation. See section 4.1 for moredetails. Periodically confirm all safety devices are properly working. Properly trainedpersonnel only must do this. If not done properly severe bodily and propertydamage could occur. Never bypass, override, tamper or remove any safety device installed on themachine. Do not use the air from this compressor for breathing air. THIS UNIT DOES NOTCOMPLY WITH OSHA 29 CFR 1910 REGULATIONS. Do not allow flammable, toxic, or corrosive gasses or dust to enter the air inlet ofthe compressor or electrical devices. Never remove, alter or deface any of the warning, danger or caution decalsapplied to the compressor.1

Carrying-in work, installation, operation, maintenance and inspections of themachine must be done by the well-trained personnel. We shall not be responsible for any personal injury and faults / damage of themachine resulting from modifications by the customer. Strictly follow the local regulations and the safety standard established in thefield. Use only KOBELCO parts. If not observed, it can cause malfunction and / orfailure. Be sure to ground the machine, or electrical problems including noise maydamage the electric unit or cause electric shock.2

Instaallation / Installation siteTTransferWhen moving thee machine using a forkkliftor a cranne, protect thet sound proofpenclosurre with a paadded cloth or paddingg toprevent damage.dDo noot drop the machinemorr carry it at aslant of 45 4 or moree when movving it.Innstallation SiteThhis machinee is designeed for indooor use only.Do notn install machinemoutdoors or seemi-outdoorrs.Installation inn a place exxposed to rainror in ahumid basemennt can causse an electrric leak, draainand / or rust.Installation inn a place wherewdust suchsas ironnpowdder, paper pulppor sannd is lifted canc cause loowinsulation performance of electrical parts and caandamaage the rotoor.Installation inn the atmossphere conttaining toxiccgas canc cause deterioratiodon of lubricaant andcorroosion in parrts.Reefer to the Installation Section of this manuaalfor greater detaail.Doo not install the machine near a workwplacewherre flame is used or thee ambient teemperaturee isover 100 F (388 C)Doo not placee flammablee objects neear themachhine.3

When installing the machine in a closed room, provide theair suction and exhaust openings. The exhaust openingsmust be equipped with a ventilation fan.4

ElecctricalElectricEWWiringm electricQualified electricians must performwiring.Leading intoo the powerr source shoould be donnenot too expose wiring.wWirinng into the controlccabinnet requiress a protectivve bushing in thethrouugh hole in order to protect the wires.wEElectricleakk (Groundedd), low insuulationperfoormance, ovver current, short circuuit,incorrrectly phassed operatioon and mallfunction ofthe safetysdevicces can prooduce sparkk in themotoor, wiring annd electric circuit.cBreakerBUse a grounded breaker for the powerr source in accordancee withthe machine modell.Do noot use the knifekswitch without anny groundedd breakers interms off protection.Innstallationoval or moddification off the safetyRemodevice oro any channge in the sets values canccause ana accident.Any changecin the set value for theelectricaal safety deevices and operationowwithouta safetyy device cann abnormallly heat thelubricannt to start a fire. Never change thee setvalue orr operate thhe machine without, orr usemodifiedd, safety deevices.5

GroundGConnecct the grounnd wire withh the grounnd terminal(Marked withw groundd symbol) on the controol panel.Groundingg must be in accordannce with all National anndLocal elecctrical code.Consult a qualifiedd electriciann for detailss.6

OperationDangerousDObjectsDo not put any infflammabless around thee machine. Neveruse an oppen flame near the maachine.The compressor canc catch fire from work being caarriedout near the machinee that produuces spark,, such aswelding.Do not touch the exhausteouttlet and thee peripheral areawhich are heated during the opeeration of thhe compresssorand couldd remain hoot even after shut downn of the maachine.This area could causse a seriouss burn.PressurePOperrate the machine withinn the limitsspecified in this maanual.RotatingRPoortionsen the poweer is on, neever touch the rotatingWheportionns even if thhe compresssor is stoppped.ny maintenaance needss to be perfoormed be surestoIf andisconnect and loock out the main power supply.ShuttdownParallelPOpperationCloose the disccharge stopp valve of the machinee which isstoppped and reliieve the sysstem pressure.7

LongLTermm ShutdowwnTurn off thhe power supply and closecthe diischarge vaalveoff the comprressor.Be sure too perform a start-up (to stabilizedd dischargeeteemperature greater thaan 175 ) onnce a monthh. This isesssential to prevent russt in the commpressor and bearingdaamage.Shuttdown InsspectionPressurePBeefore inspeccting the coompressor, stop the coompressor andaturn offo the mainn power suppply breakeer. Make suure no presssureremains in the system.PowerPSuppplyBeefore replennishing lubricating oil oro inspecting the controolboardd, be sure to turn off all the comppressors powwer supply.Reemember the compreessor is eqquipped with anautommatic startt function andamay start at ANYY time.8

LubrricationMixingMLubbricantsnly the speccified lubricating oil. NeeverUse onmix oils of different brandsbor tyypes.oration, shoortage or emmptiness offDeteriolubricant anda poor luubricant circculation ressultingfrom high viscosity canc abnormmally raise thhelubricant temperaturtre hot enouggh to start a fire.Be sure too visually check the lubricant leveel onthe lubricaant level gaauge (locateed on the primaryplubricant separator)sand, if it is low, replennish orchange it.ReplenishmRmentIf thee lubricant level is beloow the loweer limit wheen inoperatiion, replenish the lubriicant.Befoore replenisshment, be sure to turnn off the poowersupply and stop thhe compresssor. Note thattthe preessureremainns in the oil separator forf minutes after thecompreessor is stoopped. Makke sure no pressurepremainsin the systemsbefoore the lubrricant is repplenished.9

ChangingCLubricanttMMaximumseervice life off the lubricaant is 3,0000hourrs, though it depends ono the operrationalcondditions. Be suresto commpletely draain oil lubriccant,this included all tubing andd coolers.DDeterioratedd lubricant requiresrimmmediate and fullchannge.Luubricant deeterioration will cause thet deteriorrationcarbbon to adheere to the seeparator eleement. Theedeteerioration caarbon may be partiallyy heated up byoxidation heat tot start a firre and explode.WWhenchangging the lubbricant, be suresto replaacethe lubricant filtter elementt.RebuuildingA overhaul should beAnyb performeed every fiveeyeaars, regardleess of operration hourss. At that timme,chaange the maain motor bearingsbandd clean thee coil.T power supplyThesmusst be cut offf and lockedd outto performpan overhaul onn this machhine.10

Description of ComponentsMotorThe standard Kobelco Ka Series Compressor is equipped with anindustrial quality motor. The motor is suitable for service with 480 volts,240 volts and in some cases as low as 208 volts with a standard threephase 60 Hertz AC input.The motors are equipped with a NEMA standard C-face. The C-faceis used to properly align the compressor with the drive shaft of themotor.15 – 30 HP compressor packages are equipped with motors thathave a dual shaft configuration. The auxiliary shaft is used to drive thecooling fan and the motor has been designed to accommodate theextra HP draw required by the fan.40 & 50 HP compressors are equipped with a single shaft motor witha secondary fan motor.If the situation occurs where the motor needs to be replaced after thewarranty period expires it is not recommended to replace with astandard motor. You will encounter a shorter motor life. Please contactyou distributor or the factory for further consultation.Air EndThe basic air compressor is a single stage, positive displacement,lubricated rotary screw unit. The air end has been designed to providethe user with years of reliable usage.The air end utilizes the inlet valve to supply the user with air at avolume equal to the demand, up to the maximum capacity of thecompressor. The inlet valve serves as a check valve when thecompressor shuts down, preventing back spinning of the rotors. It alsoacts as a lubricant stop valve.11