PACKAGE TYPE SCREW COMPRESSOR

XG2140AV-110　　XG2140AV-110H

XG2540AV-132　　XG2540AV-132H

XG3030AV-160　　XG3030AV-160H

SPECIFICATIONS

KOBELCO
O CO CO
COMPRESSORS
O MANUFACTURING
C G
(SHANGHAI)CORPORATION

DWG. No. 4V40ZS1093P1

Printed2013.06 ISSUE 05
 P1

　CONTENTS

〔CONTENTS〕
Contents …… 1
Product Specifications …… 2
Installation Conditions …… 6
Precautions for Piping …… 10
Electric Power Facilities …… 12
Lubricating Oil …… 14
Warranty Conditions …… 15
Indemnity …… 15
〔Attached Drawing〕
(1) ITCS Controller …… 17
(2) External Dimensions …… 19
(3) Foundation Drawing …… 20
(4) System Diagram …… 21
(5) Wiring Diagram …… 22
Wiring for Automatic
(6) …… 24
Alternate Operation

WARNING
　
RESPIRATORY DISORDER

　Do not breathe in nonclean compressed

air or do not use it for any respiratory
equipment; otherwise, a respiratory
disorder may be caused.
 P2

PRODUCTS SPECIFICATIONS
◆ XG2140AV
Model
XG2140AV-110 XG2140AV-110H
Item
Frequency （Hz） 50
Power supply voltage （V） 380/415　3-phase　3-wire type
3
Air discharge volume （m /min） 21.4 20.2
Specified pressure （MPa） 0.7 0.8
Suction Pressure Atmospheric pressure (1 bar)
condition Temperature （℃(ﾟF)） 2～40（36～104）
Pressure （MPa） 0.7 0.8
Discharge Max. discharge pressure （MPa） 0.75 0.85
condition
Temperature （℃(ﾟF)） 45 {113} below (Ambient temperature condition : 30℃ {86°F})
Pressure control system Constant pressure control by the inverter (control pressure±0.01 MPa)
g
Volume control range ( )
(%) 100～50
Output （kW） 110
Type 3-phase cage induction totally enclosed
Voltage （V） 380/415
Main motor

Number of poles 4P
Protection IP55
g system
Cooling y Air cooling
g
Starter system Inverter starter
Insulation class F
Output （kW） 1.8x2
Fan motor

Type 3-phase cage induction totally enclosed

Number of poles 4P
Insulation class B
Discharge pipe diameter （A） R23 / DN80 flange
Initial lubricating oil charge （L） 100
Dimensions: W×D× H （mm） 2600 × 2000 × 2000
Weight （kg） 3820
Noise level （dB(A)） 69
NOTES:
(1)Measurement method of Air discharge volume( volumetric flow ) based on GB/T3853(Is equivalent
ISO1217 Appendix C). Suction condition : 20℃ {68゜F} 1bar 0%RH
(2)The discharge pressure gauge indicates a package outlet pressure.
(3)Lubricating oil is filled in a compressor at the factory.
　 Be sure to use『KOBELCO GENUINE SCREW OIL』at the time of the exchange.
(4)The noise data is measured at a point of an anechoic room
room, which is 1.0
1 0 meter height from the floor and 1.5
15
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.
 P3

◆ XG2540AV
Types
XG2540AV-132 XG2540AV-132H
Items
Frequency （ ）
（Hz） 50
Power supply voltage （V） 380/415　3-phase　3-wire type
3
Air discharge volume （m /min） 25.4 24.1
Specified pressure （MPa） 0.7 0.8

Suction Pressure Atmospheric pressure (1 bar)

condition Temperature （℃(ﾟF)） 2～40（36～104）
Pressure （MPa） 0.7 0.8
Discharge
Max. discharge pressure （MPa） 0.75 0.85
condition
Temperature （℃(ﾟF)） 45 {113} below (Ambient temperature condition : 30℃ {86°F})
Pressure control system Constant pressure control by the inverter (control pressure±0.01 MPa)
Volume control range (%) 100～50
Output （kW） 132
Type 3-phase cage induction totally enclosed
Voltage （V） 380/415
Main motor

Number of poles 4P
Protection IP55
Cooling system Air cooling
Starter system Inverter starter
Insulation class F
Output （kW） 3.0×2
Fan motor

Type 3-phase cage induction totally enclosed

Number of poles 4P
Insulation class Ｂ
Discharge pipe diameter （A） R23 / DN80 flange
Initial lubricating oil charge （L） 120
Dimensions: W×D× H （mm） 2600×2000×2000
Weight （kg） 3920
Noise level （dB(A)） 70
NOTES:
((1)Measurement
) method of Air discharge
g volume(( volumetric flow ) based on GB/T3853(Is
( equivalent
q
ISO1217 Appendix C). Suction condition : 20℃ {68゜F} 1bar 0%RH
(2)The discharge pressure gauge indicates a package outlet pressure.
(3)Lubricating oil is filled in a compressor at the factory.
　 Be sure to use『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.
 P4

◆ XG3030AV
Types
XG3030AV-160 XG3030AV-160H
Items
Frequency （ ）
（Hz） 50
Power supply voltage （V） 380/415　3-phase　3-wire type
3
Air discharge volume （m /min） 30.3 28.8
Specified pressure （MPa） 0.7 0.8

Suction Pressure Atmospheric pressure (1 bar)

condition Temperature （℃(ﾟF)） 2～40（36～104）
Pressure （MPa） 0.7 0.8
Discharge
Max. discharge pressure （MPa） 0.75 0.85
condition
Temperature （℃(ﾟF)） 45 {113} below (Ambient temperature condition : 30℃ {86°F})
Pressure control system Constant pressure control by the inverter (control pressure±0.01 MPa)
Volume control range (%) 100～50
Output （kW） 160
Type 3-phase cage induction totally enclosed
Voltage （V） 380/415
Main motor

Number of poles 4P
Protection IP55
Cooling system Air cooling
Starter system Inverter starter
Insulation class F
Output （kW） 3.0×2
Fan motor

Type 3-phase cage induction totally enclosed

Number of poles 4P
Insulation class Ｂ
Discharge pipe diameter （A） R23 / DN80 flange
Initial lubricating oil charge （L） 120
Dimensions: W×D× H （mm） 2600×2000×2000
Weight （kg） 4150
Noise level （dB(A)） 71
NOTES:
((1)Measurement
) method of Air discharge
g volume(( volumetric flow ) based on GB/T3853(Is
( equivalent
q
ISO1217 Appendix C). Suction condition : 20℃ {68゜F} 1bar 0%RH
(2)The discharge pressure gauge indicates a package outlet pressure.
(3)Lubricating oil is filled in a compressor at the factory.
　 Be sure to use『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.
 P5

■ Fan properties
FAN AND FAN MOTOR
Type
Items
XG2140AV XG2540AV / XG3030AV

Frequency （Hz） 50
Voltage （V） 3-phase 380/415
Output （kVA） 1.8×2 3.0×2
Input air 250m3/min@200Pa(×2) 220m3/min@300Pa(×2)
Cooling style Air cooling

■ Inverter specifications
Type INVERTER
Items XG2140AV XG2540AV XG3030AV
Frequency （Hz） 50
propertiees
Electricc

Voltage （V） 3-phase 380~480

Capacity （KVA） 198 232 330
Rated current （A） 260 304 450
Cooling system Air cooling
Details

Control mode no PG V/f control

Harmonic restraint DC reactor built in
 P6

　Installation Conditions

1. PLACE NOT TO BE INSTALLED

○Since this machine is manufactured to be used indoors, do not install it outdoors.

○ Since this machine is equipped with the precision electronic components, install it at
such place where the rain water never enters. A through care must be exercised so
that the machine is never exposed to the rain water even when the machine
is temporarily stored.
○ Do not install the machine especially at such place where there are a lot of dust and
the noxious gas such as chlorine gas, hydrogen sulfide gas, sulfur dioxide, ozone of
high density, etc.
○ It is to avoid it that you install it under the surroundings that it seems to breath in
machine tool cutting oil mist, soluble cutting liquid mist, discharge smoke of boiler,
decomposition
p gas
g of plastics
p and others. When these mist and gas
g are absorbed,, it
is clogged with the oil separator element, and it causes emergency stop.
○ Do not install the machine where the ambient temperature exceeds 40(104ﾟF).
It may cause serious accidents such as burning of the machine and fire.
○ Install the machine on a horizontal floor. If a block etc. is placed beneath the machine,
the compressor may not be running properly.
○ Install the machine to be free from heavy vibration.
○ Please note that the noise level may vary with the building structure or position
within the building where the machine is installed.

2. INSTALLATION SPACE FOR SAFE OPERATION

■ INSTALLATION SPACE
○ Allow a space of 800mm for the left side, 1000mm for the right side, 1000mm for the front,

800mm for the back and 1500mm for the top against the body.
○ Secure an appropriate space for the normal operation around the air inlet on the right
and left side and exhaust outlet on the top the unit.
○ Enough front space is required to open/close the doors and maintain the compressor
compressor.
○ Install the machine on the horizontal
floor.
 P7

■ INSTALLING A VENTILATING DUCT EXHAUST

○ Provide a fresh air inlet and an exhaust outlet Install a

ventillating fan
installed with a ventilating fan to use the
machine
hi iin a closed
l d room.
○ Provide the size of the air intake so as not to
produce negative pressure in the room.
○ Select the ventilating fan bigger than the
following table. Air supply
○ Be careful because the exhaust heat is going to circulate at the air intake ,
and the ambient temperature is higher if the ceiling is lower.
○ The machine is tripped at the room temperature of 40℃ (104ﾟF) or higher.

◆ Ventilation Method and Fan Capacity

Compressor cooling air Minimum ventilation capacity (*2)
items Generated Allowable Entire ventilation
calories Exhaust Ventilating Ventilating
pressure loss d
ductt d t & ffan
duct
air volume in exhaust duct Local ventilation
(*1)
Model
(MJ/h) (kcal/h) (m3/min) Pa(mmH2O) (m3/min) (m3/min) (m3/min) (m3/min)
1209 693 121 536
XG2140AV-110 436 104,060 415
or more or more or more or more
1451 778 145 560
XG2540AV-132 523 124,872 415 50 (5)
or more or more or more or more
1759 885 176 591
XG3030AV-160 634 151,360 415
or more or more or more or more

*1: Local ventilation is a method to exhaust air by directly exhausting one third to a half
of compressor-exhausted air using a ventilating fan installed near the compressor exhaust outle
*2: Ventilation capacity
p y indicates the value at the allowable room temperature
p of 5℃ {{9゜F}}
higher than the ambient temperature.
 P8

■ INSTALLING A VENTILATING DUCT

○ Be sure to install a ventilating duct if it is

impossible to provide a ventilating fan in

a ttotally-closed
t ll l d room.
○ Do not mount the compressor directly on METAL NETTING
the ventilating duct with screws
（at inspection, the duct can be removed easily）.
○ Install wire net at the exit of the duct so that

birds or big refuse cannot get in.

○ Prevent rain water entering into the exit of
the duct.
VENTILATING FAN
○ Minimize a duct bend (maximum tolerance of
50Pa ( 5 mmH2O)) as much as possible to
avoid resistance.
○ Maximize a radius as much as possible when
bending the duct.
○ Install a ventilating fan at the exit of the duct
if the exhaust duct has a pressure loss of more
than 50Pa ( 5 mmH2O).
○ In case of installing a ventilating fan in the duct, be sure to select a heat resistant
type 〔80℃ (176ﾟF)〕.

Sectional area of ventilation duct must be larger than ventilation area on air
compressor, or else the unit may cause serious injury.
 P9

■ INSTALLING A VENTILATING TYPE AND A VENTILATING DUCT

Sectional area of ventilation duct must be larger than ventilation area on air compressor, or else
the unit may cause serious injury.

① Entire ventilation ② Ventilating duct ③ Ventilating duct & fan

Local ventilation (*1)

CAUTION

・The ventilation capacity is   for  ・Calculate the pressure loss (resistance) in  ・The pressure loss (resistance) in the  

ventilating the 
g entire room.  ((at  the ventilating duct based on the exhaust air  ventilating duct is over 50 Pa (5 mmH2O), 
the allowable room temperature  volume of the compressor.  If the result is not  install  a ventilating fan with the 
of  5℃ {9゜F}  higher than the  more than 50 Pa (5 mmH2O) for air cooling type,  specified  capacity inside  the duct taking 
ambient  temperature) The air  the exhaust from the compressor exhaust  the pressure loss into  consideration.
supply opening should be  outlet  through the duct will be possible.
adjusted   so that the flow rate  ・Connect the ventilating duct referring to the 
will be 2 m/s or less. duct  installation mark at the top of the 
compressor.  The duct should be removable.  
(*1) Local ventilation is a method  Do not fix the duct with screws.  It may hinder  Caution
to exhaust air  directly exhausting  repair and maintenance work. Use of KOBELCO 
one third to a half of  by   genuine expansion duct is  recommended, as  To choose a type of  fan can endure 
compressor‐exhausted air using a 
compressor‐exhausted air using a shown on the next page.
shown on the next page. much heat .
ventilating  fan  installed near the  ・Minimize bents in the duct to avoid  (high temperature )[80℃ {176゜F}]
compressor exhaust  outlet. resistance.
・When installing the duct, provide a full radius.  
Duct resistance over 50 Pa (5 mmH2O) could 
reduce the exhaust volume, causing 
temperature  rise to stop the compressor. ・Turn on the ventilating fan while the 
Turn on the ventilating fan while the 
・Even if the duct is connected directly to  the  compressor  is running, and turn it off 
compressor, the temperature will rise.  In such  when  the compressor  is stopped.
a case, install a ventilating fan mentioned  in  ・The opening area of air inlet shall be 
the previous page (at the allowable room  adjusted  so that the flow rate will be 2 
temperature of 5℃{9゜F} higher than the  m/s  or less.
ambient  temperature). 
・Prevent rain water from entering the duct 
outlet.
・If the pressure loss in the ventilating duct is 
p g
over  50 Pa (5 mmH2O), 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.
 P10

Precautions for Piping

■ Piping
p g
・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
g main piping
p p g so that theyy can be closed when the operations
p 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 concave or riser piping.
・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
fl h as d
drain.
i
Hanger

Inclination Hanger Discharge air

(Slope along
the air flow.)

Stop valve Stop valve

Flange nipple Flange nipple

Drainage valve Drainage valve

Work to be executed
by the 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
corrosion.
CAUTION
 P11

■Air tank installation

In order to make pressure fluctuation small, install the piping capacity more than surely
proper capacity (air reciver tank) in 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) Model Air tank capacity (m3)

XG2140AV-110 Min 2.71 XG3030AV-160 Min 3.83

XG2140AV-110H Min 2.56 XG3030AV-160H Min 3.64
XG2540AV-132 Min 3.21
XG2540AV-132H Min 3.05

Note）This is the capacity of the case of load rate 50%, difference of upper 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）

PL
t1 t2 Pa ：Suction pressure（MPa）
D ：Difference of upper and lower limit pressure（MPa）

x ：Load rate（Used air toward air discharge volume Qs）

（t1＋t2）× QS × Pa × x（1－x）
VR＝
D

《XG2140AV-110 type calculation example》

t1＋t2＝ 0.5min 　Qs＝ 21.4ｍ3/min 　Pa＝ 0.101MPa 　D＝ 0.70－0.60＝ 0.10MPa
xx＝ 50 %（Air tank capacity is surely made the biggest at the time of load rate 50%）

0.5 × 21.4 × 0.101 × 0.5 ×（1－0.5）

VR＝ ≒ 2.71 m3
0.10
 P12

ELECTRIC POWER FACILITIES

380/50Hz (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 left 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.
In order to suppress the imbalance of current, imbalance of the voltage between phases
as less than 2 % is required.

1. SELECTION OF THE EARTH LEAKAGE BREAKER

○ Install an earth leakage breaker to prevent motor burn out, earth fault, and electrical
shock. Inrush current is supposed
pp to flow at the moment when switching
g from star
connection to delta connection. Please be sure to choose and use an earth leakage

Maximum rated current Recommendedbreakermodel

Model
380V 415V Reference MITSUBISHI

XG2140AV-110 247 A 226 A NV400-SW-3P-400A

XG2540AV-132 288 A 264 A NV630-SW-3P-500A
XG3030AV-160 346 A 317 A NV630-SW-3P-600A

* To prevent unexpected functions during start-up, use earth leakage breakers with
current sensitivity of 200mA.

2. SELECTION OF THE POWER CABLES

○ For the power cables, select EV or CV or VV cables for 600V insulated by the polyvinyl chloride.
Power cable Screw size of terminal panel
Model Voltage
5m within 10m within 20m within Power cable Earth cable

XG2140AV-110 95 mm2 95 mm2 120 mm2 M 10 M 10

380V
XG2540AV-132 120 mm2 120 mm2 120 mm2 M 10 M 10
415V

XG3030AV-160 120 mm2 150 mm2 150 mm2 M 10 M 10

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
above.
 P13

3. SELECTION OF EARTH CABLES

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

Model Voltage Earth cable

XG2140AV-110 50 mm2

380V 2
XG2540AV-132 70 mm
415V

2
XG3030AV-160 70 mm

4. 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.

Model Transformer capacity

XG2140AV-110 250 kVA or more

XG2540AV-132 300 kVA or more

XG3030AV-160 360 kVA or more

NOTE: Use appropriate cables and breaker tabulated above.

Use of any wrong size cable may overheat and burn the motor and cables.
An inverter power
p supply
pp y cannot be used.
 P14

5. Cable Connection
○ Open the control Cabinet door and the starting
boad cover. Then connect the cables to the
tterminal
i l block（R/L1,
bl k（R/L1 S/L2
S/L2, T/L3 ）.
）
Please be sure to ground.

Backup cable inlet Recommend cable

inlet
R/L1       S/L2     T/L3     E  earth cable

(connected by customer)

NOTE: Follow the marks to connection.If take a mistake

connection and would damage the inverter.

In case using the secondary recommended wiring, connect the wiring following
the shape which is shown on the left side picture, to prevent the drain,
or any liquids come into the starting panel, along the cable.

Remove the right side cover and the protection cover for the main inverter before connecting the ca
to the terminal and terminal block.
( The above-mentioned is the connection of XG3030AV.The inverter of XG2140~3030AV are setting
in the starter panel.)
 P15

　LUBRICATING OIL

1. CONTROL OF LUBRICATING OIL

○ For the long and good use of the compressor, proper control of the lubricating oil is
necessary.
○ Lubricating oil shall not be mixed with that of a different brand. Mixing oil may
cause deterioration of oil or adherents which may shorten the life of compressor
extremely.
○ Change lubricating oil when the message “Lubricating oil replacement” lights up
on the controller. This message appears every 4,000 hours. Push the reset switch
after changing the lubricating oil.
○ If you change the brand of oil, drain the oil completely, and clean the oil line by
flushing oil, and supply new oil.

2. BE SURE TO USE THE RECOMMENDED LUBRICATING OIL

○ Use the genuine lubricating oil we are recommending.

KOBELCO GENUINE SCREW OIL（20L）

GENUINE LUBRICATING OIL
PC-HD11-S001

○ If accidental contact of compressed air with food is expected, vegetable oil

"ANDEROL FGC 32" may be used. (Exchange oil within 3000 hours.)
To use the above oil, please contact our company.

ANDEROL FGC 32（19L） P-HD11-525

3. BE SURE TO USE THE RECOMMENDED LUBRICATING OIL

Two shaft seals for the main motor incorporate a grease valve.
Refill 45 g of grease through each grease valve at intervals of 2000 running hours.
　Refill
Refill grease using a grease gun while the motor is running.

KOBELCO TOUGH GREASE

GENUINE GREASE
PS-HD11-507
(Sold separately)
Never mix different brands of grease.
 P16

WARRANTY CONDITIONS

1. WARRANTY CONDITIONS
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.]
2. CONTENTS OF WARRANTY
In case a trouble should occur during the warranty period and when it is determined
that the trouble is caused clearly by our defective design, manufacture and or
execution of work, we repair or replace the parts free of change without delay.
3. EXCEPTIONS TO THE APPLICATION OF WARRANTY
Even during the warranty period of this machine, we refuse warranty in the following
cases:
· Trouble caused by the natural disasters or accidents belong human control.
· Trouble caused by a defective material selected or supplied by you, or caused by
a defect resulted from the design designated by you.
· Trouble caused by a repair or modification conducted by you without notifying us of the fact.
· Trouble caused by not adhering to the operating procedures, periodical inspections,
maintenance and storage, etc. described in the specification sheets and instruction
manuals issued by us
· Trouble caused by defective foundation, building and/or equipment other than this machine.

INDEMNITY

Under no circumstances shall, including any illegality, Kobe Steel, Ltd. be liable for
special, indirect, incidental, or consequential damages, including, but not limited to,
loss of production, loss of anticipated profits, loss of operational profits, loss of material
and products, or indirect losses, however same shall be caused.
 Ｐ17

ITCS CONTROLLER（XG）【The description of each part】

ITCS displays information of operation state, condition setup and Emergency / Caution / Maintenance on a LCD screen,and it can be easily and correctly done
depending on the use conditions.
◎ Main motor overcurrent

◎ Motor coil temperature is high

◎ Fan motor overcurrent

CY STOP
◎ Dryer failure

EMERGENC
◎ Di
Discharge
h air
i temperature
t t is
i high
hi h
After oil separator
◎ temperature is high
◎ Emergency stop

◎ Reverse phase ◎ Inverter error

◎ CPU error ◎ External em ergency

Startup disk electric
◎ Sensor error ◎ error

◎ Discharge air temperature is high

◎ After oil separator temperature is high
DISPLAY PART OPERATION PART ◎ External em ergency

ON
◎ Ambient
A bi t temperature
t t is
i high
hi h

CAUTIO
① LCD SCREEN LIQUID CRYSTAL DISPLAY SCREEN ⑧ ARROW KEY 「↑」「↓」「→」「←」 ◎ Oil separator element clogged
Operation state(discharge pressure, discharge air temperature, 「↑」「↓」「→」and「←」 are movement of cursor, and also are used ◎ Motor coil temperature is high
ambient temperature, operation time, and load rate), condition to increase or decrease values of settings. ◎ Sensor error
setup( keep pressure, auto stop pressure, auto start pressure, ⑨ 「Enter」KEY ◎ Inverter alarm
PID setting·maintenance time and, contents and ・A setting value will be decided if the key "Enter" is pressed
management for machine error are displayed. ・If the "Enter" key is pressed by the specified item (item which ◎ Suction filter change
② Power LAMP(GREEN) cursor blinks), it jumps on the screen of the item. ◎ Oil filter change
It is shown that controller is in a turning-on-electricity state. ⑩ 「Reset」KEY ◎ Oil change
③ Load LAMP(GREEN) ・Change to "setting
setting value change mode"
mode to the item of the present ◎ Oil separator element change

MAINTENANCE
It is shown that compressor is under operation. cursor position. ◎ Cooler inspection
④ Auto Start LAMP(GREEN) ・Reset Emergency, Caution and a maintenance. ◎ Motor greasing
It is shown that it is in the state of operation standby. ⑪ 「Remote／Local」KEY ◎ Monitor battery change
⑤ Emergency LAMP(RED) It changes whether starting and a stop of compressor are performed ◎ Maintenance sensor change
It is shown in a compressor that Emergency occurred and stopped. Remote or Local. In a remote case, the orange lamp of "Remote"lights ◎ Pressure loss is high
⑥ Caution LAMP(ORANGE) up, and, in a local case, the green lamp of "Local" lights up. ◎ Lamp test
It is shown in a compressor that the Caution occurred. ⑫ 「Start」KEY
⑦ Maintenance LAMP(YELLOW) A compressor starts and the green lamp lights up.
It is shown in a compressor that the Maintenance occurred and it ⑬ 「Stop」KEY
needs maintenance. A compressor stops and the red lamp lights up. ISSUE

KOBELCO COMPRESSORS (SHANGHAI) CORPORATION DRAWING No. 4V51ZS1001P1 01

 Ｐ18

ITCS CONTROLLER（XG）【The description

ITCS's main functions of indication are as follows.
◆Indication of compressor
compressor's
s operating condition
The compressor's operating condition is indicated on
the screen, including running pressure, temperature,
current, loading condition, running hour,
running count, load hour and load count.
p of the loading
g function】
◆Emergency, Caution, and Maintenance Indications
In case of an emergency or caution, the screen shows
what happens and how to deal with it, in addition to its
causes.
Maintenance indication comes out on the screen
automatically when maintenance is required and also
shows when the next maintenance time comes by
indicating the elapsed time.

◆Graph Indication

Graph indication is a useful function to see the

compressor's operating condition.
Its indication mode has a function which shows both
the operating condition in real time and running
record. The indicated data consist of three factors:
discharge pressure, current, and loading rate.
◆Setup of compressor's operation setting
Set up the compressor's operation setting on this screen.

S t up the
Set th setting
tti off operation
ti moded and
d pressure on “ ◆Running Record Indication
Setup of Compressor Setting 1”.
The compressor's running record is indicated on this screen.
*About a driving mode(effective only Local mode)
【
【[auto】 】 ：Compressor
C /
is automatically start/stop.
【manual】：Any kind of load situation continues The latest running record is indicated every five seconds and
driving. every one hour.
（C i t t ti ll
※Pressure switch （○：Valid 　－： Invalid）
Pressure settings This function gathers the running data on a day-to-day
Control Remote load signal
for controller
and week-to-week basis, and indicates those data on a
Local/Remote L
Locall Remote
R t L
Local
l Remote
R t screen of Daily Report and Weekly Report.
Pressurre switch

AUTO ○ － － ○
LOC ○ ○ － － In case of an emergency
g y stop
p or caution,, the
emergency
REM － － ○ ○ and caution screen shows data gathered for twenty
Set up the setting of operation method interlocked with minutes after the occurrence. The data will be of use
a dryer
dryer, at an instantaneous stop or a power failure in analyzing why a trouble happens.
happens
and
economical operation on “Setup of Compressor Setting
2”. ◆Alternate operation of two compressors
This alternate operating function brings about choice
of a master unit or a slave one, rotation of a capacity
◆Setup of Weeklytimer control unit, and also setting of operating pressure Set
p
the compressor's g up
timer of starting p and stopping
pp g
Set the compressor's
compressor s timer of starting up and stopping
differentials between a master unit and a slave one.
on this screen.

There are seven patterns in the setting of date and time.

The setting of using a timer every day is also equipped here. ISSUE
KOBELCO COMPRESSORS (SHANGHAI) CORPORATION DRAWING No. 4V51ZS1002P1 01
 P19

EXTERNAL DIMENSIONS (XG 2140AV, 2540AV, 3030AV)

Air inlet
APPROX 2686

Controller

2000
RC1/2
RC1/4 Oil cooler oil exit
Motor oil filling Auto drain
RC1/2
∅100 50 RC1/4 After cooler oil exit

290
Power cable inlet 60 Manual drain
RC1/2
Oli saver oil exit

250

144.5
600 1400 30 30
2600 1056 900 200 750
4×φ24 2000 100 100 100
Front side Base hole
Right side
Back side

Oil separator tank Oli supply

Interior collocation Interior collocation

80 798
70

Compressor Air exhaust flange(single delivery)

4V19HS1001P1

Air outlet 8-∅18

∅200
A
1865

∅160
Oil separator tank Air feed R 23

∅100 A Maintenance space

Power cable inlet 1:10
(backup)
（Unit mm）
180

1614

Planform KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION 4V30ZS1014P1 01

 P20
FOUNDATION DRAWING
（XG 2140AV, 2540AV, 3030AV）

※ Sold separately

4-M20×2.5 Anchor bolt※ Compressor base plate

Effective thread 50

Foundation drawing

NOTE:
1、Foundation should to furished with steel rods.
2、Foundation required to be strong the weight.
3、Horizontal level should be ±1/100.

(UNIT: mm)

KOBELCO COMPRESSORS (SHANGHAI) CORPORATION 4V31ZS1012P1 01

 P21

SYSTEM DIAGRAM (XG2140AV, 2540AV，XG3030AV)

Air outlet

Water separtor D N 8 0 Flange

After cooler

T
Pd

Oil cooler

Cooling fan
Unload pressure preserve valve

Suction fifter

Purge valve

Suction regulating
valve
Load/unload
solenoid valve

Gear box Ts Ps pressure retaining valve

Expansion joint
Motor Safety valve
OL1 Tc Compressor Oil fifter Oil separator Po
splitter LG

Inverter
Td
Oil vapour splitter

Temperature regulating valve

Air inlet

MARK NAME
Po PRESSURE SENSOR (INSIDE OIL SEPARATOR）
COMPRESSED AIR
Pd PRESSURE SENSOR (DISCHARGE PRESSURE)
Td TEMPERATURE SENSOR (DISCHARGE)
Ts TEMPERATURE SENSOR (AFTER OIL SEPARATOR)
COOLING AIR
Tc TEMPERATURE SENSOR (MOTOR COIL)
OL1 OVERCURRENT RELAY (MAIN MOTOR) LUBRICATING OIL
V2 INVERTER FAULT (CONTAIN OVERCURRENT)
Si SUCTION INDICATOR
Ta TEMPERATURE SENSOR (AMBIENT) KOBELCO COMPRESSORS (SHANGHAI) CORPORATION 4V51ZS1051P1 02
 Ｐ２２

CONNECTION DIAGRAM （XG2140AV/WV,XG2540AV/WV,XG3030AV/WV)

Pressure sensor
（Air discharge pressure） Surround ing temperature sensor

Pressure sensor Temperature sensor (Main motor coil)

(After oil separator）
Discharge temperature sensor
Pressure sensor
(In
( oil separator
p ） OS temperature sensor

CT (Option)
X1 X2 V1

PW Y1A Y1B Y2 V2

Controller
COM3
SV1
R12
S10

Y5

XB

25

Radiating fan load/unlaod suction fifter pressure

solenoid valve switch

Motor coil temperature

sensor

Main inverter Main motor

Earth

（CUSTION'S WIRING） ISSUE
KOBELCO COMPRESSORS (SHANGHAI) CORPORATIONDRAWING No. 4V51ZS1029P1 03
 P23

WIRING DIAGRAM (XG2140AV/WV, 2540AV/WV，XG3030AV/WV)

ＡＣ４１５Ｖ／５０Ｈｚ
ＡＣ３８０Ｖ／５０Ｈｚ

Surge Protector

Reverse phase relay

Controller

Surrounding temperature
Oil fifter after pressure

Motor coil temperature

Oil recyle temperature
Discharge pressure
Oil recyle pressure
Circuit protector noise fifter

OS temperature
３８０Ｖ・４１５Ｖ／２２０Ｖ　５０Ｈｚ

controller controller

Suction fifter pressure di fference switch

Inverter

Water suspension relay

Fan motor overcurrent

only for water-cooled

Reverse-phase relay
Emergency stop
Fan motor starter

Used for dryer realy(backup)

Load/unload solenoid valve

controller

External emergency

Interated sensor
Main motor

Interated sensor
With sensor
With sensor
《Input signals to compressor》

With sensor

With sensor

With motor
・Remote・Run　 （Terminal X8-COM2 → Closed：Run）
・Remote・Stop　 （Terminal X9-COM2 → Open：Stop）
Controller
・Remote・Load　 （Terminal XA-COM2 → Closed：Load）

Discharge pressure
Oil fifter after pressure
Oil recyle pressure
《Output signals from compressor》

OS temperature
Oil recyle pressure
Surrounding temperature
・Emergency stop　（Terminal Y0 - COM6 → Closed：Emergency stop）
・Caution　　　　 （Terminal Y1 - COM6 → Closed：Caution）

Maintenance output

Remote running
Remote selection
Alarm output
Emergency stop
・Maintenance　　 （Terminal Y2 - COM6 → Closed：Maintenance）
・Remote　　　　 （Terminal Y3 - COM6 → Closed：Remote）

Remote stop

Remote start
Remote load
・Running　　　　 （Terminal Y4 - COM6 → Closed：Running）
（１）Input signals to the compressor should be no-voltage contact is close at start
User is open at stop User
input.Electric current of DC24V is supplied between the
COM2-XA, X8, X9 terminals from the controller side.
　 Voltage could damage the controller.
（２）The rated load to use the output signals from the compressor should be （４）The terminal X9-COM2 has been short-circuited at the factory. （５）If the panel lamp of the controller is blinking (100 consecutive
AC250V 2A or DC 30V 2A at maximum. Remove this terminal in the remote control mode. hours have passed since the Maintenance LED came on.)
（３）The terminal COM2, COM6, XA-X9 and Y0-Y4 for remoteness is prepared Remote (input signal to controller) should be input by one shot with the lamp, but continue to be sent.
　　　in the starting panel terminal block TB2. at 500 ms or more.
When you connect with the terminal block TB2, attach a surge killer shorter pulse signals may not be recognized.
*Any modification without prior permission of KOBE STEEL may
and set the line noise at less than 800V. 　 　 　 　 　 　 　 　 　 　
invalidate the warranty even within the warranty period.

KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION 4V51ZS1052P1 02

 Ｐ２４

Only by wiring for two units , automatic alternate operation can be carried out.
WIRING FOR AUTOMATIC OPERATION
（INV＋INV）
Compressor starts group control by switching over alternately between LOADING ・THE SETTING POINTS
PRESSURE and
UNLOADING PRESSURE. 　＜The example of a setting＞
Slave unit will be started automatically if pressure becomes lower than AUTO START
PRESSURE. XG-INV XG-INV
Master performs LOAD/UNLOAD control and if air consumption decreases and unloading Setup 1 OPERATION MODE AUTO Setup 1 OPERATION MODE AUTO

Wiring, setup and starting of a compressor are as follows. PRESSURE SWITCH LOC PRESSURE SWITCH LOC

１．Wiring of a compresso（The terminals within the starting boards of two compressor are wired mutually as follows.） UNLOADING PRESSURE 0.68 MPa UNLOADING PRESSURE 0.68 MPa

XG-INV XG-INV LOADING PRESSURE 0.63 MPa LOADING PRESSURE 0.63 MPa

Ｘ８ Ｙ３ KEEP PRESSURE 0.60 MPa KEEP PRESSURE 0.60 MPa

ＸＡ Ｙ４ AUTO START PRESSURE 0.55MPa AUTO START PRESSURE 0.55MPa

Ｙ３ Ｘ８ Setup 2 DRYER PREOPERATION OFF Setup 2 DRYER PREOPERATIO OFF

CONTINUOUS OPERATION CONTINUOUS OPERATION
Ｙ４ ＸＡ AT DRYER FAULT
ON
AT DRYER FAULT
ON

ＣＯＭ２ ＣＯＭ６ ECONOMICAL OPERATION OFF ECONOMICAL OPERATION OFF

ＣＯＭ６ ＣＯＭ２ ECONOMICAL CYCLE 30sec ECONOMICAL CYCLE 30sec

The above serves as signals only for automatic alternate operation, and it differs from the usual. Setup 3 GROUP CONTROL YES Setup 3 GROUP CONTROL YES

START SELECT MASTER START SELECT MASTER

２．SETTING OF A COMPRESSOR SLAVE DIFF PRESSURE 0.03 Mpa SLAVE DIFF PRESSURE 0.03 Mpa

The following setup is performed to two compressors respectively. INITIAL CHARGE 5 min. INITIAL CHARGE 5 min.

1) IIn th
the screen off COMPRESSOR SETTING
SETTING, while
hil setting
tti off [GROUP CONTROL] as [YES]
[YES], an ititem off
[START SELECT] also sets as [MASTER] for the compressor and as [SLAVE] for another. ◇ Within initial charging time, SLAVE may not carry out continuation starting after an automatic operation start.
2) It is confirmed that it is [Local mode]. (Local lamp: lighting) ◇ Please set SLAVE DIFF PRESSURE setting to 0.01MPa or more.
Note) It doesn't start in the Remote mode.
3) The pressure setting is changed. ● UNLOADING PRESSU-------

Please set SLAVE DIFF PRESSURE setting to 0.01MPa or more. SLAVE DIFF PRESSURE ↑
UNLOADING PRESSURE + SLAVE DIFF PRESSURE ≤THE HIGHEST DISCHARGE PRESSURE . -------- ● UNLOADING PRESSURE--------------------------------------- ○ LOAD / UNLOAD

3. STARTING OF A COMPRESSOR
3 　　 LOAD / UNLOAD ● LOADING PRESSURE -------
　 Automatic alternate operation starts by pushing the "Start" button of MASTER. SLAVE DIFF PRESSURE ↑
-------- ● LOADING PRESSURE --------------------------------------- ○
「The wiring for automatic operation」 （In case of MASTER） （In case of SLAVE）

-------- ● KEEP PRESSURE --------------------------------------- ● KEEP PRESSURE

M3 SCREW
COM6

COM6
CCOM2

CCOM2

-------- ● AUTO START PRESSUR --------------------------------------- ● AUTO START PRESSURE

XG
XG‐ XG
XG‐
COM2

COM2
COM6

COM6
Y3

Y3
Y4

Y4
XA

XA
X8

X8

Terminal Panel D

Model Terminal Panel Manufacture XG-INV XG-INV

Y4

Y4
Y3

Y3
XA

XA
X8

X8

XG D KOBE STEEL LTD

Please set the pressure sum of UNLOADING PRESSURE and SLAVE DIFF
PRESSURE
lower than the highest discharge pressure.

*There
There is no function which changes MASTER by a timer
timer. ISSUE
KOBELCO COMPRESSORS (SHANGHAI) CORPORATION DRAWING No. 4V51ZS1050P1 01