Operation and Maintenance Manual KES 55 S, KES 75, KES 90: Kirloskar Pneumatic Co. LTD., Pune

Kirloskar Pneumatic Co. Ltd.
, Pune
Operation and Maintenance Manual
KES 55 S, KES 75, KES 90

Kirloskar Pneumatic Co. Ltd., Pune
Operation and Maintenance Manual
For KES 55 S, KES 75, KES 90 Models
KIRLOSKAR PNEUMATIC COMPANY LTD.,

PUNE – 411 013 INDIA
Document Number: S270.113- 121. D98
Revision Status: R01
Date: JULY. 2011
Replaces,
Document Number: S270.113- 121. D98
Price: INR 1000
Contact Information:
Head of Servicing Department

KIRLOSKAR PNEUMATIC COMPANY LTD.,
HADAPSAR INDUSTRIAL ESTATE
PUNE – 411 013 INDIA
Phone : 91 – 20 26870133/26870341
Fax : 91 – 20 26870297 / 26870634
e-mail : acdser@kpcl.net and acdmktg@kpcl.net
Toll free Number : 1800 301 00009 (directly accessible from all networks)
MACHINE IDENTIFICATION AND SALE RECORD
Owner’s name: ___________________________________
Address:___________________________________
Compressor Model:___________________________________
Compressor Serial Number:____________________________________
Year of Manufacture:____________________________________
Main motor make:____________________________________
Main motor Serial Number:____________________________________
Motor Rating: ___________kW @ ____________ Rev/min
Compressor Capacity:____________m3/min @ ___________ bar g
Date of delivery:_____________________________________
Date of Commissioning:_____________________________________
Dealer Name / Code:_____________________________________
Dealer signature / stamp:
NOTE: Always indicate Compressor Serial Number given above while communicating with
KPCL dealer / Service Centre/ Branch office regarding your compressor. The warranty on this
compressor is valid only if the dealer signs and stamps on the warranty card supplied along
with the compressor.
Message from the Managing Director

Dear Customer,
We welcome you to the family of users of Electric Screw

Air Compressors from KPCL, one of the largest
manufacturers of AIR and GAS compressors in India.
Kirloskar Pneumatic products would always give you
Value for money for years to come! We are sure that you
will be proud of its performance.
At Kirloskar, listening to the user & customer and meeting

his/her needs is a tradition as old as the group itself. For it
is they who drive us further, make us reach higher, and
engineer better solutions.
KPCL has designed your compressor to be safe, best in

performance, reliable, user friendly and easy to maintain.
To ensure a long and trouble free life of your machine,
give it proper care and maintenance as described in this
manual.
KPCL is honored to be the choice for all your compressed

air needs. We look forward to your continued satisfaction
as KPCL compressor user.
About Kirloskar Pneumatic Company
Kirloskar Pneumatic Company Ltd, a flagship company in Kirloskar

group is an ISO 9001 company. KPCL has grown over the past 50
years by serving the customers with all types of air and gas
compressors. The multi-product company has transformed with
innovative products and processes to meet the innovative demands
and applications as well as the challenges of globalization. KPCL is
Asia’s largest air compressor manufacturing company with products
ranging from 3 HP to 2MW power capacity. The company has a strong
presence in the global market with customers in more than 40
countries and partners from more than 10 countries.
KPCL operates from Pune factory with state of the art facilities for
Research & Development, Manufacturing, Metrology and other
Business processes. KPCL’s dedication in serving the customers
through its network of branch offices, dealers, distributors, service
providers and web based customer care system has earned excellent
reputation to the company and valuable customers and partners.
Driven by the Kirloskar Group philosophy of “Enriching Lives”,

KPCL believes service to customers & society through partnership with
its customers and partners worldwide guided by values, innovation,
technology and consistency in business processes.
TABLE OF CONTENTS
Section 1 USER INFORMATION Page No.
1.1 General 1
1.2 Warranty 2
1.3 ISO Symbols 3-4
1.4 Receiving the Compressor 5
1.5 Lifting the Compressor 6-8
1.6 General Installation Guidelines 9
1.7 Installation requirements 10-14
Section 2 SAFETY 15
Section 3 DOs and DON’Ts 16
Section 4 COMMISSIONING
4.1 General 17
4.2 Points to be observed before Initial Start 17
4.3 Commissioning the compressor 18-19
Section 5 TECHNICAL SPECIFICATIONS AND SALIENT FEATURES
5.1 Technical Specifications 20-22
5.2 Salient Features 23-27
Section 6 SYSTEM OPERATION 28-29
Section 7 MAINTENANCE
7.1 General 30
7.2 Maintenance Schedule 30
7.3 List of Consumables and Spare parts 31-32
Section 8 DETAILS OF SUB-ASSEMBLIES
8.1 Air Intake System 33-34
8.2 Drive System 35-36
8.3 Discharge System 37-38
8.4 Air-oil Separator Assembly 39-40
8.5 Cooling System 41-42
8.6 Lubrication System 43-44
8.7 Capacity Control System 45
8.8 Electrical System 46-47
8.9 Structure assembly 48-49
8.10 Intake Valve Assembly 50

8.11 Minimum Pressure Valve Assembly 51
8.12 Oil Filter Assembly 52
8.13 Moisture Separator 52
Section 9 MICROCONTROLLER 53-60
Section 10 SAFETY AND INTERLOCK FEATURES 61
Section 11 TROUBLE SHOOTING 62-64
1. USER INFORMATION
1.1 GENERAL
The contents in this Manual are proprietary and confidential to Kirloskar

Pneumatic Company Ltd and should not be reproduced without prior written
permission of Kirloskar Pneumatic Company Ltd.
The abbreviation KPCL used in this Manual means Kirloskar Pneumatic

Company Ltd, Hadapsar Industrial Estate, Pune - 411013.
This Manual contains instructions and technical data to cover all routine
operation and Scheduled maintenance tasks by operation and maintenance
staff. Major overhauls are outside the scope of this manual and should be
referred to an authorized KPCL Service department.
All components, accessories, pipes and connectors added to the compressed

air system should be:
• Of good quality, procured from a reputable manufacturer and, wherever

possible, be of a type approved by KPCL.
• Clearly rated for a pressure at least equal to the machine maximum
allowable working pressure.
• Compatible with the compressor lubricant/coolant.
• Accompanied with instructions for safe installation, operation and
maintenance.
The use of repair parts / lubricants / fluids other than those included within the
KPCL approved parts list may create hazardous conditions over which KPCL
has no control. Therefore KPCL cannot be held responsible for equipment in
which non–approved repair parts are installed.
KPCL reserves the right to make changes and improvements to products

without notice and without incurring any obligation to make such changes or
add such improvements to products sold previously.
1
1.2 WARRANTY
The warranty applicable for the compressor purchased by you is given in
the Warranty Certificate sent along with the Compressor. Preserve it to get
warranty service from KPCL dealer/KPCL.
KPCL does not accept any liability for damages in transit and during handling in
transport. Inspect the physical conditions of the compressor on receipt and get the
transporter’s confirmation regarding the damages on receipt on the transporter
invoice to claim the insurance.
Any other complaint should be informed to the authorized dealer of KPCL or KPCL
branch or KPCL registered office, Pune in writing within 6 days from the receipt of
complaint. Preserve the Warranty Certificate sent along with the compressor.
KPCL will not accept the warranty for any problems/damages arising out of failures
to observe the conditions given in this Manual, alterations done on the compressor
without getting written permission from KPCL, improper repairs, insufficient
maintenance and use of spare parts other than KPCL make and supplies.
KPCL reserves the right for modifications without notice in the interest of
technology progress.
2
1.3 ISO SYMBOLS
3
4
1.4 RECEIVING THE COMPRESSOR
On receipt of the compressor with packing case, the condition of the packing case
has to be checked immediately for any damages. In case of damages, the proof of
condition has to be obtained from the transporter on the transporter invoice and
then the details are to be reported to insurance authorities (if transit insurance is
done) and also to KPCL dealer / KPCL.
The condition of the compressor inside the packing case also has to be verified by
unpacking the case (except the base of the packing case). In case of damages,
follow the instructions given above.
The contents are to be verified with the packing list received with the invoice /
delivery note. Written complaint to be given to KPCL dealer / KPCL immediately, if
any item is found missing w.r.to packing list. Following items are sent with
Standard Compressor without spares /accessories:
1) One No. Key for the canopy doors
2) One no. Operation and Maintenance manual
The condition of compressor parts also to be checked by opening the canopy

doors. If any parts are missing, contact KPCL dealer / KPCL immediately.
Now the compressor has to be kept in covered condition till the site is ready for
installing the compressor. Even during this temporary storage, ensure the
compressor is kept on a raised place and covered to protect it from rain / water
logging.
5
1.5 LIFTING THE COMPRESSOR
KPCL air compressors are shipped in wooden packing cases. Refer the
figures given below to lift the compressor with overhead crane or forklift. Wooden
frame shall to be used to keep the ropes away from the canopy while lifting the
compressor with overhead crane. Soft pad / wooden panel shall be used between
canopy and forklift arm to avoid damages to canopy while lifting the compressor
using forklift.
Prior to lifting, remove the red color brackets on the base frame; inspect the
bails, ropes and support frame for their capacity and condition to suit the
weight of the compressor.
Ensure lifting hook is with functional safety latch or equivalent and is fully
engaged.
Use guide ropes or an equivalent supports to avoid the lifted unit is swinging
in air.
Do not lift the compressor in open area with high wind speed.
Ensure all the personnel are out under the compressor when suspended.
Ensure the lift operator is kept under constant observation when
compressor is suspended.
Ensure the compressor is not lifted beyond the requirement of clearance
from floor.
Check the unit is firmly sitting on the forks when forklift is used for lifting.
Ensure the compressor is slightly tilted towards forklift by tilting the forks to
avoid slipping during movement.
Ensure the compressor is resting on forklift vertical beams with pad kept
between.
Ensure the speed of the forklift / crane does not cross 5 km/hr speed.
In case of shifting the compressor to site without forklift / overhead crane,
use pipes or cylindrical rods under the compressor with wooden base of
packing case.
Use tripods with adequate capacity chain & pulley blocks to lift the
compressor from the wooden base after removing the red color brackets
fitted on base frame to hold the compressor firmly.
6
7
8
1.6 GENERAL INSTALLATION GUIDELINES

Observe the following conditions while installing the compressor:
Adhere Accident Prevention Regulations
Adequate accessibility around the compressor as in fig below
Area around the compressor/ compressor room is dry and clean
Temperature around the compressor is with +5 to +45 degC
Adequate opening for air intake and hot air exhaust
10 m radius from compressors is free from combustible materials
Fire extinguisher kept in reachable position near the compressor
Quantity of hot air to be ventilated for KES55S to KES90 models is 9182 cfm (260
m3/min). The open area around the compressor has to be kept free for operating
& maintenance personnel movement for performing the routine checks and
maintenance activities.
9
1.7 INSTALLATION REQUIREMENTS

Site preparation: The compressor does not need any special foundation or
grouting. Normal shop floor suitable for installing metal cutting machines is
sufficient. The surface of installation area should be with minimum variation to
avoid non-uniform seating of the compressor base frame. Use shims to ensure the
base frame seating on floor at all corners to avoid vibrations during running. The
compressor suction side has to be positioned towards the open area or opening on
the wall to ensure fresh atmospheric air entry to the compressor. Exhaust fan /
ducting has to be installed to avoid the hot air recirculation and increase in
temperature in the compressor. Refer the figures given on the previous page and
the following page for general guidance. The exhaust fan sizing has to be done
such that the air velocity does not exceed 5 m/sec. Installation of higher capacity
fan may result in capacity problem in the compressor. The compressor positioning
also to be such that the hot air from other compressors or equipments is not
diverted to the compressor to be installed.
Failure to observe the instructions regarding installation and ventilation will
result in increase in discharge temperature which in-turn result in frequent
tripping and pre-matured failure of parts.
Mechanical connections: The compressor is provided with 3 outlet points on

the canopy for Compressed air outlet, auto drain line from moisture separator and
manual drain from moisture separator. The moisture draining from the compressor
will have the traces of oil. Ensure the moisture drainpipe line is connected to the
central drain line with ball valves and conditions as per the local statutory
regulations for wastewater disposal. The compressor air outlet line has to be
connected to Air Receiver after installing Non-Return Valve after the ball valve on
compressor air outlet point. KPCL dealer / KPCL shall be contacted for the details
on the Air Receiver size. Ensure the air pipeline is with adequate size to avoid
pressure drops and with adequate water traps.
Electrical connections: The compressor is provided with opening on the

base frame and at the electrical panel bottom plate for power supply cable entry.
The incoming power supply line must be through a switchboard with fuses. Fuse
ratings applicable for 415 V, 50Hz, 3 Phase power supply and recommended cable
size are given in the table on next page:
10
Model Backup fuse Recommended cable size

rating
Copper cable Aluminium cable
KES 55S 160 Amps 3.5 core, 50 sq.mm 3.5 core, 95 sq.mm
KES 75 200 Amps 3.5 core, 70 sq.mm 3.5 core, 120 sq.mm
KES 90 250 Amps 3.5 core, 95 sq.mm 3.5 core, 150 sq.mm
Connect the earth line to the threaded hole next to the cable entry hole.
Follow the electrical safety norms as per local statutory regulations and electrical
standards for the safety of operating personnel and the compressor.
Refer the illustrations and drawings on the following pages for installation.
11
A --Room ventilation through the opening in the wall
B, C -- Room ventilation with exhaust system
D -- Hot air duct from compressor E -- Ducting for room heating
Refer the illustrations given above for installing the air-cooled compressor.
Best installation is with hot air exhaust duct from compressor to atmosphere and
air inlet side is kept directly inline with the air intake opening from the atmosphere.
12
Electric Circuit Diagram for KES-55S, KES-75, KES-90
13
General Arrangement Drawing for KES-55S, KES-75, KES-90

COPPER CABLE ALUMINIUM CABLE
A
⌧
HOT AIR EXHAUST
⇑ ⇑ ⇑
14
VIEW FROM A DETAILS FOR

HOT EXHAUST AIR DUCTING
2.0 SAFETY
The compressors designed and manufactured by KPCL are for safe operation at
the designated conditions. The safe operation of the compressor lies with the
personnel operating and maintaining it. Hence, those who are trained and
understood this OPERATION AND MAINTENANCE MANUAL only shall operate
the compressor.
Never start the compressor when it is not safe to do so. Never operate the
compressor with known unsafe conditions. When the compressor is unsafe, tag
the unit to indicate to other and disconnect the power supply either by removing
the fuses or removing the power wire connections to avoid accidents.
This air compressor is not explosion proof and hence it has to be installed away
from the explosion area. Do not use the air from this compressor for direct contact
with food & medicine substances and do not use for breathing purpose.
Do not modify the compressor without getting the written permission from KPCL.
Pressure release: The compressor is provided with pressure relief valve to

release the pressure from the air-oil separator tank incase of pressure exceeds the
set values and electrical interlocks fail. Do not open the valves / air lines / air-oil
separator tank connections or plugs without releasing the pressure by using the
pressure relief valve (safety valve).
Fire or Explosion: Install fire extinguishers near the compressor. Do not store
inflammable materials near the compressor. Keep the compressor clean from oil
spills to ensure safety to operating personnel and equipment.
Hot Surfaces: Do not handle/touch the hot surfaces on the compressor without
using proper protection & handling devices. Avoid body contact with hot surfaces,
oil and air.
Electrical safety: Ensure electrical safety standards are adhered for the safe
operation of the compressor and personnel. Do not store materials inside the
electrical panel even though free space is available. Attempt repairs after removing
the fuses in the incoming power supply lines and keep notice near the fuse box to
avoid accidental connections.
Waste disposal: Follow the local safety standards for disposing the used oil, filters
and other used parts of the compressor to protect the environment.
DANGER
Death or serious injury may result from inhaling compressed air without using proper
safety equipment.
15
3.0 DOs and DON’Ts
DOs
Operating personnel read this manual thoroughly and follow instructions

Clean the Compressor regularly
Check the air filter condition regularly and replace in time
Maintain correct oil level
Use genuine parts from KPCL only
Use proper tools for operation and maintenance
Attend immediately to anything unusual in the compressor
DON’Ts
Neglect the routine maintenance
Allow the leakages in the system
Clean the air filter with pressurized air
Change the settings on compressor parts
Use cleaning agents while changing the oil other than recommended
Keep tools & other material on compressor
Leave loose the free end of air line hoses
Use the air for breathing
Use the air for direct contact with food products without recommended filters
16
4.0 COMMISSIONING
4.1 GENERAL
The instructions given in this Manual is for a Standard Air Compressor without
additional equipment. Check for the visual damages after completing the
installation has to be done. Each compressor is supplied with electrical circuit
diagram -pasted inside the electrical panel. Check the condition of the parts and
connections. Each compressor is subjected to test run before dispatch. There are
chances of settings get disturbed during transport or installation Verification of
firmness of all connections has to be done after installing compressor at site. The
commissioning of the compressor has to be done by the KPCL dealer only after
the installation and connections are done.
4.2 POINTS TO BE OBSERVED BEFORE INITIAL START
Remove all supports / brackets painted in red color used for support during
transit.
Ensure the airline connections from compressor to air network are done without
gaps or loose bolts.
Ensure the electrical connections are firm and correct as per recommendations.
Ensure the moisture drain lines are connected and auto drain line ball valve is
kept open.
Ensure the oil drain ball valve on Air-oil separator tank is closed and fitted with a
threaded plug at open end of the valve.
Remove the air filter and pour 2 ltrs. of recommended oil inside the intake valve
by pressing the tappet plate. This is to ensure the lubrication oil is present inside
the airend at the time of starting.
Check and ensure the oil level in the Air-oil Separator tank of the compressor is
filled to middle level of the sight glass fitted on tank. Use the Servo system
HLP68 only. Though oil fill capacity is 40 litres, actual fill may be low since other
points in the oil line are may not be filled. Further oil fill-up to be done during the
commissioning process. Fix threaded plug at pour point and tighten it fully.
Ensure the air filter is firmly fitted on the intake valve with the clamp.
Ensure the electrical connections are done as per circuit.
Ensure the power supply line is with adequate capacity for the compressor with
Wye-delta (Star –delta) starting system for the main motor.
Ensure the ball valve on air outlet line is kept open.
If the compressor was stored for more than 3 months from the date of
manufacturing, the KPCL dealer has to be informed to do additional checks to
confirm all the moving parts like motors, airend, valves etc and critical parts are
in good conditions.
Ensure the motors are with stickers on fan cover or body to indicate direction of
rotation.
17
4.3 COMMISIONING THE COMPRESSOR
Switch ON the main power supply and confirm “Healthy” LED is glowing on the
microcontroller after displaying Date & Time and Welcome message.
Press key on the microcontroller to confirm the display “PT-1 DIS. AIR PR” is
00.0. This display to indicate the air pressure at compressor outlet.
Press again to get the display “PT-2 BEF. OIL PR” with value 00.0 to confirm
no pressure in the Air oil separator tank.
Remove the canopy door below the electrical panel to view the motor.
Press Start button (green color) on the microcontroller to make the main motor ON.
If motor is energized, switch off the compressor by pressing Off button (red color)
on microcontroller. Check and confirm the direction of the rotation is in line with the
direction arrow mark sticker pasted on the fan cover. If the direction of rotation is
wrong, check the main power supply lines and correct them. If the direction of
rotation is correct, fit the canopy cover in position.
Close the ball valve at the compressor air outlet line.
Switch ON the compressor and confirm, “Comp. ON” LED is ON. Now the
compressor will get loaded with “Load” LED in ON condition.
Run the compressor for ONE minute and switch OFF to make the oil in the oil lines
to flow back to the tank.
Check and ensure the display for PT-2 is 00.0 when the compressor is in OFF
condition. This is to ensure there is no pressurized air in air-oil separator tank
when compressor is in OFF condition after Blow-off valve releases the air from
tank.
Check the oil level on the sight glass after 5 mins. Add oil till the level reaches to
middle level of the sight glass.
Ensure the threaded plug provided on oil pour point is tightened fully.
The compressor will go to “Unload” mode once the pressure reaches maximum
pressure/unload pressure. This is when “PT-1 DIS AIR PR” display is unloading
pressure value of the model. When the compressor is in Unload mode, the “Load”
LED will go OFF.
Open the canopy panels and confirm no air and oil leakages during this run at the
joints/fittings.
Open the ball valve slowly till the pressure PT-1 value on microcontroller display is
the working pressure of the model.
Run the compressor on load to confirm the fan motor is getting switched ON and
OFF based on the oil temperature required for the satisfactory performance of
compressor. The settings for making the fan motor ON/OFF is already done in the
microcontroller program.
Run the compressor and record the values from the microcontroller display by
pressing button.
Refer the specifications given in Section 5 of this Manual for each model to confirm
the compressor performance is within the limits.
18
Ensure the temperature inside the compressor room is not more than 5 degC
above the temperature outside the room during the continuous run.
Refer Trouble –shooting guide given in this manual for any abnormalities found.
Report to KPCL, if problem persists after applying remedial actions given in the
trouble-shooting guide.
- Control . . . µ-control
SR. NO.-
D1 D2 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
P N
COM.
COM.
M O DIFIED E
NO
NO
0V OUT
NO
COM.
12V OUT
NOT USED
COMP. MOTOR O/L
START LOAD FAN
RELAY RELAY
REMOTE START
RELAY
COMMON
RTD WHITE
RTD WHITE
FAN O/L
SPP/ RVP
PRES.T.-II
RTD RED
E. STOP
PRES.T.-I
OFF
ON
C1 C2 C3 C4 C5 C6 A1 A2 A3 A4 A5
12 34
Healthy Manual Comp. ON
Faulty Remote Load DIP
Front View of Microcontroller Back View of Microcontroller
19
5.0 SPECIFICATIONS & SALIENT FEATURES

5.1 TECHNICAL SPECIFICATIONS
Sl.No.
Description Unit Data
1 Models KES-55S-8 KES-55S-9 KES-55S-10.5 KES-55S-13.5
cfm 383 358 320 276
2 Free Air Delivery
3
m /min 10.85 10.14 9.06 7.82
3 Operating Pressure bar g 7.0 8.0 9.5 12.5
4 Maximum / Unloading Pressure bar g 7.5 8.5 10.0 13.0
5 Cut-in / Reloading Pressure bar g 6.5 7.5 9.0 12.0
6 Min. Operating Pressure / MPVL opening Pr. bar g 4.0 4.0 4.0 4.0
7 Power supply conditions 415V +/- 10%, 50Hz +/- 5%, 3 Phase
8 Capacity Control system MODULATION FOR 100% TO 60%
9 Main motor rating kW(HP) 55 kW with SF 1.15
degC &
10 Operating conditions - ambient & altitude + 5 to +45 degC & 1000 m Altitude
metres
11 Fan motor rating kW(HP) 1.1
12 Type of motors (Main & Fan drive) Squirrel Cage Induction
13 Insulation & protection of motors Class F & TEFC (IP55)
14 Rated speed of main motor RPM 1485 RPM
15 Rated speed of fan motor RPM 940 RPM
16 Frame size & mounting type of main motors STD 250M
17 Frame size & mounting type of fan motor YS-2200-6
18 Efficiency of main motor at full load 94.2
19 Efficiency of fan motor at full load 76.4
20 Over load relay setting for main motor Amps 67
21 Over load relay setting for fan motor Amps 2.3
22 Type of starter for main motor STAR-DELTA STARTER
23 Type of starter for Fan motor DOL STARTER
24 Type of coupling & size/model Flexible, RB 0.12 Poona coupling
25 Oil fill capacity litres 40 ltrs.
26 Discharge Temparature ( at air end outlet ) degC Ambient+55
27 Max. allowable air temparature at outlet degC Ambient+10
Inch&
28 Air outlet port size & Qty. 2" BSP, 1 NO.
Nos.
Sound Pressure Level of the Compressor @
29 75 +/-3
1 metre distance dB(A)
30 Overall dimensions of the unit, L x B x H mm 2235 x 1115 x 1740
31 Weight of unit with out oil Kgs ???
32 Reference standard for FAD and SPC ISO 1217: 1996 Annexure C
Reference standard for Sound Pressure
33
Level Cagi Pnuerop PN8NTC2.2
20
Sl.No.
1 Models KES-75-8 KES-75-9 KES-75-10.5 KES-75-13.5
cfm 534 465 435 375
2 Free Air Delivery
3
m /min 15.12 13.17 12.32 10.62
degC &
metres
11 Fan motor rating kW(HP) 3 kW
16 Frame size & mounting type of main motors 280S
18 Efficiency of main motor at full load 93.8
20 Over load relay setting for main motor Amps 89
26 Discharge Temparature ( at air end outlet ) degC Ambient+55
Inch&
Nos.
29 75 +/-3
33 Reference standard for Sound Pressure Level Cagi Pnuerop PN8NTC2.2
21
Sl.No.
1 Models KES-90-8 KES-90-9 KES-90-10.5 KES-90-13.5
cfm 600 543 530 427
2 Free Air Delivery
3
m /min 16.99 15.38 15.01 12.09
degC &
metres
11 Fan motor rating kW(HP) 3 kW
16 Frame size & mounting type of main motors 280M
18 Efficiency of main motor at full load 94
Over load relay setting for main motor @
20 107
415V Amps
26 Airend Discharge Temparature degC Ambient+55
Inch&
Nos.
29 75 +/-3
33 Reference standard for Sound Pressure Level Cagi Pnuerop PN8NTC2.2
22
5.2 SALIENT FEATURES
Best Performance: The combination of energy efficient airend driven by efficient

motor along with control system and optimally designed accessories makes the
whole system to perform at the best possible efficiency to deliver most economical
compressor air.
Air Quality: The cyclone separation system optimized over the years of research
and tests along with the best quality coalescent type oil mist separation filter
element ensure efficient separation of oil particles from the compressed air with
minimum pressure drop. This optimally designed system ensures consistent
quality of air is delivered during all modes operating cycles.
Safety systems: The compressor is provided with multiple safety systems and
elements to protect the equipment and operating personnel. The software logic
built in the microcontroller, temperature sensor, overload relay, single-phase
preventor, Reverse rotation protection, alarm messages and safety valve provided
ensures the unit runs with adequate protections.
Pulsation – free airflow: The helical fluted rotors in the airend with optimum
Length to Diameter ratio of rotors ensures pulsation free flow of compressed air.
This gives a great advantage of getting continuous flow of air.
High Reliability: The airend with only rotating parts mounted on oil lubricated
rolling bearings and minimum number of best quality moving parts is air
compression system ensures the system operates trouble-free for longer period of
time.
Low operating costs: With rotating parts of the airend, Engine and all moving
parts well lubricated, amply sized consumables of the compressor, best suitable oil
and low operating temperature of the entire system ensures the operating costs
are much lower than conventional compressors.
Airend: This is the main component of the compressor package called as Airend.
Free atmospheric air is being compressed during the rotation of optimally designed
twin helical screws in the airend. The air end is coupled directly to the electric
motor through a set of gears. Both air-end & motor is mounted an anti vibration
pads placed on the base frame. With this arrangement we ensure less vibrations
and longer life of the compressor.
High efficiency air-end and reliable arrangement for transmission of power makes
the compressor energy efficient and reliable performance machine.
23
Electric Motor: This is flange mounting, 2 Pole, TEFC, IP 55 protection, Class F

insulation motor designed with necessary starting torque and operational load
variations. Motor is suitable for above-mentioned voltage and frequency variations.
Make of the motor is as per KPC standard.
Air Intake: Trouble free operation of this close tolerance, screw type compressor
is achieved by suction air filtration system. It is with Dry, Paper type filter element
in cartridge form for easy replacement. Complete filter assembly is within canopy
of the compressor, which avoids entry of heavy particles in the compressor.
Lubrication: Lubrication of the air-end gives duel advantage. It removes heat of

compression & lubricates screw, bearings & gears. ISO VG68 grade oil is used for
this purpose. Pressurized, cool & filtered oil is injected in the air-end and comes
out of the compressor from discharge of the air end along with compressed air.
Positive oil pressure is ensured in air/oil separator tank. Hence we do not require
any separate oil pump.
Lube oil Filtration: Spin-on type oil filter is used to filter Lube oil before injecting
to the airend. This enhances long life of the compressor and reliable operation.
Air/Oil Separation: Compressed air and lube oil is separated in a multistage air/oil
separator tank. The separator also acts as an oil reservoir. High efficient air/oil
separator element, limits oil carryover to desired level in the delivered air from
compressor package.
Lube oil Cooling: Temperature of the compressor system is maintained within

limits by cooling oil in radiator type air-cooled oil cooler. Temperature of the oil is
monitored through the temperature switch fitted in the oil line to make the fan
motor ON/OFF through the microcontroller so as to ensure uniform oil temperature
irrespective of the ambient temperature.
After Cooling: High-pressure discharge air is cooled in radiator type air-cooled

after-cooler. The condensation happens due to cooling of air & separates out in
the Moisture separator. We provide Auto drain trap to remove water form the
system.
Canopy & Base Frame: All components of the compressor package are mounted
on a single base frame. It does not require any foundation. The complete
package can be shifted with forklift or hydraulic lift trolleys by using the provision
given in the base frame.
Powder Coated Metallic Canopy of the compressor is of modular design. It is
acoustically designed to limit sound pressure level of the package to 75 dB (A) at a
distance of one meter. The noise measurement is as per Pneurop / Cagi
PN8NTC2 standard. Easily removable doors with locks are provided for easy
24
accessibility to internal components. Air outlet line is terminated outside of the

canopy for easy connection to the air network. Opening in the base frame is given
for inserting electrical power supply line from Main supply panel without making
any cutouts in the canopy or base frame.
Capacity Control: Modulation & Load/Unload capacity control is provided which

functions as per demand conditions. Power saving and optimum utilization of
compressor package is achieved due to this type of capacity control.
Safety Devices: Following mechanical safety devices are provided to ensure safe
operation of the compressor
Minimum Pressure Valve - Maintains minimum air pressure in air-oil separator tank
so that positive oil flow is ensured.
Safety Relief Valve - De-pressurize compressor system if pressure exceeds

beyond limits of the system
Blow Down Valve - Ensures proper pressure relief arrangement during the
unload condition of the compressor
Oil Level indicator - This is mounted on air/oil separator tank. It gives visual
indication of minimum & maximum level of oil present
in compressor system
Control Panel: This is auto star-delta starter cum microprocessor based control
panel packaged on the same base frame within canopy of the compressor. Panel
is wired and hooked up with main motor and all instruments with in the package.
The display of various operating parameters and setting is done on a man machine
interface (MMI) - microcontroller installed on easily accessible height on canopy
front part.
Display on MMI (microcontroller)

Delivery air pressure
Air/oil Temperature
Differential pressure across air/oil separator
Hour meter
Total running hours
Total loaded hours
Start/stop, load/unload, Emergency stop & test conditions
Reason for trip
25
Maintenance schedule (No. of Hours indication)

Replace Air Filter Element
Replace Oil Filter Element
Replace Air/Oil Separator Element
Start Up Checks
Routine Maintenance checks
Change of Lube oil
Electrical circuit diagram sticker is pasted inside the Electrical panel for ready
reference during wiring or trouble-shooting.
Safety & Control: Following Trip signals are provided to protect the machine from
abnormal operating conditions:
High air-oil mixture temperature

PT1 Pressure Transmitter fault (for air pr. at Compressor Outlet)
PT2 Pressure Transmitter fault (for air-oil at airend outlet)
RTD Temperature Sensor fault (for oil temp. at airend outlet)
Main motor over load
Fan motor overload
SPP/RVP fault (Single phase /Reverse rotation)
26
Schematic Flow Diagram of the Air Compressor
27
6.0 SYSTEM OPERATION
The Air Intake Valve provided is normally closed type. As the supply to the motor is
started on, due to the vacuum created in the compressor inlet port air enters in the
bare compressor from suction filter & small hole provided on Intake valve flap. The
compressed air is delivered to Air/oil separator. The pressure in Air/Oil separator
starts rising. This air pressure signal passes through the closed type solenoid
Valve & stops there. So intake valve remains closed. Thus compressor is in
unloaded condition. This ensures that the starting torque required is less thereby
limiting the starting current of the motor. Also the motor is started in star
connection. After a set time the starter connects the motor in delta connection &
compressor runs smoothly in unloaded condition. After a set delay time, the
Solenoid Valve is energized & it gets opened. This allows air to go air intake valve
servo cylinder & venting valve port, which will move the servo cylinder piston &
closes the venting valve. With this the Air Intake Valve is immediately get open &
compressor comes on load. It takes few seconds for the compressor to come on
load depending on the motor rating. The moment the pressure rises in the Air Oil
Separator tank, the oil flow to compressor is started, irrespective of whether the
compressor is in loaded or unloaded condition.
Air / oil separator separates the oil from air/oil mixture down to 1 to 3 PPM by
mechanical as well as with the help of air-oil separator element as described
earlier. The minimum pressure valve starts opening at a pressure of 3.5 kg/cm²
(full open at 4.0 kg/cm2). The compressed air from receiver then passes through
the after-cooler part of the combi-cooler where it is cooled with air of fan driven by
motor. An efficient moisture separator then separates the condensed moisture in
the compressed & cooled air. The separated moisture is drained by mechanical
auto-drain valve of the Moisture Separator. Pressurized air is now available at the
air delivery valve for user’s network.
When the demand for air decreases, pressure builds up in the system.
Proportional controller will senses the pressure & starts reducing outlet pressure.
This will intern start-reducing pressure at Intake valve servo cylinder & it will move
in reverse direction depending on proportional controller outlet pressure. With this
Intake valve flap will also starts closing & will ensure that air intake is less. Due to
less intake of air, power consumption will be less. This will operate up to the 60%
demand of airflow. Still if demand of air decrease or here is no demand of air,
pressure at compressor outlet starts rising. The pressure transmitter connected
after the Moisture Separator senses this pressure. When the system pressure in
the system increases beyond a set value, an electric signal is given to the Solenoid
Valve & it is de-energized. This will closes pressure signal line from receiver
connected to the Air Intake Valve servo cylinder. And the compressor is
immediately unloaded. At the same the pressure signal from receiver through the
28
Solenoid Valve is also given on the top of venting valve. The BDV is normally
open type. The pressure signal at top opens it & receiver is connected to the
suction side of the compressor. The AOS tank pressure is maintained to 1-1/2
Kg/cm^2g thru orifice during unloading. This not only ensures that the power
consumption during unloading is minimum & but also sufficient oil flow is
maintained during unloading.
Whenever the compressor stops, the Solenoid Valve de-energizes first to make
compressor unload & Air Intake Valve closes, which ensures that there is no oil
back flow from compressor to air filter. Venting valve gets opened due to pressure
signal at its top from Solenoid Valve. The air receiver gets connected to the
atmospheric pressure through venting valve to just after the Air suction filter &
pressure in the receiver is relived totally. This ensures that when the compressor is
started again, there is no pressure in the receiver.
The heat of compression is absorbed by oil besides sealing the rotor gaps and
lubricating the moving parts including bearings. The oil that is separated in Air/Oil
separator is collected in oil tank portion in Air/Oil separator. Due to the pressure
differential the oil starts flowing from AOS tank and is passed through oil cooler
part of the compact combi-cooler, where it is cooled by air of Fan & Motor. Further
it is filtered in oil filter and supplied to compressor.
If the oil is overcooled, the moisture in the air condenses and condensed water
mixes with the oil. This affects the performance and life of oil. Compressor
performance & life also gets affected. To avoid this overcooling a cooler fan is
made on & off depending on the temperature thru. Microcontroller. This switches
off the cooling fan if the oil temperature falls below a set value & switches on if oil
temperature rises over set value.
29
7.0 MAINTENANCE
7.1 GENERAL
Before carrying-out any maintenance activity, stop the compressor and wait for 1
minute for all the rotating parts to stop and air from the Air-oil separator tank is
relieved by Blow-off valve. Use proper tools during maintenance to avoid damage
to compressor parts. Ensure this Manual is read and understood. KPCL dealer /
KPCL servicing department shall be contacted to clarify the doubts and assist.
7.2 MAINTENANCE SCHEDULE
Period Activity Part / Part Number

Daily – Check oil level in Air-oil separator tank Sight glass
before Drain the moisture with manual drain valve Ball valve on canopy
starting Check air filter condition
Daily – after Check pressure & temp. reading during running Microcontroller
starting Check moisture drain through auto drain Drain line
After first Change oil Servo system HLP68
100 hrs of Change Oil Filter Element 274.01.459.50
running
After every Change Oil Filter Element 274.01.459.50
1000 hrs of Change oil Servo system HLP68
running Clean the cooler assembly core area
Change Air Filter Element 270.01.184.50
After every Additional activities apart from changing the parts
2000 hrs of given above are:
running 1) Check the oil and air line fittings for leakage Refer Recommended Spares
2) Check the electrical wiring connections list for fittings and O-rings for
3) Check the condition of contacts on contactors fittings.
4) Check the condition of rubber hoses Hose Kit - 270.00.576.50.

running 1) Replace Air-oil Separator element with gaskets 270.01.442.50
2) Check the condition of all valves for leakages Refer Recommended Spares
or sluggish action. list for kits.

running or 1) Check the condition of rubber hoses and Refer the list of recommended
ONE year replace the defective spare parts.
(which ever 2) Change the kit of spares for Minimum Pressure
is earlier) Valve, Intake Valve, Blow-Down Valve & Solenoid
valve
The above recommendation is valid for General Engineering industry only.
Life of consumables will vary depending on the operating environment.
30
7.3 LIST OF CONSUMABLES AND SPARE PARTS KITS
A. Kit of Consumables for every 4000 hrs of running-- 270.01.186.50 consists

of
1) 274.01.459.50– Oil Filter Element ----------------------------- 10 Nos.
2) 270.01.184.50– Air Filter Element ------------------------------ 4 Nos.
3) 270.01.442.50 – Air-oil Separator element with Gaskets – 1 No
The kit consists of 2 Nos of oil filter element to be replaced along with the oil after
first 100 hrs of running.
B. Kit of Consumables every 8000 hrs of running-- 270.01.187.50 consists of

1) 274.01.459.50– Oil Filter Element ----------------------------- 18 Nos
2) 270.01.184.50– Air Filter Element ------------------------------ 8 Nos
3) 270.01.442.50 – Air-oil Separator element with Gaskets – 2 No
The kit consists of 2 Nos. of oil filter element to be replaced along with the oil after
first 100 hrs of running.
The Compressor oil Servo System HLP68 is not given in the consumable list
since it can be procured directly from the oil manufacturer by the
customer/user.
The rubber & non-metallic parts like O-rings, gaskets, hoses are not considered in
the list of consumables since the life depends on the operating temperature which
in-turn depends on the operating environment, operation & maintenance
conditions. Apart from this, the gaskets and O-rings are to be replaced when the
part is damaged during the maintenance/repair of compressor parts during
operation. Hence KPCL recommends user to maintain one set of gaskets and O-
rings as stand-by stock
31
C. Kit of Spares after 8000 hrs run or ONE year
C1. for KES 55S & KES 90-8.0 & 9.0 Models- 270.01.188.50 consists of
Sl. No. ITEM No. DESCRIPTION QTY.

1 270.01.444.50. KIT OF GASKET FOR KES-55S, KES-75 & KES-90 1
2 270.01.445.50 KIT OF ‘O’ RING FOR KES-55S, KES-75 & KES-90 1
3 270.00.587.50 RUBBER ELEMENT FOR COUPLING 10
4 270.00.568.50 O' RING ID 31.5 x 3.55 DIA 2
5 270.00.589.50 O' RING ID 54.5 x 3.55 DIA 5
6 271.00.532.50 O' RING 1/4" 1
7 271.00.534.50. O' RING 3/8" 4
8 271.00.536.50. O' RING 1/2" 1
9 271.00.538.50. O' RING 3/4" 1
10 271.00.540.50. O' RING 1" 1
11 271.00.542.50. O' RING 1-1/4" 5
12 46.181450.00 DIAPHRAGM 1
13 270.01.190.50 SERVICE KIT MINIMUM PRESS VALVE ASSLY 50 NB 1
14 270.01.189.50 SERVICE KIT FOR INTAKE VALVE 1
15 270.00.576.50. HOSE KIT FOR KES-55S TO KES-90 1
C2. for KES 75 & KES 90-10.5 & 13.5 Models- 270.01.191.50 consists of
Sl. No. ITEM No. DESCRIPTION QTY.

1 270.01.444.50. KIT OF GASKET FOR KES-55S, KES-75 & KES-90 1
2 270.01.445.50 KIT OF ‘O’ RING FOR KES-55S, KES-75 & KES-90 1
3 270.00.544.50 RUBBER ELEMENT FOR COUPLING 12
4 270.00.568.50 O' RING ID 31.5 x 3.55 DIA 2
5 270.00.589.50 O' RING ID 54.5 x 3.55 DIA 5
6 271.00.532.50 O' RING 1/4" 1
7 271.00.534.50. O' RING 3/8" 4
8 271.00.536.50. O' RING 1/2" 1
9 271.00.538.50. O' RING 3/4" 1
10 271.00.540.50. O' RING 1" 1
11 271.00.544.50. O' RING 1-1/2" 5
12 46.181450.00 DIAPHRAGM 1
13 270.01.190.50 SERVICE KIT MINIMUM PRESS VALVE ASSLY 50 NB 1
14 270.01.189.50 SERVICE KIT FOR INTAKE VALVE 1
15 270.00.576.50. HOSE KIT FOR KES-55S TO KES-90 1
32

Operation and Maintenance Manual KES 55 S, KES 75, KES 90: Kirloskar Pneumatic Co. LTD., Pune

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Operation and Maintenance Manual KES 55 S, KES 75, KES 90: Kirloskar Pneumatic Co. LTD., Pune

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Kirloskar Pneumatic Co. Ltd.

Operation and Maintenance Manual

KES 55 S, KES 75, KES 90

Operation and Maintenance Manual

For KES 55 S, KES 75, KES 90 Models

KIRLOSKAR PNEUMATIC COMPANY LTD.,

Document Number: S270.113- 121. D98

Revision Status: R01

Date: JULY. 2011

Head of Servicing Department

Fax : 91 – 20 26870297 / 26870634

e-mail : acdser@kpcl.net and acdmktg@kpcl.net

MACHINE IDENTIFICATION AND SALE RECORD

Owner’s name: ___________________________________

Compressor Serial Number:____________________________________

Main motor make:____________________________________

Main motor Serial Number:____________________________________

Motor Rating: ___________kW @ ____________ Rev/min

Compressor Capacity:____________m3/min @ ___________ bar g

Dealer Name / Code:_____________________________________

Dealer signature / stamp:

Message from the Managing Director

We welcome you to the family of users of Electric Screw

At Kirloskar, listening to the user & customer and meeting

KPCL has designed your compressor to be safe, best in

KPCL is honored to be the choice for all your compressed

About Kirloskar Pneumatic Company

Kirloskar Pneumatic Company Ltd, a flagship company in Kirloskar

Driven by the Kirloskar Group philosophy of “Enriching Lives”,

8.10 Intake Valve Assembly 50

The contents in this Manual are proprietary and confidential to Kirloskar

The abbreviation KPCL used in this Manual means Kirloskar Pneumatic

All components, accessories, pipes and connectors added to the compressed

• Of good quality, procured from a reputable manufacturer and, wherever

KPCL reserves the right to make changes and improvements to products

1.3 ISO SYMBOLS

1.4 RECEIVING THE COMPRESSOR

The condition of compressor parts also to be checked by opening the canopy

1.5 LIFTING THE COMPRESSOR

1.6 GENERAL INSTALLATION GUIDELINES

1.7 INSTALLATION REQUIREMENTS

Mechanical connections: The compressor is provided with 3 outlet points on

Electrical connections: The compressor is provided with opening on the

Model Backup fuse Recommended cable size

A --Room ventilation through the opening in the wall

B, C -- Room ventilation with exhaust system

D -- Hot air duct from compressor E -- Ducting for room heating

Electric Circuit Diagram for KES-55S, KES-75, KES-90

Kirloskar Pneumatic Co. Ltd., Pune

VIEW FROM A DETAILS FOR

Pressure release: The compressor is provided with pressure relief valve to

3.0 DOs and DON’Ts

Operating personnel read this manual thoroughly and follow instructions

4.2 POINTS TO BE OBSERVED BEFORE INITIAL START

4.3 COMMISIONING THE COMPRESSOR

Faulty Remote Load DIP

Front View of Microcontroller Back View of Microcontroller

5.0 SPECIFICATIONS & SALIENT FEATURES

5.2 SALIENT FEATURES

Best Performance: The combination of energy efficient airend driven by efficient

Electric Motor: This is flange mounting, 2 Pole, TEFC, IP 55 protection, Class F

Lubrication: Lubrication of the air-end gives duel advantage. It removes heat of

Lube oil Cooling: Temperature of the compressor system is maintained within

Motor Rating: _kW @ __ Rev/min

Compressor Capacity:__m3/min @ _ bar g