Professional Documents
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KS75A/KS90A
Instruction Manual
Thank you for your purchase of KOBELCO Oil-Flooded Screw Compressor "Kobelco KS series".
You are advised to read through this instruction manual carefully before you attempt to carry
out operation and maintenance.
Please keep the manual at hand for ready reference.
Accessories
Model
KS75A KS90A
Parts name
KS75A/KS90A
Contents
Contents …………………………………………………………………………… Ⅰ
1 Safety Information …………………………………………………………………… 1
1.1 General Precautions ……………………………………………………………………… 1
1.2 Alert Symbols and Safety Marks ………………………………………………………… 2
1.3 Safety Rules ………………………………………………………………………………… 4
5 Operation …………………………………………………………………………… 29
5.1 Pre-operation Inspection to Stop ………………………………………………………… 29
5.2 Pre-operation Inspection …………………………………………………………………… 30
Initial Settings for KS Controller (Factory default settings) ……………………………………………… 31
5.3 Operation Procedure ……………………………………………………………………… 32
5.4 Setting Control Pressure …………………………………………………………………… 34
5.5 Operation Modes …………………………………………………………………………… 35
KS75A/KS90A Ⅰ
Contents
6 Troubleshooting ……………………………………………………………………… 40
6.1 Emergency Stop …………………………………………………………………………… 40
6.2 Caution ……………………………………………………………………………………… 41
6.3 Countermeasures …………………………………………………………………………… 42
6.4 Interlock List ………………………………………………………………………………… 43
6.5 Before You Suspect Failure ……………………………………………………………… 45
9 Disposal ………………………………………………………………………………… 53
11 Specifications …………………………………………………………………………… 56
11.1 Specifications ……………………………………………………………………………… 56
11.2 Electric power facilities……………………………………………………………………… 59
11.3 Wiring Diagram ……………………………………………………………………………… 61
11.4 Connection Diagram ……………………………………………………………………… 62
11.5 System Diagram …………………………………………………………………………… 63
12 Warranty …………………………………………………………………………………… 65
13 Indemnity ………………………………………………………………………………… 66
KS75A/KS90A Ⅱ
1.Safety Information
Safety Information
Please carefully read and understand the general precautions and the descriptions for alert
symbols and safety marks.
Then proceed to 1.3 Safety Rules on page 4 where you will find itemized safety instructions.
◎ We shall not be responsible for any personal injury and faults/damage of the machine
resulting from modification by the customer.
WARNING
◎ Strictly follow the local regulations and the safety standard established in the field.
KS75A/KS90A 1
1.2 Alert Symbols and Safety Marks
For safety and trouble-free operation, the following alert symbols and safety marks are given
to the important items in order to call your attention. Please follow these instructions.
Alert signals
Meanings of signals
Explanation of pictograms
The following marks are used together with alert symbols and pictographs to discriminatively
indicate actions which the operator must not take, and which the operator must take.
KS75A/KS90A 2
Check on Machine No. Name Plate
Make sure that the machine No. name plate is attached to the machine.
If the name plate is missing or not readable, contact our company or the distributor.
SCREW COMPRESSOR
MPa
MPa
m 3/min
kW r/min
Unity Input
Input Specific
Specific power
power kW/(m 3 /min)
mm
kg
中华人民共和国
The People’s Republic Of China
神钢压缩机制造(上海)有限公司
KOBELCO COMPRESSORS MANUFACTURING
(SHANGHAI) CORPORATION
PS-KAPS-KA03-513
03-5 07#(K)-(L)
KS75A/KS90A 3
1.3 Safety Rules
KS75A/KS90A 4
1.3.2 Carrying in
Carry the machine with fork arms into fork holes of the base
plate.
Put filler cloth between the sound proof cover and the fork lift
to prevent damage.
Pass nylon slings through fork holes of the base plate and
protect the front top surface of the sound proof cover with
cloth.
KS75A/KS90A 5
1.3.3 Installation / Installation site
Transfer
CAUTION
Do not drop the machine or carry it at a slant of 45 degree
or more when moving it.
Installation site
Installation
KS75A/KS90A 6
1.3.4 Electric wiring
Electric wiring
Electric wiring must be performed by qualified electricians.
Breaker
Only knife switch Use an earth leakage breaker for the power source in
accordance with the machine model.
ON
OFF
Do not use the knife switch without any earth leakage
breaker in terms of protection.
CAUTION
Installation
Removal or modification of the safety device or any change
in the set value can cause an accident.
SAFETY DEVICE
Any change in the set value for the safety device and
M
operation without the safety device can abnormally heat
ON
CAUTION lubricating oil to start a fire. Never change the set value
or operate the machine without the safety device.
CAUTION
Be sure to connect the earth wire directly to the ground.
Operation without earthing may cause electric shock and
failure in the compressor.
KS75A/KS90A 7
1.3.5 Operation
Dangerous objects
・Do not touch the exhaust outlet and the peripheral area
which are heated up during the operation and may
cause a burn.
Pressure
Rotating portions
When the power lamp is lit, never touch the rotating portions
even if the compressor is stopped.
KS75A/KS90A 8
1.3.6 Shutdown
Parallel operation
Close the stop valve of discharge pipe in the compressor
which is stopped and let the drain out.
Long-term shutdown
Turn off the power supply and close the discharge valve of
ON
the compressor.
OFF
Be sure to run the compressor (for 20 minutes) once a week.
This is essential to prevent rust in the compressor.
CAUTION
Pressure
Before inspecting the inside of compressor, or replenishing
lubricating oil, stop the compressor by pressing the Stop
button on the controller, make sure that "OIL SEPA.
PRESSURE" on the controller is 0 [MPa], and turn off the
earth leakage breaker.
Power supply
To inspect the starting board, always turn off all the power
sources.
Safety valve
The safety valve has undergone the close function test, so it
does not require overhaul.
If any problem occurs, contact our service personnel.
KS75A/KS90A 9
1.3.8 Lubrication
Lubricating oil
Use the KOBELCO EXTRA OIL or KOBELCO GENUINE SCREW OIL.
Never mix oils of different brands.
Degradation, insufficiency, discontinuous flow, and high
× L
L
×
Replenishment
If the oil level is below the lower limit when in operation,
replenish oil.
・Before refilling the lubricating oil, press the STOP
button on the KS controller and stop the compressor.
Making sure that the indication of oil separator pressure
H
on the KS controller is 0 MPa, turn off the leakage
breaker, and then refill the lubricating oil.
L
Residual pressure exists in the oil separator for
WARNING 2 minutes or more after the compressor is stopped.
Before refilling the lubricating oil, always make sure that the
pressure in the oil separator has been relieved completely.
Oil change
Maximum service life of the lubricating oil is 4,000 hours,
though it depends on the operational conditions.
Be sure to change oil in the full amount.
GENUINE
Deteriorated oil requires immediate change in the full amount.
Oil deterioration will cause the deteriorated carbon to
GENUINE adhere to the separator element.
OIL
The deteriorated carbon may be partially heated up by
WARNING
oxidization heat to start a fire and explode.
When changing lubricating oil, be sure to replace the oil
element.
1.3.9 GREASE
To use the above oil, please contact our company.
Refill(g)
brands of grease Intervals(h)
KS75A KS90A
GENUINE GREASE
KOBELCO TOUGH GREASE 2000h 60g/per 70g/per
1.3.10 Overhaul
Overhaul shall be performed every 4 years.
ON
OFF
To overhaul the compressor, cut all of the power supply.
WARNING
KS75A/KS90A 10
2.Part names and Functions
2.1 Overview
Introduction
KS75A, KS90A are one stage, air cooled oil injected compressors, and driven by motoring.
They are installed in noise insulation canopies. KS75A, KS90A models are controlled by
standard controller. User can also choose optional controller.
The controller and emergency button are mounted on the door plate of the electric cabinet.
Electrical power distributor mounted on the back side of front cover.
The standard compressor unit is rich in stereoscopic feeling as the cover of front side, left side
and right side with convex shape.
KS75A/KS90A 11
2.Part names and Functions
KS75A/KS90A
Outside View
Air inlet
KS75A/KS90A 12
Internal Construction
Axial-flow fan
Cools the oil cooler, the after Oil separator element
cooler and centrifugal impeller
using the intake air Separates and recovers
lubricating oil in compressed air.
Oil filter
Removes foreign materials in
lubricating oil.
Oil outlet
Used to drain lubricating oil in the Oil separator
motor splitter.
Oil supply port
Safety valve
Opens to discharge compressed
air when the pressure inside the
oil separator tank rises abnormally
Any modification without prior permission shall invalidate the warranty even
within the warranty period.
Please consult us whenever modification is required.
WARNING
KS75A/KS90A 13
2.3 KS Controller
Construction of KS Controller
Message monitor Alert indicator lamps
① Indicates the operating condition setting and causes of alert indic- ② "Emergency" LED (red)
ations, i.e. Emergency, Caution, and Maintenance. (See page 40.) Indicates that the compressor has been stopped
・Maintenance information due to a failure.
・Caution information ③ "Caution" LED (orange)
・Emergency stop information Indicates that an alert or maintenance
has been issued on the compressor.
④ "Start" LED (green)
① Indicates that the compressor is running or
④ standby.
③ ②
⑩ ⑪
⑤ ⑥ ⑦ ⑧ ⑨
KS75A/KS90A 14
Lamp Indications
Lamp indication (● :On ◎: Blinking)
*:If power comes back within the allowable time, the compressor will start automatically.
For details, see the separate volume, "KS Controller Instruction Manual".
KS75A/KS90A 15
3.Location for Installation
KS75A/KS90A 16
Ventilation to avoid sucking harmful gases / mist
● ●
● ● ● ● ●
● ● ● ● ● ● ● ●
● ● ● ● ● ● ● ● ● ● ●
● ● ● ● ● ● ● ● ● ●
● ● ● ● ● ● ● ● ● ● ●
● ● ● ● ● ● ● ● ● ●
● ● ● ● ● ● ● ● ● ● ● ●
● ● ● ● ● ● ● ● ● ● ● ●
● ● ● ● ● ● ● ● ● ● ● ●
● ● ● ●
● ● ●
● ● ● ●
● ● ●
● ● ● ●
● ● ●
● ● ● ●
● ● ●
● ● ● ●
● ● ●
● ● ●
KOBELCO
・Secure sufficient space away from the outlet above the inlet on both side faces of the
machine to ensure proper functions.
・Secure sufficient space away from the front and upper faces of the machine to ensure
proper opening and closing of doors, operation, and maintenance.
D or more
Width
Height
Depth
Eor more
KOBE LCO
Bor more
C or more
Aor more
[ mm ]
Dimensions Minimum maintenance space
Model Front side Right side Left side Top Rear side
Width Depth Height
A B C D E
KS75A 1000 1000 800 1000 800
2050 1273 1750
KS90A or more or more or more or more or more
KS75A/KS90A 17
3.4 Installing the Machine in an Enclosed Room
※1: Ventilation capacity indicates the value at the allowable room temperature of 5℃ {9゜F} higher than
the ambient temperature.
KS75A/KS90A 18
Installation of Ventilating duct
The capacity of ventilating duct must be higher than exhaust volume of the compressor.
Otherwise, a serious damage of the machine may occur.
① Entire ventilation ② Ventilating duct ③ Ventilating duct & fan
Exhaus t
Exhaus t
Exhaus t Exhaust
CAUTION
Air inle t
H=300
~400mm
The ventilation capacity is for ventilating ・Calculate the pressure loss (resistance) in ・The pressure loss (resistance)
the entire room. the ventilating duct based on the exhaust air in the ventilating duct is over 20
(at the allowable room temperature of volume of the compressor. If the result is not Pa (2 mmH2O), install a ventilating
5℃ {9゜F} higher than the ambient more than 20 Pa (2 mmH 2O) for air cooling type, fan with the specified capacity
temperature) the exhaust from the compressor exhaust outlet inside the duct taking the
through the duct will be possible. pressure loss into consideration.
The air supply opening should be ・Connect the ventilating duct referring to the duct
adjusted so that the flow rate will be installation mark at the top of the compressor. CAUTION
2 m/s or less. The duct should be removable.
To choose a type of fan can
Do not fix the duct with screws. endure much heat .
(high temperature )[80℃
It may hinder repair and maintenance work.
{176゜F}]
Use of KOBELCO genuine expansion duct is
recommended, as shown on the next page.
・Minimize bents in the duct to avoid resistance.
・When installing the duct, provide a full radius. ・Turn on the ventilating fan while
Duct resistance over 50 Pa (5 mmH 2O) could the compressor is running, and
reduce the exhaust volume, causing temperature turn it off when the compressor
rise to stop the compressor. is stopped.
・Even if the duct is connected directly to ・The opening area of air inlet shall
the compressor, the temperature will rise. be adjusted so that the flow rate
In such a case, install a ventilating fan mentioned will be 2 m/s or less.
in the previous page (at the allowable room
temperature of 5℃{9゜F} higher than the
ambient temperature).
・Prevent rain water from entering the duct outlet.
・If the pressure loss in the ventilating duct is over
80 Pa (8 mmH 2O), install a ventilating fan at
the duct outlet. (See method ③.)
・Follow the same installation procedure to install
a ventilating fan and air inlet as that of entire
ventilation.
The opening area for air supply shall be adjusted
so that the flow rate will be 2 m/s or less.
KS75A/KS90A 19
EXHAUST OUTLET
APOOX 2146
APOOX 1302
2050
AIR DISCHARGE
KS75A/KS90A
OUTLET FLANGE
1
DN65 OR R 2 2 2
EXHAUST OUTLET
270
CONTROL SIGNAL
CABLE INLET
100
1750
AIR INLET
250
1328
PORT FOR GREASE 165 POWER CABLE INLET
External dimensions
FILLING
600
4 ×Ø 18
BASE HOLE
60
100
168
4 ×Ø18
BASE HOLE
578 838 1176
1994 70 1244 70 UPPER SECTION
FRONT SIDE LEFT SIDE
AIR FILTER
OIL FILTER
20
(INVERTER)
M
1000
COMPRESSOR PROPER
COVER
OIL SEPARATOR ELEMENT
AXIAL-FLOW FAN
AIR FILTER 10
00
800
OIL FILTER
0
100
80
OIL SEPARATOR 0
MOTOR
PORT FOR OIL FILLING
POW ER SUPP LY BOX
(STANDARD)
COMPRESSOR PROPER
(UNIT:mm)
INTERIOR COLLOCATION: (LEFT)
INTERIOR COLLOCATION: (FRONT)
Foundation drawing
FOUNDATION DRAWING
(KS75A KS90A KS75AV KS90AV)
※ SOLD SEPARATELY
2400
2050
4× 180
1032
1600
1376
838
FOUNDATION DRAWING
NOTE:
1.FOUNDAION TO BE FURNISHED WITH STEEL RODS.
2.FOUNDATION REQUIRED TO BE STRONG ENOUGH TO SUPPORT THE WEIGHT.
3.HORIZONTAL LEVEL SHOULD BE ±1/100.
( UNIT: mm)
KS75A/KS90A 21
4.Precautions before Operation
4.1 Unloading
When unloading and carrying, use the openings on the base plate of the compressor.
The openings are large enough to fit forklift forks, which allows unloading and
carrying by a forklift.
NOTE Be sure to read the section "Carrying in" of 1.3.2 Safety Precautions on page 5
before starting work.
Forklift
Protecting
wood
Wire
Pad
・Make sure that the front cover is closed up to prevent it from opening
unexpectedly.
・The supplied fork covers are designed to reduce the noise level.
Attach the fork covers on both front and rear faces after the completion of installation.
CAUTION
・Figure(1): When lifting or moving, please attach the mounting plate as shown in figure (1).
・Figure(2): After installation and commissioning, please attach the mounting plate
and the fork hole cover as shown in figure (2)
Mounting plate
Front side Back side Front side Back side (carrying in)
Figure(1) Figure(2)
KS75A/KS90A 22
4.2 Precautions for Piping
Piping
・An unsupported long piping may cause for vibration and, as a result, the devices to
which such piping is connected may be damaged.
The piping must be properly supported (using hangers, fasteners, columns, etc.).
・When more than two units of compressors are installed and their discharge piping are
connected to the same discharge main piping, be sure to provide the stop valves before
the discharge main piping so that they can be closed when the operations of the
compressors are stopped.
・Slope the main piping in the discharge air flow direction so that condensate does not
gather in the middle of piping.
・Provide a drainage at the bottom part of pipe if there is a height difference.
・To prevent condensate reverse flow connect a discharge piping at the top of the main
piping.
Main piping
Emergency valve
Discharge ari
(If you increase
the compressor)
Main piping To prevent the reverse
flow such as drain.
Hanger
Union Union
or mor e or mor e
Connected by customer
KS75A/KS90A 23
Air tank installation
In order to make pressure fluctuation small, install a proper capacity air receiver tank
with discharge piping.
When install separate dryer, a line filter and a check valve, please install in the down
stream of air tank. In addition, please shorten the piping from a compressor to air
tank as much as possible.
*If piping pressure loss from a compressor to air tank becomes big; of driving of load /
unload become frequent, and part life shortens.
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.
t1+t2= 0.5 min Qs= 13.5 m3/min Pa= 0.101 MPa D= 0.70-0.60 = 0.10 MPa
x=50%(Air tank capacity is surely made the biggest at the time of load rate 50%)
0.5×13.5×0.101×0.5×(1-0.5)
VR = ≒ 1.704 m3
0.10
KS75A/KS90A 24
4.3 Lubricating Oil
OI○
OIL
L
×
CAUTION
・Maintain the oil level between "H" and "L" during operation.
・Do not operate with the oil level higher than "H". Otherwise,
oil may flow out into the discharged air and cause problems.
(It is not abnormal that the oil level exceeds "H" when
operation is stopped oil returns to the oil separator.)
KOBELC0
If the oil level is much higher than that in the previous run,
shut down the compressor immediately, drain the oil
completely and perform inspection.
5L(KS75A)
6L(KS90A)
There has a green mark on the mark H of oil level.It to show the oiling height
when the whole oil system have no oil.
KS75A/KS90A 25
Refilling oil
OFF
CAUTION
3 To open the oil supply port of the compressor(left,front side face),
Oil supply remove the front cover of the compressor and loosen the plug
port Loose with a wrench.
4 When closing the oil supply port, wipe off spilled oil
completely and tighten the plug securely.
Tighten
The quantity of oil required for change in full is shown below.
Unit : (L)
MODE KS75A KS90A
Quantity 32 37
・Pressure remains in the oil separator one minute or more after the compressor
is stopped. Wait for about two minutes until the pressure is released, and
then replenish oil.
CAUTION ・Oil must be supplied from the oil supply port. If oil were supplied from any
other point, the oil level could not be checked.
Draining oil
1 Stop the compressor by pressing the Stop button (red).
Make sure that "OIL SEPARATOR PRESSURE" on the
controller is 0 [MPa].
KS75A/KS90A 26
4.4 Power Supply Wiring
KS75A/KS90A
Earth cable
Power cable
TB-2
TYPE:
SER NO:
2 6
1 3
2 6
POWER:
2 5
1 2
2 5
1 1
2 4
2 4
2 3
2 3
1 0
2 2
2 2
9
2 1
2 1
8
TB-1
2 0
2 0
7
1 9
6
1 8
1 8
5
1 7
1 7
4
1 6
1 6
3
1 5
1 5
2
1 4
1 4
1
CT2 CT1
88A
MS
MC MD
THF
U3 V3 W3
V2 W2 U2
OL1
U1 V1 W1
(connected by customer)
Caution: Connection the power cable to compressor in accordance with following drawing.
KS75A/KS90A 27
MEMO
KS75A/KS90A 28
5.Operation
Stop
(See page 33.)
Periodic
inspection
(See page 47.) Pressure may remain inside
the compressor imm ediately
Shutdown for a after shutdown.
prolonged period In add ition, voltage may still
(See page 52.) exist in the inverter.
Before perform ing inspection
or maintenan ce, make sure
that the inne r pressure of
the compressor has bee n
Perform inspection and released completely and turn
maintenan ce of each part
Disposal off the breaker to redu ce the
according to runn ing hou rs or (See page 53.) voltage to 0.
ope rating time. In case of
storage for a prolonge d
period, store the compressor
indoo rs and keep it dry.
KS75A/KS90A 29
5.2 Pre-operation Inspection
Are the air inlets on the right side face, the one on
the left side face and the outlet on the upper face not blocked?
Clean!
Ready?
KS75A/KS90A 30
Initial Settings for KS Controller (Factory default settings.)
Initial Settings
Item KS75A KS75A-H KS75A-GH
KS90A KS90A-H KS90A-GH
Remote/Local Local
Load/Unload setting Local
Clock Real time
Running hour 0h
4000h
Replace suc. filter (*1)
Elapsed time: 0
4000h
Replace oil filter (*1)
Elapsed time: 0
4000h
Replace lube oil (*1)
Elapsed time: 0
4000h/2000h(*3)
Replace oil separator element (*1)
Elapsed time: 0
4000h
Inspect cooler (*1)
Elapsed time: 0
(*1) The maintenance intervals (cleaning time) are based on general operating environment.
Your compressor must be maintained according to the operating conditions at your factory.
(*2) A change period of LOAD/UNLOAD shortens when make a difference of unloaing puressure
and loading pressure small.
Please set pressure so that a change period of LOAD/UNLOAD does not become less than
1 cycle 30sec.
(*3) Please refer to brands of lubricating oil. KOBELCO EXTRA OIL: 4000hours;
KOBELCO GENUINE SCREW OIL: 2000hours.
KS75A/KS90A 31
5.3 Operation Procedure
Startup
1 Turn on the main power.
KS75A/KS90A 32
Stop
Emergency Stop
KS75A/KS90A 33
5.4 Setting Control Pressure
To set the discharge pressure using the KS controller, follow the procedure shown below.
1 Press the back key "←" several times until the display
shown in the figure on the left (main menu screen)
appears.
Setting ranges
KS75A KS75A-H KS75A-GH
KS90A KS90A-H KS90A-GH
Factory Lower Upper Factory Lower Upper Factory Lower Upper
setting limit limlt setting limit limlt setting limit limlt
Unloading pressure(MPa) 0.72 0.56 0.75 0.82 0.56 0.85 1.02 0.56 1.05
Loading pressure(MPa) 0.60 0.55 0.74 0.70 0.55 0.84 0.90 0.55 1.04
Auto start pressure(MPa) 0.55 0.30 0.73 0.65 0.30 0.83 0.85 0.30 1.03
KS75A/KS90A 34
*Confirmation of control pressure
Confirm that the capacity control function within the set range and that a cycle
(Unload Operation → Load Operation → Unload Operation) takes longer than 30 seconds.
Frequent driving narrow parts life.
Unloading Pressure
Discharge Pressure
Loading Pressure
TIME
0
More than 30 sec.
Suction
regulating
valve
safety valve
combination valve
compressor body
KS75A/KS90A 35
【AUTO】・【MANUAL】Mode
START SW ON
Load operation
NO
Dis. press.>Unloading press.
KS75A/KS90A 36
Auto running mode
NO
Lapsed time
after starting >15min
YES
NO
3 minutes Unloading
Determines there is no
YES air consumption.
NO NO
Dis. press. <Auto start press. Dis. press. <Loading press. Unloading
continued.
Y ES YE S
KS75A/KS90A 37
Emergency Stop
Running
YES
Emergency condition occurs
NO
YES
Emergency Stop Operation
NO Emergency Stop
NO
Stop Operation
YES
Unload starting
NO
Starting Operation
YES NO
To pass 10S
unload working
Unload lock released
YES
motor stop
KS75A/KS90A 38
MEMO
KS75A/KS90A 39
6.Troubelshooting
If emergency stop occurs or a caution is given, restart the compressor after the corrective
action is taken following the countermeasures. (See page 43.)
The KS controller stores up to 50 latest failure records on page 03.
KS controller display
Counter
No. Message monitor display
measures
Major factor Possible causes
Pressure setting error KC-13
M
1 a
Main motor Too many start & stop KC-11
i overcurrent Power supply error KC-06
n
Motor failure KC-09
m Main motor Power supply error KC-06
2 o
t is clogging Motor failure KC-09
o
Main motor phase Power supply error KC-06
3 r
imbalance Motor failure KC-09
e
r Too many start & stop KC-11
r Motor coil Pressure setting error KC-13
4 o
r temperature is high Power supply failure KC-06
Motor failure KC-09
Fan motor error Power supply failure KC-06
5 machine halt Motor failure KC-09
Condenser fin clogged KC-08
Ambient temperature is high KC-03
Discharge air temp. Pressure setting error KC-13
6
is high Oil cooler clogged KC-02
Oil filter clogged KC-04
7 High discharge pressure
High pressure in (Call KOBELCO distributor.)
8
oil separator tank
Discharge air temper- Oil separator element is needed to replace.
9 ature switch Stop compressor and after pressure of oil separator is zero
replace oil separator element.
phase L1 Phase error
10 sequence L2 Phase error Break power supply and check if power supply wiring is correct.
L3 Phase error
11 Temperature sensor error
12 Discharge pressure sensor error (Call KOBELCO distributor.)
13 Oil separator tank pressure sensor error
KS75A/KS90A 40
6.2 Caution
The Caution LED on the controller comes on, and the cause is shown P00.01 on the message
monitor. In this case, the compressor does not stop.
KS controller display
Counter
No. Major factor Message monitor display
measures
Possible causes
Ambient temperature is high KC-03
Discharge air temper- Pressure setting error KC-13
1
ature is getting high Oil cooler clogged KC-02
Oil filter clogged KC-04
Error of total differential Oil separator element is needed to replace.
2
pressure (Call KOBELCO distributor.)
Alarm of air fifter Air separator element is needed to replace.
3
differential pressure (Call KOBELCO distributor.)
Ambient temp. Ambient temperature should be under 40℃ {104 F}.
4
is getting high Ventilate compressor room and improve air condition.
5 High discharge pressure
(Call KOBELCO distributor.)
6 Oil separator tank pressure high
When maintenance is required,The Caution LED on the controller comes on, and the cause is
shown P00.01 on the message monitor. In this case, the compressor does not stop.
KS controller display
Counter
No. Major factor Message monitor display
measures
Possible causes
Air separator element is needed to replace.
1 Air filter element service
(Call KOBELCO distributor.)
Oil fifter is needed to replace.
2 Oil filter service
(Call KOBELCO distributor.)
Oil separator element Oil separator element is needed to replace.
3
service (Call KOBELCO distributor.)
If 100 hours or more have passed without pressing the Reset button since
the Maintenance LED on the KS controller came on, the caution lamp will blink
CAUTION at the intervals of one second.
KS75A/KS90A 41
6.3 Countermeasures
KS75A/KS90A 42
6.4 Interlock List
Emergency stop
Caution
Item Location where a failure is detected Detector Condition 1 Condition 2
1 Discharge temperature high In oil separator tank PT100 above 105℃{221゜F}
2 Discharge pressure high exhaust opening pipeline Controller Exceed
3 High pressure in oil separator tank In oil separator tank Controller Exceed
4 Startup frequency / hour Controller Controller Exceed (frequently startup)
5 Ambient temperature high Compressor air inlet Thermal Switch turned "ON"(above 43℃)
Differential pressure
Air fifter differential pressure alarm Switch turned "ON"
6 Compressor air inlet switch
7 Error of total psid high Controller Controller Exceed
8 Power error Controller X13 Connector Voltage exceed
9 timepiece error Controller Controller System self-check
10 System error Controller Controller System self-check
KS75A/KS90A 43
Maintenance*
Item Location where a failure is detected Detector Condition 1 Condition 2
1 Air filter element service Running hours different pressure Controller 4000 hours -6.2kPa
2 Oil filter service Running hours Controller 4000 hours
3 Oil filter element service Running hours Controller 4000 hours
4 Motor grease service Running hours Controller 2000 hours
5 Oil change service Running hours Controller 4000 hours*1 2000 hours*2
6 Cooler service Running hours Controller 4000 hours
Start of operation to
7 Routine service Running hours Controller 4000 hours one year or yearly
inspection to one year
KS75A/KS90A 44
6.5 Before You Suspect Failure
Motor failure Check the insulation, and repair or replace the motor.
For low capacity power supply, change the capacity
Low voltage
of the transformer. call
Motor is Thin cable Replace the cable with the specified size.
groaning. Motor failure Repair or replace the motor.
Compressor stall Overhaul the compressor proper. call
Blow-off solenoid valve failure Readjust or replace the solenoid valve. call
Low discharge Leakage from piping Tighten the fitting or replace the packing. call
pressure Clogged suction filter Clean or replace the element.
Clogged oil separator Replace the element.
Blow-off from Pressure higher than the specified value Select an air reservoir with proper capacity.
safety valve Safety valve improper adjustment or failure Readjust, repair or replace the valve.
Clogged oil recovery line Clean or replace the recovery orifice. call
High lubricating Clogged oil separator Replace the element. call
oil consumption Drain the oil so that the oil level will be between the red
Excessive lubrication
lines of the oil level gauge.
Volumetric Too short load cycle Increase the capacity of piping (air reservoir).
control failure Improper pressure setting Reset the pressure.
Use of oil other than Kobelco genuine oil. Replace the oil with Kobelco genuine oil.
Premature deteriorationHigh ambient temperature Lower the temperature by ventilation or other methods.
lubricating oil Mixture of water Inspect the air inlet and drain the oil.
Residual deteriorated lubricating oil Perform flushing at the replacement of lubricating oil.
Abnormal sound from Foreign material caught in the compressor Overhaul and repair. call
compressor proper Wear or damage on the bearing Replace the bearing. call
Other abnormal Loose bolt or screw Tighten the bolt or screw. call
sound Improper installation Fill mortar and fix the compressor horizontally.
Loose bolt or screw Tighten the bolt or screw.
Excessive Improper installation
Fill mortar and fix the compressor horizontally.
vibration Unbalance due to
contaminated cooling fan Clean the blades.
KS75A/KS90A 45
MEMO
KS75A/KS90A 46
7.Maintenance and Part Replacement
■ Warranty
Use only authorized parts. We shall not be resposible for any faults or damages caused by
unauthorized parts.
■ Service contract
KOBELCO supplies several types’ of contracts maintenance to bring you peace of mind. Consult the
authorized service shop or the sales department of KOBELCO.
■ Overview
In maintenace, all gaskets, o-ring and washers which are dismantled should be replaced.
■ Interval
Local sales department of KOBELCO can offer a preventive service plan for compressor
according to environment and operating conditions, especially maintenance intervals.
Long interval of service and inspection must include short interval of service
and inspection.
KS75A/KS90A 47
7.2 List of preventive maintenance
■ Check list
Interval Operation
Daily Check oil level
Check the data on the screen monitor
■ Interval
KS75A/KS90A 48
·TThe warranty period shall be one year.
·The maintenance intervals listed above are based on normally expected practices, and are not
guaranteed.They may be shortened depending on the operating conditions and environment.
Therefore adjustment of intervals is required according to the operating conditions.
NOTE: The maintenance intervals in the table above are base on the 4000 running hours per year.
In the operation beyond this standard, maintenance is required when the preparation time is
reached before the maintenance period.
Motor leadwire
FG
Base plate
KS75A/KS90A 49
7.4 Cleaning of Suction Filter
Cleaning
Part No.
Suction filter element PS-CE03-509
Suction filter
Suction filter Element
Element Cover
Cover
KS75A/KS90A 50
MEMO
KS75A/KS90A 51
8.Shutdown for a Prolonged Period
Do not resume operation! ・If any abnormal conditions are detected, request a service in
order to ensure a trouble-free run at the next operation.
KS75A/KS90A 52
9.Disposal
Disposal
KS75A/KS90A 53
10.Remote Control
NOTES
1) The stop operation using the Stop button on the control panel is
valid regardless of LOCAL / REMOTE selection.
○:Valid ×:Invalid
Selection Start button Stop button Remote ON Remote OFF
Local ○ ○ × ×
Remote × ○ ○ ○
KS75A/KS90A 54
Handling External Signals
Any modification without prior permission of KOBELCO MACHINERY ASIA PTE. LTD.
or KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION
CAUTION may invalidate the warranty even within the warranty period.
KS75A/KS90A 55
11.Specifications
11.1 Specifications
KS75A
Types
KS75A KS75A-H KS75A-GH
Items
Frequency (Hz) 50
Power supply voltage (V) 380,415 3-phase 3-wire type
3
Air discharge volume (m /min) 13.5 12.7 11.1
Suction Pressure Atmospheric pressure (1 bar)
condition Temperature (℃(゚F)) 2~40(36 ~104)
Pressure (MPa) 0.7 0.8 1.0
Discharge
Max. discharge pressure (MPa) 0.75 0.85 1.05
condition
Temperature (℃(゚F)) 45 {113} below (Ambient temperature condition : 30℃ {86°F})
Output (kW) 75
Type 3-phase cage induction totally enclosed
Voltage (V) 380,415
Main motor
Number of poles 2P
Protection IP55
Cooling system Air cooling
Starter system Star-Delta
Insulation class F
Output (kW) 2.2
Fan motor
NOTES:
(1)Measurement guidelines for air discharge volume in accordance with GB/T3853 (ISO1217 Appendix C).
The suction condition of compressor(body): 20 ℃{68゜F}, 1bar, 0%RH.
(2)The discharge pressure gauge indicates a package outlet pressure.
(3)Lubricating oil drained from a compressor at the factory.
Be sure to use『KOBELCO EXTRA OIL』or『KOBELCO GENUINE SCREW OIL』at the time of the exchange.
(4)The noise data is measured at a point of an anechoic room, which is 1.0 meter height from the floor and 1.5
meter length from all directions of the unit.
(5)The compressed air must not be used for respiratory equipment from which aspiration is directly made.
(6)As for the guaranteed values, consult with us separately.
KS75A/KS90A 56
KS90A
Types
KS90A KS90A-H KS90A-GH
Items
Frequency (Hz) 50
Power supply voltage (V) 380,415 3-phase 3-wire type
3
Air discharge volume (m /min) 16.2 15.4 13.9
Specific discharge pressure (MPa) 0.7 0.8 1.0
Suction Pressure Atmospheric pressure (1 bar)
condition Temperature (℃(゚F)) 2~40 (36~104 )
Pressure (MPa) 0.7 0.8 1.0
Discharge
Max. discharge pressure (MPa) 0.75 0.85 1.05
condition
Temperature (℃(゚F)) 45 {113} below (Ambient temperature condition : 30 ℃ {86°F})
Output (kW) 90
Type 3-phase cage induction totally enclosed
Voltage (V) 380,415
Main motor
Number of poles 2P
Protection IP55
Cooling system Air cooling
Starter system Star-Delta
Insulation class F
Output (kW) 3.0
Fan motor
NOTES:
(1)Measurement guidelines for air discharge volume in accordance with GB/T3853 (ISO1217 Appendix C).
The suction condition of compressor(body): 20 ℃{68゜F}, 1bar, 0%RH.
(2)The discharge pressure gauge indicates a package outlet pressure.
(3)Lubricating oil drained from a compressor at the factory.
Be sure to use『KOBELCO EXTRA OIL』or『KOBELCO GENUINE SCREW OIL』at the time of the exchange.
(4)The noise data is measured at a point of an anechoic room, which is 1.0 meter height from the floor and 1.5
meter length from all directions of the unit.
(5)The compressed air must not be used for respiratory equipment from which aspiration is directly made.
(6)As for the guaranteed values, consult with us separately.
KS75A/KS90A 57
Fan properties
FAN AND FAN MOTOR
Type
Items KS75A KS90A
Frequency (Hz ) 50
Voltage ( V) 3-phase 380,415
Output ( kW ) 2.2 3.0
Input air 11000m3/h@260Pa 13200m3/h@260Pa
Cooling system Air cooling
KS75A/KS90A 58
11.2 Electric power facilities
Remove the front cover and introduce the power cable through the opening on the right side,
then connect each cable correctly to the terminal panel in the starter box. For normal
operation, a suitable power source is required. Secure less than ±5 % of rated voltage
during operation. In order to suppress the imbalance of current, imbalance of the voltage
between phases as less than 2 % is required.
Transformer capacity
Model Tansformer capacity
When installing the breaker for the main power supply, select an earth leakage breaker.
Inrush current is supposed to flow at the moment when swiching from star cunnection
to delta connection.
Please be sure to choose and use an earth leakage breaker having a suitable electric
specification in order for it not to wark because of the inrush current flow.
Use of any breaker without high frequency measures may cause malfunction due to affection
of high frequency current.
Maximum rated current Star - delta starting current Inrush current (rms value) Recommended breaker model
Model
380V 415V 380V 415V 380V 415V Reference MITSUBISHI
KS75A/KS90A 59
Selection of cables
For the power cables, select EV or CV or VV cables for 600V insulated by the polyvinyl chloride.
GB12706.1-2002/JIS C3605.
Earth cable: Connect the earth wire to the earth terminal (marked with PE) on the power supply
terminal block.
The earth resistance should be 10Ω or less.
Cable size
Power cable Earth Screw size of terminal panel
Model Voltage
5m within 10m within 20m within cable power cable Eerth cable
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.
KS75A/KS90A 60
CAUTION
KS75A/KS90A
UA CONTROLLER
1
UB
2 X12
UC 2
3
EARTH LEAKAGE BREAKE R S10 S20 S20 X01
L1/R AC380V/AC415V 2 1
L1 AC25V R10 R20 R20 X13
L2/S 1
L2 USER
AC220V R11
L3/T BREAKER 9 C8
11.3 Wiring Diagram
61
03 R1 2
MD MC MC 1 COM1 PB-EMS
THF MAIN MAGNETIC CONTACTO R X09
OL1
MS OL1 MD 04 R2 3
MAGNETIC CONTACTOR FOR STA R MS
MS 05 R3 TE1
MAGNETIC CONTACTOR FOR DELT A MD 4
6 T1-
INSIDE OIL SEPARATOR TEMP .
5 T1+
V2 W2 U2 U3 V3 W3 1
CP3 2A
BREAKER SUCTION SOLENOID VALV E R4 4 P2- PT2
FAN MOTOR THF SV1 2
U1 V1 W1 IM X03 INSIDE OIL SEPARATOR PRESS .
01 X08
3 P2+
MC 3
IM E
MAIN MOTOR 02 R6 2 P1- PT1
SV3 4
E DISCHARGE PRESSURE
DRYER SOLENOID VALVE (BACKUP) 1 P1+
88A
R7
CONTACTOR FOR FAN MOTO R 1
User
WIRING DIAGRAM(STANDARD COMPRESSOR )
P1
P2
T1
X03 X02
R31
COM1
R21
C1
Emergency stop switch
TB-2
TYPE:
14 15 16 17 18 19 20 21 22 23 24 25 26
14 15 16 17 18 19 20 21 22 23 24 25 26
11 12 13
SER NO:
POWER:
R4
S31
10
S10/11
R10/12
R11/13
L1/R
L2/S
C6
8
TB-1 COM1
Ambient temp-switch
7
C5
CP1 CP2
6
11 CP3 C4
0
5
12 1 COM1
4
13 2
PE C2
3
COM1
2
1
L1/R L2/S
380V 1 0
CT2 CT1
415V 2 0
88A
MS
MC MD
THF
U3 V3 W3
V2 W2 U2
OL1
U1 V1 W1
V1
W1
U1
PE
U2
V2
W2
U3
V3
W3
PE
COM1
T1-
T1+
P2-
P2+
P1-
P1+
Back side
C8
C7
C6
C5
C4
C3
C2
C1
COM3
R31
R31
R20
S20
R1
R2
R3
R4
R5
R6
R7
R8
UA
UC
UB
1a
1c
1b
KS75A/KS90A 62
Drain separator
KS75A/KS90A
After cooler
Oil cooler
11.5 System Diagram
63
Suction filter TS1 SUCTION TEMP. SWITCH
TS2 TEMP. SWITCH (AFTER OIL SEPARATOR)
TS3 COIL TEMP. SWITCH
Pressure OL1 OVERCURRENT RELAY (MAIN MOTOR)
Oil return sight glass regulating
OL2 OVERCURRENT RELAY (FAN)
valve Safety valve
COMPRESSED AIR
KS75A/KS90A 64
12.Warranty
Warranty
If the machine has a failure when in proper operation according to this instruction manual or
other instructions, we will repair on our expense for certain period and on certain conditions.
Consult with our distributor.
Warranty period
The warranty period of this machine shall be 12 months from a date of completion of the test
run or 18 months from the date of shipment, whichever comes earlier.
Note) “After completion of the test run” shall mean
[At the time when the test run (procedure and activities of receiving materials test)
is completed after installation at site.]
Warranty conditions
If a failure occurs due to our design or workmanship within the warranty period, we will make
repair or change faulty parts promptly on our expense.
Exclusion of warranty
We shall not warrant any of the following faults even within the warranty period:
Consult with our distributor for repairs on the machine after the warranty period is expired.
Repairs will be made on the customer's expense upon request if the repairs can maintain
the performance.
KS75A/KS90A 65
13.Indemnity
Indemnity
Under no circumstances shall, including any illegality, Kobelco Machinery Asia Pte. Ltd
or Kobelco Compressors Manufacturing (Shanghai) Corporation be liable indirect, incidental,
or consequential damages, including, but not limited to, loss of production, for special,
loss of anticipated profits, loss of operational profits, loss of material and products,
or indirect losses, however same shall be caused.
KS75A/KS90A 66
INDONESIA
PT KOBELINDO COMPRESSORS
Cilandak Commercial Estate 110S, JI. Cilandak KKO,P.O.BOX 7038 Jks/CCE Jakarta, 12560 Indonesia
Tel:+62-21-782-7002 Fax:+62-21-782-7025