Table of Contents
Advertisement
Instruction and
Operation Manual
Kirloskar KC Series Refrigeration Compressors
Versions:
Single Stage : KC2, KC3, KC4, KC6, KC9, KC12
Two Stage
: KC21, KC31, KC42, KC51, KC63, KC72, KC84,
KC93 & KC102
Kirloskar Refrigeration
KIRLOSKAR PNEUMATIC CO. LTD.
MGMT. SYS.
©
R vA C 071
INDIAN REGISTER
OF SHIPPING 1993
ISO 9001 : 2000
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Summary of Contents for KIRLOSKAR KC Series
- Page 1 Instruction and Operation Manual Kirloskar KC Series Refrigeration Compressors Versions: Single Stage : KC2, KC3, KC4, KC6, KC9, KC12 Two Stage : KC21, KC31, KC42, KC51, KC63, KC72, KC84, KC93 & KC102 Kirloskar Refrigeration MGMT. SYS. © R vA C 071...
- Page 2 FOR USER’S RECORD TO BE FILLED IN BY KPCL MODEL: SPEC. (SBM) NO.: KPCL O.A. NO. UNIT SR.NO.: CUSTOMER’S P .O. NO. DATE OF MFG.: TO BE FILLED IN BY OWNER/USER DATE OF RECEIPT: DATE OF COMMISSIONING: APPLICATION INFORMATION: ADDRESS OF SITE (PLANT): USER’S REF.
- Page 3 FEEDBACK SHEET FOR USER’S RECORD PLEASE COMPLETE THE FOLLOWING AND SEND BACK MANAGER MARKETING (ACR DIVISION) KIRLOSKAR PNEUMATIC COMPANY LIMITED NEAR WAGHIRE COLLEGE, SASWAD-412 301. TALUKA: PURANDAR, DIST: PUNE (MAHARASHTRA) TO BE FILLED IN BY KPCL MODEL: SPEC. (SBM) NO.: KPCL O.A.
- Page 4 PREFACE This manual intended as a guide for the attendant of the Kirloskar Refrigeration Compressors type KC, contains a description of the compressor as well as service and maintenance instructions. It is necessary to go through the text carefully before installing and starting the compressor.
- Page 5 SAFETY IMPORTANT It is assumed that your safety department has established a program of safety based upon a thorough analysis of industrial hazards. Before installing and operating or performing maintenance on the equipment described in this Manual, it is suggested that you again review this program to be certain that it covers the hazards arising from high speed rotating machinery.
- Page 6 Do's & Do Not's IMPORTANT 1) Do STUDY the manual in detail. 2) Do ASCERTAIN what tools & equipments are required to carry out the job. 3) Do USE proper tools to suit the job. Avoid unnecessary dismantling. 4) Do ENSURE that all nuts, screws, pipe connections, electrical cable connections &...
- Page 7 Handle all the parts carefully. If the equipment is damaged during transportation/shipment, contact immediately the transporter and also KIRLOSKAR PNEUMATIC CO. LTD. LIFTING AND HANDLING : Lifting and handling of compressor must be planned as per the facilities available at the installation site.
- Page 8 LIFTING AND HAULING OF COMPRESSOR Before hauling/moving of compressor consider its weight given in manual/brochure provided along with compressor. Select correct size/type of lifting tackles like slings, wire ropes, shackles, rings, etc. (refer selection guidelines provided by such tools manufacturers). Tie the compressor at proper location as shown in sketch with lifting tackles, balance the compressor at its CG and natural position (do not lift in tilted condition).
- Page 9 SELECTION GUIDELINE OF LIFTING SLINGS AND SHACKLES FOR MATERIAL HANDLING MAXIMUM SAFE WORKING LOAD IN MAXIMUM SAFE WORKING LOAD IN TYPE OF SINGLE PART SLINGS KG FOR SINGLE PART SLINGS KG FOR DOUBLE PART SLINGS Min. Rope Vertical Basket Choker Min.
- Page 10 IMPORTANT PRESERVATION OF REFRIGERATION COMPRESSOR If the compressor is not to be commissioned immediately after receipt at site & to be stored for long time, then in order to avoid rusting/ damages to internal & external parts of the compressor & to water jackets, following preservation action should be taken by the end user/ contractor/erector.
- Page 11 Always maintain a log book & install an hour meter. Before commissioning of compressor, please write to ACR SERVICE DEPARTMENT at 'KIRLOSKAR PNEUMATIC CO. LTD' , HADAPSAR INDUSTRIAL ESTATE, PUNE - 411 013. Phone: 020-26870133/26870341 giving following details 30 DAYS IN ADVANCE to register your name in our data list to enable us to provide you prompt service.
-
Page 12: Table Of Contents
CONTENTS CHAPTER PAGE TECHNICAL DATA & OVERALL DIMENSIONS CONSTRUCTIONAL DETAIL GENERAL OPERATING INSTRUCTIONS CAPACITY CONTROL SYSTEM-SINGLE STAGE COMPRESSOR OPERATING INSTRUCTIONS & CAPACITY CONTROL SYSTEM TWO STAGE COMPRESSOR PARALLEL OPERATION OF COMPRESSOR PERIODICAL MAINTENANCE & ITS SCHEDULE ACCESSORIES TROUBLE SHOOTING CHART SPARE PARTS ILLUSTRATED SPARE PARTS LIST 11.1... -
Page 13: Technical Data & Overall Dimensions
KC42, KC51, KC63, KC72, KC84, KC93, and KC102. 1.1 GENERAL DATA Single Stage Compressors can also be used as booster These KC series compressors are heavy duty open compressor for ammonia applications.. type, designed for use with refrigerant R22, R134a, R502, and ammonia. There are two... - Page 14 Overall Dimensions Of Single Stage Compressors ‘E’ ‘D’ Ø 24 ‘F’ ‘G’ ‘H’ ‘J’ ‘B’ ’ ‘ ‘Y’ ‘Z’ ‘U’ ‘V’ KC 2 KC 3 KC 4 KC 6 KC 9 KC 12 Figure No. 1 Compressor Type KC12 1130 1130 1130 1130...
- Page 15 Overall Dimensions Of Two Stage Compressors ‘E’ ‘H’ ‘F’ ‘D’ ‘J’ ‘K’ ‘G’ Ø 24 ‘L’ ‘M’ ‘N’ ‘P’ ‘B’ ‘U’ ‘W’ ‘Y’ ‘Z’ ‘V’ KC 21 KC 31 KC 42 KC 51 KC 63 KC 72 KC 93 KC 102 Figure No.
- Page 16 Salient Features of Construction Discharge Valve Assembly Three concentric discharge valve rings ensure ample gas passage at low lifting height. The use of sinusoidal springs together with precision machined and lapped surface results in a trouble-free operation for a remarkably long time. Minimum inventory for spares since most parts are Cylinder Liner and Suction Valve identical throughout the KC-series compressors.
-
Page 17: Constructional Detail
connection. 2. CONSTRUCTIONAL DETAILS 2.3 CYLINDER LINER 2.1 GENERAL The renewable cylinder liners, made of fine grain cast The compressor series KC comprises of 2, 3, 4, 6, 9, 12 iron centrifugally cast, are pressed into the cylinder cylinders which are manufactured as single or two-stage jackets and can be easily replaced. - Page 18 2.6 CONNECTING RODS 2.7 CRANKSHAFT The connecting rods are made of nodular SG IRON, The crankshaft is accurately ground and dynamically fitted with split, white metal lined, precision steel balanced, thus ensuring quiet operation good running backed big end bearings and a push fit, bronze, small characteristics and high wear resistance.
- Page 19 SIGHT GLASS OIL CHANNEL IN CRANKSHAFT Figure 6 : Lubrication System Recommended Oil KIRLOSKAR ADVANTAGE AC & REFRIGERATION COMPRESSOR OIL 20 ltr smart pack Easy to buy, stock and use No risk of loose purchased adulterated and reconditioned oil No need to invest on 200 ltr drum...
- Page 20 2.11 LUBRICATING CHART Recommended Lubricants for Single Stage, Two Stage & Booster Compressors (ISO VG 68 Grade): Sr. Brand Quality of Oil Suitable for Refrigerant Evaporation Temp. Range Indian Oil (IOC) Servofriz-57/68 NH3, R12, R22 +10 to -25°C Hindustan Petroleum (HP) SEETUL-68 NH3, R12, R22 +10 to -25°C Bharat Petroleum (BP)
-
Page 21: General Operating Instructions
KIRLOSKAR PNEUMATIC compressors. 3.1 OPERATION OF COMPRESSOR. This arrangement, however, only allows the passage of... - Page 22 and the mask should be kept at the same spot, Small 3.6 PREPARATION FOR COMPRESSOR leaks can be traced with the aid of blue litmus paper, OPERATION which will fade to violet on coming into contact with When a new compressor has been installed the ammonia.
- Page 23 3.11 EVACUATION OF SYSTEM WITH l. Shut stop valve between release line and system. COMPRESSOR AND VACUUM PUMP FOR m. Start compressor and open suction stop valve FREON PLANTS: slowly. Before charging the system with refrigerant, air and n. Repeat steps 'd', 'e', 'g' and 'k'. water must be cleared from the compressor and plant.
- Page 24 h. Weigh new bottle, check the content and connect it only is discussed here, the operating manual for the to charging line. Open bottle stop valve slowly. plant concerned should be consulted. i. Start cooling water pump and open cooling water 3.18 STARTING: stop valve on condenser .
-
Page 25: Capacity Control System-Single Stage Compressor
3.21 REQUIREMENTS FOR RECOVERY, REUSE AND DISPOSAL All consumables, parts like refrigerant, oil, heat transfer medium, filters, driers, insulation materials, etc. should be recovered, reused or disposed off in proper manner. It is to be undertaken by competent person only. There should be proper facility for disposal as per regulatory rules and laws established by state/local authorities to prevent person, property, society and... - Page 26 CAPACITY CONTROL DIAGRAMS (SINGLE STAGE) Compressor KC-2 Figure 9 Cyl. Block. No. Capacity Direct Connection Solenoid Valve ON Compressor KC-3 Figure 10 Cyl. Block. No. Capacity Direct Connection Solenoid Valve 1 ON Solenoid Valve 2 ON S.V.NO.1 S.V.NO.2 Compressor KC-4 Figure 11 Cyl.
- Page 27 Compressor KC-6 Figure 12 Cyl. Block. No. Capacity 1 2 3 4 5 Direct Connection Solenoid Valve 1 ON Solenoid Valve 2 ON S.V.NO.2 S.V.NO.1 Compressor KC-9 Figure 13 Cyl. Block. No. Capacity 1 2 3 4 5 6 7 8 9 Direct Connection - - - - - Solenoid Valve 1 ON...
- Page 28 CAPACITY CONTROL DIAGRAMS (TWO STAGE) Compressor KC-21 Figure 15 Cyl. Block. No. Capacity Ø Direct Connection Solenoid Valve ON Compressor KC-31 Figure 16 Cyl. Block. No. Capacity Ø Direct Connection Solenoid Valve 1 ON S.V.NO.1 Solenoid Valve 2 ON S.V.NO.2 Compressor KC-42 Figure 17 Cyl.
- Page 29 HP 1 Compressor KC-51 Figure 18 Cyl. Block. No. Capacity Ø 1 2 3 4 5 Direct Connection Solenoid Valve 1 ON Solenoid Valve 2 ON Solenoid Valve 3 ON Solenoid Valve 4 ON S.V.NO.4 S.V.NO.3 S.V.NO.2 S.V.NO.1 Compressor KC-63 Figure 19 Ø...
- Page 30 Compressor KC-84 Figure 21 Cyl. Block. No. Capacity Ø 1 2 3 4 5 6 7 8 9 10 11 12 Direct Connection - - - - - - - Solenoid Valve 1 ON - - Solenoid Valve 2 ON S.V.NO.4 S.V.NO.3 S.V.NO.2...
-
Page 31: Operating Instructions & Capacity Control System
5. OPERATING INSTRUCTION AND a) Compressor model used CAPACITY CONTROL SYSTEM TWO STAGE b) Gas used in Refrigeration system COMPRESSOR c) Design condensing saturation temp. of system. d) Design saturation evaporation temp. of system. 5.1 GENERAL 2. Go through the capacity control diagram given for We are manufacturing following 9 types of Two Stage various two stage compressor (figure 15 to 23), Note Compressors in KC versions. - Page 32 B) Compressor started at relatively low evaporation 3. Draw horizontal line for 40°C condensing temperature and Ammonia Gas for Ø = 2, 3, 4, 5. temperature : Intersecting points, to right side of field application This situation occurs after the compressor has been bold lines, will be a1, a2, a3, a4.
- Page 33 FIELD APPLICATION DIAGRAM GAS - R22 VOLUME GAS - NH SYSTEM ‘A’ RATIO SYSTEM ‘A’ Ø = 5 Ø = 4 Ø = 3.5 Ø = 3 Ø = 2.5 Ø = 2 Ø = 1.5 -40 -30 -20 -40 -30 -20 SUCTION L.P.
-
Page 34: Parallel Operation Of Compressor
6. PARALLEL OPERATION OF COMPRESSOR No extra gas equalizing lines are necessary because the vertical location of the oil equalizing line is such, that GENERAL the prescribed oil level in the crankcase is approx, half Whenever two or more compressors are installed with way this line thus leaving ample passage to equalize the common suction header piping and these compressors crankcase pressures as well. -
Page 35: Periodical Maintenance & Its Schedule
It is empathetically pointed out that assembly of the 7. PERIODICAL MAINTENANCE AND ITS valves should be carried very carefully. Incorrectly SCHEDULE: assembled valve will immediately give rise to trouble. 7.1 The compressor, like any other machine, requires When valve components are replaced; it is important to regular maintenance. - Page 36 Topping up by means of crankcase evacuation by the 7.7 SHAFT SEAL: compressor itself causes only a short interruption in The shaft seal should be inspected after about 4,500 plant operation, provided a drum of the oil is connected hours' running. In most cases only the rubber '0' rings to the oil charging stop valve before closing the suction will have to be renewed, to ensure that a reliable seal is maintained.
- Page 37 IMPORTANT LOG SHEET DATE: COMPRESSOR NO.: TIME SUCTION DISCHARGE INTR TE CHILLER COND'R PRESSURE PRESSURE PRESSURE PRESSURE TEMP. PR. TEMP. PR. LEVEL TEMPERATURE TEMPERATURE TEMPERATURE TEMPERATURE °C °C °C °C °C °C Hourmeter should be installed during commissioning to record total hours of operation. IMPORTANT 7.13 MAINTENANCE SCHEDULE: COMPONENT OF SYSTEM...
-
Page 38: Accessories
8. ACCESSORIES: locking off are similar to those of the H.P. pressostat. A fall in the suction pressure below the preset minimum pressure 8.1 PRESSURE SWITCHES causes the electric motor to be switched off. These pressure switches are provided for safety of 8.4 OIL PRESSURE DIFFERENTIAL PRESSOSTAT compressor and plant operation. - Page 39 HIGH DIFFERENTIAL DELIVERY OIL SUCTION OIL PRESSURE PRESSURE PRESSURE 3 Ø 50 hZ. 415 V Supply CUTOUT CUTOUT CUTOUT K1: Main contactor with aux. contact (3 Nos.) (ALL MAKE SHOWN) K2: Star contactor with 1 NO + 1 NC aux. contacts K3: Delta contactor with 1 NC contacts SUPER DELTA T: Timer with 1 No.
- Page 40 12 VDC/24 VDC BYPASS (WATER FLOW SWITCH) HEATER CONNECTIONS O/L = OVER LAY DELAY L1 = INDICATING LAMP - CONDENSOR WATER FLOW (LOW-TRIP) L2 = INDICATING LAMP - DISCHARGE PRESSURE (HIGH TRIP) C1nc L3 = INDICATING LAMP - SUCTION PRESSURE (LOW-TRIP) C1no L4 = INDICATING LAMP - OIL PRESSURE (LOW-TRIP) TS = TOGGLE SWITCH (L.P.
- Page 41 8.7 FLYWHEEL AND MOTOR PULLEY: means of an adjustable injection valve. This adjustable injection valve may be of either thermostatic or manual Normally compressor is driven by V belt arrangement type, having automatic or non-automatic settings through flywheel and motor pulley. No. of V grooves for respectively.
-
Page 42: Trouble Shooting Chart
9.TROUBLE SHOOTING CHART: IMPORTANT Fault Cause Remedy 9.1 Deliery pressure too high (probably Delivery stop valve not open wide enough Open fully H.P. pressostat becomes operative) Less or too warm cooling water Increase water supply (On water cooled condensers the Gas suction pressure too high (during Partially close suction stop valve temperature indicated by delivery... - Page 43 9.TROUBLE SHOOTING CHART (CONTD.): Fault Remedy Cause 9.9 Warm suction side of H.P. safety Leaking safety valve Repair/Replace 9.10 Oil consumption too high. Automatic oil return valve from oil Repair or replace/clear separatoris defective/chocked. Worn piston rings. Fit new piston rings. Oil return valve(s) in cylinder jackets Replace defective.
-
Page 44: Spare Parts
11. ILLUSTRATED SPARES PARTS LIST 10. RECOMMENDED SPARES 10.1 INTRODUCTION The illustrated parts lists are meant for identification and accurate specification of spare parts. This chapter deals with list of recommended spare parts, In order to facilitate quick reference to the required parts, Illustrations showing spare part details and parts numbers the lists and corresponding figures are divided into the are indicated in this chapter. -
Page 45: Crankcase Assembly With Safety Valve
11.1 CRANKCASE ASSEMBLY WITH SAFETY VALVE (FIGURES-31) Name of the part Part no. Qty. Remark Name of the part Part no. Qty. Remark Crankcase ass/v. 082.01.025.50 1 For KC2 Ferrule 999.16.019.50 4 For 15 dia tube Crankcase ass/v. 083.01.025.50 1 For KC3 Union Nut 999.16.079.50 4 For 15 dia tube Crankcase assly. - Page 46 4 & 5 18A & 18B 13 14 15 16A & 16B Figure 31A Name of the part Part no. Qty. Remark Crankcase assly. 084 01 002 50 1 For KC 4 Crankcase assly. 343 01 002 50 1 For KC 31 Gasket for sight glass 351 09 013 50 2 - Oil level glass...
-
Page 47: Bearing Covers & Intermediate Bearing
11.2 BEARING COVERS AND INTERMEDIATE BEARING (FIGURES-32) Name of the part Part no. Qty. Remark Bearing Cover Assy. 336.02.001.50 1 Drive end 1 .1 Bearing Cover Drive end 336.02.002.50 1 Pin Cylindrical 999.09.575.50 1 Bearing Bust (STD) 336.02.003.50 1 * Drive end Stud for Bearing Cover 999.03.683.50 8 M12 x 100 L Bearing Cover Assly... -
Page 48: Piston & Connecting Rod Assembly
11.4 PISTON & CONNECTING ROD (FIGURE-34) Name of the part Part no. Qty Remark Piston Assy 082.03.000.50 - As reqd Gudgeon Pin 082.03.020.50 1 Piston 082,03.110.50 1 Plate Safety 082.03.040.50 1 Bolt Safety 082.03.030.50 1 Set of piston Rings 082.03,150.00 1 Connecting Rod Assy 082.04.000.50 - As reqd... -
Page 49: Suction And Discharge Valve Assembly
11.7 SUCTION & DISCHARGE VALVE ASSLY.(Figure No. 37) Name of the Part Part No. Qty. Remark Buffer spring 082.28.090.50 Cup Spring 336.12.011.50 Delivery Valve Assly. 336.12.003.50 Split Pin 999.30.265.50 Castle Nut 999.06.692.50 Stroke Limitor 336.12.005.50 Spring Valve Discharge 082.11.120.50 Spring Valve Discharge 082.11.110.50 Spring Valve Discharge 088.06.150.50 Ring Valve Discharge 082.11.040.50... -
Page 50: Oil Pump Assembly
Figure 39 11.9 OIL PUMP ASSEMBLY (Figure No. 39) Name of the Part Part No. Qty. Remark OIL PUMP ASSLY. 082.07.000.50 Pump Housing with 082.07.010.50 Bushes Driving gear complete 082.07.360.50 Driven Gear Complete 082.07.370.50 Bearing Bush 082.07.330.50 2* Included in 1.1 '0' Ring 999.12.909.50 Oil Pump Cover... -
Page 51: Oil Filter Assembly
Figure 40 11.10 OIL FILTER ASSEMBLY (Figure No. 40) Name of the Part Part No. Qty. Remark Suction Filter Assly. 336.10.023.50 1 .1 Top Housing Assly. 336.10.033.50 Pipe Bend Included in 1.1 Welding Adaptor Included in 1.1 Packing 999.18.525.50 TAH-8 Valve Assly. 351.09.003.50 Packing 999.18.525.50... -
Page 52: Lubricating Oil Lines
11 .11 LUBRICATING OIL LINES (Figure No. 41) Name of the Part Part No. Qty. Remark OIL PUMP Oil Line number A 336.14.125.50 Oil pump toOPR* HSG. 1 .1 Packing 999.18.548.50 OPR* Reducing Nipple 336.14.111.50 CRANK CASE Ferrule 999.16.019.50 For 1 5 dia Union Nut 999.16.079.50 Tubing... -
Page 53: Suction Gas Strainer Assembly
1.7 1.6 Figure 42 11.12 SUCTION GAS STRAINER ASSEMBLY (Figure No. 42) Sr. Name of the Part Part No. Qty. Remark *1a Suction Strainer Housing - 1 For KC2 *1b Suction Strainer Housing - 1 For KC3 *1c Suction Strainer Housing - 1 For KC4, 31 Suction Strainer Housing 086.12.010.50 1 For KC6, 63... -
Page 54: Capacity Control Oil Piping
11 .13 CAPACITY CONTROL OIL PIPING SPECIAL TOOL KIT FOR ASSEMBLY 11.14 Drawing No. - 082.24.025.50 (Fig No. 43) Sr. Name of the Part Part No. Remark Sr. Name of the Part Part No. Qty. Remark Union Socket screw Assly. 998.16.243.50 For 6 mm tubing 1.1 Union socket Screw... -
Page 55: Suction Discharge Stop Valve Tal Valves
-760 Hg to 16 Kgf/cm , NH3 Suction/Oil Pressure Gauge 996.00.210.03 Figure 44 -760 Hg to 16 Kgf/cm , R12 11.15 STOP VALVE ASSEMBLY FOR KC SERIES (Fig. 44) Description TYPE 50 TYPE 50/70 IN TYPE 70 TYPE 70/80 T AL80 085.06.001.50... -
Page 56: Precautions To Avoid Failures On Compressors
CAUTION 12. PRECAUTIONS TO PREVENT 12.4 RESTART: FAILURES ON COMPRESSORS Our analysis of 'Field Failures' has shown that 98% of failures (i) Use new oil (Do not use same old oil) as per required on KC compressors have occurred due to 'SYSTEM DIRT' level, reassemble covers, strainers filters etc. -
Page 57: Installation Checks
INSTALLATION CHECKS IMPORTANT Ensure full tightness of base frame to foundation after allowing (A) CRANKSHAFT RUSTING OCCURRING IN THE FIELD sufficient curing time of concrete. It is found that during installation/pressure testing stage, the (vi) Mount compressor on base frame, level it correctly and fix site staff use lot of soap-water at shaft seal area. - Page 58 (over 30 countries) for more than 15 applications. KPCL is an ISO9001-2000 company, the very first in India in its line of activities. Kirloskar Pneumatic is also an outstanding force in the areas of system engineering and turnkey projects in Refrigeration and Air-conditioning.
Need help?
Do you have a question about the KC Series and is the answer not in the manual?
Questions and answers
What is the name of KCX4 Ammonia compressor part
What is the power rating of the KC 3 and KC 4 single stage compressor? And how long do they start and stop for?
The power rating for the KIRLOSKAR KC 3 single stage compressor is 59.4 kW, and for the KC 4 compressor, it is 78.5 kW. The start/stop duration is not mentioned in the provided context.
This answer is automatically generated