Kobelco Kobelion SG900A Instruction Manual
  1. Manuals
  2. Brands
  3. Kobelco Manuals
  4. Air Compressor
  5. Kobelion SG900A
  6. Instruction manual

Kobelco Kobelion SG900A Instruction Manual

Small oil-flooded screw compressor
Hide thumbs
Table of Contents

Advertisement

Quick Links

Thank you for your purchase of KOBELCO Small Oil-Flooded Screw Compressor "Kobelion".
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
W/O dryer
SG900A
Parts name
Union
Drain separator
Fork hole cover
(magnet sheet)
Nipple
Tube
*1) Drain separator for SG900A ,SG1230A has a nipple on the main body.
SG900A/AD
W/dryer
SG900AD
―
1
*1)
―
1
4
1
1
SG900A / SG900AD
SG1230A / SG1230AD
SG1230A/AD
W/O dryer
W/dryer
SG1230A
SG1230AD
―
1
*1)
―
1
4
1
1
Nipple
Tube
Fork hole cover
(magnet sheet)
Drain separator
Union

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Kobelion SG900A and is the answer not in the manual?

Questions and answers

Related Manuals for Kobelco Kobelion SG900A

Summary of Contents for Kobelco Kobelion SG900A

  • Page 1 SG900A / SG900AD SG1230A / SG1230AD Thank you for your purchase of KOBELCO Small Oil-Flooded Screw Compressor "Kobelion". 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.

  • Page 2: Table Of Contents

        Contents 1 Safety Information････････････････････････････････････････････ 1-1 １ General Precautions................1-1 ２ Alert Symbols and Safety Marks ............1-2 ３ Safety Rules ................... 1-4 2 Part Names and Functions ････････････････････････････････････ 2-1 １ Part Names..................... 2-1 ２ Meter Panel .................... 2-8 3 Location for Installation ･･･････････････････････････････････････ 3-1 １...
  • Page 3 Contents 6 Troubleshooting ･････････････････････････････････････････････ 6-1 １ Emergency Stop..................6-1 ２ Before You Suspect Failure ..............6-3 7 Maintenance and Part Replacement ････････････････････････････ 7-1 １ Guidelines for Inspection................ 7-1 ２ Daily Maintenance.................. 7-3 ３ Insulation Test Procedures for Compressor Unit ........7-4 ４...

  • Page 4: Safety Information

        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 ３ Safety Rules on page 1-4 where you will find itemized safety instructions. １ General Precautions ◎Carrying-in work, installation, operation, maintenance and inspections of the machine must be done by the well-trained personnel.

  • Page 5: ２ Alert Symbols And Safety Marks

    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 symbols Alert symbols give you important messages to use the product correctly and prevent damage to persons and property.
  • Page 6     ■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. Machine No. name plate MODEL Type Machine No. Please let us know the model and machine No.

  • Page 7: ３ Safety Rules

    Inspection and maintenance must be done by experts. Those who have little experience must be closely FORMAN supervised. Use only genuine KOBELCO parts. If not observed, it can cause malfunction and/or failure. GENUINE Be sure to earth the machine, or the electrical problems including noise may damage the electric unit or cause electric shock.
  • Page 8     Carrying in ■When using a forklift Carry the machine with fork arms into fork holes of the base plate. Put protector between the sound proof cover and the fork lift to prevent damage. When using a crane ■ Pass nylon slings through fork holes of the base plate and protect the front top surface of the sound proof cover with cloth.
  • Page 9 Installation/Installation site ■Transfer When moving the machine using a forklift or a crane, protect the sound proof cover with a pad cloth against damage. Do not drop the machine or carry it at a slant of 45 degree or more when moving it. CAUTION ■Installation site This machine is designed for indoor use only.
  • Page 10     Electric wiring ■Electric wiring Electric wiring must be performed by qualified electricians. ELECTRICIAN ･Leading into the power source should be done not to expose wiring. Wiring in the starting board requires a protective bushing in the through hole in order to protect the wires.
  • Page 11 Operation ■Dangerous objects Do not put any inflammables around the machine. Never work using flame near the machine. ･The compressor can catch a fire from spark producing work carried out near the machine, including welding, which may result in a fire. CAUTION ･The dryer contains refrigerating gas (Fron gas).
  • Page 12     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 the compressor. Be sure to perform a break-in (for 20 minutes) once a week. This is essential to prevent rust in the compressor.
  • Page 13 Lubrication ■Lubricating oil Use the KOBELCO GENUINE SCREW OIL or recommended lubricating oil. Never mix oils of different brands. Deterioration, shortage or emptiness of lubricating oil, and a bad oil circulation resulting from high viscosity can abnormally raise the lubricating oil temperature as hot as to CAUTION start a fire.
  • Page 14     MEMO 1-11 3208P1-01...

  • Page 15: Part Names And Functions

        ２．Part Names and Functions １ Part Names ■SG900A/SG900AD Dryer exhaust outlet Compressor exhaust outlet Outside View (For dryer-integrated type only) Discharges air heated through heat Performs heat exchange using exchange in oil cooler, after cooler condenser and discharges heated air. and motor.
  • Page 16     Safety valve Opens to discharge compressed air when the pressure inside the oil separator tank rises abnormally. Oil separator element Separates and recovers lubricating oil in compressed air. Oil filter Removes foreign materials in lubricating oil. Cooler (Oil cooler+After cooler) Cools compressed air and lubricating oil.
  • Page 17     Internal Construction Blow-off solenoid valve Opens to discharge compressed air when the compressor is stopped or moisture is removed. Suction filter Pressure keeping check valve Prevents foreign materials from entering. Volumetric regulating valve Adjusts inlet air flow. Closes to prevent reverse air flow when the compressor is stopped.
  • Page 18     MEMO 3208P1-01...
  • Page 19     ■SG1230A/SG1230AD Outside View Compressor exhaust outlet Discharges air heated through heat exchange in oil cooler, after cooler Dryer exhaust outlet and motor. (For dryer-integrated type only) Performs heat exchange using Handle condenser and discharges heated air. Dryer air inlet (For dryer-integrated type only) Lets in air for cooling the condenser.
  • Page 20     Internal Construction Safety valve Opens to discharge compressed air when the pressure inside the Oil separator element oil separator tank rises abnormally. Separates and recovers lubricating Oil filter oil in compressed air. Removes foreign materials in lubricating oil. Cooler (Oil cooler + After cooler) Cools lubricating oil and compressed air.
  • Page 21     Internal Construction Blow-off solenoid valve Opens to discharge compressed air when the compressor is stopped or moisture is removed. Suction filter Prevents foreign materials from entering. Volumetric regulating valve (Integrated with the compressor proper) Adjusts inlet air flow rate. Closes to prevent reverse air flow when the compressor is stopped.

  • Page 22: ２ Meter Panel

        ２ Meter Panel POWER lamp (green) Turned ON when the breaker is turned on. 4-digit LED display RUNNING lamp (green) Displays various information on the Turned ON while the compressor is running. compressor, such as discharge temperature, operation mode, and running hours. FAULT lamp (red) Turned ON when a fault in the compressor is detected.

  • Page 23: Location For Installation

        ３．Location for Installation １ Places to be Avoided ･Avoid outdoors. This machine is designed for indoor use only. ･Avoid rain. Use or store in locations where the machine is protected from rain. Exposure to rain may cause electrical leakage or rust, as the machine is equipped with electrical parts.

  • Page 24: ３ Installation Space For Safe Operation

    ･Provide a suction or exhaust fan, or ventilation duct. ･Do not install the compressor in the downstream of gas flow. KOBELCO ３ Installation Space for Safe Operation ･Secure sufficient space away from the outlet above the inlet on both side faces of the machine to ensure proper functions.

  • Page 25: ４ Installing The Machine In An Enclosed Room

        ４ Installing the Machine in an Enclosed Room ■Installation of Ventilating Fan and Duct ･Use in a closed room will increase the room temperature, causing the compressor to stop. To avoid this, provide an air supply opening to take fresh air in and an exhaust opening to discharge hot air, on Ventilating fan the walls of the room.
  • Page 26 Use of KOBELCO genuine expansion duct is inlet and the compressor exhaust outlet. Avoid recommended, as shown on the next page. smaller clearance or duct installation direct to the ･Minimize bents in the duct to avoid resistance.
  • Page 27 5 mmH ･When installing a ventilating fan in the exhaust duct, always secure a clearance of 300 mm to 400 mm between the exhaust duct and the exhaust outlet of compressor. KOBELCO Genuine Expansion Duct Part No. Model Straight type...

  • Page 28: Precautions Before Operation

        ４．Precautions before Operation 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. Be sure to read the section "Carrying in" of ３ Safety Precautions on page 1-5 before starting work.

  • Page 29: ２ Precautions For Piping

    ２ Precautions for Piping ･Vibration may be produced in a long, unsupported piping structure and be transmitted through the pipes, resulting in damage to the devices and components connected to the piping. Therefore, it is necessary to fix such long piping with appropriate supports (lifting attachments, clamps, and/or uprights) as shown in the illustration below.

  • Page 30: ３ Lubricating Oil

        ３ Lubricating Oil Precautions for lubrication ･Use our genuine brand lubricant, "KOBELCO GENUINE SCREW OIL" or the recommended oil listed below: Recommended lubricating oil ISO VG32 equivalent Oil manufacturer Brand Newrex SHT32 ExxonMobil Mobil Rarus 424 Shell Corena Oil S32...
  • Page 31 Refilling oil Press the STOP switch (red) to stop the compressor. Make sure that the pressure in the piping has been relieved completely. Then turn off the POWER switch. Turn off the earth leakage breaker. WARNING Loosen To open the oil supply port of the compressor, remove the front cover of the compressor and loosen the plug with a wrench.

  • Page 32: ４ Power Supply Wiring

                ４ Power Supply Wiring Selection of power supply transformer If the transformer is too small or the wiring is too thin and too long, the motor may not accelerate sufficiently or may fail to start because of a sharp voltage drop at the start. Select a transformer of an adequate capacity for the motor considering proper wiring size and routing.
  • Page 33       Selection of cables Power cable: 600V rated EV cables (600V rated polyethylene cables) 600V rated CV cable (600V rated cross-linking polyethylene cables) (JIS C3605-93) Earth cable: Connect the earth wire to the earth terminal (marked with E) on the power supply terminal block.
  • Page 34     ■Cable Connection Starting borad Power cable Connected by customer (To main motor) After removing the front cover and the protection cover for the starting board, connect the cable to the terminal block. 3208P1-01...
  • Page 35 ５ Connecting the Dryer (SG1230A/AD) ① Pipe connection 1. Make sure that the following are included in the accessories supplied separately. Name Part No. Rubber hose P-FB11-655#01 Elbow ZG31U32000 2. Remove the discharge pipe flange portion (including nipple) of the compressor unit.
  • Page 36     4. Attach the discharge pipe flange, which has been removed from the compressor unit, to the discharge outlet of the dryer unit. ② Electric wiring 1. For the spec. of 200/220V, 380/400/415/440V (1) For the spec. of 200/220V Connect the main power supply cable (three-phase) and the control line (connector) from the dryer power supply box to the terminal block of the starting board of the compressor unit.
  • Page 37 2. Connect the earth wire inside the dryer unit to the terminal block of the starting board. Starting board 4-10 3208P1-01...

  • Page 38: Operation

        ５．Operation １ Procedures for Pre-operation Inspection through Stop Ensure the safety of the compressor and its Do not touch any rotating parts peripheral that could be loads, and give an or heated parts while the "All Clear" sign to the people around the compressor is running or compressor before starting the operation.

  • Page 39: ２ Pre-Operation Inspection

    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! Is the oil level normal? If the oil level is lower than the H level when the compressor is stopped, supply oil to the H level and then add oil in the following quantity.

  • Page 40: ３ Operation Procedure

        ３ Operation Procedure ■Startup Turn on the main power. Turn on the earth leakage breaker. At the same time, make sure that the POWER indicator light on the meter panel is on. Press the SELECT switch to make sure the setting for operation mode, continuous operation at dryer fault and dryer preoperation.
  • Page 41 ■Stop Press the Stop button (red).    * The compressed air in the compressor will be discharged automatically. Turn off the earth leakage breaker switch. ･If the Start button (green) and the Stop button (red) are pressed several times in a short period, the dryer safety mechanism will be started.
  • Page 42     ４ Operation Modes Operation mode Feature Functions Auto start/stop ON/OFF function added to the operational ･Motor on/off characteristics of the EC mode ensures a high level of energy 【EL】 ･Purge saving efficiency. [In this mode, economical operation is performed. If the system ･Throttling of Electronic determines there is no air consumption during purging, the...
  • Page 43 ■Volumetric Regulating Valve Kobelion SG controls intake air flow rate using the volumetric regulating valve. The volumetric regulating valve reduces the torque applied to the compressor at startup. Also this valve smoothly controls discharge air volume between 100% and 0% according to the air demand variation by adjusting the valve disc opening.

  • Page 44: ４ Selection Of P/U Operation Mode

        ■U Operation Mode In this mode, the inlet air volume will be reduced if START SW ON the air consumption decreases and the discharge gauge pressure exceeds 6.9 bar (8.3 bar for H type). Pd 6.9bar Pd 8.3bar Volumetric regulating valve throttling ■EC Operation Mode In addition to the feature of the U mode, the EC...
  • Page 45 ■EL Operation Mode In addition to the feature of the EC mode, the EL START SW ON mode will allow the compressor to stop 15-minute start-up timer automatically if the load operation is continued over starts the preset time, which provides a high level of energy saving.

  • Page 46: ５ Controller (Meter Panel) Operation

        ５ Controller (Meter Panel) Operation ■Changing Display and Setting Changing Display and Setting The 4-digit LED display can display the following items. The setting of “Operation mode”, “Continuous operation at dryer fault” and “Dryer preoperation” can be changed by pressing and holding the CHG/RESET switch for 2 seconds or more.

  • Page 47: ６ Procedure For Changing Display And Setting

    ６ Procedure for Changing Display and Setting Turn on the power Dis. temp. display Operation mode display Press and hold U mode P mode the switch for In case of 55/75 kW output, 2 sec. or more the operation modes can be changed in the order of U, EC, EL and U.
  • Page 48     ■Switching Local-Remote Pressing and holding the LOC/REM switch on the meter panel for 2 seconds or more allows switching of the starting method, Local (START switch operation on the local side) or Remote (contact signal transmission from the remote side). If “Local”...

  • Page 49: Troubleshooting

        6．Troubleshooting １ Emergency Stop If a failure occurs, the FAULT lamp on the meter panel will be turned on, and an error code will be displayed on the 4-digit display. The compressor will not be restarted even if the START switch is pressed unless the remedial actions are taken and the CHG/RESET is pressed.
  • Page 50 ■Countermeasures Troubleshoot the problem following the countermeasures in the table below. Major factor Countermeasures The dust filter should be cleaned. No.1 Dust filter clogged. Remove the dust filter and clean it by air-blowing. The cooler should be cleaned. No.2 Oil cooler clogged. Stop the compressor, make sure that the fan is stopped, and clean the cooler.

  • Page 51: ２ Before You Suspect Failure

    Volumetric control failure Improper pressure setting Reset the pressure. Use of oil other than KOBELCO GENUINE Replace the oil with KOBELCO GENUINE SCREW OIL or SCREW OIL or recommended lubricating oil. recommended lubricating oil. Premature High ambient temperature Lower the temperature by ventilation or other methods.
  • Page 52 ■Motor Overcurrent When excessive current passes in the motor coil, the thermal switch trips and the compressor shuts down. Remove the cause of overcurrent and press the thermal relay reset (blue) button. Press the CHG/RESET switch on the meter panel with the error code “FC01” displayed. Make sure that the display is changed from “FC01”...
  • Page 53     ■When the motor does not starts; Step1 Turn off the earth leakage breaker. Step2 Interchange two of the three phases in the power unit and connect again. Step3 Return the breaker on and see if the motor starts. Not running. (Motor does not run.) (Interchange R and T.) (Motor runs.)

  • Page 54: Maintenance And Part Replacement

        ７．Maintenance and Part Replacement １ Guidelines for Inspection Inspection intervals and inspection items depend on the installation site as well as operating conditions. The table below provides the rough guidelines. Sound operation is expected if these guidelines are followed. Maintenance intervals Part No.
  • Page 55 Adjust cleaning frequency according to Oil cooler ▲ the operating conditions. Cleaning After cooler Dryer ▲ W/ Dryer type only condenser Cleaning KOBELCO ★ GENUINE P-HD11-509 P-HD11-509 Oil level SCREW OIL 20 L can check, ● Recommended Replenishm −...

  • Page 56: ２ Daily Maintenance

        ２ Daily Maintenance Cleaning of dust filter ■Cleaning Remove the dust filter cover and take the filter out. The filter should be either vacuumed or cleaned with water. SG900A/SG1230AD Name SG900A (D) SG1230A (D) P-CE05-555#16 P-CE05-555#16 P-CE05-521 P-CE05-521 The following part is The following part is Dust filter required on the dryer-...

  • Page 57: ３ Insulation Test Procedures For Compressor Unit

    ３ Insulation Test Procedures for Compressor Unit This compressor has an meter panel, which consists of electronic parts, and an inverter. Various kinds of serge absorbers are also equipped for noise prevention. Therefore, if insulation tests are made on the unit at the voltage beyond the setting for the serge absorbers, it could cause wrong test results and damage on the controller.

  • Page 58: ４ Cleaning Of Suction Filter

    ･Two shaft seals for the main motor incorporate a grease valve. Refill 15 g of grease through each grease valve at intervals of 2000 running hours. Refill grease using a grease gun while the motor is running. Use KOBELCO genuine grease, “KOBELCO GENUINE SUPER GREASE” (sold separately). CAUTION ･Never mix different brands of grease.

  • Page 59: Shutdown For A Prolonged Period

        8．Shutdown for a Prolonged Period ･When the compressor is not used for a prolonged period, be sure to turn off the earth leakage breaker. ･When the compressor is not used for a prolonged period, be sure to close the discharge air valve. ･It is recommended to perform a break-in once a week for perform a break-in about 20 minutes to keep the machine in good order and to...

  • Page 60: Relocation And Disposal

        9．Relocation and Disposal ■Relocation Kobelion-SG compressors can be used in either of 50 Hz area or 60 Hz area. When relocating the compressors in a different frequency area, parts should be replaced to suit the frequency. For details, contact the designated service shop, distributor, or Customer Service of KOBE STEEL.

  • Page 61: Remote Control

        10．Remote Control ■Remote Control Setting Procedure Remote control can be selected following the procedure below. Turn on the power. Press and hold the LOC/REM switch for 2 seconds or more and turn off the LOCAL lamp. Turn off the power and connect cables to the following terminals, referring to the Wiring Diagram on page 11-5.
  • Page 62 ■Handling External Signals The following external signals are provided. (See the electric wiring diagram on page 11-5,6) <Input signals to compressor> ･Remote･Run (Terminal H-F → Closed: Run) ･Remote･Stop (Terminal G-F → Open: Stop) <Output signals from compressor> ･Fault (common) (Terminal K-I → Closed: Emergency) ･Remote (Terminal L-I →...

  • Page 63: Specifications

    30°C {86°F}. (2) The discharge pressure gauge indicates the line pressure. (3) The compressor is not lubricated when shipped. Before operation, KOBELCO GENUINE SCREW OIL or the recommended lubricating oil must be supplied. (4) Noise level is measured at 1.5 m away from the machine and 1.0 m from the floor level in an anechoic chamber.
  • Page 64       Types Dryer Items Frequency (Hz) Common to 50/60 Three-phase 200〔380･400･415〕/ 200･220〔380･400･440〕 Voltage (V) Power consumption (kW) 2.49/3.02 8.94〔4.47〕 /9.72〔4.86〕 Current (A) Outlet dew point (°C {°F}) 12 {54} under pressure Compressor Totally enclosed type (rotary type), Class E insulation Condenser Cross fin coil type forced air cooling Refrigerant control method...
  • Page 65 30°C {86°F}. (2) The discharge pressure gauge indicates the line pressure. (3) The compressor is not lubricated when shipped. Before operation, KOBELCO GENUINE SCREW OIL or the recommended lubricating oil must be supplied. (4) Noise level is measured at 1.5 m away from the machine and 1.0 m from the floor level in an anechoic chamber.
  • Page 66       Types Dryer Items Frequency (Hz) Common to 50/60 Three-phase 200〔380･400･415〕/ 200･220〔380･400･440〕 Voltage (V) Power consumption (kW) 3.58/4.3 12.78〔6.39〕/13.83〔6.92〕 Current (A) Outlet dew point (°C {°F}) 12 {54} under pressure Compressor Totally enclosed type (rotary type), Class E insulation Condenser Cross fin coil type forced air cooling Refrigerant control method...

  • Page 67: ２ Wiring Diagram

                  ２ Wiring Diagram AC380･400･415/380･400･440V 50/60Hz AC200/200･220V 380･400･415/200V (50Hz) 50/60Hz 380･400/200V (60Hz) Negative phase relay 440/220V (60Hz) ＴＲ Transformer 《Water 《Air cooling model》 cooling model》 Back stop relay Revolution speed signal Running Fan inverter signal error VHR 7N...
  • Page 68         Motor protector 《Water cooling model 》 《Inside of controller》 Fuse/1A 5197‑06 5197‑03 CL06A09 《Interior of dryer 》 Back stop Dryer running relay CN‑DRYER Thermal relay CL06A06 High press switch Dryer failure Thermal controller switch Temperature Themal switch sensor Liquid injection solenoid valve Pressure switch...

  • Page 69: ３ Connection Diagram

        ３ Connection Diagram Transformer Transformer (For dryer integrated type only) (400 V class only) Suction indicator CN-Dryer Unload lock solenoid valve Starting board Main motor 11-7 3208P1-01...
  • Page 70       3 1 2 1 3 1 Temperature sensor after oil separator Discharge temperature sensor Purge solenoid valve Pressure switch Fan inverter Fan motor S TO P FL A F LB RY RC VI A V IB RS T OU T P 24 R/L1...

  • Page 71: ４ System Diagram

        ４ System diagram ■SG900A/SG900AD SG1230A/SG1230AD Temperature sensor Fan motor Exhaust Dryer air exhaust Fan control Suction filter Condenser Air inlet High pressure switch Dust filter Check joint After Oil cooler Unload lock solenoid valve cooler Dust filter Dryer air inlet Oil separator element Strainer Filter...

  • Page 72: Warranty

        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. Each machine has a machine number on it. This number is important for quality control of the product.
  • Page 73 MEMO 12-2 3208P1-01...
  • Page 74 KOBELCO MACHINERY ASIA PTE.LTD 60 Pandan Road, Jurong, Singapore 609294, REPUBLIC OF SINGAPORE Tel: +65-6262-0586 Fax: +65-6261-3719 KOBELCO COMPRESSORS AND MACHINERY PHILIPPINES CORPORATION Ground Floor, PDAF Building Buendia Ave.cor.EDSA, Makati City, Philippines Tel: +63-2-897-8736 Fax: +63-2-897-8737 SHENG SHI KOBELCO COMPRESSORS (BEIJING) CORPORATION...

This manual is also suitable for:

Kobelion sg900adKobelion sg1230aKobelion sg1230ad

Table of Contents