Kobelco AG15A Instruction Manual

Oil-flooded screw compressor

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Thank you for your purchase of KOBELCO Oil-Flooded Screw Compressor "Kobelion AG".

You are advised to read through this instruction manual carefully before you attempt to carry

out operation and maintenance.

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Fork hole cover

KOBELCO COMPRESSORS MANUFACTURING

AG15A

AG22A

(SHANGHAI)CORPORATION

KOBELCO OIL-FLOODED SCREW COMPRESSOR

AG15A / AG22A

Instruction Manual

DWG No. 4H50ZS1223P1

ISSUE 01 Printed 2013.10

Fork hole cover

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Summary of Contents for Kobelco AG15A

Page 1 KOBELCO OIL-FLOODED SCREW COMPRESSOR AG15A / AG22A Instruction Manual Thank you for your purchase of KOBELCO Oil-Flooded Screw Compressor "Kobelion AG". You are advised to read through this instruction manual carefully before you attempt to carry out operation and maintenance.
Page 2 ■ Copyright Reserved Copyright ownership belongs to KOBELCO, shall not be reproduced, copied, or used in other ways without permission. Espeically trademark, name of models, parts name and drawings. The manual is available to AG series. AG15A/AG22A...
Page 3: Table Of Contents
Precautions for Piping ……………………………………………………………………… Lubricating Oil ……………………………………………………………………………… Power Supply Wiring ……………………………………………………………………… …………………………………………………………………………… 5　Operation Pre-operation Inspection to Stop ………………………………………………………… Pre-operation Inspection …………………………………………………………………… …………………………………………………… Initial Settings for Controller (Factory default settings) Operation Procedure ……………………………………………………………………… Setting Control Pressure …………………………………………………………………… Operation Modes …………………………………………………………………………… Ⅰ AG15A/AG22A...
Page 4 8　Shutdown for a Prolonged Period ……………………………………………………‥ 9 Disposal ………………………………………………………………………………… 10 Remote Control …………………………………………………………………………… 11 Specifications …………………………………………………………………………… Specifications ……………………………………………………………………………… 11.1 Electric power facilities……………………………………………………………………… 59 11.2 Wiring Diagram ……………………………………………………………………………… 11.3 Connection Diagram ……………………………………………………………………… 11.4 System Diagram …………………………………………………………………………… 11.5 12 Warranty …………………………………………………………………………………… 13 Indemnity ………………………………………………………………………………… Ⅱ AG15A/AG22A...
Page 5: 1　Safety Information
　 must be done by the well-trained personnel. ◎ 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. AG15A/AG22A...
Page 6: Alert Symbols And Safety Marks
Meaning of pictograms Indicates the item to be prohibited. Concrete information is given by picture or sentence in or near the mark. Indicates the forced (mandatory) item. Concrete information is given by picture or sentence in or near the mark. AG15A/AG22A...
Page 7 /min Dischange Volume Motor Output Specific Power kW/ ( m /min ) Dimensions: W×D× H Weight Serial No. Manufacture Date PS-KA03-516#(K)-(L) Please let us know the model and machine No. when asking for repair or ordering spare parts. AG15A/AG22A...
Page 8: Safety Rules
Inspection and maintenance must be done by experts. FOREPERSON Those who have little experience must be closely supervised. Use only genuine KOBELCO parts. GENUINE If not observed, it can cause malfunction and / or failure. Be sure to earth the machine, or the electrical problems including harmonics may damage the electric unit or cause electric shock.
Page 9 Lift the machine slowly keeping the slings at a 45 degree angle with the top of the sound proof cover. *For detailed information, see 4.1 Unloading on page 24. AG15A/AG22A...
Page 10: Installation Site
40゜C {104゜F}. Do not put inflammable objects near the compressor. WARNING Installation When installing the compressor in a closed room, provide air suction and exhaust openings, and equip the exhaust opening with a ventilating fan having a proper capacity. AG15A/AG22A...
Page 11: Electric Wiring
The earth resistance should be 10Ω or less. A specialist should perform the earthing work. Be sure to connect the earth wire directly to the ground. CAUTION Operation without earthing may cause electric shock and failure in the compressor. AG15A/AG22A...
Page 12 When the power lamp is lit, never touch the rotating portions even if the compressor is stopped. ・To contact any rotating part, such as ventilating fan, 　always turn off the main power. CAUTION ・Note that the compressor is automatically started when 　the pressure drops to the recovery pressure. WARNING AG15A/AG22A...
Page 13 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. AG15A/AG22A...
Page 14 1.3.8 Lubrication Lubricating oil Use the KOBELCO GENUINE SCREW OIL or KOBELCO EXTRA OIL. Never mix oils of different brands. Degradation, insufficiency, discontinuous flow, and high viscosity of lubricating oil induces unusual high temperature, and it causes ignition. Be sure to visually check the oil level on the oil gauge CAUTION and, if it is low, replenish or change the oil.
Page 15 MEMO AG15A/AG22A...
Page 16: 2　Part Names And Functions
Part names and Functions 2.1 Overview Introduction AG15A and AG22A models are air cooled oil injected compressor, and driven by motors. They are installed in noise insulation canopies. AG15A and AG22A models are equipped with new-style KOBELCO controllers. The new controller panel becomes more visibility with full color touch screen LCD and easier to operate.
Page 17: Part Names And Functions
2.2 Part names and functions AG15A/AG22A Outside View Compressor exhaust outlet Discharges air heated through heat exchange in oil cooler, after cooler. Compressor air inlet Controller (Provided on the both sides) Used to run and stop the compressor, Lets in air for oil cooler, perform various setting, and display after cooler, and cooling motor.
Page 18: Internal Construction
Closes to prevent reverse air flow Oil outlet when the compressor is stopped. Used to drain lubricating oil in the motor splitter. Any modification without prior permission shall invalidate the warranty even within the warranty period. Please consult us whenever modification is required. WARNING AG15A/AG22A...
Page 19: Controller
・ Press and keep the key for 2 seconds to release emergency, caution and maintenance. 　④「Stop」 key ・ Shut down the compressor.（Remote run and local run will be stopped.）　⑤「Start」 key ・ In local mode, press the key for 0.4 seconds to start compressor. AG15A/AG22A...
Page 20 Indicates that compressor is running. Also indicates various operating conditions in ・ combination with other lamps that are lit or blinking. Above indication lamps, indicates various operating conditions in combination ○ with more than two lamps that are lit or off. See the next page. AG15A/AG22A...
Page 21: Lamp Indications
If starting operation in this state, it will be displayed as “Remaining pressure release”. It will start, if it waits to carry out a separator unit pressure drop and becomes 0.2MPa or less. For details, see the separate volume, "Controller Instruction Manual". AG15A/AG22A...
Page 22: 3　Location For Installation
, SO , and NO KOBELCO Avoid installation in environments where the machine may suck in harmful gases containing substances listed above. Sucking in such gases may cause clogging of the oil separator CAUTION elements, resulting in malfunctional shutdown. AG15A/AG22A...
Page 23: Installation Space For Safe Operation
Ｂor more Ｃ or more Ａor more [ mm ] Dimensions Minimum maintenance space Model Front side Right side Left side Rear side Width Depth Height 1000 AG15A/AG22A 1500 1350 or more or more or more or more or more AG15A/AG22A...
Page 24: Installing The Machine In An Enclosed Room
& fan in exhaust duct [MJ/h] [kcal/h] Pa(mmH Model /min] /min] /min] /min] AG15A 14,848 20(2) AG22A 21,758 ※1: Ventilation capacity indicates the value at the allowable room temperature of 5℃ {9゜F} higher than the ambient temperature. AG15A/AG22A...
Page 25 (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.
Page 26 EXTERNAL DIMENSIONS AG15A/AG22A...
Page 27 EFFECTIVE THREAD 40 FOUNDATIO N DRAWIN G NOTE: １．FOUNDATION 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) 4H31ZS1022P1 KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION AG15A/AG22A...
Page 28: 4　Precautions Before Operation
Attach the fork covers on both front and rear faces after the completion of installation. ･Figure(1): When lifting or moving, never attach the fork hole cover. ･Figure(2): In operation, please attach the fork hole cover for reducing the noise level. Fork hole cover back view front view front view back view Figure(1) Figure(2) AG15A/AG22A...
Page 29: Precautions For Piping
Prevent drain from flowing back in the discharged air piping. Prevent the reverse flow drain. It may cause the drain separator clogging or coolers corrosion. CAUTION Keep a distance of at least 800mm from the side of unit when installing the drain separator. AG15A/AG22A...
Page 30 × × （Used air toward air discharge volume Qs）《AG15A-H type calculation example》 = 0.5 min　　Qs= 2.47 m /min　　Pa= 0.101 MPa　　D= 0.80-0.70 = 0.10 MPa x=50%（Air tank capacity is surely made the biggest at the time of load rate 50%）...
Page 31: Lubricating Oil
Lubricating oil 6000 KOBELCO EXTRA OIL 3000 KOBELCO GENUINE SCREW OIL ・Never mix different brands of lubricating oil. ・If accidental contact of compressed air with food is 　expected, vegetable oil "ANDEROL FGC 32" may be used. 　To use the above oil, please contact our company.
Page 32 　　completely and tighten the plug securely. The quantity of oil required for change in full is shown below. Unit : (L) MODEL AG15A AG22A Quantity ・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.
Page 33: Power Supply Wiring
4.4 Power Supply Wiring AG15A/AG22A Power cable Recommended cable inlet Earth cable (Connected by customer) AG15A/AG22A...
Page 34: 5　Operation
0. (See page 54.) according to runn ing hours or ope rating time. In case of storage for a prolonge d period, store the compressor indoo rs and keep it dry. AG15A/AG22A...
Page 35: Pre-Operation Inspection
Check that the oil level is between H and L after the compressor is started. Avoid overfilling as it may deteriorate the oil recovery performance and increase the oil consumption. Ready? AG15A/AG22A...
Page 36: Initial Settings For Controller (Factory Default Settings)
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: 6000hours. KOBELCO GENUINE SCREW OIL: 3000hours. AG15A/AG22A...
Page 37: Operation Procedure
4 　Select and press「Pressure setting」 button on the touch panel. Check whether each setting is correct. If the pressure is changed as requied, press「Edit」button on the bottom-right. If pressure setting required, click the window displaying the number to edit the data. AG15A/AG22A...
Page 38 The compressor will stop in 10 seconds with unloading condition after pressing the Stop button. Press the Emergency Stop button in case the compressor needs to be stopped immediately. Emergency Stop * Emergency Stop button is used only in emergency case. AG15A/AG22A...
Page 39: Setting Control Pressure
3 If the pressure is changed as desired, select the「Edit」 to enter edit list. 4 Click the pressure value to change as required. ５．After the pressure is changed as desired, press 　　the Enter key for registration. Setting ranges AG15A/AG22A AG15A-H/AG22A-H AG15A-GH/AG22A-GH Lower Upper Lower...
Page 40 Discharge pressure of compressor performs unload operation [unloading pressure] in the following by setting time of an economical cycle, and it is the mode which can keep discharge pressure than [load pressure] by reopening load operation in [load pressure]. AG15A/AG22A...
Page 41: Operation Modes
Manual running mode Control system diagram Pilot valve is on (2-position 2-way) To blow off unloading valve To unloading valve servo cylinder Solenoid valve is closed Notes：All of configuration and quantity of parts in the drawings are only for reference. AG15A/AG22A...
Page 42: Auto】・【Manual】Mode
S/V : Closed load [Auto] running mode [Manual] running mode Discharge pressure is measured to Dis. press.＜Loading press. see whether air is demanded. Unload lock released Load S/V : Open Load operation Returns to the load operation AG15A/AG22A...
Page 43 Motor auto stop Unloading Dis. press. ＜Loading press. Dis. press. ＜Auto start press. continued. Motor auto Stop lock released Unload Star delta start Unload lock released S/V : Open Load (Load S/V : Open) i t a i t a AG15A/AG22A...
Page 44 Emergency Stop Running Emergency condition occurs Emergency Stop Operation Emergency Stop Stop Operation Unload starting Starting Operation pass 10S unload working lock released Unload motor stop AG15A/AG22A...
Page 45: 6　Troubleshooting
Oil cooler clogged KC-02 Oil filter clogged KC-04 External error Check the external error input. (Call KOBELCO distributor.) Cut off power supply and check if power supply KC-06 Phase sequence wiring is correct. Discharge pressure is Please check the ventilating duct, valve and other failures.
Page 46: Caution
Oil separator element service (Call KOBELCO distributor.) Oil change service (Call KOBELCO distributor.) Cooler service Inspect the cooler. (Call KOBELCO distributor.) Maintenance sensor (Call KOBELCO distributor.) change Inspection annual (Call KOBELCO distributor.) Pressure loss is too large Discharge pressure is too large to lower the pressure setting.
Page 47: Countermeasures
Clean condenser fin. KC-09 Motor failure Stop compressor. Check if motor constants is higher than 10MΩ. If not call KOBELCO distributor. KC-11 Too many start & stop Check if pressure fluctuation is not continuous occurred. frequency Compressor must be kept running more than 2 min and kept stopped state for more than 3 min.
Page 48: Interlock List
6000 hours Start of operation to Yearly inspection Running hours Controller 6000 hours one year or yearly inspection to one year *Please refer to the manual of Part 7 for details. *(1).Use KOBELCO GENUINE SCREW OIL *(2).Use KOBELCO EXTRA OIL. AG15A/AG22A...
Page 49 MEMO AG15A/AG22A...
Page 50: Before You Suspect Failure
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 lubricating oil. Premature deteriorationHigh ambient temperature Lower the temperature by ventilation or other methods.
Page 51 MEMO AG15A/AG22A...
Page 52: 7　Maintenance And Part Replacement
Use only authorized parts. We shall not be resposible for any faults or damages caused by unauthorized parts. ■ Maintenance 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.
Page 53: List Of Preventive Maintenance
（1）： Or once per year, perform the maintenance in accordance with which one comes first. ·Please call KOBELCO distributor if timer set change required. ·Please call the customer service center of KOBELCO in case of replacing oil and oil filter element in tough conditions. WARNING ·Please pay attention to any leakage.
Page 54: Insulation Test Procedures For Compressor Unit
　 (FG: frame ground). 【Insulation test for control circuit】　1. Disconnect all the connectors inserted into the controller. 　2. Measure the insulation of terminals on the terminal block of starting board and 　 the base plate (FG: frame ground). AG15A/AG22A...
Page 55: Cleaning Of Suction Filter
　 clogged early. In such cases, early replacement is recommended. ・Operation continued without replacing or cleaning the suction filter may cause damage to the duct hose. Part No. PS-CE03-517 Suction filter element Suction filter Element Cover Cover Suction filter Element AG15A/AG22A...
Page 56 AG15A/AG22A...
Page 57: 8　Shutdown For A Prolonged Period
・Compressor is not running for a long time, lubricating oil of friction pair may drain. When powered on again, prone to friction, lead units CAUTION severely damaged. So the unit is not running for a long time, before power on again, please call Kobelco distributor. AG15A/AG22A...
Page 58: Disposal
９．Disposal Disposal To dispose of any AG series compressor, drain the lubricating oil. For details, contact the designated service shop, distributor, or Customer service of KOBELCO COMPRESSOR. AG15A/AG22A...
Page 59: Remote Control
1) The stop operation using the Stop button on the control panel is valid regardless of LOCAL / REMOTE selection. 2) LOCAL / REMOTE selection can be changed during operation. ○：Valid　×：Invalid Selection Start button Stop button Remote ON Remote OFF ○ ○ × × Local × ○ ○ ○ Remote AG15A/AG22A...
Page 60 （３）The terminal COM2, X8, X9, XA, COM4, Y20, Y21, Y22, Y23, Y24 　　　for remoteness is prepared in the starting panel terminal block TB2. Any modification without prior permission of KOBELCO MACHINERY ASIA PTE. LTD. or KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION may invalidate the warranty even within the warranty period.
Page 61: Specifications
(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.
Page 62: Fan Properties
Fan properties FAN AND FAN MOTOR Type Items AG15A AG22A Frequency （ Hz ） Voltage 3-phase 380,415 （ V ） Output 0.55 （ kW ） Input air 3850m /h@200Pa 3600m /h@300Pa Cooling system Air cooling AG15A/AG22A...
Page 63: Electric Power Facilities
Select a transformer of an adequate capacity for the motor considering proper wiring size and routing. Transformer capacity Model Voltage Tansformer capacity 380V,415V 30kVA or more AG15A 380V,415V 50kVA or more AG22A ■ Selection of power supply breaker When installing the breaker for the main power supply, select an earth leakage breaker. Star-delta current...
Page 64: Selection Of Cables
Cable size Power cable Earth cable Screw size of terminal panel Model Voltage 5m within 10m within 20m within 5m within power cable Earth cable 380V AG15A 10mm 10mm 16mm 10mm 415V 380V AG22A 10mm 16mm 16mm 16mm 415V NOTE: 20 m or longer cables must have a sectional size more than those listed above.
Page 65: Wiring Diagram
11.3 Wiring Diagram To perform remote control, read Chapter 10 "Remote Control" (page 55). CAUTION AG15A/AG22A...
Page 66: Connection Diagram
11.4 Connection Diagram Rear side of touch panel COM1 24VDC COM1 COM2 CN14 CN17 T4 T3 P2 P1 CN10 COM1 Emergency stop switch SV1 Y2C COM3 U V W PE V2 W2 PE U1 V1 W1 AG15A/AG22A...
Page 67: System Diagram
11.5 System Diagram AG15A/AG22A CONTROL VALVE IS ON(2-POSITION 2-WAY) TO BLOW OFF UNLOADING VALVE TO UNLOADING VALVE SERVO CYLINDER SOLENOID VALVE IS CLOSED MARK NAME AIR FILTER PRESSURE DIFFERENTIAL SWITCH PRESSURE SENSOR（INSIDE OIL SEPARATOR UNIT） PRESSURE SENSOR（DISCHARGE PRESSURE） SUCTION PRESSURE SWITCH TEMPERATURE SENSOR（INSIDE...
Page 68 AG15A/AG22A...
Page 69: Exclusion Of Warranty
・Any faults induced by defects in equipment other than the machine, foundation, 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. AG15A/AG22A...
Page 70: Indemnity
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.

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Ag22a