KOBELCO COMPRESSOR

GENERAL DESCIPTION

OUTLINE

Oil free compressed air is delivered from AL, the package type screw compressor unit, which
includes two compressor elements, coolers, silencers, motors and a controller, etc. two
compressor elements, the 1st and the 2nd stage elements, are speeded-up to their optimum speed
respectively by the gear apparatus driven by the electric motor.
Free-air sucked from the inlet of the unit passes through the suction filter and is compressed to
about a pressure of 2 kgf/cm2 G in the 1st stage and to the delivery pressure in the 2nd stage.
To cool down the compressed hot air the intercooler and the aftercooler are installed between the
1st and the 2nd stage, and after the 2nd stage respectively. Also, to cool down both stage elements,
water jackets are used in their casings. The male and the female rotors are supported by ball and
roller bearings in the 1st and the 2nd stage elements, and each rotors are synchronized by a pair of
timing gears.
The lubricating oil is injected into these bearings, timing gears and speed-up gears through the
oil cooler and the oil filter. The oil comes from the oil tank by the oil pump which is driven by
the motor M-2. The quantity of the delivery air is controlled by the capacity control valve
using an automatic close and open.

MAIN LINE FLOW

The suction silencer S-1, the suction filter F-1 and the capacity control valve CV-1 are
installed in the air line before the 1st stage. The suction silencer minimizes the noise which
comes from the 1st stage element through CV-1. The suction filter has the ability of straining
dust which is larger than approximately 10 microns. Loading of this filter is indicated by a red
field in the dust indicator DI-1 which is on the front gauge board. The system of the
thermocouple TE-1 and the temperature switch TIA-1 senses and indicates the air
temperature leaving the 1st stage.
This system sends an alarm signal to the controller when this temperature rises more, AL
stops immediately. The moisture, which is generated in the process of cooling down the hot
compressed air through the intercooler H-1, is separated by the drain separator DS-1 and
gathered in the drain trap and automatically drained. The pressure and the temperature of the
cooled air, after the intercooler, are shown on the pressure gauge PI-1 and the temperature
gauge TI-4 on the front gauge board. The pressure of this cooled air, of about 2 kgf/cm2G, is
used to act the balance piston in the 1st stage element and the capacity control valve.
After leaving the intercooler the cooled air is compressed to the delivery pressure in the 2nd
stage. The hot compressed air leaving the 2nd stage passes through the silencer S-2 and the
check valve V-1 and is cooled down to about 10C plus the supplied cooling water
temperature through the aftercooler H-2.

AIR FLOW DIAGRAM

2ND Stage comp.

C-2
CV-1, 2

Capacity control valve

H-1

Intercooler

H-2

Aftercooler

DS-1, 2

Drain separators

Ad-1, 2

Drain trap

SI-4

Silencer

F-1, 3
SV

Filters
Safety valve

SHV
SOL

Shuttle valve
4-Way solenoid

PA-4

Disch, press. switch

TIA-1, 2

Disch. Temp. switch

TE-1, 2

Thermocouple

DI-1

Dust indicator

The system of the thermocouple TE-2 and the temperature switch TIA-2 senses and
indicates the air temperature leaving the 2nd stage. This system sends an alarm signal to the
controller when this temperature is too high, and when this temperature rises more, AL stops
immediately. Some of the compressed air after the 2nd stage is led to the balance piston in 2nd
stage element. The moisture generated in the aftercooler is separated by the drain separator DS2 and gathered in the drain trap and automatically drained.
The discharge pressure of the 2nd stage is indicated on the pressure gauge PI-2 on the front
gauge board. The 4-way solenoid valve SOL works to close the capacity control valve CV-1
and to open the valve CV-2 receiving the signal from the discharge pressure switch PA-4
when the discharge pressure rises up to the preset max. pressure. As a result, the enclosed air,
between the check valve and the 1st stage, bleeds off to the atmosphere through the valve CV-2
and the silencer S-3, and AL is UNLOADED. Switching over the 3-way valve v12 v13
makes it possible to inspect the inlet and outlet pressure of the intercooler and the aftercooler.

OIL LINE FLOW

The oil pump GP driven by the motor M-2 supplies lubricating oil to the gear apparatus and
both stage elements from the oil tank OT. The strainer ST installed on the inlet line of the oil
pump form dust. The oil is filtered by the oil filter F-2, and cooled down through the oil cooler
H-3. The relief valves PV-1 and PV-2 are attached to the gear casing and regulate the oil
pressure approximately 2 kgf/cm2. Normal oil pressure is from 1.6 to 2.5 kgf/cm2.

OIL FLOW DIAGRAM

C-1

1st stage compressor

C-2

2nd stage compressor

M-1

M-2

Main motor
Motor, oil pump

GP

Oil pump

OT

Oil tank

ST

Strainer

F-2

Oil filter

H-3

Oil cooler

PV-1, 2
B

Relief valve
Breather

TE-3

Thermocouple

TIA-3

Temp. Switch

PA-5

Oil pressure switch

PI-3

Oil pressure gauge

LG

Oil level gauge

The system of the thermocouple TE-3 and the temperature switch TIA-3 senses and
indicates the oil temperature leaving the oil cooler. The system sends an alarm signal to the
controller when this temperature rises up to 60C and when this temperature rises up to 65C,
AL stops immediately. The oil pressure is indicated on the oil pressure gauge PI-3 on the
front gauge board. The oil pressure switch PA-5 works to stop :AL: when the oil pressure
drops below 1.5 kgf/cm2. The breather B is attached in the end of the oil filling pipe to make
smooth the oil returning flow to the oil tank from both stage elements.

WATER LINE FLOW

The supplied cooling water runs in the following lines:
a) Oil cooler - 1st stage 2nd stage
b) Intercooler
c) Aftercooler
The flow switch FS, and the water temperature switch TA-6 are installed in the line of a),
and stop the compressor when the water flow rate is not enough. Needle valves V-7 and V-8
are installed in the line of b) and c). The valve V-7 is very important to keep the air
temperature leaving the intercooler, i.e. 2nd stage suction temperature to prevent generation of
moisture which is harmful for the 2nd stage element.

COOLING WATER FLOW DIAGRAM

C-1

1st stage compressor

C-2

2nd stage compressor

H-1

Intercooler

H-2

Aftercooler

H-3

Oil cooler

FS

Flow switch

TA-6

Temperature switch cooling water

SAFETY DEVICES
Safety devices are complete to protect AL from critical operation.
NAME
Temp. switch (1)
Temp. switch (2)
Temp. switch (3)
Press. switch
Safety valve
Thermal relay
for oil pump
Thermal relay
for fan
Thermal relay
for compressor
motor
Coil
thermoswitch,
compressor
motor

CAUSE
1st disch. Temp. rises up to the preset temp.
2nd disch. Temp. rises up to the preset temp.

RESULT
Prealarm shut down
Prealarm shut down

Oil temp. rises up to 60C

Oil temp. rises up to 65C
Oil press. Drops to 1.5kgf/cm2
Disch. press. rises up to the preset press.

Prealarm
Shut down
Shut down
Air spouting

Over current

Shut down

Over current

Alarm

Over current

Shut down

Over current

Shut down

Flow switch

Shut down
Cooling water shortage

Temp. switch

Shut down

SAFETY DEVICES TABLE

NAME
Dust indicator

INDICATION
Red indicator appears at full range

Oil level gauge

Transparent gauge

Drain trap

Transparent bowl

MAINTENANCE
Cleaning or exchange of
suction filter element
Keep oil level between
MAX and MIN
Check that condensation is not
stagnant

DEVICIES FOR MAINTENANCE

3
1

4
2
5

1)
2)
3)
4)
5)

1ST discharge pressure gauge

2nd discharge pressure gauge
Oil pressure gauge
Dust indicator
Thermometer (2nd suction temperature)

11

6
14

13

12

10

6) Hour meter for running time

7) Load counter
8) Hour meter for loaded time
9) 1st discharge temperature switch
10) 2nd discharge temperature switch
11) Oil temperature switch
12) Lamp test switch
13) Reset switch
14) Bell cancel switch

MAINTENANCE
DAILY OR WEEKLY
1) Make records of operation condition of AL by filling up the Table in next page.
It helps to find disorder easily and to locate the cause of it readily.
2) The temperature of compressed air between the intercooler and the 2nd stage
element, i.e. the 2nd suction temperature indicated on the T1-4 thermometer
should be approximately 15C above the atmospheric temperature by adjusting
the valve V-7 to prevent the 2nd stage element from corrosion caused by the
moisture generated in the intercooler. This temperature can be raised by throttling
V-7, but it shall not exceed 60C in any case.
3) Check that condensation is not stagnant in the transparent bowls of two drain
traps and working interval of traps is 1-2 seconds. In the case of stagnation, turn
the adjustment screw clockwise.
4) Open the cooling water outlet valve outside the unit completely provided by the
user. Adjust the temperature rise of cooling water through the unit to about 10C
by the cooling water inlet valve outside the unit. Cooling water supplied
temperature and pressure shall not exceed 35C and 5kgf/cm2 respectively.
5) Check that the oil pressure is about 2 kgf/cm2 by the pressure gauge PI-3. It is
adjustable by turning the hex. Bolt which appears by taking off the cap of the
relief valve PV-1 in front of the gear apparatus. Turning it clockwise makes oil
pressure up, but it shall not exceed 2.5 kgf/cm2.
6) Check the dust indicator DI-1 during loading. If the red cylinder in it appears
completely, clean or exchange the suction filter element for new one immediately,
but never remove it during operation.
7) Check the level of oil in the oil tank by the level gauge LG. Always maintain it
just under the MIN line or rise above the MAX line.
8) Check that the air temperature around the unit is below 40C, ventilate the
compressor room sufficiently.
9) Check that the air pressure switch unloads AL at equal to or less than the design
pressure indicated in the data plate on the rear door of the unit. Check that an
unloading interval (time between one unload and next unload) is not shorter than
45 seconds. The shorter it is, the more the number of action of the capacity
control valve, the 4-way solenoid valve and the check valve consequentially the
shorter the life of them.

ITEMS
NORMAL
Dust indicator Not red field at all
1st discharge
1.9-2.7 kgf/cm2G
pressure
2nd discharge
Under 7
pressure (MAX)
1st discharge
temperature
Under 210
(MAX)
2nd suction
Max. 60C
temperature
2nd discharge
temperature
Under 200
(MAX)
Oil temperature
Under 65
Oil pressure

1.6-2.5 kg/cm2

Oil level

Between MAX
and MIN

Atmospheric
temperature
Cooling water
inlet
temperature
Cooling water
inlet pressure
Working
interval of drain
traps

Max. 40C
Max. 35C
Max. 5 kgf/cm2
1-2 second

RECORD OF OPERATING CONDITION

EVERY SIX MONTHS OR LESS

1) Regrease to the main motor regularly in accordance with the caution plate on the
unit cover. Type of grease shall be SHELL ALVANTA No.2.
2) Clean the top cover of AL and the main motor.
3) Remove and inspect the suction filter element during stopping and service it, if
necessary.
4) Remove the breather element and wash it in cleaning solvent and dry it
completely.
5) Inspect all pipes, tubes and hoses. Replace the damage parts and retighten leaking
connections.
6) Drain condensate in the control air filter F-3 by turning the knob at the bottom
counterclockwise during loading operation.

EVERY YEAR

1) Dismantle two drain traps and clean the parts in them.

2) Inspect the coil-spring and the pin the check valve V-1. Exchanger the check valve
assembly for new one if the LOAD COUNTER indicates the number more than
500000 for one year.
3) Test that the safety valve works accurately.
4) Replace the diaphragm, v-packings and the Teflon seat, and inspect the sleeve bearings in
the capacity control valve.
5) Check the operation data recorded by the user and judge whether the cleaning of the
water side of coolers is necessary or not. Chemical cleaning is the best way and renews
tetoron hoses in the water line after this cleaning. Never forget to fasten again the hose
bands after 30 minutes operation in this case.

1) Drain separator DS-1

2) Aftercooler H-2

1) Control air filter

2) Oil cooler

1) Temperature switch cooling water

2) Discharge pressure switch
3) Oil pressure switch

1
2

1) 1st stage element

2) Breather

1) 2nd stage element

2) Thermocouple