XG110 160kWA

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KOBELCO OIL-FLOODED SCREW COMPRESSOR

XG2140A-110  XG2140A-110H  XG2140A-110GH

XG2540A-132  XG2540A-132H  XG2540A-132GH

XG3030A-160  XG3030A-160H  XG3030A-160GH

SPECIFICATIONS

KOBELCO
O CO CO
COMPRESSORS
O MANUFACTURING
C G
(SHANGHAI)CORPORATION

No. 4V40ZS1041P1
Printed 2013.06 ISSUE 07
P1

 CONTENTS

〔CONTENTS〕
Contents …… 1
Product Specifications …… 2
Installation Conditions …… 6
Precautions for Piping …… 10
Electric Power Facilities …… 12
Lubricating Oil …… 15
Warranty Conditions …… 16
Indemnity …… 16
〔Attached Drawing〕
(1) ITCS Controller …… 17
(2) External Dimensions …… 19
(3) Foundation Drawing …… 20
(4) System Diagram …… 21
(5) Wiring Diagram …… 22
Wiring for Automatic
(6) …… 24
Alternate Operation

WARNING
 
RESPIRATORY DISORDER

 Do not breathe in nonclean compressed


air or do not use it for any respiratory
equipment; otherwise, a respiratory
disorder may be caused.
P2

PRODUCTS SPECIFICATIONS
◆ XG2140A
Model
XG2140A-110 XG2140A-110H XG2140A-110GH
Item
Frequency (Hz) 50
Power supply voltage (V) 380 / 415 3-phase 3-wire type
3
Air discharge volume (m /min) 21.4 20.2 19.7
Specified 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 1.0
condition
Temperature (℃(゚F)) 45 {113} below (Ambient temperature condition : 30℃ {86°F})
Output (kW) 110
Type 3-phase cage induction totally enclosed
Voltage (V) 380 / 415
Main motor

Number of poles 4P
Protection IP55
Cooling system Air cooling
Starter system Star-Delta
Insulation class F
Output (kW) 1.8x2
Fan motor

Type 3-phase cage induction totally enclosed


Number of poles 4P
Insulation class B
Discharge pipe diameter (A) R23 / DN80 flange
g oil charge
Initial lubricating g (L) 100
Dimensions: W×D× H (mm) 2600 × 2000 × 2000
Weight (kg) 3700
Noise level (dB(A)) 69

NOTES:
(1)Measurement method of Air discharge volume( volumetric flow ) based on GB/T3853(Is equivalent to ISO 01217
Appendix C). Suction condition : 20℃ {68゜F} 1bar 0%RH
(2)The discharge pressure gauge indicates a package outlet pressure.
(3)Lubricating oil is filled in a compressor at the factory.
  Be sure to use『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.
P3

◆ XG2540A
Types
XG2540A-132 XG2540A-132H XG2540A-132GH
Items
Frequency (Hz) 50
Power supply voltage (V) 380 / 415 3-phase 3-wire type
Air discharge volume (m3/min) 25.4 24.1 21.4
Specified pressure (MPa) 0.7 0.8 1.0
Suction Pressure Atmospheric pressure (1 bar)
condition p
Temperature ( ( ))
(℃(゚F)) ( )
2~40(36~104)
Pressure (MPa) 0.7 0.8 1.0
Discharge
Max. discharge pressure (MPa) 0.75 0.85 1.0
condition
Temperature (℃(゚F)) 45 {113} below (Ambient temperature condition : 30℃ {86°F})
Output (kW) 132
Type 3-phase cage induction totally enclosed
Voltage (V) 380 / 415
or
Main moto

Number of poles 4P
Protection IP55
Cooling system Air cooling
Starter system Star-Delta
Insulation class F
Output (kW) 3.0×2
3.0 2
Fan motorr

Type 3-phase cage induction totally enclosed


Number of poles 4P
Insulation class B 
Discharge pipe diameter (A) R23 / DN80 flange
Initial lubricating oil charge (L) 120
Dimensions: W×D× H (mm) 2600×2000×2000
Weight (kg) 3800
Noise level (dB(A)) 70

NOTES:
(1)Measurement method of Air discharge volume( volumetric flow ) based on GB/T3853(Is equivalent to ISO 01217
Appendix C)
C). Suction condition : 20℃ {68
{68゜F}
F} 1bar 0%RH
(2)The discharge pressure gauge indicates a package outlet pressure.
(3)Lubricating oil is filled in a compressor at the factory.
  Be sure to use『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
made.
(6)As for the guaranteed values, consult with us separately.
P4

◆ XG3030A
Types
XG3030A-160 XG3030A-160H XG3030A-160GH
Items
Frequency (Hz) 50
Power supply voltage (V) 380 / 415 3-phase 3-wire type
3
Air discharge volume (m /min) 30.3 28.8 25.8
Specified pressure (MPa) 0.7 0.8 1.0
Suction Pressure Atmospheric pressure (1 bar)
condition p
Temperature ( )
(℃(゚F)) 2~40(36~104)
Pressure (MPa) 0.7 0.8 1.0
Discharge
Max. discharge pressure (MPa) 0.75 0.85 1.0
condition
Temperature (℃(゚F)) 45 {113} below (Ambient temperature condition : 30℃ {86°F})
Output (kW) 160
Type 3-phase cage induction totally enclosed
Voltage (V) 380 / 415
or
Main moto

Number of poles 4P
Protection IP55
Cooling system Air cooling
Starter system Star-Delta
Insulation class F
Output (kW) 3.0×2
3.0 2
Fan motorr

Type 3-phase cage induction totally enclosed


Number of poles 4P
Insulation class B
Discharge pipe diameter (A) R23 / DN80 flange
Initial lubricating oil charge (L) 120
Dimensions: W×D× H (mm) 2600×2000×2000
Weight (kg) 3900
Noise level (dB(A)) 71

NOTES:
(1)Measurement method of Air discharge volume( volumetric flow ) based on GB/T3853(Is equivalent to ISO 01217
Appendix C)
C). Suction condition : 20℃ {68
{68゜F}
F} 1bar 0%RH
(2)The discharge pressure gauge indicates a package outlet pressure.
(3)Lubricating oil is filled in a compressor at the factory.
  Be sure to use『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
made.
(6)As for the guaranteed values, consult with us separately.
P5

■ Fan properties
INVERTER FOR FAN
Type
Items
XG2140A XG2540A / XG3030A

Frequency (Hz) 50
Voltage (V) 3-phase 380 / 415
Output (kVA) 1.8×2 3.0×2
3 3
Input air 250m /min@200Pa(×2) 220m /min@300Pa(×2)
Cooling style Air cooling
P6

 Installation Conditions

1. PLACE NOT TO BE INSTALLED

○ Since this machine is manufactured to be used indoors, do not install it outdoors.


○ Since this machine is equipped with the precision electronic components, install it at
such place where the rain water never enters. A through care must be exercised so
that the machine is never exposed to the rain water even when the machine
is temporarily stored.
○ Do not install the machine especially at such place where there are a lot of dust and
the noxious gas such as chlorine gas, hydrogen sulfide gas, sulfur dioxide, ozone of
high density, etc.
○ It is to avoid it that you install it under the surroundings that it seems to breath in
machine tool cutting oil mist, soluble cutting liquid mist, discharge smoke of boiler,
p
decomposition g of plastics
gas p g are absorbed,, it
and others. When these mist and gas
is clogged with the oil separator element, and it causes emergency stop.
○ Do not install the machine where the ambient temperature exceeds 40(104゚F).
It may cause serious accidents such as burning of the machine and fire.
○ Install the machine on a horizontal floor. If a block etc. is placed beneath the machine,
the compressor may not be running properly.
○ Install the machine to be free from heavy vibration.
○ Please note that the noise level may vary with the building structure or position
within the building where the machine is installed.

2. INSTALLATION SPACE FOR SAFE OPERATION

■ INSTALLATION SPACE
○ Allow a space of 800mm for the left side, 1000mm for the right side, 1000mm for the front,

800mm for the back and 1500mm for the top against the body.
○ Secure an appropriate space for the normal operation around the air inlet on the right
and left side and exhaust outlet on the top the unit.
○ Enough front space is required to open/close the doors and maintain the compressor.
○ Install the machine on the horizontal
floor.
P7

EXHAUST
■ INSTALLING A VENTILATING DUCT OPENING

○ Provide a fresh air inlet and an exhaust outlet Install a


ventilating fan
installed with a ventilating fan to use the
machine
hi iin a closed
l d room.
○ Provide the size of the air intake so as not to
produce negative pressure in the room.
○ Select the ventilating fan bigger than the
following table. AIR SUPPLY
○ Be careful because the exhaust heat is going to circulate at the air intake ,
and the ambient temperature is higher if the ceiling is lower.
○ The machine is tripped at the room temperature of 40℃ (104゚F) or higher.

◆ Ventilation Method and Fan Capacity


items Compressor cooling air Minimum ventilation capacity (*2)
Generated Allowable
Exhaust Entire ventilation
calories pressure loss
Ventilating Ventilating
air volume duct duct & fan
Local
in exhaust duct ventilation(*1)

Model (MJ/h) (kcal/h) (m3/min) Pa(mmH2O) (m3/min) (m3/min) (m3/min) (m3/min)


XG2140A-110 1209 693 121 536
436 104,060 415
XG2140A-110H or more or more or more or more

XG2140A-110GH 1451 778 145 560


523 124 872
124,872 415 50 (5)
XG2540A or more or more or more or more

1759 885 176 591


XG3030A 634 151,360 415
or more or more or more or more

*1: Local ventilation is a method to exhaust air by directly exhausting one third to a half
of compressor-exhausted
p air using
g a ventilating
g fan installed near the compressor
p exhaust outlet
*2: Ventilation capacity indicates the value at the allowable room temperature of 5℃ {9゜F}
higher than the ambient temperature.
P8

■ INSTALLING A VENTILATING DUCT


○ Be sure to install a ventilating duct if it is
impossible to provide a ventilating fan in
a totally-closed
ll l d room.
○ Do not mount the compressor directly on METAL NETTING

the ventilating duct with screws


(at inspection, the duct can be removed easily).
○ Install wire net at the exit of the duct so that
birds or big refuse cannot get in.
○ Prevent rain water entering into the exit of
the duct.
VENTILATING FAN
○ Minimize a duct bend (maximum tolerance of
50Pa ( 5 mmH2O)) as much as possible to
avoid resistance.
○ Maximize a radius as much as possible when
bending the duct.
○ Install a ventilating fan at the exit of the duct
if the exhaust duct has a pressure loss of more
than 50Pa ( 5 mmH2O).
○ In case of installing a ventilating fan in the duct, be sure to select a heat resistant
type 〔80℃ (176゚F)〕.

Sectional area of ventilation duct must be larger than ventilation area on


air compressor, or else the unit may cause serious injury.
P9

■ INSTALLING A VENTILATING TYPE AND A VENTILATING DUCT


Sectional area of ventilation duct must be larger than ventilation area on air compressor,
or else the unit may cause serious injury.

① Entire ventilation ② Ventilating duct ③ Ventilating duct & fan


Local ventilation (*1)

CAUTION

・The ventilation capacity is   for  ・Calculate the pressure loss (resistance) in  the  ・The pressure loss (resistance) in 


ventilating the  entire room.  (at  ventilating duct based on the exhaust air  volume  the  ventilating duct is over 50 Pa (5 
the allowable room temperature  of the compressor.  If the result is not  more than  mmH2O),  install  a ventilating fan 
of  5℃ {9゜F}  higher than the  50 Pa (5 mmH2O) for air cooling type,  the exhaust  with the specified  capacity inside  the 
ambient  temperature) The  from the compressor exhaust outlet  through the  duct taking the pressure loss into  
duct will be possible. consideration.
air supply opening should be 
・Connect the ventilating duct referring to the 
adjusted   so that the flow rate 
duct  installation mark at the top of the 
will be 2 m/s or less. Caution
compressor.  The duct should be removable.   Do 
not fix the duct with screws.  It may hinder repair 
(*1)Local ventilation is a method  and maintenance work. Use of KOBELCO genuine  To choose a type of  fan can endure 
to exhaust air by directly  much heat .
expansion duct is 
expansion recommended, as shown on the 
duct is recommended, as shown on the
exhausting one third to a half of  next page. (high temperature )[80℃ {176゜F}]
compressor‐exhausted air using  ・Minimize bents in the duct to avoid resistance.
a ventilating fan ・When installing the duct, provide a full radius.  
installed near the compressor  Duct resistance over 50 Pa (5 mmH2O) could 
exhaust outlet. reduce the exhaust volume, causing temperature 
rise to stop the compressor.
・Even if the duct is connected directly to  the  ・Turn on the ventilating fan while 
compressor, the temperature will rise.  In such a  the  compressor  is running, and turn 
case, install a ventilating fan mentioned  in the  it off when  the compressor  is 
previous page (at the allowable room  temperature  stopped.
of 5℃{9゜F} higher than the ambient  ・The opening area of air inlet shall 
temperature).  be  adjusted  so that the flow rate will 
・Prevent rain water from entering the duct outlet. be 2 m/s  or less.
・If the pressure loss in the ventilating duct is over 
50 Pa (5 mmH2O), 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.
P10

Precautions for Piping

■ Piping
p g
・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
g main piping
 the discharge p p g so that theyy can be closed when the operations
p 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 concave or riser piping.
・To prevent condensate reverse flow connect a discharge piping at the top of the main
 piping.

When connecting to the main


piping, connect the discharge
piping from the above.

Main piping
Emergency valve
Discharge air
(If you increase
the compressor)
Main piping To prevent the reverse
flow such as drain.
Hanger

Inclination Hanger Discharge air


(Slope along
the air flow.)

Stop valve Stop valve

Flange nipple Flange nipple

Drainage valve Drainage valve

Work to be executed
by the customer.

Prevent drain from flowing back in the discharged air piping.


Prevent the reverse flow drain
drain.
It may cause the drain separator clogging or coolers corrosion.
CAUTION
P11

■Air tank installation


In order to make pressure fluctuation small, install the piping capacity more than surely
proper capacity (air reciver tank) in 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.

◆Air tank capacity

Model Air tank capacity (m3) Model Air tank capacity (m3)

XG2140A-110 Min 2.71 XG3030A-160 Min 3.83


XG2140A-110H Min 2.56 XG3030A-160H Min 3.64
XG2140A-110GH Min 2.49 XG3030A-160GH Min 3.36
XG2540A-132 Min 3.21
XG2540A-132H Min 3.05
XG2540A-132GH Min 2.80

Note)This is the capacity of the case of load rate 50%, difference of upper and lower limit
p y
pressure 0.1 MPa and a cycle time ((load → unload → load)) 30seconds.

PH
VR :Air tank capacity(m3)

t1 :Unload time(min)

t2 :Load time(min)

t1+t2≧0.5min(more than 30sec.)

Qs :Air discharge volume(m3/min)


PL
t1 t2 Pa :Suction pressure(MPa)

D :Difference of upper and lower limit pressure(MPa)

x :Load rate(Used air toward air discharge volume Qs


(t1+t2)× QS × Pa × x(1-x)
VR=
D

《XG2140A-110 type calculation example》


t1+t2= 0.5min  Qs= 21.4m3/min  Pa= 0.101MPa  D= 0.70-0.60= 0.10MPa
x= 50 %(Air tank capacity is surely made the biggest at the time of load rate 50%)

0.5 × 21.4 × 0.101 × 0.5 ×(1-0.5)


VR= ≒ 2.71 m3
0.10
P12

ELECTRIC POWER FACILITIES

380V·415V/50Hz (3-phase 3-wire type), should be supplied to the unit.

Remove the front cover and introduce the power cable through the opening on the left 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.

1. SELECTION OF THE EARTH LEAKAGE BREAKER


○ Install an earth leakage breaker to prevent motor burn out, earth fault, and electrical

shock. Inrush current is supposed to flow at the moment when switching from star
connection to delta connection. Please be sure to choose and use an earth leakage breaker having a
suitable electric specification
p in order for it not to work because of the inrush current flow.

Maximum rated current Star-delta staring current Inrush current(rms value) Recommended breaker model
Model
380V 415V 380V 415V 380V 415V Reference MITSUBISHI
XG2140A-110
247 A 226 A 1125 A 1027 A 4532 A 4136 A NV630-SW-3P-500A
XG2140A-110H

XG2140A 110GH
XG2140A-110GH
288 A 264 A 1219 A 1118 A 5280 A 4840 A NV630 SW 3P 500A
NV630-SW-3P-500A
XG2540A

XG3030A 346 A 317 A 1500 A 1374 A 6338 A 5804 A NV630-SW-3P-600A

* To prevent unexpected functions during start-up, use earth leakage breakers with
current sensitivity of 200mA.

2. SELECTION OF THE POWER CABLES


○ For the power cables, select EV or CV or VV cables for 600V insulated by the polyvinyl chloride.
GB12706.1-2002

Power cable Screw size of terminal panel


Model Voltage
5m within 10m within 20m within Power cable Earth cable
XG2140A-110
95 mm2 95mm2 120 mm2 M 10 M 10
XG2140A-110H

XG2140A-110GH 380V 2
120 mm 120 mm2 120 mm2 M 10 M 10
XG2540A 415V

2 2 2
XG3030A 120 mm 150 mm 150 mm M 10 M 10

NOTE: The thicker wires than ones in the above list are required in case of the power
    cables exceeding 20 meters. Conduct wiring work so that the wires become the
same size as ones in the above list in the Local, using the relay terminals and others.
P13

3. SELECTION OF EARTH CABLES


○ Connect the grounding cable to the grounding terminal of the starting panel.

Apply the grounding of 10Ω or less to the compressor . Never fail to connect the
grounding,
di or iti causes the
h electrical
l i l shock
h k accidents
id and
d the
h compressor troubles.
bl
Also, ground the compressor directly underground.

Model Voltage Earth cable

XG2140A-110
50 mm2
XG2140A-110H
XG2140A 110H

XG2140A-110GH 380V
70 mm2
XG2540A 415V

XG3030A 70 mm2

4. Selection of power supply transformer


○ When the motor is operated, if the capacity of the transformer is insufficient and/or

the electric wire diameter is too small and/or the wiring route is too long, the voltage
drop at the time of startup will be intense and the motor may not be accelerated
properly and, in some cases, the motor will not be started at all. Therefore, it is
important to select a proper transformer suitable to the motor capacity.

Model Capacity of Transformer

XG2140A-110
250 kVA or more
XG2140A-110H

XG2140A-110GH
300 kVA or more
XG2540A

XG3030A 360 kVA or more

NOTE: Use appropriate cables and breaker tabulated above.


Use of any wrong size cable may overheat and burn the motor and cables.
p
An inverter power pp y cannot be used.
supply
P14

5. Cable Connection
○ Open the control Cabinet door and the starting

boad cover. Then connect the cables to the


t
terminal
i l block(R/L1,
bl k(R/L1 S/L2
S/L2, T/L3 )
).
Please be sure to ground.

Backup cable inlet Recommend cable inlet

R S T

动力线
Power cable Earth
接地线 cable

(connected by customer)

In case using the secondary recommended wiring, connect the wiring following
the shape which is shown on the left side picture, to prevent the drain,
or any liquids come into the starting panel, along the cable.
P15

 LUBRICATING OIL

1. CONTROL OF LUBRICATING OIL


○ For the long and good use of the compressor, proper control of the lubricating oil is

necessary.
○ Lubricating oil shall not be mixed with that of a different brand. Mixing oil may
cause deterioration of oil or adherents which may shorten the life of compressor
extremely.
○ Change lubricating oil when the message “Lubricating oil replacement” lights up
on the controller. This message appears every 4,000 hours. Push the reset switch
after changing the lubricating oil.
○ If you change the brand of oil, drain the oil completely, and clean the oil line by
flushing oil, and supply new oil.

2. BE SURE TO USE THE RECOMMENDED LUBRICATING OIL


○ Use the genuine lubricating oil we are recommending.

KOBELCO GENUINE SCREW OIL(20L)


GENUINE LUBRICATING OIL
PC-HD11-S001

○ If accidental contact of compressed air with food is expected, vegetable oil


"ANDEROL FGC 32" may be used. (Exchange oil within 3000 hours.)
To use the above oil, please contact our company.

ANDEROL FGC 32(19L) P-HD11-525

3. BE SURE TO USE THE RECOMMENDED LUBRICATING OIL


Two shaft seals for the main motor incorporate a grease valve.
Refill 45 g of grease through each grease valve at intervals of 2000 running hours.
 Refill grease using a grease gun while the motor is running.

KOBELCO TOUGH GREASE


GENUINE GREASE
PS-HD11-507
(Sold separately)
Never mix different brands of grease.
P16

WARRANTY CONDITIONS

1. WARRANTY CONDITIONS
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.]

2. CONTENTS OF WARRANTY
In case a trouble should occur during the warranty period and when it is determined
that the trouble is caused clearly by our defective design, manufacture and or
execution of work, we repair or replace the parts free of change without delay.

3. EXCEPTIONS TO THE APPLICATION OF WARRANTY


Even during the warranty period of this machine, we refuse warranty in the following
cases:
· Trouble caused by the natural disasters or accidents belong human control.
· Trouble caused by a defective material selected or supplied by you, or caused by
a defect resulted from the design designated by you.
· Trouble
oub e caused by a repair
epa o or modification
od cat o co conducted
ducted by you without
t out notifying
ot y g us o
of tthe
e fact.
act
· Trouble caused by not adhering to the operating procedures, periodical inspections,
maintenance and storage, etc. described in the specification sheets and instruction
manuals issued by us
· Trouble caused by defective foundation, building and/or equipment other than this machine.

INDEMNITY

Under no circumstances shall, including any illegality, Kobe Steel, Ltd. be liable for
special, indirect, incidental, or consequential damages, including, but not limited to,
loss of production, loss of anticipated profits, loss of operational profits, loss of material
and products, or indirect losses, however same shall be caused.
P17

ITCS CONTROLLER(XG)【The description of each part】


ITCS displays information of operation state, condition setup and Emergency / Caution / Maintenance on a LCD screen,and it can be easily and correctly done
depending on the use conditions.
◎ Main motor overcurrent

◎ Motor coil temperature is high

◎ Fan motor overcurrent

CY STOP
◎ Dryer failure

EMERGENC
◎ Discharge
Di h air
i temperature
t t is
i high
hi h
After oil separator
◎ temperature is high ◎ Emergency stop

◎ Reverse phase ◎ Inverter error

◎ CPU error ◎ External em ergency


Starter panel electric
◎ Sensor error ◎ error

◎ Discharge air temperature is high


◎ After oil separator temperature is high
DISPLAY PART OPERATION PART ◎ External emergency

ON
CAUTIO
◎ Ambient
A bi t temperature
t t is
i high
hi h
① LCD SCREEN LIQUID CRYSTAL DISPLAY SCREEN ⑧ ARROW KEY 「↑」「↓」「→」「←」 ◎ Oil separator element clogged
Operation state(discharge pressure, discharge air temperature, 「↑」「↓」「→」and「←」 are movement of cursor, and also are used ◎ Motor coil temperature is high
ambient temperature, operation time, and load rate), condition to increase or decrease values of settings. ◎ Sensor error
setup( control type, loading pressure, unloading pressure, ⑨ 「Enter」KEY ◎ Inverter alarm
auto start pressure)maintenance time and contents and ・A setting value will be decided if the key "Enter" is pressed
management for machine error are displayed. ・If the "Enter" key is pressed by the specified item (item which ◎ Suction filter change
② Power LAMP(GREEN) cursor blinks), it jumps on the screen of the item. ◎ Oil filter change
It is shown that controller is in a turning-on-electricity state. ⑩ 「Reset」KEY ◎ Oil change
③ Load LAMP(GREEN) ・Change to "setting
setting value change mode"
mode to the item of the present ◎ Oil separator element change

MAINTENANCE
It is shown that compressor is under operation. cursor position. ◎ Cooler inspection
④ Auto Start LAMP(GREEN) ・Reset Emergency, Caution and a maintenance. ◎ Motor greasing
It is shown that it is in the state of operation standby. ⑪ 「Remote/Local」KEY ◎ Monitor battery change
⑤ Emergency LAMP(RED) It changes whether starting and a stop of compressor are performed ◎ Maintenance sensor change
It is shown in a compressor that Emergency occurred and stopped. Remote or Local. In a remote case, the orange lamp of "Remote"lights ◎ Pressure loss is high
⑥ Caution LAMP(ORANGE) up, and, in a local case, the green lamp of "Local" lights up. ◎ Lamp test
It is shown in a compressor that the Caution occurred. ⑫ 「Start」KEY
⑦ Maintenance LAMP(YELLOW) A compressor starts and the green lamp lights up.
It is shown in a compressor that the Maintenance occurred and it ⑬ 「Stop」KEY
Stop」KEY
needs maintenance. A compressor stops and the red lamp lights up. ISSUE
KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION DRAWING No. 4V51ZS1022P1 01
P18

ITCS CONTROLLER(XG)【The
( ) description
p of the loading
g function】
ITCS's main functions of indication are as follows.
◆Indication of compressor's
compressor s operating condition ◆Emergency, Caution, and Maintenance Indications ' 0 7/ 0 1 / 0 1 1 2 : 0 0 0 . 6 0 MP a

The compressor's operating condition is indicated on In case of an emergency or caution, the screen shows MA I N T EN A N C E BAC K

what happens and how to deal with it, in addition to its


C L OGG ED SUC . F I L T ER

the screen, including running pressure, temperature, causes.


T A K E OU T F I L T ER E L EMEN T AND C L EA N I T
B Y B LOW I NG A I R FR OM I N S I D E .

current, loading condition, running hour, Maintenance indication comes out on the screen C
C
HANG E E L EMEN T
L OGG ED .
I F I T I S BA D L Y

automatically when maintenance is required and also SUC . F I L T ER PR OGR E S S 1 2 0 h r 0 / R E S E T


running count, load hour and load count. shows when the next maintenance time comes by SV C . 4 0 0 0 h r
V 1 . 0 0 MOV E ▲ MOV E :+ R E S E T : R E S E T

indicating the elapsed time.


D E - 0 2 ▼ MOV E :- E N T ER : S E L EC T

' 0 7/ 0 1 / 0 1 1 2 : 0 0 0 . 6 0 M P a

R U N N I N G COND I T I ON 2 ・ B A C K

A F T . O / S T E MP E R A TU R E
7 8 . 0 ℃
L
T
I
c
N E
T
P
E M
R
P
E
E
S
R
S
A
U
T
R E
UR
E
0 . 0 0 MP a
6 9 . 4 ℃
◆Graph Indication ' 0 7 / 0 1 / 0 1 1 2 : 0 0 0 . 6 0 MP a
A U X . MA C H I N E C
ON D I T I ON 6 0 %
[ MP a ] RUNN I NG R ECORD [ D I S . PR E S ] BAC K
Graph indication is a useful function to see the
D R A I N W A T E R R
A T I O 3 0 %
R U NN I N G C O U N T
. 1 5 4 t i me H I
L O A D C O U N T . 1 2 0 t i me
L O A D H O U R . 7 0 0 H r compressor's operating condition.
O P ER A T I ON MOD E MA N A U TO
V 1 . 0 0
A E - 0 4
Its indication mode has a function
f which shows both
the operating condition in real time and running
record. The indicated data consist of three factors: L O

discharge pressure
pressure, current
current, and loading rate
rate. V 1 . 0 0 0 5 1 0 1 5 2 0

◆Setup of compressor's operation setting ME - 0 3 [ m i n ]

' 0 7/ 0 1 / 0 1 1 2 : 0 0 0 . 6 0 MP a

Set up the compressor's operation setting on this screen. S E TU P O F COMPR E S SOR S E T T I NG 1 ・ B A C K

◆Running Record Indication


O P E R A T I ON MO D E A U TO MA N
Set
S t up the
th setting
tti off operation
ti moded and
d pressure on “ PR E S S U R E SW I T C H A U TO L OC R EM
' 0 7/ 0 1/ 0 1 1 2: 0 0 0. 6 0 MP a

U N L O A D I N G PR E S S . 0 . 7 3 MP a
Setup of Compressor Setting 1”. L O A D I N G PR E S S . 0 . 6 0 MP a
RUNNI NG R E COR D BACK

A U TO S T A R T PR E S S . 0 . 5 5 MP a The compressor's running record is indicated on this screen. R E CORD ( E VE R Y 5 SE C)

*About a driving mode(effective only Local mode) R E CORD ( E VE R Y 1 HOUR )

【auto】 :Compressor is automatically start/stop. [ N E X T ] DAI L Y RE PORT


WE E K L Y R E P OR T
The latest running record is indicated every five seconds and
V 1 . 0 0 ・ M O V E▲ MOV E : + R E S E T : R E S E T

【manual】:Any kind of load situation continues driving. B E - 0 4 ▼ MOV E : - EN T ER : S E L E C T


E - S T OP & CAUT I ON R E CORD

      (Compressor is not automatically stat/stop) every one hour.


V 1. 0 0 ▲ MOV E
※Pressure switch (○:Valid  -: Invalid) ' 0 7/ 0 1 / 0 1 1 2 : 0 0 0 . 6 0 MP a HE - 0 1 ▼ MOV E E NT E R : S E L E CT

Control
Pressure settings
Remote load signal
S E TU P O F COMPR E S SOR S E T T I NG 2 ・ B AC K
This function gathers the running data on a day-to-day and ' 0 7/ 0 1/ 0 1 1 2: 0 0 0. 6 0 MP a
for controller DR Y E R PR E
CON T I N UOU
O
S
P E
O
R
P
A
E
T
R
I
A
O
T
N
I ON
ON O F F
week-to-week basis, and indicates those data on a screen DAI L Y RE PORT BACK
Local/Remote Locall
L Remote
R L
Local
l Remote
R A T DR Y E R F A U L T ON O F F
of Daily Report and Weekly Report. P AGE 0 ' 0 6/ 1 2/ 3 1
PWR R E TUR N @ I N S T - O U T 0 . 5 s e c
PWR R E TUR N @B L O C K O U T 0 0 . 0 s e c
Pressurre switch

AUTO ○ - - ○ R UN N I NG H OUR 1 0 5 0 h r
ECON OM I CA L O P E . NO Y E S S T A R T & S T OP T I ME S 1 5 2 T I ME

LOC ○ ○ - -
ECON OM I CA L
[ N E X T ]
C YC L E 3 0 s
In case of an emergency stop or caution, the emergency A
D
MB
I S
I
C
E
H
N
A
T T
R GE
E MP E R A T UR E
P RE S S UR E
2 0.
0. 6
3
0

MP a

and caution screen shows data gathered for twenty


V 1 . 0 0 ・ MO V E▲ MOV E : + R E S E T : R E S E T C UR R E NT 4 9 A

REM - - ○ ○
B E - 0 5 ▼ MOV E : - EN T ER : S E L E C T L OA D I NG C ONDI T I ON 5 5 %

minutes after the occurrence. The data will be of use V 1. 0 0

in analyzing
y g whyy a trouble happens.
pp
HE - 0 4
Set up the setting of operation method interlocked with
a dryer, at an instantaneous stop or a power failure and economical operation
on “Setup of Compressor Setting 2”.
◆Alternate operation of two compressors ' 0 7/ 0 1 / 0 1 1 2 : 0 0 0 . 6 0 MP a

This alternate
Thi lt t operating
ti function
f ti brings
bi about
b t choice
h i S E TU P OF COMPR E S SOR S E T T I NG 3 BAC K

of a master unit or a slave one, rotation of a capacity


◆Setup of Weeklytimer
GR OU P CON TR OL Y E S NO

control unit, and also setting of operating pressure Set the S TA R T S E L EC T MA S T E R S L AV E

Set the compressor's


compressor s timer of starting up and stopping compressor's timer of starting up and stopping differentials S LA V E D I F F PR E S S 0 . 0 3 MP a

on this screen. between a master unit and a slave one. I N I T I A L CHAR G E 5 m i n

V 1 . 0 0 MO V E▲ MOV E : + R E S E T : R E S E T

There are seven patterns in the setting of date and time.


B E - 0 6 ▼ MOV E : - EN T ER : S E L EC T

The setting of using a timer every day is also equipped here. ISSUE
KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION DRAWING No. 4V51ZS1023P1 01
P19

EXTERNAL DIMENSIONS (XG 2140A, 2540A, 3030A)

Air inlet
APPROX 2686

Controller

2000
RC1/2
RC1/4 Oil cooler oil exit
Motor oil filling Auto drain
RC1/2
∅100 50 RC1/4 After cooler oil exit

290
Power cable inlet 60 Manual drain
RC1/2
Oli saver oil exit

250

144.5
600 1400 30 30
2600 1056 900 200 750
4×φ24 2000 100 100 100
Front side Base hole Right side
Back side

Oil separator tank Oli supply

Interior collocation Interior collocation


80 798
70

Compressor Air exhaust flange(single delivery)


4V19HS1001P1

Air outlet 8-∅18


∅200
A
1865

∅160
Oil separator tank Air feed R 23

∅100 A Maintenance space


Power cable inlet 1:10
(backup)
(Unit mm)
180

1614

Planform KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION 4V30ZS1008P1 02


P20
FOUNDATION DRAWING
(XG 2140A, 2540A, 3030A)

※ Sold separately

Compressor base plate


4-M20×2.5 Anchor bolt※
Effective thread 50

Foundation drawing

NOTE:
1、Foundation should to furished with steel rods.
2、Foundation required to be strong the weight.
3、Horizontal level should be ±1/100.

(UNIT: mm)

KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION 4V31ZS1008P1 01


P21

SYSTEM DIAGRAM (XG2140A, 2540A,XG3030A)


Air outlet

D N 8 0 Flange
After cooler Water separator

T
Pd

Oil cooler
Cooling fan

Unload pressure preserve valve

Suction fifter

Air discharge valve

Suction regulating valve


Load/unload solenoid valve

pressure
retaining valve

Gear box Ts Ps
Expansion joint
Safety valve
Motor
Compressor Oil separator element
OL1 Tc Oil fifter
Po
Air inlet
OL
Oil level gauge

Temperature control valve Td


Oil separator tank

MARK NAME
Po PRESSURE SENSOR (INSIDE OIL SEPARATOR)
COMPRESSED AIR
Pd PRESSURE SENSOR (DISCHARGE PRESSURE)
Td TEMPERATURE SENSOR (DISCHARGE)
Ts TEMPERATURE SENSOR (AFTER OIL SEPARATOR)
COOLING AIR
Tc TEMPERATURE SENSOR (MOTOR COIL)
OL1 OVERCURRENT RELAY (MAIN MOTOR) LUBRICATING OIL
V2 INVERTER FAULT (CONTAIN OVERCURRENT)
Si SUCTION INDICATOR
Ta TEMPERATURE SENSOR (AMBIENT) KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION 4V51ZS1026P1 01
P22

WIRING DIAGRAM (XG2140A,2540A ,XG3030 A)

Pressure sensor
(Air discharge pressure) Surrounding temperature
sensor
Pressure sensor
(After oil separator)
Pressure sensor Discharge temperature
sensor
(In oil separator)
OS temperature
sensor
CT (Option)

X1 X2 V1

LOAD/UNLOAD
SOLENOID VALVE Y5
SV1

XB
COM3
SUCTION FIFTER PRESSURE PW Y1A Y1B V2 Controller
DIFFERENCE SWITCH

25

R S T
(CUSTOMER’S WIRING)

4V51ZS1027P1 01
KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION
P23

WIRING DIAGRAM (XG2140A, 2540A,XG3030A)

R2 R20

S2 S20

AC380V・415V/220V 50Hz

AC380V・415V/50Hz

《Input signals to compressor》


・Remote・Run  (Terminal X8-COM2 → Closed:Run)
・Remote・Stop  (Terminal X9-COM2 → Open:Stop)
・Remote・Load  (Terminal XA-COM2 → Closed:Load) 
《Output signals from compressor》
・Emergency stop (Terminal Y0 - COM6 → Closed:Emergency stop)
・Caution     (Terminal Y1 - COM6 → Closed:Caution)
・Maintenance   (Terminal Y2 - COM6 → Closed:Maintenance)
・Remote     (Terminal Y3 - COM6 → Closed:Remote)
・Running     (Terminal Y4 - COM6 → Closed:Running)
(1)Input signals to the compressor should be no-voltage contact
input.Electric current of DC24V is supplied between the
COM2-XA, X8, X9 terminals from the controller side.
  Voltage could damage the controller.
(2)The rated load to use the output signals from the compressor should be (4)The terminal X9-COM2 has been short-circuited at the factory. (5)If the panel lamp of the controller is blinking (100 consecutive
AC250V 2A or DC 30V 2A at maximum. Remove this terminal in the remote control mode. hours have passed since the Maintenance LED came on.)
(3)The terminal COM2, COM6, XA-X9 and Y0-Y4 for remoteness is prepared Remote (input signal to controller) should be input by one shot with the lamp, but continue to be sent.
   in the starting panel terminal block TB2. at 500 ms or more.
When you connect with the terminal block TB2, attach a surge killer shorter pulse signals may not be recognized.
*Any modification without prior permission of KOBE STEEL may
and set the line noise at less than 800V.                    
invalidate the warranty even within the warranty period.

                                  KOBELCO
  COMPRESSORS
    MANUFACTURING
     (SHANGHAI)
  CORPORATION
  4V51ZS1028P1 02

                       
P24
WIRING FOR AUTOMATIC OPERATION
Only by wiring for two units of the XG, automatic alternate operation can be carried out. (XG+XG)
Compressor starts group control by switching over alternately between LOADING PRESSURE and
・THE SETTING POINTS
UNLOADING PRESSURE.
 <The example of a setting>
Slave unit will be started automatically if pressure becomes lower than AUTO START PRESSURE.
p
Master performs p
LOAD/UNLOAD control and if air consumption g time
decreases and unloading XG XG
becomes long, it will stop automatically. (*) Setup 1 OPERATION MODE AUTO Setup 1 OPERATION MODE AUTO

Wiring, setup and starting of a compressor are as follows. PRESSURE SWITCH LOC PRESSURE SWITCH LOC

1.Wiring of a compresso(The terminals within the starting boards of two compressor are wired mutually as follows.) UNLOADING PRESSURE 0.68 MPa UNLOADING PRESSURE 0.68 MPa

XG XG LOADING PRESSURE 0.63 MPa LOADING PRESSURE 0.63 MPa

X8 Y3 AUTO START PRESSURE 0.60 MPa AUTO START PRESSURE 0.60 MPa

XA Y4 Setup 2 DRYER PREOPERATION OFF Setup 2 DRYER PREOPERATIO OFF


CONTINUOUS OPERATION CONTINUOUS OPERATION
Y3 X8 AT DRYER FAULT
ON
AT DRYER FAULT
ON

Y4 XA ECONOMICAL OPERATION OFF ECONOMICAL OPERATION OFF

COM2 COM6 ECONOMICAL CYCLE 30sec ECONOMICAL CYCLE 30sec

COM6 COM2 Setup 3 GROUP CONTROL YES Setup 3 GROUP CONTROL YES

The above serves as signals only for automatic alternate operation, and it differs from the usual. START SELECT MASTER START SELECT MASTER

SLAVE DIFF PRESSURE 0.03 Mpa SLAVE DIFF PRESSURE 0.03 Mpa

2.SETTING OF A COMPRESSOR INITIAL CHARGE 5 min. INITIAL CHARGE 5 min.

The following setup is performed to two compressors respectively.


1) IIn th
the screen off COMPRESSOR SETTING
SETTING, while
hil setting
tti off [GROUP CONTROL] as [YES]
[YES], an ititem off ◇ Withi
Within iinitial
iti l charging
h i titime, SLAVE may nott carry outt continuation
ti ti starting
t ti after
ft
[START SELECT] also sets as [MASTER] for the compressor and as [SLAVE] for another. an automatic operation start.
2) By key of Remote/local, set in Local mode. However, it does not start in the Remote mode. ◇ Please set SLAVE DIFF PRESSURE setting to 0.01MPa or more.
(Please check that the lamp of Local is on.)
3) Please set the pressure sum of UNLOADING PRESSURE and SLAVE DIFF PRESSURE ● UNLOADING PRESSURE -------
+ SLAVE DIFF PRESSURE
(0.01MPa or more) lower than the highest discharge pressure. SLAVE DIFF PRESSURE ↑
-------- ● UNLOADING PRESSURE --------------------------------------- ○ LOAD / UNLOAD

3. STARTING OF A COMPRESSOR
3   LOAD / UNLOAD ● LOADING PRESSURE -------
+ SLAVE DIFF
  Automatic alternate operation starts by pushing the "Start" button of one of compressors. SLAVE DIFF PRESSURE ↑ PRESSURE

-------- ● LOADING PRESSURE --------------------------------------- ○


「The wiring for automatic operation」 (In case of MASTER) (In case of SLAVE)

-------- ● AUTO START PRESSURE ------------------------------- ● AUTO START PRESSURE


M3 SCREW
COM6

COM6
CCOM2

CCOM2

XG XG
COM2

COM2
COM6

COM6
Y3

Y3

XG XG
Y4

Y4
XA

XA
X8

X8

Terminal Panel D

Model Terminal Panel Manufacture ◇ XG performs unloading by the pressure of the sum of UNLOADING PRESSURE and DIFF.
Y4

Y4
Y3

Y3
XA

XA
X8

X8

XG D KOBE STEEL LTD Please set the pressure sum of UNLOADING PRESSURE and SLAVE DIFF
PRESSURE
lower than the highest discharge pressure.

*There
There is no function which changes MASTER by a timer
timer. ISSUE
KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION DRAWING No. 4V51ZS1024P1 01
P25
WIRING FOR AUTOMATIC OPERATION
By wiring for XG and VS, XG will serve as a backup machine of VS.If pressure becomes lower than AUTO (XG+VS)
(XG VS)
START PRESSURE in the state where VS is operating
operating, it will start automatically
automatically. And if pressure becomes higher ・THE SETTING POINTS
than UNLOADING PRESSURE, it will stop.  <The example of a setting>
When XG unloads once, the unloading drive is continued until the LOADING CONDITION of VS becomes 90%
or more, and the DISCHARGE PRESSURE becomes below the AUTO START PRESSURE besides. VS XG
Setup 1 KEEP PRESSURE 0.65 MPa Setup 1 OPERATION MODE AUTO

Wiring, setup and starting of a compressor are as follows. AUTO STOP PRESSURE 0.70 MPa PRESSURE SWITCH LOC

1.Wiring of a compressor AUTO START PRESSURE 0.60 MPa UNLOADING PRESSURE 0.68 MPa

The terminals within the starting boards of two compressor are wired mutually as follows. LOADING PRESSURE 0.64 MPa

VS XG AUTO START PRESSURE 0.60 MPa

X8 Y3 Setup 2 DRYER PREOPERATION OFF Setup 2 DRYER PREOPERATIO OFF


CONTINUOUS OPERATION
XA Y4 CONTINUOUS OPERATION ON
ON AT DRYER FAULT
Y3 X8 AT DRYER FAULT ECONOMICAL OPERATIO OFF

Y4 XA ECONOMICAL CYCLE 30sec.

COM2 COM6 Setup 3 GROUP CONTROL YES Setup 3 GROUP CONTROL YES

COM6 COM2 START SELECT MASTER START SELECT SLAVE

2.SETTING OF A COMPRESSOR SLAVE DIFF PRESSURE 0.02 Mpa SLAVE DIFF PRESSURE 0.00 MPa

XG compressor is made the following setup. INITIAL CHARGE 5 min. INITIAL CHARGE 5 min.

(1)In the screen of COMPRESSOR SETTING 3, while setting of [GROUP CONTROL] as [YES],
  an ititem off [START SELECT] also
l sets
t as [SLAVE]
[SLAVE].。 ◇ Withi
Within iinitial
iti l charging
h i time,
ti SLAVE may nott carry outt continuation
ti ti starting
t ti after
ft
(2)By key of Remote/local, set in Local mode. However, it does not start in the Remote mode. an automatic operation start.
 (Please check that the lamp of Local is on.) ◇ Please set SLAVE DIFF PRESSURE setting to 0.00MPa when you connect XG with the VS.
(3) Please set SLAVE DIFF PRESSURE setting to 0.00MPa.
(4) Please set to become a relation between the following.
The relation between KEEP PRESSURE of VS and LOADING PRESSURE of XG
and UNLOADING PRESSURE of XG: ----------------- ● AUTO STOP PRESSURE

LOADING PRESSURE (XG) < KEEP PRESSURE (VS) < UNLOADING PRESSURE (XG)
  ------------------------------- ● UNLOADING
O G PRESSURE
SS -----------

3.STARTING OF A COMPRESSOR
  Automatic operation starts by pushing the "Start" button of VS.
Starting standby is carried out when initial charging or pressure is higher than START PRESSURE. ----------------- ● KEEP PRESSURE LOAD / UNLOAD

  ------------------------------- ● LOADING PRESSURE

「The
The wiring for automatic operation」
----------- ● AUTO START PRESSURE ---- ● AUTO START PRESSURE -----------
M3 SCREW M3 SCREW M3 SCREW
XA
X8

Y4
Y3

X8
XA

Y3
Y4

XG VS
Y4
M2 XA
Y3
X8

Y4

X8
XA

Y3

Terminal Panel B Terminal Panel C Terminal Panel D


VS XG
M2
COM2

COM2
M6
COM6

M6
COM6

Model Manufacture
※When the unloading continues for 3 minutes with XG starts,and the inting proof timer passed,
Terminal Panel

VS I B KOBE STEEL LTD


VS I/II C  it stops automatically.
COM2

COM2
COM6

KOBE STEEL LTD


COM6

XG D KOBE STEEL LTD


ISSUE
KOBELCO COMPRESSORS MANUFACTURING (SHANGHAI) CORPORATION DRAWING No. 4V51ZS1025P1 01

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