Operation and Maintenance Manual KES-15, KES-18, KES-22, KES-30

Kirloskar Pneumatic Co. Ltd.
, Pune
Operation and Maintenance Manual

KES-15, KES-18, KES-22, KES-30
Kirloskar Pneumatic Co. Ltd., Pune
Operation and Maintenance Manual

for KES-15, KES-18, KES-22, KES-30
KIRLOSKAR PNEUMATIC COMPANY LTD.,

PUNE – 411 013 INDIA
Document Number : S271.069-084.D98

Publication Number : N27.21.000.034.00
Revision Status: R02
Date: July 2011
Contact Information:
Head of Servicing Department

KIRLOSKAR PNEUMATIC COMPANY LTD.,
HADAPSAR INDUSTRIAL ESTATE
PUNE – 411 013 INDIA
Phone : 91 – 20 26870133/26870341
Fax : 91 – 20 26870297 / 26870634
e-mail : acdser@kpcl.net and acdmktg@kpcl.net
Toll free Number :1800 301 00009 (directly accessible from all
networks)
MACHINE IDENTIFICATION AND SALE RECORD
Owner’s name: ___________________________________
Address:___________________________________
Compressor Model:___________________________________
Compressor Serial Number:____________________________________
Year of Manufacture:____________________________________
Main motor make:____________________________________
Main motor Serial Number:____________________________________
Motor Rating: ___________kW @ ____________ Rev/min
Compressor Capacity:____________m3/min @ ___________ bar g
Date of delivery:_____________________________________
Date of Commissioning:_____________________________________
Dealer Name / Code:_____________________________________
Dealer signature / stamp:
NOTE: Always indicate Compressor Serial Number given above while communicating with
KPCL dealer / Service Centre/ Branch office regarding your compressor. The warranty on this
compressor is valid only if the dealer signs and stamps on the warranty card supplied along
with the compressor.
Message from the Managing Director
Dear Customer,
We welcome you to the family of users of Electric Screw

Air Compressors from KPCL, one of the largest
manufacturers of AIR and GAS compressors in India.
Kirloskar Pneumatic products would always give you
Value for money for years to come! We are sure that you
will be proud of its performance.
At Kirloskar, listening to the user & customer and meeting

his/her needs is a tradition as old as the group itself. For it
is they who drive us further, make us reach higher, and
engineer better solutions.
KPCL has designed your compressor to be safe, best in

performance, reliable, user friendly and easy to maintain.
To ensure a long and trouble free life of your machine,
give it proper care and maintenance as described in this
manual.
KPCL is honored to be the choice for all your compressed

air needs. We look forward to your continued satisfaction
as KPCL compressor user.
About Kirloskar Pneumatic Company

Kirloskar Pneumatic Company Ltd, a flagship company in Kirloskar
group is an ISO 9001 company. KPCL has grown over the past 50
years by serving the customers with all types of air and gas
compressors. The multi-product company has transformed with
innovative products and processes to meet the innovative demands
and applications as well as the challenges of globalization. KPCL is
Asia’s largest air compressor manufacturing company with products
ranging from 3 HP to 2MW power capacity. The company has a strong
presence in the global market with customers in more than 40
countries and partners from more than 10 countries.
KPCL operates from Pune factory with state of the art facilities for
Research & Development, Manufacturing, Metrology and other
Business processes. KPCL’s dedication in serving the customers
through its network of branch offices, dealers, distributors, service
providers and web based customer care system has earned excellent
reputation to the company and valuable customers and partners.
Driven by the Kirloskar Group philosophy of “Enriching Lives”,

KPCL believes service to customers & society through partnership with
its customers and partners worldwide guided by values, innovation,
technology and consistency in business processes.
TABLE OF CONTENTS
Section 1 USER INFORMATION Page No.
1.1 General 1
1.2 Warranty 2
1.3 ISO Symbols 3-4
1.4 Receiving the Compressor 5
1.5 Lifting the Compressor 6-8
1.6 General Installation Guidelines 9
1.7 Installation requirements 10-15
Section 2 SAFETY 16
Section 3 DOs and DON’Ts 17
Section 4 COMMISSIONING
4.1 General 18
4.2 Points to be observed before Initial Start 18
4.3 Commissioning the compressor 19-20
Section 5 TECHNICAL SPECIFICATIONS AND SALIENT FEATURES
5.1 Technical Specifications 21-24
5.2 Salient Features 25-29
Section 6 SYSTEM OPERATION 30
Section 7 MAINTENANCE
7.1 General 31
7.2 Maintenance Schedule 32
7.3 List of Consumables and Spare parts 33-34
Section 8 DETAILS OF SUB-ASSEMBLIES
8.1 Air Intake System 35
8.2 Drive System 36-38
8.3 Discharge System 39-40
8.4 Air-oil Separator Assembly 41-42
8.5 Cooling System 43-44
8.6 Lubrication System 45-48
8.7 Capacity Control System 49
8.8 Electrical System 50-51
8.9 Structure assembly 52-53
8.10 Intake Valve Assembly 54

8.11 Minimum Pressure Valve Assembly 55
8.12 Oil Filter Assembly 56
8.13 Moisture Separator 56
Section 9 MICROCONTROLLER 57-66
Section 10 SAFETY AND INTERLOCK FEATURES 67
Section 11 TROUBLE SHOOTING 68-70
1. USER INFORMATION
1.1 GENERAL
The contents in this Manual are proprietary and confidential to Kirloskar
Pneumatic Company Ltd and should not be reproduced without prior written
permission of Kirloskar Pneumatic Company Ltd.
The abbreviation KPCL used in this Manual means Kirloskar Pneumatic

Company Ltd, Hadapsar Industrial Estate, Pune - 411013.
This Manual contains instructions and technical data to cover all routine
operation and Scheduled maintenance tasks by operation and maintenance
staff. Major overhauls are outside the scope of this manual and should be
referred to an authorized KPCL Service department.
All components, accessories, pipes and connectors added to the compressed

air system should be:
• Of good quality, procured from a reputable manufacturer and, wherever

possible, be of a type approved by KPCL.
• Clearly rated for a pressure at least equal to the machine maximum
allowable working pressure.
• Compatible with the compressor lubricant/coolant.
• Accompanied with instructions for safe installation, operation and
maintenance.
The use of repair parts / lubricants / fluids other than those included within the
KPCL approved parts list may create hazardous conditions over which KPCL
has no control. Therefore KPCL cannot be held responsible for equipment in
which non–approved repair parts are installed.
KPCL reserves the right to make changes and improvements to products

without notice and without incurring any obligation to make such changes or
add such improvements to products sold previously.
1
1.2 WARRANTY
The warranty applicable for the compressor purchased by you is given in
the Warranty Certificate sent along with the Compressor. Preserve it to get
warranty service from KPCL dealer/KPCL.
KPCL does not accept any liability for damages in transit and during handling in
transport. Inspect the physical conditions of the compressor on receipt and get the
transporter’s confirmation regarding the damages on receipt on the transporter
invoice to claim the insurance.
Any other complaint should be informed to the authorized dealer of KPCL or KPCL
branch or KPCL registered office, Pune in writing within 6 days from the receipt of
complaint. Preserve the Warranty Certificate sent along with the compressor.
KPCL will not accept the warranty for any problems/damages arising out of failures
to observe the conditions given in this Manual, alterations done on the compressor
without getting written permission from KPCL, improper repairs, insufficient
maintenance and use of spare parts other than KPCL make and supplies.
KPCL reserves the right for modifications without notice in the interest of
technology progress.
2
1.3 ISO SYMBOLS
3
4
1.4 RECEIVING THE COMPRESSOR
On receipt of the compressor with packing case, the condition of the packing case
has to be checked immediately for any damages. In case of damages, the proof of
condition has to be obtained from the transporter on the transporter invoice and
then the details are to be reported to insurance authorities (if transit insurance is
done) and also to KPCL dealer / KPCL.
The condition of the compressor inside the packing case also has to be verified by
unpacking the case (except the base of the packing case). In case of damages,
follow the instructions given above.
The contents are to be verified with the packing list received with the invoice /
delivery note. Written complaint to be given to KPCL dealer / KPCL immediately, if
any item is found missing w.r.to packing list. Following items are sent with
Standard Compressor without spares /accessories:
1) One No. Key for the canopy doors
2) One no. Operation and Maintenance manual
The condition of compressor parts also to be checked by opening the canopy

doors. If any parts are missing, contact KPCL dealer / KPCL immediately.
Now the compressor has to be kept in covered condition till the site is ready for
installing the compressor. Even during this temporary storage, ensure the
compressor is kept on a raised place and covered to protect it from rain / water
logging.
5
1.5 LIFTING THE COMPRESSOR
KPCL air compressors are shipped in wooden packing cases. Refer the
figures given below to lift the compressor with overhead crane or forklift. Wooden
frame shall to be used to keep the ropes away from the canopy while lifting the
compressor with overhead crane. Soft pad / wooden panel shall be used between
canopy and forklift arm to avoid damages to canopy while lifting the compressor
using forklift.
Prior to lifting, remove the red color brackets on the base frame; inspect the
bails, ropes and support frame for their capacity and condition to suit the
weight of the compressor.
Ensure lifting hook is with functional safety latch or equivalent and is fully
engaged.
Use guide ropes or an equivalent supports to avoid the lifted unit is swinging
in air.
Do not lift the compressor in open area with high wind speed.
Ensure all the personnel are out under the compressor when suspended.
Ensure the lift operator is kept under constant observation when
compressor is suspended.
Ensure the compressor is not lifted beyond the requirement of clearance
from floor.
Check the unit is firmly sitting on the forks when forklift is used for lifting.
Ensure the compressor is slightly tilted towards forklift by tilting the forks to
avoid slipping during movement.
Ensure the compressor is resting on forklift vertical beams with pad kept
between.
Ensure the speed of the forklift / crane does not cross 5 km/hr speed.
In case of shifting the compressor to site without forklift / overhead crane,
use pipes or cylindrical rods under the compressor with wooden base of
packing case.
Use tripods with adequate capacity chain & pulley blocks to lift the
compressor from the wooden base after removing the red color brackets
fitted on base frame to hold the compressor firmly.
6
7
8
1.6 GENERAL INSTALLATION GUIDELINES

Observe the following conditions while installing the compressor:
Adhere Accident Prevention Regulations
Adequate accessibility around the compressor as in fig below
Area around the compressor/ compressor room is dry and clean
Temperature around the compressor is with +5 to +45 degC
Adequate opening for air intake and hot air exhaust
10 m radius from compressors is free from combustible materials
Fire extinguisher kept in reachable position near the compressor
Quantity of hot air to be ventilated for KES15 to KES30 models is 3000 cfm (85 m3/min). The open area
around the compressor has to be kept free for operating & maintenance personnel movement for
performing the routine checks and maintenance activities.
9
1.7 INSTALLATION REQUIREMENTS

Site preparation: The compressor does not need any special foundation or
grouting. Normal shop floor suitable for installing metal cutting machines is
sufficient. The surface of installation area should be with minimum variation to
avoid non-uniform seating of the compressor base frame. Use shims to ensure the
base frame seating on floor at all corners to avoid vibrations during running. The
compressor suction side has to be positioned towards the open area or opening on
the wall to ensure fresh atmospheric air entry to the compressor. Exhaust fan /
ducting has to be installed to avoid the hot air recirculation and increase in
temperature in the compressor. Refer the figures given on the previous page and
the following page for general guidance. The exhaust fan sizing has to be done
such that the air velocity does not exceed 5 m/sec. Installation of higher capacity
fan may result in capacity problem in the compressor. The compressor positioning
also to be such that the hot air from other compressors or equipments is not
diverted to the compressor to be installed.
Failure to observe the instructions regarding installation and ventilation will
result in increase in discharge temperature which in-turn result in frequent
tripping and pre-matured failure of parts.
Mechanical connections: The compressor is provided with 3 outlet points on

the canopy for Compressed air outlet, auto drain line from moisture separator and
manual drain from moisture separator. The moisture draining from the compressor
will have the traces of oil. Ensure the moisture drainpipe line is connected to the
central drain line with ball valves and conditions as per the local statutory
regulations for wastewater disposal. The compressor air outlet line has to be
connected to Air Receiver after installing Non-Return Valve after the ball valve on
compressor air outlet point. KPCL dealer / KPCL shall be contacted for the details
on the Air Receiver size. Ensure the air pipeline is with adequate size to avoid
pressure drops and with adequate water traps.
Electrical connections: The compressor is provided with opening on the base

frame and at the electrical panel bottom plate for power supply cable entry. The
incoming power supply line must be through a switchboard with fuses. Fuse ratings
applicable for 415 V, 50Hz, 3 Phase power supply and recommended cable size are
given in the table on next page:
10
Model Backup fuse Recommended cable size

rating
Copper cable Aluminium cable
KES15 50 Amps 3.5 core, 6 sq.mm 3.5 core, 16 sq.mm
KES 18 50 Amps 3.5 core, 10 sq.mm 3.5 core, 16 sq.mm
Connect the earth line to the threaded hole next to the cable entry hole.
Follow the electrical safety norms as per local statutory regulations and electrical
standards for the safety of operating personnel and the compressor.
Refer the illustrations and drawings on the following pages for installation.
11
A --Room ventilation through the opening in the wall
B, C -- Room ventilation with exhaust system
D -- Hot air duct from compressor E -- Ducting for room heating
Refer the illustrations given above for installing the air-cooled compressor.
Best installation is with hot air exhaust duct from compressor to atmosphere and
air inlet side is kept directly inline with the air intake opening from the atmosphere.
12
Electric Circuit Diagram
13
General Arrangement Drawing for KES15 to KES22 Models
14
General Arrangement Drawing for KES30 Model
15
2.0 SAFETY
The compressors designed and manufactured by KPCL are for safe operation at
the designated conditions. The safe operation of the compressor lies with the
personnel operating and maintaining it. Hence, those who are trained and
understood this OPERATION AND MAINTENANCE MANUAL only shall operate
the compressor.
Never start the compressor when it is not safe to do so. Never operate the
compressor with known unsafe conditions. When the compressor is unsafe, tag the
unit to indicate to other and disconnect the power supply either by removing the
fuses or removing the power wire connections to avoid accidents.
This air compressor is not explosion proof and hence it has to be installed away
from the explosion area. Do not use the air from this compressor for direct contact
with food & medicine substances and do not use for breathing purpose.
Do not modify the compressor without getting the written permission from KPCL.
Pressure release: The compressor is provided with pressure relief valve to

release the pressure from the air-oil separator tank incase of pressure exceeds the
set values and electrical interlocks fail. Do not open the valves / air lines / air-oil
separator tank connections or plugs without releasing the pressure by using the
pressure relief valve (safety valve).
Fire or Explosion: Install fire extinguishers near the compressor. Do not store
inflammable materials near the compressor. Keep the compressor clean from oil
spills to ensure safety to operating personnel and equipment.
Hot Surfaces: Do not handle/touch the hot surfaces on the compressor without
using proper protection & handling devices. Avoid body contact with hot surfaces,
oil and air.
Electrical safety: Ensure electrical safety standards are adhered for the safe
operation of the compressor and personnel. Do not store materials inside the
electrical panel even though free space is available. Attempt repairs after removing
the fuses in the incoming power supply lines and keep notice near the fuse box to
avoid accidental connections.
Waste disposal: Follow the local safety standards for disposing the used oil, filters
and other used parts of the compressor to protect the environment.
DANGER
Death or serious injury may result from inhaling compressed air without using proper
safety equipment.
16
3.0 DOs and DON’Ts
DOs
Operating personnel read this manual thoroughly and follow instructions

Clean the Compressor regularly
Check the air filter condition regularly and replace in time
Maintain correct oil level
Use genuine parts from KPCL only
Use proper tools for operation and maintenance
Attend immediately to anything unusual in the compressor
DON’Ts
Neglect the routine maintenance
Allow the leakages in the system
Clean the air filter with pressurized air
Change the settings on compressor parts
Use cleaning agents while changing the oil other than recommended
Keep tools & other material on compressor
Leave loose the free end of air line hoses
Use the air for breathing
Use the air for direct contact with food products without recommended filters
17
4.0 COMMISSIONING
4.1 GENERAL
The instructions given in this Manual is for a Standard Air Compressor without
additional equipment. Check for the visual damages after completing the
installation has to be done. Each compressor is supplied with electrical circuit
diagram -pasted inside the electrical panel. Check the condition of the parts and
connections. Each compressor is subjected to test run before dispatch. There are
chances of settings get disturbed during transport or installation Verification of
firmness of all connections has to be done after installing compressor at site. The
commissioning of the compressor has to be done by the KPCL dealer only after
the installation and connections are done.
4.2 POINTS TO BE OBSERVED BEFORE INITIAL START
Remove all supports / brackets painted in red color used for support during
transit.
Ensure the airline connections from compressor to air network are done without
gaps or loose bolts.
Ensure the electrical connections are firm and correct as per recommendations.
Ensure the moisture drain lines are connected and auto drain line ball valve is
kept open.
Ensure the oil drain ball valve on Air-oil separator tank is closed and fitted with a
threaded plug at open end of the valve.
Remove the air filter and pour 250 ml of recommended oil inside the intake valve
by pressing the tappet plate. This is to ensure the lubrication oil is present inside
the airend at the time of starting.
Check and ensure the oil level in the Air-oil Separator tank of the compressor is
filled to middle level of the sight glass fitted on tank. Use the Servo system
HLP68 only. Though oil fill capacity is 11 litres, actual fill may be low since other
points in the oil line are may not be filled. Further oil fill-up to be done during the
commissioning process. Fix threaded plug at pour point and tighten it fully.
Ensure the air filter is firmly fitted on the intake valve with the clamp.
Ensure the electrical connections are done as per circuit.
Ensure the power supply line is with adequate capacity for the compressor with
Wye-delta (Star –delta) starting system for the main motor.
Ensure the ball valve on air outlet line is kept open.
If the compressor was stored for more than 3 months from the date of
manufacturing, the KPCL dealer has to be informed to do additional checks to
confirm all the moving parts like motors, airend, valves etc and critical parts are
in good conditions.
Ensure the motors are with stickers on fan cover or body to indicate direction of
rotation.
18
4.3 COMMISIONING THE COMPRESSOR
Switch ON the main power supply and confirm “Healthy” LED is glowing on the
microcontroller after displaying Date & Time and Welcome message.
Press key on the microcontroller to confirm the display “PT-1 DIS. AIR PR” is
00.0. This display to indicate the air pressure at compressor outlet.
Press again to get the display “PT-2 BEF. OIL PR” with value 00.0 to confirm
no pressure in the Air oil separator tank.
Remove the canopy door below the electrical panel to view the motor.
Press Start button (green color) on the microcontroller to make the main motor ON.
If motor is energized, switch off the compressor by pressing Off button (red color)
on microcontroller. Check and confirm the direction of the rotation is in line with the
direction arrow mark sticker pasted on the fan cover. If the direction of rotation is
wrong, check the main power supply lines and correct them. If the direction of
rotation is correct, fit the canopy cover in position.
Close the ball valve at the compressor air outlet line.
Switch ON the compressor and confirm, “Comp. ON” LED is ON. Now the
compressor will get loaded with “Load” LED in ON condition.
Run the compressor for ONE minute and switch OFF to make the oil in the oil lines
to flow back to the tank.
Check and ensure the display for PT-2 is 00.0 when the compressor is in OFF
condition. This is to ensure there is no pressurized air in air-oil separator tank
when compressor is in OFF condition after Blow-off valve releases the air from
tank.
Check the oil level on the sight glass after 5 mins. Add oil till the level reaches to
middle level of the sight glass.
Ensure the threaded plug provided on oil pour point is tightened fully.
The compressor will go to “Unload” mode once the pressure reaches maximum
pressure/unload pressure. This is when “PT-1 DIS AIR PR” display is unloading
pressure value of the model. When the compressor is in Unload mode, the “Load”
LED will go OFF.
Open the canopy panels and confirm no air and oil leakages during this run at the
joints/fittings.
Open the ball valve slowly till the pressure PT-1 value on microcontroller display is
the working pressure of the model.
Run the compressor on load to confirm the fan motor is getting switched ON and
OFF based on the oil temperature required for the satisfactory performance of
compressor. The settings for making the fan motor ON/OFF is already done in the
microcontroller program.
Run the compressor and record the values from the microcontroller display by
pressing button.
Refer the specifications given in Section 5 of this Manual for each model to confirm
the compressor performance is within the limits.
19
Ensure the temperature inside the compressor room is not more than 5 degC
above the temperature outside the room during the continuous run.
Refer Trouble –shooting guide given in this manual for any abnormalities found.
Report to KPCL, if problem persists after applying remedial actions given in the
trouble-shooting guide.
- Control . . . µ-control
SR. NO.-
D1 D2 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
P N
COM.
COM.
M O DIFIED E
NO
NO
0V OUT
CO M.
NO
12V OUT
NOT USED
COMP. MOTOR O/L
START LOAD FAN
RELAY RELAY
REMOTE START
RELAY
COMMON
RTD WHITE
RTD WHITE
FAN O /L
SPP/ RVP
PRES.T.-II
RTD RED
PRES.T.-I
E. STOP
OFF
ON
C1 C2 C3 C4 C5 C6 A1 A2 A3 A4 A5
12 34
Healthy Manual Comp. ON
Faulty Remote Load DIP
Front View of Microcontroller Back View of Microcontroller
20
5.0 SPECIFICATIONS & SALIENT FEATURES

5.1 TECHNICAL SPECIFICATIONS
Sl.No. Description Unit Data
1 Models KES15-7.5 KES15-8.5 KES15-10 KES15-13
2 cfm 96 87 80 66
Free Air Delivery (FAD)
m3/min 2.72 2.46 2.27 1.87
3 Operating pressure kg/cm2 7.0 8.0 9.5 12.5
4 Maximum / Unloading Pressure kg/cm2 7.5 8.5 10.0 13.0
5 Cut-in / Reloading pressure kg/cm 2
6.5 7.5 9.0 12.0
6 MPVL opening pressure kg/cm 2
4.0 4.0 4.0 4.0
7 Power supply conditions 415V +/- 10%, 50Hz +/- 5%, 3 Phase
8 Capacity Control system LOAD - UNLOAD
9 Main motor rating kW 15kW with SF 1.15
10 Operating conditions - ambient & altitude degC & metres + 5 to +45 degC & 1000 metre Altitude
11 Fan motor rating kW 0.75
12 Type of motors (Main & Fan drive) Squirrel Cage Induction
13 Insulation & protection of motors Class F & TEFC (IP55)
14 Rated speed of Main motor RPM 2935
15 Rated speed of Fan motor RPM 2800
16 160M Frame, B5 with single point support &
Frame size, Mounting type & Make of Main motor
MAKE --LHP / CGL
17 Frame size & mounting type of Fan motor 80 & B5
18 Efficiency of Main motor at full load power 91.0%
19 Efficiency of Fan motor at full load power 77.0%
20 Over Load Relay setting for Main Motor Amps 19.5
21 Over Load Relay setting for Fan Motor Amps 1.8
22 Type of starting for Main motor Wye - Delta
23 Type of starting for Fan motor DOL
24 Type of coupling & size/model Direct drive - Gear mounted on motor shaft
25 Oil fill capacity litres 11
26 Discharge Temperature (at airend outlet) degC 85 to 100
27 Air temperature at compressor outlet degC Ambient + 10
28 Air outlet port size & Qty. Inch& Nos. 1 inch BSP x 1 No
29 Sound Pressure Level of the Compressor
dB(A) 75 +/-3
@ 1 metre distance
30 Overall dimensions of the unit, L x B x H mm 1250 x 650 x 1550
31 Weight of the unit without oil kg 455
32 Reference standard for FAD and SPC ISO 1217 : 1996 Annexure C
33 Reference standard for Sound Pressure Level Cagi Pnuerop PN8NTC2.2
21

2 cfm 119 110 100 85
m3/min 3.37 3.11 2.83 2.41
3 Operating Pressure kg/cm2 7.0 8.0 9.5 12.5
4 Maximum / Unloading Pressure kg/cm 2
7.5 8.5 10.0 13.0
6.5 7.5 9.0 12.0
6 MPVL opening pressure kg/cm2 4.0 4.0 4.0 4.0
9 Main motor rating kW 18.5 kW with SF 1.15
10 degC &
Operating conditions - ambient & altitude + 5 to + 45 degC & 1000 metre Altitude
metres
16 160L Frame, B5 with single point support &
Make--LHP / CGL
20 Over Load Relay setting for Main Motor Amps 22
dB(A) 75 +/-3
@ 1 metre distance
22

2 cfm 140 133 119 102
m3/min 3.96 3.77 3.37 2.89
7.5 8.5 10.0 13.0
6.5 7.5 9.0 12.0
9 Main motor rating kW 22 kW with SF 1.15
10 degC &
metres
16 180m Frame, B5 with single point support &
Make -- LHP / CGL
20 Over Load Relay setting for Main Motor Amps 26.5
dB(A) 75 +/-3
@ 1 metre distance
33
Reference standard for Sound Pressure Level Cagi Pnuerop PN8NTC2.2
23

2 cfm 197 187 166 145
m3/min 5.58 5.30 4.70 4.11
7.5 8.5 10.0 13.0
6.5 7.5 9.0 12.0
9 Main motor rating kW 30 kW with SF 1.2
10 degC &
metres
16 180L Frame, B5 with single point support &
Make -- LHP / CGL
20 Over Load Relay setting for Main Motor Amps 36
dB(A) 75 +/-3
@ 1 metre distance
24
5.2 SALIENT FEATURES
Best Performance: The combination of energy efficient airend driven by efficient

motor along with control system and optimally designed accessories makes the
whole system to perform at the best possible efficiency to deliver most economical
compressor air.
Air Quality: The cyclone separation system optimized over the years of research
and tests along with the best quality coalescent type oil mist separation filter
element ensure efficient separation of oil particles from the compressed air with
minimum pressure drop. This optimally designed system ensures consistent quality
of air is delivered during all modes operating cycles.
Safety systems: The compressor is provided with multiple safety systems and
elements to protect the equipment and operating personnel. The software logic
built in the microcontroller, temperature sensor, overload relay, single-phase
preventor, Reverse rotation protection, alarm messages and safety valve provided
ensures the unit runs with adequate protections.
Pulsation – free airflow: The helical fluted rotors in the airend with optimum
Length to Diameter ratio of rotors ensures pulsation free flow of compressed air.
This gives a great advantage of getting continuous flow of air.
High Reliability: The airend with only rotating parts mounted on oil lubricated
rolling bearings and minimum number of best quality moving parts is air
compression system ensures the system operates trouble-free for longer period of
time.
Low operating costs: With rotating parts of the airend, Engine and all moving
parts well lubricated, amply sized consumables of the compressor, best suitable oil
and low operating temperature of the entire system ensures the operating costs
are much lower than conventional compressors.
Airend: This is the main component of the compressor package called as Airend.
Free atmospheric air is being compressed during the rotation of optimally designed
twin helical screws in the airend. The air end is coupled directly to the electric
motor through a set of gears. Both air-end & motor is mounted an anti vibration
pads placed on the base frame. With this arrangement we ensure less vibrations
and longer life of the compressor.
High efficiency air-end and reliable arrangement for transmission of power makes
the compressor energy efficient and reliable performance machine.
25
Electric Motor: This is flange mounting, 2 Pole, TEFC, IP 55 protection, Class F

insulation motor designed with necessary starting torque and operational load
variations. Motor is suitable for above-mentioned voltage and frequency variations.
Make of the motor is as per KPC standard.
Air Intake: Trouble free operation of this close tolerance, screw type compressor
is achieved by suction air filtration system. It is with Dry, Paper type filter element
in cartridge form for easy replacement. Complete filter assembly is within canopy
of the compressor, which avoids entry of heavy particles in the compressor.
Lubrication: Lubrication of the air-end gives duel advantage. It removes heat of

compression & lubricates screw, bearings & gears. ISO VG68 grade oil is used for
this purpose. Pressurized, cool & filtered oil is injected in the air-end and comes
out of the compressor from discharge of the air end along with compressed air.
Positive oil pressure is ensured in air/oil separator tank. Hence we do not require
any separate oil pump.
Lube oil Filtration: Spin-on type oil filter is used to filter Lube oil before injecting to
the airend. This enhances long life of the compressor and reliable operation.
Air/Oil Separation: Compressed air and lube oil is separated in a multistage air/oil
separator tank. The separator also acts as an oil reservoir. High efficient air/oil
separator element, limits oil carryover to desired level in the delivered air from
compressor package.
Lube oil Cooling: Temperature of the compressor system is maintained within

limits by cooling oil in radiator type air-cooled oil cooler. Temperature of the oil is
monitored through the temperature switch fitted in the oil line to make the fan
motor ON/OFF through the microcontroller so as to ensure uniform oil temperature
irrespective of the ambient temperature.
After Cooling: High-pressure discharge air is cooled in radiator type air-cooled

after-cooler. The condensation happens due to cooling of air & separates out in
the Moisture separator. We provide Auto drain trap to remove water form the
system.
Canopy & Base Frame: All components of the compressor package are mounted
on a single base frame. It does not require any foundation. The complete
package can be shifted with forklift or hydraulic lift trolleys by using the provision
given in the base frame.
Powder Coated Metallic Canopy of the compressor is of modular design. It is
acoustically designed to limit sound pressure level of the package to 75 dB (A) at a
distance of one meter. The noise measurement is as per Pneurop / Cagi
PN8NTC2 standard. Easily removable doors with locks are provided for easy
26
accessibility to internal components. Air outlet line is terminated outside of the

canopy for easy connection to the air network. Opening in the base frame is given
for inserting electrical power supply line from Main supply panel without making
any cutouts in the canopy or base frame.
Capacity Control: Load/Unload capacity control is provided which functions as

per demand conditions. Power saving and optimum utilization of compressor
package is achieved due to this type of capacity control.
Safety Devices: Following mechanical safety devices are provided to ensure safe
operation of the compressor
Minimum Pressure Valve - Maintains minimum air pressure in air-oil separator tank
so that positive oil flow is ensured.
Safety Relief Valve - De-pressurize compressor system if pressure exceeds

beyond limits of the system
Blow Down Valve - Ensures proper pressure relief arrangement during the
unload condition of the compressor
Oil Level indicator - This is mounted on air/oil separator tank. It gives visual
indication of minimum & maximum level of oil present
in compressor system
Control Panel: This is auto star-delta starter cum microprocessor based control
panel packaged on the same base frame within canopy of the compressor. Panel
is wired and hooked up with main motor and all instruments with in the package.
The display of various operating parameters and setting is done on a man machine
interface (MMI) - microcontroller installed on easily accessible height on canopy
front part.
Display on MMI (microcontroller)

Delivery air pressure
Air/oil Temperature
Differential pressure across air/oil separator
Hour meter
Total running hours
Total loaded hours
Start/stop, load/unload, Emergency stop & test conditions
Reason for trip
27
Maintenance schedule (No. of Hours indication)

Replace Air Filter Element
Replace Oil Filter Element
Replace Air/Oil Separator Element
Start Up Checks
Routine Maintenance checks
Change of Lube oil
Electrical circuit diagram sticker is pasted inside the Electrical panel for ready
reference during wiring or trouble-shooting.
Safety & Control: Following Trip signals are provided to protect the machine from
abnormal operating conditions:
High air-oil mixture temperature

PT1 Pressure Transmitter fault (for air pr. at Compressor Outlet)
PT2 Pressure Transmitter fault (for air-oil at airend outlet)
RTD Temperature Sensor fault (for oil temp. at airend outlet)
Main motor over load
Fan motor overload
SPP/RVP fault (Single phase /Reverse rotation)
28
P&I DIAGRAM OF THE AIR COMPRESSOR
29
6.0 SYSTEM OPERATION
The Air Intake Valve provided is normally open type. As the supply to the motor is
on due to the vacuum created in the compressor, air enters in the bare compressor
from suction filter. The compressed air is delivered to Air/oil separator. The
pressure in Air/Oil separator starts rising. This air pressure signal passes through
the open type solenoid Valve & is given to the inside piston of Air Intake Valve.
This closes the air intake valve & supply of air to the compressor is cut off. Thus
compressor is immediately unloaded. This ensures that the starting torque required
is less thereby limiting the starting current of the motor. Also the motor is started in
star connection. After a set time the starter connects the motor in delta connection
& compressor runs smoothly in unloaded condition. After a set delay time, the
Solenoid Valve is energized & the signal line to air intake valve is cut off &
connected to exhaust. With this the Air Intake Valve is immediately open &
compressor comes on load. It takes few seconds for the compressor to come on
load depending on the motor rating. The moment the pressure rises in the Air Oil
Separator tank, the oil flow to compressor is started, irrespective of whether the
compressor is in loaded or unloaded condition.
Air / oil separator separates the oil from air/oil mixture down to 1 to 3 PPM by
mechanical as well as with the help of air-oil separator element as described
earlier. The minimum pressure valve starts opening at a pressure of 3.5 kg/cm²
(full open at 4.0 kg/cm2). The compressed air from receiver then passes through
the after-cooler part of the combi-cooler where it is cooled with air of fan driven by
motor. An efficient moisture separator then separates the condensed moisture in
the compressed & cooled air. The separated moisture is drained by mechanical
auto-drain valve of the Moisture Separator. Pressurized air is now available at the
air delivery valve for user’s network.
When the demand for air decreased or when there is no demand, pressure builds
up in the system. The pressure transmitter connected after the Moisture Separator
senses this pressure. When the system pressure in the system increases beyond a
set value, an electric signal is given to the Solenoid Valve & it is de-energized. &
the pressure signal line from receiver is connected to the Air Intake Valve & the
compressor is immediately unloaded.. At the same the pressure signal from
receiver through the Solenoid Valve is also given on the top of Blow Down Valve.
The BDV is normally closed type. The pressure signal at top opens it & receiver is
connected to the suction side of the compressor. BDV has in-built spring
resistance which helps to maintain a minimum pressure of 2.0 kg/cm^2g during
unloading. This not only ensures that the power consumption during unloading is
minimum & but also sufficient oil flow is maintained during unloading.
30
Whenever the compressor is stops, the Solenoid Valve de-energizes. Air Intake
Valve closes, which ensures that there is no oil back flow from compressor to air
filter. BDV gets opened due to pressure signal at its top from Solenoid Valve. The
air receiver gets connected to the atmospheric pressure through BDV to just after
the Air suction filter & pressure in the receiver is relived totally. This ensures that
when the compressor is started again, there is no pressure in the receiver. The
small NRV connected in the signal line after BDV & just before Air Intake Valve
ensures that there is no oil back flow from compressor towards the air suction filter.
The heat of compression is absorbed by oil besides sealing the rotor gaps and
lubricating the moving parts including bearings. The oil that is separated in Air/Oil
separator is collected in oil tank portion in Air/Oil separator. Due to the pressure
differential the oil starts flowing from AOS tank and is passed through oil cooler
part of the compact combi-cooler, where it is cooled by air of Fan & Motor. Further
it is filtered in oil filter and supplied to compressor.
After Oil filter small qty oil is also sprayed in gearbox for the gear & pinion
lubrication. The oil is drained from the gearbox to the suction of compressor.
If the oil is overcooled the moisture in the air get condensed & mixes in the oil in
the form of water. This badly affects the performance & life of oil. Compressor
performance & life also gets affected. To avoid this overcooling a thermal switch is
provided in the oil line after the oil cooler. This switch switches off the cooling fan if
the oil temperature falls below a set value.
31
7.0 MAINTENANCE
7.1 GENERAL
Before carrying-out any maintenance activity, stop the compressor and wait for 1
minute for all the rotating parts to stop and air from the Air-oil separator tank is
relieved by Blow-off valve. Use proper tools during maintenance to avoid damage
to compressor parts. Ensure this Manual is read and understood. KPCL dealer /
KPCL servicing department shall be contacted to clarify the doubts and assist.
7.2 MAINTENANCE SCHEDULE
Period Activity Part / Part Number

Daily – Check oil level in Air-oil separator tank Sight glass
before Drain the moisture with manual drain valve Ball valve on canopy
starting Check air filter condition
Daily – after Check pressure & temp. reading during running Microcontroller
starting Check moisture drain through auto drain Drain line
After first Change oil Servo system HLP68
100 hrs of Change Oil Filter Element 271.01.432.50
running
After every
1000 hrs of Change Oil Filter Element 271.01.432.50
running
After every Change oil Servo system HLP68
1000 hrs of Clean the cooler assembly core area
running Change Air Filter 271.00.144.50
After every Additional activities apart from changing the parts
2000 hrs of given above are:
running 1) Check the oil and air line fittings for leakage Refer Recommended Spares
2) Check the electrical wiring connections list for fittings and O-rings for
3) Check the condition of contacts on contactors fittings.
4) Check the condition of rubber hoses Hose Kit - 271.01.540.50

running 1) Replace Air-oil Separator element kit 271.00.599.50
2) Check the condition of all valves for leakages Refer Recommended Spares
or sluggish action. list for kits.

running or 1) Check the condition of rubber hoses and Refer the list of recommended
ONE year replace the defective spare parts.
(which ever 2) Change the kit of spares for Minimum Pressure
is earlier) Valve, Intake Valve, Blow-Down Valve, Solenoid
valve and oil seal in Gearbox.
The above recommendation is valid for General Engineering industry only.
Life of consumables will vary depending on the operating environment.
32
7.3 LIST OF CONSUMABLES AND SPARE PARTS KITS
A. Kit of Consumables for every 4000 hrs of running - 271.01.566.50 consists

of
1) 271.01.432.50– Oil Filter Element ----------------------------- 5 Nos
2) 271.00.144.50 – Air Filter ------------------------------------------ 4 Nos
3) 271.00.599.50 – Air-oil Separator element with Gaskets – 1 No
The kit consists of 1 No. of oil filter element to be replaced along with the oil after
first 100 hrs of running.
B. Kit of Consumables for every 8000 hrs of running -- 271.01.567.50 consists

of
1) 271.01.432.50– Oil Filter Element ----------------------------- 9 Nos
2) 271.00.144.50 – Air Filter ------------------------------------------ 8 Nos
3) 271.00.599.50 – Air-oil Separator element with Gaskets – 2 Nos
The kit consists of 1 No. of oil filter element to be replaced along with the oil after
first 100 hrs of running.
The Compressor oil Servo System HLP68 is not given in the consumable list
since it can be procured directly from the oil manufacturer by the
customer/user.
The rubber & non-metallic parts like O-rings, gaskets, hoses are not considered in
the list of consumables since the life depends on the operating temperature which
in-turn depends on the operating environment, operation & maintenance
conditions. Apart from this, the gaskets and O-rings are to be replaced when the
part is damaged during the maintenance/repair of compressor parts during
operation. Hence KPCL recommends user to maintain one set of gaskets and O-
rings as stand-by stock
33
C. Kit of Spares after 8000 hrs run or ONE year

C1. for KES15 to 22 Models- 271.01.569.50 consists of
Sl. No. PART No. PART DESCRIPTION QTY.

1 271.01.194.50. GASKET FOR COVER PLATE 1
2 271.01.145.50 GASKET (FOR AIR OIL SEPERATOR) 2
3 271.01.248.50. GASKET AIR INTAKE VALVE 1
4 271.01.265.50. GASKET AIR END DELIVERY 1
5 271.00.275.50. GASKET (FOR MPVL 32) 1
6 300.07.583.50. OIL SEAL VITON FOR GEAR BOX 1
7 271.00.388.50. ‘O’ RING VITON AIR END MOUNTING FACE 1
8 271.01.299.50. ‘O’ RING ID 36 x 3.55 DIA 1
9 271.00.530.50. O’ RING 1/8” 1
10 271.00.532.50. O’ RING 1/4” 2
11 271.00.534.50. ‘O’ RING 3/8” 3
12 271.00.536.50. O’ RING 1/2” 4
13 271.00.538.50. ‘O’ RING 3/4” 5
14 271.00.540.50. ‘O’ RING 1” 3
15 271.00.542.50. O’ RING 1-1/4” 1
16 271.00.282.50 SERVICE KIT FOR MPVL-32 1
17 271.00.283.50 SERVICE KIT FOR BDV 3/8” BSP 1
18 271.00.284.50 SERVICE KIT FOR INTAKE VALVE-3” 1
19 271.01.540.50 HOSE KIT 1
C2. for KES 30 Model – 271.01.568.50 consists of

2 271.01.145.50 GASKET (FOR AIR OIL SEPERATOR) 2
3 271.01.248.50. GASKET AIR INTAKE VALVE 1
4 271.01.265.50. GASKET AIR END DELIVERY 1
5 271.00.275.50. GASKET (FOR MPVL 32) 1
7 271.00.388.50. ‘O’ RING VITON AIR END MOUNTING FACE 1
8 271.01.299.50. ‘O’ RING ID 36 x 3.55 DIA 1
9 271.00.530.50. O’ RING 1/8” 1
10 271.00.532.50. O’ RING 1/4” 2
11 271.00.534.50. ‘O’ RING 3/8” 3
12 271.00.534.50. O’ RING 1/2” 4
13 271.00.538.50. ‘O’ RING 3/4” 5
14 271.00.540.50. ‘O’ RING 1” 1
15 271.00.542.50. O’ RING 1-1/4” 3
16 271.00.282.50 SERVICE KIT FOR MPVL-32 1
17 271.00.283.50 SERVICE KIT FOR BDV 3/8” BSP 1
18 271.00.284.50 SERVICE KIT FOR INTAKE VALVE- 3” 1
19 271.01.540.50 HOSE KIT 1
34
8 DETAILS OF SUB-ASSEMBLIES OF THE COMPRESSOR
8.1 AIR INTAKE SYSTEM
2
3

1 271.01.248.50. GASKET - AIR INTAKE VALVE 1
2 REF.PLATE - 8.10 INTAKE VALVE ASSEMBLY -3" 1
3 999.01.668.50. SCREW -HEX HEAD M12X1.75X35L 4
4 999.11.274.50. WASHER-SPRING STEEL ID12.2X 2.5TH 4
5 999.18.740.50. WASHER PLAIN STEEL 14.0X2.5 4
6 999.30.536.50. HOSE CLIP, ID 80 to 100 1
7 271.00.144.50. AIR FILTER 1
35
8.2
13
14 12
15
16
19
27
20
25 21
17
DRIVE SYSTEM
24
26 18 22
23
10 11
4 32
33 9
36
5
6
7
8
29
3 20
2 34
35
1
36
28
30
31
8.2 DRIVE SYSTEM
Sl.
ITEM No. DESCRIPTION QTY.
No.
1 271.00.250.50. ELECTRIC MOTOR-30kW 1 FOR KES-30
271.00.244.50 ELECTRIC MOTOR-22kW 1 FOR KES-22
211.08.110.50 ELECTRIC MOTOR-18.5kW 1 FOR KES-18
211.08.109.50 ELECTRIC MOTOR-15kW 1 FOR KES-15
2 271.01.193.50. INNER RING 1
GEAR HOUSING FOR ELECTRICAL SCREW
4 271.01.189.50. 1
COMPRESSOR
5 999.03.702.50. STUD STD TYPE A M16X2X60L 4
6 999.11.286.50. WASHER SPRING STEEL ID16.2X 3.5TH 4
7 999.06.687.50. NUT HEX M16X2 4
8 SEE CHART GEAR
9 271.00.216.50. RETAINER,GEAR 1
10 270.00.036.50. TAB WASHER 1
11 999.01.691.50. SCREW HEX STD M16X2X40L 1
AIR END SCA 10D OF TERMOMECCANICA S
12 271.10.060.50. 1
.P.A.
13 271.00.388.50. 'O' RING VITON AIR END MOUNTING FACE 1
14 271.01.190.50. COVER FOR GEAR HOUSING 1
15 271.00.585.50. WASHER COPPER 8.2x16x1 THK. 6
16 999.01.624.50. SCREW HEX STD M8X1.25X30L 6
17 271.00.232.50. SLEEVE, COMPRESSOR 1
18 SEE CHART PINION
19 271.00.217.50. RETAINER, COMPRESSOR 1
20 271.00.389.50. TAB WASHER M10 1
23 999.11.268.50 WASHER SPRING STEELID10.2x2LTHK 14
25 271.01.191.50. COVER PLATE FOR GEAR HOUSING 1
26 999.11.250.50. WASHER SPRING STEEL ID 6.1X1.6 THK. 6
27 999.01.609.50. SCREW HEX STD M6X1X20L E 6
28 271.00.251.50. ANTI VIBRATION MTG, AVM-200 1
29 999.06.632.50 NUT HEX M10x1.5 3
30 271.01.138.50 SPACER FOR MOTOR SUPPORT 1
31 271.00.252.50. ANTI VIBRATION MTG, AVM-200 2
32 999.09.756.50. CYLINDRICAL PIN 2
33 271.01.494.50. MAGNETIC PLUG 3/4" BSP 1
34 999.01.621.50. SCREW HEX STD M8X1.25X20L E 6
35 999.11.262.50. WASHER SPRING STEEL ID8.2X2.0 THK. 6
36 999.18.720.50. WASHER PLAIN STEEL 9.0X1.6 6
37
8.2 DRIVE SYSTEM
CHART FOR GEAR AND PINION
MODEL GEAR & PINION SET NO. GEAR PINION

KES 15-7.5 271.01.763.50 271.01.838.50 271.01.839.50
KES 15-8.5 271.01.751.50 271.01.841.50 271.01.842.50
KES 15-10 271.01.746.50 271.01.844.50 271.01.845.50
KES 15-13 271.01.747.50 271.01.847.50 271.01848.50
KES 18-7.5 271.01.748.50 271.01.850.50 271.01.851.50
KES-18-8.5 271.01.749.50 271.01853.50 271.01.854.50
KES 18-10 271.01.750.50 271.01.856.50 271.01.857.50
KES 18-13 271.01.751.50 271.01.841.50 271.01.842.50
KES 22-7.5 271.01.796.50 271.01.859.50 271.01.860.50
KES 22-8.5 271.01.752.50 271.01.862.50 271.01.863.50
KES 22-10 271.01.753.50 271.0.865.50 271.01.866.50
KES 22-13 271.01.754.50 271.01.868.50 271.01.869.50
KES 30-7.5 271.01.797.50 271.01.871.50 271.01.872.50
KES 30-8.5 271.01.755.50 271.01.874.50 271.01.875.50
KES 30-10 271.01.756.50 271.01.877.50 271.01878.50
KES 30-13 271.01.757.50 271.01.880.50 271.01.881.50
38
8.3 DISCHARGE SYSTEM
23
22
20
21
20
13
18
19
15
14
18
12
9
11
10
10
2
1
3
8
4
7
6
39
8.3 DISCHARGE SYSTEM
Sl.
No.
1 271.01.265.50. GASKET, AIR END DELIVERY 1
2 999.11.274.50. WASHER SPRING STEEL ID12.2X 2.5TH 6

HOSE ASSLY. 1-1/2" x 640 mm LENGTH,
4 271.01.422.50. 1
90xST
5 999.06.650.50 NUT HEX M12x1.75 2
6 999.01.672.50. BOLT HEX HD M12X1.75X50L 2
7 271.01.299.50. 'O' RING ID 36 x 3.55 DIA 1
8 271.00.558.50. SPECIAL UNION 1-1/4" BSP x 1-1/4" BSP 1
9 271.01.535.50. HOSE ASSLY 1 1/4" X 700mmL (90 X 90) 1
10 271.00.558.50. SPECIAL UNION 1-1/4" BSP x 1-1/4" BSP 2 FOR KES-30
FOR KES-
10 271.00.560.50. SPECIAL UNION ASSLY. 1" BSP x 1-1/4" BSP 2
15,18,22
11 271.01.536.50. HOSE ASSLY 1 1/4" X 300mmL (90 X ST) 1
12 271.00.560.50. SPECIAL UNION ASSLY. 1" BSP x 1-1/4" BSP 1

13 REF.PLATE – 8.13 1" MOISTURE SEPARATOR 1
BRACKET FOR MOISTURE SEPARATOR
14 271.01.541.50. 1
WITH DELIVRY PIPE
BALL VALVE-25NB ( 1" BSP) M/s
15 270.02.682.50. 1
CAV,UFF.GIACOMO CIMBERIO,ITALY
16 999.11.268.50. WASHER SPRING STEEL ID 10.2x2.2THK. 2
17 999.01.637.50 BOLT HEX M10x1.5x22 2
18 998.16.121.50. ASSLY OF STUD TAPER MALE COUP R1/8 2
19 999.37.103.00.01 TUBE, STEEL OD 6X1.00THK 1 PART OF
CONTROL
20 998.16.123.50. ASSLY OF STUD TAPER MALE COUP R1/4 2
PIPING KIT
21 999.30.683.00. NIPPLE EXT. P 1/4" TR 1 271.01.595.50
22 275.00.732.50. BALL VALVE 1/4" BSP UNIFLOW MAKE 1
PART OF
23 --- SOCKET 1/4" BSP
CANOPY
40
8.4 AIR-OIL SEPARATOR TANK ASSEMBLY
3
1
5
4
2
9
8
16
13
15
14
26
23
17
18
19
20
25
24
11
23
10
21
22
12
41
8.4 AIR-OIL SEPARATOR TANK ASSEMBLY
Sl. QT
ITEM No. DESCRIPTION
No. Y.
1 271.01.430.50 AIR OIL SEPARATOR WITH TOPCOVER ASSLY 1
2 271.01.145.50 GASKET (FOR AIR OIL SEPARATOR) 2
3 271.00.157.50 AIR OIL SEPARTOR ELEMENT 1
4 999.11.274.50 WASHER SPRING STEEL ID12.2x2.5TH 8
5 999.01.663.50 BOLT M12x1.75x40L 8
6 999.30.687.00 NIPPLE 1/2" 1
7 270.02.618.50 BALL VALVE 1/2" 1
8 999.30.955.50 PLUG 1/2" BSP 1
9 270.00.320.50 OIL LEVEL INDICATOR 1
10 271.00.541.50 RETAINING RING1" 1
11 271.00.540.50 'O'RING 1" 1
12 271.00.578.50 PLUG 1" 1
13 201.02.113.06 PRESSURE TRANSMITTER 1
14 271.00.534.50 RETAINING RING3/8" 1
15 271.00.535.50 O'RING 3/8" 1
TEMP.SENSOR-3/8" BSP END CONNECTION PT-
16 274.05.276.50 1
100 RANGE -20 TO 200 DEG c
17 271.00.538.50. 'O' RING 3/4" 1
18 271.00.539.50. RETAINING RING 3/4" 1
SAFETY VALVE 3/4" BSP RANGE 7 TO 17 KG/CM
19 030.48.091.00. 1
SQ
20 271.01.136.50. SCAVENGING PIPE 1
21 271.00.275.50. GASKET (FOR MPVL 32) 1
22 REF. PLATE – 8.11 MPVL (32 NB) WITH BDV (G 3/8) 1
24 999.03.625.50. STUD STD TYPE A M8X1.25X38L 3
25 999.06.623.50. NUT HEX M8X1.25 3
42
8.5 COOLING SYSTEM
3
5
6
4
14
9
10
11
12
8
13
6
7
43
8.5 COOLING SYSTEM
Sl.
No.
1 211.08.235.50 1.5 HP ELECTRIC MOTOR 2 POLE TEFC 1
4 271.01.437.50 FAN COWL WITH GAURD 1
6 999.06.623.50. NUT HEX M8X1.25 6
WASHER PLAIN STEEL 9.0X1.6 (NATURAL
8 999.18.720.50. 6
FINISH)
9 271.00.281.50. FAN 8 BLADE DIA.400 WITH ADAPTOR 1 FOR KES-30
FOR KES-15,
9 271.00.265.50. FAN 4 BLADE DIA.400 WITH ADAPTOR 1
18,22
10 271.00.289.50. RETAINER FOR FAN 1
11 999.11.250.50. WASHER SPRING STEEL ID 6.1X1.6 THK.
12 999.01.610.50. SCREW HEX STD M6X1X25L E 1
13 271.00.249.50. COMBI COOLER ASSLY. 1 FOR KES-30
FOR KES-15,
13 271.00.240.50. COMBI COOLER ASSLY. 1
18,22
14 273.00.545.50. RUBBER FLAT 25 W X 3 THK 5 IN METERS
44
8.6 LUBRICATION SYSTEM

(FOR KES 30 MODELS)
17
16
20
19
18
3
15
13
14
1
11
8
10
9
6
12
23
5
7
26
25
21
24
1
2
3
22
45

(FOR KES 30 MODELS)
Sl.
No.
1 271.00.548.50 SPECIAL UNION ASSLY 3/4" BSP3/4"BSP 2
2 271.01.514.50 HOSE ASSLY 3/4" x 575mmL 1
3 271.00.557.50 SPECIAL UNION ASSLY 1"BSPx3/4"BSP 2
4 271.01.538.50 HOSE ASSLY 3/4" x 600mmL 1
5 REF. PLATE – 8.12 OIL FILTER HEAD 1
6 REF. PLATE – 8.12 SPIN-ON OIL FILTER ELEMENT 1
7 271.00.551.50 SPECIAL UNION ASSLY 3/4"BSP x1/2"BSP 1
8 271.01.537.50 HOSE ASSLY 1/2" x 900mmL 1
9 271.01.534.50 ADAPTOR ELBOW 3/4" BSP x 1/2" BSP 1
10 271.00.552.50 SPECIAL UNION 1/8"xM12x1.5 1
11 999.16.001.50. FERRULE ID6 STEEL 2 PART OF
12 999.16.063.50. UNION NUT ID6 HEAVY STEEL 1 CONTROL
13 999.37.103.00.01 PIPE GEAR LUBE LINE 1 PIPING KIT
14 999.16.069.50. UNION NUT ID10 LIGHT STEEL 1 271.01.595.50
15 271.00.553.50 SPECIAL UNION ASSLY 1/4"BSPx12mm 1
16 271.00.582.50 SPECIAL UNION ASSLY 1/2"BSPx1/2"BSP 1
17 271.01.398.50 HOSE ASSLY 1/2"x27"(90x90) 1
18 271.01.533.50 SPECIAL ELBOW 1/2"BSPx1/2"BSP 1
19 271.00.550.50 NRV 1/2" 1
20 271.00.583.50 SPECIAL UNION 1/2"BSPx1/2"BSP 1
21 271.01.136.50 SCAVENGE PIPE 1
22 271.01.154.50 HOSE ASSLY 1/4"x29" 1
24 273.01.849.50 BRACKET FOR LUBE OIL FILTER 1
46

(FOR KES 15 TO KES 22 MODEL)
16
15
19
18
17
3
14
12
13
1
10
7
8
9
5
11
22
4
6
1
25
24
20
23
1
2
1
21
47

(FOR KES 15 TO KES 22 MODEL)
Sl.
No.
1 271.00.548.50 SPECIAL UNION ASSLY 3/4" BSP3/4"BSP 4
2 271.01.514.50 HOSE ASSLY 3/4" x 575mmL 1
3 271.01.538.50 HOSE ASSLY 3/4" x 600mmL 1
4 REF. PLATE – 8.12 OIL FILTER HEAD 1
5 REF. PLATE – 8.12 SPIN-ON OIL FILTER ELEMENT 1
6 271.00.551.50 SPECIAL UNION ASSLY 3/4"BSP x1/2"BSP 1
7 271.01.537.50 HOSE ASSLY 1/2" x 900mmL 1
8 271.01.534.50 ADAPTOR ELBOW 3/4" BSP x 1/2" BSP 1
9 271.00.552.50 SPECIAL UNION 1/8"xM12x1.5 1
10 999.16.001.50. FERRULE ID6 STEEL 2 PART OF
11 999.16.063.50. UNION NUT ID6 HEAVY STEEL 1 CONTROL
12 999.37.103.00.01 TUBE SS OD6x1.0 TKK 1 PIPING KIT
13 999.16.069.50. UNION NUT ID10 LIGHT STEEL 1 271.01.595.50
14 271.00.553.50 SPECIAL UNION ASSLY 1/4"BSPx12mm 1
16 271.01.398.50 HOSE ASSLY 1/2"x27"(90x90) 1
17 271.01.533.50 SPECIAL ELBOW 1/2"BSPx1/2"BSP 1
18 271.00.550.50 NRV 1/2" 1
19 271.00.583.50 SPECIAL UNION 1/2"BSPx1/2"BSP 1
20 271.01.136.50 SCAVENGE PIPE 1
21 271.01.154.50 HOSE ASSLY 1/4"x29" 1
23 273.01.849.50 BRACKET FOR LUBE OIL FILTER 1
48
8.7 CAPACITY CONTROL SYSTEM

2
3 3
10
11
4
9 12
5
13
14
8 1 15
16
17
6
4
Sl.
No.
1 271.00.367.50 ADAPTOR FOR SOLENOID VALVE 1
2 246.02.043.50. SOLENOID VALVE 1
3 999.30.755.50. REDUCER BUSH HEX 3/8X1/4 2
4 998.16.483.50. ASSLY OF ELBOW UNION R1/4 HEAVY 2 PART OF
CONTROL
5 999.37.103.00.01 PIPE, SOLENOID VALVE TO TEE1 0.54
PIPING KIT
6 998.16.603.50. ASSLY OF UNION T R1/4 (TEE1) 1 271.01.595.50
7 999.37.103.00.01 PIPE, TEE1 TO INTAKE VALVE 0.86
8 999.30.757.50. REDUCER BUSH HEX 1/2X3/8 1
9 999.37.108.00.01 PIPE, SOLENOID VALVE TO TEE2 0.29
10 998.16.489.50. ASSLY OF ELBOW UNION R1/4 1 PART OF
CONTROL
11 998.16.605.50 ASSLY OF UNION T R1/4 (TEE1) 1
PIPING KIT
12 999.37.108.00.01 PIPE, TEE2 TO INTKAE VALVE 0.76 271.01.595.50
13 998.16.127.50 ASSLY OF UNION R1/4 1
14 999.30.879.00 TEE FEMALE 1/4" 1
15 999.30.683.00 NIPPLE HEX 1/4" 1
16 271.00.349.50 NRV 1/4" BSP 1 PART OF
17 --- NRV PIPING ASSEMBLY - INTAKE VALVE
49
8.8 ELECTRICAL SYSTEM
50
8.8 ELECTRICAL SYSTEM
PART Number
Sl. No. PART DESCRIPTION
KES-15 KES-18.5 KES-22 KES-30
Power Contactor
1 211.09.338.50 211.09.114.50 211.09.114.50 211.08.495.50
(Main & Delta)
2 Main Motor Overload Relay 211.08.243.50 211.08.244.50 211.08.244.50 211.08.245.50
Power Contactor
3 211.09.337.50 211.09.338.50 211.09.114.50 211.09.114.50
(Star)
KES-15, KES-18.5, KES-22 & KES-30
2
415V, 145 AMP. SUITABLE FOR 16-35 mm CABLE
4 Incoming Terminals
MODEL: CTS35L, MAKE: CONNECTWELL
5 Aux Contacts (NO) 211.08.250.50
6 Aux Contacts (NC) 211.08.251.50
2
Power Terminals 415V, 25 AMP., SUITABLE FOR 0.5-2.5 mm CABLE
7
(Fan Motor) MODEL: CTS2.5UN, MAKE: CONNECTWELL
2
415V, 32 AMP., SUITABLE FOR 0.5-4 mm CABLE
8 Control Terminals
MODEL: CDL4U, MAKE: CONNECTWELL
9 Fan Motor Overload Relay 211.09.348.50
10 Fan Contactor 211.08.242.50
11 Control Transformer TR1 211.08.467.50
12 Control Transformer TR2 211.09.102.50
13 Fuse Glass Fuse, 230V AC, 1 AMP
14 Fuse Glass Fuse, 230V AC, 2 AMP
15 MCB-1 211.08.470.50
16 Control Contactor (FC-2) 211.08.242.50
17 Star/Delta Timer 211.09.110.50
18 Single Phase Preventor 211.09.105.50
19 Emergency Stop Push Button 211.09.103.50
20 Microcontroller 211.08.009.50
51
8.9 STRUCTURE ASSEMEBLY (BASE FRAME AND CANOPY)
52
8.9 STRUCTURE ASSEMEBLY (BASE FRAME AND CANOPY)
Sl.No. PART DESCRIPTION QTY.

1 BASE FRAME 1
2 COMPRESSION LOCK 1
3 COMPRESSION LOCK 4
4 CONTROL PANEL BOX 1
5 CONTROL PANEL DOOR 1
6 COOLER SUPPORT 1 1
7 COOLER SUPPORT 3 1
8 DOOR 1 1
9 DOOR 2 1
10 DOOR 3 1
11 DOOR 4 1
12 EXPOSED HINGE (DHIZ 3020) 2
13 FINGER PULL (F32) 1
14 FIXED PANEL 1
15 FRONT PANEL 1
16 PILLER 1 1
17 PILLER 2 1
18 PILLER 3 1
19 ROOF 1
20 SNAP HANDLE (DHIP110) 4
21 HEX. BOLT M8X1.25X20L 26
22 SPRING WASHER 32
23 HEX. SOCKET HEAD CAP SCREW M8X25 6
53
8.10 INTAKE VALVE ASSEMBLY

12
13 11
8
3
7 5
2
6
10 1
14
Sl. No. PART No. PART DESCRIPTION QTY. REMARKS

271.00.155.50 INTAKE VALVE ASSEMBLY 3"
271.00.284.50 SERVICE KIT Consists of Sl. No. 1 to 8
1 --- O' RING 1
2 --- U' RING 1
3 --- OUTER SPRING 1
4 --- INNER SPRING 1
5 --- PLUNGER 1
6 --- PISTON 1
7 --- TEFLON RING 1
8 --- GASKET 1
9 --- BOTTOM FLANGE 1
10 --- HOUSING 1
11 --- PISTON ROD 1
12 --- ALEN BOLT 4
13 --- COVER 1
14 271.00.349.50 NRV 1/4" BSP 1
54
8.11 MINIMUM PRESSURE VALVE ASSEMBLY
15
14 13 1
11
9 5
12 2
10
8
7 6

271.00.261.50 MPVL WITH BDV ASSEMBLY 1
271.00.282.50 SERVICE KIT FOR MPVL 1
1 --- PISTON 1
2 --- PISTON RING 2
3 --- SPRING CHECK VALVE 1
4 --- CHECK VALVE 1
271.00.283.50 SERVICE KIT FOR BDV 1
5 --- O' RING 1
6 --- SPRING 1
7 --- VALVE CONE 1
8 --- VALVE 1
9 --- PLUNGER 1
10 --- O' RING 2
11 --- GASKET 1
12 --- BOTTOM ADAPTOR 1
13 --- MAIN BODY 1
14 --- TOP COVER 1
15 --- HEX HEAD SCREW. 4
55
8.12 OIL FILTER ASSEMBLY
Sl. No. ITEM No. DESCRIPTION QTY.

1 271.01.329.50 OIL FILTER HEAD 1
2 271.01.432.50 SPIN-ON OIL FILTER ELEMENT 1
8.13 MOISTURE SEPARATOR ASSEMBLY
Sl. No. ITEM No. DESCRIPTION QTY.

1 271.01.546.50. 1" MOISTURE SEPARATOR 1
2 271.01.548.50. AUTO DRAIN ASSEMBLY1" MOISTURE SEPARATOR 1
56
9.0 MICRO CONTROLLER
FRONT VIEW:
- Control . . .
Healthy Manual Comp. ON
Faulty Remote Load
REAR VIEW:
µ-control
SR. NO.-
D1 D2 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
P N
COM.
COM.
M O DIFIED E
NO
NO
0V OUT
NO
CO M.
12V OUT
NOT USED
COMP. MOTOR O/L
START LOAD FAN

RELAY RELAY
REMOTE START
RELAY
COMMON
RTD WHITE
RTD WHITE
FAN O /L
SPP/RVP
PRES.T.-II
RTD RED
E. STOP
PRES.T.-I
OFF
ON
C1 C2 C3 C4 C5 C6 A1 A2 A3 A4 A5
12 34
DIP
57
FEATURES:
• Microcontroller based design
• 5 Digital inputs
• 2 Analogue inputs (4 – 20 mA)
• 1 RTD PT100 input
• 3 Relay outputs
• Automatic /Manual Compressor Start/Stop
• Auto stop on event of Fault
• Relay output for motor starter
• Status indications on LED
• Manual unload Push Button
• Event History
• Maintenance Warnings
TECHNICAL SPECIFICATIONS:
1.Operating Temperature : 0 – 60 Deg. C

2. Protection : Front Panel – IP 56
3.Box Dimensions : 96 x 144 x 100, Enclosure – IP 42
4.Supply : 230 VAC Through isolation Transformer
10VA
5.System : 8 bit Micro controller Based Controller
with Watchdog Reset Facility
5. Noise Immunity : To Do test
6. Enclosure : Flush Panel mounted. Enclosure
with base mounted Relay card.
7.Terminal : Plug in Terminals
8.Relay Output : 3 Nos of 5 Amps Resistive Load
58
ANALOGUE INPUTS :
Sl. No. Analog Parameter Range
1. PRES.T1- Air discharge air pressure 0.0 to 16.0 BAR

(Accuracy +0.1 BAR)
2. PRES.T2- OIL pressure 0.0 to 16.0

(Accuracy + 0.1 BAR)
3. RTD- Air discharge air temperature 5 to 200°C
(Accuracy + 3 °C)
DIGITAL INPUTS:
NOTE: All digital inputs are with respect to ground. COMMON should be connected to
12V.
1. COMP. MOTOR O/L (Compressor motor overload).

2. FAN O/L (Fan overload).
3. SPP/RVP
4. REMOTE START.
5. E.STOP (Emergency stop).
OUTPUT DETAILS:
(All outputs are potential free outputs)
Sl. No. Name of Output Function of Output
1. START RELAY For compressor main motor

2. LOAD RELAY For Load/Unload solenoid switching
3. FAN RELAY For Cooling fan of compressor main motor
59
DIP SETTING DETAILS & AUTO START FEATURE:
DIP Number Position Function
1 ON Programming Enable
OFF Programming Disable
2 ON Remote Mode
OFF Local Mode
3 ON Manual mode select

OFF Auto mode select
4 - Not used
NOTE: New DIP setting will active only on next power ON.
To see DIP status on LCD screen press “ACCEPT “key at POWER ON.
Status Y means DIP SW is ON
Status N means DIP SW is OFF
Status X means DIP SW is NOT USED
Auto Restart Feature: If ACCEPT key is pressed when DIP status is being displayed
on the Screen e.g.
DIP : 1 2 3 4
Y N Y X
then following screen will appear
AUTO RESTART
DISABLE
This Auto-restart feature can be enabled or Disabled by pressing “ “ or “” key.
Enabling this feature will allow the Compressor to restart automatically when the
Discharge Air. Pressure (PT1) drops below the “Load Pressure Set Point” after the
UNLOAD TIME OVER error had occurred.
60
LED DETAILS:
LED Name Position Function
Healthy ON All inputs are OK

OFF One or more input is Not OK
Load ON Compressor is loaded

OFF Compressor is unloaded
Remote ON Remote mode selected

OFF Local mode selected
Faulty Steady ON Compressor in Fault condition

Flashing For Delta pressure fault only
OFF Compressor in OK condition
Man ON Manual mode selected

OFF Auto mode selected
Comp. ON ON Compressor is ON
OFF Compressor is OFF
61
PROGRAMMING DETAILS:
- Press “STOP” key for 15 second to set the parameter values.
- Press “ “ key to increment the parameter value.
- Press “ “ key to decrement the parameter value.
- Press “ACCEPT” key to save the parameter value and switch to next
parameter.
- Press “STOP” key to escape from programming mode.
Name of parameters Range
1. Load pressure 1.0 to 16.0 BAR

2. Unload pressure 1.0 to 16.0 BAR
3. Unload run time 1 to 600 seconds
All other program parameters can be changed as follows.
- Press “START” key for 15 second to set the parameter values.
- Press “ACCEPT” key to skip from setting “TOTAL WORKING HOURS”.
- Press “ACCEPT” key to skip from setting “TOTAL LOAD RUN HOURS”.
- Press “ “ key to increment the parameter value.
- Press “ “ key to decrement the parameter value.
- Press “ACCEPT” key to save the value and switch to next parameter.
Name of parameters Range
1. Discharge air pressure 1.0 to 16.0 BAR

2. Delta pressure 1.0 to 16.0 BAR
3. Discharge air temperature 80 to 115 °C
4. Air filter change 1 to 9999 Hours
5. Oil filter change 1 to 9999 Hours
6. Oil change 1 to 9999 Hours
7. Air oil separator 1 to 9999 Hours
8. Motor greasing 1 to 9999 Hours
9. Fan ON temperature 5 to 90 °C
13. Fan OFF temperature 5 to 80 °C
NOTE: Please refer the DIP setting details.
62
HISTORY MODE DETAILS:
- Press “ ““ ” key for history mode.

- Press “ “ key for next history mode parameter.
- Press “ “ key for previous history mode parameter.
- Press “STOP” key to escape from history mode.
Name of History mode parameters Unit
1. Longest load run Hours

2. Discharge air pressure trip Date
3. Discharge air temperature Date
4. Oil filter change Date
5. Oil change Date
6. Air filter change Date
7. Air oil separator Date
8. Motor greasing Date
RTC SETTING, AUTO OFF & CALIBRATION MODE:
RTC SETTING:
- Press “STOP” key on power ON to set the RTC.

- Press “ “ key to increment the date and time value.
- Press “ “ key to decrement the date and time value.
- Press, “ACCEPT” key to save the date and time value and switch to next date
and time value. If the value is last one then it will escape from RTC setting and
then it will enter into AUTO STOP FEATURE.
- Press “STOP” key to escape from RTC setting and then it will enter into AUTO
STOP FEATURE.
63
AUTO STOP FEATURE:

This feature enables the user to set total six OFF TIMES.
This feature can be ENABLED or DISABLED .
then following screen will appear:
AUTO STOP
DISABLE
This Auto-Stop feature can be Enabled or Disabled by pressing “ “ or “” key &
press “ACCEPT”.
If AUTO STOP is ENABLED then the six off times can be set.
- Press, “ACCEPT” key to save the OFF TIME and switch to next OFF TIME.
- At last Calibration Mode will Appear, which is described as below-
CALIBRATION MODE:
- Press, “ACCEPT” key for switching to next calibration analog parameter. If the
parameter is last one then it will escape from CALIBRATION MODE.
HOW TO OPERATE:
Test Modes:
This feature is used in fault diagnosis.
Press “Accept “ key when compressor is in OFF condition.
Note : Test modes are not for operator use.
A) Keyboard test Mode : This mode is used to check keys.

This mode will show the name of the key pressed. Press “ACCEPT” key to switch to
INPUT Test Mode.
B) Input Test Mode:
This mode is used to check all digital inputs.
Status Y means Input is present.
Status N means Input is not present (Faulty condition).
e.g.
IP NO.: 1 2 3 4 5
Y N Y Y N
Press “ACCEPT” key to switch to OUTPUT Test Mode.
C) Output Test Mode:
This mode is used to check all 3 outputs.
-Press, “UP” key to check next output.
-Press, “ACCEPT” key to Switch ON/OFF outputs.
64
Local Mode:
- Press, “START” key for 5 second to start the compressor.
- Press, “STOP” key to stop the compressor
- If any faulty condition occurs then display will show the reason and faulty LED
will be ON.
Remote Mode:
- Apply the REMOTE START (NC) digital input to start the compressor.
- Remove the REMOTE START digital input to stop the compressor.
- If any faulty condition occurs then display will show the reason and faulty LED
will be ON.
Note: Loading and unloading as per the auto/manual mode selection.
Manual Mode: -
- Press, “LOAD/UNLOAD” key to load the compressor if compressor is

ON and compressor is unloaded.
- Press, “LOAD/UNLOAD” key to unload the compressor if compressor is ON
and compressor is loaded.
Auto Mode: -
- If the discharge air pressure is below the load pressure value (settable) then
compressor will get loaded if compressor is ON.
- If the discharge air pressure is above the unload pressure value (settable) then
compressor will get unloaded if compressor is ON.
65
FAULTS:
Different possible faults are as below-
1. High discharge air pressure.
2. High delta pressure (This fault will come only once after compressor is loaded.
It will not stop the compressor functionality).
3. PT1- air pressure sensor fault.
4. PT2- oil pressure sensor fault.
5. RTD-air temperature sensor fault.
6. Main motor overload.
7. Fan motor overload.
8. SPP/RVP.
9. Emergency Stop
10. Unload time over
66
10. SAFETY AND INTERLOCK FEATURES
Safety Devices :
Following mechanical safety devices are provided to ensure safe operation of the package
Minimum Pressure Valve - Maintains minimum air pressure in air-oil separator tank
so that positive oil flow is ensured.
Safety Relief Valve - De-pressurize compressor system if pressure exceeds

beyond limits of the system.
Blow Down Valve - Ensures proper pressure relief arrangement during
operation of the system.
Air Intake Valve - Arrest back flow of oil during compressor stop condition.
Scavenging Line - Takes out oil collected in final separation process
through air/oil separator element.
Oil Level Indicator - This is mounted on air/oil separator tank. Gives visual
indication of minimum & maximum level of oil present in
compressor system.
Clogging Indicator - It is mounted between suction air filter & compressor
inlet. It gives visual indication of air filter element
clogging to an operator of the machine
Control Panel :
This is star-delta starter cum microprocessor based control panel packaged on the same base
frame within canopy of the compressor. Panel is wired and hooked up with main motor and all
instruments with in the skid. The display of various operating parameters and setting is done by
a man machine interface (MMI) installed on easily accessible height on canopy front part.
Display on MMI - Delivery air pressure
- Air/Oil Temperature
- Differential pressure across air-oil separator
- Hour Meter
Total running hours
Total loaded hours
- Start/stop, load/unload, Emergency stop & test
conditions
- Reason for trip
- Maintenance Schedule (No. of Hours indication)
Replace Air Filter Element
Replace Oil Filter Element
Replace Air-Oil Separator Element
Start Up checks
Routine Maintenance checks
Change of lubricating oil
Motor related maintenance
Safety & Control :
Following Trip signals are provided to protect the machine from abnormal operating conditions
Compressor side - High air/oil temperature
- High Discharge pressure
- Low Cooling water flow (in Star up logic and during
operation)
Motor side - Over load protection
- Phase reversal protection
67
11. TROUBLE SHOOTING

Problem Probable Reason or Parts Involved Remedy
Insufficient air flow Air intake filter clogged. Replace filter
Safety valve Leakage. Check the setting. Repair
BDV Leakage Check the setting. Repair
SOV Leakage Check & Repair
High air temperature a) Insufficient or no oil flow due to
- low oil level in tank Top-up oil
- oil filter clogged Replace oil filter element
b) Inadequate cooling of oil due to

Check motor & circuit
- fan motor not ON
Check and replace
- thermal switch failure
Check and replace/correct
- fan failure/damaged
Clean the cooler with vacuum
- air passage in the cooler cleaner after removing the fan
blocked cowl.
Check all joints, gearbox for

leakages
c) Oil loss due to leakages
Excessive oil in air Scavenge line blocked Remove the scavenge pipe/hose,
line fittings and clean the passage.
Check and correct.

Excessive oil in the tank.
Check and replace
Air-oil separator element damaged
68
Oil throw through air Leakage across Air Intake Valve. Check for damages on tappet
filter during stopping plate and the sealing ring.
Replace the defective part.
Intake valve is not closing when
Check the parts and repair /
compressor stops due to the absence of replace.
Air flow to intake valve piston is not given
due to solenoid valve failure or line
blockage
Compressor loading -Intake valve is stuck Check and repair/replace the

not happening parts.
- Solenoid Valve not functioning Check the spool and repair
- Solenoid valve is not getting energized Check electrical connections and

Microcontroller output.
- Intake valve is not opening or stuck at
closed position due to seal/piston jam in Check the Intake valve, clean
the piston or dust. and replace damaged parts
Safety valve opening Pressure transmitter is defective Check the PT (0-20mA for 0-16
during operation bar)
Setting in the microcontroller is disturbed Check the pressure setting value

for unload pressure for unloading in the controller.
Safety valve is defective Check the valve & replace
Fault indication on Loose wiring Check the connections and

Microcontroller correct
Controller is faulty Check the controller and replace.
Motor not starting Contactor is defective Check and replace.

Motor stalls after - Supply voltage is low Check and correct the power
starting - Inadequate cable for power line Check the cable size
- Intake valve not closed at starting Check the power supply to
due to solenoid valve failure or Solenoid Valve, circuit and
no air supply or electrical signal Intake Valve. Replace defective
failure to solenoid valve or parts.
leakage in the air line from
solenoid valve to Intake Valve.
69
Motor tripping during - Air pressure in the air-oil separator tank Release the air from the tank by
Starting. due to failure of blow-off valve to exhaust opening the safety valve
the air when compressor was switched off. manually. Then check the
- Motor damage/failure functioning of solenoid valve &
its circuit and Blow-off valve
- Airend damage with air connection.
- Loose connection in motor power line Check motor, airend & gears
- Gear failure
Motor tripping after Intake valve opens before the Star- delta Check the timer settings for
running few seconds changeover is completed. Star- Delta changeover
from start
Motor tripping after High starting current due to loose Check the connections and
few start /stops and connections or Intake Valve in open Intake Valve piston.
contactors jammed position during starting.
70
DETAILS OF KPCL BRANCH OFFICES

Person
PLACE ADDRESS PHONE NO FAX NO E MAIL ADDRESS
concerned
HADAPSAR 020 26870341, 020 acdmktg@kpcl.net Mr. S. Singh
PUNE INDUSTRIAL 26870133, 26870634
ESTATE, PUNE 26874590 26870297/
411 013 Reliance: 26874217
30905454
G-401-408 022 25181081, 022 kpclmum@mtnl.net.in Mr. PV Rajeev
MUMBAI KAILASH 25181082, 25181313
INDUSTRIAL 25181083
COMPLEX, PARK Reliance:
SITE, BEHIND 30945532, 5533
GODREJ
RESIDENTIALCOL
ONY,
VIKHROLI(W),
MUMBAI 400 079
208 MEGHDOOT 011 011 Mr. Rajesh
DELHI BUILDING 94 30981341,42 26429685 Kumar
NEHRU PLACE, Reliance: 26417549
NEW DELHI 110 30946820, 6821
019
NO 102, 1ST 080 22270029, 080 kpclbir@dataone.in Mr. Kishan
BANGALORE FLOOR, ANDREE 22270079 22270045 Suresh
CAPITOL, Reliance:
8/1 KH ROAD, 30619331/ 9332
BANGALORE 560
027
1ST FLOOR, 044 28193066, 044 kpcl_chn@vsnl.net Mr. Kishan
CHENNAI ELCANSO 28190436, 28194937 Suresh
COMPLEX NO.10, 28192092
COSA MAJOR Reliance:
ROAD, EGMORE, 30910143/ 0144
CHENNAI 600 008
3-5-907,403-404, 040 23260743, 040 hyd2_kpclhyd@sancharnet. Mr. Kishan
HYDERABAD MAHAVIR LOK, 23260746, 23260171 in Suresh
HIMAYATNAGAR, Reliance:
HYDERABAD 500 30910945
029
15 GANESH 033 22119080, 033 Kpclcalacd@vsnl.net Mr. B. Datta
KOLKATA CHANDRA 22119081, 22365586, kpclcal@cal2.vsnl.net.in
AVENUE, 9TH 22111905 22116948
FLOOR, Reliance:
KOLKATTA 700 30928831/ 8832
013 (ACD)
VADODARA CHI CHI TOWER 0265 2284604, 0265 Kpclbrd@icenet.net Mr Dhaval Shah
"A" KOLLOL 2284605, 2280095 shahdi@kpcl.co.in (Mobile
CHILDREN 2284606 9898098098)
HOSPITAL LANE, Reliance: 0265
TANA APPT, 30967
ELLORA PARK,
SUBHANPURA,
VADODARA 390
007
71
INSPECTION AND SERVICING RECORD SHEET
Sl. Date of Brief description of Inspection/Servicing/Parts Name and

Inspection/Servicing changed Signature
No
/Overhaul
72
Sl. Date of Brief description of Inspection/Servicing/Parts Name and

Inspection/Servicing changed Signature
No
/Overhaul
73
Notes
74
Notes
75
Contact your nearest dealer for any assistance or dial Toll free number 1800 301 00009
Document Number: S271.069- 084. D98 Publication No.-N27.21.000.034.00
Revision Status: R02
76

Operation and Maintenance Manual KES-15, KES-18, KES-22, KES-30

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Kirloskar Pneumatic Co. Ltd.

Operation and Maintenance Manual

Operation and Maintenance Manual

KIRLOSKAR PNEUMATIC COMPANY LTD.,

Document Number : S271.069-084.D98

Revision Status: R02

Date: July 2011

Head of Servicing Department

Fax : 91 – 20 26870297 / 26870634

e-mail : acdser@kpcl.net and acdmktg@kpcl.net

MACHINE IDENTIFICATION AND SALE RECORD

Owner’s name: ___________________________________

Compressor Serial Number:____________________________________

Main motor make:____________________________________

Main motor Serial Number:____________________________________

Motor Rating: ___________kW @ ____________ Rev/min

Compressor Capacity:____________m3/min @ ___________ bar g

Dealer Name / Code:_____________________________________

Dealer signature / stamp:

Message from the Managing Director

We welcome you to the family of users of Electric Screw

At Kirloskar, listening to the user & customer and meeting

KPCL has designed your compressor to be safe, best in

KPCL is honored to be the choice for all your compressed

About Kirloskar Pneumatic Company

Driven by the Kirloskar Group philosophy of “Enriching Lives”,

8.10 Intake Valve Assembly 54

The abbreviation KPCL used in this Manual means Kirloskar Pneumatic

All components, accessories, pipes and connectors added to the compressed

• Of good quality, procured from a reputable manufacturer and, wherever

KPCL reserves the right to make changes and improvements to products

1.3 ISO SYMBOLS

1.4 RECEIVING THE COMPRESSOR

The condition of compressor parts also to be checked by opening the canopy

1.5 LIFTING THE COMPRESSOR

1.6 GENERAL INSTALLATION GUIDELINES

1.7 INSTALLATION REQUIREMENTS

Mechanical connections: The compressor is provided with 3 outlet points on

Electrical connections: The compressor is provided with opening on the base

Model Backup fuse Recommended cable size

KES15 50 Amps 3.5 core, 6 sq.mm 3.5 core, 16 sq.mm

KES 18 50 Amps 3.5 core, 10 sq.mm 3.5 core, 16 sq.mm

KES 22 63 Amps 3.5 core, 10 sq.mm 3.5 core, 25 sq.mm

KES 30 80 Amps 3.5 core, 16 sq.mm 3.5 core, 25 sq.mm

A --Room ventilation through the opening in the wall

B, C -- Room ventilation with exhaust system

D -- Hot air duct from compressor E -- Ducting for room heating

Electric Circuit Diagram

General Arrangement Drawing for KES15 to KES22 Models

General Arrangement Drawing for KES30 Model

Pressure release: The compressor is provided with pressure relief valve to

3.0 DOs and DON’Ts

Operating personnel read this manual thoroughly and follow instructions

4.2 POINTS TO BE OBSERVED BEFORE INITIAL START

4.3 COMMISIONING THE COMPRESSOR

Faulty Remote Load DIP

Front View of Microcontroller Back View of Microcontroller

5.0 SPECIFICATIONS & SALIENT FEATURES

Motor Rating: _kW @ __ Rev/min

Compressor Capacity:__m3/min @ _ bar g