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KIRLOSKAR KC72 User Manual

KIRLOSKAR KC72
58 pages
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Kirloskar KC Series Refrigeration Compressors
Instruction and
Operation Manual
Versions:
Single Stage : KC2, KC3, KC4, KC6, KC9, KC12
Two Stage : KC21, KC31, KC42, KC51, KC63, KC72, KC84,
KC93 & KC102
KIRLOSKAR
KIRLOSKAR PNEUMATIC CO. LTD.
Kirloskar Refrigeration
INDIAN REGISTER
©
OF SHIPPING 1993
MGMT. SYS.
RvA C 071
ISO 9001 : 2000

Questions and Answers:

KIRLOSKAR KC72 Specifications

General IconGeneral
ModelKC72
TypeReciprocating Air Compressor
Motor Power2 HP
Power SourceElectric
Power Rating1.5 kW
Maximum Pressure175 PSI
Noise Level82 dB(A)
StagesTwo Stage
Voltage220 V

Summary

Compressor Safety Guidelines

Safety Program Review

Review safety program for hazards from rotating machinery.

Electrical and Fluid Hazards

Consider hazards from electrical power, hot oil, high pressure, and gases.

Maintenance Safety Precautions

Special precautions to prevent power application during maintenance.

Regulatory Compliance

Ensure design and operation abide by local safety and environmental laws.

Safe Operation Practices

Recommended Actions (Do's)

Instructions for correct operation, maintenance, and checks.

Prohibited Actions (Do Not's)

Prohibitions during operation and maintenance.

Initial Compressor Operations and Checks

Pre-Start Checklist

Verify tightness, alignment, oil level, safety cutouts, and gauges.

Compressor Priming

Pour oil into shaft seal cover and filter housings before starting.

Valve Operation Preparation

Apply oil and grease to glands before mounting stop valves.

Air Run Trial Procedure

Run compressor on air for five minutes to check oil pressure and loading.

Single Stage Startup

Start on reduced load, then load gradually using CCSV.

Two Stage Startup

Run on direct cylinder, then load capacity steps as temperature drops.

Critical Operating Warning

Intermediate pressure must not exceed 4 Kg/cm²g.

Mandatory Initial Maintenance

Change oil, filters, strainer after initial hours (4, 8, 50, 100 hrs).

Technical Data and Specifications

Single Stage Model Specifications

Provides technical data for KC2 to KC12 models.

Two Stage Model Specifications

Provides technical data for KC21 to KC102 models.

Salient Features of Compressor Construction

Cylinder Liner and Suction Valve Design

Describes interchangeable liners, fine boring, and hydraulic lifting mechanism.

Lubrication System and Filter Details

Explains forced lubrication, pressure regulator, and filter elements.

Discharge Valve Assembly Design

Features concentric rings, sinusoidal springs, and identical parts.

Piston and Connecting Rod Assembly

Details die cast pistons, rings, and drilled connecting rods.

Crankshaft and Main Bearings

Describes ground crankshaft, white metal bearings, and dynamic balancing.

Welded Steel Crankcase Features

Highlights low weight, heat dissipation, and gas-tight construction.

General Operating Instructions

Compressor Operation Basics

Covers suction valves, oil pump, high pressure supply, and no-load starting.

Liquid Stroke Hazards

Details risks of liquid refrigerant and protection device function.

Ammonia Safety Rules

Covers ammonia characteristics, safe storage, and leakage precautions.

Safety, Preparation, and Oil Charging

Freon Safety Rules

Details Freon characteristics, storage, leakage, and ventilation.

Compressor Room Requirements

Specifies exits, fireproofing, ventilation, accessibility, and noise control.

Initial Operation Preparation

Steps for installing and filling the compressor with oil.

Oil Charging Procedure

Details on pouring oil into the strainer and checking oil return.

Oil Pressure and Refrigerant Charging

Adjusting Oil Pressure

Procedure to set oil pressure regulator to 1.5 kg/cm² above suction pressure.

Plant Operations and Controls

Parallel Compressor Operation

Periodical Maintenance and Schedule

Component Maintenance Procedures

Lubrication Maintenance Importance

Emphasizes checking oil pressure/level and not mixing oils.

Operational Records and Maintenance Schedule

Comprehensive Maintenance Schedule

Summary of periodic checks and replacements based on operating hours.

Compressor Accessories and Safety Devices

Pressure Switches (Pressostats)

Explains function of pressure switches for safety in the control circuit.

High Pressure Pressostat Function

Details protection against excessive delivery pressure.

Low Pressure Pressostat Function

Details protection against minimum suction pressure.

Oil Pressure Differential Pressostat

Explains protection against low oil pressure.

Combined HP/LP Pressostat

Covers the single unit for high and low pressure protection.

Troubleshooting Common Faults

Fault Diagnosis and Remedies (Part 1)

Lists common faults, their causes, and suggested remedies.

Fault Diagnosis and Remedies (Part 2)

Continues listing common faults, their causes, and suggested remedies.

Troubleshooting Chart (Continued)

Fault Diagnosis and Remedies (Part 3)

Lists common faults, their causes, and suggested remedies.

Malfunctioning Loading/Unloading

Addresses issues with solenoid valves and capacity control.

Preventing Compressor Failures

Identifying Sources of Contamination

Pinpoints system areas where dirt can enter the compressor.

Contamination Prevention Methods

Covers flushing the system and using strainers with cloth bags.

Compressor Prevention Steps

Outlines pre-start checks, initial run, oil drain, and strainer cleaning.

Safe Compressor Restart Procedure

Details using new oil, checking suitability, and verifying oil pressure.

Safety During Compressor Operation

Emphasizes avoiding hot surfaces, guards, and referring to the manual.

Important Installation Checks

Crankshaft Rusting Prevention

Methods to prevent crankshaft rusting during installation phase.

Coupling and Pulley Fitment

Procedures for fitting coupling, flywheel, and pulley on the shaft.

Base Frame Installation

Ensures correct base frame, leveling, and proper stud usage.

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