ALE75-100AV Specification EN 3A40ZS1199P1-04
ALE75-100AV Specification EN 3A40ZS1199P1-04
ALE75AV-H ALE100AV-H
SPECIFICATIONS
KOBE STEEL,LTD.
CONTENTS
〔CONTENTS〕
Contents 1
Product Specifications 2
Installation Conditions 5
Electric Power Facilities 10
Lubricating Oil 12
Tips For Sound Control Measures 14
After-Sales Service 16
Warranty Conditions / Indemnity 18
〔Attached Drawings〕
(1) ITCS Controller 19
(2) External Drawing 20
(3) Installation Process 22
(4) System Diagram 23
(5) Wiring Diagram 24
(6) Outside Terminal Diagram 26
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.
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PRODUCT SPECIFICATIONS
◆ 0.75MPa{7.5bar} Specifications
Model
ALE75AV ALE100AV
Item
Frequency (Hz) 50
Voltage (V) 380
Discharge air volume (m3/min) 11.6 17.0
Consumption gas quantity between about 40~100%;
the constant pressure control by the inverter
Control system
Consumption gas quantity less than about 40%;
load and unload control
Gauge pressure 0.75 {7.5}(The setup of the constant pressure control is less
(MPa{bar}) than 0.73{7.3})
Discharge
condition
Below ambient temperature Below ambient temp.
Temperature (℃)
+20 +15
◆ 0.88MPa{8.8bar} Specifications
Model
ALE75AV-H ALE100AV-H
Item
Frequency (Hz) 50
Voltage (V) 380
Discharge air volume (m3/min) 10.1 15.7
Consumption gas quantity between about 50~100%;
the constant pressure control by the inverter
Control system
Consumption gas quantity less than about 50%;
load and unload control
Pressure (MPa{bar}) 0.1{1.0}
Suction
Temperature (℃) 20
condition
Humidity (%) 0
Gauge pressure 0.88 {8.8}(The setup of the constant pressure control is less
(MPa{bar}) than 0.86{8.6})
Discharge
condition
Below ambient temperature Below ambient temperature
Temperature (℃)
+20 +20
◆Inverter Specifications
Model
Inverter
Item
Frequency (HZ) 50
Power supply
Voltage (V) Three phase 380
Notes)
(1) The discharge air volume is the value obtained when the compressor is in the above
mentioned suction condition.
(2) As for the guaranteed values, consult with us separately.
(3) The discharge pressure shows a value after the check valve of compressor.
(4) SF is the meaning of the service factor.
(5) The noise level is measured at 1.5 m away from the machine front and 1 m from the
floor in the anechoic room, with the machine being operated at its full load. As for
the noise level of side and rear face, consult with us separately.
(6) The discharge air must not be used for respiratory equipment from which aspiration
is directly made.
(7) The inside of the unit is cooled down by the ambient air of the compressor installation
site; provide good ventilation to keep the ambient temperature below 45℃.
(8) As for the discharge temperature exceeding the standard condition, consult with
us separately.
(9) Flanges are not included for end of the air pipe.
(10) Make sure to fill the tank with the recommended lubricating oil before operation.
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INSTALLATION CONDITIONS
○ The cleaner the suction air is, the longer the machine life is. Avoid such installation
sites subjected to dust, chlorine gas, hydrogen sulfide gas, sulfur dioxide gas, highly
concentration of ozone or any other toxic gas. Also avoid underground or highly
humid place.
○ When the indoor temperature that the compressor was installed is lower than 0 ℃,
the oil viscosity is raised, and it is expected to become a starter failure. As for such
case, consult the manufacture separately.
2) Caution in installation
○ Perform foundation works on 2 positions, the compressor front and rear, with the
foundation bolts and foundation bolt's set plates attached (see the Exterior Drawing).
Always set cauls for foundation bolts, which is effective for noise prevention.
○ Be sure to connect the ground cable to the terminal installed on the operation panel.
○ The noise level changes by the size of the room where the compressor is installed,
the position, the reflective rating of the wall and so on.
○ Install the compressor on the horizontal floor, and don't install it on the shape steel
and the block. Installation on the shape steels or the blocks may cause increased noise.
○ In the case of installing the compressor's charge's and its discharge's mouth in
the room, pay attention to its mouth's position and direction.
P6
Item ※
Air tank capacity ( m3 )
Model
ALE75AV Min. 1.9
ALE75AV-H Min. 2.1
ALE100AV Min. 2.8
ALE100AV-H Min. 3.2
※) In case of load rate is 20~22%, differential pressure of upper and lower limit pressure is
0.05MPa {0.5bar}, a cycle time (load → unload → load) is 23 seconds.
The capacity shown above is for the constant pressure operation.
And also the capacity shall be selected so as to keep pressure of the discharge line over
0.29MPa {2.9bar} . When operating some machines, or to perform group control operation,
it is necessary to also examine set pressure.
(t1+t2)× Qs × Pa × x(1-x)
VR=
D
PH
VR :Air tank capacity (m3 )
t1 :Unload time (sec.)
t2 :Load time (sec.)
t1+t2 ≧ 23sec. (more than 23sec.)
Qs :Discharge air volume (m3/s)
PL
t1 t2 Pa :Suction absolute pressure (MPa {bar})
D :Difference of high pressure from
low pressure (MPa {bar})
x :Load rate (Air consumption to volume Qs)
(Air tank capacity is surely made the
biggest at the time of load rate of 50%.)
P7
2.Caution in piping
1) Discharge-air piping
○ The pipe diameter is DN50 or bigger. The discharge air pipe shall be as short as
possible so as to minimize the pressure drop in the pipe. When deciding the pipe
diameter, allow for the piping resistance.
○ 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.).
○ Slope the pipes in the air flow direction to prevent the drain from remaining in pipes.
○ When two or more screw compressor units are to be connected to the same main
discharge pipe, equip a stop valve in every discharge pipe from the unit to close
the valve while either compressor unit is in rest. Set up a drain outlet valve between
the screw compressor, and set up the stop valve of the same size in that point as well
separately. It is necessary at the time of the trial run and the maintenance.
○ For the piping extended up to the air tank, install a drain outlet, for easy draining.
○ Don't equip a check valve between a compressor and the air tank.
○ When a screw type compressor and a reciprocating type compressor are to be installed
together, the discharge pipe from a screw compressor shall be connected to
the downstream of the air tank to keep the pulsation from the reciprocating type
compressor away.
P8
2) Other piping
○ For drain discharge from the inter-cooler and the after-cooler, use a DN10 pipe.
3.Ventilation
○ Install a ventilating fan such a place where the ventilated air is never sucked again.
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.
WARNING
General ventilation
This ventilating capacity is provided when the compressor
is installed in a small room to be ventilated generally
(assuming that the allowable rise in interior temperature
Δt is 10℃). Install an exhaust fan on the upper part of
the wall at the compressor outlet side, and inlet on the lower
part of the wall at the compressor suction side. Provide such
a size of inlet opening as to keep the velocity of airflow to be
2 m/s or less.
Ventilation with exhaust duct
When the pressure loss of the exhaust duct is calculated to
be 0.2 mbar or less based on the compressor airflow quantity,
the exhaust duct can be directly connected to the compressor
outlet. When connecting the exhaust duct to the outlet,
make use of the mounting mark on the top. The exhaust duct
shall be removable. Install the exhaust fan and the inlet
according to the same procedure as in the general ventilation.
Provide such a size of inlet opening as to keep the velocity of
airflow to be 2 m/s or less.
Ventilation with exhaust duct and exhaust fan
When the pressure loss of the exhaust duct is 0.2 mbar or
more, install such an exhaust fan inside the duct as to
maintain the fan airflow quantity as above. At this time,
provide a 200-300 mm of clearance (H) between the exhaust
duct inlet and the compressor outlet. During running
the compressor, run the exhaust fan as well. On stopping
the compressor, stop the exhaust fan as well. Provide such a
size of inlet opening as to keep the velocity of airflow to be
2 m/s or less.
Note) Be careful of the position for the exhaust duct opening; noise may leak out of the duct.
○ The starter panel of this machine is installed inside front of the unit.
○ Connection to the power source must be carried out correctly referring to the attached
electrical wiring diagram and in accordance with the rules and regulations applied to
each customer.
Item Input electric current Input electric current Input electric current
Voltage
at the rated time at the max. rated in the motor max.
Model (V)
(A) time (A) rated output(A)
ALE75AV
142 156 156
ALE75AV-H
380
ALE100AV
176 194 194
ALE100AV-H
Note) The change in the allowable voltage of the inverter is±10%
○ As a short-circuit protective device for the power source, be sure to install an earth
leakage breaker instead of a knife switch with fuse which will burn the motor due to
an open-phase operation.
Considering harmonic, use the earth leakage breaker corresponding to harmonic·surge
in the following list or to harmonic·surge of other makers.
Item
Voltage(V) Diameter(mm2)
Model
ALE75AV
38
ALE75AV-H
380
ALE100AV
60
ALE100AV-H
LUBRICATING OIL
○ For the long and good use of the compressor, proper control of the lubricating oil is
necessary.
○ If you change the brand of oil, drain the oil completely, and clean the oil line by
flushing oil, and supply new oil.
○ Lubricating oil should be changed the entire quantity in 1 year or 8000 hours,
whichever comes first. But conduct sampling of every half year only in the first year,
and confirm the effectiveness of the exchange at 1 year (or 8000 hours).
○ You must use the lubricating oil of the brands recommended in the following table.
The machine has been designed for the following brands of lubricating oil.
The use of unrecommended brands could shorten the life of bearings extremely as
proper oil quantity and film cannot be maintained.
○ Since the grease valve system is adopted in the shaft seal part of the main motor.
Replenish the new grease to two places in the load-side and the fan-side according to
the following table. Undercharge or overcharge of motor grease could cause problem
on the bearing of main motor. The replenishment must be performed in an appropriate
amount (as per the specification) for every replenishment interval. Use grease gun to
replenish grease under pressure while the motor is in operation.
◆ Grease
Amount of replenishment Replenishment
Recommended grease brand interval
Load side Fan side
ALE75AV
ALE75AV-H
45g 60g 1500h
ALE100AV KOBELCO TOUGH GREASE
ALE100AV-H
○ Never mix different types of greases. Mixture of greases of different quality or brand,
or with different additives could cause deterioration and insufficient lubrication.
As a result, bearings could be damaged and extremely short-lived.
○ Do not fill the grease except the above one. The main motor is designed on the basis
of the above mentioned grease. If you use other grease, the bearing temperature will
rise and lead to damage of the bearing. It will also shorten the bearing life.
The sound level on this machine is measured at the point 1.5m from the front of
the machine and 1m above the floor in an anechoic chamber. The sound level
depends on the measuring position. It also changes according to the circumstances
and conditions under which the machine is installed. To install the machine, special
consideration should be given to sound control measures. The following are just
samples for sound control measures to be done by customers.
<Case 1>
<Case 2>
There may be gap between the Fill up the gap to avoid resonance.
compressor base plate and the floor.
<Case 3>
<Case 4>
The piping is resonant with the air tank. ・Lag the piping
・Please install the silencer between the
compressor and the air tank. Set up
the support in consideration of weight
when installing the silencer.
<Case 5>
The opening position of exhaust duct To reduce the sound level in the vicinity
can influence the sound level. of compressor room, install sound
absorbing material to the inner surface
of exhaust ducting.
Note) In constructing the exhaust ducting,
always maintain the static pressure at
20Pa or below.
<Others>
The sound level also varies according to the number of operating compressors.
For example, if three 85dB compressors operate, the sound level will be as calculated
by the following equation:
85 85 85
10 log(10 10 +10 10 +10 10 )=90dB
There are other factors that may increase the sound level.
When installing the compressor, take effective sound control measures with adequate
consideration.
AFTER-SALES SERVICE
Proper maintenance is necessary to keep the compressor in good condition for long
periods. Inside the compressor, there are various heavy equipments such as the motor,
and many of them need removing or replacing at the time of maintenance. As shown
below, the installation of the I-beam will make it safer and easier to do
the maintenance work.
ting
420
<Precaution>
(1) Select the I-beam with enough load capacity to lift the heavy load listed above.
Take the joint strength between the building and I-beam into account.
AFTER-SALES SERVICE
Proper maintenance is necessary to keep the compressor in good condition for long
periods. Inside the compressor, there are various heavy equipments such as the motor,
and many of them need removing or replacing at the time of maintenance. As shown
below, the installation of the I-beam will make it safer and easier to do
the maintenance work.
2nd-stage
810
maintenance i-beam
Name Weight(kg)
1st-stage 160
compressor unit
690
2nd-stage 80 1st-stage Compressor unit
compressor unit maintenance i-beam
1630 2030
MIN.1300
Main motor
Compressor
1st-stage 2-stage
unit
2160
<Precaution>
(1) Select the I-beam with enough load capacity to lift the heavy load listed above.
Take the joint strength between the building and I-beam into account.
WARRANTY CONDITIONS
1.Warranty conditions
The warranty period shall be 12 month after completion of the test run or 18 months
after shipment, whichever comes first.
※“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.
Even during the warranty period of this machine, we refuse warranty in the following
cases:
① Trouble caused by the natural disasters or accidents beyond human control.
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.
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KOBE STEEL,LTD.
KOBE STEEL,LTD.
KOBE STEEL,LTD.
KOBE STEEL,LTD.
P23
KOBE STEEL,LTD.
KOBE STEEL,LTD.
KOBE STEEL,LTD.
P26
5 Input signal for a compressor's remote start. Input on no-voltage contact in order not to damage the controller in taking voltage.
Remote start Input a (N.O)
6 (one shot signal) Select the contacts which can flow faint current.
7 Input for a compressor's remote loading.
Remote load Input a (N.O)
8 (status signal) 2. The output signal means the signal to be output from the compressor operating
9 + Input from the pressure sensor to control the outside panel. Use the receive circuit at AC 100-250V below 2A or at DC 30V below 2A.
Input
10 Outside start condition (option) - pressure(line pressure). (AC 100/110V below 2A is suitable)
11 LOCAL SD (4~20mA)
12 - - - - 3. The input signals of start and stop are necessary for remote operation.
13 - - - - The terminal number 3-4 is short-circuited at factory shipments.
14 - - - - Remove a short circuit wire in the case of using this terminal by remote operation.
15 Emergency stop Output a (N.O) General output on a compressor's emergency stop.
16 Caution Output a (N.O) General output on a compressor's caution. 4. Input longer than 500ms signal as to one shot signal.
17 Maintenance Output a (N.O) General output on a compressor's maintenance. In the case of a short pulse signal, a signal may be unable to be recognized.
18 Remote mode Output a (N.O) Output on a compressor's remote operation.
19 Loading Output a (N.O) Output during a compressor's loading. 5. The start orders of dryer, cooling tower and exhaust duct-ventilating fan interlock
20 Common (Output) - The common line of terminal number 15 ~19. with the auxiliary device start/stop in the unit.
21 It is possible to select the preceding operation (for 3 minutes) about the dryer.
Running Output a (N.O) Output during a compressor's running (main motor running).
22 And these terminals can be used for other auxiliary devices.
23 - - - -
24 - - - - 6. Refer to the following drawing as to the connection for the group control
25 (alternative) operation. In this case, the terminals of No.3 to No.20 can not be
Dryer Failure Input a (N.O) Input signal to display the dryer failure on the controller.
26 used for the original purpose shown in the left table.
27 Output signal to start the dryer on the compressor operating
Dryer start Output a (N.O)
28 panel. (ON: Start, OFF: Stop)
The first machine The second machine
29 Output signal to start the cooling tower on the compressor
Cooling tower start Output a (N.O)
30 operating panel. (ON: Start, OFF: Stop) TB2 TB2
31 Exhaust duct ventilating fan Output signal to start the exhaust duct-ventilating fan on the 3 3
Output a (N.O)
Auxiliary device
ISSUE