KIRLOSKAR KC Series Manual

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.
RvAC071
ISO 9001 : 2000

ACR FOR USER’S RECORD
To
TO BE FILLED IN BY KPCL
MODEL: SPEC. (SBM) NO.:
KPCL O.A. NO. UNIT SR.NO.:
CUSTOMER’S P.O. NO. DATE OF MFG.:
TO BE FILLED IN BY OWNER/USER
DATE OF RECEIPT: DATE OF COMMISSIONING:
APPLICATION INFORMATION:
ADDRESS OF SITE (PLANT):
USER’S REF. NO. OF PLANT/MACHINERY:
ADDRESS OF OWNER/USER:
NAME OF CONTACT PERSON:
TEL. NO.: FAX NO.: E-MAIL:

ACR
FOR USER’S RECORD
To
TO BE FILLED IN BY KPCL
MODEL: SPEC. (SBM) NO.:
KPCL O.A. NO. UNIT SR.NO.:
CUSTOMER’S P.O. NO. DATE OF MFG.:
TO BE FILLED IN BY OWNER/USER
DATE OF RECEIPT: DATE OF COMMISSIONING:
APPLICATION INFORMATION:
ADDRESS OF SITE (PLANT):
USER’S REF. NO. OF PLANT/MACHINERY:
ADDRESS OF OWNER/USER:
NAME OF CONTACT PERSON:
TEL. NO.: FAX NO.: E-MAIL:
FEEDBACK SHEET
MANAGER MARKETING (ACR DIVISION)
KIRLOSKAR PNEUMATIC COMPANY LIMITED
NEAR WAGHIRE COLLEGE, SASWAD-412 301.
TALUKA: PURANDAR, DIST: PUNE (MAHARASHTRA)
PLEASE COMPLETE THE FOLLOWING AND SEND BACK

PREFACE
ThismanualintendedasaguidefortheattendantoftheKirloskar
Refrigeration Compressors type KC, contains a description of
the compressor as well as service and maintenance instructions.
It is necessary to go through the text carefully before installing
andstartingthecompressor.
Symbolsusedinthismanualandtheirmeanings:
Reading the instructions periodically will result In a better
knowledge, thereby assisting in preventing avoidable
breakdowns. If abnormal operating conditions occur, the trouble
shooting chart will be of great help in tracing and rectifying the
trouble. Repairs should be carried out by qualified personnel
(refrigeration/mechanical engineer, technician, mechanic only)
assoonaspossible,otherwiseirreparabledamagemayoccur.All
thedescriptionandillustrationsarewithoutengagement.
The 'KIRLOSKAR' factories are always aspiring to improve their
productsandworkingmethods.Howeverwereservetherightsto
improve the KC series described and maintaining the main
characteristics without being obliged immediately to alter this
manualaccordingly.
Please put caution plate at the plant room entrance as “ENTRY
PROHIBITEDFORUNAUTHORISEDPERSONS”
WARNING - Read it carefully
SPECIAL ATTENTION - Important note/procedure
CAUTION
IMPORTANT

SAFETY
It is assumed that your safety department has established a
program of safety based upon a thorough analysis of industrial
hazards. Before installing and operating or performing
maintenance on the equipment described in this Manual, it is
suggested that you again review this program to be certain that it
coversthehazardsarisingfromhighspeedrotatingmachinery.
It is also important that due consideration is given to those
hazardswhicharisefromthepresenceofelectricalpower,hotoil,
high pressure, high temperature, toxic and flammable liquids,
and gases etc. Proper installation and care of protective guards,
shutdown devices and over pressure protection should also be
consideredforessentialpartsofanysafetyprogram.
Also essential are special precautionary measures to prevent the
possibility of applying power to the machine at any time when
maintenance work is in progress. The prevention of rotation due
toreverseflowindynamicmachineryshouldnotbeoverlooked.
Designofrefrigerantsystemandplantshouldabidewithdirective
principles, standards, ordinance regulatory rules and laws
established by state/local authorities. This is in view of safety and
functionality of plant operation as well as essential health and
environmentsafetyforsocietymankind.
In general, you should be guided by all basic safety rules
associatedwiththeequipmentandtheprocess.
IMPORTANT

Do's & Do Not's
Do
DONOT
1) Do STUDY the manual in detail.
2) Do ASCERTAIN what tools & equipments are required to
carryoutthejob.
3) Do USE proper tools to suit the job. Avoid unnecessary
dismantling.
4) Do ENSURE that all nuts, screws, pipe connections,
electricalcableconnections&coversareproperlytightened.
5) DoENSUREthatsuctionfilterelementsareclean.
6) Do ENSURE sufficient & recommended grade of lube oil for
compressor.
7) DoDRAINcondensatesfromallmanualdrainpoints.
8) DoCHECK oil level in tank.Oil Should be visible& should be
well above minimum level marked on oil level indicator
duringworkingcondition.
9) DoENSUREproperdirectionofrotationbeforestarting.
10) Do WATCH for unusual/abnormal sound and remove the
faultwithoutdelay.
11) Do ENSURE that the compressorroom is properly ventilated
&thereissufficientcirculationoffreshairfromatmosphere.
12) Do ENSURE that stipulated water flow is maintained, else
reduced heat transfer will lead to high temperatures, &
subsequentproblems.(Whereverapplicable)
1) DoNOTATTENDtheunitwhentheunitisinoperation.
2) DoNOTUSEcottonwasteforcleaningpurpose.
3) DoNOTATTEMPTtostarttheunitunlessfaultisrectified.
4) DoNOTCHANGEthesettingsofanyfotheinstruments.
5) Do NOT ATTEMPT to carry out maintenance/service
operation on the equipments unless the system is
depressurised(Whereverapplicable)
IMPORTANT

HANDLING
UNPACKING:
KIRLOSKAR PNEUMATIC
CO.LTD.
LIFTINGANDHANDLING:
STORAGE:
Remove the crating and boxes and account for all the items
shown on the shipping/packing list. Make sure that there are no
missing or damaged parts. Handle all the parts carefully. If the
equipment is damaged during transportation/shipment, contact
immediately the transporter and also
Lifting and handling of compressor must be planned as per the
facilities available at the installation site. Caution must be
exercisedsuchthatnocompressorpartscomeincontactwiththe
lifting ropes. Use lifting sling whenever required.Refer next page
on“LiftingandHaulingofCompressors”.
Store the compressor indoors whenever possible. Keep the
storage area clean, dry and free from extreme temperature
conditions. A rust preventive is applied to the compressor parts
before shipment. The protective effectiveness of this rust
preventiveissignificantlyaffectedbytheconditionsencountered
during an outdoor storage. Precautions must be observed in
case of an outdoor storage such that the equipment is not
subjected to extreme conditions of temperature, corrosive
environmentandexcessivemoisture.
If the compressor is to be stored for a long time after receipt
at site, please refer instructions on “Preservation of
RefrigerationCompressor”inthismanual.
IMPORTANT

Before hauling/moving of compressor consider its weight given
inmanual/brochureprovidedalongwithcompressor.
Select correct size/type of lifting tackles like slings, wire ropes,
shackles, rings, etc. (refer selection guidelines provided by such
toolsmanufacturers).
Tie the compressor at proper location as shown in sketch with
lifting tackles, balance the compressor at its CG and natural
position (do not lift in tilted condition). Lift the compressor to just
adequate heightabove the ground level formoving. See, check,
give alert to the workmen around the work area that hauling of
compressorisbeingstarted.
In short, take all necessary precautions to avoid any sort of
accidentordamageinworkplace.
It is mandatory to follow directive principles, ordinance and
regulatory laws established by state/local authorities, in view of
safetyandfunctionalityofworkenvironment.
LIFTING AND HAULING OF COMPRESSOR

SELECTION GUIDELINE OF LIFTING SLINGS AND SHACKLES
FOR MATERIAL HANDLING
Min. Rope Vertical Basket Choker
Size (mm)
12 1200 2400 900
14 1750 3500 1300
18 2500 5000 1875
20 3300 6500 2475
22 4000 8000 3000
24 4600 9200 3450
25 5000 10000 3750
28 6500 13000 4875
32 8000 16000 6000
35 9200 18400 6900
36 10400 20800 7800
38 12000 24000 9000
40 12700 25400 9625
MAXIMUM SAFE WORKING LOAD IN
KG FOR SINGLE PART SLINGS Min. Rope Vertical Basket Choker
Size (mm)
12 2400 4800 1800
14 3500 7000 2600
18 5000 10000 3750
20 6600 13200 4950
22 8000 16000 6000
24 9200 18400 6900
25 10000 20000 7500
29 13000 26000 9750
32 16000 32000 12000
35 18400 35800 13800
36 20800 41800 15600
38 24000 48000 18000
40 25400 50800 19050
MAXIMUM SAFE WORKING LOAD IN
KG FOR DOUBLE PART SLINGS
BASKET
TYPE OF SINGLE PART SLINGS
TYPE OF DOUBLE PART SLINGS
CHOKER
Note: The capacity indicated in the above table for basket hitch and choker hitch is for guidance only. Vertical
columnistheactualloadandsafeworkingloadisapplicableforverticalfallonly.
S
W
d
D
Jaw Inside Body Pin Eye Safe working loads
Inside Length Material Dia Outside tonnes
width Dia Dia
W S d D min e min Grade 30 Grade40 Grade 63 Grade
18 40 10 12 24 - - 1.0 -
20 44 12 14 28 - 1.0 1.25 -
22 49 14 16 32 1.0 1.25 1.6 2.0
25 55 16 19 36 1.25 1.6 2.0 3.25
28 62 17 20 40 1.6 2.0 2.5 -
32 70 19 22 44 2.0 2.5 3.2 4.75
34 79 22 26 52 2.5 3.2 4.0 6.5
48 80 24 28 56 3.2 4.0 5.0 8.5
45 99 27 31 62 4.0 5.0 6.3 9.5
50 110 30 35 70 5.0 6.3 8.0 12
56 124 34 39 78 6.3 8.0 10 13.5
63 139 38 44 88 8 10 12.5 17
70 154 43 50 100 10 12.5 16 25
80 176 48 55 110 12.5 16 20 35
90 198 54 62 124 16 20 25 40
100 220 60 69 138 20 25 32 55
107 236 65 75 152 25 32 40 -
117 258 71 82 164 32 40 50 -
130 206 79 91 182 40 50 63 -
140 308 84 97 194 50 63 80 -
153 337 93 110 220 63 80 - -
Note: Shackles of grade 30, 40, 63
conform to ISI specification 6132. Grade
80 shackles are made of carbon
manganese forged steel shackles with
alloy steel pins heat treated for optimum
strength.

PRESERVATION OF REFRIGERATION COMPRESSOR
If the compressor is not to be commissioned immediately after receipt at site &
to be stored for long time, then in order to avoid rusting/ damages to internal &
external parts of the compressor & to water jackets, following preservation
actionshouldbetakenbytheenduser/contractor/erector.
oWATER JACKET RUSTING: Each water jacket has two sockets of 3/4"
BSP size, one at top & other at bottom. Fit 3/4" dummy plug at the bottom
socketofwaterjacket&pouranyoneoffollowingbrandsofoil:
1.RustolinDW901ofCastroIOilCompany.
2.RP150or330ofIOCL,
3.Rustop387or388ofHP
Keep the oil in water jacket area for a day or two & then open the dummy
plug & drain oil. Or else, oil can be kept inside the water jacket till the
compressoriscommissioned.Refittheplugattopsocketofthewaterjacket
afteraboveoperation.
oSEAL COVER & SEAL: Open 3/8" BSP plug on seal cover. Pour new
refrigeration oil in sufficient quantity & rotate crankshaft. This will protect
seal assembly & also crankshaft main bearings & conn. rod big end
bearings.Refittheaboveplugafteroilapplication.
oPUMP END : Remove pressure gauge union 1/4" BSP size fitted on top of
pump housing. Pour new refrigeration oil in sufficient quantity & rotate
crankshaft. This will protect pump gears, bearings & also main bearings &
intermediatebearings.Refittheaboveunionafteroilapplication.
oINTERNAL PARTS OF THE COMPRESSOR: At the time of dispatch of
compressorfromSaswadfactory(aftershoptesting&paintingofthesame)
each compressor is evacuated & filled with Nitrogen gas at pressure of
about 2 Kg/sq.cm. However during transit/storage at site Nitrogen gas may
leak out. So, after application of oil in seal cover & pump end as described
above,evacuatethecompressor&chargeitwithdryNitrogengas.
oCRANKSHAFT PROTECTION: Apply heavy-duty grease (Servogem 3 of
IOCL)onentiretaperportionofcrankshafttoprevent rusting.
IMPORTANT

IMPORTANT
CHECKS:
BEFORESTARTINGTHECOMPRESSOR
1 Tightness&correctfitmentofflywheeloncrankshaft(tighteningtorque:35Kg.m)
2 Properalignmentofcompressor-flywheel&motor-pulley.
3 3/4ofSightglasslevelofrefrigerationoilincompressor.
4 Correctconnectionsofcompressorsafetycutouts(HP,LP,OP)
5 Mountingofgaugesonseparatepanel(notoncompressor)
PRIMING:Pouroilintoshaftsealcover(1litre).FilloilinSuction/Dischargeoilfilterhousings.
BEFORE OPERATING / MOUNTING TAL STOP VALVES: Applyoil & greasein glandsto prevent
glandleakages.
AIR RUN TRIAL : Run the compressor on air for five minutes with suction & discharge ports of
2
compressor open & check oil pressure, (Minimum 1.5 Kg/cm g). Check loading & unloading of
compressorbyoperatingcapacitycontrolsolenoidvalve(CCSV)oneatatime.
SINGLE STAGE COMPRESSOR (KC2, KC3, KC4, KC6, KC9, KC12) : Do not start compressor
on 100% load. Load compressor by operating CCSV. as per the temperature/load requirement.
BeforestoppingunloadallCCSVs.
TWO STAGE COMPRESSOR (KC2.1, KC3.1, KC4.2, KC5.1, KC6.3, KC7.2, KC8.4, KC9.3,
KC10.2) : Runthe compressor on directcylindertoachieve room temperature minus10°C& then
loadCCSV. 2
WARNING : Intermediate pressure should not go above 4 Kg/cm g as this will cause high
pressure/high discharge temp. (above 100°C) & may damage compressor (refer manual) - page
19,5.4.
MAINTENANCE (COMPULSORY) : After commissioning change/check oil, oil filters and gas-
strainerafterinitial4,8,50&100hrs ofrunningofcompressor.Thisshouldbecontinuedtilloilinthe
crankcasesumpremainsclear.Alwaysmaintainalogbook&installanhourmeter.
Before commissioning of compressor, please write to ACR SERVICE DEPARTMENT at
'KIRLOSKAR PNEUMATIC CO. LTD' , HADAPSAR INDUSTRIAL ESTATE, PUNE - 411 013.
Phone: [phone] giving following details 30 DAYS IN ADVANCE to register your
nameinourdatalisttoenableustoprovideyoupromptservice.
1) Name plate data; 2) Motor name plate data; 3) Postal address where compressor is installed
AND4)Compressorapplicationdetails.
Only after receiving above details, end user will be sent WARRANTY CARDS, Writeups & other
information/data,etc.
1) READTHEMANUALCAREFULLY.
2) DISPLAY THE MAINTENCE SCHEDULE SENT WITH COMPRESSOR IN PLANT ROOM &
FOLLOWITSTRICTLY.
3) INFORM NEAREST KPCL BRANCH OFFICE/DEALER ABOUT COMMISSIONING OF THE
COMPRESSOR.

SR. CHAPTER PAGE
NO. NO.
1. TECHNICAL DATA & OVERALL DIMENSIONS 1
2. CONSTRUCTIONAL DETAIL 5
3. GENERAL OPERATING INSTRUCTIONS 9
4. CAPACITY CONTROL SYSTEM-SINGLE STAGE COMPRESSOR 13
5. OPERATING INSTRUCTIONS & CAPACITY CONTROL SYSTEM 19
TWO STAGE COMPRESSOR
6. PARALLEL OPERATION OF COMPRESSOR 22
7. PERIODICAL MAINTENANCE & ITS SCHEDULE 23
8. ACCESSORIES 26
9. TROUBLE SHOOTING CHART 30
10. SPARE PARTS 32
11. ILLUSTRATED SPARE PARTS LIST 32
11.1 CRANKCASE ASSEMBLY WITH SAFETY VALVE 33
11.2 BEARING COVERS & INTERMEDIATE BEARING 35
11.3 CRANKSHAFT ASSEMBLY 35
11.4 PISTON & CONNECTING ROD ASSEMBLY 36
11.5 CONNECTING ROD ASSEMBLY WITH NEEDLE ROLLER BEARING 36
(FOR TWO STAGE COMPRESSOR ON HP SIDE ONLY)
11.6 CYLINDER LINER & VALVE LIFTING MECHANISM 36
11.7 SUCTION AND DISCHARGE VALVE ASSEMBLY 37
11.8 SHAFT SEAL ASSEMBLY 37
11.9 OIL PUMP ASSEMBLY 38
11.10 OIL FILTER ASSEMBLY 39
11.11 LUBRICATING OIL LINES 40
11.12 SUCTION GAS STRAINER ASSEMBLY 41
11.13 CAPACITY CONTROL OIL PIPING 42
11.14 SPECIAL TOOLS KIT FOR ASSEMBLY 42
11.15 SUCTION DISCHARGE STOP VALVE TAL VALVES 43
11.16 PRESSURE GAUGES & PRESSURE CUT-OUTS 43
12. PRECAUTIONS TO AVOID FAILURES ON COMPRESSORS 44
13. INSTALLATION CHECKS 45
CONTENTS

1. TECHNICALDATA&OVERALL DIMENSIONS KC42, KC51, KC63, KC72, KC84, KC93, and
KC102.
1.1 GENERALDATA Single Stage Compressors can also be used as booster
These KC series compressors are heavy duty open compressorforammoniaapplications..
type, designed for use with refrigerant R22,
R134a, R502, and ammonia. There are two The refrigeration capacity of each compressor is
versionsofcompressorswithfollowingmodels controllable in various steps by means of high oil
pressure control piping and solenoid valves. These
a. Single Stage Compressors-KC2, KC3, solenoid valves can be operated manually or by remote
KC4,KC6,KC9,andKC12 controlelectricalsignals.
b. Two Stage compressors-KC21, KC31,
1.3 General Technical Data : (Two Stage Compressor)
Sr.No. Description Compressor Type
KC21 KC31 KC42 KC51 KC63 KC72 KC84 KC93 KC102
01. No. of Cylinders-LP 2 3 4 5 6 7 8 9 10
No. of Cylinders-HP 1 1 2 1 3 2 4 3 2
02. Cylinder Bore mm-LP 160
Cylinder Bore mm-HP 160
03. Piston Stroke mm 110
04. Cylinder Arrangement 1xW 2xV 2xW 2xW 3xW 3xW 4xW 4xW 4xW
05. Direction of Rotation Antlclockwise looking from flywheel end
06. Standard Compressor Speeds 450, 500, 550, 600, 650, 700, 750,
(Motor rpm 1450) 800, 850, 900, 950 and 1000 rpm.
(Motor rpm 1000) 400, 450, 500, 550, 600, 650, 700. 750, 800, 850, 900, 950, & 1000 rpm.
07. Capacity control steps Ref. Chapter No.5 for each compressor
08. Oil Charge Capacity (Itrs) 10 12 13 13 20 20 32 32 32
09. Bare Compressor Weight (Kg) 535 665 900 900 1245 1245 1585 1585 1585
10. Overall Dimn. & space requirement Ref. Page No.6
11. Connection Sizes
LP Suction (mm) 65 80 80 100 100 125 125 125 125
Stop Valve sizes (NB) 70/80 80 80/100 100 100 100/125SPL100/125SPL100/125SPL100/125SPL
LP Discharge/HP Suction size (mm) 65 65 65 80 80 65 80 80 65
HP Discharge size (mm) 50 50 50 50 50 50 50 50 50
Stop Valve size (NB) 50/70 50/70 50 50 50 50 50 50 50
12. Cooling Water Flow 8 LPM/Cyl. at water inlet temperature 30 Deg. C.
for each Cyl. Jacket 15 LPM/Cyl. at water inlet temperature 30 Deg. C.
13. Recommended liquid Injection valve
For Ammonia TEA TEA TEA TEA TEA
20-2 20-3 20-5 20-5 20-8
For R22 TX TEX TEX TEX TEX
2-2.3 5-3 5-3 5-4.5 5-7.5
1.2 GENERALTECHNICAL DATA (single Stage Compressor)
Sr.No. Description No. Compressor Type
KC2 KC3 KC4 KC6 KC9 KC12
01. No. of Cylinders 2 3 4 6 9 12
02. Cylinder Bore mm 160 160 160 160 160 160
03. Piston Stroke mm 110 110 110 110 110 110
04. Cylinder Arrangement 1xV 1xW 2xV 2xW 3xW 4xW
05. Swept Vol. at 1000 rpm, m3/hr 265.4 398.1 530.8 796.2 1194.3 15.92.4
06. Direction of rotation Anticlockwise looking from flywheel end
07. Standard Compr. Speeds 450, 500, 550, 600, 650, 700, 750, 800, 850,
(Motor rpm 1450) 900, 950, & 1000 rpm.
(Motor rpm 1000) 400, 450, 500, 550, 600, 650, 700, 750,
800, 850, 900, 960 and 1000 rpm.
08. Capacity control steps Ref. Chapter No.4 for each compressor
09. Oil charge capacity (Ltrs) 9 10 12 13 20 32
10. Bare Compressor Weight (Kg) 435 535 665 900 1245 1585
11. Overall dimensions and
space requirement Ref. Page No. 5
12. Suc. Conn. Size mm 65 80 80 100 125 150
Stop Valve Size (NB) 70 80 80 100 100/125 SPL 100/150 SPL
13. Disc. Conn. Size mm 50 50 80 80 100 100
Stop Valve Size (NB) 50 50 70/80 INPL 80 100 100
Note: 1. TH.EXPANSIONvalvesshownaboveareofDanfossmakebut equivalentvalvesofSporlanorALCOmakecanbeused.
2. AboveTH.EXPANSIONvalvesareforfullcapacityof compressorat1000RPM.Forotherspeeds,pleasereferto KPCL.(H.O.)
3. JacketCoolingWatermustbedrainedoutwhilecompressorisoff.
4. Incaseofdirectdriveat1000rpmcompressorspeedwith6polesynchronousmotor,pleasereferKPCLfordrivesetarrangement. 1

Overall Dimensions Of Single Stage Compressors
Compressor Type KC2 KC3 KC4 KC6 KC9 KC12
A 935 935 935 960 960 960
B 970 1130 970 1130 1130 1130
C 885 950 874 950 950 950
D 350 350 350 375 375 375
Main Dimensions E 397 150 193.5 150 150 150
F 391 391 402.5 402.5 426 426
G 215 215 380.0 570 960 1350
H 257 253 309 345 345 345
J 948 945 1150 1447 1861 2251
Minimum required free space for
removal of Flywheel U 905 905 920 915 940 940
Crankshaft (V or W) V 905 905 920 1015 1440 1875
W 670 670 860 1015 1440 1875
Pistons & cyl. liners X 1085 1160 1085 1160 1160 1160
Y 420 545 420 545 545 545
Gas suc. strainer element Z 900 900 900 1100 1100 1100
Main Connections hole diameter in (upper part of) counter flange
Suction 1 Ø77 Ø91 Ø91 Ø116 Ø143 Ø171
Discharge 2 Ø61 Ø61 Ø91 Ø91 Ø116 Ø116
Auxiliary Connections
Suction pressure 3
Discharge pressure 4 clamp coupling for Ø6x1 mm steel precision tube
Oil pressure 5
Oil charge & drain 6
Return from oil separator 7 1/2" BSP male
Oil leakage drain of Rotary shaft seal 8 clamp coupling for Ø6x1.0 mm steel precision tube
]
]
‘D’
‘A’
100
360
‘B’
‘Y’ ‘Z’
Ø 24
‘C’
‘U’
‘V’
‘F’ ‘G’
‘J’
‘W’
‘H’
Ø 85
120
310
‘X’
‘E’
20
KC 2 KC 3 KC 6 KC 9 KC 12KC 4
Figure No. 1
2

Overall Dimensions Of Two Stage Compressors
Compressor Type KC21 KC31 KC42 KC51 KC63 KC72 KC84 KC93 KC102
A935 935 960 960 960 960 960 960 960
Main Dimensions B 1130 970 1130 1130 1130 1130 1130 1130 1130
C 843 874 950 950 950 950 950 950 950
Attention : D 270 0 270 0 0 0 0 0 0
KC21 & KC31 E 350 350 375 375 375 375 375 375 375
J is larger than F 280 173 270 310 270 270 270 270 270
H & for KC21 & G 192 223 185 195 191 191 191 191 191
KC42 K is equal to J H 285 565 960 885 1125 1125 1515 1515 1515
J 500 758 630 630 630 630 1020 1020 1020
K 500 160 630 150 150 150 150 150 150
L 385 402.5 402.5 402.5 426 426 426 426 426
M 215 380 570 570 960 960 1350 1350 1350
N 253 275 345 345 345 345 345 345 345
P 945 1150 1147 1147 1861 1861 2251 2251 2251
Minimum required free space for
removal of Flywheel U 905 920 915 915 940 940 940 940 940
Crank shaft (V or W) V 905 920 1015 1015 1440 1440 1875 1875 1875
W 670 860 1015 1015 1440 1440 1875 1875 1875
Piston & cyl. liner X 1160 1085 1160 1160 1160 1160 1160 1160 1160
Y 545 420 545 545 545 545 545 545 545
Gas suction strainer element Z 900 900 1100 1100 1100 1100 1100 1100 1100
Main Connections hole diameter in (upper part of) counter flange
LP Suction 1 Ø77 Ø91 Ø91 Ø116 Ø116 Ø143 Ø143 Ø143 Ø143
LP Discharge/HP Suction 2/3 Ø61 Ø61 Ø77 Ø61 Ø91 Ø77 Ø91 Ø91 Ø77
HP Discharge 4 Ø49 Ø49 Ø61 Ø61 Ø61 Ø61 Ø61 Ø61 Ø61
Auxiliary Connections
Suction pressure 5
Interstage pressure 6 clamp coupling for Ø6x1 mm steel precision tube
Discharge pressure 7
Oil pressure 8
Oil Charge & Drain 9 1/2" BSP male
Return from oil separator 10
Oil leakage drain of rotary shaft seal 11 Clamp coupling for Ø6x1 mm steel precision tube
Figure No. 2
‘H’
‘J’
85
310
‘K’
‘N’‘M’‘L’
‘P’
‘U’
‘V’ ‘W’
‘X’
‘E’
‘F’ ‘D’
‘G’
‘A’
‘C’
100 Ø 24
360
‘B’
‘Y’ ‘Z’
120
Ø 85
20
KC 21 KC 31 KC 42 KC 51 KC 63 KC 72 KC 93 KC 102
]
]
3

Welded Steel Crankcase
lLow in weight
lRapid heat dissipation
lGas tight and impact proof
lSmooth internal surfaces
guarantee the good oil condition.
Lubrication System & Filter
lForced lubrication by a gear pump, driven directly by
the crankshaft.
lThe pump incorporates a differential pressure regulator to
provide separate pressures for two oil systems: lubrication
system and control oil system.
lAutomatically operating hydraulic delay valve ensures
complete unloaded start.
lAmetal gauze suction filter element and a throwaway discharge
paper filter cartridges are provided for excellent filtering
capacity of the lubricating oil.
Discharge Valve Assembly
lThree concentric discharge valve rings ensure ample
gas passage at low lifting height.
lThe use of sinusoidal springs together with precision
machined and lapped surface results in a trouble-free
operation for a remarkably long time.
lMinimum inventory for spares since most parts are
identical throughout the KC-series compressors.
Cylinder Liner and Suction Valve
lInterchangeable cylinder liners are made of fine-
grained, centrifugally cast, alloy iron.
lFine boring and honing results in a mirror smooth
running surface.
lAhydraulic mechanical suction valve lifting mechanism
on each individual cylinder achieves loading and unloading.
lFor unloading, the suction valve ring is lifted from its seat
in the cylinder collar by spring tension. Admitting controlled
oil pressure to the control piston, allowing the suction valve
ring to descend on its seat effects loading or cylinder.
Crankshaft and Main Bearings
lBearing surfaces of the high quality nodular cast
iron crankshaft are ground to fine tolerances.
lMain bearings are white metal lined steel backed
bushes, pressed into the cast iron bearing covers.
Intermediate bearing blocks are provided with
split type bearing shell of the same type.
lEach crankshaft is dynamically balanced together
with the counter weights.
Salient Features of Construction
Piston/Connecting RodAssembly
lPerfect sealing and low oil consumption due to
2 compression & 1-oil scrapper rings and 2 oil rings
on each aluminium piston.
lThe nodular iron connecting rod is drilled through for
pressure lubrication of the piston pin
lSteel backed white metal shells on big end and
bronze bearing on small end of connecting rod.
lThe complete assembly can be removed from the top
for servicing without withdrawing the cylinder liner
4

connection.
2.CONSTRUCTIONALDETAILS 2.3CYLINDERLINER
2.1GENERAL The renewable cylinder liners, made of fine grain cast
The compressor series KC comprises of 2, 3, 4, 6, 9, 12 iron centrifugally cast, are pressed into the cylinder
cylinderswhichare manufacturedassingle ortwo-stage jacketsandcanbeeasilyreplaced.Anextremelysmooth
machines. These compressors are designed for surface finish is obtained by precision boring and
Ammonia, Freon R134a refrigerants but can also be honing. The collar at the top of the cylinder liner is
used for compression other gases. They are fitted with provided with holes and serves as the valve seat for the
cylinders having a bore of 160 mm. The direction of suction valve ring. The cylinders are numbered for ease
rotation is anticlockwise, while looking from the of reference (e. g. in case of complaints, overhaul
flywheel end. Maximum safe delivery pressure for
2reports etc.). Looking from the flywheel end, the
continuous operation is 20 kg/cm gauge. Minimum numbering is from right to left and increases in the
speedis450rpmandthemaximum1000rpm. directionof the oil pump. Hence for a 6-cyl. compressor
2.2 CRANKCASEANDCYLINDERJACKETS thefirst lineof cylindersfromflywheelendis numbered
from right to left, as 1,2 and 3. The second line from
Crankcase and cylinder jackets form a fabricated all righttoleftisthennumbered4,5and6.
welded, gas-tight steel structure, ensuring absolute
stiffness and mechanical strength, with a relatively low 2.4VALVES
weight and a high impact strength. After welding, the The suction and delivery valves are of ring type and of
completeunitis stress relievedandcleaned.The suction special steel. Their design ensures ample gas passage
inlet to the compressor is through suction manifold in with a minimum lift. The suction valve seat machined
which a removable strainer is fitted, thus ensuring that on the upper face of the cylinder collar and the suction
the suction gas is filtered before entering the valve ring isheldinto this seatbytwo sinusoidalsprings
compressor. The suction manifold is connected to the between the valve seat type collar of the cylinder liner
spacebetweenthecylinderlinerandjacket.Inthisspace and a stroke limiter. This stroke limiter also locates the
any oil entrained in the gas is partially separated out and delivery' valve seat and is centered by the collar of
isreturnedtothecrankcaseviaanon-returnvalve.Inthe cylinderliner.
H.P.cylindersoftwo-stagecompressors,thisnon-return
valve is replaced by a plug, as the space round the H.P. The three delivery valve rings with their valve springs
cylinderliner, being under intermediate pressure should and the stroke limiter are assembled to the delivery
not be in connection with the crankcase where a lower valveseatby meansofa centreboltwith nut.Thisunitis
pressure (L. P. suction pressure) prevails. An open held against the suction valve stroke limiter by a heavy
connection would cause a considerable reduction in buffer spring. This construction enables delivery valve
compressorcapacity. seat as well as the stroke limiter to lift in case of liquid
stroketoavoidunduematerialstresses.
The cylinder heads are provided with cooling water
jacket fitted with inlets and outlets (3/4" BSP sockets). 2.5PISTONS
Cooling is adopted if the compression temperature is The light-alloy pistons are die cast and provided with
higher than 120°C. The cooling water should be non- three piston rings and two scraper rings, one of the later
corrosive. The cooling water discharged from the being positioned below the case hardened and ground
condenser should be used for cylinder cooling as the steel gudgeon pin. Due to this an extremely good piston
water inlet temperature to the cylinder jacket must seal is obtained, none the less providing adequate
exceed the condensation temperature of the refrigerant. lubricationtogetherwithminimumoilconsumption.
The manifolds are provided with pressure gauge
Figure 3 : Schematic Construction and operation of suction and discharge valve
1. Buffer Spring
2. Discharge Valve Stroke Limiter
3. Discharge Valve with Springs
4. Discharge Valve Seat
5. Suction Valve Stroke Limiter
6. Suction Valve Ring with Springs
7. Cylinder liner, also suction valve seat
8. Cylinder Jacket
1
2
3
4
5
6
7
8
DISCHARGE
CHAMBER
SUCTION
CHAMBER
5

2.6CONNECTINGRODS
The connecting rods are made of nodular SG IRON,
fitted with split, white metal lined, precision steel
backed big end bearings and a push fit, bronze, small
end bearing bush. Internal oil ways permit oil to flow
fromthe bigendbearing tothegudgeon pinbush,which
is adequately grooved for lubrication of the gudgeon
pin.
In case of 2 stage compressors, connecting rod with
needle roller bearing (on small end side) is used on high
pressuresides.
2.7 CRANKSHAFT
The crankshaft is accurately ground and dynamically
balanced, thus ensuring quiet operation good running
characteristics and high wear resistance. All bearing
Journals are precision machined to fine tolerances.
Internal oil ways feed oil to all main and big end
bearings (see fig. 6). The crankshaft rests on precision,
whitemetal linedwalledbearingsfittedin thecrankcase
and bearing housing. In addition, in cases where
intermediate main bearings are fitted, these are of
similar construction as that of split big end bearing of
connectingrod.The bearinghousing atthe flywheelend
also incorporates the shaft seal which prevents the
passageofoilorrefrigerantoutofthecrankcase.
2.8OILPUMP
Thecompressorisfittedwithahighpressuregear pump
providedwithdifferentialpressureregulator.Inthisway
a low pressure oil supply is made available for
lubrication purposes and a high pressure oil supply for
valve lifting mechanism. This high pressure oil supply
may also be used for capacity control, when installed.
Thehydraulictimedelayprovidesanintervalofabout½
to 1 minute being the time necessary to enable the com-
pressortostartunder"no-load"conditions.(seefig.4)
The compressor is fitted with an adjustable oil pressure
regulator inserted in the oil return line. It is mounted
abovetheoillevelglass,externally,onthecrankcase.
. The regulator consists of a valve housing in which a
ball valve is held against the oil inlet by a spring. The
compression of this spring is adjusted by turning a set
pin, which is sealed by a nipple and washer, A cap.
which has to be removed before the oil pressure can be
adjusted, covers the nipple. After the cap has been
removed,thesetpincanbeturnedwiththeaidofascrew
driver. To achieve a higher pressure, the set pin should
be turned in a clockwise direction. Within crankcase a
return line leads from the oil pressure regulator to the
level glass through which the oil jet can be observed,
(seefig.5)
Figure 4 : Schematic Diagram of Oil Circuit
OILPRESSURE REGULATOR
CRANKCASE
TO CAPACITY CONTROL OILPRESSURE GAUGE
CRANKSHAFT
SHAFT
SEAL
OVERFLOW RELIEF
VALVE
TO VALVE
LIFITING
DEVICES
HYDRAULIC
TIME DELAY
HIGH PRESSURE
OILPUMP
OILSUCTION STRAINER OIL DELIVERY STRAINER
DIFFERENTIAL
PRESSURE
REGULATOR
CRANKCASE
HIGH PRESSURE
LOW PRESSURE
RETURN TO CRANKCASE
6

2.9LUBRICATIONDIAGRAM
The lubrication of the compressor is of the forced feed
type and effected by a gear pump driven from the
crankshaft.TheoilcircuitisshowninFig.5&6.
The oil enters the pump via the wire gauze suction oil
strainer. High pressure oil is fed to the differential
pressure regulator where the oil pressure is reduced and
is fed to shaft seal housing, via the paper type delivery
oil strainer, Oil reaches all main bearings, big end and
small end bearings via the internal ways in the
crankshaft and connecting rods. The thrust bearing of
the crankcase is lubricated via a separate oil way in the
bearing cover. Lubrication of the cylinder liners is
effectedbysurplusoilfromthegudgeonpinsandthebig
ends. The arrows indicate the direction in which the oil
flows. Excess of the oil is led back, via a hole in
crankshaft to the oil pump housing from where to
externallyfittedoilpressureregulator.
From the oil pressure regulator the oil is returned into
the crankcase behind the oil level glass, to complete the
lubrication circuit.Apressure gauge is connected to the
oil return line on oil pump before the oil pressure
regulator through a three way stop valve. To stop the
electric motor at the time of too low of oil pressure, one
oil pressure differential pressostat may be connected to
this3-waystopvalve.The oilpressureshouldbeadjust-
ed by means of the oil pressure regulator & should be at
2
least 1.5 kg/cm higher than the crankcase pressure.
Figure 5 : Oil Pressure Regulator
The oil level and the oil return jet are visible through the
two level glasses, which are fitted at same level but in
opposite walls of the crankcase. The oil level should
always be visible in the oil level glass whilst it is not
advisable to let it rise above its centre line. For correct
lubricanttobeused,referlubricatingchart.
2.10PRESSUREEQUALIZINGLINE
A pressure equalizing line is fitted between the suction
strainerhousingandthecrankcase.Thislineprovidesan
open connection between the crankcase and the suction
line, which is necessary for evacuating the gas from
crankcase before topping up the oil. It also prevents
pressurebuildupduetogasblow-bypastthepistons.
Recommended Oil
KIRLOSKAR ADVANTAGEAC & REFRIGERATION COMPRESSOR OIL
n20 ltr smart pack
nEasy to buy, stock and use
nNo risk of loose purchased adulterated and reconditioned oil
nNo need to invest on 200 ltr drum
nGrade ISOVG68
nSuitable for refrigerants NH3 and R22
nEvaporating temp. range: +10ºC to -25°C
Figure 6 : Lubrication System
LUBRICATING OIL PRESSURE REGUALTOR
OIL WAY TO
THRUST BEARING
EXTERNALOIL
DISCHARGE
LINE
SHAFT SEAL
HOUSING
OIL CHANNELIN CRANKSHAFTSIGHT GLASS OIL DISCHARGE FILTER
OILSUCTION
FILTER
OILPUMP
EXTERNALOIL
RETURN LINE
CAP
PACKING
NIPPLE
PACKING
O RING
SET PIN
TO OIL
LEVELGLASS
VALVE HOUSING
BALLVALVE
7

2.12SAFETYVALVE
The compressor is fitted with one or more safety valves
dependingontypeofcompressor.Thesafetyvalveisaspring-
loaded relief valve fitted between the delivery and suction
manifolds. At the time of excessive pressure in the delivery
manifold it by-passes gas back into the suction line. The
devicecanbeeasilyremovedforinspectionorrenewal.
The compressor should not be kept running with an open or
leaking safety valve as the machine would then become too
hot and the possibility of damage to, or even seizure of, the
pistonandcylinderwouldarise.Thelineonthesuctionsideof
the safety valve should be cold when the compressor is
operating. When it is found warm, the safety valve is leaking,
causing loss of capacity. In this case the safety valve must be
repairedorrenewed.
2.13VALVELIFTINGMECHANISM-
Ref.Fig.7and8
This mechanism can be subdivided into hydraulic and
mechanical components. The hydraulic assembly consists of
a piston housing with a teflon ring sealed piston controlled by
Figure 7 :Arrangement of Valve Lifting Mechanism
oilpressure.The mechanical assemblyconsists of aoperating
ringtowhich are attachedtwoactuating rods onitsunderside.
Eight valve lifting pins are located around the upper face of
the operating ring and the whole assembly is free to move in a
verticaldirection.
The actuating rods pass through a supporting ring which is
rigidly held in a groove around the outside of the cylinder
liner. Pressure springs are fitted around each actuating rod,
tending to force the operating ring in an upward direction. To
the lower end of the actuating rods is attached a semicircular
lever,thefulcrumofwhichisfixedtothesupportingring.The
movement of this lever is controlled by the piston stem of the
hydraulicassemblybearingagainstitsupperend.
In the "No-load" position the operating ring is in the upper
position, thus lifting the suction valve ring. When the
hydraulic piston is moved in towards the cylinder liner by the
high pressure oil it bears against the lever, causing the
actuating rods to be drawn down against the spring load. This
causes the valve lifting pins to be retracted thus enabling the
suctionvalveringtodescendontoits seat, thereby putting the
cylinderonload.
2.11LUBRICATINGCHART
RecommendedLubricantsforSingleStage,TwoStage&BoosterCompressors(ISOVG68Grade):
Sr. Brand Quality of Oil Suitable for Refrigerant Evaporation Temp. Range
01 Indian Oil (IOC) Servofriz-57/68 NH3, R12, R22 +10 to -25°C
02 Hindustan Petroleum (HP) SEETUL-68 NH3, R12, R22 +10 to -25°C
03 Bharat Petroleum (BP) Bharat Freezol-46/68 NH3, R12, 22 +10 to -25°C
04 Shell Clavus Oil-46/68 NH3, R12, R22 +10 to -25°C
05 Castrol Castrol Refrigeration Oil-46/68 NH3, R12, R22 +10 to -25°C
Note:
1. Notwoormorebrandsofoiltobemixedtogetherfor lubricationpurposes.
2. Whenever you need to change brand of oil from earlier one, whole refrigeration system to be flushed with Nitrogen so that no traces of earlier oil exist in
refrigerationsystem.
3. Whenevaporatingtemperatureisbelow(-)25°Csuitablesyntheticoil(ISOVG68grade)istobeused.(contactKPCLfordetails).
Figure 8 :Arrangement of Oil Control Piping for Loading-Unloading of Cylinders
UNLOADER PISTONASSY.
(V L D PISTONASSY)
COMPR.
CRANK
CASE
COMPR.
CRANK
CASE
UNLOADER PISTONASSY.
(V L D PISTONASSY)
220 VAC220 VAC
SOLENOID VALVE SOLENOID VALVE
1
3
21
3
2
OIL
PUMP OIL PUMP
SOLENOID VALVE ENERGIZED
COMPRESSOR CYLINDER ON LOAD SOLENOID VALVE NON-ENERGIZED COMPRESSOR CYLINDER UNLOADED
SUCTION VALVE RINGCYLINDER LINER
GASKET
PRESSING RING
TAP BOLT
ACTUATING ROD
PRESSURE SPRING
RING WITH
HINGED POINT
CRANKCASE
CYLINDER
VALVE LIFTING PIN
V L D PISTON
HOUSING
FULCRUM PIN
V L D PISTON ASSY.
OILPASSAGE
SEMI CIRCULAR LEVER FROM OILDISTRIBUTOR OR
THREE WAY SOLENOID VALVE OR OILPUMP
8