Kobelco KNW Series Instruction Manual
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Kobelco KNW Series Instruction Manual

Oil-free two-stage air-cooled rotary screw air compressors
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MODEL#:
SERIAL#:
INSTRUCTION MANUAL
MODEL:
KNWA00
RECORD OF CHANGE H
KOBELCO is the international trademark found on all products of KOBE STEEL, LTD.
KIMA00H1 (0204)

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Summary of Contents for Kobelco KNW Series

  • Page 1 MODEL#: SERIAL#: INSTRUCTION MANUAL MODEL: KNWA00 RECORD OF CHANGE H KOBELCO is the international trademark found on all products of KOBE STEEL, LTD. KIMA00H1 (0204)
  • Page 2 SAFETY PRECAUTIONS Safety notices, marked with this symbol, are used in this publication to emphasize that a hazardous condition exists that could cause personal injury and/or damage to the equipment. 1. Read and understand the contents of this manual before installing, operating or maintaining the compressor.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1. GENERAL DESCRIPTION....1 5.2 Programmable Logic 1.1 Compressor........ 1 Controller........27 1.2 Compressed Air Flow....3 5.2.1 CPU......... 27 1.3 Cooling Air Flow......5 5.2.2 PLC Status LED’s.... 29 1.4 Oil Flow........5 5.2.3 PLC Inputs....... 29 1.5 Capacity Control System....
  • Page 4 FIGURE 1 - KOBELCO KNW SERIES MODEL A00 AIR COMPRESSOR KIMA00H1 (0204)

  • Page 5: General Description

    1. GENERAL DESCRIPTION The Kobelco KNW Series air compressor is a heavy duty, two-stage, rotary screw design that provides completely oil-free compressed air. Compressor Oil-Free compressed air is guaranteed by a unique seal arrangement that separates the bearings and gear chambers from the compression section of each stage.
  • Page 6 FIGURE 2 - COMPRESSED AIR FLOW DIAGRAM COOLING AIR OUTLET COMPRESSOR AIR INLET AFTERCOOLER AIR INLET COOLING AIR INLET COMPRESSED AIR DISCHARGE CONDENSATE SUMP DRAIN OIL DRAIN FIGURE 3 - BACK OF COMPRESSOR KIMA00H1 (0204)

  • Page 7: Compressed Air Flow

    Air to be compressed undergoes two stages of filtration before being compressed. The air enters the cabinet through an opening that is Compressed equipped with a dust filter. The air then passes through the air inlet Air Flow silencer, a duct that is lined with a sound absorbing material. Then (Figure 2) the air is drawn through a high efficiency air filter.
  • Page 8 AFTERCOOLER EXHAUST AIR DUCT OUTLET AFTERCOOLER AIR DUCT COOLING AIR INLET (REAR) COOLER INTERCOOLER FIGURE 4 - COOLING AIR FLOW FIGURE 5 - LUBRICATION OIL FLOW DIAGRAM KIMA00H1 (0204)

  • Page 9: Cooling Air Flow

    A separate electric motor driven fan draws ambient air into the cabinet through screens in the back panel. The screens are equipped with Cooling dust filters. The air takes one of two flow paths. The first passes Air Flow directly through to the aftercooler and exhausts through the top of the (Figure 4) enclosure.
  • Page 10 FIGURE 6 - UNLOADED, COMPRESSOR OFF FIGURE 7 - LOADED, COMPRESSOR RUNNING FIGURE 8 - UNLOADED, COMPRESSOR RUNNING KIMA00H1 (0204)

  • Page 11: Capacity Control System

    The capacity control system consists of an inlet capacity control valve with an integral bleed-off valve, a 3-way solenoid valve, and a shuttle Capacity valve. Opening (loaded) and closing (unloaded) of the inlet valve is Control controlled by the solenoid valve which is controlled by the PLC (ref. System Section 5.2).
  • Page 12 COMPRESSOR OPERATOR PANEL FIGURE 9 - COMPRESSOR FRONT VIEW PILOT LIGHTS GT TERMINAL PUSHBUTTONS FIGURE 10 - COMPRESSOR OPERATOR PANEL KIMA00H1 (0204)

  • Page 13: Monitoring And Limiting

    1.6 (cont.) c. Lube oil pressure transmitter. Monitors lube oil pressure at the last bearing oil nozzle. Pressure is shown on the GT Terminal Monitoring (figure 10). Indicates condition of the lube oil system, filter, and and Limiting the setting of the relief valve. Devices d.
  • Page 14 GT-TERMINAL PILOT LIGHTS GRAPHIC TERMINAL W/ TOUCHSCREEN PUSHBUTTONS PRESS ARROWS TO CHANGE DISPLAY SCREENS FIGURE 11 - COMPRESSOR OPERATOR PANEL PRESS “ACK” TO ALARM MESSAGE SILENCE BEEPER ALARM LIGHT ALARM BEEPER PRESS “STAT” FOR ALARM DETAILS FIGURE 12 - ALARM DISPLAY KIMA00H1 (0204)

  • Page 15: Shutdowns

    Shutdown conditions are indicated by a red ALARM light on the control panel, and an appropriate message on the graphic display. In Shutdowns addition, an audible alarm sounds when an alarm occurs. The alarm beeper may be silenced by pressing ACK/Bell Cancel on the alarm page.
  • Page 16 COMPRESSOR SECTION TO OPEN PANELS STARTER SECTION ACCESS PANEL FOR INSPECTION, ACCESS PANEL PULL OUT TOP EDGE THEN LIFT PANEL UP MOUNTING BRACKETS FIGURE 13 SPACER BLOCKS SPREADERS FIGURE 14 SPACER BLOCKS FIGURE 15 KIMA00H1 (0204)

  • Page 17: Installation

    2. INSTALLATION The unit should be inspected for damage immediately upon receipt from the carrier and any claims should be made to the delivery carrier Inspection immediately. (Figure 13) The compressor unit is equipped with forklift slots for ease in handling. Spacer blocks should be placed between the compressor and forklift Handling (Figures...
  • Page 18 COOLING AIR COOLING AIR COMPRESSOR AIR INLET OUTLET INLETS AIR SYSTEM PIPING FLEXIBLE MOISTURE SERVICE VALVE REMOVE PLUG TO VIEW CONNECTOR SEPARATOR MAIN MOTOR ROTATION FIGURE 16 - REAR VIEW VENTILATION AIR OUT COMPRESSOR ROOM VENTILATION AIR IN FIGURE 17 - INSURE ADEQUATE VENTILATION FOR COMPRESSOR KIMA00H1 (0204)

  • Page 19: Air Discharge Piping

    DO NOT reduce the pipe size of the connections on the unit. The compressor is equipped with an internal check valve. Compressor Discharge discharge pressure is controlled by a system pressure sensing line Piping located at the aftercooler outlet. (Figure 16) NOTICE: DO NOT install an additional check valve between the compressor and the air distribution piping.
  • Page 20 PRESSURE GAUGE SAFETY VALVE AIR SYSTEM FLEXIBLE CONNECTOR SERVICE VALVE DRAIN VALVE DROP LEG DRAIN VALVE FIGURE 18 - AIR RECEIVER PRESSURE GAUGE SAFETY VALVE PARTICULATE RECEIVER COALESCING FILTER FILTER COMPRESSOR DRYER DRAIN VALVE DRAIN VALVE SERVICE VALVE DRAIN VALVE FIGURE 19 - TYPICAL COMPRESSOR INSTALLATION KIMA00H1 (0204)

  • Page 21: Wiring

    It is the compressor owners responsibility to insure a safe installation Wiring that complies with applicable local codes and the National Electrical Code (N.E.C.). This includes properly sized short circuit and ground fault protection, power connection wire sizing, and equipment grounding.
  • Page 22 OIL FILTER OIL PUMP OIL FILL OIL LEVEL SIGHT GAUGE FIGURE 20 - FRONT VIEW OF INTERIOR ROTATION OIL PRESSURE RELIEF VALVE DISCHARGE SUCTION FIGURE 21 - OIL PUMP KIMA00H1 (0204)

  • Page 23: Start Up

    3. START-UP Prior to starting, installation must be complete. Refer to section 2 for installation requirements. Pre Start-Up Check a. Electric power must be off during initial checks. b. Remove all loose items left in and around unit during installation. Clean inside of cabinet if necessary.
  • Page 24 COOLING FAN MOTOR AIR FILTER HOUSING INTERCOOLER SEPARATOR CAPACITY CONTROL VALVE FIGURE 22 - FRONT VIEW OF INTERIOR CHECK VALVE INTERCOOLER AFTERCOOLER OIL COOLER PRE-COOLER PRE-COOLER SAFETY VALVE COMPRESSOR COMPRESSOR 2ND STAGE 1ST STAGE DISCHARGE BLEED-OFF SEPARATOR SILENCER INTERCOOLER INTERCOOLER DRAIN DRAIN STRAINER AND...

  • Page 25: Operating Instructions

    4. OPERATING INSTRUCTIONS a. Open system air valve (external of the compressor cabinet). b. Turn on power to the unit. Confirm GT Terminal operation. Check Starting the that all temperatures read normal. Indicators at the top of the Compressor temperature and pressure pages will show running or stopped messages for motor operations.
  • Page 26 NORMAL NORMAL LEGEND LOADED READING UNLOADED READING 1st Stage Discharge 30 ~ 45 PSIG 5" HG VAC ~ 5 PSIG Pressure ~ 3.2 kg/cm 0.2 ~ 0.3 kg/cm 2nd Stage 50 ~ 125 PSIG 50 ~ 125 PSIG Discharge Pressure ~ 8.8 kg/cm 3.5 ~ 8.8 kg/cm Lube Oil...

  • Page 27: Automatic Stop

    4.2.2 a. The compressor will automatically shutdown if it runs unloaded, continuously, for 10 minutes. This interval may be programmed Automatic for a longer unloaded run time if desired. Shutdown will follow the Stop normal shutdown sequence (ref. 4.2.1. a,b,c). WARNING: The compressor is automatically controlled and may start at any time without warning.
  • Page 28 FIGURE 24 - COMPRESSOR OPERATOR PANEL WITH GT TERMINAL FIGURE 25A FIGURE 25B PRESS ARROW KEY TO CHANGE PAGE SHOWN ON GT TERMINAL FIGURE 26A FIGURE 26B PRESS CENTER OF SCREEN FOR UTILITY PAGE KIMA00H1 (0204)

  • Page 29: Electrical Controls

    5. ELECTRICAL CONTROLS Pilot lights, viewable from a distance, are provided for quick look Compressor indication of operating conditions. An audible alarm is provided for alarm annunciation. Pushbuttons are provided for specific control Operator functions, allowing continued compressor operation in the event that Panel with the GT Terminal is off-line.
  • Page 30 MOUNTING CLIPS (6) OPTION SLOT COM PORT COM PORT COM PORT DISPLAY POWER (RS-422) TO PLC (RS-485) CONNECTOR (RS-232) FIGURE 27 - BACK OF DISPLAY PLC ACCESS PANEL STARTER ACCESS PANEL FIGURE 28 - ACCESS PANELS FOR ELECTRICAL CONTROLS KIMA00H1 (0204)

  • Page 31: Display Maintenance

    (figure 25), and slide the option card into the adapter slot. A programmable logic controller (PLC) is used to monitor and control compressor operations. The standard PLC used in the KNW Series Programmable compressor is the Allen-Bradley MicroLogix 1500.
  • Page 32 PULL OUT AT TOP PLC-C PLC-X1 PLC-X2 TO REMOVE PROCESSOR OUTPUT MODULE ANALOG MODULE PROCESSOR COVER PLC INPUT OUTPUT STATUS PLC-X3 TERMINAL COVER LED’s LED’s LED’s ANALOG MODULE HINGES DOWN COVER HINGES PLC-B TERMINAL COVER PLC OUTPUT TERMINAL COVERS BASE WITH HINGES UP LED’s HINGE RIGHT...

  • Page 33: Plc Status Led's

    5.2.2 The PLC is provided with LED's to assist in monitoring operational PLC Status status of the processor, PLC inputs and outputs, and expansion modules. LED’s (Figure 29) 8 LED’s are provided for monitoring CPU status: a. POWER LED is on when control power is on to the PLC base power supply.
  • Page 34 INPUT LED’S PLC INPUTS 0V DC REFERENCE PLC OUTPUTS OUTPUT LED’S FIGURE 30 - CONFIRMING INPUTS AND OUTPUTS ON PLC USING LED’s AND VOLTMETER IF INPUT OR OUTPUT LED IS ON, VOLTMETER WILL READ +24VDC IF INPUT OR OUTPUT LED IS OFF, VOLTMETER WILL READ 0 V TERMINALS RELAYS FUSES...

  • Page 35: Plc Analog Inputs

    Slide the bottom mount clip down and the top mount clip up. Pull the module straight out. Installation is in reverse order of the removal. Kobelco KNW Series compressors are available with or without a main motor starter. A mounted X-Line starter is standard. Optional Motor Starters reduced voltage starters are shipped loose for separate mounting.
  • Page 36 INTAKE AIR DUST FILTERS CONDENSATE DRAIN VALVES OIL DRAIN VALVE FIGURE 32 - REAR VIEW OF COMPRESSOR READ OPERATING PARAMETERS GT-TERMINAL INLET AIR FILTER LUBRICATION LOAD CONTROL OIL FILTER SOLENOID VALVE OIL LEVEL SIGHT GAUGE FIGURE 33 - FRONT VIEW, INSIDE OF COMPRESSOR KIMA00H1 (0204)

  • Page 37: Maintenance

    6. MAINTENANCE NOTE: DO NOT STORE SPARE PARTS OR TOOLS IN CABINET. A list of service part numbers and replacement intervals can be found Daily on page 36. a. Check and record all operating parameters on the daily operating record furnished with the assembly. (See Appendix A) b.
  • Page 38 END PANEL SCREWS 1 INSIDE 1 ON BACK FIGURE 34 - TO REMOVE END PANEL FOR SERVICING REMOVE 2 SCREWS INDICATED, PULL TOP OF PANEL OUT THEN LIFT CHECK VALVE INTERCOOLER OIL COOLER AFTERCOOLER PRE-COOLER OIL SUMP SAFETY VALVE COMPRESSOR 1ST STAGE COMPRESSOR 2ND STAGE...

  • Page 39: Two Year

    6.4 (cont.) f. Dismantle and clean discharge separator automatic drain. g. Check daily operating records for intercooler and aftercooler Yearly efficiency. Clean cooler cores if required. The preferred method of cleaning the exterior is to blow the core off with compressed air in a direction parallel to the fins in order not to damage them.
  • Page 40 INLET AIR FILTER INLET AIR FILTER MOUNTING PLATE GEAR HOUSING OIL SUMP OIL FILL PORT OIL FILTER OIL LEVEL SIGHT GAUGE OIL PRESSURE RELIEF VALVE OIL PUMP FIGURE 36 - FRONT VIEW INTERIOR OF COMPRESSOR SECTION KIMA00H1 (0204)

  • Page 41: Filter Maintenance

    6.6 (cont.) b. The system lube oil capacity is: Lubrication MODEL KNW: A00-A A00-B A00-C A00-D A00-E CAPACITY: 12 QUARTS 15 QUARTS TABLE 4: LUBE OIL CAPACITY c. The oil level viewed on the sight gauge will vary when the compressor is operating.

  • Page 42: Service Parts List

    2 YR T3344 DISCHARGE SEPARATOR W/ AUTO DRAIN TABLE 5 - SERVICE PARTS FOR KNW SERIES A00 NOTE: Service intervals shown are the maximum recommended for most installations. Operating conditions at some installations may require more frequent servicing. The compressor should be inspected regularly and serviced as conditions require.

  • Page 43: Standby And Stored Units

    7. STAND-BY AND STORED UNITS Back-up or stand-by compressors must be run weekly to assure that no condensation is allowed to accumulate internally. When operated, Stand-By a stand-by unit should run long enough to reach full operating Compressors temperature. (30 minutes). For storage intervals of one month or less, if power is available, open the manual drains on the bottom of automatic drain traps and run the Short Term...

  • Page 44: Problem Solving

    8. PROBLEM SOLVING TABLE 6 - COMPRESSOR PROBLEM SOLVING CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1. Unit will not start. 1. Low supply voltage. 1. Check fuses or circuit breaker. 2. Programmable controller problem 2. Check for proper voltage and 3. Power failure. connections.
  • Page 45 TABLE 6 (cont.) - COMPRESSOR PROBLEM SOLVING 10. Abnormal noise from 1. Coupling problems. 1. Inspect and repair coupling. compressor element. 2. Gear trouble 2. Overhaul. 3. Bearing trouble. 3. Replace bearings. 11. Abnormal noise from oil pump. 1. Oil level too low. 1.

  • Page 46: Plc

    TABLE 7 - PROGRAMMABLE LOGIC CONTROLLER (PLC) PROBLEM SOLVING CONDITION POSSIBLE CAUSE SUGGESTED REMEDY 1. PLC “POWER” light off. 1. Control circuit fuse blown. 1. Check transformer voltage. 2. Faulty transformer. 2. Replace any blown fuses. 3. Faulty power supply. 3.

  • Page 47: Appendix A - Daily Operating Record

    Appendix A - Daily Operating Record KIMA00H1 (0204)
  • Page 48 DATE SERVICE PERFORMED SERVICED BY ____________________ ____________________ ____________________ MAIL TO: Attention: Field Engineering 14650 SW 72nd Ave. Portland, OR, 97224-7943 KIMA00H1 (0204)

  • Page 49: Unit Dimensions

    Appendix B - Unit Dimensions, Minimum Working Clearances VIEW FRONT VIEW KIMA00H1 (0204)
  • Page 50 Appendix B (cont.) - Unit Dimensions and Field Connections REAR VIEW SIDE VIEW KIMA00H1 (0204)
  • Page 51 Appendix B (cont.) - Unit Dimensions, Field Connections and Mounting KIMA00H1 (0204)
  • Page 52 KIMA00H1 (0204)
  • Page 53 Instruction Manual Revisions Revision Date Description 11 Feb 04 Page 13, add hazardous location warning Page 33, add “Inspect sump breather” to monthly mainetnance. KIMA00H1 (0204)
  • Page 54 Rogers Machinery Co., Inc. 14650 S.W. 72nd Ave. Portland, Oregon, 97224-7962 P.O.Box 230429 Portland, Oregon, 97281-0429 Phone: (503) 639-0808 Fax: (503) 639-0111 www.knw-series.com E-Mail: kobelco@rogers-machinery.com KIMA00H1 (0204)

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