Table of Contents
Advertisement
MODEL
GPKD-1550-H
INSTRUCTION MANUAL
CATERPILLAR C18 TIER 4 FINAL – 1550 CFM
KOBELCO is the international trademark found on all products of Kobe Steel, Ltd.
C:\Users\acg\AppData\Local\Microsoft\Windows\INetCache\Content.Outlook\QUQH0O0M\GPKD-
1550-H CAT Diesel Instruction Manual.doc APRIL2020
AIR-COOLED
ROTARY SCREW
AIR COMPRESSORS
OIL-FREE TWO-STAGE
SERIAL
GPKD-1550-H
1806119004
1806119033
–
The information in this manual is
current as of its publication date
and applies to compressor serial
numbers
1806119004
1806119033.
through
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Rogers KNW Series
Summary of Contents for Rogers KNW Series
- Page 1 AIR-COOLED ROTARY SCREW AIR COMPRESSORS OIL-FREE TWO-STAGE MODEL SERIAL 1806119004 1806119033 GPKD-1550-H – INSTRUCTION MANUAL The information in this manual is current as of its publication date and applies to compressor serial numbers 1806119004 through 1806119033. GPKD-1550-H CATERPILLAR C18 TIER 4 FINAL – 1550 CFM KOBELCO is the international trademark found on all products of Kobe Steel, Ltd.
- Page 2 THIS PAGE LEFT BLANK...
- Page 3 SAFETY PRECAUTIONS Safety notices, marked with this symbol, are used in this publication to emphasize that a hazardous condition that could cause personal injury and/or damage to the equipment exists. 1. Read and understand the contents of this manual before installing, operating or maintaining the compressor.
-
Page 4: Table Of Contents
Instruction Manual ROGERS KNW SERIES OIL-FREE ROTARY SCREW AIR COMPRESSORS MODEL: GPKD-1550-H NOTE: A companion publication, “Description of Operations” (e.g. K2A075A) for the HMI/PLC programs, contains detailed instructions on HMI operation and compressor controls. A separate publication from Caterpillar “SEBU9106-14”... - Page 5 Fuel System Primary/Secondary Filter (Water Separator) Element ......... 39 Standby and Stored Units ..... 39 7.1. Standby Units .......... 39 7.2. Short-term Storage ........39 7.3. Long-term Storage ........40 Typical Operating Conditions ....41 Operating Temperatures and Pressures ....41 Troubleshooting ........
-
Page 6: General Description
The result is a very stable and quiet running package. The KNW Series compressor includes a separately driven oil pump for drive gear, timing gear, and bearing lubrication. The compressor lube oil pump starts first, then, after oil pressure is established, the Diesel engine starts. -
Page 7: Compressed Air Flow
1.2. Compressed Air Flow FIGURE 1 - COMPRESSED AIR FLOW Air to be compressed enters the cabinet, then in to two air filter housings (See Figure 9). The air then flows through a two-stage, high efficiency air filter. Filtered air flows through a flex connector into the CCV, and then into the inlet of the compressor 1st stage. -
Page 8: Cooling Air Flow
• 2nd Stage Discharge air temperature • Compressor Outlet air temperature The monitored temperatures and pressures are displayed on the HMI. The PLC continuously monitors for high temperatures, providing a warning if a temperature approaches the design maximum and a shutdown if any reaches the limit. Compressor outlet air pressure is monitored to provide load and unload pressure control and a high outlet air pressure alarm. -
Page 9: Oil Flow For Lubrication
1.4. Oil Flow for Lubrication FIGURE 3 - OIL FLOW Oil for bearing and gear lubrication is stored in the oil sump, located in the lower section of the main gear case/compressor housing. A sight gauge, located on the side of the oil sump, is provided to check oil level. -
Page 10: Capacity Control System
The PLC monitors oil temperature which is displayed on the HMI. A warning is provided as the temperature approaches maximum operating temperature and a shutdown if it reaches the limit. 1.5. Capacity Control System The capacity control system consists of an inlet capacity control valve (CCV) with an integral bleed-off valve, a 4-way solenoid valve, and a shuttle valve. - Page 11 interstage pressure (D) increases, transferring the shuttle valve (4) and pressurizing the operating chamber (B), keeping the capacity control valve open. FIGURE 5 - COMPRESSOR LOADED When the compressor is running, compressor outlet air pressure is monitored by a pressure sensor on the air piping. When the compressor outlet air pressure reaches the upper limit of the desired operating range, the 4-way solenoid valve is de-energized, venting the operating chamber (B) to atmosphere and pressurizing the spring chamber (A).
-
Page 12: Monitoring And Limiting Devices
1.6. Monitoring and Limiting Devices The compressor is equipped with the following monitoring and limiting devices: • Compressor 1st stage suction air pressure transmitter. Monitors pressure at the compressor inlet. Pressure is displayed on the HMI. This pressure is monitored for loaded and unload condition, and condition of the inlet air filter. -
Page 13: Alerts And Alarms
1.7. Alerts and Alarms An 'Alert' condition indicates that the compressor requires attention, but continued operation will not harm the compressor. Alerts are indicated by a blue pilot light, the buzzer sounding, and a message on the HMI. The buzzer can be silenced by acknowledging the alert message at the HMI;... -
Page 14: Component Locations
1.8. Component Locations REAR VIEW Cooling Air Louvers (Leave Doors Compressed Closed) Air Outlet Weather Tie-down Plugs (Do Tie-down D-Ring Not Block) D-Ring SIDE VIEW Cooling Air Aux. Louvers Engine (Leave Doors Emergency Gauge Closed) Stop Condensate Cluster Drains (Do Not Block Compressed Automatic) - Page 15 FRONT VIEW Cooling Air Louvers (Leave Doors Control Closed) Panel / Interface (HMI) External DEF and Emergency Fuel Tank Stop Connections Engine Oil, Compressor Oil, Engine Coolant Service Drain Ports SIDE VIEW Cooling Air Louvers (Leave Doors Diesel Closed) Diesel Exhaust Fuel Fluid...
- Page 16 TOP / ISOMETRIC VIEW Lifting Frame Eyelet Lifting Engine Frame Exhaust Eyelet Outlet Lifting Frame Eyelet Engine Coolant Fill Hatch Diesel Fuel Lifting Tank Frame Fill Eyelet Emergency Stop Control Panel / Interface (HMI) Diesel Exhaust Fluid 120VAC External (DEF) Heat Trace / DEF and Tank Fill...
- Page 17 Aftercooler Moisture Separator Aftercooler Core Stage Discharge to Aftercooler Pipe Discharge Stage Check Valve Discharge Silencer Moisture Separator to Compressor Outlet Pipe FIGURE 7 – AFTERCOOLER PLUMBING DETAIL...
- Page 18 Stage Discharge to Intercooler Pipe Intercooler Core Intercooler to Stage Pipe Moisture Separator to Stage Inlet Intercooler Moisture Separator FIGURE 8 – INTERCOOLER PLUMBING DETAIL...
- Page 19 Engine Exhaust Aftertreatment (In Housing) Engine Radiator Inlet Compressor Air Inlet Charge Air Filters Cooler Outlet Charge Air Cooler Inlet Engine Air Inlet Filter Diesel Fuel Tank (Left) FIGURE 9 – ISOMETRIC VIEW VARIOUS ENGINE PLUMBING...
- Page 20 Engine Exhaust Aftertreatment Inlet Charge Air Cooler Outlet Charge Air Cooler Inlet Engine Air Inlet Filter Engine Radiator Engine Inlet Compressor Radiator Air Inlet Outlet Filters Diesel Fuel Tank (Right) FIGURE 9A – ISOMETRIC VIEW, VARIOUS ENGINE PLUMBING, ROTATED VIEW...
- Page 21 Note: The engine used in the GPKD-1550-H has remote-mounted secondary fuel filters, located near the interstage moisture separator. Note (2): The design of the oil pan is not the extended type as shown in the diagram. FIGURE 10a – ENGINE LEFT SIDE...
- Page 22 Note: The design of the oil pan is not the extended type as shown in the diagram. FIGURE 10b – ENGINE RIGHT SIDE...
-
Page 23: Installation
2. Installation 2.1. Inspection Immediately upon receipt, the compressor should be inspected for damage. If any damage is found, claims should be made against the carrier. 2.2. Handling Lifting Frame Eyelet Spacer blocks FIGURE 11 - FORKLIFT HANDLING FIGURE 12 - CRANE HANDLING The compressor unit is equipped with forklift slots for ease in handling. -
Page 24: Location
2.4. Location The unit should be installed in a well-ventilated location, free from excessive dust. Do not install in an area where chlorine gas, hydrogen sulfide gas, sulfur dioxide gas, highly concentrated ozone, or any other toxic, corrosive or flammable gasses are present. It is important to provide a source of clean intake air. - Page 25 CAUTION: Do not install an additional check valve between the compressor and the plant compressed air system piping. Doing so will prevent correct compressor operation and may damage the compressor. A flexible connection is required between the outlet of the compressor and the plant compressed air system piping.
-
Page 26: Air Receiver
2.7. Air Receiver Safety relief valve Air system header Drop leg with drain valve Pressure gauge Flexible connection (hose) Drain valve FIGURE 13 - TYPICAL AIR RECEIVER CONFIGURATION A properly sized air receiver should be located as close to the discharge of the compressor as possible, and before any air treatment accessories such as filters and dryers. -
Page 27: Wiring
NOTICE: It is the compressor owner's responsibility to: 1. Verify that the receiver and the receiver installation comply with the applicable local, state, and national codes. 2. Obtain the proper licenses for the receiver. 3. Arrange periodic inspections necessary to maintain those licenses. 2.8. -
Page 28: Start-Up
3. Start-Up 3.1. Pre-start Checks Prior to starting, the installation must be complete. Refer to section 2 for installation requirements. a. Turn off barrel-style battery safety disconnects for initial checks. b. Remove all loose items left in and around unit during installation. Clean inside of cabinet if necessary. - Page 29 o. Perform LED Test (found in Terminal Options, see Description of Operations manual for more information). Confirm that all pilot lights operate and that the audible alarm sounds.
-
Page 30: Initial Start-Up
3.2. Initial Start-up NOTICE: The compressor has separate auxiliary motors that start in sequence. The sequence is event driven and controlled by the PLC. For details consult the “Description of Operation” manual for the PLC program provided for the compressor. If the engine has not been started for several weeks, fuel may have drained from the fuel system. -
Page 31: Stopping The Compressor
a. The PLC waits for 5 seconds to allow the engine controller time to come online, then starts the oil pump and engine fuel booster pump. b. When oil pressure is greater than 3 PSI for 2 seconds, the engine starter is energized. -
Page 32: Electrical Controls
5.1. Compressor Control Panel KNW Series air compressors come with a color HMI with touch screen. The HMI shows current operating conditions, pressures, and temperatures. Messages to direct the operator for service, pre-alarms, and shutdowns will be shown when necessary. -
Page 33: Hmi Maintenance
• H2O Temp: Displays coolant temperature of the engine. • Tachometer: Displays rotation per minute of the Diesel engine. • Pressure gauge marked "Oil Pressure": Shows lubricant pressure at the Diesel engine. • Fuel Level: Shows the level of fuel in the internal fuel tank. -
Page 34: Daily
user is also responsible for the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, to determine the maintenance intervals. -
Page 35: Every 250 Service Hours
6.3. Every 250 Service Hours a. Inspect and adjust engine belts. Replace as needed. b. Obtain engine oil sample. c. Inspect, clean, and tighten engine grounding stud. 6.4. Monthly a. Review event list for alerts and unreported shutdowns. b. Inspect control air filter. c. -
Page 36: Every 2500 Service Hours
h. Replace check valve on intercooler condensate drain line. i. Check daily operating records for intercooler and aftercooler 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. If a pressure washer is used care must be taken to avoid wetting any electrical connections. -
Page 37: Every 5000 Service Hours
b. Inspect starter motor. 6.11. Every 5000 Service Hours a. Clean ARD spark plug (part of aftertreatment system). b. Replace DEF filter. c. Replace DEF injector. d. Clean Diesel particulate filter. 6.12. Every 6000 Service Hours or 3 Years a. Add engine coolant extender (ELC). 6.13. -
Page 38: Filters
Cat oils have been developed and tested to provide the full performance and life that has been designed and built into Cat engines. Cat DEO-ULS or oils that meet the Cat ECF-3 specification, the API CJ-4, the newer API CK-4, and/ or ACEA E9 are required for use in the applications listed below. -
Page 39: Sump Breather
6.16.3 Sump Breather Inspect the sump breather element monthly. If the element is saturated it should be replaced. A small amount of oil may be present in the housing outside the filter element; this is normal and will drain back to the sump. 6.16.4 Control Air Filter Inspect element monthly. -
Page 40: Long-Term Storage
7.3. Long-term Storage NOTICE: If an engine is not used, oil can run off the following parts that normally receive lubrication: cylinder walls, piston rings, main bearings, connecting rod bearings, crankshaft and gears. This lack of lubricant allows corrosion to begin to appear on the metal. -
Page 41: Typical Operating Conditions
l. Apply a heavy amount of Cat Multipurpose Grease (MPGM) to all outside parts that move, such as rod threads, ball joints, linkage. m. Install moisture barrier (plastic sheeting) on inlet air panels and louvers, cooling air outlet grill and bleed-off silencer. Ensure all covers are airtight and weatherproof. Use a waterproof weather resistant tape such as Kendall No. - Page 42 PRESSURES TEMPERATURES 0” ~ 18” H O Vacuum, Loaded Inlet (Air) 75°F Stage Suction (Air) 24” ~ 26” Hg Vacuum, Unloaded Stage Discharge (Air) 350°F 25 ~ 35 PSIG Pressure, Loaded Stage Suction (Air) 105°F Interstage (Air) 13” ~ 15” Hg Vacuum, Unloaded Stage Discharge (Air) 365°F Compressor Outlet...
-
Page 43: Troubleshooting
9. Troubleshooting This table focuses on mechanical faults and conditions. For electrical faults that will cause an alarm or alert message on the HMI, see the Description of Operations. For engine trouble, refer to the CAT Operation and Maintenance Manual SEBU9106-14 or contact your local Caterpillar dealer. - Page 44 CONDITION POSSIBLE CAUSE SUGGESTED REMEDY High compressor Dirty aftercooler core. Clean aftercooler (see section 6.4). outlet air temp. Obstructed cooling air flow. Check for and remove any foreign material blocking air flow. High ambient temperature. See High Inlet Air Temperature. High oil Oil level too high.
- Page 45 CONDITION POSSIBLE CAUSE SUGGESTED REMEDY Safety valve lifts Pressure settings too high. Set load and unload settings to proper in normal range for motor horsepower. Defective pressure transmitter. operation. Replace transmitter. Service valve to air system closed. Open valve. Oil level rises Condensation in oil.
-
Page 46: Plc (See Description Of Operations Manual For Additional Details)
CONDITION POSSIBLE CAUSE SUGGESTED REMEDY Intercooler High 2nd stage inlet temp. See above. pressure above Defective 2nd stage. Replace 2nd stage. normal. Balance valve open. Adjust balance valve. Check transmitters, wiring, IO Blocks Pressure transmitter malfunction. 9.2. (See Description of Operations Manual for additional details) CONDITION POSSIBLE CAUSE SUGGESTED REMEDY... - Page 48 THIS PAGE LEFT BLANK...
- Page 49 Rogers Machinery Co., Inc. 14650 SW 72nd Ave. Portland, Oregon, 97224-7962 P.O. Box 230429 Portland, Oregon, 97281-0429 Phone: (503) 639-0808 Fax: (503) 639-0111 www.rogers-machinery.com E-Mail: kobelco@rogers-machinery.com...
Need help?
Do you have a question about the KNW Series and is the answer not in the manual?
Questions and answers