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MODEL:
INSTRUCTION MANUAL
KOBELCO is the international trademark found on all products of Kobe Steel, Ltd.
C:\Users\XUPD18ZMH\AppData\Local\Microsoft\Windows\INetCache\Content.Outlook\VDV00GPY\690062
M.1 Operations Manual Rental Electric Compressors.doc
AIR-COOLED
OIL-FREE
ROTARY SCREW
AIR COMPRESSORS
SERIAL NO:
MODEL: KNWA0-EHR, KNWA0-EPXR, KNWA0-
EHR2, KNWA1-GHR, KNWA1-GPXR, KNWA1-
GHR2, KNWA2-DPXR, KNWA2-DHR2
Electric Rental Units
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Table of Contents
Related Manuals for Kobelco ROGERS KNW Series
Summary of Contents for Kobelco ROGERS KNW Series
- Page 1 AIR COMPRESSORS MODEL: SERIAL NO: INSTRUCTION MANUAL MODEL: KNWA0-EHR, KNWA0-EPXR, KNWA0- EHR2, KNWA1-GHR, KNWA1-GPXR, KNWA1- GHR2, KNWA2-DPXR, KNWA2-DHR2 Electric Rental Units KOBELCO is the international trademark found on all products of Kobe Steel, Ltd. C:\Users\XUPD18ZMH\AppData\Local\Microsoft\Windows\INetCache\Content.Outlook\VDV00GPY\690062 M.1 Operations Manual Rental Electric Compressors.doc...
- Page 2 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.
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Page 3: Table Of Contents
Instruction Manual ROGERS KNW SERIES OIL-FREE ROTARY SCREW AIR COMPRESSORS MODEL: KNWA0-EHR, KNWA0-EPXR, KNWA0-EHR2, KNWA1-GHR, KNWA1-GPXR, KNWA1-GHR2, KNWA2-DPXR, KNWA2-DHR2 A companion publication, “Description of Operation” for the HMI/PLC program, NOTE: contains detailed instructions on HMI operation and compressor controls. Revisions... -
Page 4: General Description
1. General Description 1.1. Compressor The Rogers KNW Series air compressor is a heavy duty, two-stage, rotary screw design that provides completely oil-free compressed air. 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 5: Compressed Air Flow
1.2. Compressed Air Flow FIGURE 1 - COMPRESSED AIR FLOW Air to be compressed enters an air inlet silencer through an opening in the cabinet. The air inlet silencer is a duct lined with sound absorbing material. The air then flows through a two-stage, high efficiency air filter. -
Page 6: Cooling Air Flow
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 pressure alarm. -
Page 7: Capacity Control Valve
After filtration the oil enters the compressor oil passages. An oil pressure control valve is provided to regulate a constant pressure for component lubrication by returning excess oil back to the sump. The oil flows through internal passages, and external tubing, to lubricate all bearings, timing gears, and drive gears. -
Page 8: Monitoring And Limiting Devices
To load, the 4-way solenoid valve (3) energizes, the CCV spring chamber (A) is disconnected from atmosphere and is connected to 1st stage inlet vacuum. The vacuum in spring chamber (A), and on the inside of the inlet valve disc, help to pull the inlet valve (1) open while closing the bleed-off valve (2). -
Page 9: Alerts And Alarms
operation of the pilot lights by briefly illuminating all lights and. The operation of the compressor is not affected by an LED test. 1.7. Alerts and Alarms An 'Alert' condition indicates that the compressor requires attention, but continued operation will not harm the compressor. An 'Alarm' condition indicates that continued operation could be dangerous to the compressor, and immediately shuts down the compressor. -
Page 10: Installation
2. Make sure the ball valve to the back pressure regulator valve is open. Run the compressor and allow system pressure to reach desired value; if required, open bleed valve at receiver to ensure compressor stays loaded. 3. Turn the adjusting screw on the top of the valve to raise or lower the pilot threshold. There is a pressure gauge on the valve. -
Page 11: Location
surface. The compressor air end and motor assembly is vibration isolated from the cabinet, frame, and base. Additional isolation is not required. 2.4. Location The unit should be installed in a well ventilated location, free from excessive dust or dripping liquids. 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. -
Page 12: Air Receiver
compressors should be to the top of the header. The header should be equipped with drop legs and drains for moisture traps. See figure 13. 2.7. Air Receiver Safety relief valve Service valve Air system header Drop leg with drain valve Pressure gauge Flexible connection... -
Page 13: Wiring
3. Arrange periodic inspections necessary to maintain those licenses. 2.8. Wiring It is the compressor owner's responsibility to ensure a safe installation 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 14: Initial Start-Up
f. Confirm service valves for the automatic condensate drain valves are open. g. Manually rotate cooling fan and main motor coupling. Confirm that both turn freely and that there are no interferences or unusual noises. h. Turn on electric power to unit. Confirm HMI operation, showing proper model number, serial number, and program number. -
Page 15: Stopping The Compressor
b. Turn power on. Confirm HMI operation. Check that all temperatures read normal. c. Press the Start button. The oil pump will start. Check oil pressure. The RUN light will turn on. d. The compressor motor will start when oil pressure is established. e. -
Page 16: Installation
De-installation To shut down and disconnect the compressor prior to removing it from a site: a. Press the "Stop" button to shut down the compressor. b. Shut off electrical power to the compressor at the external supply circuit breaker; follow standard lock-out and tag-out procedures. WARNING: Conductors supplying power to the starter panel are HIGH VOLTAGE. -
Page 17: Programmable Logic Controller
If the HMI requires replacement, disconnect the communication cable, the DC24V power connector and the grounding wire. Use a Phillips screwdriver to remove the four mounting clips. 6.2. Programmable Logic Controller A programmable logic controller (PLC) is used to monitor and control compressor operations. -
Page 18: Weekly
b. Adjust or service as required or indicated. c. Check for proper operation of the intercooler and aftercooler automatic drain valves. The valves should pulse briefly each 1-2 second while the compressor is loaded. The intercooler automatic drain will not operate while the compressor is unloaded. The intercooler drain line has a check valve to prevent backflow of drained condensate while the compressor is unloaded. - Page 19 e. Replace shuttle valve diaphragm. f. Replace 4-way solenoid valve. g. Replace balance pistons diaphragms. 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.
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Page 20: Lubrication Oil
7.5. Lubrication Oil The correct oil for lubrication is a quality turbine oil, containing rust and oxidation inhibitors and corresponding to ISO VG 68. DO NOT mix different brands or grades of oil. The compressor was initially filled with 76 Products Company turbine oil ISO VG 68 having a viscosity of 336 SUS @ 100F (38C). -
Page 21: Standby And Stored Units
Standby and Stored Units 8.1. Standby Units Back-up or stand-by compressors must be run weekly to assure that no condensation is allowed to accumulate internally. When operated, a stand-by unit should be allowed to reach full operating temperature for 30 minutes. 8.2. - Page 22 available for comparison to site readings. Contact your local distributor for more information. Pressures and temperatures shown are typical for an average compressor installation. Ambient temperature 70°F, 500’ elevation. Set 125 PSIG unload to 115 PSIG load, operating 75% loaded. See Description of Operations for more information on alerts and alarms.
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Page 23: Troubleshooting
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. 10.1. Compressor CONDITION POSSIBLE CAUSE SUGGESTED REMEDY Unit will not start. Low supply voltage. Check fuses or circuit breaker. - Page 24 CONDITION POSSIBLE CAUSE SUGGESTED REMEDY Failure to load. 4-way solenoid valve defective. Repair or replace unloading valve. Capacity Control Valve diaphragm Replace diaphragm. ruptured. Repair Capacity Control Valve. Capacity Control Valve bushings Check transmitter connections and wiring. defective. Press load button. Trouble with pressure transmitters.
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Page 25: Plc
CONDITION POSSIBLE CAUSE SUGGESTED REMEDY Compressor back Defective discharge check valve. Repair or replace. spins on shutdown. Intercooler pressure Dirty air inlet filter. Clean or replace elements. below normal or Defective 1st stage Replace 1st stage. pulsating. Pressure transmitter malfunction. Check transmitters, wiring, IO Blocks. -
Page 26: Appendix A: Performance Data
APPENDIX A: Performance Data This table shows typical performance data values. For exact data, consult serial-number- specific documentation for your compressor including electrical drawing. Model A0-EHR A0-EPXR A1-GHR A1-GPXR A2-DHR A2-DPX2 Pressure 40 - 135 PSIG 40 - 135 PSIG 40 - 135 PSIG 40 - 135 PSIG 40 - 150 PSIG... - Page 27 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 Web: knw-series.com E-Mail: knwseries@rogers-machinery.com...
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