Kobelco KNW Series Manual
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Kobelco KNW Series Manual

Kobelco KNW Series Manual

Oil-free two-stage rotary screw air compressors
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MODEL#:
SERIAL#:
DESCRIPTION OF OPERATION
For compressors equipped with the
KNW Series Compressor Operator Panel
with Graphic Touchscreen "HMI Terminal"
PROGRAM NUMBER:
KL011B
KOBELCO is the international trademark found on all products of KOBE STEEL, LTD.
H:\10\Eng\DOCS\KNW\DescrOps\KL1_099\KL011B.doc

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Summary of Contents for Kobelco KNW Series

  • Page 1 MODEL#: SERIAL#: DESCRIPTION OF OPERATION For compressors equipped with the KNW Series Compressor Operator Panel with Graphic Touchscreen “HMI Terminal” PROGRAM NUMBER: KL011B KOBELCO is the international trademark found on all products of KOBE STEEL, LTD. H:\10\Eng\DOCS\KNW\DescrOps\KL1_099\KL011B.doc...

  • Page 2: Safety Precautions

    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

    Description of Operation PROGRAM NUMBER: KL011B MODEL NUMBER: SERIAL NUMBER: Revisions Revision Author Date Description KL001J 01-Oct-2012 Internal program changes; no screen updates. KL011A 25-Jan-2013 Revisions for 2013 model year. 16-Aug-2013 Client/Server Lead/Lag through ENI module. KL011B 09-Oct-2013 Internal program changes; no screen updates. Overview ........................

  • Page 4: Overview

    ........................37 APPENDIX 1: Index of Alerts and Alarms ..............39 1. Overview The Kobelco KNW Series air compressor is a heavy duty, two-stage, rotary screw design that provides completely oil-free compressed air. Air is drawn in from outside the...

  • Page 5: Compressor Control

    Operations Manual. 2. Compressor Control The Kobelco KNW Series Oil-Free Rotary Screw Air Compressor Operator Panel uses a Programmable Logic Controller (PLC) to control and monitor compressor operation. PLC operations include controlled sequential starting and stopping, pressure control, and protection from conditions that could damage the compressor.

  • Page 6: Interface Contacts

    Red pilot light. Indicates the compressor has shutdown due to an ALARM "Alarm" condition. The light flashes until the "Alarm" is acknowledged, then is on steady until the "Alarm" condition is reset. Beeper. An audible alarm which sounds for an Alert or an Alarm. WARNING Blue pushbutton marked with “R”.

  • Page 7: Numerical Keypad For Data Entry

    Numerical Keypad for Data Entry Exit without changing number Enter selected digit to value Backspace Clear value Forward one number Delete number Back one number Accept new value Value can be changed one number at a time or cleared and a new value entered. Current value displayed at top.

  • Page 8: Hmi Terminal Main Screens

    2.4 HMI Terminal Main Screens The following screens are used to display compressor operational information and navigate to settings screens. 'Splash' screen � Displays automatically on power-up � Displays model number, serial number, and program version number. � Touch anywhere on screen to bring up 'Temperatures' screen 'Temperatures' screen �...

  • Page 9: Pressures' Screen

    'Pressures' screen � Accessible from: Splash, Temperatures, Menu. � Displays compressor temperature readings, standby status, lead/lag status, and local/remote status. � May display special status messages, as described for 'Temperatures' screen. � Allows manual selection of Lead/Lag and Local/Remote status; see section 5.1 and 5.2.
  • Page 10 � "Diagnostic" brings up Diagnostics section of menu (shown to left; selected menu section is identified with red color): o "I/O Diagnostic": see section 5.4. o "Terminal Diagnostic": brings up diagnostic screens; see section 6.1. o "Alarm List" : see section 4. o "Trend Data": graph of past temperature and pressure readings;...

  • Page 11: Transducer Calibration

    2.5 Transducer Calibration Under normal circumstances, it should not be necessary to calibrate any transducer. All transducers are factory calibrated before shipment. Before attempting to calibrate a transducer, check it for proper operation, proper type, and range. Calibration is done from the Transducer Calibration screen, accessible from the Menu.

  • Page 12: Start Initiated' Screen

    1. The oil pump starter will energize immediately to start the oil pump. The "Start Initiated" screen will display if the Pressure or Temperature screen was selected; the oil pump graphic will animate, and the RUN light will be turned on. 2.

  • Page 13: Pressure Setpoints' Screen

    setpoints stored in the PLC. The PLC controls a 4-way solenoid valve which operates the capacity control valve. If discharge pressure is lower than the "LOAD" set point, the PLC will energize the solenoid valve, loading the compressor. The LOAD light turns on and “LOADED”...

  • Page 14: Shutdown Sequence

    disables the alert. � Pressure units are selectable. Pressure settings are factory set as specified by customer. Maximum available pressure is dependant on compressor size, gear ratio, horsepower, and elevation. 3.3 Shutdown Sequence The PLC controls the timed Shutdown sequence of the compressor. Once the Shutdown sequence has begun, the compressor will not restart until the sequence is complete.

  • Page 15: Shutdown Delays' Screen

    'Shutdown Delays' screen � Accessible from: Menu, other Delay screens. � "Lube Oil Pump Stop": affects shutdown sequence time; see above. � "Vent Fan Stop" affects shutdown sequence time; see above. � "Standby Cabinet Cooling": If enabled, allows the cooling fan to run if a temperature alert occurs while the compressor is in Standby.

  • Page 16: Standby Delays' Screen

    does not drop below the Load pressure setting, the compressor will shut-down in Stand- By mode. In "Smart" mode, when the compressor is unloaded, the program uses the difference between successive system pressure measurements, taken every 30 seconds, to calculate expected pressure at the end of the "Standby Delay" time. If the calculated pressure is above the load pressure setting for six consecutive 30-second cycles, the compressor will shut-down in stand-by mode.

  • Page 17: Auto Restart, Timed Load Cycle

    3.5 Auto Restart, Timed Load Cycle The "Timed Load Cycle Power Saver" option prevents the compressor from running loaded for excessive periods of time in response to low demand. When enabled, if the compressor is running loaded, system pressure is above the Load setpoint, and pressure is increasing, a timer is started.

  • Page 18: Alerts And Alarms

    4. Alerts And Alarms An Alert is any condition that requires operator intervention that does not shut down the compressor; an Alarm is a condition that shuts the compressor down immediately. After an Alarm has occurred, the compressor will not operate until the condition that caused the alarm has ceased.

  • Page 19: Alarm Delays' Screen

    'Alarm Delays' screen � Accessible from: Menu, other Delay screens. � "Motor Service Alert" sets hours motor runs before Motor Service Alert occurs; see section 6.5. A '0' in this field disables the alert. � "Low Lube Oil Pressure": time for which the Low Lube Oil Pressure alarm is temporarily disabled on start- up, to allow the oil pump to start.

  • Page 20: Temperature Alarms/Alerts

    Temperature Alarms/Alerts Temperature alerts and alarms occur when the compressor senses dangerously high temperature. Alerts occur at a lower temperature than alarms, and are disabled when the compressor is off. If a temperature alarm occurs while the compressor is not running, the cabinet cooling fan may be set to turn on temporarily in an attempt to reduce compressor cabinet temperature.
  • Page 21 SETPOINT 580 (304) 455 (235) 412 (211) 412 (211) 400 (204) �F (�C) 1st STAGE DISCHARGE ALERT �F (�C) MINIMUM LIMIT 32 (0) 32 (0) 32 (0) 32 (0) 32 (0) 590 (310) 464 (240) 421 (216) 421 (216) 410 (210) �F (�C) MAXIMUM LIMIT 590 (310) 464 (240) 421 (216) 421 (216) 410 (210) �F (�C) 1st STAGE DISCHARGE ALARM...

  • Page 22: Special-Purpose Compressor Control Options

    5. Special-Purpose Compressor Control Options 5.1 Lead/Lag Control When a compressor is set up for Lead/Lag control, it will operate at either of two pressure ranges, determined by whether the compressor is in Lead or Lag. Lead/Lag status can be selected using the HMI Terminal. Compressors can be rotated between Lead and Lag status, to equalize wear, or to meet changing demands better by using different-capacity compressors at different times.

  • Page 23: Lead/Lag And Remote Modes' Screen, Lead/Lag Settings

    and begins to operate using lag setpoints. Terminal must be modified by programming tool to include client communication. � SERVER: Compressor is connected to other compressor by Ethernet, as described below. When either compressor changes from Lead to Lag or vice versa, the other will change to the opposite setting.

  • Page 24: Client/Server Lead/Lag Option

    � Screen appears as shown when "Automatic" or "Client" lead/lag mode and "Hours" auto rotate mode are selected. � In "Hours" mode, compressor will switch from Lead to Lag or vice versa after operating for the specified number of hours. Client/Server Lead/Lag Option Two compressors in Client/Server Lead/Lag mode must be connected using a crossover Ethernet cable.

  • Page 25: Local/Remote Operation

    Node 1 and Node 2 PLCs are factory configured. If the modules are connected correctly, the green "Link" light beside each RJ-45 port will be lit. If machines are not connected properly, a "Loss of Network Comms" alert will occur. 5.2 Local/Remote Operation When a compressor is set up for Local/Remote control, it can be operated based on either local system pressure as determined by the compressor’s own sensors, or on...

  • Page 26: Lead/Lag And Remote Modes' Screen, Remote Settings

    � REMOTE RUN AND LOAD: Both starting and loading are controlled by remote maintained contacts; the run contact must be closed for the compressor to run, and the load contact must be closed for the compressor to load. � REMOTE UNLOAD: Starting and stopping are determined by the local Start and Stop buttons.

  • Page 27: Setback Mode

    5.3 Setback Mode "Setback Mode" allows the compressor to operate at a lower pressure than normal at specified times. If standard system pressure is not required except during standard on- shift times, but a lower pressure must be maintained constantly, "Setback Mode" will save energy by operating the compressor less while off-shift.

  • Page 28: Pressure Setback Times' Screen

    'Pressure Setback Times' screen � Accessible from: Pressure Setback Settings. "Back" returns to Pressure Setback Settings. � "Monday - Friday": Settings apply to all weekdays. o "Full Pressure Start Time" determines time of day at which compressor will begin to operate at standard pressure setting.

  • Page 29: Inputs

    Inputs Normally, Inputs 6 and 7 are used for remote control functions and Inputs 5 and 10 are used for external alarm contacts. Input 5 may also be used for remote control functions if the compressor is configured accordingly. Some input modes are designed to work with specific lead/lag or remote mode, and are selected automatically when these modes are used, and may not be available for manual selection.
  • Page 30 � Input 6, I:0/6: o None o Rem Start / Rem Run: Input for a remote signal. In Remote Run, Remote Run And Load, or Remote Start/Stop mode, this input must receive a continuous signal for the compressor to run. o External Lead/Lag: As described above.

  • Page 31: Outputs

    Outputs Outputs 0-3 on PLC-X1 output module are used for four status relays (Running, Loaded, Alert, and Alarm), as described in section 2.2. Additional relays may be connected to the remaining outputs to monitor the status conditions described below. Available output options are: �...

  • Page 32: Starter Configuration

    5.5 Starter Configuration Compressors can be configured to operate using various types of main motor starter. Normally, 00, 0, and 1 frame compressors use a two-step Wye-Delta starter; 2 and 3 frame compressors use a solid-state soft starter. Consult factory for further information about available starter options.

  • Page 33: External Pressure Switch' Screen

    'External Pressure Switch' screen � Accessible from: Menu. � "Pressure Switch Configuration" determines mode; see above. � "Change Position", if Lead/Lag configuration is selected, will rotate the outputs, changing the output now designated as "PS1" to "PS2" and vice versa, at the specified times.

  • Page 34: Temperature And Pressure Trends

    The terminal will indicate that data is transferring; when it is done, the drive can be removed safely. Data files are in CSV format and can be opened in Microsoft Excel. Location of USB port for datalogging 6.3 Temperature and Pressure Trends "Trending"...

  • Page 35: Temperature Trend' Screen

    screen. Trend chart settings T4 - TREND CHARTS User Factory Minimum Maximum Units Setting Setting Limit Limit PRESSURES, TIME SCALE 2400 99999 Sec. PRESSURES, MINIMUM VALUE Chart PRESSURES, MAXIMUM VALUE Chart TEMPERATURES, TIME SCALE 2400 99999 Sec. TEMPERATURES, MINIMUM VALUE Chart TEMPERATURES, MAXIMUM VALUE Chart...

  • Page 36: Pressure Trend' Screen

    'Pressure Trend' screen � Accessible from: Trend Settings. "Back" returns to Trend Settings. � Displays pressure readings for: o 1st Stage Suction o Interstage o Compressor Outlet o Lube Oil 6.4 Terminal Settings These options affect the HMI. Exercise care when modifying "Current Date/Time", as time affects automatic lead/lag and pressure setback operation.

  • Page 37: Service' Screen

    load counter indicates that the compressor is due for maintenance; these timers are normally reset during service by the service technician. A "Motor Service Alert" occurs when the motor run timer indicates that the motor has run for long enough to require service. Additionally, the compressor tracks 'short cycles' .
  • Page 38 � "Short Cycles" displays total number of short cycles since counter was last reset. � "Short Cycle Alert Threshold": number of short cycles that must be detected before alert occurs. A 0 in this field disables the alert. � "Motor Run Hours Remaining To Next Motor Service"...

  • Page 39: Appendix 1: Index Of Alerts And Alarms

    APPENDIX 1: Index of Alerts and Alarms The following messages may be displayed when an Alert or Alarm occurs. An Alert will not shut the compressor down, but requires operator intervention to correct as soon as possible. An Alarm will shut the compressor down; the compressor will not run until the condition has been corrected.
  • Page 40 MESSAGE DISPLAYED CAUSE/NOTES CORRECTIVE ACTION [ALARM 0009] RUNNING 1st stage suction air transducer Check transducer, wiring, and input modules; check IN REVERSE reports pressure rise instead of pressure tubing. Observe motor for correct rotation; if expected drop. rotation is incorrect, lock off power to compressor and exchange two leads.
  • Page 41 MESSAGE DISPLAYED CAUSE/NOTES CORRECTIVE ACTION [ALARM 0201] HIGH 1st Air temperature at first stage Check RTD, wiring, and input modules; check actual STAGE DISCHARGE discharge is over Alarm point. temperature with infrared gun or temperature gauge in TEMP RTD port. Check programmed setpoint (see Settings pages) against recorded user settings.
  • Page 42 MESSAGE DISPLAYED CAUSE/NOTES CORRECTIVE ACTION [ALARM 0304] LOW LUBE Oil level switch reports low oil Verify that inputs are correctly configured. Inspect OIL SUMP LEVEL level. Alarm only active if input switch and wiring. If switch is operating properly, is configured accordingly; see check oil sump for leaks and add oil of the same type section 5.
  • Page 43 MESSAGE DISPLAYED CAUSE/NOTES CORRECTIVE ACTION [ALERT 0703] Faulty transducer; poor Inspect transducer, wiring, input modules. INTERSTAGE connections. TRANSDUCER OPEN [ALERT 0704] CHECK 1st 1st stage suction transducer Check transducer, wiring, and input modules; check STAGE TRANSDUCER fails to report expected pressure tubing.
  • Page 44 MESSAGE DISPLAYED CAUSE/NOTES CORRECTIVE ACTION [ALERT 0805] FAILED TO Less than 10 PSIG at Inspect transducer, capacity control valve, unloading LOAD intercooler while compressor is valve and associated tubing, shuttle valve, and loaded. 10 second delay unloading valve relay. Capacity control valve before alert.
  • Page 45 MESSAGE DISPLAYED CAUSE/NOTES CORRECTIVE ACTION [ALERT 1005] POWER Power lost while running or in If necessary, the compressor can be programmed to LOSS standby. restart automatically after power failure. Consult factory for more information. [ALERT 1006] LOSS OF Applicable to client/server Check communication cables between display and CLIENT/SERVER COMMS lead/lag compressors only.
  • Page 46 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.knw-series.com E-Mail: kobelco@rogers-machinery.com...

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