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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:
KL100B
KOBELCO is the international trademark found on all products of KOBE STEEL, LTD.
H:\10\Eng\DOCS\KNW\DescrOps\KL100_199\KL100B.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: KL100B KOBELCO is the international trademark found on all products of KOBE STEEL, LTD. H:\10\Eng\DOCS\KNW\DescrOps\KL100_199\KL100B.doc...
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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 4: Table Of Contents
Description of Operation PROGRAM NUMBER: KL100B MODEL NUMBER: SERIAL NUMBER: Revisions Revision Author Date Description KL100A 09-Mar-2015 Updates to 2015 standard; Micrologix 1400 processor. KL100B 28-May-2015 Internal program mods for use with PSIG-calibrated transmitters. 1. Overview ........................5 2. Compressor Control ....................5 2.1. -
Page 5: Overview
6.6. Daily Report ......................40 APPENDIX 1: Index of Alerts and Alarms ..............42 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 6: Pilot Devices
2.1. Pilot Devices Pilot devices are located adjacent to the HMI terminal for operational control and indication. These include: STANDBY Green pilot light. Indicates the compressor is not running, but may automatically start at any time. Start will occur when system pressure drops to a programmed pressure. -
Page 7: Hmi Terminal Overview
2.3. HMI Terminal Overview The HMI terminal shows requested information on selectable screens. The terminal may also be used to modify settings affecting compressor operation, and to change the configuration of the compressor. Blue touchzones with white lettering are used for navigation; pressing a blue touchzone will bring up the screen identified on the touchzone, unless otherwise specified. -
Page 8: 'Temperatures' Screen
'Temperatures' screen • Displays compressor temperature readings, standby status, lead/lag status, and local/remote status. • May display “PLC NOT IN RUN”. This message indicates that the PLC is not in RUN mode. • Top status line shows current operation of compressor. •... -
Page 9: Menu Screen
'Pressures' screen, VFD machine • Screen is as shown when compressor is configured for VFD control. See section 3.3 for more information on VFD setup. • Accessible from: Title, Temperatures, Nav. • Press any displayed pressure to bring up calibration screen for that sensor. •... -
Page 10: Transducer Calibration
• "Virtual Pres. Sw": see section 5.6. • "Standby Control": see section 3.5. • "Lead/Lag & Remote Mode": see section 5.1, 5.2. • "Input/Output": see section 5.4. • "Starter Configuration": see section 5.5. • "Time Load & Standby Mode": see section 3.5, 3.6. -
Page 11: Normal Compressor Operation
'Transducer Calibration' screen • PE2 shown. Similar for other transducers. • "Raw Input" displays current unscaled reading of selected transducer. • "Calibrated Pressure" displays current pressure value at selected transducer. • "Automatic Elevation Calibration" enables or disables auto elevation calibration for selected transducer. •... -
Page 12: Loading Operation
4. The cooling fan starter will energize to start the fan motor; cooling fan animation will display. When Up-To-Speed (UTS)/Transition Check is enabled the Fan will start 1.5 seconds after the UTS/Transition signal from the starter is active. If UTS/ Transition Check is disabled the Fan will start 1.5 seconds after Lube Oil Pressure is achieved. - Page 13 'Pressure Setpoints' screen • "Compressor Unload" and "Load" determine load and unload points in standard operation. Designation changes to "Lead" when Lead/Lag is enabled. • "Lag Unload" and "Load" determine load and unload points when operating in Lag mode. See section 5.3.
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Page 14: Vfd Control
'System Pressure Setpoints' screen • Shown for VFD-controlled compressors. Loading and unloading is controlled by system pressure transducer, instead of compressor outlet pressure. • "VFD Speed" brings up VFD Pressure Control screen; see section 3.3. • "Low Alert" determines pressure at •... -
Page 15: Shutdown Sequence
3.4. 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. The Shutdown sequence is as follows: 1. The load solenoid de-energizes, unloading the compressor. After 5 seconds, the main motor run relay de-energizes, stopping the compressor. -
Page 16: Standby
3.5. Standby Standby mode allows the compressor to shut down automatically when it has not been loaded for a period of time, in order to conserve energy. While the compressor is in Standby, the green "Standby" light on the control panel will be lit. The compressor will restart automatically from Standby if it detects a drop in pressure below the "Load"... -
Page 17: Timed Load Cycle
'Standby Control' screen • "Into Standby": If pressure is decreasing at a rate that that would cause the compressor to restart within this time, the compressor will not be allowed to enter Standby. • "From Standby": If pressure is increasing at a rate that would cause the compressor to restart within this time, and compressor is in Standby, it will restart immediately. -
Page 18: Auto Restart
compressor is running loaded, system pressure is above the Load setpoint, and pressure is increasing, a timer is started. After the "Timed Load Cycle" delay has passed, the compressor will unload even if system pressure is below the Unload pressure setpoint. 'Timed Load Cycle and Standby Mode' screen •... -
Page 20: Fan Vfd Control
Default "Other Delay" settings: FACT FACT FACT FACO FACT USER SETTI SETPOINT SETTIN SETTI SETTI SETTI SETTI UNITS NG - NG - NG - NG - NG - 0/A0 1/A1 2/A2 LEAD AUTO RESTART Sec. MINIMUM LIMIT Sec. MAXIMUM LIMIT Sec. -
Page 21: Alerts And Alarms
'Fan VFD Control' screen • Accessible from: Temperatures, Pressures. Press 'Fan' graphic to bring up Fan VFD Control settings, if enabled. • All temperatures are in °F. • Fan speed is determined according to both "2nd Stage Suction" and "Compressor Outlet" temperatures; whichever speed is higher is used. -
Page 22: 'Alarm History' Screen
When an Alert or Alarm has occurred, the HMI will display the Alarms screen. the Alert or Alarm light as appropriate will turn on, and the beeper will sound. The beeper may be silenced by pressing the “ACK” key. This will not reset the alarm. While an alarm is active, most screens will display a red 'Alarm Active' message. - Page 23 'Alarm and Other Delays' screen • "Main 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.
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Page 24: Temperature Alarms/Alerts
FACT FACT FACT FACO FACT USER SETTI SETPOINT SETTIN SETTI SETTI SETTI SETTI UNITS NG - NG - NG - NG - NG - 0/A0 1/A1 2/A2 MINIMUM LIMIT Sec. MAXIMUM LIMIT Sec. Temperature Alarms/Alerts Temperature alerts and alarms occur when the compressor senses dangerously high temperature. - Page 25 FACTO FACTO FACTO FACOT FACTO USER SETPOINT SETTI SETTIN UNITS SETTIN SETTIN SETTIN SETTIN G - 00/ G - 0/A0 G - 1/A1 G - 2/A2 G - 3 °F (°C) MAXIMUM LIMIT (310) (240) (216) (216) (210) 1st STAGE DISCHARGE °F (°C) ALARM (310)
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Page 26: Special-Purpose Compressor Control Options
FACTO FACTO FACTO FACOT FACTO USER SETPOINT SETTI SETTIN UNITS SETTIN SETTIN SETTIN SETTIN G - 00/ G - 0/A0 G - 1/A1 G - 2/A2 G - 3 °F (°C) MINIMUM LIMIT 32 (0) 32 (0) 32 (0) 32 (0) 32 (0) 180 (82) °F (°C) MAXIMUM LIMIT... - Page 27 • EXTERNAL: Lead/Lag status is determined by an external signal; requires configured input (see below). A dry contact signal from the customer control system is required for each compressor. • ETHERNET SYNC CLIENT, SERVER: Compressor is connected to other compressor by Ethernet, as shown on electrical schematic. Compressor alternates between Lead and Lag automatically, at intervals selected on Configuration screen.
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Page 28: Local/Remote Operation
• In "Hours" mode, compressor will switch from Lead to Lag or vice versa after operating for the specified number of hours. • Screen appears as shown when "Automatic" or "Client" lead/lag mode and "Hours" auto rotate mode are selected. 'I/O Sync Settings' screen •... - Page 29 In Remote modes that include remote starting, the local Start button is used to "arm" the compressor to remote control; when the compressor is placed in Remote mode, the Standby light will flash to indicate confirmation of remote control. When the Start button is pressed, the Standby LED will remain solid to indicate that the compressor may start at any time when the Remote Run contact closes.
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Page 30: Setback Mode
• START-STOP AND LOAD: In this mode starting and stopping are controlled by two remote contacts, as in Start-Stop Inputs mode; loading and unloading is controlled by a third maintained contact. Additionally, on VFD-controlled compressors, the VFD can be set to change speed according to a remote signal, rather than according to the system pressure sensor. - Page 31 'Pressure Setback Settings' screen • "Setback Mode" enables Setback mode and selects type of Setback operation; see above. • "Unload Pressure" determines pressure at which the compressor will unload when operating in Setback. Pressure units are selectable. • "Load Pressure" determines pressure at which the compressor will load when operating in Setback mode.
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Page 32: Input/Output Configuration
5.4. Input/Output Configuration The compressor PLC includes a number of input and output signals which can be configured to meet the needs of the application, such as external alarm contacts and specialized status contacts. In some cases selecting a Lead/Lag or Local/Remote setting will automatically set input or output configuration options. -
Page 33: Outputs
• Z-Purge Pressure Switch: Input for a pressure switch from a Z-Purge pressurization device, used in hazardous conditions to reduce the risk of sparking. • Vibration: Input for a vibration switch; triggers an alarm when excess vibration at the air end is detected. •... -
Page 34: 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 35: Informational Settings
'Virtual Pressure Switch' screen • "Unload" and "Load" determine system pressure readings at which associated output will de-energize and energize. • "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 "Lead"... - Page 36 'Temperature Trend' screen • "Legend" brings up list of chart colors. • "Trend Config" brings up configuration popup. • Displays temperature readings for: o Compressor Inlet o 1st Stage Discharge o 2nd Stage Suction o 2nd Stage Discharge o Compressor Outlet •...
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Page 37: Panel Options
Trend Config • "Time" determines range of time over which values are shown. • "Max Scale" and "Min Scale" determine largest and smallest values shown on chart. • "Clear Data" erases all recorded data for the specified chart. • Accessible from each trend screen. •... -
Page 38: Service Information
'Panel Options' screen • "Alarm List Return": If an alarm is active and 'Esc' has been used to return to previous screen, length of time before 'Alarm' screen is automatically brought up again. • "Screen Rotation": Seconds between automatic scrolling between Pressure and Temperature screens. -
Page 39: 'Meters' Screen
'Meters' screen • Run Hours" displays total time the compressor has been run. • "Loaded Hours" displays total time the compressor has been loaded. • "Load Cycles" displays total number of load/unload cycles since last service. • "Short Cycles" displays total number of short cycles since counter was last reset. -
Page 40: "Support" Screen
"Support" screen • Shows contact information for local service facility. • "Diagnostic" brings up diagnostic screens; see section 6.1. • "Daily Report" brings up Daily Report screen; see section 6.6. • Accessible from: Menu. 6.6. Daily Report In order to detect possible problems in advance, operating conditions of the machine should be recorded daily and sent to Rogers Machinery regularly for review. - Page 41 When compressor services are performed, the services should be recorded on the 'Service Performed' screen. These records are part of the Daily Report, and will be added to the report when it is generated. 'Service Performed' screen • Allows recording of compressor services.
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Page 42: 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 43 M E S S A G E CAUSE/NOTES CORRECTIVE ACTION DISPLAYED 0010 PE1 UNDIRECTED Pressure sensors detect Inspect compressor motor starter. Check to (Alarm) RUN DETECTED compressor is operating when it ensure PLC is correctly configured for your should be stopped. starter type.
- Page 44 M E S S A G E CAUSE/NOTES CORRECTIVE ACTION DISPLAYED 0201 TE2 HIGH 1st STAGE Air temperature at first stage Check RTD, wiring, and input modules; (Alarm) DISCHARGE TEMP discharge is over Alarm point. check actual temperature with infrared gun or temperature gauge in RTD port.
- Page 45 M E S S A G E CAUSE/NOTES CORRECTIVE ACTION DISPLAYED 0302 INCOMING POWER Phase monitor input reports Verify that inputs are correctly configured. (Alarm) OUT-OF-PHASE problem with incoming power Inspect phase monitor, check power phase. Alarm only active if input is connections.
- Page 46 M E S S A G E CAUSE/NOTES CORRECTIVE ACTION DISPLAYED TE5 HIGH Air temperature at compressor Check RTD, wiring, and input modules; (Alert) COMPRESSOR discharge is nearing Alarm point. check actual temperature with infrared gun OUTLET TEMP or temperature gauge in RTD port. Check programmed setpoint (see Settings pages) against recorded user settings.
- Page 47 M E S S A G E CAUSE/NOTES CORRECTIVE ACTION DISPLAYED 0712 PE5 OUT OF RANGE - Faulty transducer; poor Inspect transducer, wiring, input modules. (Alert) TRANSDUCER OVER connections. or CHANNEL <2mA 0713 PE5 OUT OF RANGE - Faulty transducer; poor Inspect transducer, wiring, input modules.
- Page 48 M E S S A G E CAUSE/NOTES CORRECTIVE ACTION DISPLAYED 0810 LOW COOLING WATER Cooling water flow switch tripped, Verify that inputs are correctly configured. (Alert) FLOW indicating low flow. Alert only active Check switch operation and wiring. If if input is configured accordingly;...
- Page 49 M E S S A G E CAUSE/NOTES CORRECTIVE ACTION DISPLAYED 1009 VFD REMOTE SPEED Applicable to VFD compressors Check wiring, signal source, and PLC input (Alert) SIGNAL LOSS with remote speed signal enabled. module. Remote speed signal has failed. 1010 PE1 ELEVATION Calibration data from transmitter is...
- Page 50 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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