Kobelco KNW Series Instruction Manual Download

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KIMA00H1 (0204)

MODEL#:

SERIAL#:

INSTRUCTION MANUAL

MODEL:

KNWA00

RECORD OF CHANGE H

KOBELCO is the international trademark found on all products of KOBE STEEL, LTD.

Summary of Contents for KNW Series

Page 1: ...KIMA00H1 0204 MODEL SERIAL INSTRUCTION MANUAL MODEL KNWA00 RECORD OF CHANGE H KOBELCO is the international trademark found on all products of KOBE STEEL LTD ...

Page 2: ...to meet OSHA 29 CFR 1910 or FDA 21 CFR 178 3570 4 Do not allow flammable toxic or corrosive gases to enter the air inlet system or electrical devices 5 Never attempt to work on compressor or remove guards panels covers shields etc while the compressor is in operation 6 Periodically confirm that all safety and shutdown devices are operating properly 7 Do not override any safety or shutdown device 8...

Page 3: ... Lubrication 35 2 4 Location 13 6 7 Filter Maintenance 37 2 5 Cooling Air 13 6 7 1 Dust Filters 37 2 6 Air Discharge Piping 15 6 7 2 Inlet Air Filter 37 2 7 Air Receiver 15 6 7 3 Lube Oil Filter 37 2 8 Wiring 17 6 7 5 Sump Breather 37 3 START UP 19 SERVICE PARTS LIST 38 3 1 Pre Start Up Check 19 3 2 Initial Start Up 19 7 STANDBY and STORED UNITS 39 4 OPERATING INSTRUCTIONS 21 7 1 Stand by Compress...

Page 4: ...KIMA00H1 0204 FIGURE 1 KOBELCO KNW SERIES MODEL A00 AIR COMPRESSOR ...

Page 5: ...ating steel cabinet All compressor mounting points are vibration isolated Flexible connections between the compressor assembly and the cabinet insure that no vibration and its related noise are transmitted to the cabinet The result is a very stable and quiet running assembly The KNW Series compressor features a separately driven oil pump for drive gear timing gear and bearing lubrication The lube ...

Page 6: ... 0204 2 FIGURE 2 COMPRESSED AIR FLOW DIAGRAM FIGURE 3 BACK OF COMPRESSOR COOLING AIR OUTLET AFTERCOOLER AIR INLET COOLING AIR INLET COMPRESSOR AIR INLET COMPRESSED AIR DISCHARGE CONDENSATE DRAIN SUMP OIL DRAIN ...

Page 7: ... cooled aftercooler where it is cooled to within approximately 15 F 8 C of the ambient air temperature An ASME safety valve is downstream of the check valve The compressed air exits the unit into a moisture separator where condensed moisture is removed before the air enters the plant air system The compressed air circuit is monitored with the following discrete devices a Inlet air filter service s...

Page 8: ...KIMA00H1 0204 4 FIGURE 4 COOLING AIR FLOW FIGURE 5 LUBRICATION OIL FLOW DIAGRAM AFTERCOOLER EXHAUST AIR DUCT AIR OUTLET COOLING FAN OIL COOLER INTERCOOLER AIR INLET REAR AFTERCOOLER AIR DUCT ...

Page 9: ...ump discharge relief valve is provided to maintain a constant pressure for component lubrication by relieving excessive pressure back to the suction of the pump Oil leaving the pump is cooled to approximately 28 F 15 C above ambient air temperature in the oil cooler and is then filtered before entering an oil gallery on the rear of the compressor first stage A portion of the lube oil passes throug...

Page 10: ...KIMA00H1 0204 6 FIGURE 6 UNLOADED COMPRESSOR OFF FIGURE 7 LOADED COMPRESSOR RUNNING FIGURE 8 UNLOADED COMPRESSOR RUNNING ...

Page 11: ...ly valve which rotates and is operated by a slider on the capacity control valve shaft Air is now drawn into the compressor stages through the inlet air filter compressed and discharged through the check valve to the air piping system As air is compressed interstage pressure F increases transferring the shuttle valve 3 and pressurizing the operating chamber C keeping the capacity control valve ope...

Page 12: ...KIMA00H1 0204 8 FIGURE 9 COMPRESSOR FRONT VIEW FIGURE 10 COMPRESSOR OPERATOR PANEL COMPRESSOR OPERATOR PANEL PILOT LIGHTS GT TERMINAL PUSHBUTTONS ...

Page 13: ...oaded hours assists in tracking air usage and available excess capacity k Normal condition indication lights on the Compressor Operator Panel 1 Standby 2 Run 3 Loaded A lamp test is available using the GT Terminal which tests all indicating lights on the control panel and the alarm beeper if power is on This test does not affect normal compressor operation 1 7 Alerts A blue ALERT light and an appr...

Page 14: ...PERATOR PANEL FIGURE 12 ALARM DISPLAY PUSHBUTTONS PILOT LIGHTS ALARM LIGHT GT TERMINAL GRAPHIC TERMINAL W TOUCHSCREEN ALARM BEEPER PRESS STAT FOR ALARM DETAILS ALARM MESSAGE PRESS ARROWS TO CHANGE DISPLAY SCREENS PRESS ACK TO SILENCE BEEPER ...

Page 15: ... HOT Air Discharge Prealarm High Discharge Air Temperature Shutdown Indicates a problem with the aftercooler or cooling air flow e Warning HOT Lube OIL Prealarm High Lube Oil Temperature Shutdown Indicates a problem with the lube oil cooling system f Low Lube Oil Pressure Indicates low lube oil level in sump lube oil pump failure fouled cooler or piping clogged oil filter or improper setting of th...

Page 16: ...12 FIGURE 13 FIGURE 14 FIGURE 15 MOUNTING BRACKETS TO OPEN PANELS FOR INSPECTION PULL OUT TOP EDGE THEN LIFT PANEL UP COMPRESSOR SECTION ACCESS PANEL STARTER SECTION ACCESS PANEL SPACER BLOCKS SPREADERS SPACER BLOCKS ...

Page 17: ...rated ozone or any other toxic corrosive or flammable gasses are present WARNING The compressor shall not be located where potentially explosive atmospheres may occur The compressor and controls are not rated for installation in hazardous classified locations Any contaminates in the atmosphere will be compressed along with the air therefore it is important to provide a source of clean intake air A...

Page 18: ...EQUATE VENTILATION FOR COMPRESSOR COOLING AIR OUTLET COOLING AIR INLETS MOISTURE SEPARATOR SERVICE VALVE FLEXIBLE CONNECTOR AIR SYSTEM PIPING COMPRESSOR AIR INLET VENTILATION AIR OUT VENTILATION AIR IN COMPRESSOR ROOM REMOVE PLUG TO VIEW MAIN MOTOR ROTATION ...

Page 19: ... compressors should be at the top of the header The header should be equipped with drop legs for moisture traps 2 7 Air Receiver Figure 18 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 The piping from the compressor discharge should be connected near the bottom of the recei...

Page 20: ...ESSOR INSTALLATION SERVICE VALVE FLEXIBLE CONNECTOR DRAIN VALVE DRAIN VALVE DROP LEG SAFETY VALVE AIR SYSTEM SERVICE VALVE COMPRESSOR SAFETY VALVE PRESSURE GAUGE DRAIN VALVE DRAIN VALVE DRAIN VALVE RECEIVER COALESCING FILTER PARTICULATE FILTER DRYER PRESSURE GAUGE ...

Page 21: ...iring schematic provided with the assembly must be consulted Be sure the motors are wired for the proper voltage and agree with the plant power system The compressor is equipped with a programmable controller to automatically control the starting operating and stopping sequences This controller also monitors critical parameters during operation and provides for protection of the machine in the eve...

Page 22: ...KIMA00H1 0204 18 FIGURE 20 FRONT VIEW OF INTERIOR FIGURE 21 OIL PUMP OIL LEVEL SIGHT GAUGE OIL FILTER OIL FILL SUCTION OIL PRESSURE RELIEF VALVE DISCHARGE ROTATION OIL PUMP ...

Page 23: ...omer furnished compressed air service valve fully located external of the compressor cabinet Start Up b Press the Start button The lube oil pump will start Observe for proper rotation Press the Stop button Check for oil leaks If oil pump rotation is incorrect interchange two of the conductors supplying power to the panel NOTICE Factory motor connections are made to insure correct rotation of all t...

Page 24: ...INTERCOOLER SEPARATOR CAPACITY CONTROL VALVE COOLING FAN MOTOR AFTERCOOLER INTERCOOLER CHECK VALVE OIL COOLER PRE COOLER SAFETY VALVE COMPRESSOR 2ND STAGE COMPRESSOR 1ST STAGE PRE COOLER DISCHARGE SEPARATOR BLEED OFF SILENCER INTERCOOLER DRAIN SOLENOID VALVE INTERCOOLER DRAIN STRAINER AND CHECK VALVE ...

Page 25: ...ressor A 5 second delay is initiated each time the compressor unloads When the stop signal is present the shutdown sequence will begin when this delay is completed 4 2 1 Manual Stop a Press the Stop button The compressor will unload and the LOAD light will turn off The GT Terminal will show UNLOAD on the temperature or pressure page b 5 seconds after unloading the main motor starter will drop out ...

Page 26: ...ompressor Outlet Temperature Approx 15o F 8o C above ambient Approx 15o F 8o C above ambient Lube Oil Temperature 100o F 150o F 38o C 65o C 100o F 150o F 38o C 65o C TABLE 2 TYPICAL OPERATING TEMPERATURES LEGEND PREALARM SHUTDOWN 1st Stage Discharge Temperature 580o F 304o C 590o F 310o C 2nd Stage Suction Temperature 165o F 74o C 175o F 79o C 2nd Stage Discharge Temperature 580o F 304o C 590o F 3...

Page 27: ...ound in the electrical cabinet with the other manuals This will serve as a guide to correct operation Table 1 Table shows typical expected operating pressure ranges The operating pressures will vary based on programmed pressure settings compressor characteristics and ambient conditions Table 2 Table shows typical expected operating temperature ranges The operating temperatures will vary based on t...

Page 28: ...MA00H1 0204 24 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 ...

Page 29: ...Event History list Pressing the center of the screen will show a Utility page which is a menu of control selections including the Lamp test key During normal operation four pages are available for viewing of compressor conditions a When the graphic display is first energized page PG1 will be shown figure 22 This page shows the model number serial number of the compressor and the operating program ...

Page 30: ...FIGURE 27 BACK OF DISPLAY FIGURE 28 ACCESS PANELS FOR ELECTRICAL CONTROLS PLC ACCESS PANEL STARTER ACCESS PANEL DISPLAY POWER CONNECTOR COM PORT RS 422 COM PORT RS 485 COM PORT TO PLC RS 232 MOUNTING CLIPS 6 OPTION SLOT ...

Page 31: ...ations The standard PLC used in the KNW Series compressor is the Allen Bradley MicroLogix 1500 The PLC as supplied is comprised of a base unit a processor CPU and three expansion modules The base unit has 16 discrete inputs that operate at 24 volts DC 12 discrete outputs six that operate at 24 volts DC and six that use relays and a 24VDC power supply that provides power to the CPU The CPU controls...

Page 32: ...SOR COVER PLC X1 OUTPUT MODULE OUTPUT LED s PLC B BASE WITH POWER SUPPLY PLC X2 ANALOG MODULE STATUS LED s PLC X3 ANALOG MODULE PLC END CAP TERMINAL COVERS HINGE RIGHT PLC C PROCESSOR COVER HINGES PLC INPUTS PLC OUTPUTS COM PORT 0 COM PORT 1 RUN REM PROG SWITCH EPROM MODULE BATTERY BATTERY CLIP FOR NEW BATTERY BATTERY CONNECTOR FOR NEW BATTERY LEVER FOR MODULE CONNECTOR MOUNT CLIP SCREW MOUNT CLIP...

Page 33: ... is connected to the GT Terminal 5 2 3 PLC Inputs Figure 29 During normal operation input LED s are on only if the input is receiving a voltage signal from an external control device The PLC program does not control the operation of these indicators These LED s may be on even if the PLC is not operating To troubleshoot suspected input problems measure the DC voltage at the input terminal reference...

Page 34: ...R WILL READ 24VDC IF INPUT OR OUTPUT LED IS OFF VOLTMETER WILL READ 0 V FIGURE 31 STARTER ENCLOSURE RELAYS FUSES FAN STARTER OIL PUMP STARTER RUN RELAY POWER SUPPLY MAIN MOTOR STARTER OVERLOAD RELAY MOTOR STARTER PROTECTORS TERMINALS CURRENT SWITCH GROUND LUG FUSES 0V DC REFERENCE INPUT LED S PLC INPUTS OUTPUT LED S PLC OUTPUTS ...

Page 35: ...tarter is standard Optional reduced voltage starters are shipped loose for separate mounting Several types and all makes of starters are available including a X Line starter Standard b Solid State reduced voltage starter with or without a bypass contactor c Wye Delta reduced voltage starter open or closed transition d Auto Transformer reduced voltage starter e Part Winding reduced voltage starter ...

Page 36: ...OMPRESSOR FIGURE 33 FRONT VIEW INSIDE OF COMPRESSOR INTAKE AIR DUST FILTERS CONDENSATE DRAIN VALVES INLET AIR FILTER LUBRICATION OIL FILTER OIL DRAIN VALVE OIL LEVEL SIGHT GAUGE LOAD CONTROL SOLENOID VALVE READ OPERATING PARAMETERS GT TERMINAL ...

Page 37: ...f necessary to unload compressor g Test pilot lights by pressing Lamp Test key on Utility page refer to figure 26 6 2 Weekly a Inspect interior of the compressor cabinet for abnormal conditions including excessive dust leaks and loose parts b Drain condensate in intercooler and aftercooler by opening manual drain valves WARNING Lines are pressurized 6 3 a Review event list for alerts and unreporte...

Page 38: ...FT FIGURE 35 END VIEW OF COMPRESSOR INTERIOR AFTERCOOLER INTERCOOLER CHECK VALVE OIL COOLER SAFETY VALVE COMPRESSOR 2ND STAGE COMPRESSOR 1ST STAGE PRE COOLER DISCHARGE SEPARATOR BLEED OFF SILENCER INTERCOOLER DRAIN SOLENOID VALVE INTERCOOLER DRAIN STRAINER AND CHECK VALVE END PANEL SCREWS 1 INSIDE 1 ON BACK OIL SUMP ...

Page 39: ...ire periodic testing of the Safety Valve by a certified testing agency It is the responsibility of the compressor owner to have the valve properly tested at the mandated intervals j Motor lubrication should be at the motor manufacturer s recommended intervals k Test low oil pressure shutdown l Test all temperature shutdowns 6 5 Two Year a Dismantle and inspect capacity control valve assembly Repla...

Page 40: ...204 36 FIGURE 36 FRONT VIEW INTERIOR OF COMPRESSOR SECTION INLET AIR FILTER INLET AIR FILTER MOUNTING PLATE OIL FILL PORT OIL LEVEL SIGHT GAUGE OIL FILTER OIL PRESSURE RELIEF VALVE OIL PUMP GEAR HOUSING OIL SUMP ...

Page 41: ...e the compressor is operating The compressor must be off and power disconnected before servicing can be performed For the safety of the maintenance personnel lock out and tag out procedures must be strictly adhered to 6 7 1 Cabinet 1 Remove access cover by loosening thumb screw and lifting cover out Dust Filters 2 Dust may be removed from filters with a stiff brush or a vacuum cleaner Filters may ...

Page 42: ... 2 YR K3168 DUST FILTER SHORT 3 2 YR K3169 DUST FILTER LONG 3 2 YR T3170 CHECK VALVE 2nd STAGE DISCHARGE 1 2 YR T3344 DISCHARGE SEPARATOR W AUTO DRAIN 1 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 an...

Page 43: ...hen open the manual condensate drains Operate loaded for 5 minutes while discharging to atmosphere a Stop the unit and add 1 to 2 quarts vapor phase inhibitor oil to gear case Run the compressor unloaded 2 minutes b Install pipe plug or cap on air outlet pipe d Install moisture barrier plastic sheet on inlet air panels cooling air outlet grill and bleed off silencer e Install silica gel desiccant ...

Page 44: ...nts 2 Maximum 104 F 40 C F ambient 3 Replace 2nd stage 5 High 2nd stage suction air temperature 1 Dirty dust filters 2 Dirty intercooler core 1 Clean dust filters see section 6 7 2 Clean intercooler see section 6 4 6 High 2nd stage discharge air temperature 1 High second stage discharge pressure 2 Dirty intercooler core 3 2nd stage element not in order 1 Lower operating pressure to normal 2 Clean ...

Page 45: ...lter element 3 Repair or replace relief valve 4 Locate and repair leak 5 Replace pump 6 Clean cooler see section 6 5 m 16 Oil leakage from air vents on 1st or 2nd stage 1 Gearcase sump breather element plugged 2 Oil level too high 1 Replace breather element 2 Lower oil level to center of sight gauge 17 Oil leakage from vent on motor adapter 1 Gearcase sump breather element plugged 2 Shaft seal wor...

Page 46: ...ion 2 Faulty PLC 1 Tighten wiring connections 2 Measure voltage on input terminal If present and LED is not lit then replace PLC 6 Analog OK light off 1 Analog input fault 2 Analog module low voltage 3 Analog input voltage too high 1 Check for loose wires 2 Check for voltage on inputs 3 Check power supply voltage 4 Check for shorted RTD signal conditioner or faulty pressure transducer 7 Temperatur...

Page 47: ...KIMA00H1 0204 43 Appendix A Daily Operating Record ...

Page 48: ...KIMA00H1 0204 44 DATE SERVICE PERFORMED SERVICED BY ____________________ ____________________ ____________________ MAIL TO Attention Field Engineering 14650 SW 72nd Ave Portland OR 97224 7943 ...

Page 49: ...KIMA00H1 0204 45 Appendix B Unit Dimensions Minimum Working Clearances TOP VIEW FRONT VIEW ...

Page 50: ...KIMA00H1 0204 46 Appendix B cont Unit Dimensions and Field Connections SIDE VIEW REAR VIEW ...

Page 51: ...KIMA00H1 0204 47 Appendix B cont Unit Dimensions Field Connections and Mounting ...

Page 52: ...KIMA00H1 0204 48 ...

Page 53: ...KIMA00H1 0204 Instruction Manual Revisions Revision Date Description 1 11 Feb 04 Page 13 add hazardous location warning Page 33 add Inspect sump breather to monthly mainetnance ...

Page 54: ...1 0204 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 ...

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