MODEL#: SERIAL#:

INSTRUCTION MANUAL

MODEL:
KNWA00
RECORD OF CHANGE H

KOBELCO is the international trademark found on all products of KOBE STEEL, LTD.
KIMA00H1 (0204)

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 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.

2. Electricity and compressed air are dangerous. When performing

maintenance or service work, make absolutely sure the electrical supply is
disconnected and locked out. The discharge air lines service valve
(customer furnished) must be closed and the compressor relieved of all
internal pressure. DO NOT rely on the discharge air line check valve.

3. Compressed air from this unit must not be used for breathing or food
processing without adequate filtering and monitoring 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. Make certain all associated pipe and equipment beyond this

compressor is compatible with maximum pressures and temperatures to
be encountered during normal and adverse operation. Do not use plastic
pipe in the compressed air system.

9. Keep doors closed during normal operation. The noise level inside
cabinet exceeds 90 decibels (dbA) and the operating temperature of some
components is sufficient to burn the skin.

10. Never assume it is safe to work on the compressor because it is not

operating. Many installations have automatic start/stop controls, and the
compressor may start at any time.

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 TABLE OF CONTENTS
1. GENERAL DESCRIPTION................. 1
1.1 Compressor................................ 1
1.2 Compressed Air Flow................. 3
1.3 Cooling Air Flow......................... 5
1.4 Oil Flow....................................... 5
1.5 Capacity Control System............ 7
1.5.1 Unloaded, Off...................7
1.5.2 Loaded, Running............. 7
1.5.3 Unloaded, Running.......... 7
1.6 Monitoring and Limiting
Devices....................................... 7
1.7 Alerts........................................... 9
1.8 Shutdowns.................................. 9
2. INSTALLATION...................................13
2.1 Inspection....................................13
2.2 Handling...................................... 13
2.3 Foundation.................................. 13
2.4 Location...................................... 13
2.5 Cooling Air.................................. 13
2.6 Air Discharge Piping................... 15
2.7 Air Receiver................................ 15
2.8 Wiring.......................................... 17
3. START UP............................................ 19
3.1 Pre-Start Up Check....................... 19
3.2 Initial Start Up................................ 19
4. OPERATING INSTRUCTIONS............ 21
4.1 Starting the Compressor............... 21
4.2 Stopping the Compressor............. 21
4.2.1 Manual Stop.......................21
4.2.2 Automatic Stop.................. 23
4.3 Normal Operating Conditions........23
5. ELECTRICAL CONTROLS................. 25
5.1 Compressor Operator Panel
5.1.1 GT Terminal
Page Selection.................25
5.1.2 Display Maintenance....... 27
5.1.3 GT Terminal Options....... 27
KIMA00H1 (0204)
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5.2 Programmable Logic
Controller.................................... 27
5.2.1 CPU................................. 27
5.2.2 PLC Status LED’s............ 29
5.2.3 PLC Inputs....................... 29
5.2.4 PLC Outputs.................... 29
5.2.5 PLC Analog Inputs........... 31
5.2.6 Expansion Module
Replacement....................31
5.3 Motor Starter............................... 31
6. MAINTENANCE.................................. 33
6.1 Daily............................................ 33
6.2 Weekly........................................ 33
6.3 Monthly........................................33
6.4 Yearly.......................................... 33
6.5 Two Year.....................................35
6.6 Lubrication.................................. 35
6.7 Filter Maintenance...................... 37
6.7.1 Dust Filters.......................37
6.7.2 Inlet Air Filter.................... 37
6.7.3 Lube Oil Filter...................37
6.7.5 Sump Breather.................37
SERVICE PARTS LIST.......................38
7. STANDBY and STORED UNITS........ 39
7.1 Stand-by Compressors............... 39
7.2 Short Term Storage.................... 39
7.3 Long Term Storage.................... 39
8. PROBLEM SOLVING......................... 40
Problem-Cause & Remedy
Compressor................................ 40
PLC ............................................ 42
APPENDIX
A. Daily Operating Record ..................43
B. Unit Dimensions ............................. 45
 FIGURE 1 - KOBELCO KNW SERIES
MODEL A00 AIR COMPRESSOR

KIMA00H1 (0204)

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 1. GENERAL DESCRIPTION

1.1 The Kobelco KNW Series air compressor is a heavy duty, two-stage,
Compressor 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. The dual vent seal design insures that no oil or
its vapor can contaminate air that is being compressed.
The two-stage design provides higher output pressures at a lower
operating temperature than would be available from a single-stage
design. Both compressor stages are mounted on a heavy duty cast
iron gear case for permanent alignment. The stages are driven
through precision machined gears, selected for optimum operating
speed to maximize efficiency and reduce rotor thrust.
Timing gears are used to separate the rotors and to assist in reducing
thrust on the rotors and the rotor bearings, thus extending bearing life.
The Kobelco KNW Series Oil-Free Air Compressor is a complete
operating system. A flange-mounted permanently aligned drive motor,
intercooler, aftercooler, capacity control valve assembly, lube oil
system, compressor controls, and related accessories, are all
mounted inside a sound attenuating 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 oil pump
starts first, then, after a brief delay, the compressor drive motor starts.
Starting of the drive motor is delayed to allow pressurized lubrication
of the bearings and gears during acceleration of the compressor. The
pump is also timed to stop after the compressor. Oil pressure is
maintained while the compressor coasts to a stop. Maximum
component life is assured by thorough lubrication of moving
components.
Another feature of the KNW Series is the direct operating capacity
control valve and bleed-off system. This unique valve design provides
for extended service intervals and eliminates the need for a bleed-off
cooler.
The KNW Series Compressor Operator Panel is a state-of-the-art
control system combining robust industrial controls with leading edge
operator interface and programmable logic controller technology.
Exclusive to KNW Series compressors is the GT Terminal, a versatile
graphic touchscreen display with clear graphics and user-friendly
operation, showing all necessary compressor information in an easy to
understand format.

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 FIGURE 2 - COMPRESSED AIR FLOW DIAGRAM

COOLING
AIR OUTLET

COMPRESSOR
AIR INLET
AFTERCOOLER
AIR INLET

COOLING
AIR INLET

COMPRESSED
AIR DISCHARGE

SUMP CONDENSATE
OIL DRAIN DRAIN

FIGURE 3 - BACK OF COMPRESSOR

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 1.2 Air to be compressed undergoes two stages of filtration before being
Compressed compressed. The air enters the cabinet through an opening that is
Air Flow equipped with a dust filter. The air then passes through the air inlet
(Figure 2) silencer, a duct that is lined with a sound absorbing material. Then
the air is drawn through a high efficiency air filter. Filtered air flows
through a flex connector, into the capacity control valve, and then into
the inlet of the compressor first stage.

The compressor first stage compresses the filtered air to

approximately 37 PSIG. The compressed air is discharged into the air-
cooled intercooler where it is cooled to approximately 115°F (46°C).
The cooled, compressed air then passes through the moisture
separator to remove any condensed moisture from the air stream
before entering the compressor second stage.

The compressor second stage compresses interstage air to the

system operating pressure as controlled by the pressure setting. The
hot compressed air then passes through the system check valve and
air-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 switch

b. Discharge high air pressure switch
c. Discharge air safety relief valve

The Programmable Logic Controller, PLC, (ref. Section 5.2) monitors

the compressed air circuit for the following:

a. First stage discharge air temperature

b. Interstage air pressure
c. Second stage suction air temperature
d. Second stage discharge air temperature
e. Compressor discharge air pressure
f. Compressor discharge air temperature

The air temperatures are displayed on the GT Terminal. The PLC

continuously monitors for excessive heat, providing a warning if
temperatures approach the recommended maximum and a shutdown
if they reach the limit. The interstage pressure is monitored to provide
load/unload indication and to confirm capacity control valve operation.
The pressure at the compressor discharge is monitored to provide
load and unload pressure control and a high pressure alarm.

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 AFTERCOOLER EXHAUST AIR
AIR DUCT OUTLET

AFTERCOOLER
AIR DUCT
COOLING
FAN
AIR INLET
(REAR)

OIL
COOLER

INTERCOOLER

FIGURE 4 - COOLING AIR FLOW

FIGURE 5 - LUBRICATION OIL FLOW DIAGRAM

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 1.3 A separate electric motor driven fan draws ambient air into the cabinet
Cooling through screens in the back panel. The screens are equipped with
Air Flow dust filters. The air takes one of two flow paths. The first passes
(Figure 4) directly through to the aftercooler and exhausts through the top of the
enclosure. In the second path, air enters near the motor, cools the
compressor motor and passes into the compressor section of the
cabinet. The air then goes through both the intercooler and oil cooler
which are mounted side by side. The fan draws all the air through the
exhaust chamber and out the top of the enclosure.

When the compressor unloads, hot air is discharged through the

bleed-off silencer, pulled through the fan and exhausted. A
temperature switch shuts down the compressor if the air temperature
inside the cabinet exceeds 150°F (65°C).
1.4 Oil for bearing and gear lubrication is stored in a sump, in the lower
Lubrication section of the main gear case/compressor housing. A sight glass,
Oil Flow located on the side of the oil sump, is used to monitor the oil level.
(Figure 5) Lube oil is drawn from the sump by a separate motor driven oil pump.
An oil pump 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 through a tube to an oil gallery on the
rear of the compressor second stage. Lube oil flows from the oil
galleries to the front of each stage to lubricate and cool the front
bearings and drive gears. Lube oil passes through internal passages
from the galleries to lubricate the rear bearings and the timing gears.
All lube oil drains back into the sump.
The lube oil circuit is monitored with the following discrete devices:
a. Sump oil level indicator.
b. Lube oil filter differential switch.
The Programmable Logic Controller, PLC, (ref. Section 5.2) monitors
the lubrication circuit for the following:
a. Lube oil pressure
b. Lube oil temperature
The oil temperature is displayed on the GT Terminal. The PLC
monitors the lube oil temperature. A warning is provided as the
temperature approaches the recommended maximum operating
temperature, and a shutdown if it reaches the limit. The lube oil
pressure is monitored for alarm shutdown if the oil pressure is too low
while the compressor is operating.

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 FIGURE 6 - UNLOADED, COMPRESSOR OFF

FIGURE 7 - LOADED, COMPRESSOR RUNNING

FIGURE 8 - UNLOADED, COMPRESSOR RUNNING

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 1.5 The capacity control system consists of an inlet capacity control valve
Capacity with an integral bleed-off valve, a 3-way solenoid valve, and a shuttle
Control valve. Opening (loaded) and closing (unloaded) of the inlet valve is
System controlled by the solenoid valve which is controlled by the PLC (ref.
Section 5.2). The PLC monitors compressor operating conditions and
system air pressure to determine when loaded or unloaded operation
is required.
1.5.1 When the compressor is off, the spring in the capacity control valve
Unloaded, holds the inlet valve (1) closed and the bleed-off valve (2) open. The
Off solenoid valve (4) is deenergized. When the compressor is started
(Figure 6) pressures at the 1st stage inlet (B) and interstage (F) are both
negative, keeping the capacity control valve in the unloaded position.
1.5.2 The compressor remains unloaded until the main drive motor reaches
Loaded, full speed, and lube oil pressure reaches 10 psig. After the
Running compressor reaches full speed and oil pressure is established, the
(Figure 7) solenoid valve (4) is energized, the capacity control valve operating
chamber (C) is disconnected from 1st stage inlet vacuum and is
vented to atmosphere (A) through the shuttle valve (3). Vacuum on
the spring side of the operating chamber piston helps pull the inlet
valve (1) open and closes the bleed-off valve (2). The inlet valve (1) is
a butterfly 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 open.
1.5.3 System pressure is monitored by a pressure sensor on the discharge
Unloaded, air piping. When the discharge pressure reaches the upper limit of the
Running desired operating range, the solenoid valve is de-energized, de-
(Figure 8) pressurizing the operating chamber (C). The spring closes the inlet
valve (1) and opens the bleed-off valve (2).
When unloaded a very slight amount of air is drawn through the inlet
valve (1) to cool the compressor during unloaded operation. 2nd stage
discharge air (G) is vented (D) to atmosphere (E) out of the bleed-off
silencer. The check valve prevents system air pressure from
pressurizing the compressor.
1.6 The compressor assembly is equipped with the following monitoring
Monitoring devices:
and Limiting a. Interstage air pressure transmitter. Monitors air pressure at the
Devices intercooler outlet. The pressure is shown on the GT Terminal
(Figures 9-11) (figure 10). Indicates condition of the intercooler and the
compressor stages.
b. Outlet air pressure transmitter. Monitors air pressure at the
aftercooler outlet connection to plant air system. Pressure is
shown on the GT Terminal (figure 10). Indicates condition of the
aftercooler and the compressor stages.

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 COMPRESSOR OPERATOR PANEL

FIGURE 9 - COMPRESSOR FRONT VIEW

PILOT LIGHTS GT TERMINAL

PUSHBUTTONS

FIGURE 10 - COMPRESSOR OPERATOR PANEL

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 1.6 (cont.) c. Lube oil pressure transmitter. Monitors lube oil pressure at the
Monitoring last bearing oil nozzle. Pressure is shown on the GT Terminal
and Limiting (figure 10). Indicates condition of the lube oil system, filter, and
Devices the setting of the relief valve.
d. First stage discharge air temperature sensor. Temperature is
shown on GT Terminal (figure 10). Indicates condition of the
compressor first stage.
e. Second stage inlet air temperature sensor. Temperature is
shown on the GT Terminal (figure 10). Indicates condition of the
intercooler.
f. Second stage discharge air temperature sensor. Temperature is
shown on the GT Terminal (figure 10). Indicates condition of the
compressor second stage.
g. Lube oil temperature sensor. Temperature is shown on the GT
Terminal (figure 10). Indicates condition of the oil cooler.
h. Aftercooler discharge air temperature sensor. This is the
temperature of the air delivered to the air out service connection,
and is shown on the GT Terminal (figure 10). Indicates condition
of the aftercooler.
i. Total running time is shown on the GT Terminal (figure 10).
j. Total loaded time is shown on the GT Terminal (figure 10). An
accumulated count of loaded 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 A blue ALERT light, and an appropriate message on the GT Terminal,
Alerts indicates that service is required or that a temperature prealarm exists
(temperature is approaching the shutdown point). In addition, an
audible alarm sounds when an alert occurs. The alarm may be
silenced without resetting the indication.
The GT Terminal indicates the following conditions as an ALERT:
a. Service inlet air filter. Indicates that the inlet air filter or the dust
filters are dirty, filter pressure drop exceeds 25 “H2O
b. Service oil filter. Indicates that the lube oil filter is dirty, filter
pressure drop exceeds 15 PSID.
c. Compressor service required. Indicates that 2 years have
elapsed since start-up, or the capacity control valve has cycled
1,000,000 times. Service must be scheduled.
d. Temperature prealarm (applies to all temperatures monitored).
Indicates that a temperature is approaching the shutdown point.
Refer to the appropriate paragraph of section 1.8 for details of
each monitored temperature. See page 22 for setpoint table.

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 GT-TERMINAL
PILOT LIGHTS GRAPHIC TERMINAL W/ TOUCHSCREEN

PUSHBUTTONS PRESS ARROWS TO CHANGE DISPLAY SCREENS

FIGURE 11 - COMPRESSOR OPERATOR PANEL

PRESS “ACK” TO
ALARM MESSAGE SILENCE BEEPER

ALARM LIGHT ALARM BEEPER PRESS “STAT” FOR ALARM DETAILS

FIGURE 12 - ALARM DISPLAY

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 1.8 Shutdown conditions are indicated by a red ALARM light on the
Shutdowns control panel, and an appropriate message on the graphic display. In
addition, an audible alarm sounds when an alarm occurs. The alarm
beeper may be silenced by pressing ACK/Bell Cancel on the alarm
page. The Bell Cancel does not reset the alarm. A "DRY" relay
contact is provided as a combined signal for remote indication if any
alarm occurs. A table of setpoints is located on page 22.
The GT Terminal indicates the following shutdown conditions:
a. High 1st Discharge Air Temperature (Shutdown)
Warning: HOT 1st Discharge (Prealarm)
Indicates a problem with the first compressor stage.
b. Warning: HOT 2nd Suction (Prealarm)
High 2nd Suction Air Temperature (Shutdown)
Indicates a problem with the intercooler or cooling air flow.
c. Warning: HOT 2nd Discharge (Prealarm)
High 2nd Discharge Air Temperature (Shutdown)
Indicates a problem with the second compressor stage or a
problem with the intercooler.
d. Warning: 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 the relief
valve.
g. Lube Oil Pump Motor Overload
Indicates continued over-current operation of the oil pump motor,
problem with lube oil pump or motor, or high oil pressure.
h. Cooling Fan Motor Overload
Indicates continued over-current operation of the cabinet cooling
fan motor, problem with fan or motor. Also check for obstructed
air flow into or out of the cabinet.
i. Compressor Drive Motor Overload
Indicates continued over-current operation of the drive motor for
the compressor, excessive discharge pressure or a problem with
either compressor stage.
j. High Cabinet Temperature
Indicates an obstruction of the cooling air flow.
k. High Discharge Air Pressure
Indicates a problem with the capacity control system.
l. Main Starter Failure
Indicates a problem with the main starter or controls.

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 COMPRESSOR SECTION TO OPEN PANELS STARTER SECTION
ACCESS PANEL FOR INSPECTION, ACCESS PANEL
PULL OUT TOP EDGE
THEN LIFT PANEL UP

MOUNTING BRACKETS
FIGURE 13

SPACER BLOCKS
SPREADERS

FIGURE 14
SPACER BLOCKS

FIGURE 15

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 2. INSTALLATION

2.1 The unit should be inspected for damage immediately upon receipt
Inspection from the carrier and any claims should be made to the delivery carrier
(Figure 13) immediately.
2.2 The compressor unit is equipped with forklift slots for ease in handling.
Handling Spacer blocks should be placed between the compressor and forklift
(Figures mast to insure the cabinet will not be damaged during handling.
14 & 15) When handling the unit with an overhead crane, the lifting straps or
chains should pass through the forklift slots. Spacers and spreader
bars should be utilized to avoid damage to the enclosure.
2.3 The compressor and motor assembly are vibration isolated from the
Foundation housing and base plate, additional isolation is not required. The
assembly should be mounted on a level, horizontal floor. Holes are
provided on each end of the compressor for installing bolt down
brackets.
2.4 The unit should be installed indoors in a clean, well ventilated area,
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.
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.
An external source of clean inlet air to the compressor may need to be
provided.
The machine must be protected against freezing and excessive
ambient temperatures.
For ease of panel removal and maintenance provide ample clearance
around the compressor. A minimum of four feet is required in front of
the compressor. At least three feet is recommended for each end and
for the back.
2.5 The compressor should be located where sufficient ventilation is
Cooling available to cool the compressor. The cooling air inlet and discharge
Air must not be blocked. The warm air exiting the cooling air outlet must
(Figure 17) be prevented from being drawn into the cooling air inlet. Ventilation
may need to be provided if the room in which the compressor is
installed exceeds 104°F (40°C) during compressor operation.
Air ducts may be connected to air inlets or outlets if desired. However
ducts must be sized to permit no more than 1” H2O restriction at full
flow.

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 COOLING AIR COOLING AIR COMPRESSOR
OUTLET INLETS AIR INLET

AIR SYSTEM
PIPING

MOISTURE SERVICE VALVE FLEXIBLE

REMOVE PLUG TO VIEW
SEPARATOR CONNECTOR
MAIN MOTOR ROTATION

FIGURE 16 - REAR VIEW

VENTILATION
AIR OUT
COMPRESSOR
ROOM

VENTILATION
AIR IN

FIGURE 17 - INSURE ADEQUATE VENTILATION FOR COMPRESSOR

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 2.6 DO NOT reduce the pipe size of the connections on the unit.
Air The compressor is equipped with an internal check valve. Compressor
Discharge discharge pressure is controlled by a system pressure sensing line
Piping located at the aftercooler outlet.
(Figure 16)

)
NOTICE: DO NOT install an additional check valve between the
compressor and the air distribution piping. Doing so will prevent
correct compressor operation and may damage the compressor.
An external moisture separator is provided and must be mounted on
the air discharge of the compressor. A flexible connection is required
between the outlet of the separator and the air system piping.
The discharge piping must be properly supported to prevent strain on
the compressor piping or cabinet.
For safe servicing of the compressor a manual isolating valve must be
installed in the discharge piping at a convenient location close to the
unit.
It is possible that additional condensation can occur in the
downstream piping. Vertical pipe runs, and low points in the piping
system, should be equipped with drop legs for moisture traps.
If multiple compressors are piped into a common discharge header,
the connections from the compressors should be at the top of the
header. The header should be equipped with drop legs for moisture
traps.
2.7 A properly sized air receiver should be located as close to the
Air discharge of the compressor as possible, and before any air treatment
Receiver accessories, such as filters and dryers.
(Figure 18) The piping from the compressor discharge should be connected near
the bottom of the receiver and piping to the plant system should be
connected near the top of the receiver. The receiver must have
provisions for draining accumulated condensate.
WARNING: The receiver must be equipped with an approved (ASME)
safety valve. The compressor owner is responsible for the proper
sizing, installation, and maintenance, and for periodic inspection and
testing, of the safety valve.
Generally the receiver should be sized for a minimum of 2 gallons of
storage for each cubic foot of compressor air delivery. The size of the
air receiver will directly affect the load cycle time of the compressor.
Increasing the capacity of the air system will result in fewer load
cycles, reducing wear on the compressor components.
NOTICE: It is the compressor owners responsibility to:

)
1) Insure that the receiver, and the receiver installation, comply with
the applicable local, state, and national codes.
2) To obtain the proper licenses for the receiver.
3) Arrange periodic inspections required to maintain those licenses.

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 PRESSURE GAUGE

SAFETY VALVE
AIR SYSTEM

FLEXIBLE
CONNECTOR

SERVICE VALVE DRAIN VALVE DROP LEG DRAIN VALVE

FIGURE 18 - AIR RECEIVER

PRESSURE GAUGE
SAFETY VALVE RECEIVER COALESCING PARTICULATE
FILTER FILTER
COMPRESSOR
DRYER

SERVICE VALVE DRAIN VALVE DRAIN VALVE

DRAIN VALVE

FIGURE 19 - TYPICAL COMPRESSOR INSTALLATION

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 2.8 It is the compressor owners responsibility to insure a safe installation
Wiring 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.
The compressor unit is available with many motor, starter, and
sequence control options. Therefore, the wiring 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 event of a problem.
Carefully read Section 5, Electrical Controls, for a description of the
standard controls. For custom control schemes a separate
“Description of Operation” is provided with the electrical schematic.

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 OIL FILTER

OIL PUMP

OIL FILL

OIL LEVEL SIGHT GAUGE

FIGURE 20 - FRONT VIEW OF INTERIOR

ROTATION OIL PRESSURE

RELIEF VALVE

DISCHARGE
SUCTION

FIGURE 21 - OIL PUMP

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 3. START-UP
3.1 Prior to starting, installation must be complete. Refer to section 2 for
Pre Start-Up installation requirements.
Check a. Electric power must be off during initial checks.
b. Remove all loose items left in and around unit during installation.
Clean inside of cabinet if necessary.
c. Check oil level in gear case. The oil level sight gage is located at
the bottom of the gear case and can be checked by removing the
front left access panel. (figure 20). The oil level must be
maintained between the Min. and Max. lines. DO NOT overfill.
The oil supplied with the unit comes from 76 Products Company.
See paragraph 6.6 for designation. If necessary to add oil,
replenish with the same lubricant or replace the oil completely
with a suitable replacement. DO NOT MIX LUBRICANTS.
d. Check electrical wiring to all motors and transformers for proper
voltage connection.
e. Turn on electric power to unit. Confirm GT Terminal operation,
showing proper model and serial numbers.
f. Press the Lamp Test key. Confirm that all pilot lights operate and
that the audible alarm sounds.

) NOTICE: It is mandatory to have a factory trained representative

present for initial start-up.
3.2 a. Open customer furnished compressed air service valve fully
Initial (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 three motors if incoming power is connected properly.
WARNING: Conductors supplying power to the starter panel are
HIGH VOLTAGE. Power connections and motor connections should
only be made by qualified personnel, with the supply power shut off;
properly disconnected, locked out, and tagged out.
c. Press the Start button. When the oil pump starts the cooling fan
motor will also start. Observe fan for proper rotation.
d. Three seconds after the oil pump starts the main motor will start.
Stop unit by pressing the Stop button, while observing the main
motor for correct rotation. Rotation may be viewed through an
access port on the end of the machine (figure 16). If it is
necessary to reverse main motor rotation, be sure to turn off
main power supply. Note: change only the main motor rotation.
e. Open system valve(s) as required to allow full load operation at
maximum discharge pressure.
f. Press the Start button. Operate the compressor at least 1/2 hour
at maximum conditions after temperatures have stabilized.

KIMA00H1 (0204) 19

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 COOLING FAN
MOTOR

AIR FILTER
HOUSING

INTERCOOLER
SEPARATOR

CAPACITY CONTROL
VALVE

FIGURE 22 - FRONT VIEW OF INTERIOR

CHECK VALVE INTERCOOLER

AFTERCOOLER
OIL COOLER

PRE-COOLER
PRE-COOLER

SAFETY VALVE

COMPRESSOR COMPRESSOR
2ND STAGE 1ST STAGE

DISCHARGE BLEED-OFF
SEPARATOR SILENCER

INTERCOOLER INTERCOOLER
DRAIN DRAIN
SOLENOID VALVE STRAINER AND
CHECK VALVE

FIGURE 23 - END VIEW OF INTERIOR

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 4. OPERATING INSTRUCTIONS
4.1 a. Open system air valve (external of the compressor cabinet).
Starting the b. Turn on power to the unit. Confirm GT Terminal operation. Check
Compressor that all temperatures read normal. Indicators at the top of the
temperature and pressure pages will show running or stopped
messages for motor operations.
c. Press the Start button. The lube oil pump will start. Check oil
pressure. The RUN light will turn on. The GT Terminal will show
“OIL PUMP RUNNING”.
d. The cooling fan will start when the oil pump starts. The GT
Terminal will show “FAN MOTOR RUNNING”.
e. The compressor motor will start 3 seconds after the cooling fan
starts. The GT Terminal will show “COMPRESSOR RUNNING”.
f. The compressor will load 5 seconds after oil pressure reaches 10
psig. The LOAD light will turn on. The GT Terminal will show
“LOADED” on the temperature or pressure page. Note: If manual
unload is selected the compressor will not load.
g. The compressor will unload when system pressure reaches the
unload pressure setting. The LOAD light will turn off.

4.2 A 5 second delay is initiated each time the compressor unloads. When
Stopping the the stop signal is present the shutdown sequence will begin when this
Compressor delay is completed.

4.2.1 a. Press the Stop button. The compressor will unload and the LOAD
Manual light will turn off. The GT Terminal will show “UNLOAD” on the
Stop temperature or pressure page.
b. 5 seconds after unloading the main motor starter will drop out. If
the compressor had run unloaded for at least 5 seconds the main
motor starter will drop out when the Stop button is pressed. The
GT Terminal will show “COMPRESSOR STOPPED”. The compressor
will coast to a stop.
c. The lube oil pump continues to operate for 5 seconds after the
compressor starter drops out, then turns off. The GT Terminal
will show “OIL PUMP STOPPED”.
c. The fan continues to operate for 20 seconds after the
compressor starter drops out, then turns off. The RUN light will
turn off. The GT Terminal will show “FAN MOTOR STOPPED.
d. Note that the STANDBY pilot light is not on. This indicates that the
compressor has been stopped manually and must be manually
restarted.
WARNING: When compressor service is being performed the air
service valve must be closed and the power disconnected. Safety
procedures must be strictly followed, with lock-out and tag-out
procedures required.

KIMA00H1 (0204) 21

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 NORMAL NORMAL
LEGEND LOADED READING UNLOADED READING
1st Stage Discharge 30 ~ 45 PSIG 2.1 5" HG VAC ~ 5 PSIG -
Pressure ~ 3.2 kg/cm2 0.2 ~ 0.3 kg/cm2
2nd Stage 50 ~ 125 PSIG 3.5 50 ~ 125 PSIG
Discharge Pressure ~ 8.8 kg/cm2 3.5 ~ 8.8 kg/cm2
Lube Oil 10 ~ 20 PSIG 0.7 10 ~ 20 PSIG
Pressure ~ 1.4 kg/cm2 0.7 ~ 1.4 kg/cm2

TABLE 1 : TYPICAL OPERATING PRESSURES

NORMAL LOADED NORMAL UNLOADED

LEGEND READING READING
1st Stage Discharge 375 F. ~ 550oF.
o
(190oC Less than 400oF.
Temperature ~ 288oC.) (Less than 204oC.)
2nd Stage Suction Approx. 25 F. (14oC.)
o
above 15oF. (8oC.)
Temperature ambient above ambient
2nd Stage 375 F. ~ 525oF.
o
Less than 400oF.
Discharge Temperature (190oC. ~ 275oC.) (Less than 204oC.)
Compressor Outlet Approx. 15oF. (8oC.) above Approx. 15oF. (8oC.)
Temperature ambient above ambient
o o
Lube Oil 100 F. ~ 150 F. (38 C. 100 F. ~ 150oF.
o o
(38oC.
Temperature ~ 65oC.) o
~ 65 C.)

TABLE 2 : TYPICAL OPERATING TEMPERATURES

LEGEND PREALARM SHUTDOWN

1st Stage Discharge
580oF (304oC) 590oF (310oC)
Temperature
2nd Stage Suction
165oF (74oC) 175oF (79oC)
Temperature
2nd Stage
580oF (304oC) 590oF (310oC)
Discharge Temperature
Compressor Outlet
125oF (52oC) 135oF (57oC)
Temperature
Lube Oil
150oF (66oC) 160oF (71oC)
Temperature
High Cabinet 150oF (66oC)
Temperature Switch (Not Adjustable)
Lube Oil 10 PSIG (0.7 kg/cm2)
Pressure Decreasing
Inlet Air Filter 25 “H2O Vacuum
Service Switch (Factory set)
Lube Oil Filter 15 PSID
Service Switch (Factory set)
High Compressor Outlet 5 PSI above Maximum 60 Second delay after Alert
Pressure Switch Compressor Operating Pressure

TABLE 3 : ALERT AND ALARM SETPOINTS

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 4.2.2 a. The compressor will automatically shutdown if it runs unloaded,
Automatic continuously, for 10 minutes. This interval may be programmed
Stop for a longer unloaded run time if desired. Shutdown will follow the
normal shutdown sequence (ref. 4.2.1. a,b,c).
WARNING: The compressor is automatically controlled and may start
at any time without warning.
b. The STANDBY pilot light will be on to indicate that the compressor
is in standby, ready to restart automatically at any time.
c. The compressor will automatically restart when the system
pressure reaches the programmed load pressure set point.

4.3 A log of the operating conditions recorded during the factory test can
Normal be found in the electrical cabinet with the other manuals. This will
Operating serve as a guide to correct operation.
Conditions

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 temperature control valve
settings, compressor characteristics, and ambient conditions.
Normally operating temperatures will stabilize after one hour of
continuous compressor operation. In extreme cases, depending on
site conditions, several hours may be needed.

Table 3 Table shows the shutdown temperatures and pressures. Also shown
are the temperature prealarm warning temperatures. The pre-alarm
and shutdown temperatures shown are maximums and may be set
lower. Refer to section 6 for information on set point adjustment.

KIMA00H1 (0204) 23

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 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

24 KIMA00H1 (0204)

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 5. ELECTRICAL CONTROLS
5.1 Pilot lights, viewable from a distance, are provided for quick look
Compressor indication of operating conditions. An audible alarm is provided for
Operator alarm annunciation. Pushbuttons are provided for specific control
Panel with functions, allowing continued compressor operation in the event that
GT Terminal the GT Terminal is off-line.
(Figure 24) The GT Terminal is a touchscreen LCD monitor, showing operating
conditions, pressures, and temperatures. Messages to direct the
operator for service, pre-alarms, and shutdowns will be shown when
necessary. Required settings for pressure control, temperature
alarms, and control time delays are viewable and may be modified
using the touchscreen. The GT Terminal will automatically ‘dim’ to a
sleep condition if inactive, and awakens on any touch contact.
5.1.1 Touch zones, or “keys” are used for page selection. Pressing the right
GT Terminal arrow [Æ] key will show the next page, as detailed under the arrow.
Page Pressing the left arrow [Å] key will show the previous page, as
Selection detailed under the arrow.
(Figures Unmarked touch zones are present on the first four pages. Pressing
24-26) the upper right corner of the screen will show an 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 numbers.
NOTICE: The serial number, model number, and current program
) number must be provided when contacting the factory.
b. Page PG2 shows the operating temperatures of the compressor that
are monitored by the PLC. The temperatures may be displayed in
either °F or °C, selected by pressing the °F (°C) symbol.
c. Page PG3 shows the operating pressures of the compressor that
are monitored by the PLC. The pressures may be displayed in
either PSIG or Kg/cm2, selected by pressing the PSIG (Kg/cm2)
graphic block on the receiver picture.
d. Page PG4 shows elapsed times for compressor running hours and
for compressor loaded hours, and the load cycle count for service
scheduling.
Any of these pages may be assigned as the default page, which will
automatically show, after a delay, if no touch screen operations are
performed.
Detailed operating instructions are available in a separate document,
referenced by program version, i.e. “COP_HJ1B” is the operating
instructions for the Compressor Operator Panel / GT terminal using
program version HJ1B.
KIMA00H1 (0204) 25

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 MOUNTING CLIPS (6)

OPTION SLOT

DISPLAY POWER COM PORT COM PORT COM PORT

CONNECTOR (RS-422) TO PLC (RS-485)
(RS-232)

FIGURE 27 - BACK OF DISPLAY

PLC ACCESS PANEL

STARTER ACCESS PANEL

FIGURE 28 - ACCESS PANELS FOR ELECTRICAL CONTROLS

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 5.1.2 The GT Terminal uses an LCD (liquid crystal display) with fluorescent
Display backlighting. LCD’s are sensitive to heat and to direct sunlight.
Maintenance Maximum operating temperature is 120°F (50°C). The compressor is
to be located indoors and care should be taken that direct sunlight
does not shine on the GT Terminal.
The touchscreen is a polyester film and is sensitive to abrasion. Do
not wear gloves when operating and do not press on the screen with
hard or sharp objects. A replaceable screen overlay is available to
extend the service life of the touchscreen.
Use only a clean soft cloth and mild detergent to clean the screen.
If the GT Terminal requires replacement use an “allen” (hex) wrench to
remove the six mounting clips. When loosened, the top and bottom
clips slide out of grooves on the display frame.
5.1.3 An option slot is provided for an Ethernet communication card. The
GT Terminal Ethernet card allows for remote monitoring of compressor data that is
Option shown on the graphic display.
To install the Ethernet card, turn off power to the GT Terminal, remove
the slot cover on the rear left end of the display (figure 25), and slide
the option card into the adapter slot.

5.2 A programmable logic controller (PLC) is used to monitor and control

Programmable compressor operations. The standard PLC used in the KNW Series
Logic compressor is the Allen-Bradley MicroLogix 1500.
Controller The PLC, as supplied, is comprised of a base unit, a processor (CPU),
(Figure 29) 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 PLC operations and
communications. One expansion module is provided for eight relay
outputs. Two expansion modules are provided, each with four analog,
4-20 mA inputs.
5.2.1 The CPU houses the PLC processor and program memory. The CPU
CPU slides into a slot on the front of the PLC base. A RUN-REM-PROG
(Figure 29) switch is behind the left cover, this switch must be in the run position
for the compressor to operate.
A memory module (EPROM) is located behind a cover on the front of
the CPU. The EPROM provides permanent PLC program storage.
The program can be updated by installing a new EPROM. To replace
the EPROM module shut off power to the PLC, remove the CPU front
cover, squeeze the sides of the EPROM (arrows shown on figure
29B) and pull out the bottom of the module. To install new EPROM
insert the top of the module first, then rotate the module down until the
connector engages and the module snaps into place.
A battery is located behind the CPU cover. The battery protects
accumulated count values during power outages. The battery is not
replaceable, however a new battery can be installed in the provided
battery clip, see figure 29B.

KIMA00H1 (0204) 27

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 PULL OUT AT TOP PLC-C PLC-X1 PLC-X2
TO REMOVE PROCESSOR OUTPUT MODULE ANALOG MODULE
PROCESSOR COVER
PLC INPUT OUTPUT STATUS PLC-X3
TERMINAL COVER LED’s LED’s LED’s ANALOG MODULE
HINGES DOWN

COVER
HINGES

PLC-B TERMINAL COVER PLC OUTPUT TERMINAL COVERS PLC

BASE WITH HINGES UP LED’s HINGE RIGHT END CAP
POWER SUPPLY
PLC CPU
STATUS LED’s

FIGURE 29A - PLC

BATTERY CLIP LEVER FOR
FOR NEW BATTERY MODULE MOUNT CLIP
CONNECTOR
RUN-REM-PROG PLC INPUTS SCREW
SWITCH

COM PORT 1

BATTERY

PLC OUTPUTS COM PORT 0 SCREW

BATTERY CONNECTOR EPROM MOUNT CLIP

FOR NEW BATTERY MODULE

FIGURE 29B - PLC WITH COVERS REMOVED

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 5.2.2 The PLC is provided with LED's to assist in monitoring operational
PLC Status status of the processor, PLC inputs and outputs, and expansion
LED’s modules.
(Figure 29) 8 LED’s are provided for monitoring CPU status:
a. POWER LED is on when control power is on to the PLC base
power supply. If LED is off check external power supply and fuses.
b. RUN LED is on when the PLC is operating normally and the
installed program is running. If LED is off, the PLC is inoperable.
Check that the RUN-REM-PROG switch is in the RUN position.
c. FAULT LED is on when a program operation or hardware problem
occurs in the PLC. Cycle power to the control panel to “reboot” the
PLC. If this fails to clear the problem, contact the factory.
d. FORCE LED is used during program development and should be
off. Contact the factory if this LED is on.
e. BAT LO LED is on when PLC battery has discharged. New battery
needs to be installed.
f. COMM 0 LED flashing indicates activity on communication port 0.
g. DCOMM LED on indicates PLC default to communication port 0.
h. COMM 1 LED flashing indicates activity on communication port 1,
which is connected to the GT Terminal.
5.2.3 During normal operation input LED's are on only if the input is
PLC receiving a voltage signal from an external control device. The PLC
Inputs program does not control the operation of these indicators. These
(Figure 29) 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 referenced to 0V at the power supply (figure 30). If
+24 volts DC is measured the LED for that input should be on, if the
LED is off then the input is defective. If no power is measured at an
input the LED should be off, if the LED is on then the input is
defective.

5.2.4 During normal operation output LED’s will be on when the PLC
PLC operating program directs an output to energize. This is not an
Outputs indication that the output is operating. All LED’s, and their indicated
(Figure 29) outputs, will be off if the PLC is not operating.
To troubleshoot suspected output problems measure the DC voltage
at the output terminal referenced to 0V at the power supply (figure 30).
If the LED for an output is on, then +24 volts DC should be present, if
no power is measured then the output is defective. If +24 volts is
measured when the LED is off, then the output is defective.
This applies to outputs on the base unit and the expansion module.

KIMA00H1 (0204) 29

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 INPUT LED’S

PLC INPUTS

0V DC
REFERENCE

PLC OUTPUTS
OUTPUT LED’S

FIGURE 30 - CONFIRMING INPUTS AND OUTPUTS ON PLC

USING LED’s AND VOLTMETER
IF INPUT OR OUTPUT LED IS ON, VOLTMETER WILL READ +24VDC
IF INPUT OR OUTPUT LED IS OFF, VOLTMETER WILL READ 0 V

TERMINALS RELAYS

FUSES

MOTOR STARTER
POWER SUPPLY PROTECTORS

FUSES
GROUND LUG

RUN RELAY MAIN MOTOR

STARTER

OVERLOAD RELAY

FAN STARTER OIL PUMP STARTER

CURRENT SWITCH

FIGURE 31 - STARTER ENCLOSURE

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 5.2.5 The analog input modules have one LED for status indication. The
PLC LED is labeled “OK” and is used to verify that there is no problem with
Analog the analog module. If the OK LED is not on check the power supplies
Inputs and module connections. Cycle power to the PLC to “reboot”. If the OK
(Figure 29) light is still off, replace the module.
5.2.6 To replace an expansion module turn off power to the PLC. Remove
Expansion the wiring terminal by removing the terminal mounting screws (figure
Module 29B). Push the module connector lever fully to the right for the module
Replacement being removed, as well as the lever on the module to the immediate
right of the module being removed. This disconnects internal electrical
connectors. Slide the bottom mount clip down and the top mount clip
up. Pull the module straight out.

Installation is in reverse order of the removal.

5.3 Kobelco KNW Series compressors are available with or without a
Motor main motor starter. A mounted X-Line starter is standard. Optional
Starters reduced voltage starters are shipped loose for separate mounting.
(Figure 31) 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.
Note: May require special motor.

Accessories are available with the main motor starter, including circuit
breaker, fusible disconnect, non-fusible disconnect, power-factor
correction capacitors, phase monitor, or KW monitor. Consult the
factory and/or starter nameplate data for service and parts
information.

X-line starters are provided for starting the lube oil pump and the
cooling fan. The starters have integral Motor/Starter protectors (MSP)
which provide both short-circuit and overload protection. The
adjustable settings are to be set at the nameplate amperage of the
motor. The MSP’s have rotary operators with positions for off, on, and
tripped, and a manual test button. If the MSP trips turn the rotary
operator to the off position to reset, then turn back to on, before
attempting to reset the control panel alarm.

KIMA00H1 (0204) 31

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 INTAKE AIR
DUST FILTERS

CONDENSATE
DRAIN VALVES
OIL DRAIN
VALVE

FIGURE 32 - REAR VIEW OF COMPRESSOR

READ OPERATING PARAMETERS

GT-TERMINAL

INLET AIR
FILTER

LUBRICATION
LOAD CONTROL
OIL FILTER
SOLENOID VALVE

OIL LEVEL SIGHT

GAUGE

FIGURE 33 - FRONT VIEW, INSIDE OF COMPRESSOR

32 KIMA00H1 (0204)

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 6. MAINTENANCE
6.1 NOTE: DO NOT STORE SPARE PARTS OR TOOLS IN CABINET.
Daily A list of service part numbers and replacement intervals can be found
on page 36.
a. Check and record all operating parameters on the daily operating
record furnished with the assembly. (See Appendix A)
b. Adjust or service as required or indicated.
c. Inspect air intake dust filters, clean or replace if required.
d. Check for proper operation of the intercooler automatic drain
(approx. 1/2 second each minute). A solenoid valve drains
accumulated condensate from the separator, with the open time
and operating interval controlled by the PLC. The intercooler
automatic drain does not operate when the compressor is
unloaded. A strainer is provided in-line with the solenoid valve,
service as necessary.
e. Check operation of the discharge separator automatic drain. This
is a float drain that discharges accumulated condensate from the
separator. If the separator is full of water, service the drain valve.
f. Check operation of capacity control valve by observing
load/unload cycle. Press manual unload if necessary to unload
compressor.
g. Test pilot lights by pressing Lamp Test key on Utility page (refer
to figure 26).
6.2 a. Inspect interior of the compressor cabinet for abnormal
Weekly 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 unreported shutdowns.
Monthly b. Inspect air inlet filter, replace as required.
c. Inspect sump breather element. Replace if saturated and oil is
present outside of the breather housing.
d. Mail daily operating record card to the factory, keeping copy for
your file. The daily operating record cards are regularly reviewed
by trained service personnel to look for unusual trends and to
assist in predictive maintenance. This lifetime service is included
in the purchase price of the compressor assembly and will aid in
providing long, economical and trouble free operation of the
compressor.
6.4 a. Drain sump and fill with new oil. Oil should be drained while hot.
Yearly See section 6.6 for lubricant information.
b. Replace oil sump breather element.
c. Replace oil filter.
d. Inspect discharge check valve for wear; repair or replace as
required.
e. Clean Y-strainer on intercooler condensate drain piping.

KIMA00H1 (0204) 33

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 END PANEL SCREWS
1 INSIDE
1 ON BACK

FIGURE 34 - TO REMOVE END PANEL FOR SERVICING

REMOVE 2 SCREWS INDICATED, PULL TOP OF PANEL OUT THEN LIFT

CHECK VALVE INTERCOOLER

AFTERCOOLER OIL COOLER

OIL SUMP PRE-COOLER

SAFETY VALVE
COMPRESSOR
1ST STAGE
COMPRESSOR
2ND STAGE

BLEED-OFF
DISCHARGE SILENCER
SEPARATOR

INTERCOOLER INTERCOOLER
DRAIN DRAIN
SOLENOID VALVE STRAINER AND
CHECK VALVE

FIGURE 35 - END VIEW OF COMPRESSOR INTERIOR

34 KIMA00H1 (0204)

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 6.4 (cont.) f. Dismantle and clean discharge separator automatic drain.
Yearly g. 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. Contact factory for more information.
h. Check daily operating records for oil cooler efficiency. Clean
cooler core exterior if necessary. If the inside of the oil cooler
needs cleaning, disconnect the cooler from the oil plumbing. Oil
passages, when slightly fouled, are to be cleaned with ethylene
perchlorate or an equivalent solvent. Cleaning time is between
10 and 30 minutes. After cleaning, blow out the solvent with
compressed air.
WARNING: Take care when using solvent so that it is not allowed to
contaminate the surrounding areas. Consult the solvent supplier's
Material Safety Data Sheet for application and disposal requirements.
i. Inspect safety valve for abnormal wear or damage.
WARNING: Federal, State, and Local regulations require 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 a. Dismantle and inspect capacity control valve assembly. Replace

Two Year diaphragm and Teflon slider. Inspect sleeve bearings and shaft
for wear.
b. Replace load control solenoid valve.
c. Replace dust filters.
d. Replace 2nd stage discharge check valve.
e. Replace discharge moisture separator.
f. Reset unloading system service counter to zero.
6.6 a. The correct lubricating oil is a good quality turbine oil containing
Lubrication 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 @ 100°F (38°C). If necessary
to add oil and this brand is not available, drain completely and
refill with a suitable replacement. DO NOT MIX LUBRICANTS
WARNING: Do not add or drain lube oil while 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 followed.

KIMA00H1 (0204) 35

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 INLET AIR FILTER

INLET AIR FILTER

MOUNTING PLATE

GEAR HOUSING
OIL SUMP

OIL FILL PORT

OIL FILTER OIL LEVEL

SIGHT GAUGE
OIL PRESSURE
RELIEF VALVE

OIL PUMP

FIGURE 36 - FRONT VIEW INTERIOR OF COMPRESSOR SECTION

36 KIMA00H1 (0204)

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 6.6 (cont.) b. The system lube oil capacity is:
Lubrication
MODEL KNW: A00-A A00-B A00-C A00-D A00-E
CAPACITY: 12 QUARTS 15 QUARTS
TABLE 4: LUBE OIL CAPACITY
c. The oil level viewed on the sight gauge will vary when the
compressor is operating. Fill the sump to the upper limit of the
gauge, then run the compressor. Stop the unit and add oil as
necessary to maintain the oil level near the center of the sight
gauge.
d. The oil pressure is controlled by the relief valve located on the
discharge of the oil pump. The adjusting cap is held in position with
a lock nut. The correct operating pressure is 15 PSIG (minimum
10 PSIG - maximum 20 PSIG). Adjustments, if necessary, should
be made while the unit is at normal operating temperature.
Rotating the adjusting cap clockwise increases the oil pressure
and counterclockwise decreases the oil pressure.

6.7 Do not service filters while the compressor is operating. The

Filters 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 1. Remove access cover by loosening thumb screw and lifting cover
Cabinet out.
Dust 2. Dust may be removed from filters with a stiff brush or a vacuum
Filters cleaner. Filters may be washed with a mild detergent if necessary.
Allow to dry thoroughly before installing.

6.7.2 1. Inspect the air filter element every month, Replace if dirty, if
Inlet Air service alert is present, or once per year.
Filter 2. To access air filter, remove left front access panel and remove the
four thumb screws from the filter mounting plate.
3. Install a new filter gasket with the filter.

6.7.3 1. Remove and replace element when indicated by service alert or

Lube Oil once per year.
Filter 2. Install a new filter gasket with the filter.

6.7.4 1. Inspect element monthly, replace if element is saturated and oil is

Sump present outside of the breather housing.
Breather 2. Replace element once per year.

KIMA00H1 (0204) 37

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 SERVICE PART
INTERVAL NUMBER DESCRIPTION QTY
1 YR H3149 INLET AIR FILTER W/ SEAL WASHER 1
1 YR F3333 LUBE OIL FILTER ELEMENT 1
1 YR F3444-ELEM SUMP BREATHER ELEMENT 1
2 YR K4574 CAPACITY CONTROL VALVE REBUILD KIT 1
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 and serviced as conditions require.

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 7. STAND-BY AND STORED UNITS

7.1 Back-up or stand-by compressors must be run weekly to assure that

Stand-By no condensation is allowed to accumulate internally. When operated,
Compressors a stand-by unit should run long enough to reach full operating
temperature. (30 minutes).

7.2 For storage intervals of one month or less, if power is available, open
Short Term the manual drains on the bottom of automatic drain traps and run the
Storage unit for 15 minutes.

7.3 Before stopping, bring the unit to normal operating temperatures then
Long Term open the manual condensate drains. Operate loaded for 5 minutes
Storage 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 bag in the intercooler separator.
f. Place silica gel desiccant bags inside enclosure.
g. Place warning label on front of unit stating:
"CAUTION: Remove silica gel packs and moisture barriers,
change oil, and replace drain plugs before restarting unit."
h. Replace silica gel packs every 2 months.
i. Turn main motor shaft, by hand, at least two full revolutions every
month.

KIMA00H1 (0204) 39

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 8. PROBLEM SOLVING
TABLE 6 - COMPRESSOR PROBLEM SOLVING
CONDITION POSSIBLE CAUSE SUGGESTED REMEDY
1. Unit will not start. 1. Low supply voltage. 1. Check fuses or circuit breaker.
2. Programmable controller problem 2. Check for proper voltage and
3. Power failure. connections.
4. Compressor in alarm. 3. Reset alarm condition.
2. Compressor shuts down on 1. Low Voltage. 1. Check for proper voltage and
motor overload. 2. 1st or 2nd stage not in order. connections.
3. Operating pressure too high. 2. Check all operating parameters for
4. 2nd stage suction temp too high. abnormal conditions.
5. High intercooler pressure. 3. Lower pressure within limits of
6. Low intercooler pressure. motor.
4. 2nd stage not in order.
5. 1st stage not in order.
3. Compressor shuts down on 1. High ambient temp. 1. Maximum 104° F (40° C)
high cabinet temperature. 2. Dirty dust filters. 2. Clean dust filters (see section 6.7).
3. Dirty coolers. 3. Clean coolers (see section 6.4).
4. Obstructed cooling air flow. 4. Check for and remove any foreign
material blocking air ducts.
4. High 1st stage discharge air 1. Inlet filter plugged. 1. Change filter elements.
temperature. 2. High ambient temp. 2. Maximum 104°F (40°C) F ambient
3. 2nd stage not in order. 3. Replace 2nd stage
5. High 2nd stage suction air 1. Dirty dust filters. 1. Clean dust filters (see section 6.7).
temperature. 2. Dirty intercooler core. 2. Clean intercooler (see section 6.4).
6. High 2nd stage discharge air 1. High second stage discharge 1. Lower operating pressure to
temperature. pressure. normal.
2. Dirty intercooler core. 2. Clean intercooler (see section 6.4)
3. 2nd stage element not in order
7. High compressor discharge 1. Dirty dust filters. 1. Clean dust filters (see section 6.7).
air temp. 2. Dirty aftercooler core. 2. Clean aftercooler (see section 6.4).
8. High oil temperature 1. Oil level too high. 1. Lower oil level to center of sight
2. Dirty dust filters. gauge.
3. Dirty oil cooler core. 2. Clean dust filters
4. Gearcase sump breather element 3. Clean oil cooler (see section 6.4).
plugged. 3. Replace element
9. Failure to load. 1. Solenoid unloading valve defective. 1. Repair or replace unloading valve.
2. Capacity Control Valve diaphragm 2. Replace diaphragm.
ruptured. 4. Repair Capacity Control Valve.
3. Capacity Control Valve bushings 5. Check transmitter connections and
defective. wiring.
4. Trouble with pressure transmitters. 6. Press load button.
5. Manual unload selected. 7. Check output to unloading valve for
6. PLC Control not sending signal to voltage.
unloading valve. 8. Replace unloading valve relay.
7. Unloading valve relay defective.

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 TABLE 6 (cont.) - COMPRESSOR PROBLEM SOLVING
10. Abnormal noise from 1. Coupling problems. 1. Inspect and repair coupling.
compressor element. 2. Gear trouble 2. Overhaul.
3. Bearing trouble. 3. Replace bearings.
11. Abnormal noise from oil pump. 1. Oil level too low. 1. Raise oil level to maximum.
2. Defective pump. 2. Replace pump.
3. Coupling problems. 3. Replace coupling.
12. Abnormal noise from capacity 1. Bushings bad in Capacity Control 1. Rebuild valve.
control valve when loading. valve. 2. Repair or replace.
2. Solenoid valve trouble. 3. Check tubing and correct faults.
3. Control tubing leaks.
13. Safety valve lifts in normal 1. Pressure settings too high. 1. Set load and unload settings to
operation. 2. Defective pressure transducer. proper range for motor horsepower.
3. Service valve to plant closed. 2. Replace transducer.
3. Open valve.
14. Oil level rises without adding 1. Condensation in oil. 1. Change oil.
oil.
15. Oil pressure drops during 1. Oil level too low. 1. Add oil to maximum level.
operation. 2. Oil filter plugged. 2. Replace filter element.
3. Relief valve defective. 3. Repair or replace relief valve.
4. Oil leak. 4. Locate and repair leak.
5. Oil pump defective. 5. Replace pump.
6. Oil cooler dirty. 6. Clean cooler (see section 6.5.m).
16. Oil leakage from air vents on 1. Gearcase sump breather element 1. Replace breather element.
1st or 2nd stage. plugged. 2. Lower oil level to center of sight
2. Oil level too high. gauge.
17. Oil leakage from vent on motor 1. Gearcase sump breather element 1. Replace breather element.
adapter. plugged. 2. Replace shaft seal.
2. Shaft seal worn.
18. Unit shuts down for no 1. Unloading timer timed out 1. Unit designed to shut down if
apparent reason. 2. Intermittent power outage. unloaded for 10 min. Consult
factory.
2. Compressor must be manually
restarted after power is restored.
19. Low capacity. 1. Defective bleed-off valve disc. 1. Replace disc.
2. Defective diaphragm in capacity 2. Replace diaphragm.
control valve. 3. Clean or replace element.
3. Dirty air inlet filter.
20. Compressor back spins on 1. Defective discharge check valve. 1. Repair or replace.
shutdown.
21. Intercooler pressure below 1. Dirty air inlet filter. 1. Clean or replace elements.
normal. 2. Defective 1st stage 2. Replace 1st stage
3. Defective transmitter. 3. Check and replace if necessary.
22. Intercooler pressure above 1. High 2nd stage inlet temp. 1. Clean intercooler (see section 6.5.l)
normal. 2. Defective 2nd stage. 2. Replace 2nd stage.

KIMA00H1 (0204) 41

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 TABLE 7 - PROGRAMMABLE LOGIC CONTROLLER (PLC)
PROBLEM SOLVING
CONDITION POSSIBLE CAUSE
1. PLC “POWER” light off. 1. Control circuit fuse blown.
2. Faulty transformer.
3. Faulty power supply.
4. Overload on power supply.
5. Loose wiring connection.
2. PLC “FAULT” light on. 1. System fault.
2. CPU fault.
3. PLC “RUN” light off. 1. RUN/REM/PROG switch not in
“RUN”
2. No PLC program.
2. System fault.
4. No output lights on PLC. 1. RUN/REM/PROG switch not in
“RUN”
2. No PLC program.
3. Faulty PLC.
4. Loose wiring connection.
5. No input lights on PLC. 1. Loose wiring connection.
2. Faulty PLC
6. Analog “OK” light off 1. Analog input fault.
2. Analog module low voltage.
3. Analog input voltage too high.
7. Temperature readings on 1. Faulty power supply
display abnormal. 2. Loose wiring connection
3. RTD failure.
4. Signal conditioner faulty.
5. Analog module faulty.
6. Shorted pressure transducer.
8. GT Terminal: Screen blank. 1. No control power.
2. Fuse blown.
9. GT Terminal: Dim screen 1. Display in sleep mode.
2. No backlighting.
3. Bad viewing angle.
4. Faulty display.
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SUGGESTED REMEDY
1. Check transformer voltage.
2. Replace any blown fuses.
3. Measure output of power
supply. Must be 24VDC +/- .5V.
4. Check DC circuit for excess
load or short circuit.
5. Tighten wiring connections.
1. Check EPROM installation.
2. Cycle power to PLC.
1. Check switch.
2. Check EPROM installation.
3. Cycle PLC power.
1. Check switch.
2. Check EPROM installation.
3. Cycle PLC power.
4. Tighten wiring connections.
1. Tighten wiring connections
2. Measure voltage on input
terminal. If present, and LED is
not lit, then replace PLC.
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.
1. Measure output of power
supply. Must be 24VDC +/- .5V
2. Tighten wiring connections.
3. Check RTD for broken or
twisted wires. Replace if
damaged.
4. Measure voltage at terminal 2.
Must be 1 - 5 volts DC.
5. Check to insure proper
mounting of module.
6. Check module connections.
1. Check control power circuit.
2. Replace display fuse.
1. Touch screen.
2. Adjust backlighting brightness
3. Adjust Display contrast
4. Replace display.
KIMA00H1 (0204)
 Appendix A - Daily Operating Record

KIMA00H1 (0204) 43

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 DATE SERVICE PERFORMED SERVICED BY

____________________
____________________
____________________

MAIL TO:

Attention: Field Engineering

14650 SW 72nd Ave.
Portland, OR, 97224-7943

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 Appendix B - Unit Dimensions, Minimum Working Clearances

TOP
VIEW

FRONT
VIEW

KIMA00H1 (0204) 45

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 Appendix B (cont.) - Unit Dimensions and Field Connections

REAR
VIEW

SIDE
VIEW

46 KIMA00H1 (0204)

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 Appendix B (cont.) - Unit Dimensions, Field Connections and Mounting

KIMA00H1 (0204) 47

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 48 KIMA00H1 (0204)

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 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.

KIMA00H1 (0204)

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 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

KIMA00H1 (0204)

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