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www.knw-series.com
40-500 HP170-2400 SCFM40-150 PSIG
OIL-FREE, ROTARY SCREW AIR COMPRESSORSTwo-stage, Air-cooled and Water-cooled
Fixed Speed or VFD
15548-01_KNW_40to500HP_r4.indd 1 4/1/11 12:33:24 PM
Simple and Efficient with High Reliability
3
Standard water-cooled model
The Kobelco KNW Series
assembly is designed and
constructed to exacting quality
standards. These standards
result in assemblies with long
operating life, minimum
maintenance and low
operating costs.
The Kobelco KNW Series
oil-free rotary screw air
compressor is designed,
manufactured, assembled, and
tested in the United States
and is delivered ready for
operation. The two-stage
rotary screw compressor
provides completely oil-free air
because no oil is allowed in the
compression chambers.
Both compression stages employ
a new patented Super Rotor
design, which is acknowledged
to be the most efficient, two-
stage, oil-free rotary screw air
compressor on the market.
This new asymmetric rotor
profile provides the lowest
power consumption per cubic
foot of compressed air.
The efficiency is further
enhanced by a unique
load/unload control system
that is simple and trouble free.
The compressor air end is a
heavy-duty, two-stage design
with each stage driven by a
common gear.
These components are arranged
in a single modular design to
form a compact unit which
is mounted on vibration
isolators to a structural steel
base. No special foundation
considerations are required.
High Quality, Quiet and Energy Efficient
Kobelco is the international trademark of Kobe Steel, Ltd.
2
15548-01_KNW_40to500HP_r9.indd 2 4/14/11 10:50:53 AM
Simple and Efficient with High Reliability
3
Water-cooled model
Kobelco KNW Series precision
machined timing gears are
mounted on each rotor shaft
to maintain accurate clearances
between the rotors. The
bearings are anti-friction
type for long life and smooth
operation. The electric motor
is directly coupled to the input
drive shaft through a flexible
coupling.
Axial thrust is reduced by
incorporating an air pressure
operated thrust balance
piston on each stage.
This arrangement minimizes
thrust loading thus increasing
bearing life.
The state-of-the-art
programmable microprocessor
controller maximizes operating
efficiency and versatility.
The sound attenuated enclosure
assures quiet operation. Doors
are hinged and pinned allowing
easy removal for inspection
and maintenance.
High Quality, Quiet and Energy Efficient
Kobelco is the international trademark of Kobe Steel, Ltd.
2
15548-01_KNW_40to500HP_r9.indd 3 4/14/11 10:50:54 AM
Dual Vent Seals withStainless Steel RingsEach shaft seal consists of floatingstainless steel rings and an oillabyrinth inserted between the rotorchamber and the bearings. Each seal is buffered by gas from thecompression chamber which is purgedto atmosphere ensuring that nolubricating oil or its vapor can enterthe compression chamber.
Advanced Design Features
Lubrication of Gears and BearingsLubrication prior to start-up, duringoperation and after shutdown issupplied by an independent motordriven gear pump. Compressoroperation is not allowed until oilpressure is established. During thecoast down period the oil pumpcontinues to provide full lubricationuntil the compressor stops. This designincreases gear and bearing life and isnot standard on competitive units.4
Vent 1
Vent 2
Designed, manufactured and assembled in the USA.
*Patent Numbers 4583927 and 4671749
Oil Pump
Filter
Level Gauge
Cooler
High Efficiency RotorsThe new patented Super Rotor* profileis the most efficient in the industry.The machined forged steel rotor setshave the most precise tolerances in the industry. FDA approved rotorcoating further increases volumetricefficiency for the life of the machine.
63544 RM Brochure q6 10/3/08 2:38 PM Page 4 63544 RM Brochure q6 10/3/08 2:38 PM Page 5
4
Designed, manufactured and assembled in the USA.
63544 RM Brochure q6 10/3/08 2:38 PM Page 4
Two-stage oil-free compression module.
Component Arrangement Showing Typical Air Flow (Water-cooled)
Load and Unload Control or VFDBoth controls provide energy efficient operation while eliminating adjustments and minimizing maintenance. When the compressor unloads the brake horsepower drops to approximately 18% of full load, significantly reducing overall energy cost. The compressor will shut down after operating unloaded for a period of time and will automatically restart on pressure demand.
Capacity Control Valve
Diagram showing the controlvalve assembly in both theunloaded (top portion) andloaded (bottom portion)positions.
5
Capacity Control Valve The efficient and simple capacity control system is aload/unload type with a directoperating disc valve and no dischargeair recirculation. During unloading thebleed-off air is released to atmospherethrough a muffler. The control is anelectro-pneumatic device using onlyspring and air pressure. No oil orhydraulic cylinders are used in theoperation of this valve.
Air Inlet
Aftercooler
Air Discharge
Low Pressure Stage
High Pressure Stage
Intercooler
Loaded LoadedUnloaded Unloaded Loaded
100% 100%
18%
90%
Disc
harg
e Pr
essu
re
Pow
er C
onsu
mptio
n
Time
Key to illustrations
Vacuum
Atmospheric Pressure
Interstage Pressure
Discharge Pressure
Lubricating Oil
Power Consumption
15548-01_KNW_40to500HP_r8.indd 4 4/12/11 5:22:34 PM
Dual Vent Seals withStainless Steel RingsEach shaft seal consists of floatingstainless steel rings and an oillabyrinth inserted between the rotorchamber and the bearings. Each seal is buffered by gas from thecompression chamber which is purgedto atmosphere ensuring that nolubricating oil or its vapor can enterthe compression chamber.
Advanced Design Features
Lubrication of Gears and BearingsLubrication prior to start-up, duringoperation and after shutdown issupplied by an independent motordriven gear pump. Compressoroperation is not allowed until oilpressure is established. During thecoast down period the oil pumpcontinues to provide full lubricationuntil the compressor stops. This designincreases gear and bearing life and isnot standard on competitive units.4
Vent 1
Vent 2
Designed, manufactured and assembled in the USA.
*Patent Numbers 4583927 and 4671749
Oil Pump
Filter
Level Gauge
Cooler
High Efficiency RotorsThe new patented Super Rotor* profileis the most efficient in the industry.The machined forged steel rotor setshave the most precise tolerances in the industry. FDA approved rotorcoating further increases volumetricefficiency for the life of the machine.
Two-stage oil-free compression module.
63544 RM Brochure q6 10/3/08 2:38 PM Page 4 63544 RM Brochure q6 10/3/08 2:38 PM Page 5
Component Arrangement Showing Typical Air Flow (Water-cooled)
Load and Unload Control or VFDBoth controls provide energy efficient operation while eliminating adjustments and minimizing maintenance. When the compressor unloads the brake horsepower drops to approximately 18% of full load, significantly reducing overall energy cost. The compressor will shut down after operating unloaded for a period of time and will automatically restart on pressure demand.
Capacity Control Valve
Diagram showing the controlvalve assembly in both theunloaded (top portion) andloaded (bottom portion)positions.
5
Capacity Control Valve The efficient and simple capacity control system is aload/unload type with a directoperating disc valve and no dischargeair recirculation. During unloading thebleed-off air is released to atmospherethrough a muffler. The control is anelectro-pneumatic device using onlyspring and air pressure. No oil orhydraulic cylinders are used in theoperation of this valve.
Air Inlet
Aftercooler
Air Discharge
Low Pressure Stage
High Pressure Stage
Intercooler
Loaded LoadedUnloaded Unloaded Loaded
100% 100%
18%
90%
Disc
harg
e Pr
essu
re
Pow
er C
onsu
mptio
n
Time
Key to illustrations
Vacuum
Atmospheric Pressure
Interstage Pressure
Discharge Pressure
Lubricating Oil
Power Consumption
15548-01_KNW_40to500HP_r4.indd 5 4/1/11 12:33:33 PM
Touchscreen Operator Interface
6
Installation and Start-up SupervisionA factory trained field representativewill supervise installation and start-up.This same representative will also train your maintenance personnel inthe operation and maintenance of the assembly. Our commitment is to provide a trouble free, reliableinstallation of which we can both be proud.
Touchscreen Display withGraphicsComplete status indication is displayedcontinuously during operation, whilein stand-by or after emergencyshutdown. Discrete push buttons withlights for quick indication of operatingstatus. Ethernet card with emailcapability also available (optional).
Allen BradleyProgrammable Logic ControllerThe microprocessor initiates andsequences the proper events duringstart-up, operation and shutdown. It monitors system functions, safetydevices and instrumentation. Themicroprocessor incorporates anerasable programmable read only
memory chip (EPROM) for permanent program storage. Programs can bechanged to meet various plantrequirements. In addition, interfacingwith other equipment and plantmonitoring systems is easilyaccomplished.
.
Rogers KNW Series Heat of Compression Regenerative Air Dryers
Standard Equipment and Safety Devices
7
Safety DevicesAll safety shutdowns are indicated bymessage on display and alarm light.
Compressor motor overloadshutdown and lightOil pump motor overload shutdown and lightFan motor overload shutdown and lightHigh first stage air dischargetemperature shutdown and lightHigh second stage suctiontemperature shutdown and lightHigh second stage air dischargetemperature shutdown and lightHigh oil temperature shutdown and lightLow oil pressure shutdown and lightHigh cabinet temperature shutdownand light
Service IndicatorsAir inlet filter condition indicatorOil filter condition indicatorOil level gaugeRoutine maintenance
Pressure IndicatorsFirst stage air discharge Second stage air discharge Oil pressureFirst stage suction
Temperature IndicatorsFirst stage air discharge Second stage air inletSecond stage air discharge First stage suction
Aftercooler temperature shutdownand lightStarter failure lightTemperature pre-shutdown alarmRelief valve
Additional DevicesStart/stop push buttonsLamp testAudible alarm Acknowledge switchReset switchCommon alarm contacts for remote indicationEvent alarm logSAE oil circuit fittingsPetes plugs for pressure transmitterlocationsEmergency stop button
Heat of Compression Dryer Benefits
Zero purge air lossLowest energy cost of any type ofdryerLow dewpoint suppressionSimple designMinimum maintenanceDelivered with interconnectingpiping and after filterAsk for bulletin #KNWHOC 0703 formore details
Lube oilAftercooler temperature
Additional IndicatorsStand-by mode lightOil pump run lightFan run lightCompressor run lightCompressor load lightAlarm lightHour meter – running timeHour meter – loaded timeManual unload light and switch
Controls and Instrumentation
Designed specifically for use with Kobelco KNW Series Oil Free compressors
Water - cooled assembly Standard Allen-Bradley PLCBuilt in sequencing capability–up to four compressors. Interfacing with plant monitoring systems easily accomplished (optional)(Allen Bradley Ethernet module shown)
15548-01_KNW_40to500HP_r9.indd 6 4/14/11 10:50:59 AM
Touchscreen Operator Interface
6
Installation and Start-up SupervisionA factory trained field representativewill supervise installation and start-up.This same representative will also train your maintenance personnel inthe operation and maintenance of the assembly. Our commitment is to provide a trouble free, reliableinstallation of which we can both be proud.
Touchscreen Display withGraphicsComplete status indication is displayedcontinuously during operation, whilein stand-by or after emergencyshutdown. Discrete push buttons withlights for quick indication of operatingstatus. Ethernet card with emailcapability also available (optional).
Allen BradleyProgrammable Logic ControllerThe microprocessor initiates andsequences the proper events duringstart-up, operation and shutdown. It monitors system functions, safetydevices and instrumentation. Themicroprocessor incorporates anerasable programmable read only
memory chip (EPROM) for permanent program storage. Programs can bechanged to meet various plantrequirements. In addition, interfacingwith other equipment and plantmonitoring systems is easilyaccomplished.
Standard Allen-Bradley PLCBuilt in sequencing capability—up to four compressors. Interfacing with plant monitoring systems easily accomplished (optional).(Optional Allen Bradley Ethernet module shown)
Rogers KNW Series Heat of Compression Regenerative Air Dryers
Standard Equipment and Safety Devices
7
Safety DevicesAll safety shutdowns are indicated bymessage on display and alarm light.
Compressor motor overloadshutdown and lightOil pump motor overload shutdown and lightFan motor overload shutdown and lightHigh first stage air dischargetemperature shutdown and lightHigh second stage suctiontemperature shutdown and lightHigh second stage air dischargetemperature shutdown and lightHigh oil temperature shutdown and lightLow oil pressure shutdown and lightHigh cabinet temperature shutdownand light
Service IndicatorsAir inlet filter condition indicatorOil filter condition indicatorOil level gaugeRoutine maintenance
Pressure IndicatorsFirst stage air discharge Second stage air discharge Oil pressureFirst stage suction
Temperature IndicatorsFirst stage air discharge Second stage air inletSecond stage air discharge First stage suction
Aftercooler temperature shutdownand lightStarter failure lightTemperature pre-shutdown alarmRelief valve
Additional DevicesStart/stop push buttonsLamp testAudible alarm Acknowledge switchReset switchCommon alarm contacts for remote indicationEvent alarm logSAE oil circuit fittingsPetes plugs for pressure transmitterlocationsEmergency stop button
Heat of Compression Dryer Benefits
Zero purge air lossLowest energy cost of any type ofdryerLow dewpoint suppressionSimple designMinimum maintenanceDelivered with interconnectingpiping and after filterAsk for bulletin #KNWHOC 0703 formore details
Lube oilAftercooler temperature
Additional IndicatorsStand-by mode lightOil pump run lightFan run lightCompressor run lightCompressor load lightAlarm lightHour meter – running timeHour meter – loaded timeManual unload light and switch
Controls and Instrumentation
Designed specifically for use with Kobelco KNW Series Oil Free compressors
Water - cooled assembly Standard air-cooled assembly with Allen-Bradley VFD
Variable Speed Drive PotentialEnergy Savings
Lower system pressure reduces kW and leak load No current spikes at start up Frequent stops and starts allowed Excellent as trim compressor Option of having VFD shipped loose Large speed range, depending on model Lower unloaded kW Shorter unloaded run time
Integrated Variable Speed Drive
15548-01_KNW_40to500HP_r6.indd 7 4/11/11 11:26:11 AM
Rogers Machinery Company, Inc.14650 S.W. 72nd AvenuePortland, Oregon 97224-7943P.O. Box 230429Portland, Oregon 97281-0429503/639-0808Fax [email protected]
Regional Offices:Columbus, OHHouston, TXNewark, NJSan Jose, CA
KNW (01-10)
Litho in USA
Designed, manufactured and assembled in the USA.
Specifications Subject To ChangeWithout Notice
Compressed air discharged from thiscompressor should not be used forbreathing air unless properly purified. Kobelco and Rogers Machinery Company, Inc. assume noresponsibility or liability for the
MEMBERMEMBER MEMBER
KNW (04-11)
15548-01_KNW_40to500HP_r8.indd 8 4/12/11 5:22:40 PM