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

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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

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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

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Rogers Machinery Company, Inc.14650 S.W. 72nd AvenuePortland, Oregon 97224-7943P.O. Box 230429Portland, Oregon 97281-0429503/639-0808Fax 503-639-0111www.knw-series.comkobelco@rogers-machinery.com

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)

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