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Rogers KNW Series
Design Features
Two-Stage Design
Rogers KNW Series rotary screw compressors deliver 100% oil-free air for your critical applications. Heavy duty, two-stage compression module with thrust balancing for long bearing life in each stage. Designed, tested and manufactured in the USA. No other oil-free compressor manufacturer has made that commitment to the North American market. Also available as single stage design for low pressure applications.
Coated Rotors
ASTM 1144 steel rotors with exclusive PTFE coating on rotors and shafts for maximum efficiency and corrosion protection. Gears and bearings are lubricated by a unique motor driven oil pump that provides positive lubrication prior to start-up, through operation and after shutdown. This is an especially important feature for VFD models and not available on competitive offerings.
Unique Design Features
Key design features ensure long air end life. All features may not be available on competitive models. Features Include:
- Non contact maintenance free air and oil seals
- Thrust balance compensation
- Cooling jackets
- Dual vents to atmosphere ensure oil-free air
- Vacuum degassed thrust and radial bearings
- Premium AGMA rated gears
- All models meet the requirements of NFPA 99 for
use as a medical air compressor
Superior Components
Thrust balance pistons on each stage provide maximum air end life. The stainless steel, non wearing air and oil seals with dual vents to atmosphere, assure oil-free air. These features are not found on competitive models. Competitors use carbon rings with single vents and no thrust balance.
Compressor Control and Monitoring
The Rogers KNW Series oil-free rotary screw air compressor uses an Allen Bradley programmable controller to control and monitor compressor operation. Operations include:
- Controlled sequential starting and stopping
- Pressure control
- Protection from conditions that could damage the compressor.
Additional features include:
- Pilot lights, viewable from a distance, are provided for indication of operating conditions
- An audible alarm is provided for alarm annunciation
- Push buttons are provided for specific control functions, allowing continued compressor operation in the event the terminal is off-line
HMI Terminal
The HMI terminal is an LCD graphic display with touch screen. The HMI terminal shows operating conditions, pressures, and temperatures. Messages are sent to direct the operator for service, pre-alarms, and alarms, and will be shown when necessary. Required settings for pressure control, temperature alarms, and control time delays are viewable and may be modified using the touch screen. The HMI terminal will automatically “dim” to a sleep condition if inactive and awakens on any touch contact. A universal communication module is also available to handle virtually any Ethernet or Serial driver. They can be designed according to customer preference. The VFD data, if applicable, includes KW, amps, hertz and rpm.
Data Collection
The USB through door port is provided below the HMI. Also included is an SD memory card. Both provide the ability to download:
- Data loggers
- Alarm history
- Compressor status report
- Daily report from the HMI
These files can then be opened using Microsoft Excel. External memory (USB, SD) provides the ability to update or modify the existing HMI project.
Pressure & Temperature Monitoring
Compressor pressure and temperatures are monitored using smart sensor technology and I/O link communication. Real time pressure and temperature values are displayed on the HMI. Pressure and temperature trends are also on the HMI. All values are also available for remote monitoring. I/O link is specifically designed for communication with smart sensors and allows detailed diagnostics of sensor health.
Pre and Post Lubrication of Gears Bearings
Unique to Rogers KNW Series: Lubrication prior to start up, during operation and shutdown is supplied by an independent motor-driven gear pump. The compressor will not operate until oil pressure is established. The design increases gear and bearing life and is not offered on competitive models. All oil-side piping is stainless steel and has SAE leak-free fittings.
Heavy Duty Input Bull Gear Design
The Input bull gear is supported on each side. Competitors use an overhung design. The labyrinth type seal used on the drive end ensures leak-free operation. Competitors use a lip seal design, which is prone to wear and leakage. These features found on the Rogers KNW Series ensure a long operating life and eliminate oil leaks.
Capacity Control: Fixed Speed or VFD
Fixed speed, also known as load-unload, provides energy-efficient operation during loaded and unloaded operation. During unloaded operation, brake horsepower is reduced to approximately 18% of full load. This reduces the overall energy cost significantly. The valve is a positive-closing disc type with orifices, using spring and air pressure to activate. Unloaded horsepower is guaranteed and repeatable. The valve is designed for 1,000,000 load-unload cycles and is easily serviced.
Highly Efficient Cooling System
Rogers KNW Series water-cooled models feature highly efficient, removable, copper tube bundles. Internal turbulators provide optimum heat transfer with minimal pressure drop. Shells are made of carbon or optional stainless steel with an ASME stamp.
Water-cooled models include a thermostatic valve on the intercooler and an automatic shut-off valve on the cooling water inlet. Air is inside of the tubes and water is in the shell.
Air-cooled heat exchangers are made of heavy-duty aluminum with a special coating and are designed for all published operating conditions. Rogers KNW Series air-cooled models include a thermostatic mixing valve to insure proper oil temperature in changing ambient temperatures. All water and air-cooled models have oversized moisture separators with automatic drains for maximum efficiency.
Heavy Duty Inlet Air Filter with Pre-Filter
The inlet air filter is easily accessible and includes a cleanable prefilter which extends element life. The air filter is rated at 5 microns and is 99% efficient. A filter change notice is indicated on the HMI.
Heavy Duty, Corrosion-Resistant Finish
All Rogers KNW Series compressors are protected by a unique powder coating system. The powder coating is applied to the base, frame and enclosure. This finish is chip and corrosion resistant and keeps the compressor looking new throughout its lifetime. Other finishes are available for extreme environments.
