Rogers KI-25-125 - User Manual

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1.

Model #: __________________ Serial #: __________________

®

Rotary Screw Air Compressors

Table of Contents

Questions and Answers

N
nwhiteheadAug 17, 2025
How to fix a Rogers KI-25-125 that fails to start?
- M
  morgansamanthaAug 17, 2025
  If your Rogers Air Compressor isn't starting, there are several potential causes. First, ensure the power is turned “ON” by closing the main disconnect. Check for blown fuses in the control circuit or the 460-volt Phase Protector and replace them after correcting the cause. See if the high air temperature switch is open. Overload relays might have tripped; reset them after addressing the overload condition, then press the reset keypad. Inspect the starter contactor for malfunctions, burnt contacts, or loose connections. Verify the incoming power supply and check pressure, temperature switches, or remote devices for defects. Ensure all wire connections are tight, and examine the 120 VAC and 24 VDC power supply. Reset any alarms and wait for the Start Delay Timer to finish counting down.
M
Matthew WatsonAug 20, 2025
Why is the overload relay tripping on my Rogers KI-25-125?
- D
  Debra BishopAug 20, 2025
  Overload relay tripping in your Rogers Air Compressor can stem from several issues. Check for excessive discharge pressure and lower the full load pressure setting at the pilot valve or Compressor Display panel. Low voltage, power factor, or voltage imbalance can also cause this; verify voltage, amperages, and power factor while the unit operates at full load and pressure. Ensure the overload setting matches the motor nameplate within the Compressor Control panel. Faulty motor or loose motor or starter wiring could also be responsible. Check all wiring terminals for tightness and contact. If the motor is faulty, remove it and have it tested at a motor manufacturer repair center.
A
Anthony EdwardsAug 23, 2025
What to do if my Rogers Air Compressor experiences an unscheduled shutdown?
- K
  Katie WolfeAug 23, 2025
  An unscheduled shutdown of your Rogers Air Compressor can be due to several factors. Begin by checking the compressor display. A high air discharge temperature could be the cause. Also, verify the incoming power supply, and inspect pressure switches, temperature switches, or remote devices for any defects. Ensure all wire connections are secure and tight. High reservoir pressure or a faulty Compressor Control Display could also lead to shutdowns. Replace the display if necessary.
M
Melanie DavenportAug 28, 2025
Why is my Rogers KI-25-125 Air Compressor using excessive lubricant?
- K
  Kelly GomezAug 28, 2025
  Excessive lubricant consumption in your Rogers Air Compressor can be attributed to several factors: * A ruptured lubricant cooler may be leaking; check for leaks and replace if needed. * Leaks in lubricant tubing and connections should be inspected and repaired. * A seal failure may require seal replacement. Also, ensure you're using the correct, non-contaminated lubricant. A faulty or damaged separator element or leaks from lubricant filter gaskets or the reservoir cover can also contribute to high consumption. Inspect and replace gaskets and separator elements as necessary.
M
Martin MyersSep 2, 2025
How do I stop excessive lubricant carry-over in my Rogers Air Compressor?
- D
  David WashingtonSep 2, 2025
  To address excessive lubricant carry-over in your Rogers Air Compressor, start by ensuring the lubricant level in the reservoir isn't too high; lower it to the recommended level after depressurization and check the drainage for condensation. Inspect the scavenging system for plugged or broken lines, cleaning or replacing them as needed. Excessive lubricant foaming, often due to water in the lubricant, can also cause carry-over; change the lubricant and consider increasing the operating temperature. Ensure the reservoir pressure doesn't fall below 80 PSIG when running loaded. Finally, verify the scavenging line is properly adjusted.
K
Kayla DavisSep 5, 2025
What causes frequent air/lubricant separator clogging in my Rogers KI-25-125 Air Compressor?
- T
  Traci BakerSep 5, 2025
  Frequent clogging of the air/lubricant separator in your Rogers Air Compressor can stem from several issues. Check for a faulty air filter or inlet line and replace elements or the air inlet connection as needed. A faulty lubricant filter or filter head can also cause clogging; replace the lubricant filter element and inspect the filter head for an open bypass. Lubricant breakdown or contamination can also lead to this issue; change the lubricant at prescribed intervals and ensure lubricant samples are analyzed frequently. Also, make sure you are using only Rogers’ replacement elements and do not attempt to clean separator elements. Mixing different grades or types of lubricant can cause separator clogging.
W
william33Sep 8, 2025
Why is the discharge pressure high on my Rogers Air Compressor?
- C
  Corey SchneiderSep 8, 2025
  High discharge pressure in your Rogers Air Compressor can occur if it fails to unload, often due to incorrectly set load/unload pressure settings; reset these to the desired levels. A faulty control line filter can also contribute; check for leaks, clean the filter, and replace the element. Ensure the inlet valve is fully closed; inspect and adjust it as necessary. Leaky control air lines can also cause high pressure; inspect and repair any leaks. Finally, a plugged separator can restrict flow; replace it with a new air/lubricant separator and determine the cause of the contamination.
K
Kristin GriffinSep 12, 2025
What should I do if my Rogers Air Compressor does not load?
- E
  Elizabeth MarshSep 12, 2025
  If your Rogers Air Compressor isn't loading, start by checking for improper pressure settings and correct them. Look for loose wiring connections and tighten the wiring terminals. A faulty air inlet valve assembly or a faulty unloading solenoid valve could also be the cause; repair or replace these as necessary. Check for a faulty differential pilot valve, cleaning or replacing it if the orifice is plugged, or if there is ice in the valve. Also, check the control air regulator for faults, servicing, replacing, and/or setting the regulator as needed. Finally, inspect the control air filter for clogs and clean or replace the filter element.
B
bill20Nov 24, 2025
Why does my Rogers KI-25-125 Air Compressor have low reservoir pressure or low air delivery?
- C
  Chelsea NguyenNov 24, 2025
  Low reservoir pressure or air delivery in your Rogers Air Compressor could be due to several reasons. Start by checking the air system for excessive leaks in service lines and fix them. Ensure the inlet valve is fully open; if not, replace the valve. A plugged air intake filter can also restrict airflow, so clean or replace it. Verify that the air pressure settings are correctly set to the desired load and unload pressure. Inspect the blowdown or unloading valve for faults and repair or replace if needed, ensuring correct control settings and wiring connections. Check for restrictions in the system, such as in the separator element, aftercooler, dryer, and filters, and watch out for ice formation inside the aftercooler. Repair or replace a faulty control line regulator or safety relief val...
A
Andrew CastilloDec 1, 2025
What causes high discharge air temperature in my Rogers KI-25-125?
- M
  Melissa WrightDec 1, 2025
  High discharge air or lubricant injection temperature in your Rogers Air Compressor can result from several issues. Ensure adequate circulation of cooling air at the cooler for air-cooled models. Check for a low lubricant level in the reservoir and add lubricant to the recommended level. Restrictions in the lubricant lines or a clogged lubricant filter can also cause this problem; clean or replace the filter as needed. Inspect the lubricant cooler for varnishing and deposits. High ambient temperatures may also contribute, so ventilate the room or relocate the compressor if necessary. Verify correct fan rotation, ensuring it pushes air through the cooler. Confirm you're using the recommended lubricant. A faulty temperature regulating valve or faulty sensors can also lead to high temperature...

Summary

Warning Summary

General Safety Precautions

Critical warnings for safe installation, operation, and maintenance of the compressor.

Chapter 2: Installation Instructions

Site Preparation and Setup

Covers location, foundation, and initial checks for proper installation.

Chapter 4: Compressor Lubricant

Lubricant Selection and Service Intervals

Details lubricant requirements, checks, and recommended change schedules.

Filter and Separator Maintenance

Chapter 5: Air Inlet Filter

Chapter 6: Compressor Operations

Initial Start-Up Procedures

Crucial steps for safely bringing the compressor online for the first time.

Chapter 7: Troubleshooting Guide

Common Operational Problems and Solutions

Addresses issues like failure to start, unexpected shutdowns, and overloads.

System-Specific Troubleshooting

Covers problems related to lubricant, separators, pressure, temperature, and vibration.

Rogers KI-25-125 Specifications

General

Model	KI-25-125
Power	2.2 kW
Max Pressure	8 bar
Weight	28 kg
Dimensions	600 x 300 x 600 mm

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