Rogers KI-30-150 User Manual

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1.

Model #: __________________ Serial #: __________________

®

Rotary Screw Air Compressors

Table of Contents

Questions and Answers:

V
Victoria HarperAug 17, 2025
How to fix a Rogers KI-30-150 Air Compressor that fails to start?
- J
  Jennifer NorrisAug 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.
R
ryan42Aug 20, 2025
Why is the overload relay tripping on my Rogers Air Compressor?
- M
  Michele AndersenAug 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.
E
ecervantesAug 23, 2025
What to do if my Rogers KI-30-150 Air Compressor experiences an unscheduled shutdown?
- K
  Kenneth ThomasAug 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.
F
fthomasAug 28, 2025
Why is my Rogers KI-30-150 Air Compressor using excessive lubricant?
- E
  Emily DouglasAug 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.
A
ashleysmithSep 3, 2025
How do I stop excessive lubricant carry-over in my Rogers KI-30-150?
- S
  Scott MyersSep 3, 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.
J
jasonyoungSep 5, 2025
What causes frequent air/lubricant separator clogging in my Rogers Air Compressor?
- C
  Cynthia SotoSep 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.
D
Deanna LynnSep 8, 2025
Why is the discharge pressure high on my Rogers Air Compressor?
- T
  Taylor FranklinSep 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.
L
Lisa SullivanSep 12, 2025
What should I do if my Rogers KI-30-150 Air Compressor does not load?
- T
  Timothy PayneSep 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.

Rogers KI-30-150 Specifications

General

Model	KI-30-150
Power Source	Electric
Power	30 HP
Pressure	150 PSI
Tank Capacity	120 Gallons
Phase	3

Summary

Warning Summary

General Safety Precautions

Key safety warnings regarding electrical hazards, pressure, and hot surfaces.

Warning Summary – Continued

Personnel Safety and Equipment Handling

Focuses on safe operation around moving parts and electrical connections.

Chapter 1: General Information

Compressor Description and Principles

Overview of the KI/KIV Series compressors and their operating principles.

Description of Air Flow

Details the path of air through the compressor system.

Lubricant Flow and Cooling System

Air and Lubricant Separator System

Standard Capacity Control System

KI Series Load/Unload Operation

KIV Series VFD Control

Chapter 2: Installation Instructions

Installation Details

Location Requirements

Compressor Rotation Check

Critical steps for verifying correct compressor rotation direction.

Cooling System

Cooling Air Flow and Ventilation

Chapter 3: Electrical Information

Electrical System Overview

Starter and Wiring Diagram

Voltage Configuration

Details on changing wiring for different voltage configurations (10-50 HP).

Motor Rotation and Controls

Motor Rotation Verification

Critical importance of checking and verifying correct motor rotation.

Compressor Drive Motor Details

Chapter 4: Compressor Lubricant

Compressor Lubrication Procedures

General Lubricant Information

Lubricant Service Intervals

Recommended intervals for lubricant changes and sampling.

Special Lubricant System Maintenance

Lubricant Filter Service

Lubricant Filter Change Intervals

Separator Element Replacement

Spin-On Separator Element Replacement (10-20 HP)

Top Hat Separator Element Replacement (25-100 HP)

Top Hat Separator Replacement Procedure

Air Inlet Filter Service

Air Inlet Filter Function and Replacement

Air Inlet Filter Service Procedure

Filter Removal and Reinstallation

Chapter 6: Compressor Operations

Compressor Operations

Initial Start-Up Procedures

Step-by-step guide for the initial start-up of the compressor unit.

Unit Start-Up and Stopping

Starting the Unit (Post-Initial)

Procedures for starting the compressor after initial setup.

Normal Unit Shutdown

Instructions for performing a normal shutdown of the compressor.

Service Intervals and Checks

Daily Checks and Indicator-Based Service

Daily checks and service actions based on indicators or gauges.

Scheduled Maintenance Intervals

Maintenance tasks for 1,000, 3,000, and 6,000 hour intervals.

Chapter 7: Troubleshooting Guide

Troubleshooting Common Issues

Failure to Start and Unscheduled Shutdowns

Diagnosing and resolving issues related to starting and unexpected shutdowns.

Overload Relay Tripping

Troubleshooting causes for overload relay tripping.

Lubricant Related Troubleshooting

Excessive Lubricant Consumption Causes

Identifying and addressing causes of excessive lubricant consumption.

Lubricant Carry-Over and Separator Issues

Troubleshooting lubricant carry-over and frequent separator clogging.

Air Pressure and Delivery Troubleshooting

Low Reservoir Pressure / Air Delivery Issues

Diagnosing low reservoir pressure and air delivery problems.

High Discharge Pressure Causes

Temperature Related Troubleshooting

High Discharge Air Temperature

Addressing high discharge air and lubricant injection temperatures.

Compressor Not Loading Issues

Filter and Safety Valve Troubleshooting

Frequent Lubricant Filter Clogging

Safety Valve Operation Issues

Valve and Control System Troubleshooting

Erratic Inlet Valve Operation Causes

Display Panel and Reservoir Pressure Issues

Important Pre-Operation Checks

Shipping Brackets and Support Nuts

Instructions to remove shipping brackets and loosen support nuts before operation.

Start-Up Report

Shutdown Device Verification

Procedure to verify the proper operation of all shutdown devices.

Related product manuals

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Rogers KI-25-125

Rogers KIV Series

Rogers KIV-50-125

Rogers KNW Series