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Rotrex C15-16 Technical Handbook

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Summary of Contents for Rotrex C15-16

  • Page 1 WWW.ROTREX.COM...
  • Page 2 2. ROTREX TECHNOLOGY BASICS 2.1 System overview 2.2 Supercharger internal structure 2.3 Traction drive principles and key benefits 3. CHOOSING THE RIGHT ROTREX 3.1 General guidelines 3.2 Supercharger selection example: boosting 105hp to 150hp 4. DESIGNING AND HANDLING INTERFACES 4.1 Pulleys and other drive types 4.2 Belt drives...

  • Page 3: Revision History

    Updated image for chapter 4.4 Lubrication circuit Updated to follow revised supercharger design of 2022, including pulley adapter update Pulley mounting description changed to reflect new standard aluminium pulley and pulley adapter design Illustrations updated C8 Range removed C38R Range added WWW.ROTREX.COM Page 2 of 41...
  • Page 4 Section 2 - “Rotrex technology basics” – provides essential information on how a Rotrex unit works and the benefits it brings to you and your customers. Section 3 - “Choosing the right Rotrex” – provides a useful guideline to selecting the best Rotrex unit for a particular application.
  • Page 5 Rotrex offers technical and commercial support to OEM customers, official Rotrex distributors and kit builders during the entire development cycle to ensure a proper quality level in all Rotrex based applications. The diagram below represents an ideal application development cycle.
  • Page 6 Technical Handbook Rev. 1.6 Introduction Phases 2 and 3 (in red) are the stages where Rotrex expertise is most important since it is here design feedback can prevent quality and operational issues more effectively. Therefore, Rotrex strongly recommends doing the following: A.

  • Page 7: System Overview

    Rev. 1.6 Rotrex technology basics 2. Rotrex technology basics 2.1 System overview The picture above shows a standard Rotrex C-type supercharger system highlighting main components and their location.  Supercharger: Centrifugal air compression through high-speed traction drive featuring internal dry sump dual action oil vane pump ...
  • Page 8 Technical Handbook Rev. 1.6 Rotrex technology basics 2.2 Supercharger internal structure As the cross-section above shows, the supercharger contains three internal subsystems: A. Input & pump: Connecting the pulley drive to the traction drive and powering the dual action vane pump. The dual action vane pump sucks oil from the canister,...
  • Page 9 The Rotrex patented traction drive uses a steel annulus with a small pre-span to secure contact between the roller planets and the sun shaft with a reasonable force. The ramp or wedge effect increases efficiency and reliability in the transmission by regulating the torque transfer capability on demand through self-adjusting planet geometry.

  • Page 10: General Guidelines

    The comparison table above shows the working area of each supercharger model within the C-range. For compressor maps please refer to the technical datasheets. If in doubt, please contact your Rotrex supplier. Regardless of the supercharger type and model, always make sure to run it within its respective operating speed range specified in the technical datasheet.
  • Page 11 Technical Handbook Rev. 1.6 Choosing the right Rotrex 3.2 Supercharger selection example: boosting 105hp to 150hp The following example shows the process of supercharger sizing, for a given engine, to provide a more detailed explanation of how to choose the best supercharger for a given application.
  • Page 12 4. Designing and handling interfaces 4.1 Pulleys and other drive types Rotrex provides 8 and 10 ribbed PK-type pulleys ranging from Ø70 to Ø110mm in diameter in steps of 5mm (i.e., Ø70, Ø75, Ø80...). Check the technical datasheets for available pulley sizes for specific superchargers.

  • Page 13: Belt Drives

    Minimum 90° Belt wrap for high power pulleys such as crank and supercharger: Optimum 180° Minimum 120° Belt span: Minimum 75mm (~3”) Maximum 300mm (~12”) WWW.ROTREX.COM Page 12 of 41...

  • Page 14: Belt Alignment

    Although quite rare, there are some engines that rotate counter-clockwise. When choosing a Rotrex supercharger please ensure correct rotational direction of the input, see Section 3.1. By driving the supercharger from the back side of a double-sided belt the rotational direction is reversed.
  • Page 15 23mm from the supercharger bracket face. See Section 6.1 for a specification of the belt overhang limitations. Good belt placement Wrong belt placement WWW.ROTREX.COM Page 14 of 41...
  • Page 16 Include surface treatments to prevent corrosion and improve looks. Remember that some surface treatments build a considerable layer on top of the material, and this should be accounted for to remain inside the specified dimensional tolerance range WWW.ROTREX.COM Page 15 of 41...

  • Page 17: Lubrication Circuit

    Designing and handling interfaces 4.4 Lubrication circuit The special Rotrex oil system is an integral part of the design and function of the Rotrex C-type supercharger. These superchargers have been developed and extensively tested with special Rotrex traction fluid. To maintain the ultimate level of performance and durability it is vital that the unit is run exclusively with Special Rotrex traction fluid.
  • Page 18 Oil Cicuit Installation Example Filter: Between canister and SC oil inlet Canister: Below SC Oil Cooler: Between SC outlet and canister, with access to cooling air Oil lines: Good routing, no contact with sharp edges or hot components WWW.ROTREX.COM Page 17 of 41...
  • Page 19 Failure to comply with these specifications can compromise the overall reliability and may result in permanent damage of the supercharger and/or other systems in the application. If the application requires customized oil routing (not using the parts included in the Rotrex package seen in Section 4.4), please contact your Rotrex supplier.
  • Page 20 Cut the hose direction of the filter! using scissors or a sharp Following the same method, knife. Again, slide a hose continue fitting the clamp over each end of the remaining parts of the oil hose. system. WWW.ROTREX.COM Page 19 of 41...
  • Page 21 To ensure proper oil circulation and adequate lubrication, it is important to prime the oil system before the engine is started for the first time after the supercharger installation. The priming process is done the easiest with all oil components in place and installed WWW.ROTREX.COM Page 20 of 41...
  • Page 22 Measuring oil level in any other way will not give a true reading of the oil volume in the system and can lead to overfilling or starvation and consequent damage, foaming or leaks. WWW.ROTREX.COM Page 21 of 41...
  • Page 23 Please note: the above procedure is a general Rotrex procedure that may not apply to your specific installation. Contact your Rotrex supplier for more detailed information about your installation. WWW.ROTREX.COM...

  • Page 24: Air Ducting

    The supercharger should be delivered to the end user or installer with a pre-set outlet direction. To support this, every Rotrex unit includes a warning label as shown below. WARNING! WARNING! ...
  • Page 25 4.5.2 Ducting Proper attention to air ducting is core to a healthy forced induction system. The following section should aid in understanding the main aspects involved in designing a ducting system for a Rotrex supercharger installation. Air filter Air mass...
  • Page 26 Using custom inlet restrictors voids warranty. In case it is deemed mandatory for the success of the application/project, please contact Rotrex directly for assistance. WWW.ROTREX.COM Page 25 of 41...
  • Page 27 A Partially blocked air filter will result in significant vacuum which can cause surge or easily collapse a soft hose. Rotrex urges the customer to minimize the use of soft materials in the entire air ducting system.

  • Page 28: Technical Handbook

    Keep a close eye on electronic control performance over time and under different variables such as fuel grades and altitude. Rotrex recommends building a monitoring/logging system into the test vehicles to make sure the most important parameters are well within acceptable values.
  • Page 29 Rotrex recommends running the final application on more than one vehicle for a minimum of 25000 km (15000 miles) per vehicle under harsh driving conditions (city and highway) monitoring vehicle performance, traction fluid conditions (mainly temperatures and level) and belt drive conditions constantly and thoroughly –...
  • Page 30 Section 6.8 of this document contains a sample of the Rotrex standard customer claim form. If you have a problem with a Rotrex supercharger fill out this form and send it to the company who sold you the Rotrex supercharger. Please try to include as many details as possible since this information will be the key to determining the cause of the problem and to the effective implementation of any needed corrective action.

  • Page 31: Support Material

    Technical Handbook Rev. 1.6 Important notes and info sources 6. Support material 6.1 Pulley ring design guide for C15, C30 and C38 WWW.ROTREX.COM Page 30 of 41...
  • Page 32 Technical Handbook Rev. 1.6 Important notes and info sources 6.2 Pulley ring drawing for C15, C30 and C38 WWW.ROTREX.COM Page 31 of 41...
  • Page 33 Technical Handbook Rev. 1.6 Important notes and info sources 6.3 Pulley ring design guide for C38R WWW.ROTREX.COM Page 32 of 41...
  • Page 34 Technical Handbook Rev. 1.6 Important notes and info sources 6.4 Pulley ring drawing for C38R WWW.ROTREX.COM Page 33 of 41...
  • Page 35 Remove the bolts The standard bolts and old pulley are M6x10 T30 Torx Mount the new pulley Tighten the 6 bolts and screw the bolts in in a cross pattern to 10 Nm (7.4 ft-lbs) WWW.ROTREX.COM Page 34 of 41...
  • Page 36 Technical Handbook Rev. 1.6 Important notes and info sources 6.5.2 Steel pulleys (Up to dec 2021) WWW.ROTREX.COM Page 35 of 41...
  • Page 37 Technical Handbook Rev. 1.6 Important notes and info sources 6.6 Bracket design guide 6.6.1 Bracket design guide for C15 WWW.ROTREX.COM Page 36 of 41...
  • Page 38 Technical Handbook Rev. 1.6 Important notes and info sources 6.6.2 Bracket design guide for C30 WWW.ROTREX.COM Page 37 of 41...
  • Page 39 Technical Handbook Rev. 1.6 Important notes and info sources 6.6.3 Bracket design guide for C38 WWW.ROTREX.COM Page 38 of 41...
  • Page 40 Technical Handbook Rev. 1.6 Important notes and info sources 6.6.4 Bracket design guide for C38R WWW.ROTREX.COM Page 39 of 41...
  • Page 41 Important notes and info sources 6.7 New Application Development Feedback Form Dear Rotrex Customer: this document is intended to collect as much information as possible about your application in the early stages of its development. Completing this form thoroughly and submitting it with good complimentary information will help us providing useful feedback aimed to improve your development process.
  • Page 42 State the country/region, min and max temperatures of the area Oil reservoir type Plastic Aluminium Custom Rotrex plastic, aluminum reservoir or custom type Oil cooler None Rotrex std. 10 rib Other Does the application use an oil cooler – if so state type...

This manual is also suitable for:

C15-20C15-60C30-64C30-74C30-84C30-94 ... Show all

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