Related Manuals for Champion ROTORCHAMP RCOF20
Summary of Contents for Champion ROTORCHAMP RCOF20
- Page 1 CHAMPION 13- -11- -605 1st Edition February, 1999 ROTORCHAMP OIL- - FREE ROTARY SCREW COMPRESSORS MODELS RCOF20 - 20 HP RCOF25 - 25 HP RCOF30 - 30 HP OPERATING AND SERVICE MANUAL...
- Page 2 They are ready to respond and assist you by pro- air compressor with these services: viding fast, expert maintenance and repair services. For the location of your local authorized Champion Air Compressor distributor refer to the yellow pages of your phone directory or contact: Factory: Champion 1301 N.
- Page 3 FOREWORD Champion Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be as- sured of receiving maximum service from this machine the owner must exercise care in its operation and mainte- nance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment.
- Page 4 This book covers the following models: Air Cooled Parts List RCOF20 13- - 11- - 507 RCOF25 13- - 11- - 507 RCOF30 13- - 11- - 507 INSTRUCTIONS FOR ORDERING REPAIR PARTS When ordering parts, specify Compressor MODEL, required per unit, quantity is indicated in parenthesis. Method of Cooling, HORSEPOWER and SERIAL SPECIFY EXACTLY THE NUMBER OF PARTS RE- NUMBER (see nameplate on unit).
- Page 5 TABLE OF CONTENTS Remanufactured Air Ends ............... . Foreword .
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Page 6: Table Of Contents
INDEX Air and Water Discharge Temperature ..Blowdown Valve ......AIR FILTER, SECTION 6 . - Page 7 INDEX Filter, Heavy Duty Air (Standard) ... . Oil Level Sight Glass ..... . Oil Reservoir Drain .
- Page 8 INDEX Sequencing Compressors with Temperature Differential, Water Injection Auto Sentry- - W ..... . . Cooler, Air Cooled Radiator ... . . Service Advisories .
- Page 9 LIST OF ILLUSTRATIONS Figure # Description Page Figure 1- - 1 Typical Compression Cycle ..........Figure 1- - 2 Compressor End .
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Page 10: Compression Principle
SECTION 1 GENERAL INFORMATION FIGURE 1- - 1 - - TYPICAL COMPRESSION CYCLE COMPRESSOR - - The Champion Rotary Screw com- duction and pressure increase continues until the air/ pressor is a single stage, positive displacement rotary water mixture trapped in the interlobe cavity by the ro-... -
Page 11: Figure 1- - 2 Compressor End
302EWC797 (Ref. Drawing) FIGURE 1- - 2 - - COMPRESSOR END 302EWC797 (Ref. Drawing) FIGURE 1- - 3 - - COMPRESSOR END (CONTROL BOX REMOVED) 13- 11- 605 Page 2... -
Page 12: Figure 1- - 4 Motor Drive End
302EWC797 (Ref. Drawing) FIGURE 1- - 4 - - DRIVE MOTOR END 302EWC797 (Ref. Drawing) FIGURE 1- - 5 - - DRIVE COMPONENT SIDE 13- 11- 605 Page 3... -
Page 13: Figure 1- - 6 Air/Water Schematic
13- 11- 605 Page 4... - Page 14 SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards, and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel.
- Page 15 Failure to observe these notices could result in damage to equipment. Stop the unit if any repairs or adjustments on or around the compressor are required. D Disconnect the compressor unit from its power source, tag and lockout be- fore working on the unit - - this machine is automatically controlled and may start at any time.
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Page 16: Decals
DECALS 300EWC077 206EAQ077 301EWC077 211EAQ077 207EAQ077 13- 11- 605 Page 7... - Page 17 DECALS 216EAQ077 222EAQ077 206EWD077 221EAQ077 208EAQ077 13- 11- 605 Page 8...
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Page 18: Air- - Cooled Units, Location
SECTION 2 INSTALLATION, COOLERS AND WATER SYSTEMS GENERAL - - On receipt of the unit, check for any dam- age that may have occurred during transit or handling. Report any damage or missing parts as soon as pos- sible. Do not install this compressor in a location that may be subject to tem- peratures below 32_ F. -
Page 19: Compressor Water Specification
FOUNDATION - - The Champion Rotary Screw com- pressor requires no special foundation, but should be mounted on a smooth, solid surface. Whenever pos- sible install the unit near level. Temporary installation... -
Page 20: Air Receiver, Auxiliary
Total Hardness Maximum Limit in Mg/L* as CaCO Water Classification Total Hardness as CaCO 120 parts per million 0 - - 60 Soft Either Total Dissolved Solids 500 parts per million 61 - - 120 Moderately Hard or Specific Conductance 800 Micromhos/cm 120 - - 180 Hard... -
Page 21: Air/Water Reservoir With Integral Moisture
DISCHARGE SERVICE LINE - - The discharge service voir, providing water storage capacity for the system line connection on the unit is made from the right side and the upper portion serves as primary air/water sepa- at base level from the motor end of the package. When ration. -
Page 22: Air And Water Discharge Temperature
COMPRESSOR INJECTION WATER SYSTEM GROUNDING - - Equipment must be grounded in ac- CHECK - - The following readings are based on an am- cordance with Section 250 of the National Electrical bient temperature of 80_ F. inlet cooling air on air- - Code. -
Page 23: Electric Motor Grease Recommendations
ELECTRIC MOTOR GREASE RECOMMENDATIONS (- 30_ to 50_ C) MANUFACTURER TRADE NAME CHEVRON SRI #2 SHELL DOLIUM R EXXON UNIREX #2 EXXON POLYREX ELECTRIC MOTOR REGREASING INTERVAL Relubrication Type of Service Typical Examples Rating Interval Up to 150 HP (112 KW) 18 Months Standard One- - or Two- - Shift Operation... -
Page 24: Drinking Water Regulation, U.s. Epa
U.S. EPA National Drinking Water Regulations * Primary Secondary Maximum Contaminant Level Constituents Constituents Parts Per Million Inorganic Arsenic 0.05 Barium Cadmium 0.01 Chromium 0.05 Fluoride Lead 0.05 Mercury 0.002 Nitrate- - Nitrogen Selenium 0.01 Silver 0.05 Chloride Copper Iron Manganese 0.05 Sulfate... - Page 25 Never allow motor to reach full speed. achieve maximum service of this screw compressor. Use only genuine Champion filters designed and speci- fied for this compressor. System Pressure - - Set the controls to the de- sired unload and load pressures. DO NOT EX-...
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Page 26: Check, Daily
STARTING THE UNIT - - It is a good practice to prime the compressor air end and separator/reservoir prior to initial start- - up following the installation of the compres- sor package and following a manual draining of the wa- Operation at excessive discharge air ter reservoir. -
Page 27: Auto Sentry- - W Operation
SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION - - The Champion Rotor- dicate if the control is waiting for a reservoir blowdown, Champ waterflooded rotary screw compressor is pre- along with the remaining pressure. The controls also wired with all controls, motor, and starter for the voltage delay initial loading of the compressor until a startup and horsepower at the time of ordering. -
Page 28: Auto Sentry- - W Control Display
storage to allow the compressor to be stopped for peri- lers is achieved by interconnection of a communica- ods of light demands. Operation during periods of tions cable to expansion board connectors. A ”unit moderate to heavy demands is identical to the low de- number”... - Page 29 Remaining Blowdown Time BD TMR Motor Protective Devices - - Overload heaters are furnished for the starter in the voltage range specified. Remaining Auto Time AUTO TMR There are three (3) overloads in the starter of proper size for the starter and its enclosure. Note that motor Remaining blowdown and auto times are only available nameplate current must be multiplied by 0.577 for wye- - in Low Demand, Automatic, and Sequence modes, as...
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Page 30: Main Adjustments Menu
High Pressure - - The AUTO SENTRYR- - W will first Main Adjustments Menu attempt to unload and blow down the unit if excessive The compressor must be stopped prior to making pressures are detected in the reservoir or the plant sys- any adjustments. -
Page 31: Figure 4- - 2 Flow Chart For Set- - Up Programming
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Page 32: Auto Sentry- - W Controller
In the top line, “BLOWDOWN TIME” is displayed. grammed here to operate correctly in SE- The bottom line will indicate a time between 1 and QUENCE mode. Adjust as required, and press 20 minutes. It is factory set at 10 minutes. This [ENTER] to proceed. -
Page 33: Configuration Adjustments
This completes the sequence adjustments. The verify the function of the temperature shutdown controller will return to the main adjustments system. menu. In the top line, “AUTO RESTART” is displayed. The bottom line will indicate either ”OFF” or ”ON” Configuration Adjustments The factory setting is ”OFF”, and the controller will display a power failure shutdown after power has In the top line, “HI SYS PRES LIM”... -
Page 34: Establishing Initial Sequence
It will then listen on the com- A proper sequencing installation requires two or more munications line for a call from the master. Champion rotary air compressors complete with AUTO If no call is received, it will assume position three and SENTRY - - W controllers, piped into a common air again wait for a call from the master. -
Page 35: Automatic Sequence Change
vidual compressor. The effective unload point for com- whose timer was initially set at 30 seconds (15 x [3 - - pressor control is the programmed unload point minus 1]), has counted down 20 seconds (the total time that 3(rotation number - - 1). So while compressors count system pressure was below 90 PSI). -
Page 36: Connection Of Expansion Board And External Control Circuits
bers. Number 2 becomes number 1, the new master, Here’s how it works: The master continually receives number 3 becomes number 2, etc. system pressure values from every machine in the se- quence rotation. The values are averaged and this av- erage is then distributed to all lag compressors. -
Page 37: Alarm Relay
Remote On / Off - - Remote on- - off control of the sys- If no additional switch is desired, this input must be tem requires only a simple two- - wire control, with an jumpered to operate the compressor. Connect a jump- isolated contact suitable for 120 volts, 1 amp. -
Page 38: Blowdown Valve
Never paint, lubricate or alter a relief valve. Do not plug vent or restrict dis- charge. Operation of unit with improper relief valve setting can result in severe per- sonal injury or machine damage. Insure properly set valves are in- stalled and maintained. -
Page 39: Air Filter Vacuum Switch
305EWC797- A (Ref. Drawing) FIGURE 4- - 4 - - INLET VALVE monitor coolant pressure and monitor the condition of the water filter. Air Filter Vacuum Switch - - This switch is used to monitor air filter condition and alert the user if the filter requires service or replacement. -
Page 40: Control Transformer
Terminal Strip - - This provides connections for all 110- - 120 volt devices not contained within the enclo- sure. Fan Starter - - The starter is used to provide control Automatic restarting or electrical and overload protection for the fans. Overload heaters shock can cause injury or death. -
Page 41: Figure 4- - 6 Control Tubing Schematic
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Page 42: Figure 4- - 7 Control Schematic - - Compressor At Full Load - - Constant Speed Mode
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Page 43: Figure 4- - 8 Control Schematic - - Compressor Unloaded - - Constant Speed Mode
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Page 44: Figure 4- - 9 Control Schematic - - Compressor Unloaded And Blown Down - - Low Demand Mode
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Page 45: Figure 4- - 10 Wiring Diagram - - Full Voltage
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Page 46: Figure 4- - 11 Wiring Diagram - - Wye Delta
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Page 47: Figure 4- - 12 Auto Sentry R - - W Controller Display
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Page 48: Compressor Oil System
Material Safety Data Sheets (MSDS) are available for all RotorLub lubricants from your authorized Champion distributor or by calling 815- - 875- - 3321. The drive end bearings of the air end should be lubri-... -
Page 49: Figure 5- - 1 Oil Level Gauge
306EWC797- A (Ref. Drawing) FIGURE 5- - 1 - - OIL LEVEL SIGHT GLASS 13- 11- 605 Page 40... -
Page 50: Figure 5- - 2 Flow Diagram (Air Cooled)
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Page 51: Air Filter, Section 6
Never use elements that are damaged, ruptured or wet. Never use gaskets that won’t seal. Keep spare Use only genuine Champion air filter elements and gaskets on hand to re- elements on Champion compressor duce downtime. Store elements in a units. - Page 52 Pressure drop through a filter with a freshly tube when required by ramming a clean dry cloth cleaned element is below three (3) inches (76 through the tube. Wipe the inside of the filter body to mm) of water with the compressor running at full remove any dirt falling from the inlet tube before rein- load - - this would indicate a rupture or crack.
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Page 53: Belt Drive, Section 7
SECTION 7 BELT DRIVE Proper drive belt tension and alignment are provided at loosen belt tension. Remove the belts, and replace with the factory, however, good practice dictates checking new belts. Check for correct belt tension and sheave the drive alignment and tension after shipment and be- alignment, tighten the motor foots bolts, and re- - attach fore initial start- - up. - Page 54 SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST - - Air Filter - - Operating conditions determine frequency Every 125 Hours Operation of service. The “CHANGE AIR FILTER” message ap- pears on the display accompanied by a yellow indicator Check for dirt accumulation on oil/aftercooler core in the status area of the keypad will signal that the air faces and the cooling fan.
- Page 55 MAINTENANCE SCHEDULE (See detail notes above) Maintenance Action Indicated Every Every Every Every Every By Auto- 1000 2000* Year Sentry Hours Hours Hours Hours Change Air Filter Change Water Filter Check For Proper Load/Unload Check Discharge Pressure/Temp Check Dirt Accumulation on Cooler Check Reservoir Oil Level Change Compressor Lubricant (RotorLub 800)
- Page 56 SECTION 9 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start. 1. Wrong lead connections. 1. Change leads. 2. Blown fuses in control 2. Replace fuse. box. 3. Motor starter overload 3. Reset and investigate heaters tripped. cause of overload. 4.
- Page 57 3. Clogged water injection filter 3. Replace filter or clean or cooler (interior). cooler. Champion factory remanufactured replacement compressor air end units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13- 11- 605...
- Page 58 SECTION 10 TROUBLE SHOOTING AUTO SENTRY - -W CONTROLLER DISPLAY MODES A green power on light is located in the lower right corner of the keypad. It lights whenever the controls are energized. A steady light indicates that automatic restarting is not enabled, the compressor must be restarted manually follow- ing a power failure.
- Page 59 HIGH DISCH TEMP The temperature was greater than 180 degrees F (82 degrees C) at the airend discharge. Ensure that the compressor receives adequate cooling air or water, and that the coolers are not plugged. LOW AMB TEMP The temperature was less than 40 degrees F (4 degrees C) at the airend discharge.
- Page 60 Message Action Needed HIGH RESVR PRESS Pressure in excess of the programmed high pressure limit has been de- tected. This shutdown will occur if a loss of pneumatic controls occurs. Check the inlet valve, all control piping, solenoid valves, and all other con- trol devices to find the cause for the inlet valve not closing.
- Page 61 Message Action Needed POWER FAILURE The power to the compressor unit has been turned off and back on. Press [STOP/RESET] and select an operating mode. SHORTED THERMSTR The controller has detected a shorted connection to the airend discharge thermistor. This normally indicates a faulty connection (e.g. wire strands touching) at the controller connector 7;...
- Page 62 Symptom Recommended action Compressor runs, but In the CONSTANT RUN and LOW DEMAND modes, the compressor will does not load. not load until the pressure drops below load pressure. Refer to the operat- ing instructions for further information. If pressure is below the load pres- sure, check that the inlet valve operates freely.
- Page 63 GENERAL PROVISIONS AND LIMITATIONS Company’s judgment is proved not to be as warranted. Champion (the “Company”) warrants to each original Labor shall be limited to the amount specified in the retail purchaser (“Purchaser”) of its new products from Company’s labor rate schedule.
- Page 64 For additional information,service or spare parts,contact your local representative or Champion, Customer Service Department, 1301 N. Euclid Ave. Princeton, IL 61356 Telephone: (815) 875- - 3321 Fax: (815) 872- - 0421 Sales and Service in all major cities. Specifications subject to change without notice.