Related Manuals for Champion ROTORCHAMP RCOF
Summary of Contents for Champion ROTORCHAMP RCOF
- Page 1 13-11-609 CHAMPION ® Version: 04 August 1, 2003 ® ROTORCHAMP OIL-FREE ROTARY SCREW COMPRESSORS MODELS RCOF (EWC99D) 20, 25 & 30 HP OPERATING AND SERVICE MANUAL...
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Page 2: Maintain Compressor Reliability And Performance With
Champion Compressor genuine parts, manufactured to design tolerances, are developed for optimum dependability – specifically for Champion compressor systems. Design and material innovations are the result of years of experience with hundreds of different compressor applications. Reliability in materials and quality assurance is incorporated in our genuine replacement parts. -
Page 3: Foreword
FOREWORD Champion Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment. -
Page 4: Table Of Contents
TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Champion Compressor Parts And Support Services ............i Remanufactured Airends ........................i Foreword............................ii List Of Illustrations ..........................i v Section 1, General Information......................1 Section 2, Installation, Coolers And Water Systems ................5 Section 3, Starting &... -
Page 5: List Of Illustrations
LIST OF ILLUSTRATIONS Figure 1-1 – Typical Compression Cycle ....................1 Figure 1-2 – Package Illustration......................2 Figure 1-3 – Air/Water Schematic ......................3 Figure 2-1 – Typical Compressor Room ....................6 Figure 2-2 – Air Flow Chart ........................6 Figure 2-3 – Inlet Line Lengths......................8 Figure 2-4 –... -
Page 6: Section 1, General Information
GENERAL INFORMATION Figure 1-1 – TYPICAL COMPRESSION CYCLE COMPRESSOR - The Champion Rotary Screw compressor is a single stage, positive displacement rotary machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity roller bearings located outside the compression chamber. Single width cylindrical roller bearings are used at the inlet end of the rotors to carry part of the radial loads. -
Page 7: Figure 1-2 - Package Illustration
307EWC797-B (Ref. Drawing) Figure 1-2 – PACKAGE ILLUSTRATION... -
Page 8: Figure 1-3 - Air/Water Schematic
308EWC797-F (Ref. Drawing) Figure 1-3 – AIR/WATER SCHEMATIC... - Page 9 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: DANGER Failure to observe these notices could result in injury to or death of personnel.
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Page 10: Section 2, Installation, Coolers And Water Systems
SECTION 2 INSTALLATION, COOLERS AND WATER SYSTEMS GENERAL - On receipt of the unit, check for any damage that may have occurred during transit or handling. Report any damage or missing parts as soon as possible. CAUTION Do not electric weld on the compressor or base; bearings can be damaged by passage of current. -
Page 11: Figure 2-1 - Typical Compressor Room
heat exchanger at the top of the unit. The air-cooled unit with the standard enclosure requires sufficient flow, Figure 2-2, page 6, for the compressor water/aftercooling system and for electric motor cooling. Do not block the air flow to and from the unit. Allow three and one-half (3-1/2) feet to the nearest obstruction on the control box end of the unit. - Page 12 FOUNDATION - The Champion Rotary Screw compressor requires no special foundation, but should be mounted on a smooth, solid surface. Whenever possible, install the unit near level. Temporary installation may be made at a maximum 10° angle lengthwise or 10° sidewise.
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Page 13: Figure 2-3 - Inlet Line Lengths
WARNING The use of make-up water exceeding the quality units outlined in the “RO Water filter”, Section 8, may result in damage to critical compressor components by corrosion and/or scaling action of impurities in the water. NOTICE Water may no longer be potable after use in the compressor. AUXILIARY AIR RECEIVER - An auxiliary air receiver is not required if the piping system is large and provides sufficient storage capacity to prevent rapid cycling. - Page 14 DISCHARGE SERVICE LINE - The discharge service line connection on the unit is made from the right side at base level from the motor end of the package. When manifolding two or more rotary screw units on the same line, each unit is isolated by the check valve in the unit discharge line. If a rotary screw unit is manifolded to another compressor, be sure the other compressor has a check valve in the line between the machine and the manifold.
- Page 15 Air and Water Discharge Temperature - 105° F to 125° F - Read on the “AUTO SENTRY W” control panel. Compressor Injection Water Inlet Temperature - 90° F to 110° F - Check anywhere on the line from the heat exchanger to the compressor inlet. Water Injection Cooler Temperature Differential (Air Cooled Heat Exchanger - The water temperature differential depends on the temperature of the air at the water injection cooler fan and the cleanliness of the core faces.
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Page 16: Figure 2-4 - Grease Recommendations
MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings. The charts below show recommended grease qualities and regreasing intervals for ball bearing motors. For additional information, refer to the motor manufacturer’s instructions. -
Page 17: Section 3, Starting & Operating Procedures
Use only genuine Champion filters designed and specified for this compressor. 2. Air Filter - Inspect the air filter to be sure it is clean and tightly assembled. Refer to Section 6, page 40, for complete servicing instructions. - Page 18 6. Grounding - Equipment must be grounded in accordance with Section 250 of the National Electrical Code. WARNING Failure to properly ground the compressor package could result in controller malfunction. 7. Rotation - Check for correct motor rotation using “JOG MODE.” An arrow on the compressor/motor belt guard shows correct rotation.
- Page 19 11. Initial Water Fill/Adjusting RO Timer - You package is shipped with all water drained. The water receiver must be filled with filtered water (reverse osmosis filter) prior to operating the compressor unit: • Ensure that the make-up water feed line is installed and the ball valve is open. •...
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Page 20: Section 4, Controls & Instrumentation
SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION - The Champion Twistair water-flooded rotary screw compressor is prewired with all controls, motor, and starter for the voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply, to the shop air line, and to the appropriate water supply. - Page 21 When first starting, the controller will keep the compressor fully unloaded and blown down until the system pressure drops below the load pressure. Low Demand Mode Operation - This mode is similar to the “Continuous Run” mode, except for its behavior under unloaded conditions.
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Page 22: Figure 4-1 - Auto Sentry W Controller Display
Remaining blowdown and auto times are only available in Low Demand, Automatic, and Sequence modes, as appropriate. If no keys are pressed for 5 seconds, the display will revert to its normal mode. The display is also used as a service reminder for normal maintenance items. If service is recommended, the yellow LED next to the service symbol will come on, and a message will alternate with the normal lower line message. - Page 23 SERVICE ADVISORIES The AUTO SENTRY W controller turns on an advisory when it detects operation which needs service attention, but does not warrant shutting down the compressor. Some of these are normal maintenance procedures, and are intended to serve as a reminder to perform routine service. Others are conditions which can reduce the maximum compressor performance.
- Page 24 Water Filter Differential Pressure - The pressure drop across the water filter is continually monitored by the AUTO SENTRY W. The unit will be shut down at a differential pressure of approximately 40 psid (2.8 bars). This becomes active only after the compressor has been running and pressures have had time to stabilize.
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Page 25: Figure 4-2 - Flow Chart For Setup Programming
300EWC1255 (Ref. Drawing) Figure 4-2 – FLOW CHART FOR SETUP PROGRAMMING... - Page 26 PROGRAMMING AND SETUP FOR THE AUTO SENTRY W CONTROLLER Programming and setup is accomplished with the PROGRAM keys. See Figure 4-2, page 20. In all steps, the [ENTER] key will cause the controller to accept the displayed value into memory and advance to the next programming function.
- Page 27 6. In the top line, “AUTO TIME” is displayed. The bottom line will indicate a time between 5 and 20 minutes. It too, is factory set at 10 minutes. Its function is to prevent too frequent motor starting, and to allow the motor a ‘cool-down’ period before stopping. 7.
- Page 28 In the top line, “TRANSFER INTERVAL” is displayed. The bottom line will indicate a number of hours in the range of 1 to 5000. It is factory set at 24. This is the number of hours that this machine will stay in the role of “master” or ”lead” compressor. Normally it is desirable to set this to the same value on all sequenced units to equalize running hours.
- Page 29 In the top line, “AUTO RESTART” is displayed. The bottom line will indicate either ”OFF” or ”ON” The factory setting is ”OFF”, and the controller will display a power failure shutdown after power has been restored. Set this feature to ON when it is necessary to have the compressor automatically restart after a power interruption.
- Page 30 Installation A proper sequencing installation requires two or more Champion rotary air compressors complete with AUTO SENTRY W controllers, piped into a common air system, interconnected as described above. For best performance, the units must be piped directly to the receiver, without any intervening check valves, dryers, or other restrictions.
- Page 31 If no call is received, it will assume position three and again wait for a call from the master. After another lack of a master call, it assumes position two. Subsequently, it assumes position one which makes it the master. As soon as a master is established, it immediately attempts to call all other units and assigns them successive rotation positions.
- Page 32 This is how it works: Whenever the system pressure is below the programmed LOAD PRESSURE, the PSET of each lag compressor is incremented 1 PSI every thirty seconds. Thus, after a short interval (about five minutes in this example), the PSET of the last sequenced compressor will climb up until either it equals the LOAD PRESSURE, or a decrease in demand causes the actual system pressure to rise above the LOAD PRESSURE.
- Page 33 Since these pressure variations are not constant (they will vary due to demand changes, compressor load / unload changes, and number of compressors running), any scheme to compensate for the pressure variations must be dynamic. The exclusive dynamic unload point control feature enables this error correction scheme to be accomplished rather easily.
- Page 34 Remote On / Off - Remote on-off control of the system requires only a simple two-wire control, with an isolated contact suitable for 120 volts, 1 amp. This may be a switch, a timer contact, a relay contact, or a PLC output.
- Page 35 OTHER CONTROL DEVICES In addition to the electronic controller noted above, the following components are also used to control operation of the compressor unit. Refer to air/water schematic, Figure 1-3, page 3, for their relative location. Relief Valve (vv) - A pressure relief valve is installed in the final discharge line and set to approximately 120-125% of the unit’s full load operating pressure for protection against over pressure.
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Page 36: Figure 4-3 - Auxiliary Pressure Switch/Receiver Unloaded Pressure Tabulation
Model Power – bhp Line Pressure – psig Receiver Pressure – psig Figure 4-3 – AUXILIARY PRESSURE SWITCH/RECEIVER UNLOADED PRESSURE TABULATION Check Valve (Aux Blowdown) (i, next to b) – This check valve prevents back flow of air from the airend immediately after halting operation. - Page 37 System Pressure Transducer (s) - This device measures the delivery air pressure supplied to the customer. The AUTO SENTRY W controller uses this measurement for loading/unloading logic. It is located in the starter enclosure. Reservoir Pressure Transducer (t) - This device measures the discharge pressure from the water cooler.
- Page 38 Emergency Stop/Push Button - This is a maintained push-button, and removes power from the controller outputs regardless of controller status. It is located on the upper section of the panel, next to the keypad. This should be used for emergency purposes only - use the keypad [STOP/RESET] for normal controlled stopping.
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Page 39: Figure 4-4 - Wiring Diagram - Full Voltage
305EWC546-B (Ref. Drawing) Page 1 of 2 Figure 4-4 – WIRING DIAGRAM – FULL VOLTAGE 13-11-609 Page 34... - Page 40 305EWC546-B (Ref. Drawing) Page 2 of 2 13-11-609 Page 35...
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Page 41: Figure 4-5 - Wiring Diagram - Full Voltage Less Starter
306EWC546-B (Ref. Drawing) Page 1 of 2 Figure 4-5 – WIRING DIAGRAM – FULL VOLTAGE LESS STARTER 13-11-609 Page 36... - Page 42 306EWC546-B (Ref. Drawing) Page 2 of 2 13-11-609 Page 37...
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Page 43: Section 5, Lubrication
A tag on the reservoir fill cap indicates the type of oil in the reservoir as it left the factory. RECOMMENDED LUBRICANT - Champion compressors are factory filled with RotorLub™ lubricants. These lubricants are formulated to the highest quality standards and are factory authorized, tested and approved for use in rotary screw compressors. -
Page 44: Figure 5-1 - Oil Level Sight Glass
LUBRICANT MAINTENANCE INTERVAL - The oil reservoir at the discharge end of the airend has a capacity of approximately 32 oz. (.8 liters). The oil bath type lubrication utilized does not require an oil filter or dedicated circulation hardware. As such, discharge end lubricant change intervals of 2000 hours are recommended as the only maintenance requirement in lieu of filter changes and circulation system maintenance. -
Page 45: Section 6, Air Filter
Clean every 50 to 150 operating hours depending on dust conditions. NOTICE Use only genuine Champion air filter elements on Champion compressor units. Genuine parts are available through your authorized Champion distributor. To service: Remove the wing nut and pull out the filter element. - Page 46 Inspect the element for ruptures or cracks in the pleated media; replace the element if any are found. Inspect the gasket on the bottom (outlet end) of the element; replace the entire element if the gasket is damaged. A spare element will keep down time to a minimum. Allow the element to air dry COMPLETELY.
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Page 47: Section 7, Belt Drive
SECTION 7 BELT DRIVE Proper drive belt tension and alignment are provided at the factory; however, good practice dictates checking the drive alignment and tension after shipment and before initial start-up. Sheaves should align straight across the front with a straight edge. The best tension is just enough tension to keep belts from “squealing”... -
Page 48: Figure 7-1 - Belt Tension 3Vx Belts
Deflection Force (Lbs.) (N) Deflection (Inches) (mm) Deflection Deflection Motor Force Pounds (Newtons) H.P. (Kw) No. of Belts (per belt) Inches (mm) 20 (15 kW) 6 to 7 (1.3 to 1.5) 5/16 (8) 25 (19 kW) 6 to 8.5 (1.3 to 1.9) 5/16 (8) 30 (22 kW) 6 to 7 (1.3 to 1.5) -
Page 49: Section 8, Ro Water Filtration System
SECTION 8 RO WATER FILTRATION SYSTEM General Information: The water mass utilized by the water-flooded screw compressor typically contains solids in dissolved and suspended forms. These solids, of organic and inorganic nature, are present in the local water supply or are deposited by the air stream pumped through the compressor, and usually contain corrosive and fouling agents. - Page 50 The capillary tube (mm) controls the flow of wash water used to flush away the contaminants captured by the RO membrane. The flushing process, active whenever the membrane is filtering water, requires 3.5 gpm of treated water for every 1 gpm of treated water delivered. The fast-flush valve (ll) is provided to intensify the flushing process during periodic maintenance.
- Page 51 CAUTION Ensure that the PLC “run/stop” mode selection switch remains in the “run” position at all times – except during reprogramming. Failure to do so will halt the timed operation of the RO Filter System and will damage its membrane by fouling. RO System Specifications : Clean water flow capacity: 73 gpd (192ml/min) at 50 psig, 70°...
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Page 52: Figure 8-1 - Plc Connections And Cycle Time Combinations
Initial Set-Up and Operation: The RO system is fully assembled and integrated into the compressor package. As delivered, the new RO membrane contains a FDA approved preservative solution to prevent microbiological growth and freezing. This preservative will be flushed during the initial hours of operation. Adjusting the cycle timer. - Page 53 Maintenance: Monitoring the water quality. The performance of the RO system is directly related to the quality of the incoming raw water. It is critical that an on-site water-sampling schedule be originated to monitor the performance of the RO system. By comparing specified rejection rates to those experimentally observed, the performance of the RO system is determined.
- Page 54 Monitoring the water flow In addition to the water quality, it is important that the filtered water flow be checked monthly: • Turn off the isolation valve (pp) on the water tank (nn). • If the compressor is not running, just open the filtered water test point (qq), let it run for a few seconds to depressurize the line, and then time-collect a sample of the steady stream.
- Page 55 RO membrane The operational live of the RO membrane also varies with the quality of the raw feed water. As a general rule, it should be replaced every 1-2 years. Typical signs that the device is plugging up are a decrease of clean water flow and a decrease of rejection of levels of compounds found in the site water.
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Page 56: Section 9, Maintenance Schedule
SECTION 9 MAINTENANCE SCHEDULE SERVICE CHECK LIST Air Filter - Operating conditions determine frequency of service. When the air pressure differential across the filter reaches 25” H O, the “CHANGE AIR FILTER” message appears on the display accompanied by a yellow indicator in the status area of the keypad signaling that the air filter requires servicing or changing. - Page 57 Every 125 Hours Operation Check for dirt accumulation on oil/aftercooler core faces and the cooling fan. If cleaning is required, clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable safety solvent in a direction opposite that of the cooling fan air flow. This cleaning operation will keep the exterior cooling surfaces clean and ensure effective heat dissipation.
- Page 58 IF OIL IS ANALYZED at the end of a maintenance interval (2000 hr. max.), and is found in good condition, it may be used for the next 2000 hour interval – Champion provides free oil analysis services. OTHERWISE, IF OIL IS NOT ANALYZED at the end of any interval, it must be changed.
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Page 59: Section 10, Troubleshooting
SECTION 10 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start 1. Wrong lead connections. Change leads. 2. Blown fuses in control box. Replace fuse. 3. Motor starter overload Reset and investigate heaters tripped. cause of overload 4. Pressure in reservoir. Inspect blowdown valve. - Page 60 Condensate return strainer 1. Inspect and clean. in package discharge air and/or orifice plugged. NOTICE Champion factory remanufactured replacement compressor airend units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13-11-609 Page 55...
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Page 61: Section 11, Troubleshooting Auto Sentry W Controller
SECTION 11 TROUBLESHOOTING AUTO SENTRY W CONTROLLER W 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 following a power failure. - Page 62 ADVISORY TROUBLESHOOTING GUIDE All advisories are indicated on the keypad by a yellow indicator in the Status area, and one of the following messages alternating with the normal lower line display. Perform service or maintenance as indicated, the clear the advisory as instructed in Section 4. Message Action Needed CHNG AIR FILTER...
- Page 63 Message Action Needed EXTERNAL DEVICE 120 volts has been removed from J1-4 of the expansion board. This is normally jumpered directly to terminal 9, but the jumper may be removed to add a field installed shutdown switch. Reset the external switch. HIGH DIS TEMP R This indicates that the controller has detected a rapid temperature rise in the airend discharge.
- Page 64 Message Action Needed LV RELAY 120 volts has been removed from J1-4 of the expansion board. This is normally jumpered directly to terminal 9, but the jumper may be removed to add a field installed shutdown switch. Reset the external switch. MOTOR CONTACT The controller has attempted to turn off the compressor, but is still receiving a return signal from the starters’...
- Page 65 Message Action Needed WATER PRESS 120 volts has been removed from J1-4 of the expansion board. This is normally jumpered directly to terminal 9, but the jumper may be removed to add a field installed shutdown switch. Reset the external switch. ZERO XDUCER Signal voltage has fallen too low at transducer: (A) Final discharge, (B) Water Injection, or (C) Reservoir.
- Page 66 Message Action Needed Compressor runs, but In the CONSTANT RUN and LOW DEMAND modes, the compressor will not does not load load until the pressure drops below load pressure. Refer to the operating instructions for further information. If pressure is below the load pressure, check that the inlet valve operates freely.
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Page 67: Section 12, Troubleshooting The Ro Filtration System
SECTION 12 TROUBLESHOOTING THE RO FILTRATION SYSTEM Problem: None or low water production Reasons: Solutions: Raw water feed (gg) turned off......Open raw feed water valve. Pre-filters (ll, hh) fouled or plugged...... Replace cartridges. Raw water feed pressure below 50psig....Improve pressure condition. - Page 68 INDEX Air Filter, Section 6 ............40 Discharge Service Line............ 9 Air Flow In The Compressor System........1 Electrical Wiring............. 10 Auto Sentry W Controller Enclosure ................ 7 Alarm Relay ..............29 Foundation............... 7 Automatic Sequence Change........27 General................5 Auxiliary Shutdown............
- Page 69 GENERAL PROVISIONS AND LIMITATIONS Champion (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, made with good material and workmanship. No warranty is made with respect to: Any product which has been repaired or altered in such a way, in the Company’s judgment, as to affect the product adversely.
- Page 70 Princeton, Illinois 63156 USA Phone: (815) 875-3321 Fax: 815-872-0421 © champion@championpneumatic.com E-mail: 2000 Gardner Denver, Inc. Litho in U.S.A. Plants in Princeton IL, and Manteca, CA Due to Champion’s continuing product development program, specification and materials are subject to change without notice.