Champion CADRSASP12, Operation Maintenance Manual & Parts List

Page 1: ...D SHOULD ALWAYS BE AVAILABLE TO THOSE PERSONNEL OPERATING THIS UNIT READ UNDERSTAND AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT TO PREVENT INJURY OR EQUIPMENT DAMAGE TWO STAGE TWO CYLINDER DUPLEX AIR COMPRESSOR UNIT MODEL CADRSASP12 CADRSASP13 Form No CQF3422 VER 01 07 18 2017 ...

Page 2: ...sor with these services 1 Trained parts specialists to assist you in selecting the correct replacement parts 2 A full line of factory tested CHAMPLUB compressor lubricants specifically formulated for use in Champion compressors 3 Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor Authorized distributor service technicians are factory trained and ski...

Page 3: ...s 4 Introduction 5 Warranty 5 Dimensions And Specifications 6 Installation 7 thru 16 Operation 16 17 Maintenance Guide 18 Maintenance 19 Maintenance 20 Compressor Oil Specifications 21 Lubricant 21 Torque Values 21 Troubleshooting Chart 22 23 Parts List Unit 24 thru 27 Compressor Repair Parts List 28 thru 34 Receiver Drain Timer 36 Unit Hazard Decal Listing 37 38 Pump Hazard Decals 39 Record Of Ma...

Page 4: ...ration in any way 12 Be sure no tools or rags or loose parts are left on the compressor or drive parts 13 Do not use flammable solvents for cleaning the air inlet filter or element and other parts 14 Exercise cleanliness during maintenance and when making repairs Keep dirt away from parts by covering parts and exposed openings with clean cloth or Kraft paper 15 Do not operate the compressor withou...

Page 5: ...N This reciprocating compressor must not be used for breathing air To do so will cause serious injury whether air is supplied direct from the compressor source or to breathing tanks for later use Any and all liabilities for damage or loss due to injury death and or property damage including consequential damages stemming from the use of this compressor to supply breathing air will be disclaimed by...

Page 6: ...it manufactured by CHAMPION to be free from defects in material and workmanship under normal use and service for a period of twelve 12 months from date of installation or eighteen 18 months from date of shipment by CHAMPION or CHAMPION distributor whichever may occur first CHAMPION makes no warranty in respect to components and accessories furnished to CHAMPION by third parties such as ELECTRIC MO...

Page 7: ...1 5 16 16 1 2 2VB 20 NOTE H P Exhaust Opening 3 4 Tubing Flywheel Rotation Clockwise when viewed from front flywheel to rear SPECIFICATIONS MODEL BORE STROKE INCHES NO OF CYLINDERS OIL CAPACITY QTS WEIGHT LBS PRESSURE PSIG CU FT REV MIN MAX RPM R15B 4 5 8 2 1 2 x 3 2 2 109 175 02914 400 990 PERFORMANCE PUMP PRESSURE PSIG MOTOR H P PUMP RPM DISPLACEMENT CFM COOLING AIR FLOW CFM HEAT REJECTION BTU H...

Page 8: ...t installations require bolting to floor Bolt holes in tank or base feet are provided Before bolting or lagging down shim compressor level Avoid putting a stress on a tank foot by pulling it down to floor This will only result in abnormal vibration and possible cracking of Air Receiver The vibro isolator pads which came with the unit will need to be installed on the unit Tanks bolted directly to a...

Page 9: ...r property damage ELECTRICAL POWER SUPPLY It is essential that the power supply and the supply wiring are adequately sized and that the voltage corresponds to the unit specifications Branch circuit protection must be provided at installation as specified in the National Electrical Code NEC All wiring should be performed by a licensed electrician or electrical contractor Wiring must meet applicable...

Page 10: ...9 FIGURE 1 DUPLEX CONTROL PANEL WIRING DIAGRAM ...

Page 11: ... disconnect or circuit breaker must be provided by installer LOCK OUT OR TAG OUT ALL SOURCES OF POWER 1 Connect wire for one incoming power line to L1 2 Connect wire for one incoming power line to L2 3 Connect wire for one incoming power line to L3 FIGURE 2 COMPRESSOR POWER CONNECTIONS ...

Page 12: ...11 INSTALLATION CONT D CIRCUIT BREAKERS 1 Factory wired No wiring required Figure 3 Circuit Breaker ...

Page 13: ...12 INSTALLATION CONT D MOTOR CONTACTORS 1 Factory wired No wiring required FIGURE 4 MOTOR CONTACTORS ...

Page 14: ...13 LINE TERMINAL INSTALLATION CONT D PRESSURE SWITCHES SEE FIGURES 4 5 1 Factory wired No wiring required FIGURE 5 PRESSURE SWITCH CONNECTIONS PRESSURE SWITCH FIGURE 4 PRESSURE SWITCH ...

Page 15: ...14 INSTALLATION CONT D LOW OIL LEVEL MONITOR 1 Factory wired No wiring required FIGURE 6 LOW OIL LEVEL MONITOR ...

Page 16: ...15 INSTALLATION CONT D ELECTRIC TANK DRAIN 1 Factory wired No wiring required FIGURE 7 ELECTRIC TANK DRAIN ...

Page 17: ...h both compressors run until receiver pressure reaches the cut out pressure setting of the lead pressure switch To manually set lead compressor set Auto Comp1 Comp2 switch to Comp1 or Comp2 for corresponding compressor to be lead To disable power to a compressor set its corresponding disconnect switch to off set it corresponding TOA switch to off and set the Auto Comp1 Comp2 to the opposite compre...

Page 18: ... bowl chamber and maintain the same level as in the crankcase The float moves vertically up or down as the oil level changes If the oil level is below minimum allowable operating level the reed switch will open thus stopping the motor A magnet holds the float and prevents the compressor from starting IMPORTANT NOTE The Oil Monitor does not eliminate the compressor owner s responsibility for period...

Page 19: ...f power supply at wall switch WEEKLY MAINTENANCE 1 Clean dust and foreign matter from cylinder head motor fan blade air lines intercooler and tank 2 Remove and clean intake air filters Do not exceed 15 PSIG nozzle pressure when cleaning element parts with compressed air Do not direct compressed air against human skin Serious injury could result Never wash elements in fuel oil gasoline or flammable...

Page 20: ...ank Open drain valve daily to drain condensation Do not open drain valve if tank pressure exceeds 25 PSIG The automatic tank drain equipped compressor requires draining manually once a week PRESSURE SWITCH The pressure switch is automatic and will start compressor at low pressure and stop when the maximum pressure is reached It is adjusted to start and stop compressor at the proper pressure for th...

Page 21: ...continues to escape through the release valve it is an indication that the check valve is leaking This can be corrected by removing check valve and cleaning disc and seat If check valve is worn badly replace same Before removing check valve be sure all air is drained out of tank and power is disconnected Failure to do so may result in injury or equipment damage THE INTERSTAGE PRESSURE RELIEF VALVE...

Page 22: ...ld be made Maintain oil level at the full line CHANGING TO SYNTHETIC LUBRICANT Applies to diester based synthetic lubricant only If changing to synthetic lubricant the following steps must be completed 1 Compressor must run for a 25 hour break in period using ChampLub ISO 100 oil 2 Thoroughly drain existing oil from crankcase 3 Fill crankcase with a full charge of synthetic lubricant 4 Run compres...

Page 23: ...or replace Warning Relieve tank pressure before servicing 3 Be sure that fuses and heaters are properly rated 4 Check with voltmeter Be sure voltage corresponds to unit specifications 5 Replace motor Tank pressure builds up slowly 1 Air leaks 2 Dirty air filter 3 Defective compressor valves 1 Tighten fittings 2 Clean or replace 3 Install new valve plate assembly Tank pressure builds up quickly 1 E...

Page 24: ... from centrifugal unloader when unit is stopped 1 Check valve stuck in open position 1 Replace check valve Warning Relieve tank pressure before servicing System does not alternate 1 Starter tripped 2 Loose wiring 3 Defective alternator 4 Defective motor 1 Reset starter If starter trips repeatedly have electrical system inspected by an electrician 2 Check and tighten all wiring connections 3 Replac...

Page 25: ...24 PARTS ILLUSTRATION MODEL CADRSASP12 307CAD810 A Ref Drawing ...

Page 26: ...witch 2 P14202A 47 Bracket 1 P14418B 13 Compressor 2 Z2412 48 Electric Drain 1 P14240A 14 Screw 8 M3460 49 Strainer 1 P13749A 15 Nut 16 M3483 50 Tube Fitting 2 86A40 16 Filter 2 P04999A 51 Elbow 1 M3088 17 Motor 2 24CA6647 52 Drain Tube 05 FT M2471 18 Screw 8 M3440 53 Tube Insert 2 P10118A 19 V Belt 4 5L680 54 Tubing 5 25 FT P10117A 20 Screw 2 M568 55 Tube Fitting 1 M2862 21 Pulley 2 M7009D 56 Tee...

Page 27: ...26 DUPLEX CONTROL PANEL MOUNTING 305CAD810 A Ref Drawing ...

Page 28: ... Screw M3471 4 4 Washer M3481 4 5 Nut M3424 4 6 Screw 75LM97 4 7 Conduit Conn M1883 3 8 Wire M2444 11 0FT 9 Wire M3753 7 0FT 10 Conduit Flex M2461 5 0FT 11 Conduit Conn M1757 3 12 Conduit Conn M1606 1 13 Wire M2438 5 0FT 14 Conduit Extra Flex CC1019312 2 0FT 15 Nut M3485 4 16 Conduit Conn P04131A 1 17 Fitting P13259A 1 ...

Page 29: ... 2 Pipe plug 64AA5 1 3 Key U8 1 4 Flywheel NR7A 1 5 Hex head cap screw M738 1 6 Hex nut M2955 1 7 Pipe plug 64A5 1 8 Oil level gauge RE714 1 9 Pipe nipple M492 1 10 Pipe cap M461 1 11 Governor housing gasket set includes 11A 11B 11C 11D Z130 1 11A Governor housing gasket 032 Thick SE1430 1 11B Governor housing gasket 005 007 Thick SE1430A 1 11C Governor housing gasket 010 Thick SE1430B 1 11D Gover...

Page 30: ...igh pressure piston with pin includes items 43 44 ZP02709C 1 43 Piston pin R1021 2 44 Piston pin retaining ring R10102 4 45 Low pressure piston ring set Z798 1 46 High pressure piston ring set Z797 1 47 Cylinder P12237D 1 48 Hex head cap screw M2345 6 49 Low pressure discharge valve assembly Z813 1 50 Valve gasket P04135A 1 51 Discharge valve seat M2097 1 52 Valve disc RE1061 1 53 Valve spring RE1...

Page 31: ...lve cage P14224B 1 82 Valve spring P13866A 2 83 Valve disc P13865A 1 84 Intake valve seat P14118B 1 85 Gasket Valve HPIN CQP14870A 1 86 Hex head machine screw M3220 1 87 High pressure intake manifold P12302B 1 88 Interstage pressure relief valve M3685 1 89 Intake filter P04999A 1 90 Intake filter element P05050A 1 Complete compressor pump gasket set items 11 14 32 Z764 1 Low pressure piston kit it...

Page 32: ... Qty 1 Compression Fitting M2879 1 2 Tube Unloading w Fittings ZSB250A 1 3 Compression Fitting M2864 1 4 Breather Tube w Fitting ZUB375 1 5 Compression Fitting M2864 1 6 Compression Fitting 86A40 1 7 Intercooler w Fittings Z9140 1 8 Compression Nut VP106173 1 C420 B Ref Drawing ...

Page 33: ...TEM DESCRIPTION PART NO QTY 1 Losc Switch VP1153306 1 2 O Ring 2009222 2 3 Tube Oil CC1153304 1 4 Cap L030 1 5 Conduit Connector M1757 1 6 Conduit CC1019312 1 ft 7 Compression Fitting M2863 1 C508 D Ref Drawing ...

Page 34: ...S ITEM DESCRIPTION PART NO QTY 1 Auto Comp1 Comp2 Switch P12523A 1 2 Test Off Auto Switch VP1095446 2 3 N O Contact TEN000977 6 4 N C Contact 24CA7111 1 5 Elapsed Time Meter TEN004553 2 6 Circuit Breaker Handle TEN000784 2 ...

Page 35: ... 24CA6989 2 D Transformer TEN004560 1 E Primary Fuse P10956A 2 F Secondary Fuse TEN004559 1 G Alternator TEN001127 1 H Base Alternator TEN001128 1 I Timer Lag Start TEN004554 1 J Base Timer TEN004555 1 K Line Terminal Ground 24CA5989 1 L Line Terminal 24CA6097 3 M Terminal Block 24CA5984 11 N Ground Terminal Block 24CA5986 2 ...

Page 36: ...STENER SIZE 1 4 NOTICE The duplex control panel will control two 2 5HP compressors operating at 460V 3phase 60Hz The panel will automatically start and stop the units as well as alternate the starting of units Upstream protection fusible disconnect or circuit breaker must be provided by installer FRONT VIEW SIDE VIEW ...

Page 37: ...he pressure vessel is depressurized prior to any attempt to install or remove the Drain Timer DO NOT REMOVE the power cord or timer from the valve while the Drain Timer is plugged in If the drain does not seem to be working properly contact your distributor Any attempt to repair the drain without authorization will VOID WARRANTY 1 Fully drain the vessel by opening an auxiliary gate valve or push t...

Page 38: ... 11a NOT USED 11b DECAL Synthetic or Food Grade Inserts 12 NOT USED 13 DECAL Pressure Setting 95 125 PSIG 14 DECAL Pressure Setting 140 175 PSIG 14 NOTICE Read and Retain Manuals 15 NOT USED 16 DECAL Rotation Direction 17 NOT USED 18 DECAL Pressure Switch P14677A PUMP HAZARD DECAL LISTING PAGE DESCRIPTION PART NO 39 PUMP DECAL SHEET MASTER P13805A NOT USED A1 NOTICE Lubricants A2 DECAL Rotation Di...

Page 39: ...38 UNIT HAZARD DECALS ...

Page 40: ...39 PUMP HAZARD DECALS F ...

Page 41: ...0 RECORD OF MAINTENANCE SERVICE Daily DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR CHECK V BELTS EVERY 3 MONTHS INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 42: ...1 RECORD OF MAINTENANCE SERVICE Daily DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR CHECK V BELTS EVERY 3 MONTHS INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 43: ...2 RECORD OF MAINTENANCE SERVICE Daily DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR CHECK V BELTS EVERY 3 MONTHS INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 44: ... CQF3332VER01 CQF3332VER01 For additional information contact your local representative or visit www championpneumatic com 2016 Champion Inc Printed in U S A ...