Champion R Series, Operation & Service Manual

Page 1: ...Electric Drive Compressors Units R 10 15 R 30 R 40 R 70 THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION AND 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 ...

Page 2: ...upport your Champion air compressor 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 technic...

Page 3: ...s and Decals 6 Safety and Operation Precautions 6 Unit Hazard Decal List See Page 8 7 Pump Hazard Decal List See Page 9 7 Unit Hazard Decals 8 Pump Hazard Decals 9 Installation 10 Air Receiver Installation 13 Operation 14 Low Oil Shutdown Control 16 Compressor Oil Specifications 18 Guide to Maintenance 20 Maintenance Checklist 26 Troubleshooting Chart 27 Maintenance Log 29 ...

Page 4: ...rtup or 30 months from date of shipment from Company whichever occurs first Service will be provided by Company representative or authorized service personnel for repair or replacement of any product or part which in the Company s sole judgement is proved not to be as warranted Labor shall be limited to the amount specified in the Company s labor rate schedule All costs of transportation of produc...

Page 5: ...n in any way 12 Be sure no tools 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 without guards...

Page 6: ...TION This Oil Lubricated Compressor must not be used for breathing air without adequate downstream filters purifiers and controls 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 injuries death and or property damage including consequential damages stemming from the use...

Page 7: ...move Fan Guard 11a NOTICE Lubricant 11b NOT USED 12 DECAL Synthetic or Food Grade Inserts 13 NOT USED 14 DECAL Pressure Setting 95 125 PSIG 14 DECAL Pressure Setting 140 175 PSIG 15 NOTICE Read and Retain Manuals 16 NOT USED 17 DECAL Rotation Direction 18 NOT USED P14677A DECAL Pressure Switch Pump Hazard Decal List See Page 9 PART NO DESCRIPTION P13805A PUMP DECAL SHEET MASTER A1 NOT USED A2 NOTI...

Page 8: ...R Series Electric 8 CQF3473 v 01 Operation Service April 17 2018 Unit Hazard Decals ...

Page 9: ...R Series Electric 9 CQF3473 v 01 Operation Service April 17 2018 Pump Hazard Decals F ...

Page 10: ...vel the compressor unit It is recommended that optional vibration isolator pads be installed with the unit Tanks anchored directly to a concrete floor without vibration isolator pads will not be warranted against cracking Champion vibration isolator pads must be used for extended warranty to apply to ASME air receivers See Air Receiver Installation section Do not tighten the anchor screws nuts dow...

Page 11: ...lectrician or electrical contractor Wiring must meet applicable codes for area of installation The table gives recommended wire sizes based on the 2017 NEC WIRE SIZE AWG 75 C COPPER 40 C AMBIENT MOTOR HP 3 PHASE 1 PHASE 200 208V 230V 460V 575V 115V 208V 230V 2 14 12 14 12 14 14 14 14 8 4 12 8 12 10 3 12 10 14 10 14 14 14 14 6 3 10 6 10 8 5 10 6 12 8 14 12 14 12 8 4 8 4 7 1 2 8 4 10 6 14 10 14 10 4...

Page 12: ...A union connection to the unit and water drop leg is recommended Install a flexible connector between the discharge of the unit and the plant air piping Plant air piping should be periodically inspected for leaks using a soap and water solution for detection on all pipe joints Air leaks waste energy and are expensive Minimum Pipe Sizes For Compressor Air Lines Based on clean Smooth Schedule 40 Pip...

Page 13: ...s shims are not provided It is the compressor owner s responsibility to provide a suitable foundation and isolator installation Do not tighten the anchor screws nuts down completely this will result in undesirable stress on the tank foot This can cause abnormal vibration and possible cracking of the air receiver resulting in injury or equipment damage TEN011442 00 Ref Drawing CUT AWAY VIEW OF ANCH...

Page 14: ... If the receiver pressure falls below the cut in pressure setting of the lag PS2 pressure switch both compressors run until receiver pressure reaches the cut out pressure setting of the lead PS1 pressure switch CONTINUOUS RUN units are equipped with a ball valve pilot valve and head unloaders to provide continuous run capabilities The pilot valve acts as an automatic air switch allowing air to flo...

Page 15: ... c When the air receiver pressure drops to the cut in setting of the pressure switch the machine will start d Repeat steps a thru c three times 9 Check for proper operation of the head unloaders if equipped a Open the ball valve located next to the pilot valve b When the air receiver pressure reaches the cut in setting of the pilot valve the head unloaders will activate The air compressor continue...

Page 16: ...rating level the reed switch will open thus stopping the motor A magnet holds the float and prevents the compressor from starting In order to start the compressor the following steps must be taken 1 Fill crankcase to recommended capacity as indicated when level reaches the middle of the oil sight glass 2 Turn cam reset knob 90 clockwise IMPORTANT NOTE The Oil Monitor does not eliminate the compres...

Page 17: ...in crankcase when compressor is shut off b Check crankcase oil for proper viscosity This is particularly important for temperature conditions below 32 F Oil which is too thick can slow the response of the mechanism causing float to register a low level c Change oil regularly Clean oil insures proper operation of the Oil Monitor as well as compressor See Compressor Oil Specification and Maintenance...

Page 18: ... excellent performance in high temperature applications Do not mix oil types weights or brands Emulsification of oil white milky substance indicates unsafe accumulation of moisture and may be evidence compressor is oversized for application Failure to promptly consult your local distributor or Champion Customer Service can be grounds to deny warranty LUBRICANT ISO 100 MINERAL CHAMPLUB ISO 100 DESC...

Page 19: ...IC DIESTER BASED LUBRICANT If changing to synthetic lubricant the following steps must be completed 1 Compressor must run for the break in period using CHAMPLUB ISO 100 lubricant 2 During the break in period a careful and regular check of the oil level should be made Maintain oil level at the full line 3 After the break in period thoroughly drain existing oil from crankcase 4 Add a full charge of ...

Page 20: ...parts which can cause injury or equipment damage Valves must be reinstalled in original position Valve gaskets should be replaced each time valves are serviced PRESSURE RELIEF VALVE The pressure relief valve is an automatic pop valve Each valve is properly adjusted for the maximum pressure permitted by tank specifications and working pressure of the unit on which it is installed If it should pop i...

Page 21: ...sure adjustment nut 3 2 Check reading on the tank pressure gauge Set the compressor maximum pressure by turning threaded cap 1 clockwise to increase pressure or counter clockwise to decrease pressure 3 After pressure is set tighten locknut 4 Be careful not to move threaded cap 1 PILOT VALVE DIFFERENTIAL PRESSURE ADJUSTMENT Proceed with the following instructions while compressor is running 1 Loose...

Page 22: ...ressure release valve spring and ball Clean thoroughly and return parts in the same order in which they were removed See Centrifugal Unloader section in parts list for diagram Loose drive belts can also cause unloader to leak by preventing the compressor from reaching proper speed See BELTS page 24 CHECK VALVE The check valve closes when the compressor stops operating preventing air from flowing o...

Page 23: ...n intervals TORQUE VALUES Component Fastener Size Thread Model Torque Governor Housing 3 8 16 R10 R15 400 Inch lb Governor Housing 7 16 20 R30 R40 R70 550 Inch lb Cylinder Flange 7 16 20 R10 R15 R30 400 Inch lb Cylinder Flange 1 2 13 R40 R70 900 Inch lb Governor Spindle Screw 7 16 20 R10 R15 R30 R40 R70 470 Inch lb Rod Bolt 5 16 18 R10 R15 R30 230 Inch lb Rod Bolt 7 16 20 R40 R70 400 Inch lb Manif...

Page 24: ... the motor pulley and compressor flywheel 6 Place the tension checker squarely on one belt at the center of the belt span Apply a force on the plunger perpendicular to the belt span until the bottom of the large o ring is even with the bottom of the straight edge 7 Remove the tension checker and read the force applied from the bottom of the small o ring on the deflection force scale 8 Compare the ...

Page 25: ...9 R30 10 175 758 8 15 B 81 2 4 8 7 0 R30 15 125 175 1049 11 15 B 85 2 5 4 7 8 R40 15 125 919 11 40 B 103 2 5 3 7 7 R40 15 175 782 9 75 B 100 2 5 9 8 5 R70 20 125 715 8 95 B 100 3 5 7 8 2 R70 20 175 665 8 35 B 100 3 6 0 8 7 R70 25 125 919 11 40 B 103 3 5 7 8 3 R70 25 175 782 9 75 B 101 3 6 4 9 3 R70 30 125 175 919 11 40 B 103 3 6 6 9 6 1 The values given in the BELT DEFLECTION FORCE table are calcu...

Page 26: ...on Section for details on how to check and set proper tension c If necessary loosen mounting hardware which secures motor to base Slide motor within slots of baseplate to achieve proper tension d Check the alignment of pulleys The compressor flywheel and motor sheave should be aligned within 1 2 with notched belts and 2 with wrapped belts Adjust if necessary e Tighten mounting hardware to secure m...

Page 27: ...ve motor 1 Adjust or replace Warning Relieve tank pressure before servicing 2 Clean or replace Warning Relieve tank pressure before servicing 3 Be sure that fuses and coils 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 6 Tighten fittings 7 Clean...

Page 28: ...hten bolts Replace gaskets 4 Replace rings 5 Replace cylinder Air escapes from centrifugal unloader when unit is running 1 Centrifugal unloader release valve dirty or detective 1 Clean or replace valve Air escapes 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 Duplex ...

Page 29: ...ervice April 17 2018 Maintenance Log DAILY CHECK OIL LEVEL DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR MONTHLY INSPECT AIR SYSTEM EVERY 3 MONTHS CHANGE OIL INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 30: ...ervice April 17 2018 Maintenance Log DAILY CHECK OIL LEVEL DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR MONTHLY INSPECT AIR SYSTEM EVERY 3 MONTHS CHANGE OIL INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 31: ...ervice April 17 2018 Maintenance Log DAILY CHECK OIL LEVEL DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR MONTHLY INSPECT AIR SYSTEM EVERY 3 MONTHS CHANGE OIL INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

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