Champion ROTORCHAMP RCOF20, Operating And Service Manual

Page 1: ...CHAMPIONR ROTORCHAMP OIL FREE ROTARY SCREW COMPRESSORS MODELS RCOF20 20 HP RCOF25 25 HP RCOF30 30 HP OPERATING AND SERVICE MANUAL 13 11 605 1st Edition February 1999 ...

Page 2: ...ested RotorLub compressor lubricants specifically formulated for use in Champion compressors 4 Repair and maintenance kits designed with the necessary parts to simplify servicing your com pressor Authorized distributor service technicians are factory trained and skilled in compressor maintenance and re pair They are ready to respond and assist you by pro viding fast expert maintenance and repair s...

Page 3: ...will result in economical operation and minimum downtime Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored Warning is used to indicate the presence of a hazard which cancause severeperson al injury death or substantial property damage if the warning is ignored Caution is used to indicate the pr...

Page 4: ...the right of the inlet housing All orders for Parts should be placed with the nearest authorized distributor Where NOT specified quantity of parts required per compressor or unit is one 1 where more than one is required per unit quantity is indicated in parenthesis SPECIFY EXACTLY THE NUMBER OF PARTS RE QUIRED DO NOT ORDER BY SETS OR GROUPS To determine the Right Hand and Left Hand side of a compr...

Page 5: ...tion 1 General Information 1 Section 2 Installation Coolers and Water Systems 9 Section 3 Starting Operating Procedures 16 Section 4 Controls Instrumentation 18 Section 5 Lubrication 39 Section 6 Air Filter 42 Section 7 Belt Drive 44 Section 8 Maintenance Schedule 45 Section 9 Trouble Shooting 47 Section 10 Trouble Shooting Controls 49 Warranty Last Page ...

Page 6: ...e 18 Constant Run Mode 18 Low Demand Mode 18 Sequence Mode 19 Automatic Mode Operation 18 Auxiliary Air Receiver 11 BELT DRIVE SECTION 7 44 Belt Tension Checking 44 Blowdown Valve 29 Check Daily 17 Checking Belt Tension 44 Compressor 1 Compressor Injection Water Inlet Temperature 13 Compressor Injection Water System 13 Compressor Oil System 39 Compressor Water Specification 10 Constant Run Mode Op...

Page 7: ...Motor Grease Recommendations 14 Motor Lubrication 13 Motor Protective Devices 20 Motor Regreasing Interval 14 Oil Level Sight Glass 39 Oil Reservoir Drain 10 Oil Specifications 39 Oil System Compressor 39 Operation Automatic Mode 18 Constant Run Mode 18 Low Demand Mode 18 Sequence Mode 19 Piping Control 11 Power Failure Shutdown 21 Pressure Differential Water Injection Cooler Air Cooled Radiator 1...

Page 8: ...ir and Water Discharge 13 Compressor Injection Water Inlet 13 Temperature Differential Water Injection Cooler Air Cooled Radiator 13 Terminal Strip 31 Thermistor Discharge 30 Transducer Injection Pressure 29 Reservoir Pressure 29 System Pressure 29 Transformer Control 31 TROUBLE SHOOTING SECTION 9 47 TROUBLE SHOOTING AUTO SENTRY W CONTROLLER SECTION 10 49 Trouble Shooting Auto Sentry W Controller ...

Page 9: ...er Display 19 Figure 4 2 Flow Chart for Set Up Programming 22 Figure 4 3 Blowdown Valve 29 Figure 4 4 Inlet Valve 30 Figure 4 5 Shuttle Valve 30 Figure 4 6 Control Tubing Schematic 32 Figure 4 7 Control Schematic Compressor at Full Load Constant Speed Mode 33 Figure 4 8 Control Schematic Compressor Unloaded Constant Speed Mode 34 Figure 4 9 Control Schematic Compressor Unloaded and Blown Down Low ...

Page 10: ...be enters the secondary rotor grove normal volume is reduced and pressure in creases Water is injected into the cylinder to remove the heat of compression and seal internal clearances Volume re duction and pressure increase continues until the air water mixture trapped in the interlobe cavity by the ro tors passes the discharge port and is released to the air water reservoir C Each rotor cavity fo...

Page 11: ...13 11 605 Page 2 FIGURE 1 2 COMPRESSOR END 302EWC797 Ref Drawing FIGURE 1 3 COMPRESSOR END CONTROL BOX REMOVED 302EWC797 Ref Drawing ...

Page 12: ...13 11 605 Page 3 FIGURE 1 4 DRIVE MOTOR END 302EWC797 Ref Drawing FIGURE 1 5 DRIVE COMPONENT SIDE 302EWC797 Ref Drawing ...

Page 13: ...13 11 605 Page 4 FIGURE 1 6 AIR WATER SCHEMATIC 300EWC797 B Ref Drawing ...

Page 14: ... the oil filler plug drain plugs covers or break any connections etc in the compressor air or oil system until the unit is shut down and the air pressure has been relieved D Electrical shock can and may be fatal D Compressor unit must be grounded in accordance with the National Electrical Code A ground jumper equal to the size of the equipment ground conductor must be used to connect the compresso...

Page 15: ... and lockout be fore working on the unit this machine is automatically controlled and may start at any time D An Excess Flow Valve should be on all compressed air supply hoses ex ceeding 1 2 inch inside diameter OSHA Regulation Section 1926 302 D Do not exceed the rated maximum pressure values shown on the nameplate D Do not operate unit if safety devices are not operating properly Check peri odic...

Page 16: ...13 11 605 Page 7 DECALS 206EAQ077 300EWC077 301EWC077 211EAQ077 207EAQ077 ...

Page 17: ...13 11 605 Page 8 DECALS 216EAQ077 206EWD077 222EAQ077 221EAQ077 208EAQ077 ...

Page 18: ...ipment or personal injury LOCATION The compressor should be installed in a clean well lighted and ventilated area with ample space all around the unit for maintenance Select a location that provides a cool clean and dry source of air In some cases it may be necessary to install the air filter at some distance from the compressor to obtain proper air supply Do not install this compressor in a locat...

Page 19: ...les may require the use of mounting bolts and shims to provide uniform support for the base OIL RESERVOIR DRAIN The oil drain plug is located at the bottom of the discharge end of the compressor See FIGURE 5 1 page 40 ENCLOSURE The compressor electric motor water cooler and aftercooler are mounted inside the enclo sure Service doors are provided for maintenance access Be sure to allow enough space...

Page 20: ...d water is not rec ommended AUXILIARY AIR RECEIVER An auxiliary air receiv er is not required if the piping system is large and pro vides sufficient storage capacity to prevent rapid cycl ing When used an air receiver should be of adequate size provided with a relief valve of proper setting a pressure gauge and a means of draining condensate MOISTURE SEPARATOR TRAP Since the unit is equipped with ...

Page 21: ...ctions into one vessel On one end of the vessel the lower half functions as a reser voir providing water storage capacity for the system and the upper portion serves as primary air water sepa ration The reservoir also provides limited air storage for control and gauge actuation Secondary moisture separation is achieved downstream of the aftercooler on the other end of the vessel CHANGING THE SYSTE...

Page 22: ...ry wired for all start er to motor and control connections for the voltage spe cified on the order It is necessary only to connect the unit starter to the correct power supply The standard unit is supplied with an open drip proof motor a NEMA 12 starter and control enclosure See Location para graph for distance to nearest obstruction on starter and control box sides of the unit Electrical shock ca...

Page 23: ...of Service Typical Examples Rating Interval Up to 150 HP 112 KW 18 Months Standard One or Two Shift Operation Above 150 HP 112 KW 12 Months Up to 150 HP 112 KW 9 Months Severe Continuous Operation Above 150 HP 112 KW 6 Months Up to 150 HP 112 KW 4 Months Very Severe Dirty Locations High Ambient Temperature Above 150 HP 112 KW 2 Months ELECTRIC MOTOR REGREASING INTERVAL ...

Page 24: ...1 Trichloroxypropionic Acid 2 4 5 Tp Silvex 0 01 Total Trihalomethanes 0 1 Toxaphene 0 005 Radionuclides Radium 226 and 228 combined 5 pCi L Alpha Particle 15 0 pCi l Beta Particle 4 mRem year Biological Coliform Bacteria 10 L monthly average Physical Characteristics Turbidity 5 NTU Color 15 Color Units Corrosivity Noncorrosive Foaming Agents 0 5 Odor 3 threshold odor number pH 6 5 to 8 5 Total Di...

Page 25: ...nspect the airfilter tobe sureit is clean and tightly assembled Refer to Section 6 Air Fil ter page 42 for complete servicing instructions Be sure the inlet line if used is tight and clean 3 Piping Refer to Section 2 Installation page 9 and make sure piping meets all recommenda tions 4 Electrical Check the wiring diagrams furnished with the unit to be sure it is properly wired See FIGURE 4 10 and ...

Page 26: ...he 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 ter reservoir Pour 2 to 3 gallons of water in through the inlet valve to prime the unit Start the unit by pushing the RUN key The unit will reach normal operating temperature in approximately 5 minutes Check the package operating in...

Page 27: ...sure The controls also delay initial loading of the compressor until a startup delay has been completed Constant Run Mode Operation This mode is best used in applications where there are no long periods of unloaded operation or for minimum response time to sudden demands The compressor unit will start and run continuously using its controls to load and unload the compressor This matches average de...

Page 28: ...will be automatically staged for each lag unit up to 8 total For more in formation refer to the sequencing instructions later in this chapter An optional expansion board must be installed for se quencing operation Communication between control lers is achieved by interconnection of a communica tions cable to expansion board connectors A unit number must be assigned to each unit in this mode but th...

Page 29: ... each shutdown To re sume operation the cause of the shutdown must be corrected and the controller reset by pressing the STOP RESET key Motor Protective Devices Overload heaters are furnished for the starter in the voltage range specified There are three 3 overloads in the starter of proper size for the starter and its enclosure Note that motor nameplate current must be multiplied by 0 577 for wye...

Page 30: ...m line shows the variable that is capable of being altered by programming The following is a step by step guide to programming the AUTO SENTRYR W Remember between each step it is necessary to press the ENTER key to store the new value and advance to the next step Main Adjustments Menu 1 The compressor must be stopped prior to making any adjustments If the unit is running press the STOP RESET key t...

Page 31: ...13 11 605 Page 22 FIGURE 4 2 FLOW CHART FOR SET UP PROGRAMMING 300EWC1255 Ref Drawing ...

Page 32: ...ber corre sponding to the number of compressors that are currently installed on this air system that alsohave AUTO SENTRYR W controllers It should be noted that all AUTO SENTRYR W compressors on the system must have the same number pro grammed here to operate correctly in SE QUENCE mode Adjust as required and press ENTER to proceed Setting the value in step 1 to one indi cates that no sequencing i...

Page 33: ...MIT is displayed The bottom line will indicate 190 degrees F This is the maximum and proper setting for compres sor operation It may be temporarily lowered to verify the function of the temperature shutdown system 3 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...

Page 34: ... observed The serial communications inter face meets RS 485 standards the most widely used interface in harsh industrial environments today How ever it is still recommended that the communications cables be routed through metallic conduit to provide them with both mechanical protection and electromag netic shielding Each expansion circuit board has two modular jacks which accept RJ 12 telephone pl...

Page 35: ...essure to rise above 90 PSI The 3 unit whose timer was initially set at 30 seconds 15 x 3 1 has counted down 20 seconds the total time that system pressure was below 90 PSI If air demand in creases again the pressure will have to fall below 90 PSI for only 10 seconds more to start unit 3 As was previously stated a lag compressor s unload point PSET for short is UNLOAD PRESSURE 3 rotation number 1 ...

Page 36: ...lgorithm used by the AUTO SENTRYR W 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 Here s how it works The...

Page 37: ... factory or field connection of shutdown switches not included on the standard package Simply connect a two wire switch to terminals 9 and 24 The switch must be selected which has contacts closed for normal conditions and open to shutdown the compressor If the contact is opened the compressor will be shut down and will dis play a user selectable message refer to unit setup ad justments for list of...

Page 38: ...25 30 psig Seal Purge Air Pressure Regulator This pressure regulator is used to provide a constant and low control pressure for proper seal operation The regulator should be set for 5 7 psig Inlet Seal Buffering Water Pressure Regulator This pressure regulator is used to provide a constant and low pressure water supply for proper operation of FIGURE 4 3 BLOWDOWN VALVE compressor inlet seals The re...

Page 39: ...ormally simply monitors and maintains coolant level If water cannot be adequately drained the controller will shut down due to high water level Water Solenoid Valves FIGURE 1 6 page 4 The fill and drain valves respond to the signal from the water level switches to maintain water level The fill valve adds coolant to the system by injection into the compressor The drain valve drains water from the r...

Page 40: ...o provide control and overload protection for the fans Overload heaters should be selected and adjusted based on the motor nameplate amps and the instructions located inside the cover of the electrical enclosure Main Starter This starter is used to provide control and overload protection for the main drive motor Full voltage starters employ a single contactor overload heaters should be selected an...

Page 41: ...13 11 605 Page 32 FIGURE 4 6 CONTROL TUBING SCHEMATIC 300EWC797 B Ref Drawing ...

Page 42: ...13 11 605 Page 33 FIGURE 4 7 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD CONSTANT SPEED MODE 301EWC797 A Ref Drawing ...

Page 43: ...13 11 605 Page 34 FIGURE 4 8 CONTROL SCHEMATIC COMPRESSOR UNLOADED CONSTANT SPEED MODE 303EWC797 A Ref Drawing ...

Page 44: ...13 11 605 Page 35 FIGURE 4 9 CONTROL SCHEMATIC COMPRESSOR UNLOADED AND BLOWN DOWN LOW DEMAND MODE 304EWC797 A Ref Drawing ...

Page 45: ...13 11 605 Page 36 FIGURE 4 10 WIRING DIAGRAM FULL VOLTAGE 301EWC546 A Ref Drawing ...

Page 46: ...13 11 605 Page 37 FIGURE 4 11 WIRING DIAGRAM WYE DELTA 302EWC546 A Ref Drawing ...

Page 47: ...13 11 605 Page 38 FIGURE 4 12 AUTO SENTRY W CONTROLLER DISPLAY ...

Page 48: ...s must be adhered to for maximum compressor protection and efficiency See Maintenance Schedule page 45 High temperature operation can cause damage to equipment or per sonal injury Do not repeatedly restart the unit after high temperature stops operation Find and correct the malfunction be fore resuming operation LUBRICANT MAINTENANCE INTERVAL The oil reservoir at the discharge end of the air end h...

Page 49: ...13 11 605 Page 40 FIGURE 5 1 OIL LEVEL SIGHT GLASS 306EWC797 A Ref Drawing ...

Page 50: ...13 11 605 Page 41 FIGURE 5 2 FLOW DIAGRAM AIR COOLED 300EWC797 A Ref Drawing ...

Page 51: ...by soaking about 15 minutes in warm water with a mild nonsudsing detergent Rinse the element thoroughly with clean water a hose may be used if the water pressure does not exceed 40 psig 2 8 bar 4 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 ...

Page 52: ...pect the inlet screen and tube for dirt accumulation each time the filter is serviced Clean the tube when required by ramming a clean dry cloth through the tube Wipe the inside of the filter body to remove any dirt falling from the inlet tube before rein stalling the element Causes of short element life include severe dust conditions infrequent servicing improper cleaning or contamination by oil o...

Page 53: ...n belt tension Remove the belts and replace with new belts Check for correct belt tension and sheave alignment tighten the motor foots bolts and re attach the wire guard CHECKING BELT TENSION Using a spring scale apply a perpendicular force to each belt at the midpoint of the span and measure the deflection Correct deflec tion force and deflection are shown in FIGURE 7 1 To tighten belts merely in...

Page 54: ...2 page 12 Motor Lubrication Refer to Section 2 page 13 Every 8 Hours Operation 1 Observe if the unit loads and unloads properly 2 Check discharge pressure and temperature 3 Drain the petcock on the control line air pressure regulator 4 Check Panel Status indicators and message line for advisories Every 125 Hours Operation 1 Check for dirt accumulation on oil aftercooler core faces and the cooling ...

Page 55: ...nload D Check Discharge Pressure Temp D Check Dirt Accumulation on Cooler D Check Reservoir Oil Level D Change Compressor Lubricant D D D RotorLub 800 Check Relief Valve D Check Check Valve Seals Every Year D Drain Petcock on Inlet Valve Control Line D Add Grease to Inlet End Bearings D Inspect Make Up Water Treatment Cartridge D Or 3 months whichever comes first MAINTENANCE SCHEDULE See detail no...

Page 56: ...ter a short time Air Temperature this section page 48 2 High discharge 2 Replace switch temperature switch malfunction 3 Blown fuse in starter 3 Replace fuse control box investigate if fuses continue to blow 4 Motor starter overload 4 Reset and investigate heaters trip cause of overload Compressor does not 1 Improperly adjusted 1 Refer to Section 4 unload or load control and adjust control 2 Air l...

Page 57: ... 4 Minimum pressure valve 4 Disassemble and clean stuck closed valve High discharge air 1 Dirty or clogged cooler face 1 Clean cooler temperature 2 Insufficient cooling 2 Provide unrestricted supply air flow of cooling air 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...

Page 58: ...redisplay the last alternate display Any will scroll through the list with additional presses DIF PRES The pressure drop across the water filter RES PRES The pressure in the water reservoir INJ PRES The pressure between the filter and injectors SYS PRES The pressure at the service connection DIS TMP The temperature at the airend discharge TOT HRS The total hours of compressor running LOAD HRS The ...

Page 59: ...e Emergency Stop button has been pressed Pull it back out to its nor mal position If the button has not been pressed check that the contact block is firmly mounted in the right or left not center position of the opera tor Check for loose connections which would remove 120 volts from con nector 5 8 of the controller EXTERNAL DEVICE 120 volts has been removed from J1 4 of the expansion board This is...

Page 60: ...T The controller has attempted to turn off the compressor but is still receiv ing a return signal from the starters auxiliary contacts Check that the starter operates freely and that the contact blocks are properly installed on the starter MOTOR OVERLOAD One of the motor overload relays within the electrical control box has tripped indicating high motor shaft load low voltage or excessive imbal an...

Page 61: ...tom Recommended action No display Check incoming power to the compressor unit Ensure that the discon compressor stopped nect is on and that fuses have not blown or circuit beaker tripped If pow er is being properly supplied to the control box check the fuses located at the fan starter the control transformer fuses and the fuse located on the AUTO SENTRYR W keypad chassis Compressor will not start ...

Page 62: ...orage Refer to the operating instructions for further information Display is illegible The LCD contrast is adjustable from all black to all green To adjust find the small adjustment screw located on the larger circuit board behind the keypad Using a small screwdriver adjust for the most pleasing display Erratic pressures The sequencing system transmits low level signal between units to com in SEQU...

Page 63: ...roved not to be as warranted Labor shall be limited to the amount specified in the Company s labor rate schedule Labor costs in excess of the Company rate schedule amounts or labor provided by unauthorized service per sonnel is not provided for by this warranty All costs of transportation of product labor or parts claimed not to be as warranted and of repaired or re placement parts to or from such...

Page 64: ...99 Champion For additionalinformation service orspare parts contact yourlocal 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 Litho in U S A ...