Gardner Denver Champion ROTORCHAMP EFD99A, Operating And Service Manual

Page 1: ...CHAMPION 13 8 627 Version 04 May 2 2006 ROTORCHAMP BASE MOUNTED COMPRESSORS MODELS EFD99A 40 50 HP OPERATING AND SERVICE MANUAL...

Page 2: ...providing 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...

Page 3: ...dicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored WARNING Warning is used to indicate the presence of a hazard whic...

Page 4: ...irends ii Foreword iii Index v List Of Illustrations vii Section 1 General Information 1 Section 2 Installation 7 Section 3 Starting Operating Procedures 14 Section 4 Controls Instrumentation 17 Secti...

Page 5: ...t Recommended 27 Upgrade Procedure 31 Lubrication Motor 13 Lubrication Cooling And Sealing 1 Lubrication Oil Cooler Oil Filter Separator Section 5 27 Maintenance Schedule Section 8 43 Moisture Separat...

Page 6: ...s Operation 43 Every 8 Hours Operation 43 Every Year 43 Motor Lubrication 43 Sheave Alignment 41 Starting Operating Procedures Section 3 15 Starting The Unit 18 Unit Cold 18 Unit Hot 18 Stopping The U...

Page 7: ...tallation 9 Figure 4 1 Control Schematic 17 Figure 4 2 Key Pad 18 Figure 4 3 Wiring Diagram Full Voltage 22 Figure 4 4 Wiring Diagram Full Voltage 23 Figure 5 1 Flow Diagram 24 Figure 5 2 Approximate...

Page 8: ...B As meshing continues more of the main rotor lobe enters the secondary rotor grove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression...

Page 9: ...13 8 627 Page 2 Figure 1 2 COMPRESSOR ILLUSTRATION 300EFD797 A Ref Drawing...

Page 10: ...ing not suitable for human consumption Do not loosen or remove the oil filler plug drain plugs covers the thermostatic mixing valve or break any connections etc in the compressor air or oil system unt...

Page 11: ...d tagout before working on the unit this machine is automatically controlled and may start at any time An Excess Flow Valve should be on all compressed air supply hoses exceeding 1 2 inch inside diame...

Page 12: ...13 8 627 Page 5 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 13: ...13 8 627 Page 6 DECALS 216EAQ077 217EAQ077 222EAQ077 221EAQ077 208EAQ077...

Page 14: ...reezing temperatures in a clean well lighted well ventilated area with ample space all around including above for maintenance If a low ceiling is encountered the hot discharge air may need to be ducte...

Page 15: ...possible install the unit near level Temporary installation may be made at a maximum 5 angle lengthwise or 5 sidewise Mounting bolts are not normally required However installation conditions such as...

Page 16: ...Service panels are provided for maintenance access Be sure to allow enough space around the unit for the panels to be removed Any of the enclosure panels may be removed by opening the latch and liftin...

Page 17: ...nsheltered outside installations should be avoided where possible Installation next to a heated building where enough heat can be used to keep the compressor room above freezing will save many complic...

Page 18: ...ed 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 manif...

Page 19: ...The following charts show recommended grease qualities and regreasing intervals for ball bearing motors For additional information refer to the motor manufacturer s instructions The following procedur...

Page 20: ...EGREASING INTERVAL Type of Service Typical Rating Relubrication 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 Se...

Page 21: ...lter and air oil separator is necessary to achieve maximum service and extended drain intervals of RotorLub 4000 lubricant Use only genuine Champion filters designed and specified for this compressor...

Page 22: ...e controls to the desired load pressure DO NOT EXCEED THE MAXIMUM OPERATING PRESSURE ON THE COMPRESSOR NAMEPLATE See Operation Adjustments in the Controller Operating and Service Manual WARNING Operat...

Page 23: ...To start press STOP RESET then press RUN 3 Run for approximately five minutes or until the temperature stabilizes The unit is equipped with a minimum 70 psig pressure check valve No special procedure...

Page 24: ...or to starting the STOP RESET key must be pressed to place the controller into its READY state as indicated on the display Compressor operation may then be started by pressing the RUN key While in any...

Page 25: ...t to approximately 120 125 of the unit s full load operating pressure for protection against overpressure Periodic checks should be made to ensure its operation The relief valve should be tested for p...

Page 26: ...e is supplied to the top of the cylinder to load the compressor Check Valve Figure 4 1 page 17 This valve is normally closed while the compressor is loaded or stopped While running unloaded it opens t...

Page 27: ...ency purposes only use the keypad STOP RESET for normal controlled stopping WARNING Automatic restarting or electrical shock can cause injury or death Open and lock main disconnect and any other circu...

Page 28: ...ervoir Close the service valve 2 Disconnect lockout and tagout the power supply to the starter 3 Tighten the nut down on the minimum pressure check valve cover 4 Remove the four 4 bolts holding the co...

Page 29: ...13 8 627 Page 22 Figure 4 3 WIRING DIAGRAM FULL VOLTAGE 300EFD546 C Ref Drawing Page 1 of 2...

Page 30: ...13 8 627 Page 23 Figure 4 4 WIRING DIAGRAM FULL VOLTAGE 300EFD546 C Ref Drawing Page 2 of 2...

Page 31: ...nt via an oil return line through an orifice and back into the compressor RECOMMENDED LUBRICANT Champion compressors are factory filled with RotorLub lubricants These lubricants are formulated to the...

Page 32: ...d The oil should be visible in the white range a flashlight must be used of the gauge If there is only red showing on the gauge the oil level is too high and must be drained If the oil level is in the...

Page 33: ...3 U S Gallons 11 Liters Bottom of Site Glass to Top of Site Glass 3 U S Quart 3 Liters Figure 5 2 APPROXIMATE OIL SYSTEM CAPACITIES OIL CHANGE INTERVAL Recommended oil change intervals are based on oi...

Page 34: ...he air oil reservoir 5 Close the drain valve If the drained oil and or the oil filter element are contaminated with dirt flush the entire system the reservoir oil cooler and lines Inspect the air oil...

Page 35: ...orage of oils Changing the oil will be of little benefit if done in a careless manner CAUTION Excessive oil carryover can damage equipment Never fill oil reservoir above the top of the site glass LUBR...

Page 36: ...filter and reinstall used filter 4 Fill system with a 50 percent charge of the new lubricant Start the machine and stay there to observe Allow the machine to run about five minutes at temperature or...

Page 37: ...l cooling of the oil reservoir short loaded cycle in high humidity or malfunctions of the thermal valve may result in moisture in the oil system which is detrimental to compressor lubrication and coul...

Page 38: ...il reservoir separation chamber and all piping and tubing may be at high temperature during and after operation 1 Stop unit and be sure no air pressure is in the oil reservoir 2 Disconnect lockout and...

Page 39: ...l from the air stream Oil impinging on the inside of the separator element drains directly back into the oil reservoir by gravity Oil collected outside the element is returned through tubing to the co...

Page 40: ...ir service valve located after the compressor package discharge 3 Disconnect lockout and tagout the power supply to the starter 4 Remove the minimum pressure check valve air oil separator housing cove...

Page 41: ...66 C to 74 C Install a tee at the oil filter outlet and check with a thermometer Oil Inlet Pressure Check at the fitting in the line near the compressor oil inlet With air receiver pressure at 100 ps...

Page 42: ...when inspection indicates an accumulation of dirt on the outside of the element Inspect every few days until experience determines the proper time interval for servicing To Service 1 Be certain the u...

Page 43: ...rupture crack or pin holes in the pleated media Inspection should be done by placing a bright light inside the element WARNING Do not oil this element Never operate unit without element Never use elem...

Page 44: ...k the motor base up to loosen the belt tension Remove the belts 4 Install new belts tighten belts using the adjust screws Check for correct belt tension 5 Check sheave alignment See SHEAVE ALIGNMENT p...

Page 45: ...down the jack bolts on one side or the other of the hinged plate Check for alignment with straight edge It also may be necessary to use the nuts that are on the jack bolts to push up on one side or t...

Page 46: ...13 8 627 Page 39 Motor H P No of Belts Deflection Force Pounds Deflection In Inches 40 6 6 8 5 3 8 50 6 6 8 5 3 8 Figure 7 1 BELT TENSION 3VX BELTS...

Page 47: ...ing 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 ope...

Page 48: ...ir Oil Level Check for Proper Load Unload Check Dirt Accumulation on Cooler Change Oil Filter Element Clean Oil Return Strainer Change Compressor Lubricant RotorLub 4000 Check Relief Valve Check Condi...

Page 49: ...otor starter overload heaters trip 4 Reset and investigate cause of overload Compressor does not unload or load 1 Improperly adjusted control 1 Refer to SECTION 4 page 17 and adjust control 2 Air leak...

Page 50: ...compressed air system 7 Check for leaks fix any leaks found 8 V Belts broken 8 Replace 9 V Belts slipping 9 Test belt tensioning 10 Pressure limits incorrectly set 10 Check correct pressure limits in...

Page 51: ...ricating coolant 6 Inoperative minimum pressure valve 6 Replace seals in valve 7 Operation at elevated discharge temperatures 7 Reduce temperature See High Discharge Air Temperature this section 8 Sca...

Page 52: ...Operation with lower voltages will reduce motor life and load capacity As voltages get further below the design range other symptoms may show up Low voltages may lead to high motor currents The overlo...

Page 53: ...ide labor by Company representative or authorized service personnel for repair or replacement of any product or part thereof which in the Company s judgment is proved not to be as warranted Labor shal...

Page 54: ...orth Euclid Avenue Princeton Illinois 63156 USA Phone 815 875 3321 Fax 815 872 0421 E mail champion championpneumatic com Plants in Princeton IL and Manteca CA Due to Champion s continuing product dev...