Champion ROTORCHAMP EWF99C-100 Service manual

CHAMPION®
13-11-614
Version: 00
July 1, 2003
ROTORCHAMP
OIL-FREE ROTARY SCREW
COMPRESSORS
MODELS
EWF99C - 100, 125 & 150 HP
OPERATING AND
SERVICE MANUAL

13-11-614 Page 2
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE CHAMPION® COMPRESSOR PARTS AND SUPPORT SERVICES
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.
Your authorized Champion Compressor distributor offers all the backup you’ll need. A worldwide network of authorized distributors
provides the finest product support in the air compressor industry. Your local authorized distributor maintains a large inventory of
genuine parts and he is backed up for emergency parts by direct access to the Master Distribution Center (MDC) in Memphis,
Tennessee.
Your authorized distributor can support your Champion air compressor with these services:
1. Trained parts specialists to assist you in selecting the correct replacement parts.
2. Factory warranted new and remanufactured rotary screw airends. Most popular model remanufactured airends are maintained
in stock at the Remanufacturing Center in Indianapolis, IN., for purchase on an exchange basis with liberal core credit available
for the replacement unit.
3. A full line of factory tested RotorLub™ compressor lubricants specifically formulated for use in Champion compressors.
4. Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor.
Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair. They are ready to
respond and assist you by 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:
Champion
1301 N. Euclid Ave.
Princeton, Il. 61356
Phone: [phone]
Fax: [phone]
REMANUFACTURED AIRENDS
Whenever an airend requires replacement or repair, Champion offers an industry unique, factory remanufactured airend exchange
program. From its modern Remanufacturing Center in Indianapolis, IN., Champion is committed to supplying you with the highest
quality, factory remanufactured airends that are guaranteed to save you time, aggravation and money.
ImmediatelyAvailable
Repair downtime costs you money, which is why there are over 200 remanufactured units in inventory at all times, ready for
immediate delivery.
Skilled Craftsmen
Our Remanufacturing assembly technicians average over 20 years experience with air compression products.
Precision Remanufacturing
All potentially usable parts are thoroughly cleaned, inspected and analyzed. Only those parts that can be brought back to original
factory specifications are remanufactured. Every remanufactured airend receives a new overhaul kit: bearings, gears, seals,
sleeves and gaskets.
ExtensiveTesting
Champion performs testing that repair houses just don’t do. Magnaflux and ultrasonic inspection spot cracked or stressed castings,
monochromatic light analysis exposes oil leaks, and coordinate measurement machine inspects to +/- .0001”, insuring that all
remanufactured airends meet factory performance specifications.
Warranty
Champion backs up every remanufactured airend with a new warranty…18 months from purchase, 12 months from service.
Champion remanufactured airends deliver quality without question…year in and year out.
Call Champion for information on the airend exchange program and the name of your authorized distributor.
Phone Number: [phone]
Fax: [phone]

13-11-614 Page 3
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. Careful adherence to these
instructions will result in economical operation and minimum downtime.
DANGER
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
Warning is used to indicate the presence of a hazard which can cause severe
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard which will or can cause
minor personal injury or property damage if the warning is ignored.
NOTICE
Notice is used to notify people of installation, operation or maintenance
information which is important but not hazard-related.
This book covers the following models:
HP PSI MODEL PARTS LIST
100, 125 & 150 100, 125 & 150 EWF99C 13-11-514

13-11-614 Page 4
TABLE OF CONTENTS
Maintain Compressor Reliability And Performance With Genuine
Champion Compressor Parts And Support Services.........................................................................2
Remanufactured Airends.....................................................................................................................2
Foreword............................................................................................................................................3
List Of Illustrations ..............................................................................................................................5
Section 1, General Information.............................................................................................................6
Section 2, Installation, Coolers And Water Systems............................................................................12
Section 3, Starting & Operating Procedures........................................................................................21
Section 4, Controls & Instrumentation.................................................................................................24
Section 5, Lubrication........................................................................................................................48
Section 6, Air Filter............................................................................................................................50
Section 7. Coupling...........................................................................................................................52
Section 8, Ro Water Filtration System................................................................................................53
Section 9, Maintenance Schedule......................................................................................................60
Section 10, Troubleshooting ..............................................................................................................63
Section 11, Troubleshooting Auto Sentry W Controller.........................................................................65
Section 12, Troubleshooting The Ro Filtration System.........................................................................71
Index................................................................................................................................................72

13-11-614 Page 5
LIST OF ILLUSTRATIONS
Figure 1-1 – Typical Compression Cycle ..............................................................................................6
Figure 1-2 – Package Illustration..........................................................................................................7
Figure 1-3 – Air/Water Schematic ........................................................................................................9
Figure 2-1 – Typical Compressor Room.............................................................................................13
Figure 2-2 – Air Flow Chart................................................................................................................13
Figure 2-3 – Inlet Line Lengths...........................................................................................................18
Figure 2-4 – Grease Recommendations .............................................................................................20
Figure 2-5 – Regreasing Interval........................................................................................................20
Figure 4-1 – Auto Sentry W Controller Display ....................................................................................26
Figure 4-2 – Flow Chart For Setup Programming ................................................................................29
Figure 4-3 – Auxiliary Pressure Switch/Receiver Unloaded Pressure Tabulation ...................................39
Figure 4-4 – Wiring Diagram – Full Voltage With Expansion Board.......................................................42
Figure 4-5 – Wiring Diagram – Wye Delta With Expansion Board.........................................................44
Figure 4-6 – Wiring Diagram – Full Voltage Less Starter......................................................................46
Figure 5-1 – Oil Level Gauge.............................................................................................................49
Figure 6-1 – Heavy Duty Air Filter (Standard)......................................................................................50
Figure 7-1 – Installation Of Coupling Cushions....................................................................................52
Figure 8-1 – PLC Connections And Cycle Time Combinations .............................................................56

13-11-614 Page 6
SECTION 1
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. Angular contact ball bearings at the discharge end locate each rotor axially
and carry all thrust loads and the remainder of the radial loads.
COMPRESSION PRINCIPLE(Figure 1-1) - Compression is accomplished by the main and secondary rotors
synchronously meshing in a one-piece cylinder. The main rotor has four (4) helical lobes 60°apart. The secondary
rotor has six (6) matching helical grooves 60°apart to allow meshing with main rotor lobes.
The air inlet port is located on top of the compressor cylinder near the drive shaft end. The discharge port is at the
bottom on the opposite end of the compressor cylinder.
Figure 1-1 is an inverted view to show inlet and discharge ports. The compression cycle begins as rotors unmesh at
the inlet port and air is drawn into the cavity between the main rotor lobes and secondary rotor grooves (A). When
the rotors pass the inlet port cutoff, air is trapped in the interlobe cavity and flows axially with the meshing rotors (B).
As meshing continues, more of the main rotor lobe enters the secondary rotor grove, normal volume is reduced and
pressure increases.
Water is injected into the cylinder to remove the heat of compression and seal internal clearances. Volume reduction
and pressure increase continues until the air/water mixture trapped in the interlobe cavity by the rotors passes the
discharge port and is released to the air/water reservoir (C). Each rotor cavity follows the same “fill-compress-
discharge” cycle in rapid succession to produce a discharge air flow that is continuous, smooth, and shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure 1-4, page9andFigure 1-5, page10) - Air enters the air filter
and passes through the inlet unloader valve to the compressor. After compression, the air/water mixture flows to the
separator/reservoir tank where most of the water is removed by velocity change and impingement. The air flows to
the aftercooler, then to the moisture separator where the water that has condensed out is removed from the air
stream. The air then flows through the package discharge check valve and to the plant air system.
WATER SYSTEM (Figure 1-4, page9and Figure 1-5, page 10) - Water is forced by air pressure from the
separator/reservoir tank through the heat exchanger, the system water filter and into the water injection manifold
where the water is distributed to the compression chamber injection ports. The water removes the heat of
compression and seals internal clearances. Seals minimize water leakage out of the compression chamber.
LUBRICATION - Lubricating oil flows from the oil reservoir into the oil pump, where it is delivered, under pressure,
into the oil filter, and subsequently, injected onto the bearings and gears. The oil drains, by gravity, from the bottom
of the gear and discharge housings back into the oil reservoir.

13-11-614 Page 7
Figure 1-2– PACKAGE ILLUSTRATION – AIR-COOLED
309EWF797-A
(Ref. Drawing)

13-11-614 Page 8
Figure 1-3– PACKAGE ILLUSTRATION – WATER-COOLED
310EWF797-A
(Ref. Drawing)

13-11-614 Page 9
Figure 1-4– AIR-COOLED SCHEMATIC
307EWF797-A
(Ref. Drawing)

13-11-614 Page 10
Figure 1-5– WATER-COOLED SCHEMATIC
308EWF797-A
(Ref. Drawing)

13-11-614 Page 11
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.
•Keep fingers and clothing away from revolving fan, drive coupling, etc.
•Do not use the air discharge from this unit for breathing – 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 until the unit is shut down and
the air pressure has been relieved.
•Electrical shock can and may be fatal.
•Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable
local electrical codes. Wiring and electrical service must be performed only by qualified
electricians.
•Open main disconnect switch, tag and lockout before working on the control.
•Disconnect the compressor unit from its power source, tag and lockout before working on the
unit – this machine is automatically controlled and may start at any time.
WARNING
Failure to observe these notices could result in damage to equipment.
•Stop the unit if any repairs or adjustments on or around the compressor are required.
•Disconnect the compressor unit from its power source, tag and lockout 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 diameter (OSHA Regulation, Section 1926.302).
•Do not exceedthe rated maximum pressure values shown on the nameplate.
•Do not operate unit if safety devices are not operating properly. Check periodically. Never
bypass safety devices.
•Do not disconnect the compressor unit from its power source for more than two days. During
normal operation or fouling, reverse osmosis of the membrane may occur. Refer to your
Operating and Service manual for details concerning the reverse osmosis water filtration
system.

13-11-614 Page 12
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.
LIFTING UNIT - Proper lifting and/or transporting methods must be used to prevent damage. Tow motor
fork clearance is provided by the equipment isolators bolted to the base of the unit. The unit may also be
moved into location by rolling on bars.
CAUTION
Lift compressor unit by base only. Do not use other places such as motor,
compressor or discharge manifold piping as lifting points.
DANGER
The eyebolts or lugs provided on the motor are for lifting the motor only and
should not be used to lift any additional weight. All eyebolts must be securely
tightened. When lifting the motor, the lifting angle must not exceed 15 degrees.
Failure to observe this warning may result in damage to equipment 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.
WARNING
Do not install this compressor in a location that may be subject to temperatures
below 32°F. (0°C).
Below freezing temperatures will cause damage to the compressor.

13-11-614 Page 13
The air-cooled unit requires cooling air as well as air to the compressor inlet. Proper ventilation MUST be
provided; hot air must be exhausted from the compressor operating area. A typical inlet-outlet air flow
arrangement is shown in Figure 2-1, page 13.
Air-Cooled Units - A combination water/aftercooler is supplied as standard equipment on all air-cooled
units. An air-cooled motor and fan are mounted on the cooling module. Air is drawn into the enclosure
through roof-mounted grills (main driver side of package), blown through the cooling cores, and
exhausted through roof-mounted grills (cooler side of package).
The air-cooled unit with the standard enclosure requires sufficient flow, Figure 2-2, page 13, 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.
Allow three (3) feet to the nearest obstruction above and on other sides of unit. For continuous efficiency,
the heat exchanger and aftercooler cores must be periodically cleaned with either vacuum or compressed
air. If wet cleaning is required, shield the motor and spray on a mild soap solution, then flush with clean
water.
Figure 2-1– TYPICAL COMPRESSOR ROOM
Minimum Air Flow * For Compression and Cooling
Cubic Feet/Minute (Cubic Meters/Minute)
HP (kW) Air-Cooled Water-Cooled
100 – 150 (75 – 112) 20,500 (580) 2200 (62)
* 80°F (27°C) Inlet Air
Figure 2-2– AIR FLOW CHART

13-11-614 Page 14
WARNING
For copper water coolers, do not use any cleaning solution that is not
compatible with copper. Use of improper solution may result in damage to the
cooler.
Water-Cooled Units - Shell and tube water and aftercooling cores are supplied as standard equipment
on all water-cooled units. A small air-cooled motor and fan are used to ventilate the enclosed package.
See “Air Cooled Units” for location recommendations.
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.
Mounting bolts are not normally required. However, installation conditions such as piping rigidity, angle of
tilt, or danger of shifting from outside vibration or moving vehicles may require the use of mounting bolts
and shims to provide uniform support for the base.
OIL RESERVOIR DRAIN - The oil drain is piped from the bottom of the reservoir to the frame (See
Package Illustrations on pages 7and 8, for details). The drain connection is about 4 inches (100 mm)
above the floor level. If this impedes oil drainage, consider the following options:
•Elevate the package of blocks to obtain the desired drain height.
•Provide an oil sump/trough below the floor level and pump or bail the drained oil.
•Evacuate the oil charge with vacuum.
CAUTION
If the package is raised above floor level, the voids between the base frame and
the floor may increase the package noise level and/or affect air-cooled core
performance. Said voids must be blocked with solid, sound absorbing
materials.
Oil Breather - Potential contamination of the compressed air stream with gear box oil vapors, vented
through the breather, may be avoided by piping said vapors away from the package confines.
CAUTION
When remote mounting the oil breather, avoid low spots on the piping where oil
could collect and affect vapors venting.
ENCLOSURE - The compressor, electric motor, water cooler and aftercooler are mounted inside the
enclosure.

13-11-614 Page 15
Service doors are provided for maintenance access. Be sure to allow enough space around the unit for
the doors to be opened and removed as necessary for service procedures. The enclosure doors are held
by two latches and lift away from the enclosure. The air filter, water filters, and water treatment cartridge
are easily accessible through a side or end door.
DANGER
Do not operate the compressor with the coupling guard removed. Exposed
rotating components may cause injury to personnel.
COMPRESSOR WATER SPECIFICATION - The compressor unit is supplied with an integral filtration
system (by reverse osmosis) to ensure adequate quality levels for the injection water system. In order to
maintain the water filtration system working at peak efficiency, the incoming water supply must meet a
number of requirements. Please refer to the “RO Water Filter”, Section 8, of this manual for details.
WARNING
Back flow Preventers must be installed on the potable water supply line to the
compressor to prevent high pressure air from blowing into the water supply.
WARNING
Use of compressor initial fill and make-up water not meeting all water
specification standards noted may result in contamination of the discharge air
stream.
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.
COOLING WATER SPECIFICATION - Water-Cooled water and aftercooler cores must be provided with
an adequate source of coolant. The following requirements must be met:

13-11-614 Page 16
Water Quality - In order to protect the package components in contact with the cooling water against
attack by corrosive and fouling agents, we recommend that the cooling water meet the following quality
standards
Total Dissolved Solids (TDS).................. <500 ppm
Iron....................................................... <2 ppm
Total Hardness...................................... <60 ppm
Silica.................................................... <25 ppm
Oil and Grease...................................... <5 ppm
Sulfate.................................................. <50 ppm
Chloride................................................ <50 ppm
Nitrate................................................... <2 ppm
Corrosivity............................................. Langelier Index between 0 to 1
Unlike the internal injection water system, the cooling water system does not have any form of filtration or
treatment. It is the responsibility of the end user to ensure that cooling water of adequate quality is used.
The water quality tests described in the “RO Water Filtration System”, SECTION 8, may also be used to
monitor the quality of the cooling water.
Water Flow Requirements - The following conditions of service are recommended to achieve adequate
cooler core performance:
Water Cooler Pressure 100 HP 125 HP 150 HP
Water flow for 30°F rise (gpm.................................... All 17.8 22.0 26.3
Water Flow for 15°F rise (gpm).................................. All 35.7 44.0 52.7
Maximum water flow and pressure loss (gpm @ psi) ... All ------- 55 @ 12.6 -------
Operating pressure range (psi)................................... All ------- 40 to 150 -------
Operating temperature range (°F).............................. All ------- 60 to 90 -------
Aftercooler
Water flow for 30°F rise (gpm.................................... All 1.1 1.9 2.3
Water Flow for 15°F rise (gpm).................................. All 2.2 3.7 4.7
Maximum water flow and pressure loss (gpm @ psi) ... All ------- 55 @ 10.7 -------
Operating pressure range (psi)................................... All ------- 40 to 150 -------
Operating temperature range (°F).............................. All ------- 60 to 90 -------
Notes: •Estimate of core pressure drop at lower than maximum flowrate = (GPM/GPM max.).
•Flows exceeding maximum rate will cause severe erosion and will void unit warranty.
•Water temperature below 60°F may:
-produce excessive cooling and condensate formation, overtaxing the separation
device and allowing water carryover into the customer pipe works.
-result in low water velocities (e.g., to check cooling rate) which promote tube
fouling.
•Water temperature above 90°F may cause recurring high discharge temperature
shutdowns.

13-11-614 Page 17
COOLING WATER PIPING - On packages equipped with water-cooled cores, the water inlet and outlet
are located on the base frame side – See “Package Illustrations”, Figure 1-2and Figure 1-3, pages 7& 8,
for details. The pipe network shall be sized to support the maximum required water flow, pressure and
temperature limits listed under the “Water Flow Requirements” table.
COOLING WATER CONTROL DEVICES - Water cooled packages may be equipped with the following
optional flow control devices:
Water Flow Regulation Valve (Figure 2-3)– This (stand alone) device is adjustable to compensate for
varying cooling water inlet temperature and pressure, and is to be mounted in the package cooling water
outlet line.
To decrease water flow (increase compressor discharge temperature) turn the adjusting screw from left to
right (increase spring tension), and to increase water flow(decrease compressor discharge temperature),
turn the adjusting screw the opposite way. The groove at the lower edge of the adjusting screw is a
visual reference to use with the 0 to 8 index scale. Use the compressor discharge temperature display to
monitor the adjustments made to water flow.
These valves are delicate instruments. Care must be used when handling the capillary tube; a kink or
break in the tubing or connections will make the valve inoperative. Never attempt to change capillary
length – excess capillary tube should be carefully coiled and placed so that damage will not take place in
normal maintenance.
If a leak develops through the packing, tighten the packing gland nut firmly with a wrench to reseat the
packing around the valve stem, then back off the nut until loose again, and finally finger-tighten the nut.
An occasional drop of oil on the valve stem, at the packing nut, will prolong packing life.
If the valve malfunctions, check for bends, binding, paint, or corrosion on the valve stem, fouling of the
valve internals, or damage of the capillary assembly. Use a strainer to prevent solids from blocking the
valve.
Water Flow Stop Valve – This (stand alone) magnetic solenoid-operated valve is energized by the
package controller to shut off water flow when the package is not operating – refer to wiring diagrams
included in this manual for interconnection details. The device shall be mounted in the package cooling
water outlet line.
Figure 2-3– WATER CONTROL VALVE
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. When used, an air receiver should be of

13-11-614 Page 18
adequate size, provided with a relief valve of proper setting, a pressure gauge and a means of draining
condensate. A system with adequate volume would produce consecutive compressor unload cycles of
no less than 30 seconds.
MOISTURE SEPARATOR/ORIFICE- Since the unit is equipped with a built-in aftercooler, an integral
moisture separator and drain trap is furnished with the unit. The moisture from the trap is piped to the
compressor inlet flange.
INLET LINE - Where an inlet line is used between the air filter and the compressor, it must be
thoroughly cleaned on the inside to prevent dirt or scale from entering the compressor. If welded
construction is used, the line must be shot blasted and cleaned to remove welding scale. In either
case, the inlet line must be coated internally by galvanizing or painting with a moisture and oil-proof
sealing lacquer. Up to ten (10) feet in length, the inlet line should be the full size of the inlet opening on
the compressor. If an extra-long line is necessary, the pipe size should be increased according to “Inlet
Line” chart, Figure 2-4, page 18.
Accessibility for inlet air filter servicing must be considered when relocating the filters from the unit to a
remote location.
Length of Inlet Line Diameter of Pipe Size
0 to 10 Feet (0 to 3 Meters).............................. Same as Compressor Inlet Opening
10 to 17 Feet (3 to 5 Meters).............................. One size Larger Than Inlet Opening
17 to 38 Feet (5 to 11.5 Meters)......................... Two Sizes Larger Than Inlet Opening
Figure 2-4– INLET LINE LENGTHS
DISCHARGE SERVICE LINE - The discharge service line connection on the unit is at base level. See
“Package Illustrations, Figure 1-2and Figure 1-3, pages 7& 8. 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. If a rotary screw and reciprocating compressor are
manifolded together, an air receiver must be located between the two units.
DANGER
Discharge air used for breathing will cause severe injury or death. Consult
filtration specialists for additional filtration and treatment equipment to meet
health and safety standards.
The oil-free air discharging from the EWF package is saturated with water vapor at discharge
temperature. An air dryer may be required if the air is used in a moisture sensitive process. In addition,
the compressed air may be mixed with atmospheric contaminants entering the intake of the compressor.
UNIT WATER DRAIN - The unit drain ports should be connected to a floor drain(s). Drain line(s) must
slope downward, away from the unit, to allow effluent to flow by gravity, and must be vented to the
atmosphere to avoid the accidental back flow of said effluent into the package. As necessary, the
automatic water management system will open the drain solenoid valve to drain excess water. Since the
drain solenoid valve may open at any point during compressor operation, high temperature water under
pressure may be discharge from the unit. During operation, a small, steady stream of wash water is
normally discharged by the water treatment filter via the drain port.

13-11-614 Page 19
DANGER
Hot water under pressure will cause severe personal injury or death. Do not
operate compressor until a water drain line is installed from compressor water
drain port to a floor drain.
AIR/WATER RESERVOIR - The air/water reservoir-separator combines multiple functions into one
vessel. The lower half functions as a reservoir, providing water storage capacity for the system and the
upper portion serves as primary air/water separation. The reservoir also provides limited air storage for
control and gauge actuation.
COMPRESSOR INJECTION WATER SYSTEM CHECK - The following readings are based on an
ambient temperature of 80°F inlet cooling air on air-cooled units with the cooling system in good, clean
condition. The compressor should be at operating temperature at the time of the checks. One-half hour
of loaded operation is usually sufficient to reach level-out operating temperatures.
Air and Water Discharge Temperature - 120°F to 155°F - Read on the “AUTO SENTRY W” control
panel.
Compressor Injection Water Inlet Temperature - 100°F to 120°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. As ambient temperatures and core restrictions increase, the injection water
outlet temperature will increase. The injection water outlet temperature is approximately the same as the
package exhaust air temperature. The outlet temperature may be checked by installing a tee in the water
line between the separator/reservoir and the cooler.
Water Injection Cooler Pressure Differential (Air Cooled Heat Exchanger) - 5 to 7 psid - Check
injection water pressure differential in the same place as temperature. (See above.)
ELECTRICAL WIRING - Standard Units - The RotorChampcompressor is factory wired for all starter to
motor and control connections for the voltage specified 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” paragraph, page 12, for distance to nearest
obstruction on starter and control box sides of the unit.
WARNING
Electrical shock can cause injury or death. Open main disconnect switch, tag
and lockout before working on starter/control box.
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.

13-11-614 Page 20
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.
The following procedure should be used in regreasing:
1. Stop the unit.
2. Disconnect, tag and lockout the unit from the power supply.
3. Remove the relief plug and free hole of hardened grease.
4. Wipe lubrication fitting clean and add grease with a hand-operated grease gun.
5. Leave the relief plug temporarily off. Reconnect the unit and run for about 20 minutes to expel
the excess grease.
6. Stop the unit. Replace the relief plug.
7. Restart the unit.
WARNING
Rotating machinery can cause injury or death. Open main disconnect, tag and
lockout power supply to the starter before working on the electric motor.
ELECTRIC MOTOR GREASE RECOMMENDATION (-30°C TO 50°C)
Manufacturer Trade Name
Chevron SRI #2
Shell Dolium R
Exxon Unirex #2
Exxon Polyrex
Figure 2-5– GREASE RECOMMENDATIONS
ELECTRIC MOTOR REGREASING INTERVAL
Type of Service Typical Examples 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
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
Figure 2-6– REGREASING INTERVAL