Champion ROTORCHAMP RCOF20 Service manual

CHAMPIONR
ROTORCHAMP
OIL--FREE ROTARY SCREW
COMPRESSORS
MODELS
RCOF20 -20 HP
RCOF25 -25 HP
RCOF30 -30 HP
OPERATINGAND
SERVICEMANUAL
13--11--605
1stEdition
February,1999

13-11-605 Pagei
MAINTAIN COMPRESSOR RELIABILITYAND PERFORMANCEWITH
GENUINECHAMPIONRCOMPRESSOR
PARTSAND SUPPORTSERVICES
ChampionRCompressorgenuine parts,manufac-
tured to design tolerances,are developed foroptimum
dependability---- specificallyforChampionRcompres-
sorsystems.Design and material innovationsarethe
resultofyearsofexperiencewith hundredsofdifferent
compressorapplications.Reliabilityinmaterialsand
qualityassurance areincorporated in ourgenuine re-
placementparts.
Yourauthorized ChampionRCompressordistributor
offersall the backup you’ll need.Aworldwide network
ofauthorized distributorsprovidesthe finestproduct
supportinthe aircompressorindustry.Yourlocalau-
thorized distributormaintainsalarge inventoryofgenu-
ine parts.
Yourauthorized distributorcan supportyourChampion
aircompressorwiththeseservices:
1.Trained parts specialiststo assistyou inselect-
ing the correctreplacementparts.
2.Factorywarranted newand remanufactured
rotary screwairends.Mostpopularmodel
remanufactured airendsaremaintained instock
atChampion forpurchase on an exchange basis
withliberalcorecreditavailableforthe replace-
mentunit.
3.Afull line of factorytested RotorLub compressor
lubricants specificallyformulated forusein
Champion compressors.
4.Repairand maintenancekitsdesigned withthe
necessarypartstosimplify servicing yourcom-
pressor.
Authorized distributorservicetechniciansarefactory--
trained and skilled incompressormaintenance and re-
pair.Theyarereadytorespond and assistyou bypro-
viding fast, expertmaintenance and repairservices.
Forthelocation ofyourlocalauthorizedChampion AirCompressordistributor refertothe yellowpages
ofyourphonedirectoryorcontact:
Factory:
Champion
1301 N.EuclidAve.
Princeton, IL 61356
Phone:[phone]
Fax:[phone]
INSTRUCTIONSFORORDERINGREPAIRPARTS
When ordering parts,specifyCompressorMODEL,
Method ofCooling,HORSEPOWERand SERIAL
NUMBER(see nameplate on unit).The SerialNumber
isalsostamped on top of the cylinderflange tothe right
of the inlethousing.
All ordersforParts should be placed withthe nearest
authorized distributor.
WhereNOTspecified,quantityofpartsrequired per
compressororunitisone (1);wheremorethan one is
required perunit, quantityisindicated in parenthesis.
SPECIFY EXACTLYTHENUMBEROFPARTSRE-
QUIRED.
DONOTORDERBY SETSORGROUPS.
To determine the RightHand and Left Hand side ofa
compressor,stand at the motorend and looktoward
the compressor.RightHand and Left Hand areindi-
cated in parenthesisfollowing the partname,i.e.(RH)
&(LH),when appropriate.

13-11-605 Pageii
FOREWORD
Champion RotaryScrewcompressorsarethe resultofadvanced engineering and skilled manufacturing.To be as-
sured ofreceiving maximumservicefromthismachine the ownermustexercisecareinitsoperation and mainte-
nance.Thisbookiswritten to givethe operatorand maintenance departmentessential information forday-to-day
operation,maintenance and adjustment. Carefuladherencetotheseinstructionswill resultin economicaloperation
and minimumdowntime.
Dangerisusedtoindicatethepresenceofahazardwhichwillcause severepersonal
injury,death,orsubstantialpropertydamageif thewarning isignored.
Warningisusedtoindicatethepresenceofahazardwhichcancausesevereperson-
al injury,death,orsubstantialpropertydamageif thewarning isignored.
Caution isusedtoindicatethepresence ofahazardwhichwill orcancause minor
personal injuryorpropertydamageif thewarning isignored.
Noticeisusedto notifypeopleofinstallation,operationor maintenanceinformation
whichisimportantbutnothazard--related.

13-11-605 Pageiii
Thisbook coversthefollowing models:
HPAirCooledPartsList
20 RCOF20 13--11--507
25 RCOF25 13--11--507
30 RCOF30 13--11--507
INSTRUCTIONSFORORDERINGREPAIRPARTS
When ordering parts,specifyCompressorMODEL,
Method ofCooling,HORSEPOWERand SERIAL
NUMBER(see nameplate on unit).The SerialNumber
isalsostamped on top of the cylinderflange tothe right
of the inlethousing.
All ordersforParts should be placed withthe nearest
authorized distributor.
WhereNOTspecified,quantityofpartsrequired per
compressororunitisone (1);wheremorethan one is
required perunit, quantityisindicated in parenthesis.
SPECIFY EXACTLYTHENUMBEROFPARTSRE-
QUIRED.
DONOTORDERBY SETSORGROUPS.
To determine the RightHand and Left Hand side ofa
compressor,stand at the driveside of the package and
looktowardthe compressor.RightHand and Left Hand
areindicated in parenthesisfollowing the partname,
i.e.(RH)&(LH).

13-11-605 Pageiv
TABLEOFCONTENTS
Remanufactured AirEndsi........................................................................
Forewordii.....................................................................................
InstructionsForOrdering RepairPartsiii.............................................................
Index v........................................................................................
Listof Illustrations viii............................................................................
Section 1,GeneralInformation 1...................................................................
Section 2, Installation,Coolersand WaterSystems9..................................................
Section 3,Starting &Operating Procedures16.......................................................
Section 4,Controls&Instrumentation 18............................................................
Section 5,Lubrication 39.........................................................................
Section 6,AirFilter42...........................................................................
Section 7,BeltDrive 44..........................................................................
Section 8,MaintenanceSchedule 45...............................................................
Section 9,TroubleShooting 47....................................................................
Section 10,TroubleShooting Controls49............................................................
WarrantyLastPage..............................................................................

INDEX
13-11-605 Page v
Airand WaterDischarge Temperature 13........
AIRFILTER,SECTION6 42..................
AirFilterVacuumSwitch 30...................
AirFilter,Heavy Duty(Standard)42............
Compression Principle 1......................
AirFlowinthe CompressorSystem1...........
AirReceiver,Auxiliary11.....................
Air--Cooled Units,Location 9..................
Air/WaterReservoirwithIntegralMoisture
Separator12............................
AutoSentry--WControlDisplay19.............
AutoSentry--WController
AlarmRelay28..........................
AutomaticSequenceChange 26............
AuxiliaryShutdown 28.....................
Configuration Adjustments24...............
Connection ofExpansion Board and External
ControlCircuits27....................
Establishing InitialSequence 25............
HowAutoSentry--WControlsPressurewhile
Sequencing 26.......................
Installation 25...........................
MainAdjustmentsMenu 21................
MaintenanceAdjustments23...............
Operation 25............................
Operation Adjustments21.................
OtherControlFeatures24..................
OtherFeatures27........................
Programming and Setup 21................
RemoteOn/Off 28........................
SequenceAdjustments23.................
UnitSetup Adjustments24.................
AutoSentry--WOperation 18..................
AutomaticMode 18.......................
ConstantRun Mode 18....................
Low Demand Mode 18.....................
SequenceMode 19.......................
AutomaticMode Operation 18.................
AuxiliaryAirReceiver11.....................
BELTDRIVE,SECTION7 44.................
BeltTension,Checking 44....................
BlowdownValve 29..........................
Check,Daily17.............................
Checking BeltTension 44.....................
Compressor1..............................
CompressorInjection WaterInlet
Temperature 13.........................
CompressorInjection WaterSystem13.........
CompressorOil System39...................
CompressorWaterSpecification 10............
ConstantRun Mode Operation 18..............
ControlAirPressureRegulator29..............
ControlDevices,Other28....................
ControlPiping 11............................
ControlTransformer31.......................
CONTROLS&INSTRUMENTS,
SECTION4 18..........................
Controls&Instruments,GeneralDescription 18...
DailyCheck 17.............................
Decals7–8................................
Discharge Check Valve 29....................
Discharge Service Line 12....................
Discharge Thermistor30.....................
Drain,Oil Reservoir10.......................
Drain,UnitWater12.........................
Drinking WaterRegulation,U.S.EPA 15.........
ElectricMotorGreaseRecommendations14.....
ElectricMotorRegreasing Interval14...........
ElectricalWiring 13..........................
StandardUnits13........................
ElementLife,Filter42.......................
Emergency Stop Push--Button 30..............
Emergency Stop Shutdown 21.................
Enclosure 10...............................
ExternalDeviceShutdown 21.................
Fan Starter31..............................
FeederCartridge,Make--up Water,
Changing 12............................
FilterElement42............................
FilterElementLife 42........................

INDEX
13-11-605 Page vi
Filter,Heavy DutyAir (Standard)42............
Filter,SystemWater,Changing 12.............
Foundation 10..............................
GENERALINFORMATION,SECTION1 1.......
GreaseRecommendations,ElectricMotor14....
Grounding 13...............................
High PressureShutdown 21...................
High TemperatureShutdown 20................
High WaterLevelShutdown 20................
Injection PressureTransducer29..............
InletLine 11................................
InletSealBuffering WaterPressure
Regulator29............................
InletTube 43...............................
InletValve 29..............................
INSTALLATION,SECTION2 9................
Installation,General9........................
Lifting Unit9...............................
Line,Discharge Service 12...................
Line, Inlet11...............................
Location 9.................................
Air--Cooled Units9........................
Low Demand Mode Operation 18...............
Lubricant, Recommended 39..................
LubricantMaintenanceInterval39..............
LUBRICATION,SECTION5 39................
Lubrication 1...............................
Motor13................................
MagneticUnloaderSolenoidValve 29...........
MainStarter31.............................
MAINTENANCE SCHEDULE,SECTION8 45....
Make--up WaterFeederCartridge,Changing 12...
MoistureSeparator/Trap 11...................
MotorGreaseRecommendations14............
MotorLubrication 13.........................
MotorProtectiveDevices20..................
MotorRegreasing Interval14..................
Oil LevelSightGlass 39......................
Oil ReservoirDrain 10........................
Oil Specifications39.........................
Oil System,Compressor39...................
Operation
AutomaticMode 18.......................
ConstantRun Mode 18....................
Low Demand Mode 18.....................
SequenceMode 19.......................
Piping,Control11...........................
PowerFailureShutdown 21...................
PressureDifferential,WaterInjection Cooler,
AirCooled Radiator13....................
Prestart--UpInstructions16...................
AirFilter16.............................
CompressorOil 16........................
Electrical16.............................
Enclosure 17............................
Grounding 16............................
Operating Mode 17.......................
Piping 16...............................
Rotation 16..............................
SystemPressure 16......................
Programming and Setup,AutoSentry--W
Controller21............................
ProtectiveShutdowns20.....................
Recommended Lubricant39...................
Regreasing Interval,ElectricMotor14..........
Regulator
ControlAirPressure 29....................
InletSealBuffering WaterPressure 29.......
SealPurge AirPressure 29................
ReliefValve 28.............................
Remanufactured AirEndsi...................
RepairParts,Ordering Instructionsiii...........
ReservoirPressureTransducer29.............
SafetyPrecautions5–6......................
SealPurge AirPressureRegulator29...........
Separator/Trap,Moisture 11...................
SequenceMode Operation 19.................

INDEX
13-11-605 Page vii
Sequencing Compressorswith
AutoSentry--W25.......................
ServiceAdvisories20........................
ServiceCheck List45.......................
AirFilter45.............................
Every1000 HoursOperation 45.............
Every125 HoursOperation 45..............
Every2000 HoursOperation 45.............
Every8HoursOperation 45................
EveryYear45...........................
MotorLubrication 45......................
WaterFilter45...........................
WaterTreatmentHousing/Cartridge 45.......
Shutdowns
Emergency Stop 21.......................
ExternalDevice 21.......................
High Pressure 21.........................
High Temperature 20......................
High WaterLevel20......................
MotorProtectiveDevices20...............
Other21................................
PowerFailure 21.........................
WaterFilterDifferential20.................
ShuttleValve 29............................
SightGlass,Oil Level39.....................
Specifications,Oil 39........................
Starter
Fan 31.................................
Main 31................................
STARTING&OPERATINGPROCEDURES,
SECTION3 16..........................
Starting the Unit17..........................
Stopping the Unit17.........................
Strip,Terminal31...........................
Switch,AirFilterVacuum30..................
Switches,WaterLevel30.....................
SystemPressureTransducer29...............
SystemWaterFilter,Changing 12..............
Temperature
Airand WaterDischarge 13................
CompressorInjection WaterInlet13.........
TemperatureDifferential,WaterInjection
Cooler,AirCooled Radiator13.............
TerminalStrip 31............................
Thermistor,Discharge 30.....................
Transducer
Injection Pressure 29.....................
ReservoirPressure 29.....................
SystemPressure 29......................
Transformer,Control31......................
TROUBLE SHOOTING,SECTION9 47.........
TROUBLE SHOOTINGAUTOSENTRY--W
CONTROLLER,SECTION10 49...........
TroubleShooting AutoSentry--WController
AdvisoryTroubleShooting 49...............
ControlsTroubleShooting 52...............
DisplayModes49........................
ShutdownTroubleShooting 50..............
Tube, Inlet43..............................
U.S.EPA NationalDrinking WaterRegulation 15. .
UnitWaterDrain 12..........................
Valve
Blowdown 29............................
Discharge Check 29......................
Inlet29.................................
MagneticUnloaderSolenoid 29.............
Relief28................................
Shuttle 29...............................
WaterSolenoid 30........................
WarrantyLastPage.........................
WaterFilterDifferentialShutdown 20...........
WaterFilter,Changing 12.....................
WaterInjection CoolerPressureDifferential,
AirCooled Radiator13....................
WaterInjection CoolerTemperatureDifferential,
AirCooled Radiator13....................
WaterLevelSwitches30.....................
WaterSolenoidValves30....................
WaterSpecification,Compressor10............
WaterSystem1............................
Wiring,Electrical13.........................

13-11-605 Page viii
LISTOFILLUSTRATIONS
Figure # Description Page
Figure 1--1TypicalCompression Cycle 1.................................................
Figure 1--2CompressorEnd 2..........................................................
Figure 1--3CompressorEnd (ControlBoxRemoved)2......................................
Figure 1--4MotorDriveEnd 3...........................................................
Figure 1--5DriveComponentSide 3.....................................................
Figure 1--6Air/WaterSchematic4.......................................................
Figure 2--1TypicalCompressorRoom9..................................................
Figure 2--2AirFlow Chart9............................................................
Figure 2--3AdditionalWaterLimitations11................................................
Figure 2--4USGSClassification ofWater11..............................................
Figure 2--5InletLine Lengths11........................................................
Figure 4--1AutoSentryR--WControllerDisplay19..........................................
Figure 4--2Flow Chart forSet--UpProgramming 22.........................................
Figure 4--3BlowdownValve 29..........................................................
Figure 4--4InletValve 30..............................................................
Figure 4--5ShuttleValve 30............................................................
Figure 4--6ControlTubing Schematic32..................................................
Figure 4--7ControlSchematic-- CompressoratFull Load -- ConstantSpeed Mode 33.............
Figure 4--8ControlSchematic-- CompressorUnloaded -- ConstantSpeed Mode 34...............
Figure 4--9ControlSchematic-- CompressorUnloaded and BlownDown-- Low Demand Mode 35...
Figure 4--10 Wiring Diagram-- Full Voltage 36...............................................
Figure 4--11 Wiring Diagram-- WyeDelta 37................................................
Figure 4--12 AutoSentryR--WControllerDisplay38..........................................
Figure 5--1Oil LevelGauge 40..........................................................
Figure 5--2Flow Diagram(AirCooled)41.................................................
Figure 6--1Heavy DutyAirFilter (Standard)42.............................................
Figure 7--1BeltTension 3VX Belts44....................................................

13-11-605 Page 1
SECTION1
GENERALINFORMATION
FIGURE1--1-- TYPICALCOMPRESSION CYCLE
COMPRESSOR-- The Champion RotaryScrewcom-
pressorisasinglestage,positive displacementrotary
machine using meshing helicalrotorsto effectcom-
pression.Bothrotorsaresupported between high ca-
pacityrollerbearingslocated outside the compression
chamber.Singlewidthcylindricalrollerbearingsare
used at the inletend of the rotorstocarrypartof the ra-
dial loads.Angularcontactball bearingsat the dis-
charge end locate eachrotoraxiallyand carryall thrust
loadsand the remainderof the radial loads.
COMPRESSIONPRINCIPLE(FIGURE1--1) -- Com-
pression isaccomplished bythe main and secondary
rotors synchronouslymeshing in a one--piececylinder.
The mainrotorhas six(6)helical lobes60_apart. The
secondaryrotorhaseight(8)matching helicalgrooves
45_apart to allowmeshing withmainrotorlobes.
The airinletportislocated on top ofthe compressorcyl-
indernearthe driveshaft end.The discharge portisat
the bottomon the opposite end of the compressorcylin-
der.FIGURE1--1isan inverted viewtoshowinletand
discharge ports.The compression cycle beginsasro-
torsunmesh at the inletportand airisdrawnintothe
cavitybetween the mainrotorlobesand secondaryro-
torgrooves(A).When the rotorspass the inletportcut-
off, airistrapped inthe interlobe cavityand flowsaxially
withthe meshing rotors(B).Asmeshing continues,
more of the mainrotorlobe entersthe secondaryrotor
grove,normalvolumeisreduced and pressurein-
creases.
Waterisinjected intothe cylindertoremovethe heatof
compression and seal internalclearances.Volumere-
duction and pressureincreasecontinuesuntil the air/
watermixturetrapped inthe interlobe cavitybythe ro-
torspassesthe discharge portand isreleased tothe
air/water reservoir (C).Eachrotorcavityfollowsthe
same“fill--compress--discharge”cycleinrapidsucces-
sion to produceadischarge airflowthatis continuous,
smooth,and shock free.
AIRFLOWINTHECOMPRESSORSYSTEM
(FIGURE1--4,page 3) -- Airentersthe airfilterand
passesthrough the inletunloadervalvetothe com-
pressor.Aftercompression, the air/watermixtureflows
tothe separator/reservoirtankwheremostof the water
isremoved by velocity change and impingement. The
airflowstothe aftercooler, then tothe moisturesepara-
torwherethe waterthathas condensed outisremoved
fromthe airstream.The airthen flowsthrough the
package discharge check valve and tothe plantairsys-
tem.
WATERSYSTEM(FIGURE1--6,page 4) -- Wateris
forced byairpressurefromthe separator/reservoir
tankthrough the heatexchanger, the systemwaterfil-
terand intothe waterinjection manifoldwherethe wa-
terisdistributed tothe compression chamberinjection
ports.The water removesthe heatofcompression and
sealsinternalclearances.Sealsminimizewaterleak-
age outof the compression chamber.
LUBRICATION-- Oil inthe oil reservoirat the dis-
charge end of the airend lubricatesthe discharge end
bearings.Greasefittingsarelocated at the inletend of
the airend forperiodiclubrication of the inletend bear-
ings.

13-11-605 Page 2
FIGURE1--2-- COMPRESSOREND
302EWC797
(Ref.Drawing)
FIGURE1--3-- COMPRESSOREND (CONTROLBOXREMOVED)
302EWC797
(Ref.Drawing)

13-11-605 Page 3
FIGURE1--4-- DRIVE MOTOREND
302EWC797
(Ref.Drawing)
FIGURE1--5-- DRIVE COMPONENTSIDE
302EWC797
(Ref.Drawing)

13-11-605 Page 4
FIGURE1--6-- AIR/WATERSCHEMATIC
300EWC797-B
(Ref.Drawing)

13-11-605 Page 5
SAFETY PRECAUTIONS
Safetyiseverybody’sbusiness and isbased on youruse ofgood common sense.All situationsorcircumstances
cannotalways be predicted and covered byestablished rules.Therefore,useyourpastexperience,watch out for
safetyhazards,and be cautious.
Some generalsafetyprecautionsare given below:
Failureto observe these notices couldresultininjuryto ordeath ofpersonnel.
DKeepfingers and clothing away from revolving fan,drive belts,etc.
DDo notuse the airdischargefromthisunit forbreathing -- notsuitableforhu-
manconsumption.
DDo notloosen or remove theoil fillerplug,drain plugs,covers,orbreak any
connections,etc., inthe compressorairoroil systemuntil theunitis shut
downand the airpressurehas beenrelieved.
DElectricalshock canand may befatal.
DCompressorunitmustbegroundedinaccordancewiththeNationalElectrical
Code.Aground jumperequaltothe sizeof theequipmentgroundconductor
mustbeusedtoconnect the compressor motorbase totheunitbase.
DFanmotorsmustremain groundedtothemain base through the starter
mounting panel inaccordance withtheNationalElectricalCode.
DOpenmain disconnectswitch,tagand lockoutbeforeworkingon thecontrol.
DDisconnect the compressorunit fromitspowersource,tagand lockoutbe-
foreworking on theunit -- thismachineis automatically controlledand may
startatanytime.

13-11-605 Page 6
Failureto observe these notices couldresultin damagetoequipment.
DStop theunitifanyrepairsoradjustmentsonoraroundthe compressorare
required.
DDisconnect the compressorunit fromitspowersource,tagand lockoutbe-
foreworking on theunit -- thismachineis automaticallycontrolledandmay
startatanytime.
DAnExcess FlowValve should beon all compressedairsupplyhoses ex-
ceeding 1/2inchinsidediameter.(OSHA Regulation,Section 1926.302)
DDonotexceedtheratedmaximumpressurevaluesshownonthenameplate.
DDo notoperateunitifsafetydevicesarenotoperating properly.Checkperi-
odically.Neverbypass safetydevices.

13-11-605 Page 7
DECALS
206EAQ077 300EWC077
301EWC077
211EAQ077 207EAQ077

13-11-605 Page 8
DECALS
216EAQ077
206EWD077
222EAQ077
221EAQ077 208EAQ077

13-11-603 Page 9
SECTION2
INSTALLATION,COOLERSAND WATERSYSTEMS
GENERAL-- Onreceiptof the unit, check foranydam-
age thatmayhave occurred during transitorhandling.
Reportanydamage ormissing partsas soon aspos-
sible.
Do notelectricweld on the compres-
sororbase;bearingscanbedamaged
bypassageofcurrent.
LIFTINGUNIT-- Properlifting and/ortransporting
methodsmustbe used to preventdamage.Towmotor
fork clearanceisprovided bythe equipmentisolators
bolted tothe base of the unit. The unitmayalso be
moved intolocation byrolling on bars.
Lift compressorunitbybase only.Do
notuse otherplaces suchas motor,
compressorordischargemanifold
piping as lifting points.
The eyeboltsorlugsprovided on the
motorareforlifting themotoronly
and should notbeusedtolift any
additional weight.All eyeboltsmust
be securelytightened.Whenlifting
themotorthelifting anglemustnot
exceed15degrees.Failuretoobserve
thiswarning may resultin damageto
equipmentorpersonal injury.
LOCATION-- The compressorshould be installed in a
clean,well--lighted,and ventilated area with ample
space all around the unit formaintenance.Selecta
location thatprovidesacool,clean,and dry source of
air. Insomecasesitmaybe necessarytoinstall the air
filteratsome distancefromthe compressorto obtain
properairsupply.
Do notinstall this compressorina
location thatmay be subject totem-
peratures below32_F.(0_C.).
Belowfreezing temperatures will
cause damagetothe compressor.
The air--cooled unitrequires cooling airaswell asairto
the compressorinlet. Properventilation MUSTbe pro-
vided;hotairmustbe exhausted fromthe compressor
operating area.Atypical inlet--outletairflowarrange-
mentis showninFIGURE2--1.
Air-CooledUnits-- An aircooled heatexchangerand
aftercooleris supplied as standard equipmenton all
air--cooled units.The aircooled motorsand fansare
mounted withinthe cooling module;airisdrawnintothe
FIGURE2--1-- TYPICALCOMPRESSOR ROOM
*80_F(27_C)InletAir
MinimumAirFlow*ForCompression
And Cooling -- CubicFeet/Minute
(CubicMeters/Minute)
HP(KW)AirCooled
20 -- 30 (15 -- 22)5,200 (147)
FIGURE2--2-- AIRFLOWCHART

13-11-603 Page 10
enclosurethrough louversinthe side panels, through
the aftercoolerand exhausted through the heatex-
changerat the top of the unit. The air--cooled unitwith
the standard enclosurerequires sufficient flow,
FIGURE2--2,page 9, forthe compressorwater/after-
cooling systemand forelectricmotorcooling.Do not
block the airflowto and fromthe unit. Allowthree and
one--half(3--1/2)feet tothe nearestobstruction on the
controlboxend of the unit. Allowthree (3)feet tothe
nearestobstruction above and on othersidesofunit.
Forcontinuousefficiency, the heatexchangerand af-
tercoolercoresmustbe periodically cleaned with either
vacuumorcompressed air. If wetcleaning isrequired,
shieldthe motorand sprayonamildsoap solution, then
flushwithclean water.
Forcopperwatercoolers,do notuse
any cleaning solution thatisnotcom-
patiblewithcopper.Use ofimproper
solution may resultin damagetothe
cooler.
FOUNDATION-- The Champion RotaryScrewcom-
pressor requiresno specialfoundation,butshould be
mountedonasmooth,solidsurface.Wheneverpos-
sibleinstall the unitnearlevel.Temporaryinstallation
maybe made atamaximum10_anglelengthwise or
10_sidewise.
Mounting boltsare notnormallyrequired.However,
installation conditions such aspiping rigidity,angle of
tilt, ordangerofshifting fromoutside vibration ormov-
ing vehiclesmayrequirethe use ofmounting boltsand
shimsto provide uniformsupport forthe base.
OILRESERVOIR DRAIN-- The oil drain plug islocated
at the bottomof the discharge end of the compressor.
(See FIGURE5--1,page 40.)
ENCLOSURE-- The compressor,electricmotor,water
coolerand aftercooleraremounted inside the enclo-
sure.
Service doorsare provided formaintenance access.
Besureto allowenough space around the unit forthe
doorsto be opened and removed asnecessaryforser-
vice procedures.The enclosure doorsare held bytwo
latchesand lift awayfromthe enclosure.The airfilter,
waterfilters,and watertreatmentcartridge are easily
accessiblethrough a side orend door.
Do notoperatethe compressorwith
thebeltguardremoved.Exposed
beltsmay cause injuryto personnel.
COMPRESSORWATERSPECIFICATION-- The
compressorinitialfill and make--up watermustmeet
the United StatesEnvironmentalProtection Agency
NationalPrimaryand SecondaryDrinking WaterReg-
ulations(See Table,page 15.)Byrequiring potable
waterfit forhuman consumption,a qualitylevel isde-
fined whichismostgenerallyreadilyavailable.
BackflowPreventersmustbe
installedonthepotablewatersupply
linetothecompressortopreventhigh
pressure airfromblowingintothewa-
tersupply.
Use ofcompressorinitialfill and
make--up waternotmeeting all water
specification standardsnotedmay
resultincontamination of thedis-
charge airstream.
Compressorwaterseal leakagemay
occur.You musthave potablemake--
up wateravailable.
Water may no longerbepotable after
use inthe compressor.

13-11-603 Page 11
MaximumLimit
1)TotalHardness asCaCO3120 partspermillion
2)EitherTotalDissolved Solids500 partspermillion
orSpecificConductance 800 Micromhos/cm
3)pH7.5to 9.0
FIGURE2--3-- ADDITIONALWATERLIMITATIONS
TotalHardness
inMg/L*asCaCO3WaterClassification
0-- 60 Soft
61 -- 120 ModeratelyHard
120 -- 180 Hard
Greaterthan 180 VeryHard
FIGURE2--4-- USGSCLASSIFICATIONOFWATER
*1Mg/L=Approx.1 ppm
In addition tothe requirementsof the NationalDrinking
WaterRegulations, the limitslisted inFIGURE2--3
shall notbe exceeded.
Use ofcompressorinitialfill and
make--up waterexceeding these lim-
its couldresultinexcessive scale
formation whichcanfacilitate corro-
sive activity and equipmentdamage
or malfuction.
Thisunitisequipped with a food--grade hexameta-
phosphatefeedercartridge which dissolves slowlyin
waterto preventscale and inhibitcorrosive activity.
The use ofawaterconsidered to be “hard”or “very
hard”bythe U.S.GeologicalSurvey(See FIGURE2--4
forthe U.S.G.S.classification ofwater) will resultinin-
creased frequency ofrequired waterfilterand cartridge
replacementsand lead toscale build--up whichcan
cause equipmentmalfunction and/ordamage. If a pro-
posed watersupplyisquestionable, the watershould
be analyzed. If the waterdoesnotcomplywiththis
specification,awatertreatmentservicecan recom-
mend equipment tosatisfythis specification.Hardness
can often be reduced byusing a sodiumion exchange
watersoftener.The use ofdeionized waterisnotrec-
ommended.
AUXILIARYAIR RECEIVER-- An auxiliaryair receiv-
erisnotrequired if the piping systemislarge and pro-
vides sufficientstorage capacityto preventrapidcycl-
ing.When used,an air receivershould be ofadequate
size,provided withareliefvalve ofpropersetting,a
pressure gauge and a meansofdraining condensate.
MOISTURE SEPARATOR/TRAP-- Sincethe unitis
equipped with a built--in aftercooler,an integralmois-
tureseparatorand draintrap isfurnished withthe unit.
The moisturefromthe trap ispiped tothe unitdrainline.
CONTROLPIPING-- Externalcontrolpiping isnotnec-
essary sincethe unitisfactorywired and piped forthe
controlsystemspecified.
INLET LINE-- Whereaninletline isused between the
airfilterand the compressor,itmustbe thoroughly
cleaned on the inside to preventdirtorscalefromen-
tering the compressor.Ifweldedconstruction is
used,thelinemustbe shotblastedand cleanedto
remove welding scale.In eithercase, the inletline
mustbe coated internallybygalvanizing orpainting
withamoisture and oil--proofsealing lacquer.Uptoten
(10)feetinlength, the inletline should be the full size
of the inletopening on the compressor. If an extra--
long line isnecessary, the pipe sizeshould be in-
creased according toInletLine Chart, FIGURE2--5.
Accessibilityforinletairfilterservicing mustbe consid-
ered when relocating the filtersfromthe unit to a remote
location.
Length of InletLine DiameterofPipe Size
0to10Feet(0to3Meters)Same asCompressorInletOpening..................................
10 to17Feet(3to5Meters)One Size LargerThan InletOpening..................................
17 to38Feet(5to 11.5Meters)TwoSizesLargerThan InletOpening...............................
FIGURE2--5-- INLET LINELENGTHS