Champion CRN Series User manual

REFRIGERATED
TYPE
COMPRESSED
AIR DRYERS
SERVICE DEPARTMENT: [phone]
INSTRUCTION MANUAL
CRN SERIES
Models: CRN25, CRN35, CRN50, CRN75
5004822 Rev. A 2/09
CONTENTS
GENERAL SAFETY INFORMATION ....................... 2
RECEIVING, MOVING, AND UNPACKING.............. 2
1.0 INSTALLATION .............................................. 3
2.0 OPERATION................................................... 4
3.0 MAINTENANCE ............................................. 5
SIZING ................................................................. 5
ENGINEERING DATA ........................................... 6
P&I DIAGRAM...................................................... 7
WIRING DIAGRAM............................................... 8
DIMENSIONS / WEIGHTS ..................................... 9
TROUBLESHOOTING GUIDE................................. 10
PARTS LIST.......................................................... 11
WARRANTY......................................................... 12

2
GENERAL SAFETY INFORMATION
1. PRESSURIZED DEVICES:
This equipment is a pressure
containing device.
• Donotexceedmaximumoperating
pressure as shown on equipment
serial number tag.
• Makesureequipmentisdepressurizedbefore
workingonordisassemblingitforservice.
2. ELECTRICAL:
This equipment requires electricity to
operate.
• Installequipmentincompliance
with all applicable electrical codes.
• Standardequipmentissupplied
withelectricalenclosuresnotintendedforinstallation
inhazardousenvironments.
• Disconnectpowersupplytoequipmentwhen
performinganyelectricalservicework.
3. BREATHING AIR:
• Airtreatedbythisequipmentmay
notbesuitableforbreathingwithout
furtherpurication.
 Refertoapplicablestandardsand
specicationsfortherequirementsfor
breathing quality air.
RECEIVING, MOVING, AND UNPACKING
A. RECEIVING
Thisshipmenthasbeenthoroughlychecked,packed
andinspectedbeforeleavingourplant.Itwas
received in good condition by the carrier and was so
acknowledged.
CheckforVisibleLossorDamage.Ifthisshipment
showsevidenceoflossordamageattimeofdelivery
toyou,insistthatanotationofthislossordamagebe
made on the delivery receipt by the carrier’s agent.
B. UNPACKING
CheckforConcealedLossorDamage.Whena
shipment has been delivered to you in apparent
goodorder,butconcealeddamageisfoundupon
unpacking,notifythecarrierimmediatelyandinsiston
his agent inspecting the shipment. Concealed damage
claims are not our responsibility as our terms are F.O.B.
pointofshipment.
C. MOVING
Inmovingortransportingdryer,donottipdryeronto
its side.
D. STORAGE/SHUT DOWN
Dryer should not be stored outside (either
packedorunpacked)orexposedtotheweather.Damage
to electrical and control components may result.
IMPORTANT: Donotstoredryerintemperaturesabove
130°F(54.4°C).

3
IMPORTANT:
READPRIORTOSTARTINGTHISEQUIPMENT
1.0 INSTALLATION
1.1 Location
A. Fortypicalplacementinacompressedairsystem,see
drawing.
B. Aircompressorintake–Locateaircompressorsothat
contaminantspotentiallyharmfultothedryer(e.g.
ammonia)arenotdrawnintotheairsystem.
C. Dryershouldbeinstalledinamoderatelyheated,well
ventilatedarea.Avoidlocationsimmediatelyadjacent
tocoldexteriorwindowsorwalls,oradjacenttohigh
temperature ovens or boilers.
D. Clearances:Minimumrequirementsforfreeairow
and service access
FrontandRightSidePanel:18inches(610mm)
LeftSidePanel:12inches(305mm)
RearPanel:NoClearanceRequired
E. Standardunitsaredesignedtooperatein40to110°F
(4to43°C)ambienttemperatures.
F. Installationsinaltitudesabove4500feet(1370meters)
–Dryerisadjustedtooperateinaltitudesupto4500
feet(1370meters).Ifdryerisinstalledinanaltitude
abovethis,andhasnotbeenpresetatthefactory
forthisaltitude,contactmanufacturer’sService
Department.
G. Theinstallationofaexibleconnectionpriortothe
dryer is recommended to prevent possible damage
fromvibration.
NOTE:Outdoorinstallation–Standardunitsaredesigned
forindoorinstallation.Contactmanufacturerifinstalling
outdoors.
1.2 Mounting
Mountthedryeronalevelsolidsurface.Holesareprovided
in the dryer base to permanently mount the dryer to the
oor.
Aftercooler
Separator
DryerOil Removal
Filter
Compressor
1.3 Piping connections
A. AirInlet-Connectcompressedairlinefromairsource
toairinlet.(Referencemarkingsondryer,orsee
calloutdrawingbelowforairin/outletconnection
locations.)
RefertoSerialNumberTagformaximum
workingpressure.Donotexceeddryer’sMaximum
WorkingPressure.
NOTE:
Installdryerinairsystemathighestpressurepossible(e.g.
beforepressurereducingvalves).
NOTE:
Installdryeratcoolestcompressedairtemperature
possible.Maximuminletcompressedairtemperature:
120°F(49°C).Ifinletairexceedsthistemperature,precool
theairwithanaftercooler.
B. AirOutlet—Connectairoutlettodownstreamairlines.
C. By-passpiping—
 Ifservicingthedryerwithoutinterruptingtheair
supplyisdesired,pipingshouldincludeinletandoutlet
valvesandanairby-passvalve.
Power Cord
Separator/Filter
Condenser Air Flow
On/O Switch
Power On-Light
Dew point Temperature Indicator
Optional
Cold Coalescing
Filter
Drain
Air Inlet
Air Outlet

4
2.0 OPERATION
2.1 Minimum/Maximum operating conditions
A. Maximuminletairpressure:refertodryerserial
number tag
B. Minimuminletairpressure:30psig(2.1barg)
C. Maximuminletairtemperature:120°F(49°C)
D. Maximumambienttemperature:110°F(43°C)
E. Minimumambienttemperature:40°F(4°C)
2.2 Start-up
1. ConrmOn/OffSwitchisinthe“Off”position.
2. Energizedryer.Greenpower-onlightwillilluminate.
2.3 Operating check points
Checkthefollowingonaperiodicbasis:
A. Greenpoweronlightisilluminated.
B. Dewpointindicatorisingreenarea.
C. Condensateisdischargingfromdrain.
1.4 Electrical connections
A. Dryerisdesignedtooperateonthevoltage,phase,
andfrequencylistedontheserialnumbertag.
B. Installinareceptacleofpropervoltage.
NOTE:Refrigerationcondensingunitisdesignedtorun
continuously and should NOTbewiredtocycleon/offwith
the air compressor.
1.5 Moisture separator
A. Separator(andOilRemovalFilterwhereapplicable)
hasanexternaldrainwhichautomaticallydischarges
collectedcondensate.Itmaybedesirabletopipethe
condensatefromtheAutomaticDrainoutlettoa
suitable drain.
NOTE:Dischargeisatsystempressure.Drainlineshould
be anchored.
NOTE: Condensate may contain oil. Comply with applicable
laws concerning proper disposal.
B. Separatorhasaknurledttingwithexibledrain
tubingattached.Besureknurledttingistightened
byturningitcounter-clockwisebeforeoperatingdryer.
TO CLOSE
TURN COUNTERCLOCKWISE
Standard Control Panel
On/Off
Switch
PowerOn
Light
DewPoint
Temperature
Indicator

5
3.0 MAINTENANCE
3.1 Condenser coil
Cleanoffaccumulateddustanddirtmonthlyoras
necessary in dirty environments.
3.2 Moisture Separator/Filter and optional Oil
Removal Filter
Replacelterelementwhenpressuredropacross
dryerisexcessiveorannually.
3.3 Check separator daily to be sure automatic
drain is discharging.
3.4 Replace drain mechanism annually.
Tofacilitateservice,maintenancekitsareavailable.
Pleaserefertopage11.
SIZING
Todeterminethemaximuminletowcapacityofadryer
atvariousoperatingconditions,multiplytheratedcapacity
fromTable1bythemultipliersshowninTable2.
Example:Howmanyscfmcananair-cooledmodelCRN50
handlewhencompressedairtobedriedisat80psigand
90°F;andambientairtemperatureis80°F?
Answer:50x1.17x1.12=66scfm.
TABLE 1
Ratedcapacity(scfm)andpressuredrop@100psiginlet
pressure,100°Finlettemperature,and100°Fambient
temperature
MODEL 25 35 50 75
Ratedcapacity(scfm) 60 Hz
50 Hz
25
21
35
29
50
42
75
63
TABLE 2
Air capacity correction factors (Multipliers)
INLETCOMPRESSEDAIRCONDITIONS
INLET INLETTEMPERATURES
PRESSURES 80°F 90°F 100°F 110°F
psig kg/cm227°C 32°C 38°C 43°C
50
80
100
125
150
175
200
3.5
5.6
7.0
8.8
10.5
12.3
14.0
1.35
1.50
1.55
1.63
1.70
1.75
1.80
1.05
1.17
1.23
1.31
1.37
1.42
1.47
0.84
0.95
1.00
1.07
1.13
1.18
1.22
0.69
0.79
0.82
0.91
0.95
0.99
1.03
COOLINGMEDIUM
AMBIENT
TEMPERATURE MULTIPLIER
°F °C
80
90
100
110
27
32
38
43
1.12
1.06
1.00
0.94
Bowl
O-Ring Wave Spring
Pneumatic Pilot
Operated Drain
Tube
Separator Element
or Optional Oil Removal
Element

6
ENGINEERING DATA
MODEL CRN25 CRN35 CRN50 CRN75
AIR SYSTEM DATA
RatedAirFlowat100°F&100psigInlet,100°FAmbient(scfm)
60 Hz 25 35 50 75
RatedAirFlowat95°F&100psigInlet,77°FAmbient(scfm)
50 Hz 27 37 53 80
Minimum/MaximumInletCompressedAirPressure 30/232psig(2.1/16.0barg)
Minimum/MaximumInletCompressedAirTemperature 40°/120°F(4/49°C)
Minimum/MaximumAmbientTemperature 40°/110°F(4/43°C)
OutletAirTemperature(nominalatratedconditions) 85°F(29°C)
REFRIGERATION SYSTEM DATA
Compressor Type Hermetic-CapacitorStart,InductionRun-Non-Cycling
RefrigerationCapacity@RatedFlow(BTU/h)*
60 Hz (115V) 1,087 1,619 2,184 2,971
60 Hz (230V) 1,080 1,678 1,885 2,441
50 Hz 1,296 2,040 1,796 2,506
RefrigerantType R-134a
RefrigerantCharge SeeSerialTagonDryer
SuctionPressureSetting(hotgasby-passvalve) 30.5psig(2.1barg)
Air-Cooled Condenser
AirFlowAcrossCondenser(cfm) 60 Hz 206 206 200 188
50 Hz 165 165 160 150
ELECTRICAL DATA
Nominal Voltage 115/1/60
VoltageRange 90-135
InputPower@RatedFlow(watts)* 205 253 410 589
MinimumCircuitAmpacity 4.2 3.5 6.3 9.3
MaximumOvercurrentProtector (amps) 15 15 15 15
CompressorRatedLoadAmps 2.9 2.4 4.7 7.1
CompressorLockedRotorAmps 14.2 20.1 28.0 40.0
CompressorWindingResistance,Main/Start(ohms) 3.2/3.4 3.3/3.8 1.9/6.6 1.0/2.9
Nominal Voltage 208-230/1/60
VoltageRange 198-254
InputPower@RatedFlow(watts)* ————
MinimumCircuitAmpacity 2.0 2.9 4.1 4.8
MaximumOvercurrentProtector (amps) 15 15 15 15
CompressorRatedLoadAmps 1.2 2.0 3.1 3.7
CompressorLockedRotorAmps 5.7 9.2 11.7 16.1
CompressorWindingResistance,Main/Start(ohms) 14.5/14.8 10.2/16.4 7.1/15.4 6.1/17.5
Nominal Voltage 220-240/1/50
VoltageRange 198-254
InputPower@RatedFlow(watts)* ————
MinimumCircuitAmpacity 2.0 2.9 4.1 4.9
MaximumOvercurrentProtector (amps) 15 15 15 15
CompressorRatedLoadAmps 1.2 2.0 3.1 3.7
CompressorLockedRotorAmps 5.7 9.2 11.7 16.1
CompressorWindingResistance,Main/Start(ohms) 14.5/14.8 10.2/16.4 7.1/15.4 6.1/17.5
Notes:
*60Hz:35°FEvaporator&100°FAmbient;50Hz:35°FEvaporator&77°FAmbient.

7
P&I DIAGRAM
ModelsCRN25throughCRN75
REFRIGERATION SYSTEM
ACCESS
VALVE
M
HOT GAS
BYPASS
VALVE
CONDENSATE
COMPRESSED AIR OUT
COMPRESSED AIR IN
COMBINED
AIR-AIR HEAT EXCHANGER/EVAPORATOR
CONDENSATE
SEPARATOR
W/AUTOMATIC DRAIN
PROCESS GAS SYSTEM
CONDENSATE
OPTIONAL OIL
COALESCING
SEPARATOR
W/AUTOMATIC DRAIN
REFRIGERATION
COMPRESSOR
FILTER/DRYER
CAPILLARY
TUBE
CONDENSER
FAN
TEMPERATURE
SENSOR

8
WIRING DIAGRAM
ModelsCRN25throughCRN75
COMPRESSOR HARNESS
IO
PE
GROUND STUD
L2
L1
L2L1 PE
POWER ON PILOT LIGHT
T2 T2
T1 T1
PE T2
T1 T1
CAP
115/1/60
208 - 230/1/60 220 - 240/1/50
POWER CORD SUPPLIED
10 11
1312
MP
FM
PE
POTENTIAL RELAY
MOUNTED ON COMPRESSOR
MTR
LEGEND
CAP -StartCapacitor FM -FanMotor MP -MotorProtector MTR-Compressor

9
DIMENSIONS / WEIGHTS
MODEL CRN25 CRN35 CRN50 CRN75
FLOWRATE(SCFM) 25 35 50 75
DIM“A”–AIRI/OCONNECTIONS 1/2"MPT 3/4”MPT
WEIGHT,lbs(kg) 86(39) 90(41) 95(43) 106(48)
NOTE:DimensionsandWeightsareforreferenceonly.Requestcertieddrawingsforconstructionpurposes.
AIR FLOW
“A” I/O CONNECTION
2 (51)
18 (457)
16.1/8 (410)
1.3/4 (44)
26 (660)
1.1/4 (32)
18.7/8 (479)
3/8” TUBE
DRAIN CONNECTION
ELECTRICAL CORD
14.1/8 (359)
20.15/16 (532)
3.7/16 (87)
9.13/16 (249)
1.15/16 (49)
17.1/2 (445)
14.1/8 (359)
1.1/2 (38)
Ø5/16
4-PLACES TYP.
20.1/2 (521)
FRONT VIEW RIGHT SIDE VIEW
BOTTOM VIEW

10
TROUBLESHOOTING GUIDE
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
A. Water downstream of
dryer.
1. Residualfreemoistureremainingin
downstream pipelines.
2. Airby-passsystemisopen.
3. Inletandoutletconnectionsare
reversed.
4. Temperatures surrounding air lines
downstreamofdryerhavedropped
below dryer’s dew point rating.
5. Excessivefreemoisture(bulkliquid)
at dryer inlet.
6. Condensatenotbeingautomatically
drained.
 Drainmechanismiscloggedor
inoperative.
 Drainlineisrestrictedorfrozen.
7. Dryeroverloadedresultingin
elevated dew point.
8. Refrigerationsystemnot
functioningproperlyresultingin
elevated dew point.
Blow out system with dry air.
Checkvalvepositions.
Checkforcorrectconnection.
Insulateorheattraceairlinesexposedto
low ambients or dry air to lower dew point.
Installseparatoraheadofdryer.
Replacedrainmechanismifinoperative.
Open drain line.
Checkinletairtemperatureandpressure,
owrate(compressorcapacity)and
ambient air temperature.
SeeDbelow.
B. High pressure drop
across dryer.
1. Excessiveairow.
2. Freezingofmoistureinevaporator
becauseofrefrigerationsystem
improperlyfunctioning.
3. Separatororoptionaloilremoval
lterelementclogged.
Checkowrate.
SeeDbelow.
Replacelterelement(s).
C. Dew point indicator
in red area.
1. Dryeroverloadedresultinginhigh
air outlet temperature.
2. Refrigerationsystemnot
functioningproperlyresultingin
high air outlet temperature.
3. Temperature sensor not properly
attached,uninsulated,or
malfunctioning.
SeeA7.
SeeDbelow.
Checksensorbulb.
D. Refrigeration system
not functioning
properly.
1. Poweronlightoff.
2. Refrigerantcompressor
cyclesonandoff.
a. ON/OFFswitchis“OFF”.
b. Linedisconnectswitchopen.
c. Blownfuses,openbreaker.
d. Faultywiring,looseterminals.
a. Highorlowambientconditions.
b. Dirty,cloggedcondenserns,
obstructedairowacross
condenser,ornonfunctioningfan
motor.
Turnswitch“ON”.
Close disconnect switch.
Checkforcontinuity.
Haveelectriciancheckelectrical
connections.
Checkmin./max.temperatureranges
Cleancondenserandcheckforfreeair
ow,ifproblempersistscontactqualied
refrigerationrepairmanormanufacturer’s
service department.

11
PARTS LIST
PARTS DESCRIPTION - 115/1/60 CRN25 CRN35 CRN50 CRN75
CondensingUnit G5004703 G5004704 G5004705 G5004706
Compressor G5004855 G5004856 G5004857 G5004858
StartRelay G5004863 G5004864 G5004865 G5004866
StartCapacitor G5004870 G5004871 G5004872 G5004873
FanMotor G5004876 G5004876 G5004877 G5004876
Fan Blade G5004808 G5004808 G5004879 G5004808
HotGasBy-PassValve G3232557 G3232557 G3232557 G3232557
RefrigerantFilter/Dryer G5004781 G5004781 G5004781 G5004781
DewPointTemperatureIndicator G3224008 G3224008 G3224008 G3224008
CondensateDrain G3152270 G3152270 G3152270 G3152270
On-OffSwitch G3230777 G3230777 G3230777 G3230777
IndicatorLight G3227421 G3227421 G3227421 G3227421
PARTS DESCRIPTION - 220-240/1/50-60 CRN25 CRN35 CRN50 CRN75
CondensingUnit G5004842 G5004843 G5004844 G5004845
Compressor G5004859 G5004860 G5004861 G5004862
StartRelay G5004867 G5005419 G5004868 G5004869
StartCapacitor G5004874 G5004875 G5004875 G5005420
FanMotor G5004878 G5004878 G5004878 G5004878
Fan Blade G5004808 G5004808 G5004879 G5004808
HotGasBy-PassValve G3232557 G3232557 G3232557 G3232557
RefrigerantFilter/Dryer G5004781 G5004781 G5004781 G5004781
DewPointTemperatureIndicator G3224008 G3224008 G3224008 G3224008
CondensateDrain G3152270 G3152270 G3152270 G3152270
On-OffSwitch G3230777 G3230777 G3230777 G3230777
IndicatorLight G5004850 G5004850 G5004850 G5004850
Maintenance Kits
Model CRN25 CRN35 CRN50 CRN75
Standard CRNMK2 CRNMK2 CRNMK3 CRNMK4
WithOptionalColdCoalescer CRNMK12 CRNMK12 CRNMK13 CRNMK14
KitIncludes:condensatedrain,lterelement,O-ring,threadedadapter,wavespring,draintube,lubricant,instructionsheet

WARRANTY
Themanufacturerwarrantstheproductmanufacturedbyit,whenproperlyinstalled,operated,applied,andmaintained
inaccordancewithproceduresandrecommendationsoutlinedinmanufacturer’sinstructionmanuals,tobefreefrom
defectsinmaterialorworkmanshipforaperiodasspeciedbelow,providedsuchdefectisdiscoveredandbroughttothe
manufacturer’sattentionwithintheaforesaidwarrantyperiod.
Themanufacturerwillrepairorreplaceanyproductorpartdeterminedtobedefectivebythemanufacturerwithinthe
warrantyperiod,providedsuchdefectoccurredinnormalserviceandnotasaresultofmisuse,abuse,neglectoraccident.
Normalmaintenanceitemsrequiringroutinereplacementarenotwarranted.Thewarrantycoverspartsandlaborforthe
warrantyperiodunlessotherwisespecied.Repairorreplacementshallbemadeatthefactoryortheinstallationsite,at
thesoleoptionofthemanufacturer.Anyserviceperformedontheproductbyanyoneotherthanthemanufacturermust
rstbeauthorizedbythemanufacturer.
Unauthorizedservicevoidsthewarrantyandanyresultingchargeorsubsequentclaimwillnotbepaid.Productsrepaired
orreplacedunderwarrantyshallbewarrantedfortheunexpiredportionofthewarrantyapplyingtotheoriginalproduct.
Theforegoingistheexclusiveremedyofanybuyerofthemanufacturer’sproduct.Themaximumdamagesliabilityofthe
manufactureristheoriginalpurchasepriceoftheproductorpart.
THEFOREGOINGWARRANTYISEXCLUSIVEANDINLIEUOFALLOTHERWARRANTIES,WHETHERWRITTEN,ORAL,ORSTATUTORY,
ANDISEXPRESSLYINLIEUOFTHEIMPLIEDWARRANTYOFMERCHANTABILITYANDTHEIMPLIEDWARRANTYOFFITNESSFORA
PARTICULARPURPOSE.THEMANUFACTURERSHALLNOTBELIABLEFORLOSSORDAMAGEBYREASONOFSTRICTLIABILITYIN
TORTORITSNEGLIGENCEINWHATEVERMANNERINCLUDINGDESIGN,MANUFACTUREORINSPECTIONOFTHEEQUIPMENTOR
ITSFAILURETODISCOVER,REPORT,REPAIR,ORMODIFYLATENTDEFECTSINHERENTTHEREIN.
THEMANUFACTURER,HISREPRESENTATIVEORDISTRIBUTORSHALLNOTBELIABLEFORLOSSOFUSEOFTHEPRODUCTOR
OTHERINCIDENTALORCONSEQUENTIALCOSTS,EXPENSES,ORDAMAGESINCURREDBYTHEBUYER,WHETHERARISINGFROM
BREACHOFWARRANTY,NEGLIGENCEORSTRICTLIABILITYINTORT.
Themanufacturerdoesnotwarrantanyproduct,part,material,component,oraccessorymanufacturedbyothersandsold
orsuppliedinconnectionwiththesaleofmanufacturer’sproducts.
Warranty Period
Partsandlaborfortwo(2)yearsfromthedateofshipmentfromthefactory;heatexchangersarecovered(parts
only)foranadditionalthree(3)years(totalofve[5]).
Onunitsthatmanufacturerrequestsbereturnedtothefactory,aonetimeremoval/reinstallationlaborallowanceas
notedintheServiceWarrantyPoliciesandProceduresHandbookwillapply.Freighttothefactoryfromtheinstallationsite
andtotheinstallationsitefromthefactorywillbepaidbythemanufacturer;meansoftransportationtobespeciedby
manufacturer.
AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE MATERIAL IS
RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.
SERVICE DEPARTMENT : [phone]
www.championpneumatic.com
Champion
1301 North Euclid Avenue
Princeton, Illinois 61356 USA
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Plants in Princeton, IL, and Manteca, CA
Due to Champion’s continuing product development program,specifications and
materials are subject to change without notice or obligation.
© 2009 Gardner Denver
Litho in U.S.A.
5004822 Rev. A 2/09