Champion HRA20-12 Operation & Maintenance Manual Download Page 1

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OPERATION/MAINTENANCE

MANUAL & PARTS LIST

TWO STAGE/FOUR CYLINDER R70A

AIR COMPRESSOR & UNITS

WARNING

THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION AND SHOULD ALWAYS BE

AVAILABLE TO THOSE PERSONNEL OPERATING THIS UNIT.

READ, UNDERSTAND AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING THIS

EQUIPMENT TO PREVENT INJURY OR EQUIPMENT DAMAGE.

MODEL R70A COMPRESSOR

MODEL HRA25-12 UNIT

Form No. F3234 VER: 09 07/01/2009

C469-A
(Ref. Drawing)

C324-A
(Ref. Drawing)

Summary of Contents for HRA20-12

Page 1: ...PORTANT SAFETY INFORMATION AND SHOULD ALWAYS BE AVAILABLE TO THOSE PERSONNEL OPERATING THIS UNIT READ UNDERSTAND AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT TO PREVENT INJURY OR EQUIPMENT DAMAGE MODEL R70A COMPRESSOR MODEL HRA25 12 UNIT Form No F3234 VER 09 07 01 2009 C469 A Ref Drawing C324 A Ref Drawing ...

Page 2: ...orrect replacement parts 2 A full line of factory tested CHAMPLUB compressor lubricants specifically formulated for use in Champion compressors 3 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 b...

Page 3: ...arranty 6 Dimensions And Specifications 7 Installation 8 9 10 Operation 11 Maintenance 12 13 14 Compressor Pilot Valve Differential Pressure Adjustment 15 Compressor Oil Specifications 16 Torque Valves 16 Trouble Shooting Guide 17 18 Unit Repair Parts List 19 thru 21 Compressor Repair Parts List 22 thru 25 Constant Speed Head Unloader 26 Unit Hazard Decal Listing 27 Unit Hazard Decals 28 Pump Haza...

Page 4: ...or restrict operation in any way 12 Be sure no tools or rags or loose parts are left on the compressor or drive parts 13 Do not use flammable solvents for cleaning the air inlet filter or element and other parts 14 Exercise cleanliness during maintenance and when making repairs Keep dirt away from parts by covering parts and exposed openings with clean cloth or Kraft paper 15 Do not operate the co...

Page 5: ...N THE PARTS LIST SECTION DANGER This reciprocating compressor must not be used for breathing air To do so will cause serious injury whether air is supplied direct from the compressor source or to breathing tanks for later use Any and all liabilities for damage or loss due to injury death and or property damage including consequential damages stemming from the use of this compressor to supply breat...

Page 6: ...ufactured by CHAMPION to be free from defects in material and workmanship under normal use and service for a period of twelve 12 months from date of installation or eighteen 18 months from date of shipment by CHAMPION or CHAMPION distributor whichever may occur first CHAMPION makes no warranty in respect to components and accessories furnished to CHAMPION by third parties such as ELECTRIC MOTORS G...

Page 7: ...tion Clockwise when viewed from front flywheel to rear SPECIFICATIONS MODEL BORE STROKE INCH NO of CYLINDERS OIL CAPACITY QTS WEIGHT LBS MAXIMUM PRESSURE PSIG CU FT REV MIN MAX RPM R70A 6 1 4 3 1 4 x 4 4 6 1 3 450 175 142 425 1000 PERFORMANCE PUMP OUTPUT PRESS PSIG MOTOR H P PUMP RPM DISPL CFM COOLING AIR FLOW CFM HEAT REJECTION BTU HR APPROX PULLEY O D INCHES R70A 125 20 770 109 4 2580 44 700 8 9...

Page 8: ...abnormal vibration and possible cracking of air receiver It is recommended that unit be set on optional vibro isolator pads Tanks bolted directly to a concrete floor without isolators will not be warranted against cracking Champion vibro isolators or approved equivalent must be installed for extended warranty to apply to ASME receivers 4 If installing a bare pump or base mounted unit make certain ...

Page 9: ...ed on the 1999 NEC WIRE SIZE AWG 75 C COPPER 30 C AMBIENT 3 PHASE MOTOR HP 200 208V 230V 460V 575V 20 3 0 4 1 8 6 10 6 25 1 000 2 00 6 4 8 6 30 0 0000 1 000 6 3 8 4 Values in for Duplex Unit w one incoming power line to both motors All models require a properly sized magnetic starter as specified in the National Electric Code NEC See Figure 1 1 for simplex wiring diagram and Figure 1 2 for duplex ...

Page 10: ...harge pipe out of unit The table gives recommended minimum pipe sizes A union connection to the unit and water drop leg is recommended Install a flexible connector between the discharge of the unit and the plant air piping Plant air piping should be periodically inspected for leaks using a soap and water solution for detection on all pipe joints Air leaks waste energy and are expensive Minimum Pip...

Page 11: ... flow from the receiver to the head unloader mechanism thus actuating it To operate unit in continuous run open needle valve located next to pilot valve The pilot valve is now able to sense receiver pressure When the receiver pressure reaches the cut out pressure setting of the pilot valve the pilot valve opens and air is released to the unloader mechanism The compressor stops compressing air and ...

Page 12: ...Turn off power supply at wall switch WEEKLY MAINTENANCE 1 Clean dust and foreign matter from cylinder head motor fan blade air lines intercooler and tank 2 Remove and clean intake air filters WARNING Do not exceed 15 PSIG nozzle pressure when cleaning element parts with compressed air Do not direct compressed air against human skin Serious injury could result Never wash elements in fuel oil gasoli...

Page 13: ...top compressor at the proper pressure for the unit on which it is installed Do not readjust BELTS Drive belts must be kept tight enough to prevent slipping If belts slip or squeak see V belt maintenance in preceding section CAUTION If belts are too tight overload will be put on motor and motor bearings COMPRESSOR VALVES If compressor fails to pump air or seems slow in filling up tank disconnect un...

Page 14: ...his can be corrected by removing check valve and cleaning disc and seat If check valve is worn badly replace same Before removing check valve be sure all air is drained out of tank and power is disconnected Failure to do so may result in injury or equipment damage THE INTERSTAGE PRESSURE RELIEF VALVE is provided to protect against interstage over pressure and is factory set for maximum pressure of...

Page 15: ...5 psig less than setting of pressure switch 3 After pressure is set tighten locknut 4 Be careful not to move threaded cap 1 COMPRESSOR PILOT VALVE DIFFERENTIAL PRESSURE ADJUSTMENT Proceed with the following instructions while compressor is running 1 Loosen locknut 2 and back off several turns 2 Check reading on the tank pressure gauge Set the pressure to 30 psig differential unload at 170 psig rel...

Page 16: ...ssor operation a careful and regular check of the oil level should be made Maintain oil level at the full line CHANGING TO SYNTHETIC LUBRICANT Applies to diester based synthetic lubricant only 1 Compressor must run for a 25 hour break in period using ChampLub ISO 100 oil 2 Thoroughly drain existing oil from crankcase 3 Fill crankcase with a full charge of synthetic lubricant 4 Run compressor for 2...

Page 17: ...y rated 4 Check with voltmeter Be sure voltage corresponds to unit specifications 5 Replace motor Tank pressure builds up slowly 1 Air leaks 2 Dirty air filter 3 Defective compressor valves 1 Tighten fittings 2 Clean or replace 3 Install new valve plate assembly Tank pressure builds up quickly 1 Excessive water in tank 1 Drain tank Discharge pressure relief valve pops off while compressor is runni...

Page 18: ...l unloader when unit is stopped 1 Check valve stuck in open position 1 Replace check valve Warning Relieve tank pressure before servicing System does not alternate Duplex units only 1 Starter tripped 2 Loose wiring in alternator 3 Defective alternator 4 Defective motor 1 Reset starter If starter trips repeatedly have electrical system inspected by an electrician 2 Check and tighten all wiring conn...

Page 19: ...05A P14205A P14205A 7 Pressure Switch 175 PSIG P14202A P14202A P14202A P14202A P14202A P14202A 8 Pressure Relief Valve M2843 M2843 M2843 M2843 M2843 M2843 9 Motor 20 HP 20 HP 25 HP 25 HP 30 HP 30 HP 10 Tank P03665D P03564D P03665D P03564D P03665D P03564D 11 Isolation Valve M2688 M2688 M2688 M2688 M2688 M2688 P005345A P005345A P03710A P03710A P03710A P03710A PULLEY PULLEY PULLEY PULLEY PULLEY PULLE...

Page 20: ...Guard Z674 Z674 Z674 3 Base Plate P03538C P03538C P03538C 4 Motor 20 HP 25 HP 30 HP P05345A P03710A P03710A Pulley Pulley Pulley P05622A P05621A P05621A 5 Pulley 125 PSIG Bushing Bushing Bushing P05634A P03710A Pulley P09311B Pulley P05622A P05621A 5 Pulley 175 PSIG Bushing Bushing 125 PSIG B100 3 B103 3 B103 3 6 Belts 175 PSIG B100 3 B100 3 B103 3 C467 A Ref Drawing ...

Page 21: ...542 125 PSIG P14205A P14205A P14205A 7 Pressure Switch 175 PSIG P14202A P14202A P14202A 8 Pressure Relief Valve M2847 M2487 M2487 9 Motor 20 HP 25 HP 30 HP 10 Tank P12127D P12127D P12127D 11 Isolation Valve M2688 M2688 M2688 P05345A P03710A P03710A Pulley 2 Pulley 2 Pulley 2 P05622A P05621A P05621A 12 Pulley 125 PSIG Bushing 2 Bushing 2 Bushing 2 P05634A P09311B 2 P03710A Pulley 2 Pulley 2 P05622A...

Page 22: ...22 COMPRESSOR REPAIR PARTS ILLUSTRATION Models R70A C308 B Ref Drawing ...

Page 23: ...Unloader muffler assembly Z4593 1 26 Hex head machine screw M3473 6 27 Release valve kit includes items 28 29 30 31 Z12414A 1 28 Release valve plunger SE586B 1 29 Release valve ball P07841A 1 30 Release valve spring SE591 1 31 Release valve cap NR101 1 32 Flywheel P05723C 1 33 Key M1506 1 34 Flywheel washer M1394 1 35 Hex head cap screw M2265 1 36 Low pressure connecting rod assembly includes 39 4...

Page 24: ...ead cap screw P04779A 16 60 Low pressure discharge manifold M1423 2 61 High pressure intake manifold M1431 2 62 High pressure discharge manifold M1508 2 63 Interstage pressure relief valve CC1009750 2 64 Intake filter P07447A 2 65 Intake filter element P05051A 2 Complete compressor pump gasket set items 10 14 49 Z10889 1 Low pressure piston kit items 42 43 44 45 Z9108 2 High pressure piston kit it...

Page 25: ...er includes compression fittings ZM1432 1 6 Right intercooler includes compression fittings ZM1433 1 7 Intercooler clamp M1537 1 8 Intercooler clamp M1538 1 9 Hex head cap screw M3471 2 10 Speed nut P03699A 2 11 Compression nut M1418 4 12 Ferrule P06064A 4 13 Right discharge tube includes compression fittings ZM1532 1 14 Left discharge tube includes compression fittings ZM1533 1 15 Discharge tee M...

Page 26: ...ring LP Spring HP Nut Hex Lock Washer Gasket HP Only Actuating Tube Manifold Tube Manifold Tube Intermediate Tube Compression Fitting 1 4 x1 8 NPTx90 Compression Tee 1 4 x1 4 x1 8 NPT Pilot Valve Straight Compression Fitting 1 4 x1 8 NPT Mounting Bracket Cap Screw LP HU Manifold Assembly items 1 9 HP HU Manifold Assembly items 1 10 2 2 4 4 4 2 2 2 2 2 2 8 12 2 1 1 1 1 2 3 1 1 1 1 2 2 P09712D M1426...

Page 27: ...T USED 11b DECAL Synthetic or Food Grade Inserts 12 NOT USED 13 DECAL Pressure Setting 95 125PSIG 14 DECAL Pressure Setting 140 175PSIG 14 NOTICE Read and Retain Manuals 15 INSTRUCTIONS Dual Control 16 DECAL Rotation Direction 17 NOT USED 18 DECAL Pressure Switch P14677A PUMP HAZARD DECAL LISTING PAGE DESCRIPTION PART NO 29 PUMP DECAL SHEET MASTER P13805A NOT USED A1 NOTICE Lubricants A2 DECAL Rot...

Page 28: ...28 UNIT HAZARD DECALS ...

Page 29: ...29 PUMP HAZARD DECALS F ...

Page 30: ...0 RECORD OF MAINTENANCE SERVICE Daily DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR CHECK V BELTS EVERY 3 MONTHS INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 31: ...1 RECORD OF MAINTENANCE SERVICE Daily DRAIN MOISTURE FROM TANK WEEKLY CLEAN FILTER CLEAN COMPRESSOR CHECK V BELTS EVERY 3 MONTHS INSPECT VALVE ASSEMBLIES TIGHTEN ALL FASTENERS TEST PRESSURE RELIEF VALVE ...

Page 32: ...3321 Fax 815 872 0421 E mail champion championpneumatic com 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 Copyright 2009 Gardner Denver Inc Printed in U S A F3234VER09 F3234VER09 ...

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