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Summary of Contents for C15-16

Page 2: ...p and maintenance 19 4 5 Air ducting 23 4 5 1 Compressor house adjustment 23 4 5 2 Ducting 24 5 IMPORTANT NOTES AND INFO SOURCES 27 5 1 Testing and verification 27 5 2 Installer and end user documenta...

Page 3: ...bracket design guides for the C8 C15 C30 and C38 Version 1 5 Released 12 04 2019 o Updated chapter 4 5 2 Air ducting recirc inlet restrictors o Updated chapter 6 4 2 C15 bracket drawing o New pulley r...

Page 4: ...ation Section 2 Rotrex technology basics provides essential information on how a Rotrex unit works and the benefits it brings to you and your customers Section 3 Choosing the right Rotrex provides a u...

Page 5: ...egic perspectives the viability of the project The outcome can lead to approval revision or dismissal Phase 3 Design verification Takes the revised base specification from phase 2 and verifies the des...

Page 6: ...Inform your Rotrex supplier of the outcome of your technical and market analysis The purpose is to revise key assumptions to provide constructive feedback aimed to prevent quality and operational issu...

Page 7: ...location Supercharger Centrifugal air compression through high speed traction drive featuring internal dry sump dual action oil vane pump Oil cooler Acting as main cooling element Canister Oil reserv...

Page 8: ...n vane pump sucks oil from the canister pumps it into the traction drive sucks oil from the unit sump and pumps it back out into the canister through the cooler B Traction drive Multiplying input spee...

Page 9: ...uid momentarily increases viscosity under high surface pressure enhancing the traction drive performance by securing the optimum friction between rolling elements while cooling and protecting the syst...

Page 10: ...w this will be affected under boost conditions This can very well be modelled using advanced engine calculation tools and theory However using a simple rule of thumb along with the information provide...

Page 11: ...he expected flow Flow kg s hpsupercharged 1200 Since the target power in this example is 150hp we have the following flow 150 1200 0 125 The approximate pressure ratio needed to produce this power on...

Page 12: ...e internal thread connection resulting in supercharger damage Never use an impact wrench when mounting or changing pulleys Section 6 3 of this document explains the procedure for assembling and disass...

Page 13: ...e a reasonable evaluation of the durability of the belt drive A more simplistic approach can be taken for prototype work These guidelines are rule of thumb only and must be accompanied by many hours o...

Page 14: ...e same method can be used to install a supercharger in a mirrored position compared to the other front end components so that a clockwise rotating engine drives a supercharger mounted in a mirrored po...

Page 15: ...or several seconds then returns louder a misalignment problem is likely If the noise immediately increases after the belt is sprayed slip is likely Besides noise belt dust and burnt rubber smell are o...

Page 16: ...tability and durability Include a minimum of 3 strong fixing points to help prevent excessive vibration and bending during operation Remember to avoid materials that will corrode when mounted onto alu...

Page 17: ...everything needed hoses fittings filter cooler and canister for your application development and commercialization We strongly recommend using these oil sets as they have gone through extensive testi...

Page 18: ...percharger must be positioned above all oil system components filter canister oil cooler and oil lines to prevent any potential oil leakage from the supercharger Remember that the canister needs to be...

Page 19: ...kinks in the oil lines Engine vibration and movement must be considered when routing the oil lines It is important to place the oil cooler where the risk of clogging debris stones sand etc can is mini...

Page 20: ...fitting to prevent leaks 2 Mount the oil cooler in front of other coolers in a location with good air flow Place the oil cooler below or level with the supercharger s shaft The threads for the fitting...

Page 21: ...e of the supercharger must be installed facing downwards and horizontal within 15 Mounting the supercharger outside this tolerance will prevent the scavenge side of the pump to work properly and jeopa...

Page 22: ...ing the engine within 5 seconds top up traction fluid before the oil level reaches the bottom of the canister Check that the oil level is between the min and the max indicators on the dipstick while t...

Page 23: ...this document and check the oil level 7 Remove the canister cap 2 Slide away the two hose clamps on the oil filter and remove the oil filter 1 To avoid traction oil spilling into the engine compartmen...

Page 24: ...he torque stated in the respective datasheet Tightening of the two large counter bore bolts must be done incrementally turning each bolt a couple of turns making sure the compressor housing is not mou...

Page 25: ...er To prevent surge it is necessary to relieve the system from excessive pressure through re circulation or blow off A BOV will prevent surge by allowing air to circulate from outlet to inlet of the s...

Page 26: ...ate dynamic forces applied directly to the rotating impeller wheel and may cause damage to the supercharger and or reduce lifetime Using custom inlet restrictors voids warranty In case it is deemed ma...

Page 27: ...e oil maintenance interval found in Section 4 4 2 Do not make unnecessary sharp bends in the air ducting as bends will cause pressure drop resulting in loss of output Using a minimum of bends in the i...

Page 28: ...nd level are verified it is necessary to check that the oil remains below the maximum temperature during harsh climate and operating conditions Dedicated desert hot climate testing is highly recommend...

Page 29: ...nd thoroughly as well as other engine parameters affected by supercharging Perform dyno tests to monitor performance variations across vehicles and environments during the DVT phase If a problem is id...

Page 30: ...corrective action Important notes on claim handling Contact the company who sold you the Rotrex supercharger to ask what to do next If asked to return the claimed unit then always return it with the...

Page 31: ...Technical Handbook Rev 1 6 WWW ROTREX COM Page 30 of 41 Important notes and info sources 6 Support material 6 1 Pulley ring design guide for C15 C30 and C38...

Page 32: ...urements in mm Not specified tolerances 0 1mm Surface finish in Ra Not specified surface 3 2 Ra Angles in Not specified angle tolerance 0 1 Not specified edge corner tolerances 0 3 Update ERP Released...

Page 33: ...Technical Handbook Rev 1 6 WWW ROTREX COM Page 32 of 41 Important notes and info sources 6 3 Pulley ring design guide for C38R...

Page 34: ...Technical Handbook Rev 1 6 WWW ROTREX COM Page 33 of 41 Important notes and info sources 6 4 Pulley ring drawing for C38R...

Page 35: ...e bolts and old pulley 3 Mount the new pulley and screw the bolts in 4 Tighten the 6 bolts in a cross pattern to 10 Nm 7 4 ft lbs Make sure the mounting surfaces between the pulley and pulley adapter...

Page 36: ...Technical Handbook Rev 1 6 WWW ROTREX COM Page 35 of 41 Important notes and info sources 6 5 2 Steel pulleys Up to dec 2021...

Page 37: ...Technical Handbook Rev 1 6 WWW ROTREX COM Page 36 of 41 Important notes and info sources 6 6 Bracket design guide 6 6 1 Bracket design guide for C15...

Page 38: ...Technical Handbook Rev 1 6 WWW ROTREX COM Page 37 of 41 Important notes and info sources 6 6 2 Bracket design guide for C30...

Page 39: ...Technical Handbook Rev 1 6 WWW ROTREX COM Page 38 of 41 Important notes and info sources 6 6 3 Bracket design guide for C38...

Page 40: ...Technical Handbook Rev 1 6 WWW ROTREX COM Page 39 of 41 Important notes and info sources 6 6 4 Bracket design guide for C38R...

Page 41: ...information Company Date Address Engineering contact Tel Email Purchasing contact Tel Email General project information Vehicle brand model and code Engine code and description Expected yearly sales v...

Page 42: ...vehicle S C mileage when problem first encountered Something out of the ordinary was observed at S C mileage S C mileage when claimed Claim at S C mileage May be same as above Climate conditions State...

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Rotrex C15-16, Technical Handbook

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