User and Maintenance Manual
EK100
Rev. 12.2022
If you have any questions on this equipment please contact Technical Support at:
Nuvair
1600 Beacon Place
Oxnard, CA 93033 USA
Phone:
Fax:
Email:
+
1.805.815.4044
+
1
.
805.486.0900
[email protected]
Hours:
Monday through Friday
8:00 am to 5:00 pm
Pacific Time
This User Manual contains important safety information and should always be available to
those personnel operating this equipment. Read, understand, and retain all instructions
before operating this equipment to prevent injury or equipment damage.
Every effort was made to ensure the accuracy of the information contained within. Nuvair,
however, retains the right to modify its contents without notice. If you have problems or questions
after reading the manual, stop and call Nuvair at +1.805.815.4044 for information.
Exploded View of
EK100 Compressor
EK100 Manual Page 3
WARNING, PROHIBITION, MANDATORY LABEL INFORMATION
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.
Boxed text formats are used, within this manual, to alert users of the following
conditions:
Safety Labels are used, within this manual and affixed to the appropriate areas of the
compressor package, to alert users of the following conditions:
Indicates a hazard with a high level of risk, which if not avoided, WILL result in death or serious
injury.
Equipment Starts Automatically
Cutting of Finger or Hand Hazard, Rotating
Impeller Blade
Cutting of Finger or Hand Hazard, Rotating Fan
Blade
Health Hazard, Explosive Release of Pressure
High Voltage, Hazard of Shock, Burn, or Death
Present until Electrical Power is Removed
Entanglement of Fingers or Hand/Rotating Shaft
EK100 Manual Page 4
Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or
serious injury.
Asphyxiation Hazard, Poisonous Fumes or Toxic Gases in Compressed Air
Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or
moderate injury.
Burn Hazard, Hot surface
PROHIBITION/MANDATORY ACTION REQUIREMENTS
Do not Operate Compressor with Guard Removed
Do Not Lift Equipment with Hook, No Lift Point
Handle Package at Forklift Points Only
Lockout Electrical Equipment in De-Energized
State
Loud Noise Hazard, Wear Ear Protection
Read the Operator’s Manual Before Proceeding
with Task
EK100 Manual Page 5
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:
Failure to observe these notices will result in injury to or death of personnel.
Keep fingers and clothing away from rotating fan, drive coupling, etc.
Disconnect the compressor unit from its power source, lockout and tagout before working on the
unit, this machine is automatically controlled and may start at any time.
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, lockout and tagout and check for voltage before working on the
control.
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.
Do not use the air discharge from this unit for breathing, not suitable for human consumption.
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 exceed the 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.
EK100 Manual Page 6
GENERAL INFORMATION
FIGURE 1-1 COMPRESSOR CYCLE
COMPRESSOR - The 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 anti-
friction bearings located outside the compression chamber. Roller bearings are used at the inlet end of
the rotors to carry part of the radial loads. Angular contact ball and roller 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 five (5) helical lobes 90° apart.
The secondary rotor has six (6) matching helical grooves 72° 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 near the bottom at 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 the rotors unmesh at the inlet port and air is
drawn into the cavity between the main rotor lobes and the 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.
Oil is injected into the cylinder to remove the heat of compression and seal internal clearances. Volume
reduction and pressure increase continues until the air/oil mixture trapped in the interlobe cavity by the
rotors passes the discharge port and is released to the oil 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 1-3) Air enters the air filter and passes through the
inlet unloader valve and on into the compression chamber where oil is injected into the air. After
compression, the air/oil mixture passes into the oil reservoir where most of the entrained oil is removed by
velocity change and impingement and drops back into the reservoir. The air and remaining oil then
passes through the air/oil separator. The air then passes through the minimum pressure/check valve, the
after cooler and the optional moisture separator and into the plant air lines.
LUBRICATION, COOLING AND SEALING - Oil is forced by air pressure from the oil reservoir through
the oil cooler, thermostatic mixing valve, and oil filter and discharge into the compressor main oil gallery.
A portion of the oil is directed through internal passages to the bearings and shaft oil seal. The balance
of the oil is injected directly into the compression chamber to remove heat of compression, seal internal
clearances and lubricate the rotors.
EK100 Manual Page 7
Terminal Strip - This device provides an interconnection between the controller and the low voltage
hardware such as sensors and switches within the enclosure.
Main Starter
For Fixed Speed variant models, a Wye/Delta reduced voltage starter provides control and overload
protection for the main drive motor. The overloads are adjustable and are factory set based on the motor
nameplate amps and the instructions located inside the control box door.
For Variable Speed variant models, a variable speed drive provides the overload protection for the
main drive motor as well as compressor speed modulation.
Wiring diagrams for the standard configurations are illustrated in the following pages of this section.
NOTICE
Read the Operator’s Manual before operating the compressor. It is critical that the
detailed instructions for the controller, found in the controller manual are read and
understood. Once the appropriate parameters have been selected into the controller,
compressor operation may commence. For convenience, a “Quick Start” excerpt from
the controller manual is shown in Section 3.
FIELD CONVERSION OF MULTI-VOLTAGE ELECTRICAL SYSTEM – For fixed speed tri-voltage
models to convert the compressor package from its as-built voltage configuration to one of its optional
ones, contact Champion and request “Instructions, Tri-Voltage Conversion”, document TED000631.
EK100 Manual Page 8
MISCELLANEOUS CONTROL DEVICES - Refer to Figure 4-29 for the schematic diagram of the control system.
Air Inlet Filter (1) - Captures solid impurities in the air stream entering compressor inlet. It also attenuates noise
emitted by the compressor inlet.
Intake Regulator Assembly (2) - This device controls the intake of atmospheric air entering the compressor
during the Load/Unload phases of operation.
During the loaded state: The inlet poppet (pressure control valve 2.2) remains open and allows
atmospheric air to enter the compressor inlet.
During the unloaded state: The 2-way solenoid valve (Y1) feeds pressurized air underneath the piston
(actuating cylinder 2.1), forcing it and the inlet poppet (2.2) upward and blocking-off the compressor
intake. Excess gas is vented to atmosphere. A small purge line (non-return valve 2.3) allows a stream of
air to reach the rotors and keep them from unstable, noisy operation and producing sufficient pressure to
maintain cooling / lubricating oil flow.
Electric Motor (3) – Drives the compressor (4) via a belt drive assembly (5), and drives the package
ventilation fan from a secondary rear shaft. It is energized by the Wye/Delta starter (variable frequency drive in
variable speed models), which in turn is controlled by the controller.
Pressure Reservoir (6) – Separates by inertial effects the bulk of the compressed air and injection oil streams
and serves as a sump for the latter.
Fine Air/Oil separator (7) - Intercepts and coalesces the aerosol oil stream in the compressed air exiting the
inertial separation process within the reservoir.
Oil Filler Cap (8) – Oil fill port on the reservoir.
Oil drain (9) – Ball valve drains the oil from the reservoir and the oil trapped in the oil cooler and associated
hoses.
Oil Level Indicator (10) - This gauge is located on the oil reservoir and indicates the oil level. See “Oil Level
Gauge” on Section 5 for more details.
Oil Filter (11) - Captures solid impurities in the oil entering the compressor injection port.
Oil Cooler (12) – The air-cooled heat exchanger removes heat from the oil stream prior to injection.
Pressure Relief Valve (13) – This device protects the pressure containing components of the compressor
package against high pressure exceeding 217 psig. See Section 9, for maintenance information.
Minimum Discharge Pressure/Check Valve (14) - This device maintains minimum pressure (65 psig) within the
air/oil sump, thus ensuring adequate lubricating oil injection flow to the compressor even when no air delivery into
the system is taking place. It also functions as a check valve to prevent reversed air flow from the system line
during compressor stoppage. See Section 9 for maintenance information.
Air cooler (15) – The air-cooled heat exchanger removes heat from the air stream prior to exit from the package.
Oil fine separator extractor (16) – This annular orifice, built into the air/oil separator element adaptor pipe,
controls the amount of oil and compressed air that is returned from the air/oil separator back into the compressor.
Solenoid Valve (Y1) - This 2-way valve controls the position of the inlet valve in response to signals from the
Controller.
Pressure Sensor - Sump Dry Side (B1) - This device is connected after the minimum pressure valve. It
converts the pressure in the plant air system into an electrical signal for use by the controller for monitoring and
control load/unload operation.
Pressure Sensor - Sump Wet Side (B2) - This device is connected to the oil sump. It converts the pressure in
the oil sump into an electrical signal for use by the controller for monitoring and control. Its signal, when
compared to that of sensor (B1), indicates the pressure loss across the air/oil separator element and it can also
trigger a shutdown event in case an exceedingly high pressure is detected.
Temperature Sensor - Sump Wet Side (R2) - This device is connected to the oil sump. It converts the
temperature in the oil sump into an electrical signal for use by the controller for monitoring and control. Its signal
is used to monitor compressor temperature and also trigger a shutdown event in case an exceedingly high is
detected.
The following items additional are provided with the Total System variant:
Receiver – Provides storage of compressed air and serves as a support for the compressor unit and optional
dryer.
Refrigerated dryer – The [optional] electric refrigerated dryer cools and lowers the dew point of the compressed
air stream delivered by the compressor unit by removing the condensed water vapor entrained.
Dryer bypass valve – These [optional] valves allow the isolation of the refrigerated dryer (from the compressed
air line) for troubleshooting or maintenance purposes.
Condensate drain valve – This device provides drainage from the receiver. It, along with the receiver, replaces
the water separator shipped loose with the basic package.
Pressure relief valve – This device protects the pressure containing components included with the received
against high pressure exceeding 195.5 psig. Section 9 for maintenance information.
Pressure gauge – This device monitors the compressed air pressure within the receiver.
EK100 Manual Page 9
EK100 Manual Page 10
LUBRICATION
OIL COOLER, OIL FILTER & SEPARATOR
COMPRESSOR OIL SYSTEM - Lubricating oil is employed to absorb the heat of compression, lubricate
moving parts and seal internal clearances between the rotor and the air cylinder. Pressure differential
between the air/oil sump and the final injection point into the compressor is used to move the oil mass
through the various oil system components. Refer to Figure 4-29 for the arrangement of the oil system
components.
Oil exits the air/oil sump and is delivered to the heat exchange and thermal mixing valve, where cold (oil
cooler branch) and hot (oil bypass branch) are mixed to the desired compressor injection temperature.
The tempered oil is cleansed via the oil filter before injection into the compressor casing.
RECOMMENDED LUBRICANT - Champion compressors is factory filled with one of several Champion
RotorLub lubricants. These lubricants are formulated to the highest quality standards and are factory
authorized, tested and approved for use in rotary screw compressors. RotorLub lubricants are available
through your authorized Champion compressor distributor.
OIL SPECIFICATIONS - This machine has a standard factory fill of RotorLub 4000 – which is a 4000
hour lubricant. However, other lubricants are available for factory fill which may have other hour ratings
and compositions. Reference the serial tag, affixed to the side of the machine, for the lubricant that was
shipped with the machine.
OIL LEVEL INDICATOR (GAUGE) indicates the amount of oil in the oil reservoir, see Fig 5-1 for details.
Read oil level when unit is shut off and the foam has settled out. In operation the oil level will fluctuate as
the compressor loads and unloads. Adequate oil level falls between the MAX and MIN limits of the sight
glass:
The approximate oil system total capacity is 2.5 Gals (9.5 L)
FIGURE 5-1 Oil Level Sight Glass
EK100 Manual Page 11
Before draining, adding, or changing the lubricant oil in the compressor, be aware of the
following hazards associated with these tasks:
Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout power
supply to the starter before removing valves, caps, plugs, fittings, bolts and filters.
Compressor, air/oil reservoir, separator chamber and all piping and tubing may be at
high temperature during and after operation.
Use of improper lubricants will cause damage to equipment. Do not mix different types
of lubricants or use inferior lubricants.
Improper equipment maintenance with use of synthetic lubricants will damage
equipment. Oil filter and oil separator change intervals remain the same as for
Champion genuine RotorLub lubricants, see “Maintenance Schedule”, page 82.
High temperature operation can cause damage to equipment or personal injury. Do not
repeatedly restart the unit after high temperature stops operation. Find and correct the
malfunction before resuming operation.
Read the oil level when the unit is shut off for an accurate measurement.
EK100 Manual Page 12
Safety Sheets (SDS) are available for all RotorLub lubricants at web address.
www.championpneumatic.com/contactus.aspx
LUBRICANT CHANGE PROCEDURE - If upgrading to a different lubricant type (e.g., longer life, higher
temperature, food grade, etc.), following the proceeding steps, see Figure 1-3 for hardware details:
1. Be sure the unit is completely off and that no air pressure is in the oil reservoir.
2. Disconnect, tag and lockout the power supply to the starter.
3. Thoroughly drain oil system while hot:
Remove the plug and open the drain valve at the lower left hand side of the oil core tank. Once the
oil has been drained, close the drain valve and reinstall the plug.
Remove and drain oil from the oil filter. Reinstall the used filter.
4. Fill the system with a 50 percent charge of the new lubricant:
Start the machine and monitor its operation.
Allow the machine to reach a stable discharge temperature (5-7 minutes), then shut down.
5. Thoroughly drain oil system.
6. Replace used oil filter and air/oil separator element with new ones.
7. Fill the system with a full charge of the new lubricant.
8. Machine should then be run normally; however, total run time after the initial change-out should be 50
percent of normal anticipated service life of the new lubricant.
Drain all lubricant from the system, change the filter and separator, and replace with a full charge
of the new lubricant.
9 Subsequent lubricant change-outs should be at normal intervals. See “Oil Change Interval” in this
Section for details.
COLD AMBIENT OPERATION - See “Installation for Cold Weather Operation”, Section 2.
ADDITION OF OIL BETWEEN CHANGES must be made when the oil level is below the minimum level of
the sight glass as read while the unit is completely off and blown down, and the foam has settled out.
1. Be sure the unit is completely off and that no air pressure is in the oil reservoir.
2. Disconnect, lockout and tagout the power supply to the starter.
3. Wipe away all dirt around the oil filler plug located on top of the oil sump.
4. Remove the oil filler plug and add oil as required to return the oil level to the middle of the sight
gauge.
5. Install oil filler plug, run and check for leaks.
DO NOT OVERFILL (you should see oil slightly above the full line after running fully loaded and then
shutting down the machine and allowing the foam to settle out). The quantity required to raise the oil
level from “ADD” to “FULL” is shown on page 55. Repeated addition of oil between oil changes may
indicate excessive oil carry-over and should be investigated.
Excessive oil carry-over can damage equipment. Never fill oil reservoir above the
“FULL” marker.
OIL CHANGE INTERVAL - Recommended oil change intervals are based on oil temperature - see Figure
5-2 for typical trends for the standard lubricant (RotorLub 4000 / RotorLub 4K) and a synthetic lubricant
(RotorLub 8000 / RotorLub 8K). Consult Champion for additional lubricant types available for your
compressor.
When operating conditions are severe (very dusty, high humidity, etc.), it will be necessary to change the
oil more frequently. Operating conditions and the appearance of the drained oil must be surveyed and the
oil change intervals planned accordingly by the user. Champion offers a free oil analysis program with the
RotorLub lubricants, and we recommend a sample be sent in at 100 hours on a new unit.
Discharge Temperature
RotorLub
4000 /
RotorLub 4K
Change
Interval
RotorLub
8000 /
RotorLub 8K
Change
Interval
RotorLub
8000
TH
/
RotorLub
8K-HT
Change
Interval
RotorLub
4000FG
Change
Interval
Up to 180°F (82°C)
4000 hrs.
8000 hrs.
8000 hrs.
4000 hrs.
180° to 190°F (82°C to 88°C)
3000 hrs.
6000 hrs.
6000 hrs.
3000 hrs.
190° to 200°F (88°C to 93°C)
2000 hrs.
4000 hrs.
4000 hrs.
2000 hrs.
200°F+ (93°C)
1000 hrs.
2000 hrs.
2000 hrs.
1000 hrs.
FIGURE 5-2 Oil Change Interval
DRAINING AND REFILLING THE OIL SYSTEM - Always drain the complete system. Draining when the
oil is hot will help to prevent varnish deposits and carry away impurities, see Figure 1-3 for hardware
details.
EK100 Manual Page 13
1. Be sure the unit is completely off and that no air pressure is in the oil reservoir.
2. Disconnect, lockout and tagout the power supply to the starter.
3. Thoroughly drain oil system while system is hot:
Remove the plug and open the drain valve at the lower left hand side of the oil core tank. Once
the oil has been drained, close the drain valve and reinstall the plug. Make sure to provide a
suitable pan to catch the 2.5 gal. (9.5 l) oil charge.
If the drained oil and/or oil filter element is contaminated, discontinue this procedure and follow
instead the "Lubricant Change Procedure" in this section.
4. Replace both used oil filter and air/oil separator element with new ones.
Remove each spin-on element.
Clean each gasket face of the filter body.
Coat each new element gasket with clean lubricant used in the unit
Screw each new element on the filter body and tighten by hand. Tighten 1/2 turn more after
gasket makes contact. DO NOT OVERTIGHTEN ELEMENT.
5. Wipe away all dirt around the oil filler plug.
6. Remove the oil filler plug and add oil as required to return the oil level to the full marker on the gauge.
7. Install the oil filler plug and operate the unit for about a minute allowing oil to fill all areas of the
system. Check for leaks.
8. Shut down unit, allowing the oil to settle, and be certain all pressure is relieved.
9. Add oil, if necessary, to bring level to “FULL.”
Use only CLEAN containers and funnels so no dirt enters the reservoir. Provide for clean storage of oils.
Changing the oil will be of little benefit if done in a careless manner.
Use only the replacement element shown on the filter tag or refer to the parts list for the
part number.
Excessive oil carry-over can damage equipment. Never fill oil reservoir above the
“FULL” marker.
Improper oil filter maintenance will cause damage to equipment. Replace filter element
every 1000 hours of operation. More frequent replacement could be required depending
on operating conditions. A filter element left in service too long may damage equipment
MOISTURE IN THE OIL SYSTEM – During periods of low ambient temperatures, light duty cycles, high
humidity, or in the event of thermal mixing valve malfunction, the oil charge residing in the sump may not
reach a high enough temperature to keep water vapor from condensing as liquid water, a condition that
contaminates the oil charge, may cause excessive oil carryover, or result in compressor failure.
EK100 Manual Page 14
To help the end user determine if the compressor package is operating under potential water condensing
conditions, the charts in Fig 5-3 and 5-4 have been provided. To use, find the prevailing ambient
temperature along the horizontal scale of the chart, move vertically from this point until intercepting the
slanted line corresponding to the operating discharge pressure; and finally, move horizontally from this
point to read the corresponding water vapor dew point on the vertical scale. The compressor discharge
temperature must be maintained at a minimum of 10F (5.5C) above this dew-point temperature to
prevent condensation accumulation in the lubricant reservoir. Note that the charts conservatively assume
100% relative humidity for the ambient air.
The presence of water in the oil may be identified by one of the following means:
Oil drawn from the oil sampling valve attached to the sump (see Fig 1-3).
Oil volume drained during an oil exchange.
Periodic (e.g., every 2000 hours) oil sample analyzed by a reputable laboratory.
If water is found in the oil, drain sufficient volume of oil until no visible water is found - the heavier water
will collect at the low elevations of the oil system, thus it will likely be expelled first. If this condition
persists, consider the following solutions to avoid water condensation in the compressor oil:
Make sure that the correct setting for the thermostatic mixing valve element is used - value is
stamped on valve body.
If the standard thermostatic element (55ºC/131°F) does not prevent water condensation, consult
your application with Champion. The standard thermostatic element may be replaced with a
high temperature one (70ºC/158°F) and the oil charge changed (see "Lubricant Change
Procedure in this section) with a high temperature one (RotorLub and RotorLub high
temperature). Depending on the prevailing ambient temperature, the controller setting for the
high discharge temperature shutdown may have to be reset to 240ºF also.
THERMOSTATIC MIXING VALVE. This device, housed within the compressor body, mixes hot and
cooled oil and delivers a tempered mixture to the oil filter and finally the compressor injection port, see Fig
1-3 for its location.
Its thermostatic element expands with heat, it will stroke from just opening to fully open state within a
27°F (15°C) temperature change. Within these two temperature limits the valve gradually mixes hot
separator oil with cooled heat exchanger oil to maintain a nearly constant oil injection temperature.
Above this range of oil temperature, the valve blocks all hot oil and only cooled oil is delivered.
The valve’s nominal setting is stamped on the valve body. It may be verified by immersing the valve
assembly into an open container with lubricating oil, raising its temperature to its nominal setting and
checking that the element strokes fully from closed to open.
CL15-22 Models
Standard valve opening temp = 131°F (55°C), fully open temp = 158°F (70°C)
Optional valve opening temp = 158°F (70°C), fully open temp = 185°F (85°C)
CLRS15-22 Models
Standard valve opening temp = 158°F (70°C), fully open temp = 185°F (85°C)
Optional Element. If the compressor is used in a predominantly cold (<32ºF, 0ºC) and/or humid
environment, proper oil viscosity and avoidance of water vapor condensation in the oil system may be
achieved by using a higher setting (185ºF, 85ºC) thermostatic element. Consult Champion for details.
OIL SUMP (RESERVOIR) - This device provides the inertial separation of air and oil streams discharged
by the compressor - the bulk (98%) of the air/oil separation is done at this step. It also serves as a
holding and degassing volume for the major portion of the oil charge. It provides limited air storage for
control and gauge actuation.
EK100 Manual Page 15
EK100 Manual Page 16
AIR / OIL SEPARATOR - This device provides the final (2%) of the air/oil separation, typically 2 ppm oil
content at the final discharge of the compressor package. It is housed in a removable spin-on cartridge.
Its high level of performance may be affected by the following conditions:
Compromised media (e.g., ruptured).
Contaminated media (e.g., vanish, moisture, inadequate oil type).
High oil level in oil sump.
Blockage of oil return orifice.
Abnormally frequent or fast depressurization cycles.
Oil separator element life cannot be predicted; it will vary greatly depending on the conditions of
operation, the quality of the oil used and the maintenance of the oil and air filters. The condition of the
separator can be determined by pressure differential or by inspection.
Separator Pressure Differential - The pressure drop across the separator is equivalent to the difference
between the two (2) pressure sensors in use. Use the measured pressure difference to forewarn of a
potentially contaminated air-oil separator element:
The pressure differential value may be calculated by subtracting the system pressure value from
the compressor discharge pressure value.
A pressure differential of 8 psi may indicate a moderately dirty element.
A pressure differential of 15 psi may indicate a severely dirty element, replace as soon as
possible.
Using an oil separator element at excessive pressure differential can cause damage to
equipment. Replace the separator when the pressure differential has reached 15 psi.
OIL FILTER, AIR/OIL SEPARATOR ELEMENT INSPECTION PROCEDURE
1. Remove the spin-on element.
2. Clean the gasket seating surface of the head.
3. Inspect the element internals by shinning a light unto the media surface. If signs of contamination
(dirt, rust, varnish, etc.) or damage is evident, replace the element.
4. Before reassembly, coat the element gasket with the same lubricant used in the unit.
5. Screw on until gasket makes contact. Hand tighten 1/3 to 1/2 turn extra.
6. Run the unit and check for leaks.
EK100 Manual Page 17
FIGURE 5-3 Dew Point Chart F
FIGURE 5-4 Dew Point Chart C
EK100 Manual Page 18
BELT DRIVE SYSTEM
The motor power is transmitted to the compressor with a system comprised of heavy-duty v-belts,
sheaves, and bushings. Belt tension is provided by the motor weight with the help of a free-pivoting
bracket, see Figure 8-1 for details.
FIGURE 8-1 Motor Jacking Assembly
FIGURE 8-2 V-Belt Drive Components
EK100 Manual Page 19
UNPACKING THE V-BELT SYSTEM
To protect the belts from shock and strain during transportation, the free-swinging side of the motor frame
is locked in place by means of a carrier bracket assembly. Proceed to prepare the belt system for
operation as follows, refer to Figure 8-2, for component description:
1. Unlatch and remove the door panel opposite to the main cooling fan panel to gain access to the
v-belt system.
2. Lift motor by loosening jam-nut (6) and turning adjusting bolt (2) clockwise via access hole.
3. Loosen and remove fastening screws (3) and (4) as well as carrier bracket (1). Keep this
hardware for future use, such as relocating compressor package.
4. Check alignment of the sheave set and make sure that v-belts are properly seated in sheave
grooves.
5. Screw out adjusting bolt (2) and secure with jam-nut (6) to allow motor weight to rest on v-belts.
SHEAVE SET ALIGNMENT
1. Use a straight edge for alignment checks.
2. Check parallel alignment. It should be simple to control by moving one of the sheave/bushing
pairs along the shaft to match the other.
3. Check angular alignment. The misalignment A = ArcTan * ((X2-X1)/D), where calculated A is in
degrees and measured X1, X2 and D are in inches or mm.
4. The allowable total misalignment is 0.5 degrees for best belt longevity. As reference, 0.5 degrees
represents a gap (e.g., X1-X2) of 0.05" (1.33mm) over a 6" diameter sheave.
FIGURE 8-3 Measuring Angular Misalignment
Check sheave misalignment prior to start compressor operation. Failure to do so may
shorten the operational live of the belts.
EK100 Manual Page 20
REPLACING THE COMPRESSOR BELTS
When signs damage (e.g., wear, tear, breakage, etc.) appear on any belt, replace the complete set of
three (3) v-belts as follows:
1. Disconnect, lockout and tagout the power supply to the starter
2. Unlatch and remove the door panel opposite to the main cooling fan panel to gain access to the
v-belt system, see Figure 8-3 for details.
3. Remove the compressor shaft belt guard.
4. Raise the motor to remove the belt set. This is accomplished by turning the jacking screw
clockwise (after loosening the jam nut) and raising the motor body until the v-belts can be
dismounted from the motor sheave.
5. Replace the old belts with new ones. For proper belt life, use only genuine Champion belts.
6. Check the sheave alignment.
7. Turn the jacking screw counter-clockwise to lower motor and transfer its weight unto the belt
set. Make sure that the belts remain aligned into each corresponding groove. Keep turning
jacking screw until it clears base frame surface by at least one inch and jam in with provided
nut.
REPLACING THE SHEAVES
1. Follow steps 1 through 4 given above to replace the compressor belts.
2. Remove the belts.
3. Carefully sketch or photograph the orientation of each sheave/bushing pair as they sit on their
respective shaft. You'll need this information to re-install each pair.
4. Loosen and remove the mounting screws securing the sheave to companion bushing. Install
the removed screws in the jack holes provided on the sheave and turn each in to pry the
bushing loose from the sheave. Remove the sheave and bushing from the shaft.
5. When installing a new sheave / bushing pair, remove all protective grease their surfaces.
6. Insert the mounting screws in the sheave / bushing pair and lightly tighten them.
7. Clean the shaft and mount the sheave / bushing pair. Align the motor sheave to the air end
sheave. When mounting the sheave / bushing pair, the bushing clamps to the shaft first, the
sheave can still be moved a little. This can affect the alignment of the sheaves.
8. Tighten the mounting screws evenly.
9. Tap the bushing lightly with a drift, and retighten the screws. REPEAT THIS PROCEDURE
SEVERAL TIMES TO MAKE SURE THE BUSHING AND SHEAVE ASSEMBLY IS TIGHT ON
THE SHAFT.
10. Fill the holes in the bushing/sheave with grease to protect them from dirt and debris.
11. Replace the old belts with new ones. For proper belt life, use only genuine Champion belts.
12. Check the sheave alignment, refer to Sheave Set Alignment Figure 8-3.
EK100 Manual Page 21
SERVICING OF MISCELLANEOUS DEVICES
This section will cover basic maintenance of various control devices used with the compressor package.
Refer to Fig 9-1 for pictorial with general locations of these devices.
FIGURE 9-1 Exploded View of EK100 Compressor
EK100 Manual Page 22
INLET CONTROL VALVE ASSEMBLY (2)
Inlet-Valve Assembly - This device is located within and below the intake flange of the compressor, see
Figure 9-2 for internal details and Figure 4-29 for schematic details.
During the loaded state, the inlet poppet remains open and enables atmospheric air to enter the
compressor inlet, this is done by venting to atmosphere the gas trapped underside of the piston via a
check valve. During the unloaded state, a two-way solenoid valve feeds pressurized air underneath the
piston, forcing it and the inlet poppet upward and blocking-off the compressor intake.
FIGURE 9-2 Inlet Valve Assembly
Item
Description
110
Cylinder
120
Piston
130
Inlet Poppet
170
Piston Retainer Spring
180
Compression Spring, Piston
190
Compression Spring, Poppet
200
Check Valve
EK100 Manual Page 23
Air/oil pressure will cause severe personal injury or death. Shut down compressor,
relieve system of all pressure, disconnect, lockout and tagout power supply to the
starter before removing valves, caps, plugs, fittings, bolts and filters.
Inlet Valve (Body) Inspection - The valve does not require maintenance or lubrication. If air/oil leaks
develop across the valve disc during pressurized conditions (e.g., machine stopped), valve seals should
be inspected for wear and tear signs:
1. Be sure the unit is completely off and oil sump is depressurized.
2. Disconnect, lockout and tag out power supply to the compressor package.
3. Close (when provided) valve isolating compressor package from air system.
4. Refer to Figure 9-1 for hardware details.
5. Loosen and remove the air filter element.
6. Remove four bolts securing inlet flange to the compressor body and remove the flange.
7. Remove the poppet assembly and the poppet return spring.
8. Unscrew the valve body from the compressor housing using the hex pattern provided on the
valve body, see Figure 9-3 for details.
9. Inspect poppet seals (O-rings) for wear and tear.
10. In case of noted malfunction (e.g., valve will not open/close properly with good air signal), unless
a damaged or worn component can be identified and/or repaired, replace the complete inlet valve
assembly.
Remove retainer ring to release piston assembly free.
Inspect the piston seal and piston return spring. If any component if found worn of damaged,
replace the complete valve.
Re-assembly the piston assembly in reverse order.
11. Reinstall inlet valve in reverse order.
FIGURE 9-3 Inlet Valve Body Hex
EK100 Manual Page 24
PRESSURE RELIEF VALVE (19)
Pressure Relief Valve - This device protects the pressure-containing components of the compressor
package against pressures exceeding 218 psig. It is installed on the wet-side of the oil sump.
FIGURE 9-4 Pressure Relief Valve
Before inspecting the pressure relief valve, release air pressure, lockout and tagout the
power supply to the compressor package. Failure to release pressure or properly
disconnect the power may result in personal injury or death.
Never paint, lubricate or alter a relief valve. Do not plug vent or restrict.
Operation of the unit with improper relief valve setting can result in severe personal
injury or machine damage. Ensure properly set valves are installed and maintained.
Pressure Relief Valve Check During Operation - The pressure relief valve has no user-serviceable or
repairable components. However, it should be tested for proper operation at least once every year. To
test the pressure relief valve:
Raise the system operating pressure to its normal level
Pull the stem ring to open valve and let it vent for a few seconds.
Release the stem ring to close the valve.
EK100 Manual Page 25
MINIMUM PRESSURE VALVE (26)
Minimum Pressure Valve (MPV) Inspection – This device has no user-serviceable or repairable
components. If it fails to maintain adequate minimum pressure (65 psig) or fails to check the backflow of
system compressed air after compressor stoppage, replace it as follows:
FIGURE 9-5 Minimum Pressure Valve and Seat
Air/oil pressure will cause severe personal injury or death. Shut down compressor,
relieve system of all pressure, disconnect, lockout and tagout power supply to the
starter before removing valves, caps, plugs, fittings, bolts and filters.
1. Be sure the unit is completely off and that no air pressure is in the oil reservoir and in the air cooled
after cooler. Close the service valve.
2. Disconnect lockout and tagout the power supply to the starter.
3. Unscrew the minimum pressure valve assembly from compressor housing and remove.
4. Inspect the valve seat surface screwed into the compressor housing. Cleanse or replace as needed.
Note that fitting an O-ring on the hex wrench body helps hold the seat in position during installation.
5. Assemble the MPV assembly into the host manifold.
6. Run the unit and check for leaks.
7. If a new MPV has been fitted, its proper setting must be adjusted:
a. Make sure the site pipe system has a means to vent the compressor air to atmosphere with a
valve. If this is not available, temporarily fit a ball valve.
b. Start the compressor and monitor the wet and dry sump pressure sensors at the controller
display.
c. Open the site vent valve to limit the dry sump pressure to about 40 psig (2.8 bar)
d. Loosen the jam nut on the TMV adjusting stem and screw it in until the wet sump reaches 70
psig (4.8 bar).
e. Tighten the jam nut on the TMV adjusting stem.
f. Close the site vent valve.
EK100 Manual Page 26
THERMOSTATIC MIXING VALVE (27)
Thermostatic Mixing Valve (TMV) Inspection – This device has no user-serviceable or repairable
components. Refer to Section 5, for further details on this device. If it fails to maintain adequate
compressor discharge temperature, replace it as follows:
FIGURE 9-6 Thermostatic Mixing Valve
1. Be sure the unit is completely off and that no air pressure is in the oil reservoir and in the air cooled
after cooler. Close the service valve.
2. Disconnect lockout and tagout the power supply to the starter.
3. Unscrew the hex cap holding the TMV assembly within the manifold block. Retrieve the TMV body
and its spring from the compressor housing.
4. Inspect the valve seat surfaces for damage or foreign matter. Note its setting temperature, it is
stamped on the valve seat area.
5. Immerse the valve body in a bath of compressor oil; heat the oil slowly and note the temperatures at
which seat first starts moving and at it finally stops moving. Replace the device if one of the
following conditions is present:
a. The stamped setting on the valve seat is not correct.
b. The seat fails to stroke fully at the correct temperature.
6. Assemble the TMV assembly into the housing in the reverse order.
7. Run the unit and check for leaks.
EK100 Manual Page 27
MAINTENANCE SCHEDULE
SERVICE CHECK LIST
Air Filter and Pre-Filter - Operating conditions determine frequency of service. See “Air Filter,” Section 7.
Motor Lubrication - Refer to Section 2.
Every 8 Hours Operation
1. Check the reservoir oil level, add oil if required. See Section 5.
2. Observe if the unit loads and unloads properly.
3. Check discharge pressure and temperature.
4. Check control panel display for advisory text messages.
Every 125 Hours Operation
1. Check for dirt accumulation on oil, air core finned faces and the cooling fan. If cleaning is required,
clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable
safety solvent in a direction opposite that of the cooling fan air flow. This cleaning operation will
keep the exterior cooling surfaces clean and ensure effective heat dissipation.
Every 2000 Hours Operation
1. Change oil filter element.
Every 4000 Hours Operation
1. Change the compressor lubricant. Under adverse conditions, change more frequently (refer to “Oil
Change Interval”, Figure 5-2. Flush system if required.
Every Year
1. Check the pressure relief valve for proper operation. See Section 9.
2. Change oil separator. See “Removal of Oil Separator for Inspection or Replacement”, Section 5, for
further details.
EK100 Manual Page 28
AIREND GROUP / GRUPO DE AVIACIÓN / GROUPE AIREND / GRUPO AIREND
311EJC810-EB
(Ref. Drawing)
EK100 Manual Page 29
B/M: 300EJC4001, 330&332EJC4013
ITEM DESCRIPTION DESCRIPCIÓN LA DESCRIPTION DESCRIÇÃO QTY PART NO. ITEM
1 AIREND EK100NK AIREND EK100NK AIREND EK100NK AIREND EK100NK 1 A11982074 1
2 INTAKE CONTROLLER CONTROLADOR DE ENTRADA CONTRÔLEUR D'ADMISSION CONTROLADOR ADMISSÃO 1 A11985074 2
3 SUCTION FLANGE BRIDA DE SUCCION BRIDE D'ASPIRATION FLANÇA DE SUCÇÃO 1 ZS1060583 3
4 SCREW TORNILLO VIS PARAFUSO 4 A93040680 4
5 HOSE CLIP ABRAZADERA COLLIER DE SERRAGE MANGUEIRA CLIP 1 A93616840 5
*6 AIR FILTER FILTRO DE AIRE FILTRE À AIR FILTRO DE AR 1 300KCA1445 *6
7 FITTING ADECUADO RACCORD APROPRIADO 3 A13309474 7
8 TUBING (IN METERS) TUBERÍA (EN METROS) TUYAUTERIE (EN MÈTRES) TUBULAÇÃO (EM METROS) .61 A91801030 8
9 BLOW OFF VALVE VÁLVULA DEL DESCARGAR SOUPAPE DE COUPURE VÁLVULA DE ESCAPE 1 A11984374 9
10 FITTING ADECUADO RACCORD APROPRIADO 1 A13310474 10
11 SCREW TORNILLO VIS PARAFUSO 4 95044-248 11
12 NOZZLE BOQUILLA AJUTAGE BOCAL 1 A11981674 12
13 PIPE SEAL SELLO DE TUBO JOINT DE TUYAUTERIE TUBO DE VEDAÇÃO 1 A93196770 13
14
DOUBLE FITTING,
SEPARATOR
AJUSTE DOBLE, SEPARADOR OUBLE FITTING, SEPARATOR
MONTAGEM DUPLA,
SEPARADOR
1 ZS1060271 14
*15 AIR/OIL SEPARATOR SEPARADOR DE AIRE/ACEITE SEPARATEUR AIR / HUILE SEPARADOR DE AR / ÓLEO 1 300KCA035 *15
16 SOLENOID VALVE VÁLVULA DE SOLENOIDE ELECTROVANNE VÁLVULA SOLENOIDE 1 100015591 16
17
PRESSURE TRANSDUCER TRANSDUCTOR DE PRESIÓN TRANSDUCTEUR DE PRESSION TRANSDUTOR DE PRESSÃO 2 47749803001
17
18 TEMPERATURE PROBE PROBETA DE TEMPERATURA SONDE DE TEMPÉRATURE SONDA DE TEMPERATURA 1 100013684 18
19 PRESSURE RELIEF VALVE VÁLVULA DE ALIVIO DE PRESIÓN SOUPAPE LIMITATION PRESSION VÁLVULA ALÍVIO PRESSÃO 1 100003009 19
*20 OIL FILTER FILTRO DE ACEITE FILTRE À L'HUILE FILTRO DE ÓLEO 1 300KBA1446 *20
21 LABEL ETIQUETA ÉTIQUETTE RÓTULO 2 A05021878 21
22 ELBOW CODO COUDE COTOVELO 2 A93581670 22
23
PLASTIC HOSE
(IN METERS)
MANGUERA PLÁSTICA
(EN METROS)
TUYAU EN PLASTIQUE
(EN MÈTRES)
MANGUEIRA DE PLÁSTICO
(EM METROS)
.15 A91801060 23
24 HEXAGON SPUD HEXÁGONO ESCARDA HEXAGONE PATATE HEXÁGONO ESCARDILHO 1 A93580260 24
25 HEXAGON SPUD HEXÁGONO ESCARDA HEXAGONE PATATE HEXÁGONO ESCARDILHO 2 A93580270 25
26
MINIMUM PRESSURE
VALVE
VÁLVULA DE PRESIÓN MÍNIMA SOUPAPE DE PRESSION MINIMUM
VÁLVULA DE PRESSÃO
MÍNIMA
1 100015593 26
27
THERMOSTATIC VALVE
55°C
70°C
VÁLVULA TERMOSTÁTICA
55°C
70°C
SOUPAPE THERMOSTATIQUE
55°C
70°C
VÁLVULA TERMOSTÁTICA
55°C
70°C
1
1
A11203274
89560169
27
28 REDUCER REDUCTOR RÉDUCTEUR REDUTOR 1 100016114 28
29
ADAPTOR ADAPTADOR ADAPTATEUR ADAPTADOR
1 100003603 29
30 OIL SAMPLING VALVE
VALVULA DE MUESTREO DE
ACEITE
VANNE D'ÉCHANTILLONNAGE
D'HUILE
VÁLVULA DE AMOSTRAGEM
DE ÓLEO
1 86N345 30
31
PRESSURE NON RETURN
VALVE SEAT
ASIENTO DE LA VÁLVULA DE NO
RETORNO A PRESIÓN
SIÈGE DE SOUPAPE DE RETOUR
SANS RETOUR
ASSENTO DA VÁLVULA DE
PRESSÃO SEM RETORNO
1 A11984174 31
35 GASKET EMPAQUETADOR JOINT DE CULASSE GAXETA 1 25BC865 35
36 PIPE SEAL SELLO DE TUBO JOINT DE TUYAUTERIE TUBO DE VEDAÇÃO 1 A93191540 36
37 SHAFT SEAL KIT KIT DE SELLO DE EJE KIT DE JOINT D'ARBRE KIT DE VEDAÇÃO DO EIXO 1
A11988474
37
38 WASHER, BONDED ARANDELA RONDELLE ARRUELA 1
CZ9613
38
* Parts included in maintenance kits 302KCA6032 (CL15-22) and 301EJC6032 (CLRS15-22) / Piezas incluidas en los kits de mantenimiento 302KCA6032 (CL15-22) y 301EJC6032 (CLRS15-22)
* Pièces incluses dans les kits maintenance 302KCA6032 (CL15-22) et 301EJC6032 (CLRS15-22) / Peças incluídas nos kits manutenção 302KCA6032 (CL15-22) e 301EJC6032 (CLRS15-22)
EK100 Manual Page 30
INLET VALVE
VÁLVULA DE ENTRADA
SOUPAPE D'ADMISSION
VÁLVULA DE ADMISSÃO
A11985074-01
(Ref. Drawing)
EK100 Manual Page 31
B/M: A11985074
ITEM DESCRIPTION DESCRIPCIÓN LA DESCRIPTION DESCRIÇÃO QTY PART NO. ITEM
110 CYLINDER CILINDRO CYLINDRE CILINDRO 1 A11985274 110
120 PISTON PISTÓN PISTON PISTÃO 1 A11985474 120
130 NON RETURN PISTON PISTON NO DEVOLUCIÓN PISTON NON RETOUR PISTÃO NÃO DEVOLVER 1 A11985674 130
140 PIPE SEAL SELLO DE TUBO JOINT DE TUYAUTERIE TUBO DE VEDAÇÃO 1 A93190940 140
150 PIPE SEAL SELLO DE TUBO JOINT DE TUYAUTERIE TUBO DE VEDAÇÃO 1 A93199270 150
170 SPRING RING ANILLO ELÁSTICO RING SPRING ANEL DE PRIMAVERA 1 A93148820 170
180
COMPRESSION
SPRING
RESORTE DE
COMPRESIÓN
RESSORT DE COMPRESSION MOLA DE COMPRESSÃO 1 A93300500 180
190
COMPRESSION
SPRING
RESORTE DE
COMPRESIÓN
RESSORT DE COMPRESSION MOLA DE COMPRESSÃO 1 A93300510 190
200 NON RETURN VALVE VÁLVULA DE RETENCIÓN CLAPET ANTI-RETOUR VÁLVULA DE NÃO RETORNO 1
A07715741
200
210 AUTOL FLOW GREASE GRASA AUTOL FLOW GRAISSE AUTOMATIQUE À FLUX GRAVAÇÃO DE FLUXO AUTOL .001
A92132160
210
Nuvair
Phone +1.805.815.4044
Fax +1.805.486.0900
1600 Beacon Place
Oxnard, CA 93033 USA
[email protected]
www.nuvair.com