Champion CRN75 User manual

Brand: Champion

Model: CRN75

Type: User manual

This manual is also suitable for

Champion CRN75 is a refrigerated air dryer designed to remove moisture and contaminants from compressed air systems, delivering clean and dry air for various applications. With a rated air flow capacity of 75 scfm at 100°F and 100 psig inlet pressure, it effectively handles the needs of small to medium-sized businesses and industrial operations.

REFRIGERATED

TYPE

COMPRESSED

AIR DRYERS

SERVICE DEPARTMENT: (724) 746-1100

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

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).

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

Dryer

Oil 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

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

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

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/cm

27°C 32°C 38°C 43°C

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

100

110

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

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.

P&I DIAGRAM

ModelsCRN25throughCRN75

REFRIGERATION SYSTEM

ACCESS

VALVE

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

WIRING DIAGRAM

ModelsCRN25throughCRN75

COMPRESSOR HARNESS

GROUND STUD

L2L1 PE

POWER ON

PILOT LIGHT

CAP

115/1/60

208 - 230/1/60

220 - 240/1/50

POWER CORD SUPPLIED

10 11

1312

POTENTIAL RELAY

MOUNTED ON COMPRESSOR

MTR

LEGEND

CAP -StartCapacitor

FM -FanMotor

MP -MotorProtector

MTR-Compressor

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

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.

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 : (724) 746-1100

www.championpneumatic.com

Champion

1301 North Euclid Avenue

Princeton, Illinois 61356 USA

Phone: 815/875-3321

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.

Litho in U.S.A.

5004822 Rev. A 2/09

Champion CRN75 User manual

Brand: Champion

Model: CRN75

Type: User manual

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Champion CRN75 User manual

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