Champion CRN250 User manual

Brand: Champion

Model: CRN250

Type: User manual

This manual is also suitable for

CRN SERIES

Models: CRN125, CRN150, CRN200, CRN250

SERVICE DEPARTMENT: (724) 746-1100

N SERIES

REFRIGERATED

COMPRESSED

AIR DRYERS

Contents

INSTRUCTION MANUAL

Models: CRN125, CRN150, CRN , C N250

7610.478.40D/0401037610.478.40D/0401037610.478.40D/040103

INTERNAL USE ONLY

7610.721.74 1/04

CA18-2-650, 1st Ed.

7610.478.40D/040103

INTERNAL USE ONLY

CRN300, CRN400, CRN500, CRN750

GENERAL SAFETY INFORMATION........................2

RECEIVING, MOVING, UNPACKING.......................2

1.0 INSTALLATION.....................................................3

2.0 OPERATION......................................................4-7

3.0 MAINTENANCE.................................................8-9

SIZING........................................................................10

ENGINEERING DATA...............................................11

ELECTRICAL SCHEMATICS...............................12-13

DIMENSIONS / WEIGHTS..................................14-15

TROUBLESHOOTING...........................................16-17

PARTS LIST ............................................................18

WARRANTY................................................................20

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.

GENERAL SAFETY INFORMATION

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.

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: WATER-COOLED UNITS - If unit is shut down

below freezing temperatures, the water-cooled

condenser may freeze and cause permanent damage.

Condenser must be drained when the unit is shut down.

IMPORTANT: Do not store dryer in temperatures above

130°F, 54.4°C.

3. BREATHING AIR:

• Air treated by this equipment

may not be suitable for breathing

without further purification.

Refer to applicable standards and

specifications for the requirements for breathing

quality air.

RECEIVING, MOVING, AND UNPACKING

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 flow

and service access

125 - 750 scfm models

Front 24 inches (610 mm)

Back 24 inches (610 mm)

Sides 12 inches (305 mm)

E. Standard units are designed to operate in ambients:

Air-cooled: 45 to 110°F (7 to 43°C).

Water-cooled: 45 to 130°F (7 to 54°C).

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.

NOTE: Outdoor installation–Standard units are designed

for indoor 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 floor.

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 on pages 14 and 15 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:

110°F (43°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.

D. Water-cooled models - cooling water inlet and outlet

1. Connect cooling water supply to cooling

water inlet.

2. Connect cooling water return line to cooling

water outlet connection.

NOTE: Strainer and water regulating valve are supplied on

water-cooled models. Also, it is recommended to add

water inlet/outlet temperature and pressure gauges to

the water piping.

Aftercooler

Separator

Dryer

Oil Removal

FilterCompressor

I - Controller Level 2

Separator/

Filter

Optional

Cold Coalescing Filter

Control

Panel

Timed Drain(s)

(NOT SHOWN)

Air

Connection

I - Controller Level 3

Separator/

Filter

Optional

Cold Coalescing Filter

Control

Panel

Air

Connection

Demand Drain(s)

(shown with Optional

Cold Coalescing Filter)

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 kgf/cm

)

C. Maximum inlet air temperature: 110°F (43°C)

D. Maximum ambient temperature:

Air-cooled models: 110°F (43°C)

Water-cooled models: 130°F (54°C)

E. Minimum ambient temperature: 45°F (7°C)

2.2 Start-up

IMPORTANT: Energize dryer disconnect switch (provided

by others, sec NEC) 24 hours before refrigeration

compressor is started! Never use the disconnect switch to

shut-down the dryer for a extended period of time

(except for repair). Failure to follow these instructions

may result in a non-warrantable compressor failure.

NOTE: It is recommended that dryer be started 15

minutes before compressed air flow begins.

NOTE: If there is no power to the control board for a

period of two weeks or more, it may return to the

default mode.

1. Confirm On/Off Switch is in the “Off” position.

2. On water-cooled models: after 24 hours, begin

cooling water flow.

3. Check for proper electrical voltage.

4. Energize dryer. Green power-on light will illuminate.

5. Slowly pressurize unit air side by opening inlet

isolation valve. Check for leaks.

6. After 15 minutes, open outlet isolation valve slowly.

7. Close air by-pass valve.

8. Identify I-Controller version Level on dryer

A. Models with I-Controller Level 2 - proceed to

Step 9.

B. For Models with I-Controller Level 3, see Section

2.7 for further instructions.

9. Toggle ON/OFF switch to the ON position.

1.4 Electrical connections

IMPORTANT: Use copper supply wires only.

A. Dryer is designed to operate on the

voltage, phase, and frequency listed

on the serial number tag.

B. If dryer is supplied with a cord and

plug, install in a

receptacle of proper voltage.

C. Electrical entry on larger dryers is through a hole in

the cabinet. It is located on the right side panel when

facing the front of the unit. Top right corner. Connect

power source to the terminal strip in the electrical

enclosure as shown on the electrical schematic

included with the dryer.

If optional disconnect is supplied, use entry hole in

disconnect enclosure.

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.

1. For minimum inlet air pressures that fall between

column values, the setting for the lower pressure is

recommended. (i.e. select the 100 psi column values

for 124 psi inlet pressure listed in Table 1.)

Table 1 Timed drain illuminated LED Settings

2.3 Timer Drain

(Only Models with I-Controller Level 2)

NOTE: The Timer Drain LED level has been pre-

programmed at the factory for your specific dryer.

Programming is based upon a minimum of 100 psi

saturated inlet air pressure and maximum energy

efficiency. The drain open time is fixed at one second and

a small amount of air will be exhausted with each cycle.

Generally, no adjustment to the timer is required.

If water is present downstream of the

dryer, always verify that any condensate drains installed

upstream of the dryer are draining properly before

attempting to readjust the LED setting.

Inlet Pressure

75 100* 125 150 200 225

1253333 44

1502333 34

2002333 33

2502223 33

3001222 33

4001223 34

5001122 33

7501111 22

Flow (scfm)

Table 2 LED Legend

* Recommended and pre-programmed factory settings for each dryer. Assumes

CAGI ADF100 inlet conditions with 100°F ambient and 10°F air-cooled aftercooler

approach temperature.

Minutes

LED between

Illuminated Drain Cycles

33 F......................39 F

1 C.......................4 C

2.4 Timer Drain Programming Mode

1. Press the “Drain Interval Program” button (the

“Condensate Draining” LED will start to flash, and the

illuminated LED on the “Dew Point Temperature

Indicator” will identify the factory setting for “Minutes

Between Drain Cycles.” (See Table 1)

2. Press and release the “Drain Interval Selector” button

to sequence the “Minutes Between Drain Cycle LED’s”

from left to right until reaching your selection. The

“Red” LED is not used (Reference Table 2 for “Drain

Cycle Intervals”)

3. To initiate the new setting, press the “Drain Interval

Program” button (this will store the new setting and

exit the program).

4. Exiting the Program will cause the Timer Drain to

discharge and begin a new cycle.

NOTE: Failure to perform step 3 within 25 seconds of

completing step 2 will cause the unit to revert back to the

previous setting.

NOTE: In the event of a brief or extended period of

power loss, the unit will retain the existing program

setting and will begin a new cycle once power is

reapplied. Had drain been ready to drain before the loss

of power, the drain bowl’s capacity would prevent

downstream flooding. Condensate will drain completely

within a couple of cycles. (Manually pressing the “Push-to-

Test” button would drain bowl immediately)

2.5 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.

Condensate Draining

(Flashes in

programming

mode)

Drain Interval

Program

°F......................39

......................39

°F

1°C.......................4°C

Dew Point

Temperature

Indicator

Drain Interval

Selector

(LED illuminated

indicates drain

cycle setting)

2. Where the dryer is consistently operating at less

than maximum capacity, it may be possible to

increase the LED set point to minimize air loss.

Discretionary adjustments to the dryer should only

be made on a hot, humid day when the maximum

expected air load is flowing through the dryer.

Failure to do so may prevent the condensate from

draining completely when operating under peak

load conditions.

I - Controller Level 2 - Standard

°F......................39°F

1°C.......................4°C

On/Off

Switch

Switch Legend

Power On

Light

Compressor

On Light

Dew Point

Temperature

Indicator

Drain

Push-to-Test

Condensate

Draining

2.7 I-Controller Level 3 –

(Optional on 200-750 scfm models)

Dryers upgraded with the optional I-Controller Level 3

include text messaging on the Vacuum Fluorescent Text

Display (VFTD), Alert/Alarm condition display panel

warning lights, process diagram LED indicator lights,

Demand Operated Condensate Drains(s) and SURE-SAVE

Heat Reliever as standard features.

Programming, Start-up and, Operating Instructions

Dryers are pre-programmed in accordance with the

manufacturers recommendations. Programming details

are listed within Table 1.

NOTES:

a) Programming can be accomplished while dryer is in

either the ON or OFF mode.

b) The OPERATION sub-directory list automatically scrolls

sequentially every 3 seconds. Press the (ENTER) key

repeatedly to scroll manually.

2.6 SURE-SAVE Cooling Injection

(Optional: 125-750 scfm model)

Standard: Models with I-C Level 3 Controller

Dryers outfitted with the SURE-SAVE option automatically

protect the refrigeration compressor from damage due

to excessive inlet air temperatures. A temperature sensor

continually monitors the compressor operating

conditions. If the temperature exceeds standard design

conditions, the SURE-SAVE cooling injection valve

automatically redirects cooling energy back to the suction

side. This allows continued operation with an elevated

pressure dew point rather than initiate a high

temperature shutdown. To protect the dryer, high inlet

air temperature shutdown will occur if inlet air

temperature exceeds 140°F.

VFTD Text Viewing Instructions

1. Press (Right-Arrow) or (Left-Arrow) to select from the

following Main Menu items: OPERATION,

MAINTENANCE, CONFIGURATION, UNIT SET UP

2. Press the (ENTER) key to access the sub-directory of

the Main Menu item of your choice.

NOTE: Press (ENTER) repeatedly to sequence through the

sub-directory text displays listed in table 1.

Operation Maintenance Configuration Unit Set Up

(view) (view) (programmable*) (factory (programmable*) (factory

setting) setting)

Dew Point Hours Gardner Denver n/a *Dew Point Set Pt 50°F/

Temp (°F/°C) to Service IC3 Ver (xxx) (50°F-95°F) 10°C

Ambient Temp Total *Set Language Eng., English *Ambient Set Pt 105°F/

(°F/°C) Hours Spanish, French ( 95°F-122°F) 41°C

Inlet Air Temp *Set Date Current *Inlet Air Set Pt 105°F/

(°F/°C) MO/DA/YR (95°F-140°F) 41°C

HR:MIN:SEC *Set Time Eastern *Service Interval 2000

MO/DA/YR HR:MIN:SEC Standard (0-4000 Hours) Hours

Dryer *Set Temp

ON (OFF) °F/°CF

Table 1

Vacuum

Fluorescent

Text Display

Switch

Off

Switch

Gauge

LED’s

Temperature

LED’s

Drain LED

Alarm Light

Warning/

Maintenance

Light

Reset

Compressor

Running Light

Drain Push-

to-Test

Power-on

Light

Programming

Buttons

I-Controller Level 3 - (Optional)

Programming Instructions (CONFIGURATION or UNIT

SET UP modes only)

1. Press (Right-Arrow) or (Left-Arrow) to select from the

following Main Menu items: OPERATION,

MAINTENANCE, CONFIGURATION, UNIT SET UP

2. Press the (ENTER) key to access the sub-directory of

the Main Menu item of your choice.

Note: Press (ENTER) repeatedly to sequence through

the sub-directory text displays as listed in table 1.

3. To reprogram your selection, press and release and/

or hold down the (+) or (-) key until you reach the

desired value

4. Press (ENTER) to accept the new setting.

NOTES:

a) Display will automatically return to normal operating

mode 30 seconds after last key is depressed.

b) Programming automatically reverts back to prior

settings in 30 seconds if (ENTER) is not depressed.

Start-up Instructions - I-Controller Level 3 (Continued

from Section 2.2)

1. Energize dryer.

A. Green POWER ON light will illuminate.

B. VFTD will read “GARDNER DENVER IC3 (version)”

Text display automatically sequences at 3 second

intervals in the following order:

a. AMBIENT AIR TEMP (°F or °C)

b. INLET AIR TEMP (°F or °C)

c. TIME/DATE (hours: minutes: seconds/month/

day/year)

d. DRYER OFF or ON (status)

e. DEW POINT TEMP (°F or °C)

C. LEDs – The GREEN Thermometer LEDs on the

Process Diagram will illuminate when the

corresponding temperature point is shown in the

VFTD.

2. Depress Green (START) button.

A. The Green “COMPRESSOR ON” panel light

and process diagram LED will illuminate.

NOTE: If dryer is started while “DRYER OFF” is displayed

within the VFTD, it will change to “DRYER ON” with the

next display rotation.

Programming Buttons

Right ArrowLeft Arrow

Enter

2.8 Electronic Demand Drain – I-Controller Level 3

A. An automatic electric demand drain (EDD)

discharges condensate removed by the

separator.

B. All standard I-Controller Level 3 models are supplied

with one EDD. Models with the additional (optional)

cold coalescing filter are supplied with a second EDD.

C. For manual draining, convenient dryer

depressurization, and EDD service, a three-way valve

at the bottom of the moisture separator and before

the EDD is installed. For manual draining, turn the

valve handle so it is in a horizontal position. Open the

petcock on the side of the dryer base pan to

discharge the condensate or to depressurize the

dryer if it has been by-passed. The petcock can be left

in a throttled (partially opened) position should there

be a problem with EDD.

The drains are piped to the right side panel, bottom

right corner of the unit.

Discharge is at system pressure. Drain line

should be anchored.

NOTE: Condensate may contain oil. Comply with

applicable laws concerning proper disposal.

D. Verify that isolation valves are open. If the drain fails

to discharge after the valve is energized, the

electronic control circuit will repeatedly energize the

valve in an attempt to clear the discharge port. If,

after 60 seconds, the drain still fails to discharge, the

control circuit then switches to the alarm mode. In

this mode the valve is de-energized and the red alarm

light is activated on the drain and control panel and

the green LED on the process diagram. The valve is

then automatically energized every 4 minutes for 5

seconds. Check the drain operation. Push drain

(push-to-test) button on the I-Controller level 3

control panel to energize drain. A flow of condensate

and/or air should be present at the drain outlet. The

alarm mode automatically clears after the drain

returns to normal operation.

E. Condensate enters the reservoir (1) through the inlet

port. When the condensate level in the reservoir

covers the capacitance sensor, an electronic signal is

sent to the solid state countdown processor. The

processor delays the opening of the solenoid valve

for a given period of time. Once the time has

elapsed, the solid state processor transmits

information to energize the coil in the solenoid valve

(2).The magnetic force of the coil causes the solenoid

core (3) to move, closing the pilot air supply line and

opening the pilot air exhaust line. After the pilot air

above the diaphragm (4) is vented, pressure in the

reservoir opens the discharge port and forces the

condensate through the discharge port and outlet

piping.

2.9 Operating Instructions – I-Controller Level 3

1. Check the following on a periodic basis:

a. Power-on light glows (green) indicating power to

the dryer

b. Compressor-on light glows (green) indicating the

refrigeration compressor is operating

c. VFTD is automatically scrolling every 3 seconds

through OPERATION mode readings and settings

d. Warning/Maintenance Alert light (yellow) is NOT

flashing

e. Alarm light (red) is NOT flashing

f. Condensate is draining

2. ALARM/ALERT Fault Condition Activation

(See wiring diagram for N/O contact location.)

Upon activation, text identifying the Fault will be

displayed on the VFTD. An Audible Alarm will sound, a

Flashing Panel light (Warning/Yellow or, Alarm/Red)

and, a Flashing Process Diagram LED (Green or Red)

combine to indicate the fault condition. Where

applicable (see table 2 on page 17) a normally open

(N/O) circuit will activate a customer supplied remote

alarm.

NOTE: If yellow Alert light or, red Alarm light ARE flashing,

see fault condition identified in VFTD window. Reference

the condition in the Troubleshooting Guide on page 17.

3. AUTO RESTART Function

Software programming allows the dryer to

automatically restart in the event of an interruption

of power. Consult factory for details.

4. REMOTE START/STOP Function

Software programming allows the dryer to be

stopped and started by a remotely controlled signal.

Consult factory for details.

5. DOWNLOADABLE MEMORY Function

Software programming allows the dryer to store the

last 10 alarm related events. Output command

delivers the events complete with the date, time and,

fault condition. Consult factory for details.

6. RS-232 & RS-485 Communications Capable

Dedicated pin arrangement is used to monitor dryer

operation from a host computer. Consult factory for

details.

3.2 Moisture Separator/Oil Removal Filter

NOTE: Prepackaged maintenance kits are available that

include all necessary filter and timed drain valve

components. Maintain maximum performance and

efficiency with Genuine Parts. See page 18 for ordering

information.

When to replace the Separator/Filters

Replace filter element when pressure drop across

dryer is excessive or annually.

Dryers have the option of one or two stages of

filtration. The directions for servicing either filter is

identical.

When removing liquids at rated flow conditions, an

increase in pressure drop will occur as the separator/

filter elements become loaded with solid particles.

Procedure for Separator / Filter Element

Replacement 125-500 scfm models

THIS FILTER IS A PRESSURE CONTAINING

DEVICE. DEPRESSURIZE BEFORE SERVICING. If filter has not

been depressurized before disassembly, an audible alarm

will sound when the bowl begins to be removed from the

head. If this occurs, stop disassembly, isolate and

completely depressurize filter before proceeding.

200 thru 500 scfm models

Separator Element

or Optional Oil Removal

Element

Wave

Spring

Bowl

O-ring

Timer Drain Valve - Standard

3.0 MAINTENANCE

3.1 Condenser coil

A. Air-cooled - clean off accumulated dust and dirt

monthly or as necessary in dirty environments.

B. Water-cooled - clean strainer monthly, more often if

required. Shut off water, remove small plug to relieve

pressure, then remove large plug to remove strainer.

Clean strainer and replace.

125 thru 150 scfm Models

Separator Element or

Optional Oil Removal Element

Timer Drain Valve - Standard with I-Controller Level 2

Demand Drain - I-Controller Level 3 Only

1. Isolate dryer (close inlet and outlet valves if installed)

or shut off air supply.

2. Depressurize filter by slowly opening manual drain

by-pass valve.

3. Remove bowl

a. For 125 through 150 scfm models - bayonet

mount - push bowl up, turn bowl 1/8th turn to

your left, and pull bowl straight down

b. For 200 through 500 scfm models - threaded

bowls - unscrew bowl from head using hand,

strap wrench or C spanner.

4. Clean filter bowl

5. Replace moisture separator element.

a. Replacing complete Grade B element.

1) Pull off old element and discard

2) Make certain o-rings on male of replacement

element adaptor are in place and push

element into filter head.

NOTE: Do not handle Oil Removal Filter elements by

outside foam cover. Handle by bottom end cap only.

6. After making certain that o-ring inside top of bowl

(and on bayonet mount heads, wave spring) are in

place, reassemble bowl to head.

NOTE: Make certain o-ring is generously lubricated. (Use

lubricant provided)

NOTE: Wave spring ends should be pointed down to

prevent the wave spring from interfering with

reassembly.

3.3 Check separator daily to be sure automatic drain

is discharging.

NOTE: Units with two stage filtration have two sets of

drains.

3.4 Blow down separator weekly by pushing test

button on control panel.

3.5 Rebuild drain mechanism annually.

To facilitate service, maintenance kits are available.

See page 18.

Gasket

Coupling

Half

Grooved Shell

Grooved Upper

Shell Cap

Bolts

3 & 4

Depressurize the unit before servicing.

Failure to do this may result in injury. The unit must be

depressurized before the couplings are removed.

a. For normal element replacement, the separator

shell assembly must be removed. Remove the

insulation from the upper shell cap.

Check to be sure the unit is depressurized.

b. Release the condensate drain line quick

disconnect fitting.

c. Remove the two bolts on the upper and lower

shell couplings (3). Remove the couplings,

exposing the gaskets.

d. Slide the upper piping gasket down and the lower

piping gasket up on to the separator shell (1).

e. Slide the separator shell assembly out.

f. Remove the element retainer plate (5).

g. Remove the separator/filter element (6) by simply

pulling and lifting them out of the element

sealing port (1a). Discard the old element.

h. Inspect the inside surfaces of the separator shell

(1), the element seal plate, and sealing port (1a).

i. Lubricate the new separator/filter element o-ring

seals according to the element package

instructions.

j. Install the new element by carefully pushing it in

to the element sealing port (1a).

k. Reinstall the element retainer plate (5).

l. Inspect the upper and lower shell cap gaskets and

apply a thin coat of lubricant to the outside and

to the sealing lips of these gaskets.

m. Slide the separator shell assembly back in.

n. Slide the gaskets into position, centering them

between the coupling grooves.

o. Replace the upper and lower shell cap couplings

(3). Tighten the bolts evenly and alternately.

Uneven tightening may cause the gaskets

to pinch and not seal! Gasket damage may result!

p. Reinstall the insulation.

q. Slowly repressurize the dryer.

r. Inspect the assembly for air leaks.

NOTE: Further disassembly is not required or

recommended for maintenance.

s. Disassemble condensate drain valve(s).

t. Rebuild drain valves using Genuine Parts. See page

18 for ordering information.

750 scfm model

Timer Drain - Standard - I-Controller Level 2

Demand Drain - I-Controller Level 3 Only

NOTE: Threaded bowl to head connection, generously

lubricate threads with a high grade/temperate lubricant

150 °F, 66°C. (Use lubricant provided).

7. Disassemble condensate drain valve(s).

8. Rebuild drain valves using Genuine Parts. See page 18

for ordering information.

Procedure for Separator / Filter Element

Replacement 750 scfm model

The separator/filter assembly consists of: the

separator shell assembly 1, the upper shell cap 2, the

upper shell coupling and gasket 3, the upper piping

coupling and gasket 4, the element retainer plate 5,

and the separator/filter element 6.

COOLING MEDIUM*

AMBIENT

TEMPERATURE MULTIPLIER

°F °C

80 27 1.12

90 32 1.06

100 38 1.00

110 43 0.94

INLET COMPRESSED AIR CONDITIONS

INLET INLET TEMPERATURES

PRESSURES 80°F90°F 100°F 110°F

psig kgf/cm

27°C32°C38°C 43°C

50 3.5 1.35 1.05 0.84 0.69

80 5.6 1.50 1.17 0.95 0.79

100 7.0 1.55 1.23 1.00 0.82

125 8.8 1.63 1.31 1.07 0.91

150 10.5 1.70 1.37 1.13 0.95

175 12.3 1.75 1.42 1.18 0.99

200 14.0 1.80 1.47 1.22 1.03

SIZING

Determining dryer capacity at actual operating conditions

To determine the maximum inlet flow 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 750 scfm

model handle when compressed air to be dried is at 200

psig and 100°F; ambient air temperature is 80°F; and a

38°F dew point temperature is desired?

Answer: 750 x 1.22 x 1.12 x 1.0 = 1,025 scfm.

TABLE 2

Air capacity correction factors (Multipliers)

MODELS 125 150 200 250 300 400 500 750

Rated capacity 60 Hz 125 150 200 250 300 400 500 750

of air-cooled 50 Hz 104 125 167 208 250 333 417 625

models (scfm)

TABLE 1

Rated capacity (scfm) and pressure drop @ 100 psig inlet

pressure, 100°F inlet temperature, and 100°F ambient

temperature

*Air-cooled models; water-cooled models use 1.15 multiplier if cooling

water is below 35°C, 95°F.

OUTLET DEWPOINT

DEWPOINT

TEMPERATURE MULTIPLIER

°F °C

38 3 1.0

45 7 1.2

50 10 1.3

ENGINEERING DATA

MINIMUM - MAXIMUM OPERATING CONDITIONS

Min.-Max. Inlet Air Pressure (compressed air at inlet to dryer) Minimum 30 psig (2.1 kgf/cm

) Maximum (1)

Max. Inlet Air Temperature (compressed air at inlet to dryer) 110°F (43°C)

Min.-Max. Ambient Temperature

Air-cooled 45°F (7°C) - 110°F (43°C)

Water-cooled 45°F (7°C) - 130°F (54°C)

REFRIGERATION SYSTEM DATA

Compressor Type Hermetic - Non-Cycling

Refrigeration Compressor Horsepower 3/4 1 1-1/2 2 3

BTU/HR - Refrigeration Only @ 35°F Evaporator & 100°F Ambient 60/50 Hz 6020 / 5017 8660 / 7217 15600 / 13000 17400 / 14500 26700 / 22250

Outlet Air Temperature (nominal at rated conditions) 85°F (29°C)

Refrigerant Type R-134a

Refrigerant Charge See dryer serial number tag

Suction Pressure Setting (controlled by hot gas by-pass valve) 31.5 31.5 31.5 31.5 31.5

Compressor Control Ranges (psig) (out-in) High - 281-190 281-190 281-190 281-190

Low - 24-34 24-34 24-34 24-34

Condenser Fan Switch Setting (in-out)(psig) Fan 1 110-70 113-78 113-78 113-78 113-78

(air-cooled models) Fan 2 - - - 183-124 183-124

Air Flow Across Condenser (cfm) (air-cooled models) 60/50 Hz 530 / 440 672 / 560 1093 / 911 2650 / 2208 2650 / 2208

Condenser Cooling Water Requirements (water-cooled models)

Recommended Water Pressure (psig) 40 Min. - 120 Max*.

Gallons Per Minute Of Flow Required With 85°F Cooling Water 60/50 Hz 2.2 / 1.8*** 2.9/2.4 4.8/4.0 5.8/4.8 12/10

Inlet Water Connection 1/2” Female

ELECTRICAL

Nominal Voltage 115/1/60 208-230/3/60 208-230/3/60 208-230/3/60 208-230/3/60

Max.- Min. voltage 127-104 253-187 253-187 253-187 253-187

Rated Load Amps** 14.7 8.4 11.5 13.6 22.9

Locked Rotor Amps** 66.3 51 65.5 75 90

Minimum Circuit Ampacity 18.3 10.5 16.9 17.1 31.7

Branch Circuit Fuse Size (amps) 24 15 20 25 45

Watts @ 35°F Evaporator & 100°F Ambient 1060 1335 1940 2620 3600

Resistance (Ohms) Three phase (Total) - 1.77 1.256 1.058 0.853

Single phase Start C/S 3.15 - - - -

Run C/R 0.416 - - - -

Nominal Voltage 208-230/1/60 460/3/60 460/3/60 460/3/60 460/3/60

Max. - Min. Voltage 253-198 506-414 506-414 506-414 506-414

Rated Load Amps** 8.3 4.0 4.9 6.2 11

Locked Rotor Amps** 33.5 25 33 40 45

Minimum Circuit Ampacity 10.5 5.2 9.2 9.6 15.6

Branch Circuit Fuse Size (amps) 15 15 15 15 20

Watts @ 35°F Evaporator & 100°F Ambient 1060 1335 1940 2620 3600

Resistance (ohms) Three phase (Total) 7.92 - 7.44 4.95 4.11 0.853

Single phase Start C/S 7.92 - - - -

Run C/R 1.55 - - - -

Nominal Voltage 220-240/1/50 380-420/3/50 380-420/3/50 380-420/3/50 380-420/3/50

Max. - Min. Voltage 264-198 462-342 462-342 462-342 462-342

Rated Load Amps** 7.6 4.0 4.9 5.7 9.9

Locked Rotor Amps** 53.0 25 33 45 45

Minimum Circuit Ampacity 9.9 5.2 9.2 9.6 15.6

Branch Circuit Fuse Size (amps) 15 15 15 15 20

Watts @ 35°F Evaporator & 100°F Ambient 930 1068 1552 2096 3030

Resistance (ohms) Three phase (Total) - - 7.44 4.95 4.11 0.853

Single phase Start C/S 10.49 - - - -

Run C/R 1.8 - - - -

Nominal Voltage 220-240/1/50 575/3/60 575/3/60 575/3/60 575/3/60

Max. - Min. Voltage 264-198 632-518 632-518 632-518 632-518

Rated Load Amps** 7.6 3.2 3.9 4.6 7.9

Locked Rotor Amps** 53.0 25 33 40 45

Minimum Circuit Ampacity 9.9 4.2 7.4 7.7 12.8

Branch Circuit Fuse Size (amps) 15 15 15 15 15

Watts @ 35°F Evaporator & 100°F Ambient 930 1335 1940 2620 3600

Resistance (ohms) Three phase (Total) - 7.44 4.95 4.11 0.853

Single phase Start C/S 10.49 - - - -

Run C/R 1.8 - - - -

MODELS 125 & 150 200 250, 300 & 400 500 & 600 750

(1) Maximum Inlet Pressure - 232 psig (16.3 kgf/cm

) I - Controller Level 2

200 psig (14 kgf/cm

) I - Controller Level 3

* Allows continued operation with some restriction in the water strainer

** Air-cooled models only

*** 150 scfm model only

Electrical Schematics

Models 125, & 150 - 115V/60 Hz (I-Controller Level 2)

Model 125 & 150 - 208-230V/60 Hz; 220-240V/50 Hz (I-Controller Level 2)

Legend

SW - ON/OFF Switch 2FU - Primary Fuse

CON - Contactor 3FU - Primary Fuse

TR1 - Transformer Control 1FU - Secondary Fuse

MTR - Compressor DRN1 - Drain Solenoid - Standard

1FM - Fan Motor DRN2 - Drain Solenoid (Oil Coalescing Option)

2FM - Fan Motor (RNC300-750 Only) EDD1 - Electric Demand Drain

1FPS - Fan Pressure Switch Fan 1 EDD2 - Electric Demand Drain (Oil Coalescing Option)

2FPS - Fan Pressure Switch Fan 2 (RNC300-750 Only) TC1/TC2/TC3 - Temperature Sensor, Thermistor

LPCO - Low Pressure Cutout Switch CAP - Start Capacitor

HPCO - High Pressure Cutout Switch TB - Terminal Block

SSMP - Solid State Motor Protection SR - StartRelay

HTR - Crankcase Heater FM - Fan Motor

OL - Overload

CUSTOMER CONNECTION/

POWER CORD

CON PE

BLU

GROUND

DRN1

DRN2

FPS

CON N

NEUTRAL

LINE

BRN

CON L1

CON

CAP

MTR

NOT USED

ON WATER-COOLED UNITS

COIL

COMP

DRAIN

NEUTRAL

DRAIN

TC1

TB 5

IC2 OPTION

BOARD ADDITION AND DRAINS

(SEE OPTION NOTES)

CUSTOMER CONNECTION/

POWER CORD

CAP

FPS

MTR

TB 1

TB PE

TB 2

TB 4

TB 3

TB PE

DRN1

DRN2

BRN

BLU

LINE

NEUTRAL

GROUND

NOT USED

ON WATER-COOLED UNITS

DRAIN

NEUTRAL

COMP

TB 5

TC1

Optional Notes:

1. IC2-Includes IC2 Instrument Panel and Timed Solenoid Drains.

2. IC3-Includes IC3 Control Panel and Demand Drains

3. DRN2-Optional Cold Coalescing Drain

4. 575-3-60 Supplied from equipment mounted transformer

5. Water-Cooled units: Fan Motor(s) and Fan Pressure Switch(es) are removed.

Models 200 thru 750 - 230-400-460-575V/3/50-60 Hz

(I-Controller Level 2)

Models 200 thru 750 - 230-400-460-575V/3/50-60 Hz

(I-Controller Level 3)

P4P1 P2 P3

FOR 575-3-60

380/420-3-50

(SEE DETAIL A)

230-3-60

460-3-60

24V

TC1

TC2

TC3

CON

COIL

P6P5 P7 P8 P9 P10

P11

P12

OPTIONAL

EDD2

ALARM

ALARM TEST

EDD1

TEST

CON

DRAIN ALARM

24 VAC

TB TB

HPCO

SSMP

LPCO

CONNECTION

CUSTOMER

575V

DETAIL "A"

(575V TRANSFORMER BANK)

460V

TO TB L3

TO TB PE

TO TB L2

TO TB L1

TRANSFORMER CONNECTION (TR1)

575V CONNECTION SHOWN. (H6, H1)

FOR: USE TAPS:

208V H6 / H5

230V H6 / H4

460V H6 / H2

380-420V H6 / H3

2FU

INLET

TEMP

SEPARATOR

TEMP

IC3 CONTROL PANEL

REMOTE

START/STOP

AMBIENT

TEMP

DRAIN TESTPOWER ON

FAULT

POWER

MTR

TB TB TB TB

1FU 6.25 AMP

2FU/3FU 230V-2 AMP

2FU/3FU 460/575V-1 AMP

1FU

TR1

GND

FUSE SIZES TR1:

3FU

1FPS

2FPS

1FM

2FM

RNC500-750

USED ON

CONNECTION

CUSTOMER

OPTIONAL POWER

DISCONNECT

HTR

L N

CUSTOMER

CONNECTION

CUSTOMER

CONNECTION

Electrical Schematics

DIMENSIONS/WEIGHTS

DimensionsDimensions

Dimensions

inchesinches

inches

ModelsModels

Models

125125

125

150150

150

200200

200

250250

250

A 33-1/8 33-1/8 39-1/2 39-1/2

B 25-5/16 25-5/16 32-3/8 32-3/8

C 26 26 32-3/8 32-3/8

D 4-1/8 4-1/8 5-5/16 5-5/16

E 9-7/16 9-7/16 12-5/8 12-5/8

F 4-1/2 4-1/2 4 4

G 20-11/16 20-11/16 24-7/16 24-7/16

H 24-3/16 24-3/16 21-3/16 21-3/16

I 24 24 29-3/4 29-3/4

J 21-13/16 21-13/16 27-1/8 27-1/8

Inlet/Outlet

Connections 1 MPT 1 MPT 1-1/2 MPT 1-1/2 MPT

Weight lbs 229 244 410 410

Weight lbs with

Oil Removal Filter 237 252 423 423

125 thru 150 scfm models

200 thru 250 scfm models

TOP VIEW

FRONT VIEW RIGHT SIDE VIEW

TOP VIEW

FRONT VIEW RIGHT SIDE VIEW

AIR FLOW

DIMENSIONS/WEIGHTS

Dimensions

inches

Model 300 400 500 750

A 49 49 49 55-1/2

B 32-3/8 32-3/8 32-3/8 32-3/8

C 47-1/25 47-1/25 47-1/25 1-1/2

D 5-13/16 5-13/16 5-13/16 5-7/8

E 13-7/8 13-7/8 13-7/8 13-15/16

F 4 444

G 33-9/16 33-9/16 33-9/16 38-3/4

H 37-9/16 37-9/16 37-9/16 42-3/4

I 44-3/4 44-3/4 44-3/4 48-3/4

J 27-1/8 27-1/8 27-1/8 27-1/16

Inlet/Outlet

Connections 1-1/2 MPT 2 MPT 2-1/2 MPT 2-1/2 MPT

Weight lbs 631 672 701 968

Weight lbs with

Oil Removal Filter 644 704 733 1038

TOP VIEW FRONT VIEW RIGHT SIDE VIEW

300 thru 500 scfm models

750 scfm models

TOP VIEW FRONT VIEW

RIGHT SIDE VIEW

AIR FLOW

TROUBLESHOOTING GUIDE

SYMPTOM

A. Water downstream of dryer

B. High pressure drop across

dryer

C. Dew point indicator in red

area

D. Refrigeration system not

functioning properly

1. Power On light off

2. Compressor on light off

3. Refrigerant compressor

cycles on and off

POSSIBLE CAUSE(S)

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 dryers dew point

rating

5. Excessive free moisture (bulk

liquid) at dryer inlet

6. Condensate not being automati-

cally drained

Drain mechanism is clogged or

inoperative.

Drain line is restricted or frozen.

Electric drains–timer not set to

allow for sufficient condensate

removal

7. Dryer overloaded resulting in

elevated dew point.

8. Refrigeration system not func-

tioning properly resulting in

elevated dew point.

1. Excessive air flow

2. Freezing of moisture in evapora-

tor because of refrigeration

system improperly functioning.

3. Separator or optional Oil Removal

filter element clogged.

1. Dryer overloaded resulting in high

air outlet temperature.

2. Refrigeration system not func-

tioning properly resulting in high

air outlet temperature.

3. Dryer is running with no load

a. Power failure

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. Air-cooled models–Dirty, clogged

condenser fins, obstructed air

flow across condenser, or non

functioning fan motor or fan

control switch.

CORRECTIVE ACTION

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

Electric drains–reset time so that all liquid

is discharged

Check inlet air temperature and pressure,

flow rate (compressor capacity) and

ambient air or water temperature.

See D below

Check flow rate

See D below

Replace filter element(s).

See A 7

See D below

Light will go out when air flow is

established

Check power to unit

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

flow, if problem persists contact qualified

refrigeration repairman or manufacturer’s

service department.

I - CONTROLLER LEVEL 3

Alert/Alarm Condition Indicators

TABLE 2

I-Controller Level 3 Alert/Alarm Fault Status Indicator Guide

Text Window Fault Condition Panel Lights Process Diagram LEDs* Audible Alarm (1)

Fault Event Alarm Alert / Compressor Thermometer Gauge Separator /Filter Contacts N/O Contacts N/C

Notification Identification Maintenance Drain

LCD text See Troubleshooting Section Red Yellow Green Green Red Green Alarmed Normal

ALERT AMBIENT TEMP High Ambient Air Temperature - Flashes ON/OFF Flashes - - - N/C

ALERT INLET AIR TEMP High Inlet Air Temperature - Flashes ON/OFF Flashes - - - N/C

ALARM DEW POINT TEMP High Dew Point Temperature Flashes - ON Flashes - - N/O N/C

SHUTDOWN LOW PRESSURE Low Compressor Suction Pressure Flashes - OFF - Flashes - N/O (2) N/C

SHUTDOWN HIGH PRESSURE High Compressor Discharge Pressure Flashes - OFF - Flashes - N/O (2) N/C

SHUTDOWN MOTOR PROTECT Compressor Motor Overload Flashes - OFF - - - N/O (2) N/C

ALERT MAINTENANCE Perform Standard Maintenance Reminder - Flashes ON - - - N/C

ALARM DRAIN Failure to Drain Condensate Flashes - ON - - Flashes N/O N/C N/C

* During an Alert/Alarm condition, the Process Diagram LED rotation ceases. The Fault based LED will “Flash” until the fault condition is resolved.

(1) Depress the (RESET) button to silence the Audible Alarm. The Fault Condition will remain visible in the VFTD text window until corrected.

(2) The Refrigeration Compressor will remain “”OFF”” until the fault condition is corrected.

TROUBLESHOOTING GUIDE

I-Controller Level 3

VFTD READING

(Fault conditions)

POSSIBLE CAUSE(S) CORRECTIVE ACTION

ALERT AMBIENT TEMP 1. Poor ventilation Ensure ventilation is adequate for heat load

(High Ambient Air Temperature) Ensure compressor is not ventilated toward dryer

ALERT INLET AIR TEMP 1. No aftercooler on compressor Install an aftercooler

(High Inlet Air Temperature) 2. Dirty aftercooler Clean aftercooler

3. Poor Ventilation Ensure ventilation is adequate for heat load

ALARM DEW POINT TEMP 1. Refrigerant leak Have serviced by a qualified refrigeration

(High Dew Point Temperature) technician

2. System Overload Review ambient, inlet, and air flow conditions

3. Dirty Condenser Blow dust out of condenser fins

SHUTDOWN LOW PRESSURE 1. Low ambient condition Elevate ambient temperature

(Low Compressor Suction Pressure) 2. Refrigerant leak Have serviced by a qualified refrigeration technician

3. Improper Hot Gas Bypass Properly adjust HGBV

Valve setting

SHUTDOWN HIGH PRESSURE 1. Fan(s) not working Check condenser fan function

(High Compressor 2. High ambient condition Ensure ventilation is adequate for heat load

Discharge Pressure) Ensure compressor is not ventilated toward dryer

3. System overload Review ambient, inlet, and air flow conditions

SHUTDOWN MOTOR PROTECT 1. Motor overloads triggered Check voltage. Check for short to ground

(Compressor Motor Overload) 2. Refrigerant leak Have serviced by a qualified refrigeration technician

ALERT MAINTENANCE 1. Pre-set Maintenance interval Blow dust out of condensers, verify drain function,

check pressure drop across dryer

ALARM DRAIN 1. Failure to discharge condensate Check automatic discharge line for closed hand

valve or kink in hose

(Failure to Drain Condensate) Clean and rebuild drain valve

Verify power to valve with Push-to-Test button

PARTS

200 250, 300 & 400 500 750 200 250, 300, & 400 500 750

DESCRIPTION 208230/3/60 460/3/60, 575/3/60 & 380420/3/60

Condensing Unit (aircooled) C413012716 C413012719 C413012514 C41301291 C413012717 C413012720 C413012715 C41301292

Compressor C413010853 C413010855 C413010857 C413010864 C413010854 C413010856 C413010858 C413010865

Fan Motor C610523837 C610523839 C610523839 C610523839 C610523838 C610523840 C610523840 C610523840

Fan Blade C414022722 C414022723 C414022724 C414022724 C414022722 C414022723 C414022724 C414022724

Crankcase heater C592032712 C592032712 C592032712 C592032712 C592032713 C592032713 C592032713 C592032713

Condenser (aircooled) C413011123 C413011124 C413011125 C413011128 C413011123 C413011124 C413011125 C413011128

Refrigerant Low Pressure Switch C413013822 C413013822 C413013822 C413013822 C413013822 C413013822 C413013822 C413013822

Refrigerant High Pressure Switch (aircooled) C413013825 C413013825 C413013825 C413013825 C413013825 C413013825 C413013825 C413013825

Fan CutOut Switch (Fan 1) C413013823 C413013823 C413013823 C413013823 C413013823 C413013823 C413013823 C413013823

Fan CutOut Switch (Fan 2) N/A N/A C413013824 C413013824 N/A N/A C413013824 C413013824

Hot Gas ByPass Valve (aircooled) C41306905 C41306905 C41306905 C413069019 C41306905 C413069018 C41306905 C413069019

Hot Gas ByPass Valve (watercooled) C413069018 C413069018 C413069018 C413069019 C413069018 C413069018 C413069018 C413069019

ByPass Valve Strainer C41307015 C41307015 C41307015 C41307017 C41307015 C41307015 C41307015 C41307017

Thermal Expansion Valve N/A N/A N/A C413082922 N/A N/A N/A C413082922

Filter Drier (Liquid Line) C41301662 C41301662 C41301662 C41301662 C41301662 C41301662 C41301662 C41301662

Sight Glass N/A N/A N/A C41307253 N/A N/A N/A C41307253

Accumulator C413000616 C413000616 C413000616 C413000616 C413000616 C413000616 C413000616 C413000616

High Temperature Sensor C61503332 C61503332 C61503332 C61503332 C61503332 C61503332 C61503332 C61503332

Contactor C59101359 C59101359 C59101359 C591013518 C59101359 C59101359 C59101359 C59101359

Auxillary Contacts C611010121 C611010121 C611010121 C611010121 C611010121 C611010121 C611010121 C611010121

Transformer 230/400/460 C612009214 C612009214 C612009214 C612009214 C612009214 C612009214 C612009214 C612009214

Fuse Primary C592027428 C592027428 C592027428 C592027428 C592027427 C592027427 C592027427 C592027427

Fuse Secondary C592027426 C592027426 C592027426 C592027426 C592027426 C592027426 C592027426 C592027426

Digital PC Board (IC 2.0)w/high temp. sensor C59455768 C59455768 C59455768 C59455768 C59455768 C59455768 C59455768 C59455768

Digital PC Board (IC 3.0) w/high temp. sensor C59455769 C59455769 C59455769 C59455769 C59455769 C59455769 C59455769 C59455769

*ELECTRIC DRAIN Valve w/24V Coil (50/60 Hz) C481074146 C481074146 C481074146 C481074146 C481074146 C481074146 C481074146 C481074146

Power Transformer (575 V ) C61202771 C61202771 C61202771 C61202771 C61202771 C61202771 C61202771 C61202771

Refrigerant High Pressure Switch(watercooled) C413013836 C413013836 C413013836 C413013836 C413013836 C413013836 C413013836 C413013836

SureSave Valve C413082943 C413082943 C413082943 C413082943 C413082943 C413082943 C413082943 C413082943

OnOff Switch C611070613 C611070613 C611070613 C611070613 C611070613 C611070613 C611070613 C611070613

Condensing Unit (H

Ocooled) C413013744 C413010862 C413010646 C413010655 C413013745 C413010863 C413010647 C413010656

Cooling Water Regulating Valve C413014522 C413014522 C413014522 C413014522 C413014523 C413014522 C413014522 C413014523

Cooling Water Strainer C47317351 C47317351 C47317351 C47317351 C47317351 C47317351 C47317351 C47317351

Cooling Water Strainer Screen C47317355 C41307355 C41307355 C41307355 C41307355 C41307355 C41307355 C41307355

* Timer Valve Rebuild Kit(s) is included in Maintenance Kits (IController Level 2 Only)

125 150

PARTS 115/1/60 208230/1/60 220240/1/50 115/1/60 208230/1/60 220240/1/50

DESCRIPTION 100/1/50

100/1/50

Condensing Unit (aircooled) C413013431 C413013432 C413013433 C413013431 C413013432 C413013433

Compressor (Only) C413010850 C413010851 C413010852 C413010850 C413010851 C413010852

Overload C592557813 C592557814 C592557815 C592557813 C592557814 C592557815

Start Relay C594568313 C594568314 C594568315 C594568313 C594568314 C594568315

Start Capacitor C591010337 C591010338 C591010339 C591010337 C591010338 C591010339

Fan Motor C610523835 C610523836 C610523836 C610523835 C610523836 C610523836

Fan Blade C414022721 C414022721 C414022721 C414022721 C414022721 C414022721

Hot Gas ByPass Valve (aircooled) C98021 C98021 C98021 C98021 C98021 C98021

Hot Cas ByPass Valve (watercooled) C413069018 C413069018 C413069018

Condenser (aircooled) C413011122 C413011122 C413011122 C413011122 C413011122 C413011122

Dryer C413016514 C413016514 C413016514 C413016514 C413016514 C413016514

Fan Pressure Switch C413013813 C413013813 C413013813 C413013813 C413013813 C413013813

Contactor C591013411 N/A N/A C591013411 N/A N/A

ByPass Valve Strainer C41307018 C41307018 C41307018 C41307018 C41307018 C41307018

Light Assy., green C635045725 C635045723 C635045723 C635045725 C635045723 C635045723

OnOff Switch C611070613 C611070613 C611070613 C611070613 C611070613 C611070613

High Temperature Sensor C61503332 C61503332 C61503332 C61503332 C61503332 C61503332

Digital PC Board (IC 2.0)w/high temp. sensor C59455768 C59455768 C59455768 C59455768 C59455768 C59455768

Condensing Unit (H

Ocooled) N/A N/A N/A 413013434 413013435 413013436

PARTS LIST

Model 125 150 200 250 300 400 500 750

Standard CRNMK5 CRNMK5 CRNMK6 CRNMK6 CRNMK7 CRNMK8 CRNMK8 CRNMK9

With Optional Cold Coaleser CRNMK15 CRNMK15 CRNMK16 CRNMK16 CRNMK17 CRNMK18 CRNMK18 CRNMK19

Maintenance Kits (1)

(1) Standard dryers with the Optional I-Controller Level 3 include one Demand Drain P/N G05-7880-65.

Units with the Optional Cold Coalescer have two. Order one Rebuild Kit P/N G05-7880-65R for each drain trap in addition to kit.

NOTES

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 specified 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 specified. 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 first 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 STATU-

TORY, 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 five [5]). Lifetime heat exchanger warranty (parts only) requires a CFF

Series prefilter on the initial purchase and annual filter element replacements with genuine CFF Series elements.

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

specified 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

2004 Gardner Denver, Inc.

Litho in U.S.A.

7610.721.74 1/04

CA18-2-650, 1st Ed.

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.

Champion CRN250 User manual

Brand: Champion

Model: CRN250

Type: User manual

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