Rotrex C15-16 Versionshinweis

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Technical Handbook

Rev. 1.6

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Index

INTRODUCTION 3

1. THE IDEAL APPLICATION DEVELOPMENT CYCLE 4

2. ROTREX TECHNOLOGY BASICS 6

2.1 System overview 6

2.2 Supercharger internal structure 7

2.3 Traction drive principles and key benefits 8

3. CHOOSING THE RIGHT ROTREX 9

3.1 General guidelines 9

3.2 Supercharger selection example: boosting 105hp to 150hp 10

4. DESIGNING AND HANDLING INTERFACES 11

4.1 Pulleys and other drive types 11

4.2 Belt drives 12

4.2.1 Belt routing 12

4.2.1 Belt alignment 13

4.3 Brackets 15

4.4 Lubrication circuit 16

4.4.1 Designing a good lubrication circuit 17

4.4.2 Installation, start-up, and maintenance 19

4.5 Air ducting 23

4.5.1 Compressor house adjustment 23

4.5.2 Ducting 24

5. IMPORTANT NOTES AND INFO SOURCES 27

5.1 Testing and verification 27

5.2 Installer and end user documentation 28

5.3 Claim handling 29

5.4 Important information sources 29

6. SUPPORT MATERIAL 30

6.1 Pulley ring design guide for C15, C30 and C38 30

6.2 Pulley ring drawing for C15, C30 and C38 31

6.3 Pulley ring design guide for C38R 32

6.4 Pulley ring drawing for C38R 33

6.5 Pulley changing and removal procedure 34

6.5.1 Aluminium pulleys 34

6.5.2 Steel pulleys (Up to dec 2021) 35

6.6 Bracket design guide 36

6.6.1 Bracket design guide for C15 36

6.6.2 Bracket design guide for C30 37

6.6.3 Bracket design guide for C38 38

6.6.4 Bracket design guide for C38R 39

6.7 New Application Development Feedback Form 40

6.8 Customer Claim Form 41

Technical Handbook

Rev. 1.6

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Index

Version 1.1 – Released 29-10-2012

oOriginal

Version 1.3 – Released 16-05-2013

oCorrected the supercharger selection example section 3.2

oText changed to “Incorrect pulley change voids warranty” in

section 6.3 to correspond to the latest version of Setup and

Maintenance leaflet V9.0

Version 1.4 - Released 04-06-2014

oUpdated oil level checking procedure in section 4.4.2

oUpdated maintenance procedure in section 4.4.2

oUpdated bracket design guides for the C8, C15, C30 and C38

Version 1.5 – Released 12-04-2019

oUpdated chapter 4.5.2 Air ducting (recirc. & inlet restrictors)

oUpdated chapter 6.4.2 C15 bracket drawing

oNew pulley ring design guide for C38R, section 6.3 & 6.4

oNew bracket design guide for C38R, section 6.4.5

Version 1.6 – Released 1-1-2022

oDrawing ‘6.3.2 Aluminium pulleys’ removed

oUpdated image for chapter 4.4 Lubrication circuit

oUpdated to follow revised supercharger design of 2022,

including pulley adapter update

oPulley mounting description changed to reflect new standard

aluminium pulley and pulley adapter design

oIllustrations updated

oC8 Range removed

oC38R Range added

Revision history

Technical Handbook

Rev. 1.6

WWW.ROTREX.COM Page 3 of 41

Introduction

This document is a general guide and explains the core knowledge required to

successfully create a Rotrex supercharger system. This handbook should be

used as a reference when designing, installing, and servicing a Rotrex

supercharger system. For guidance and information on your specific kit please

always contact the company who sold you the Rotrex supercharger or the

company from whom you intend to buy the Rotrex supercharger (your Rotrex

supplier). Rotrex only deals directly with approved distributors, kit builders and

OEM customers.

This document contains important information regarding Rotrex products and services

related to the “C” range of superchargers (C15, C30, C38 and C38R product families). It

is structured in 6 main sections:

Section 1 - “The ideal development cycle” – summarizes how best to develop a successful

Rotrex installation.

Section 2 - “Rotrex technology basics” – provides essential information on how a Rotrex

unit works and the benefits it brings to you and your customers.

Section 3 - “Choosing the right Rotrex” – provides a useful guideline to selecting the best

Rotrex unit for a particular application.

Section 4 - “Designing and handling interfaces” – Provides a series of guides to design,

manufacture and install critical systems interfacing with the Rotrex unit (pulley-belt drive,

bracket, ducting and lubrication systems).

Section 5 - “Important notes and info sources” – highlights further key considerations and

information resources.

Section 6 - “Support material” – Contains a series of appendices with important drawings,

specifications and forms supporting the guidelines.

Following the instructions and recommendations contained in this document is vital for a

successful Rotrex installation. For the Rotrex warranty to apply, all the described

requirements must be followed, however throughout this handbook we have further

highlighted some of the more common mistakes to make it as easy as possible to

successfully develop a new Rotrex application.

Technical Handbook

Rev. 1.6

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Introduction

1. The ideal application development cycle

Rotrex offers technical and commercial support to OEM customers, official Rotrex

distributors and kit builders during the entire development cycle to ensure a proper quality

level in all Rotrex based applications. The diagram below represents an ideal application

development cycle.

Phase 1

Base

specification

A set of desired specifications for

a particular application

Phase 2

Feasibility

analysis<

Takes the outcome of phase 1

and evaluates, from technical,

financial, and strategic

perspectives, the viability of the

project. The outcome can lead to

approval,

revision,

or dismissal

Phase 3

Design

verification

Takes the revised base

specification from phase 2 and

verifies the design. The outcome

of this phase is the product

specification for production.

Phase 4

Production

Implementation of product

specification into manufacturing

operation.

Phase 5

Market

feedback

Evaluation of market response to

product

Naming of project

Initial base spec

Technical analysis

Market analysis

Capability analysis

Revised base

specification



Project plan

Prototype test run

DVT

0 series preparation

Marketing plan

Approval

Documentation

package

0 series production

Control plan

0 series feedback report

8 months feedback

report

1.5 year feedback

report

Stage

Milestones

Description

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Introduction

Phases 2 and 3 (in red) are the stages where Rotrex expertise is most important since it

is here design feedback can prevent quality and operational issues more effectively.

Therefore, Rotrex strongly recommends doing the following:

A. Choose the Rotrex supercharger that best suits your application (after identifying

a business opportunity, evaluating the market potential and the development

effort/investment needed). For this purpose, you will find useful information in

Section 3 of this document

B. Design the main interfaces (bracket, drive, ducting and lubrication systems). For

this purpose, you will find useful information in Sections 4 and 6 of this document

C. Inform your Rotrex supplier of the outcome of your technical and market analysis.

The purpose is to revise key assumptions to provide constructive feedback aimed

to prevent quality and operational issues. Section 6.5 of this document contains a

form for this purpose

D. Create a revised base specification based on the feedback and adjust your initial

design accordingly

E. Create a project plan (including test/validation program and estimated product

launch date) and send a summary copy to your Rotrex supplier in order to

coordinate joint efforts and synchronize key events

F. Design and implement a proper approval process for the application including

testing and documentation verification ensuring product quality. For this purpose,

you will find useful information in Section 5 of this document

G. Send regular updates along the process. In case of any doubt or difficulty don’t

hesitate to contact your distributor or Rotrex

Technical Handbook

Rev. 1.6

WWW.ROTREX.COM Page 6 of 41

Rotrex technology basics

2. Rotrex technology basics

2.1 System overview

The picture above shows a standard Rotrex C-type supercharger system highlighting main

components and their location.

 Supercharger: Centrifugal air compression through high-speed traction drive

featuring internal dry sump dual action oil vane pump

 Oil cooler: Acting as main cooling element

 Canister: Oil reservoir. De-foaming and venting of oil system. Acting as a

secondary oil cooling element

 Filter: Protecting traction drive from any particles through cellulose and magnetic

filtering

 Pulley: Connecting the supercharger to crankshaft via belt

Technical Handbook

Rev. 1.6

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Rotrex technology basics

2.2 Supercharger internal structure

As the cross-section above shows, the supercharger contains three internal subsystems:

A. Input & pump: Connecting the pulley drive to the traction drive and powering the

dual action vane pump. The dual action vane pump sucks oil from the canister,

pumps it into the traction drive, sucks oil from the unit sump and pumps it back

out into the canister through the cooler

B. Traction drive: Multiplying input speed powering the centrifugal compressor. The

traction drive is covered in detail in Section 2.3

C. Centrifugal compressor: Providing boost through high efficiency turbo-

compressor design

These interdependent subsystems work together, supported by the lubrication circuit, to

deliver optimum performance and reliability.

A B

Technical Handbook

Rev. 1.6

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Rotrex technology basics

2.3 Traction drive principles and key benefits

A traction drive transmits power through friction forces between rolling elements. High

speeds, low noise and high efficiency are just some of the advantages of traction drives

over traditional gear transmissions.

The Rotrex patented traction drive uses a steel annulus with a small pre-span to secure

contact between the roller planets and the sun shaft with a reasonable force. The ramp

or wedge effect increases efficiency and reliability in the transmission by regulating the

torque transfer capability on demand through self-adjusting planet geometry. This is a

key operational feature since friction is highly dependent on surface pressure, slip and

temperature conditions in the traction fluid.

Developed specifically for use in Rotrex superchargers, the special traction fluid

momentarily increases viscosity under high surface pressure, enhancing the traction drive

performance by securing the optimum friction between rolling elements while cooling and

protecting the system.

The diagram below represents the dynamics explained above.

This unique traction drive delivers the following key benefits:

• Speed capability released up to 240.000 RPM (depending on model)

 Allowing reliable utilization of highly efficient impellers delivering improved

boost conditions

• Great power density (around 20 kW/kg) resulting in unparalleled compactness

 Accelerating application development and simplifying installation = lower

costs

• Low noise and smooth operation

 Improving NVH and customer satisfaction

• High efficiency

 Causing less heat and requiring less energy

Pressure and slip

are kept under

optimum conditions

through the

patented ramp

effect

(within

Temperature is kept within

optimum range through oil

circuit: cooling, cleaning,

and de-foaming

Power is transmitted

through friction forces

between rolling elements.

Friction given by special

traction fluid depends on:

Pressure

Slip

Temperature

Technical Handbook

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WWW.ROTREX.COM Page 9 of 41

Choosing the right Rotrex

3. Choosing the right Rotrex

3.1 General guidelines

1 Power output is dependent on engine type, cooling of charge air, cam profile and timing, compression ratio

etc.

2 CCW: Counter Clock Wise rotation direction seen from the pulley side

3 CW: Clock Wise rotation direction seen from the pulley side

The amount of air delivered by the supercharger and consequently the boost pressure is

determined by the supercharger model and the impeller speed in conjunction with the

engine size and speed. The comparison table above shows the working area of each

supercharger model within the C-range. For compressor maps please refer to the

technical datasheets. If in doubt, please contact your Rotrex supplier.

Regardless of the supercharger type and model, always make sure to run it within its

respective operating speed range specified in the technical datasheet. Exceeding these

speed values will void warranty.

The optimum supercharger for a given application will depend on many variables of which

some are hard to know accurately (e.g., volumetric efficiency or how this will be affected

under boost conditions). This can very well be modelled using advanced engine calculation

tools and theory. However, using a simple “rule of thumb” along with the information

provided here and in the flow maps will be adequate in many cases.

Supercharger comparison table

Model

Input

rotation

direction

Pulley

dia.

[mm]

Air inlet

hose dia.

[mm]

Air outlet

hose dia.

[mm]

Max impeller

speed

[rpm]

Max

pressure

ratio

Max flow

[kg/s]

Power range1

[engine kW]

Max

adiabatic

efficiency

[%]

C15-16 CW3 70-90 60 45 201,500 2.46 0.15 60-125kW

(82-170hp) 70

C15-20 CW3 70-90 60 45 180,000 2.94 0.15 50-120kW

(68-163hp)

C15-60 CW3 70-90 60 45 150,000 2.34 0.22 90-175kW

(122-238hp)

C30-64 CW3 70-110

60 50 120,000 2.68 0.28 120-235kW

(163-320hp)

C30-74 CW3 70-110

60 50 120,000 2.82 0.31 135-255kW

(184-347hp)

C30-84 CW3 70-110

76 50 120,000 2.82 0.32 140-265kW

(190-360hp)

C30-94 CW

CCW2 70-110

76 50 100,000 2.52 0.39 145-320kW

(197-435hp) 71

C38-61 CW3 70-110

76 63 90,000 2.90 0.48 200-410kW

(272-557hp)

C38-71 CW3 70-110

76 63 90,000 2.82 0.55 210-455kW

(286-620hp)

C38-81 CW3 70-110

76 63 90,000 2.85 0.58 220-485kW

(300-660hp)

C38-91 CW3 70-110

76 63 90,000 2.94 0.63 260-530kW

(354-720hp)

C38-92 CW3 70-110

89 63 90,000 2.94 0.63 260-530kW

(354-720hp)

C38R-112

CCW2 75-110

89 63 90,000 3.34 0.84 340-720kW

(455-965hp) 75

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