Table of Contents
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D10 (TD)
D15 (TD)
DRS 15 (TD)
Rotary Screw
Air Compressor
Units
- - -
Installation
And
Start-up Data
Authorized distributor service technicians are factory trained and skilled in compressor maintenance
and repair. They are ready to respond and assist you by providing fast, expert maintenance and repair
services.
Contents:
Quick Start ............................................................
Safety Precautions ...........................................
Unpacking And Inspection ..................................
Installation – Mechanical ...................................
Lubrication .....................................................
Installation – Electrical ......................................
Motor Maintenance Instructions ............................
Start-Up Procedures .........................................
Preventative Maintenance Schedule ....................
Maintenance Procedures ......................................
'CSC300' Controller ............................................... 21
Common Compressor Faults ...............................
Variable Speed Drive ........................................... 31
Separator Filter & Refrigerated Air Dryer ............... 37
Trouble-Shooting Guide ...................................... 40
Warranty ......................................................... 43
Please read this manual before
Compressor Unit. It contains
valuable information that will
Please keep this manual in a
safe place for future reference.
procedures in this reference manual apply
- 1 -
D10.D15.DRS15-MANS
installing or using your Air
help in the receiving,
installation, use, and
maintenance of the Unit.
All of the information, policies, and
exclusively to Champion.
Apr '19
Page:
2
4
5
6
8
9
11
12
13
15
30
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Table of Contents
Related Manuals for Champion D15
Summary of Contents for Champion D15
- Page 1 D10.D15.DRS15-MANS Apr ‘19 Contents: Page: D10 (TD) Quick Start ……………..........Safety Precautions ……………………………………. D15 (TD) Unpacking and Inspection …………………………..DRS 15 (TD) Installation – Mechanical …………………………….. Lubrication …………………………………………….. Rotary Screw Installation – Electrical ……………………………….. Motor Maintenance Instructions …………………..Air Compressor Start-up Procedures …………………………………..
- Page 2 [458 mm] Installation Kit IK515 Note: Dimensions indicated are typical for Flex-Hose & all D10, D15 and DRS 15 Units, Vibration Isolators ie base-mounted and tank-mounted. (sold separately) The Unit must be located indoors, in a dry, clean, Ensure that the floor under the Unit is smooth, level and cool, dust free, and well ventilated area.
- Page 3 D10.D15.DRS15-MANS Apr ‘19 Quick Start (cont’d) Unit Operation Shown below is the ‘CSC300’ Controller which regulates the operation of the Unit. It is used to start and stop the Unit, and it provides information as to system pressure, temperature, etc.
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Page 4: Safety Precautions
D10.D15.DRS15-MANS Apr ‘19 Safety Precautions In order to operate the Compressor Unit safely and correctly, we have opted to use the following symbols to make you aware of important points. These points relate to user safety and preventing equipment problems. Please pay close attention to these sections. -
Page 5: Unpacking And Inspection
Shipments of Champion products are the property of the Consignee when the products leave our facility. Champion is not responsible for any damages or shortages caused to the product after it has left our shipping dock. - Page 6 D10.D15.DRS15-MANS Apr ‘19 Installation – Mechanical Moving of the Unit When moving the Air Compressor, the forklift or hand lift forks go under the Unit from the directions as indicated. When lifting from position ‘A’, use extended forks. Please be advised that care...
- Page 7 D10.D15.DRS15-MANS Apr ‘19 Installation – Mechanical (cont’d) Shown below are items which assist in making a good installation. These are both intake and exhaust ductwork, helping the Unit to a) draw in clean outside air and b) exhaust the warmer air away from the Unit. The warmer air may be used, with the inclusion of a damper in the exhaust ducting, to warm the interior of the building during the colder months of the year.
- Page 8 Oil level on a monthly basis. damage may result from use, however limited, without oil. Use only Champion lubricant. As well, do not mix Champion lubricant with any other lubricant. Subsequent Oil Changes Drain the existing oil from the Unit. (Please be...
- Page 9 D10.D15.DRS15-MANS Apr ‘19 Installation - Electrical General Information It is your responsibility to ensure that the Compressor Ensure that a suitable Fused Disconnect or Breaker Unit is electrically connected in a safe and correct is sized and installed according to the appropriate manner.
- Page 10 D10.D15.DRS15-MANS Apr ‘19 Installation – Electrical (cont’d) Electrical Connection The Electrician is to bring power to the Unit through the ¾” conduit hole located on the Right Panel. The Electrical Panel is accessible by means of opening the Unit Front RH Panel as shown at right.
- Page 11 D10.D15.DRS15-MANS Apr ‘19 Motor Maintenance Instructions Cleaning To ensure that the Motor operates at optimum temperatures and provides years of trouble-free service, periodically clean the outside of the Motor Housing of any build-up of dust, etc. Though it is not anticipated that, if installed correctly and in a suitable environment, there should not be much build-up on the Motor, keeping the Housing clean will allow the Motor to operate more efficiently.
- Page 12 D10.D15.DRS15-MANS Apr ‘19 Start-up Procedures Unit Controls 4) During normal operation of the Unit, keep the Start Button Stop Button Access Panels closed at all times. Allows the Unit to Use this to shut start. the Unit off. Allows 5) Ensure the Ball Valve on the Unit is closed, press the Unit to idle and the ‘Start’...
- Page 13 Noted on the following pages are general Maintenance guidelines based on average working conditions. Should the Unit be worked under extreme conditions, please contact your Champion Distributor for further input. As well, all maintenance/service work must be carried out by a qualified Technician.
- Page 14 Oil sample bottles are to be obtained from your local authorized Champion distributor. b) The Champion oil used in the maintenance schedule is rated as a 4000 hour oil. A complete Oil change must be done every 4000 hours of Unit operation, or every 12 months, whichever occurs first.
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Page 15: Maintenance Procedures
2) Remove the Air Filter Element from the Unit. 3) Clean the Intake Valve area of any dust or build-up. 4) Install a new Air Filter (Champion Part Number ‘DSC-001931-CH’), ensure it fits snugly on the Intake Valve Assembly, and tighten the Filter Clamp. - Page 16 Oil Drain Tube Drain Tube to face upwards. Fill the Oil Reservoir to the center of the Sight Glass, as indicated at right. Do not under or overfill. Correct Oil Level Use only Champion lubricant. Oil Drain Valve - 16 -...
- Page 17 D10 (TD) 83 / 73 6 lb / 0.27" (10bar) 145 psig D15 (TD) 92 / 81 6 lb / 0.23" (10bar) Notes: * Belt tension data for new Belts having run for approx. 10 hours. ** Pound Force and Inch Deflection figures are for new Belts only.
- Page 18 D10.D15.DRS15-MANS Apr ‘19 Maintenance Procedures (cont’d) Changing the Scavenge Line ‘In-Line’ Filter Intake Valve The ‘DSC-612’ In-Line’ Filter is located in the Scavenge Line between the Air-Oil Separator and the Air End, and removes any particles from the oil before it enters the Air End.
- Page 19 D10.D15.DRS15-MANS Apr ‘19 Maintenance Procedures (cont’d) Thermo Valve Repair Kit The Thermostatic Valve, or commonly called ‘Thermo Spring Valve’, provides a means of re-directing the oil to be cooled. At start-up, the oil travels from the Oil Reservoir, through the Oil Filter, and into the Air End.
- Page 20 D10.D15.DRS15-MANS Apr ‘19 Maintenance Procedures (cont’d) Shaft Seal Repair Kit Removing old Shaft Seal Remove the bolts of the seal housing (1) • Extract inner ring (4) from the shaft • Be careful not to damage the shaft • Clean surfaces carefully •...
- Page 21 Description of Controller The ‘CSC300’ Controller is the ‘brains’ of the D10, D15 and DRS 15 Rotary Screw Compressor Units. It monitors, enables, and indicates the various functions of the Unit. The Controller voltage requirement is 24 volts +/- 15%.
- Page 22 Unit. Any adjustments made to the above parameters by others (other than a qualified Technician) resulting in the incorrect operation of the Unit, damage to the Unit, or damage to property is not covered by the Champion Warranty.
- Page 23 D10.D15.DRS15-MANS Apr ‘19 ‘CSC300’ Controller (cont’d) Controller Structure The chart below indicates the various fields of the ‘CSC300’ Controller, some require an Access Code. As suggested on the previous page, only those qualified should be permitted to make any adjustments to the parameters.
- Page 24 D10.D15.DRS15-MANS Apr ‘19 ‘CSC300’ Controller (cont’d) Page ‘P16’ – Warning alarm Page ‘P18’ – I/O CONFIG Page ‘P20’ – Diagnostics 01 Service hours 1 08 DI5 function 01 Digital input 1 02 Service hours 2 09 DI5 OK: NO/NC 13 EQUIP OUT PRESS...
- Page 25 D10.D15.DRS15-MANS Apr ‘19 ‘CSC300’ Controller (cont’d) Adjusting the parameters of the Controller could adversely affect the operation of the Unit. Only those individuals with knowledge of the Unit should be permitted to make any adjustments. Access Code Entry To gain entry to areas of the Controller in which an Access Code is required: 2.
- Page 26 D10.D15.DRS15-MANS Apr ‘19 ‘CSC300’ Controller (cont’d) 9. Using the ‘Up’ and ‘Down’ keys, change 10. Press ‘Enter’ to move to the following the first digit of the Access Code to the digit. Using the ‘Up’, ‘Down’, and ‘Enter’ appropriate number keys, input the access code.
- Page 27 D10.D15.DRS15-MANS Apr ‘19 ‘CSC300’ Controller (cont’d) Page Menus Once the correct Access Code has been entered, access will be given to pages reflecting that Code. Refer to Page 23 and 24 for available pages. Use ‘Enter’ and ‘Escape’ keys on the Controller to navigate between menu page navigation and menu content navigation.
- Page 28 D10.D15.DRS15-MANS Apr ‘19 ‘CSC300’ Controller (cont’d) Error Log Menu Any issues that the Unit may have are stored on an Error Log. It places in its memory the last 50 faults in chronological order. If all 50 faults have been used, any new faults will become ‘01’, and all others will be moved back one step.
- Page 29 D10.D15.DRS15-MANS Apr ‘19 ‘CSC300’ Controller (cont’d) Advanced Phase Detection Advanced Phase Detection feature of the CSC300 controller is utilized in fixed speed units. It measures the phase sequence of the incoming power to prevent motor from rotating in the wrong direction. If the following error is visible on the Screen and the Unit will not start, simply switch power leads L1 and L3.
- Page 30 D10.D15.DRS15-MANS Apr ‘19 Common Compressor Faults Common Faults Noted below are the most common Faults experienced. ‘CSC300’ Alarms There is an issue with the Unit, but it will still operate. Code: Description: Most Common Items to Check: A:0083 Motor phase imbalance...
- Page 31 Apr ‘19 Variable Speed Drive Your Champion DRS 15 Rotary Screw Compressor Unit has been equipped with a Vacon ‘Variable Speed Drive’, or ‘VSD’. A Compressor with an integral VSD can handle the constant loads for an extended period of time (running at close to 100% duty cycle), but it can also run at slower speeds to accommodate lower air demands at other times of the day.
- Page 32 D10.D15.DRS15-MANS Apr ‘19 Variable Speed Drive (cont’d) Operating Screen Typical Drive Status Indicators on Screen - 32 -...
- Page 33 D10.D15.DRS15-MANS Apr ‘19 Variable Speed Drive (cont’d) Keypad Buttons Reset Button Used to rest active Faults Select Button Used to switch between two latest displays May be useful to see how changing one value influences another. Enter Button Used for:...
- Page 34 D10.D15.DRS15-MANS Apr ‘19 Variable Speed Drive (cont’d) Menu Button Navigation Chart - 34 -...
- Page 35 D10.D15.DRS15-MANS Apr ‘19 Variable Speed Drive (cont’d) Monitoring Menu The Monitoring Menu, accessible at the ‘Main Menu’ by pressing the ‘Main Menu Right’ button when ‘M1’ is visible on the first line of the display, indicates the values for the various running parameters as in shown below.
- Page 36 D10.D15.DRS15-MANS Apr ‘19 Variable Speed Drive (cont’d) Common VSD Fault Codes Noted below are the most common fault codes that may appear on the VSD. For a more thorough list, please check the manual which deals exclusively with the Vacon Variable Speed Drive and which accompanied the Unit.
- Page 37 D10.D15.DRS15-MANS Apr ‘19 Separator Filter and Refrigerated Air Dryer Your Unit may be equipped with a Separator Filter and an ‘ASD Series’ Refrigerated Air Dryer Unit as indicated below. These items are located in the compressed air lines after the air is compressed but before it enters the Air Receiver.
- Page 38 D10.D15.DRS15-MANS Apr ‘19 Separator Filter and Refrigerated Air Dryer (cont’d) Motors. Typical Dryer Operation The Dryer will operate as follows: Pressing the ‘On/Off’ Button for 3 seconds will start the Unit • There is a time delay of up to 2 minutes before the Refrigerant Compressor starts.
- Page 39 D10.D15.DRS15-MANS Apr ‘19 Separator Filter and Refrigerated Air Dryer (cont’d) Typical Separator Filter As previously noted, the Separator Filter is located between the Air End and the Refrigerated Dryer. It contains a 1 micron Separator Element which protects the Dryer Unit by removing liquids and solid particles 1 microns and larger.
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Page 40: Trouble Shooting Guide
Compressor Unit unless you are familiar with it, as there are many issues that may come into play, the most important being personal safety and the welfare of the Unit. Should you have any questions, or require servicing to your Unit, please contact your local Champion Distributor/Service Center. - Page 41 D10.D15.DRS15-MANS Apr ‘19 Trouble Shooting Guide (cont’d) Condition: Cause: Suggested Correction: B. No or Insufficient Air Flow. Air Filter is dirty. Replace the Air Filter. Oil Separator is blocked. Replace the Oil Separator. Intake Valve is faulty. Repair or replace the Intake Valve.
- Page 42 D10.D15.DRS15-MANS Apr ‘19 Trouble Shooting Guide (cont’d) Condition: Cause: Suggested Correction: E. Intake Valve Leaks Oil Intake Valve Seal leaks. Repair using an Intake Valve Repair Kit. When Unit Stops. Intake Valve stuck in open position. Repair or replace the Intake Valve.
- Page 43 COMPRESSOR PRODUCTS Standard Warranty Oil‐Lubricated Rotary Screw Packages D Series, DRS Series STANDARD WARRANTY Champion (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, free of defects in material and workmanship. This Standard Warranty statement applies to compressors shipped after May 1 , 2015. STANDARD WARRANTY PERIOD The Company’s obligation under this warranty is limited to repairing or, at its option, replacing, during normal business hours at an authorized service facility of the Company, any part which in its judgment proved not to be as warranted within the applicable warranty period as follows. Regular maintenance in accordance with the service manual is required. Use of genuine Champion OEM parts and lubricants are highly recommended. If a component failure is deemed a result of using non‐genuine Champion parts and lubricants, warranty will not be allowed. COMPONENT STANDARD WARRANTY COVERAGE DETAILS 12 months from startup or 15 months from date of Package All components within the package, excluding normal wear items shipment to first purchaser, whichever occurs first Normal wearing items, such as shaft seals and inlet valve components, along with the servicing of these items is not covered under the warranty 12 months from startup or 15 months from date of Airend unless deemed as material or workmanship defects. Any disassembly or shipment to first purchaser, whichever occurs first partial disassembly of the airend, or failure to return the “unopened” airend per Company instructions, will be cause for denial of warranty. Electric 12 months from startup or 15 months from date of ...
- Page 44 PREMIUM WARRANTY PLAN PERIOD Champion (the “Company”) shall warrant the components identified below to be free of defects in material and workmanship for the warranty period. Normal wearing components and servicing of these items is not covered under the premium warranty. The Company’s obligation under this warranty is limited to repairing or, at its option, replacing, during normal business hours at an authorized service facility of the Company, any part which in its sole judgment proved not to be as warranted within the applicable warranty period as follows.
- Page 45 Every 2000hrs or 6 months, whichever occurs first Participation in Champion’s oil analysis sampling program is required. An oil sample must be sent to our lubricant analysis laboratory every 2000 hours or every 6 months, whichever occurs first. Any recommendations detailed in the oil analysis report must be followed as outlined in the report.
- Page 47 FULL LOAD CURRENT (AMPS) NOMINAL MODEL PRESSURE ACFM @ LOAD FILTER WEIGHT SOUND @ RECEIVER DRYER 3-PHASE PRESSURE ELEMENT 1 METRE GAL. 200V 230V 460V ASD-40 D10TD 125-145 65 dBA 32.2 115V, 60Hz, MICRON 5.24A ASD-60 D15TD 125-145 69 dBA 48.3 1175 115V, 60Hz,...
- Page 49 VFD INPUT CURRENT RATING (AMPS) NOMINAL ACFM @ LOAD PRESSURE MODEL PRESSURE FILTER WEIGHT SOUND @ RECEIVER DRYER 3-PHASE ELEMENT 1 METRE GAL. MAX. CAP. MIN. CAP. 200V 230V 460V ASD-60 DRS 15TD 135-145 1175 115V, 60Hz, MICRON 6.96A FUSE FUSE DISCONNECT KIT NO.
- Page 51 PART NUMBER DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY. DSC-002703 AIR END DD-00091 3/8"NPT X 1/2"DIA PNEU. FITTING DSC-365 AE O-RING R-8504 PE TUBING 1/2" OD DSC-001952 INTAKE VALVE PLATE DSC-002940 COPPER SEAL RING M8, 1MM THICK DSC-001930 INTAKE VALVE SS-1523 1/4"...
- Page 52 ITEM NO. PART NUMBER DESCRIPTION QTY. DSC-002703 AIR END DSC-001930 INTAKE VALVE DSC-001951 SOLENOID VALVE DSC-158 PNEUMATIC ELBOW 1/4"BSPP X 6MM DSC-380 1/4"BSPP STRAIGHT X 6MM TUBE FITTING DSC-482 PNEUMATIC TUBE BLACK 6MM OD DSC-263 1/8" BONDED WASHER DSC-677 ORIFICE 1MM DSC-001359 ELBOW 1/8"NPT(M) - 1/8"NPT(M) DSC-612...
- Page 53 1. Air inlet filter 2. Intake valve 2.1 Intake valve - NO 2.2 Discharge control screw 2.3 2/2 Solenoid valve - NO 3. Main motor 4. Air end 5. Belt drive 6. Air/Oil receiver 7. Combo block 7.1 Air/Oil separator 7.2 Oil Filter 7.3 Minimum pressure valve 7.4 Thermostatic valve...
- Page 54 PANEL SCHEMATIC FUSE TABLE FUSE SIZE (AMPS) CC TIME DELAY 5MM TIME DELAY POWER BLOCK VOLTAGE CT1 - CURRENT TRANSFORMER #1 - R7 AND R8 FOR PROGRAMMABLE POWER CIRCUIT SCHEMATIC CT2 - CURRENT TRANSFORMER #2 RELAY OUPUT FUNCTION PRIMARY FUSE F1 / F2 - EMERGENCY STOP L1 L2 L3 GND - MOTOR STARTER...
- Page 55 - EMERGENCY STOP - PRESSURE TRANSDUCER - SOLONOID N.C. POWER CIRCUIT SCHEMATIC - TEMPERATURE SENSOR WHT TO #19 TERMINAL RSS - REMOTE START/STOP L2 L3 GND MASTER/SLAVE (REFER TO REMOTE START I NSTALLATION INSTRUCTIONS, BLK TO #20 TERMINAL MASTER/SLAVE DSC-002851) NXS INVERTER - R7 AND R8 FOR 10 15 14...