Champion D5 Installation And Service Data

Rotary screw air compressor units

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Rotary Screw

Air Compressor

Units

- - -

Installation

And

Service 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 ..................................

'CSC15' Controller...........................................

Common Compressor Faults .............................

Separator Filter and Refrigerated Air Dryer............

Troubleshooting Guide .....................................

Warranty .......................................................

Please read this manual before

installing or using your Air

Compressor Unit. It contains

valuable information that will

help in the receiving,

installation, use, and

maintenance of the Unit.

Please keep this manual in a

safe place for future reference.

All of the information, policies, and

procedures in this reference manual apply

- 1 -

exclusively to Champion.

D5-MANS

Mar '19

Page:

Table of Contents

Summary of Contents for Champion D5

Page 1: Table Of Contents
All of the information, policies, and procedures in this reference manual apply exclusively to Champion. 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.
Page 2: Quick Start
D5-MANS Mar ’19 Quick Start 36” Unit [915mm] Nameplate Model No. Mechanical Installation Serial No. (Refer to Page 6) Unit voltage 18” [458mm] Installation Kit 18” IK515 [458mm] Flex-Hose & 18” Vibration Isolators [458mm] (sold separately)  The Unit must be located indoors, in a dry, clean, cool, dust free, and well ventilated area.
Page 3 D5-MANS Mar ’19 Quick Start (cont’d) Unit Operation Shown below is the ‘CSC15’ Controller which regulates the operation of the Unit. Unit Status LEDs, Hour Meter, and ON/OFF switch are located on the control panel cover. Turn the Selector Switch to ‘ON’ position.
Page 4: Safety Precautions
D5-MANS Mar ’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 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: Installation - Mechanical
D5-MANS Mar ’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. Please be advised that care must be taken when moving and positioning the Units as they are top heavy.
Page 7 D5-MANS Mar ’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: Air Compressor Lubrication
Oil level on a monthly basis. damage may result from use, however limited, without oil. Use only Champion lubricant. Also, do not mix the Champion lubricant with any other lubricant. Subsequent Oil Changes Drain the existing oil from the Unit. (Please be...
Page 9 D5-MANS Mar ’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 D5-MANS Mar ’19 Installation – Electrical (cont’d) Do not attempt to operate the Unit without first checking whether there is oil in the Air End Reservoir. Add oil as required. Serious damage may result from use, however limited, without oil.
Page 11: Motor Maintenance Instructions
D5-MANS Mar ’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: Start-Up Procedures
D5-MANS Mar ’19 Start-up Procedures Unit Controls Start/Stop Switch 6) Once the Unit reaches 145 psi (10bar), it will idle for 1 Start position: minute and shut off. allows the Unit to start. Default Offload Time of this unit is 1 minute. It would...
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.
Page 15: Maintenance Procedures
2) On the new ‘DSC-002832-CH’ Air / Oil build-up. Separator, lubricate the Separator Gasket with 4) Install a new Air Filter (Champion Part Number Compressor Oil. ‘DSC-001569’), place the Element Top on the 3) Hand tighten the new Air / Oil Separator snug Filter, and fasten down with the Wing Nuts.
Page 16 Cooler, Tubing, etc.) Close the Drain Valve. Fill the Oil Reservoir to the top of the Oil Fill Port as shown below. Do not under or overfill. See drawing below. Use only Champion lubricant. Air End Oil Drain - 16 -...
Page 17 D5-MANS Mar ’19 Maintenance Procedures (cont’d) Adjusting the Drive Belts This unit is equipped with a Belt Tensioning Device that constantly maintains the proper drive tension for the Belt. The loosening and tightening of the Drive Belt is done by way of moving the Belt Tensioning Roller up or down on the belt, respectively.
Page 18 D5-MANS Mar ’19 Maintenance Procedures (cont’d) Intake Valve Repair Kit The Intake Valve Assembly is located directly below the Intake Filter, and should be rebuilt after a maximum of 10,000 hours of Unit operation. Please order (1) ‘DSC-001712 Intake Valve Repair Kit. Shown below are the various components associated with the Intake Valve Repair Kit.
Page 19 D5-MANS Mar ’19 Maintenance Procedures (cont’d) Thermo Valve Repair Kit The Thermostatic Valve Assembly is located at the back of the Air End and to the bottom left of the pulley, and should be rebuilt after a maximum of 6,000 hours of Unit operation.
Page 20 D5-MANS Mar ’19 Maintenance Procedures (cont’d) Minimum Pressure Valve Repair Kit The Minimum Pressure Valve is located beside the Air Oil Separator, and a) acts to ensure there is a back-pressure of approx. 80 psi (5.5bar) to provide sufficient lubrication in the Air End and b) acts to stop compressed air from flowing backwards ie.
Page 21 D5-MANS Mar ’19 Maintenance Procedures (cont’d) Temperature Switch The Temperature Switch is located below the Oil Filter in the tee of the Oil Tube going to the Cooler. The Temperature Switch reads the oil temperature of the unit. If the oil temperature reaches 105ºC (220ºF) the unit will shut down, please refer to Page...
Page 22 D5-MANS Mar ’19 ‘CSC15’ Controller Shown below is the ‘CSC15’ Controller which regulates the operation of the Unit. Unit status LEDs, Hour Meter, and ON / OFF switch are located on the control panel cover. Note: 1. Do not stop the Unit by use of a disconnect or breaker.
Page 23 D5-MANS Mar ’19 ‘CSC15’ Controller (cont’d) Controller Interface A PLC is programmed to monitor and enables various functions of the compressor. It is accessed by way of removing the control panel cover. The Operator Interface for the PLC is shown below.
Page 24 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 25 Resetting the Service Alarm The D5 compressor must be serviced every 2000 hours. The Controller is programmed to count down from 2000 hours to 0 hours. Once it reaches 0 hours, the Red LED light on the control panel cover flashes in slow frequency and an error message appears on the Controller screen, this indicating that service is due.
Page 26: Common Compressor Faults
D5-MANS Mar ’19 Common Compressor Faults Common Faults Noted below are the most common Faults experienced. ‘CSC15’ Alarms There is an issue with the Unit, but it will still operate. Indication: Description: Most Common Items to Check: Service Due Service unit (please refer to Preventative Maintenance Schedule on pg. 13) [ Slow flash] ‘CSC15’...
Page 27: Separator Filter And Refrigerated Air Dryer
D5-MANS Mar ’19 Separator Filter and Refrigerated Air Dryer Your Unit may be equipped with a Separator Filter and an ‘ASD15’ Refrigerated Air Dryer Unit as indicated below. These items are located in the compressed air lines after the air is compressed and after the Air Receiver.
Page 28 D5-MANS Mar ’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 29 D5-MANS Mar ’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 micron and larger.
Page 30: Troubleshooting 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 31 D5-MANS Mar ’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 32 D5-MANS Mar ’19 Trouble Shooting Guide (cont’d) Condition: Cause: Suggested Correction: F. Oil Consumption is Too Oil level is too high. Reduce the oil level to the proper level. High. Oil Return Line (Scavenge Line) is blocked. Clean and/or replace the Scavenge Line Sight Glass.
Page 33: Warranty
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 34 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 35 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 37 DESCRIPTION OF DRAWING IMPORTANT NOTE: This print is the confidential property of DRIVE COMPONENTS D5 SCREW COMPRESSOR GARDNER DENVER, INC. It is not to be used or reproduced in any manner, nor submitted to other parties for examination DRAWING NO.
Page 38 DESCRIPTION OF DRAWING IMPORTANT NOTE: This print is the confidential property of SYSTEM COMPONENTS D5 SCREW COMPRESSOR GARDNER DENVER, INC. It is not to be used or reproduced in any manner, nor submitted to other parties for examination DRAWING NO.
Page 39 P & ID DIAGRAM not to be used or reproduced in any manner, nor submitted to other parties for examination D5 SCREW COMPRESSOR without the prior approval of GARDNER DENVER, INC. GARDNER DENVER, INC. is continuously trying to improve its products, specifications subject to change without notice.
Page 40 ELECTRICAL SCHEMATICS IMPORTANT NOTE: This print is the confidential property of GARDNER DENVER, INC. It is not to be used D5 SCREW COMPRESSOR WITH MICROPROCESSOR or reproduced in any manner, nor submitted to other parties. GARDNER DENVER, INC. is continously trying to improve its products, specifications subject to change without notice.

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