Champion L Series User & Service Manual
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Champion L Series User & Service Manual

Frame 1 single stage base-mounted & tank-mounted compressor
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L-SERIES FRAME 1
SINGLE STAGE
BASE-MOUNTED &
TANK-MOUNTED
COMPRESSOR
Original User &
Service Manual
MODELS:
CL7-11D
10 & 15 HP
CLRS7-11D
7 & 11 kW
13-25-628
Version 04
Revision EB
July 2022

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  • Page 1 L-SERIES FRAME 1 SINGLE STAGE BASE-MOUNTED & TANK-MOUNTED COMPRESSOR Original User & Service Manual MODELS: CL7-11D 10 & 15 HP CLRS7-11D 7 & 11 kW 13-25-628 Version 04 Revision EB July 2022...
  • Page 2 Compressor genuine parts, manufactured to design tolerances, are developed for optimum dependability, specifically for Champion compressor systems. Design and material innovations are the result of years of experience with hundreds of different compressor applications. Reliability in materials and quality assurance is incorporated in our genuine replacement parts.
  • Page 3 WARNING – PROHIBITION – MANDATORY LABEL INFORMATION Champion Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment.
  • Page 4 Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or serious injury. Asphyxiation Hazard, Poisonous Fumes or Toxic Gases in Compressed Air Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or moderate injury.

  • Page 5: Safety Precautions

    SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices will result in injury to or death of personnel.
  • Page 6 TABLE OF CONTENTS Maintain Compressor Reliability and Perfomance with Genuine Champion Compressor Parts and Support ............................. Services ....................Instructions for Ordering Repair Parts Warning - Prohibition – Mandatory Label Information ........................................Safety Precautions ......................Section 1, General Information ........................

  • Page 7: Section 1 General Information

    SECTION 1 GENERAL INFORMATION Figure 1-1 COMPRESSOR CYCLE COMPRESSOR - The rotary screw compressor is a single stage, positive displacement rotary machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity anti- friction bearings located outside the compression chamber. Roller bearings are used at the inlet end of the rotors to carry part of the radial loads.
  • Page 8 Figure 1-2 COMPRESSOR ILLUSTRATION, EXTERNAL DETAILS 302ECA797-00 (Ref. Drawing) (CL7-11 Model shown with controller set for “front” display) Page 1 of 2 13-25-628 v04 Rev EB Page 8...
  • Page 9 Figure 1-3 COMPRESSOR ILLUSTRATION, INTERNAL DETAILS (CL7-11 Model shown with controller set for “top” display) 13-25-628 v04 Rev EB Page 9...
  • Page 10 314ECB804-A (Ref. Drawing) Figure 1-4 COMPRESSOR ILLUSTRATION, TOTAL SYSTEM (CL7-11 Base Model with 120 gallon receiver and XCNC dryer shown) 13-25-628 v04 Rev EB Page 10...

  • Page 11: Section 2 Installation

    SECTION 2 INSTALLATION GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit. Report any damage or missing parts as soon as possible. Do not electric weld on the compressor or base; bearings can be damaged by passing of current.
  • Page 12 For continuous efficiency, the cooler cores must be periodically cleaned with either vacuum or compressed air. If wet cleaning is required, shield motor and spray on a mild soap solution and flush with clean water. NOTICE Coolers are aluminum; do not use any cleaning solution that is not compatible with aluminum.
  • Page 13 ENCLOSURE - The compressor, electric motor, oil cooler and after cooler are mounted inside the enclosure. Service panels are provided for maintenance access. Be sure to allow enough space around the unit for the panels to be removed. Any of the enclosure panels may be removed by opening the latch and lifting it up slightly.
  • Page 14 When the unit must be installed in an outdoors installation and/or exposed to ambient temperatures below freezing (32°F, 0°C), contact Champion for recommendations. When using a Total System with a compressed air dryer option, refer to Section 10 for details.
  • Page 15 Discharge air used for breathing will cause severe injury or death. Consult filtration specialists for additional filtration and treatment equipment to meet health and safety standards. ELECTRICAL WIRING - Standard Units – The stand alone compressor package is factory wired for all connections from the starter to the motor, for the horsepower and voltage specified on the order.
  • Page 16 GROUNDING - Equipment must be grounded in accordance with Section 250 of the National Electrical Code. Failure to properly ground the compressor package could result in injury or death. Install ground wiring in accordance with the National Electrical Code and any applicable local codes.

  • Page 17: Section 3 Starting & Operating Procedures

    Regular maintenance and replacement at required intervals of the oil filter, air filter and air/oil separator is necessary to achieve maximum service and extended drain intervals of Champion genuine RotorLub lubricants. Use only genuine Champion filters designed and specified for this compressor.
  • Page 18 Failure to properly ground the compressor package could result in controller malfunction. V-Belt System - Refer to Section 8 for detailed instruction to unpack and check the alignment of the belt system. The motor jacking hardware must be re-configured, the main motor carrier bracket removed, and belts engaged and the belt sheaves alignment checked prior to compressor operation.
  • Page 19 10. For your convenience, the following excerpt from the Controller manual is presented to assist in programming the basic operating parameters. However, we strongly recommend you read the Controller manual before attempting operating the compressor package. Figure 3-1 GD Pilot Controller Layout and Main Screen ...
  • Page 20 Operation at excessive discharge air pressure can cause personal injury or damage to equipment. Do not adjust the operating discharge air pressure above the maximum stamped on the unit nameplate. 11. Enclosure - Check for damaged panels or doors. Check all screws and latches for tightness. Be sure doors are closed and latched.

  • Page 21: Stopping The Unit

    STARTING THE UNIT - Observe the following starting procedures: Unit Cold or Hot: 1. When using a Total System with a compressed air dryer option, refer to Section 10 for operating details. 2. Open the air service valve (customer furnished) between the main air system and the check valve on the package.

  • Page 22: Section 4 Controls & Instrumentation

    CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION The Champion rotary screw compressor is pre-wired with all controls, motor, and starter for the voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply and to the shop airline.
  • Page 23 Section 3. FIELD CONVERSION OF MULTI-VOLTAGE ELECTRICAL SYSTEM - To convert the compressor package from its as-built voltage configuration to one of its optional ones, contact Champion and request “Instructions, Tri-Voltage Conversion”, document TED000579. 13-25-628 v04 Rev EB...
  • Page 24 303ECB546-C (Ref. Drawing) FIGURE 4-2 WIRING DIAGRAM, FIXED SPEED, 380V, 50/60Hz Page 1 of 3 13-25-628 v04 Rev EB Page 24...
  • Page 25 303ECB546-C FIGURE 4-3 WIRING DIAGRAM, FIXED SPEED, 380V, 50/60Hz (Ref. Drawing) Page 2 of 3 13-25-628 v04 Rev EB Page 25...
  • Page 26 303ECB546-C (Ref. Drawing) FIGURE 4-4 WIRING DIAGRAM, FIXED SPEED, 380V, 50/60Hz Page 3 of 3 13-25-628 v04 Rev EB Page 26...
  • Page 27 305ECB546-B (Ref. Drawing) FIGURE 4-5 WIRING DIAGRAM, FIXED SPEED, 575V, 60Hz Page 1 of 3 13-25-628 v04 Rev EB Page 27...
  • Page 28 305ECB546-B (Ref. Drawing) FIGURE 4-6 WIRING DIAGRAM, FIXED SPEED, 575V, 60Hz Page 2 of 3 13-25-628 v04 Rev EB Page 28...
  • Page 29 305ECB546-B (Ref. Drawing) FIGURE 4-7 WIRING DIAGRAM, FIXED SPEED, 575V, 60Hz Page 3 of 3 13-25-628 v04 Rev EB Page 29...
  • Page 30 307ECB546-C (Ref. Drawing) Page 1 of 3 FIGURE 4-8 WIRING DIAGRAM, FIXED SPEED, 208V-230V/460V, 60Hz 13-25-628 v04 Rev EB Page 30...
  • Page 31 307ECB546-C (Ref. Drawing) Page 2 of 3 FIGURE 4-9 WIRING DIAGRAM, FIXED SPEED, 208V-230V/460V, 60Hz 13-25-628 v04 Rev EB Page 31...
  • Page 32 307ECB546-C (Ref. Drawing) Page 3 of 3 FIGURE 4-10 WIRING DIAGRAM, FIXED SPEED, 208V-230V/460V, 60Hz 13-25-628 v04 Rev EB Page 32...
  • Page 33 300EJB546-F (Ref. Drawing) Page 1 of 4 Figure 4-11 WIRING DIAGRAM, VARIABLE SPEED, 230V, 60Hz 13-25-628 v04 Rev EB Page 33...
  • Page 34 300EJB546-F (Ref. Drawing) Figure 4-12 WIRING DIAGRAM, VARIABLE SPEED, 230V, 60Hz Page 2 of 4 13-25-628 v04 Rev EB Page 34...
  • Page 35 300EJB546-F Figure 4-13 WIRING DIAGRAM, VARIABLE SPEED, 230V, 60Hz (Ref. Drawing) Page 3 of 4 13-25-628 v04 Rev EB Page 35...
  • Page 36 300EJB546-F (Ref. Drawing) Figure 4-14 WIRING DIAGRAM, VARIABLE SPEED, 230V, 60Hz Page 4 of 4 13-25-628 v04 Rev EB Page 36...
  • Page 37 301EJB546-F (Ref. Drawing) Page 1 of 4 Figure 4-15 WIRING DIAGRAM, VARIABLE SPEED, 380V/460V, 60Hz 13-25-628 v04 Rev EB Page 37...
  • Page 38 301EJB546-F (Ref. Drawing) Page 2 of 4 Figure 4-16 WIRING DIAGRAM, VARIABLE SPEED, 380V/460V, 60Hz 13-25-628 v04 Rev EB Page 38...
  • Page 39 Figure 4-17 WIRING DIAGRAM, VARIABLE SPEED, 380V/460V, 60Hz 301EJB546-F (Ref. Drawing) Page 3 of 4 13-25-628 v04 Rev EB Page 39...
  • Page 40 301EJB546-F (Ref. Drawing) Page 4 of 4 Figure 4-18 WIRING DIAGRAM, VARIABLE SPEED, 380V/460V, 60Hz 13-25-628 v04 Rev EB Page 40...
  • Page 41 302EJB546-D (Ref. Drawing) Page 1 of 4 Figure 4-19 WIRING DIAGRAM, VARIABLE SPEED, 575V, 60Hz 13-25-628 v04 Rev EB Page 41...
  • Page 42 302EJB546-D (Ref. Drawing) Figure 4-20 WIRING DIAGRAM, VARIABLE SPEED, 575V, 60Hz Page 2 of 4 13-25-628 v04 Rev EB Page 42...
  • Page 43 302EJB546-D (Ref. Drawing) Page 3 of 4 Figure 4-21 WIRING DIAGRAM, VARIABLE SPEED, 575V, 60Hz 13-25-628 v04 Rev EB Page 43...
  • Page 44 302EJB546-D (Ref. Drawing) Figure 4-22 WIRING DIAGRAM, VARIABLE SPEED, 575V, 60Hz Page 4 of 4 13-25-628 v04 Rev EB Page 44...
  • Page 45 MISCELLANEOUS CONTROL DEVICES - Refer to Figure 4-23 for the schematic diagram of the control system. Intake [Air] Filter (1) - Captures solid impurities in the air stream entering compressor inlet. It also attenuates noise emitted by the compressor inlet. Inlet-Valve Assembly (2) - This device controls the intake of atmospheric air entering the compressor during the Load/Unload phases of operation.
  • Page 46 Solenoid Valve (Y1) - This 2-way valve controls the position of the inlet valve in response to signals from the GD Pilot Controller. Pressure Sensor - Sump Dry Side (B1) - This device is connected after the minimum pressure valve. It converts the pressure in the plant air system into an electrical signal for use by the GD Pilot controller for monitoring and control load/unload operation.
  • Page 47 300ECB797-00 (Ref. Drawing) Figure 4-23 PIPING AND INSTRUMENTATION ILLUSTRATION 13-25-628 v04 Rev EB Page 47...

  • Page 48: Section 5 Lubrication Oil Cooler, Oil Filter & Separator

    The tempered oil is cleansed via the oil filter before injection into the compressor casing. RECOMMENDED LUBRICANT - Champion compressors is factory filled with one of several Champion RotorLub lubricants. These lubricants are formulated to the highest quality standards and are factory authorized, tested and approved for use in rotary screw compressors.
  • Page 49 Improper equipment maintenance with use of synthetic lubricants will damage equipment. Oil filter and oil separator change intervals remain the same as for Champion genuine RotorLub lubricants, See “Maintenance Schedule”. High temperature operation can cause damage to equipment or personal injury. Do not repeatedly restart the unit after high temperature stops operation.
  • Page 50 All materials used in Champion compressor units are compatible with RotorLub 8000 Lubricant. Use caution when selecting downstream components such as air line lubricating bowls, gaskets and valve trim. RotorLub 8000 Synthetic Lubricant is not compatible with low nitrile Buna N or acrylic paints.
  • Page 51 Operating conditions and the appearance of the drained oil must be surveyed and the oil change intervals planned accordingly by the user. Champion offers a free oil analysis program with the RotorLub lubricants, and we recommend a sample be sent in at 100 hours on a new unit.
  • Page 52 DRAINING AND REFILLING THE OIL SYSTEM - Always drain the complete system. Draining when the oil is hot will help to prevent varnish deposits and carry away impurities, see Figure 1-3 for hardware details. 1. Be sure the unit is completely off and that no air pressure is in the oil reservoir. 2.
  • Page 53 (185ºF, 85ºC) thermostatic element. Consult Champion for details. OIL SUMP (RESERVOIR) - This device provides the inertial separation of air and oil streams discharged by the compressor, the bulk (98%) of the air/oil separation is done at this step.
  • Page 54 AIR / OIL SEPARATOR - This device provides the final (2%) of the air/oil separation, typically 2ppm oil content at the final discharge of the compressor package. It is housed in a removable spin-on cartridge. Its high level of performance may be affected by the following conditions: ...
  • Page 55 Figure 5-3 Dew Point Chart ׄ ° F Figure 5-4 Dew Point Chart °C 13-25-628 v04 Rev EB Page 55...

  • Page 56: Section 6 Heat Exchangers (Oil/Air)

    HEAT EXCHANGER MAINTENANCE - All the required hardware, mechanical and electrical connections have been made at the Champion factory, thus the only regular maintenance required is to keep the exterior core fins free from dirt and other airborne debris per the following procedure:...
  • Page 57 Compressor, air/oil sump and all piping and tubing may be at high temperature during and after operation. Do not attempt inspection or cleaning of air-cooled heat exchangers until cooling fan has stopped rotating. Disconnect lockout and tag out package from power supply. Air-cooled heat exchanger cores are fabricated from aluminum.
  • Page 58 The ventilation system for the air-cooled package relies on positive back pressure to cool the heat exchanger. Make sure that the enclosure panels that surround the heat exchanger area are closed during compressor operation, or the compressor discharge temperature will reach shutdown levels quickly. FIGURE 6-2 Cooler Access 13-25-628 v04 Rev EB Page 58...

  • Page 59: Section 7 Air Filters

    In turn, the longevity of the filter element depends on the cleanliness of the local environment. NOTICE Use only genuine Champion air filter elements on Champion compressor units. Genuine parts are available through your authorized Champion distributor. Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use solvents other than water.
  • Page 60 PACKAGE PRE-FILTER MAINTENANCE 1. Remove the central screw and washer securing the pre-filter to the grill assembly and remove the pre-filter media (17). See Figure 7-2 for component details. Note: do not remove the fan grill. 2. Cleanse the pre-filter media with compressed air or with water to remove debris trapped in its fibers.

  • Page 61: Section 8 Belt Drive System

    SECTION 8 BELT DRIVE SYSTEM The motor power is transmitted to the compressor with a system comprised of heavy-duty v-belts, sheaves, and bushings. Belt tension is provided by the motor weight with the help of a free-pivoting bracket, see Figure 8-1 for details. Figure 8-1 Motor Jacking Assembly Figure 8-2 V-Belt Drive Components 13-25-628 v04 Rev EB...
  • Page 62 UNPACKING THE V-BELT SYSTEM To protect the belts from shock and strain during transportation, the free-swinging side of the motor frame is locked in place by means of a carrier bracket assembly. Proceed to prepare the belt system for operation as follows, refer to Figure 8-2 for component description: 1.
  • Page 63 (after loosening the jam nut) and raising the motor body until the v-belts can be dismounted from the motor sheave. Replace the old belts with new ones. For proper belt life, use only genuine Champion belts. Check the sheave alignment.

  • Page 64: Section 9 Servicing Of Miscellaneous Devices

    SECTION 9 SERVICING OF MISCELLANEOUS DEVICES This section will cover basic maintenance of various control devices used with the compressor package. Refer to Fig 9-1 for pictorial with general locations of these devices. INLET CONTROL VALVE ASSEMBLY Inlet-Valve Assembly - This device is located within and below the intake flange of the compressor - see Figure 9-1 for internal details and Figure 4-23 for schematic details.
  • Page 65 Inlet Valve (Body) Inspection - The valve does not require maintenance or lubrication. If air/oil leaks develop across the valve disc during pressurized conditions (e.g., machine stopped), valve seals should be inspected for wear and tear signs: 1. Be sure the unit is completely off and oil sump is depressurized. 2.
  • Page 66 Figure 9-3 Exploded View of EK76 Compressor 13-25-628 v04 Rev EB Page 66...

  • Page 67: Pressure Relief Valve

    PRESSURE RELIEF VALVE Pressure Relief Valve - This device protects the pressure-containing components of the compressor package against pressures exceeding 218 psig. It is installed on the wet-side of the oil sump. Figure 9-4 Pressure Relief Valve Before inspecting the pressure relief valve, release air pressure, lockout and tagout the power supply to the compressor package.

  • Page 68: Minimum Pressure Valve

    MINIMUM PRESSURE VALVE Minimum Pressure Valve (MPV) Inspection – This device has no user-serviceable or repairable components. If it fails to maintain adequate minimum pressure (70 psig) or fails to check the backflow of system compressed air after compressor stoppage, replace it as follows: Figure 9-5 Minimum Pressure Valve and Seat Air/oil pressure will cause severe personal injury or death.

  • Page 69: Thermostatic Mixing Valve

    INPUT SHAFT SEAL ASSEMBLY Input Shaft Seal Maintenance – This device has no user-serviceable or repairable components. If oil leaks past its seal and unto the external portion of the shaft, contact Champion to have it inspected and/or repaired by a trained mechanic.
  • Page 70 4. Remove dust and debris from fan with a vacuum cleaner or replace if not operational. Contact Champion for a replacement cooling fan assembly. 5. Shake off debris and gently wash foam filter medial under tap water and dry off completely.
  • Page 71 VFD Cooling Fan Removal and Replacement 1. Make sure that steps 1 and 2 of “Cooling System Inspection” have been completed. 2. Depress the right and left sides of the fan cover tabs and pull upward. Remove the fan cover from the top of the drive per Figure 9.8, one (1) fan assembly shown, but the same procedure applies to two (2) fan assembly.

  • Page 72: Section 10 Tank Mounted Compressor - Total System

     Installation - Package must installed in a location with an ambient temperature range of 40ºF to 110ºF (3ºC to 43ºC). Consult Champion for operation outside this range.  Discharge service pipe - The discharge service line connection is provided at the outlet of the bypass valve assembly.

  • Page 73: Section 11 Maintenance Schedule

    SECTION 11 MAINTENANCE SCHEDULE SERVICE CHECK LIST Air Filter and Pre-Filter - Operating conditions determine frequency of service. See “Air Filter,” Section 7. Motor Lubrication - Refer to Section 2. Every 8 Hours Operation Check the reservoir oil level, add oil if required. See Section 5.. Observe if the unit loads and unloads properly.
  • Page 74 MAINTENANCE SCHEDULE (See Detail Notes above) Every Every Every Every Every As Indicated Every Maintenance Action 2000 4000 by Controller Year Hours Hours Hours Hours Hours        Check/Change Air Filter     ...

  • Page 75: Section 12 Troubleshooting

    SECTION 12 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Check main disconnect, fuses and No electrical power. supply line. Motor starter overload Reset and investigate cause of relay tripped. overload. Pressure in reservoir. Inspect unload valve. Compressor fails to start Wrong lead connections Change leads.
  • Page 76 SYMPTOM POSSIBLE CAUSE REMEDY Restricted air filter. Clean or replace filter. Partially open inlet valve. Inspect, clean or replace inlet valve. Minimum pressure valve Replace valve. stuck closed. Oil separator clogged. Replace. Condensate drain Inspect and replace. solenoid valve is faulty. Leaks in the compressed Check for leaks, fix any leaks Compressor does not...
  • Page 77 Inspect and cleanse. Ruptured oil separator Replace element. element. Tighten all fittings and Loose assembly. gaskets. Foaming caused by use of Use Champion lubricating incorrect oil. coolant. Inoperative minimum Inspect and/or replace. Oil carryover pressure valve. Reduce temperature. See “High Discharge Air Operation at elevated Temperature”, this...
  • Page 78 TROUBLESHOOTING VOLTAGE PROBLEMS The compressor package has been designed, built, and tested to operate within one of the following standard ranges: 200-208 Volts, 60 Hertz (Fixed Speed models only) 230-240 Volts, 60 Hertz 380-400 Volts, 60 Hertz 460-480 Volts, 60 Hertz 575-600 Volts, 60 Hertz Connection to higher voltages will reduce the life of electrical devices within the compressor package.
  • Page 79 13-25-628 v04 Rev EB Page 79...
  • Page 80  For additional information, contact your local representative or visit: www.championpneumatic.com ©2022 Gardner Denver, Inc. Printed in U.S.A.

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