Related Manuals for Champion CL7-11D
Summarization of Contents
Maintain Compressor Reliability and Performance with Genuine Champion Parts
Contact Champion for Distributor and Support Information
Find contact information for Champion distributors and support services.
Instructions for Ordering Repair Parts
Guidance on how to specify and order replacement parts for compressors.
Warning, Prohibition, and Mandatory Label Information
Boxed Text Formats for User Alerts
Explains text formatting used to alert users of specific conditions.
Safety Label Usage and Meaning
Describes the use and meaning of safety labels on the compressor.
General Warning and Caution Statements
Prohibition and Mandatory Action Requirements
Lists mandatory actions and prohibitions for safe operation.
Comprehensive Safety Precautions
Danger Alerts and Necessary Actions
Details critical dangers and necessary precautions for personnel safety.
Warning Alerts and Equipment Protection Actions
Outlines warnings and actions to prevent equipment damage.
Section 1 General Information
Compressor Overview and Function
Describes the rotary screw compressor and its basic components.
Compression Principle Explained
Details the mechanics of the compression cycle using meshing rotors.
Airflow and Oil System Description
Explains air flow through the system and the role of lubrication.
Section 2 Installation Guidelines
General Installation and Initial Inspection
Initial checks and general guidelines upon unit receipt.
Lifting and Transporting the Unit Safely
Proper methods for lifting and moving the compressor package.
Location Requirements for Air-Cooled Units
Guidelines for selecting an appropriate installation location.
Foundation and Drainage Requirements
Foundation Mounting Guidelines
Specifies requirements for mounting the compressor on a stable surface.
Oil Sump and Cooler Drainage Procedures
Instructions for draining the oil sump and oil cooler.
Enclosure and Cold Weather Installation
Enclosure Panel Access and Safety Precautions
Details access to panels and safety precautions regarding the enclosure.
Considerations for Cold Weather Installation
Methods for installing the compressor in cold weather conditions.
Installation for Cold Weather Operation
Auxiliary Air Receiver and Optional Components
Information on auxiliary receivers and optional moisture separators.
Piping and Control System Connections
Guidelines for discharge service lines and control piping.
Electrical Wiring Standards and Safety
Electrical Wiring Standards and Procedures
Instructions for performing electrical wiring according to codes.
Electrical Wire Sizing Data
Chart providing data for sizing electrical power wires for the package.
Grounding and Motor Lubrication
Grounding Requirements and Associated Safety
Details grounding procedures and associated safety hazards.
Motor Lubrication Specifications
Information on motor bearing lubrication during its operational life.
Section 3 Starting & Operating Procedures
Pre-Start Up Checklist Items
Essential checks before initial unit operation.
Compressor Oil Level Check Procedure
Procedure for checking and maintaining the compressor oil level.
Air Filter and Piping Inspection
Inspecting air filters and ensuring proper piping connections.
Electrical and Grounding Checks
Verifying electrical connections and grounding for safe operation.
Belt System and Motor Rotation Checks
V-Belt System Setup and Alignment
Instructions for setting up and aligning the V-belt system.
Verifying Correct Motor Rotation Direction
Procedure to ensure the motor rotates in the correct direction.
GD Pilot Controller Operation and Settings
Controller Hardware Layout and Functions
Overview of the GD Pilot controller's physical layout and button functions.
Setting Pressure Parameters (Cut-out/Cut-in)
How to adjust cut-out and cut-in pressure settings on the controller.
Selecting Operating Modes
Guidance on selecting the appropriate operating mode for the compressor.
Enclosure Checks and Operational Safety Warnings
Enclosure Panel Integrity Check
Inspecting enclosure panels and latches for tightness and damage.
Automatic Restart and Emergency Stop Safety
Safety procedures related to automatic restarts and emergency stops.
Unit Starting, Stopping, and Daily Checks
Starting the Compressor Unit Safely
Step-by-step guide for starting the compressor unit safely.
Properly Stopping the Compressor Unit
Procedure for properly shutting down the compressor.
Routine Daily Operational Checks
Routine checks to perform daily for optimal performance.
Section 4 Controls & Instrumentation Overview
General System Description
Overview of the compressor package's main components and wiring.
GD Pilot Controller Details and Functions
In-depth look at the GD Pilot controller's hardware and functions.
Emergency Stop and Control Transformer
Information on the emergency stop button and control power supply.
Electrical System Components and Conversion
Terminal Strip and Main Starter Overview
Description of terminal strips and main starter functions for motors.
Field Conversion of Electrical Systems
Guidance on converting the compressor's electrical system configuration.
Section 9 Miscellaneous Control Devices
Intake Air Filter and Inlet Valve Assembly
Details on the air intake filter and the inlet valve assembly.
Electric Motor and Oil System Components
Description of the electric motor, oil sump, and related parts.
Pressure Relief and Discharge Valves
Information on pressure relief and minimum discharge pressure valves.
Solenoid Valves, Sensors, and System Components
Solenoid Valve and Pressure/Temperature Sensors
Details on solenoid valves and various pressure/temperature sensors.
Receiver, Dryer, and Drain Systems
Information on receivers, dryers, and condensate drainage systems.
Section 5 Lubrication System Details
Compressor Oil System Overview
Explanation of how lubricating oil is circulated and used in the compressor.
Recommended Lubricants and Specifications
Details on approved lubricants and their specifications for Champion compressors.
Oil Level Indicator (Gauge) Usage
How to check and maintain the correct oil level using the sight glass.
Hazards Associated with Lubricant Handling
Safety for Draining, Adding, or Changing Oil
Critical safety warnings and procedures before handling compressor lubricant.
Lubricant Change Procedure
Lubricant Compatibility and Change Steps
Steps for changing compressor lubricant, including compatibility notes.
Cold Ambient Operation Considerations
Considerations for operating the compressor in cold environments.
Oil Addition and Change Interval Guidelines
Adding Oil Between Scheduled Changes
Procedure for adding oil when the level is low between changes.
Oil Change Interval Recommendations
Recommended intervals for changing compressor lubricant based on temperature.
Draining and Refilling the Oil System
Complete Oil System Drainage Procedure
Step-by-step guide for completely draining and refilling the oil system.
Oil System Moisture and Thermostatic Valve
Moisture in Oil System and Prevention Methods
Identifying and preventing moisture issues in the oil system.
Thermostatic Mixing Valve Function
Description of the thermostatic mixing valve's role in oil temperature regulation.
Oil Sump (Reservoir) Description
Details on the oil sump's function in separation and storage.
Air/Oil Separator and Maintenance Procedures
Air/Oil Separator Function and Conditions
Explains the final air/oil separation stage and factors affecting its performance.
Separator Pressure Differential Monitoring
How to use pressure differential to assess separator element condition.
Oil Filter and Separator Inspection Procedure
Steps for inspecting and replacing oil filter and air/oil separator elements.
Section 6 Heat Exchangers (Oil/Air)
Oil/Air Heat Exchanger Operation
Explains the function of heat exchangers in cooling oil and air.
Ventilation Configuration and Requirements
Details on the ventilation system and airflow requirements for cooling.
Heat Exchanger Maintenance Procedures
How to clean and maintain the air-cooled heat exchanger cores.
Heat Exchanger Cleaning and Safety
Heat Exchanger Cleaning Safety Precautions
Critical safety steps before inspecting or cleaning heat exchangers.
Heat Exchanger Core Cleaning Method
Procedure for cleaning the aluminum heat exchanger cores using compressed air.
Section 7 Air Filters
Compressor Air Filter Description
Details on the single-stage, high-efficiency air filter element.
Air Filter Element Inspection and Replacement
Steps for inspecting and replacing the air filter element.
Package Pre-Filter Maintenance
Pre-Filter Cleaning Procedure
How to clean the pre-filter media to remove trapped debris.
Section 8 Belt Drive System
Belt Drive System Components
Overview of belts, sheaves, and bushings in the drive system.
Unpacking and Setting Up the V-Belt System
Steps for unpacking and preparing the V-belt system for operation.
Sheave Set Alignment Procedures
Methods for aligning sheaves to ensure proper belt longevity.
Replacing Compressor Belts and Sheaves
Procedure for Replacing Compressor V-Belts
Procedure for replacing worn or damaged V-belts.
Replacing Sheaves and Bushings
Steps for removing and installing compressor sheaves and bushings.
Section 9 Servicing of Miscellaneous Devices
Inlet Control Valve Assembly Overview
Description of the inlet control valve assembly and its operation.
Inlet Valve (Body) Inspection and Servicing
Inspecting the Inlet Valve Body and Seals
Procedure for inspecting the inlet valve body, seals, and piston assembly.
Pressure Relief Valve Maintenance
Pressure Relief Valve Function and Safety
Explains the pressure relief valve's purpose and critical safety warnings.
Pressure Relief Valve Operational Check
Annual procedure for testing the proper operation of the relief valve.
Minimum Pressure Valve (MPV) Inspection and Adjustment
MPV Inspection and Replacement Procedure
How to inspect, replace, and adjust the minimum pressure valve.
Thermostatic Mixing Valve and Shaft Seals
Thermostatic Mixing Valve Inspection
Procedure for inspecting the thermostatic mixing valve for proper function.
Input Shaft Seal Maintenance
Guidance on handling oil leaks from input shaft seals.
Electrical Box Cooling System Maintenance (Variable Speed)
Cooling System Inspection and Cleaning
Steps for inspecting and cleaning external filters, fans, and heatsinks.
VFD Cooling Fan Removal and Replacement
VFD Fan Removal and Replacement Procedure
Step-by-step guide for removing and replacing VFD cooling fans.
Section 10 Tank Mounted Compressor - Total System
Total System Description and Components
Overview of the total system including receiver and dryer options.
Dryer Installation and Operation Notes
Key considerations for installing and operating optional dryers.
System Piping and Electrical Connections
Guidelines for discharge piping and electrical power connections.
Section 11 Maintenance Schedule
Air Filter and Motor Lubrication Tasks
Maintenance tasks for air filters and motor lubrication.
Scheduled Maintenance by Operating Hours
Maintenance intervals based on 8, 125, 2000, and 4000 hours of operation.
Annual Maintenance Checks
Annual inspections for pressure relief valves and oil separators.
Maintenance Schedule Summary Table
Air Filter and Inlet Filter Maintenance Schedule
Schedule for checking and changing air and inlet filters.
Oil Separator and Oil Level Check Schedule
Maintenance schedule for oil separators and reservoir oil levels.
Load/Unload, Cooler, and Oil Filter Tasks Schedule
Schedule for checking load/unload, cooler dirt, and changing oil filters.
Lubricant Change and Relief Valve Check Schedule
Schedule for changing compressor lubricant and checking relief valves.
Section 12 Troubleshooting Guide
Compressor Fails to Start Issues
Possible causes and remedies for the compressor not starting.
Compressor Stops Shortly After Starting
Troubleshooting steps for compressors that stop after a short runtime.
Compressor Load/Unload Problems
Diagnosing issues with the compressor not unloading or cycling excessively.
Slow Compressor Start-Up Issues
Causes and solutions for slow compressor start-up.
Troubleshooting Pressure and Temperature Issues
Compressor Not Reaching Load Pressure
Identifying and resolving issues preventing the compressor from reaching load pressure.
High Discharge Air Temperature Causes
Troubleshooting high discharge air temperatures and related causes.
Excessive Oil Consumption Diagnosis
Identifying causes and solutions for excessive oil consumption.
Troubleshooting Oil Carryover and Water Issues
Oil Carryover Causes and Remedies
Addressing oil carryover issues, including overfilling and temperature problems.
Water in Air Delivery Line Issues
Troubleshooting excessive water in the compressed air delivery line.
Troubleshooting Voltage Problems
Operating Voltage Ranges
Lists the standard voltage ranges for compressor operation.
Effects of High and Low Voltages
Explains how voltage variations impact motor current and compressor performance.
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