Champion D10 Installation And Start-Up Data Download | Manualshive

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D10.D15.DRS15-MANS

Apr ‘19

- 1 -

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

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.

Contents:

Page:

Quick Start …………….............................................

2

Safety Precautions …………………………………….

4

Unpacking and Inspection …………………………....

5

Installation – Mechanical ……………………………..

6

Lubrication ……………………………………………..

8

Installation – Electrical ………………………………..

9

Motor Maintenance Instructions ………………….......

11

Start-up Procedures …………………………………..

12

Preventative Maintenance Schedule ………………..

13

Maintenance Procedures ……...……...……...…….....

15

‘CSC300’ Controller ……...……...……...……..............  21
Common Compressor Faults  ………………..………..  30
Variable Speed Drive ……...……...……...…………….  31
Separator Filter & Refrigerated Air Dryer   ……………   37
Trouble-Shooting Guide  ………………………………..  40
Warranty  …………………………………………………  43

D10 (TD)
D15 (TD)

DRS 15 (TD)

Rotary Screw

Air Compressor

Units

- - -

Installation

And

Start-up Data

1
2
3
...
»

Summary of Contents for D10

Page 1: ...killed in compressor maintenance and repair They are ready to respond and assist you by providing fast expert maintenance and repair services Contents Page Quick Start 2 Safety Precautions 4 Unpacking and Inspection 5 Installation Mechanical 6 Lubrication 8 Installation Electrical 9 Motor Maintenance Instructions 11 Start up Procedures 12 Preventative Maintenance Schedule 13 Maintenance Procedures...

Page 2: ... F Ensure that the floor under the Unit is smooth level and capable of bearing the weight of the Compressor If installed in a compressor room ensure that the room is adequately ventilated The unit must be anchored to the floor using isolator pads Fusible Disconnect Refer to Page 9 for proper sizing Note Dimensions indicated are typical for all D10 D15 and DRS 15 Units ie base mounted and tank moun...

Page 3: ... 2 Do not stop the Unit by use of a disconnect or breaker Emergency Stop Will quickly shut the Unit off Is only to be used in an emergency Stop Causes the Unit to enter Idle mode and then shut off Using the Emergency Stop Button disconnect or breaker to stop the Unit will not allow the Unit to go through an unloading sequence and could result in damage to the Motor Starter or other electrical comp...

Page 4: ... stops Shut off all power to the Unit before automatically serious injury may attempting to repair or maintain result from working on the Compressor the Compressor with the power still in the on position As the Unit starts and stops Shut off all power to the Unit before automatically do not come into attempting to repair or maintain contact with moving parts the Compressor Air compressed by the Un...

Page 5: ...he product has been received contact the transport company immediately to file a claim Depending on the problem it may be wise to photograph the damage Also it may be wise to discuss with the carrier representative the time allotted to give notice of loss or damage to the product there may be guidelines which limit timeframes of same 4 Do not attempt further unpacking or operation of the product A...

Page 6: ...e Unit and ease of servicing Ensure that the floor under the Unit is smooth level and capable of bearing the weight of the Compressor The Compressor must sit squarely on the floor Ensure that the Unit is anchored to the floor using isolator pads If installed in a compressor room ensure that the room is adequately ventilated One Horsepower produces approximately 2500 BTU HR See Page 7 The ambient t...

Page 7: ...on 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 Intake and Exhaust Ducting ...

Page 8: ...lubricant available in both 1 US gallon 3 8 litre jugs or 5 US gallon 18 9 litre pails Any remaining oil may be used for top ups The MK D1015 CH Maintenance Kit includes 2 Oil Filter DSC 603 CH 1 Air Oil Separator Filter DSC 302 CH 2 Air Filters DSC 001931 CH 1 In Line Filter DSC 612 1 Oil Sample Kit 308KBA6003 Do not attempt to operate the Unit without first checking whether there is oil in the O...

Page 9: ...al electrical codes Electrical wiring and conduit from the building supply through the Compressor Cabinet and to the Switch in the Compressor Control Panel must be rated for 90 C 194 F or higher Failure to observe any of the above precautions could result in severe personal injury or death and or damage to the Unit Failure to correctly connect the Compressor to your building s electrical services ...

Page 10: ...vice centre It is critical that the Motor and Air End in the Rotary Screw Unit be turning in the correct manner Irreparable damage will be done if the Unit rotates in the opposite direction This unit is equipped with Advanced Phase Detection which prevents unit from rotating in the reverse direction If the following error is visible on the Screen and the Unit will not start simply switch power lea...

Page 11: ...of the bearings Noted below is a chart outlining the interval at which the Motor should be lubricated this is based on the Motor horsepower This must be part of a regular maintenance schedule Motor HP Interval Weight of Grease Volume of Grease in Hours Ounces Grams Cubic Inch Teaspoon 10 9 500 0 61 17 4 1 2 3 9 15 3 600 0 61 17 4 1 2 3 9 The above chart is based on a standard environment in which ...

Page 12: ...es and shut off 7 Open the Ball Valve slightly and allow the air to bleed from the Tank Once the pressure reaches approx 125 psi 8 6bar the Unit will start and begin to compress air after a short delay For VSD units this pressure is 135 psi 9 3bar 8 Measure the amp draw as the Unit reaches maximum pressure 9 Close the Ball Valve allow the Unit to reach maximum pressure idle and shut off Once off c...

Page 13: ... this the oil must be changed more often than noted below When servicing the Air Compressor shut off all power to the Unit and drain it of air pressure It is the responsibility of the Compressor owner to ensure that a regular Maintenance Schedule is followed Note Participation in Champion s oil analysis sampling program is required to receive the extended warranty Any recommendations detailed in t...

Page 14: ...il analysis report must be followed as outlined in the report 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 If other champion lubricant is used please refer to the Warr...

Page 15: ... bucket under the original Oil Filter to capture any spillage use the strap wrench to turn the Oil Filter counter clockwise The Oil may still contain oil so care must be taken 3 On the replacement DSC 603 CH Oil Filter lubricate the Filter Gasket with Compressor Oil 4 Hand tighten the Oil Filter snug Changing the Air Intake Filter 1 Loosen the Filter Clamp at the base of the Intake Filter 2 Remove...

Page 16: ...ush These items could damage the cooling coils Oil Changes Drain the existing oil by a turning the Oil Drain Tube downwards and b opening the Oil Drain Valve Please be advised that the Unit cannot be drained fully of oil as some oil may remain in various components ie Cooler Tubing etc Close the Drain Valve and turn the Drain Tube to face upwards Fill the Oil Reservoir to the center of the Sight G...

Page 17: ...r End vertically either towards or away from the Motor To adjust the Belt tension simply 1 loosen the 4 Slider Bolts holding the Air End in place 2 tighten turn clock wise the Adjusting Nut on the Top of the Belt Tensioner Screw 3 re torque the 4 Slider Bolts to 22 ft lbs 29 8 Nm Belt tensions for both new and older Belts are noted below Slider Bolts 2 of 4 Motor Pulley Air End Pulley Air End Adju...

Page 18: ...e Valve Reconnect the DIN Connector to the Solenoid and re attach the Intake Filter Please order 1 DSC 001950 Intake Valve Repair Kit Shown at right are the various components associated with the Intake Valve Repair Kit Changing the Scavenge Line In Line Filter 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 th...

Page 19: ...right are included in the DSC 111 1 Thermo Valve Repair Kit Spring Clip End Cap Spring Minimum Pressure Valve Repair Kit The Minimum Pressure Valve has two purposes when installed in the Rotary Screw Compressor Unit 1 It allows the Unit to build up pressure up to approx 65 psi 4 5bar before allowing the compressed air to flow through the cooler and 2 it acts as a one way or check Valve stopping ai...

Page 20: ...grease to hold the o ring in place Installing new Seal Housing with new Shaft Seal Place DSC 002953 installation shaft sleeve tool 6 on the shaft of the air end Push the seal housing 1 onto the rotor shaft and hold it against the shaft seal inner ring The oil seal 3 is pre installed onto the seal housing 1 at the factory Then push the seal housing 1 carefully into final position Install the housin...

Page 21: ...estricted parameters an Access Code is required Factory Level allows access to areas of the Controller that only factory personnel can access an Access Code is required Controller Operator Interface Up Scrolls up through the parameters or increases the value of a parameter Stop Causes the Unit to enter Idle mode and then shut off Down Scrolls down through the parameters or decreases the value of a...

Page 22: ...pressure above the Offload Pressure at which an alarm will be noted High Pressure Shutdown The pressure above the Offload Pressure at which an alarm will be noted and the Unit will shut off Idle Shutdown The amount of time the Unit will idle run but not compress air after it has reached the Unload Pressure before shutting off Routine Service Hours The maximum allowable time between regular mainten...

Page 23: ...s 1 to 21 Service hours 8 22 Weekly service 23 Annual service 24 Bi annual service Page P10 Equip settings 1 01 Control mode 02 Allow force offload 03 Start pressure 04 Load pressure 05 Off load pressure 10 RS485 1 CONFIG 11 RS485 2 CONFIG 12 Start source 13 Load source 14 Language 15 Time 16 Time format 17 Daylight saving 18 Date 19 Date format 20 LCD light level 21 Pressure unit 22 Temperature u...

Page 24: ...ty Shown if active 01 COMP1 priority to 08 COMP8 priority Page P21 Run schedule 01 Run schedule 02 Workday edit 03 Schedule entry to 30 Schedule entry Page P81 ISC settings Shown if active 01 ISC compressors 02 ISC start delay 03 ISC damping 04 ISC tolerance 05 ISC DI1 FCN 06 ISC DI2 FCN 07 ISC DI3 FCN 08 ISC XPM pressure 09 ISC PRESS SENS Page P14 Motor protection 01 Main MTR protect 02 Fan MTR p...

Page 25: ...ess Down key to highlight P09 04 Service 1 2 Press the Down key to navigate to P09 Access page 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 1 When navigation location is at P00 3 The screen shown below will appear 5 The screen shown below will appear 6 Press ...

Page 26: ...rrect Access Code you will have access to pages of the Controller reflecting that code 9 Using the Up and Down keys change the first digit of the Access Code to the appropriate number 10 Press Enter to move to the following digit Using the Up Down and Enter keys input the access code ...

Page 27: ...ller Once the appropriate page has been high lighted press Enter to access its menu content Use the Up and Down keys to navigate between menu content items Below indicates the user has navigated to P01 menu item 06 To adjust an editable parameter navigate to it and press the Enter key An edit menu popup window will appear Use the Up or Down key until the desired value is highlighted then press Ent...

Page 28: ...ults will become 01 and all others will be moved back one step This ensures that only the most recent faults appear Shown below is a typical Error Log Menu The Error Log is on Page 03 of the Controller and it does not require an access code Use Up or Down keys to view the recorded data at the time of the fault Press Enter to see the list of Errors Press Enter to see details of the selected error U...

Page 29: ... and L3 E 0090 Phase Sequence Note If the Motor is replaced Motor Rotation must be visually verified Advanced Motor Protection Current Sensors are used to provide Under Current Detection Rotor Lock Overload Phase Imbalance and Motor Overload protection to fixed speed compressors Combined CSC300 offers protection equivalent to Trip Class 10A for the main motor Current carrying cable through these C...

Page 30: ...Unit and the Unit will not operate until the Fault has been addressed Code Description Most Common Items to Check E 0010 Emergency Emergency stop switch is pressed E 0082 Motor Overload Motor drawing high amps low voltage high pressure settings low oil level E 0083 Motor phase Imbalance Check motor connections in the control panel and motor connection box E 0090 Phase Sequence Rotation of Motor wr...

Page 31: ...e variable speed technology match the varying air demands and therefore have the ability to impact your energy consumption some energy providers have offered rebates when these Units are purchased Consult your local energy provider to determine if this applies Shown below is a DRS 15 Unit with a Variable Speed Drive VSD Interface The VSD Controller Interface is shown at right It provides a means o...

Page 32: ...D10 D15 DRS15 MANS Apr 19 32 Variable Speed Drive cont d Operating Screen Typical Drive Status Indicators on Screen ...

Page 33: ...utton Right key 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 a confirmation of selection b Fault history reset Browse Button Up Browse the main menu and pages of sub menus Edit values Browse Button Down Browse the main menu and pages of sub menus Edit values Menu...

Page 34: ...D10 D15 DRS15 MANS Apr 19 34 Variable Speed Drive cont d Menu Button Navigation Chart ...

Page 35: ... Motor Temperature Calculated motor temperature V1 11 Voltage Input V AI1 V1 12 Current Output mA AI2 V1 13 DIN1 DIN2 DIN3 Digital input statuses V1 14 DIN4 DIN5 DIN6 Digital input statuses V1 15 D01 R01 R02 Digital and relay output statuses V1 16 Analogue Output mA A01 V1 17 Multimonitoring Items Displays three selectable monitoring values Code Signal Name Unit Description Variable Speed Drive co...

Page 36: ...e occur contact the Distributor faulty operation component failure 25 Microprocessor watchdog faulty operation Reset the fault and restart the Unit fault component failure Contact Distributor 31 IGBT temperature IGBT Inverter Bridge overtemp protection has detected too Check loading hardware high a short term overload current Check motor size Make identification run 32 Fan cooling Cooling Fan of f...

Page 37: ...charge automatically under pressure It is recommended that pneumatic drain tubes be anchored and filtered as per your local municipality regulations More detailed information concerning the Dryer Unit is included in the Dryer manual The information contained in this manual is a quick reference only To Air Receiver On Off Button LED s for Compressor Drain and Fan Test Programming Buttons Dryer Cont...

Page 38: ... Unit is operating will run the Fan at full speed for several seconds after which the Unit will stop The LED will be on continually while the Fan runs at full speed As well as showing the dew point the readout may indicate several fault codes as suggested below The readout will indicate a variety of fault codes the most common being as follows Motors Typical Dryer Operation Typical Fault Codes Ene...

Page 39: ...he Canister Head Install the new O ring making sure it is properly seated Place the new 1 micron Separator Filter Element into the Bowl the filter is self centring Screw the Canister with the Element inside it to the Canister Head until the indicators line up Gauge will return to green when Filter is once again under pressure Typical Separator Filter Arrow Indicates Direction of Air Flow Dual Indi...

Page 40: ...t No power to the Unit Loose and or missing wires in the electrical circuit Emergency Stop Button pressed in Motor Overload is tripped Compressor over heated and stopped Compressor stopped by over pressure Unit has timed out shut off because pressure has not gone below cut in pressure of 120 psi Power interruption Check that power at the disconnect or breaker is on Also check any primary and secon...

Page 41: ...ermo Valve is faulty Oil Filter is blocked Temperature Sensor is faulty Thermostat is faulty Pressure is too high Cabinet door panel is open off Check cooling air circulation Check the air circulation in and around the Unit Clean the Heat Exchanger Add oil as required Change to the factory recommended oil Check and repair as necessary Replace the Oil Filter Check the wiring to the Temperature sens...

Page 42: ...d be oversized for the tank capacity G Compressor Surges Restriction in Heat Exchanger or Hoses Pressure Transducer setting is incorrect or malfunctioning Blockage at Unit outlet Dryer is freezing up not allowing air to pass through Air Receiver is too small Flush out or replace Set pressure as per instructions or replace Check for obstructions in outlet piping Check that the Dryer parameters are ...

Page 43: ...R OF THE COMPANY THIS WARRANTY SHALL NOT BE EFFECTIVE AS TO ANY CLAIM WHICH IS NOT PRESENTED WITHIN 30 DAYS AFTER THE DATE UPON WHICH THE PRODUCT IS CLAIMED NOT TO HAVE BEEN AS WARRANTED ANY ACTION FOR BREACH OF THIS WARRANTY MUST BE COMMENCED WITHIN ONE YEAR AFTER THE DATE UPON WHICH THE CAUSE OF ACTION OCCURRED ANY ADJUSTMENT MADE PURSUANT TO THIS WARRANTY SHALL NOT BE CONSTRUED AS AN ADMISSION ...

Page 44: ...ckage 12 months 1 year from startup or 15 months from date of shipment to first purchaser whichever occurs first All components within the package excluding normal wear items Airend 60 months 5 years from date of initial startup or 63 months from shipment whichever occurs first Normal wearing items such as shaft seals and inlet valve components along with the servicing of these items is not covere...

Page 45: ...LAN IS SUPPLEMENTAL TO THE STANDARD WARRANTY COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND EITHER EXPRESS OR IMPLIED THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLY AGREED THAT EXCEPT AS TO THE TITLE COMPANY MAKES NO OTHER WARRANTIES EXPRESSED IMPLIED OR STATUTORY INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY THIS WARRANTY SHALL NOT BE EFFECTIVE AS TO ANY CLAIM WHICH IS...

Page 46: ......

Page 47: ...S 10ºC 50ºF MIN 40ºC 104ºF MAX 4 APPROACH TEMP FROM TANK 5ºC 41ºF REMOVABLE TOP PANEL INSERTS WITH 1 4 MOUNTING DUCTIBLE EXHAUST AIR OUTLET REMOVABLE SIDE PANEL 10 3 8 26 1 2 13 7 16 12 3 8 17 7 16 ECN NO REVISION DESCRIPTION DATE REV 1 1 LT to change without notice DESCRIPTION OF DRAWING DRAWING NO SHT NO REV NAME OF PROJECT DRAWN BY CHECKED BY DATE SCALE is continually trying to improve its prod...

Page 48: ......

Page 49: ...TE REV 00 1 1 LT DRS15TD SE REVISION DESCRIPTION subject to change without notice DESCRIPTION OF DRAWING DRAWING NO SHT NO REV NAME OF PROJECT DRAWN BY CHECKED BY DATE SCALE INC is continually trying to improve its products specifications WITH DRYER DM 02 20 19 N T S SALES ENGINEERING DRAWING IMPORTANT NOTE This print is the confidential property of GARDNER DENVER INC It is not to be used or repro...

Page 50: ......

Page 51: ...DSC 001397 2 AIR OIL RECEIVER 1 36 DSC 002050 ISOLATOR A O TANK 3 37 SS 1525 3 8 FLAT WASHER 3 38 SS 1502 3 8 LOCKWASHER 3 39 SS 657 3 8 16 HEX NUT 3 40 DSC 572 ADAPTER 3 4 NPTM JIC8 2 41 DSC 567 ADAPTER R3 4 JIC8 2 42 DSC 001616 ADAPTER 3 4 NPTM 3 4 NPTF 1 43 DSC 237 DSC 572 ADAPTER D15TD ADAPTER D10TD 1 44 SS 2118 3 4 NPT X 3 1 2 GALV NIPPLE BASE MTD ONLY 1 MAINTENANCE KITS NO PART NUMBER DESCRI...

Page 52: ...65 PSI 1 19 DSC 427 BONDED WASHER 3 8 1 20 DSC 001568 ADAPTER 1 8 BSPPM 1 4 BSPPF 1 21 DSC 278 ADAPTER 3 8 BSPM X 1 4 BSPF 1 22 DSC 001237 PRESSURE TRANSDUCER CSC200300 1 23 DSC 001366 PRESS TRANSD CABLE CSC200300 0 5 24 DSC 002868 SOLENOID CABLE ASSY 1 MAINTENANCE KITS M1 DSC 002718 SHAFT SEAL KIT M2 DSC 001950 INTAKE VALVE REPAIR KIT M3 DSC 111 1 THERMAL VALVE REPAIR KIT M4 DSC 410 MINIMUM PRESS...

Page 53: ...e valve 7 4 Thermostatic valve 7B Outlet minimum pressure valve 7E Inlet thermostatic valve Inlet from the de oiler tank 7G Recovery oil 7H Air connection control line 7I Inlet de oiler tank 7M Air connection After minimum pressure valve 7P Safety valve connection 7R Return from the oil cooler 7R1 Return thermostatic valve Inlet to the screw 7U Outlet thermostatic valve Inlet to the oil cooler 8 O...

Page 54: ...SFORMER 2 E EMERGENCY STOP K1 MOTOR STARTER P PRESSURE TRANSDUCER S SOLONOID N C T TEMPERATURE SENSOR RSS REMOTE START STOP N O REFER TO REMOTE START INSTALLATION INSTRUCTIONS DSC 002851 AMP MAX 1 75 X FULL LOAD MOTOR A2 A1 E 8 8 8 8 POWER BLOCK PRIMARY FUSE F1 F2 SECONDARY FUSE F3 GROUND TERMINAL TRANSFORMER 1 2 3 4 5 6 TERMINAL BLOCKS 3 4 5 0 24VAC 1 2 L1 L2 L3 CT11 CT12 CT21 CT22 3 4 5 CT1 CT2 ...

Page 55: ...1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 C AN1 AN1 AN2 AN3 C AN2 C AN3 3 4 6 5 7 X01 DIGITAL INPUTS X02 ANALOGUE INPUTS X03 E 10 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 24 25 26 NXS INVERTER CONTROL CONNECTION BOARD OPT A1 BOARD OPT A2 3 4 8 10 21 22 23 8 RSS 10 MICROPROCESSOR E EMERGENCY STOP P PRESSURE TRANSDUCER S SOLONOID N C T TEMPERATURE SENSOR RSS REMOTE START STOP REFER TO REMOTE START ...

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