Champion D5, Installation And Service Data

Page 1: ...ation Electrical 9 Motor maintenance instructions 11 Start up Procedures 12 Preventative Maintenance Schedule 13 Maintenance procedures 15 CSC15 Controller 22 Common Compressor Faults 26 Separator Filter and Refrigerated Air Dryer 27 Troubleshooting Guide 30 Warranty 33 Please read this manual before installing or using your Air Compressor Unit It contains valuable information that will help in th...

Page 2: ...talled in a compressor room ensure that the room is adequately ventilated The unit must be anchored to the floor using isolator pads Ensure the oil level in the Air End is between the top maximum or bottom minimum thread as shown The correct rotation is as shown The Unit is equipped with an Anti Rotation Switch Check that the rotation is correct Drain condensate water from oil tank If compressor w...

Page 3: ...s been applied to the unit Hour Meter Displays the number of running hours Using the 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 components Damage caused in this manner is not covered by the manufacturers Warranty Start Stop Switch ON position Starts compressor OFF position Co...

Page 4: ...automatically do not come into attempting to repair or maintain contact with moving parts the Compressor Air compressed by the Unit is not Never breath untreated compressed suitable for inhaling It may contain air produced by the Compressor vapours harmful to your health Do not direct air stream at body Compressor capable of pressures 50psi Compressor Air End Motor and Never touch the Air End Moto...

Page 5: ...oduct 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 Also d...

Page 6: ...the 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 The ambient temperatur...

Page 7: ...re 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 TYPICAL DUCTING INSTALLATION LAYOUT ...

Page 8: ...itre pails Any remaining oil may be used for top ups The MK D5 CH Maintenance Kit includes 2 Oil Filter DSC 603 CH 1 Air Oil Separator Filter DSC 002832 CH 2 Air Filters DSC 001569 1 Oil Sample Kit 308KBA6003 This Kit should be used in the regular servicing of your Unit Do not attempt to operate the Unit without first checking whether there is oil in the Air End Reservoir Add oil as required Serio...

Page 9: ... Ensure that a suitable Fused Disconnect or Breaker is sized and installed according to the appropriate local 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 an...

Page 10: ...ing power to L1 and L2 See page 12 for start up procedures Motors Motors 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 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 U...

Page 11: ...ngs 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 5 12 000 0 3 8 4 0 6 2 0 The above chart is based on a standard environment in which the Motor is operating of 40 C For other ...

Page 12: ...is unit is 1 minute It would switch from 1 minute to 3 minutes if rate of pressure decay is high 7 Open the Ball Valve slightly and allow the air to bleed from the Tank Once the pressure reaches approx 110 psi 7 6bar the Unit will start and begin to compress air after a short delay 8 Measure the amp draw when the Unit reaches the maximum pressure of 145 psi 10bar 9 Close the Ball Valve allow the U...

Page 13: ...combat 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 detaile...

Page 14: ...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 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 m...

Page 15: ... 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 Remove the Nut holding the Top half of the Housing and then remove the T...

Page 16: ...n cleaning the Heat Exchanger do not use sharp objects or a wire brush These items could damage the cooling coils Heat Exchanger Oil Changes Drain the existing oil by turning the Oil Drain Tube down and opening the 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 Fill the Oil Reservoir to th...

Page 17: ...ws HP Deflection Frequency New After Run 5 10mm deflection with 40N at centre span 39 with 9 Lb Force 96 Hz 93 Hz Spring Belt Hand Wheel Roller Using a Frequency Analyzer After the belts have been installed it is recommended that the belt tension be set to a frequency listed in the above table To obtain the correct frequency the use of a Frequency Analyzer FA 9000 is recommended 1 Place the belts ...

Page 18: ...w 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 A Intake Valve Open Intake Valve Closed A A Air Inlet B Air Outlet C Control Line of Intake Valve C ...

Page 19: ... of Unit operation Please order 1 DSC 002057 Thermo Valve Repair Kit Thermo Valve Operation The Thermostatic Valve Assembly helps to maintain an optimum oil temperature in the Unit allowing the hotter oil once the Unit reaches operating temperature to flow through the Heat Exchanger This is as indicated below When Oil is Cool at Start up As Unit Reaches Operating Temperature Hot Oil to Heat Exchan...

Page 20: ... 80 psi 5 5bar to provide sufficient lubrication in the Air End and b acts to stop compressed air from flowing backwards ie as a one way Valve Please order 1 DSC 001713 Minimum Pressure Valve Repair Kit Shown at right are the various components included in the Kit Shaft Seal Kit Please order 1 DSC 002835 Shaft Seal Kit Shown below are the various components included in the Kit DSC 002835 Shaft Sea...

Page 21: ... for corrective action To replace the Switch please order DSC 002801 Temperature Switch Anti Rotation Switch Anti Rotation Switch The Anti Rotation Switch is set to send an error to the PLC once the pressure read at the Switch has reached approx 8 psi and the unit will shut down This prevents the Air End from rotating in the wrong direction Please refer to Page 26 for corrective action The Anti Ro...

Page 22: ... and could result in damage to the Motor Starter or other electrical components Damage caused in this manner is not covered by the manufacturer s Warranty Power Light Turns on when power has been applied to the unit Hour Meter Displays the number of running hours Start Stop Switch ON position Starts compressor OFF position Compressor unloads for 10 seconds and then stops Fault Light Compressor fau...

Page 23: ...he operation and service of the Unit 1 Unit Status 2 Running hours and the remaining service hours 1 2 Shut off all power to the Air Compressor Unit before attempting any repair or maintenance Control panel voltage is 230Vac Hazardous voltage cause severe injury or death Down Up Used to scroll through the options or can be used to change Q4 function OK Used to accept the selection displayed Forwar...

Page 24: ...minute if rate of pressure decay is slow Idle Shutdown Timer 3 minutes if rate of pressure decay is high Blowdown Time The period of time required to discharge pressure from the air end when the Unit stops after idle shutdown Service Due Hours The maximum allowable time between regular maintenance service of the Unit Model Load Pressure Offload Pressure Load Delay seconds Idle Shutdown minute s Bl...

Page 25: ... running Service Due message will appear on the display This indicates that the Unit requires service Please refer to the Maintenance Schedule on page 14 of this manual for the required service 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...

Page 26: ...e Unit will not operate until the Fault has been addressed Indication Description Most Common Items to Check On Solid Anti Rotation Rotation of Motor wrong Solenoid Valve not relieving pressure Intake Valve Orifice clogged Fast Flash Power Interruption Power failure occurred power was interrupted before Unit completed its Stop Sequence Two Flashes Excessive Temperature Ambient temp high Unit dirty...

Page 27: ...ressed air lines after the air is compressed and after the Air Receiver More detailed information concerning the Dryer Unit is included in the Dryer manual The information contained in this manual is a quick reference only Dryer Controls On Off Button LED s for Compressor Drain and Fan Test Programming Buttons Separator Filter Dryer Model and Serial Numbers From Air Receiver Refrigerated Air Dryer...

Page 28: ...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 Energy Sa...

Page 29: ...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 Dual Indicating Gauge DF001 Arrow pointing to Green Filter Element is Clean Arro...

Page 30: ...on Distributor Service Center Condition Cause Suggested Correction A Unit won t start No power to the Unit Loose and or missing wires in the electrical circuit Motor Overload is tripped Compressor over heated and stopped Unit shut off because pressure is not below 110 psi Automatic Idle Time stopped the Unit Power interruption Check that power at the disconnect or breaker is on Also check primary ...

Page 31: ...lty 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 sensor Replace the Sensor if necessary Secure the door panel to the Unit D Compressor Starts Slowly Intake Valve S...

Page 32: ...could be oversized for the tank capacity G Compressor Surges Restriction in Hoses Pressure Switch setting is incorrect or malfunctioning Blockage at Unit outlet Flush out or replace Set pressure as per instructions or replace Check for obstructions in outlet piping H High Power Consumption Improper air pressure settings Blowdown Solenoid is not functioning The voltage in the building is too low or...

Page 33: ...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 34: ...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 35: ...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 36: ......

Page 37: ...C 002814 FAN ASSEMBLY 1 18 SS 1506 1 2 MEDIUM LOCKWASHER 1 19 SS 01941 1 2 13 X 3 4 SHCS 1 20 DSC 002840 BELT TENSION ROD ASSEMBLY 1 21 DSC 002822 BELT TENSION GUIDE 1 22 DSC 002829 TENSION ARM ASSEMBLY 1 23 SS 10196 M8 SHOULDER SCREW 10X16MM 1 24 SS 1537 M12 FLAT WASHER 2 25 DSC 002839 ROLLER BEARING ASSEMBLY 1 26 SS 10133 M12 X 45MM HHCS 1 27 DSC 002823 SPRING 1 28 DSC 002824 HAND WHEEL 1 29 MH ...

Page 38: ...12 TIA 5165 SAFETY VALVE 165PSI 1 13 DSC 263 1 8 BONDED WASHER 1 14 DSC 001659 ADAPTER 1 8 BSPPM 1 4 NPTF 1 15 DSC 102 ANTI ROTATION PRESSURE SWITCH 1 16 DSC 002833 RUN TEE JIC 8 M X JIC 8 F X JIC 8 M 1 17 DSC 002834 ADAPTER A5 TEMP PROBE 1 18 DSC 001217 BONDED WASHER 1 4 BSPP 1 19 DSC 002801 TEMPERATURE SWITCH 1 4 BSPP NC 240VAC 1 20 DSC 002803 1 2 STEEL TUBE OIL FROM COOLER 1 21 DSC 002802 1 2 S...

Page 39: ...1 4 Air end 1 5 Scavenge check valve 1 6 Scavenge orifice 1 7 Oil Filter 1 8 Thermostatic valve 1 9 Air Oil separator 1 10 Minimum pressure valve 1 11 Air Oil receiver 1B Outlet minimum pressure valve 1M Air connection After minimum pressure valve 1P Safety valve connection 1R Return from the oil cooler 1U Outlet thermostatic valve Inlet to the oil cooler 2 Main motor 3 Belt drive 4 Oil cooler 5 O...

Page 40: ...ur meter panel mounted 300Vac RC ALT01 RC suppressor 250Vac RSS1 2 DSC 002845 Remote start stop switch 2 pos maintained TS DSC 002801 Temperature switch 240Vac OL DSC 001284 Overload relay 16 24A DSC 002805 G DSC 002804 Pilot light green 230Vac S DSC 002957 Solenoid with cable SV DSC 002838 16mm push button switch 250Vac VR DSC 002807 250V varistor for solenoid F1 F2 SS 9877 1 0 A 5 mm fuse PLC DS...