Champion D6 Series, Installation And Service Data

Page 1: ...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 CSC50 Controller 21 Common Compressor Faults 24 Separator Filter and Refrigerated Air Dryer 25 Trouble Shooting Guide 28 Warranty 31 Please read this manual before installing or using your Air Compress...

Page 2: ...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 Note Dimensions indicated are typical for all variations of D6 7 5 Series Units ie base...

Page 3: ...y use of a disconnect or breaker Start Allows the Unit to begin compressing air Stop Causes the Unit to enter Idle mode and then shut off Digital Readout Provides system pressure temperature etc 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 ...

Page 4: ...re 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 M...

Page 5: ...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 Also...

Page 6: ...s to the various sides this being for both the proper ventilation of 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 Units is anchored to the floor using isolator pads If installed in a compressor room ensure that the room is adequately ventilated On...

Page 7: ...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: ...litre pails Any remaining oil may be used for top ups The MK D67 CH Maintenance Kit includes 2 Oil Filter DSC 603 CH 1 Air Oil Separator Filter DSC 002476 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 Ser...

Page 9: ...the amp rating for the Unit This information is required in sizing a Disconnect Fuses and or a suitable Breaker As well the enclosed electrical schematic indicates the correct wiring and fuse types and sizes 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 observ...

Page 10: ...il Electrical Connection The Electrician is to bring power to the Unit at the Electrical Panel accessible by means of removing the Unit LH Panel A licensed Electrician is to determine the appropriate Disconnect Breaker and wire size based on the Unit amp draw as indicated on the sales drawing at the back of this booklet Motors The correct rotation is as indicated by the arrow on the Air End or as ...

Page 11: ...ng 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 7 1 2 9 500 0 61 17 4 1 2 3 9 The above chart is based on a standard environment in which the Motor is operating of 40 C For other cond...

Page 12: ...point the Motor will continue to run but not compress air 6 Once the Unit reaches 145 psi 10bar it will idle for 5 minutes and shut off Do not place any materials in close proximity to the Compressor Placing materials against or close to the Unit will limit the cooling required and could lead to premature failure 7 Open the Ball Valve slightly and allow the air to bleed from the Tank Once the pres...

Page 13: ...re 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 the oil analysis report must be f...

Page 14: ...lined 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 Warranty on Page 31 for further information c ...

Page 15: ...rator 1 If necessary use a strap wrench to turn the original Separator counter clockwise 2 On the new DSC 002476 CH Air Oil Separator lubricate the Separator Gasket with Compressor Oil 3 Hand tighten the new Air Oil Separator snug Note Do not over tighten the Separator Filter on the Unit as it may become very difficult to remove at a later date Changing the Oil Filter The Oil Filter should be chan...

Page 16: ... 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 Drain Port 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 Fill the Oil Reservoir to the top of the Oil Fill Port ...

Page 17: ...End Bolts to lock the Air End in position Maintenance Procedures cont d Adjusting the Drive Belts The tightening and loosening of the Drive Belts is done by way of moving the Air End horizontally either towards or away from the Motor Air End Hold Down Bolt 1 of 4 Slider Bolts Tension Bracket Adjusting Nut Units of Serial Numbers of 37622 and Less To adjust the Belt tension simply 1 loosen the 4 Ai...

Page 18: ...own below are the various components associated with the Intake Valve Repair Kit 1 2 3 4 5 6 7 8 9 10 11 The DSC 001712 intake valve kit includes the following items 1 Conical Spring Large 2 Hex nut 3 Conical Spring Small 4 Piston 5 V ring 6 O ring 2 mm Width Intake Valve Groove 7 O ring 2 62 mm Width Air End Housing 8 Lock Washer 9 Plate Set 10 O ring 1 5 mm Width 11 Rod Groove for Item 6 Current...

Page 19: ...ater or 1 DSC 001711 Thermo Valve Repair Kit if your Unit has a serial number of 37213 and lower Shown at right are the various components associated with the 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 Th...

Page 20: ... 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 002055 Shaft Seal Kit Shown below are the various components included in the Kit Also sold separately is the DSC 002534 Front Cover but is not required when rep...

Page 21: ...rface for the CSC50 Controller is shown below Description of Interface 1 Main Display Value 0 1 to 999 2 Main Display Value Units C F Bar PSI 3 User Menu Item Display Value 0 1 to 99999 4 User Menu Item Display Value Units C F Bar PSI 5 Status Symbols Started Running Loaded 6 Service Fault Symbols Service Fault Alarm Required Warning Trip Start Allows the Unit to begin compressing air Up Scrolls f...

Page 22: ...t Conditions If a fault condition occurs the Fault Triangle with either switch on steady Alarm Warning or flash Trip Shutdown The User Menu will indicate the appropriate fault condition More Common Faults Alarm Warning Unit will continue to operate Shutdown Trip Unit will stop A 2118 High Pressure E 0010 Emergency Stop A 2128 High Temperature E 0020 Motor Overload A 2816 Power Failure detected E 0...

Page 23: ...the Controller When new the counter is set for 2000 hours As the Unit operates the Timer counts down from 2000 until it reaches 0 Once it reaches 0 the A 4804 Service Due fault code will appear on the Controller The Timer will continue to count down going into the negative values Service Interval Timer Access Code 0009 The Timer must be reset as follows 1 Turn the Compressor off but ensure there i...

Page 24: ...refer to Preventative Maintenance Schedule on pg 13 CSC50 Shutdown Errors There is an issue with the Unit and the Unit will not operate until the Fault has been addressed Code Description Most Common Items to Check E 0020 Motor Overload Motor drawing high amps low voltage higher pressure settings low oil level loose wires E 0040 Anti Rotation Rotation of Motor wrong Solenoid Valve not relieving pr...

Page 25: ... lines after the air is compressed but before it enters the Air Receiver This allows for what is termed a dry Tank 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 From Air End Separator Filter Dryer Model and Serial Numbers To Air Receiver Refrigerated Air Dryer On Off Button LED s...

Page 26: ...t 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 ...

Page 27: ... 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 The label shown above is included with a replacement Filter Element and should be affixed to ...

Page 28: ...d 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 shut off because pressure is not below 120 psi Automatic Idle Time stopped the Unit Power interruption Check that power at the disconnect or breaker is on Also check any primary and secondary fuses Check that all wiring ...

Page 29: ...ssor oil Thermo 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 Tempe...

Page 30: ... psi differential Also the Unit could 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 Flush out or replace Set pressure as per instructions or replace Check for obstructions in outlet piping Check that the Dryer param...

Page 31: ...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 32: ...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 33: ...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...

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Page 36: ...CAL BUSHING 1 X 3 4 7 5HP 3PH 1 16 MH 9027 MOTOR HARNESS 5 230 1 1 16 MH 9028 MOTOR HARNESS 5 200 3 7 5 460 3 1 16 MH 9029 MOTOR HARNESS 7 5 230 1 1 16 MH 9030 MOTOR HARNESS 7 5 200 230 3 1 20 SS 26 3 8 16 X 1 1 4 HHCS D6 ONLY 4 20 SS 23 3 8 16 X 3 4 HHCS D7 5 ONLY 4 22 SS 10012 SPACER 1 1 8 DIA X 5 8 D6 ONLY 4 23 SS 657 3 8 16 HEX NUT 10 24 DSC 001330 VIBRATION ISOLATOR 4 25 DSC 002242 SUB BASE 1...

Page 37: ...63 ADAPTER 3 8 BSPPM JIC8 2 21 DSC 002239 OIL INLET TUBE 1 22 DSC 002238 OIL OUTLET TUBE 1 23 DSC 001238 TEMPERATURE SENSOR CSC200300 1 24 DSC 002237 AIR HOSE TO COOLER 1 25 DSC 002220 ADAPTER SH 1 2 BSPP JIC 8 1 26 DSC 002219 COPPER WASHER 1 2 BSPP 1 27 DSC 001676 SOLENOID 24V 1 28 DSC 001568 ADAPTER 1 8 BSPPM 1 4 BSPPF 1 29 DSC 001237 PRESSURE TRANSDUCER CSC200300 1 30 DSC 001366 PRESS TRANSD CA...

Page 38: ... NO 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...

Page 39: ...02851 4 2 5 3 2 1 4 1 3 200 230 460 VOLTAGE FUSE SIZE AMPS F1 F2 F3 5HP 7 5HP 16 23 14 22 7 11 5HP NA 36 NA OVERLOAD SETTING 7 5HP NA 23 NA 1PH 3PH CC CLASS TIME DELAY 5MM TIME DELAY 1 75 X FULL LOAD CURRENT AMP MAX GND STARTER FUSE CHART WARNING REPLACE WITH THE SAME FUSE TYPE RATING IMPORTANT NOTE This print is the confidential property of GARDNER DENVER INC It is not to be used or reproduced in...

Page 40: ...NA 1PH 3PH CC CLASS TIME DELAY 5MM TIME DELAY STARTER FUSE CHART WARNING REPLACE WITH THE SAME FUSE TYPE RATING IMPORTANT NOTE This print is the confidential property of GARDNER DENVER INC It is not to be used or reproduced in any manner nor submitted to other parties for examination without the prior approval of GARDNER DENVER INC GARDNER DENVER INC is continuously trying to improve its products ...