Champion D5 Manuel

D5-MANS

Mar ’19

- 1 -

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.

Rotary Screw

Air Compressor

Units

- - -

Installation

And

Service Data

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

‘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 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.

D5-MANS

Mar ’19

- 2 -

Quick Start

Mechanical Installation

(Refer to Page 6)

Lubrication Rotation

(Refer to Page 8) (Refer to Page 10)

18”

[458mm]

18”

[458mm]

The Unit must be located indoors, in a dry, clean, cool,

dust free, and well ventilated area.

Allow a minimum 18” (458mm) around and 36” (915mm)

above Unit.

The ambient temperature should be between 10°C and

40°C (50°F and 104°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.

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 work-cycle experiences long

pauses, condensate will gather in oil tank.

Drain condensate EVERY 50HRS OR WEEKLY.

(Refer to Page 8 for details)

36”

[915mm]

Installation Kit

IK515

Flex-Hose &

Vibration Isolators

(sold separately)

18”

[458mm]

Unit

Nameplate

Model No.

Serial No.

Unit voltage

D5-MANS

Mar ’19

- 3 -

Quick Start (cont’d)

Unit Operation

Shown below is the ‘CSC15’ Controller which regulates the operation of the Unit. Unit Status LEDs, Hour Meter,

and ON/OFF switch are located on the control panel cover.

Starting the Unit: Turn the Selector Switch to ‘ON’ position.

Stopping the Unit: Turn the Switch to ‘OFF’ position, unit will unload for 10 seconds prior to stopping.

Note:

1. Do not stop the Unit by use of a disconnect or breaker.

Power Light

Turns on when power

has 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:

Compressor unloads for 10

seconds and then stops

Fault Light

Compressor fault indicator:

ON Solid = Anti-Rotation

Fast Flash = Power Interruption

Slow Flash = Service Due*

Two Flashes = High Temp Fault

Three Flashes = Overload Fault

*Depress ‘Reset’ button within

cabinet to clear fault.

D5-MANS

Mar ’19

- 4 -

Safety Precautions

In order to operate the Compressor Unit safely and correctly, we have opted to use the following symbols to make

you aware of important points. These points relate to user safety and preventing equipment problems. Please pay

close attention to these sections.

The following hazards may occur during the normal use

of the equipment. Please read the following chart.

Area: Hazard: Safeguards:

What may occur if precautions are not

observed.

Tampering with the Unit while under Relieve all pressure from the Unit

full or partial pressure may cause an before attempting any repair or

explosion. maintenance work.

As the Unit starts and 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 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, Motor, or

Tubing become hot when running. Tubing during or immediately after

Touching these areas may cause operation.

serious burns.

As the electrical components on the Do not install in hazardous locations.

Compressor are General Purpose, The Compressor must be a minimum

there is a potential for explosion, should of 20 feet (6.1 meters) from any source

vapours be present in the area. of potentially explosive vapours.

What to look for. How to avoid the hazard.

2 0 F T

6 . 1 m

Important safety Information.

A hazard that may cause

serious injury or loss of life.

Important information that

indicates how to prevent

damage to equipment, or how

to avoid a situation that may

cause minor injury.

Information that you should

pay special attention to.

D5-MANS

Mar ’19

- 5 -

Unpacking and Inspection

It is the responsibility of the receiver of the goods, either the Distributor or Customer, to ensure that the product

has been shipped in full, and has arrived in suitable condition. Damage to the product may not be visible at time

of off-loading, but may only become apparent upon unpacking or start-up.

Some areas to initially check are as follows:

a) Check for damage to the crating and/or packaging.

b) Check the exterior of the Cabinet for damage, either cosmetic or mechanical.

c) If there is mechanical damage, open the Cabinet to determine whether there is any internal

damage to the Unit.

Should there be damage to the product or shortages in shipment:

1) Stop any further unpacking or operation of the product.

2) Make note of the problem on the Freight Bill, should it concern a shortage or visible

damage to the product.

3) Should the damage be noticed only after the 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, do not discard

any packing material used.

5) A Loss or Damage Claim must be submitted to the carrier and supported by the

following documents:

- Copy of Freight Bill of Lading

- Copy of the Invoice and Estimate to repair, in case of damage

- Damage Report

- Copy of photos, if applicable

Each Champion Air Compressor is carefully tested and inspected

before shipment. Though every attempt is made to ensure the safe

and complete shipment of our product, freight damage or

misplacement of goods may occur.

Shipments of Champion products are the property of the

Consignee when the products leave our facility. Champion is not

responsible for any damages or shortages caused to the product

after it has left our shipping dock.

D5-MANS

Mar ’19

- 6 -

The Compressor must not be operated in

a confined area where the heat from the

Unit cannot readily escape.

Installation – Mechanical

Moving of the Unit

When moving the Air Compressor, the

forklift or hand lift forks go under the Unit

from the directions as indicated.

Please be advised that care must be taken

when moving and positioning the Units as

they are top heavy.

Location of the Unit

Items to consider when installing the Unit are as

follows:

The Unit must be located indoors, in a dry, clean,

cool, dust free, and well ventilated area. If

possible, the Compressor should be located in

a separate room or area, away from the

general operations of the shop.

Allow approximately a minimum of 18” (458mm)

around and 3 feet (915mm) above the Unit for

easy access 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 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 temperature should be between

10°C and 40°C (50°F to 104°F).

If installing the Unit on a mezzanine, ensure that

the structure can safely support the weight of

the Unit. As well, the sound level of the Unit

may increase due to the harmonics created by

the structure; use Vibration Pads to lessen this.

When anchoring the Unit, ensure that there is

approx.. ¼” (0.75cm) between the Nut and the

Compressor Foot (as shown below). Do not

bolt down tightly.

Many common Compressor problems can be

attributed to the location or installation of the Unit.

Make sure the Unit is in a suitable location, and

installed correctly.

Compressor

Foot

¼” (0.75 cm)

Gap

Floor

Isolator

Pad

D5-MANS

Mar ’19

- 7 -

Installation – Mechanical (cont’d)

Shown below are items which assist in making a good installation. 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.

TYPICAL DUCTING INSTALLATION LAYOUT

D5-MANS

Mar ’19

- 8 -

Lubrication

Air End

Initial Start-up

Each Compressor Unit built is extensively tested at

the factory before shipment. The Unit is shipped with

the original oil in it as used for testing purposes.

Check the Oil level and for any Oil leaks on a daily

basis. This must be done when the Unit is off. Top up

the Oil level on a monthly basis.

Use only Champion lubricant. Also, do not mix the

Champion lubricant with any other lubricant.

Subsequent Oil Changes

Drain the existing oil from the Unit. (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 as

shown below. Do not under or overfill. See drawing

below.

Use only Champion 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-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. Serious

damage may result from use, however

limited, without oil.

Use of improper oil may negatively affect

Compressor performance or shorten Unit life.

Resulting problems are not covered by the

Champion Air Compressor Warranty.

Condensation (water) may form in the Air End

if the compressor work cycle experiences

long pauses. If this occurs, the condensate

MUST be drained EVERY 50HRS OR

WEEKLY:

- Wait for compressor to cool for approx.

2HRS.

- Remove service panel

- Slowly open the oil drain valve on the air

end & drain condensate

- When the first traces of oil appear, close

the cap/valve

- Top up the Air End with new oil using only

Champion lubricant.

Oil Drain

D5-MANS

Mar ’19

- 9 -

Installation - Electrical

When making power and control wiring connections, please observe the following precautions:

Ensure that all wiring, fusing, etc is done in a manner that meets with the appropriate codes and

regulations.

See the sales drawing and electrical schematic contained in this booklet for Unit amp draw, as well as

Unit fuse sizes and overload settings.

A licensed Electrician is to determine the appropriate Disconnect/Breaker and wiring sizes based on the

Unit amp draw and the appropriate Electrical Code.

General Information

It is your responsibility to ensure that the Compressor

Unit is electrically connected in a safe and correct

manner. Any electrical work should be carried out

by a competent Electrician, and be done in such

a way that it meets all applicable Codes and

Regulations.

Ensure that a suitable Fused Disconnect or Breaker

is installed in the electrical supply before the

Compressor Unit.

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,

and/or damage to the Unit.

Failure to correctly connect the

Compressor to your building's electrical

services may result in serious personal

injury or damage to the equipment.

Install all covers and panels before

applying power to the Unit.

Failure to install proper fuse protection

may void the unit warranty

Before servicing the Unit, ensure the

power source has been shut down and

locked off.

Read and understand the information

contained in this manual before installing

or operating the Unit.

This product must be connected to a

grounded, metallic, permanent wiring

system, or an equipment-grounding

terminal or lead on the product.

Wiring Practices

Fixed Speed Units:

Use TIME-DELAY type fuse.

Max. Allowable Fuse = 1.75 x Motor Full Load Amp

D5-MANS

Mar ’19

- 10

Installation – Electrical (cont’d)

Wiring must be done in a manner that 230 volts +/- 5% is available at the Motor terminals during start-up. Contact

your local Distributor or Service Centre if additional information is needed.

The Warranty that exists on the Electric Motor is that of the original manufacturer. In the event of a Motor failure,

locate a certified EISA motor service centre.

Electrical Connection

The Electrician is to bring

power to the Unit through

the ¾” conduit hole

located on the top of the

unit. The Electrical Panel

is accessible by means of

opening the Front Control

Panel Cover.

Connect ground wire to

Protective Earth terminal.

Bring 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

Unit rotates in the opposite direction. The correct

rotation is shown at right.

The Unit is equipped with an Anti-Rotation

Switch. If the Unit will not start and an ‘Anti

Rotation’ error is noted on the Controller, change

the connections at the motor connection box to

the following:

Motor L#1 & Motor L#5 with Harness Black

Motor L#4 & Motor L#8 with Harness White

Motor/Air End Rotation

Bring power to

Terminal Blocks

L1, L2

Starter

Overload Relay

PLC

Protective

Earth

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