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Champion D10 - User Manual

Champion D10
55 pages
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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 ………………………………………………
D10 (TD)
D15 (TD)
DRS 15 (TD)
Rotary Screw
Air Compressor
Units
- - -
Installation
And
Start-up Data

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Champion D10 and is the answer not in the manual?

Summary

Quick Start Guide

Initial Lubrication Check

Details checking the oil level in the reservoir using the sight glass.

Unit Operation and Controller

Start and Stop Procedures

Explains how to start and stop the compressor unit using the controller.

Emergency Stop Functionality

Details the function and proper use of the emergency stop button.

Safety Precautions

Safety Symbols and Warning Meanings

Explains safety symbols and their importance for hazard prevention.

Hazard Identification and Safeguards

Lists potential hazards and recommended safeguards during operation.

Unpacking and Inspection

Initial Inspection Points

Details initial checks for crating, packaging, and cabinet damage.

Mechanical Installation

Unit Location and Anchoring

Specifies ideal location requirements, ventilation, and anchoring for the unit.

Lubrication Procedures

Initial Start-up Lubrication

Instructions for initial oil level check and topping up with Champion lubricant.

Electrical Installation

General Electrical Safety and Requirements

Emphasizes safe electrical connection by qualified personnel and proper wiring.

Fused Disconnects and Fuse Selection

Details requirements for fused disconnects, breakers, and fuse types.

Electrical Connection and Motor Rotation

Electrical Connection Details

Explains power connection through conduit and terminal blocks.

Motor and Air End Rotation Verification

Emphasizes correct motor rotation to prevent irreparable damage to the Air End.

Start-up Procedures

Unit Controls Overview

Identifies and explains the function of unit start, stop, and emergency stop buttons.

Initial Start-up Steps

Step-by-step guide for performing the initial start-up of the compressor unit.

Maintenance Procedures

Changing the Oil Filter

Step-by-step guide for replacing the oil filter element.

Replacing the Air;Oil Separator

Instructions for replacing the air/oil separator filter.

Heat Exchanger and Oil Procedures

Oil Changes Procedure

Step-by-step guide for draining and refilling the compressor oil.

Shaft Seal Repair

Installing New Shaft Seal

Procedures for installing the new shaft seal, including O-ring.

CSC300 Controller Overview

Controller Interface and Operation

Explains the controller's interface, display elements, and button functions.

CSC300 Controller: Access Code Entry

Entering the Access Code

Guide to entering the correct access code to unlock controller functions.

CSC300 Controller: Access Code Input

CSC300 Controller: Error Log

Viewing the Error Log

Explains how to access the error log and view recorded faults.

CSC300 Controller: Motor Protection

Phase Detection Functionality

Explains the feature that prevents motor rotation in the wrong direction.

Advanced Motor Protection Features

Describes motor protection features provided by current sensors.

Common Compressor Faults

CSC300 Controller Alarms

Lists common alarms from the CSC300 controller and items to check.

CSC300 Controller Shutdown Errors

Lists common shutdown errors and their potential causes/checks.

Variable Speed Drive (VSD)

VSD Overview and Benefits

Introduces the Variable Speed Drive (VSD) and its energy-saving benefits.

VSD Operating Screen and Indicators

Common VSD Fault Codes

VSD Fault Code Reference

Provides a list of common VSD fault codes, possible causes, and corrective measures.

Dryer Operation and Faults

Typical Dryer Fault Codes

Lists common fault codes for the dryer, such as ESA, PFI, HEH.

Troubleshooting Guide: Startup Issues

Unit Wont Start Troubleshooting

Addresses common causes and corrections when the unit fails to start.

Compressor Stopped by Over-pressure

Explains causes and corrections for the compressor stopping due to over-pressure.

Troubleshooting Guide: Air Flow and Overheating

No or Insufficient Air Flow Issues

Addresses causes and corrections for lack of or low air flow.

Unit Overheating Troubleshooting

Explains causes and corrections for the unit overheating.

Troubleshooting Guide: Operational Issues

Electrical Schematics: Controller and VSD Wiring

Summary

Quick Start Guide

Initial Lubrication Check

Details checking the oil level in the reservoir using the sight glass.

Unit Operation and Controller

Start and Stop Procedures

Explains how to start and stop the compressor unit using the controller.

Emergency Stop Functionality

Details the function and proper use of the emergency stop button.

Safety Precautions

Safety Symbols and Warning Meanings

Explains safety symbols and their importance for hazard prevention.

Hazard Identification and Safeguards

Lists potential hazards and recommended safeguards during operation.

Unpacking and Inspection

Initial Inspection Points

Details initial checks for crating, packaging, and cabinet damage.

Mechanical Installation

Unit Location and Anchoring

Specifies ideal location requirements, ventilation, and anchoring for the unit.

Lubrication Procedures

Initial Start-up Lubrication

Instructions for initial oil level check and topping up with Champion lubricant.

Electrical Installation

General Electrical Safety and Requirements

Emphasizes safe electrical connection by qualified personnel and proper wiring.

Fused Disconnects and Fuse Selection

Details requirements for fused disconnects, breakers, and fuse types.

Electrical Connection and Motor Rotation

Electrical Connection Details

Explains power connection through conduit and terminal blocks.

Motor and Air End Rotation Verification

Emphasizes correct motor rotation to prevent irreparable damage to the Air End.

Start-up Procedures

Unit Controls Overview

Identifies and explains the function of unit start, stop, and emergency stop buttons.

Initial Start-up Steps

Step-by-step guide for performing the initial start-up of the compressor unit.

Maintenance Procedures

Changing the Oil Filter

Step-by-step guide for replacing the oil filter element.

Replacing the Air;Oil Separator

Instructions for replacing the air/oil separator filter.

Heat Exchanger and Oil Procedures

Oil Changes Procedure

Step-by-step guide for draining and refilling the compressor oil.

Shaft Seal Repair

Installing New Shaft Seal

Procedures for installing the new shaft seal, including O-ring.

CSC300 Controller Overview

Controller Interface and Operation

Explains the controller's interface, display elements, and button functions.

CSC300 Controller: Access Code Entry

Entering the Access Code

Guide to entering the correct access code to unlock controller functions.

CSC300 Controller: Access Code Input

CSC300 Controller: Error Log

Viewing the Error Log

Explains how to access the error log and view recorded faults.

CSC300 Controller: Motor Protection

Phase Detection Functionality

Explains the feature that prevents motor rotation in the wrong direction.

Advanced Motor Protection Features

Describes motor protection features provided by current sensors.

Common Compressor Faults

CSC300 Controller Alarms

Lists common alarms from the CSC300 controller and items to check.

CSC300 Controller Shutdown Errors

Lists common shutdown errors and their potential causes/checks.

Variable Speed Drive (VSD)

VSD Overview and Benefits

Introduces the Variable Speed Drive (VSD) and its energy-saving benefits.

VSD Operating Screen and Indicators

Common VSD Fault Codes

VSD Fault Code Reference

Provides a list of common VSD fault codes, possible causes, and corrective measures.

Dryer Operation and Faults

Typical Dryer Fault Codes

Lists common fault codes for the dryer, such as ESA, PFI, HEH.

Troubleshooting Guide: Startup Issues

Unit Wont Start Troubleshooting

Addresses common causes and corrections when the unit fails to start.

Compressor Stopped by Over-pressure

Explains causes and corrections for the compressor stopping due to over-pressure.

Troubleshooting Guide: Air Flow and Overheating

No or Insufficient Air Flow Issues

Addresses causes and corrections for lack of or low air flow.

Unit Overheating Troubleshooting

Explains causes and corrections for the unit overheating.

Troubleshooting Guide: Operational Issues

Electrical Schematics: Controller and VSD Wiring

Champion D10 Specifications

General IconGeneral
BrandChampion
ModelD10
CategoryAir Compressor
LanguageEnglish

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