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Champion L Series - User Manual

Champion L Series
80 pages
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L-SERIES FRAME 1
SINGLE STAGE
BASE-MOUNTED &
TANK-MOUNTED
COMPRESSOR
Original User &
Service Manual
MODELS:
CL7-11D
10 & 15 HP
CLRS7-11D
7 & 11 kW
13-25-628
Version 04
Revision EB
July 2022
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Summary

Maintain Compressor Reliability and Performance

Genuine Champion Compressor Parts and Support Services

Details the benefits of genuine parts and distributor support services for reliability and performance.

Contacting Champion and Distributors

Provides contact information and methods to locate authorized Champion distributors.

Instructions for Ordering Repair Parts

Guidelines for specifying compressor model, serial number, and required parts for ordering.

Safety Warnings and Label Information

Mandatory Label Information Overview

Explains the use of warning, prohibition, and mandatory label information in the manual.

Danger Hazard Identification

Defines DANGER level hazards and lists associated safety symbols.

Warning Hazard Identification

Defines WARNING level hazards and lists associated safety symbols.

Caution Hazard Identification

Defines CAUTION level hazards and lists associated safety symbols.

Prohibition and Mandatory Actions

Lists required and prohibited actions for safe compressor operation.

Safety Precautions

Danger Safety Precautions

Lists critical safety measures to avoid death or serious injury.

Warning Safety Precautions

Lists safety measures to avoid equipment damage.

Section 1: General Information

Compressor Overview

Describes the rotary screw compressor mechanism and its components.

Compression Principle

Explains how air is compressed by the meshing rotors.

Air Flow in the Compressor System

Details the path of air through the compressor system.

Lubrication, Cooling, and Sealing System

Explains the role of oil in lubrication, cooling, and sealing.

Section 2: Installation

General Installation Guidelines

Covers initial checks and general advice for unit installation.

Lifting Unit Procedures

Provides instructions and precautions for safely lifting the compressor unit.

Unit Location Requirements

Specifies environmental and spatial requirements for unit placement.

Air-Cooled Unit Ventilation

Details ventilation requirements for air-cooled units.

Foundation and Mounting

Describes foundation requirements and mounting considerations.

Oil Sump and Oil Cooler Drain

Explains how to drain the oil sump and oil cooler.

Enclosure Access and Operation

Discusses maintenance access and proper enclosure operation.

Electrical Wiring Standards

Covers wiring according to electrical codes and standards.

Electrical Wire Sizing Data

Provides data for sizing electrical power wires.

Grounding Requirements

Details equipment grounding according to the National Electrical Code.

Motor Lubrication Details

Information on motor lubrication and sealed bearings.

Installation for Cold Weather Operation

Sheltered Installation Recommendations

Advises on installing the unit inside a heated shelter for cold climates.

Auxiliary Air Receiver Requirements

Specifies requirements for an auxiliary air receiver if used.

Optional Moisture Separator;Trap

Information on the optional moisture separator and trap.

Control Piping and Inlet;Discharge Lines

Details control piping, inlet, and discharge service line connections.

Section 3: Starting & Operating Procedures

Prestart-Up Instructions

Steps to check and service before operating a new unit.

Air Filter Inspection

Guidance on inspecting the air filter and inlet line.

Piping and Electrical Checks

Instructions for checking piping and electrical connections.

Grounding and Dryer System

Notes on grounding and operating with a compressed air dryer.

V-Belt System Checks

Instructions for unpacking and checking the v-belt system.

Motor Rotation Verification

Procedures for checking and ensuring correct motor rotation.

GD Pilot Controller Layout and Hardware

Details the controller layout, buttons, and display functions.

Setting Cut-out and Cut-in Pressure

Instructions for adjusting pressure settings on the controller.

Selecting Operating Mode

Guidance on choosing the automatic operation mode.

Starting the Unit Procedures

Step-by-step guide for starting the compressor unit.

Stopping the Unit Procedures

Steps for stopping compressor operation.

Daily Check Recommendations

Lists daily checks to perform on the unit.

Section 4: Controls & Instrumentation

General Description of Controls

Overview of the compressor package's pre-wired controls and starter.

GD Pilot Controller Overview

Details the functions and features of the GD Pilot controller.

Emergency Stop Pushbutton Function

Explains the purpose and location of the emergency stop button.

Control Transformer and Fuse Blocks

Describes the control transformer and fuse block functions.

Terminal Strip and Main Starter

Information on terminal strips and main starter types for fixed/variable speed models.

Electrical System Conversion

Guidance on field conversion of the multi-voltage electrical system.

Miscellaneous Control Devices

Intake Air Filter

Captures solid impurities and attenuates inlet noise.

Inlet-Valve Assembly

Controls atmospheric air intake during load/unload phases.

Electric Motor and Belt Drive

Drives the compressor and ventilation fan via a belt drive.

Oil Sump and Separator Components

Covers oil sump, air/oil separator, filler cap, drain, level indicator, and filter.

Oil Cooler and Pressure Relief Valve

Details the oil cooler and the pressure relief valve function.

Minimum Discharge Pressure;Check Valve

Maintains minimum pressure and prevents backflow.

Air Cooler and Scavenge Orifice

Describes the air cooler and scavenge line orifice.

Solenoid Valve and Pressure Sensors

Describes solenoid valve and sump pressure sensors.

Temperature Sensor and Total System Components

Details sump temperature sensor, receiver, and refrigerated dryer.

Dryer and Condensate Management Valves

Covers dryer bypass, drain isolation, and condensate drain valves.

Receiver Pressure Relief and Gauge

Explains pressure relief valve and pressure gauge on the receiver.

Section 5: Lubrication

Oil Cooler, Filter, and Separator System

Overview of the oil system components.

Compressor Oil System Operation

Details how oil is circulated for cooling and lubrication.

Recommended Lubricants

Information on Champion RotorLub lubricants.

Oil Specifications and Level Indicator

Specifies oil type and how to check the oil level.

Lubricant Compatibility and SDS

Information on lubricant compatibility and Safety Data Sheets.

Lubricant Change Procedure

Step-by-step guide for changing the compressor lubricant.

Adding Oil Between Changes

Procedure for adding oil when the level is low.

Oil Change Interval Guidelines

Recommended intervals for changing compressor lubricant based on temperature.

Draining and Refilling the Oil System

Detailed steps for draining and refilling the oil system.

Moisture in the Oil System

Discusses preventing and identifying water contamination in the oil.

Thermostatic Mixing Valve Function

Explains the thermostatic mixing valve's role in regulating oil temperature.

Oil Sump (Reservoir) Function

Describes the oil sump's function in separation and storage.

Air;Oil Separator Function and Conditions

Details the separator's role and factors affecting its performance.

Separator Pressure Differential Monitoring

Explains how to monitor pressure drop across the separator.

Oil Filter and Separator Element Inspection

Procedure for inspecting and replacing filter and separator elements.

Section 6: Heat Exchangers (Oil;Air)

Oil;Air Heat Exchanger Function

Explains how heat is rejected from oil to air.

Ventilation Configuration

Describes the air-cooling system and fan setup.

Heat Exchanger Maintenance

Instructions for cleaning heat exchanger exterior fins.

Section 7: Air Filters

Compressor Air Filter Description

Details the single-stage cellulose media air filter.

Air Filter Element Inspection and Replacement

Procedure for inspecting and replacing the air filter element.

Package Pre-Filter Maintenance

Instructions for cleaning and replacing the pre-filter media.

Section 8: Belt Drive System

Belt Drive System Overview

Explains power transmission via v-belts, sheaves, and bushings.

Unpacking and Preparing the V-Belt System

Steps to prepare the belt system after unpacking.

Sheave Set Alignment Procedures

How to check and ensure proper alignment of sheaves.

Replacing Compressor Belts

Step-by-step guide for replacing the v-belts.

Replacing Sheaves and Bushings

Procedure for replacing sheaves and bushings.

Section 9: Servicing of Miscellaneous Devices

Inlet Control Valve Assembly

Details the inlet valve assembly and its function.

Inlet Valve Body Inspection and Repair

Procedure for inspecting and potentially repairing the inlet valve body.

Pressure Relief Valve Function and Testing

Explains the relief valve's purpose and how to test it.

Minimum Pressure Valve (MPV) Inspection and Adjustment

Covers MPV inspection, replacement, and setting adjustment.

Thermostatic Mixing Valve (TMV) Inspection

Procedure for inspecting the TMV for proper temperature regulation.

Input Shaft Seal Assembly Maintenance

Guidance on input shaft seal leaks and repairs.

Electrical Box Cooling System Maintenance

Cooling System Inspection and Cleaning

Steps for inspecting and cleaning the electrical box cooling hardware.

VFD Cooling Fan Removal and Replacement

Procedures for removing and replacing VFD cooling fans.

Section 10: Tank Mounted Compressor - Total System

Total System Description

Overview of tank-mounted compressors with optional dryers.

Total System Installation and Operation

Key considerations for installation, discharge piping, and dryer operation.

Electrical Connections and General Purpose Filter

Details electrical power connections and optional general purpose filters.

Section 11: Maintenance Schedule

Service Check List Overview

Lists maintenance tasks and their recommended intervals.

Maintenance by Operating Hours

Details checks required at 8, 125, 2000, and 4000-hour intervals.

Annual Maintenance Checks

Outlines maintenance tasks to be performed yearly.

Section 12: Troubleshooting

Compressor Fails to Start Issues

Lists causes and remedies for the compressor not starting.

Compressor Starts;Stops or Cycles Issues

Addresses issues with short run times, cycling, and slow starts.

Compressor Load;Unload and Pressure Issues

Covers problems with loading, unloading, and pressure range.

Compressor Does Not Reach Load Pressure

Causes and remedies for the compressor failing to reach load pressure.

High Discharge Air Temperature

Identifies causes and solutions for high discharge air temperatures.

Excessive Oil Consumption Issues

Explains causes and remedies for excessive oil consumption.

Oil Carryover Troubleshooting

Addresses causes and remedies for oil carryover.

Excessive Water in Air Delivery Troubleshooting

Covers issues with water in the delivered air.

Troubleshooting Voltage Problems

Voltage Range and Effects

Details operating voltage ranges and their impact on the compressor.

High;Low Voltage Symptoms

Describes symptoms related to high or low supply voltage.

Summary

Maintain Compressor Reliability and Performance

Genuine Champion Compressor Parts and Support Services

Details the benefits of genuine parts and distributor support services for reliability and performance.

Contacting Champion and Distributors

Provides contact information and methods to locate authorized Champion distributors.

Instructions for Ordering Repair Parts

Guidelines for specifying compressor model, serial number, and required parts for ordering.

Safety Warnings and Label Information

Mandatory Label Information Overview

Explains the use of warning, prohibition, and mandatory label information in the manual.

Danger Hazard Identification

Defines DANGER level hazards and lists associated safety symbols.

Warning Hazard Identification

Defines WARNING level hazards and lists associated safety symbols.

Caution Hazard Identification

Defines CAUTION level hazards and lists associated safety symbols.

Prohibition and Mandatory Actions

Lists required and prohibited actions for safe compressor operation.

Safety Precautions

Danger Safety Precautions

Lists critical safety measures to avoid death or serious injury.

Warning Safety Precautions

Lists safety measures to avoid equipment damage.

Section 1: General Information

Compressor Overview

Describes the rotary screw compressor mechanism and its components.

Compression Principle

Explains how air is compressed by the meshing rotors.

Air Flow in the Compressor System

Details the path of air through the compressor system.

Lubrication, Cooling, and Sealing System

Explains the role of oil in lubrication, cooling, and sealing.

Section 2: Installation

General Installation Guidelines

Covers initial checks and general advice for unit installation.

Lifting Unit Procedures

Provides instructions and precautions for safely lifting the compressor unit.

Unit Location Requirements

Specifies environmental and spatial requirements for unit placement.

Air-Cooled Unit Ventilation

Details ventilation requirements for air-cooled units.

Foundation and Mounting

Describes foundation requirements and mounting considerations.

Oil Sump and Oil Cooler Drain

Explains how to drain the oil sump and oil cooler.

Enclosure Access and Operation

Discusses maintenance access and proper enclosure operation.

Electrical Wiring Standards

Covers wiring according to electrical codes and standards.

Electrical Wire Sizing Data

Provides data for sizing electrical power wires.

Grounding Requirements

Details equipment grounding according to the National Electrical Code.

Motor Lubrication Details

Information on motor lubrication and sealed bearings.

Installation for Cold Weather Operation

Sheltered Installation Recommendations

Advises on installing the unit inside a heated shelter for cold climates.

Auxiliary Air Receiver Requirements

Specifies requirements for an auxiliary air receiver if used.

Optional Moisture Separator;Trap

Information on the optional moisture separator and trap.

Control Piping and Inlet;Discharge Lines

Details control piping, inlet, and discharge service line connections.

Section 3: Starting & Operating Procedures

Prestart-Up Instructions

Steps to check and service before operating a new unit.

Air Filter Inspection

Guidance on inspecting the air filter and inlet line.

Piping and Electrical Checks

Instructions for checking piping and electrical connections.

Grounding and Dryer System

Notes on grounding and operating with a compressed air dryer.

V-Belt System Checks

Instructions for unpacking and checking the v-belt system.

Motor Rotation Verification

Procedures for checking and ensuring correct motor rotation.

GD Pilot Controller Layout and Hardware

Details the controller layout, buttons, and display functions.

Setting Cut-out and Cut-in Pressure

Instructions for adjusting pressure settings on the controller.

Selecting Operating Mode

Guidance on choosing the automatic operation mode.

Starting the Unit Procedures

Step-by-step guide for starting the compressor unit.

Stopping the Unit Procedures

Steps for stopping compressor operation.

Daily Check Recommendations

Lists daily checks to perform on the unit.

Section 4: Controls & Instrumentation

General Description of Controls

Overview of the compressor package's pre-wired controls and starter.

GD Pilot Controller Overview

Details the functions and features of the GD Pilot controller.

Emergency Stop Pushbutton Function

Explains the purpose and location of the emergency stop button.

Control Transformer and Fuse Blocks

Describes the control transformer and fuse block functions.

Terminal Strip and Main Starter

Information on terminal strips and main starter types for fixed/variable speed models.

Electrical System Conversion

Guidance on field conversion of the multi-voltage electrical system.

Miscellaneous Control Devices

Intake Air Filter

Captures solid impurities and attenuates inlet noise.

Inlet-Valve Assembly

Controls atmospheric air intake during load/unload phases.

Electric Motor and Belt Drive

Drives the compressor and ventilation fan via a belt drive.

Oil Sump and Separator Components

Covers oil sump, air/oil separator, filler cap, drain, level indicator, and filter.

Oil Cooler and Pressure Relief Valve

Details the oil cooler and the pressure relief valve function.

Minimum Discharge Pressure;Check Valve

Maintains minimum pressure and prevents backflow.

Air Cooler and Scavenge Orifice

Describes the air cooler and scavenge line orifice.

Solenoid Valve and Pressure Sensors

Describes solenoid valve and sump pressure sensors.

Temperature Sensor and Total System Components

Details sump temperature sensor, receiver, and refrigerated dryer.

Dryer and Condensate Management Valves

Covers dryer bypass, drain isolation, and condensate drain valves.

Receiver Pressure Relief and Gauge

Explains pressure relief valve and pressure gauge on the receiver.

Section 5: Lubrication

Oil Cooler, Filter, and Separator System

Overview of the oil system components.

Compressor Oil System Operation

Details how oil is circulated for cooling and lubrication.

Recommended Lubricants

Information on Champion RotorLub lubricants.

Oil Specifications and Level Indicator

Specifies oil type and how to check the oil level.

Lubricant Compatibility and SDS

Information on lubricant compatibility and Safety Data Sheets.

Lubricant Change Procedure

Step-by-step guide for changing the compressor lubricant.

Adding Oil Between Changes

Procedure for adding oil when the level is low.

Oil Change Interval Guidelines

Recommended intervals for changing compressor lubricant based on temperature.

Draining and Refilling the Oil System

Detailed steps for draining and refilling the oil system.

Moisture in the Oil System

Discusses preventing and identifying water contamination in the oil.

Thermostatic Mixing Valve Function

Explains the thermostatic mixing valve's role in regulating oil temperature.

Oil Sump (Reservoir) Function

Describes the oil sump's function in separation and storage.

Air;Oil Separator Function and Conditions

Details the separator's role and factors affecting its performance.

Separator Pressure Differential Monitoring

Explains how to monitor pressure drop across the separator.

Oil Filter and Separator Element Inspection

Procedure for inspecting and replacing filter and separator elements.

Section 6: Heat Exchangers (Oil;Air)

Oil;Air Heat Exchanger Function

Explains how heat is rejected from oil to air.

Ventilation Configuration

Describes the air-cooling system and fan setup.

Heat Exchanger Maintenance

Instructions for cleaning heat exchanger exterior fins.

Section 7: Air Filters

Compressor Air Filter Description

Details the single-stage cellulose media air filter.

Air Filter Element Inspection and Replacement

Procedure for inspecting and replacing the air filter element.

Package Pre-Filter Maintenance

Instructions for cleaning and replacing the pre-filter media.

Section 8: Belt Drive System

Belt Drive System Overview

Explains power transmission via v-belts, sheaves, and bushings.

Unpacking and Preparing the V-Belt System

Steps to prepare the belt system after unpacking.

Sheave Set Alignment Procedures

How to check and ensure proper alignment of sheaves.

Replacing Compressor Belts

Step-by-step guide for replacing the v-belts.

Replacing Sheaves and Bushings

Procedure for replacing sheaves and bushings.

Section 9: Servicing of Miscellaneous Devices

Inlet Control Valve Assembly

Details the inlet valve assembly and its function.

Inlet Valve Body Inspection and Repair

Procedure for inspecting and potentially repairing the inlet valve body.

Pressure Relief Valve Function and Testing

Explains the relief valve's purpose and how to test it.

Minimum Pressure Valve (MPV) Inspection and Adjustment

Covers MPV inspection, replacement, and setting adjustment.

Thermostatic Mixing Valve (TMV) Inspection

Procedure for inspecting the TMV for proper temperature regulation.

Input Shaft Seal Assembly Maintenance

Guidance on input shaft seal leaks and repairs.

Electrical Box Cooling System Maintenance

Cooling System Inspection and Cleaning

Steps for inspecting and cleaning the electrical box cooling hardware.

VFD Cooling Fan Removal and Replacement

Procedures for removing and replacing VFD cooling fans.

Section 10: Tank Mounted Compressor - Total System

Total System Description

Overview of tank-mounted compressors with optional dryers.

Total System Installation and Operation

Key considerations for installation, discharge piping, and dryer operation.

Electrical Connections and General Purpose Filter

Details electrical power connections and optional general purpose filters.

Section 11: Maintenance Schedule

Service Check List Overview

Lists maintenance tasks and their recommended intervals.

Maintenance by Operating Hours

Details checks required at 8, 125, 2000, and 4000-hour intervals.

Annual Maintenance Checks

Outlines maintenance tasks to be performed yearly.

Section 12: Troubleshooting

Compressor Fails to Start Issues

Lists causes and remedies for the compressor not starting.

Compressor Starts;Stops or Cycles Issues

Addresses issues with short run times, cycling, and slow starts.

Compressor Load;Unload and Pressure Issues

Covers problems with loading, unloading, and pressure range.

Compressor Does Not Reach Load Pressure

Causes and remedies for the compressor failing to reach load pressure.

High Discharge Air Temperature

Identifies causes and solutions for high discharge air temperatures.

Excessive Oil Consumption Issues

Explains causes and remedies for excessive oil consumption.

Oil Carryover Troubleshooting

Addresses causes and remedies for oil carryover.

Excessive Water in Air Delivery Troubleshooting

Covers issues with water in the delivered air.

Troubleshooting Voltage Problems

Voltage Range and Effects

Details operating voltage ranges and their impact on the compressor.

High;Low Voltage Symptoms

Describes symptoms related to high or low supply voltage.

Champion L Series Specifications

General IconGeneral
Voltage230
Stages2
Noise Level78
Tank Capacity80 gallons
Tank Size80 gallons

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