Champion ci 40, ci 110 Parts And Operation Manual

Parts and Operator’s Manual

Ci 40 - Ci 110

Read this manual prior to installation and operation of this machine.

Manual No.: 975203 Rev. H Effective: July 2002

Model : _____________

Serial Number: _____________

Champion Compressors Ltd. Manual No. 975203 Rev H

CONTENTS

1.0 PARTS ORDERING PROCEDURE.....................................................1

2.0 RECOMMENDED SPARE PARTS LIST.............................................2

3.0 INTRODUCTION.................................................................................3

4.0 SAFETY..............................................................................................4

4.1 General Safety Notes................................................................4

5.0 GENERAL DESCRIPTION AND OPERATION....................................6

5.1 General Description of the Dominator Ci Series........................6

5.2 Principle of Operation ...............................................................7

5.3 Control System .........................................................................8

5.4 Operating Temperature .............................................................8

6.0 TECHNICAL DATA..............................................................................9

7.0 INSTALLATION AND PRE START CHECKS....................................10

7.1 Location..................................................................................10

7.2 Connection To Air System ......................................................10

7.3 Electrical Connection..............................................................11

7.3.1 Ci 40 - 75 (Stop / start control).......................................11

7.3.2 Ci 75 / 110 (Star-delta, CSU).........................................12

7.3.3 Motor Rotation Direction................................................12

7.4 Mechanical Checks.................................................................13

7.4.1 Airend Check.................................................................13

7.4.2 Oil Level Check .............................................................13

7.4.3 Vee Belt Check ..............................................................13

7.4.4 System Isolating Gate Valve Check...............................14

8.0 OPERATION.....................................................................................15

8.1 Start-Up Procedure.................................................................15

8.2 Function Of Controls...............................................................15

8.2.1 Stop / Start (Standard Ci 40 - 75):.................................15

8.2.2 Star-delta, CSU (Option Ci75, Standard Ci 110):...........16

8.3 Control Pressure Switch..........................................................17

8.4 Protection Devices..................................................................18

8.5 Thermo Bypass-Valve.............................................................18

9.0 OPTIONS..........................................................................................19

Champion Compressors Ltd. Manual No. 975203 Rev H

9.1 Lead/Lag, Remote Monitoring & Control.................................19

9.1.1 Central Control Box Operation...................................... 20

9.2 Lead/Lag Control.................................................................... 22

9.2.1 Lead / Lag Control Box Operation.................................22

9.3 Lead / Lag Pressure Switches................................................ 23

9.4 Acoustic Hood (Ci 40/55)........................................................24

9.5 Clean Air Pack (Dryer)............................................................24

9.6 Dirty Environment Filter (Cyclopac)........................................ 24

9.7 No Neutral & Hour-meter (Ci 40/55/75)..................................24

9.8 Duplex....................................................................................24

9.9 Base-mount............................................................................25

9.10 Sump Heater and Thermal Fan..............................................25

9.11 Auto Restart Option................................................................25

9.12 Phase Failure Relay (Ci 75/110 only)..................................... 25

10.0 MAINTENANCE ................................................................................ 26

10.1 General .................................................................................. 26

10.2 Daily Operation.......................................................................26

10.3 Maintenance Schedule........................................................... 27

10.3.1 Initial Service - 250 hours............................................27

10.3.2 Every 1,500 Hours....................................................... 27

10.3.3 Every 3,000 Hours (Or Yearly)....................................27

11.0 GENERAL ASSEMBLY COMPONENTS - Ci 40 / 55........................ 30

12.0 GENERAL ASSEMBLY COMPONENTS- Ci 75................................ 34

13.0 GENERAL ASSEMBLY COMPONENTS- Ci 110.............................. 40

14.0 INTEGRATED SCREW COMPONENTS- Ci 40 / 55.........................44

15.0 INTEGRATED SCREW COMPONENTS- Ci 75 / 110....................... 46

16.0 ELECTRICAL STARTER ASSEMBLY - Ci75SD/110........................48

17.0 CLEAN AIR PACK ASSEMBLIES.....................................................52

18.0 CYCLOPAC AIR INTAKE ASSEMBLIES.......................................... 56

19.0 ACOUSTIC HOOD ASSEMBLY........................................................58

20.0 AUTODRAIN ASSEMBLY.................................................................60

21.0 CONTROL BOX DOOR ASSEMBLY................................................62

22.0 CENTRAL CONTROL BOX ASSEMBLY..........................................64

23.0 LEAD / LAG CONTROL BOX DOOR ASSEMBLY............................ 66

Champion Compressors Ltd. Manual No. 975203 Rev H

24.0 LEAD / LAG CONTROL BOX ASSEMBLY........................................68

25.0 DUPLEX ASSEMBLIES ....................................................................70

26.0 TROUBLESHOOTING.......................................................................72

27.0 GENERAL ARRANGEMENT DRAWINGS........................................73

29.0 CHAMPION NETWORK....................................................................91

APPENDIX A DN - METRIC NOMINAL SIZES..........................................94

Champion Compressors Ltd. Manual No. 975203 Rev H

1.0 PARTS ORDERING PROCEDURE

When ordering parts always indicate the Serial No. and Model No. of the compressor.

The parts should be ordered from the nearest Champion Branch or Champion Distributor from whom the compressor was purchased (see 29.0 Champion Network). If for any reason parts cannot be obtained in this manner, please contact Champion Compressors Head Office directly.

When ordering parts, please be careful to check with your part number selection for either assembly or kit. If you have any questions, please contact your nearest Champion Branch.

Champion Compressors Ltd. Manual No. 975203 Rev H

2.0 RECOMMENDED SPARE PARTS LIST

Description Repair Kit

No.

Qty.

2.1 Parts required per 1,500 hour (Type B) Service

Standard Air Filter Element - Ci 40-55 278766 1 Standard Air Filter Element - Ci 75-110 278767 1 Oil Filter Element Cartridge - Ci 40-110 278877 1 Cyclonic Air Filter Element - Ci 40-110(Optional) 270092 1 Lubricant - Shell Corena CH46 (See Section 6) 831015

2.2 Parts required per 3,000 hour (Type C) Service (As above plus:)

Separator Element - Ci 40-55 278773 1 Separator Element - Ci 75-110 278765 1 Microfilter Element - Ci 40-55 (If fitted) 211756 1 Microfilter Element - Ci 75-110 (If fitted) 211760 1 Vee Belts (Refer Section 9.0 / 10.0) 2

2.3 Machine Spares

Thermo Valve Repair Kit - 70ºC - Ci 40-110 278875 1 Thermo Valve Repair Kit - 80ºC - Ci 40-110 278876 1 Minimum Pressure Valve Repair Kit - Ci 40-110 278775 1 Inlet Controller - Ci 40-55 278905 1 Inlet Controller - Ci 75-110 278830 1 Airend Seal Kit - Ci 40-110 278763 1 Sight Glass Kit - Ci 40-110 278780 1 O-ring Kit - Ci 40-110 278874 1

Tensiometer 270965 1

2.4 Upgrade Kits

Cyclonic Air Filter Kit - Ci 40-55 159022 Cyclonic Air Filter Kit - Ci 75-110 159023

No Neutral, Hour Meter - Ci 40-55 159021 Clean Air Pack (CRD006) - Ci 40 159036 Clean Air Pack (CRD009) - Ci 55 159037 Clean Air Pack (CRD012) - Ci 75 159038 Clean Air Pack (CRD018) - Ci 110 159039 Acoustic Hood - Ci40-55 159017 Auto Drain Kit 159041

Spare parts Warranty: Type B Service items are warranted f or 1000 hours. ULTIMIZER is warranted for 4000 hours (or 1 year, whichever occurs first). CHAMPION Vee belts are warranted for 6000 hours, if installed by a Champion approved technician. The parts subjected to warranty must be returned (freight pre-paid), with proof of purchase to Champion Compress ors. In general, machine spare parts are warranted for six months from the date of invoice and subject to Champion Compress ors Ltd. standard Warranty P ol i cy, and Terms and Conditions of Sale of Goods.

Champion Compressors Ltd. Manual No. 975203 Rev H

3.0 INTRODUCTION

The Dominator range of rotary screw compressors provides efficient compressed air in a modular design, which allows for customisation and future expansion of air requirements.

The standard Dominator range of air compressors has many features and innovations.

Some of these advanced features are as follows:

• Advanced, modified profile screw element.

• Integrated machine componentry for less connections, eliminating oil leaks.

• Simplified intake controller.

• Integrated spin-on separator element for easy servicing and very low oil

carry-over.

• Integrated oil filter, air filter and over pressure protection.

• Minimum noise emission through innovative design.

• Simple machine control and adjustment.

• Easy access to service components.

• Compact modular design which allows for flexible installation and complete

package models, with air receiver and refrigerant dryer, all mounted on the one unit.

• Integrated thermovalve optimised for ambient conditions. This operator's manual is written to assist the end user in gaining maximum

use from their compressor unit. Please familiarise yourself with the contents before placing the unit into service. Correct installation and on going maintenance using the Champion Maintenance Program and Service Contract will provide years of trouble-free service.

A copy of this manual should be given to the personnel responsible for operating the machine within your organisation.

All requests for information, service and spare parts should be directed to your nearest Champion Compressors’ Customer Support Division, or your Authorised Champion Compressors’ Service Agent.

Champion Compressors Ltd. Manual No. 975203 Rev H

4.0 SAFETY

4.1 General Safety Notes

Champion Compressors manufacture the Dominator Ci series so that they can be operated safely. Persons operating the compressor are ultimately responsible for their own safety. The following safety precautions are suggested as a guide to reduce the risk of injuries throughout the life of your compressor.

• Do not operate the compressor in an unsafe condition. Tag the compressor with an appropriate Warning Tag and render it inoperative by disconnecting the power at the source. This will prevent others from being able to operate it until it is repaired.

• Correct hearing protection must be worn by person(s) working on or around the compressor whilst the compressor is in operation.

• Before removing the oil filler cap ensure the compressor is not running and is not pressurised. Shut down the compressor, isolate and bleed the compressor air receiver before attempting to remove the oil filler cap. Vent all internal pressure before opening any line, fitting, valve, drain plug, connection or other component. If you are unsure how to do this contact your nearest Champion Service Agent.

• Do not vary pressure switch setting from those listed in Section 8.3 without prior approval from Champion Compressors’ Engineering Department. Failure to comply to this may void your warranty.

• Do not tamper with or remove the integrated screw or air receiver safety valves.

• Clean up spills of lubricant or other combustibles immediately. Keep sparks and other ignition sources at a safe distance. Do not allow smoking near the compressor.

• Keep electrical wiring and connections clean, free from dust, oil and tightly clamped.

• Do not operate compressor or optional dryer with any protective guards or panels removed. This includes the Ci 75 & 110 cabinet, fan & belt guards or motor fan cowlings. Keep loose clothing and parts of the body away from fans and other moving parts at all times.

Champion Compressors Ltd. Manual No. 975203 Rev H

Avoid touching hot fluid, hot surfaces and points of air discharge. The surfaces of the cooler, motor and airend can become very hot in high ambient conditions.

• Do not directly breathe the air from this compressor.

• Do not direct compressed air at any part of a person’s body.

When making adjustments or repairs to exposed live parts of the system maintain dry footing, stand on insulating surfaces and do not contact any other portion of the compressor. Make adjustments with one hand only so as to minimise the possibility of creating a current path through the heart. Do not leave the compressor unattended with open electrical enclosures. If necessary to do so, disconnect and lock out all power at the source.

All electrical service or installation work must be carried out by a qualified / certified electrician.

Champion Compressors Ltd. Manual No. 975203 Rev H

5.0 GENERAL DESCRIPTION AND OPERATION

5.1 General Description of the Dominator Ci Series

Your new Dominator rotary screw compressor will provide you with product reliability and greatly reduced maintenance, if maintained and operated in accordance with this manual.

The protection devices fitted to this compressor are provided to offer safety of operation. The operator is solely responsible for personal safety at all times. These devices should not be adjusted except by an authorised Champion Compressors service agent.

The machines can be adjusted to operate at maximum capacity at pressures of 780,1000 & 1300 kPa, but are supplied as standard at 780 kPa.

For pressure other than standard, check with Champion Compressors’ Support Division should you wish to vary the operating pressure of your

machine. As standard, each compressor is mounted on an air receiver. The Ci 40 & 55

is mounted on one 150L air receiver, and the Ci 75 & 110 are mounted on twin tank 220L air receivers.

Optionally, each model can be accompanied by a clean air package consisting of a refrigerated dryer and microcoalescing filter. Each model is also available in a version mounted on rubber feet, for applications where a receiver already exists. The innovative modular design of the Ci series allows for easy configuration changes, (See Section 9 for full option descriptions).

The Ci 40 - Ci 75 machines all employ three phase direct-on-line starting (DOL) via a combination pressure switch / off-auto control / starter and motor overload. These machines will start and stop automatically depending on system pressure requirements, while the lever control on the pressure switch is set to ‘Auto’ mode. The Ci 75 is also supplied with an hour meter indicating hours of operation for service intervals.

Champion Compressors Ltd. Manual No. 975203 Rev H

The Ci 110 uses a three phase star-delta starter panel mounted in the lid of the compressor cabinet. This machine runs continuously, loading and unloading as required to meet system pressure needs. An Off/Auto switch mounted in the lid panel of the compressor is provided as a means of control. An hour meter is provided indicating hours of operation for service intervals.

The Star-delta, Constant Speed Unload (CSU) option is available on the Ci 75 by customer request.

Service access for your machine is excellent, with ample space provided to allow for easy servicing of components. All the serviceable components on the machine are located in convenient positions requiring minimum disturbance to your compressor package. All models employ a vertical fan mounted oil cooler, and on the Ci 75 and Ci 110, an air aftercooler is also provided as standard.

5.2 Principle of Operation

The main functional components of a Dominator rotary screw air compressor are the integrated rotary screw airend, the drive motor and cooler assemblies. Unlike other rotary screw air compressors, the integrated rotary screw airend performs the task of multiple system components. This has the advantage of reducing the number of connections between components, and also reducing system complexity.

The integrated screw rotors draw air through the air filter and intake controller. Oil is injected into the compression space to provide cooling, sealing and lubrication of the rotors and bearings as they turn, compressing the air. The compressed air/oil mixture is discharged into the integrated separator vessel, where most of the oil is removed from the air/oil mixture by mechanical separation. The glass fibre spin-on separator element removes the remaining oil.

The oil that is removed by the separator element is returned to the airend sump via the purge line sight glass. The oil is collected in the separator vessel and piped to the oil filter, where oil is cleaned before being cooled in the oil cooler and re-injected into the airend.

After the separator element, the compressed air then flows through the minimum pressure valve to the air receiver (via the air aftercooler on Ci 75 &

110). The moisture condensation is accumulated in the air receiver and removed by means of the receiver drain valve or auto drain.

Champion Compressors Ltd. Manual No. 975203 Rev H

The minimum pressure valve maintains pressure in the integrated screw during start-up and during off-load operation to assist oil circulation. Backflow of compressed air from the air mains into the separator is prevented by a non-return valve which is incorporated in the minimum pressure valve.

5.3 Control System

The purpose of the control system is to regulate the compressor air intake to match the amount of air being used. The major components of the control system are the intake controller, solenoid valve and pressure switch.

As the compressor starts (Stop / Start control only) or switches into DELTA (or run) mode (Star-delta, CSU Only), the solenoid valve is energised, allowing the air to enter the compressor. The system pressure rises.

The compressor pumps until the pre-set UN-LOAD pressure switch setting is reached. The pressure switch then de-energises the solenoid valve, closing the intake valve and allowing the integrated screw to reduce sump pressure. On the stop/start models (standard on Ci 40, 55, 75) the compressor will come to a stop. The load/unload models (standard Ci 110) will continue to unload (producing no air) for a set time, governed by the setting of the run-on timer, after which the compressor will enter standby mode, ready to automatically start when air demand exists.

When mains pressure falls to the pre-set LOAD pressure switch setting, the solenoid valve is energised, signalling for the inlet valve to open, thus allowing the compressor to build up pressure to the pre-set level again. This cycle continues as long as air demand is present.

5.4 Operating Temperature

This unit is designed to work from 0°C to temperatures in excess of 40°C. Where site ambient temperatures will exceed 40°C (for example in a boiler

room), then it is better to duct the cooling air to the compressor. The oil temperature is regulated by a thermo-bypass valve. For details on thermobypass valve operation refer to Section 8.5.

Champion Compressors Ltd. Manual No. 975203 Rev H

6.0 TECHNICAL DATA

UNIT

Ci 40 Ci 55 Ci 75 Ci 110

Pressure BAR 7 10 13 7 10 13 7 10 13 7 10 13

cfm 19 16 14 28 21 18 42 34 29 60 50 42

l/s 9.0 7.6 6.6 13.2 9.9 8.5 19.8 16.0 13.7 28.3 23.6 19.8

FAD

(Capacity)

/min 0.54 0.45 0.40 0.79 0.59 0.51 1.19 0.96 0.82 1.70 1.41 1.19

Drive

System

BELTS 2XPZ 2XPZ 2XPZ 2XPZ

Cooling Air

Vol.

L/Sec 250 250 1000 1000

Heat

Rejection

kW 5.1 7.0 9.5 13.4

Oil Fill Litres 3.5 3.5 4.0 4.0

Av. Sound

Pressure

Level

(10 Bar)

dB(A)

@ 1m

Air Outlet

Discharge

Size

BSP ‘F’

DN20

3/4”

DN20

3/4”

DN25

1”

DN25

1”

Motor kW 4.0 5.5 7.5 11.0

RPM 50Hz

2890 2930 2930 2955

RPM 60Hz

3440 3480 3450 3545

IP 55 55 55 55

FLC / 380/50

8.5 / 9.4 11.8 / 12.9 15.7 / 17.3 (9.9) 22.8 / 14.3

o/load 415/50

8.1 / 8.9 11.1 / 12.2 14.7 / 16.2 (9.3) 21.2 / 13.4

Setting † 440/60

8.8 / 9.7 11.8 / 12.9 15.4 / 16.0 (9.7) 22.3 / 14.1

Australia:

Cable Size *

mm²

1.0 1.5 1.5 2.5

Fuse Size ♦

(MOTOR START)

25 32 35 35

Oils:

Factory Fill (Mineral)

SMARTLUBE CH46 SMARTLUBE CH46 SMARTLUBE CH46 SMARTLUBE CH46

High Ambient (Mineral)

SHELL CORENA S68 SHELL CORENA S68 SHELL CORENA S68 SHELL CORENA S68

Synthetic ♣

SULLUBE 32

SULLUBE 32 SULLUBE 32 SULLUBE 32

Motor Bearings SEALED BEARINGS - NO SERVICE REQUIRED

* Example as per AS3008.1.1 Selection of cables Table 12 (Column 4). Note that no

de-rating factors have been applied. Refer to AS3008.1.1 for correct selection and installation.

♦ If circuit breakers are to be used, use only circuit breakers equivalent to MOTOR

START FUSE. ♣ Refer Champion Service if a change from mineral based oil to synthetic is required. † Overload settings in brackets are for Ci-75 with Star-delta starter.

Champion Compressors Ltd. Manual No. 975203 Rev H

7.0 INSTALLATION AND PRE START CHECKS

WARNING: Incorrect Installation May Void War ranty.

Before installing your Champion Compressor check carefully for any transport damage. Contact Champion Compressors immediately if any such damage is found.

7.1 Location

The compressor cabinet as supplied is not weather-proof, and the compressor should be installed inside (or in a sheltered location outside). The compressor should be installed in such a way that the locations with respect to walls and ceiling meet the requirements of the model general assembly diagrams. (Refer Section 27).

The compressor must be placed on a flat surface and it must remain level at all times. Packing shims should be used to level the compressor. The unit must not be securely bolted down. When the need exists location pins should be used.

IMPORTANT: Locate the compressor in an adequately ventilated area. Hot air from the discharge duct must not recirculate to the air intake. Do not install in an area where exhaust fumes from other equipment can be drawn into the intake (or other toxic, noxious or corrosive fumes, chemicals or substances).

Where more than one compressor is installed in one location, not only must proper care be taken with regard to access to each individual machine, but special attention should be taken to ensure that there is no possibility of the heated cooling air discharge from any one machine being directed into the intake of another machine.

7.2 Connection To Air System

The compressor is supplied with either a 3/4” Gate valve (Ci 40/55) or 1” Gate Valve (Ci 75/110) loose for installation into to ends of the compressor’s air receiver. The connecting plant airline connection should be at least the size of the prescribed gate valve, and if the pipe run is of any great length, the pipe sizes should be increased by one size to minimise any pressure drop.

Note

: In base mount option configuration, the pressure switch is

supplied loose (on a 2m fly lead). This must

be fitted into the air supply

to provide a control signal for correct compressor operation.

Champion Compressors Ltd. Manual No. 975203 Rev H

7.3 Electrical Connection

The electrical installation must be checked by a licensed electrician to ensure that it is adequate for starting and running the compressor. Refer to Section 6

- ‘Technical Data’.

NEUTRAL CONNECTION IS REQUIRED ON SOME MODELS.

Champion Compressors has provided a circuit diagram at the rear of this operator’s manual

7.3.1 Ci 40 - 75 (Stop / start control)

All the mains supply leads connect to the compressor within the cover of the combination pressure switch and starter. There is connection for 3 phases, earth and neutral. Note: The neutral connection is made on the shunt

relay contact block (located inside pressure switch cover), at terminal ‘C1’ marked on the relay. Please refer to circuit diagram supplied with your

machine.

Note:- A No-Neutral option is available for your compressor. Please contact Champion Compressor’s customer support department for assistance.

Fig. 1 - Electrical Connection Ci 75 (Stop / Start Control)

Champion Compressors Ltd. Manual No. 975203 Rev H

7.3.2 Ci 75 / 110 (Star-delta, CSU)

The main supply leads connect to the compressor through conduit entry points on both the cabinet panels and electrical enclosure. The three phase wires connect directly to terminals marked. Connection of the earth wire should be bolted to the starter enclosure using the M6 earthing bolt provided. Please refer to the circuit diagram supplied with your machine.

Fig. 2 - Electrical Connection - Ci75SD - 110

7.3.3 Motor Rotation Direction

The power supply must be correctly connected for the motor to rotate in the correct direction. This can be checked by toggling the Off/Auto switch located on the pressure switch / starter (Stop / Start) or the compressor lid (StarDelta, CSU). Note that if your machine is fitted with an auto restart facility, there may be a delay of up to 30 seconds after toggling the Off/Auto switch. The motor and airend rotate in the direction indicated by the arrow marked ‘D’ on the airend and motor fan cowling (anti-clockwise viewed from drive shaft end). In the event that the motor has been disconnected or removed for service reasons, ensure that the power supply is reconnected in the correct sequence prior to start-up.

Change incoming power leads only. Refer to Work instruction Q36-34a for correct wiring sequence.

WARNING: Rotation in the wrong direction will damage the airend and will void warranty.

Champion Compressors Ltd. Manual No. 975203 Rev H

7.4 Mechanical Checks

WARNING: Ensure that the machine is electricall y isolated before checks are made.

7.4.1 Airend Check

Ensure that the airend is not hydro-locked by rotating the driven pulley by hand through two complete revolutions.

7.4.2 Oil Level Check

Sight glasses are used to check both dynamic and static oil levels on these models. The upper sight glass is used to check the static oil level, whilst the lower sight glass is used to check the dynamic level.

Top-ups: Add prescribed grade of oil. Ensure that the oil filler cap is firmly secured and seated properly on the seal, do not over tension.

7.4.3 Vee Belt Check

Pulley alignment must be checked by using a straight edge to confirm that the pulley faces are flush, and drive shafts parallel. The maximum misalignment allowable is 0.5mm.

Check that all belts are seated in their grooves. The belt tension is maintained by sliding the motor, via adjusting jacking bolts located at the feet of the motor. Correct belt tension is achieved with the use of a Tensiometer (Champion Part No. 270965). Refer to Figure 3. Set the large o-ring so that the o-ring bottom is at the 7mm mark. Ensure that the small o-ring is set at the zero mark. Hold the top of the Tensiometer and press it at right angles to the belts, midway between the airend pulley and motor pulley into one of the v-belts. When the bottom of the large o-ring is level with the top of the other belts stop pressing it in and read the kilogram figure off the bottom of the small o-ring. Move the small o-ring back to the zero mark and repeat the operation for the other belts. Record the results.

Rotate the motor pulley through one complete revolution and measure the belts again, recording the results. Once again rotate the motor pulley and take another set of readings. Average three sets of readings to ascertain a belt tension figure.

Champion Compressors Ltd. Manual No. 975203 Rev H

The belt tension must be adjusted between the minimum, maximum and initial values (1.3 x Maximum) listed in the table below:

Model Minimum Maximum Initial

Ci 40 1.3 kg 1.8 kg 2.3 kg Ci 55 1.4 kg 2.0 kg 2.6 kg Ci 75 1.5 kg 2.1 kg 2.7 kg

Ci 110 1.9 kg 2.7 kg 3.6 kg

New belts should be initially tensioned to 1.3 times the maximum running tension settings outlined above. Belt tension needs to be adjusted five minutes after these belts are fitted and the compressor is run, then again ten minutes later. This will ensure that the belts have completed their initial “stretch”. After this first fifteen minutes of operation, the belts should be correctly tensioned to the table above.

Fig. 3 - Belt Tensiometer Part Number 270965

7.4.4 System Isolating Gate Valve Check

Check that the isolating gate valve fitted to the compressor is open.

Champion Compressors Ltd. Manual No. 975203 Rev H

8.0 OPERATION

8.1 Start-Up Procedure

If the compressor has not been started for a period of two months or longer, carry out all the pre-start checks outlined in Section 7 prior to starting machine.

1. Drain moisture from the compressors’ air receiver.

2. Drain any water that has condensed in the oil sump, (See Section 10.2)

3. Check that the proper oil level is visible in the upper oil sight glass.

Top up if necessary. Warning : Allow five minutes for oil level to settle before opening the filler plug.

4. Ensure the isolating valve is opened.

5. Turn the ‘Off-Auto’ switch to auto (located on the lid on Star-delta

models) or adjust the lever to the ‘Auto’ position indicated on the pressure switch (Stop/Start models).

Warning : Do not restart the unit within 30 seconds of shutdown. This allows the separator vessel to fully vent, and prevents starting against load.

Should the machine show any excessive vibration, shut down and contact the Champion Customer Support Division immediately.

To shut the compressor down, turn the ‘Off-Auto’ switch to the Off position (Star-delta models) or move the lever on the pressure switch to the OFF position (Stop/Start Models).

8.2 Function Of Controls

8.2.1 Stop / Start (Standard Ci 40 - 75):

The On / Off control, and system pressure gauge for the Ci 40 - 75 machines is located on the pressure switch / starter assembly. While the switch is in the ‘Auto’ position, the machine will start and stop according to system pressure. For directions on setting the pressure switch cut-in and cut-out pressures, refer to section 8.3.

Champion Compressors Ltd. Manual No. 975203 Rev H

8.2.2 Star-delta, CSU (Option Ci75, Standard Ci 110):

The ‘Off-Auto’ switch, emergency stop button and hour meter are located on the lid of the machine. Unlike the Ci40 and 55 Dominators, the Ci 110 has constant speed unloading as standard. The compressor runs off load rather than stopping when the upper pressure setting has been reached. There is a run on timer fitted to ensure that during periods of low air usage, the compressor does not run unnecessarily. The factory setting of this timer is six minutes, but it may be adjusted with specific installation requirements. Please refer to Champion Compressors prior to any adjustments being made, as an incorrect setting may result in damage to the compressor.

The compressor may start at any time whilst the compressor is in ‘Auto’ mode. Please note that if your machine is fitted with Auto Restart option, there may be a starting delay of up to 30 seconds after powering up the compressor. If the emergency stop button is used to stop the compressor or to cut power to the compressor, the Auto/Off switch must be toggled to restart the compressor.

Warning : Do not remove covers or attempt any service without first ensuring the compressor is isolated from the mains power supply, as the compressor could start at any time.

Champion Compressors Ltd. Manual No. 975203 Rev H

8.3 Control Pressure Switch

The control pressure switch (tank mounted or supplied loose on base mounts for line mounting) has been set prior to leaving the factory with the following settings:

Nominal Operating Pressure (kPa)

Nominal Pressure Differential (kPa)

Load Pressure (kPa)

Unload Pressure (kPa)

780 120 660 780 1000 120 880 1000 1300 120 1180 1300

If the settings have “drifted” during transport, it will be necessary to adjust them on site. This is accomplished as follows (refer Figure 4):

1. Remove the protective cover from the pressure switch assembly.

2. (a) To increase pressure - turn range screw clockwise (b) To reduce pressure - turn range screw anticlockwise

3. (a) To increase differential - turn differential screw clockwise (b) To reduce differential - turn differential screw anticlockwise

For safety reasons, under no circumstances adjust the setting differently to the ones listed above. If different pressure settings are desired refer to your Champion Compressors Service Agent

Adjust under pressure

Fig. 4 - Control Pressure Switches

Champion Compressors Ltd. Manual No. 975203 Rev H

8.4 Protection Devices

The Dominator range is protected by a high oil temperature switch (set at 100°C) and a motor thermal overload (settings detailed in Section 6). On the

Stop / Start models, the temperature switch trips the motor overload (located in the pressure switch) and this requires manual resetting (switch off / switch on). The Star-delta, CSU models’ temperature switch disconnects power from the starter coils, stopping the compressor. The temperature switch will automatically reset once the unit has cooled down. The Star-delta, CSU models motor overload (located in the enclosure) once tripped, must be manually reset. After any fault, the Off/Auto switch must be toggled to start the compressor.

In all instances of compressor stopping due to a protecti on tr ip, urgent action must be taken to rectify the fault prior to the compressor being restarted.

8.5 Thermo Bypass-Valve

All the Dominator series compressors are fitted with thermo bypass valves. This valve insures optimum oil temperature (approx. 70°C) during periods of low load cycles or on cold days. This valve will prevent excessive condensation build up in the oil. For export machines, an 80ºC thermoslide may be fitted to reduce water condensation in humid environments.

Champion Compressors Ltd. Manual No. 975203 Rev H

9.0 OPTIONS

The following is a selection of options, which may have been ordered with your compressor.

9.1 Lead/Lag, Remote Monitoring & Control.

A pair of compressors may be controlled by a central control box, equipping the package with ‘Lead / Lag’, ‘Duty / Standby’, and ‘Remote monitoring and control’ capabilities.

Lead/Lag controls allow two compressors to operate in tandem. One unit is selected to be the lead unit and the other the lag unit. In this situation, the lead unit will provide the base air supply for the plant requirement. The lag unit will provide any additional air as required during peak demands. The lead and lag functions should be alternated between the two units by regularly reversing the selector switch on a periodic (daily or weekly) basis.

Duty/Standby operation may be selected as an alternative to Lead/Lag. Power is supplied to one compressor only (the ‘duty’ compressor). In the event that the ‘duty’ compressor must be stopped, (eg. routine service), the ‘standby’ compressor may be called upon so that there is no interruption to the plant’s supply of compressed air.

NOTE:

When more than one compressor is installed with a parallel connection, care must be taken when piping the discharge air. Incorrect piping may result in condensate accumulating in the mains piping and draining back to a compressor that remains idle or on Standby for a period of time. Generally, having the compressor discharge pipework higher than the junction to the mains piping at some point will avoid the problem.

Champion Compressors Ltd. Manual No. 975203 Rev H

Remote monitoring of the compressor status, (“Fault”, “Standby”, “Run”), is achieved by utilising the voltage-free contacts contained within the control box.

Remote Control of the compressors is achieved by connecting a remote switch to the terminals contained within the control box.

Two Hour Meters to record ‘hours run’ for each compressor are mounted inside the control box. No mains neutral wire is required for compressors fitted with this option unless the Clean Air Pack is included. (Refer Section 9.5).

9.1.1 Central Control Box Operation.

The control box offers a number of configurations in which to operate the two compressor units. (Refer Fig.5):

Fig. 5 - Control Panel, Central Contr ol Box

Champion Compressors Ltd. Manual No. 975203 Rev H

‘Compressor A or Compressor B’ - Set the “A / B / AB” selector switch to either ‘A’ or ‘B’ to run one compressor only. The other compressor will not run, it can be switched to run in the event of the primary compressor being out of service, i.e. a true ‘Duty / Standby’ application.

‘Compressor A and

Compressor B’ - Set the “A / B / AB” selector switch to

‘AB’ to supply power to both compressor units. The compressors will now run in Lead / Lag mode, with the ‘Lead A / Lead B’ selector switch determining which compressor will supply the base air supply for the demand. As stated above, the Lead and Lag functions should be alternated between the two units by regularly reversing the selector switches on a periodic (daily or weekly) basis.

Note : The control box does not have the facility to set both units to Lead or both to Lag. This configuration is neither useful or advisable.

‘Local or Remote Control’ - Set the “LOCAL / REM” Selector switch for each compressor unit to start or stop the machine either locally or at a remote location. (Refer Electrical Circuit Diagram at rear of manual).

The “EMERGENCY STOP” button will isolate power from both compressors irrespective of the control mode selected.

Champion Compressors Ltd. Manual No. 975203 Rev H

9.2 Lead/Lag Control.

Similar to the central control box, a pair of compressors may be controlled by a lead/lag control box, equipping the package with ‘lead / lag’ capability.

9.2.1 Lead / Lag Control Box Operation.

The lead / lag control box offers lead / lag only in which to operate the two compressor units. (Refer Fig.6):

Fig. 6 - Control Panel, Lead/Lag Control Box

The ‘Lead A / Lead B’ selector switch determines which compressor will supply the base air supply for the demand. As stated above, the Lead and Lag functions should be alternated between the two units by regularly reversing the selector switches on a periodic (daily or weekly) basis.

Individual Start / Stop selector switches enable electrical isolation of the motors only of one or both units.

Champion Compressors Ltd. Manual No. 975203 Rev H

When a fault is detected, or the Emergency Stop button is depressed, the machine will not start until the fault is removed and the Fault Reset button is pressed.

9.3 Lead / Lag Pressure Switches

The central and lead / lag control boxes contain two pressure switches, (lead and lag), which have been factory set as listed below.

Lead / Lag Pressure Switch Settings

Nominal Operating Pressure (kPa)

Nominal Pressure Differential (kPa)

Lead Load Pressure (kPa)

Lead Unload Pressure (kPa)

Lag Load Pressure (kPa)

Lag Unload Pressure (kPa)

780 80 700 780 650 730 1000 80 920 1000 870 950

If the settings have “drifted” during transport, it will be necessary to adjust them on site. This is accomplished as follows (refer Figure 7):

1. (a) To increase pressure - turn range screw anticlockwise (b) To reduce pressure - turn range screw clockwise

2. (a) To increase differential - turn differential screw clockwise (b) To reduce differential - turn differential screw anticlockwise

For safety reasons, under no circumstances adjust the setting differently to the ones listed above. If different pressure settings are required refer Champion Compressors.

Fig. 7 - Control Pressure Switch (Central Control Box)

Champion Compressors Ltd. Manual No. 975203 Rev H

9.4 Acoustic Hood (Ci 40/55).

The Ci 40/55 Dominators are available with an acoustic hood. This cabinet helps to reduce the noise level, as well as acting as a protective cover for the compressor. Ci75 / 110 models have the hoods fitted as standard.

9.5 Clean Air Pack (Dryer).

The clean air pack provides clean, moisture free air. A refrigerant dryer is teamed in series with a microcoalescent filter or filters to remove any moisture and oil carry-over in the discharge air supply.

NOTE: A 240V connection must be available for wiring of the refrigerant dryer. The dryer must be individually wired to the supply, as it is not hardwired to the compressor electrics.

9.6 Dirty Environment Filter (Cyclopac).

For operation in dirty environments, a heavy-duty Cyclonic air filter is offered as an externally mounted option. (Refer Section 18).

9.7 No Neutral & Hour-meter (Ci 40/55/75)

Where no neutral facility exists at the installation location, the no neutral option may be fitted, allowing connection with three phase power leads and an earth lead. Also included is an hour meter to record hours run, not standard on Ci40 / 55. As stated above, if a refrigerant dryer is incorporated, a 240V connection for single phase power supply to the dryer is necessary.

9.8 Duplex

The Duplex is a pair of Dominators mounted on a common twin air receiver, approximately three times the volume of a standard air receiver. The compressor units are controlled by either the 'Lead / Lag' Control box providing ‘lead / lag’ operation (Refer Section 9.2) or the ‘Lead / Lag, Remote Monitoring and Control’ box providing ‘duty / standby’ or ‘lead / lag’ operation (Refer Section 9.1).

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Champion ci 40, ci 110 Parts And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual