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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: _____________...
7.4.4 System Isolating Gate Valve Check.......14 OPERATION ..................15 Start-Up Procedure ..............15 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 Control Pressure Switch............17 Protection Devices ..............18 Thermo Bypass-Valve.............18...
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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...
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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...
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.
(freight pre-paid), with proof of purchase to Champion Compressors. In general, machine spare parts are warranted for six months from the date of invoice and subject to Champion Compressors Ltd. standard Warranty Policy, and...
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.
Manual No. 975203 Rev H SAFETY 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.
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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.
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.
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.
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...
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.
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.
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.
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.
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.
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...
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’...
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.
- 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 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).
Champion Compressors Ltd. Manual No. 975203 Rev H OPTIONS The following is a selection of options, which may have been ordered with your compressor. 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...
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.
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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.
Champion Compressors Ltd. Manual No. 975203 Rev H 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. 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.
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. 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.
Manual No. 975203 Rev H 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.
/ filter(s) before entering the ‘dry’ receiver. An additional filter may be fitted at the discharge of the ‘dry’ receiver. The Dirty Environment Filter and Acoustic Hood (Ci 40 / 55) options are available in conjunction with the Duplex option. Base-mount Where an air receiver or equivalent exists at the installation location, a Dominator may be ordered without an integrated receiver.
Champion Compressors offers a variety of Maintenance Management solutions which provide regular maintenance to ensure long life and trouble free service from your compressor. Contact your Champion Compressors representative to arrange this service. 10.2 Daily Operation Prior to starting drain any water from oil sump through drain valve until oil begins to flow (Oil floats on water).
10.3.1 Initial Service - 250 hours The oil should be changed after the first 250 hours of service, and then after every 1,500* hours of service. Use only Champion recommended oil. (See Section 6 for 'Recommended Lubricants') 10.3.2 Every 1,500 Hours Change the compressor oil and oil filter (use prescribed grade only)*.
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Champion Compressors Ltd. Manual No. 975203 Rev H THIS PAGE HAS BEEN LEFT BLANK...
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Champion Compressors Ltd. Manual No. 975203 Rev H A.R. = As Required N.S.S. = Not Sold Separately...
Champion Compressors Ltd. Manual No. 975203 Rev H 13.0 GENERAL ASSEMBLY COMPONENTS- Ci 110...
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Champion Compressors Ltd. Manual No. 975203 Rev H 13.0 GENERAL ASSEMBLY COMPONENTS - Ci 110 - (9800745 Rev E) Item Part No. Description Qty. 511135 Air Receiver 301020 Airend - Integrated Screw Motors - 380/415/440 V 50 Hz, 440V 60Hz...
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Champion Compressors Ltd. Manual No. 975203 Rev H 13.0 GENERAL ASSEMBLY COMPONENTS - Ci 110 (Continued)
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Champion Compressors Ltd. Manual No. 975203 Rev H 13.0 GENERAL ASSEMBLY COMPONENTS - Ci 110 - (9800745 Rev E) - Continued Item Part No. Description Qty. 631173 Bush - Reducing - 1/2"BSP M to 1/4"BSP F 541026 Gate Valve - 1” BSP 621220 Nipple - Gal - 1”...
Lower system pressure. Faulty solenoid valve. Replace solenoid valve. 26.4 Compressor does not provide enough air. Too much air usage. Contact Champion. Compressor may be too small. Inlet filter blocked. Clean or replace. Throttle not opening fully. Overhaul / replace.
Champion Compressors Ltd. Manual No. 975203 Rev H 27.0 GENERAL ARRANGEMENT DRAWINGS Fig. 8 - Ci 40 / 55 Standard.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 9 - Ci 75 Standard.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 10 - Ci 75SD / 110 Standard.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 11 - Ci 40 / 55 Acoustic Hood.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 12 - Ci 40 Dryer Option.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig 13 - Ci 55 Dryer Option.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 14 - Ci 75 Dryer Option.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 15 - Ci 75SD Dryer Option.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 16 - Ci 110 Dryer Option.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 17 - Ci 40 / 55 Base Mount.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 18 - Ci 40 / 55 Base Mount with Acoustic Hood.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 19 - Ci 75 Base Mount.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 20 - Ci 75SD / 110 Base Mount.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 21 - Ci 75 Cyclopac Option.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 22 - Ci 75SD / 110 Cyclopac Option.
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Champion Compressors Ltd. Manual No. 975203 Rev H Fig. 23 - Ci 40 - 110 Duplex (Control Box & Clean Air Pack shown).
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How does it compare to your expectations? Other Comments:__________________________________________________________ ________________________________________________________________________ Other comments related to our level of service during the purchasing, delivery and commissioning process:_____________________________________________________ ________________________________________________________________________ ________________________________________________________________________ Please detach this page and fax it to: Champion Compressors Head Office (Melbourne): (+613) 9703 8077...
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Champion Compressors Ltd. Manual No. 975203 Rev H 28.0 CUSTOMER FEEDBACK SHEET Please return fax this document to : Champion Compressors (+613) 9703 8077...
Champion Compressors Ltd. Manual No. 975203 Rev H 29.0 CHAMPION NETWORK FACTORY AND HEAD OFFICE Princes Highway, Hallam, Victoria 3803 Tel: (613) 9703 8000 Fax: (613) 9703 8053 AUSTRALIAN SALES AND SERVICE LOCATIONS NEW SOUTH WALES Champion Compressors Ltd Champion Compressors Ltd...
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Champion Compressors Ltd. Manual No. 975203 Rev H 29.0 CHAMPION NETWORK (Continued) FACTORY AND HEAD OFFICE Princes Highway, Hallam, Victoria 3803 Tel: (+613) 9703 8000 Fax: (+613) 9703 8053 INTERNATIONAL DISTRIBUTORS AND SERVICE LOCATIONS Finland Malaysia Scandinavian Champions Oy Compressed Air Packaging & Services Vakkistentie 22 Sdn.
Champion Compressors Ltd. Manual No. 975203 Rev H APPENDIX A DN - METRIC NOMINAL SIZES DN - Nominal Size for Valves, Flanges and Fittings. International Definition see ISO 6708-1980 Nominal size (DN): A numerical designation of size which is common to all components in a piping system other than components designated by outside diameters or by thread size.
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Any alterations or modifications to the equipment carried out by any 9. TERMS AND CONDITIONS OF SALE OF GOODS This warranty policy is to be read in conjunction with Champion party, without the express written approval of the Seller, will render the warranty null and void.