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Champion is an Australian team committed to the design and delivery of innovative compressed air and cooling solutions in partnership with our customers.
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Excellent resistance to moisture and solvents – prevents binding off Low micron rating at maximum efficiency for optimum continual performance Moulded soft seals prevent air leakages and stress points to ensure smooth compressor operation “Champion Genuine Parts” Protect Your Compressor and Your Warranty...
Section 11.0 - CHAMPION NETWORK). Ask about the dollars you will save. We Care At Champion, we care about our customers. Your air compressor is vital to the successful operation of your plant and business, and you expect it to give reliable service.
This commitment to design simplicity and functional reliability makes the Champion Marathon range the most advanced available in the world today. The Champion Marathon range of heavy-duty compressors has as standard many features and innovations, including: •...
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C SAFETY Champion Compressors manufacture their compressors so that they can be operated safely, however, those that operate the compressor are ultimately responsible for their own safety. The following safety precautions are suggested as a guideline with the aim of preventing injuries throughout the life of your compressor.
3. Keep electrical wiring and connections clean and free of dust, and keep all electrical connections tight. 4. Ensure that only Champion Compressors approved oils are used in the compressor. 5. Keep the compressor in a well ventilated area. Discharge cooling air can raise ambient temperature significantly.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Electrical Shock 1. Adjustments or repairs to exposed live parts of the system should only be carried out by authorised and licensed personnel. When making adjustments or repairs to exposed live parts of the compressor, maintain dry footing, stand on insulating surfaces and do not contact any other portion of the compressor.
(either by rain or from any other sources). If the compressor has been exposed to water, do not operate it and contact Champion Compressors Customer Care Division for assistance.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C GENERAL DESCRIPTION Your new Champion Marathon rotary screw compressor will provide you with product reliability and greatly reduced maintenance, if maintained and operated in accordance with this manual. The compressor can be adjusted for maximum capacity operation at pressures of up to 1300kPa, but is supplied as standard at 780kPa.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C The access panels must be removed in the following sequence: 1. The service access door is opened by undoing the quarter turn latches, lowering the door outwards and lifting off the complete panel.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Principle of Operation The main functional components of a rotary screw air compressor are the rotary screw airend and an air / oil separator vessel (refer Figure 2 - Flow Schematic). The airend rotors draw air through the air filter and inlet control valve.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Control System The purpose of the control system is to open the compressor inlet control valve to allow compressed air to be generated. The system incorporates an inlet control valve with a normally closed inlet valve plate, an actuating piston, two solenoid valves and a pressure transducer (refer Figure 3 - Control System Schematic).
Normal compressor operating temperature is between 70° C and 90° C. Champion Marathon compressors are fitted with a thermovalve which is set to open at 70° C and will only circulate the oil through the oil cooler once this temperature is reached.
Under high humidity and low operating temperature conditions, water (formed by condensation) may collect in the oil. To ensure trouble free operation, Champion Marathon compressors are fitted with an oil bypass thermovalve, which is set at 70° C (the temperature required to evaporate water).
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C TECHNICAL DATA Machine Specifications MODEL Unit CSE37 CSE45 Free Air Delivery at 780kPa Operating /min 6.18 7.38 Pressure Free Air Delivery at 1000kPa Operating /min 5.22 6.06 Pressure Free Air Delivery at...
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Electrical Specifications 4.2.1 Australian Specifications Unit CSE37 CSE45 415V, 3φ, 50Hz Drive Motor Size (nominal) Fan Motor Size Drive Motor Thermal 41.6 50.2 Overload Setting Fan Motor Thermal Overload Setting Maximum 72.2...
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 4.2.2 International Specifications Unit CSE 37 CSE 45 Drive Motor Supply Size Voltage / (nominal) Frequency Fan Motor Size Drive Motor Thermal 45.6 54.8 Overload Fan Motor 380V / Thermal 50Hz...
Champion Compressors Customer Care Division, or warranty may be void. Refer to Champion Compressors Customer Care Division for ISO grades of oil that may be used for the ambient temperatures shown. Mixing of different lubricants within the compressor will void all warranties.
If a compressor is to be changed from a synthetic based lubricant to a mineral lubricant (or vice versa), or the brand of lubricant is going to be changed, then contact Champion Compressors Customer Care Division for advice on the correct oil change procedure. Mixing of different lubricants within the compressor will void all warranties.
INSTALLATION AND PRE START CHECKS General Warning: Incorrect installation may void warranty. Before installing your Champion compressor, check carefully for any transport damage. Contact Champion Compressors Customer Care Division immediately if any such damage is noted. The compressor should preferably be lifted by fork lift truck. Care should be...
The compressor should be installed in accordance with the minimum distances indicated in Figure 5 - Location. Consult Champion Compressors Customer Care Division for assistance in correct placement of your compressor.
Pre-heated inlet air will also reduce the performance output of your compressor. The compressor should be installed in accordance with the minimum distances indicated in Figure 5 - Location. Consult Champion Compressors Customer Care Division for assistance in correct placement of your compressor.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Air System Management 5.5.1 Typical Air System - Wet Air Receiver Figure 6 - Typical Air System - Wet Air Receiver shows a typical air system with a “Wet” air receiver, which is suited to the humid Australian environment.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 5.5.2 Typical Air System - Dry Air Receiver Figure 7 - Typical Air System - Dry Air Receiver shows a typical air system with a “Dry” air receiver, which is suited to a dry European climate. In the...
Hazard Levels A, B or C. As your Champion Marathon compressor is fitted with a Hazard Level C pressure vessel, the owner / manager of the compressor / pressure vessel must register the equipment with the local authority.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 5.7.2 Motor Rotation Direction Warning: Rotation in the wrong direction can damage the airend and may void your warranty. Before attempting to check motor rotation direction, you must familiarise yourself with Section 6.0 - OPERATION of this manual.
AS3008.1 Electrical Installation - Selection of Cables. Check the relevant authorities for local regulations. For international standards, refer to your local Agent (refer Section 11.0 - CHAMPION NETWORK) for supply and installation details to suit your local regulations. Mechanical Checks Warning: Ensure that the compressor is electrically isolated before these checks are made.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 5.8.3 Vee Belt Check Check that all belts are correctly seated in their grooves. The belt tension is maintained by adjusting a jacking nut located above the airend. Refer to Section 8.8 - Belt Tension Adjustment for the correct belt tension measurement and adjustment methods.
Before Starting Your Compressor 6.1.1 Compressor Protection Features Please note that your Champion Marathon compressor controller is capable of many advanced electronic functions. These functions are an integral part of your compressor, designed to optimise the performance of your system by adding additional protection to the motor, airend and electrical switchgear.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Pressing the Emergency Stop button at any time will cause the compressor to immediately stop. The electronic controller will display “EMERGENCY STOP” in the status text line indicating an emergency stop has been enacted. The Emergency Stop button must be reset, and the Reset button pressed before the compressor can be restarted.
Section 3.3 - Operating Temperature. 10. Ensure that the compressor runs smoothly and that no excessive vibration is evident. Should the compressor show any excessive vibration, shut it down and contact Champion Compressors Customer Care Division immediately. Subsequent Start-Up Procedure 1.
• Numerous built in compressor protection features The information in this manual is intended as a basic overview of the functions of the electronic controller. For more detailed information, please obtain a copy of the “Electronic Controller Advanced Configuration” manual from Champion Compressors Customer Care Division.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Digital Display Clear Start Status Up / + Down / - Stop Fault Enter Reset Figure 8 - Champion Electronic Controller...
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 6.5.1 Digital Display The Champion electronic controller has a digital display capable of displaying several parameters at once (refer Figure 9 - Digital Display). DEL TEMPERATURE Figure 9 - Digital Display...
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Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Enabled Functions (Item 4) This section of the display symbolically displays the status of enabled functions. RS485 sequencing (flashing = data link fault) Power failure automatic restart Condensate drain active Remote start / stop control...
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 6.5.2 Display Symbols Below is a list of common display symbols and a description of their meaning. Access code required / locked Item unlocked (can be edited) Item locked (cannot be edited) / scrolling parameter locked as default...
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 6.5.3 Status Text Descriptions Below is a list of some common status and operating parameter items that may be displayed by the electronic controller. The operating parameters can be accessed by scrolling through the display using the up and down arrows.
6.5.4 LED Indicators The Champion electronic controller has two LED indicator lights located to the right of the digital display. The green Status LED provides a visual indication of the compressor operational status, while the red Fault LED provides a visual indication of the fault status of the compressor.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 6.5.5 Faults and Warnings Fault types are identified symbolically. Below are the fault warning symbols that may be displayed. Shutdown, Trip, Immediate Stop Faults Alarm or Warning Run Inhibit The fault warning symbol alternates with the display symbol that is relevant to the type of fault (refer Section 6.5.2 - Display Symbols).
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Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Display Description Alarms: POWER FAILURE There has been an interruption to the power supply LINE PRESS HIGH The line (discharge) pressure is too high SCREW TEMP HIGH The airend discharge temperature is too high...
Division. Adjusting the nominal operating pressure above the maximum working pressure of your compressor (as per the serial number plate) may damage your compressor and void your warranty. High Temperature Shutdown The Champion Marathon range of compressors has two devices for high temperature protection. 6.6.1 Screw Over Temperature The compressor is fitted with an accurate airend discharge temperature transducer.
Due to higher relative humidities, compressors for export may be fitted with an 80° C thermovalve, at the discretion of Champion Compressors or the local distributor.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Run-On Timer In line with Champion Compressors philosophy of keeping energy consumption to a minimum, the compressor electronic controller provides a Run-On Timer function. This function monitors the length of time that the compressor runs without actually compressing air.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C OPTIONS The following is a selection of factory fitted options which may have been ordered with your compressor. Deluxe Monitoring The Deluxe Monitoring option adds the following features to your compressor.
In the event of excessive drive motor temperature, the electronic controller will shut down the compressor, and will display “MOTOR OVERTEMP”. This fault will require rectification and reset. Refer to Champion Compressors Customer Care Division for assistance in rectifying the fault. 7.1.5...
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Modulating Control Modulating control may be fitted to provide constant delivery pressure when it is desirable to not have any fluctuation of delivery air pressure. The customer is given the option of operating the compressor in modulating mode or in the standard CSU (Constant Speed Unload) mode.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Dirty Environment Pack The compressor cabinet air inlet opening may be fitted with a low air resistance, replaceable filter mat when the compressor is to be installed in dirty or dusty environments (refer Section 9.0 - GENERAL ARRANGEMENT DRAWINGS).
After a Routine Start Observe the electronic controller display for any abnormal readings (i.e. temperature or pressure) and whether any faults are present. Check whether there are any oil or air leaks. Refer to Champion Compressors Customer Care Division to resolve any issues.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Maintenance Schedule Recommendations Refer to the Parts Manual for all part numbers of items mentioned in this section. 8.3.1 Initial Service - 250 Hours • Change the compressor oil (mineral oil only)*.
Every 8,000 Hours • Change synthetic oil (Sullube) Note: Service intervals may be extended if the compressor is installed in a clean, cool environment. Refer to Champion Compressors Customer Care Division for advice on the correct service interval for your installation.
Note that the fan motor bearings are double shielded and are replaced whole when necessary. Ensure that bearings are replaced with the correct part (refer Champion Compressors Customer Care Division). Do not use standard sealed bearings in fan motors. The main drive motor should be lubricated as follows: 1.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Maintenance Instructions Refer to the Parts Manual for all part numbers of items mentioned in this section. Warning: Do not attempt any maintenance when the compressor is running or pressurised. Stop the compressor, relieve all internal pressure and isolate the power supply before performing maintenance.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 8.5.2 Air Filter Maintenance The air filter element should be inspected every 1500 hours of service and if necessary, replaced. The electronic controller will display a warning when the air filter has exceeded it’s useful service life (Full Monitoring option only), however holes in the element will only be detected by visual inspection.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 8.5.3 Air / Oil Separator Element Maintenance The separator element should be replaced at least every 6000 hours of service, or when indicated by the electronic controller (Deluxe Monitoring and Full Monitoring options only). Separator elements may need to be replaced more frequently where dusty or hot conditions prevail.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 8.5.4 Inlet Control Valve Maintenance The inlet control valve should be functionally checked every 6000 hours. Use the following procedure when servicing the inlet control valve (refer Figure 13 - Inlet Control Valve Assembly): 1.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 8.5.5 Purge Line Filter Maintenance The purge line filter should be cleaned after the first 250 hours of service, checked every 1500 hours of service for blockages or other problems, and be replaced when the separator element is replaced.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 8.5.6 Minimum Pressure Valve Maintenance The minimum pressure valve should be inspected when replacing the oil separator element. Use the following procedure when servicing the minimum pressure valve (refer Figure 15 - Minimum Pressure Valve Assembly): 1.
3000 hours of service thereafter. Oil changes should be more frequent where the compressor is operating in a hot or dusty environment. Use only Champion recommended oils (refer Section 4.3 - Lubricant Specifications). Access to oil drain tap is via the left hand door.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 8.6.1 Oil Level The maximum oil level should be measured when the compressor is cold or has been stopped for 30 minutes. The minimum oil level should be measured when the compressor is running.
8.8.1 Belt Tension Measurement Belt tension is measured by using a Tensiometer (Champion Part No. 270965 - refer Figure 17 - Belt Tension Adjustment). Use the following procedure to measure belt tension. 1. Set the large o-ring so that the o-ring bottom is at the 8mm mark.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C other belts stop pressing it in and read the kilogram figure off the bottom of the small o-ring. 4. Move the small o-ring back to the zero mark and repeat the operation for the other belts.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Belt Replacement Belt replacement should be carried out in the same manner as belt tension adjustment. The only variation is to unwind the jacking nut sufficiently to remove the old belts and replace them with a new set of belts.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 8.10 Pulley Alignment In the event of the motor or airend having been removed and refitted, pulley alignment will have to be carried out. The misalignment of pulleys can cause rapid wear of the vee belt form, considerably shortening the service life of both belts and pulleys.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 11.0 CHAMPION NETWORK FACTORY AND HEAD OFFICE 11-15 Marlo Place, Hallam, Victoria, Australia, 3803 Tel: (+613) 9703 8000 Fax: (+613) 9703 8053 AUSTRALIAN SALES AND SERVICE LOCATIONS New South Wales - Sydney New South Wales - Wollongong Champion Compressors Pty.
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Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C INTERNATIONAL DISTRIBUTORS AND SERVICE LOCATIONS FACTORY AND HEAD OFFICE 11-15 Marlo Place, Hallam, Victoria, Australia, 3803 Tel: (+613) 9703 8000 Fax: (+613) 9703 8053 New Zealand Papua New Guinea Secair N.Z. Ltd.
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Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C INTERNATIONAL DISTRIBUTORS AND SERVICE LOCATIONS FACTORY AND HEAD OFFICE 11-15 Marlo Place, Hallam, Victoria, Australia, 3803 Tel: (+613) 9703 8000 Fax: (+613) 9703 8053 Thailand United Arab Emirates Integrated Industrial & Engineering Co.
Installation (if Champion installed): How would you rate the installation? How does it compare to your expectations? Other Comments: _____________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ Please detach this page and fax it to: Champion Compressors Head Office (Melbourne): Fax: (+613) 9703 8077...
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Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C Please return fax this document to: Champion Compressors (+613) 9703 8077...
9. TERMS AND CONDITIONS OF SALE OF GOODS Any alterations or modifications to the equipment carried out by This warranty policy is to be read in conjunction with Champion any party, without the express written approval of the Seller, will Compressors Pty.
Champion Compressors Pty. Ltd. Manual No. 975425 Rev. C 14.0 APPENDIX B - DN - METRIC NOMINAL SIZES DN - Nominal Size for Valves, Flanges and Fittings. International Definition refer 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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