DCI C1103 User manual

• (D)C1103
• (D)C1203
• (D)C2106
• (D)C2206
• (D)C3210
C Series
COMPRESSOR
Copyright © 2006 DCI. All Rights Reserved.
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(D
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Compressor Service & Maintenance Manual
92311, Rev. C, 08/13

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Compressor Service, Maintenance, and Parts Manual
Section I: INTRODUCTION
A. General Specifications
Section II: THEORY OF OPERATION
A. While Running
B. Theory of Operation While Not Running
Section III: MAINTENANCE
A. Compressor Head Intake Filter
B. Coalescing Filter
C. Time Operated Purge Valve
D. Tank Drain
Section IV SERVICE REPAIR INSTRUCTIONS
A. Troubleshooting Chart
B. Electrical
1. Replacing Pressure Switch
2. Replacing Power Switch
3. Replacing Compressor Head
4. Replacing Time Operated Purge Valve
C. Pneumatic
1. Replacing Check Valve
2. Replacing Differential Filter Indicator
3. Replacing Automatic Filter Float Drain
4. Replacing Desiccant Chamber
Section V ILLUSTRATED PARTS BREAKDOWN
A. Parts Listing
B. Electrical Schematic
C. Plumbing Schematic
C1000 Series Service & Maintenance Manual
Introduction SECTION I
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Introduction
C1000 Series Service & Maintenance Manual
Introduction
SECTION I
Combination
Wrenches
Blade
Screwdrivers:
Voltmeter
Phillips
This manual contains the necessary information to perform all “field serviceable” aspects of the DCI Oil-less Air Compressor line.
Please take the time to read this manual and understand the proper operation and service procedures before attempting to service
this machine. Our unique dryer purge system operates much differently than conventional air compressors. Understanding the
proper operation and design will ensure years of dependable operation.
Below is a listing of the basic tools required to properly service this equipment.
If you have any questions or need assistance in regards to any aspect ot the service and / or repair of this machine, please contact
the DCI Technical Support Department at:
Technical Support
1-800-624-2793
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INTRODUCTION
This manual contains the necessary instructions for the maintenance and/or service of the DCI air compressors.
There are 3 basic configurations available; single and dual head available in 115V and 230V, and the triple head available in 230V.
NOTE: ALL VOLTAGES +/- 5%
Configurations
1. Single 1 horsepower compressor head on 20 gal. Horizontal tank. (See Fig. A)
2. Dual 1 horsepower compressor heads on 20 gal. Horizontal tank. (See Fig. B)
3. Dual 1 horsepower heads on 30 gal. horizontal tank. (Not Shown)
Introduction
C1000 Series Service & Maintenance Manual
Introduction
Picture of Single
Horizontal Compressor
Model #C1103 & #C1203
Picture of Dual
Horizontal Compressor
Model # C2106 & #C2206
SECTION I
Fig. A Fig. B
Picture of Triple
Horizontal Compressor
Model # C3210
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C1000 Series Service & Maintenance Manual
Introduction
Model Specifications
C1103 3
C1203 3
C2106 6
C2206 6
C3210 10
3
C
1103
C3210 10
C2106 6
SECTION I
MODEL SPECIFICATIONS
Model CFM @ 80PSI Total HP Tank Capacity Dimensions (inches) Voltage Amps Circuit Breaker
L D H
C1103 3.95 1 20 34 24 29.5 115 13.4 15
C1203 3.95 1 20 34 24 29.5 230 6.7 10
C2106 7.95 2 20 34 24 29.5 115 26.8 30
C2206 7.95 2 20 34 24 29.5 230 13.4 15
C3210 11.85 3 30 46 26 36 230 21.1 30
NOTE: ALL VOLTAGES ARE +/- 5%
MODEL NUMBER MAXIMUM SIMULTANEOUS USERS
NOTE: Number of users based on 1.5cfm @ 80psi per user. Additional equipment such as air abrasion units, blow-guns, and lab equipment should
be factored into the system requirements.
Site Requirement Templates and additional technical information available through our Technical Service Department.
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C1000 Series Service & Maintenance Manual
Theory of Operation
Theory of Operation
THEORY OF OPERATION
While Running
To start the compressor, the user shall activate the compressor head or heads with the power switches located on the front center
of the machine. The selected motors will then begin to run and build pressure in the tank and piping system.
A. The air is taken in through the intake filters, located on the rear of each compressor cylinder. The dirt and dust is filtered out
of the intake filter to 5 microns in this process.
B. The air is then compressed with the pistons in each cylinder, and then travels through the after-cooler (copper) tubing, which
cools the air to help condense any moisture “humidity” taken in during the process of compression.
C. The wet / dirty compressed air and condensed moisture then travel through a coalescing filter assembly. This filter allows the
condensed moisture to fall to the bottom of the filter bowl via gravity, where it will be automatically expelled via the float
drain contained in the bottom of the filter bowl. The compressed air also travels through the coalescing filter element, which
removes 99.998% of all particles down to 0.01 microns. A filter change indicator located on the top of the filter housing
shows the condition of the element, and alerts the operator as to when the element is in need of replacement. GREEN
indicates the element has more useful life, while RED indicates the element is in need of replacement.
NOTE: The indicator only functions while compressed air is traveling through the filter with compressor running. The indicator
will ALWAYS read “GREEN” with compressors not running.
D. The compressed air then travels through the bottom of the desiccant “drying chamber”, where the remaining contained
moisture is reduced to a pressure dewpoint of -100°F, and then travels into the main storage tank for use in the dental
operatory.
E. When reaching its cut-off pressure of 100psi, the pressure switch will open and the compressor motors will stop.
NOTE: The time operated dryer purge valve DOES NOT open and purge when compressor stops, as it does on most competitive
brands. See Theory of Operation “While Not Running” for more information as to the proper operation of our purge valve.
SECTION II
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C1000 Series Service & Maintenance Manual
Theory of Oporation
Theory of Operation
THEORY OF OPERATION
While Not Running
A. When the motors stop after reaching the cut-out pressure of 100psi, the user will have clean / dry air ready for use in
the dental operatory. The compressor will remain in this “idle” state until the tank pressure drops to 80 psi, at which time
the compressor motors will turn on and return the running mode of operation.
B. The “Time Operated” dryer purge valve operates on a time basis instead of a “single cycle” basis used on most other
types of dental air compressors. Two timers, “located on the front of the valve assembly”, control how often and the
duration of each purge cycle.
SECTION II
NOTE: The compressor does not purge when the
compressor cycles off!
C. The “Left” timer knob on the purge valve, controls the
duration of the purge cycles. This timer is factory preset
and should not be adjusted. The factory setting is at the
maximum of 10 seconds.
D. The “Right” timer knob on the purge valve controls how
often the compressor purges moisture from the drying
chamber. The factory setting is 7 minutes, and should NOT
be adjusted.
E. A “TEST” button is located between the two timer knobs
to allow a technician to verify that the valve is operating
correctly.
By purging the drying chamber on a time basis, the DCI air
compressors ensure the drying chamber desiccant remains dry,
even during heavy usages, for consistent air quality.
Plumbing Schematic
Left
Motor Right Motor
Check
Valve Check Valve
Aftercooling
Tubing
Coalescing
Filter
Condensate
Drain
Drying Chamber
Flow/Check
Drying System
Pressure Gauge
Dryer Bypass
Ball Valve
To
Storage
Tank
Strainer
Shutoff
Valve
Time Purge
Valve
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C1000 Series Service & Maintenance Manual
Theory of Oporation
Theory of Operation
THEORY OF OPERATION
While Not Running
Electrical Schematic
SECTION II
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C1000 Series Service & Maintenance Manual
Maintenance
Maintenance
SECTION III
Unscrew the filter bowl by turning counter-clockwise. Lower the filter bowl to access the
filter element contained inside. The filter element is held in place with an O-ring and
internal ridges located in the bowl. Replace with DCI Part Number 2006, and reassemble
the filter bowl. Turn the dryer bypass valve to the ON position and check compressor for
proper operation by turning the power switches on.
NOTE: A “popping” relief valve indicates a clogged coalesing element OR
the Dryer Bypass valve is closed.
B. Coalescing Filter Element
The coalescing filter element should be checked with the compressor motors running. If
the indicator located on the top of the filter housing remains GREEN, the filter element has
additional useful life. However, if the indicator turns RED, the element should be changed.
To change the element, first turn off the compressor motor switches. Then turn off the
Dryer bypass valve as shown in (Fig. E). With dryer bypass valve in OFF position, press the
TEST button on the time operated purge valve to bleed pressure off of the drying system.
Depressurization of the drying system can be confirmed by reading the drying system
pressure gauge located on top of the drying chamber.
WARNING: DO NOT ATTEMPT TO SERVICE WITH SYSTEM PRESSURIZED.
Fig. D
Fig. E
ON
OFF
COMPRESSOR MAINTENANCE SCHEDULE
Maintenance Item Frequency
Intake Filter Elements Every Six Months (semi-annually)
Coalescing Filter Element Every 90 Days
Time Operated Purge Valve Every 60 Days
Tank Drain Every 90 Days
A. Compressor Head Intake Filter Elements
Dirty intake filter elements reduce the amount of air the compressor can take in. This
reduces air output and increases the load of the motors. Every six months, remove
the intake filter cover as shown in (Fig. D), to check for excessive dirt or discoloration.
Replace with DCI Part Number 2012 if needed. The filters are located on the rear of each
compressor cylinder.
MAINTENANCE
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