USER MAINTENANCE. Presentation Overview 1.Compressor function 2.Maintenance Routine 3.Problem solving.

USER MAINTENANCE

Presentation Overview

1. Compressor function

2. Maintenance Routine

3. Problem solving

1. Compressor Function

i. Pumping group description

ii. The air compression process

iii. Safety Valves

iv. Pressure maintaining valve

i. Pumping Group Description

The main parts of a pumping unit are:

o Cylinders / heads

o Pistons / con-rods

o Crankcase / shaft

i. Pumping Group Description

o Cylinders are connected

with Stainless Steel pipes

o The pipes move pressurized airbetween the first,Second and thirdCylinders cooling it at the same time .

Each cylinder has two valves :Each cylinder has two valves :

Suction valveSuction valveAllows air into cylinder Allows air into cylinder

to be compressed by to be compressed by

the piston.the piston.

Release valveRelease valveAllows pressurized air out after theAllows pressurized air out after the

piston has compressed it further.piston has compressed it further.

i. Pumping Group Description

i. Pumping Group Description

o Lubrication is achieved via a splash* andpump * *feed system

oThe main drivewheel provides air flow tocool the machine via fan blades

* MCH 6, 8,13 & 16 * * TROPICAL RANGE

i. Pumping Group Description

o The Coltri Sub range uses 3 types of pumping unit :

MCH 6 4 cylinders, splash feed

MCH 8,13,16 & 323 cylinders, splash feed

Tropical plus range incorporate pump and splash feed

MCH 364 cylinders, oil pump

o Filtration PathFiltration Path

Intake FilterIntake Filter

Water SeparatorWater Separator

Main Filtration Main Filtration TowerTower

. .

i. Pumping Group Description

ii.ii. The Air Compression The Air Compression ProcessProcess

 - First Stage safety valve:

8 Bar- Second Stage safety valve: 50 Bar- Third Stage safety valve: 225/330 Bar

iii.iii. Safety ValvesSafety Valves

iv.iv. Pressure Maintaining Pressure Maintaining ValveValveo The function is to retain a The function is to retain a

120 – 120 – 150150 bar pressure in the bar pressure in the

filter tower to ensure efficient filter tower to ensure efficient

filtrationfiltrationo Filter media functions best with Filter media functions best with

air flowing @ 120 - 150 bar air flowing @ 120 - 150 bar

Check valve setting weeklyCheck valve setting weekly

iv.iv. Pressure Maintaining Pressure Maintaining ValveValveo To set valve:To set valve:Start compressor & open filling Start compressor & open filling valvevalve

Check gauge on separator Check gauge on separator for internal pressurefor internal pressure

Adjust by turning lower capAdjust by turning lower cap

Anti clockwise Anti clockwise - -Clockwise Clockwise + +. .

Maintenance routine

i. Air Intake filter

ii. Filter cartridge

iii.Oil changes and types

iv.Safety checks

v. Compresor cleaning

Maintenance RoutineMaintenance Routine

o Gently blow clean every 20 hrs and re-insert rotating position. o Change filter regularly:

MCH 6 100 hrsMCH 13 80 hrs MCH 16 70 hrs

i.i. Air Intake FilterAir Intake Filter

o Replace before air startsReplace before air starts

to smell:to smell:

MCH 6 MCH 6 50 Hrs*50 Hrs*

MCH 13 MCH 13 50 Hrs* 50 Hrs*

MCH 16 MCH 16 40 Hrs*40 Hrs**@ 20 Celsius ambient temp. Filter lifespan decrease when ambient *@ 20 Celsius ambient temp. Filter lifespan decrease when ambient

temperature and humidity increase. Halve the values listed above for temperature and humidity increase. Halve the values listed above for temperature of 30 degrees and above.temperature of 30 degrees and above.

ii.ii. Filter CartridgeFilter Cartridge

iii.iii. Oil Changes & TypeOil Changes & Type

After initial 50 operating Hrs and then every:

MCH6* 50 hrs synthetic oil

MCH 13/16* 200 hrs synthetic oil

MCH 36 * 250 hrs synthetic oil

* Coltri Synthetic Oil only recommended. Mineral and synthetic oils must not be mixed

iii.iii. Oil Changes &TypeOil Changes &Type

o Synthetic oils Coltri Oil CE 750

iv.iv. Safety ChecksSafety Checks

o Check motor-engine and compressor boltsCheck motor-engine and compressor bolts

o Check V belt tightness Check V belt tightness

o Check electric power supplyCheck electric power supply

o Check compressor oil levelCheck compressor oil level

o Check function of safety valve and theirCheck function of safety valve and their calibration. calibration. ** *If valves blow stop machine,*If valves blow stop machine, Call technicianCall technician

o A dirty machine overheats, and does not allow to see clearly oil or air leaks.

o A weekly rinse with medium/low strength pressure pump will avoid this

o Ensure that water does not enter the air intake, electric motor or electrical parts of the compressor system.

v.v. Compressor CleaningCompressor Cleaning

ii. Air Odor

iii.Compressor overheats

iv.Decreasing air output

v. Electric motor fails to start

vi.Electric motor runs slowly

Problem SolvingProblem Solving

o Problem: Filter cartridge exhausted Solution: Replace cartridge

o Problem: Piston rings worn out Solution: Replace piston rings

o Problem: Use of wrong oil Solution: Refer to user manual for correct lubricant

i. Air Odori. Air Odor

o Problem: Compressor running backwardso Solution: Check 3 phase connection

o Problem: Dirty intercoolers Solution: Clean intercoolers

o Problem: Suction /Release valve are not functioning,

Solution: Clean or replace

ii. Compressor Overheatsii. Compressor Overheats

o Problem:Problem: Insufficient ventilation or Insufficient ventilation or ambient ambient

temperature above temperature above 40 Celsius 40 Celsius

Solution:Solution: Re-site compressor or Re-site compressor or use use additional forced ventilation additional forced ventilation

ii. Compressor Overheatsii. Compressor Overheats

o Problem: Suction/release valve malfunction

Solution: Clean or change valves

o Problem: 3rd/4th stage piston worn Solution: Replace piston and rings

o Problem: Loose fitting or leaking gaskets Solution: Check leaks with soap solution & tighten fitting or replace gaskets

iii. Decreasing air outputiii. Decreasing air output

o Problem:Problem: Intake air filter blocked Intake air filter blocked

Solution:Solution: Clean/replace filter Clean/replace filter

o Problem:Problem: Air intake extension bent Air intake extension bent or or too small too small Solution:Solution: Use larger section non Use larger section non

collapsing pipe/hose collapsing pipe/hose

o Problem:Problem: Piston rings worn Piston rings worn Solution:Solution: Replace piston rings Replace piston rings

iii. Decreasing air outputiii. Decreasing air output

iv. Electric Motor fails to iv. Electric Motor fails to startstartProblem: Problem: Three Phase, no supply or Three Phase, no supply or one one phase “down” phase “down”

Single Phase, No supplySingle Phase, No supplySolution:Solution: Check supply, phases and Check supply, phases and

condenser, electronic condenser, electronic switches switches

& relays& relays

Problem: Problem: Tight bearings within motorTight bearings within motorSolution:Solution: lubricate/service motor lubricate/service motor

Problem:Problem: Loose electrical connection Loose electrical connection Solution:Solution: Tighten connections Tighten connections

Problem:Problem: Insufficient power supply Insufficient power supply Solution:Solution: Check rating of supply Check rating of supply

Problem:Problem: Loose drive belt Loose drive belt Solution:Solution: Tighten belt Tighten belt

v. Electric Motor runs v. Electric Motor runs slowlyslowly