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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