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

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Presentation on theme: "USER MAINTENANCE. Presentation Overview 1.Compressor function 2.Maintenance Routine 3.Problem solving."— Presentation transcript:


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

3 1.Compressor Function i.Pumping group description ii. The air compression process iii. Safety Valves iv. Pressure maintaining valve

4 i.Pumping Group Description The main parts of a pumping unit are: o Cylinders / heads o Pistons / con-rods o Crankcase / shaft

5 i.Pumping Group Description o Cylinders are connected with Stainless Steel pipes o The pipes move pressurized air between the first, Second and third Cylinders cooling it at the same time.

6 Each cylinder has two valves : Suction valve Allows air into cylinder to be compressed by the piston. Release valve Release valve Allows pressurized air out after the piston has compressed it further. i.Pumping Group Description

7 o Lubrication is achieved via a splash* and pump * * feed system o The main drive wheel provides air flow to cool the machine via fan blades * MCH 6, 8,13 & 16 * * TROPICAL RANGE

8 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 & 32 3 cylinders, splash feed Tropical plus range incorporate pump and splash feed MCH 36 4 cylinders, oil pump

9 o Filtration Path Intake Filter Water Separator Main Filtration Tower. i.Pumping Group Description

10 ii.The Air Compression Process

11 - First Stage safety valve: 8 Bar - Second Stage safety valve: 50 Bar - Third Stage safety valve: 225/330 Bar iii.Safety Valves

12 iv.Pressure Maintaining Valve o The function is to retain a 120 – 150 bar pressure in the 120 – 150 bar pressure in the filter tower to ensure efficient filter tower to ensure efficient filtration filtration o Filter media functions best with air bar air bar Check valve setting weekly Check valve setting weekly

13 iv.Pressure Maintaining Valve o To set valve: Start compressor & open filling valve Check gauge on separator for internal pressure Adjust by turning lower cap Anti clockwise - Clockwise +.

14 Maintenance routine i. Air Intake filter ii.Filter cartridge iii.Oil changes and types iv.Safety checks v.Compresor cleaning Maintenance Routine

15 o Gently blow clean every 20 hrs and re-insert rotating position. o Change filter regularly: MCH hrs MCH hrs MCH hrs i.Air Intake Filter

16 oReplace before air starts to smell: MCH 6 50 Hrs* MCH Hrs* MCH Hrs* 20 Celsius ambient temp. Filter lifespan decrease when ambient temperature and humidity increase. Halve the values listed above for temperature of 30 degrees and above. ii.Filter Cartridge

17 iii.Oil 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

18 iii.Oil Changes &Type o Synthetic oils Coltri Oil CE 750

19 iv.Safety Checks o Check motor-engine and compressor bolts o Check V belt tightness o Check electric power supply o Check compressor oil level o Check function of safety valve and their calibration. * calibration. * *If valves blow stop machine, *If valves blow stop machine, Call technician Call technician

20 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.Compressor Cleaning

21 i. Air Odor ii. Compressor overheats iii. Decreasing air output iv. Electric motor fails to start v. Electric motor runs slowly Problem Solving

22 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 Odor

23 o Problem: Compressor running backwards o 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 Overheats

24 o Problem: Insufficient ventilation or ambient temperature above 40 Celsius Solution: Re-site compressor or use additional forced ventilation Solution: Re-site compressor or use additional forced ventilation ii. Compressor Overheats

25 o Problem: Suction/release valve malfunction Solution: Clean or change valves o Problem: 3 rd /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 output

26 o Problem: Intake air filter blocked Solution: Clean/replace filter Solution: Clean/replace filter o Problem: Air intake extension bent or too small Solution: Use larger section non collapsing pipe/hose Solution: Use larger section non collapsing pipe/hose o Problem: Piston rings worn Solution: Replace piston rings Solution: Replace piston rings iii. Decreasing air output

27 iv. Electric Motor fails to start Problem: Three Phase, no supply or one phase down Single Phase, No supply Single Phase, No supply Solution: Check supply, phases and condenser, electronic switches & relays & relays

28 Problem: Tight bearings within motor Solution: lubricate/service motor Problem: Loose electrical connection Solution: Tighten connections Problem: Insufficient power supply Solution: Check rating of supply Problem: Loose drive belt Solution: Tighten belt v. Electric Motor runs slowly

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