2 Presentation Overview 1. Compressor function 2. Maintenance Routine 3. Problem solving
3 1. Compressor Function i. Pumping group description The air compression processSafety ValvesPressure maintaining valve
4 i. Pumping Group Description The main parts of a pumping unit are:Cylinders / headsPistons / con-rodsCrankcase / shaft
5 i. Pumping Group Description Cylinders are connectedwith Stainless Steel pipesThe pipes movepressurized airbetween the first,Second and thirdCylinders cooling it at the same time .
6 i. Pumping Group Description Each cylinder has two valves :Suction valveAllows air into cylinderto be compressed bythe piston.Release valveAllows pressurized air out after thepiston has compressed it further.
7 i. Pumping Group Description Lubrication isachieved via a splash* andpump * *feed systemThe main drivewheel provides air flow tocool the machine via fan blades* MCH 6, 8,13 & 16 * * TROPICAL RANGE
8 i. Pumping Group Description The Coltri Sub range uses 3 types of pumping unit :MCH 64 cylinders, splash feedMCH 8,13,16 & 323 cylinders, splash feedTropical plus range incorporate pump andsplash feedMCH 364 cylinders, oil pump
9 i. Pumping Group Description Filtration PathIntake FilterWater SeparatorMain Filtration Tower.
11 iii. Safety Valves First Stage safety valve: 8 Bar First Stage safety valve:8 BarSecond Stage safety valve:50 BarThird Stage safety valve:225/330 Bar
12 iv. Pressure Maintaining Valve The function is to retain a120 – 150 bar pressure in thefilter tower to ensure efficientfiltrationFilter media functions best withair barCheck valve setting weekly
13 iv. Pressure Maintaining Valve To set valve:Start compressor & open filling valveCheck gauge on separatorfor internal pressureAdjust by turning lower capAnti clockwise -Clockwise.
14 Maintenance Routine Air Intake filter ii. Filter cartridge iii. Oil changes and typesiv. Safety checksv. Compresor cleaning
15 i. Air Intake Filter Gently blow clean every 20 hrs and re-insert rotating position.Change filter regularly:MCH hrsMCH hrsMCH hrs
16 ii. Filter Cartridge Replace before air starts to smell: MCH 6 50 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.
17 iii. Oil Changes & TypeAfter 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 &TypeSynthetic oilsColtri Oil CE 750
19 iv. Safety Checks Check motor-engine and compressor bolts Check V belt tightnessCheck electric power supplyCheck compressor oil levelCheck function of safety valve and theircalibration. **If valves blow stop machine,Call technician
20 v. Compressor CleaningA dirty machine overheats, and does not allow to see clearly oil or air leaks.A weekly rinse with medium/low strength pressure pump will avoid thisEnsure that water does not enter the air intake, electric motor or electrical parts of the compressor system.
21 Problem Solving Air Odor Compressor overheats Decreasing air output Electric motor fails to startElectric motor runs slowly
22 i. Air Odor Problem: Filter cartridge exhausted Solution: Replace cartridgeProblem: Piston rings worn outSolution: Replace piston ringsProblem: Use of wrong oilSolution: Refer to user manual forcorrect lubricant
23 ii. Compressor Overheats Problem: Compressor running backwardsSolution: Check 3 phase connectionProblem: Dirty intercoolersSolution: Clean intercoolersProblem: Suction /Release valve are not functioning,Solution: Clean or replace
24 ii. Compressor Overheats Problem: Insufficient ventilation or ambient temperature above CelsiusSolution: Re-site compressor or use additional forced ventilation
25 iii. Decreasing air output Problem: Suction/release valve malfunctionSolution: Clean or change valvesProblem: 3rd/4th stage piston wornSolution: Replace piston and ringsProblem: Loose fitting or leaking gasketsSolution: Check leaks with soap solution& tighten fitting or replace gaskets
26 iii. Decreasing air output Problem: Intake air filter blockedSolution: Clean/replace filterProblem: Air intake extension bent or too smallSolution: Use larger section non collapsing pipe/hoseProblem: Piston rings wornSolution: Replace piston rings
27 iv. Electric Motor fails to start Problem: Three Phase, no supply or one phase “down”Single Phase, No supplySolution: Check supply, phases and condenser, electronic switches& relays
28 v. Electric Motor runs slowly Problem: Tight bearings within motorSolution: lubricate/service motorProblem: Loose electrical connectionSolution: Tighten connectionsProblem: Insufficient power supplySolution: Check rating of supplyProblem: Loose drive beltSolution: Tighten belt