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Presentation on theme: "USER MAINTENANCE."— Presentation transcript:


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

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

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

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

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

7 i. Pumping Group Description
Lubrication is achieved via a splash* and pump * * feed system 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
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 i. Pumping Group Description
Filtration Path Intake Filter Water Separator Main Filtration Tower .

10 ii. The Air Compression Process

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

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

13 iv. Pressure Maintaining Valve
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 Air Intake filter ii. Filter cartridge
iii. Oil changes and types iv. Safety checks v. Compresor cleaning

15 i. Air Intake Filter Gently blow clean every 20 hrs and
re-insert rotating position. Change filter regularly: MCH hrs MCH hrs MCH 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 & 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 Synthetic oils Coltri Oil CE 750

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

20 v. Compressor Cleaning A 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 this Ensure 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 start Electric motor runs slowly

22 i. Air Odor Problem: Filter cartridge exhausted
Solution: Replace cartridge Problem: Piston rings worn out Solution: Replace piston rings Problem: Use of wrong oil Solution: Refer to user manual for correct lubricant

23 ii. Compressor Overheats
Problem: Compressor running backwards Solution: Check 3 phase connection Problem: Dirty intercoolers Solution: Clean intercoolers Problem: Suction /Release valve are not functioning, Solution: Clean or replace

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

25 iii. Decreasing air output
Problem: Suction/release valve malfunction Solution: Clean or change valves Problem: 3rd/4th stage piston worn Solution: Replace piston and rings Problem: Loose fitting or leaking gaskets Solution: Check leaks with soap solution & tighten fitting or replace gaskets

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

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

28 v. Electric Motor runs slowly
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

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