Transcript USER MAINTENANCE - Welcome - Coltri Compressors Maldives

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.
o
Pumping Group Description
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 .
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.
i.
Pumping Group Description
o
Lubrication is
achieved via a splash* and
pump * *
feed system
oThe main drive
wheel provides air flow to
cool the machine via fan blades
* MCH 6, 8,13 & 16 * * TROPICAL RANGE
i.
o
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
i.
Pumping Group Description
o Filtration Path
Intake Filter
Water Separator
Main Filtration
Tower
ii. The Air Compression
Process
iii. Safety Valves
- First Stage safety valve:
8 Bar
- Second Stage safety valve:
50 Bar
- Third Stage safety valve:
225/330 Bar
iv. Pressure Maintaining Valve
o
The function is to retain a
120 – 150 bar pressure in the
filter tower to ensure efficient
filtration
o Filter media functions best with
air flowing @ 120 - 150 bar
Check valve setting weekly
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
+
.
Maintenance
Routine
Maintenance routine

i. Air Intake filter
ii.
iii.
iv.
v.
Filter cartridge
Oil changes and types
Safety checks
Compresor cleaning
i.
Air Intake Filter
o Gently blow clean every 20 hrs and
re-insert rotating position.
o Change filter regularly:
MCH 6
MCH 13
MCH 16
100 hrs
80 hrs
70 hrs
ii. Filter Cartridge
o Replace before air starts
to smell:
MCH 6
50 Hrs*
MCH 13
50 Hrs*
MCH 16
40 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.
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
iii. Oil Changes &Type
o Synthetic oils
Coltri Oil CE 750
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. *
*If valves blow stop machine,
Call technician
v.
Compressor Cleaning
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.
Problem Solving
i. Air Odor
ii. Compressor overheats
iii. Decreasing air output
iv. Electric motor fails to start
v. Electric motor runs slowly
i. Air Odor
o Problem:
Solution:
Filter cartridge exhausted
Replace cartridge
o Problem:
Piston rings worn out
Solution: Replace piston rings
o Problem:
Solution:
Use of wrong oil
Refer to user manual for
correct lubricant
ii. Compressor Overheats
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
o Problem: Insufficient ventilation or
ambient temperature above
40 Celsius
Solution: Re-site compressor or use
additional forced ventilation
iii. Decreasing air output
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 output
o Problem: Intake air filter blocked
Solution: Clean/replace filter
o Problem: Air intake extension bent or
too small
Solution: Use larger section non
collapsing pipe/hose
o Problem: Piston rings worn
Solution: Replace piston rings
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
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