Coltri Sub
Coltri Sub
VERSION: English
INSTRUCTION
MANUAL
2 TECHNICAL DESCRIPTION
2.1 Operating principle ............................................................................................................... 10
2.2 Description of the pump unit ................................................................................................. 11
2.2.1 Monobloc unit ............................................................................................................. 12
2.2.2 Head unit .................................................................................................................... 13
2.2.3 Safety valves ............................................................................................................... 13
2.2.4 Lubricating unit ............................................................................................................ 14
2.2.5 Pressure maintenance valve ........................................................................................ 14
2.2.6 Cooling pipes .............................................................................................................. 14
2.2.7 Filters .......................................................................................................................... 15
2.2.8 Frame and sound-proofed casing ................................................................................. 16
2.3 Machine control ................................................................................................................... 16
3 TECHNICAL CHARACTERISTIC
3.1 Technical characteristics of the pump unit ............................................................................ 18
3.1.1 Machine series MCH 13-16-26-32/ET .......................................................................... 18
3.1.2 Sizes and weights ....................................................................................................... 19
3.2 Noise ................................................................................................................................... 19
2 Index
UNPACKING AND HANDLING THE MA
UNPA CHINE
MACHINE 5
5.1 Unpacking the machine ........................................................................................................ 25
INSTALLA
INSTALLATION
ALLATION 6
6.1 Positioning ........................................................................................................................... 27
CONTR OL P
CONTROL ANEL
PANEL 7
7.1 Control panel ........................................................................................................................ 34
STAR
STAR
ARTT UP 8
8.1 Filling the machine ............................................................................................................... 36
USE 9
9.1 Preliminary operations ......................................................................................................... 40
Index 3
PUTTING THE MA CHINE OUT OF OPERA
MACHINE TION
OPERATION
10 AND DISMANTLING THE MACHINE
11 MAINTENANCE
11.1 General notes ...................................................................................................................... 48
12 TR OUBLESHOO
TROUBLESHOO TING
OUBLESHOOTING
12.1 List of faults ......................................................................................................................... 62
13 MACHINE DIAGRAMS
13.1 Compression diagram .......................................................................................................... 63
13.2 Electrical diagram ................................................................................................................ 64
4 Index
SPARE P
SPARE AR
PAR TS
ARTS 14
14.1 Exploded view of the machine parts .................................................................................. 69
Monobloc .......................................................................................................................... 70
Pistons rod unit ................................................................................................................. 72
Cylinders unit .................................................................................................................... 74
Head unit .......................................................................................................................... 76
Cooling pipes .................................................................................................................... 78
Filtering system ................................................................................................................ 80
MCH 13-16/ET condensate trap ........................................................................................ 82
MCH 26-32/ET condensate trap ........................................................................................ 84
MCH 13-16/ET .................................................................................................................. 86
MCH 26-32/ET .................................................................................................................. 88
MCH 26-32/ET front panel ................................................................................................. 90
Index 5
To make the manual easier to read, the following terms have been adopted:
DANGER
The term DANGER is used when failure to comply with the regulations or tampering with the
parts could lead to serious injury or even death.
WARNING
The term WARNING is used when failure to comply with the instructions could cause damage to the
machine and other parts associated with the same or to the surrounding area.
To protect exposed persons or objects, a special booklet entitled “SAFETY REGULATIONS” is supplied
with the machine and must be considered an integral part of the Compressor Instruction Manual.
This manual is the property of AEROTECNICA COLTRI S.r.l. and any copying of the same, even partial, is
prohibited.
6 Use in brief
USE IN BRIEF
The following information must be referred to and applied only when this manual and the
“Safety regulations” manual have been read and their contents have been understood and
assimilated.
- Check whether or not the area where the machine is installed has suitable ventilation
(see chapter 6.1).
- If the machine is installed in a place without the required characteristics above, connect the air intake
extension (see chapter 6.2.1).
- Connect the refill hoses to the machine (see chapter 6.2.2).
- Connect the switchboard to the mains power supply (see chapter 6.2.3).
- Check the level of the lubricating oil in the pump unit (see chapter 8.2). If the level is too low, turn off
the machine and add or change the oil (see chapter 8.1).
- Turn on the machine using the main switch (see chapter 7.1).
- Check the direction of rotation of the motor. If the direction of rotation does not coincide with the one
shown on the belt guard, turn off the machine and invert the two phases on the main power supply
(see chapter 7.2).
- Check the operation of the safety valve (see chapter 9.1).
- Check for wear on the cylinders to be filled (see chapter 9.1).
- Set the pressure switch on the control panel to the refill pressure value given on the cylinder
(see chapter 8.1).
- Fit the hose attachment on the cylinder and check that the taps on the hose are open
(see chapter 9.2).
- Turn on the cylinder tap and start up the compressor (see chapter 9.2).
- When the filling operation has been completed, the compressor is stopped automatically by the
pressure switch, turn off the cylinder and the hose taps.
- Press the pressure bleed button and disconnect the cylinder attachment (see chapter 9.2).
Use in brief 7
1 GUARANTEE AND ASSIST
GUARANTEE ANCE
ASSISTANCE
1.1 Guarantee
AEROTECNICA COLTRI S.r.l. guarantees its compressors against any design or manufacturing defect
or fault and against any fault in the materials for a period of twelve months from the delivery of the
machine. The customer must inform AEROTECNICA COLTRI S.r.l. in writing of any fault and/or defect
that may be found within eight days from its discovery by means of a registered letter with advice of
receipt or telegramme, otherwise the guarantee will become null and void.
The guarantee is only valid against faults or defects that may arise with the compressor used under
proper operating conditions according to the instructions given in this manual and with the maintenance
carried out at the intervals as provided for.
The guarantee expressly excludes any faults arising as a result of improper use of the machine, of
atmospheric agents and of damage due to transport; the guarantee does not cover the expendable
materials and materials required for the periodic maintenance which are at the customer’s entire
expense. The guarantee will, in any case, become automatically null and void if the compressor is
tampered with or if it has been serviced by technicians who are not authorized to do so by
AEROTECNICA COLTRI S.r.l.
Any compressor that is acknowledged to be faulty due to defects in the design, manufacturing or materials
used, will be repaired or replaced free of charge by AEROTECNICA COLTRI S.r.l. at its factory in San
Martino della Battaglia (BRESCIA). The customer will be responsible for the costs of transport and
carriage as well as for any spare parts and expendable materials.
If it should be necessary for service to be carried out under the guarantee at the customer’s premises,
the latter will be responsible for the travel and transfer costs for the staff sent out by
AEROTECNICA COLTRI S.r.l.
Taking delivery of the machine and/or of any faulty components or the transfers for the inspection of
faults and/or defects as notified by the customer, will not, however, denote any implicit acknowledgement
regarding the effectiveness of the guarantee.
Repairs and/or replacements made by AEROTECNICA COLTRI S.r.l. during the guarantee period will
not extend the duration of the same.
Acknowledgment of the guarantee does not itself imply any liability for compensation on the part of
AEROTECNICA COLTRI S.r.l.
AEROTECNICA COLTRI S.r.l. does not assume any responsibility for injury to persons or damage to
property or for any other direct or indirect damage (loss of production or missed profit, etc.) that may be
attributable to faults or defects of the compressor, except for those cases in which a serious fault can be
attributed to the company.
1.2 Assistance
The AEROTECNICA COLTRI S.r.l. technicians are available for any kind of routine or additional
maintenance work.
The request for technical assistance must be sent to AEROTECNICA COLTRI S.r.l. at the following
address:
AEROTECNICA COLTRI S.r.l.
Via Colli Storici, 177
25010 San Martino della Battaglia (BRESCIA) ITALIA
Fax: +39 030 9910283
e-mail: [email protected]
Technical description 9
2.1 Operating principle
1 2
3 4
The air circulating around the compressor, which does not contain any harmful fumes, is taken into the
intake filter and introduced through the intake valve into the cylinder of the first stage where the first
compression takes place.
A part of the heat produced in the compression is dissipated by the flow of air created by the fan through
the head and relative valves, piston, cylinder, monobloc and lubricating oil; the heat remaining in the
compressed air is dissipated in the long piping connecting one stage of the compression to another and
which acts as a radiator; the temperature at the hose outlet is just a few degrees higher than that of the
environment.
The operating temperatures of each stage are: at the pipe connection that goes to the intake cylinder:
about 15-20 °C above the environmental temperature (it feels warm to the touch), to the pipe connection
that starts from the head (from the discharge valve), about 80-100 °C.
10 Technical description
The intake air contains a certain degree of humidity according to atmospheric conditions. During the
compression and subsequent cooling, the humidity condenses and together with the particles of lubricating
oil forms a milky white emulsion that precipitates into the separators.
The compression diagram is included in chapter 13.
The pumping unit has the task of producing compressed air at high pressure (200-300 bar) and purifying
it by means of the decantation and filtering systems until it reaches a level of purity equal to or higher
than the limits set by the standards DIN 3188 - UNI EN 132 - CGA/E, or to increase the pressure of the
gas inhaled (only inert - non-explosive gases).
This unit consists of the following components (Fig. 5-6):
Table 1
N° Description N° Description
5
6
Technical description 11
2.2.1 Monobloc unit
12 Technical description
Head unit (Fig. 10) 2.2.2
The purpose of the safety valves (see figure 5) is to protect the machine (and the cylinders) from
overpressure.
These valves are pre-calibrated in the factory at the following pressures:
- safety valve for 1st stage: 8 bar;
- safety valve for 2nd stage: 50 bar;
- safety or final valve for 3rd stage: 225 bar - or 330 bar.
WARNING
Under no circumstances may these valves be altered to increase the calibrated pressure.
If these valves should come into operation, check the cause that has led to the maximum pressure and
take steps according to the instructions given in paragraph 12.1.
Any tampering with the safety valves causes serious damage and an immediate cancellation of the
guarantee.
Technical description 13
2.2.4 Lubricating unit
11
This valve is fitted after the final filter. Just a few seconds after the compressor has been started up, it
keeps the pressure of the entire system at 100 ± 20 bar (see exploded view Chapter 14), for the purpose
of eliminating as much water as possible from the air. It also acts as a non-return valve.
12
14 Technical description
Filters 2.2.7
13
14
Technical description 15
2.2.8 F
Frr ame and sound-pr oof
sound-proof ed casing (Fig
oofed (Fig.. 15-16)
15
16
MCH 13-16/ET
The machine function controls are located on an
electric control panel (Fig. 17).
Apart from the various control buttons, this panel
also includes an hour counter that enables the
number of machine operating hours to be
memorized.
17
16 Technical description
MCH 26-32/ET
This model also has the same control buttons as
for model MCH 13-16/ET.
For model MCH 26-32/ET, the same controls are
doubled up on two independent control panels
(Fig. 18) which each control one of the two pump
units present inside the refill station.
18
Technical description 17
3 TECHNICAL CHARACTERISTIC
The pump unit consists of: three compression stages, three cylinders, forced air cooling by means of a
large diameter fan, splash lubrication with immersed tangs, stainless steel cooling pipes.
Table 1
MCH 13/ET MCH 16ET MCH 26/ET MCH 32/ET
Max. non-continuous peak
pressure
225 o 330 bar - 3200 o 4700 psi
Max. non-continuous working
pressure
Capacity approx. 210 lt/min 13 m3/h approx. 260 lt/min 16 m3/h approx. 420 lt/min 26 m3/h approx. 520 lt/min 32 m3/h
Speed of rotation 1350 r.p.m. 1550 r.p.m. 1350 r.p.m. 1550 r.p.m.
Piston stroke 40 mm
400V - 50Hz
Tension and frequency 440V - 60Hz
(three-phase) 230V - 50Hz
230V - 60Hz
18 Technical characteristics
Sizes and weights (Fig. 18-19) 3.1.2
18 19
Table 2
Noise 3.2
The Compact series of compressors have been designed and built with the objective of reducing acoutsic
pressure to a minimum.
Technical characteristics 19
The reading of the machine noise level was taken
from the “operator’s work place” (Fig. 20), with the
following methods and results:
20
Table 3
Level of acoustic pressure at the operator’s work place dB(A) 79,4 dB(A) 81 dB(A) 72,4 dB(A) 75
Level of acoustic power dB(A) 91,5 dB(A) 94,5 dB(A) 92,7 dB(A) 97,1
Peak level - - - -
INSTRUMENTS
Bruel & Kjacr sound level integrating meter Mod. 2231 cl. 1
Microphone for sound level meter Mod. 4155 cl. 1
Gauge Mod. 4230 cl. 2
Whenever the machines are used for work in environments where the daily noise level to which the
operators are exposed is higher than 80 dBA, the employer must take steps to apply all the measurements
necessary to safeguard the operator’s health. In particular, the operators must, if necessary, use all the
individual protection devices to protect themselves from the noise level.
20 Technical characteristics
PRECAUTIONS FOR USE AND
PRECAUTIONS
MAINTENANCE 4
Refer to the specific “Safety Regulation Manual” which is supplied enclosed with this manual (and which
forms an integral part of the same).
The MCH 13-16-26-32/ET Compact series of compressors are electrically driven, automatically operated
machines.
Therefore the term “operator” as repeatedly defined in this manual refers to the following professional
figures:
- PERSON IN CHARGE OF MAINTENANCE, this is the person entrusted with the handling, installation,
start-up, regulation, cleaning, repair, changing of the tooling and maintenance of the machine.
This person must be a qualified member of staff who has followed courses of specialization and who
has had experience with the handling, installation, start-up and maintenance of machines and plants
of a mechanical, electrical and pneumatic type.
It is always advisable for the person in charge of maintenance to follow a training and specialization
course on the machine given by the AEROTECNICA COLTRI S.r.l. technicians.
- PERSON IN CHARGE OF OPERATION, this is the person responsible for operating the machine whose
work must be limited only to filling the cylinders and the control operations.
This person must be perfectly acquainted with all the machine instructions and operating methods as
described in this manual and the regulation manual.
21
The MCH 13-16/ET Compact (Fig. 22) and MCH 26-32/ET Compact (Fig. 23) series of compressors
are equipped with a series of protection guards fitted with screws and safety devices to guarantee the
operator’s safety, by limiting the work area and ensuring good operating conditions.
The figure shows the safety devices provided on the compressors and the information labels applied.
22
23
22 Precautions for use and maintenance
Table 1
POSITION SAFETY DEVICE DESCRIPTION INSPECTION
Safety valves. Protect the third stage and the cylinders The safety valve must be checked at
from being overfilled; it is calibrated each refill; start up the compressor with
during the inspection of the compres- the cylinder valves closed and the end
1 sors. valve open. Check that the safety valve
starts operating correctly with the pres-
s ur e g a ug e , o p e n t he va l ve s a nd
proceed with the refill.
Manual condensate discharge taps. The c o nd e ns a t e i s a m i l k y- w hi t e Open the discharge taps every 10-15
emulsion formed of oil and water. minutes and make sure the condensate
The absorption of water by the filter comes out visibly and consistently.
causes wear on the fi lter i tself and If the condensate is discharged automa-
consequent contamination. tically, check that it operates correctly by
4
opening the manual discharge taps. The
condensate should be present in mini-
mum quantities.
Active carbon filter and molecular sieve. The quality of the air depends to a great The cartridge must be replaced before
extent on the conditions of the filter and the air becomes foul smelling.
5 sieve. For the frequency of replacement, see
the instructions in Chapter 11, "Main-
tenance".
6 Electrical switcboard built to EN 60204-1 regulations with IP 54 level of protection and fitted with a lock and key.
Pressure switch that can be manually calibrated showing the maximum cylinder filling pressure; when the set pressure is reached,
9 the compressor turns off.
Sealed hour counter to memorize the actual hours of operation in order to be able to carry out the maintenance procedures at
10 the proper intervals.
11 Danger of crushing hands symbol (if the side panels are removed).
20 Rating plate on the electric motor giving data concerning voltage, phases, frequency, breaking capacity.
23 Hose area : danger of direct contact by the operator if breakage should occur during cylinder filling.
(see chapter 11) Warning to cut off the power supply before carrying out any maintenance work.
In some areas of the machine there are some residual risks that could not be eliminated during the
design phase or protected by guards due to the particular operation of the compressors model
MCH 13-16-26-32/ET Compact (Fig. 24-25). Each operator must be aware of the residual risks present
on the machine in order to avoid possible accidents.
24 25
Table 2
POSITION DESCRIPTION
Danger of polluting the air produced owing to the possibility of mixing fumes or vapours from the lubricating oil with
1 the compressed air produced.
Electrical danger. Use the machine with suitable protection from the electrical power supply especially in the presence
2 of water and humidity.
Danger deriving from the noise emitted by the compressor if maintenance work is carried out without the safety
3 guards.
Pump unit area : danger from heat. For any maintenance operation (requiring the removal of the safety guard) wait
4 about 30 minutes after turning off the engine.
Transmission belt area: danger of crushing or dragging by the belts when maintenance work is carried out without
5 the safety guards.
6 Cooling fan area: danger of impact and abrasion if the cylinders are refilled without the safety guards.
The machines in the Compact series are delivered fully assembled, but with the hoses supplied
separately.
The compressors are packed in cardboard boxes fitted on europallets to make handling and transportation
easier.
26
Having removed the compressor from its pack as described in the previous paragraph, the machine can
be moved to its place of installation.
27
28
26 Unpacking and handling the machine
I NST
TAALLA TION
ATION 6
This chapter provides a description of the operations for installing the machine.
The following instructions presume that the operator has already become familiar with the regulations
given in Chapter 4, “Precautions for use and maintenance”.
WARNING
Before proceeding with the installation operations described below, read Chapter 4, “Precautions for use
and maintenance” carefully and proceed as directed.
Posit io n in g 6.1
1 Position the machine in the chosen area and check that it is on a level (the plane should not be at an
angle of more than 5° to assure perfect lubrication). For the machine sizes, see paragraph 3.1.2
“Sizes and weights”.
WARNING
The compressors used on board boats can be certified with inspections by R.I.Na (Italian Register of
Shipping), to be requested as a special supply.
2 Check that in the place chosen for installation there are suitable ventilation conditions:
- a good change of air (several windows), no dust and no risks of explosion, corrosion or fire.
3 Use in environments with a temperature of over 40 °C makes it necessary to use synthetic lubricating
oil and air-conditioning must be provided for the environment.
Installation 27
4 Position the machine at a minimum distance
of 1 m. from the surrounding walls and at a
distance of not less than 1.5 m. from the
ceiling in order not to compromise the proper
operation and cooling of the pump unit
(Fig. 29).
29
5 Make sure that the machine is in a well-lit area, so that each detail can be clearly made out (especially
the writing on the plates).
Add artificial lighting to the area if the natural lighting is not suffieint for the requirements mentioned.
6.2 Connections
If the machine is installed in a place without the ventilation features as referred to in the previous
paragraph, it is necessary to fit the system with an extension to take in air from the outside or from a
place with the above-mentioned ventilation characteristics.
28 Installation
MCH 13-16/ET Compact
To connect the extension, proceed as follows:
MCH 13-16/ET Compact
1 Remove the upper protective cover by
unscrewing the fixing screws (Fig. 31).
31
32
WARNING
Only use a flexible pipe provided with a steel spiral internal reinforcement to prevent bending and a
consequent reduction in the cross section.
Installation 29
2 Connect the extension pipe to the connector
(Fig. 33) (2 in model MCH 26-32/ET
Compact).
33
30 Installation
36 MCH 26-32/ET Compact
37
5 Position the end of the extension on which the intake filter is fitted (air intake) in a ventilated place
protected from atmospheric agents.
38
Installation 31
7 Make sure that there are no bends or
breakages along the length of the pipe
(Fig. 39).
If the extension should have broken during
the connection to the head, it must be
replaced.
WARNING
Make sure that the air intake is away from
exhaust fumes given off by internal-combustion
engines or harmful fumes.
39
For the compressor model MCH 26-32/ET Compact, the following operations must be carried
out twice (bearing in mind that this model is double.
40
2 Connect hose N°2 in the same way as described in the previous point (4 for the model MCH 26-32/ET
Compact).
3 A torque wrench should be available to fasten the hoses.
32 Installation
4 Tighten the hoses to the machine with a
torque wrench setting of 15Nm (Fig. 41).
41
NOTE:
- the hoses should be replaced every so often (every year or every 1000 hours) or when they show signs
of being scratched. For this purpose, check the number of operating hours of the hoses that are to be
disconnected (on the hour counter).
- The minimum radius of curvature of each hose must not be less than 250 mm.
WARNING
Before fitting the plug, make sure that the
installation has been set up in accordance with
the regulations in force in the country where the
compressor has been installed.
3 The mains power supply should be provided with an effective grounding system. It is particularly
important to check that the earth resistance value complies with the protection and operating
requirements of the electrical installation of the compressor.
WARNING
An effective machine earthing system is of fundamental importance for safety purposes.
Installation 33
7 CONTR OL P
CONTROL ANEL
PANEL
This chapter provides a description of the functions carried out by the various devices fitted on the
control panel.
The control panel has three operating buttons and the hour counter to memorize the number of machine
operating hours (Fig. 43-44).
1 ON - green button.
It enables the compressor to be started up.
The button has a light inside that comes on
when it is pressed.
(The general switch must be in the “ON”
position).
4 HOUR COUNTER
It enables the actual operating hours to be
memorized in order to be able to carry out
the maintenance work as provided for.
44
34 Control panel
Indication and control devices 7.2
Apart from the control panel, the front panel of the machine is also fitted with some devices to control the
pressure, the discharge of the condensate, the strainer filter and the level of the lubricating oil
(Fig. 45-46). Bear in mind that for model MCH 26-32/ET Compact, all the devices are double.
2 Pressure switch
It enables the maximum cylinder filling
pressure to be set and displayed.
During the cylinder filling phase, the pressure
switch stops the compressor when it reaches
the maximum pressure as shown by the red
cursor.
3 Strainer filter
The purpose of this device is to withhold the
impurities present in the air before they enter
the cylinders.
46
Control panel 35
8 STAR
STAR
ARTT UP
This chapter describes the operations regarding the machine start up phase.
The following instructions presume that the operator has already become familiar with the precautions
given in Chapter 4 “Precautions for use and maintenance” and that the machine has been installed
according to the instructions given in the previous chapter.
WARNING
Before proceeding with the start up operations described below, read chapter 4, “Precautions for use
and maintenance” very carefully and follow the advice given.
47
36 Start up
MCH 13-16/ET Compact
The oil is added by removing the cap marked with
the word “OIL” (Fig. 48) for model MCH 13-16/ET,
while for model MCH 26-32/ET the two oil caps
located on the upper cover of the machine
(Fig. 49) and marked with the letters “A” and “B”
must be unscrewed.
The quantity of oil to be poured in is 1.5 lt. and the
level should be checked with the machine turned
off, bearing in mind that an excess amount of oil
may cause infiltrations in the cylinders and a
deposit on the valves. On the contrary, if the oil
level is too low, the tang of the connecting rod is
prevented from providing the correct lubrication with
the possibility of causing a seizure of the cylinders.
49
Checks 8.2
50
Start up 37
2 Turn the machine on by moving the general
switch to the “ON” position. Check that the
machine has been switched on by looking to
see the red light of the “OFF” button (Fig. 51).
3 Run the compressor for about 10 minutes then
leave it at a standstill for 20 minutes.
51
52
38 Start up
5 The operation to check the level of the lubricant must be carried out when the machine arrives and
then before starting up the compressor. It must be remembered that if the level is too low or too high
it may compromise the running of the compressor.
6 In order to check the correct connection of the electrical phases, the engine should be turned on and
the direction of rotation checked.
54
55
WARNING
The yellow/green wire corresponds to the earthing.
DO NOT disconnect or invert this wire.
56 57
Start up 39
9 USE
This chapter describes the operations required for refilling the cylinders.
The following instructions presume that the operator has already become familiar with the precautions
given in Chapter 4 “Precautions for use and maintenance” and that the machine has been started up
according to the instructions given in the previous chapter.
WARNING
Before proceeding to use the machine as described below, read chapter 4, “Precautions for use and
maintenance” very carefully and follow the advice given.
1 Check that the safety valve is operating properly by starting up the compressor with the end taps
turned off so that the pressure in the circuit rises quickly and the valve comes into operation at the
set pressure.
The valve is pre-calibrated in the factory at a pressure of 225 bar or 330 bar.
WARNING
Under no circumstances may the calibration pressure of these valves be increased. Any tampering
with the safety valves may cause serious damage to the machine or to persons and a cancellation of
the guarantee.
DANGER
If the cylinders should show evident signs of internal and/or external corrosion, it is not advisable to
proceed with the filling operation, even if they comply with inspection requirements.
WARNING
Only use inspected cylinders provided with the relative approval.
The cylinder operating and filling pressure values are given on the cylinders themselves.
It is prohibited to exceed this refill pressure value.
40 Use
After refilling, the cylinders must not be emptied
completely, even during winter storage, to prevent
damp air from getting in (Fig. 58).
58
60
Use 41
MANUAL CONDENSATE DISCHARGE
4 Place a container under the two condensa-
te sniffle valves and then proceed with the
manual discharge by turning on the
repsective taps (Fig. 61).
61
62
63
42 Use
Refilling the cylinders 9.2
During this operation, the operator’s position is that shown in chapter 3.2 “Noise”.
WARNING
During the refilling of the cylinders it is compulsory for staff who are not involved with the task to keep a
distance of at least three metres. Furthermore, it is not permitted to disconnect the hoses from the
connectors or from the refill tap while the machine is under pressure.
INDICATION
During the cylinder refill phase, it is advisable to immerse the cylinders in cold water in order to reduce
the drop in pressure when the cylinders cool down.
64
65
Use 43
1 Fit hose attachment “1” to the cylinder valves
and turn on tap “2” (Fig. 66).
66
67
68
4 When the cylinder has been filled, the compressor is stopped automatically by the pressure switch.
44 Use
5 Turn off the cylinder tap and that of the hoses
(Fig. 69).
69
70
71
The machine is, in any case, provided with an emergency system that automatically blocks it when:
1) the pressure set on the pressure switch is reached;
2) there is a temporary cut in the power supply;
3) the heat release of the electric motor trips due to an overload.
After an emergency stop and before proceeding with a subsequent operation, it is necessary to check
that the cause of the emergency has been eliminated.
Use 45
PUTTING THE MA CHINE OUT OF OPERA
MACHINE TION
OPERATION
10 AND DISMANTLING TH E MACHINE
THE
This chapter provides instructions to be followed for long machine standstills or for the dismantling of
the same.
WARNING
Before carrying out any procedure on the machine, read Chapter 4, “Precautions for use and maintenance”
with care.
If the compressor is not to be used for prolonged periods, remove the active carbon cartridge from the
strainer filter.
Run the compressor idle for a few minutes to drain off any residue condensate. Stop the compressor,
remove the intake filter, start up the compressor again spraying a few drops of oil into the intake hole so
that a light film of lubricant is sucked in and penetrates the internal parts of the compressor.
Stop the compressor and refit the intake air filter. Clean the external parts and try to remove any saline
humidity and oily deposits. Protect the compressor from dust and water by storing it in a clean, dry
place.
Turn the machine off using the general switch (position “0”) and remove the power plug.
Carry out a general cleaning operation on the machine and all its components.
When using the compressor, special waste products are produced. It must be remembered that waste
from industrial processes, agricultural, artisan and commercial activities and service industries cannot
be disposed of together with normal urban waste either because of their quality or quantity.
Old or obsolete machinery is also to be considered as special waste.
Special care must be taken with the disposal of worn active carbon filters which, being a waste product
that cannot be disposed of together with normal urban waste, must be dealt with in compliance with the
laws in force in the country where the compressor is installed.
The operations required for stripping and demolishing the machine must be carried out by
qualified staff.
To dismantle the machine, follow the regulations imposed by the laws in force in the user’s country.
Before demolishing the machine, an inspection must be requested by the competent authority with the
issuing of a relative report.
Disconnect the machine from the power supply.
Remove any interfacing that there may be between the compressor and other machines, checking
carefully that any interfacing between other machines that are still in use remain operative.
Empty the tank containing the lubricating oil and store it according to legal requirements.
Proceed with the stripping of the individual machine components, grouping them together according to
their composition. The machine consists mainly of components made of steel, stainless steel, cast
iron, aluminium and plastic.
Finally, send the materials for scrap in accordance with the laws in force in the country where the
compressor is installed.
During all the dismantling phases, follow the safety warnings given in this manual with great
care.
This chapter includes instructions concerning the preventive, routine and additional maintenance
operations.
In the specifications for the preventive maintenance operations for the various devices indication is also
given of the frequency of such procedures.
Before consulting the chapter, read Chapter 4 “Precautions for use and maintenance” with care.
WARNING
All the routine and additional maintenance operations must be carried out with the machine at a standstill
(the compressor at a standstill) and with the power supply disconnected.
The residue pressure in the machine (pump circuit) must be eliminated.
Any operation carried out on the machine must only be undertaken having read and carefully applied the
regulations listed in Chapter 4 “Precautions for use and maintenance”.
All the operations described in the following paragraphs, for model MCH 26-32/ET Compact,
must be repeated twice (one for every component that is the same).
To keep the machine in good working condition, it must be cleaned very thoroughly.
Having been designed and built according to the most advanced technological criteria, this type of refill
station requires very limited preventive and routine maintenance operations.
However, it is essential to follow the indications given in this chapter very carefully and to follow the
intervals between operations as suggested.
48 Maintenance
During the guarantee period no responsibility is taken for any damage or operating faults due to a failure
to comply with the regulations in force.
The following paragraph enables all the routine and additional maintenance operations carried out on the
machine to be recorded.
This paragraph should be filled in carefully and any operations carried out to solve problems should also
be reported.
Pr e v enti v e maintenance (T
(Taa b le 1) 11.2
Table 1
INTERVALS
Maintenance 49
11.3 Changing the lubricant oil (T
(Taa b le 2)
The quantity of oil for the lubrication of the pump unit must be checked every 25 hours.
To carry out this operation, see chapter 8 “Start up”.
The oil must be changed every 250 operating hours or yearly.
When changing the oil, it must be remembered that a mixture of different oils cannot be used.
The oil must have the following characteristics:
Table 2
cu.cm. 1500
Sump capacity
litres/gallons 1.5/0.476
72
2 Unscrew the hexagonal closing cap located in front of the oil discharge.
50 Maintenance
3 Open the oil discharge two taps (Fig. 73)
and discharge all the oil in the sumps.
73
4 Close the discharge tap and replace the hexagonal closing cap.
5 Carry out the filling operations as described in chapter 8 “Start up”.
WARNING
To dispose of waste oils follow the instructions given in chapter 10.2 “Disposal of waste products” with
great care.
Maintenance 51
11.4 Checking the transmission belt
74
75
52 Maintenance
2 By exerting a pressure of at least 5 Kg., check
that the belt does not flex by more than 5 mm.
compared to its original position (Fig. 76).
76
77
3 Carry out the measurement procedure again and if necessary, repeat the operations until a maximum
distance of 5 mm. is reached.
4 Replace the covers securing the appropriate screws tightly (see point 1).
Air intak
intakee filter 11.5
The intake filter must be checked to make sure it is in good order every 25 operating hours.
The filter is cleaned by blowing air inside the cartridge when it has been removed.
Replace the cartridge turning it by 60° compared to its initial position.
Maintenance 53
MCH 13-16/ET Compact
The filter must be replaced every 125 operating
hours with the following procedure:
MCH 13-16/ET Compact
1 Remove the upper protective cover by
unscrewing the securing screws (Fig. 78).
78
79
80
54 Maintenance
3 Remove the filter and replace it with a new
one (Fig. 81).
To order a new spare filter, refer to chapter
14 “Spare parts”.
81
4 Refit the safety guard and tighten the screws (see point 1).
Table 3
Multiplicative
°C °F
coefficients
50 122 0.20
40 104 0.34
30 86 0.57
20 68 1
10 50 1.85
5 41 2.60
0 32 3.80
Maintenance 55
Table 4
Check the sealing O-Rings and replace them if they are damaged.
Leave the cartridge in the filter when the compressor is not in use.
Maintain a pressure of 40-70 bar inside the filter to prevent outside dampness from getting in.
82
83
56 Maintenance
- unscrew the used cartridge from the internal
cap (Fig. 84) and then screw in the new one;
84
- screw up the internal cap having lubricated or replaced the sealing O-Rings if they are worn and
having lubricated the threads of the external cap using silicone grease.
WARNING
The used active carbon filter cannot be disposed of together with urban waste. To dispose of the active
carbon filter, follow the instructions given in chapter 10.2, “Disposal of waste products” with great care.
The refill hose must be in good condition especially in the area of the connections.
The plastic sheath that covers the hose must not show any signs of abrasion otherwise if any humidity
infilatrates, it could corrode the steel plait and reduce its resistance. The hose must be replaced
periodically (annually) and/or when it shows signs of wear. Failure to comply with this regulation could
cause serious danger to the operators. Make sure that the minimum radius of curvature of the hose is
not less than 250 mm.
To connect the hose, follow the instructions given in chapter 6.2.2, “Connecting the refill hose”.
Maintenance 57
11.8 Intak
Intakee and disc har g e v alv
dischar es
alves
The 2nd stage intake valve can be removed for maintenance purposes while those of the 1st, 2nd (only
discharge) and 3rd stages must be entirely replaced. The seats must be cleaned carefully using petrol
and soft brass or nylon brushes.
The torque wrench setting for the head bolts of the 3rd stage is initially 1 Kgm. Having moved the head
closer, tighten the bolts to 2.2 Kgm, making sure that the piston is at the bottom dead centre during the
operation.
Avoid using steel brushes or screwdrivers. The interval between maintenance operations is 400-600
working hours. If any parts are damaged or worn, they must be replaced. The discharge valves can be
removed from the outside while the intake valves can only be removed when the head of the cylinder has
been taken off.
NOTE: the valve replacement procedure must be carried out at the work bench by specialized technicians
who have specific equipment for the stripping operation.
In any case, it is preferable to contact AEROTECNICA COLTRI S.r.l. who will supply the necessary
technical assistance.
11.9 Heads
85
58 Maintenance
- The head of the 2nd stage (B) is made of
aluminium (Fig. 86), the valves are screwed
in; the intake valve inside is removed using
a special pin wrench while the discharge
valve is on the outside and is removed with
a non-adjustable wrench or a box wrench.
86
- The head of the 3rd stage (C) is made of
aluminium (Fig. 87), the intake valve is
screwed inside and is removed using a
special pin wrench while the discharge val-
ve is on the oustide and is kept in position
by the threaded dowel which is screwed into
the cover.
87
Cylinders 11.10
88
Maintenance 59
11.11 Ma
M a i n t e n a n c e programme
Use the following pages to note the routine and additional maintenance operations carried out on the
machine.
If the maintenance programme is filled in accurately, it will be easier for the technician to intervene if
assistance is required.
Date: ..................................................................................................................................................
Operation carried out: .........................................................................................................................
Date: ..................................................................................................................................................
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60 Maintenance
Date: ..................................................................................................................................................
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Operation carried out: .........................................................................................................................
Maintenance 61
12 TR OUBLESHOO
TROUBLESHOO TING
OUBLESHOOTING
This chapter describes the faults that may arise during machine operation.
For each fault, the cause and the solution to be adopted are specified.
Table 1 below lists all the faults that may arise during operation and the relative solution.
Table 1
PROBLEM CAUSE SOLUTION
The electric motor does not start A phase is missing Check the fuses
The safety valve of the 2nd stage discharges The 3rd stage valves are not working Replace them
The motor power is insufficient Check the motor and the power line
The speed of rotation and
capacity are reduced
The belt slips Tighten the belt
The valves are not working Contact the technical assistance service
The 3rd stage piston is worn Contact the technical assistance service
The connections are loose or the gaskets Check the leaks with water and soap and
The capacity is reduced without a reduction leak eliminate them
in the speed of rotation
The intake filter is blocked Replace it
The piston or compression rings are worn Contact the technical assistance service
The compressor overheats The cooling pipes are dirty Contact the technical assistance service
62 Troubleshooting
MACHINE DIAGRAMS 13
This chapter provides the plans and diagrams of the systems installed on the machine.
Machine diagrams 63
13.1 Electrical diagram
64 Machine diagrams
The model MCH 26-32/ET Compact compressor
Machine diagrams 65
The model MCH 26-32/ET Compact compressor
66 Machine diagrams
POS. TO BE READ
GENERAL
QS1 MAIN SWITCH
QF1 PRIMARY AUSILIARIES PROTECTION SWITCH
TC1 AUSILIARIES TRASFORMER (380/220 OR 220/220)
QF2 SECONDARY AUSILIARIES PROTECTION SWITCH
BP1 PRESSURE SWITCH
SQ1 MECHANICAL PROTECTION CONTROL
SQ2 MECHANICAL PROTECTION CONTROL
MOTOR M1
QM1 OVERLOAD RELEASE MOTOR PROTECTION SWITCH
KM1 MOTOR CONTROL CONTACTOR
M1 MOTOR
SB1 STOPPING PUSH BOTTON
SB2 STOPPING PUSH BOTTON
SB3 PURGE PUSH BOTTON
HL2 READY STATE RUNNING SIGNALING (GREEN)
HL1 RUNNING SIGNALING (RED)
PT1 HOURS COUNTER
KT1 CHARGE-PURGE TIMER
Y1 SOLENOID VALVE TO CHARGE
Y2 SOLENOID VALVE TO PURGE
MOTOR M2
QM2 OVERLOAD RELEASE MOTOR PROTECTION SWITCH
KM2 MOTOR CONTROL CONTACTOR
M2 MOTOR
SB5 STOPPING PUSH BOTTON
SB6 STOPPING PUSH BOTTON
SB7 PURGE PUSH BOTTON
HL4 READY STATE RUNNING SIGNALING (GREEN)
HL3 RUNNING SIGNALING (RED)
PT2 HOURS COUNTER
KT2 CHARGE-PURGE TIMER
Y3 SOLENOID VALVE TO CHARGE
Y4 SOLENOID VALVE TO PURGE
Machine diagrams 67
68
SPARE P
SPARE AR
PAR TS
ARTS 14
14.1 Exploded view of the machine parts .............................................................................. 69
Monobloc ........................................................................................................................ 70
Pistons rod unit ............................................................................................................... 72
Cylinders unit .................................................................................................................. 74
Head unit ......................................................................................................................... 76
Cooling pipes .................................................................................................................. 78
Filtering system ............................................................................................................... 80
MCH 13-16/ET condensate trap ...................................................................................... 82
MCH 26-32/ET condensate trap ...................................................................................... 84
MCH 13-16/ET .................................................................................................................. 86
MCH 26-32/ET .................................................................................................................. 88
MCH 26-32/ET front panel ............................................................................................... 90
Spare parts 69
090
088
076
071
070
016 008
058
074
70
059 062
073
060
061 055
065 042 055
040
068
050
001
091
064
054
Monobloc
052
067
066
Spare parts
Monobloc
Spare parts 71
118 072
117 118/A
117/A 099
113 132
115 113/A
098
116 119 112
116/A 110 112/A
111
194
120
118
127 114 130
122 131
121 193
107
72
128
109
192
129
108
104
100 106
101 105
Spare parts 73
124
126
018
123 017
125 022
002
002/A
191 024
190
007 043
043/A
021 039
019
74
015
037
038
Cylinders unit
Spare parts
Cylinders unit
Spare parts 75
041
026 014
011
013 010
009
006
012
032
033
034
031 027 049
005
025 056
030 004
003 051
029 003/A 047
028
76
035
046
020
196
044 195
048
045
Head unit
Spare parts
Head unit
Spare parts 77
138
137
135
023 139
134
136
140
142
082
079
141 133
075 080
081
077
074
78
036
089
186 185
086 087
Cooling pipes
085
087
197
Spare parts
083
084
Cooling pipes
Spare parts 79
Filtering system
152
153
154
155
156
157
097
158
189
188
187
159
160
198
80 Spare parts
Filtering system
Spare parts 81
MCH 13-16/ET condensate trap
173
181
172
182
171
096
165
168 166
169 167
176 170
023 094
174 091
036 092 320
175 145
198
183
184
82 Spare parts
MCH 13-16/ET condensate trap
Spare parts 83
MCH 26-32/ET condensate trap
146
215
147 069
322 145
148
149
150
151
181
182 173
096 172
171
165
166
168
167
169
170
176
023
174 094
091
036 092
175
198
103 179
089
178
102
198
183
184
84 Spare parts
MCH 26-32/ET condensate trap
Spare parts 85
312
311
310
309
308
209
307
208
217 211
210
210/A
255
254
232 224
233
234 221
235 302
253
222
86
252
272
MCH 13-16/ET
301
300
250
256 258
279
257
276
251
Spare parts
231
230
MCH 13-16/ET
POS. CODE DESCRIPTION
208 13-04-0208 COMPLETE LOCK
209 13-04-0209 SWITCHBOARD PANEL
210 SC000310 280 BAR PRESSURE SWITCH
210/A SC000315 330 BAR PRESSURE SWITCH
211 13-04-0211 PRESSURE GAUGE WITH FLANGE
217 13-04-0217 RELOAD RAMP ALUMINIUM BLOCK
221 13-04-0221 LP CONDENSATION DISCHARGE SOLENOID VALVE
222 13-04-0222 HP CONDENSATION DISCHARGE SOLENOID VALVE
224 13-04-0224 CONDENSATION DISCHARGE ALUMINIUM BLOCK
230 13-04-0230 OIL DISCHARGE COCK
231 13-04-0231 ¹/2" OIL DISCHARGE CAP
232 13-00-0164 CONDENSATE DISCHARGE HANDWHEEL
233 13-00-0163 CONDENSATE DISCHARGE SPRING
234 13-00-0162 NYLON CONDENSATE DISCHARGE
235 13-00-0161 CONDENSATE DISCHARGE TAP CASING
250 13-04-0400 COMPACT FRONT PANEL
251 13-04-0401 COMPACT LEFT-HAND SIDE PANEL
252 13-04-0402 COMPACT REAR PANEL
253 13-04-0403 COMPACT RIGHT-HAND SIDE PANEL
254 13-04-0404 COMPACT UPPER INSTRUMENT PANEL
255 13-04-0405 COMPACT UPPER PANEL
256 13-04-0406 MOTOR-COMPRESSOR SUPPORT
257 13-04-0407 BASE
258 13-04-0408 COMPACT OIL LEVEL PLATE
272 13-04-0272 CONDENSATION DISCHARGE CAN COMPLETE WITH PIPE FITTINGS
276 16-05-030 VIBRATION-DAMPING SUPPORT
279 13-04-0279 VIBRATION DAMPNER WITH DOUBLE ATTACHMENT
300 SC000450 BC INT COCK
301 SC000460 BC DIN 200 BAR COCK
301/A SC000470 BC DIN 300 BAR COCK
302 13-04-238 HP 1200 mm. PIPE
307 13-04-0203 OFF PLATE
308 13-04-0204 ON PLATE
309 13-04-0205 MANUAL PURGE PLATE
310 13-04-0202 YELLOW CONDENSATION DISCHARGE BUTTON
311 13-04-0201 GREEN START BUTTON
312 13-04-0200 RED STOP BUTTON
Spare parts 87
325
326
327 329
328
272
330
331
332
333
88
335
334 336
279
337
MCH 26-32/ET
Spare parts
MCH 26-32/ET
POS. CODE DESCRIPTION
272 13-04-0272 CONDENSATION DISCHARGE CAN COMPLETE WITH PIPE FITTINGS
279 13-04-0279 VIBRATION DAMPNER WITH DOUBLE ATTACHMENT
325 13-04-0409 PUMP UNITS REAR PANEL
326 13-04-0410 COMPACT UPPER PANEL
327 13-04-0411 OIL REFILL CAP B
328 13-04-0412 OIL REFILL CAP A
329 13-04-0413 COMPACT STAY BOLT M6
330 13-04-0414 COMPACT LEFT-HAND SIDE PANEL
331 13-04-0415 LEFT INTERNAL CONVEYOR
332 13-04-0416 RIGHT INTERNAL CONVEYOR
333 13-04-0417 MOTOR-COMPRESSOR SUPPORT
334 13-04-0418 UPPER INTERNAL CONVEYOR
335 13-04-0419 COMPACT REAR PANEL
336 13-04-0420 COMPACT RIGHT-HAND SIDE PANEL
337 13-04-0421 BASE
Spare parts 89
208
213
205
204
203
207
215
209 211 216
237
202 216
201 217
200
210
210/A 219
90
227 220
228
229
235 338
232 234
233
MCH 26-32/ET front panel
Spare parts 91
AEROTECNICA COLTRI S.r.l.
Registered office: Via Rio Ponale, 7 - 25010 Rivoltella di Desenzano D/Garda - BRESCIA - ITALY
Factory: Via Colli Storici, 177 - 25010 San Martino della Battaglia - BRESCIA - ITALY
Tel. +39 030 9910297-9910301 - Fax +39 030 9910283
e-mail: [email protected] Internet: http://www.coltrisub.it