AEROTECNICA COLTRI MCH 13-16/ET Standard, Use And Maintenance Manual

Page 1: ...otor STANDARD with electric motor www aerotecnicacoltri com High pressure compressors for pure breathing air and technical gases USE AND MAINTENANCE MANUAL High pressure compressors for pure breathing air and technical gases USE AND MAINTENANCE MANUAL ...

Page 2: ...pag 2 di 64 Use and Maintenance Manual M MC CH H8 8 1 11 1 E EM M M MC CH H1 13 3 1 16 6 E ET T Standard ...

Page 3: ...ar rd d M MC CH H 8 8 1 11 1 E EM M S St ta an nd da ar rd d HIGH PRESSURE COMPRESSORS FOR PURE BREATHING AIR AND TECHNICAL GASES IMPORTANT BEFORE USING THE COMPRESSOR READ THIS MANUAL CAREFULLY Via Colli Storici 177 25010 SAN MARTINO DELLA BATTAGLIA BS ITALY Tel 39 030 9910301 Fax 39 030 9910283 www coltrisub it www coltrisub com coltrisub coltrisub it ...

Page 4: ... Should you require any clarification when using the compressor for the first time or at any other time it is used please remember that AEROTECNICA COLTRI is at your complete disposal Should you need to contact us our fax number is 39 030 9910283 For routine or unscheduled maintenance note that AEROTECNICA COLTRI international technical service is able to provide you with assistance and spare part...

Page 5: ...89 392 93 44 and 93 68 according to the specifications of the following harmonized standards EN 292 1 91 EN 292 2 91 EN 60204 1 92 ISO 3746 ISO 11202 and also complies with the provisions of Italian Dlgs 476 92 as per EEC directives 89 336 and 92 31 according to the specifications of the following harmonized industrial environment standards EN 50081 2 August 1993 EN 50082 2 March 1995 DESENZANO DE...

Page 6: ...essor with the end tap closed and check that air is discharged freely when the gauge value is equal to the valve setting see section 6 4 1 Bottle refill see section 6 6 fit the hose connector 1 on the bottle connector 3 closed A open the condensate discharge taps 2 and bottle taps 4 start the compressor B When refill is complete close filling valve taps 2 and bottle taps 4 A switch off compressor ...

Page 7: ...Know the machine 19 3 1 2 Protective clothing 19 3 1 3 Emergency equipment 19 3 1 4 Checks and maintenance 19 3 2 General precautions 20 3 2 1 Important safety information 21 3 2 2 Accident prevention 21 3 2 3 Working safety 21 3 2 4 Residual risk zones 22 3 3 Safety info labels location 23 3 3 1 Safety info labels description 24 3 4 General safety regulations 26 3 4 1 Care and maintenance 26 3 4 ...

Page 8: ...il level check 37 6 2 2 Checking that the flex hoses are in good condition 38 6 2 3 Storing technical documentation 38 6 3 Control panel optional 38 6 4 Preliminary tasks 39 6 4 1 Checking the safety valves 39 6 5 Starting and shutting down 40 6 5 1 Starting and shutting down MCH 8 11 EM Standard 40 6 5 2 Starting and shutting down MCH 13 16 ET Standard 40 6 5 3 Starting and shutting down with con...

Page 9: ... 53 8 1 Stopping the machine for a brief period 53 8 2 Stopping the machine for a long period 53 CHAPTER 9 DISMANTLING AND PUTTING OUT OF SERVICE 54 9 1 Waste disposal 54 9 2 Dismantling the compressor 54 CHAPTER 10 INSTRUCTIONS FOR EMERGENCY SITUATIONS 55 10 1 Fire 55 CHAPTER 11 MAINTENANCE REGISTER 56 11 1 Assistance service 56 11 2 Scheduled maintenance 56 11 3 Using the compressor under heavy ...

Page 10: ...olli Storici 177 25010 SAN MARTINO DELLA BATTAGLIA BRESCIA ITALY Tel 39 030 9910301 39 030 9910297 Fax 39 030 9910283 http www coltrisub it http www coltrisub com e mail coltrisub coltrisub it Appendices Safety regulations PRELIMINARY INFORMATION 1 GENERAL 1 1 REQUIRED OPERATOR TRAINING 1 2 This manual must be read carefully all compressor operators maintenance personnel must read this entire manu...

Page 11: ...her users or subsequent owners in the event of resale keep the manual in good condition and ensure its contents remain undamaged do not remove tear or re write any part of the manual for any reason keep the manual protected from damp and heat if the manual is lost or partially damaged and its contents cannot be read it is advisable to request a copy from the manufacturer Important you must underst...

Page 12: ...wing suggestions carefully 1 before using the compressor gain familiarity with the tasks to be completed and the admissible working position 2 the operator must always have the instruction manual to hand 3 program all work with due care and attention 4 you must have a detailed understanding of where and how the compressor is to be used 5 before starting work make sure that safety devices are worki...

Page 13: ...to compressor defects and flaws loss of production or earnings etc except in cases where serious negligence is demonstrated WARNING Maintenance and repairs must only be carried out using original spare parts AEROTECNICA COLTRI Spa cannot be held liable for any damages caused by failure to observe this rule The compressor is guaranteed as per the contractual agreements made at the time of sale Fail...

Page 14: ...rly as described in section 7 11 2 Changing the active carbon filters Drain the condensate regularly as illustrated in section 7 9 Condensate discharge The power lead plug must be disconnected if there is a problem during use before carrying out any cleaning or maintenance tasks Never pull the plug out by tugging the lead Make sure the lead is not bent at a sharp angle and that it does not rub aga...

Page 15: ...en partially the systems and equipment described in this instruction manual especially as safety guards and safety symbols are concerned It is also forbidden to carry out work in any way other than that described or to neglect the illustrated safety tasks The safety information and the general information given in this manual are highly important To ensure maximum working efficiency AEROTECNICA CO...

Page 16: ...s carefully running and tested prior to delivery A new compressor must nevertheless be used with caution during the first 5 working hours so as to complete proper running in of its components If the compressor is subject to an excessive workload during initial use its potential efficiency will be prematurely compromised and functionality soon reduced During the running in period proceed as follows...

Page 17: ...e compressor for breathing air and technical gases Compatible process gases Nitrogen Helium Natural gas Methane 2 BASIC INFORMATION ON THE COMPRESSOR Each compressor has an identification label a attached to its frame AEROTECNICA COLTRI S r l Via Colli Storici 177 25010 DESENZANO D G BS ITALY Tel 030 9910301 9910297 Fax 030 9910283 MODEL POWER MOTOR YEAR S N TYPE MCH 13 16 ET STANDARD 4KW ELECTRIC...

Page 18: ...t or damaged a copy can be requested from the manufacturer Make sure all users have understood the regulations for use and the meaning of the symbols on the compressor Observance of these technical instructions can prevent accidents instructions have been drawn up in compliance with EEC Machinery Directive 89 392 and subsequent amendments In any case always observe national safety regulations Do n...

Page 19: ...nd function of all the controls instruments indicators warning lights and the various info plates labels All operators must use accident prevention items such as gloves hard hat eye goggles accident prevention shoes and ear defenders against noise Make sure a first aid cabinet and a CO2 fire extinguisher are near the compressor Keep the extinguisher fully loaded Use according to standards in force...

Page 20: ...employers are legally obliged to comply with Before carrying out any work on the compressor each operator must have a perfect understanding of how the compressor works know how to use the controls and have read the technical information contained in this manual IMPORTANT Removing or tampering with any safety device is strictly forbidden All installation routine or unscheduled maintenance work must...

Page 21: ...for the production of high pressure breathing air The laws regulations standards and directives in force for such machines have been complied with Materials parts production procedures and quality controls all comply with the strictest safety and reliability standards Using the compressor for the purposes described in this manual handling it with due diligence and carrying out maintenance and over...

Page 22: ...fter switching off the machine wait 30 minutes for the machine to cool down before carrying out maintenance work 4 Danger deriving from noise emitted by the compressor 5 Fire risk 6 Risk of being crushed or dragged in the transmission belt zone 7 Danger of impact abrasion with the cooling fan 8 Danger of direct contact with operator if hose breaks during bottle refill DANGER In some compressor zon...

Page 23: ... ET T Standard Cap 3 _ Safety regulation AEROTECNICA COLTRI S r l Via Colli Storici 177 25010 DESENZANO D G BS ITALY Tel 030 9910301 9910297 Fax 030 9910283 MODEL YEAR S N TYPE MCH 13 16 2004 MOTOR THREE PHASE POWER 4 Kw 0000 STANDARD 1 2 4 3 4 5 8 7 6 7 9 9 9 SAFETY INFO LABELS LOCATION 3 3 ...

Page 24: ...he arrow invert two of the three phases on the main power lead 2 a a Warning info plates about the dangers that derive from a lack of knowledge about the compressor and its functions and the consequent risks b Read the use and maintenance manual carefully before using the compressor 4 a b a Hands at risk of being crushed in transmission belt zone b Moving parts in transmission belt and cooling zon...

Page 25: ...table b Oil level check info plate Check lubricating oil level every 5 working hours and change it every 50 working hours For information on how to check see 7 6 2 Checking the oil level For information on how to change the oil see 7 6 3 Changing the lubricating oil USESPECIALOIL FORHIGHPRESSURE COMPRESSORS WARNING CHECK OIL LEVEL EVERY 5 HOURSAND CHANGE OIL EVERY 50 WORKING HOURS 7 a b a Condensa...

Page 26: ...y familiar with working procedures Keep the compressor and the surrounding area clean at all times Before starting work check that safety devices guards are in good working order Make sure no one is in the compressor danger zone Interrupt work if anyone is in the danger zone and tell them to leave Never leave the machine unattended when it is running Check that a fire extinguisher is present Make ...

Page 27: ...nel For component maintenance revision tasks not covered by this manual please contact AEROTECNICA COLTRI Oil and grease stains scattered tools or broken pieces constitute a danger to personnel as they may cause slips and falls Always keep the compressor and the surrounding work area clean and tidy Clean the compressor with a pressurised hot water or steam jet and commercially available detergents...

Page 28: ...ts of the 2 nd and 3 rd stage heads Pressure valve of 3rd stage have no threads Splash lubrication occurs by oil thrower pins screwed onto the 2 nd and 3 rd stage connecting rods Third stage lubrication is of the oil vapour type Pressure maintenance valve 4 1 4 This valve is fitted after the final filter When the compressor is switched on it keeps internal system pressure at 100 20 bar so as to re...

Page 29: ...combustion type 4 Compressor 5 Pressure gauge 6 Intake filter 7 Final condensate separator 8 Active carbon air filter molecular sieve 9 1st stage 10 2nd stage 11 3rd stage 12 Monobloc 13 Oil filler plug 14 Safety valve 15 Maintenance valve 16 Cooling fan 17 Belt 18 Anti vibration device 19 Condensate discharge taps 20 Oil drain plug 1 2 3 5 6 7 8 4 11 9 10 12 13 14 15 16 17 18 18 19 19 19 20 ...

Page 30: ... Standard 4 3 1 AEROTECNICA COLTRI S r l Via Colli Storici 177 25010 DESENZANO D G BS ITALY Tel 030 9910301 9910297 Fax 030 9910283 MODEL YEAR S N TYPE MCH 13 16 2004 MOTOR THREE PHASE POWER 4 Kw 0000 STANDARD 880mm 640mm 480mm Motor Electric 3 phase Motor power 4 kW 5 5 Hp 4 8 kW 6 5 Hp Voltage and frequency 230V 50Hz 400V 50Hz 230V 60Hz 400V 60Hz 440V 60Hz 480V 60Hz Unit pumpung 1350 rpm Peak no...

Page 31: ...he operators are exposed to on a daily basis exceeds 80 dBA the employer must apply all necessary health and safety measures It is especially important that operators wear ear defenders to protect them from noise Motor Electric 3 phase Motor power 5 5 kW 7 5 Hp 6 6 kW 9 Hp Voltage and frequency 230V 50Hz 400V 50Hz 230V 60Hz 400V 60Hz 440V 60Hz 480V 60Hz Unit pumpung 1550 rpm Peak non continuous pr...

Page 32: ...e level of noise to which the operators are exposed to on a daily basis exceeds 80 dBA the employer must apply all necessary health and safety measures It is especially important that operators wear ear defenders to protect them from noise Motor Electric single phase Motor power 3 kW 4 Hp Voltage and frequency 230V 50Hz 230V 60Hz Unit pumpung 900 rpm Peak non continuous pressure 225bar 3200PSI 300...

Page 33: ... level of noise to which the operators are exposed to on a daily basis exceeds 80 dBA the employer must apply all necessary health and safety measures It is especially important that operators wear ear defenders to protect them from noise Motor Electric single phase Motor power 4 kW 5 5 Hp Voltage and frequency 230V 50Hz 230V 60Hz Unit pumpung 1200 rpm Peak non continuous pressure 225bar 3200PSI 3...

Page 34: ...nce manual use and maintenance manual appendix safety regulations lubricating oil 2 litres active carbon and molecular sieve filte cartrige HANDLING 5 2 After separating the compressor from its packaging it can be transported to the designated placement area Transfer will require the use of a fork lift or transpallet of suitable load bearing capacity the forks must be positioned in the support fee...

Page 35: ...cooling of the pumping unit Make sure that lighting in the area is sufficient to identify every detail such as the writing on the info labels use artificial lighting where daylight is on its own insufficient 1 m min 1 5 m 1 m If the compressor is installed in an area without the necessary ventilation requisites described in section 5 3 1 Positioning it will be necessary to install an air intake ex...

Page 36: ...ficient ground earth check that the earth resistance value complies with the protection operational requirements of the compressor electrical system WARNING Before inserting the plug check that the electrical system complies with the standards in force in the country of installation A proper earth ground system is an essential safety requisite An efficient compressor ground earth system is an esse...

Page 37: ...e arrow it will be necessary to disconnect the electrical power supply and invert two of the three phases on the main power lead AEROTECNICA COLTRI S r l Via Colli Storici 177 25010 DESENZANO D G BS ITALY Tel 030 9910301 9910297 Fax 030 9910283 MODEL YEAR S N TYPE MCH 13 16 2004 MOTOR THREE PHASE POWER 4 Kw 0000 STANDARD DANGER Before carrying out this task disconnect the compressor from the mains...

Page 38: ...mergency pushbutton In an emergency situation stop the compressor by pressing the red emergency pushbutton f Check that the emergency shutdown pushbutton is working properly at the start of each working day by switching on the compressor and pressing it If the compressor fails to shut down immediately after pressing the emergency pushbutton disconnect the compressor from the power supply and conta...

Page 39: ...vant fitting are in good condition After being refilled do not empty the bottles completely not even during winter storage or long periods of inactivity this will stop humidity getting in IMPORTANT Tampering with the safety valve to increase the pressure setting is strictly forbidden Tampering with the safety valve can seriously damage the compressor cause serious injury to personnel and renders t...

Page 40: ...tage and that there is a proper earth contact connect the compressor up to the mains power supply turn the socket switch a to its ON position for models with three phase electric motor check that the direction of rotation of the electric motor is as indicated by the arrow on the cover if it is not refer to 6 1 2 Checking for proper electrical connection To switch the motor off again turn the socke...

Page 41: ... in cold water so as to reduce the pressure drop WARNING During bottle refill those not involved in the refill procedure must maintain a safety distance of at least 3 metres Also it is forbidden to disconnect the hoses from the fittings or the refill tap while the machine is under pressure The available bottle refill connectors are BC DIN 230 Cod SC000470 BC DIN 300 USA Cod SC000460 SP BC DIN 300 ...

Page 42: ...ntil all the residual air in the fitting has been expelled Unscrew the fixing knob c by rotating it anticlockwise Disconnect the bottle coupling IMPORTANT If an emergency situation arises during refill shut down the compressor immediately see 6 5 Starting and shutting down The compressor is nevertheless equipped with a safety system that shuts it down automatically when The pressure setting on the...

Page 43: ...vation of the compressor requires thorough cleaning This type of refill station designed and built according to the most advanced technological criteria requires only minimum preventive and routine maintenance Before carrying out any maintenance tasks run checks and or controls on the compressor switch off the compressor remove the plug from the mains socket The residual pressure present in the co...

Page 44: ...piston rings worn Contact technical assistance Air smells of oil Filter cartridge exhausted Replace Piston rings worn Contact technical assistance Compressor overheats Direction of rotation wrong Check direction of rotation Cooling tubes dirty Contact technical assistance Incomplete valve closure Contact technical assistance causing overload of another stage 5 10 30 40 50 250 500 1000 2000 3000 40...

Page 45: ...ve any traces of oil immediately Both oil and filter are classified as special wastes and must therefore be disposed of in compliance with the anti pollution laws in force All maintenance work must be carried out with the compressor OFF and the power supply lead unplugged from the mains socket Oil table 7 6 1 Checking the oil level 7 6 2 Sump capacity litres 1 5 Recommended oils COLTRI OIL CE750 C...

Page 46: ...ipient recipient capacity of at least 3 litres required open the top plug b open the plug a and let all the oil drain out close the drain plug a fill the oil sump with 1 5 litres of oil from top oil plug see 7 6 1 Oil table close the oil top plug b switch on the compressor and run it depressure area for 30 seconds switch off the compressor and remove the plug from the power socket check the oil le...

Page 47: ...t these tasks if the compressor has only ju st shut down wait for the compressor to cool All maintenance work must be carried out with the compressor OFF and the power supply lead unplugged from the mains socket The air intake filter must be changed every 250 working hours or annually To change the filter proceed as follows turn the air filter cover a by rotating it anticlockwise remove the air fi...

Page 48: ...ried out with the compressor OFF and the power supply lead unplugged from the mains socket IMPORTANT The condensate must be discharged at the end of every working day Condensation accumulates in the condensate sepa rator the condensate must be discharged every 10 15 minutes of compressor use To discharge the condensate open the drain valves a and collect the condensate in an appropriate recipient ...

Page 49: ...grooves of both pulleys and that belt tension is correct If the tension of the new belt still fails to comply with the necessary requisites contact AEROTECNICA COLTRI assistance service c b a d d TRANSMISSION BELT 7 10 Belt tension must be checked monthly The transmission belts must be replaced every 500 working hours of the compressor DANGER Do not carry out these tasks if the compressor has only...

Page 50: ...rk must be carried out with the compressor OFF and the power supply lead unplugged from the mains socket Depressurise the entire compressor circuit before carrying out any maintenance tasks Filter replacement frequency calculation table 7 11 1 Changing the active carbon filter molecular sieve 7 11 2 To change the active carbon filters a proceed as follows vent all the compressed air inside the cir...

Page 51: ...e filter plug and cartridge f g If these O rings deteriorate air is vented through the cap c If you notice any venting replace the O rings When changing the O rings observe the precautions described at the beginning of the relevant section of the manual e c e IMPORTANT It is essential that there be a filtration cartridge inside the active carbon filters a every time the compressor is used WARNING ...

Page 52: ...with a torque of 15 Nm a a DANGER Do not carry out these tasks if the compressor has only just shut down wait for the compressor to cool All maintenance work must be carried out with the compressor OFF and the power supply lead unplugged from the mains socket Vent the air from the compressor before carrying out any maintenance tasks Tank refill pressure is very high therefore before refilling the ...

Page 53: ...ilter cartridge Run the compressor for a few minutes without actually filling bottles so as to flush out all the residual condensate Stop the compressor disassemble the intake filter restart the compressor and spray a few drops of oil into the air intake hole so that a light film of lubricant is aspirated and penetrates the interior of the compressor Stop the compressor and refit the air intake fi...

Page 54: ... laws in force where the compressor is used Bear in mind that it is compulsory to record loading unloading of exhausted oils special wastes and toxic harmful wastes that derive from heavy light industry processes Exhausted oils special wastes and toxic harmful waste must be collected by authorised companies It is especially important that exhausted oils be disposed of in compliance with the laws i...

Page 55: ... EM M M MC CH H1 13 3 1 16 6 E ET T Standard Cap 10 _ Instructions for emergency situations 10 INSTRUCTIONS FOR EMERGENCY SITUATIONS FIRE 10 1 In the event of fire use a CO2 extinguisher in compliance with the relevant standards in force Contact the fire brigade ...

Page 56: ...er by way of an official stamp signature and inspection date the number of working hours is also registered The maintenance schedules coupons easily let you know when our assistance service should be contacted to carry out work ASSISTANCE SERVICE 11 1 SCHEDULED MAINTENANCE 11 2 Where compressors are used in particularly difficult conditions high levels of pollution presence of solid particulate in...

Page 57: ...nance register Date Assistance service stamp Maintenance technician s signature Type of work and notes Date Assistance service stamp Maintenance technician s signature Type of work and notes Date Assistance service stamp Maintenance technician s signature Type of work and notes SCHEDULED MAINTENANCE REGISTRY COUPONS 11 5 ...

Page 58: ...andard Cap 11 _ Maintenance register Date Assistance service stamp Maintenance technician s signature Type of work and notes Date Assistance service stamp Maintenance technician s signature Type of work and notes Date Assistance service stamp Maintenance technician s signature Type of work and notes ...

Page 59: ...andard Cap 11 _ Maintenance register Date Assistance service stamp Maintenance technician s signature Type of work and notes Date Assistance service stamp Maintenance technician s signature Type of work and notes Date Assistance service stamp Maintenance technician s signature Type of work and notes ...

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Page 64: ...media biz www coltrisub com AEROTECNICA COLTRI Spa Via Colli Storici 177 25010 SAN MARTINO DELLA BATTAGLIA BS ITALY Tel 39 030 9910301 Fax 39 030 9910283 www coltrisub it www coltrisub com coltrisub coltrisub it ...