AEROTECNICA COLTRI MCH-36, Use And Maintenance Manual

Page 1: ...USE AND MAINTENANCE MANUAL Hight pressure compressor for breathing air and technical gases www coltrisub com...

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Page 3: ...SAN MARTINO DELLA BATTAGLIA BS ITALY Tel 39 030 9910301 Fax 39 030 9910283 www coltrisub it www coltrisub com coltrisub coltrisub it MCH 36 HIGH PRESSURE COMPRESSOR FOR BREATHING AIR AND TECHNICAL GAS...

Page 4: ...using the compressor for the first time or at any other time it is used please remember that AEROTECNICA COLTRI Srl is at your complete disposal Should you need to contact us our fax number is 39 030...

Page 5: ...ions 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...

Page 6: ...rn others when doing checks maintenance 18 3 2 General precautions 19 3 2 1 Important safety information 20 3 2 2 Accident prevent 20 3 2 3 Working safety 20 3 2 4 Safety info labels location 21 3 2 5...

Page 7: ...in good condition 34 6 2 3 Storing technical documentation 34 6 3 Control panel 35 6 3 1 Power indicator light 35 6 3 2 Direction of rotation indicator light 36 6 3 3 Lubricating oil level warning lig...

Page 8: ...2 Changing the transmission belts 49 7 10 Condensate discharge 50 7 10 1 SILENT automatic condensate discharge 50 7 10 2 OPEN V M automatic condensate discharge 50 7 11 Active carbon filters molecular...

Page 9: ...2005 Machine type High pressure compressor for breathing air and or technical gases Model MCH 36 Manufacturer s data AEROTECNICA COLTRI S r l Via Colli Storici 177 25010 SAN MARTINO DELLA BATTAGLIA BR...

Page 10: ...working life of the compressor make sure updates are incorporated in the manual make sure the manual is given to other users or subsequent owners in the event of resale keep the manual in good conditi...

Page 11: ...iod In replacing the faulty part AEROTECNICA COLTRI Srl shall not be liable for any other expenses sustained by the dealer or his customer such as presumed damage present or future lost earnings or fi...

Page 12: ...reements made at the time of sale Failure to observe the regulations and instructions for use contained in this manual shall render the warranty null and void WARNING A compressor that has been acknow...

Page 13: ...ntakes are a long way from fume exhausts Compressors used on boats can be certified via a R I Na Registro Navale Italiano test this should be requested at the time of order Improper use could have ser...

Page 14: ...per seal by wetting them with soapy water eliminate any leaks Do not attempt to repair high pressure hoses by welding them Do not empty the bottles completely not even during winter storage as this pr...

Page 15: ...6 minutes After the first 50 hours carry out in addition to the scheduled maintenance the following tasks change the compressor oil change the oil filter check and adjust nuts and bolts AREA OF MACHIN...

Page 16: ...dioxide Nitrogen also dry Benzene Butadiene Helium Sulphur hexafluoride Natural gas Synthesis gas Hydrogen Methane Carbon monoxide Propane 2 2 IDENTIFYING THE COMPRESSOR Each compressor has an identi...

Page 17: ...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 ins...

Page 18: ...sor carefully every day it is used as per the task list given in this manual 3 1 GENERAL SAFETY RULES 3 SAFETY REGULATIONS 3 1 1 KNOW THE MACHINE 3 1 2 WEAR PROTECTIVE CLOTHING All operators must use...

Page 19: ...ore 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 i...

Page 20: ...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 purpos...

Page 21: ...4 SAFETY INFO LABELS LOCATION 3 2 5 SAFETY INFO LABELS DESCRIPTION A B C D E F Warning label Unauthorised unqualified personnel are forbidden from opening the control panel The power supply must alwa...

Page 22: ...arator must be emptied regularly as per the instructions in this manual C Hot parts warning label Label warning that lubrication and maintenance must never be carried out with the compressor running L...

Page 23: ...ng fan zone 4 Danger of direct contact with operator in the event of hose burst during bottle refill 5 Danger deriving from noise emitted by the compressor 6 Fire risk 7 Risk of being crushed or dragg...

Page 24: ...ck 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...

Page 25: ...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...

Page 26: ...in place by a bracketing system The 4th stage valves are disassembled by removing the head 4 1 4 COOLING PIPES LUBRICATION The cooling pipes are made of stainless steel Lubrication with low pressure...

Page 27: ...1000 PSI 4th stage 225 bar 3300 PSI 5th stage 330 bar 4700 PSI Oil pressure 4 bar cold 1 5 bar during routine use 1 bar minimum pressure Motor power 15kW Voltage and frequency 400V 50Hz 440V 60Hz 230V...

Page 28: ...Cap 4 _ Technical data pag 28 Use and maintenance manual MCH 36 4 1 8 DIMENSIONS AND WEIGHTS A A B B C C MCH 36 A mm B mm C mm Weight Kg SILENT 1300 800 1800 457 OPEN VM 1000 800 1540 365...

Page 29: ...auges 4 Hoses 5 Refill taps 6 Condensate collection can 7 Condensate collection recipient 8 Electric motor 9 Compressor 10 Oil filter 11 Air filter 12 Safety mesh 13 Anti vibration devices 14 Cooling...

Page 30: ...r and ceiling should be at least 1 5 m These distances ensure proper compressor operation and proper cooling of the pumping unit Make sure that lighting in the area is sufficient to identify every det...

Page 31: ...with the air intake filter in a properly ventilated area sheltered from weather and exhaust fumes Point the air intake against the wind Check that there are no kinks or breaks along the pipe If it is...

Page 32: ...s power supply especially as regards rated current and voltage The mains power system must have an efficient ground earth check that the earth resistance value complies with the protection operational...

Page 33: ...tained in the packaging For filling instructions sees section 7 6 3 Changing the lubricating oil and filter 6 1 1 FILLING WITH LUBRICATING OIL Check for proper connection of electrical phases by check...

Page 34: ...is an integral part of the compressor and must always be handed over in the event of a change of ownership WARNING 6 2 1 LUBRICATING OIL LEVEL CHECK Inspect the refill hoses and make sure there are no...

Page 35: ...Manual condensate discharge pushbutton 7 Cabinet interior cooling air temperature 8 Hour counter 9 Oil pressure gauge 10 1st stage pressure gauge 11 2nd stage pressure gauge 12 3rd stage pressure gau...

Page 36: ...t the compressor from the mains power supply Do not invert or disconnect the ground earth wire yellow green DANGER 6 3 4 ON PUSHBUTTON Press the green ON pushbutton 4 to start the com pressor The comp...

Page 37: ...e carried out by qualified personnel 6 3 8 HOUR COUNTER The hour counter 8 indicates the hours of effective compressor operation use this information to observe maintenance schedules 6 3 9 LUBRICATING...

Page 38: ...n 16 bar 230 PSI and 20 bar 290 PSI switch off the compressor and contact AEROTECNICA COLTRI S r l 6 3 12 3rd STAGE PRESSURE GAUGE The gauge 12 indicates the pressure inside the 3rd compression stage...

Page 39: ...f 330 bar 6 3 15 EFILL HOSE CONNECTION There are four hose connection fittings 15 Hose taps not in use must be closed Bottle refill pressure is very high before starting refilling check that the bottl...

Page 40: ...relevant fittings 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 Use onl...

Page 41: ...the instructions shown in paragraph 9 1 Waste dispo sal c a b The available bottle refill connectors are 6 5 BOTTLE REFILL INT DIN230 DIN300USA DIN300 ITALIAN CONNECTOR FOR SELF PROTECTING SCBA During...

Page 42: ...e taps d and e by rotating them clockwise Open the bleed tap f by rotating it anticlockwise until all the residual air in the fitting has been expelled Unscrew the fixing knob c by rotating it anticlo...

Page 43: ...ria 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 m...

Page 44: ...ion speed and flow Motor power too low Check the motor and the line rate decrease The belt slips Restore proper belt tension The flow rate diminishes Valves not working Contact technical assistance wi...

Page 45: ...is above the maximum level position a recipient under the drain tap b so that the oil flows into the exhausted oil recipient open the drain tap and let the oil flow out until the oil level returns wi...

Page 46: ...he fittings c and remove the pipe b remove the fixing screws e and the cover d replace the filter f with a new one re close the plug d with the screws e put the pipe b back and tighten the fittings c...

Page 47: ...wait for the com pressor to cool All maintenance work must be carried out with the compressor OFF and the power supply lead unplugged from the mains socket DANGER The air intake filter must be change...

Page 48: ...t the safety valve trips at the right pressure observe the gauge you can open the taps and pro ceed with the refill To check for proper transmission belt tension a exert a pressure of approximately 10...

Page 49: ...w belt are identical to those of the old one insert the new belt on the internal groove of the electric motor pulley e insert the belt on the internal groove of the fan pulley while simultaneously tur...

Page 50: ...n outflow of condensate water with lubricating oil is normal during refills the quantity will depend on the level of humidity in the air The condensate must be disposed of as per the instructions in s...

Page 51: ...92 0 32 3 8 35x3 8 133 1596 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...

Page 52: ...ive carbon filter cartridge d and replace it with a new one replace the O ring e on the plug c every time the filter is changed close the filter and screw it on with the wrench a There are sealing O r...

Page 53: ...nance tasks DANGER To change the bottle refill hoses proceed as follows disconnect the bottle refill hoses by unscrewing the fittings a at their extremities 17 mm wrench replace the old hoses with new...

Page 54: ...g 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...

Page 55: ...the compressor or any of its parts any longer you must proceed with its dis mantling and putting out of service These tasks must be carried out in compliance with the standards in force Use of the co...

Page 56: ...rgency situations pag 56 Use and maintenance manual MCH 36 10 1 FIRE 10 INSTRUCTIONS FOR EMERGENCY SITUATIONS In the event of fire use a CO2 extinguisher in compliance with the relevant standards in f...

Page 57: ...Cap 11 _ Maintenance register pag 57 Use and maintenance manual MCH 36 11 MAINTENANCE REGISTER Date Component Task and notes Signature...

Page 58: ...Cap 11 _ Maintenance register pag 58 Use and maintenance manual MCH 36 11 MAINTENANCE REGISTER Date Component Task and notes Signature...

Page 59: ...Cap 11 _ Maintenance register pag 59 Use and maintenance manual MCH 36 11 MAINTENANCE REGISTER Date Component Task and notes Signature...

Page 60: ...Cap 12 _ Notes pag 60 Use and maintenance manual MCH 36 12 NOTES...

Page 61: ...Cap 12 _ Notes pag 61 Use and maintenance manual MCH 36 12 NOTES...

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