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Comprehensive Guide to Compressor Function and Maintenance

This presentation provides an overview of compressor functionality, routine maintenance, and troubleshooting methods. It covers the air compression process, essential safety valves, and pressure maintenance valves for optimal operation. Key components of the pumping group are detailed, including cylinders, pistons, and essential lubrication systems. Maintenance routines focus on air intake filters, oil changes, safety checks, and compressor cleaning techniques. Additionally, common problems such as overheating and decreasing air output are addressed with solutions to ensure reliability and performance.

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Comprehensive Guide to Compressor Function and Maintenance

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  1. USER MAINTENANCE

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

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

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

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

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

  7. i. Pumping Group Description • Lubrication is achieved via a splash* and pump* * feed system • The main drive wheel provides air flow to cool the machine via fan blades * MCH 6, 8,13 & 16 * * TROPICAL RANGE

  8. i. Pumping Group Description • The Coltri Sub range uses 3 types of pumping unit : MCH 6 4 cylinders, splash feed MCH 8,13,16& 32 3 cylinders, splash feed Tropical plus range incorporate pump and splash feed MCH 36 4 cylinders, oil pump

  9. i. Pumping Group Description • Filtration Path • Intake Filter • Water Separator • Main Filtration Tower • .

  10. ii. The Air Compression Process

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

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

  13. iv. Pressure Maintaining Valve • To set valve: • Start compressor & open filling valve • Check gauge on separator • for internal pressure • Adjust by turning lower cap • Anti clockwise - • Clockwise + • .

  14. Maintenance Routine Maintenance routine • Air Intake filter ii. Filter cartridge iii. Oil changes and types iv. Safety checks v. Compresor cleaning

  15. i. Air Intake Filter • Gently blow clean every 20 hrs and re-insert rotating position. • Change filter regularly: MCH 6 100 hrs MCH 13 80 hrs MCH 16 70 hrs

  16. ii. Filter Cartridge • 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.

  17. iii. Oil Changes & Type After initial 50 operating Hrs and then every: MCH6* 50 hrs synthetic oil MCH 13/16* 200 hrs synthetic oil MCH 36 * 250 hrs synthetic oil * Coltri Synthetic Oil only recommended. Mineral and synthetic oils must not be mixed

  18. iii. Oil Changes &Type • Synthetic oils Coltri Oil CE 750

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

  20. v. Compressor Cleaning • A dirty machine overheats, and does not allow to see clearly oil or air leaks. • A weekly rinse with medium/low strength pressure pump will avoid this • Ensure that water does not enter the air intake, electric motor or electrical parts of the compressor system.

  21. Problem Solving • Air Odor • Compressor overheats • Decreasing air output • Electric motor fails to start • Electric motor runs slowly

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

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

  24. ii. Compressor Overheats • Problem: Insufficient ventilation or ambient temperature above 40 Celsius • Solution:Re-site compressor or use additional forced ventilation

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

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

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

  28. v. Electric Motor runs slowly Problem: Tight bearings within motor Solution: lubricate/service motor Problem: Loose electrical connection Solution: Tighten connections Problem: Insufficient power supply Solution: Check rating of supply Problem: Loose drive belt Solution: Tighten belt

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