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AEROTECNICA COLTRI MCH 14 TECH NITROX SERIES Instruction Manual

Low and high pressure compressors
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Special equipment and compressors for underwater activities
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ow and High pressure
ow and High pressure
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C
ompressors
ompressors
MCH 14 TECH NITROX
MCH 14 TECH NITROX
VERSION: English
I
NSTRUCTION
M
ANUAL
Revision:
DOC MCH 14 TECH-NITROX-09-01

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  • Page 1 Special equipment and compressors for underwater activities ow and High pressure ow and High pressure ompressors ompressors MCH 14 TECH NITROX MCH 14 TECH NITROX VERSION: English NSTRUCTION ANUAL Revision: DOC MCH 14 TECH-NITROX-09-01...

  • Page 2: Table Of Contents

    USE IN BRIEF Use in brief ............................. 7 GUARANTEE AND ASSISTANCE Guarantee ..........................8 Assistance ........................... 8 TECHNICAL DESCRIPTION Operating principle ....................... 10 Description of the pump unit high pressure compressor ............12 2.2.1 Crankcase - High pressure compressor ..............13 2.2.2 Valve head unit - High pressure compressor ..............
  • Page 3 UNPACKING AND HANDLING THE MACHINE Unpacking the machine ......................26 Pack contents........................27 Handling the machine......................27 INSTALLATION Positioning ........................... 28 Connections ......................... 29 6.2.1 Connecting the extension for the air intake ..............29 6.2.2 Connecting the filling hoses ..................33 6.2.3 Electrical connections ....................
  • Page 4 MESSA FUORI SERVIZIO E SMANTELLAMENTO MACCHINA 10.1 Instructions for extended storage ..................58 10.2 Disposal of waste products ....................58 10.3 Dismantling the machine ...................... 59 MAINTENANCE 11.1 General notes ......................... 61 11.2 Preventive maintenance ....................61 11.3 Changing the lubricant oil ....................62 11.4 Checking the drive belt ....................
  • Page 5 REGISTRER 13.1 Register ..........................83 MACHINE DIAGRAMS 14.1 Compression diagram ......................84 14.2 Compression diagram - High pressure compressor .............. 85 14.3 Electrical diagrams ......................86 SPARE PARTS 15.1 Exploded view of the machine parts .................. 89 Crankcase ........................91 Piston rod unit........................
  • Page 6 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.

  • Page 7: 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).

  • Page 8: Guarantee

    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.
  • Page 9 TECHNICAL DESCRIPTION This chapter provides a technological description of the machine and its main components. Operating principle ......................10 Description of the pump unit ..................... 12 2.2.1 Crankcase ........................13 2.2.2 Valve head unit ......................14 2.2.3 Safety valves ......................14 2.2.4 Lubricating unit ......................

  • Page 10: Operating Principle

    Operating principle WARNING : THE FILLING STATION PRODUCES RESPIRABLE AIR/NITROX. The filling stations in the “MCH 14 TECH NITROX” series are of the semi-soundproofed type (Fig. 1). This model is provided with two compressors, the first is low pressure (superior) and the second high pressure (inferior);...
  • Page 11 This system supplies a breathable gas stream consisting of an elevated oxygen content relative to normal atmospheric content of approximately 21% O by volume. This technique employs gas separation technology utilizing a permeable membrane to separate certain gas molecules from other gas molecules allowing a controlled flow of output gasses of differing oxygen concentrations.

  • Page 12: Description Of The Pump Unit

    Description of the pump unit H i g h p r e s s u r e c o m p r e s s o r 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).

  • Page 13: Crankcase - High Pressure Compressor

    Crankcase - High pressure compressor 2.2.1 The crankshaft, the pistons and the cylinders also form a part of this unit. The crankcase (Fig. 5) is made of aluminium alloy, the two flanges with the ball and roller bearings that support the crankshaft are oil- tight with the crankcase due to the O-Rings fitted.

  • Page 14: Valve Head Unit

    Valve head unit (Fig. 8) - High pressure compressor 2.2.2 The head unit includes the discharge and inlet valves. The head of the 1 stage is of a lamellar type and includes both the inlet and the discharge. The inlet and discharge valves are located directly in threaded seats on the 2 and 3 stage heads.

  • Page 15: Pressure Maintenance Valve - High Pressure Compressor

    Pressure maintenance valve - High pressure compressor 2.2.5 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 15), for the purpose of eliminating as much water as possible from the air.

  • Page 16: Pilot Valves

    ACTIVATED CARBON FILTER AND MOLECULAR SIEVE (Fig. 12) The filter consists of an aluminium tube (B) that holds the filter cartridge (A). The shell of the cartridge contains the activated carbon (C) and the molecular sieve (D) placed between felt disks. The condition of the cartridge is of fundamental importance for the quality of the air (see paragraph 11.7 for replacement instructions).

  • Page 17: Frame And Sound-Proofed Casing

    Air in line to device being actuated can then escape through upper seat and out vent hole. The pressure at which the Pilot Valve is “on” or “off” is controlled by the spring which has been installed at the factory. A small adjustment can be made in the field by changing the spring force by compressing the spring more or less with the adjusting screw provided by the Pilot Valve.

  • Page 18: Technical Characteristics Of The Pump Unit

    TECHNICAL CHARACTERISTIC This chapter provides some technical information concerning the machine. Technical characteristics of the pump unit ............... 18 3.1.1 Sizes and weights ..................... 18 3.1.2 Machine series MCH 14 TECH NITROX ..............19 Noise level .......................... 20 Technical char acteristics of the pump unit - l o w a n f h i g h p r e s s u r e c o m p r e s s o r The pump unit consists of: three compression stages, three cylinders, forced air cooling by means of a large diameter fan, splash lubrication with immersed pins, stainless steel cooling pipes.

  • Page 19: Machine Series Mch 14 Tech Nitrox

    3.1.2 Machine series MCH 14 TECH NITROX Table 1 High pressure compressor: Maximum Block Output Pressure 300 bar - 4700 psi Final System Discharge Pressure 225 bar - 3200 psi Number of Stages Number of Cylinders Capacity ca 230 Lt/min. 14 m3/h 5 - 8.0 SCFM Lubricant Synthetic Nitrox 2 manual...

  • Page 20: Noise Level

    Noise level The MCH 14 TECH NITROX series of compressors have been designed and built with the objective of reducing acoutsic pressure to a minimum. The reading of the machine noise level was taken from the “operator’s work place” (Fig. 16), with the...
  • Page 21 PRECAUTIONS FOR USE AND MAINTENANCE Refer to the specific “Safety Regulation Manual” which is supplied enclosed with this manual (and which forms an integral part of the same). Machine area diagrams ..................... 22 4.1.1 Safety devices ......................23 4.1.2 Residual risk areas ....................25 WARNING THE COMPONENTS YOU WILL BE USING CONTAIN ELEMENTS THAT MAY EXPOSE YOU TO BOTH LOW AND HIGH-PRESSURE GAS STREAMS.

  • Page 22: Machine Area Diagrams

    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.

  • Page 23: Safety Devices

    Safety devices 4.1.1 The MCH 14 TECH NITROX (Fig.18) 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.
  • Page 24 Table 1 POSITION SAFETY DEVICE DESCRIPTION INSPECTION Safety valves. Protect the third stage and the cylinders The safety valve must be checked at from bei ng overfilled; it is calibrated e a c h f i lli ng o p e ra t i o n; s ta r t up t he during the inspection of the compres- compress or with the cyli nder valves sors.

  • Page 25: Residual Risk Areas

    Residual risk areas 4.1.2 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 14 TECH NITROX (Fig. 19-20-21). Each operator must be aware of the residual risks present on the machine in order to avoid possible accidents.

  • Page 26: Unpacking And Handling The Machine

    Handling the machine ......................27 U n p a c k i n g t h e m a c h i n e The machines in the MCH 14 TECH NITROX series are delivered fully assembled, but with the hoses supplied separately.

  • Page 27: Pack Contents

    Pack contents The standard equipment with which the machine is supplied is: - 2 1200 mm filling tubes with tap; - operating and maintenance booklet; - enclosure with the Instruction Manual (Safety regulations); - lubricating oil in cans (4 lt ). Handling the machine Having removed the compressor from its pack as described in the previous paragraph, the machine can be moved to its place of installation.

  • Page 28: Positioning

    I N S TA L L ATION 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”. Positioning .........................

  • Page 29: Connections

    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.
  • Page 30 To connect the extension, proceed as follows: 1 Remove the left-hand side protective cover (looking at the compressor from the front), by unscrewing the fixing screws (Fig. 27). WARNING Only use a flexible pipe provided with a steel spiral internal reinforcement to prevent bending and a consequent reduction in the cross section.
  • Page 31 3 Pass the pipe through the hole located in the rear guard (Fig. 29-30). Installation...
  • Page 32 4 Fit the additional intake filter on the end of the extension pipe (Fig. 31). 5 Position the end of the extension on which the intake filter is fitted (air intake) in a ventilated place protected from atmospheric agents. 6 Direct the air intake in a position “upwind” (Fig.

  • Page 33: Connecting The Filling Hoses

    C onnect i n g the fi ll i ng ho se s 6.2.2 1 Screw hose N° 1 into the special attachment “A” (Fig. 34) without securing it too tightly (see point 4). 2 Connect hose N°2 in the same way as described in the previous point. 3 A torque wrench should be available to fasten the hoses.

  • Page 34: Electrical Connections

    E l e c t r i c a l c o n n e c t i o n s 6.2.3 The compressor is delivered equipped with an electrical cable and a 4 pin plug 32A (Fig. 42). 1 For the electrical connection, the plug simply has to be connected to a mains power supply socket.

  • Page 35: Control Panel

    CONTROL PANEL This chapter provides a description of the functions carried out by the various devices fitted on the control panel. Control panel........................34 Indication and control devices ..................35 Pannello di comando The control panel has three operating buttons and the hour counter to memorize the number of machine operating hours (Fig.

  • Page 36: Indication And Control Devices

    I n d i c a t i o n a n d c o n t r o l d e v i c e s 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.
  • Page 37 7 HP compressor (high pressure) lubricating oil level indicator 8 Percentage O analyser situated at the exit of the membrane 9 Percentage O analyser situated at the exit of the refilling ramp 10 Positive pressure control gauge of the HP suction compressor 11 Membrane supply pressure control pressure gauge 12 Accumulation tank pressure control pressure gaug 13 Temperature thermometer fitted inside casing frame...

  • Page 38: Filling The Machine

    START 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.

  • Page 39: Checks

    The oil is added by removing the two oil caps located on the upper cover of the machine (Fig. 41) unscrewed. The quantity of oil to be poured in is 1.5 lt. for the high pressure compressor and 2 lt. for the low pressure compressor and the level should be checked with the machine turned off, bearing in mind that an excess amount of oil may cause...
  • Page 40 4 Check the level of the lubricating oil of the pump unit by looking at the indicator located The indicators are marked by the letters “A” and “B” (Fig. 44-45) and correspond to the same marks also shown on the relative oil caps. When oil has to be added, this indication will be used to establish, according to the indicator, which cap has to be unscrewed for...
  • Page 41 If the direction of rotation does not correspond with that shown by the arrow located on the front panel covering the fan or directly on the motors (Fig. 46-47) that can be seen by removing the side panel on the side of the motor, the power supply must be switched off and two of the three phases must be inverted on the main power line (Fig.

  • Page 42: Calibrate Analyzers

    C a l i b r a t e a n a l y z e r s Calibrate both the analyzers to 20.9 as follow: please read analyzer manual for more specific instructions, especially if analyzers will be located in a hot and/or high humidity area.

  • Page 43: Low Pressure Compressor Pilot Valve

    High pr essur e compr essor Pilot Valve 8.4.1 Pressure adjustment Proceed with the following instructions while compressor is running (Fig. 50a): Loosen locknut (4) and back off several turns. Do not turn differential adjuster (3). Check reading on the tank pressure gauge at 12 bar (170 psig).
  • Page 44 U S E This chapter describes the operations required for filling 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.
  • Page 45 After filling, the cylinders must not be emptied completely, even during winter storage, to prevent damp air from getting in (Fig. 51). 3 Check the condition of the hoses and the relative attachments. See paragraph 6.2.2 “Connecting the filling hoses”. AUTOMATIC CONDENSATE DISCHARGE 4 For the models provided with an automatic condensate discharge,...
  • Page 46 MANUAL CONDENSATE DISCHARGE 5 Place a container under the two condensate sniffle valves and then proceed with the manual discharge by turning on the respective taps (Fig. 53). This operation should also be carried out during the cylinder filling operations, every 15/20 minutes only on the models without an automatic condensate discharge feature.

  • Page 47: Filling The Cylinders

    Filling the cylinders During this operation, the operator’s position is that shown in chapter 3.2 “Noise level”. WARNING During the filling 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 filling tap while the machine is under pressure.
  • Page 48 STEP 1 Switch on the analyser (Fig. 57). Close (clockwise), then open, (counter clockwise), the Nitrogen Valve 1/2 turn. (Fig. 58). Make sure the low pressure feed air shut-off switch is off. (Fig. 59). Set up one fill bottle and attach the hoses to high pressure compressor.
  • Page 49 STEP 3 1 - Low pressure panels 2 - High pressure panel and gauges 3 - Oil levels NOTE: before turning on the compressors, check the lubricant levels gauges (Pos.3 Figura 61) for both compressors. Low pressure Compressor Turn on low pressure compressor and allow tank to come up to full pressure approximately 13 bar (185 psi) (range 12-13 bar 175-190 psi) see the value on the...
  • Page 50 High pressure compressor High pressure Compressor Turn on HP compressor. Allow pressure to build up to approximately 160 bar (2300psi) (Fig. 63). NOTE: Auto shut-off occurs at 220 bar (3200psi), see Parag. 9.1 (pag. 55). Manual restart will be necessary. Crack open the unconnected fill whip to maintain 160 bar (2300 psi).
  • Page 51 STEP 4 Turn on membrane system by turning LP feed air valve switch to ON position (Fig. 65). Feed air will now pass through the LP regulator “B” and LP filtration “C” and continue on to the membrane heater (Fig. 66). LP regulator and thermostat have been factory set and may only need fine-tuning.
  • Page 52 STEP 5 When permeate pressure gauge “F” reaches 0,07 bar (1psi) (approximately 3-5 minutes), system is now ready to be adjusted to the nitrox percentage level needed for the fill. (Fig. 68). NOTE: If permeate pressure gauge does not reach (1psi), slightly adjust the LP regulator as follows: Pull down the bottom of the regulator to unlock.
  • Page 53 HP Fill Whip. You are venting through the fill whip all nitrox until both analyzers show the chosen % + or - 0.5% 02. The system should stabilize within 5-8 minutes. If the system doesn’t stabilize within 8 minutes, you should call us for trouble shooting assistance AEROTECNICA COLTRI S.r.l.
  • Page 54 STEP 7 Slowly adjust, no more than a fraction turn, the nitrogen valve until the chosen percentage of nitrox is achieved. Clockwise decreases 02 reading; counter clockwise increases 02 reading. Wait approximately 1 minute before any additional adjustment is made (Fig. 72). Keep in mind the permeate pressure gauge needs to remain at approximately 0,07 - 0,1 bar (1-1.5 psi) and a slight adjustment with the LP...
  • Page 55 STEP 9 Check all system gauges : RECOMMENDED SETTING/MAXIMUM GAUGE ALLOWABLE READING Temperature 110° F / 43° C Feed air pressure to regulator 12-13 bar (175-190 psi) Feed air pressure to membrane 10-12 bar (150-180 psi) Nitrox delivery pressure to compressor 0,07 a 0,18 bar (1 a 2.5 psi) (permeate stream) Oxygen analyzers...
  • Page 56 3 Start up the HP compressor by pressing the corresponding button. (General switch to“ON” and then press the green button) (Fig. 76) (left panel). 4 When the cylinder has been filled, the compressor is stopped automatically by the pressure switch. 5 Turn off the cylinder tap and that of the hoses (Fig.
  • Page 57 If an emergency situation should arise during the filling of the cylinders, press the “OFF” button located on the control board (Fig. 79). The machine is 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;...

  • Page 58: Instructions For Extended Storage

    MACHINE SHUTDOWN AND DISMANTLING PROCEDURES This chapter provides instructions to be followed for extended storage or for the dismantling of the machine. 10.1 Instructions for extended storage ..................58 10.2 Disposal of waste products ....................58 10.3 Dismantling the machine ....................59 WARNING Before carrying out any procedure on the machine, read Chapter 4, “Precautions for use and maintenance”...

  • Page 59: Dismantling The Machine

    It is important to remember that the loading and discharge of waste oil, special waste products and toxic or harmful waste products deriving from industrial or artisan processes must be registered. The collection of waste oils and special toxic or harmful waste products must be carried out by specially authorized companies.
  • Page 60 M A INTENANCE 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. 11.1 General notes ........................

  • Page 61: General Notes

    General notes 11.1 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 filling 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.

  • Page 62: Changing The Lubricant Oil

    The oil must have the following characteristics: LOW PRESSURE COMPRESSOR - Table 2 cu.cm. 2000 Sump capacity litres/gallons AEROTECNICA COLTRI SPECIAL SYNTHETIC OIL Recommended oils SYNTHETIC NITROX EZ 1000 above +10 °C (50 °F) SAE 20 W/40 summer Viscosity of the oil from +10 °C to -15 °C (50°...
  • Page 63 To change the oil, proceed as follows: 1 Use a way with a minimum capacity of 2.5 lt. capacity under the oil discharge tap (Fig. 80). 2 Unscrew the hexagonal closing cap located in front of the oil discharge. 3 Open the oil discharge two taps (Fig.

  • Page 64: Checking The Drive Belt

    Checking the drive belt 11.4 The drive belt is checked by measuring the yield of the same. This operation must be carried out every 250 machine operating hours as described below: 1 Remove the protective cover as shown in figures 82 by unscrewing the fixing screws. 2 By exerting a pressure of at least 5 Kg., check that the belt does not yield by more than 5...

  • Page 65: Lp Moisture/Oil Vapor Filters - Low Pressure Compressor

    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). WARNING: never operate the compressors without the protection belt. Its removal will expose rotating parts, which could cause injury to the operator or damage the machine.
  • Page 66 The housings are attached directly on the front panel. (Fig. 87). WARNING: Special attention needs to be given to the arrangement of the three LP filtration bowls. Properly reinstall each element and bowl to the correct housing. Improper sequence can cause damage to downstream components.

  • Page 67: Suction Filtre - High Pressure Compressor

    - Pull the filter element in a downward motion. The element will pull off the mounting post. (Fig. 90). - Replace the elements and reassemble in reverse order. Operational Note: Visual gauges on top of the housings assist with replacement intervals. Elements should be visually inspected quarterly and replaced on demand.
  • Page 68 1 Remove the left-hand side protective cover (looking at the compressor from the front), by unscrewing the fixing screws (Fig. 92). 2 Press cap n° 1 lightly and turn it in an anti- clockwise direction (Fig. 93). 3 Remove the filter and replace it with a new one (Fig.

  • Page 69: Activated Carbon Filter And Molecular Sieve - High Pressure Compressor

    Activated carbon filter and molecular sieve - 11.6 h i g h p r e s s u r e c o m p r e s s o r The cartridges must be replaced before the air becomes foul-smelling. The quality of the air depends to a large extent on the condition of the filtering cartridge.
  • Page 70 To replace the activated carbon filter, proceed as follows: - unscrew the external cap using a lever between the screws “A” (Fig. 95); - remove the external cap and the internal cap (Fig. 96); - unscrew the used cartridge from the internal (Fig.

  • Page 71: Filling Hose - High Pressure Compressor

    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.

  • Page 72: Valves Heads - High Pressure Compressor

    Valve heads - High pressure compressor 11.9 - The head of the 1 stage (A) is of the lamellar type (Fig. 98). It must be fitted so that the word “TOP” remains upwards and the flaps correspond with the openings in the cover of the head.

  • Page 73: Cylinders - High Pressure Compressor

    Cylinders - High pressure compressor 11.10 After removing the cylinders, it is necessary to check, when they are replaced, that the piston at the maximum point and the upper edge of the cylinder are on the same level (Fig. 101). Adjust any differences that there may be by making the base of the cylinder thicker using gaskets.

  • Page 74: Pressure On/Off

    11.11.3 Pr es s ure on/of f This switch is automatic and starts the compressor at a low pressure and turns it off when it has reached the maximum pressure level set. It is pre-set to start and switch off the compressor at the correct pressure for the unit on which it is installed.

  • Page 75: Control Valve

    Control valve 11.11.7 This valve closes when the compressor stops, preventing air escaping from the tank through the discharge pressure valve. If air continues to escape through the discharge valve when the compressor has stopped, it means that the control valve is leaking. To solve this problem, remove the control valve and clean the disc and where it is seated.

  • Page 76: Maintenance Programme

    11.12 M a i n t e n a n c e p r o g r a m m e 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.
  • Page 77 Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................
  • Page 78 Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................Operation carried out: ......................... Date: ..............................

  • Page 79: List Of Faults

    TROUBLESHOOTING This chapter describes the faults that may arise during machine operation. For each fault, the cause and the solution to be adopted are specified. 12.1 List of faults ........................79 List of faults 12.1 Table 1 below lists all the faults that may arise during operation and the relative solution. Table 1 PROBLEM CAUSE...
  • Page 80 12.1.1 Low pressure compressor Troubleshooting...
  • Page 81 EXPLANATION ON TABLE REGARDING POSSIBLE PROBLEMS Check all fuses and the on/off switches for the motor to ensure that power is being supplied. Check for any slow or faulty cables. A magnetic starter includes a reset button which is used to restart the motor in the event of disruption to the power supply.
  • Page 82 The centrifugal discharge valve may jam because of a foreign body. To clean it, unscrew the hexagonal screw positioned at the base of one of the dischargers, remove the spring and the ball. To remove the ball, it may be necessary to “shake” the fan. Clean or replace, whichever is necessary. 17/18 Before carrying out maintenance to the control valve, make sure that the pressure inside the tank is equal to ZERO.

  • Page 83: Registrer

    REGISTRER 13.1 Register ..........................83 It is obligatory to display a machine log book (register), which contains refill gas registration and the following list of information. The machine log book should NOT be made up of loose pages and must be durable. It must contain at least the following information: - Date;...

  • Page 84: Machine Diagrams

    MACHINE DIAGRAMS This chapter provides the plans and diagrams of the systems installed on the machine. 13.1 Compression diagram ......................84 13.2 Electrical diagram ......................86 14.1 N I T ROX c o m p r e s s i o n d i a g r a m Machine diagrams...
  • Page 85 C o m p r e s s i o n d i a g r a m - H i g h p r e s s u r e 14.2 compressor - only air Machine diagrams...

  • Page 86: Electrical Diagrams

    14.3 Electrical diagram Machine diagrams...
  • Page 87 Machine diagrams...
  • Page 88 POS. GENERAL MAIN SWITCH PRIMARY AUXILIARY PROTECTION SWITCH AUXILIARY TRASFORMER (380/220 OR 220/220) SECONDARY AUXILIARY PROTECTION SWITCH PRESSURE SWITCH DOOR MICROSWITCH DOOR MICROSWITCH MOTOR M1 OVERLOAD RELAY MOTOR PROTECTION SWITCH MOTOR CONTROL CONTACTOR MOTOR STOP BUTTON STOP BUTTON DRAIN BUTTON READY STATE RUNNING SIGNAL (GREEN) RUNNING SIGNAL (RED) HOUR COUNTER...

  • Page 89: Exploded View Of The Machine Parts

    SPARE PARTS 15.1 Exploded view of the machine parts ................89 Crankcase ........................91 Piston rod unit ......................... 93 Cylinder unit ........................95 Valve head unit ....................... 97 Cooling pipes ........................99 Filtering system ....................... 101 Condensate separator ..................... 103 Pulley - Crankcase and Cylinder - Low pressure compressor ........

  • Page 91: Crankcase

    Crankcase High pressure compressor POSIZ. CODICE DESCRIZIONE 13-00-0001 MONOBLOCCO 13-01-0008 TIRANTE PRIMO STADIO 13-03-0016 TIRANTE TERZO STADIO 13-02-0040 TIRANTE SECONDO STADIO 13-00-0042 CUSCINETTO RULLI FLANGIA NU305 13-00-0050 FLANGIA LATO FILTRI 13-00-0052 RACCORDO PORTATUBO SCARICO OLIO 13-00-0021 RACCORDO ANGOLO ¹/ TUBO 8 mm RILSAN 13-00-0055 ANELLO ELASTICO SEEGER J 62 13-00-0018 DADO 8 mm 13-00-0009 RONDELLA PIANA 8 mm...
  • Page 92 118/A 117/A 113/A 112/A 116/A...

  • Page 93: Piston Rod Unit

    Piston rod unit High pressure compressor POS. CODE DESCRIPTION 13-00-0072 SEEGER RETAINING RING A 30 13-00-0098 CRANKSHAFT 13-00-0099 KEY 13-00-0100 COUNTERWEIGHT 13-00-0101 8 mm. SELF-LOCKING NUT 13-00-0104 8x65 TCE SCREW 13-00-0105 THIRD STAGE CONNECTING ROD ASSEMBLY 13-00-0106 SPACER 13-01-0107 FIRST STAGE CONNECTING ROD ASSEMBLY 13-00-0106 SPACER 13-00-0105 SECOND STAGE CONNECTING ROD ASSEMBLY 13-00-0110 SEEGER RETAINING RING...
  • Page 94 002/A 043/A...

  • Page 95: Cylinder Unit

    Cylinder unit High pressure compressor POS. CODE DESCRIPTION 13-01-0002 FIRST STAGE 88 mm. CYLINDER 002/A 16-01-0002 FIRST STAGE 95 mm. CYLINDER 13-01-0007 FIRST STAGE CYLINDER O-RING 13-00-0015 THIRD STAGE CYLINDER O-RING 13-02-0017 THIRD STAGE GUIDING CYLINDER 13-00-0018 8 mm. BOLT 13-00-0019 LUBRICATION INDICATOR PIPE 13-00-0021 CORNER ¹/ PIPE FITTING 8 mm.
  • Page 96 003/A...

  • Page 97: Valve Head Unit

    Valve head unit High pressure compressor POS. CODE DESCRIPTION 13-01-0003 FIRST STAGE 88 mm. GASKET 003/A 16-01-0003 FIRST STAGE 95 mm. GASKET 13-01-0004 FIRST STAGE HEAD WITH VALVES 13-01-0005 FIRST STAGE GASKET 13-01-0006 FIRST STAGE HEAD COVER 13-00-0009 8 mm. FLAT WASHER 13-00-0010 SCREW 8x55 TCE 13-01-0011 INTAKE FILTER COVER O-RING 13-00-0012 STRAIGHT ¹/...

  • Page 99: Cooling Pipes

    Cooling pipes High pressure compressor POS. CODE DESCRIPTION 13-03-0023 6 mm. COOLING PIPE 13-00-0036 8 mm. PIPE 13-00-0074 FAN-HOLDING HUB 13-00-0075 8x30 TCE SCREW 13-00-0077 COOLING FAN 13-00-0079 12 mm. FLAT WASHER 13-00-0080 12x35 TCE SCREW 13-00-0081 10x40 TCE SCREW 13-00-0082 FAN FLANGE 13-00-0083 GALVANIZED PIPE-HOLDING BRACKET 13-00-0084 6x15 TCE SCREW...
  • Page 100 Filtering system High pressure compressor Spare parts...

  • Page 101: Filtering System

    Filtering system High pressure compressor POS. CODE DESCRIPTION 13-00-0097 CLEANER FILTER 13-00-0152 VITE 8x30 TCE 13-00-0153 VITE 8x12 TCE 13-00-0154 UPPER FILTER CAP 13-00-0155 FILTER CAP O-RING 13-00-0156 INTERNAL FILTER CAP 13-00-0155 FILTER CAP O-RING 13-00-0158 FILTER CARTRIDGE O-RING 13-00-0155 FILTER CAP O-RING 13-00-0160 LOWER FILTER CAP 13-00-0187 MESH DISK DIAM.
  • Page 102 Condensate separator L o w p r e s s u r e c o m p r e s s o r Spare parts...

  • Page 103: Condensate Separator

    Condensate separator L o w p r e s s u r e c o m p r e s s o r POS. CODE DESCRIPTION 13-03-0023 6 mm. COOLING PIPE 13-00-0036 8 mm. PIPE 13-04-0226 HP 300 mm. PIPE 13-00-0089 10 mm.

  • Page 104: Pulley - Crankcase And Cylinder - Low Pressure Compressor

    Pulley - Crankcase and cylinder L o w p r e s s u r e c o m p r e s s o r Spare parts...

  • Page 105: Piston Rod Unit - Low Pressure Compressor

    Piston rod unit L o w p r e s s u r e c o m p r e s s o r Spare parts...

  • Page 106: Cylinder, Valve And Filter Unit - Low Pressure Compressor

    Cylinder - Valve and Filter unit L o w p r e s s u r e c o m p r e s s o r Spare parts...

  • Page 107: Description Of The Pump Unit Low Pressure And Pipes

    Pump unit L o w p r e s s u r e c o m p r e s s o r Spare parts...
  • Page 108 I nt rod uct io n 16.1 16.1.1 The Mini O2DII oxygen analyser has been designed to measure oxygen levels from between 0.1 and 100%. 16.1.2 The analyser is used to check levels of oxygen present in cylinders or monitoring a gas mixing control panel, but should never be used for both operations at the same time.
  • Page 109 16.2 Controls 16.2.1 The analyser has an in-built on/off switch which is at the side or on the front of the machine. Move the switch upwards or downwards to switch the machine on and move it to the central position to switch it off. When the unit is switched on, the screen of the analyser will show an oxygen value but the machine should not be used until after calibration (see section 3.0).
  • Page 110 Air calibration 16.3 16.3.1 Before using the machine it is essential to carry out the air calibration each time. The instructions are as follows: 16.3.2 Make sure that the sensor seal and any other flow adapter has been removed and that the reading on the screen has stabilised.
  • Page 111 16.4 Operation 16.4.1 The analox Mini O2DII is supplied with a single DII adapter that enables the analyser to be connected directly to the outlet of the nitrox tank. 16.4.2 Make sure that the sensor seal has been removed. Connect the DII adapter to the analyser pushing the adapter onto the turret of the sensor.
  • Page 112 16.6 Tr o u b l e s h o o t i n g SYMPTOM REASON SOLUTION Battery symbol Flat battery Ch’ange the battery Empty screen Switched off Switch on Bad connection Check screen connection Check battery connection Zero reading Sensor not inserted Check connection Expired sensor...
  • Page 113 16.7 M a i n t e n a n c e 16.7.1 Replacing the battery. Unscrew the 4 screws that are in each corner of the apparatus and lift the cover carefully. Slid the battery from the spring support and disconnect the electrical wire. Connect the electric wire to the new battery and slide the battery behind the spring support.
  • Page 114 16.8 Care of the Mini O2DII 16.8.1 Even though the Mini O2DII has been designed to be water resistant, avoid immersion in liquids and do not leave outside without protection. 16.8.2 The Mini O2DII has been built to withstand minimal blows or falls but being a precision oxygen analyser it should be taken care of to guarantee correct long term efficiency.
  • Page 115 16.9 Safety infor mation for the Mini O2DII 16.9.1 Flat batteries should be destroyed according to the local regulations in force. 16.9.2 Used sensors or those that leak or are damaged in another way, should be destroyed safely according to the local regulations in force. 16.9.3 IThe sensor contains KOH, a potassium hydroxide solution, a dangerous substance, which can cause the following effects:...
  • Page 116 16.10 D e t a i l s Interval 0. 1 – 100.0% Oxygen Precision +/- 1% of the reading Definition 0.1% Oxygen Reaction time 90 in less than 15 seconds Type of sensor Analox 9212-5 Sensor life More than 36 months in air 24 months guarantee in air Battery Alkaline...
  • Page 117 AEROTECNICA COLTRI S.r.l. Sede legale: Via Rio Ponale, 7 - 25010 Rivoltella di Desenzano D/Garda - BRESCIA - ITALY Stabilimento: Via Colli Storici, 177 - 25010 San Martino della Battaglia - BRESCIA - ITALY Tel. 030 9910297 - 030 9910301 - Fax 030 9910283 e-mail: coltrisub@coltrisub.it...

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