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

High pressure compressors for pure breathing air and technical gases
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MCH 8-11/EM
MCH 13-16/ET
USE AND MAINTENANCE MANUAL
USE AND MAINTENANCE MANUAL
STANDARD
STANDARD
with electric motor
with electric motor
High pressure compressors for pure breathing air and technical gases
High pressure compressors for pure breathing air and technical gases

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  • Page 1 w w w. a e ro t e c n i c a c o l t r i . c o m MCH 8-11/EM MCH 13-16/ET USE AND MAINTENANCE MANUAL USE AND MAINTENANCE MANUAL STANDARD STANDARD with electric motor with electric motor High pressure compressors for pure breathing air and technical gases High pressure compressors for pure breathing air and technical gases...
  • Page 2 M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T Use and Maintenance Manual 2 di 64 Standard...
  • Page 3 M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T S S t t a a n n d d a a r r d d M M C C H H 8 8 - - 1 1 1 1 / / E E M M S S t t a a n n d d a a r r d d HIGH PRESSURE COMPRESSORS FOR PURE BREATHING AIR AND TECHNICAL GASES...
  • 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...
  • Page 5 Carlo Coltri This manual is the property of AEROTECNICA COLTRI Spa. Reproduction, whole or partial, is forbidden M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T...
  • Page 6 - switch off compressor, except for models with pressure switch (B); - bleed the pressure from the filling valve tap via the Model: MCH 13-16/ET Standard bleed tap 5 (A); - disconnect the connector 1 from the bottle (A). Maintenance: - After the first 5 working hours change the oil again (see section “7.6.3”).

  • Page 7: Table Of Contents

    Contents CONTENTS CHAPTER 1 – GENERAL 1.1 Preliminary information 1.2 Required operator training 1.3 Important information for the user 1.4 Foreword 1.5 Warranty 1.6 Assistance 1.7 Responsibility 1.8 Purpose of the machine 1.9 Where the machine may be used 1.10 Running in and testing the compressor 1.10.1 Tightening torque values CHAPTER 2 –...
  • Page 8 6.4.1 Checking the safety valves 6.5 Starting and shutting down 6.5.1 Starting and shutting down MCH 8-11/EM Standard 6.5.2 Starting and shutting down MCH 13-16/ET Standard 6.5.3 Starting and shutting down with control panel 6.6 Tank refill CHAPTER 7 – MAINTENANCE 7.1 Foreword...
  • Page 9 Contents CONTENTS 7.11 Active carbon filter / molecular sieve 7.11.1 Filter replacement frequency calculation table 7.11.2 Changing the active carbon filter / molecular sieve 7.12 Changing the flex hoses CHAPTER 8 – STORAGE 8.1 Stopping the machine for a brief period 8.2 Stopping the machine for a long period CHAPTER 9 –...

  • Page 10: Chapter 1 - General

    PRELIMINARY INFORMATION Do not destroy or modify the manual and update it with inserts published by producer only. Machine type: High pressure compressor for breathing air and/or technical gases Model: MCH 13-16/ET Standard MCH 8-11/EM Standard Revision n°: 00 Manual version: 04/2007 Manufacturer’s data: AEROTECNICA COLTRI Spa.

  • Page 11: Important Information For The User

    Cap.1 _ General IMPORTANT INFORMATION FOR THE USER The information/instructions for compressor use contained in this manual only concern the: AEROTECNICA COLTRI Mod.: MCH13-16/ET Standard. MCH8-11/EM Standard. The instruction manual must be read and used as follows: - read this manual carefully, treat it as an essential part of the compressor;...

  • Page 12: Foreword

    AEROTECNICA COLTRI Spa shall repair or replace those parts it acknowledges to be faulty during the warranty period. In replacing the faulty part AEROTECNICA COLTRI Spa 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 fines.

  • Page 13: Assistance

    A compressor that has been acknowledged as faulty on account of flaws in design, workmanship or used materials shall be repaired or replaced free of charge by AEROTECNICA COLTRI Spa at its plant in San Martino della Battaglia (BRESCIA); costs regarding transport, delivery of spare parts and any materials subject to wear shall be met by the customer.

  • Page 14: Purpose Of The Machine

    Cap.1 _ General PURPOSE OF THE MACHINE The compressors mod. MCH8-11/EM MCH13-16/ET Standard have been designed and built for the purpose of obtaining excellent quality breathing air by drawing it from the surrounding environment. The air, free from any harmful fumes, is passed through an intake filter and, after the filtration cycle, is stored in bottles constructed to contain air at high pressure.
  • Page 15 - It is forbidden to use the compressor under conditions / for purposes other than those indicated in this manual and AEROTECNICA COLTRI cannot be held liable for breakdowns, problems or accidents caused by failure to observe this rule.

  • Page 16: Where The Machine May Be Used

    Cap.1 _ General WHERE THE MACHINE MAY BE USED The compressors mod. MCH8-11/EM MCH13-16/ET Standard have been designed and built for the purpose of obtaining excellent quality breathing air by drawing it from the surrounding environment. The air, which must be free from any harmful fumes, is passed through an intake filter and, after the filtration cycle, is stored in bottles constructed to contain air at high pressure.

  • Page 17: Chapter 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 MCH 13-16/ET STANDARD TYPE SC000296 S/N. 0010 YEAR 2005 MOTOR ELECTRIC THREEPHASE...

  • Page 18: General Instructions

    - Should you have any other queries or suggestions as to how to improve the manual please contact the manufacturer. - Should you sell the compressor AEROTECNICA COLTRI invites you to provide us with the details of the new owner so that any new additions to the manual can be sent on.

  • Page 19: Chapter 3 - Safety Regulations

    Cap.3 _ Safety regulation 3 - SAFETY REGULATIONS GENERAL SAFETY RULES 3.1.1 Know the machine The compressor must only be used by qualified personnel. They must have an understanding of the arrangement and function of all the controls, instruments, indicators, warning lights and the various info plates/labels.

  • Page 20: General Precautions

    Any modification to the compressor that has not been expressly authorised by AEROTECNICA COLTRI shall exonerate the manufacturer from any civil or penal liability. IMPORTANT - Removing or tampering with any safety device is strictly forbidden.

  • Page 21: Important Safety Information

    Cap.3 _ Safety regulation IMPORTANT - Never place hands or introduce screwdrivers, keys or other tools into moving parts. - Never clean with flammable fluids. - Periodically check the info plates/labels and restore/replace them where necessary. - The workplace must be kept clean, tidy and free from objects that might hinder movement. - Operators must avoid carrying out “awkward”...

  • Page 22: Residual Risk Zones

    Cap.3 _ Safety regulation 3.2.4 Residual risk zones DANGER In some compressor zones there remain residual risk s that were not possible to eli- minate at the design stage or for which safety guards could not be provided without compromising the functionality of the compressor. To prevent accidents all operators must be aware of the residual risks on this com- pressor.

  • Page 23: Safety Info Labels: Location

    Cap.3 _ Safety regulation SAFETY INFO LABELS: LOCATION AEROTECNICA COLTRI S.r.l. Via Colli Storici 177 25010 DESENZANO D/G (BS) ITALY Tel. 030/9910301-9910297 Fax. 030/9910283 MODEL MCH 13-16 TYPE STANDARD S/N. 0000 YEAR 2004 MOTOR THREE-PHASE POWER 4 Kw M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T...

  • Page 24: Safety Info Labels: Description

    To check the safety valve refer to “7.8 Checking the safety valve”. IMPORTANT Should the safety valve fail to work pr operly contact the AEROTECNICA COLTRI technical assistance service. a Cooling fan direction of rotation info label. When using the machine for the first time check that the fan rotates in the direction indicated by the arrow.
  • Page 25 Cap.3 _ Safety regulation a Maximum working pressure. a Cartridge change info label. Filter with active carbon molecular sieve cartridge. FILTER WITH CARTRIDGE To change the filter refer to “7.11.1 Filter replacement TO BE REPLACED AT REGULAR frequency calculation table” and “7.11.2 Changing INTERVALS –...

  • Page 26: General Safety Regulations

    Cap.3 _ Safety regulation GENERAL SAFETY REGULATIONS 3.4.1 Care and maintenance Damage and accidents are often caused by maintenance errors, such as: - no oil, - insufficient cleaning, - compressed air circuit inefficiency (flex hoses damaged, loose pipes, screws etc.). Maintenance work must be carried out with due care and attention: your safety depends on it.

  • Page 27: Maintenance Precautions

    Cap.3 _ Safety regulation MAINTENANCE PRECAUTIONS 3.5.1 Warning signs Before doing any maintenance work, stop the engine/motor and make sure the compressed air system is depressurised. If other people start the engine or act on the control pushbuttons/keys while maintenance work is in progress there is a risk of serious injury or death.

  • Page 28: Chapter 4 - Technical Data

    Cap.4 _ Technical data 4 - TECHNICAL DATA TECHNICAL CHARACTERISTICS 4.1.1 Crankcase, crankshaft, cylinders, pistons The crankcase is made of aluminium alloy; the flanges with roller bearings on the filter sides and ball bea- rings on the fan side that support the crankshaft are kept oil-tight with the crankcase by O-rings between flan- ge and crankcase and the oil retainer between flange and motor shaft.

  • Page 29: Machine Parts

    Cap.4 _ Technical data MACHINE PARTS 1 Frame 2 Cover 3 Motor (electric or internal combustion type) 4 Compressor 5 Pressure gauge 6 Intake filter 7 Final condensate separator 8 Active carbon air filter / molecular sieve stage 10 2 stage 11 3 stage...

  • Page 30: Technical Characteristics

    Cap.4 _ Technical data TECHNICAL CHARACTERISTICS 4.3.1 MCH 13/ET Standard AEROTECNICA COLTRI S.r.l. Via Colli Storici 177 25010 DESENZANO D/G (BS) ITALY Tel. 030/9910301-9910297 Fax. 030/9910283 MODEL MCH 13-16 TYPE STANDARD S/N. 0000 YEAR 2004 MOTOR THREE-PHASE POWER 4 Kw...

  • Page 31: Mch 16/Et Standard

    Cap.4 _ Technical data 4.3.2 MCH 16/ET Standard AEROTECNICA COLTRI S.r.l. Via Colli Storici 177 25010 DESENZANO D/G (BS) ITALY Tel. 030/9910301-9910297 Fax. 030/9910283 MODEL MCH 13-16 TYPE STANDARD S/N. 0000 YEAR 2004 MOTOR THREE-PHASE POWER 4 Kw 880mm Motor Electric, 3-phase...

  • Page 32: Mch 8/Em Standard

    Cap.4 _ Technical data 4.3.3 MCH 8/EM Standard AEROTECNICA COLTRI S.r.l. Via Colli Storici 177 25010 DESENZANO D/G (BS) ITALY Tel. 030/9910301-9910297 Fax. 030/9910283 MODEL MCH 13-16 TYPE STANDARD S/N. 0000 YEAR 2004 MOTOR THREE-PHASE POWER 4 Kw 880mm Motor Electric, single-phase...

  • Page 33: Mch 11/Em Standard

    Cap.4 _ Technical data 4.3.4 MCH 11/EM Standard AEROTECNICA COLTRI S.r.l. Via Colli Storici 177 25010 DESENZANO D/G (BS) ITALY Tel. 030/9910301-9910297 Fax. 030/9910283 MODEL MCH 13-16 TYPE STANDARD S/N. 0000 YEAR 2004 MOTOR THREE-PHASE POWER 4 Kw 880mm Motor Electric, single-phase...

  • Page 34: Chapter 5 – Handling And Installation

    Cap.5 _ Handling and installation 5 - HANDLING AND INSTALLATION UNPACKING Standard series compressors are sent fully assembled, with the flex hoses separate. The compressor is packed in a cardboard box on a pallet to simplify handling and transport. The box containing the compressor must be moved according to the instructions shown on the box itself.

  • Page 35: Installation

    Cap.5 _ Handling and installation INSTALLATION WARNING Before proceeding with the installation tasks described below, read Chapter 3 “SAFETY REGULATIONS” carefully. 5.3.1 Positioning - Position the compressor in the designated area and check it is level. For compressor dimensions please consult section 4.3 “Technical characteristics”. - Check that the area in which the compressor is to min.

  • Page 36: Electrical Connection

    Cap.5 _ Handling and installation 5.3.3 Electrical connection The compressor is supplied with an electrical lead Model: MCH-8/EM and, depending on the model, with a plug (see Schuko plug supplied diagram at right). To connect up to the power supply just insert the plug in the mains power socket.

  • Page 37: Chapter 6 – Using The Compressor

    CHECKS TO BE RUN AT THE START OF EACH WORKING DAY Inspect the exterior of the compressor (couplings, pipes, pneumatic components etc.) and check for any oil leaks. Replace parts where necessary or contact AEROTECNICA COLTRI. 6.2.1 Lubricating oil level check Check that the lubricating oil level (a) is within acceptable limits (i.e.

  • Page 38: Storing Technical Documentation

    If the compressor fails to shut down immediately after pressing the emergency pushbutton disconnect the compressor from the power supply and contact AEROTECNICA COLTRI. WARNING It is forbidden to alter pressure parameters without authorisation from AEROTECNICA COLTRI.

  • Page 39: Preliminary Tasks

    It is forbidden to refill them at a pressure greater than that indicated. IMPORTANT Should the safety valve fail to work properly contact the AEROTECNICA COLTRI assistance service. M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T...

  • Page 40: Starting And Shutting Down

    (if it is not refer to “6.1.2 Checking for proper electrical connection”). 6.5.2 Starting and shutting down the MCH 13-16/ET Standard Before starting the engine open the condensate discharge points to prevent a “strained” start.

  • Page 41: Tank Refill

    Cap.6 _ Using the compressor TANK REFILL IMPORTANT During refill the operator must be in the work area. It is advisable, during the bottle refill phase, to submerge the bottles 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.
  • Page 42 Cap.6 _ Using the compressor To refill bottles proceed as follows: - Fit the hose connector (a) to the bottle valve (b). - Screw in the fixing knob (c) until it is completely tightened. - Check that the bleed tap (f) is closed by rotating it clockwise.

  • Page 43: Chapter 7 – Maintenance

    Cap.7 _ Maintenance 7 - MAINTENANCE WARNING Maintenance tasks must only be carried out by the AEROTECNICA COLTRI Customer Assistance Service or qualified personnel. DANGER All maintenance tasks must be carried out with the compressor off and the power lead unplugged from the mains socket.

  • Page 44: Scheduled Maintenance Table

    Cap.7 _ Maintenance SCHEDULED MAINTENANCE TABLE 500 1000 2000 3000 4000 Maintenance hours hours hours hours hours hours hours hours hours hours hours Condensate discharge Automatic shutdown check Lubricating oil level check Main functions check Clean condensate discharge valves Condensate discharge O-rings Condensate discharge valves Belt wear and tension Clean separator filter element...

  • Page 45: Checking And Changing The Lubricating Oil

    Cap.7 _ Maintenance CHECKING AND CHANGING THE LUBRICATING OIL After putting the compressor into service the lubricating oil must be changed after the first 50 working hours. The lubricating oil must be changed every 250 hours working hours or annually. IMPORTANT The compressor must be placed on a solid surface with a tilt of no more than 5°.

  • Page 46: Changing The Lubricating Oil

    Cap.7 _ Maintenance 7.6.3 Changing the lubricating oil The lubricating oil must be changed every 250 working hours or annually. To change the oil proceed as described: - position a recipient under the drain plug (a) so that the oil flows into the exhausted oil recipient (recipient capacity of at least 3 litres required).

  • Page 47: Changing The Intake Filter

    Cap.7 _ Maintenance CHANGING THE INTAKE FILTER After putting the compressor into service the intake filter must be changed after the first 50 working hours. The air filter must then be changed every 250 working hours or annually. Rotate the filtration cartridge in the filter by 90° every 50 hours.

  • Page 48: Checking The Safety Valve

    Once you have checked, using the gauge, that the safety valve trips properly at maximum working pressure, open the taps and start the refill. IMPORTANT Should the safety valve fail to operate properly contact the AEROTECNICA COLTRI technical assistance service. CONDENSATE DISCHARGE IMPORTANT The condensate must be discharged at the end of every working day.

  • Page 49: Transmission Belt

    Cap.7 _ Maintenance 7.10 TRANSMISSION BELT 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 just shut down; wait for the compressor to cool.

  • Page 50: Active Carbon Filter / Molecular Sieve

    Cap.7 _ Maintenance 7.11 ACTIVE CARBON FILTER / MOLECULAR SIEVE The active carbon filter must be replaced at intervals calculated on the basis of the characteristics of the environment in which the compressor is located. To calculate these intervals refer to the table below. The filter must nevertheless be replaced before the air becomes malodorous.
  • Page 51 Cap.7 _ Maintenance - remove the filter plug (c). - unscrew the cartridge (e) from the plug (c). - replace the cartridge (e) with a new one. - screw the new cartridge onto the plug (c). - close the filter plug (c) and tighten with the wrench (b).

  • Page 52: Changing The Flex Hoses

    Cap.7 _ Maintenance 7.12 CHANGING THE FLEX HOSES IMPORTANT The hoses must be changed periodically (every 3 years or ever 1000 hours) or when they show signs of abrasion/wear/damage. The bending radius of the hoses must not be less than 250 mm. DANGER Do not carry out these tasks if the compressor has only just shut down;...

  • Page 53: Chapter 8 – Storage

    Cap.8 _ Storage 8 - STORAGE Should the compressor not be used, it must be stored in a dry sheltered area at an ambient temperature of between 0 °C and 40 °C. Store the compressor away from sources of heat, flames or explosive. STOPPING THE MACHINE FOR A BRIEF PERIOD If you do not intend to use the compressor for a brief period proceed with general cleaning.

  • Page 54: Chapter 9 – Dismantling And Putting Out Of Service

    Cap.9 _ Dismantling and putting out of service 9 - DISMANTLING AND PUTTING OUT OF SERVICE Should you decide not to use the compressor or any of its parts any longer you must proceed with its dismantling and putting out of service. These tasks must be carried out in compliance with the standards in force.

  • Page 55: Chapter 10 – Instructions For Emergency Situations

    Cap.10 _ Instructions for emergency situations 10 - INSTRUCTIONS FOR EMERGENCY SITUATIONS 10.1 FIRE In the event of fire use a CO2 extinguisher in compliance with the relevant standards in force. Contact the fire brigade. M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T Use and Maintenance Manual Standard 55 di 64...

  • Page 56: Chapter 11 – Maintenance Register

    ASSISTANCE SERVICE Customers continue to receive assistance after the purchase of a compressor. To this end AEROTECNICA COLTRI has created an assistance network covering the entire country. IMPORTANT Our qualified technicians are at your disposal at any time to carry out maintenance work or repairs;...

  • Page 57: Scheduled Maintenance Registry Coupons

    Cap.11 _ Maintenance register 11.5 SCHEDULED MAINTENANCE REGISTRY COUPONS Date Type of work and notes ‘Assistance’ service stamp Maintenance technician’s signature Date Type of work and notes ‘Assistance’ service stamp Maintenance technician’s signature Date Type of work and notes ‘Assistance’ service stamp Maintenance technician’s signature M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T...
  • Page 58 Cap.11 _ Maintenance register Date Type of work and notes ‘Assistance’ service stamp Maintenance technician’s signature Date Type of work and notes ‘Assistance’ service stamp Maintenance technician’s signature Date Type of work and notes ‘Assistance’ service stamp Maintenance technician’s signature M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T Use and Maintenance Manual 58 di 64...
  • Page 59 Cap.11 _ Maintenance register Date Type of work and notes ‘Assistance’ service stamp Maintenance technician’s signature Date Type of work and notes ‘Assistance’ service stamp Maintenance technician’s signature Date Type of work and notes ‘Assistance’ service stamp Maintenance technician’s signature M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T Use and Maintenance Manual Standard...

  • Page 60: Chapter 12 - Notes

    Cap.12 _ Notes 12 - NOTES M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T Use and Maintenance Manual 60 di 64 Standard...
  • Page 61 Cap.12 _ Notes 12 - NOTES M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T Use and Maintenance Manual Standard 61 di 64...
  • Page 62 Cap.12 _ Notes 12 - NOTES M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T Use and Maintenance Manual 62 di 64 Standard...
  • Page 63 Cap.12 _ Notes 12 - NOTES M M C C H H 8 8 - - 1 1 1 1 / / E E M M - - M M C C H H 1 1 3 3 - - 1 1 6 6 / / E E T T Use and Maintenance Manual Standard 63 di 64...
  • Page 64 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 w w w. c o l t r i s u b. c o m...

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Mch 8-11/em standard

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