AEROTECNICA COLTRI MCH 14 TECH NITROX SERIES Page 97 Instruction Manual Download

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Valve head unit

High pressure compressor

POS.

CODE

DESCRIPTION

003

13-01-0003 FIRST STAGE 88 mm. GASKET

003/A

16-01-0003 FIRST STAGE 95 mm. GASKET

004

13-01-0004 FIRST STAGE HEAD WITH VALVES

005

13-01-0005 FIRST STAGE GASKET

006

13-01-0006 FIRST STAGE HEAD COVER

009

13-00-0009 8 mm. FLAT WASHER

010

13-00-0010 SCREW 8x55 TCE

011

13-01-0011 INTAKE FILTER COVER O-RING

012

13-00-0012 STRAIGHT ¹/

PIPE FITTING 10 mm

013

13-01-0013 INTAKE FILTER O-RING

014

SC000370 LUBRICATION INDICATOR PIPE

020

13-03-0020 THIRD STAGE INLET VALVE

025

13-00-0025 STRAIGHT ¹/

- PIPE FITTING 6 mm.

026

13-01-0026 INTAKE FILTER SPRING

027

13-03-0027 THIRD STAGE HEAD

028

13-03-0028 THIRD STAGE EXHAUST VALVE

029

13-03-0029 VITON O-RING FOR THIRD STAGE EXHAUST VALVE

030

13-03-0030 3rd STAGE HEAD COVER

031

13-00-0031 8x50 TCE SCREW

032

13-00-0032 STAINLESS STEEL 8 mm. CAP NUT

033

13-03-0033 8 mm. COPPER WASHER

034

13-03-0034 8x25 STAINLESS STEEL DOWEL

035

13-00-0035 STRAIGHT ¹/

PIPE FITTING 8 mm.

041

13-01-0041 INTAKE FILTER COVER

044

13-02-0044 SECOND STAGE INLET VALVE

045

13-02-0045 LONG STRAIGHT ¹/

PIPE FITTING 10

046

13-02-0046 SECOND STAGE HEAD

047

13-02-0047 LONG STRAIGHT ¹/

PIPE FITTING 10

048

13-00-0048 8x25 TCE SCREW

049

13-02-0049 SECOND STAGE EXHAUST VALVE

051

13-02-0051 SECOND STAGE COPPER GASKET

056

13-02-0056 VITON O-RING FOR 2nd STAGE VALVE

195

13-00-0195 FIRST STAGE SAFETY VALVE

196

13-02-0051 SECOND STAGE COPPER GASKET

Spare parts

Summary of Contents for MCH 14 TECH NITROX SERIES

Page 1: ...ure Compressors MCH 14 TECH NITROX Low and High pressure Compressors MCH 14 TECH NITROX Revision DOC MCH 14 TECH NITROX 09 01 INSTRUCTION MANUAL VERSION English Special equipment and compressors for underwater activities ...

Page 2: ...ntenance valve High pressure compressor 15 2 2 6 Cooling pipes High pressure compressor 15 2 2 7 Filters High pressure compressor 15 2 2 8 Pilot valves 16 2 2 9 Frame and sound proofed casing High pressure compressor 17 2 3 Machine control High pressure compressor 17 3 TECHNICAL CHARACTERISTIC 3 1 Technical characteristics of the pump unit 18 3 1 1 Sizes and weights 18 3 1 2 Machine series MCH 14 ...

Page 3: ...take 29 6 2 2 Connecting the filling hoses 33 6 2 3 Electrical connections 34 CONTROL PANEL 7 1 Control panel 35 7 2 Indication and control devices 36 7 START UP 8 1 Filling the machine 38 8 2 Checks 39 8 3 Calibrate analyzers 42 8 4 Low pressure compressor Pilot Valve 43 8 4 1 Pressure adjustment 43 8 4 2 Differential pressure adjustment 43 8 USE 9 1 Preliminary operations 43 9 2 Filling the cyli...

Page 4: ...lter and molecular sieve high pressure compressor 69 11 7 Filling hose High pressure compressor 71 11 8 Inlet and discharge valves High pressure compressor 71 11 9 Valves heads High pressure compressor 72 11 10 Cylinders High pressure compressor 73 11 11 General maintenance instructions for the low pressure compressor 73 11 11 1 Pressure discharge valve 73 11 11 2 Tank drainage valve 73 11 11 3 Pr...

Page 5: ...ase and Cylinder Low pressure compressor 104 Piston rod unit Low pressure compressor 105 Cylinder valve and filter unit Low pressure compressor 106 Description of the pump unit low pressure and pipes 107 15 MACHINE DIAGRAMS 14 1 Compression diagram 84 14 2 Compression diagram High pressure compressor 85 14 3 Electrical diagrams 86 14 Index 16 ENCLOSURE 16 1 Enclosure 108 REGISTRER 13 1 Register 83...

Page 6: ...ply with the instructions could cause damage to the machine and other parts associated with the same or to the surrounding area LABEL APPLIED TO THE COMPRESSORS 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...

Page 7: ...achine using the main switch see chapter 7 1 Check the direction of rotation of the motor If the direction of rotation does not coincide with the one shown on the belt guard turn off the machine and invert the two phases on the main power supply see chapter 7 2 Check the operation of the safety valve see chapter 9 1 Check for wear on the cylinders to be filled see chapter 9 1 Set the pressure swit...

Page 8: ...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 If it should be necessary for service to be carried out under the guarantee at the customer s premises the latter will be responsible for the travel and transfer costs for the staff sent out by AEROTECNICA COLTRI S r l Takin...

Page 9: ...ription 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 14 2 2 5 Pressure maintenance valve 15 2 2 6 Cooling pipes 15 2 2 7 Filters 15 2 2 8 Pilot valves 16 2 2 9 Frame and sound proofed casing 17 2 3 Machine control 17 TECHNICAL DESCRIPTION 2 Technical description ...

Page 10: ...of compression Fig 2 The filling stations in the MCH 14 TECH NITROX series are of the semi soundproofed type Fig 1 2 This system supplies to output percentages nitrox in oxygen of 22 to 40 for volume The alimentacion of the low pressure supplies air tothe membrane and the membrane supplies nitrox the high pressure compressor Technical description WARNING THE FILLING STATION PRODUCES RESPIRABLE AIR...

Page 11: ...en content of the Grade E air second the norms UNI EN 132 CGA E and DIN 3188 20 9 is raised to output percentages upwards of 23 to 40 A needle valve in the outlet stream of the waste gas nitrogen controls the relative O2 concentrations while input pressure regulation allows control of the output volume of the membrane This outlet volume control is required to balance the input requirements of the ...

Page 12: ...xplosive gases This unit consists of the following components Fig 3 4 3 Table 1 4 N Description N Description 1 Intake filter 12 2nd stage safety valve 2 1st stage head 13 Crankcase 3 2nd stage head 14 Filter holding bracket 4 3rd stage head 15 Fan 5 1st stage cylinder 16 Oil cap 6 2nd stage cylinder 17 Final condensate separator 7 3rd stage guiding cylinder 18 Condensate separator between stages ...

Page 13: ...h pressure compressor 5 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 The crankshaft and the connecting rods turn exclusively on roller or ball bearings Fig 6 The three connecting rods ar...

Page 14: ...e following pressures 1st stage safety valve 8 bar 2nd stage safety valve 50 bar 3rd stage safety or final valve 225 bar or 330 bar WARNING Under no circumstances may these valves be adjusted to increase the calibrated pressure If these valves blow check the cause that has led to the maximum pressure and take steps according to the instructions given in paragraph 12 1 Any tampering with the safety...

Page 15: ...ts as a non return valve 2 2 5 Pressure maintenance valve High pressure compressor Technical description 2 2 7 Filters High pressure compressor 11 INTAKE FILTER Fig 11 The intake filter is coupled directly to the lid of the 1st stage head The intake filter consists of a cylindrical aluminium casing provided with a screw cap that holds the filtering cartridge A special attachment is provided on the...

Page 16: ...ff air switch When in the on position it allows air to flow from the tank through the Valve to some device such as a compressor suction unloader thus actuating it In the off position Fig 13a this valve stops the flowofairthroughthevalveandreleasethepressure in the line to the device The Pilot Valve works as follows Tank air pressure acts on the bottom of the valve When pressure is great enough to ...

Page 17: ...l panel Fig 14 Apart from the various control buttons this panel also includes an hour counter that enables the number of machine operating hours to be memorized The same controls are doubled up on two independent control panels which each control one of the two pump units present inside the filling station Technical description Air in line to device being actuated can then escape through upper se...

Page 18: ... 1 1 Sizes and weights 18 3 1 2 Machine series MCH 14 TECH NITROX 19 3 2 Noise level 20 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 TECHNICAL CHARACTERISTIC 3 3 1 Technical characteristics of the pump unit low anf high pressure compressor 15 ...

Page 19: ...n stroke 40 mm Intermediate pressures 1 stage 5 bar 70 psig 2 stage 40 bar 570 psig 3 stage 225 330 bar 3200 4800 psig Power motor 2x 5 5Kw 7 5HP Tension and frequency three phase 400V 50Hz 440V 60Hz 230V 50Hz 230V 60Hz Membrane Operating Temperature Range 38 46 C 100 115 Fahrenheit Input Operating Pressure Range Air UNI EN 132 DIN 3188 CGA E Input Gas Composition 14 28 m3 h Output Gas Composition...

Page 20: ...h In particular the operators must if necessary use all the individual protection devices to protect themselves from the noise level The reading of the machine noise level was taken from the operator s work place Fig 16 with the following methods and results 16 Table 2 Technical characteristics METHODS OF MEASUREMENT ISO 3746 MCH 14 TECH NITROX Level of acoustic pressure at the operator s work pla...

Page 21: ...ins automatic condensate drains Use Auto Purge feature to test for proper operation However when compressor is in operation open manual condensate drain bleeder valves at least once a day to ensure that the auto drain is working properly Cautionary Operational Note DO NOT USE ANY FORM OF MINERAL OIL IN ANY COMPRESSOR IN THIS SYSTEM Use only EZ 1000 Compressor Lubricant Cautionary Operational Note ...

Page 22: ...nance of machines and plants of a mechanical electrical and pneumatic type 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 th...

Page 23: ... 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 4 1 1 Safety devices 18 Model MCH 14 TECH NITROX compressor ...

Page 24: ...comes foul smelling For the frequency of replacement see the instructions in Chapter 11 Main tenance 6 Electrical switcboard built to EN 60204 1 regulations with IP 54 level of protection and fitted with a lock and key 7 8 Pressure gauge showing the operating pressure 9 Pressure switch that can be manually calibrated showing the maximum cylinder filling pressure when the set pressure is reached th...

Page 25: ... vapours from the lubricating oil with the compressed air produced 2 Electrical danger Use the machine with suitable protection from the electrical power supply especially in the presence of water and humidity 3 Danger deriving from the noise emitted by the compressor if maintenance work is carried out without the safety guards 4 Pump unit area danger from heat For any maintenance operation requir...

Page 26: ...eries are delivered fully assembled but with the hoses supplied separately The compressors are packed in cardboard boxes fitted on europallets to make handling and transportation easier To unpack the boxes containing the machine follow the instructions given on the outside of the boxes with great care Fig 22 Unpacking and handling the machine UNPACKING AND HANDLING THE MACHINE 5 5 1 Unpacking the ...

Page 27: ...scribed in the previous paragraph the machine can be moved to its place of installation To carry out this operation it is necessary to use a fork lift truck or transpallet of a suitable capacity the forks of which must be positioned between the feet of the europallet on which the machine is placed Fig 23 Model MCH14TECHNITROX isfittedwithspecial side members fixed under the structure Fig 24 that e...

Page 28: ...he place chosen for installation there are suitable ventilation conditions a good change of air several windows no dust and no risks of explosion corrosion or fire 3 When operating in environments with a temperature of over 40 C 104 F it is necessary air conditioning must be provided for the environment Installation I NSTALLATION 6 6 1 Positioning This chapter provides a description of the operati...

Page 29: ...rtificial lighting to the area if the natural lighting is not suffieint for the requirements mentioned If the machine is installed in a place without the ventilation features as referred to in the previous paragraph it is necessary to fit the system with an extension to take in air from the outside or from a place with the above mentioned ventilation characteristics This extension which is supplie...

Page 30: ...e 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 27 2 Connect the extension pipe to the connector Fig 28 28 ...

Page 31: ...31 Installation 3 Pass the pipe through the hole located in the rear guard Fig 29 30 28 29 ...

Page 32: ...es given off by internal combustion engines or harmful fumes The following operations must be carried out twice bearing in mind that this model is double 33 Installation 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 ai...

Page 33: ...h should be available to fasten the hoses 34 35 4 Tighten the hoses to the machine with a torque wrench setting of 15Nm Fig 35 NOTE the hoses should be replaced every so often every year or every 1000 hours or when they show signs of being scratched For this purpose check the number of operating hours of the hoses that are to be disconnected on the hour counter The minimum radius of curvature of e...

Page 34: ...orce in the country where the compressor has been installed 2 Also check that the details on the machine rating plate are compatible with the mains power supply especially the nominal current and input voltage 3 The mains power supply should be provided with an effective grounding system It is particularly important to check that the earth resistance value complies with the protection and operatin...

Page 35: ...ton has a light inside that comes on when the power supply is connected 3 MANUAL DRAIN yellow button To drain the condensate This function permits the pressure present inside the condensate separators and the filter to be discharged draining off the con densate through the electromagnetically controlled valves This operation is normally carried out by the timer at regular intervals 4 HOURCOUNTER I...

Page 36: ...ing phase the pressure switch stops the compressor when it reaches the maximum pressure as shown by the red cursor 3 Sieve filter The purpose of this device is to withhold the impurities present in the air before they enter the cylinders 4 Condensate discharge taps HP high pressure They enable the condensate that has accumulated during machine operation to be discharged by hand The condensate is d...

Page 37: ...sure gauge 12 Accumulation tank pressure control pressure gaug 13 Temperature thermometer fitted inside casing frame 14 Heater temperature thermometer 15 Heating system thermostat 16 Battery oil feeder filters 17 Membrane supply pressure regulator 18 Percentage O2 regulation needle valve nitrogen discharge 39 Control panel System configuration Typical low pressure high pressure configuration NOTE ...

Page 38: ...Checks 39 8 3 Calibrate analyzers 42 8 4 Low pressure compressor Pilot Valve 43 8 4 1 Pressureadjustment 43 8 4 2 Differential pressure adjustment 43 WARNING Before proceeding with the start up operations described below read chapter 4 Precautions for use and maintenance very carefully and follow the advice given Fill the lubricating oil sump of the pump unit when the machine is switched off The m...

Page 39: ...s On the contrary if the oil level is too low the pin of the connecting rod is prevented from providing the correct lubrication with the possibility of causing a seizure of the cylinders To check the quantity of oil poured in see the following paragraph 1 Turn on the manual condensate discharge taps Fig 42 Start up 8 2 C h e c k s 42 41 43 2 Turn the machine on by moving the general switch to the ...

Page 40: ... up following theinstructionsgiveninthepreviousparagraph If the level is too high discharge some of the oil as described in chapter 11 4 Changing the lubricating oil To dispose of the oil refer to chapter 10 2 Disposal of waste 44 45 5 The operation to check the level of the lubricant must be carried out when the machine arrives and then before starting up the compressor It must be remembered that...

Page 41: ...g 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 48 46 47 WARNING Theyellow greenwirecorrespondstotheearthing DO NOT disconnect or invert this wire 48 ...

Page 42: ... the fitting covering the sensor a Fig 49 Remove the fitting covering the sensor b Fig 49 Expose the sensor to ambient air for approximately 15 seconds Adjust the meter until the reading c stabilizes to 20 9 Fig 50 Re connect the sensor fitting to the analyzer WARNING Never connect an O2 analyzer directly to a high or low pressure air nitrox source 49 8 3 Calibrate analyzers 50 Start up c ...

Page 43: ...of threaded cap 1 Proceeding with the following instructions while compressor is running 1 Loosen locknut 2 and back off several turns 2 Controllare il manometro sul serbatoio Check reading on the tank pressure gauge Set the pressure to 2 bar 30 psi differential unload at 12 bar 170 psi and reload at 10 bar 140 psi Turn nut 3 clockwise to increase differential pressure or counterclockwise to decre...

Page 44: ...the pressure in the circuit rises quickly and the valve blows at the set pressure The valve is factory set at a pressure of 225 bar WARNING Under no circumstances may the calibration pressure of these valves be increased Any tampering with the safety valves may cause serious damage to the machine or to persons and a cancellation of the guarantee 2 Check the condition of the cylinders to be filled ...

Page 45: ...ISCHARGE 4 For the models provided with an automatic condensate discharge a special condensate collection tank has been fitted in the side compartment of the compressor Fig 52 The outlet of water vapourized with lubricating oil should be considered normal during filling the quantity is in direct relation to the percentage of humidity present in the air The condensate must be disposed of according ...

Page 46: ...itch off pressure Fig 54 54 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 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 Use ...

Page 47: ...N 200 and DIN 300 Fig 55 are available Each filling hose can be connected to a cylinder so that more than one cylinder can be filled at the same time Thefollowingoperationsmustberepeatedforeach hose that is to be connected to the cylinder to be filled Furthermore it should be borne in mind that each control panel on the machine is provided with controls that carry out the same functions see chapte...

Page 48: ...ure compressor Close clockwise then open counter clockwise the Nitrogen Valve 1 2 turn Fig 58 58 Switch on the analyser Fig 57 57 STEP 2 NOTE Only one fill whip is attached at this point to a tank The other whip is used to control compressor pressure during setup only The second bottle or storage tanks can be attached after Step 9 Fig 60 60 ...

Page 49: ...s 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 manometer A Fig 62 NOTE Il compressore è dotato di un depressore per il funzionamento a vuoto rag giunta la pressione massima 61 62 Use ...

Page 50: ...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 AIR STREAM CAUTION do not direct any gas stream at any part of the body 64 Use ...

Page 51: ...n C and continue on to the membrane heater Fig 66 LP regulator and thermostat have been factory set and may only need fine tuning Allow system to stabilize and come up to pressure and temperature approximately 5 8 minutes Regulator pressure D range will be approximately 10 12 Bar Temperature E range will be between 35 C and 43 C 95 110 F Fig 67 65 66 67 Use ...

Page 52: ...re gauge does not reach 1psi slightly adjust the LP regulator as follows Pull down the bottom of the regulator to unlock Then adjust Clockwise increases pressure counter clockwise decreases pressure If the psi is lower than 1 adjust the regulator up slightly If the psi is higher than 1 lower the regulator slightly Fig 69 NOTE Regulator pressure D will never be higher than tank pressure A Fig 68 68...

Page 53: ...start supplying nitrox we start to displace the compressors need for air we can hear the suction getting quieter at the same time the needle of the nitrox permeate pressure gauge starts to rise We continue to add pressure to the system until we get about 1psi of Nitrox pressure You are now pumping nitrox through the compressor through the purification filter system out through the HP Fill Whip You...

Page 54: ... lower the regulator slightly STEP 8 When the proper concentration of nitrox is achieved and the permeate pressure gauge reads 1psi the HP Fill Whip can now be closed and the dive tanks or storage cylinders can now be filled according to the manufacturer recommendation Monitor compressor operation The Auto Condensate Drains will activate every 10 15 minutes Remember to manually drain bleed valves ...

Page 55: ...on tap 2 Fig 74 Use GAUGE RECOMMENDED SETTING MAXIMUM 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 permeate stream 0 07 a 0 18 bar 1 a 2 5 psi Oxygen analyzers Showing the proper reading for intended fill ...

Page 56: ...ped automatically by the pressure switch 78 77 5 Turn off the cylinder tap and that of the hoses Fig 77 6 Press the pressure bleed button on the filling tap and then disconnect the cylinder attachment Fig 78 Auto Drains will bleed valves every 12 15 minutes When fill is complete follow shutdown steps 1 2 4 5 CAUTION DO NOT TURN ON LP COMPRESSOR FOR AIR FILLS ONLY DOING SO CAN DAMAGE THE MEMBRANE U...

Page 57: ...ly 3 the heat release of the electric motor trips due to an overload After an emergency stop and before proceeding with a subsequent operation it is necessary to check that the cause of the emergency has been eliminated 79 SHUTDOWN STEPS 1 After filling is complete close tank 2 HP Compressor and LP compressor will automatically shut down at 220 bar 3200 psi 3 Turn off LP feed air switch Membrane s...

Page 58: ...y and oily deposits Protect the compressor from dust and water by storing it in a clean dry place WARNING DEPRESSURIZE THE UNIT Turn the machine off using the general switch position 0 and remove the power plug Carry out a general cleaning operation on the machine and all its components When using the compressor special waste products are produced It must be remembered that waste from industrial p...

Page 59: ...he competent authority with the issuing of a relative report WARNING DEPRESSURIZE THE UNIT Disconnect the machine from the power supply Remove any interfacing that there may be between the compressor and other machines checking carefully that any interfacing between other machines that are still in use remain operative Empty the tank containing the lubricating oil and store it according to legal r...

Page 60: ... 9 Valves heads High pressure compressor 72 11 10 Cylinders High pressure compressor 73 11 11 General maintenance instructions for the low pressure compressor 73 11 11 1 Pressure discharge valve 73 11 11 2 Tank drainage valve 73 11 11 3 Pressure on off 74 11 11 4 Belts 74 11 11 5 Compressorvalves 74 11 11 6 Centrifugal discharger and discharge pressure valve 74 11 11 7 Control valve 75 11 11 8 Pre...

Page 61: ...1 7 2 Check the compressor oil level O 3 First compressor oil change 4 Change compressor oil 5 Intake filter cartridge O 6 Operation of the end safety valve O 7 Operation and tightness of the filling valve O 8 Alignment of the compressor needle with the Owhen the compressor is depressurized O 9 Tightening of the cooling pipes O 10 Tightening of the connecting pipes O 11 Belt tension and wear O 12 ...

Page 62: ...L SYNTHETIC OIL SYNTHETIC NITROX EZ1000 Viscosity of the oil summer winter above 10 C 50 F SAE 20 W 40 from 10 C to 15 C 50 a 5 F SAE 10 W below 15 C 5 F SAE 5 W Maximum tilt of the compressor with the oil level at maximum degrees 5 LOW PRESSURE COMPRESSOR Table 2 Sump capacity cu cm litres gallons 1 5 0 476 Recommended oils AEROTECNICA COLTRI SPECIAL SYNTHETIC OIL SYNTHETIC NITROX EZ1000 Viscosit...

Page 63: ...harge tap and replace the hexagonal closing cap 5 Carry out the filling operations as described in chapter 8 Start up NOTES 1 Do not mix oil types weights or brands Consult factory for the use of synthetic lubricants 2 For the first 100 hours of compressor operation a careful and regular check of the oil level should be made Maintain oil level at the full line WARNING To dispose of waste oils foll...

Page 64: ...d in the innermost race of the fan turning it by hand to enable the belt to go over the diameter of the fan and to fit into the race 82 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 Checking the drive belt 83 2 B...

Page 65: ...hine 11 5 Suction filtre 11 5 1 LP Moisture Oil Vapor Filters 85 Remove the upper protective cover by unscrewing the securing screws Fig 85 86 Unscrew the wing nut positioned above the filter cover by hand or with pliers This system uses three stage moisture oil vapor filters as a final filtration point for the Grado E UNI EN 132 DIN 3188 CGA E air prior to entering the membrane The purpose of thi...

Page 66: ...mproper sequence can cause damage to downstream components Gas flow input is as follows Bowl 1 HF 7 with sight gauge and auto drain float Bowl 2 HF 5 with sight gauge and auto drain float Bowl 3 HF 1 no sight gauge or auto drain float Inspect the filter cartridges as shown Push up on the bottom housing and rotate counter clockwise Fig 88 Lower the bottom housing off to expose the filter elements F...

Page 67: ...housings assist with replacement intervals Elements should be visually inspected quarterly and replaced on demand The interior of the bowls can be cleaned with a diluted solution of Simple GreenTM and flushed thoroughly with clean water This will assist to prolong the life of the element bowl and auto drain Condensate tank To manually discharge the tank first place a suitable container under the t...

Page 68: ...move the filter and replace it with a new one Fig 94 To order a new spare filter refer to chapter 14 Spare parts 4 Refit the safety guard and tighten the screws see point 1 94 1 Remove the left hand side protective cover looking at the compressor from the front by unscrewing the fixing screws Fig 92 ...

Page 69: ... 322 214 644 50 Table 5 Maintenance 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 For this reason it is important to comply with the intervals as specified The frequency of replacement has been calculated for use of the compressor with intake air at a tempe rature of 20 C 68 F see ta...

Page 70: ...r 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 96 95 unscrew the used cartridge from the internal Fig 97 and then screw in the new one 97 Maintenance ...

Page 71: ...The interval between maintenance operations is 400 600 working hours If any parts are damaged or worn they must be replaced The discharge valves can be removed from the outside while the inlet valves can only be removed when the head of the cylinder has been taken off NOTE the valve replacement procedure must be carried out at the work bench by specialized technicians who have specific equipment f...

Page 72: ... is made of aluminium Fig 99 the valves are screwed in the inlet valve inside is removed using a special pin wrench while the discharge valve is on the outside and is removed with a non adjustable wrench or a box wrench The head of the 3rd stage C is made of aluminium Fig 100 the inlet valve is screwed inside and can be removed using a special pin wrench while the discharge valve is on the oustide...

Page 73: ...e discharge valve This is a safety valve Each valve is checked at the correct time for the maximum pressure permitted by the characteristics of the tank and for the pressure for of the unit on which it is installed If it blows all the air in the tank will have to be let out so that it can then be reset correctly Do not make any changes This valve must be opened daily to let out the condensate Do n...

Page 74: ...t for the final check The washers on the valves should be replaced every time the valves are removed from the pump The centrifugal discharger is activated by two regulating weights It is completely closed and lubricated by the compressor guard When the compressor is activated the regulating weights open automatically compressing the main spring thus allowing the discharge pressure valve to close W...

Page 75: ...at it is not connected to the mains as this could injure the operator or damage the machinery Used to protect against excessive interstage pressure and is set at a maximum pressure of 5 bar 75 psi DO NOT RESET If the discharge pressure valve blows it means that there are problems Switch off the compressor immediately establish where the malfunction is and correct it Check the cylinder head valves ...

Page 76: ...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 11 12 Maintenance programme 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 inte...

Page 77: ...ion 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 Operation carried out Date Operation carried out Date Operation carried out Date Operation carried out Date Operation carried out Date Operation carried out Maintenance ...

Page 78: ...ion 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 Operation carried out Date Operation carried out Date Operation carried out Date Operation carried out Date Operation carried out Date Operation carried out Maintenance ...

Page 79: ...belt slips Tighten the belt The capacity is reduced without a reduction in the speed of rotation The valves are not working Contact the technical assistance service The 3rd stage piston is worn Contact the technical assistance service The connections are loose or the gaskets leak Check for leaks with water and soap and eliminate them The intake filter is blocked Replace it The intake extension is ...

Page 80: ...80 Troubleshooting 12 1 1 Low pressure compressor ...

Page 81: ... and the cables must be clean given that dirt acts as an insulator This can be carried out simply by blowing away the dirt or by using a wire brush 10 The belts must be fairly tight to enable the necessary energy to be transmitted to the compressor If they are too tight the motor will overload If by pressing on a belt the upper part is in line with the lower part of the belt adjacent the tension i...

Page 82: ... and elimi nate the pressure in the tank 20 The motor pulley and the fly wheel must be aligned to prevent deterioration of the side panels of the belts If this is not the case disconnect the unit from the mains and adjust the pulley by loosening the screw and positioning the pulley in the correct direction WARNING before adjusting the pulley disconnect from the mains 21 It is necessary to periodic...

Page 83: ...hould NOT be made up of loose pages and must be durable It must contain at least the following information Date Tank matriculation number Check on oxygen O2 content by qualified company and signature Operator check for oxygen content O2 and signature Mod Form filled out by hand by the operator in depth explanation of operation Company that certificates the nitrox and file number Register ...

Page 84: ...chine diagrams MACHINE DIAGRAMS 14 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 NITROX compression diagram ...

Page 85: ...85 Compression diagram High pressure compressor only air Machine diagrams 14 2 ...

Page 86: ...86 Machine diagrams 14 3 Electrical diagram ...

Page 87: ...87 Machine diagrams ...

Page 88: ... MOTOR SB1 STOP BUTTON SB2 STOP BUTTON SB3 DRAIN BUTTON HL2 READY STATE RUNNING SIGNAL GREEN HL1 RUNNING SIGNAL RED PT1 HOUR COUNTER KT1 CHARGE DRAIN Y1 SOLENOID VALVE CHARGING Y2 SOLENOID VALVE DRAINING MOTOR M2 QM2 OVERLOAD RELAY MOTOR PROTECTION SWITCH KM2 MOTOR CONTROL CONTACTOR M2 MOTOR SB5 STOP BUTTON SB6 STOP BUTTON SB7 PURGE PUSH DRAIN BUTTON HL4 READY STATE RUNNING SIGNAL GREEN HL3 RUNNIN...

Page 89: ...ead unit 97 Cooling pipes 99 Filtering system 101 Condensate separator 103 Pulley Crankcase and Cylinder Low pressure compressor 104 Piston rod unit Low pressure compressor 105 Cylinder valve and filter unit Low pressure compressor 106 Description of the pump unit low pressure and pipes 107 15 1 Exploded view of the machine parts ...

Page 90: ...90 076 088 090 060 059 058 065 061 050 091 067 066 055 042 052 064 054 016 062 008 070 071 068 040 055 001 074 073 Crankcase High pressure compressor Spare parts ...

Page 91: ...13 00 0018 DADO 8 mm 059 13 00 0009 RONDELLA PIANA 8 mm 060 13 00 0018 DADO 8 mm 061 13 00 0061 O RING TUBO CARICO OLIO 062 13 00 0062 O RING FLANGIA 064 13 00 0064 TUBO CONTROLLO LIVELLO OLIO 065 13 00 0065 RACCORDO TUBO CARICO OLIO 066 13 00 0048 VITE 8x25 TCE 067 13 00 0067 VITE 6x35 TCE 068 13 00 0062 O RING FLANGIA 070 13 00 0070 CUSCINETTO A SFERE 6302 071 13 00 0071 FLANGIA LATO VENTOLA 073...

Page 92: ... 127 120 100 104 101 105 106 128 107 108 129 194 111 110 131 130 114 098 132 099 072 115 117 117 A 118 118 A 119 118 192 193 109 112 112 A 113 113 A Piston rod unit High pressure compressor 116 116 A Spare parts ...

Page 93: ...2 0113 2nd STAGE 36 mm PISTON RINGS 113 A 16 02 0113 2nd STAGE 38 mm PISTON RINGS 114 13 00 0110 SEEGER RETAINING RING 115 13 00 0110 SEEGER RETAINING RING 116 13 01 0116 FIRST STAGE 88 mm PIN 116 A 16 01 0116 FIRST STAGE 95 mm PIN 117 13 01 0117 FIRST STAGE 88 mm PISTON 117 A 16 01 0117 FIRST STAGE 95 mm PISTON 118 13 01 0118 1st STAGE 88 mm PISTON RINGS 118 A 16 01 0118 1st STAGE 95 mm PISTON RI...

Page 94: ...94 126 124 125 123 017 018 015 019 021 002 002 A 022 007 038 037 039 043 043 A 190 191 024 Cylinder unit High pressure compressor Spare parts ...

Page 95: ...PIPE FITTING 8 mm RILSAN 022 13 00 0018 8 mm NUT 024 13 00 0018 8 mm NUT 037 13 02 0037 SECOND STAGE 60 mm GUIDING CYLINDER 038 13 00 0015 GUIDING CYLINDER O RING 039 13 00 0039 SECOND STAGE CYLINDER O RING 043 13 02 0043 SECOND STAGE 36 mm CYLINDER 043 A 16 02 0043 SECOND STAGE 38 mm CYLINDER 123 13 03 0123 3rd STAGE VITON O RING 124 13 03 0124 SET OF 3rd STAGE PISTON RINGS 125 13 03 0125 14 mm T...

Page 96: ...96 034 033 032 031 028 029 030 035 025 027 020 003 003 A 004 005 006 012 010 009 011 013 041 026 014 046 196 045 051 047 049 056 044 048 195 Valve head unit High pressure compressor Spare parts ...

Page 97: ...3 03 0027 THIRD STAGE HEAD 028 13 03 0028 THIRD STAGE EXHAUST VALVE 029 13 03 0029 VITON O RING FOR THIRD STAGE EXHAUST VALVE 030 13 03 0030 3rd STAGE HEAD COVER 031 13 00 0031 8x50 TCE SCREW 032 13 00 0032 STAINLESS STEEL 8 mm CAP NUT 033 13 03 0033 8 mm COPPER WASHER 034 13 03 0034 8x25 STAINLESS STEEL DOWEL 035 13 00 0035 STRAIGHT 4 PIPE FITTING 8 mm 041 13 01 0041 INTAKE FILTER COVER 044 13 02...

Page 98: ...98 036 089 083 084 186 086 185 087 077 074 135 134 138 136 140 139 133 075 141 142 137 023 080 081 079 082 085 087 197 Cooling pipes High pressure compressor Spare parts ...

Page 99: ...nd STAGE 10 mm COOLING PIPE 086 13 00 0086 6 mm NUT 087 13 00 0087 6x30 TCE SCREW 089 13 00 0089 10 mm 2nd 3rd STAGE COOLING PIPE 133 13 00 0133 6 mm PIPE HOLDING BRACKET 134 13 00 0134 VIBRATION DAMPING PIPE HOLDING RUBBER WASHER 135 13 00 0135 SINGLE 6 mm PIPE HOLDING BRACKET 136 13 00 0136 DOUBLE 6 mm PIPE HOLDING BRACKET 137 13 00 0137 SELF LOCKING 6MA NUT 138 13 00 0137 SELF LOCKING 6MA NUT 1...

Page 100: ...100 153 152 156 155 154 158 097 157 159 160 198 188 187 189 Filtering system High pressure compressor Spare parts ...

Page 101: ... CAP 155 13 00 0155 FILTER CAP O RING 156 13 00 0156 INTERNAL FILTER CAP 157 13 00 0155 FILTER CAP O RING 158 13 00 0158 FILTER CARTRIDGE O RING 159 13 00 0155 FILTER CAP O RING 160 13 00 0160 LOWER FILTER CAP 187 13 00 0187 MESH DISK DIAM 39 mm 188 13 00 0188 FILTER CARTRIDGE INTERNAL SPRING 189 13 00 0189 FELT DISK DIAM 40 mm 198 13 00 0144 CORNER 8 PIPE FITTING 6 mm Spare parts ...

Page 102: ... Condensate separator Low pressure compressor 182 181 036 175 198 089 178 103 102 198 183 184 179 023 174 091 094 092 176 171 172 173 168 169 170 165 166 167 148 149 150 151 147 146 215 069 145 322 Spare parts ...

Page 103: ...65 SAFETY VALVE ADJUSTMENT COVER 166 13 00 0166 SAFETY VALVE SPRING 167 13 00 0167 SMALL SAFETY VALVE PISTON 168 13 00 0168 SMALL S V PISTON O RING 169 13 00 0169 SAFETY VALVE BODY 170 13 00 0170 NYLON SAFETY VALVE SEAT 171 13 00 0171 SAFETY VALVE SEAT SPRING 172 13 00 0172 SAFETY VALVE O RING 173 13 00 0173 SAFETY VALVE CONNECTOR 174 13 00 0174 STRAIGHT 8 PIPE FITTING 6 175 13 00 0174 STRAIGHT 8 ...

Page 104: ...104 Pulley Crankcase and cylinder Low pressure compressor Spare parts ...

Page 105: ...105 Piston rod unit Low pressure compressor Spare parts ...

Page 106: ...106 Cylinder Valve and Filter unit Low pressure compressor Spare parts ...

Page 107: ...107 Pump unit Low pressure compressor Spare parts ...

Page 108: ...ture compensated for at least two years Energy is supplied by a 9V 400 hour battery that enables operation for three years before it has to be changed 16 1 4 The Mini O2DII an autonomous unit water and shock resistant has been designed specifically for underwater sector sport NITROX commercial and military where hostile environmental conditions are the norm and not the exception 16 1 5 The Mini O2...

Page 109: ...ould not be used until after calibration see section 3 0 16 2 2 The flat battery signal is a symbol in the form of a battery that appears in the corner of the screen If it appears change the battery before using the instrument see section 7 0 Maintenance 16 2 3 At the front of the machine there is an impermeable calibration handle Turn it fully from left to right and then fully to the left the rea...

Page 110: ...in BARs and multiply by the percentage of atmospheric oxygen 20 9 Therefore set the reading during calibration to the level calculated equal to the percentage of oxygen at the surface When measuring the level of oxygen in the sample divide the reading by the same atmospheric pressure value to obtain the real percentage of oxygen present in the sample For example At an atmospheric pressure of 0 8 B...

Page 111: ...en the cylinder valve until gas can be heard hissing through the flow adapter WARNING Open the cylinder valve VERYCAREFULLY 16 4 4 Close the cylinder valve after fifteen seconds when the Mini O2DII shows a stabilised reading If in doubt carefully repeat the process and make sure the flow of gas is gentle 16 4 5 A couple of seconds after the gas flow has stopped the reading will begin to change to ...

Page 112: ... faulty sensor Condensation on sensor Check flow Move the machine away Replace sensor Dry the face of the sensor Reading does not change when the calibration handle is turned Faulty connections Sensor broken Check connections Replace sensor Sections of the screen are missing Faulty screen Return to vendor Impossible to calibrate Faulty sensor Sensor not in the air High altitude Replace sensor Chec...

Page 113: ...2 Replacing the sensor a Serial number for replacing the sensor 9100 9212 5A b Remove the 4 screws that are in each corner of the machine and lift the cover carefully c Take out the flow adapter if installed and slide the sensor out of the cover d Disconnect the online connections from the sensor e Destroy the old sensor according to local regulations in force regarding materials containing lead a...

Page 114: ... 4 Protect the Mini O2DII from direct sunlight for long periods and do not expose it to extreme temperatures both high and low 16 8 5 The Mini O2DII sensor is an electrochemical mechanism containing a corrosive electrolyte Always check that it is not leaking and avoid contact with parts of the body or clothes In the event of contact with the electrolyte wash the effected part abundantly with water...

Page 115: ...e permanent loss of sight FIRST AID PROCEDURE SKIN wash the affected part abundantly with water and take off contaminated clothing If burning persists call a doctor INGESTION Drink large quantities of fresh water Do not induce vomiting Call a doctor EYES Wash abundantly with water for at least 15 minutes and call a doctor immediately 16 9 4 Information on handling of the sensor MiniO2DII oxygen se...

Page 116: ...n 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 9V PP3 Battery life 4000 hours Up to 36 months of continuous use Operating temperature From 5 a 50 C Storage temperature From 5 a 50 C Pressure Sensitive to partial oxygen pressure ...

Page 117: ...onale 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 Internet http www coltrisub it ...

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