Coltri Sub MCH 13/ETC User manual

Revision:
INSTRUCTION
MANUAL
VERSION: English
Special equipment and compressors for underwater activities
High Pressure Compressors
High Pressure Compressors
DOC.STANDARD-06-00
MCH 8/EM
MCH 13-16/DH
MCH 13-16/ETC MCH 13-16/ET
MCH 13-16/DY
MCH 13-16/SH
STANDARD
MCH 8/EM
MCH 13-16/DH
MCH 13-16/ETC MCH 13-16/ET
MCH 13-16/DY
MCH 13-16/SH
STANDARD

2
GUARANTEE AND ASSISTANCE
1.1 Guarantee ............................................................................................................................ 11
1.2 Assistance........................................................................................................................... 11
1
2
USE IN BRIEF
TECHNICAL DESCRIPTION
2.1 Operatingprinciple ............................................................................................................... 14
2.2 Description ofthe pump unit.................................................................................................15
2.2.1Monobloc unit .............................................................................................................16
2.2.2Head unit .................................................................................................................... 17
2.2.3Safetyvalves ............................................................................................................... 17
2.2.4Lubricating unit............................................................................................................ 18
2.2.5Pressuremaintenancevalve ........................................................................................ 18
2.2.6Cooling pipes .............................................................................................................. 18
2.2.7 Filters.......................................................................................................................... 19
2.2.8Frame andsound-proofedcasing................................................................................. 20
2.3 Machinecontrol ................................................................................................................... 21
3TECHNICAL CHARACTERISTIC
3.1 Technical characteristics of the pump unit............................................................................ 22
3.1.1STANDARD seriesof refillstations.............................................................................. 23
3.1.2 Sizes and weights....................................................................................................... 24
3.2 Noise ................................................................................................................................... 25
4PRECAUTIONS FOR USE AND MAINTENANCE
4.1 Machinearea diagrams........................................................................................................ 26
4.1.1Safety devices............................................................................................................. 27
4.1.2Residualrisk areas ..................................................................................................... 29
Usein brief..................................................................................................................................... 7
Index

3
5
UNPACKING AND HANDLING THE MACHINE
5.1 Unpacking themachine........................................................................................................30
5.2 Pack contents...................................................................................................................... 30
5.3 Handling themachine........................................................................................................... 31
6
INSTALLATION
6.1 Positioning ........................................................................................................................... 32
6.2 Connections......................................................................................................................... 33
6.2.1Connectingthe air intakeextension............................................................................. 33
6.2.2Connecting therefill hoses .......................................................................................... 35
6.2.3Electrical connectionfor modelsMCH 8/EM-MCH13-16/ETC -MCH 13-16/ET ......... 36
CONTROL PANEL
7.1 Controlpanel........................................................................................................................ 38
7.1.1Wall-mounted controlpanel formodelswithelectric powersupply(optional) ............... 39
7.1.2Controls on boardthe internalcombustion engines ..................................................... 40
7.2 Indicationand controldevices .............................................................................................. 41
7
START AND STOP
8.1 Fillingthe machine............................................................................................................... 42
8.2 Checks ................................................................................................................................44
8.2.1 Models with electric power supply ............................................................................... 44
8.2.2 Models with petrol supply............................................................................................ 46
8.2.3 Models with diesel fuel supply..................................................................................... 50
8.2.4Stopping theinternal combustionengine ..................................................................... 55
8
USE
9.1 Preliminaryoperations ......................................................................................................... 57
9.2 Refillingthe cylinders ........................................................................................................... 58
9
Index

4
10 PUTTING THE MACHINE OUT OF OPERATION
AND DISMANTLING THE MACHINE
10.1 Instructionsfor prolongedmachine standstills ...................................................................... 62
10.2 Disposalof wasteproducts .................................................................................................. 66
10.3 Dismantlingthe machine...................................................................................................... 66
MAINTENANCE
11.1 Generalnotes ...................................................................................................................... 69
11.2 Preventivemaintenance........................................................................................................ 69
11.3 Changing the lubricantoil ..................................................................................................... 70
11.4 Checking the transmission belt ............................................................................................ 71
11.5 Air intake filter...................................................................................................................... 73
11.6 Activecarbonfilter andmolecular sieve ................................................................................ 74
11.7 Refillhose ............................................................................................................................ 76
11.8 Intakeanddischargevalves.................................................................................................. 77
11.9 Heads .................................................................................................................................. 77
11.10 Cylinders.............................................................................................................................. 78
11.11 Internalcombustion engines................................................................................................. 79
11.11.1Maintenance programme.......................................................................................... 79
11.11.2Oil change ............................................................................................................... 80
11.11.3 Air filter .................................................................................................................... 81
11.11.4Sedimentsump (onlyforpetrol engines) .................................................................. 82
11.11.5Spark plugs(only forpetrolengines) ........................................................................ 83
11.11.6 Minimumcarburettor regulation(only petrolengines)............................................... 85
11.11.7Fuel filter.................................................................................................................. 85
11.11.8 Battery 12 Volt (not supplied by Aerotecnica Coltri) ................................................. 86
11.2 Maintenanceoperations ....................................................................................................... 88
11
TROUBLESHOOTING
12.1 List of faults ......................................................................................................................... 90
12
Index

5
SPARE PARTS
14.1 Explodedview ofthe machineparts .................................................................................... 95
Monobloc ............................................................................................................................ 96
Pistons rod unit...................................................................................................................98
Cylindersunit ...................................................................................................................... 100
Headunit ............................................................................................................................ 102
Coolingpipes ...................................................................................................................... 104
Filtering system .................................................................................................................. 106
Condensatetrap.................................................................................................................. 108
MCH13-16/ETC .................................................................................................................. 110
MCH13-16/ET .................................................................................................................... 112
MCH 8/EM .......................................................................................................................... 114
MCH13-16/SH.................................................................................................................... 116
MCH13-16/DY.................................................................................................................... 118
14
MACHINE DIAGRAMS
13.1 Compressiondiagram .......................................................................................................... 92
13.2 Electricalsdiagrams ............................................................................................................93
13
Index

6
To makethemanual easierto read, thefollowing termshavebeen adopted:
DANGER
The term DANGER is used when failure to comply with the regulations or tampering with the
parts could lead to serious injury or even death.
WARNING
The term WARNING is used when failure to comply with the instructions could cause damage to the
machine and other parts associated with the same or to the surrounding area.
LABELAPPLIED TOTHE COMPRESSORS
To protectexposedpersons orobjects,a specialbookletentitled “SAFETY REGULATIONS” issupplied
withthemachine andmustbe consideredanintegral partofthe Compressor InstructionManual.
Editor’snote: This manualrefers specifically tothe “STANDARD” series ofrefill stationswhich,as later
explained, may be supplied in various arrangements although they all work on the same
operatingprinciple.
Forthis reason,the illustrationsgiven inthe InstructionManualshouldbeconsideredonly
asindications insofar asthey referto just oneversion ofrefill station in the“STANDARD”
series.
This manual is the property of AEROTECNICA COLTRI S.r.l. and any copying of the same, even partial, is
prohibited.
Use in brief

7
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.
VERSIONWITH ELECTRIC ENGINE
- Check whether or not the area where the machine is installed has suitable ventilation
(seechapter 6.1).
- Ifthe machineis installedinaplacewithout therequired characteristicsabove, connecttheairintake
extension(see chapter 6.2.1).
- Connect the refill hoses to the machine (see chapter 6.2.2).
- Connect the switchboard to the mains power supply (see chapter 6.2.3).
- Checkthe level ofthe lubricating oilin the pumpunit (see chapter8.2). Ifthelevel istoolow,turn off
the machine and add or change the oil (see chapter 8.1).
- Turn on the machine using the main switch (see chapter 7.1).
- Checkthe direction ofrotation ofthe motor. If thedirection ofrotation does notcoincide withthe one
shown on the belt guard, turn off the machine and invert the two phases on the main power supply
(seechapter 7.2).
- Checkthe operation ofthe safetyvalve(see chapter9.1).
- Check for wear on the cylinders to be filled (see chapter 9.1).
- Set the pressure switch on the control panel to the refill pressure value given on the cylinder
(seechapter 8.1).
- Fit the hose attachment on the cylinder and check that the taps on the hose are open
(seechapter 9.2).
- Turn on the cylinder tap and start up the compressor (see chapter 9.2).
- When the filling operation has been completed, the compressor is stopped automatically by the
pressure switch, turn off the cylinder and the hose taps.
- Press the pressure bleed button and disconnect the cylinder attachment (see chapter 9.2).
USE IN BRIEF

8
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.
VERSIONWITH PETROLENGINE
- Check whether or not the area where the machine is installed has suitable ventilation
(seechapter 6.1).
- Ifthe machineis installedinaplacewithout therequired characteristicsabove, connecttheairintake
extension(see chapter 6.2.1).
- Connect the refill hoses to the machine (see chapter 6.2.2).
- Checkthe level ofthe lubricating oilin the pumpunit (see chapter8.2). Ifthelevel istoolow,turn off
the machine and add or change the oil (see chapter 8.1).
- Checktheoil levelofthe internalcombustionengineusingthedipstickprovided (seechapter11.11.2).
- Addfuel to thetank (unleaded petrolof the recommendedtype).
- Checkthe operation ofthe safetyvalve (see chapter9.1).
- Check for wear on the cylinders to be filled (see chapter 9.1).
- Fit the hose attachment on the cylinder and check that the taps on the hose are open
(seechapter 9.2).
- Turn on the cylinder tap and start up the compressor (see chapter 9.2).
- When the filling operation has been completed, the compressor is stopped automatically by the
pressure switch, turn off the cylinder and the hose taps.
- Press the pressure bleed button and disconnect the cylinder attachment (see chapter 9.2).
- Movethe fuel leverto the“open”position (inan anti-clockwise direction).
- Move the air lever to the “closed” position (in a clockwise direction).
- Turnthe accelerator leverslightly in ananti-clockwise direction.
ENGINE WITH PULL START
- Move the engine start switch to the “ON” position.
- Pull the starter cord until a certain resistance is felt, then pull hard.
ENGINEWITH ELECTRIC START
- Move the engine start switch to the “START” position and keep it in this position until the engine
starts up.
USE IN BRIEF
Use in brief

9
STOPPINGTHE ENGINE
In an emergency, simply move the engine switch to the “OFF” position.
To stop theengine under normalcircumstances:
- turn the accelerator lever in an anti-clockwise direction as far as it will go;
- movethe engine switchto “OFF”;
- movethe fuel leverto “OFF” (ina clockwise direction).
Use in brief

10
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.
VERSIONWITH DIESELENGINE
- Check whether or not the area where the machine is installed has suitable ventilation
(seechapter 6.1).
- Ifthe machineis installedinaplacewithout therequired characteristicsabove, connecttheairintake
extension(see chapter 6.2.1).
- Connect the refill hoses to the machine (see chapter 6.2.2).
- Checkthe level ofthe lubricating oilin the pumpunit (see chapter8.2). Ifthelevel istoolow,turn off
the machine and add or change the oil (see chapter 8.1).
- Check the oil level in the diesel motor using the dipstick provided (see chapter 11.11.2).
- Add fuel to the tank (diesel fuel of the recommended type).
- Checkthe operation ofthe safetyvalve (see chapter9.1).
- Check for wear on the cylinders to be filled (see chapter 9.1).
- Fit the hose attachment on the cylinder and check that the taps on the hose are open
(seechapter 9.2).
- Turn on the cylinder tap and start up the compressor (see chapter 9.2).
- When the filling operation has been completed, the compressor is stopped automatically by the
pressure switch, turn off the cylinder and the hose taps.
- Press the pressure bleed button and disconnect the cylinder attachment (see chapter 9.2).
- Movethe fuel leverto the“open”position (inan anti-clockwise direction).
- Turnthe acceleratorleverto the“START”position.
ENGINE WITH PULL START
- Slowly pull the starter cord until a certain resistance is felt.
- Releasethe cordslowly. Pressthe decompressionlever downwards.Grip thehandle tightlyand pull
the cord firmly. Use both hands if necessary.
ENGINEWITH ELECTRIC START
- Turnthe engine starterkey tothe“START”position andkeepit inthis position untilthe enginestarts
up.
- Release the key as soon as the engine starts up.
USE IN BRIEF
Use in brief

11
GUARANTEE AND ASSISTANCE
AEROTECNICA COLTRI S.r.l. guarantees itscompressors againstany designor manufacturingdefect
or fault and against any fault in the materials for a period of twelve months from the delivery of the
machine.The customer mustinform AEROTECNICA COLTRI S.r.l. in writingof anyfaultand/or defect
that may be found within eight days from its discovery by means of a registered letter with advice of
receiptor telegramme, otherwisethe guaranteewill become nulland void.
The guarantee is only valid against faults or defects that may arise with the compressor used under
properoperating conditionsaccording tothe instructionsgiveninthismanual andwith themaintenance
carriedout atthe intervalsas providedfor.
The guarantee expressly excludes any faults arising as a result of improper use of the machine, of
atmospheric agents and of damage due to transport; the guarantee does not cover the expendable
materials and materials required for the periodic maintenance which are at the customer’s entire
expense. The guarantee will, in any case, become automatically null and void if the compressor is
tampered with or if it has been serviced by technicians who are not authorized to do so by
AEROTECNICA COLTRI S.r.l.
Anycompressorthat isacknowledgedtobe faultyduetodefectsinthedesign, manufacturingormaterials
used,willbe repaired orreplaced free of chargeby AEROTECNICA COLTRI S.r.l. at itsfactory in San
Martino della Battaglia (BRESCIA). The customer will be responsible for the costs of transport and
carriageaswell asforany sparepartsand expendablematerials.
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
AEROTECNICACOLTRI S.r.l.
Taking delivery of the machine and/or of any faulty components or the transfers for the inspection of
faultsand/or defectsasnotified bythe customer, willnot,however, denoteanyimplicit acknowledgement
regardingthe effectivenessoftheguarantee.
Repairsand/or replacements madeby AEROTECNICA COLTRI S.r.l. duringthe guarantee periodwill
not extend the duration of the same.
Acknowledgment of the guarantee does not itself imply any liability for compensation on the part of
AEROTECNICACOLTRI S.r.l.
AEROTECNICA COLTRI S.r.l. does not assume any responsibility for injury to persons or damage to
propertyor foranyother director indirectdamage (lossofproduction ormissed profit,etc.) that may be
attributableto faultsor defectsofthe compressor, exceptfor thosecases inwhicha seriousfault canbe
attributed to the company.
Guarantee
Assistance
The AEROTECNICA COLTRI S.r.l. technicians are available for any kind of routine or additional
maintenancework.
The request for technical assistance must be sent to AEROTECNICA COLTRI S.r.l. at the following
address: AEROTECNICACOLTRI S.r.l.
Via Colli Storici, 177
25010San Martinodella Battaglia(BRESCIA) ITALIA
Fax:[phone]
e-mail:[email protected]
Guarantee and assistance
1
1.1
1.2

12
This chapter provides a technological description of the machine and its main components.
2.1 Operating principle ........................................................................................................... 14
2.2 Description of the pump unit............................................................................................ 15
2.2.1 Monobloc unit.......................................................................................................... 16
2.2.2 Head unit .................................................................................................................. 17
2.2.3Safety valves............................................................................................................. 17
2.2.4 Lubrication unit........................................................................................................ 18
2.2.5Pressure maintenancevalve .................................................................................... 18
2.2.6 Cooling pipes ........................................................................................................... 18
2.2.7 Filters ........................................................................................................................ 19
2.2.8 Frame and sound-proofed casing............................................................................ 20
2.3 Machine control ................................................................................................................ 21
TECHNICAL DESCRIPTION
2
Technical description

13
1
The “Standard” series of refill stations can be supplied in versions that run on electric single or three-
phase inputs, petrol or diesel fuel.
- MCH8/EMSTANDARD(Fig.1)Electricsingle
phase;
- MCH13-16/ETC STANDARD(Fig. 2)Electric
three-phase;
- MCH 13-16/ET STANDARD (Fig. 3) Electric
three-phase;
2
3
Technical description

14
4
5
All the compressors fitted inside the refill stations are of the high pressure type with forced air cooling
and 3 stages of compression. The air circulating around the compressor, which does not contain any
harmfulfumes, is takeninto the intakefilter and introducedthrough the intakevalve intothecylinder of
the first stage where the first compression takes place.
Apart ofthe heatproduced inthe compressionis dissipatedby theflow ofair createdby thefan through
the head and relative valves, piston, cylinder, monobloc and lubricating oil; the heat remaining in the
compressedair isdissipated inthe longpipingconnectingonestage ofthe compressionto anotherand
whichacts as aradiator; the temperatureat the hoseoutlet is justa fewdegreeshigher thanthatof the
environment.
The operating temperatures of each stage are: at the pipe connection that goes to the intake cylinder:
about15-20 °Cabove theenvironmentaltemperature(itfeels warmto thetouch), tothepipeconnection
thatstarts from thehead (fromthe discharge valve),about 80-100°C.
6
2.1 Operating principle
- MCH 13-16/SH Petrol (Fig. 4) (HONDA
engine);
- MCH 13-16/DY Diesel (Fig. 5) (YANMAR
engine);
- MCH 13-16/DH Diesel (Fig. 6) (HONDA
engine).
Technical description

15
2.2
Description of the pump unit
Thepumping unithasthetaskof producingcompressed airathighpressure(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
thanthelimits setbythe standardsDIN3188 -UNIEN 132 -CGA/E, or toincrease the pressureof the
gasinhaled (onlyinert- non-explosivegases).
This unit consists of the following components (Fig. 7-8):
Table 1
The intake air contains a certain degree of humidity according to atmospheric conditions. During the
compressionandsubsequentcooling,thehumiditycondensesandtogetherwiththeparticlesoflubricating
oil forms a milky white emulsion that precipitates into the separators.
Thecompression diagram isincluded in chapter13.
7
8
Technical description
N° Description N° Description
1Intake filter 12 2nd stage safety valve
21st stage head 13 Monobloc
32nd stage head 14 Filter-holding bracket
43rd stage head 15 Fan
51st stage cylinder 16 Oil cap
62nd stage cylinder 17 Final condensate separator
73rd stage guiding cylinder 18 Condensate separator between stages
81st-2nd stage cooling pipe 19 Condensate discharge connection
92nd-3rd stage cooling pipe 20 Maintenance valve
10 Final cooling pipe 21 Pipe-fastening bracket
11 1st stage safety valve 22 3rd stage or final safety valve

16
2.2.1
9
10
11
Technical description
Thecylinders aremadeof castiron (Fig.11),while
the pistons are made of aluminium and have
traditional multiple compression rings. The high
pressure stage piston has an anti-wear coating.
The relative cylinder is given a self-lubricating
treatment.
Monobloc unit
The gooseneck, the pistons and the cylinders
also form a part of this unit.
The monobloc (Fig. 9) is made of aluminium
alloy, the two flanges with the ball and roller
bearings that support the gooseneck are oil-
tight with the monobloc due to the O-Rings
fitted.
The gooseneck and the connecting rods only
turn on roller or ball bearings (Fig. 10).
The three connecting rods are fitted on the
gooseneck with a single crank angle.

17
2.2.3
2.2.2
12
Technical description
The purpose of the safety valves (see figure 7) is to protect the machine (and the cylinders) from
overpressure.
Thesevalves arepre-calibrated inthefactory atthe followingpressures:
- safetyvalve for 1st stage:8bar;
- safetyvalve for2nd stage: 50bar;
- safetyor final valvefor 3rd stage:225 bar-or 330bar.
WARNING
Underno circumstances maythese valves bealtered to increasethe calibrated pressure.
Ifthese valves shouldcome intooperation, check thecause thathas led tothe maximumpressure and
takestepsaccording to theinstructionsgiven in paragraph12.1.
Any tampering with the safety valves causes serious damage and an immediate cancellation of the
guarantee.
Head unit (Fig. 12)
Safety valves
The head unit includes the discharge and intake
valves.
The head of the 1st stage is of a lamellar type and
includes both the intake and the discharge.
Theintakeanddischargevalvesarelocateddirectly
in their threaded seats of the heads of the 2nd and
3rd stages.
Theintakevalvescanberemovedusingthespecial
pinwrench(cod.SC000480),having firstremoved
theheads.
The discharge valves can be removed from the
outside.
SeeChapter 11,“Maintenance”.

18
2.2.4
13
2.2.5
2.2.6
14
Technical description
Lubricating unit
Cooling pipes (Fig. 14)
The cooling pipes between the 1st and 2nd stage,
betweenthe2nd and3rd stageandafterthe3rd stage
are made of stainless steel, like those for the
passageofair betweentheseparator andthefilter.
This valve is fitted after the final filter. Just a few seconds after the compressor has been started up, it
keepsthe pressureof theentiresystemat100 ±20 bar(see explodedviewChapter14),for thepurpose
of eliminating as much water as possible from the air. It also acts as a non-return valve.
Pressure maintenance valve
Lubrication is carried out by means of a tang
screwed into the end part of the connecting rods
of the 2nd and 3rd stages (Fig. 13).
The 3rd high pressure stage is lubricated by oil
vapours.

19
ACTIVECARBON ANDMOLECULAR SIEVEFILTER (Fig. 16)
The filter consists of an aluminium tube (B) that
holdsthefilter cartridge(A).
Theshellofthecartridgecontainstheactivecarbon
(C) and the molecular sieve (D) placed between
felt disks.
The condition of the cartridge is of fundamental
importanceforthequalityof theair(see paragraph
11.7for replacementinstructions).
16
2.2.7
Filters
15
INTAKE FILTER (Fig. 15)
The suction filter is coupled directly to the lid of
the 1st stage head.
Theintake filterconsists ofa cylindricalaluminium
casing provided with a screw cap that holds the
filteringcartridge.
A special attachment is provided on the filter for
the connection of an extension (optional) which
enablesairto betakenfrom theoutsidewhen the
compressor is installed in a place without ideal
ventilation.
For the compressor to operate properly, the filter
maintenance must be carried out as provided for
andat the intervalsrecommended (instructionsin
paragraph11.6).
Technical description

20
2.2.8 Frame
Thecompressorandtheengine(electricorinternal
combustion) are fitted on a welded steel frame
coated with epoxy resins.
Theframe consists ofa coated guardand is fitted
with handles to be able to move the refill station
more easily.
For the various models, the frames produced are
of 3 types that can be considered to be similar to
eachother:
a) frame formodels MCH13-16/ETC (Fig.17);
b) frameformodelsMCH8/EMandMCH13-16/ET
(Fig.18);
c) frameformodelsMCH13-16/DY(Fig.19);
d) frame for models MCH 13-16/SH and
MCH 13-16/DH (Fig. 20).
E
Technical description
17
MCH13-16/ETCFRAME
18
MCH 8/EM - MCH 13-16/ET FRAME
19
MCH13-16/DYFRAME
20
MCH13-16/SH -MCH 13-16/DH FRAME