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COMPACK 2

KTC COMPACK 2 Operation And Maintenance Manual

CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
OPERATION AND MAINTENANCE MANUAL FOR
COMPACK 2 COMPRESSOR
(SOLUTION FOR BUS)
ENGLISH VERSION
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
SUMMARY
1 GENERAL WARNINGS AND INFORMATION FOR THE USER ................... 4
1.1 DEFINITION OF REGULATED RELATIONSHIPS ................................................... 4
1.1.1 DECLARATIONS .............................................................................................. 4
1.1.2 WARRANTY...................................................................................................... 5
1.1.3 RETURNS .......................................................................................................... 5
1.2 RULES APPLY .............................................................................................................. 6
1.3 GENERAL INFORMATION ......................................................................................... 6
1.3.1 WARNINGS AND PRECAUTIONS ................................................................. 6
1.4 HOW TO SEE THE MANUAL ..................................................................................... 6
1.5 CE MARKING ............................................................................................................... 7
1.6 MAINTENANCE AND SUPPORT INFORMATION OF THE MACHINE................ 8
1.7 INSTRUCTIONS FOR SAFE OPERATION................................................................. 8
1.8 LABELS POSITION .................................................................................................... 11
2 TECHNICAL DATA COMPRESSOR ................................................................ 14
3 DIMENSIONS...................................................................................................... 15
4 UNPACKING ....................................................................................................... 17
5 LOCATION .......................................................................................................... 17
6 CONNECTION AND START UP ...................................................................... 19
6.1 GENERAL WARNINGS ............................................................................................. 19
6.2 USE OF THE COMPRESSOR ..................................................................................... 20
6.3 COMPRESSOR LUBRICATION ................................................................................ 21
6.4 USING THE COMPRESSOR WITH SYNTHETIC OILS .......................................... 22
6.5 CONNECTION AND START UP ............................................................................... 23
6.5.1 GENERAL WARNINGS ................................................................................. 23
6.5.2 CONNECTING OF THE POWER CABLE OF COMPRESSOR ................... 23
6.6 ELECTRICAL CONNECTION OF COMPRESSOR .................................................. 24
6.6.1 FUSE AND BREAKER.................................................................................... 24
6.6.2 GROUND CONNECTION ............................................................................... 25
6.6.3 SIZING OF ELECTRIC CABLE ..................................................................... 25
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
6.7 AIR CONNECTION OF COMPRESSOR ................................................................... 26
7 FIRST START ...................................................................................................... 27
8 CONTROL PANEL ............................................................................................. 28
8.1 ELECTRIC DIAGRAM ............................................................................................... 29
9 HEATING RESISTANCE OF OIL ..................................................................... 33
10 PNEUMATIC SCHEME AND MACHINE DESCRIPTION ............................. 34
11 ORDINARY MAINTENANCE OF COMPRESSOR ......................................... 35
11.1 REPLACEMENT OF OIL FILTER ............................................................................. 37
11.2 REPLACEMENT OF SEPARATOR FILTRE............................................................. 37
11.3 CHANGING OIL .......................................................................................................... 38
11.4 REPLACEMENT OF AIR FILTER ............................................................................. 39
12 MAINTENANCE SCHEDULE ........................................................................... 40
13 TROUBLESHOOTING ....................................................................................... 42
14 APPENDIX .......................................................................................................... 44
14.1 MAINTENANCE CONTROL BOARD ...................................................................... 44
15 COMMERCIAL PARTS, SPARE PARTS AND RELATED
DOCUMENTATION .......................................................................................... 45
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
1 GENERAL WARNINGS AND INFORMATION FOR THE USER
1.1 DEFINITION OF REGULATED RELATIONSHIPS
1.1.1 DECLARATIONS
The compressor must be used solely as indicated in this manual. This manual must be kept on hand in a known, easily accessible place because it should be used throughout the machine's entire working life. When making any requests, always indicate model and serial number.
TEST CERTIFICATE
We hereby declare that the compressor has passed testing.
The following checks were performed:
-All parts have been assembled correctly and are functioning properly;
-The unit has passed electrical testing;
-The pressurized parts have passed testing;
-There are no leakages in the oil and air circuits;
-The outside of the machine is not defective;
-The air yield, power consumption and operating temperature parameters are all within normal ranges;
The Tester
________________
DECLARATION OF CONFORMITY
K.T.C. S.r.l., the manufacturer, on its own responsibility, declares that the air compressor identified by the label on the front page of this document, complies with the essential requirements laid out in the following DIRECTIVES – STANDARDS
2009/105/CE - 2014/35/CE – 2006/42/CE – 2014/30/CE - EN60204-1 - EN1012-1
K.T.C. S.r.l. holds the relevant technical dossier.
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
1.1.2 WARRANTY
The KTC S.R.L guarantees its products from manufacturing or design defects for a period of 24 months from the date of commissioning, which must be communicated to KTC S.R.L, filling out the form within the technical documentation supplied with the machine. Not getting no communication, the guarantee will be recognized for 24 months by referring to the following shipment date on the sales invoice KTC S.R.L.
Are excluded from the warranty the components for their specific use is subject to usury.
Interventions under warranty can be made exclusively by KTC SR.L. or technical assistance centres authorized by KTC SR.L. shipment of any product made to KTC S.R.L, for Interventions under warranty must be authorized in advance in writing by KTC S.R.L, which decides in its sole discretion whether to authorise or use of its own Authorized technical assistance Center.
In both cases, the expedition to KTC S.R.L will be prepaid with the charge of the shipping invoice. Repair or replacement under warranty includes free replacement of machine components, defective recognized.
The warranty lapses for damage caused by negligence, incorrect installation, use and or do not comply with the instructions described in "use and maintenance booklet"; in the case of alterations or repairs carried out with non-original spare parts or by KTC S.R.L personnel not authorized by KTC S.R.L.
Defective items replaced under warranty, are withdrawn from the authorized service center. Are excluded from any warranty repair or compensation for damages occurring during transport (one­way or return from an authorized technical assistance Center). Is any type of compensation for damage caused to persons or things, resulting from a failure and inappropriate use of purchased and downtime (the customer must protect itself for this case). Warranty service is provided only to buyer in compliance with contractual and administrative rules that present the specification documentation attesting to the purchase period. This is the only valid warranty recognized by KTC S.R.L JURISDICTION. Any dispute will be exclusively the competence of the courts of Vicenza.
1.1.3 RETURNS
Returns are made using the RMA (return material authorization) procedure. To open said procedure, the customer must send a request to KTC.
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
1.2 RULES APPLY
As expressed in the declaration of conformity (chap. 1.1.1), the air compressor is identified by the label on the front of this document complies with the essential requirements of DIRECTIVE - LAW
2009/105/CE - 2014/35/CE – 2006/42/CE – 2014/30/CE - EN60204-1 - EN1012-1
1.3 GENERAL INFORMATION
The compressor should be used only as indicated in this manual, which should be stored carefully in a place easily accessible and familiar, since it will follow the entire life of the machine. For any requests always specify model and serial number.
1.3.1 WARNINGS AND PRECAUTIONS
Before each operation, read carefully this user manual. Failure of the information and instructions contained in it can cause damage to property and injury to persons.
• The machine was designed and built for the following functions. Any other commitment is not allowed.
• Installation and maintenance must be performed by qualified personnel. Always follow the safety
rules.
• The manufacturer disclaims any liability for damage to persons or things to the machine in question, caused by incorrect use of the same, failure or superficial compliance with security policies in this manual, by even slight changes, from use of non-original spare parts.
1.4 HOW TO SEE THE MANUAL
Symbols have been identifying situations requiring extra attention. These symbols may appear next to a text, a picture next to or on top of the page. Give full attention to the meaning of the symbols: their function is to avoid repeating the key terms or notices of darkness, to be considered "reminders". See the page below whenever doubts arise about their meaning.
WARNING: This highlights an important description regarding hazardous conditions, safety warnings, information of utmost importance.
MACHINE STOPS: Each operation must be performed with the machine stopped
ATTENTION MACHINE IN PRESSURE: every operation must be performed for a machine without pressure in the air/oil separator tank (0 bar).
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
REMOVE POWER: every operation must be performed on the machine when the power is turned off.
QUALIFIED: any intervention highlighted by this symbol is the exclusive competence
of a technician
1.5 CE MARKING
The CE marking certifies that the compressor complies with the health and safety requirements outlined in the European Directives indicated in the EC declaration of conformity. The marking is printed with silver lettering on a black polyester adhesive label (L:90mm H:80mm). The label is placed as indicated in figure 1 and bears the following information:
CE marking Compressor model Serial number Maximum working pressure Power supply voltage and frequency Nominal power Weight Manufacture year
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
1.6 MAINTENANCE AND SUPPORT INFORMATION OF THE MACHINE
Our assistant service is at your disposal to provide all information necessary to resolve any problems that might arise.
For further information please contact customer service or your local dealer. Only with the use of original spare parts can guarantee the best performance of the our compressor. Please observe the instructions given in chapter maintenance and use only original spare parts.
The use of the non original spare parts will automatically make void the warranty.
1.7 INSTRUCTIONS FOR SAFE OPERATION
WARNING! Below is a list of important instructions for safe use of the compressor. Follow these instructions carefully. Improper use or maintenance of the compressor can cause injury to the user.
1. Never Touch any Moving Parts
Never allow parts of the body to come near moving parts of the machine.
2. Never Use the Compressor if the Protection Guards have been Removed
Never use the compressor unless all guards are assembled. If maintenance requires removing any of the guards, make sure that they are properly reinstalled before starting up the unit. Never bypass the safety devices installed on the compressor. This is strictly forbidden.
3. Protective Grids
Never insert objects or body parts into protective grids as this can cause injury and can damage the compressor.
4. Use the Compressor Correctly
Always operate the compressor following the instructions given in this manual. Never allow children or unauthorized persons to use the compressor.
5. Always Wear Eye Protection
Always wear goggles or other equivalent form of eye protection. Do not direct air toward parts of the body, your own or others.
6. Work Clothing
Do not wear inappropriate clothing or accessories. If necessary, wear a cap that covers the hair.
7. Use the Compressor Sensibly
Never use the compressor while under the effect of alcohol, drugs or medications that can cause drowsiness.
8. Personnel Intervention
Before performing any form of intervention, the personnel must be aware of all compressor functions and controls.
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
9. Compressor Usage Never use the compressor for any purpose other than those specified in the user's manual.
10. Air Jets
Never direct air jet toward persons or animals.
11. Hot Parts
To prevent burns, never touch the hoses, motor or other hot parts.
12. Work Area
Keep the compressor work area clean and well ventilated. Never use the compressor in a place containing paints, solvents or combustible/explosive materials.
13. Compressor Maintenance
Check the outside of the compressor. If the power supply cord is damaged, repair or replace it. Contact an Authorized Service Centre if necessary.
14. Check for Defective Parts and Air Leaks
Check the alignment of moving parts, hoses, pressure gauges, pressure reducers, tyre connections or other parts important to compressor function. Make certain that all screws, bolts and lids are thoroughly secured. Any damaged parts must be repaired by an Authorized Service Centre
15. Protect Yourself Against Thermal Shocks
Prevent accidentally coming into contact with metal parts of the compressor such as hoses, tanks or grounded parts. Never use the compressor if water or moisture is present in the area.
16. Disconnect the Compressor
When servicing the compressor or when turning it off when it is not running, always disconnect it from the power supply and completely vent the pressure in the tank.
17. Handling
Never move the compressor while it is connected to the power supply or when the tank is pressurized. Before unplugging the compressor make certain that the switch is set to OFF.
18. Precautions for the Power Supply Cord
Never unplug the unit by pulling on the cord. Never step on or crush the power supply cord. Keep it away from heat, oil or sharp surfaces. Never turn off the compressor by pulling on the power supply cord. Use the red emergency button to stop the compressor.
19. Electrical Extension Cords
If the compressor is used outdoor, use power supply cords rated for outdoor use.
20. Cleaning of the Intake Grid and Plastic Parts
Keep the ventilation grid clean. If the unit is used in a particularly dirty environment, clean the grid regularly. Never use solvents, thinners or other substances containing hydrocarbons as they can damage the plastic parts. Clean with soapy water or an appropriate liquid cleaner.
Compressor Rated Voltage Use the compressor at the voltage indicated on the label. Using the compressor at a different voltage can burn out or damage the electric motor.
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
Pag.10 di 45
21. Compressor Defects
If the compressor makes strange noises or vibrates excessively during operations, check that it is functioning properly and, if necessary, contact an Authorized Service Centre.
22. Spare Parts
Use only original spare parts which can be purchased from our distributors. Use of non original spare parts voids the warranty and can lead to compressor malfunction. Repairs must be carried out by an Authorized Service Centre.
23. Pneumatic Circuit
Use hoses, connections and pneumatic tools rated to handle pressures above the operating pressure.
24. Tank
Never unscrew any tank connections without first checking to ensure that the pressure has been vented. Never make holes, welds or modifications on the tank.
25. Compressor Modifications
Never make any unauthorized modifications to the compressor. Such modifications can cause damage and serious injury. Consult an Authorized Service Centre for any operations.
26. Using the Compressor for Painting
Never use the compressor in confined spaces or near open flames. Make certain that the work area is adequately ventilated. In addition, wear a special mask to protect nose and mouth.
THE TERMINALS OF THE ELECTRIC MOTOR ARE STILL LIVE EVEN WHEN THE COMPRESSOR IS OFF, DISCONNECT THE PLUG FROM THE ELECTRICAL SOCKET
KEEP THIS MANUAL INTACT AND ON HAND, AVAILABLE TO ANYONE USING THE COMPRESSOR!
WE RESERVE THE RIGHT TO MAKE ANY MODIFICATIONS WE DEEM NECESSARY WITHOUT PRIOR NOTICE!
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
Pag.11 di 45
1.8 LABELS POSITION
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
Pag.12 di 45
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
Pag.13 di 45
ATTENTION: Do not perform any maintenance on this machine before:
• have stopped all moving
parts
• disconnect the power supply
• you have downloaded all
air pressure.
Maintenance and repairs are performed by authorized personnel!
ATTENTION:
Hot surface
ATTENTION:
Component or system
under pressure
High oil temperature
safety thermostat
CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law.
USER MANUAL AND INSTALLATION COD. 091052 - REV. 07 - DATE 11/2016
Pag.14 di 45
2 TECHNICAL DATA COMPRESSOR
• When the environmental temperature is below 5 ° C is necessary to choose a lubricant ISO VG 32.
• For temperatures below 0° adopt a heater for the specific oil. If necessary, contact an authorized service center KTC.
** Value detected at the maximum operating pressure *** Sound level measured in free field at 1 meter ± 3 dB (A) at maximum operating pressure.
Model
COMPACK 2 V230/3/50
10 bar
COMPACK 2 V400/3/50
10 bar
Machine type
Oil injected screw compressor
Oil injected screw compressor
Drive
Direct coupling
Direct coupling
Type of screw
ADAM S60 C
ADAM S60 C
Flow rate (ISO 1217 annex B 1996)
0.29 m3/min - 10.24 cfm
0.29 m3/min - 10.24 cfm
Max. working pressure
10 bar g - 145 psi g
10 bar g - 145 psi g
Min. working pressure
5 bar g - 72.5 psi g
5 bar g - 72.5 psi g
Maximum power consumption**
3.0 kW - 4 hp
3.0 kW - 4 hp
Max. air/oil outlet temperature
105 °C - 221°F
105 °C - 221°F
Max. environmental temperature
45 °C - 113 °F
45 °C - 113 °F
Min. environmental temperature*
5 °C - 41 °F
5 °C - 41 °F
Weight
40 kg - 88.2 lb
40 kg - 88.2 lb
Power Supply Voltage
230/3/50
400/3/50
Max. current consumption
11,5 A
6 A
Degree of electrical motor protection
IP 54
IP 54
Class of insulation
F
F
Service Factor
S1
S1
Oil Quantity
1.5 lt
1.5 lt
Air Outlet connection
3/8”
3/8”
Oil residue in air
< 3 ppm
< 3 ppm
Electrical Motor
MEC90
MEC90
Heating Oil Resistance
24 V / 35 W / 1,5 A
24 V / 35 W / 1,5 A
Sound Level***
< 70 dBA
< 70 dBA
Air Tank Capacity
/
/
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