KTC COMPACK 2 Operation And Maintenance Manual

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OPERATION AND MAINTENANCE MANUAL FOR

COMPACK 2 COMPRESSOR

(SOLUTION FOR BUS)

ENGLISH VERSION

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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

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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

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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.

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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.

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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).

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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

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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.

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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.

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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!

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1.8 LABELS POSITION

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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

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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

Drive

Direct coupling

Type of screw

ADAM S60 C

Flow rate (ISO 1217 annex B 1996)

0.29 m3/min - 10.24 cfm

Max. working pressure

10 bar g - 145 psi g

Min. working pressure

5 bar g - 72.5 psi g

Maximum power consumption**

3.0 kW - 4 hp

Max. air/oil outlet temperature

105 °C - 221°F

Max. environmental temperature

45 °C - 113 °F

Min. environmental temperature*

5 °C - 41 °F

Weight

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

Class of insulation

Service Factor

Oil Quantity

1.5 lt

Air Outlet connection

3/8”

Oil residue in air

< 3 ppm

Electrical Motor

MEC90

Heating Oil Resistance

24 V / 35 W / 1,5 A

Sound Level***

< 70 dBA

Air Tank Capacity

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3 DIMENSIONS

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4 UNPACKING

The machine must be unpacked by qualified personnel using suitable tools.

The compressor is to be lifted with a forklift truck rated for the weight of the unit.

 Check that the outside packaging is intact.  Unpack the machine carefully.  Check that the outside of the machine is intact.  Dispose of the packaging in compliance with current environmental regulations.

5 LOCATION

Install the compressor at the site point indicated at the time the order was placed. If the unit is installed at a different site, the manufacturer cannot be held responsible for any ensuing problems.

Unless specified otherwise at the time the order is placed, the compressor must run normally under the environmental conditions indicated below.

The room where the compressor is installed must comply with current accident prevention standards and must meet the following requirements:

 Protected from rain and frost.  Relatively free of dust. In time, a dusty environment can lead to damage and operating problems.  Adequately ventilated and of such size that environmental temperature remains steady (min. 5°C,

max. 45°C) when the machine is running. At the maximum admissible environmental temperature (45°C) and with a relative humidity above 80% machine performance can reduce. Likewise, machine performance may be reduced when the unit is installed at an altitude of 1000 m above sea level.

 If hot air exhaust is inadequate, install exhaust fans at the highest position possible (see figure 4).  Lighting: the compressor is built considering current standards and seeking to reduce shadow

zones to the barest minimum, thus facilitating operator intervention; as the compressor room lighting system is deemed important for personnel safety, there must not be any shadows, glaring lights or stroboscopic effects due to the lighting.

 Potentially explosive and/or flammable atmospheres: in its standard configuration, the compressor

is not designed to work in environments where there is the risk of explosion and/or fire;

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In this version, the compressor must be set between a floor and legs of the compressor, through no.4 M8 screws. If necessary, refer to ch. 3 DIMENSIONS to assess the interests of a puncture.

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6 CONNECTION AND START UP

6.1 GENERAL WARNINGS

Before starting compressor for the first time it is compulsory to make sure that:

 Incoming voltage is the same as indicated on the number plate .  Main automatic switch on the wall, must follow the engineering data (see chapter 6.6.1).  Check that oil level is correct (see chapter 11.3).  The electrical connection are made using cables with adequate section (see chapter 6.6.3).

CAUTION! Carefully comply with the SAFETY WARNINGS regarding use of the machine.

For the European market, the tanks are complaint with Directive 87/404/EEC while the compressors are built in compliance with Directive 98/37/EEC.

Check the label on the compressor and at the beginning of this manual for indication of your model.

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6.2 USE OF THE COMPRESSOR

The compressor is designed and manufactured exclusively to produce compressed air.

The compressor is not suitable for use in explosion-proof and flammable products.

ANY OTHER USE OTHER THAN EXPECTED FROM THE MANUFACTURER TO RISE FROM LIABILITY 'LINKED TO RISK THAT SHOULD BE INCURRED.

USING THE COMPRESSOR AS OTHERWISE AGREED UPON PURCHASE BY THE MANUFACTURER DISCLAIMS ANY RESPONSIBILITY 'FOR ANY DAMAGE TO PROPERTY, AND PERSONS TO THE MACHINE.

WARNING! NEVER POINT THE JET OF AIR ON PEOPLE OR PETS. DO NOT USE THE AIR FOR A RESPIRATORY OR FOOD OR PHARMACEUTICAL MANUFACTURING PROCESS WHERE THE AIR PRODUCED PRIOR TO BE TREATED TO MAKE APPROPRIATE USE THAT IS REQUIRED.

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6.3 COMPRESSOR LUBRICATION

CAUTION! Before performing any operation involving draining or topping up compressor oil, unplug the compressor and wait until the system has reached atmospheric pressure.

Use adequate protection when handling lubricants.

We recommend a lubricant compatible with the ISO VG 46 oil (mineral-based oil) used during testing. The pour point must be at least -8+10°C and the flash point higher than +200°C.

KTC Oilscrew plus 46

For use of incompatible oils, follow the procedure described in chapter 6.4

Never mix different types of oil

We recommend using oil with a VG32 rating for cold climates and VG68 for tropical climates.

CAUTION: for machines without oil or warehouse storage for a long proceed as described below:

Absence of oil:

1. Place the oil in the reservoir through the oil filler plug provided (ch. 10.3). To see the

amount of oil provided the technical data (ch. 2).

2. Feed approximately 0.1 l of lubricant in through the regulator intake opening while

keeping the suction valve shutter lowered and manually turning the screw rotors in the right direction.

3. Starting the compressor, initially alternating switching to short shutdowns, to facilitate

the filling of all the parts of the plant.

4. Start the machine for about 10 minutes with average operating.

5. Turn the machine off and wait for it depressurized (0 bar). Check the oil level by the

viewer (ch. 10.3) and, if necessary, proceed with the replacement of oil by means of the filler cap on the tank (ch. 10.3).

Long storage

From Point 2 to point 5

CAUTION! When lowering the suction valve shutter be careful not to damage the throttle valve Oring.

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6.4 USING THE COMPRESSOR WITH SYNTHETIC OILS

If you wish to use a synthetic lubricant, carefully follow the procedure below.

1. Extract the mineral lubricant already contained in the circuit of the compressor through a

special drain cock, taking care to collect the same on a suitable container for disposal.

2. Proceed by washing with detergent oil circuit. If you don’t have a special detergent for

cleaning oil you can use the same synthetic lubricant that you want to use the machine. We recommend two cycles of loading and unloading oil, at each cycle will start up the machine for about 5 min and then proceed with the final charge of synthetic oil that will be used.

ATTENTION!

It 's necessary to replace the oil filter and separator cartridge, contaminated by the mixture of the two oils. Always check the oil level to each load through the special viewer (cap.10.3).

ATTENTION!

If you do not the cycle of "washing" described above, problems can occur due to the lubrication of possible incompatibility of mixing of the lubricants. Handle the lubricant with appropriate protections. Dispose of lubricants according to environmental regulations.

ATTENTION!

Before carrying out any mining operation or topping up oil on the compressor, disconnect the power supply and wait until the pressure inside the separator tank is 0 bar.

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6.5 CONNECTION AND START UP

6.5.1 GENERAL WARNINGS

At first start up the machine and check that:

- The supply voltage corresponds to that indicated on the label.

- The sizing of the main switch on the wall, must follow the instructions of the technical data table (see section 6.6.1).

- Check for proper oil level (see section 11.3).

- The electrical connections are made using cables of appropriate size (see section 6.6.3)

ATTENTION!

Carefully follow the SAFETY PRECAUTIONS on the use of the machine. For the European market tanks are built in accordance with Directive 87/404/EEC, while the compressors are built in accordance with Directive 98/37/EEC. Check your model on the data plate on the compressor and the beginning of this manual.

6.5.2 CONNECTING OF THE POWER CABLE OF COMPRESSOR

Plug the power cable through the cable gland and follow the path indicated by the red arrow as shown in the figure below:

ATTENTION! To connect the wires in the correct plug terminals, follow the electric scheme in Cap. 8.1

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6.6 ELECTRICAL CONNECTION OF COMPRESSOR

The electrical connection to the electrical line is carried out by the end user. He bear the costs and responsibility for quality and compliance standards, which must be performed by trained personnel in accordance with accident prevention regulations EN 60204.

6.6.1 FUSE AND BREAKER

It is recommended to install the connector, the circuit breaker and fuses near the compressor (not more than 3 meters). The circuit breaker and the fuses must have the characteristics shown in the following table:

 The voltage (volts) must correspond to that indicated on the nameplate of the electrical

machine; the tolerance must be within the + / -5%.

 The plug of the power cable should not be used as a switch. Do not remove power while unit

is running; for emergency action to switch of the compressor or on the appropriate line switch (breaker), see table.

Never use the ground instead of neutral. The ground connection must be made in accordance with safety regulations (EN 60204). Verify that the mains voltage corresponds to that required for the proper functioning of the compressor.

Voltage

V230/3/50-60

Voltage

V400/3/50-60

Magnetothermic

Curve “ D “

3 poles **

Fuse with delay*

Magnetothermic

Curve “ D “

3 poles **

Fuse with delay*

3,0

16 A

12 aM

10 A

10 aM

* Raccomended type of fuse refer to class of use: gL/gG, aM

** Magnetotermic switch with “D“ curve, characteristics of adjustment according to IEC 60 898 specific motors starter

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6.6.2 GROUND CONNECTION

The compressor must be connected to the ground during its use, in order to protect the operator from accidental electric shocks. It 's necessary that the connections are made by a technician or an authorized service center. The grounding conductor yellow / green wire of the power of the compressor must only be connected to terminal of the compressor. The ground wire connected to a facility must be properly equipped with mandatory safety switch.

6.6.3 SIZING OF ELECTRIC CABLE

Do not use a damaged cable but make sure it is in good condition. This section must be appropriate to the current requested by the compressor. A little section of power cable can cause a voltage drop with consequent loss of power and excessive heating of the cable itself, which can cause irreparable consequences on the device supply. The cable section must be in proportion to its length. For variations and modifications contact a qualified service center.

Avoid any risk of electric shock. Never use the compressor with a damaged power cable. It is recommended to be checked periodically by a qualified power cords. Never use the compressor in areas where they can be hazardous leakage current.

All electrical installations and maintenance on facility must be performed by a qualified technician.

230 V - 3 phase

50 Hz

400 V - 3 phase

50 Hz

3.0

2.5 mm²

1.5 mm²

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6.7 AIR CONNECTION OF COMPRESSOR

Be sure to use compressed air tubing with features and cross section appropriate to the compressor. Do not repair a faulty tube, but proceed with the replacement.

Connect the compressor to the pneumatic network by using the special attack female 3/8" arranged on the compressor and illustrated. We recommend using a pipe with a diameter equal to or greater than the output of the compressor 3/8 ".

It is recommended during installation to connect a ball valve between the air tank and the line as indicated above, (if not present in the supply).

Attention! The compressor does not require not-return valves because it is already installed within. The valve mounting could cause incorrect operation of the compressor.

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7 FIRST START

First start of compressor (operational test)

After following all steps of assembly of the compressor shown in Chapter 4, you can proceed with the operation of preparing the compressor for the first start.

ATTENTION!

In this compressor is NOT PRESENT a control device that ensures the correct rotation of the screw

. If the supply phases are correctly positioned the compressor will start as indicated on the arrow on the body of the screw as shown in Figure 10. (Check with motor fan)

If the phases of the supply line are positioned INCORRECTLY, the inverse rotation will damage the airend.

Swap the connections of two phases of power line and restart the compressor.

Figure 10

ATTENTION!

The reverse rotation of the screw from the direction of the arrow shown on the body (see figure 10) may damage the screw!

ATTENTION!

In case of replacement of the electric motor, at the time of restart is absolutely necessary to visually check the direction of rotation of the screw unit.

ATTENTION!

It's absolutely necessary to strictly follow the SAFETY PRECAUTIONS on the use of the machine.

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8 CONTROL PANEL

ATTENTION! The manual control of the compressor (on / off) can be managed only by the switch placed over the pressure switch and in case of arrest for excessive temperature can be reset by pressing the reset button of the thermostat (see the picture below). Any other control will be managed by the final user (via controller or inverter) which shall be solely responsible. How to manage the various controls, refer to the wiring diagram.

ATTENTION! After an emergency stop at high temperature release the line switch. Reset the thermostat, unscrewing the cap hexagon and pressing the button inside.

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8.1 ELECTRIC DIAGRAM

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shall safeguard its rights to the full extent of the law.

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Heavy duty POWER and CONTROLLER connectors with spring terminal connectors

Inserts for section conductors: 0.14 - 2.5 mm2

- AWG 26 – 14 conductors stripping lenght: 9...11 mm Necessary Tool: 0.5x3.5mm Flat screwdriver

1)Insert the flat screwdriver

3)Insert the wire conductor, then remove the screwdrive

2)Push the screwdriveng to open up the spring connector

4)Check the wire conductor is correct fixed

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9 HEATING RESISTANCE of OIL

ATTENTION! In the compressor is installed a heating resistance, which has the function of maintaining the oil of the compressor at a temperature of about 50-60 °C even when this is not in operation so as to avoid formation of water condensation inside the air/oil separator tank.

For electrical characteristics see the ch. 2

IMPORTANT! So it is essential that this resistance is fed even when the compressor is not in operation, in each case after 2 or 3 days of stationary car

is advisable to disconnect this power in such a way as to prevent the batteries from discharging.

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10 PNEUMATIC SCHEME AND MACHINE DESCRIPTION

1- Intake valve 2- Screw compressor 3- Air tank 4- Solenoid valve 3/2 5- Safety valve 6- Manometer 7- Oil cooler 9- Minimum pressure valve 11- Pressure switch 12- Oil return from air/oil separator 13- Separator filter 15- Air/oil separator tank 16- Air filter 17- Oil filter 22- Oil recovery viewer 25- Thermostatic valve 26- Electric cooling fan 29- Electric motor 30- Oil level 31- Oil discharge

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11 ORDINARY MAINTENANCE OF COMPRESSOR

The following table is a plan for maintenance of the compressor. The work hours listed in the table refer to the optimal use of the machine and can therefore vary depending on the working environment and the number of cycles.

ATTENTION: USE ONLY GENUIINE PARTS!!!

ATTENTION: HOT PARTS INSIDE!!!

MACHINE

CODE

DESCRIPTION

HOURS OF WORK

COMPACK 2

N11L0119

OIL CHANGE

every 1000 hours

K10

COMPACK 2

De-oiler cartridge

K11

COMPACK 2

Oil filter cartridge

K12

COMPACK 2

Air filter cartridge

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EVERY LEVEL CONTROL AND POSSIBLE OIL TOPPING OFF THE MUST BE MADE WITH MACHINE STOPPED AND SYSTEM DEPRESSURIZED.

WASTE LUBRICANT MUST BE DISPOSED IN ACCORDANCE WITH THE REGULATIONS.

FOR HEAVY ENVIRONMENTAL CONDITIONS (ex. ESPECIALLY DUSTY PLACES) THE MAINTENANCE SCHEDULE WILL BE MORE CLOSE. CONSULT AN AUTHORIZED SERVICE CENTER.

THE NON COMPLIANCE OF THE TIMES OF MAINTENANCE OF OIL FILTERS, AIR FILTERS AND SEPARATOR FILTERS MAY CAUSE DAMAGE TO THE COMPRESSOR.

IT IS ABSOLUTELY ESSENTIAL TO FOLLOW CAREFULLY THE INSTRUCTIONS ON THE USE OF SAFETY TO USE PROPERLY THE MACHINE.

MAINTENANCE MUST BE EXERCISED BY EXPERTS. IN ANY CASE TO FOLLOW SAFETY RULES APPLICABLE (USE APPROPRIATE SAFETY).

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11.1 REPLACEMENT OF OIL FILTER

Unscrew with a specific tool (chain or belt) to replace the cartridge filter, lubricate the gasket of the new cartridge before attaching the support, the mounting is done by hand, after tightening the cartridge and placed on the base just 'around ½ ensure the seal.

Be careful before you screw the filter cartridge oil the seal. Hand tighten the new filter cartridge.

11.2 REPLACEMENT OF SEPARATOR FILTRE

Remove with a specific tool (chain or belt) to replace the cartridge filter, lubricate the gasket of the new cartridge before attaching the support, the mounting is done by hand, after tightening the cartridge and placed on the base just 'around ½ ensure the seal.

Be careful before you screw the filter cartridge oil the seal. Hand tighten the new filter cartridge.

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11.3 CHANGING OIL

Change the oil as indicated in the table on cap 9.1 extending the number of hours before replacement depends on the type of oil used but in no case can oil be used for more than one year. If the compressor is not used frequently (a couple of hours a day), we recommend changing the oil every 6 months and periodically opening the oil drain ball valve to check for condensation residues.

When the oil drain ball valve is opened, oil starts flowing out of the screw assembly. Always keep on all necessary equipment to collect the oil.

Open filling cap. Open emptying cap.

Once emptied, close the emptying cap.

Then top up the oil until the right level is read on the window (see figure 12). Then tighten the oil filling cap once more. After having replaced the oil and oil filter, run the compressor for about 10 minutes, turn it off and check the oil level. If necessary, top up.

MAX OIL LEVEL

MIN OIL LEVEL

Figure 13

Never mix different types of oil. Make certain that the oil circuit is completely empty before performing any maintenance. Always replace the filter at each oil change.

Filling cap

Emptying cap

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11.4 REPLACEMENT OF AIR FILTER

Renew the air filter cartridge every 1000 hours a year of work. Unscrew the top cover and replace the filter cartridge. The duration of the air filter and proportionate to the type of environment and contamination by dust. If you are heavily contaminated environments, it is necessary to reduce the period to replace the air filter.

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12 MAINTENANCE SCHEDULE

Codice/Code

Modello/Type

MOTOR

ORE/HOURS

Contenuto / Content

LISTINO/LIST

N11L0119

COMPACK 2

trifase/3ph

400/50/3

1000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator Filter

- Olio / Oil

€ 140

N11L0284

2000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator Filter

- Olio / Oil

- Anello elastico trasmissione /Elastic ring of trasmission

€ 160

N11L0285

8000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator Filter

- Olio / Oil

- Anello elastico trasmissione /Elastic ring of trasmission

- Valvola minima pressione/Minimum pressure valve

- Valvola termostatica/Thermostatic valve

- Valvola di aspirazione/Inlet valve

- Cuscinetto MOTORE/Motor bearing

- Kit paraolio PackSmart/ PackSamrt shaft seal KIT

€ 340

N11L0286

20000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator Filter

- Olio / Oil

- Anello elastico trasmissione /Elastic ring of trasmission

- Kit paraolio PackSmart/ PackSamrt shaft seal KIT

- Kit ricambio cuscinetti PackSmart/ PackSmart bearing

€ 470

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The maintenance program is set considering all installation and operating parameters recommended by the Manufacturer.

The Manufacturer recommends keeping a log of the maintenance works performed on the compressor.

The table indicates working hours for a standard machine. These working hours can be modified depending on work environment and cycle numbers.

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13 TROUBLESHOOTING

Problem

Cause

Resolution

Stop machine for oil thermostat intervention

Excessive temperature of air/oil mixture exiting the screw (max 105°C)

- Check the oil level

- Check the clean of cooler.

- Check when the machine is running if the fan works To restart the machine must be switched off and press the reset thermostat button located under the cover of the thermostat. If the arrest due to high temperature persists, contact the service center.

Stop machine intervention thermal compressor motor

- Switch 0/1 on the pressure switch unarmed and compressor is stopped.

- High temperature of motor.

- High power consumption.

- If the intervention happens when the compressor is on, check that the phases are stable.

- If it happens when the compressor is running, make sure the internal pressure of the group and replace the separator cartridge.

- If the motor draws a current higher than the rated current, contact an authorized service technician. Do not insist too much with the starts because they could cause serious damage to the electrical plant of compressor

Opening safety valve

Pressure switch doesn’t work and the pressure exceeds the value set by the safety valve.

- Remove the cover and check if the pressure switch has traces of oxide or dirt. If there are, remove them with a mild antioxidant

- Intake valve does not close, check that it is locked.

The compressor runs but the pressure remains low

- The intake valve does not open

- Loss of air that prevents the increase pressure

- Coupling screw-engine to check

- When the machine is off and depressurized safely, remove the air filter and check if the shutter moves

- Check if there are leaks from the pipes that disperse the air produced.

- Check carefully if the motor runs but does not transmit the motion to the screw.

Contact a service center

Leakage of oil from the air filter.

- The oil level is too high

- Oil recovery viewer dirty

- Separator Cartridge exhausted

- Remove excess oil with the machine stopped and checking the oil sight glass.

- Remove the oil recovery viewer and clean it. If necessary replace it.

- Replace the air/oil separator cartridge, making sure to clean his nipple

Safety valve group vented air compressor is running.

- The pressure has exceeded the limit of opening of the safety valve.

- The separator cartridge air / oil filter is clogged.

- Replace the safety valve.

- Replace the air/oil separator cartridge

- Contact an authorized service centre

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Problem

Cause

Resolution

Motor thermal sensor causes machine to stop.

Main motor overloaded.

Low line voltage.

Phase missing. High oil separator pressure.

Make certain that electric power supply is correct. Check that the 3 power phases are at approximately the same value and that the cables are firmly secured to the terminal. Check that the cables are not damaged. Make certain the main motor ventilation is free of any fouling or foreign objects.

If the motor is running in two phases, have it checked by a qualified technician. If necessary, have the motor repaired or replaced.

The oil separator differential pressure is above 1.0 bar causing high system absorption. Have the unit checked by qualified personnel. Environmental temperature too high: air the room. To start up the machine again, reset it using the special button on the control panel.

When starting up the unit for the first time, the machine does not start. Phase anomaly alarm.

The line phases are not correct.

Invert two power supply phases on the main switch. (only for 3 phases version) CAUTION!! UNPLUG THE MACHINE.

Excessive oil consumption.

Oil not suitable for the compressor operation. Air-oil separator cartridge spent or defective. Oil recovery viewer clogged. Oil level too high.

Replace oil, fill machine with the oil indicated by the manufacturer. Replace oil separator cartridge. Clean or replace oil recovery window. Top up oil until it reaches the level indicated in the manual.

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14 APPENDIX

14.1 MAINTENANCE CONTROL BOARD

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15 COMMERCIAL PARTS, SPARE PARTS AND RELATED

DOCUMENTATION

For further information please consult the web site www.ktc-air.com

For further information please contact customer service or your local dealer.

ATTENTION!

 Do not touch the moving parts when the compressor is running.

 All maintenance of the compressor must be carried off (pressure and temperature) and

circuit switched off.

 Maintenance must be performed by qualified personnel. Always follow the safety rules in

force (use appropriate safeguards).

We reserve the right to make changes to this manual, in our discretion and without notice.

The manufacturer disclaims any liability for personal injury, property damage caused by incorrect operation of the compressor unit, failure or superficial compliance with security policies in this document, by even slight changes, from tampering and the use of spare parts are not original.

KTC COMPACK 2 Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual