KTC KME 18-22-30-37 Operation And Maintenance Manual

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OPERATION AND INSTALLATION MANUAL COD. 091003 - KME 18-22-30-37 - REV. 07 - DATA 11/2016 pag.1 of 68

OPERATION AND MAINTENANCE MANUAL FOR

KME 18-22-30-37 COMPRESSORS

ENGLISH VERSION

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CONTENTS

1 GENERAL WARNINGS AND INFORMATION FOR THE USER ................... 5

1.1 DEFINITION OF REGULATED RELATIONSHIPS ................................................... 5

1.1.1 DECLARATIONS ............................................................................................................... 5

1.1.2 WARRANTY ....................................................................................................................... 6

1.1.3 RETURNS ........................................................................................................................... 6

1.2 APPLICABLE STANDARDS ....................................................................................... 7

1.2.1 CE MARKING..................................................................................................................... 7

1.3 CAUTIONS AND SAFETY WARNINGS .................................................................... 8

1.3.1 INSTRUCTIONS FOR SAFE OPERATION ...................................................................... 8

1.4 CONTACTS AND USEFUL ADDRESSES ................................................................ 11

2 DESCRIPTION OF THE MACHINE AND OPERATING PRINCIPLE ........... 12

2.1 MACHINE DESCRIPTION ......................................................................................... 12

2.2 OPERATING PRINCIPLE ........................................................................................... 13

3 PRESENTATION OF THE MANUAL: CONTENT AND CONSULTATION 14

3.1 SYMBOLS, GLOSSARY AND NOTES ON GRAPHIC LAYOUT .......................... 14

4 DATA AND TECHNICAL SPECIFICATIONS ................................................. 15

5 INSTALLATION ................................................................................................. 17

5.1 CHARACTERISTICS AND STORAGE CONDITIONS ............................................ 17

5.2 TRANSPORT ............................................................................................................... 17

5.3 UNPACKING ............................................................................................................... 17

5.4 HANDLING.................................................................................................................. 18

5.5 LOCATION .................................................................................................................. 19

5.6 FOUNDATIONS .......................................................................................................... 19

5.7 CONNECTION AND START-UP ............................................................................... 21

5.7.1 GENERAL WARNINGS ................................................................................................... 21

5.7.2 CONNECTING THE POWER SUPPLY CORD OF THE COMPRESSOR .................... 22

5.7.3 CONNECTING THE COMPRESSOR TO THE ELECTRICAL POWER SUPPLY ...... 23

5.7.4 INFORMATION ON THERMAL RELAY CALIBRATION .......................................... 25

5.7.5 WIRING DIAGRAM KME 18-22-30-37 400V ................................................................ 26

5.7.6 COMPRESSOR CONNECTION TO ELECTRICAL POWER SUPPLY ........................ 32

5.7.7 FIRST START-UP ............................................................................................................. 33

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5.8 CLEANING AND DISINFECTION ............................................................................ 34

5.9 REINSTALLATION AND REUSE ............................................................................. 34

5.10 DEMOLITION AND DISPOSAL ................................................................................ 34

6 OPERATION AND USE ..................................................................................... 35

6.1 DESCRIPTION OF THE OPERATION ...................................................................... 35

6.2 RANGE OF APPLICATIONS ..................................................................................... 35

6.3 PROPER AND IMPROPER USE ................................................................................ 35

6.4 OPERATING AND ENVIRONMENTAL LIMITS .................................................... 35

6.5 WORKSTATION AND DANGEROUS AREAS ........................................................ 35

6.6 SAFETY DEVICES AND SIGNALS .......................................................................... 36

6.6.1 POSITION OF THE LABELS ........................................................................................... 36

6.7 DANGERS AND RISKS THAT CAN BE ELIMINATED ......................................... 37

6.8 PERSONAL PROTECTIVE EQUIPMENT, SAFE WORKING PROCEDURES AND

TRAINING ................................................................................................................... 37

6.9 COMPRESSOR LUBRICATION ............................................................................... 38

6.9.1 GENERAL RECOMMENDATIONS ................................................................................ 38

6.9.2 USING THE COMPRESSOR WITH SYNTHETIC OILS ............................................... 39

7 INSTRUCTIONS FOR THE USER .................................................................... 40

7.1 DESCRIPTION OF THE CONTROL DEVICES ........................................................ 40

ELECTRONIC CONTROLLER ............................................................................................ 40

7.1.1 BUTTON LAYOUT .......................................................................................................... 41

7.2 ALARMS LIST............................................................................................................. 42

7.3 DESCRIPTION OF THE OPERATIONS TO BE PERFORMED .............................. 43

7.4 START, STOP AND EMERGENCY STOP FUNCTIONS ........................................ 45

7.5 RESET CONDITIONS ................................................................................................. 45

8 COMPRESSOR MAINTENANCE ..................................................................... 46

8.1 SCHEDULED MAINTENANCE ................................................................................. 46

8.1.1 BELT TENSIONING ......................................................................................................... 47

8.1.2 USING AN OPTIKRIK TENSION GAUGE .................................................................... 53

8.1.3 SUCTION PRE-FILTER MAINTENANCE ..................................................................... 54

8.1.4 REPLACING THE OIL FILTER ...................................................................................... 56

8.1.5 REPLACING THE OIL SEPARATOR FILTER .............................................................. 56

8.1.6 CHANGING THE OIL ...................................................................................................... 57

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8.1.7 REPLACING THE AIR FILTER ...................................................................................... 57

8.1.8 MAINTENANCE SCHEDULE ......................................................................................... 58

8.2 UNSCHEDULED MAINTENANCE ........................................................................... 63

9 TROUBLESHOOTING ...................................................................................... 64

10 COMMERCIAL PARTS, SPARE PARTS AND PERTINENT

DOCUMENTATION .......................................................................................... 66

11 APPENDIX .......................................................................................................... 67

11.1 MAINTENANCE CHECK SHEET ............................................................................. 67

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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

KTC S.r.l. guarantees its products from manufacturing or design defects for a period of 24 months from the date of initial start-up. To inform K.T.C. S.r.l. of this date, fill out the special form supplied with the machine technical documentation and send it in. If no communication is received, the warranty shall be recognized for 24 months starting from the date on which the unit was shipped; that is the date indicated on the K.T.C. S.r.l. invoice.

The warranty does not cover parts subject to wear.

Repair works covered under the warranty can only be performed by K.T.C. S.r.l. or a K.T.C. S.r.l. Authorized Service Centre.

Shipment of any product being returned for service under the warranty must be authorized in advance, and in writing, by K.T.C. S.r.l. Moreover, K.T.C. S.r.l., in its unquestionable wisdom, can decide whether to authorize such shipment or have one of its Authorized Service Centres do the work.

In both cases, shipment to K.T.C. S.r.l. must be made carriage paid with shipping costs charged in the invoice. Repairs or replacements covered by the warranty include free replacement of parts of the machine that are recognized as defective.

The warranty does not cover damages caused by negligence, by incorrect use or installation or by

non compliance with the warnings indicated in the “Operation and Maintenance Manual”.

Moreover the warranty is voided if modifications or repairs are made with non original K.T.C. S.r.l. spare parts or performed by anyone not authorized to do so by K.T.C. S.r.l.

Defective parts replaced under the warranty are retained by the Authorized Service Centre. The warranty does not cover repairs or reimbursement for damage due to shipping (to or from the Authorized Service Centre). The warranty does not cover any type of reimbursement for injuries or damages to people or things derived from improper use of the model purchased or due to machine down time (the customer must take steps to prevent this). Service covered under the warranty is guaranteed only to purchasers who have met their contractual and administrative obligations and who are able to show the documentation certifying the purchase period. This is the only valid warranty recognized by K.T.C. S.r.l. court having jurisdiction. For any disputes the competent court is that of Vicenza, Italy.

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 K.T.C.

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1.2 APPLICABLE STANDARDS

As outlined in the declaration of conformity (chap. 1.1.1.), the air compressor identified by the label on the front page of this document complies with the essential requirements outlined in the following DIRECTIVES – STANDARDS

2009/105/CE - 2014/35/CE – 2006/42/CE – 2014/30/CE - EN60204-1 - EN1012-1

1.2.1 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

Figure 1

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1.3 CAUTIONS AND SAFETY WARNINGS

Read this operation manual carefully before performing any operations. Non-compliance with the instructions contained herein can lead to injury and property damage.

 The machine has been designed and built to operate as reported below. Any other use is

considered unacceptable.

 Only qualified personnel can install and service the machine. Always follow accident prevention

standards.

 The manufacturer is relieved of any responsibility for injuries and machine or property damage

caused by incorrect use of the compressor, non-compliance or inadequate compliance with the safety criteria reported herein, modifications (even minor modifications) and by use of non original spare parts.

1.3.1 INSTRUCTIONS FOR SAFE OPERATION

CAUTION! 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 user injury.

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 machine.

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.

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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.

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. If necessary, contact an Authorized Service Centre.

14. Check for Defective Parts and Air Leaks

Check alignment of moving parts, hoses, pressure gauges, pressure reducers, pneumatic 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 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.

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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.

21. 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.

22. 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.

23. 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.

24. Pneumatic Circuit

Use hoses, connections and pneumatic tools rated to handle pressures above the operating pressure.

25. 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.

26. 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.

27. 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.

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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1.4 CONTACTS AND USEFUL ADDRESSES

Our technical services department is at your disposal, ready to provide any information you may need and to help you resolve any problems that may arise.

For any information, please log onto our website www.ktc-air.com

For any clarifications you may require, contact our customer services department or your area

retailer. Only original spare parts can guarantee best performance of our compressors. We recommend carefully following the instructions given in the chapter on maintenance and always use only original spare parts.

Using non original parts automatically voids the warranty.

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2 DESCRIPTION OF THE MACHINE AND OPERATING PRINCIPLE

2.1 MACHINE DESCRIPTION

1- Suction valve 2- Screw compressor 4- 3/2 Solenoid valve 5- Pressure relief safety valve 7- Oil radiator 8- Air radiator 9- Low pressure valve 10- Power button

11- Pressure switch 12- Oil return from separator 13- Oil separator filter 14- Air/oil delivery hose from screw assembly 15- Air/oil separator tank 16- Suction filter 17- Oil filter 22- Oil recovery window

25- Thermostatic valve 26- Electric cooling fan 27- Suction pre-filter panel 28- Drive belt 29- Electric motor 30- Oil level 31- Oil discharge 32- Control panel

33- Electric panel 34- oil filling cap 35- Air tank 36- Condensate drainage 37- pressure gauge 38- Air outlet line lever cock

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2.2 OPERATING PRINCIPLE

 During the initial phase of start up, the electric motor ref. 29 (with "star" power supply),

rotates slowly. The solenoid valve ref. 4 is not powered and thus the suction valve ref. 1 it controls remains closed. The length of this phase can be set.

 During the second phase, the "delta" power supply accelerates the motor to reach the set

operating r.p.m. The solenoid valve ref. 4 is powered and the suction valve ref. 1 is opened, thus allowing air to pass through the suction filter ref. 16 and enter the screw compressor ref. 2. This starts the compression phase.

 The air/oil mixture delivered by the screw compressor ref. 2 is conveyed into the air/oil

separator tank ref. 15.

 An initial portion of the oil is separated from the air mechanically and deposits at the bottom

of the tank while the air collects at the top.

 By force of pressure the air is forced to flow through the oil separator filter ref. 13 and, after

further separation of the oil, it is sent on to the low pressure valve ref. 9. This allows passage of the air only after the pressure set point has been reached. When this happens, the air passes through the air radiator ref. 8, where it is cooled, and then continues on to the operating tank ref. 35. The oil removed from the air inside the oil separator filter is sent, through the oil return from separator line ref. 12, into the screw compressor. The amount of oil can be monitored through oil recovery window ref. 22.

 In the model with drier, the air passes through the drier before reaching the operating tank.  Unless the unit has an automatic drainage, the condensate accumulated inside the tank must

be eliminated manually through the condensate drainage ref. 36.

 The pressure sends oil at the bottom of the tank to the thermostatic valve ref. 25. This valve

sends the oil with a temperature above the set point to the oil radiator ref. 7 where it is cooled. Once cooled, the oil returns to the thermostatic valve, is mixed with hot oil coming from the tank and is again checked by the thermostatic valve. Once the temperature set point (low) is exceeded, the oil is sent to the oil filter ref. 17 and then into the screw compressor.

 When the set maximum working pressure is reached, the pressure switch ref. 11 remove

power from the solenoid valve ref. 4 and trips the circuit. The suction valve ref. 1 closes air flow and the compressor enters in "no-load" operating mode. This situation remains in force until the system minimum pressure setting is reached. If consumption is low or has stopped unit will continue operate in no-load mode for a set amount of time and then reverts to stand-by mode. (see chapter 7).

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3 PRESENTATION OF THE MANUAL: CONTENT AND

CONSULTATION

3.1 SYMBOLS, GLOSSARY AND NOTES ON GRAPHIC LAYOUT

This manual uses symbols to highlight situations that require utmost attention. These symbols can be located beside a text, a figure or at the top of a page. Pay utmost attention to the meaning of the symbols: They are used to avoid redundant repetition of

technical concepts or safety warnings and must be considered as “reminders”. Always refer to this

page whenever you have any doubts as to their meaning.

CAUTION: indicates an important note regarding hazardous conditions, safety warnings, information of primary importance.

MACHINE DOWN: all operations must be performed with the machine down.

CAUTION: MACHINE PRESSURIZED: all operations must be performed with the machine depressurized, with no pressure in oil separator tank.

UNPLUG: all operations must be performed with the machine unplugged from the power supply.

QUALIFIED PERSONNEL: all operations indicated with this symbol must be performed only by specially trained personnel.

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4 DATA AND TECHNICAL SPECIFICATIONS

* When the environmental temperature is below 5°C, an ISO VG 32 lubricant must be used

** Value detected with working pressure: 10 bar g ***Noise measured in an open field at 1 metre from the unit ±3 dB(A) at maximum working pressure.

Modello

KME 18

KME 22

KME 30

KME 37

Machine type

Oil injected screw compressor

Drive

Belt drive

Type of screw

Pack Smart V90

Pack Smart V90 / V110

Pack Smart V110

Type of fluid handled

air

Flow rate (ISO 1217 annex B 1996)

2.54 m3/min - 90 cfm

3.02 m3/min - 107 cfm

4.21 m3/min - 149 cfm

4.91 m3/min - 173.4 cfm

Max. working pressure

13 bar g - 188.5 psi g

Min. working presure

5 bar g - 72.5 psi g

Maximum power consumption**

18.5 kW - 25 hp

22 kW - 30 hp

30 kW - 40 hp

37 kW - 50 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

370 kg - 815 lb

422 kg - 930 lb

455 kg - 1003 lb

510 kg - 1124 lb

Power supply voltage

See machine label

Motor efficiency

IE 1

IE 3

IE 1

IE 3

IE 1

IE 3

IE 1

IE 3

Max. current consumption (motor)

36A-400V 63A-230V

33.5A-400V 58A-230V

43A-400V 75A-230V

40A-400V 69A-230V

57 A-400V

98A-230V

52A-400V 90A-230V

70 A-400V

121A-230V

----

Max. current consumption (access.)

2.5A - 400V ---- 4A - 230V

Service factor

S6-75%

S1-100%

S6-75%

S1-100%

S6-75%

S1-100%

S6-75%

S1-100%

Electric motor protection rating

IP 55

Insulation class

F F F

Oil charge

12 litri

Air outlet connection

1 1/4”

Maximum fan flow rate

5100 m3/h

Oil residue in air

<3 ppm

Electric motor

MEC160

MEC180

Noise level

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5 INSTALLATION

5.1 CHARACTERISTICS AND STORAGE CONDITIONS

During periods of inactivity, before being unpacked (storage), the compressor must be kept at a temperature of between +5 °C and +45 °C and in a dry place sheltered from the weather. Once unpacked, when the unit is not going to be used (prior to start-up or when production is interrupted), the compressor should be protected with a tarpaulin to protect dust from gathering on the mechanical and electric mechanisms. If the compressor has remained inactive for a long period of time, before starting it up again, change the oil and check function.

5.2 TRANSPORT

To ensure that the unit is protected and does not incur shipping damages, the compressor is screwed onto a wooden pallet and covered with a cardboard box. All shipping information is printed on the compressor package (data and pictograms).

5.3 UNPACKING

When unpacking the unit, carefully check that the contents match what is indicated in the shipping documents.

The user must dispose of packaging in compliance with current national regulations.

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

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5.4 HANDLING

The compressor is to be lifted with a fork lift 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.

The compressor should be handled as indicated in figures 2

Figure 2

THE COMPRESSOR CAN BE LEFT ON THE PALLET WHICH MAKES SUBSEQUENT MOVEMENT EASIER.

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5.5 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;

5.6 FOUNDATIONS

Once the position for the compressor has been identified, check that it is set on a flat surface. The machine does not require foundations or any specific preparation of the support surface (foundation works).

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CAUTION!!

Do not insert any check valves between the compressor and the tank.

 The ducting must not exceed 3 metres in length; if this proves necessary, install

a fan on the outlet side (see figure 4).

 The ducting must have a uniform section of 0.3 m².  Condensation must not be discharged into the environment or into the sewers.

The well must be fit with a valve and removable container, or it must be connected to a special unit to separate the air from the water.

Figura 4

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5.7 CONNECTION AND START-UP

5.7.1 GENERAL WARNINGS

When starting up the unit for the first time, make certain that:

 The power supply matches the requirements indicated on the label.  The wall-mounted general switch is proportioned according to the indications in the technical data

table (see chapter 5.7.3.3).

 The oil is at the correct level (see chapter 8.1.6).  The electrical connections have been made using cables of adequate section (see chapter 5.7.3.2)

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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5.7.2 CONNECTING THE POWER SUPPLY CORD OF THE COMPRESSOR

1- Insert the power supply cord through the cable seal and run it as indicated by the red arrow in

figure 5.

Figure 5

2- Connect L1 L2 L3 to the disconnecting switch as indicated in figure 6.

Figure 6

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5.7.3 CONNECTING THE COMPRESSOR TO THE ELECTRICAL POWER SUPPLY

The machine is connected to the electrical power network by the customer, at his own expense and responsibility, using qualified personnel and in compliance with accident prevention standard EN 60204

5.7.3.1 Ground connection

To protect the operator from electric shocks, the compressor must be grounded during use. The ground connection must be carried out by a qualified technician or by a specialized service centre. The ground connection on the compressor power supply cord must be connected only to the terminal on the compressor itself. Before replacing the plug of the power supply cord, make certain that the ground is connected.

5.7.3.2 Sizing the Power Supply Cable

Never use damaged cables. Always make certain that the cable is in good condition. Use only cables with an adequate size to the compressor's maximum current absorption. If the cable is too thin, there will be a drop in voltage, power loss and the unit will overheat. The cable section must be proportioned to the cable length and to the ambient temperature of the room where the cables are used. The values indicated below refer to an ambient temperature within 40°C:

Avoid all risks of electric discharges. Never use the compressor if the power supply cord or extension cord are damaged. Check the electrical cables regularly. Never use the compressor in dangerous environments where electrical discharges can occur.

Installation must be performed by a qualified technician.

220/240 V

50/60 Hz

380/415 V

50/60 Hz

18.5

35 mm²

16 mm²

50 mm²

25 mm²

70 mm²

35 mm²

95 mm²

50 mm²

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5.7.3.3 Fuses and Magnetothermal Switch

It is advisable to install the outlet, the Magnetothermal Switch and fuses near the compressor (not more than 3 metres away). The Magnetothermal Switch and fuses must have the characteristics indicated in the table below:

 Always check that the installed power, in kW, is at least double the absorbed power rating of the

electric motor.

 The line voltage must match the electrical parameters indicated on the machine label; the

acceptable variation must not exceed 6%.

 The power supply plug must not be used as a switch; it must be plugged into a power outlet

controlled by an adequate differential switch (circuit breaker).

Never use the ground in place of the neutral. Ground connection must be performed in compliance with accident prevention standards (EN 60204). Make certain that the line voltage matches that required for good compressor function.

POWER

Rated voltage

220/240 V

Rated voltage

380/415 V

Magnetotermico

Fusibile

Magnetotermico

Fusibile

18.5

100 A

80 aM

63 A

50 aM

100 A

100 aM

63 A

63 aM

160 A

125 aM

100 A

80 aM

160 A

160 aM

100 A

100 aM

The values refer to aM (time-lag) fuses.

The values refer to "D-type" switches.

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5.7.4 INFORMATION ON THERMAL RELAY CALIBRATION CAUTION!!

Turn off power to the compressor before performing any work on the electric box. To ensure that the compressor will operate properly at full continuous load at maximum working pressure, make certain that the room temperature does not exceed + 45°C. Make certain that the compressor working temperature remains below the set cut-off value - SEE PARAMETER ON ELECTRICAL CONTROLLER (T. MAX). Check the air/oil exchanger and keep it clean. For problems related to high environmental temperature, we recommend using special oils rated for high temperatures and contact an Authorized Service Centre to solve the problem.

Adjustment of thermal relay FR1 must reflect the values indicated in the table below; if the thermal relay trips, check absorption and voltage at the line terminals during operation and check the power connections inside the electrical panel and on the motor terminals. The thermal relay FR1 is set as indicated in the table below:

- For models with STAR/DELTA start-up:

Power kW

Rated voltage 380/415V-3ph

Rated voltage 220/240V-3ph

18.5

21 A

37 A

25 A

44 A

35 A

59 A

42 A

72 A

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5.7.5 WIRING DIAGRAM KME 18-22-30-37 400V

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SERIE - POTENZA

SERIES - POWER

KME 18KW

KME 22KW

KME 30KW

KME 37KW

ALIMENTAZIONE

POWER SUPPLY

400/440V 50/60Hz

AVVIAMENTO

TYPE OF START

STAR / DELTA

CODICE

CODE

034021

034022

034023

034027

SIGLA SIGN

DESCRIZIONE DESCRIPTION

PRODUTTORE SUPPLIER

MODELLO MODEL

INTERRUTTORE GENERALE MAIN SWITCH

ABB

OT63FT3

OT80FT3

OT100FT3

ACCESSORI ACCESSORIES

ABB

OTS63T3

OTS125T3

ACCESSORI ACCESSORIES

ABB

OHYS2AJ

CONTATTORE LINEA LINE CONTACTOR

SIEMENS

3RT1026-1AC20

3RT1034-1AC20

3RT1035-1AC20

CONTATTORE TRIANGOLO DELTA CONTACTOR

SIEMENS

3RT1026-1AC20

3RT1034-1AC20

3RT1035-1AC20

ACCESSORI ACCESSORIES

SIEMENS

3RA1924-2B

CONTATTORE STELLA STAR CONTACTOR

SIEMENS

3RT1024-1AC20

3RT1026-1AC20

3RT1034-1AC20

SALVAMOTORE VENTILATORE FAN MOTOR PROTECTOR

SIEMENS

3RV1011-1CA10

3RV1011-0GA10

CONTATTORE VENTILATORE FAN CONTACTOR

SIEMENS

3RT1015-1AB01

FR1

TERMICO MOTORE THERMAL MOTOR

SIEMENS

3RU1126-4DB0 (20-25A)

3RU1136-4EB0 (22-32A)

3RU1136-4FB0 (28-40A)

3RU1136-4HB0 (40-50A)

FS1

RELE' SEQUENZA FASI PHASES SEQUENCE RELAY

GAVAZZI

DPA51

TR1

TRASFORMATORE AUSILIARE AUXILIARY TRANSFORMER

0-230-400-440V/0-18(10VA)/0-24(80VA)

PULSANTE EMERGENZA EMERGENCY BUTTON

SIEMENS

3SB3000-1HA20

PORTAFUSIBILE FUSE-HOLDER

MERSEN

CMS10 2P / 10.3X38

PORTAFUSIBILE FUSE-HOLDER

MERSEN

CMS10 1P / 10.3X38

PORTAFUSIBILE FUSE-HOLDER

MERSEN

CMS10 1P / 10.3X38

FY4

MORSETTO PORTAFUSIBILE FUSE-HOLDER TERMINAL

SIEMENS

8WA1011-1SF12 / 5X20

FY5

MORSETTO PORTAFUSIBILE FUSE-HOLDER TERMINAL

SIEMENS X X X X

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5.7.6 COMPRESSOR CONNECTION TO ELECTRICAL POWER SUPPLY

Make certain that the compressed air hoses used have adequate maximum pressure rating and section for the compressor. Never repair defective hoses; they must always be replaced.

Connect the compressor to the pneumatic system using the special G 1-1/4” female connection arranged on the compressor and indicated in the figure.

It is recommended to use a hose having a diameter equal to or greater than the G 1-1/4" compressor outlet.

Figure 8

A check valve is already installed inside the compressor.

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5.7.7 FIRST START-UP

The first compressor start up (operational testing) must be performed by a qualified technician. Remember, for the technical warranty to be valid, that the registered test report (R.C.R.) attached to the documentation must be filled out (see notes on sales clauses).

After having taken all compressor assembly steps illustrated in chapter 5, prepare the machine for first start-up.

Every time the compressor is turned on, the control panel runs a check on the power supply line phases to ensure that the screw assembly is turning in the right direction.

 If the power supply line phases have been correctly positioned, the screw will turn as indicated by

the arrow in figure 9.

 If the power supply line phases are not positioned correctly, the machine blocked alarm will

appear on the panel. In this case, switch connection of the two power supply phases on the line and start up the compressor again.

Figure 9

WARNING! Reverse screw rotation - turning opposite the direction indicated by the arrow in relief on the body of the machine (see figure 9) - can damage the screw assembly!

WARNING! If the electric motor is replaced, when it is started up once more, always visually inspect the assembly to ensure that the screw is turning in the right direction.

WARNING! Always carefully follow the SAFETY WARNINGS regarding use of the machine. This is extremely important.

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5.8 CLEANING AND DISINFECTION

Keeping the installation site and the compressor clean is essential to good machine operation and keeps operating and maintenance costs down (see chap. 5.5).

Installation site and compressor disinfection is essential to guarantee good air quality in the compressor room and in the area where the compressed air is used (workshop).

5.9 REINSTALLATION AND REUSE

Reinstallation and reuse of the machine must be performed by qualified personnel and only after checking the condition of the machine itself. The points indicated in the previous chapters hold here as well.

5.10 DEMOLITION AND DISPOSAL

If the compressor is to be demolished and disposed of, this must be performed in compliance with current regulations. Always contact an authorized waste disposal and recycling facility.

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6 OPERATION AND USE

6.1 DESCRIPTION OF THE OPERATION

For the machine functions, see chap. 2.

6.2 RANGE OF APPLICATIONS

The machine is suited to all those applications requiring compressed air at the flow rate and pressure outlined in the technical data sheet (see chap. 4).

6.3 PROPER AND IMPROPER USE

CAUTION! The compressor is designed and built solely to produce compressed air. The manufacturer is relieved of any responsibility for risks ensuing from any other use.

CAUTION! Any use of the compressor that differs from the agreements made at the time of purchase relieves the manufacturer of any responsibility for ensuing injury or property damage or damage to the machine itself.

CAUTION! The electrical system cannot be used in flame-proof areas and with flammable products.

CAUTION! Never direct air jet toward persons or animals. Never use compressed air for breathing or in production processes where the air produced is in direct contact with foodstuffs, unless previously treated and filtered.

6.4 OPERATING AND ENVIRONMENTAL LIMITS

The operating and environmental limits are indicated in the table containing the technical data and characteristics (see chap.4).

6.5 WORKSTATION AND DANGEROUS AREAS

During normal operation of the machine, the operator works on the side where the electronic controller is located. Once correctly connected to the electrical and pneumatic system (see chap. 5), the machine is completely protected on the outside and thus there are no dangerous areas accessible during normal operation.

When scheduled and unscheduled maintenance is performed, the machine is completely open. These operations must be performed under safe conditions by qualified personnel (see chap. 8).

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6.6 SAFETY DEVICES AND SIGNALS

The machine is equipped with safety devices and signals to prevent situations dangerous for the operator and the machine itself. These devices and signals come in the form of labels placed at dangerous points, and alarms that are displayed on the electronic controller.

6.6.1 POSITION OF THE LABELS

Figure 10

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6.7 DANGERS AND RISKS THAT CAN BE ELIMINATED

See chap. 6.6.

6.8 PERSONAL PROTECTIVE EQUIPMENT, SAFE WORKING PROCEDURES AND

TRAINING

Use of the compressor does not require any PPE. Our technical services department is at your disposal, ready to provide any information you may need and to help you resolve any problems that may arise. For any information, please log onto our website www.ktc-air.com.For any clarifications you may require, contact our customer services department or your area retailer.

SIGNAL

MEANING

CAUTION:

Never perform any maintenance

on this machine without having

unplugged it from the power

supply and completed vented the

air pressure

CAUTION: Hot surface

CAUTION:

pressurized part or system

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6.9 COMPRESSOR LUBRICATION

6.9.1 GENERAL RECOMMENDATIONS

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 6.9.2

Never mix different types of oil

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

Before starting up compressors without oil, feed approximately 0.8 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.

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

Feed the mineral-based lubricant into the oil tank using the special top-up hole and fill until the right level is read on the window. The amount of oil to be fed is indicated in Ch. 4.

Start up the compressor, initially switching it on and off sequentially and quickly and then starting it up.

Once initially filled with oil, turn off the compressor, vent the pressure and, if necessary, top up the lubricant from the top-up hole until the right level is read on the window.

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6.9.2 USING THE COMPRESSOR WITH SYNTHETIC OILS

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

 Drain all mineral oil from the compressor circuit using the oil drain cock.

 Feed the synthetic lubricant or detergent oil into the oil tank through the top-up hole and fill

up to the correct level.

 Before starting up the compressor or the first time after installation, feed approximately 0.8

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.

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

 Start up the compressor, initially switching it on and off sequentially and quickly and then

starting it up.

 Then turn off the compressor and drain all lubricant from the system using the cock.

 Through the oil top-up hole, feed new synthetic lubricant in until it reaches the set level;

then start up the compressor and run it steady for about 10 minutes.

 Turn off the compressor, vent the pressure and, if necessary, top up by feeding the

lubricant through the top-up hole until the right level is read on the window.

WARNING! If the above-mentioned “washing” cycle is not performed, the mixing of incompatible lubricants may cause problems in lubrication. Use adequate protection when handling lubricants. Dispose of mineral lubricants in compliance with current environmental regulations.

WARNING! 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.

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7 INSTRUCTIONS FOR THE USER

7.1 DESCRIPTION OF THE CONTROL DEVICES

ELECTRONIC CONTROLLER

Ktronic¹º

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7.1.1 BUTTON LAYOUT

START BUTTON

if there is no active alarm, pressing this button starts the compressor

STOP BUTTON

when pressed, this button stops the compressor after a set period of time

ALARM IN PROGRESS WARNING

REMOTE CONNECTION WARNING

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7.2 ALARMS LIST

TYPE OF ALARM

DESCRIPTION

"ALLARME NTC > "

"NTC alarm"

Temperature probe failure

"ALTA T. OLIO"

"OIL HIGH TEMP.AL"

T. MAX setting exceeded

"BASSA T. OLIO"

"OIL LOW TEMP."

T. MIN setting exceeded

"TERMICO COMPRES."

"MOTOR TH. SWITCH "

Main motor thermal relay setting exceeded

"TERMICO VENTIL."

"FUN TH. SWITCH AL"

Electric fan thermal relay setting exceeded

"ALLARME TRASDUT."

"PRESSURE TRD AL."

Transducer failure

"EMERGENZA ATTIVA"

"Emergency SWITCH"

Mushroom head emergency stop button

pressed

"ANOMALIA FASI "

"AC. Phase ERROR "

Phase sequence inverted

"ALLARME SISTEMA!"

"SISTEM ALARM !!!"

General alarm

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7.3 DESCRIPTION OF THE OPERATIONS TO BE PERFORMED

MAIN PAGE

ALARMS HISTORY page 16/16 Description of pressure calibration Scroll history using for Set ( STOP ) and Reset (START)

to continue scrolling through the screens

MACHINE STATUS

INDICATOR

OFF: machine not running STOP: request to stop machine START: request to start machine LOAD: machine loaded EMPTY: machine empty PAUSE: machine in stand-by mode

DISPLAY OF

ALARMS, IF ANY

OIL

TEMPERATURE

COMPRESSOR

PRESSURE

TOTAL MACHINE

HOURS

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PROGRAMMING KEYPAD

Key: MULTIFUNCTION

 Resets currently saved alarms.  Switches from main page of the current menu to a subpage.  In data entry mode, this key selects the setting subfield in maintenance mode and, if kept

pressed for 4 sections, cancels and resets the time on the maintenance timer.

 When pressed on any page, after a 5 second delay, it returns to the main menu.

Key: ENTER

 This key activates the data change mode and saves the modifications.  When in data entry mode, the value to be modified flashes on the screen.

 If the page selected has several fields that can be modified, using makes it possible to

move between fields.

Key:

 Normally used in data entry mode to change page.  These keys are used to modify the selected value, keeping them pressed for more than 1

second automatically increases or decreases the value (rapid modification).

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7.4 START, STOP AND EMERGENCY STOP FUNCTIONS

Figura 11

START See chap. 7.1 STOP See chap. 7.1

EMERGENCY STOP

Achieved by pressing the Emergency button (see figure).

This mechanically engaged button immediately stops the compressor if an emergency arises. When this button is engaged, the compressor cannot perform any operation.

7.5 RESET CONDITIONS

To reset emergency button functions, turn the button clockwise; this will enable the compressor to start.

EMERGENCY BUTTON

POWER SWITCH

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8 COMPRESSOR MAINTENANCE

8.1 SCHEDULED MAINTENANCE

Figure 12

The table below reports the compressor maintenance schedule. The hours of operation indicated in the table refer to optimal use of the machine and can thus vary depending on the work site and number of cycles.

CAUTION!!! USE ONLY ORIGINAL SPARE PARTS!!!

CAUTION!!! HOT PARTS INSIDE!!!

KIT

MACHINE

CODE

CODE DESCRIPTION

HOURS OF OPERATION

K10 K11 K12

KME 18

N11L0103

Oil separator filter

Oil filter

Air filter cartridge

Oil

every 2000 hours

KME 22

N11L0111

KME 30

N11L0104

KME 37

N11L0104

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8.1.1 BELT TENSIONING

Make certain that the pulleys installed on the shaft are properly aligned with each other and that the belts are correctly tightened.

For belt drive, we recommend using a “POLY V” belt. The recommended tension values are given in the table below.

CAUTION!!!

THE BELT CAN BE TIGHTENED USING AN OPTIKRIK BELT TENSION GAUGE (see chap. 10.2)

CAUTION!!! MAKE CERTAIN THAT THE PULLEYS INSTALLED ON THE SHAFT ARE PROPERLY ALIGNED WITH EACH OTHER AND THAT THE BELTS ARE CORRECTLY TIGHTENED.

CAUTION!!! EXCESSIVE BELT TENSION DECREASES THE LIFE OF THE SCREW BEARINGS.

WHEN THE MACHINE IS RUNNING, THE DRIVE MUST BE PROTECTED TO

PREVENT INJURY.

MODEL

INITIAL TENSION WITH NEW BELT

BELT TENSION ALREADY TESTED OR

RETENSIONING

Hz N Hz

KME 18

1071

100

714

KME 22

1735

1157

KME 30

2017

1345

KME 37

2337

1558

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1- Loosen the screws (1) and open the panel (2)

2- Loosen the screws (3)

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4- Loosen the electric motor fixing screws (5) and (6).

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7-To reduce belt tension, loosen nut (7) and tighten nut (8). To increase belt tension, loosen nut (8) and tighten nut (7) and, once the desired tension has been achieved, close nut (8).

CAUTION!

TO REPLACE THE BELT, LOOSEN NUT (7), MANUALLY GRIP THE SIDES OF THE BELT, RAISE THE MOTOR ALL THE WAY AND LOCK IT IN PLACE WITH THE SCREWS (5). WITHDRAW THE BELT FROM THE PULLEYS AND REPLACE IT. THEN, LOOSEN SCREWS (5) AND TIGHTEN THE BELT AS INDICATED AT POINT 4.

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5- Secure the screws (5) to a

torque of 85Nm and then tighten screws (6) to a torque of 50Nm.

6- Reposition the protective casing (4) and tighten the screws (3).

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7- Close the panel (2) and tighten screws (1).

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8.1.2 USING AN OPTIKRIK TENSION GAUGE

Figura 13

Figure 14 Figure 15

1-Figure 13 (A, B or C) shows the three correct ways to grip the gauge so that the pressure is applied only on the

pressure pad.

2-Reset the indicator arm by lowering it completely as indicated in figure 14.

3-Position the tension gauge on the taut side of the belt, with the part resting of the indicator arm set

at the mid-point between the pulleys, as indicated in figure 15.

Check gauge alignment ensuring that it is parallel with the belt branch.

4-Press slowly on the pressure pad. When you hear a “click”, immediately stop and remove the tension gauge; this must be done very

carefully to prevent compromising the measurement reading taken by the indicator arm.

5-Read the tension on the indicator arm as shown in figure 13.

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8.1.3 SUCTION PRE-FILTER MAINTENANCE

Figure 16

1 Raise the protection grid (1) aligning the tabs (see part 1) with the openings on the panel (3).

2 Withdraw the protection grid (1) and remove the pre-filter panel (2) so it can be cleaned or

replaced.

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CLEAN THE PANEL WITH A JET OF AIR OR WASH IT WITH WATER. DO NOT USE SOLVENTS.

THE PRE-FILTER PANEL MUST BE CLEANED OR REPLACED WITH THE MACHINE OFF AND WITH THE UNIT AT ATMOSPHERIC PRESSURE.

OIL LEVEL CHECKS AND TOP UPS MUST BE PERFORMED WITH THE MACHINE OFF AND WITH THE UNIT AT ATMOSPHERIC PRESSURE.

THE OIL REMOVED MUST BE DISCARDED IN COMPLIANCE WITH CURRENT LAW.

IN SEVERE WORKING ENVIRONMENTS (e.g.: PARTICULARLY DUSTY WORK SITES), THE MAINTENANCE INTERVAL MUST BE SHORTER.

INCORRECT MAINTENANCE OF THE OIL FILTER, AIR FILTER AND OIL SEPARATOR CAN DAMAGE THE UNIT. LEAVING CARTRIDGES IN OPERATION FOR LONGER THAN THE INDICATED TIME CAN DAMAGE THE COMPRESSOR.

ALWAYS CAREFULLY COMPLY WITH THE SAFETY WARNINGS REGARDING USE OF THE MACHINE. THIS IS ABSOLUTELY ESSENTIAL.

MAINTENANCE MUST BE CARRIED OUT BY SPECIALISED PERSONNEL. ALWAYS FOLLOW CURRENT ACCIDENT PREVENTION STANDARDS (USE ADEQUATE PROTECTION).

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8.1.4 REPLACING THE OIL FILTER

Perform all maintenance as described in this manual or following the indications provided by the retailer or Authorized Service Centre. Open the rear panel and remove the filter cartridge using the special spanner. Then replace the spent cartridge with a new one.

Before screwing down the filter cartridge, oil the gasket. Manually screw down the new cartridge.

Figure 17

8.1.5 REPLACING THE OIL SEPARATOR FILTER

Replace the oil separator filter after the number of hours indicated in the manual or after checking its differential pressure. To do so, open the rear panel and remove the filter cartridge using the special spanner. Then replace the spent cartridge with a new one.

Before screwing down the oil separator cartridge, oil the gasket. Manually screw down the new cartridge.

Figure 18

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8.1.6 CHANGING THE OIL

Change the oil as indicated in the table point 8.1.8. 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 cock to check for condensation residues.

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

Unscrew the oil filling cap on the oil separator tank and open the drain cock. Once emptied, close the drain cock. Then top up the oil until the right level is read on the window (see figure 19). 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 LEVEL OIL

MIN LEVEL OIL

Figura 19

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.

8.1.7 REPLACING THE AIR FILTER

Replace the cartridge following the indications in the maintenance table; in dusty environments we recommend replacing the filter early, contact an Authorized Service Centre for information. To replace the cartridge, unscrew the upper lid. Always clean the container paying particular attention not to let any material fall into the suction valve.

Figure 20

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8.1.8 MAINTENANCE SCHEDULE

Codice/Code

Modello/Type

MOTOR

ORE/HOURS

Contenuto / Content

LISTINO/LIST

N11L0103

KME 18 / PLUS

8-10-13Bar

400/50/3

2000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

€ 280

N11L0109

KME 18 / PLUS

8Bar

400/50/3

4000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

€ 360

N11L0228

KME 18 / PLUS

10-13Bar

400/50/3

4000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

€ 360

N11L0229

KME 18 / PLUS

8Bar

400/50/3

8000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi valvola aspirazione/

Intake valve KIT

- Kit valvola minima pressione

/Minimum pressure valve KIT

- Kit valvola

termostatica/Thermostatic valve KIT

- Kit paraolii vite/ Screw Shaft seal

KIT

- Kit cuscinetti MOTORE/Motor

bearing

€ 740

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N11L0230

KME 18 / PLUS

10-13Bar

400/50/3

8000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi valvola aspirazione/

Intake valve KIT

- Kit valvola minima pressione

/Minimum pressure valve KIT

- Kit valvola

termostatica/Thermostatic valve KIT

- Kit paraolii vite/ Screw Shaft seal

KIT

- Kit cuscinetti MOTORE/Motor

bearing

€ 740

N11L0231

KME 18 / PLUS

8Bar

400/50/3

20000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi cuscinetti vite /

Screw bearing kit

€ 640

N11L0232

KME 18 / PLUS

10-13Bar

400/50/3

20000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi cuscinetti vite /

Screw bearing kit

€ 640

N11L0111

KME 22 / PLUS

8-10-13 Bar

400/50/3

2000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

€ 360

N11L0233

KME 22 / PLUS

8-10Bar

400/50/3

4000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

€ 440

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N11L0234

KME 22 / PLUS

13Bar

400/50/3

4000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

€ 440

N11L0235

KME 22 / PLUS

8-10Bar

400/50/3

8000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi valvola aspirazione/

Intake valve KIT

- Kit valvola minima pressione

/Minimum pressure valve KIT

- Kit valvola

termostatica/Thermostatic valve KIT

- Kit paraolii vite/ Screw Shaft seal

KIT

- Kit cuscinetti MOTORE/Motor

bearing

€ 870

N11L0236

KME 22 / PLUS

13Bar

400/50/3

8000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator Filt

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi valvola aspirazione/

Intake valve KIT

- Kit valvola minima pressione

/Minimum pressure valve kit

- Kit valvola

termostatica/Thermostatic valve

- Kit paraolii vite/ Screw Shaft seal

KIT

- Kit cuscinetti MOTORE/Motor

bearing

€ 870

N11L0237

KME 22 / PLUS

8-10Bar

400/50/3

20000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi cuscinetti vite /

Screw bearing kit

€ 920

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N11L0238

KME 22 / PLUS

13Bar

400/50/3

20000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi cuscinetti vite /

Screw bearing kit

€ 920

N11L0104

KME 30-37

/PLUS

8-10-13Bar

400/50/3

2000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

€ 310

N11L0110

KME 30-37

/PLUS

8-10Bar

400/50/3

4000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

€ 470

N11L0241

KME 30 / PLUS

13Bar

400/50/3

4000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

€ 470

N11L0242

KME 30 / PLUS

8-10Bar

400/50/3

8000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi valvola aspirazione/

Intake valve KIT

- Kit valvola minima pressione

/Minimum pressure valve KIT

- Kit valvola

termostatica/Thermostatic valve KIT

- Kit paraolii vite/ Screw Shaft seal

KIT

- Kit cuscinetti MOTORE/Motor

bearing

€ 1.190

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N11L0243

KME 30 / PLUS

13Bar

400/50/3

8000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi valvola aspirazione/

Intake valve KIT

- Kit valvola minima pressione

/Minimum pressure valve KIT

- Kit valvola

termostatica/Thermostatic valve KIT

- Kit paraolii vite/ Screw Shaft seal

KIT

- Kit cuscinetti MOTORE/Motor

bearing

€ 1.190

N11L0244

KME 30 / PLUS

8-10Bar

400/50/3

20000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi cuscinetti vite /

Screw bearing kit

€ 950

N11L0245

KME 30 / PLUS

13Bar

400/50/3

20000

- Filtro Aria / Air Filter

- Filtro Olio / Oli Filter

- Filtro Separatore / Separator

Filter

- Olio / Oil

- Cinghia /Belt

- Prefiltro / Prefilter

- Kit ricambi cuscinetti vite /

Screw bearing kit

€ 950

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.

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8.2 UNSCHEDULED MAINTENANCE

Unscheduled maintenance must be performed by an Authorized Service Centre.

For any information, please log onto our website www.ktc-air.com

For any clarifications you may require, contact our customer services department or your area retailer.

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9 TROUBLESHOOTING

Problem

Cause

Resolution

High oil temperature limit has tripped causing machine to stop.

Low oil level Too high environmental temperature

Air oil exchanger clogged Temperature probe failure

Top up oil level and check that exchanger is clean and the electric fan is functioning properly.

Check environmental temperature parameters.

Replace temperature probe.

Motor thermal protection has tripped causing 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 that 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.

Fan motor or electric cooling fan motor thermal protection has tripped causing the machine to stop.

The thermal protection of the electric fan motor has tripped.

High power absorption. High temperature.

Make certain that electric power supply is correct. Make certain that the 3 power phases are at approximately the same value. Make certain that the power cords are firmly tightened to the terminal. Make certain that the power supply cords are not damaged. Make certain the cooling fan air intake grid 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. Magnetothermal switch failure, fuse blown, replace the damaged fuse.

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Problem

Cause

Resolution

High pressure safety has tripped causing the machine to stop.

The pressure exceeds the alarm set point.

Transducer does not detect pressure properly.

Check line pressure, vent pressure and return to operating set point.

Low temperature safety has tripped causing machine to stop.

Environmental temperature below the electronic controller setting.

In this phase, if the start button is pressed intermittently, the machine starts in STAR mode and the temperature should return to above the setting. As soon as it does, the machine will start running again in automatic mode.

Check the environmental temperature and, if necessary, use a heating resistance on the oil circuit. Contact an Authorized Service Centre.

Compressor runs but does not charge.

Suction valve does not open.

Auxiliary power disconnected, solenoid valve fuses blown.

Make certain that the transducer is connected both electrically and pneumatically.

Check that the solenoid valve installed on the suction regulator is functioning properly.

Possible check valve or minimum pressure valve failure. Contact an Authorized Service Centre.

Check the fuses for the solenoid valve installed on the terminal inside the starter itself.

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. WARNING!!! UNPLUG THE MACHINE.

Oil leaking from air filter.

Oil level is too high. Suction valve defective.

Drain the oil until the correct level is reached. For the valve, contact an Authorized Service Centre.

Pressure relief safety valve vented.

During no-load operation the machine is not depressurized.

Oil separator cartridge clogged.

Contact an Authorized Service Centre.

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 viewer. Top up oil until it reaches the level indicated

in the manual.

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10 COMMERCIAL PARTS, SPARE PARTS AND PERTINENT

DOCUMENTATION

For any information, please log onto our website www.ktc-air.com

For any clarifications you may require, contact our customer services department or your area retailer.

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11 APPENDIX

11.1 MAINTENANCE CHECK SHEET

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WARNING!

 Never touch moving parts while the compressor is running.

 All compressor maintenance operations must be performed with the machine off (at

environmental pressure and temperature) and with the unit unplugged.

 Maintenance must be carried out by qualified personnel. Always follow current accident

prevention standards (use adequate protection).

The manufacturer reserves the right to make any modifications to the present manual it

deems fit and to do so without prior notice.

The manufacturer is relieved of any responsibility for injuries and property damage caused by incorrect use of the compressor assembly, non-compliance or inadequate compliance with the safety criteria indicated herein, modifications (even minor modifications) and by tampering and use of non original spare parts.

KTC KME 18-22-30-37 Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual