KTC COMPACK 2 Operation And Maintenance Manual
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KTC COMPACK 2 Operation And Maintenance Manual

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CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written
authorization. K.T.C. shall safeguard its rights to the full extent of the law.
OPERATION AND MAINTENANCE MANUAL FOR
COMPACK 2 COMPRESSOR
(SOLUTION FOR BUS)
ENGLISH VERSION
Pag.1 di 45
USER MANUAL AND INSTALLATION
COD. 091052 - REV. 07 - DATE 11/2016

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  • Page 1 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. OPERATION AND MAINTENANCE MANUAL FOR COMPACK 2 COMPRESSOR (SOLUTION FOR BUS) ENGLISH VERSION Pag.1 di 45...

  • Page 2: Table Of Contents

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. SUMMARY GENERAL WARNINGS AND INFORMATION FOR THE USER ....4 DEFINITION OF REGULATED RELATIONSHIPS ...........
  • Page 3 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. AIR CONNECTION OF COMPRESSOR ..............26 FIRST START ......................

  • Page 4: General Warnings And Information For The User

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 1 GENERAL WARNINGS AND INFORMATION FOR THE USER 1.1 DEFINITION OF REGULATED RELATIONSHIPS 1.1.1 DECLARATIONS...

  • Page 5: Warranty

    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.

  • Page 6: Rules Apply

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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 –...

  • Page 7: Ce Marking

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. REMOVE POWER: every operation must be performed on the machine when the power is turned off.

  • Page 8: Maintenance And Support Information Of The Machine

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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.
  • Page 9 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 9. Compressor Usage Never use the compressor for any purpose other than those specified in the user's manual. 10.
  • Page 10 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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.

  • Page 11: Labels Position

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 1.8 LABELS POSITION Pag.11 di 45 USER MANUAL AND INSTALLATION COD.
  • Page 12 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. Pag.12 di 45 USER MANUAL AND INSTALLATION COD.
  • Page 13 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. ATTENTION: Do not perform any maintenance on this machine before: •...

  • Page 14: 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 ±...

  • Page 15: Dimensions

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 3 DIMENSIONS Pag.15 di 45 USER MANUAL AND INSTALLATION COD.
  • Page 16 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. Pag.16 di 45 USER MANUAL AND INSTALLATION COD.

  • Page 17: Unpacking

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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.
  • Page 18 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. In this version, the compressor must be set between a floor and legs of the compressor, through no.4 M8 screws.

  • Page 19: Connection And Start Up

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. CONNECTION AND START UP GENERAL WARNINGS Before starting compressor for the first time it is compulsory to make sure that: ...

  • Page 20: Use Of The Compressor

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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.

  • Page 21: Compressor Lubrication

    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.

  • Page 22: Using The Compressor With Synthetic Oils

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. USING THE COMPRESSOR WITH SYNTHETIC OILS If you wish to use a synthetic lubricant, carefully follow the procedure below.

  • Page 23: Connection And Start Up

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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.

  • Page 24: Electrical Connection Of Compressor

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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.

  • Page 25: Ground Connection

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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.

  • Page 26: Air Connection Of Compressor

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. AIR CONNECTION OF COMPRESSOR Be sure to use compressed air tubing with features and cross section appropriate to the compressor.

  • Page 27: First Start

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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.

  • Page 28: Control Panel

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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).

  • Page 29: Electric Diagram

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 8.1 ELECTRIC DIAGRAM Pag.29 di 45 USER MANUAL AND INSTALLATION COD.
  • Page 30 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. Pag.30 di 45 USER MANUAL AND INSTALLATION COD.
  • Page 31 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. Pag.31 di 45 USER MANUAL AND INSTALLATION COD.
  • Page 32 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. Heavy duty POWER and CONTROLLER connectors with spring terminal connectors Inserts for section conductors: 0.14 - 2.5 mm2 - AWG 26 –...

  • Page 33: Heating Resistance Of Oil

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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.

  • Page 34: Pneumatic Scheme And Machine Description

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 10 PNEUMATIC SCHEME AND MACHINE DESCRIPTION 1- Intake valve 2- Screw compressor 3- Air tank...

  • Page 35: Ordinary Maintenance Of 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. MACHINE CODE DESCRIPTION HOURS OF WORK COMPACK 2 OIL CHANGE COMPACK 2 De-oiler cartridge N11L0119 every 1000 hours...
  • Page 36 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. EVERY LEVEL CONTROL AND POSSIBLE OIL TOPPING OFF THE MUST BE MADE WITH MACHINE STOPPED AND SYSTEM DEPRESSURIZED.

  • Page 37: Replacement Of Oil Filter

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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...

  • Page 38: Changing Oil

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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.

  • Page 39: Replacement Of Air Filter

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 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.

  • Page 40: Maintenance Schedule

    - Filtro Aria / Air Filter - Filtro Olio / Oli Filter - Filtro Separatore / Separator Filter - Olio / Oil - Anello elastico trasmissione /Elastic ring of trasmission - Valvola minima COMPACK 2 pressione/Minimum pressure 400/50/3 trifase/3ph N11L0285 8000 valve €...
  • Page 41 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. The maintenance program is set considering all installation and operating parameters recommended by the Manufacturer.

  • Page 42: Troubleshooting

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 13 TROUBLESHOOTING Problem Cause Resolution - Check the oil level - Check the clean of cooler.
  • Page 43 CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. Problem Cause Resolution Make certain that electric power supply is correct.

  • Page 44: Appendix

    CONFIDENTIAL - This document is the property of K.T.C. S.r.l. and cannot be reproduced or issued to third parties without written authorization. K.T.C. shall safeguard its rights to the full extent of the law. 14 APPENDIX 14.1 MAINTENANCE CONTROL BOARD Pag.44 di 45 USER MANUAL AND INSTALLATION COD.

  • Page 45: User Manual And Installation Pag.2 Di

    K.T.C. shall safeguard its rights to the full extent of the law. 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! ...

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